CD102 PDF

Important safety instructions
H Observe the general and press-specific safety instructions in the operating manual. H At first start-up or after the exchange of equipment or components check the correct functioning of all safety equipment. H Control cabinet and machine housing have to be locked while the press is in operation. They may only be opened for repair purposes. H Make sure that the main power switch is turned off and that there is no voltage applied to the press before you open the control cabinet or the machine housing. H If it is necessary to repair the press while it is connected to the mains supply, please pay attention to general safety precautions. H Never exchange components and units while the press is connected to the mains supply. H Safety equipment must not be modified. Do not remove earth conductors. If it is necessary to disconnect these conductors, please remember to reconnect them after you are finished. H If extra accessories not corresponding to Heidelberg specifications are installed or mounted, Heidelberg does not accept any liability whatsoever. In each case these accessories must be controlled or locked in a way that no hazards can arise when the press and its devices are operated.
Attention:
Observe these handling instructions when you replace electronic boards with electrostatically sensitive devices (ESDs)!
Handling and replacing electronic boards

+80C
25C Storage: NEVER below 25C NEVER above +80C ALWAYS pack into the protective container for ESDs. NEVER replace when power is on. NEVER use force to insert.
Protective measures for ESDs to be observed when replacing electronic boards
DISCHARGE static charges.
UNPACK from the protective container for ESDs.
REPLACE electronic boards.
PACK into the protective container for ESDs.
2. Speedmaster CD102
Table of contents
2. Speedmaster CD 102
7 7 12 17 17 19 21 28 31 31 39 39 45 45 47 53 59 67 77 85 96 104 110 Main drive M1 Direct-current main motor M1 Brushless main motor Pile centering Block diagram 11B10 Pile centering 11M9 Pile centering 11B55 Inactivating pile centering Pile merging 11M8 Adjustment of pile support plate Suction head height control 11M5 Suction head height adjustment Size adjustment Block diagram 11M4 Adjustment of format wheels 11M6 Suction head/format adjustment 11M11/11M12 Pile stops D.S./O.S. 1M4 Cover guide height adjustment 1M2/1M3 Print-free margin D.S./O.S. 1...nM5 Adjustment of printing pressure 1M7/1M8 Adjustment of pull lays 12M5 Sheet slowdown/format adjustment 12M6/12M7 Sheet joggers D.S./O.S.
1 438
Table of contents
119 119 121 124 127 140 143 146 149 152 155 158 161 161 163 166 170 186 189 192 195 198 201 204 207 207 210 223 231 238 241 247 251
Feeder pile control Block diagrams Layout Overview of components Function 11M1 Main pile motor (Preset) 11M1 Main pile motor (standard) 11M2 Auxiliary pile motor 11B11 Auxiliary pile detection 11B33 Upper main pile limitation 11B35 Automatic pile transport 11S34 Bottom main pile limitation Delivery pile control Block diagrams Layout Overview of components Function 12M1 Main pile motor (Preset) 12M1 Main pile motor (standard) 12M2 Auxiliary pile motor 12B65 Changeover fast/slow 12B69 Pile height control 12B129 Delivery upper edge of pile 12S34 Bottom main pile limitation Sheet alignment Block diagram 1B13/ 1B49 Sheet alignment control 1B9/1B10 Pull lay control 1B11 Double-sheet detector 11M3 Automatic sheet arrival control 11M3 Automatic sheet arrival control (standard version) 11M3 Automatic sheet arrival control (Preset version) 11M7 Automatic misalignment control
Table of contents
259 259 267 267 271 275 275 276 278 281 286 292 296 297 301 303 305 305 308 311 314 317 318 321 321 322 323 325 328
Sheet monitoring 1...nB48/ 1...nB48a Sheet travel monitor Plate clamping device Autoplate 1...nB53 Coarse register monitoring Washup devices Control by command Washup Messages Service display Washup Blanket washup device (GTW) Inking roller washup device (FWW) Impression cylinder washup device (DZW) M43, M50 ... M56 Washup brush motors E9 Washup solution container B1, B54, B55 Sensors at the washup solution container 1...nB43 Monitoring the ink blade Inking unit Servo-drive ink fountain roller Servo-drive diagonal register 1...nM6 Servo-drive lateral register Servo-drive circumferential register Inking unit temperature control E39 Inking unit temperature control Dampening 1...nM1 Pan roller motors 1...nM45 Blower motor for dampening system 1...nB32 Sensor Dampening solution control E40 Central dampening solution supply / cooling and circulating unit E41 Dampening solution mixing unit
Table of contents
329 329 330 332 333 338 343 345 346 347 348
Central lubrication Basic concept Service display Fault messages Grease lubrication Oil lubrication M44 Oil pump 12M47 Motor for grease lubrication 1F33 Pressure monitoring oil lubrication 1 bar 1F34 Pressure monitoring oil lubrication 12 bars 12B47 Lubrication monitoring 1 and 12B77 Lubrication monitoring 2
351 351 353 355 357 357 369 369 371 373 377 379 380 381 382 383 386 388
Pneumatic system 15Y11 Admission of pressure, pneumatic system 15B14 Pressure sensor Pneumatic system E4 Pneumatic system compressor Suction and blast air 1M9 Blast air regulation at the feeder Other components E4a Varnish supply unit L-B32 Level in coating pan 12E2 Powder spray unit 12M35 Blower motor for powder spray device 12S68 Switch Powdering cycle 12S9, -a, -b, -c Monitoring the IR slide-in dryer E8 Air supply cabinet E39 Inking unit temperature control 12E3 Static electricity eliminator WSA Intercom IDS Encoder
Table of contents
393 393 408 409 411 413 415 417 423 429 431 435 437
Location diagrams ZSG Central control cabinet ZSP Central control console Position switches Solenoid valves Motors Sensors Control panels Operators controls ZSP Control panel of control console Abbreviations Equipment identification Position codes
Table of contents
Main drive
M1 Direct-current main motor
Main drive
M1 Direct-current main motor Layout
The dc main motor is a dc shunt motor. Its layout varies depending on the manufacturer, motor power and type of construction. The illustration below shows one example of the components of the main motor M1.
Representation of a dc main motor M1
1 2 3 4 5 6 7 8
Installation area of fan impeller Ventilation cover Terminal box for main motor M1 ( contains all connections for M1 ) Hoop for manual release of brake Terminal box of brake Brake Y1 Installation area of carbon brushes and commutator Motor support rails or motor baseplate
Main drive
Attention:
Make sure the motor is disconnected from the power supply before working on it! Make certain to leave a minimum gap of 6 mm in the terminal box between neighbouring conducting parts carrying different potentials! Shut the terminal box tight! Terminal box of SIEMENS main motor
1 2 3 4 5 6 7 8 9
Terminal box of a SIEMENS main motor
Entries for motor connecting cables Connection PE conductor Connection armature circuit + / A1 Connection armature circuit / A2 Connection field circuit + / F1 Connection field circuit / F2 Connector X1 / connection to optocoupler module 15U5 (monitoring of carbon brushes) and brake control module BAM ( BAM-X1) Connector X2 / connection to interference suppressor module ESM ( motor coding ) Connecting cable to brake Y1
Terminal box of BAUMLLER main motor
1 2 3 4 5 6 7 8
Terminal box of a BAUMLLER main motor
Connection PE conductor Connector X1 / connection to optocoupler module 15U5 (monitoring of carbon brushes) and brake control module BAM ( BAM-X1) Connector X2 / connection to interference suppressor module ESM ( motor coding ) Connection field circuit / F2 Connection field circuit + / F1 Connection armature circuit + / A1 Connection armature circuit / A2 Entries for motor connecting cables
Main drive
Removal and installation of brake 1 2 3 4 1 2 3 4

Brake at main motor
Connecting cable of brake Terminal box of brake Fixing bolts of brake Brake of main motor M1
Removal of defective brake Turn off the main switch on the central control cabinet ZSG and make sure no-one can turn the power back on. Disconnect the connecting cable terminal box 2 of the brake. Loosen the fixing bolts
1 from the
3 of the brake.
Pull the brake off the main motor shaft.
1 2 3 4 5 1 2 3
Connecting cable of brake Terminal box of brake Fixing bolts of brake Brake of main motor M1 Square driver of motor shaft
Installation of the new brake Place the new brake on the square driver the motor shaft. Tighten the fixing bolts
5 of
3 uniformly. Connect the connecting cable 1 of the brake to the terminal box 2.
Main motor with brake removed
Main drive
Removal/installation of carbon brushes 1 2 3 4 5

Ventilation covers of main motor Terminals of carbon brushes Carbon brushes Clamp-type carbon brush holder Brush-rocker ring
Removal of carbon brushes
Note: Always replace all carbon brushes of the main motor.

All carbon brushes should be from the same set of spare parts to guarantee that they are all from the same material.
Ventilation covers of main motor
1 2 3
Turn off the main switch on the central control cabinet ZSG and make sure no-one can turn the power back on. Remove all ventilation covers installation side of the brake.
1 on the
Disconnect the wires of the carbon brushes from the terminals 2.
Note: With certain motors it is necessary to turn the brush-rocker ring 5 for brush removal. Before turning the brush-rocker ring 5, mark its position in relation to the stator ( e.g. colour line ) if no markings exist so far.
Loosen the retaining screws 6 ( but do not turn them out completely ) and turn the brush-rocker ring 5 ( see illustration on next page). Flip up the clamp-type brush holder 4 and take out all used carbon brushes 3.
5
Layout of brush-rocker ring (example)
10
Main drive
2 3 4 5 6
Carbon brush connections Carbon brushes Clamp-type carbon brush holder Brush-rocker ring Fixing bolts for brush-rocker ring
Installation of new carbon brushes When replacing a set of carbon brushes, clean all the cooling-air paths, e.g. with dry, oil-free compressed air. Any deposits of carbon dust on the insulating parts of the commutator and the brush-rocker ring must be removed completely, e.g. by cleaning these parts with a non-linting cloth.
1
Fastening the brush-rocker ring (example)
Insert the new carbon brushes 3 and connect them to the terminals. Close the clamp-type brush holder 4.
Note: The carbon brushes must rest correctly on the commutator and run smoothly in the brush boxes.
If the brush-rocker ring 5 was turned before, it must be brought back in its initial position and locked after replacement of the carbon brushes. Pay attention to the markings! Screw down the covers
1 again.
Note: The ventilation slots in the ventilation covers must point downward to maintain the type of protection.
11
Main drive
M1 Brushless main motor
M1 Brushless main motor Construction with terminal board (from 37kW)
Main motor M1 with terminal box
1 2 3 4 5 6
Motor shaft Terminal box of main motor Terminal box of brake Rotor position encoder Plug of rotor position encoder Lever for manual release of the brake
12
Main drive
Rotor position encoder

The rotor position encoder consists of three components: sensor, rotating part, adjusting ring.
Attention:
Do not loosen the safety screws of the adjusting ring of the rotor position encoder! Displacement of the adjusting ring results in displacement of the rotor position encoder in relation to the actual position of the rotor of the main motor. If the adjusting ring is not in its normal position or defective, the main motor must be replaced!
Layout

Front view of rotor position encoder
1 2 3 4
Pin base X2 / connection to BLT4 Safety screws of adjusting ring Sensor Adjusting ring
X2
1
Pin assignment 2 3 7 6 4 5 6 7 X2 Plug connection to ZSG (BLT4) Function DC +15 V 15 V
Pin
Pin base X2, 7-pole
13
Main drive

Rotor position encoder of main motor M1
1 2 3 4 5 6 7 1 2 3 4
Motor casing / brake Adjusting ring End-float washers (not always provided) Motor shaft Rotating part Connector M1-X2 Sensor part
Removal Turn off the main switch and make sure no-one can turn the power back on. Remove connector X2. Remove the sensor (four fixing bolts). Replace the sensor or rotating part.
Note: Put the end-float washers back in place between the rotating part and motor.
Installation
Reinstall all parts and connect the rotor position encoder.
14
Main drive
Connection
Main motors with < 37 kW are connected by means of prefabricated plugs. For EMC reasons, main motors with 37 KW or more are connected via a terminal board.
1 2 3 4 5 6
PE conductor connection Motor winding W (threaded bolt M12) Motor winding V (threaded bolt M10) Motor winding U (threaded bolt M8) PE conductor connection Plug for motor code, brake and temperature sensor
Terminal box of main motor BAUMLLER 37KW Please note: The terminal studs of the motor terminal board and the eye rings of the connecting cables have different diameters. Thus the cables cannot be mixed up.
Terminal N is used for measuring purposes only.
Pin assignment
X1 1 5 2 6 1 2 3 2 6 1 5 4 5 Plug connection in motor terminal box Function Motor code 0 Motor code 1 Motor code Temperature sensor Brake + Brake Pin
Pin and socket bases, 6-pole
15
Main drive
M1 Brushless main drive
16
Pile centering
Block diagram
Pile centering
Block diagram
The pile centering function comprises:
Pile centering 11B10 Inactivating pile centering 11B55
the sensor Pile centering 11B10, the sensor Inactivating pile centering 11B55, the servo-drive Pile centering 11M9.
Pile centering 11M9
SSM1
SSM1
The pile centering function compensates for the lateral displacement of the paper pile at the feeder. The sensor Pile centering 11B10 senses the lateral edge of the pile. The required distance between the sensor and the lateral pile edge is 130 " 2 mm. If the difference between the required and actual distance exceeds the tolerance limits, the electronic control system corrects the position of the paper pile through the servo-drive Pile centering 11M9. If the pile support plate reaches the sensor Inactivating pile centering 11B35 during its upward movement, the electronic control system stops the automatic control. Automatic control is resumed as soon as the pile support plate is below the sensor 11B35 and the sensors 11B10 and 11B35 detect paper or the pile support plate lies on the floor (position switch 11S34 actuated).
SSK
EAK 1
SAK
ESK
REK1
REK386
DSK
DNK
SVM
ZID Displays
MID11
MID12
Legend:
Data line Control lines
Block diagram for pile centering

17
Pile centering
Block diagram
Activating and inactivating pile centering
Selecting the display
Symbol Pile centering on / off
Activating and inactivating pile centering: in the preselection display, by means of the function button.
If the symbol is lit, pile centering is active.
Preselection/coarse display, pile centering
18
Pile centering
11B10 Pile centering

The sensor 11B10: senses the lateral pile edge (actual distance), with the required distance = 130 2 mm.
11B10
Where? approx. 25 mm below the upper edge of the pile.
Automatic control through the electronic control system: 130 2 mm if the difference between the required distance and actual distance exceeds the tolerance limits, by activating the servo-drive Pile centering 11M9.
Required distance for pile centering
No automatic control: within the tolerance limits of the required distance.
Output signal of sensor 11B10: analog voltage, digitization on the SSK1.
Signal flow: Sensor 11B10 Servo-drive distributor module (11LVT: 2SSM1) backplane SSR: X14 servo-drive control board SSK1.
19
Pile centering
Place of installation
11B10
PU1 and Preset feeder
Removal and installation
black
11LVT1
2SSM1 X5: D4 X2: +8 X2: 8
blue brown
Check

130 2 mm
1646 70
20
Pile centering
11M9 Pile centering
11M9 Pile centering Automatic positioning

Condition: Automatic pile centering is switched on in the preselection display.
The servo-drive 11M9 positions the pile support frame at the feeder. The sensor 11B10 senses the lateral edge of the pile. If the difference between the required distance and the actual distance exceeds the tolerance limits, the servo-drive control board SSK regulates the servo-drive 11M9. If the pile support plate reaches the sensor 11B35 while moving up, the electronic control system stops the automatic control.
Manual positioning for feeder without NON-STOP facility:

Condition: Automatic pile centering is switched off in the preselection display.
Pushbuttons Main pile centering Plus button Minus button The pushbuttons "Main pile centering" control the servo-drive 11M9. Maximum positioning range: +/ 30 mm in relation to the centre of the feeder. Plus button Minus button = movement towards D.S. = movement towards O.S.
21
Pile centering
11M9 Pile centering
NON-STOP feeder
The positioning of the pile support plate by means of pushbuttons depends on the position of the toggle switch Auxiliary pile on/off.
Toggle switch Auxiliary pile on / off
Toggle switch in position "Off": ON OFF Main pile control activated. The pushbuttons Main pile centering control the servodrive. Maximum positioning range: 35mm in relation to the centre of the feeder. movement towards D.S. movement towards O.S.
Pushbuttons Main pile centering Plus button Minus button
Plus button = Minus button =
The pile support frame and pile support plate can move max. 35 mm in the same direction together. Toggle switch in position ON: Toggle switch Auxiliary pile on / off Pushbuttons Auxiliary pile centering Plus button Minus button ON OFF Auxiliary pile control activated. The pushbuttons Auxiliary pile centering control the pile support frame. Maximum positioning range: 35mm in relation to the centre of the feeder.
The pile support frame and pile support plate can move max. 35 mm in the same direction together.
Indication of position in MID

During manual positioning, the electronic control system indicates the present position of the pile support frame in the press display MID. The displayed value represents the absolute position in relation to the centre of the feeder.
11
2 0
Indication of position of pile support frame
1 2
Present position Position code
22
Pile centering
11M9 Pile centering
11M9
Operator side
Technical data
Motor data U P = = DC 24 V 5 W
Potentiometer data U R = = DC 10 V 10 KW
23
Pile centering
11M9 Pile centering
Interconnection diagram
X10 X5
SSR
SSR X10
X11 X12 X3 X13 X14 X4
SSR X14
11 11LVT1 2SSM1: X2
X3 X4 X1 X2 X5
Backplane of servodrive plug-in unit SSR
2SSM1: X4
2SSM1
Servo-drive distributor module 2SSM1
11M9: X1
3 2
4 5 1
11M9
Servo-drive 11M9
11M9:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 2SSM 1 X5: C1 X5: C2 X5: C3 X5: C4 X5: C5 SSR X10: X10: X14: X14:
+ 10V 0V
X2: X2: X4: X4:
1 2 3 4
B14 D14 3 4
X4: 5
X14: 5
24
Pile centering
11M9 Pile centering
1
1
ON OFF
2
2
06
2048 2
Set the toggle switch Auxiliary pile ON/OFF to OFF. Select the service display SSK1. Bring the pile support plate into its central position (set to 20482 inc).
Remove the servo-drive Pile centering 11M9.
Set the distance between the side frame and the pile support frame to 83 mm. 25
Pile centering
11M9 Pile centering
4
4)
07
2048 2 1M9: X1
Fit the motor baseplate and gear wheel. Connect plug 11M9: X1. Set to 20482 inc.
Install the servo-drive.
26
Pile centering
11M9 Pile centering
Checking the operating range 1

Servo-drive Pile centering 11M9
Condition: The pile support plate is in its central position (2048 inc).
Input 35 mm + 35 mm Incremental value 3686 " 23 inc 409 " 23 inc
Service display Values, incremental values servodrives
27
Pile centering
11B55 Inactivating pile centering

If the pile support plate reaches the sensor 11B55 during 11B55 Production run or Paper run,
the electronic control system switches the pile centering function off. The remaining sheets on the pile are still printed. For the pile change, the operator lowers the pile support plate and places paper on it. If the sensors Automatic pile transport 11B35 and Inactivating pile centering 11B55
detect the paper, the preselected pile centering function is active again.
Sensor 11B55
28
Pile centering
11B55
Adjustment
black
FAM64 XE: 55 +1 1
brown blue
11LVT1
Check
0010
29
Pile centering
30
Pile merging
11M8 Adjustment of pile support plate
Pile merging
The servo-drive 11M8 is only installed at the NONSTOP feeder of Preset presses. The servo-drive 11M8 positions the pile support plate at the feeder. The positioning of the pile support plate depends on the position of the toggle switch Auxiliary pile on/off.
Toggle switch in position Off ON OFF Main pile control activated. The pushbuttons Auxiliary pile centering control the servodrive 11M8. Maximum positioning range: 30 mm in relation to the centre of the feeder. Plus button Minus button = movement towards D.S. = movement towards O.S.
Pushbuttons Auxiliary pile centering Plus button Minus button
The pile support frame and pile support plate can move max. 35 mm in the same direction together. When the pile support plate reaches the position switch 11S39 Pile support plate limitation while moving down, the electronic control system positions the pile support plate (through 11M8) the pile support frame (through 11M9)
Pushbutton Main pile down
relative to the centre of the feeder. During positioning, the function Main pile down is blocked. Approx. 30 seconds after the beginning of positioning, the electronic control system releases the function Main pile down again.
31
Pile merging
Toggle switch in position ON ON OFF Auxiliary pile control activated. The pushbuttons Auxiliary pile centering control the servodrive 11M8. Maximum positioning range: 30 mm in relation to the centre of the feeder. Plus button Minus button = movement towards D.S. = movement towards O.S.
Pushbuttons Main pile centering Plus button Minus button
The pile support frame and pile support plate can move max. 35 mm in the same direction together. During the downward movement, the servo-drive 11M8 positions
Pushbutton Main pile down
the pile support plate
relative to the centre of the feeder. As soon as the pile support plate lies on the ground (position switch 11S34 actuated), this function is stopped. The pile support plate cannot be positioned anymore. NON-STOP mode: When pile centering is active, the electronic control system regulates the pile support frame. To ensure that the pile support plate keeps its position on the floor, it is displaced by the same value as the pile support frame, however in the opposite direction.
32
Pile merging
11M8
Operator side
Technical data
33
Pile merging
X10 X5
SSR
SSR X10
X11 X12 X3 X13 X14 X4
SSR X13
11 11LVT1 2SSM1: X1
X3 X4
X2 X1 X5
2SSM1: X3
2SSM1
11M8: X1
3 2
4 5 1
11M8
Servo-drive 11M8
11M8:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 2SSM 1 X5: B1 X5: B2 X5: B3 X5: B4 X5: B5 SSR X10: X10: X13: X13:
+ 10V 0V
X1: X1: X3: X3:
3 4 8 7
B12 D12 8 7
X3: 6
X13: 6
34
Pile merging
1
1
ON OFF
2
2
07
2048 2
Set the toggle switch Auxiliary pile ON/OFF to OFF. Select the service display SSK1. Bring the pile support frame into its central position (set to 20482 inc).
Remove the servo-drive Adjustment of pile support plate 11M8.
Frame .
Guide Set the distance between the pile support plate guide and the pile support frame to 31.5 mm. 35
Pile merging
4
4)
06
2048 2 1M8: X1
Mount the servo-drive on the motor baseplate. Fit the gear wheel. Connect plug 11M8: X1. Set to 2048 inc.
Tighten the chain.
36
Pile merging

Servo-drive Adjustment of pile support plate 11M8
Condition: The pile support frame is positioned in the centre of the feeder.
Off-centre position: 00 Input 30 mm Incremental value 3461 " 23 inc 634 " 23 inc
Service display Values, incremental values servo-drives
+ 30 mm
37
Pile merging
38
Suction head height control
11M5 Suction head height adjustment

The servo-drive 11M5 positions the suction head vertically. The servo-drive can be controlled with the pushbuttons Suction head height. Pushbuttons Suction head height Plus button Minus button Actuation of one of the pushbuttons: suction head positions vertically, positioning range +/ 20 mm, indication of position in feeder MID. = suction head moves up (+ 20 mm). = suction head moves down ( 20 mm).
Plus button Minus button
39
11M5
Preset feeder
Technical data
40
X10 X5
SSR
SSR X10
X11 X12 X3 X13 X14 X4
SSR X12
11 11LVT1 1SSM1: X1
X3 X4
X2 X1 X5
1SSM1: X4
1SSM1
11M5: X1
3 2
4 5 1
11M5
Servo-drive 11M5
+ 10V 0V
X2: X2: X4: X4:
1 2 3 4
B6 D6 3 4
X4: 5
X12: 5
41
20 mm
Remove the servo-drive Suction head height adjustment 11M5.
Set the distance (20 mm) at the suction head guide rail.
3
4)
03
2456 2
11M5: X1
42
Connect plug 11M5: X1. Set to 2456 2 inc.

Servo-drive Suction head height adjustment 11M5 Input 20 + 20 Incremental value 880 " 4 inc 3215 " 4 inc
Service display Values, incremental values servodrives
43
44
Size adjustment
Block diagram
Size adjustment
Block diagram
Adjustment of format wheels 11M4 M Suction head/ format adjustment 11M6 M Pile stop D.S. 11M11 SSM M Pile stop O.S. 11M12 SSM M Sheet jogger D.S. 12M6 SSM M Sheet jogger O.S. 12M7 SSM M SSM M SSM M Cover guide height adjustment 1M4 SSM M Adjustment of printing pressure 1...nM5 Sheet slowdown/ format adjustment 12M5 M Adjustment of pull lay D.S. 1M7 SSM SSM M Adjustment of pull lay O.S. 1M8
SSM
SSM
SSK1/2/3
Displays
SAK
ESK
SVM
MID11
MID12
REK1
REK386
DSK
DNK
ZID
Legend:
Data line
Control lines
Block diagram size adjustment

45
Size adjustment
Block diagram
Command: PRESETTING Attention:

To avoid damage to the press, make sure nothing is in the way of the following servo-drives when the command Presetting is active: suction head, pile stops D.S. and O.S., format wheels, pull lays D.S. and O.S., sheet slowdown, sheet joggers D.S. and O.S.
Selecting the command

As a result of the inputs in this command mode, various servo-drives on the press are positioned automatically.
1020
After command enabling the electronic control system positions the following servo-drives: On the feeder
720 1.00
Suction head/format adjustment Pile stops D.S. and O.S. Adjustment of format wheels
Command in control console display ZID
On printing unit / coating unit Adjustment of pull lays D.S. and O.S. Cover guide height adjustment Adjustment of printing pressure
On the delivery Sheet slowdown/format adjustment Sheet joggers D.S. and O.S.
46
Size adjustment
11M4 Adjustment of format wheels

The servo-drive 11M4 positions the format wheels on the feeder. Automatic positioning Automatic positioning: is effected through the command Presetting; depends on inputs into CPTRONIC, such as: paper length, paper thickness, front lay adjustment (smallest value); depends on inputs into CPC1-04, such as: coating unit register. Positioning accuracy: 0.25 mm. End of automatic positioning: Pushbuttons Format wheels Plus button Minus button when the new desired position has been reached, when one of the pushbuttons Format wheels is actuated.
Manual positioning Actuation of one of the pushbuttons Format wheels: the format wheels are repositioned irrespective of the preset format, indication of the position in the feeder MID, when the command Presetting is active, automatic positioning is stopped immediately. = movement towards maximum format.
Plus button
Minus button = movement towards minimum format.
Fault message in the ZID

Adjustment of format wheels The symbol appears in the display Feeder/Warning. The symbol appears: during positioning while the press is on Run.
The symbol goes off: when positioning is over and the press is on Run, when one of the pushbuttons Format wheels is actuated and the press is on Run.
47
Size adjustment
11M4
Operator side
Technical data
48
Size adjustment
X10 X5
SSR
SSR X10
X11
X12 X3 X4
SSR X11
X13 X14
11 11LVT1 1SSM1: X1
X3 X4
X2 X1 X5
1SSM1: X3
1SSM1
11M4: X1
3 2
4 5 1
11M4
Servo-drive 11M4
11M4:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: B1 X5: B2 X5: B3 X5: B4 X5: B5 SSR X10: B4 X10: D4 X11: 8 X11: 7 X11: 6
+ 10V 0V
X1: X1: X3: X3:
3 4 8 7
X3: 6
49
Size adjustment
9.00 9.00
1020
720 1.00
Set the print-free margin to 9 mm.
Enter the paper thickness Enter the paper width Enter the paper length Enable the command Paper
(1.0 mm). (1020 mm). (720 mm). size adjustment.
Remove the servo-drive Adjustment of format wheels 11M4.
Bring the format wheels into their central position.
50
Size adjustment
. Format wheels
. Sheet of paper
Set the distance ( 722.5 mm ) between the front lays and format wheels.
02
3871 2
11M4: X1
Attach the gear wheel to the motor shaft. Connect plug 11M4: X1. Set to 3871 " 2 inc.
51
Size adjustment

Servo-drive Adjustment of format wheels 11M4
SM102: Print-free margin: 10.00 mm Paper length: Paper thickness: 720 mm 1.50 mm 8.00 mm 280 mm 1.50 mm 288 2 inc
Incremental value: 3876 2 inc CD102:
Print-free margin: 10.00 mm Paper length: Paper thickness: 720 mm 2.00 mm
8.00 mm 280 mm 2.00 mm 288 2 inc
Incremental value: 3886 2 inc
52
Size adjustment
11M6 Suction head/format adjustment

The servo-drive 11M6 positions the suction head to the entered paper length. Automatic positioning Automatic positioning: is effected through the command Presetting; depends on the entered sheet length.
Positioning accuracy: 0.30 mm. Automatic positioning range: max. 720 mm, min. 500 mm because of danger of collision with the lateral pile stops, in the case of sheet lengths below 500 mm, the suction head stops at the lower limit (500 mm), manual positioning if the sheets are shorter (less than 500 mm).
End of automatic positioning: when the new desired position has been reached, when the lower limit (500 mm) of the positioning range has been reached, when one of the pushbuttons Suction head format is actuated.
Manual positioning Pushbuttons Suction head format Plus button Minus button Actuation of one of the pushbuttons Suction head format: the servo-drive Suction head/ format adjustment 11M6 is controlled, the suction head positions irrespective of the preset format, indication of the position in the feeder MID, automatic positioning is stopped immediately. = to max. 730 mm.
Plus button
Minus button = to min. 280 mm.
53
Size adjustment

Suction head/format adjustment The symbol appears in the display Feeder/Warning. The symbol appears: during positioning while the press is on Run, when the lower limit is reached during automatic positioning.
The symbol goes off: when positioning is over and the press is on Run, when one of the pushbuttons Suction head format is actuated and the press is on Run.
54
Size adjustment
11M6
Preset feeder
Technical data
55
Size adjustment
X10 X5
SSR
SSR X10
X11
X12 X3 X4
SSR X12
X13 X14
11 11LVT1 1SSM1: X2
X3 X4
X2 X1 X5
1SSM1: X4
1SSM1
11M6: X1
3 2
4 5 1
11M6
Servo-drive 11M6
11M6X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: D1 X5: D2 X5: D3 X5: D4 X5: D5 SSR X10: X10: X12: X12:
+ 10V 0V
X2: X2: X4: X4:
3 4 8 7
B8 D8 8 7
X4: 6
X12: 6
56
Size adjustment
Front sheet stop
Governor foot Marking
3 2
Remove the servo-drive Suction head/format adjustment 11M6. Set the distance between the front sheet stop and the marking on the governor foot to 720 mm.
Note: To compensate for the backlash, the 720 mm must be set from the max. possible distance.
2
4)
11M6: X1
04
462 2
11M6: X1 Connect plug 11M6: X1. Set to 462 2 inc. 57
Size adjustment

Servo-drive Suction head/format adjustment 11M6 Incremental value 3634 " 2 inc 389 " 2 inc
Paper length 280 mm 730 mm
58
Size adjustment
11M11/11M12 Pile stops D.S./O.S.

The servo-drive 11M11 positions the pile stop on the D.S. The servo-drive 11M12 positions the pile stop on the O.S. Automatic positioning Automatic positioning: is effected through the command Presetting, depends on the inputs into CPTRONIC, such as: sheet width, off-centre position, preselected pull direction. Positioning accuracy: 0.3 mm. End of automatic positioning: when the new desired position has been reached, when one of the pushbuttons Pile stops larger format or Pile stops smaller format is actuated.
Manual positioning Pushbutton Pile stops larger format Actuation of pushbutton Pile stops larger format: Control of servo-drives Pile stop D.S. 11M11 and Pile stop O.S. 11M12, irrespective of the preset format, the pile stops position to a larger format.
Actuation of pushbutton Pile stops smaller format: Pushbutton Pile stops smaller format Control of servo-drives Pile stop D.S. 11M11 and Pile stop O.S. 11M12, irrespective of the preset format, the pile stops position to a smaller format.
Actuation of one of the pushbuttons: indication of the position in the feeder MID, the off-centre position can be up to 50 mm, automatic positioning is stopped immediately. = to max. 1040 mm.
Plus button
59
Size adjustment

Pile stop D.S. The symbols appear in the display Feeder/Warning. The symbols appear: Pile stop O.S. during positioning while the press is on Run.
The symbols go off: when positioning is over and the press is on Run, when one of the pushbuttons Pile stop D.S. or Pile stop O.S. is actuated and the press is on Run.
Prepiling
This function can only be activated in the preselection display. To inactivate it, press the corresponding button once more.
The lateral pile stops move together when the pile support plate moving down is stopped by means of the button Pile stop and the pile support plate is in front of the position switch Pile support plate limitation 11S39.
The distance between the stops is: sheet width entered + 5 mm O.S., + 5 mm D.S. The 5 mm O.S. + 5 mm D.S. are added to the entered value by the electronic control system. Preselection/coarse display, prepiling The lateral pile stops move apart when the pile is raised.
The distance between the stops is: sheet width entered + 25 mm O.S., + 25 mm D.S. The 25 mm O.S. + 25 mm D.S. are added to the entered value by the electronic control system.
Symbol Prepiling
60
Size adjustment
11M12 11M11
Operator side
Technical data
61
Size adjustment
Interconnection diagram 11M11

X10 X5
SSR
SSR X10
X15 X16 X3 X17 X18 X4
SSR X15
11 3SSM2: X1 11LVT1
Backplane of servo-drive plug-in unit SSR
3SSM1: X2
X2 X1
X3
3SSM2
11M11: X1
3 2
4 5 1
11M11
Servo-drive 11M11
11M11:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 3SSM 2 X5: A1 X5: A2 X5: A3 X5: A4 X5: A5 SSR X10: X10: X15: X15:
+ 10V 0V
X1: X1: X3: X3:
1 2 3 4
B18 D18 3 4
X3: 5
X15: 5
62
Size adjustment

X10 X5
SSR
SSR X10
X15 X16
SSR X15
X17 X18
X3
X4
11 3SSM2: X1 11LVT1
3SSM2: X2
X2 X1
X3
3SSM2

11M12: X1
3 2
4 5 1
11M12
Servo-drive 11M12
+ 10V 0V
X1: X1: X2: X2:
3 4 8 7
B20 D20 8 7
X2: 6
X15: 6
63
Size adjustment
11M11

Remove the servo-drive Pile stop D.S. 11M11 or Pile stop O.S. 11M12.
11M12
D.S.
O.S. O.S. D.S.
D.S./O.S. = 180 mm Set the distance between the side frame D.S. (or side frame O.S.) and the pile stop D.S. (or pile stop O.S.) to 180 mm.
64
Size adjustment
09
3015 2
10
1072 2 11M11: X1 11M12: X1
Fit the motor baseplate and gear wheel. Connect plug 11M11: X1 (or 11M12: X1). 11M11 (D.S.) = set to 30152 inc. 11M12 (O.S.) = set to 10722 inc.
1020
720 1,00
Select the command Presetting. Press the button Input. The servo-drives position to the displayed format.
65
Size adjustment
Checking the operating range 1 2

Servo-drive Pile stop D.S. 11M11 Servo-drive Pile stop O.S. 11M12
Position the pile stops manually to the maximum format (press the button Pile stops larger format). Incremental value for 11M11: 3231 2 inc Incremental value for 11M12: 856 2 inc Position the pile stops manually to the minimum format (press the button Pile stops smaller format).
Incremental value for 11M11: 783 2 inc Incremental value for 11M12: 3304 2 inc
66
Size adjustment
1M4 Cover guide height adjustment

For cover guide height adjustment a servo-drive is installed on the operator side of the 1st printing unit. With this servo-drive the cover guides (gripper opening) on the transfer gripper are adjusted. By means of a mechanical device (eccentric bush) gripper opening can be adjusted within a range from 0.1 mm to 1.9 mm.
Positioning
The new desired position is always approached from the direction of the widest gripper opening (1.9 mm). Actual position Reversal point Example 1: The new desired position is larger than the actual position. When the new desired position has been entered, the servo-drive first positions to the reversal point 1 and then to the new desired position 2. Example 2: New desired position Actual position The new desired position is smaller than the actual position. When the new desired position has been entered, the servo-drive moves to the new desired position.
New desired position 1.9mm
Example 1
1.9mm
Example 2
Automatic positioning Entering the paper thickness When the command Presetting has been enabled, the electronic control system positions the cover guides on CD102 and SM102 (only with REK386): to twice the paper thickness entered plus 0.1 mm (max. 1.9 mm),
SM74 and SM52: to twice the paper thickness entered (max. 1.9 mm).
67
Size adjustment
Manual positioning After actuating the button Cover guide height adjustment, the operator can make adjustments with the left-hand +/ buttons.
Indication of the present value of the cover guide height adjustment
Actual value/coarse display, cover guide height adjustment
68
Size adjustment
Printing unit 1 and feeder
Technical data
69
Size adjustment
X10 X5
SSR
SSR X20
X21
X22 X3 X4
X23
X24
SSR X23
1 2SSM1: X2
X3 X1 X2 X5 X4

1LVT1
2SSM1: X4
2SSM1
1M4: X1
1M4
Servo-drive 1M4
1M4:X1 1 2 4 5 6 2SSM 1 X5: D1 X5: D2 X5: D3 X5: D4 X5: D5 SSR X20: X20: X23: X23:
+ 10V 0V
X2: X2: X4: X4:
3 4 8 7
B12 D12 8 7
X4: 6
X23: 6
70
Size adjustment
Removal and installation of motor
1
1
0 1
2
15Q66

1M4
1M4
1M4
71
Size adjustment
brown blue
red
1 2
2
black
1M4

1 2
3
1M4 0 1
15Q66
72
Size adjustment
Removal and installation of potentiometer
1
2
310 . 0
3 1
0 1
15Q66
1M4
73
Size adjustment
defective
new
5
1 M4: X1
2 1
0 blue black red 15Q66 1
beige yellow black
4 5 6
08
1016 4
74
Size adjustment
1M4
75
Size adjustment
Checking the operating range

Preset version:
Servo-drive Cover guide height adjustment 1M4 Paper thickness 0.01 mm 1.00 mm Incremental value 676 " 4 inc 3260 " 4 inc

Standard version:
Servo-drive Cover guide height adjustment 1M4 Paper thickness 0.01 mm 1.00 mm Incremental value 676 " 4 inc 3260 " 4 inc
76
Size adjustment
1M2/1M3 Print-free margin D.S./O.S.

Running direction of paper The print-free margin on the sheet is adjusted by means of two servo-drives. These servo-drives change the position of the front lay stop. The front lays are fitted on a shaft which, for adjustment of the print-free margin, can be adjusted parallel or at an angle (to the feed table). For this purpose, one servo-drive is installed on the drive side and one on the operator side. With these two servo-drives the front lays can be influenced in such a way that the print-free margin measures between 10 mm and 12 mm. The adjustment is made at the central control console.
Front lays 2mm Adjustment of front lays to change the "Printfree margin"
Graphical representation in the ZID

Graphical representation Print-free margin Minimum value Maximum value Current value D.S. Current value O.S.
Actual value/fine display Print-free margin

Print-free margin O.S.
To adjust the print-free margin, press the corresponding function button. Then make the adjustment within a range from 10.0 mm to 12.0 mm by means of the left-hand +/ buttons.
Print-free margin D.S. and O.S. Print-free margin D.S.
77
Size adjustment
1M2 = D.S. 1M3 = O.S.
Technical data
78
Size adjustment
X10 X5
SSR
SSR X10
X15 X16 X3 X17 X18 X4
SSR X18
1 1LVT1
X3 X4

1SSM1: X1
1SSM1 X3
X2 X1 X5
1SSM 1
Servo-drive distributor module SSM 1
X3 X1
SSM3
X2
X3 X1
SSM3
X2
1M2
1M3
Servo-drives 1M2 and 1M3

1M3 SSM3 X3: 1 X3: 2 X3: 3 X3: 4 X3: 5
+ 10V 0V
1M2 SSM3 X3: 1 X3: 2 X3: 3 X3: 4 X3: 5
SSM 1 X5: A1 X5: A2 X5: A3 X5: A4
X1: X1: X3: X3:
1 2 3 4
SSR X10: X10: X18: X18:
B30 D30 3 4
SSM1 X5: B1 X5: B2 X5: B3 X5: B4
X1: X1: X3: X3:
3 4 8 7
SSR X10: B32 X10: D32 X18: 8 X18: 7 X18: 6
X5: A5 X3: 5
X18: 5
X5: B5 X3:6
79
Size adjustment
1
1
0 1
4
15Q66 1M2 (1M3)
24
1
1M2 (1M3)
2 3
24
80
Size adjustment
1
1
216 . 0
2
0 1 15Q66
3
1M2 (1M3)
2 1
24
2 1
81
Size adjustment
4
2
. Pull rail
1
Front lay
defective
new
6
2
0 1 15Q66
82
Size adjustment
05
1M2 2048 6
06
1M3 2048 6
1
1M2 (1M3)
224 3
83
Size adjustment

Preset version:
1 2
Servo-drive Print-free margin D.S. 1M2 Servo-drive Print-free margin O.S. 1M3 Input 8 mm 10 mm Incremental value 3850 " 4 inc 246 " 4 inc

Standard version:
1 2
Servo-drive Print-free margin D.S. 1M2 Servo-drive Print-free margin O.S. 1M3 Input 8 mm 10 mm Incremental value 3850 " 4 inc 246 " 4 inc
84
Size adjustment
1...nM5 Adjustment of printing pressure

The servo-drive Adjustment of printing pressure changes the gap between blanket cylinder and impression cylinder. The rotation of the drive is transmitted to the blanket cylinder via a worm gear and a gear segment. The operator thus influences the pressure exerted on the print sheet during the printing process. Automatic positioning When the paper thickness is entered under the command Presetting, the servo-drive automatically positions to the value: paper thickness 0.1 mm = pressure.
Examples: 0.07 0.1 = 0.50 0.1 =
0.03 ! 0.03 x 1 = 0.03 0.40 ! 0.40 x 1 = 0.40
The correction factor (1) ensures that the result is shown correctly in the Actual value display.
1 2 3
Paper thickness entered Symbol for the paper thickness entered Upper adjustment limit for the printing pressure (max. gap between blanket cylinder and impression cylinder). SM102 = 0.75 mm, CD102, CU on SM102 = 1.20 mm. Graphical representation of the printing pressure Present value of the printing pressure 0 position of the printing pressure Lower adjustment limit (0.3 mm) for the printing pressure (min. gap between blanket cylinder and impression cylinder)
4
Explanation of the display
5 6 7
85
Size adjustment
Manual positioning

Graphical representation of the adjustment of the printing pressure The servo-drive can be positioned manually with the right-hand +/ buttons. If no printing unit has been selected in the Printing unit/actual value display, all drives respond. If only one drive is to be positioned, the corresponding printing unit must be selected before.
Actual value/coarse display, adjustment of printing pressure
Note: The software limits the maximum pressure to 0.55. The max. pressure is composed of
the automatic positioning value (0.10) and the manual positioning value (max. 0.45).
86
Size adjustment
1...nM5
L-M5
1...8M5
Operator side
Technical data
87
Size adjustment
Interconnection diagram for printing unit 1...nM5

PU1, PU3, PU5 PU2, PU4 PU6, PU7, PU8 PU1 PU2 PU3 PU4 PU5 PU6 PU7 PU8 = = = = = = = = SSR SSR SSR SSR SSR SSR SSR SSR X24 X25 X26 X27 X28 X31 X32 X33
X5
SSR X20 SSR X30
X20
X30
SSR
X25
X26 X3 X4
X27
X28
1...8
1SSM2: X1
1...8LVT1
1...8M5: X1
1SSM2 X2
X1 X2 X3
1...8M5: X1
1SSM2
Servo-drive 1...8M5 Servo-drive distributor module 1SSM2
1...8M5:X1 1SSM 2 + 10V 0V 1 2 4 5 X3: X3: X3: X3: A1 A2 A3 A4 X1: X1: X2: X2: 1 2 3 4
SSR PU1 X20: B14 X20: B14 X24: 3 X24: 4 X24: 5 SSR PU5 X20: B30 X20: D30 X28: 3 X28: 4 X28: 5
PU2 X20: X20: X25: X25:
B18 D18 3 4
PU3 X20: X20: X26: X26:
B22 D22 3 4
PU4 X20: X20: X27: X27:
B26 D26 3 4
6 X3: A5 1...8M5:X1 1SSM 2 1 2 4 5 6 X3: X3: X3: X3: A1 A2 A3 A4
X2: 5
X25: 5 PU6 X30: X30: X31: X31:
X26: 5 PU7 X30: X30: X32: X32:
X27: 5 PU8 X30: X30: X32: X32:
+ 10V 0V
X1: X1: X2: X2:
1 2 3 4
B2 D2 3 4
B6 D6 3 4
B10 D10 3 4
X3: A5
X2: 5
X31: 5
X32: 5
X32: 5
88
Size adjustment
Interconnection diagram for coating unit 2...nM5

PU3, PU5 PU2, PU4 PU6, PU7, PU8 PU2 PU3 PU4 PU5 PU6 PU7 PU8 PU9 = = = = = = = = SSR SSR SSR SSR SSR SSR SSR SSR X25 X26 X27 X28 X31 X32 X33 X34
X5
SSR X20 SSR X30

X25 X26
X20
X30
SSR
X3 X27 X28
X4

2..9 1SSM2: X1 2...9LVT1
2...9M5: X1
1SSM2 X2
X1 X2 X3
2...9M5: X1
Servo-drive 2...9M5
1SSM2
Servo-drive control module 1SSM2

2...9M5:X1 1SSM 2 + 10V 0V 1 2 4 5 X3: X3: X3: X3: A1 A2 A3 A4 X1: X1: X2: X2: 1 2 3 4 SSR PU2 X20: X20: X25: X25: X25: SSR PU6 X30: X30: X31: X31:
B18 D18 3 4 5
PU3 X20: X20: X26: X26:
B22 D22 3 4
PU4 X20: X20: X27: X27:
B26 D26 3 4
PU5 X20: X20: X28: X28:
B30 D30 3 4
6 X3: A5 2...9M5:X1 1SSM 2 1 2 4 5 6 X3: X3: X3: X3: A1 A2 A3 A4
X2: 5
X26: 5 PU7 X30: X30: X32: X32:
X27: 5 PU8 X30: X30: X32: X32:
X28: 5 PU9 X30: X30: X34: X34:
+ 10V 0V
X1: X1: X2: X2:
1 2 3 4
B2 D2 3 4
B6 D6 3 4
B10 D10 3 4
B14 D14 3 4
X3: A5
X2: 5
X31: 5
X32: 5
X32: 5
X34: 5
89
Size adjustment
1
1
0 1
1...8M5 X1
Switch off the press. Open the guard on the O.S.
Disconnect 1...8M5 X1.
4
1
2 3
90
Loosen the fixing bolts on the motor.
Remove the defective motor.
Size adjustment
3 2 1
Install the new motor.
Tighten the fixing bolts.
7
1
brown 1 2 blue blue brown
2
0 1
1...8M5 X1
... 0.30 ...-1.20
Connect the motor. Start the press.
The value on the display changes in positive direction (0.30). The value on the display changes in negative direction (1.20).
91
Size adjustment
1
1
0 1
1...8M5 X1
Switch off the press. Open the guard on the O.S.
Disconnect the potentiometer from 1...8M5 X1.
1
Turn the mechanism to the 0 value of the scale by means of the hexagon.
Loosen the stud on the gear wheel. Pull the gear wheel off the potentiometer. Loosen the nut on the potentiometer. Replace the potentiometer.
92
Size adjustment
1...8M5 X1
1
blue black red 4 5 6 beige yellow black
2
0 1
Connect the new potentiometer. Start the press.
Select service display 2.
1
PU1 ... PUn = 1234 8 inc
2 3 4
Set the potentiometer to 1234 8 inc.
Fasten the potentiometer. Put the gear wheel back in place and fasten it with the stud.
93
Size adjustment
... 0.30
Check the operating range: 0.30 = 616 8 inc
10
...-1.20
Check the operating range: 1.20 = 3550 8 inc
94
Size adjustment

Preset version
Servo-drive Adjustment of printing pressure 1M5 Input + 0.30 1.20 Incremental value 616 " 8 inc 3550 " 8 inc
95
Size adjustment
1M7/1M8 Adjustment of pull lays

The servo-drive 1M7 positions the pull lay on the D.S. The servo-drive 1M8 positions the pull lay on the O.S.
Automatic positioning
Automatic positioning: is effected through the command Presetting, depends on the inputs into CPTRONIC, such as sheet width, off-centre position, pull direction, precision adjustment of pull lay.
After actuation of the input button, the electronic control system positions: the pull lay in use to the sheet width entered, the pull lay not in use 15 mm outside the entered sheet width.
1M7 1M8
A pneumatic clamping mechanism locks the pull lay in position. The pneumatic clamping mechanism opens after actuation of the input button for the command Presetting. The pneumatic clamping mechanism closes: when the pull lay is in the new position, if the new position is not reached in less than 4 minutes (fault message 7FFF in Dyn-test).
The electronic control system determines the position of each pull lay via two potentiometers: Potentiometer for precision adjustment during coarse positioning through the potentiometer in the servo-drive, during precision positioning through the potentiometer near the servo-drive.
Servo-drives Adjustment of pull lays
96
Size adjustment
Precision adjustment of pull lay
Symbol and indication of the current value for the precision adjustment of the pull lay
The symbol shows the active pull lay: Arrow pointing up = pull lay on D.S. active
Arrow pointing down = pull lay on O.S. active With the right-hand +/ buttons the active pull lay can be precision-adjusted. Adjustment is possible within a range of 5 mm in relation to the preset format.
Actual value/coarse display, Adjustment of pull lays
97
Size adjustment
1M7 1M8
1Y47
Potentiometer for precision adjustment
Operator side
Technical data
98
Size adjustment

X20 X5
SSR
SSR X20
X21 X22 X3 X23 X24 X4
SSR X21
1 11LVT1 1SSM1: X2
X3 X4
X2 X1 X5
1SSM1: X4
1SSM1

3 2 4 5 1
1M7: X1
1M7
Servo-drive 1M7 (with potentiometer for coarse adjustment)

+ 10V 0V Pin Pin Pin Pin 1 2 3 4 X5: X5: X5: X5: C1 C2 C3 C4 X2: X2: X4: X4: 1 2 3 4 X20: X20: X21: X21: B2 D2 3 4
Potentiometer (for precision adjustment)
X5: D3 X5: D4 X5: D5
X4: 8 X4: 7 X4: 6
X21: 8 X21: 7 X21: 6
Pin 5
X5: C5
X4: 5
X21: 5
99
Size adjustment

X20 X5
SSR
SSR X20
X21
X22 X3 X4
SSR X22
X23 X24
1 11LVT1 2SSM1: X1
X3 X4
X2 X1 X5
2SSM1: X3
2SSM1

3 2 4 5 1
1M8: X1
1M8
Servo-drive 1M8 (with potentiometer for coarse adjustment)

+ 10V 0V Pin Pin Pin Pin 1 2 3 4 X5: X5: X5: X5: A1 A2 A3 A4 X1: X1: X3: X3: 1 2 3 4 X20: X20: X22: X22: B6 D6 3 4
Potentiometer (for precision adjustment)
X5: B3 X5: B4 X5: B5
X3: 8 X3: 7 X3: 6
X22: 8 X22: 7 X22: 6
Pin 5
X5: A5
X3: 5
X22: 5
100
Size adjustment
1Y47
Remove the servo-drive Adjustment of pull lay D.S. 1M7 (or Adjustment of pull lay O.S. 1M8).
Actuate the solenoid valve 1Y47 manually and hold it in this position (pneumatic clamping mechanism is open).
3
2 1
O.S.
1 3
D.S.
2 3
Set the distance between the side frame D.S. (or O.S.) and the inside of the pull lay stop to 55 mm. Let go of the solenoid valve 1Y47.
Note: Because of the backlash, the distance between the side frame and pull lay stop must first be smaller than 55 mm. Then the correct value of 55 mm must be set.
101
Size adjustment
01
3055 2
03
3055 2
1M7: X1 1M8: X1 Fit the gear wheel. Connect plug 1M7: X1 (or 1M8: X1). 1M7 (D.S.) = set to 30552 inc. 1M8 (O.S.) = set to 30552 inc.
1020
1,00
720
102
Size adjustment

Servo-drive Adjustment of pull lay D.S. 1M7 Servo-drive Adjustment of pull lay O.S. 1M8
Only compare the new servo-drive with the indicated values. Maximum sheet width Precision adjustment: 0.00 mm (2048 inc) Sheet width: 1040 mm Off-centre position: 00
For 1M7: pulling towards D.S. Incremental value: 3155 4 inc For 1M8: pulling towards O.S. Incremental value: 3155 4 inc Minimum sheet width Precision adjustment: 0.00 mm (2048 inc) Sheet width: 420 mm Off-centre position: 00 For 1M7: pulling towards D.S. Incremental value: 933 4 inc For 1M8: pulling towards O.S. Incremental value: 933 4 inc
103
Size adjustment
12M5 Sheet slowdown/format adjustment

The servo-drive 12M5 positions the sheet slowdown at the delivery to the entered sheet length. Automatic positioning Automatic positioning: is effected through the command Presetting, depends on the entered sheet length.
Positioning accuracy: 0.50 mm. Positioning range: max. 720 mm, min. 500 mm (because of danger of collision with the sheet joggers), in the case of sheet lengths below 500 mm, the suction head stops at the lower limit (500 mm), manual positioning if the sheets are shorter (less than 500 mm).
End of automatic positioning: when the new desired position has been reached, when the lower limit (500 mm) of the positioning range has been reached, when one of the pushbuttons Sheet slowdown format is actuated.
Manual positioning Pushbuttons Sheet slowdown format Plus button Minus button Actuation of one of the pushbuttons Sheet slowdown format: the sheet slowdown positions irrespective of the preset format, indication of the position in the delivery MID, automatic positioning is stopped immediately. = to max. 730 mm.
Plus button
104
Size adjustment

Sheet slowdown/format adjustment The symbol appears in the display Delivery/ Warning. The symbol appears: during positioning while the press is on Run, when the lower limit is reached during automatic positioning.
The symbol goes off: when positioning is over and the press is on Run, when one of the pushbuttons Sheet slowdown format is actuated and the press is on Run.
105
Size adjustment
12M5
Operator side
Technical data
106
Size adjustment
X10 X5
SSR
SSR X10
X15 X16 X3 X17 X18 X4
SSR X16
12 12LVT1 1SSM1: X1
X3 X4
1SSM1: X3
X2 X1
X5
1SSM1

3 4 5 1
12M5: X1
12M5
Servo-drive 12M5
+ 10V 0V
X1: X1: X3: X3:
3 4 8 7
B24 D24 8 7
X3: 6
X16: 6
107
Size adjustment
Rear paper stop
3 2
Front paper stop
Set the distance between the front and rear paper stops to 600 mm.
Remove the servo-drive Sheet slowdown / format adjustment 12M5.
Note: To compensate for the backlash, the 600 mm must be set from the max. possible distance.
12M5: X1
12
1370
Coupling part 108 Mount the coupling part. Connect plug 12M5: X1. Set to 1370 inc.
Size adjustment

Servo-drive Sheet slowdown / format adjustment 12M5 Paper length Incremental value 280 mm 720 mm 730 mm 3540 " 3 inc 556 " 3 inc 498 " 3 inc
109
Size adjustment
12M6/12M7 Sheet joggers D.S./O.S.

The servo-drive 12M6 positions the sheet jogger on the D.S. The servo-drive 12M7 positions the sheet jogger on the O.S. Automatic positioning Automatic positioning: is effected through the command Presetting, depends on the inputs into CPTRONIC, such as: sheet width, off-centre position.
Positioning accuracy: 1.0 mm. End of automatic positioning: when the new desired position has been reached, when one of the pushbuttons Sheet jogger D.S. or Sheet jogger O.S. is actuated.
Manual positioning Pushbuttons Sheet jogger D.S. Plus button Minus button Pushbuttons Sheet jogger O.S. Plus button Minus button Actuation of one of the pushbuttons Sheet jogger D.S.: the servo-drive Sheet jogger D.S. 12M6 is controlled, the sheet jogger on the D.S. positions irrespective of the preset format.
Actuation of one of the pushbuttons Sheet jogger O.S.: the servo-drive Sheet jogger O.S. 12M7 is controlled, the sheet jogger on the O.S. positions irrespective of the preset format.
Actuation of one of the pushbuttons Sheet jogger: indication of the position in the delivery MID, the off-centre position can be up to 50 mm, automatic positioning is stopped immediately.
Plus button = to max. 1040 mm. Minus button = to min. 420 mm.
110
Size adjustment

Sheet jogger D.S. The symbols appear in the display Delivery/ Warning. The symbols appear: Sheet jogger O.S. during positioning while the press is on Run.
The symbols go off: when positioning is over and the press is on Run, when one of the pushbuttons Sheet jogger D.S. or Sheet jogger O.S. is actuated and the press is on Run.
111
Size adjustment
D.S. = 12M6 O.S. = 12M7
Delivery
Technical data
112
Size adjustment

X10 X5
SSR
SSR X10
X15 X16 X3 X17 X18 X4
SSR X17
12 12LVT1 1SSM1: X2
X3 X4
1SSM1: X4
X2 X1 X5
1SSM1

3 4 5 1
12M6: X1
12M6
Servo-drive 12M6
+ 10V 0V
X2: X2: X4: X4:
1 2 3 4
B26 D26 3 4
X4: 5
X17: 5
113
Size adjustment

X10 X5
SSR
SSR X10
X15 X16 X3 X17 X18 X4
SSR X17
12
12LVT1 1SSM1: X2
X3 X4
1SSM1: X4
X2 X1 X5
1SSM1

3 4 5 1
12M7: X1
12M7
Servo-drive 12M7
12M7:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: D1 X5: D2 X5: D3 X5: D4 X5: D5 SSR X10: X10: X17: X17:
+ 10V 0V
X2: X2: X4: X4:
3 4 8 7
B28 D28 8 7
X4: 6
X17: 6
114
Size adjustment
Cam follower
Control cam
Remove the servo-drive Sheet jogger D.S. 12M6 (or Sheet jogger O.S. 12M7).
Inch the press until the cam follower of the sheet jogger has reached the highest point of the control cam.
Set the distance between the sheet jogger D.S. (or O.S.) and the side frame D.S. (or O.S.) to 55 mm. 115
Size adjustment
4
4)
12M6: X1 12M7: X1
13
704 2
14
704 2
Fit the gear wheel. Connect plug 12M6: X1 (or 12M7: X1). 12M6 (D.S.) = set to 7042 inc. 12M7 (O.S.) = set to 7042 inc.
1020
720 1.00
116
Size adjustment

Servo-drive Sheet jogger D.S. 12M6 Servo-drive Sheet jogger O.S. 12M7
The indicated values are valid for both servodrives. Sheet width: 1040 mm Incremental value: 704 3 inc Sheet width: 420 mm Incremental value: 3392 3 inc
117
Size adjustment
118
Feeder pile control
Block diagrams
Feeder pile control

Block diagrams Block diagram (Preset)
Pile height
Switches and sensors
Controls
Safety circuit
SEK
EAK_11
Press control
REK2
ESK
Auxiliary drive control
A A A
HAK_01 B LTK500 BAK
C B B
HAK_02 B
STK1
Main pile
M 11M1
M 11M2
Auxiliary pile
Preset feeder with auxiliary pile
119
Feeder pile control
Block diagrams
Block diagram (Standard)
Pile height
Controls
Safety circuit
SEK
EAK_11
Press control
REK2
ESK
HAK_01 B
HAK_02 B
STK1
STK2
Main pile
M 11M1
M 11M2
Auxiliary pile
Standard feeder with auxiliary pile
120
Feeder pile control
Layout
Layout Overview
The pile control of the feeder is used to control the main pile and auxiliary pile. It consists of the following functional units: Press control: Detection and evaluation of input signals for controlling the pile drives Safety circuit: Detection and evaluation of safety signals for the emergency shutdown of pile drives Auxiliary drive control: Control of pile motors
The following components are part of the pile control: SEK Safety input board
EAK_11 Input/output board on board slot 11 (signal acquisition feeder) REK2 ESK Processor board on board slot 2 (press control) Input/output control board
HAK_01 Auxiliary drive board on board slot 1 HAK_02 Auxiliary drive board on board slot 2 STK1 STK2 BAK LTK500 Pile control board on board slot 1 Pile control board on board slot 2 Brake control board Power part board 500W
121
Feeder pile control
Layout
Press control
The press control detects the signals of the switches and sensors on the feeder via the inputs of EAK_11. REK2 evaluates these signals and generates control signals for the pile motors. The control signals for pile motors are passed on to the auxiliary drive control via the ESK. The ESK is provided with the following operation set for controlling the individual pile motors: REK2 ESK Auxiliary drive control Pile stop (pile height control off) Pile up (slow) Pile down (slow) Pile up, fast (at main pile only) Pile down, fast (at main pile only) Pile height control on Rack mode (parameter: rack height)
Inputs
EAK_11
Press control
Safety circuit
The SEK registers the signals of those switches on the feeder which are relevant to safety. It evaluates these signals and if necessary it generates control signals for the emergency shutdown of the pile drives. These control signals are directly passed on to the auxiliary drive control. The signals of the safety circuit always take priority over the signals of the press control. Auxiliary drive control The ESK is provided with the following operation set for controlling the individual pile motors: Pile drive enabled Pile up blocked Pile down blocked
Inputs
SEK
Safety circuit
122
Feeder pile control
Layout

The auxiliary drive control conditions the control signals of SEK and ESK and regulates the individual pile drives. Each drive is assigned with a control section (component of a HAK) and a power part (dependent on the motor used). Depending on the press version, the assignments listed in the following are possible - see also block diagrams. Control section HAK01 Part A HAK01 Part A HAK01 Part C
Safety circuit
Press control
HAK_01
HAK_02
LT
LT
Drive Main pile (Preset) Main pile (standard) Auxiliary pile
Power part BAK+LTK500 Part A STK1 Part A STK2 Part A
M 11M1
M 11M2
The signal of the governor foot for controlling the pile heights is conditioned in the power parts of the main pile and of the auxiliary pile. Both power parts pass the conditioned signal to the relevant control section. See chapter Control systems / auxiliary drive control for further information on auxiliary drive control.
123
Feeder pile control
Overview of components
Overview of components Preset feeder
11M1
11S56
11M2 11B35
11S34 11S37 11S31
11S65
11S32
11S36
11B33 11B11 11S39
Components on the Preset feeder
124
Feeder pile control
Standard feeder
11M1
11S33
11M2 11S34 11S37 11S36 11S32 11S65 11S31
11S35
11S39
Components on the standard feeder
125
Feeder pile control
Motors
Equipment Function with nonstop D D Preset without nonstop D Standard with nonstop D D without nonstop D Brushless motor Three-phase a.c. motor Remarks
11M1 11M1 11M2
Main pile drive (Preset) Main pile drive (standard) Auxiliary pile drive

Equipment 11B11 11S31 11S32 11S33 11B33 11S34 11B35 11S35 11S36 11S37 11S39 11S56 11S65 Function with nonstop D D D D D D D D D D D D D Preset without nonstop D D D D D Standard with without nonnonstop stop D D D D D D D D D D D D D D Remarks
Auxiliary pile detection Suction head limitation Upper pile safety Upper main pile limitation Upper main pile limitation Bottom main pile limitation Automatic pile transport Automatic pile transport Upper limitation of auxiliary pile Bottom limitation of auxiliary pile Pile support plate limitation Switching off the auxiliary pile Pile height control (governor foot)
D D
126
Feeder pile control
Function
Function Pile height control of main pile (Preset)

The automatic pile height control of the main pile on the feeder is activated as soon as one of the following conditions is met:
11S65 11B35
The sensor automatic pile transport (11B35) detects paper when raising the main pile (actuation of the button main pile up, 11S24) The press turns, the feeder is engaged and the sensor automatic pile transport (11B35) detects paper
Switching points of main pile height control

Pile height control
Governor foot is positioned vertically 11S65 detects too little paper Pile up (by the value set)
With the automatic pile height control, the pile is controlled so that the upper edge is always at the level of the governor foot (11S65) - with governor foot in vertical position. As soon as the sensor detects too little paper on the pile, the pile is moved upwards by a presettable height (the pile lift increment at the feeder can be adjusted between 0.5 mm and 2.5 mm on the ZID). The position of the governor foot can be altered by means of the suction head height control. The automatic pile height control on the feeder is stopped under the following circumstances: actuation of an emergency stop switch actuation of the suction head limitation switch (11S31) actuation of the upper pile safety switch (11S32) actuation of the upper main pile limitation switch (11B33) actuation of the upper auxiliary pile limitation switch (11S36) (only in case of non-stop) actuation of the pile stop button (11S26) actuation of the main pile down button (11S25) Sheeter in operation (extra accessory) The sensor automatic pile transport (11B35) does not detect any paper (only during the first 30 sheets in the closed loop control)
Sequence of main pile height control
127
Feeder pile control
Function
Automatic pile height control of main pile (standard)

The automatic main pile height control on the feeder is activated as soon as one of the following conditions is met:
11S65 11S35
The sensor automatic pile transport (11S35) detects paper when raising the main pile (actuation of the button main pile up, 11S24) The press turns, the feeder is engaged and the switch automatic pile transport (11S35) detects paper
Switching points of the automatic main pile height control

Automatic pile height control
Governor foot is positioned vertically 11S65 detects too little paper Pile up (by preset value)
The pile is controlled by the automatic pile height control so that its upper edge is always at the level of the governor foot (11S65) - with vertically positioned governor foot. As soon as the sensor detects too little paper on the pile, the pile is raised by the adjustable height (the pile lift increment on the feeder can be set between 0.5 mm and 2.5 on the ZID). The position of the governor foot can be adjusted (manually) via the suction head height control. The automatic pile height control on the feeder is stopped under the following circumstances: actuation of an emergency stop switch actuation of the suction head limitation switch (11S31) actuation of the upper pile safety (11S32) actuation of the upper main pile limitation switch (11S33) actuation of the upper auxiliary pile limitation switch (11S36) (only in case of non-stop) actuation of the pile stop button (11S26) actuation of the main pile down switch (11S25) sheeter in operation (extra accessory) The sensor automatic pile transport (11S35) does not detect any paper (only during the first 30 sheets in the closed-loop control)
Sequence of the automatic pile height control for the main pile
128
Feeder pile control
Function
Automatic pile height control of auxiliary pile

The automatic pile height control of auxiliary pile on the feeder is activated as soon as the toggle switch is in position auxiliary pile on (11S27) and the sensor/switch automatic pile transport (Preset: 11B35, standard: 11S35) detects paper. The pile is controlled by the automatic pile height control so that the upper edge of the pile is always at the level of the governor foot (11S65) - with governor foot positioned vertically. As soon as the sensor detects too little paper on the pile, the pile is raised by an adjustable height (the pile lift increment on the feeder can be adjusted between 0.5 mm and 2.5 mm on the control console display ZID). The position of the governor foot can be altered via the suction head height control.
11S65 11B35
Switching points of the automatic pile height control of auxiliary pile

Governor foot is positioned vertically 11S65 detects too little paper Pile up (by preset value)
The automatic pile height control at the feeder is stopped under the following circumstances: actuation of an emergency stop switch actuation of the suction head limitation button (11S31) actuation of the upper pile safety switch (11S32) actuation of the upper auxiliary pile limitation switch (11S36) actuation of the pile stop button (11S26) actuation of the auxiliary pile down button (11S29) unloading the auxiliary pile detection sensor (11B11) (only with Preset) sheeter in operation (extra accessory) The sensor automatic pile transport (11B35) does not detect any paper.
Sequence of the automatic pile height control for the auxiliary pile
129
Feeder pile control
Function
Transport of main pile

11S24
Main pile up The main pile can only be raised manually if the automatic pile height control of the main pile is not active. The upwards movement of the main pile is controlled via the button main pile up (11S24) on the feeder operation panel. If one of the following circumstances is met upon actuation of the button, the main pile moves upwards: The toggle switch (11S27) is in position auxiliary pile on The sensor auxiliary pile detector (11B11) is damped (only in case of non-stop with Preset) The toggle switch is in position auxiliary pile off (11S27) and the automatic pile transport (Preset: 11B35, standard: 11S35) detects no paper
11B33
fast
Switching points of main pile up

Main pile up
Permissible start condition 11S24 (keep pressed) Main pile up, fast Preset: 11B33 or 11B35 Standard: 11S33 or 11S35 Main pile stop
When the pile support plate reaches the upper main pile limitation (Preset: 11B33, standard: 11S33) or when the automatic pile transport (Preset: 11B35, standard: 11S35) detects paper, the transport of the main pile stops. The upwards movement of the main pile is interrupted under the following circumstances: actuation of an emergency stop switch actuation of the suction head limitation switch (11S31) actuation of the upper pile safety switch (11S32) actuation of the upper auxiliary pile limitation switch (11S36) (only in case of non-stop) actuation of the main pile down button (11S25) actuation of the pile stop button (11S26) sheeter in operation (extra accessory)
Sequence of main pile up
The pile transport can only be continued if the respective cause has been eliminated.
130
Feeder pile control
Function
Main pile down

11S25 11S26
The downward movement of the main pile is controlled via the button main pile down (11S25) on the feeder operation panel. The speed is changed (slow/fast) depending on the position of the main pile. The button main pile down (11S25) is furnished with a self-stopping mode. If the button is actuated, the main pile moves downwards at fast speed. When it reaches the pile support plate limitation (11S39), the main pile stops. In case of the preset version, the pile support plate is automatically centered in this position (maximum duration: 25 s). During this centering process, the control does not respond to the actuation of the main pile down button (11S25). If the main pile down button (11S25) is actuated again, the main pile (without self-stopping) moves further downwards at slow speed. When it reaches the bottom main pile limitation (11S34), the main pile stops. The downward movement of the main pile is interrupted if one of the following conditions is met: actuation of an emergency stop switch actuation of the lower end stop switch (11S34) actuation of the pile support plate limitation switch (11S39) actuation of the pile stop button (11S26) actuation of the main pile up button (11S24)
fast
11S39 slow 11S34
Switching points of main pile down

Main pile down
Permissible start condition 11S25 (self-stopping mode) Main pile down, fast 11S39 Preset: main pile stop and automatic centering of the pile support plate Standard: main pile stop 11S25 (no self-stopping mode) Main pile down, slow 11S34 Main pile stop
An interrupted pile transport can only be continued after elimination of the cause.
Sequence of main pile down and passing both speed ranges
131
Feeder pile control
Function
Transport of auxiliary pile

Preconditions The auxiliary pile can only be transported if the switch switching off the auxiliary pile (11S56) is clear. (Only with Preset) Auxiliary pile up
11S28
The auxiliary pile can only be moved up manually, if the automatic pile height control of the auxiliary pile is not active. The upwards movement of the auxiliary pile is controlled via the button auxiliary pile up (11S28) on the feeder operation panel. The auxiliary pile moves upwards at a constant speed. When it reaches the upper auxiliary pile limitation (11S36), the transport mechanism of the auxiliary pile stops. The upwards movement of the auxiliary pile is interrupted if one of the following conditions is met: actuation of an emergency stop switch actuation of the suction head limitation switch (11S31) actuation of the upper pile safety (11S32) actuation of the pile stop button (11S26) actuation of the auxiliary pile down button (11S29) sheeter is in operation (extra accessory)
11S36
fast
Switching points of auxiliary pile up

Auxiliary pile up
Permissible starting point 11S28 (keep pressed) Auxiliary pile up 11S36 Auxiliary pile stop
An interrupted pile transport can only be continued after the respective cause has been eliminated.
Sequence of auxiliary pile up
132
Feeder pile control
Function
Auxiliary pile down

11S29
The downwards movement of the auxiliary pile is controlled via the button auxiliary pile down (11S29) on the delivery operation panel. The auxiliary pile moves downwards at a constant speed. When it reaches the bottom auxiliary pile limitation (11S37), the transport mechanism of the auxiliary pile stops.
fast
The downward movement of the auxiliary pile is stopped if one of the following conditions is met:
11S37
actuation of an emergency stop switch actuation of the upper main pile limitation sensor (11B33) (only in case of Preset with non-stop) actuation of the pile stop button (11S26) actuation of the auxiliary pile up button (11S28) sheeter is in operation (extra accessory)
Switching points of auxiliary pile down

Auxiliary pile down
Permissible starting point 11S29 (keep pressed) Auxiliary pile down 11S37 Auxiliary pile stop
An interrupted pile transport can only be continued if the respective cause has been eliminated.
Sequence of auxiliary pile down
133
Feeder pile control
Function
Non-stop operation (Preset)

Preconditions The non-stop operation on the Preset feeder requires the following preconditions: The press is in production mode The toggle switch (11S27) is in position auxiliary pile off The non-stop bar is unhinged so that the switch switching off the auxiliary pile (11S56) is clear The non-stop bar is at the level of the pile board (starting position for inserting the support rods)
Basic function The non-stop operation on the Preset feeder consists of the following sub-steps: Transfer of pile: Inserting the support rods creates main and auxiliary pile. The auxiliary pile takes over the automatic pile height control Pile change: The (empty) main pile moves downwards. There it is loaded and moves back up to the auxiliary pile Pile merging: Main and auxiliary pile are merged by pulling out the support rods. The main pile takes over the automatic pile height control again.
134
Feeder pile control
Function
Main pile
Automatic pile height control of main pile on
Auxiliary pile
Automatic pile height control of auxiliary pile off
Inserting support rods
Inserting support rods 11S27 auxiliary pile on Auxiliary pile up, slow
Pile transfer
11B11 damped Automatic pile height control of main pile off Awaiting starting point Main pile down, fast 11S39 Main pile stop Centering main pile (automatically) 11S25 (no self-stopping mode) Main pile down, slow 11S34
11B11 damped Auxiliary pile stop Automatic pile height control of auxiliary pile on
Pile change
Main pile stop (loading) 11S24 Main pile up, fast
Main pile stop Aligning main pile (manually) 11S24 Main pile up, fast 11B11 not damped Automatic pile height control of main pile on 11S27 auxiliary pile off Automatic pile height control of auxiliary pile off Removing support rods Removing support rods 11S29 Auxiliary pile down 11S37 Auxiliary pile stop
Pile merging
Sequence of non-stop operation (Preset)

135
Feeder pile control
Function
Pile transfer The support rods are inserted (manually) and the toggle switch (11S27) is brought into the position auxiliary pile on. The auxiliary pile moves upwards until the sensor auxiliary pile detection (11B11) is damped. This activates the automatic pile height control on the auxiliary pile and deactivates it on the main pile. When reaching the starting point (dependent on the automatic pile height control of the auxiliary pile), the main pile moves automatically downwards. Pile change The main pile stops when reaching the pile support plate limitation (11S39). In this position, the pile support plate is automatically centered (max. duration: 25 s). When actuating the button main pile down (11S25), the main pile moves further downwards at slow speed. When reaching the bottom limit position (11S34), the main pile stops and can be loaded. When actuating the button main pile up (11S24), the pile moves back upwards. The main pile must be aligned manually just before it reaches the auxiliary pile. Pile merging When reaching the auxiliary pile, the sensor auxiliary pile detection (11B11) is no longer damped, whereupon the automatic pile height control of the main pile is activated again. The toggle switch is put into the position auxiliary pile off (11S27), this deactivates the automatic pile height control on the auxiliary pile. The support rods are pulled out (manually). Upon actuation of the button auxiliary pile down (11S29) the non-stop bars move downwards. When reaching the bottom auxiliary pile limitation (11S37), the non-stop bars stop (starting position).
136
Feeder pile control
Function
Non-stop operation (standard)

Preconditions The non-stop operation on the standard feeder requires the following preconditions: The press is in production mode. The toggle switch is in position auxiliary pile off (11S27) The non-stop bar is at the level of the pile support board (starting position for inserting the support rods)
Basic function The non-stop operation on the standard feeder consists of the following sub-steps: Pile transfer: Inserting support rods creates main and auxiliary pile. The auxiliary pile takes over the automatic pile height control Pile change: The (empty) main pile moves downwards. There it is loaded and moves back up to the auxiliary pile Pile merging: Main and auxiliary pile are merged by pulling out the support rods. The main pile takes over the automatic pile height control again.
137
Feeder pile control
Function
Main pile
Auxiliary pile
Automatic pile height control of auxiliary pile off
Inserting support rods
Inserting support rods 11S28 Auxiliary pile up, slow
Pile transfer
11S27 Auxiliary pile on Automatic pile height control of main pile off
11S27 auxiliary pile on Automatic pile height control of auxiliary pile on
11S25 (self-stopping mode) Main pile down, fast 11S39 Main pile stop 11S25 (no self-stopping mode)
Pile change
Main pile down, slow 11S34 Main pile stop (loading) 11S24 Main pile up, fast Height of auxiliary pile reached Main pile stop
11S27 auxiliary pile off Automatic pile height control of main pile on Removing support rods
11S27 auxiliary pile off Automatic pile height control of auxiliary pile off Removing support rods 11S29 Auxiliary pile down 11S37 Auxiliary pile stop
Pile merging
Sequence of nonstop operation (standard)
138
Feeder pile control
Function
Pile transfer The support rods are inserted (manually). Through actuation of the auxiliary pile up button (11S28), the non-stop bars are moved upwards (until the support rods are slightly lifted). The toggle switch (11S27) is brought into position auxiliary pile on, this activates the automatic pile height control on the auxiliary pile and deactivates it on the main pile. Pile change When actuating the button main pile down (11S25), the main pile moves in self-stopping mode downwards at fast speed. The main pile stops when reaching the pile support plate limitation (11S39). When actuating the button main pile down (11S25) once more, the main pile (without self-stopping mode) moves downwards at slow speed. When reaching the bottom limitation (11S34) the main pile stops and can be loaded. When actuating the button main pile up (11S24), the main pile moves upwards at fast speed. The main pile must be moved up to the auxiliary pile, so that the auxiliary pile is relieved. Pile merging The toggle switch is put into position auxiliary pile off (11S27), this reactivates the automatic pile height control on the main pile and deactivates it on the auxiliary pile. The support rods are pulled out (manually). When actuating the button auxiliary pile down (11S29), the non-stop bars move downwards. When reaching the bottom limitation of auxiliary pile (11S37), the non-stop bars stop (starting position).
139
Feeder pile control
11M1 Main pile motor (Preset)
11M1 Main pile motor (Preset) Place of installation

11M1
Place of installation of main pile motor (Preset)
Layout 1 2 3 4
Motor electronics Motor and brake Gear unit Male connector
Layout of main pile motor (Preset)
140
Feeder pile control
Task and function

The main pile motor moves the main pile upwards and downwards by means of pile chains. A brushless motor is used which can perform the following functions: Speed control Changeover between two different speed levels (fast and slow) Electric deceleration (controlled by the respective power part) Stopping or emergency braking by means of the brake installed
The motor is provided with the following internal functions for the purpose of controlling and monitoring: Commutation and speed detection by means of Hall signals Temperature detection through resistor
Technical specifications
Output: 0.18/0.36 kW Power supply: DC 120 V Speed (gear unit): 5.7/40 min1 Ratio: 100:1 Resistor code: 2 (560 W)
141
Feeder pile control
Pin assignment
Pin Function X1 motor line (slow) Y1 motor line (slow) Z1 motor line (slow) X2 motor line (fast) Y2 motor line (fast) Z2 motor line (fast) Brake (reference potential DC) Brake (DC +24 V) Hall 1 Hall 2 Hall 3 Resistor code PTC (temperature monitoring) Auxiliary supply of motor electronics UH Ground auxiliary supply PE conductor
1 2 3 4 5
A B C
A1
1 2 3 4 5
B1 C1 A2 B2 C2 C5 B5 B4 A5
Pin assignment on main pile motor (Preset)
B3 A4 A3 C4 C3
142
Feeder pile control
11M1 Main pile motor (standard)
11M1 Main pile motor (standard) Place of installation

11M1
Place of installation of main pile motor (standard)
Layout 1 2 3 4
Layout of main pile motor (standard)
143
Feeder pile control
Task and function

The main pile motor moves the main pile upwards and downwards by means of the pile chains. A three-phase induction motor is used which carries out the following functions: Changeover between two different speed levels (fast and slow) Stopping and emergency braking by means of the brake installed
The motor is provided with the following internal functions for the purpose of controlling and monitoring: Speed detection via Hall signals Temperature detection via resistor
Output: 0.13/0.42 kW Power supply: 220 V / 50 Hz 265 V / 60 Hz Speed (gear unit): 9.5/41.5 min1 (220V) 11.5/49.7 min1 (265V) Ratio: 66:1 Resistor code: 2 (560 W)
144
Feeder pile control
Pin assignment
Pin A1 A B C 1 2 3 4 5 B1 C1 A2 B2 C2 A3 B5 C5 B4 Function Winding U1 (slow) Winding V1 (slow) Winding W1 (slow) Winding U2 (fast) Winding V2 (fast) Winding W2 (fast) N1, N2 Brake (reference potential DC) Brake (DC +24 V) Hall 1 Hall 2 Resistor code PTC (temperature monitoring) Auxiliary voltage of motor electronics UH Ground auxiliary voltage PE conductor
pin assignment of main pile motor (standard)
A5 C3 B3 C4 A4
145
Feeder pile control
11M2 Auxiliary pile motor
11M2 Auxiliary pile motor Place of installation
11M2
11M2
Preset feeder
Standard feeder
Place of installation of auxiliary pile motor
Layout 1 2 3 4
Layout auxiliary pile motor

146
Feeder pile control
Task and function

The auxiliary pile motor moves the auxiliary pile upwards and downwards by means of the pile chains. A three-phase induction motor is used which can execute the following functions: Changeover between two different speed levels (fast and slow) Stopping and emergency braking by means of the brake installed
The motor is provided with the following internal functions for the purpose of controlling and monitoring: Speed detection via Hall signals Temperature detection via resistor
Output: 0.09/0.4 kW Power supply: 220 V / 50 Hz 265 V / 60 Hz Speed (gear unit): 11.3/48.4 min1 (220V) 13.9/58.7 min1 (265V) Ration: 57:1 Resistor code: 8 (56 kW)
147
Feeder pile control
Pin assignment
Pin A1 A B C 1 2 3 4 5 B1 C1 A2 B2 C2 A3 B5 C5 B4 Function Winding U1 (slow) Winding V1 (slow) Winding W1 (slow) Winding U2 (fast) Winding V2 (fast) Winding W2 (fast) N1, N2 Brake (reference potential DC) Brake (DC +24 V) Hall 1 Hall 2 Resistor code PTC (temperature monitoring) Auxiliary voltage motor electronics UH Ground auxiliary voltage PE conductor
Pin assignment main pile motor (standard)
A5 C3 B3 C4 A4
148
Feeder pile control
11B11 Auxiliary pile detection
11B11 Auxiliary pile detection Place of installation
11B11
Place of installation 11B11 (Preset feeder)
Layout 1 2
Sensor Cable
Sensor 11B11 with cable
149
Feeder pile control
Task and function

The inductive sensor 11B11 monitors whether the non-stop bar is loaded. In case of a loaded non-stop bar, the auxiliary pile presses a trip bar downwards. The sensor detects the trip bar (metal). Switching output: normally open contact
Connection
Core colour 11B11 brown blue black Function + 24V DC 24V DC signal Terminal 12X2: +1 12X2: 1 FEM64: XE11
Cable end sensor 11B11

The sensor is screwed down to a base plate which is located at the non-stop bar.
Removal and installation 11B11
150
Feeder pile control
Setting
14 0.2 mm
In its basic setting the sensor protrudes the base plate by 14 mm (see figure).
Setting 11B11
Checking the circuit state

EAK_11 E11 11B11 The output signal of the sensor 11B11 reaches the EAK_11, input 11.
Signal flow
Position signal E11
The input signal E11 can be checked on the service display EAK: 0: 1: The sensor detects no metal (the trip bar is unloaded) The sensor detects metal (the trip bar is loaded)
Service display, signal E11
151
Feeder pile control
11B33 Upper main pile limitation
11B33 Upper main pile limitation Place of installation
11B33
Layout 1 2
Sensor Cable
152
Feeder pile control
Task and function

The inductive sensor 11B33 monitors whether the pile support plate has reached the uppermost position. The sensor detects the pile support plate (metal). Switching output: normally closed contact
Connection

The sensor is screwed down to the non-stop bar.
153
Feeder pile control
Setting
In its normal position the sensor protrudes the non-stop bar by 24 mm (see figure).
24 mm
Setting 11B33

EAK_11 E33 11B33 The output signal of the sensor 11B33 reaches EAK_11, input 33.
Signal flow
Position signal E33
The input signal E33 can be checked on the service display EAK: 0: 1: The sensor detects metal (the pile support plate is located at level of the sensor) The sensor detects no metal (the pile support plate is located below the sensor)
154
Feeder pile control
11B35 Automatic pile transport
11B35 Automatic pile transport Place of installation
11B35
Layout 1 2
Sensor Cable
155
Feeder pile control
Task and function

The capacitive sensor 11B35 detects whether the upper edge of the pile (paper) is at the respective height. Switching output: normally open contact
Connection

The sensor 11B35 is screwed down to the pile support frame in a special holder. When installing the cable make sure that no moveable parts are touched (risk of wearing through). The tape driving shaft is particularly critical.
156
Feeder pile control

EAK_11 E35 11B35 The output signal of the sensor 11B35 reaches EAK_11, input 35.
Signal flow
Position signal E35
The input signal E35 can be checked on the service display: 0: 1: The sensor does not detect an object (the upper edge of pile is below the sensor) The sensor detects an object (the upper edge of pile is at the level of the sensor)
157
Feeder pile control
11S34 Bottom main pile limitation
11S34 Bottom main pile limitation Place of installation

11S34 11S34
Preset feeder
Standard feeder
Components
Place of installation 11S34
Task and function

The position switch 11S34 deactivates the pile drive when the main pile has reached its lowest position. There is a trip cam at the pile change which actuates the position switch via a shifter mechanism.
158
Feeder pile control
Setting
To set the bottom main pile limitation, the main pile chains must be shortened or lengthened accordingly. The position switch 11S34 must not be changed. Basically the following procedure for shortening or lengthening the main pile chains applies. Furthermore, the instructions and safety hints of the service manual for the mechanics are to be obeyed.
Lower the pile support plate of the feeder until the pile support plate rests on the floor or on an elevation (e.g. pallets) and the pile chains are relaxed Lengthen or shorten the main pile chains accordingly

EAK_11 E34 11S34 The output signal of the switch 11S34 reaches EAK_11, input 34.
Signal flow
Position signal E34
The input signal E34 can be checked on the service display EAK: 0: 1: switch is actuated switch is not actuated
Note: The signal is also displayed on the service display SEK. Service display, signal E34
159
Feeder pile control
Components
160
Delivery pile control
Block diagrams

Block diagrams Block diagram (Preset)
Pile height
Controls
Outputs
Safety circuit
SEK
EAK_12
Press control
REK2
ESK
A A A
HAK_01 B LTK500 BAK
C B B
HAK_02 B
LTK50
Main pile
M 12M1
M 12M2
Auxiliary pile
Preset delivery with auxiliary pile
161
Block diagrams
Block diagram (standard)
Pile height
Controls
Outputs
Safety circuit
SEK
EAK_12
Press control
REK2
ESK
HAK_01 B
HAK_02 B
STK1
LTK50
Main pile
M 12M1
M 12M2
Auxiliary pile
Standard delivery with auxiliary pile
162
Layout
Layout Overview
The pile control of the delivery is used to control main pile and auxiliary pile and other outputs (solenoid-operated valves). It consists of the following functional units: Press control: recording and evaluating input signals for controlling the pile drives and outputs Safety circuit: recording and evaluating safety-relevant signals for emergency shutdown of pile drives Auxiliary drive control: control of pile motors
The following components are part of the pile control: SEK Safety input board
EAK_12 Input/output board on board slot 12 (signal acquisition delivery) REK2 ESK Processor board on board slot 2 (press control) Input/output control board
HAK_01 Auxiliary drive board on board slot 1 HAK_02 Auxiliary drive board on board slot 2 STK1 BAK LTK500 LTK50 Pile control board on board slot 1 Brake control board Power part board 500W Power part board 50W
163
Layout
Press control
Inputs Outputs The press control records the signals of the switches and sensors on the delivery and the delivery controls via the inputs of EAK_12. REK2 evaluates these signals and generates control signals for the pile motors and solenoid-operated valves. The solenoid-operated valves are controlled via the outputs of EAK_12. The control signals for the pile motors are passed on to the auxiliary drive control via the ESK. The ESK has the following operation set for controlling the individual pile motors: ESK Auxiliary drive control Pile stop (pile height control off) Pile up (slow) Pile down (slow) Pile up, fast (only for main pile) Pile down, fast (only for main pile) Pile height control on Rack mode (parameter: rack height)
EAK_12
REK2
Press control
Safety circuit
The SEK detects the signals of the safety-relevant switches on the delivery. It evaluates these signals and if necessary it generates control signals for the emergency shutdown of pile drives. These control signals are passed on directly to the auxiliary drive control. The signals of the safety circuit take priority over the signals of the press control. Auxiliary drive control The ESK is provided with the following operation set for controlling the individual pile motors: Pile drive enabled Pile up blocked Pile down blocked
Inputs
SEK
Safety circuit
164
Layout

The auxiliary drive control prepares the control signals of SEK and ESK and controls the individual pile drives. Each drive is assigned with a control section (component of a HAK) and a power part (dependent on the motor used). Depending on the press version, the assignments listed below are possible - see also block diagrams. Control section HAK01 Part B HAK01 Part B HAK02 Part A
Safety circuit
Press control
HAK_01
HAK_02
LT
LT
LT
Drive Main pile (Preset) Main pile (standard) Auxiliary pile (with auxiliary pile at feeder) Auxiliary pile (no auxiliary pile at feeder)
Power part BAK+LTK500 Part B STK1 Part B LTK50 Part A
12M1 12M2 12M2
HAK01 Part C
LTK50 Part A
The signal of the capacitive sensor for the automatic pile height control is prepared in the power part of the main pile. The prepared signals is passed on to the power part of the auxiliary pile. Both power parts pass the signal on to the corresponding control section. See chapter control systems / auxiliary drive control for further details about the auxiliary drive control.
165
Overview of components Operator side
12S130 12S55 12S56 12S33 12S34 12S131 12S35 12Y11 12Y13 12Y14/15 12Y49
12B69 12S42 12S41 12B129a
12Y60/61 12S34b 12B129 12S42 12S117
12B65
Components on the operator side
166
Drive side
12M1 12M2 12S39 12S55a
12S130a 12Y62 12S34a 12S38 12S36
Components on the drive side
167
Motors
Equipment 12M1 12M1 12M2 Function with nonstop D D Preset without nonstop D Standard with without nonnonstop stop D D D Remarks
Main pile drive (Preset) Main pile drive (standard) Auxiliary pile drive
Brushless motor Three-phase a.c. motor

Equipment 12S33 12S34 12S34a 12S34b 12S35 12S36 12S38 12S39 12S41 12S42 Function with nonstop Upper main pile limitation Bottom main pile limitation Bottom main pile limitation Bottom main pile limitation Sheet jogger 1 Sheet jogger 2 Overshooting control Monitoring suction drum Pile rake stop Pile rake down D D D D D D D D D Preset without nonstop D D D D D D D Standard with without nonnonstop stop D D D D D D D D D D D D D D D D D D Remarks
only with raised delivery, same function as 12S34 only with raised delivery, same function as 12S34
12S55 12S55a 12S56 12B65 12B69 12S117
Upper auxiliary pile limitation Upper auxiliary pile limitation Bottom auxiliary pile limitation Changeover fast/slow Pile height control switching point 1: changeover fast/slow switching point 2: upper main pile limitation Upper edge of pile at delivery Upper edge of pile at delivery Angular stop O.S. Angular stop D.S. Pile down, slow
D D D D D D D D D
D D D D D
with board fitting on D.S. with rake fitting on O.S. same function as 12S55
12B129 12B129a 12S130 12S130a 12S131
D D D D D D D D
D D D D D D D D
Receiver (light barrier) Transmitter (light barrier) same function as 12S130
168
Solenoid-operated valves
Equipment 12Y11 12Y13 12Y14 12Y15 12Y49 12Y60 12Y61 12Y62 Function with nonstop D D D D D D D D Preset without nonstop D D D D Standard with without nonnonstop stop D D D D D D D D D D D D Remarks
Sheet stop Sheet catcher Supporting cross bar on Supporting cross bar off Locking of sheet stops Rack delivery on Rack delivery off Suction air sheet catcher
only with rake only with rake only with board only with board
169
Function
Function Automatic pile height control

The automatic pile height control on the delivery is automatically activated as soon as one of the following conditions is met:
12B69
The height control for the main pile at the feeder is on The automatic pile height control for the auxiliary pile control on the feeder is on The paper run is switched on The sheeter is in operation (extra accessory)
The automatic pile height control on the feeder is stopped under the following circumstances:
Switching points of the automatic pile height control

Permissible start condition
Actuation of the pile stop button (12S124) Actuation of the main pile up (12S45) or main pile down (12S46) button (main pile only) Actuation of the auxiliary pile up (12S53) or auxiliary pile down (12S54) button (auxiliary pile only) Opening of the sheet stop (12Y11)
12B69 detects paper Pile down (by 2 mm)
Sequence of automatic pile height control
Under normal circumstances the automatic pile height control refers to the main pile. In addition, the automatic pile height control at the auxiliary pile is activated and deactivated in non-stop operation (see chapter non-stop operation). The automatic pile height control controls the pile in such a way that the upper edge is always at the level of the sensor automatic pile height control (12B69). As soon as the sensor detects the upper edge of the pile (paper), the pile is lowered by 2 mm. In case the sensor automatic pile height control (12B69) fails to work, an emergency control is automatically activated. With this emergency control, the delivery pile is moved downwards synchronously to the feeder pile.
170
Function
Transport of main pile (Preset)

On the Preset version, the main pile is driven by a brushless motor by means of which three speed levels are passed. Main pile up
12S45
12S117/2 12B69 12S117/1 12B65
slow
The upwards movement of the main pile is controlled by means of the button main pile up (12S45) on the delivery operation panel. Depending on the position of the main pile, the speed is changed (fast/slow). When reaching the upper main pile limitation (12S117/switching point 2) or the automatic pile transport (12B69), the transport mechanism of the main pile stops. The upwards movement of the main pile is interrupted under the following circumstances:
fast 12S131 slow
Actuation of an emergency stop switch Actuation of the overshooting control switch (12S38) Actuation of the sheet jogger switch (12S35 or 12S36) Actuation of the monitoring suction drum switch (12S39) Actuation of the angular stop switch (12S130) Opening of the sheet stop (12Y11) (only if no non-stop operation) Actuation of the main pile down button (12S46)
Switching points of main pile up (Preset)

Main pile up
Permissible start condition 12S45 (keep pressed) Main pile up, slow
12S131 Main pile up, fast 12B65 or 12S117/1 Main pile up, slow 12B69 or 12S117/2 Main pile stop
The continuation of an interrupted pile transport is only possible after elimination of the respective cause.
Sequence of main pile up and passes through all three speed levels (Preset)
171
Function
Main pile down

12S46 12S124
The downward movement of the main pile is controlled by means of the button main pile down (12S46) on the delivery operation panel. Depending on the position of the main pile, the speed is changed (fast/slow). The button main pile down (12S46) is equipped with a self-stopping mode. If the button was actuated for more than 1.5 s, the main pile moves down to the bottom main pile limitation (12S34). The self-stopping mode can be interrupted by means of the button pile stop (12S124). The downward movement of the main pile is interrupted under the following circumstances:
slow 12S117/1 12B65 fast 12S131 slow 12S34
Actuation of an emergency stop switch Actuation of the pile stop button (12S124) Actuation of the main pile up button (12S45)
Switching point of main pile down (Preset)

Main pile down
Permissible start condition 12S46 (self-stopping mode after 1.5 s) Main pile down, slow 12B65 or 12S117/1 Main pile down, fast 12S131 Main pile down, slow 12S34 Main pile stop
The interrupted pile transport can only be continued after elimination of the respective cause.
Sequence of main pile down and passing through all three speed levels (Preset)
172
Function
Transport of main pile (standard)

On the standard version the main pile is driven by a three-phase a.c. motor, by means of which two speed levels are passed. Main pile up
12S45
12S33 12B69
The upwards movement of the main pile is controlled by means of the button main pile up (12S45) on the delivery operation panel. The main pile moves upwards at a constant speed (fast). When reaching the upper main pile limitation (12S33) or the automatic pile transport (12B69), the transport mechanism of the main pile stops. The upwards movement of the main pile is interrupted under the following circumstances:
fast
Actuation of an emergency stop switch Actuation of the overshooting control switch (12S38) Actuation of the sheet jogger switch (12S35 or 12S36) Actuation of the monitoring suction drum switch (12S39) Actuation of the angular stop switch (12S130) Opening of the sheet stop (12Y11) (only if no non-stop operation) Actuation of the main pile down button (12S46)
Switching points of main pile up (standard)

Main pile up
12S45 (keep pressed) Main pile up, fast 12S33 or 12B69 Main pile stop
An interrupted pile transport can only be continued after elimination of the respective cause.
Sequence of main pile up (standard)
173
Function
Main pile down

12S46 12S124
The downward movement of the main pile is controlled by means of the button main pile down (12S46) on the delivery operation panel. Depending on the position of the main pile, the speed is changed (fast/slow). When reaching the bottom limit position (12S34), the transport mechanism of the main pile stops. The button main pile down (12S46) is provided with a self-stopping mode. If the button was actuated for more than 1.5 s, the main pile moves down to the bottom main pile limitation (12S34). The self-stopping mode can be interrupted by means of the button pile stop (12S124). The downward movement of the main pile can be interrupted under the following circumstances: Actuation of an emergency stop switch Actuation of the pile stop button (12S124) Actuation of the main pile up button (12S45)
fast
12S131 slow 12S34
Switching points of main pile down (standard)
Main pile down

Permissible start condition 12S46 (self-stopping mode after 1.5 s) Main pile down, fast 12S131 Main pile down, slow 12S34 Main pile stop
Sequence of main pile down and passing through both speed levels (standard)
174
Function
Transport of auxiliary pile

Auxiliary pile up
12S53
The upward movement of the auxiliary pile is controlled by means of the button auxiliary pile up (12S53) on the delivery operation panel. The auxiliary pile moves upwards at a constant speed. When reaching the upper auxiliary pile limitation (12S55), the transport of the auxiliary pile stops. The upward movement of the auxiliary pile is interrupted under the following circumstances: Actuation of an emergency stop switch Actuation of the overshooting control switch (12S38) Actuation of the sheet jogger switch (12S35 or 12S36) Actuation of the monitoring suction drum switch (12S39) Actuation of the angular stop switch (12S130) Triggering of the sensor automatic pile height control (12B69) Opening of the sheet stop (12Y11) (only if no non-stop operation) Actuation of the auxiliary pile down button (12S54)
12S55
Switching points of auxiliary pile up

Auxiliary pile up
Permissible start condition 12S53 (keep pressed) Auxiliary pile up 12S55 Auxiliary pile stop
Sequence of auxiliary pile up
175
Function
Auxiliary pile down

12S54
The downward movement of the auxiliary pile is controlled by means of the button auxiliary pile down (12S54) on the delivery operation panel. The auxiliary pile moves downwards at a constant speed. When reaching the bottom auxiliary pile limitation (12S56), the transport mechanism of the auxiliary pile stops. The downward movement of the auxiliary pile is interrupted under the following circumstances:
12S56
Actuation of an emergency stop switch Actuation of the angular stop switch (12S130) Actuation of the auxiliary pile up button (12S53)
Switching points of auxiliary pile down

Auxiliary pile down
Permissible start condition 12S54 (keep pressed) Auxiliary pile down 12S56 Auxiliary pile stop
Sequence of auxiliary pile down
176
Function
Non-stop operation
Basic function The separation of pile occurs in non-stop operation by means of rake or board in the main pile and auxiliary pile. The auxiliary pile takes over the automatic pile height control, the main pile executes a pile change or a rack formation. After that the two piles are remerged. The rack function is a special version of the non-stop operation which is selected and adjusted (if available) by means of the control console. Besides main and auxiliary pile further components are involved in the non-stop operation: Sheet catcher Sheet stop front edge (only with rake) Supporting cross bar (only with rake) Guide rails (only with board)
177
Function
Main pile
Permissible start condition 12S42
Auxiliary pile
Pile separation
Main pile down, fast Pile change: 12S41 or 12B129 Rack: adjusted rack height Main pile stop (insert rake/board) 45 mm paper on auxiliary pile Automatic pile height control of main pile on (insert rake/board) 45 mm paper on auxiliary pile Automatic pile height control of auxiliary pile on
12S46 (self-stopping) Main pile down, fast 12S131
Pile change (rack)
Main pile down, slow 12S34 Main pile stop (unloading) 12S45 Main pile up, slow 12S131 Main pile up, fast
Rake: 12B129 Board: 12S41 free
Rake: 12B129 Board: 12S41 free Automatic pile height control of auxiliary pile off (pull out rake/board) Rake: 12S42 free Board: 12S10 actuated
Pile merging
Automatic pile height control of main pile off (pull out rake/board) Time delay 10 s
Auxiliary pile up 12S55 (starting position) Auxiliary pile stop
Sequence of non-stop operation
178
Function
Note: The following must be observed with the sequence of the non-stop operation (see figure):
The steps for unloading are omitted with the rake function Not all speed alterations are executed in case of the standard version
Pile separation When putting on the rake/board (12S42), the main pile moves downwards at fast speed. The main pile stops under the following circumstances:
12S41 12B129
Pile change: Inserting the rake/board (12S41) or lowering the upper edge of pile until it is at the level of the light barrier (12B129) rake: When reaching the preset rake height (the rake height can be adjusted on the ZID between 20 mm and 300 mm in increments of 10 mm)
12S42 12S41
As soon as 45 mm of paper are placed on the auxiliary pile, main and auxiliary pile execute pile height regulations. Pile change The main pile moves downwards in self-stopping mode by pressing the button main pile down (12S46, for more than 1.5 s). After the main pile has been emptied it moves back to the level of the auxiliary pile when actuating the button main pile up (12S45). When moving upwards and downwards the main pile runs through the same speed levels as described in the paragraph Transport of main pile. Rack After positioning the rack, the main pile moves back to the level of the auxiliary pile by actuation of the button main pile up (12S45) .
Switching points for pile separation and pile merging
179
Function
Pile merging The main pile moves upwards until the corresponding condition is met. Rake: the upper edge of the pile has reached the height of the light barrier (12B129) Board: the main pile lifts the board from underneath (12S41 free)
The automatic pile height control for main and auxiliary pile is interrupted for 10 seconds. Within this period, the rake/ board can be pulled out. Then the main pile takes over the automatic pile height control again. The auxiliary pile frame moves upwards back into its basic position. In case of the version with board, the guide rails must be retracted in addition - see paragraph guide rails. Sheet catcher When separating the pile, the sheet catchers retain the paper coming from above, this activity is supported by suction air activated in addition. When putting on the rake/board (12S42), the main pile moves downwards (see pile separation). If the preset moment of application is reached, the sheet catchers extend (12Y13) and the suction air is switched on (12Y62). The moment of application can be adjusted on the ZID within a range of 1 to 9 press rotations.
Extending and retracting sheet catcher

Sheet catcher
Permissible start condition 12S42 Main pile down Moment of application reached Extending sheet catcher (12Y13) Suction air on (12Y62) 12S41 Suction air off (12Y62) Retracting sheet catcher (12Y13)
When inserting the rake/board (12S41), the suction air is switched off (12Y62) and the sheet catchers retract (12Y13).
Sequence of extending and retracting sheet catcher

180
Function
Front edge sheet stop (with rake) The front edge sheet stop is locked during the entire non-stop operation with rake. The locking facility can also be operated manually on the control console. After putting on the rake (12S42), the locking facility is switched on (12Y49). When pulling out the rake (12S42 free), the locking facility is switched off again (12Y49).
Front edge sheet stop

Front edge sheet stop
Permissible start condition 12S42 Sheet stop locked (12Y49) 12S42 free Sheet stop released (12Y49)
Sequence of front edge sheet stop
181
Function
Supporting cross bar (with rake) The supporting cross bar is needed for the non-stop operation with rake to put on the rods of the rake. Dependent on the press-specific version, there are two different options for controlling the supporting cross bar. Without time delay: When putting on the rake (12S42), the supporting cross bar extends (12Y14). When pulling out the rake (12S41 and 12S42 free) the supporting cross bar retracts again (12Y15). With time delay: When inserting the rake (12S41 and 12S42) the supporting cross bar extends after 3 seconds (12Y14). When pulling out the rake (12S41 and 12S42 free) the supporting cross bar retracts again (12Y15).
Extending and retracting supporting cross bar

Cross bar without delay time
Permissible start condition 12S42 Extending cross bar (12Y14) Pile change or forming a rack 12S41 and 12S42 free Retracting cross bar (12Y15)
Sequence of extending and retracting supporting cross bar (without delay time)
Cross bar with delay time
Permissible start condition 12S41 and 12S42 Await time (3 s) Extending cross bar (12Y14) Pile change or forming a rack 12S41 and 12S42 free Retracting cross bar (12Y15)
Sequence of extending and retracting supporting cross bar (with delay time)
182
Function
Guide rails (with board)

12S10
The guide rails are needed for the non-stop operation with board to act as a lateral support of the board. By pressing the button pile board on/off (12S10) the guide rails extend (12Y60). After that the board can be inserted in the guide rails. After completion of the unloading process or after insertion of spacer angles for a rack, the main pile moves back to the height of the auxiliary pile (12S41 becomes clear). By pressing the button pile board on/off (12S10) the guide rails retract (12Y61).
Extending and retracting guide rails

Guide rail
Permissible start condition 12S10 Extending guide rail (12Y60) Pile change or forming a rack 12S41 free and 12S10 Retracting guide rail (12Y61)
Sequence of extending and retracting guide rails
183
Function
Removal of sample sheet

12S11
The removal of sample sheet is controlled by means of the button sample sheet removal (12S11) on the delivery operation panel. When the button is actuated, the automatic pile height control is interrupted. The sheet catchers extend (12Y13), for reason of better adhesion it is possible to additionally activate suction air (optional) (12Y62). The stop shaft swings up (12Y11) and the sheet can be removed. Actuating the button sample sheet removal (12S11) again, cancels the removal of sample sheet, the pile executes the automatic pile height control. When removing a sample sheet the locking of the front edge sheet stop (12Y49) is deactivated if it was activated beforehand.

Permissible start condition 12S11 Extending sheet catcher (12Y13) Suction air on (12Y62) - optional Swinging up stop shaft (12Y11) 12S11 Suction air off (12Y62) - optional Retracting sheet catcher (12Y13) Swinging back stop shaft (12Y11)
Sequence of sample sheet removal
184
Function
Paper blockage
Paper blockage
Permissible start condition Stop condition Paper supply at feeder blocked
In case of a paper blockage, the paper supply is blocked at the feeder. To trigger a paper blockage, either main pile or auxiliary pile must meet one of the following stop conditions. Main pile: (Only if the delivery is not in non-stop operation) Switch pile down slow (12S131) overshot Switch bottom main pile limitation (12S34) reached
Sequence of paper blockage
Auxiliary pile: Switch bottom auxiliary pile limitation (12S56) reached Maximum paper height in non-stop operation reached (depending on paper thickness between 1500 and 4000 sheets)
The paper blockage is only cancelled after elimination of the respective cause.
185
12M1 Main pile motor (Preset) Place of installation
12M1
Place of installation of main pile motor (Preset)
Layout 1 2 3 4
Layout of main pile motor (Preset)
186
Task and function

The main pile motor moves the main pile upwards and downwards via the pile chains. A brushless motor is used which can execute the following functions: Speed control Changeover between two different speed levels (fast and slow) Electrical deceleration (controlled by the corresponding power part) Stopping or emergency braking by means of installed brakes
The motor is provided with the following internal functions for the purpose of control and monitoring: Commutation and speed recording via Hall signals Temperature recording via resistor
Output: 0.18/0.36 kW Power supply: DC 120 V Speed (gear unit): 5.7/40 min1 Ratio: 100:1 Resistor code: 2 (560 W)
187
Pin assignment
Pin Function X1 motor line (slow) Y1 motor line (slow) Z1 motor line (slow) X2 motor line (fast) Y2 motor line (fast) Z2 motor line (fast) Brake (reference potential DC) Brake (DC +24 V) Hall 1 Hall 2 Hall 3 Resistor code PTC (temperature monitoring) Auxiliary voltage motor electronics UH Ground auxiliary voltage PE conductor
1 2 3 4 5
A B C
A1
1 2 3 4 5
B1 C1 A2 B2 C2 C5 B5 B4 A5
Pin assignment of main pile motor (Preset)
B3 A4 A3 C4 C3
188
12M1 Main pile motor (standard) Place of installation
12M1
Place of installation of main pile motor (Standard)
Layout 1 2 3 4
Layout of main pile motor (standard)
189
Task and function

The main pile motor moves the main pile upwards and downwards by means of the pile chains. A three-phase induction motor is used which can execute the following functions: Changeover between two different speed levels (fast and slow) Stopping and emergency braking by means of the installed brake
The motor is provided with the following internal functions for the purpose of controlling and monitoring: Speed recording via Hall signals Temperature recording via resistor
Output: 0.13/0.42 kW Power supply: 220 V / 50 Hz 265 V / 60 Hz Speed (gear unit): 9.5/41.5 min1 (220V) 11.5/49.7 min1 (265V) Ratio: 66:1 Resistor code: 2 (560 W)
190
Pin assignment
Pin A1 A B C 1 2 3 4 5 B1 C1 A2 B2 C2 A3 B5 C5 B4 Function Winding U1 (slow) Winding V1 (slow) Winding W1 (slow) Winding U2 (fast) Winding V2 (fast) Winding W2 (fast) N1, N2 Brake (reference potential DC) Brake (DC +24 V) Hall 1 Hall 2 Resistor code PTC (temperature monitoring) Auxiliary voltage of motor electronics UH Ground auxiliary voltage PE conductor
Pin assignment of main pile motor (standard)
A5 C3 B3 C4 A4
191
12M2 Auxiliary pile motor Place of installation
12M2
Place of installation of auxiliary pile motor
Layout 1 2 3 4
Gear unit Motor Motor electronics Circular connector
Layout of auxiliary pile motor
192
Task and function

The auxiliary pile motor moves the auxiliary pile upwards and downwards by means of the pile chains. A brushless motor is used which can execute the following functions: Speed control Electric deceleration (controlled by the corresponding power part) Deceleration through the self-locking gear unit
The motor is provided with the following internal functions for the purpose of controlling and monitoring: Commutation and speed recording via Hall signals
Output: 30 Watt Power supply: DC 48 V Speed (gear unit): 1 min1 Ratio: 2564:1 Resistor code: 5 (5.6 kW)
193
Pin assignment
Pin 1 2 3 4 6 7 8 9 11 12 Function X motor line Y motor line Z motor line Hall C Hall B Auxiliary voltage of motor electronics UH Hall A Ground auxiliary voltage Resistor code PE conductor
Pin assignment auxiliary pile motor
13 14
194
12B65 Changeover fast/slow
12B65 Changeover fast/slow Place of installation
12B65
Place of installation 12B65
Layout 1 2
Sensor Cable
195
Task and function

The ultrasonic sensor 12B65 monitors whether the upper edge of the pile (paper, pallet or pile support plate) is at the corresponding height. The output signal is used to change the speed to fast/slow. Switching output: normally closed contact
Connection
Core colour 12B65 brown blue black Function + 24V DC 24V DC signal Terminal 12X2: +1 12X2: 1 12X2: 116

The sensor 12B65 is fixed to the control lever by means of two screws. When installing the cable there must be enough room for the rotary movement of the lever.
196

EAK_12 E65 12B65 12S117/1 The output signal of the sensor 12B65 reaches EAK_12, input E65 via the switch 12S117/switching point 1 (at the control lever).
Signal flow
Position signal E65
The input signal E65 can be checked on the service display EAK: 0: The sensor 12B65 detects an object (the pile is at the level of the sensor) or 12S117/ switching point 1 is actuated (the pile support plate presses the control lever upwards) The sensor 12B65 does not detect any object (the pile is below the sensor) or 12S117/switching point 1 is not actuated (the control lever is not actuated)
1:
197
12B69 Pile height control
12B69 Pile height control Place of installation
12B69
Place of installation 12B69
Layout 1 2
Sensor Cable
198
Task and function

The capacitive sensor 12B69 monitors whether the upper edge of the pile (paper) is level with the sheet stop. Based on this sensor signal, the control systems regulates the position of the delivery pile. Switching output: normally open contact
Connection
Core colour 12B69 brown blue black Function + 24V DC 24V DC signal Terminal 12X2: +1 12X2: 1 12X2: 69

The sensor 12B69 is fixed to the support on the sheet jogger shaft by means of a screw. When installing the cable there must be enough room for the rotary movement of the stop shaft and for the adjustment of the sensor at the support. The cable must not be fixed to movable parts (except for the sheet jogger shaft). These are in particular the following points: Sheet catcher hose Non-stop frame
199
Setting
In the normal position the sensor is fixed in the bottom third of the oblong hole (see figure) and the rack height is adjusted to 70 mm. Depending on the condition of the pile or the printing material, this position can be altered.
approx. 50 mm
Note: A repositioning of the sensor needs to be considered in non-stop operation for the rack height (adjustable on the control console)
Normal setting

EAK_12 E70 HAK_01 12B69 HAK_02 The output signal of the sensor 12B69 reaches EAK_12, input 70 and the HAK control sections of the main and auxiliary pile drive (exact assignment see block diagram).
Signal flow
Position of signal E70
The input signal E70 can be checked on the service display EAK: 0: 1: The sensor detects no object (the pile is below the sensor) The sensor detects an object (the pile is located at the level of the sensor)
Note: The signal is also displayed as status signal on the service display of the two respective HAK control sections.
200
12B129 Delivery upper edge of pile
12B129 Delivery upper edge of pile Place of installation
12B129a
12B129
Place of installation 12B129 and 12B129a
Layout 1 2
12B129 Sensor Cable
12B129a
Sensor 12B129 and 12B129a with cable
201
Task and function

The light barrier 12B129 monitors whether the upper edge (paper, pallet or pile support plate) of the main pile is located at the respective level underneath the auxiliary pile. By means of this sensor signal, the separation and merging of the pile is controlled in non-stop operation with board. The light barrier consists of a transmitter (12B129a) and a receiver (12B129). Switching output: dark switching
Connection
12B129 12B129 Core colour brown blue Function + 24V DC 24V DC signal Terminal 12X2: +1 12X2: 1 FAM64:XA29
black 12B129a
12B129a
Core colour brown blue
Function + 24V DC 24V DC
Terminal 12X2: +1 12X2: 1
Cable end sensor 12B129a
202

Transmitter and receiver of the light barrier are screwed down to the support (metal plate). Both supports can be relocated in height through the oblong holes. Both supports must be at the same level. When installing the cable there must be enough room for the upward and downward movement of the non-stop frame. O.S. In its normal position, the light barrier should be set as high as possible to prevent a lowering of the pile below the rear edge stop.
D.S.
12B129a
12B129

EAK_12 E77 12B129a 12B129 The output signal of the sensor 12B129 (receiver) reaches EAK_12, signal E77.
Signal flow
The input signal E77 can be checked on the service display EAK: 0: 1: The light barrier is not interrupted The light barrier is interrupted
203
12S34 Bottom main pile limitation Place of installation
12S34
Place of installation 12S34
Task and function

The position switch 12S34 switches the main pile drive off when the main pile has reached its lowest position. There is a pin on the pile chain which actuates the position switch via a shifter mechanism. Principle of operation: normally closed contact
204
Setting 1 2 3
Lower the pile support plate of the delivery until the pile support plate rests on the floor and the pile chains are relaxed. Slacken the fixing bolt 2.
1 at the control plate
Adjust the control plates so that the position switch 12S34 is actuated in this position of the delivery pile support plate.
Position switch 12S34
Mounting plate with (actuated) position switch
205

EAK_12 E34 12S34 12S34a 12S34b The output signal of the switch 12S34 reaches EAK_12, input 34 via the switches 12S34a and 12S34b (if available).
Signal flow
The input signal E34 can be checked on the service display EAK: 0: 1: at least one switch is actuated no switch is actuated
206
Sheet alignment
Block diagram
Sheet alignment
Block diagram
Double-sheet detector SM74 / 52 O.S. D.S. 1B66 1B65 Sheet alignment control D.S. 1B13 O.S. 1B49 Pull lay control D.S. 1B9 O.S. 1B10 1B11 Double-sheet detector SM102/CD102
RL12 1AUM1
RL12
SUM1 RL12
SUM1 RL12
DBE
Automatic misalignment control 11M7 Automatic sheet arrival control SM102/CD102 = 11M3 SM74 = 1M7
Sheet stop finger O.S . 1Y15 D.S . 1Y46
Gripper opening
1Y16
SSM1 M
SSM1
SSK
EAK 1
IDS Displays
SAK
ESK
SVM
MID11
MID12
REK1
REK2
DSK
DNK
ZID
Legend:
Data line
Control lines
Block diagram of sheet alignment

207
Sheet alignment
Block diagram
The sheet alignment system consists of: the sheet alignment control BAK, the pull lay control ZMK, the double-sheet detector DBE, the automatic sheet arrival control BAR (not on SM52), the automatic misalignment control (only on SM102 with Preset and CD102).
As a result of mechanically controlled sequences of motions, the sheet is aligned with the sheet alignment system before it enters the first printing unit. At the same time, the electronic control system: registers the point of time of sheet arrival, monitors sheet infeed, detects double-sheets.
From different sensors the electronic control system receives information from the area of the front lays at certain interrogation points. The sensor signals are processed on the processor board 2 (REK2). The REK2 shows the result of the evaluation on the control console display ZID and the press displays MID. Simultaneously, the electronic control system activates various actuators (drives, valves etc.) in the press.
208
Sheet alignment
Block diagram
Degree values relevant to sheet alignment

The illustration opposite shows the different interrogation points in the area of the front lays. The relation between the degree values and the processes in the press is explained in more detail on the next pages. To make the relation clear, the illustration shows the operation points Feeder ON and Feeder OFF. Table of degree values: Feeder ON Feeder OFF SM52 SM74 285_ 303_ 20_ 330_ 42,5_ 330_ 40_ 15_ 72_ SM102 CD 102 192,0_1 170,0_1 222,0_ 200,0_ 208,0_1 186,0_1 238,0_ 216,0_ 336,0_ 313,0_ 311,0_ 3,0_ 289,0_ 341,5_
BAK ZMK DBE
1 2 3 4 5
230_
Interrogation points
1 only for presses with Preset feeder
209
Sheet alignment
1B13/1B49 Sheet alignment control
1B13/1B49 Sheet alignment control Block diagram

For correct sheet transfer from the feeder into the first printing unit, the sheet must be placed against the front lays as follows:
BAK
FK Front lays ANK 1B13/1B49 Paper
Sheet alignment control D.S. 1B13 O.S. 1B49
1 and 20_ 3, SM74 between 285_ 1 and 40_ 3, SM102 between 222_ 1 and 336_ 3, SM102 with Preset between 192_ 1 and 336_ 3, CD102 between 200_ 1 and 313_ 3, CD102 with Preset between 170_ 1 and 313_ 3. The optimum sheet arrival of the electric 2 is as
SM52 between 240_ follows: for SM74 at 303_, for SM102 at 238_, for SM102 with Preset at 208_, for CD102 at 216_. for CD102 with Preset at 186_.
RL12
RL12
1 LVT1 1EVM4
MID12
Displays MID11
The following applies to the degrees listed (see block diagram):

ZID
At 1 and paper run: the ANK must not detect paper. At 3 and paper run: the ANK must detect paper. At 5 and paper run: to analyze the information provided by the pull lay control (1B9/1B10) the ANK must detect paper.
EAK 1
DNK
ESK
SVM
DSK
The sensors (1B13 and 1B49) of the sheet alignment control register at which point of time the sheets arrive at the front lays. Each sensor housing contains an ANK and FK sensor. ANK = sensor for sheet alignment control FK = sensor for overshooting-sheet control
REK2
Legend:
Note: Speedmaster SM52 is only equipped with one sensor (1B49) of the sheet alignment control.
Block diagram of sheet alignment control

210
Sheet alignment
The signals of the sensors are transmitted to the amplifiers (RL12) where they are amplified. The signals from the amplifiers reach the processor board REK2 via the distribution box 1LVT1, the input/output distributor module EVM (only SM52), the input/ output board EAK and the input/output control board ESK.
The REK2 analyzes the signals of the sheet alignment control. The evaluated signals are required for the following functions of the printing press: sheet alignment at the front lays, misaligned-sheet display (trend display), automatic sheet arrival control (servo-drive 11M3/1M7), automatic misalignment control (servo-drive 11M7).
The REK2 shows the result of the evaluation on the control console display ZID and the press displays MID. D.S. Circuit states of the ANK and FK sensors in the MID
1
O.S.
FK display (sensor for overshooting control) ANK display (sensor for sheet alignment control)
Circuit states displayed on the MID
With the help of the MID on the control panel of the feeder, the FK sensors 1 and ANK sensors 2 can be adjusted and monitored. The MID reflects the circuit state of the corresponding sensor on the drive side and on the operator side. Symbol lit Symbol not lit = = sensor detects paper sensor does not detect paper
The FK and ANK displays are visible when the switch Safe on the control panel of the feeder is set to Safe and the printing speed is x 3500 i.p.h.
Note: On Speedmaster SM52 the symbols of two sensors are displayed, even though only one sensor if fitted.
211
Sheet alignment
Sheet alignment errors detected by the ANK sensors

The ANK sensors detect:
BAK SM52 240_ SM74 285_ SM102 222_ SM102 with Preset 192_ CD102 200_ CD102 with Preset 170_
early sheets (first sheet), late sheets (missing sheets), misaligned sheets.
Paper (first sheet)
An early sheet exists if the first sheet of the sheet stream already covers the ANK sensor at press angle 1. The feeder and press stop immediately. The sheets are held back on the feed table.
Early sheet
A late sheet exists if none of the ANK sensors detects paper at press angle 3. The feeder stops and the remaining sheets are held back on the feed table. The sheets inside the press are printed and transported to the delivery. The press speed is then reduced to 3 000 i.p.h.
BAK SM52 20_ SM74 330_ SM102 336_ SM102 with Preset 336_ CD102 313_ CD102 with Preset 313_
Late sheet
A misaligned sheet exists if only one of the ANK sensors either on the drive side or on the operator side detects paper at press angle 3. The feeder stops and the remaining sheets are held back on the feed table. The sheets inside the press are printed and transported to the delivery. The press speed is then reduced to 3 000 i.p.h.
BAK SM74 330_ SM102 336_ SM102 with Preset 336_ CD102 313_ CD102 with Preset 313_
O.S.
Paper
Paper
D.S.
Note: On SM52 misalignment control is not required.
Misaligned sheet
212
Sheet alignment
Sheet alignment error detected by the FK sensors

The FK sensors detect:
BAK SM52 20_ SM74 330_ SM102 336_ SM102 with Preset 336_ CD102 313_
overshooting sheets.
Paper
Given a continuous sheet flow, an overshooting sheet exists if one of the FK sensors detects paper at press angle 3. The feeder and press stop immediately. The shingled sheets remain on the feed table.
Overshooting sheet
Note: The press can be started again from the feeder even if the FK sensor still detects the sheet of paper after the fault message Overshooting sheet. The press stops as soon as the pushbutton Production run or the illuminated pushbutton Feeder ON is pressed.
Extended functions
The extended functions are only active with the inductive double-sheet detector of SM52 and SM74. During paper transport: The control system monitors the paper transport on the feed table. For this purpose, the control system needs the signal from the FK sensor and the measuring result of the double-sheet detector. If during paper run the FK sensors do not detect a sheet being fed in although the double-sheet detector has registered a good sheet (no double-sheet), the control system switches the feeder off. There is probably a paper jam on the feed table. In the case of a double-sheet: The control system stops the press immediately (emergency stop) if the FK sensors detect paper in the case of a double-sheet. Thus no multiple sheets are fed into the press.
213
Sheet alignment
Misaligned-sheet display (trend display)

During paper run or production run, the misalignedsheet display appears on the MID. This display changes permanently and is a trend indication for the operator. The misaligned-sheet display does not intervene in press control. The ANK sensors of the sheet alignment control detect the misaligned sheet at the front lays. This misalignment between the drive side (D.S.) and operator side (O.S.) is determined and converted into a degree value. The degree value is represented as a line symbol on the MID (see ill.). The display is only visible if no settings and adjustments, fault messages, malfunctions or other information
Display of misaligned sheet. Drive side advanced.
Good sheet Optimum sheet arrival Misaligned sheet, D.S. advanced Display of misalignment up to max. 18 Misaligned sheet, O.S. advanced Display of misalignment up to max. 18
are indicated on the MID.
Note: The fault message Misaligned sheet and the misaligned-sheet display are not identical.
214
Sheet alignment
The sensors of the sheet alignment control are located at the front lays.
1B13 1B49
Place of installation of sheet alignment control
Layout and task

Running direction of paper FK ANK Reflex sensor Amplifier
The reflex sensors on the drive side and operator side of the sheet alignment system serve for paper detection. Each reflex sensor has two optical sensors ANK and FK monitoring the sheet alignment. The FK and ANK sensors are fitted in a housing. Viewed in the running direction of the paper, the paper first covers the ANK sensor. ANK = sensor for sheet alignment control FK = sensor for overshooting sheet control In the amplifier of the reflex sensor, the sensor signals are amplified and transmitted to the electronic control system. The amplifiers of the two reflex sensors are located at the side frame on the O.S., under the feed table.
X2
X1 To 1LVT1
Reflex sensor with amplifier
Pin assignment
ground free +24K FK+ ANK+ free ANK FK
Pin assignment 1B49:X1/1B13:X1
215
Sheet alignment
2
1/21
Position the press: SM102: 100 3 degrees CD102: 70 3 degrees
Loosen the fixing bolt on the brass block (1/21 rev.).
O.S. D.S.
Pull off the reflex sensor with the brass block towards the front.
Remove the amplifier.
216
Sheet alignment
Disconnect the cable leading to 1LVT1.
Remove the reflex sensor.
7
2 1
Slide the new reflex sensor into the guide of the holder.
Note: To fix the reflex sensor in position, carefully tighten the fixing bolt (tightening torque approx. 1 Nm).
Tighten the fixing bolt.
Turn the handwheel anticlockwise until the end stop comes to rest on the cross bar.
217
Sheet alignment
10
O.S.
D.S.
Connect the cable coming from 1LVT1 to the amplifier.
Fasten the amplifier.
11
1.5 2.0 mm
12
Push the reflex sensor and brass block on the guide pins through to the stop. Check the distance (1.5 2.0 mm).
Tighten the fixing bolt on the brass block.
218
Sheet alignment
Adjustment
1
0
Bring the bending in the 0 position. Press the pushbutton Forward until the sheet stop fingers are raised.
Position the press: SM102: 333 1 degree CD102: 310 1 degree
Turn the handwheel anticlockwise until the end stop comes to rest on the cross bar.
219
Sheet alignment
Turn the handwheel back by one revolution.
Place a sheet of paper of max. width (102cm) and approx. 20cm length against the front lays.
MID
MID
D.S. O.S.
D.S. O.S.
Turn the adjusting screw until the ANK symbol on the MID just lights up.
Turn the adjusting screw until the ANK symbol on the MID just lights up. Both ANK symbols on the MID must be lit.
220
Sheet alignment
10
2 1/6
Turn the handwheel clockwise for 1.3 mm +/0.1 mm (2 1/6 revs), using the scale as a reference.
Both ANK symbols must be lit. The FK symbols must not be lit.
11
1.3 mm +/ 0.1 mm FK ANK Front lay
MID
10 mm Paper
D.S. O.S.
Check the distance between the front lays and ANK sensor.
221
Sheet alignment

1B13 in the service display of the EAK: Input 13 = ANK (O.S.) Input 15 = FK (O.S.) 1B49 in the service display of the EAK: Input 49 = ANK (D.S.) Input 51 = FK (D.S.) 1 0 = sensor detects paper = sensor does not detect paper
Service display Present input/output, input/output board EAK
222
Sheet alignment
1B9/1B10 Pull lay control
1B9/1B10 Pull lay control Block diagram

The pull lay control (ZMK) monitors the entire pull procedure, i. e. the correct sheet infeed and the pull end position. The following applies to the degrees listed (see block diagram): At 4 and paper run: the ZMK must not detect any paper. At 5 and paper run: the ZMK and ANK must detect paper. At 5 and no paper run: the ZMK signal is not analyzed because the sheet alignment control does not detect paper.
ZMK
SM52 330_ SM74 15_ SM102 311_ CD102 289_ SM52 42.5_ SM74 72_ SM102 3_ CD102 341.5_ Paper
1B9/1B10
Pull lay control D.S. 1B9 O.S. 1B10 Audible signal device 12 H 55 SUM1 RL12 SUM1 RL12 Audible signal device 11 H 55
The reflex sensors on the drive and operator sides serve for paper detection. Depending on the pull direction only one of the two reflex sensors is necessary for monitoring. The pull direction is entered under the command Presetting. Only the reflex sensor of the active pull lay is interrogated. In the signal conversion modules SUM 1 the signals of the reflex sensors are amplified. The circuit state of each sensor is signalled by an LED on the corresponding SUM 1 (LED is lit = reflex sensor detects paper). SM52 only: On SM52 the signals are amplified by the amplifiers of the reflex sensors RL12.
1 LVT 1 1EVM4
12 LVT 1 12EVM4
11 LVT 1 11EVM4
EAK 1
EAK 12
EAK 11
Displays MID12 MID11 ZID
The electronic control system evaluates the signals of the signal conversion modules. The signals from the amplifiers reach the processor board REK2 via the distribution box 1LVT1, the input/output distributor module EVM (SM52 only), the input/ output board EAK, the input/ output control board ESK.
ESK
SVM
DNK DSK
REK2 Legend: Data line Control lines
Block diagram of pull lay control

223
Sheet alignment
The REK2 analyzes the signals of the pull lay control. In the case of a pull or sheet infeed error, it passes the fault message to the control console display ZID, the press displays MID and the audible signal devices 11H55 and 12H55. For an acoustic fault message to be output, the function Audible signal device / pull lay control must be switched on in the central control console. D.S. Circuit states of the ZMK sensors on the MID
Display of pull lay control
O.S.
Circuit states displayed on the MID
With the help of the MID on the control panel of the feeder, the reflex sensors 1 B9 and 1 B10 can be monitored. The MID reflects the circuit state of the corresponding sensor. Symbol lit Symbol not lit = sensor detects paper = sensor does not detect paper
The circuit states of the reflex sensors are visible when the switch Safe on the control panel of the feeder is set to Safe and the printing speed is x 3500 i.p.h.
When does a sheet infeed error/pull error exist?

ZMK SM52 330_ SM74 15_ SM102 311_ CD102 289_ Paper
A sheet infeed error exists if the sheet is already below the reflex sensor at the interrogation point. The sensor detects paper.
Sheet infeed error
224
Sheet alignment
ZMK SM52 42.5_ SM74 72_ SM102 3_ CD102 341.5_ 1B13/1B49 1B9/1B10 Paper
A pull error exists if, at the interrogation point: the ANK sensors (1B13/1B49) detect the print sheet and the ZMK sensor does not detect the print sheet.
Pull error
225
Sheet alignment
The pull lays with the reflex sensors are fitted on two cross bars in front of the transfer gripper drum. One pull lay is fitted on the operator side (1B10) and one on the drive side (1B9).
1B9 1B10
Place of installation of pull lays
Signal conversion modules SUM1
Under the feed table, the two signal conversion modules SUM1 are fitted on a support bar. Each is allocated to one of the pull lays.
Place of installation of signal conversion modules
226
Sheet alignment
Adjustment (Preset version)

The adjustment must be made: for the first start-up when changing the printing material (paper) in the case of frequent fault messages. Enter the required sheet width in the command mode Presetting. After command enabling, the control system positions the pull lay to the entered format. Set the selector switch Safe on the control panel at the feeder to Safe. Press the illuminated pushbutton Feeder, so that the button is lit. Press the pushbutton Forward until the sheet stop fingers are raised. Press the pushbutton Forward until the pull lay stop is below the upper edge of the sheet metal plate. The pull rail must not have grabbed the sheet yet. The sheet can still be moved. Pull the sheet against the pull lay stop; the paper must be under the reflex sensor 1. Turn the knurled head screw 2 clockwise, until the green LED at the corresponding signal conversion module goes off. Turn the knurled head screw 2 anticlockwise, until the green LED just lights up. Turn the knurled head screw 2 anticlockwise for another 10 notch positions (= 0.3 mm; corresponds to approx. 1/4 rev. of 2). Take out the sheet. The LED of the reflex sensor goes off.
2 3
5
Adjustment of pull lays
a) b) Pull direction of sheet of paper Running direction of paper
6 7 8
c) Edge for format adjustment
227
Sheet alignment
Adjust the spring pressure with the knurled head screw 3. The pressure the pull roll exerts on the printing material must be so strong that each sheet is pulled reliably to the pull lay stop. The locking nut 4 prevents the pressure from changing once it has been set. Reflex sensor Knurled head screw Knurled head screw Locking nut
1 2 3 4
228
Sheet alignment
Adjustment (standard version)

1 mm The adjustment must be made: a b for the first start-up when changing the printing material (paper) in the case of frequent fault messages. Loosen the tommy bar screw 1 and position the pull lay so that it complies with the sheet size at the feeder. Move the magnet cover plate 2 with recess until it is approx. 1mm away from the pull lay stop 3.
1 2
Note: The pull lay stop must not lie on the magnet cover plate while the paper is being pulled.
3
+ -
Set the selector switch Safe on the control panel at the feeder to Safe. Press the illuminated pushbutton Feeder, so that the button is lit. Press the pushbutton Forward until the sheet stop fingers are raised. Press the pushbutton Forward until the pull lay stop is below the upper edge of the sheet metal plate. The pull rail must not have grabbed the sheet yet. The sheet can still be moved. Pull the sheet against the pull lay stop; the paper must be under the reflex sensor 4. Loosen the knurled head screw bit.
4
c
5
a) b) Pull direction of sheet of paper Running direction of paper
6 7 8 9
c) Edge for format adjustment
5 a little
Turn the knurled head screw 6 clockwise, until the green LED at the corresponding signal conversion module goes off. Turn the knurled head screw 6 anticlockwise, until the green LED just lights up. Turn the knurled head screw 6 anticlockwise for another 14 notch positions (= 0.4 mm; corresponds to approx. 1/4 rev. of 6).
229
Sheet alignment
q w e
Retighten the knurled head screw 5. The LED of the corresponding reflex sensor must still be lit. Take out the sheet. The LED of the reflex sensor goes off. Adjust the spring pressure with the knurled head screw 8. The pressure the pull roll exerts on the printing material must be so strong that each sheet is pulled reliably to the pull lay stop. The locking nut 9 prevents the pressure from changing once it has been set.
Pull lay
Checking the sensing distance of the reflex sensors

This check must be carried out: . for the first start-up in the case of frequent fault messages.
The distance between the lower edge of the reflex sensor and the surface of the magnet cover plate 2 must be 4.5 5 mm. When fitting the reflex sensor pay attention to this.
Sensing distance
1 2 3 4 5
Tommy bar screw Magnet cover plate Pull lay stop Reflex sensor Knurled head screw
6 7 8 9
Knurled head screw Paper Knurled head screw Locking nut Lower edge of reflex sensor
230
Sheet alignment
1B11 Double-sheet detector
1B11 Double-sheet detector Block diagram

Optical sensor system Transmitter 1B11S Receiver 1B11E The double-sheet detector monitors sheet infeed at the feeder. It detects multiple sheets and irregularities in the sheet flow and thus prevents malfunctions. An optical sensor system consisting of a transmitter (1 B11 S) and a separate receiver (1 B11 E) transmits light through the paper. The receiver supplies a signal. The amplitude of the signal depends on the thickness and nature of the printing material. The control device DBE supplies the optical sensor system with operating voltage. Apart from this, the control device helps to process the sensor signal and to adjust the double-sheet detector to the printing material used. Shortly before the sheet enters the first printing unit, the electronic control system checks the amplitude of the signal supplied by the receiver. Monitoring occurs at the following press angles: EAK 1
ZID
Control device DBE 1LVT1

Displays MID12 MID11
336 _ (SM102), 313_ (CD102).
DNK
If the light does not pass through the paper at this point, there are two or more sheets. The signal reaches the processor board REK2 via the distribution box 1 LVT1, the input / output board EAK, the input / output control board ESK.
ESK
SVM
DSK
REK2
Legend:
Block diagram of double-sheet detector
The REK 2 analyzes the signals from the doublesheet detector. If there is a double-sheet, REK 2 stops the feeder. The electronic control system reduces the press speed to 3 000 i.p.h. Simultaneously, REK 2 transmits a fault message to the control console display ZID and the press displays MID.
231
Sheet alignment
Fault messages in the case of a double-sheet

Press display MID The fault symbol # appears under the pictogram for double-sheet.
MID after detection of a double-sheet

Selection Control console display ZID Selection of the display Entire press (production run display). Symbol Double-sheet detector The symbol Double-sheet detector appears if the sensor 1B65 or 1B66 detects a double-sheet.
Selection and symbol

Selection Selection of the display Feeder / warning
Symbol Electronic double-sheet detector
The symbol Electronic double-sheet detector appears if the sensor 1B65 or 1B66 detects a double-sheet.
Selection and symbol
232
Sheet alignment
The control device of the double-sheet detector is fitted near the signal conversion modules at the sheet alignment system.
Control device
Control device of double-sheet detector

The sensor is fitted on the press centreline in the area of the front lays.
Sensor of double-sheet detector
Sensor of double-sheet detector
233
Sheet alignment
Layout
Components of double-sheet detector
1 2 3 4

Control device of double-sheet detector DBE with operators controls 1 B11 S Transmitter with connecting cable and fixing bracket 1 B11 E Receiver with connecting cable and fastening element Cable to distribution box 1LVT1 at PU 1. It comprises: the power supply for the control device DBE (+ 24 V) the signal line from the control device DBE to the electronics. Potentiometer for adjustment of sensitivity
6 7
The LED lights up as soon as there are two or more sheets. Selector switch for adjustment of paper thickness
Paper thick
Control device off
Paper thin
234
Sheet alignment
Connection and pin assignment
X1
1LVT1 at PU1 1B11 Transmitter
Control device
X2
X3 1B11 Receiver
Connection principle
Pin assignment of connector X1: Contact no. on X 1 1 2 3 4 5 Function Ground 24 V +24 V Signal Core identification 1 +1 XE 11 Terminal in LVT X2: 1 X2: + 1 FEM 64 XE 11
235
Sheet alignment

The transmitter and receiver are each screwed to the fastening elements with one screw. Each fastening element is held in place by two screws. The distance between transmitter and receiver must be between 8 mm 12 mm.
Note: The upper edge of the receiver 1 B11 E must be flush with the table edge.
The transmitter and receiver must be in perfect alignment, i.e. arranged on the same centreline. The control device is screwed to the fixing bracket with 3 screws. The fixing bracket is screwed to the press with two screws.
Components of double-sheet detector
1 2 3 4 5 6 7
Receiver 1 B11 E Transmitter 1 B11 S Fastening element for receiver Fastening element for transmitter Screws for fastening element Fixing bracket for control device Screws for fixing bracket
236
Sheet alignment
Adjustment Attention:
The adjustment must be carried out: each time the printing material changes, if printed sheets are printed on again.
Prerequisite for adjustment: press ready to run, paper run possible.
1 2
Check the distance between the transmitter and receiver: required distance 8 12 mm. The receiver does not jut out from the table edge. Position the press to a press angle of 281 1 degrees (CD102) or 304 1 degrees (SM102) and place a sheet of maximum width against the front lays and pull lay stop. Set the selector switch for paper thickness 0 to and turn the potentiometer anticlockwise to the stop. The LED is lit. Turn the potentiometer slowly clockwise and watch the LED :
if..
.. LED
goes off:
.. LED
does not go off:
Continue turning the potentiometer clockwise for another 10 scale marks. Continue with
5 6 7
8.
Set the selector switch 0 to and turn the potentiometer anticlockwise to the stop. Turn the potentiometer clockwise until the LED goes off. Continue turning the potentiometer clockwise for another 10 scale marks.
Check the functioning of the double-sheet detector with a simulated double-sheet.
237
Sheet alignment
11M3 Automatic sheet arrival control

possible sheet arrival BAK optimum sheet arrival 285_ 222_ 192_ 200_ 170_ 303_ 238_ 208_ 216_ 186_ 330_ SM74 336_ SM102 336_ SM102 with Preset 313_ CD102 313_ CD102 with Preset
The automatic sheet arrival control influences the transport of the sheets to the front lays. It regulates the shingle stream in such a way that the individual sheets are positioned against the front lays at a certain press angle (see illustration). By means of a servo-drive (11M3) the drive chain of the feeder is adjusted. Thus the point of time of sheet arrival is controlled.
Point of time of sheet arrival

Sheet alignment control D.S. 1B13 O.S. MID11 1B49 MID12 RL12 RL12 DNK DSK ZID Displays
1LVT1
The ANK sensors (1B13/1B49) register when the sheets arrive at the front lays. On the basis of the ANK signals the computer on the processor board REK2 determines the point of time of sheet arrival. If there is a deviation from the optimum sheet arrival, the shingle stream at the feeder must be regulated. REK2 passes the new reference values for sheet arrival to the servo-drive control board SSK. The SSK controls the servo-drive 11M3. If the automatic sheet arrival control reaches the end of its control range in the process, the symbol End of positioning range appears on the press displays MID and on the control console display ZID (production run display). The press control is not affected by this.
EAK
ESK
SVM
SSK
SAK
1SSM1
REK2
11M3
M Automatic sheet arrival control
Legend:
Data lines Control lines
Block diagram of automatic sheet arrival control
238
Sheet alignment
The symbol End of positioning range will, however, only disappear when the operator repositions the servo-drive manually. This can be done at the control console by means of the Sheet arrival control function.
End of positioning range displayed on the press display MID
Activating and inactivating the automatic sheet arrival control
Selecting the automatic sheet arrival control
Symbol Automatic sheet arrival control on / off
Inactivating and activating the automatic sheet arrival control: in the preselection display, by means of the function button.
If the symbol is lit, the automatic sheet arrival control is active.
Preselection/coarse display
Sheet arrival control

The sheet arrival control is automatically activated when the operator switches off the automatic sheet arrival control. Symbol of the sheet arrival control in the ... actual value / coarse display For the sheet arrival control the operator enters a fixed value. The setting is made at the control console by means of the right-hand +/buttons. Press model actual value / fine display SM102 CD102 SM74 Setting range Standard Preset version version 2 to +18 10 to +10 10 to +10 4 to +16
239
Sheet alignment
Graphical representation of sheet arrival

The graphical representation of sheet arrival is only visible during paper run.
Selecting the fine display

Deviation from optimum sheet arrival D.S. Mean value of the two deviations Deviation from optimum sheet arrival O.S.
Note: The display is updated with a delay. Actual value/fine display

The misaligned-sheet display on the MID gives the operator information about sheet arrival. Optimum sheet arrival Sheet arrives at the front lays before the optimum sheet arrival
Misaligned-sheet display
Sheet arrives at the front lays after the optimum sheet arrival
240
Sheet alignment
11M3 Automatic sheet arrival control (standard version)
11M3 Automatic sheet arrival control (standard version) Place of installation
Technical data
241
Sheet alignment
X10 X5
SSR
SSR X10
X11 X12 X3 X13 X14 X4
SSR X11
11 11
1SSM2: X1
11LVT1
1SSM2: X2
X1 X3 X2
1SSM2
11M3: X1
3 2
4 5 1
11M3
Servo-drive 11M3
11M3:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: A1 X5: A2 X5: A3 X5: A4 X5: A5 SSR X10: B2 X10: D2 X11: 3 X11: 4 X11: 5 SIGNAL Motor + Motor 10V Tap
+ 10V 0V
X1: X1: X3: X3:
1 2 3 4
X3: 5
242
Sheet alignment
1
1
0 1
2 2 1
4
1
3 1 2
243
Sheet alignment
5
2
1 2 mm
7
1
8
3 2 1
22 5 4
0 1
244
Sheet alignment
10
11
12
2 1 1
245
Sheet alignment
13

Servo-drive Automatic sheet arrival control 11M3 Input + 18 2 Incremental value 3134 " 4 inc 963 " 4 inc
246
Sheet alignment
11M3 Automatic sheet arrival control (Preset version)
11M3 Automatic sheet arrival control (Preset version) Place of installation
11M3
Operator side
Technical data
247
Sheet alignment
X10 X5
SSR
SSR X10
X11 X12 X3 X13 X14 X4
SSR X11
11 11LVT1 1SSM1: X1
X3 X4
X2 X1 X5
1SSM1: X3
1SSM1
11M3: X1
3 2
4 5 1
11M3
Servo-drive 11M3
11M3:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: A1 X5: A2 X5: A3 X5: A4 X5: A5 SSR X10: B2 X10: D2 X11: 3 X11: 4 X11: 5
+ 10V 0V
X1: X1: X3: X3:
1 2 3 4
X3: 5
248
Sheet alignment
2
1 2
2.0 mm (approx. 1 rev.)
Remove the servo-drive Automatic sheet arrival control 11M3.
Turn the mechanism against the upper stop. Set the distance ( 2.0 mm ).
01
3891 2 11M3: X1
Fasten the servo-drive to the mounting plate. Insert plug 11M3: X1. Set to 3891"2 inc. 249
Sheet alignment

Servo-drive Automatic sheet arrival control 11M3 Input + 10 10 Incremental value 205 " 4 inc 3891 " 4 inc
250
Sheet alignment
11M7 Automatic misalignment control

Sheet alignment control D.S. 1B13 O.S. MID11 1B49 MID12 RL12 RL12 ZID DNK DSK Displays
The automatic misalignment control influences the position of the sheets in such a way that they arrive parallel to the front lays. Automatic control is effected through: the servo-drive 11M7, the guide rail (D.S.) of the forwarding suckers at the suction head. by the ANK sensors on the D.S. and O.S.
The misalignment is registered:

1LVT1
The deviation between the registered values is an indication of the misalignment of the sheets in relation to the front lays (not to the feed table). EAK ESK
SVM
If the misalignment exceeds three degrees, the automatic control compensates for the deviation. The automatic misalignment control does not intervene in press control.
SSK
SAK
1SSM1
REK2
11M7
M Automatic misalignment control
Legend:
Block diagram of automatic misalignment control

Position of guide rail D.S. at suction head Position of sheet Front lays O.S. D.S.
The graphical representation on the left shows the mechanical principle of the misalignment correction.
Principle of the misalignment correction

251
Sheet alignment
Activating and inactivating the automatic misalignment control
Selecting the automatic misalignment control
Symbol Automatic misalignment control on / off
Inactivating and activating the automatic misalign ment control: in the preselection display, by means of the function button.
If the symbol is lit, the automatic misalignment control is active.
Preselection/coarse display
Misalignment control
The misalignment control is automatically activated when the operator switches off the automatic misalignment control. Symbol of the misalignment control in the ... actual value/coarse display actual value/fine display For the misalignment control the operator enters a fixed value. The setting is made at the control console by means of the right-hand +/ buttons. Setting range Press model SM102 CD102 10 to +10 10 to +10
252
Sheet alignment
Graphical representation of sheet arrival
Selecting the fine display

The graphical representation of sheet arrival also gives the operator information about the misalignment of the sheets during paper run. Deviation from optimum sheet arrival D.S. Mean value of the two deviations Deviation from optimum sheet arrival O.S.
Actual value/fine display Note: The display is updated with a delay.
During paper run or production run, the misalignedsheet display appears in the MID. This display changes permanently and is a trend indication for the operator. Good sheet optimum sheet arrival Misaligned sheet, D.S. advanced Display of misalignment up to max. 18 Misalignedsheet display Misaligned sheet, O.S. advanced Display of misalignment up to max. 18
253
Sheet alignment
11M7
Preset feeder
Technical data
254
Sheet alignment
X10 X5
SSR
SSR X10
X11 X12 X3 X13 X14 X4
SSR X13
11 11LVT1 2SSM1: X1
X3 X4
X2 X1 X5
2SSM1: X3
2SSM1
11M7: X1
3 2
4 5 1
11M7
Servo-drive 11M7
11M7:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 2SSM 1 X5: A1 X5: A2 X5: A3 X5: A4 X5: A5 SSR X10: X10: X13: X13:
+ 10V 0V
X1: X1: X3: X3:
1 2 3 4
B10 D10 3 4
X3: 5
X13: 5
255
Sheet alignment
O.S. D.S. O.S. D.S.
Guide rails Remove the servo-drive Automatic misalignment control 11M7. Position the guide rails of the forwarding suckers parallel to each other.
3
4)
05
2048 2
11M7: X1 256 Insert plug 11M7: X1. Set to 2048 2 inc.
Sheet alignment

Servo-drive Automatic misalignment control 11M7 Input 10 +10 Incremental value 1434 " 2 inc 2662 " 2 inc
257
Sheet alignment
258
Sheet monitoring
1...nB48/1...nB48a Sheet travel monitor
Sheet monitoring
The sheet travel monitor Paper run Reflex sensor 1...9B48 Paper Control switch 1...9B48a Segment disk Impression cylinder monitors the paper run, is fitted in each printing unit, consists of: the reflex sensor 1...9B48, the control switch 1...9B48a, the segment disk for the control switch.
The reflex sensor detects the front edge of the paper at the impression cylinder. The control switch and the segment disk determine the point of time of the interrogation. The signals from the reflex sensor and control switch are combined in the reflex sensor and transmitted to the control system. Signals during paper run (see illustration): The segment disk is within the operating range of control switch 1...9B48a. At the same time, the reflex sensor 1...9B48 detects the front edge of the paper. The LED on the reflex sensor 1...9B48 is lit. No signal to the control system.
LED
Irregularity in paper run No paper
LED 1 LVT1
Displays MID12 MID11 ZID
Signals in the case of irregularities in the paper run (see illustration): The segment disk is within the operating range of control switch 1...9B48a. At the same time, the reflex sensor 1...9B48 does not detect paper. The LED on the reflex sensor 1...9B48 is not lit. Signal to control system. REK2 intervenes in press control.
EAK 1
DNK
ESK
SVM
DSK
REK2
Legend:
Block diagram of sheet travel monitor

259
Sheet monitoring
The electronic control system analyzes the signals from the reflex sensor as long as there is paper in the press. Via the input/output board EAK of the corresponding printing unit and the input/output control board ESK the signals are transmitted to the processor board REK2. In the case of a fault, REK2 intervenes in press control and triggers various processes: press and feeder stop, dampening systems and inking units are thrown off, impression throw-off, display of fault at printing unit, in press displays MID and control console display ZID.
In the MID, the position code of the corresponding printing unit appears under the fault symbol.
Fault display in MID

Fault display in production run display (ZID) Symbol Blanket control detects paper (fault display in ZID) In the ZID (production run display), the fault symbol appears with the corresponding position code. Simultaneously, the symbol Blanket control detects paper appears in the fault display. The fault can be acknowledged and deleted by pressing the button allocated to the symbol. The fault is eliminated: after removing the sheet from the base or after removing the piece of sheet from the blanket and after lifting the guard Plate cylinder.
The electronic control system allows the press to continue running.
260
Sheet monitoring
Service display
To check the input 48, select the service display Present input/output (e.g. EAK2_02) of the corresponding printing unit. Buttons to be pressed for this selection:
1)
2)
3)
4)
Service display EAK2_02 of PU2
Circuit state of input 48: 1 = reflex sensor detects paper, no signal to the control system. 0 = reflex sensor does not detect paper, signal to control system.
Input 48 (sheet travel monitor 1...9B48)
261
Sheet monitoring
1...nB48 (middle of press) 1...nB48a (operator side)
Impression cylinder in printing unit
Speedmaster CD operator side
262
Sheet monitoring
Components
Reflex sensor 1...nB48
Reflex sensor 1...nB48 detects does not paper detect paper 24V LED (LED lit) 0V (LED not lit) 3 4 2 1
ca. 24V
0V
Reflex sensor
Control switch 1...nB48a
Control switch
Adjustment
Adjustment of reflex sensor 1...nB48
Adjustment of control switch 1...nB48a
263
Sheet monitoring
1...nB48
70 1 mm Remove reflex sensor 1...nB48. Fit the reflex sensor and insert the plug. Set the distance (70 1 mm) between the reflex sensor and impression cylinder.
4
1.0_
LED LED LED
Turn the impression cylinder in the direction of printing (see arrow) so that the LED just lights up (reflex sensor detects cylinder surface).
Turn the impression cylinder back by 1.0 (see arrow). The LED is not lit.
1...nB48a 1...nLVT1 Remove control switch 1...nB48a. Withdraw the plug from 1...nB48. Fit the control switch and connect it with the reflex sensor (see circuit diagram).
264
Sheet monitoring
7
1...nB48a Segment disk 0.8 1.0 mm
The segment disk must run in the middle of the recess and must not contact the control switch. Pay attention to both segments.
Select the service display Present input/ output of the corresponding printing unit.
Direction of printing
2) 1
1) Loosen the segment disk. Turn the segment disk in the direction of printing until input 48 changes from 1 to 0. Fasten the segment disk. Check the adjustment.
265
Sheet monitoring
266
Plate clamping device
Autoplate

Autoplate Method of functioning
The main components of Autoplate are: a modified plate cylinder with air supply and two pneumatic bars to open the front and rear clamping bars, a pressing bar which is brought into contact with the plate cylinder by two cylinders, two position switches which monitor the position of the pressing bar, four pneumatic valves which actuate the pneumatic bars, the two cylinders of the pressing bar and the control air for the air supply.
For actuation of the cylinders an operating pressure of approx. 6 bars is required. This pressure is generated by the pneumatic system compressor E4 and is kept at a constant level by the maintenance unit. The compressor is switched on after Main switch on.
Air supply, connections: S Control air, air supply 1 Opening the rear clamping bar 2 Opening the front clamping bar Control panel Pressing bar Position switch Finger guard 2: n S 25 a Monitoring the pressing bar D.S. n S 25 b Monitoring the pressing bar O.S. Pneumatic n Y7 n Y 61 n Y 62 n Y 63 valves from top to bottom: Pressing bar on / off Control air, air supply Opening the front clamping bar Opening the rear clamping bar
2 3 4 5
Operator side of printing unit
Note: Before the rear or front clamping bar is opened, control air must be admitted to the air supply facility in the plate cylinder. For this purpose, the plate cylinder must be at standstill; otherwise the gaskets could become subject to abrasion. This, in turn, could cause unintentional venting of the control line. Then the rear and front clamping bars cannot be opened anymore.
267
Autoplate
Fault display
Button sequence
The pressing bar and / or the upper finger protecting bar was actuated. The following position switches can be actuated: Monitoring the pressing bar n S 25 a (drive side) n S 25 b (operator side), Monitoring finger guard 2 n S 25 (operator side).
Malfunctions in 2nd printing unit
268
Autoplate
Block diagram
E4 n Y7 n Y 61 n Y 62 n Y 63
n S4
n S17
n S59 n H59
n S 25a / n S 25b
EAK15
EAKn
SEK
REK1 DSK DNK ZID REK2
ESK
Legend: Parallel data line Serial data line
SAK
Control line Pneumatic line
Electronic control system
Block diagram Autoplate

E4 n Y7 n Y61 n Y62 n Y63 n S4 n S17 Pneumatic system compressor Pneumatic valve Pressing bar on / off Pneumatic valve Control air, air supply Pneumatic valve Opening the front clamping bar Pneumatic valve Opening the rear clamping bar Selector switch Safe Pushbutton Position
n S59 / n H59 Illuminated pushbutton Plate clamping n S25 a / b Position switch Monitoring the pressing bar D.S./O.S. 269
Autoplate
Sequence of functions
The indicated press angles are valid for printing unit 1. From unit to unit these values differ as follows: Speedmaster SM 102 74.57 _ , Speedmaster CD 102 197.28 _.
Condition: The plate cylinder will only turn to the correct position for plate clamping/unclamping, if the coarse register is set to zero or if the coarse register sensor n B53 has acquired the current press angle (see also chapter Coarse register monitoring).
Positioning the plate cylinder
Unclamping the rear edge of the plate
Plate removal
Unclamping / clamping the front edge of the plate
Plate insertion
Clamping the rear edge of the plate
Actuation of operators controls:
Opening the rear clamping bar n Y63 actuated
0.3 s
0.3 s
2.0 s
Opening the front clamping bar n Y62 actuated
0.3 s 1.0 s
2.0 s
Air supply control air n Y61 actuated
0.5 s
Enabling main motor
2.0 s
0.5 s
Enabling main motor
Enabling main motor
0.5 s 1.8 s
Pressing bar on / off n Y7 actuated Press angle
0.5 s
264.8 _
322.6 _
297.5 _
270
1...nB53 Coarse register monitoring
1...nB53 Coarse register monitoring Place of installation

The sensor Coarse register monitoring B53 is fitted in each printing unit. It is located behind the servo-drive of the circumferential register where it is screwed to a fixing angle.
B53
Place of installation of sensor Coarse register monitoring
Layout/connection 1 2 3
Sensor Locking nut Connecting cable Function DC 24V ground 24V output signal
Core brown blue black
Layout of sensor Coarse register monitoring 1...nB53
271
Task/function 1 2
Positioning bolt Sensor B53
Sensor and positioning bolt
The inductive sensor 1...nB53 registers the manual coarse adjustment of the circumferential register. After each coarse adjustment of the circumferential register, the operator must turn the press at crawl speed for at least one full revolution. Only then can the sensor register the adjustment and pass the corresponding adjustment value on to the press control system. While the press turns at crawl speed, the sensor sees the positioning bolt rotating past it. The zero position of the plate cylinder serves as a reference point for the sensor. If the sensor detects a deviation from the reference point with the help of the positioning pin, the value is passed on to the press control system. The deviation corresponds to the coarse adjustment of the register. The press control system determines the press angle on the basis of the adjustment value. Thus exact positioning of the plate cylinder is possible again (e.g. important for the function Autoplate).
Note: To ensure that the sensor recognizes the manual coarse adjustment of the register, the press must turn at crawl speed for min. 1 revolution after every adjustment.
Removal and installation 1 2

Positioning bolt Sensor B53
1.0 mm 0.5 mm
The sensor must be installed in such a way that there is a distance of 1 mm 0.5 mm between the positioning bolt and the sensor. Tighten the sensor with the locking nut and carry out the Adjustment (see next page).
Fitting the sensor "Coarse register monitoring
272
Adjustment
Note: The adjustment is necessary after every:
installation and removal of the sensor, exchange of the software, exchange of the processor boards REK 1 / 2 and of the display control board DSK, basic initialization of REK 1 / 2 and DSK, first start-up. Set the circumferential register on all printing units manually to 0. Insert the positioning bolt at 52 mm 1. Also refer to the operating manual, chapter C Printing unit, circumferential register Setting to zero .
Set the circumferential register to zero on CPC 1-04 (precision setting). Also refer to the operating manual for CPC 1-04. Set perfector presses to straight printing. Turn the press at crawl speed. Select the function Coarse register adjustment value 2 for each printing unit at the control console (Service display, Printing unit). The corresponding symbol lights up. The symbol cannot be deactivated anymore. The operator guidance disappears. The reference-point run starts. After the zero position of the coarse register has been detected by the sensor, the function 2 becomes inactive. The sensor has determined the zero position and has passed it on to the press control system.
3 4 5
273
274
Washup devices
Control by command Washup
Washup devices
Control by command Washup Selection of functions
Command Washup
Actual value display Printing unit selection
Service display
Printing unit selection
The command Washup can be aborted any time with the button Delete.
Input
Only with start-up warning
Control by command Washup

275
Washup devices
Messages
Messages Faults at print start and during printing
Messages
Press not ready to run
Fault in the press. Washing cannot be carried out.
Note: Terminate the command Washup with the button Delete. To locate the fault select Entire press and the fault display.
Paper in the press
On command initiation there is still paper in the press. Washing can only be carried out when the paper has been transported out of the printing units into the delivery. Only applies to presses with UV dryer The blanket and inking rollers may only be washed 180 s after the last drying. If the command is enabled earlier, the symbol will light up and the remaining waiting time will be indicated. The washup programme only starts after the waiting time.
Dryer waiting time
276
Washup devices
Messages
Not enough water
Not enough water in the washup solution container E9: Sensor B1 "Monitoring water" (blanket / inking roller washup device).
Not enough washup solution
Not enough washup solution in the washup solution container E9: Sensor B54 "Monitoring washup solution, blanket washup device". Sensor B55 "Monitoring washup solution, inking roller washup device.
Inking roller washup device monitoring of ink blade
In the displayed printing unit the ink blade is not fitted. The sensor nB43 is not damped.
277
Washup devices
Service display Washup
Service display Washup Functions of the blanket washup device GTW

Button sequence
With the help of the Service display, spray procedures with water and washup solution can be initiated. Apart from this, the washup blades can be thrown on/off. All functions can be activated during standstill of the press or during Run. The functions can be activated either printing unit by printing unit or for all units simultaneously. The corresponding solenoid valves are then actuated in the printing units.
Functions of the washup devices

Spraying with water Solenoid valve 1...nY54 actuated.
Spraying with washup solution
Solenoid valves 1...nY52 and 1...nY55 actuated.
Washup blade on/off
Solenoid valve 1...nY53 actuated.
Functions of the impression cylinder washup device DZW

Spraying with water Solenoid valve 1...nY43 actuated. The washup brush motors M43, M50...M56 start up. Solenoid valve 1...nY42 actuated. The washup brush motors M43, M50...M56 start up.
278
Washup devices
Functions of the inking roller washup device FWW

Button sequence
With the help of the Service display, spray procedures with water and washup solution can be initiated. Apart from this, the ink blades can be thrown on/off. All functions can be activated during standstill of the press or during Run. The functions can be activated either printing unit by printing unit or for all units simultaneously. The corresponding solenoid valves are then actuated in the printing units.
Functions of the washup devices

Spraying with water Solenoid valve 1...nY44 actuated.
Ink blade on/off
279
Washup devices
Selecting the washup solution

Button sequence
If you press the button Entire press in the Service display, you can choose between washing with mineral oil-based and vegetable oil-based washup solution. After a change, the parameters will be reset to default values.
Choosing between mineral oil-based and vegetable oil-based washup solution
Selectable functions Washing the blanket Washing the inking rollers Washing the impression cylinder
Mineral oil-based solution
Vegetable oil-based solution
280
Washup devices
Blanket washup device (GTW)
Blanket washup device (GTW) Block diagram
1...nY54
1...nY52
1...nY55
1...nY53
1...nY56
E4
E9
EAK Parallel data line Serial data line DSK REK2 ESK Control line Washup solution or water conduit DNK2 Pneumatic line ZID
Block diagram Washing the blanket

E4 E9 Y52 Y53 Y54 Pneumatic system compressor Washup solution container Blanket, washup solution Blanket, washup blade Blanket, water Y55 Y56 Blanket, washup brush Blanket, driving clutch
281
Washup devices
Layout 1 2 3 4 5 6 7 8 9
Blanket cylinder Rubber roller Rider roller Drop tubes for water and washup solution Wiper roller Washup blade Ink trough Spray tube for washup solution, washup brush Washup brush
Blanket washup device
Function
When the command has been enabled and the washup speed reached (5 000 i.p.h.), the drive of the washup brush is engaged by the solenoid valve nY56. The washup brush then turns at washup speed. The wiper roller and washup brush are driven. When the washup brush has been engaged and the 1st spray procedure has occurred, the washup device is brought in the position for washup (nY53), i.e. thrown on the blanket cylinder. First spraying with washup solution occurs. The solution is sprayed onto the blanket cylinder in two different ways: via the drop tube (nY52), rider roller and rubber roller and via the washup solution spray tube for the washup brush and the washup brush (nY55).
282
Washup devices
After the spray procedures with washup solution spraying with water occurs (nY54). The blade is in permanent contact with the wiper roller. The ink removed by the blade is collected in the ink trough and passed to a reservoir from there. Such a reservoir is provided on the drive side of each printing unit. After washing of the blanket, the press stays in operation (3000 i.p.h.).
283
Washup devices
Setting the number of cylinder revolutions and spray procedures for water and washup solution
Button sequence
The first actuation of the function button allocates the corresponding device to the right-hand and left-hand +/ buttons. After the allocation, the parameters can be changed with the +/ buttons. Pressing the function button again inactivates the device again.
Blanket washup device selected

Changeover between settings for water (top) and for washup solution (bottom) with the 1st function button (above the left-hand +/ buttons). Enter the number of cylinder revolutions with the left-hand + / buttons. water from 0 to 50 washup solution from 0 to 150. Enter the number of spray procedures with the right-hand +/ buttons. The setting range for the spray procedures goes from 10% to 100%. 10% = 1 spray procedure. 100% = 10 spray procedures.
284
Washup devices
Example
Setting for water: 10 30% 10 cylinder revolutions 3 spray procedures
Setting for washup solution: 40 30% 40 cylinder revolutions 3 spray procedures
Flow chart: Washing with washup solution and water

1.2 s
Water (nY54)
0.7 s (0.3 s if vegetablebased)
Washup solution (nY52) Blanket washup brush (nY55) Blanket driving clutch (nY6) Blanket washup blade (nY53) Revolutions 0 4 40 99 104 102
0.3 s
285
Washup devices
Inking roller washup device (FWW)
Inking roller washup device (FWW) Block diagram
1...nY44
1...nY50
1...nY9
1...nY10
1...nY11
1...nY51
E4
E9
EAK Parallel data line Serial data line DSK REK2 ESK Control line Washup solution or water conduit DNK2 Pneumatic line
ZID
Block diagram Washing the inking rollers

E4 E9 Y9 Y10 Y11 Pneumatic system compressor Washup solution container Inking form rollers Ink ductor Dampening rollers Y44 Y50 Y51 Inking rollers, water Inking rollers, washup solution Ink blade
286
Washup devices
Layout 1 2 3 4 5 6 7 8
Ink fountain roller Ink ductor Drop tubes for water and washup solution Dampening roller Plate cylinder Inking form roller Distributor cylinder Ink blade with rubber strip and ink fountain

Inking roller washup device
Function
When the command has been enabled and the washup speed reached (5 000 i.p.h.), washup solution is sprayed onto the inking rollers. For this purpose, the valve nY50 Inking rollers washup solution is actuated. Then the ink ductor is thrown on (nY10). After 40 cylinder revolutions and two spray procedures, the ink blade is thrown on ( nY51). The preselected spray procedures / cylinder revolutions are carried out. After the last spray procedure, the ink ductor is thrown off. Simultaneously, the inking form rollers (nY9) are brought into contact with the plate cylinder. When the inking form rollers are thrown off again, the plate cylinder is predampened during 20 revolutions, nY11 actuated. The press stops when washing is completed.
287
Washup devices
Setting the number of cylinder revolutions and spray procedures for water and washup solution
Button sequence
The first actuation of the function button allocates the corresponding device to the right-hand and left-hand +/ buttons. After the allocation the parameters can be changed with the +/ buttons. Pressing the function button again inactivates the device again.
Inking roller washup device selected Changeover between settings for water (top) and for washup solution (bottom) with the 1st function button (above the left-hand +/ buttons). Enter the number of cylinder revolutions with the left-hand + / buttons. Water: 0 ... 500 Washup solution: 150 ... 1000; if the ink fountain roller is washed in addition: 225 ... 1500. Enter the number of spray procedures with the right-hand + / buttons. Setting possible from 0% ... 100%.
Setting 100% 90% 80% 70% 60% 50% L 0%
1 spray procedure every ... 16 20 24 28 32 36 L 56
revolutions
The first spray procedure lasts 0.8 s, the others 0.4 s.
288
Washup devices
Additional washing of printing plate and ink fountain roller

Additional washing of printing plate Additional washing of ink fountain roller Condition: Before selecting the function Additional washing of ink fountain roller, remove the ink from the ink fountain and carry out an ink shut-off at CPC 1-04. The printing plate and ink fountain roller can be washed in addition via the inking roller washup device. The inputs are valid for the selected printing units.
Example
Setting for water: 50 70% 50 cylinder revolutions one spray procedure every 28 revolutions
Setting for washup solution: 225 70% 225 cylinder revolutions one spray procedure every 28 revolutions
289
Washup devices
Flow chart: Washing with mineral oil-based washup solution without water
If printing plate is washed as well
Dampening rollers (n Y11) Inking form rollers (n Y9) Ink ductor (n Y10) Ink blade (n Y51) Water (nY44) Washup solution (n Y50) Revolutions
0.4 s 0.2 s 0.2 s
66% of preselected cylinder revolutions if printing plate is washed as well 80% of preselected cylinder revolutions if printing plate is washed as well
20
20
40
30 20
Preset spray procedures washup solution
Preselected cylinder revolutions washup solution
Flow chart: Washing with mineral oil-based washup solution without water
Flow chart: Washing with mineral oil-based washup solution and water
Dampening rollers (n Y11) Inking form rollers (n Y9) Ink ductor (n Y10) Ink blade (n Y51) Water (nY44) Washup solution (n Y50) Revolutions
0.2 s 0.4 s 0.4 s
as 1st section above (without water)
x1
x2
x2
Preset spray procedures water
40
30
20
Preselected cylinder revolutions water
Flow chart: Washing with mineral oil-based washup solution and water
290
Washup devices
Flow chart: Washing with vegetable oil-based washup solution and water
If printing plate is washed as well
Dampening rollers (nY11) Inking form rollers (nY9) Ink ductor (nY10) Ink blade (nY51) Water (nY44) Washup solution (nY50) Revolutions
0.4 s 0.2 s 80% of preselected cylinder revolutions if printing plate is washed as well
66% of preselected cylinder revolutions if printing plate is washed as well
8
0.2 s
0.4 s
0.4 s
x1
x1
x1
x1
x2
x2
80
30 20
Preset spray procedures water
Flow chart: Washing with vegetable oil-based washup solution and water
291
Washup devices
Impression cylinder washup device (DZW)
Impression cylinder washup device (DZW) Block diagram
1...nY43
1...nY42
1...nY41
M50 ... M56, M43
E4
E9
EAK Parallel data line Serial data line DSK REK2 ESK Control line Washup solution or water conduit DNK2 Pneumatic line
ZID
Block diagram Washing the impression cylinder

E4 E9 Pneumatic system compressor Washup solution container 1...nY41 1...nY42 1...nY43 Impression cylinder, washup brush Impression cylinder, washup solution Impression cylinder, water
M50 ... M56, M43 Washup brush motors
292
Washup devices
Layout 1 2 3 4 5 6 7
Impression cylinder washup device
Impression cylinder Spray tube for water Washup brush motor Washing trough Spray tube for washup solution Blade Washup brush
Function
Each printing unit has a washup brush which is connected with the washup brush motor via gears. The motor is located in the middle of the printing unit, under the impression cylinder. When the command has been enabled and the washup speed of 5000 i.p.h. has been reached, the following functions are initiated: starting up the washup brush motors M50 ... M56, M43 throwing on the washup brushes (1...nY41) opening the spray tubes for washup solution (1...nY42) opening the spray tubes for water (1...nY43).
The washup solution and water for the impression cylinder washup device come from the washup solution container E9 which also supplies the blanket washup device. After washing, the press stays in operation (3000 i.p.h.).
293
Washup devices
Setting the number of cylinder revolutions and the spray duration for water and washup solution
Button sequence
The first actuation of the function button allocates the corresponding device to the right-hand and left-hand +/ buttons. After the allocation the parameters can be changed with the +/ buttons. Pressing the function button again inactivates the device again.
Impression cylinder washup device selected
Changeover between settings for water (top) and for washup solution (bottom) with the 1st function button (above the left-hand +/ buttons). Enter the number of cylinder revolutions for water and washup solution with the left-hand +/ buttons: Water: Washup solution: 0 and 30 0, 50 and 100
Enter the spray duration for water and washup solution with the right-hand +/ buttons: Setting range from 0 to 100%. Dependent on the setting, the basic pulse duration for washup solution and water is shortened or lengthened.
Setting 0% 10% L 50% L 90% 100%
Change in basic pulse duration 0.5 s 0.4 s L 0 L + 0.4 s + 0.5 s
294
Washup devices
Example
Setting for water: 0 50% 0 cylinder revolutions basic spray duration +/ 0 s
Setting for washup solution: 50 50% 50 cylinder revolutions spray duration 0 s
Washup brush motor (M43, M50...M56) Impression cylinder washup brush (n Y41) Water (nY43)
2.0 s+/x 0.7s+/x 0.7 s+/x 0.5 s+/x 0.5 s 1,0 s
Spray duration
3.0 s+/x
2.0 s+/x
1.0 s+/x
Washup solution (n Y42) 25 Revolutions

25
25
25
15
15
30
295
Washup devices
M43, M50...M56 Washup brush motors
M43, M50 ... M56 Washup brush motors Place of installation

The washup brush motors are located in the middle of each printing unit, below the impression cylinder. They are accessible through the lower opening in the side frame on the O.S. These washup brush motors are only available for CD102.
Washup brush motor in printing unit
Pin assignment
Pin A2
A B C 1 2 3 4 5
Function AC 400 / 480 V phase U AC 400 / 480 V phase V AC 400 / 480 V phase W PE conductor
B3 C2
Plugs M43-X1, M50-X1 ... M56-X1
296
Washup devices
E9 Washup solution container
E9 Washup solution container Block diagram 1 2

15K4M M4 B1 M4 B54 B55 E9 F70 B1 B54 B55 F70 Pressure reducer with check valve Safety valve Contactor, pneumatic system compressor Pneumatic system compressor Sensor Monitoring water. Sensor Monitoring washup solution, blanket washup device Sensor Monitoring washup solution, inking roller washup device Washup solution container Pressure switch
15K4M
E9
EAK
ESK
REK Pneumatic line Control line Parallel data line
Block diagram: washup solution container E9
297
Washup devices
Warnings
Symbols appear in the following displays if there are malfunctions in connection with the washup solution container: Not enough washup solution production run display, display which appears after initiating the command Washup, fault display Entire press/warning.
Not enough washup solution in the washup solution container E9. Sensor B54 Monitoring washup solution, blanket washup device. Sensor B55 Monitoring washup solution, inking roller washup device. Not enough water in the washup solution container E9. Sensor B1 Monitoring water. At an air pressure x 0.48 bars, pressure switch F 70 responds. In the control console display ZID both symbols appear: Not enough washup solution and Not enough water.
Not enough water
Insufficient pressure in the container
298
Washup devices
Place of installation of washup solution container E9
Washup solution container E9
The washup solution container is located under the footboard on the O.S. (on presses with up to 5 units at the 2nd unit, with 6 units at the 3rd unit; with 7 or more units one container at the 2nd unit and one at the 6th unit).
Layout Attention:
Only refill the washup solution container with the press switched off or the air supply shut off (stop-cock closed).
1 2 3 4 5 6 7 8 9 q
Washup solution container E9
Refill opening with cover and sieve Pressure regulator with manometer Three-way stop-cock Solenoid valve Check valve Pressure switch F70 Safety valve Sensor B55 Monitoring washup solution, inking roller washup device Sensor B1 Monitoring water Sensor B54 Monitoring washup solution, blanket washup device Terminal box with terminal strip E9-X1
299
Washup devices
Task
The washup solution container E9 supplies: the blanket washup device with water and washup solution, the inking roller washup device with water and washup solution.
In order to deliver water and washup solution, the pressure in the container must be between 0.48 bars and 1.0 bar. The pressure reducer reduces the air pressure from the pneumatic system compressor M4 to 0.5 bars. If the pressure drops below 0.48 bars, the pressure switch F70 responds. A warning appears in the control console display ZID. If the air pressure rises above 1.0 bar, the safety valve opens. The sensors B1, B54 and B55 monitor the liquid levels. If the levels drop below the min. permissible values, a warning appears in the control console display ZID. The initiated washup procedure is completed, but a new washup procedure cannot be started anymore.
Pin assignment E9-X1

Pin 3 4 5 2 1 1 2 3 4 5 Function DC 24 V 24 V Monitoring water Monitoring washup solution, blanket washup device Monitoring washup solution, inking roller washup device
Plug E9-X1
300
Washup devices
B1, B54, B55 Sensors at the washup solution container
B1, B54, B55 Sensors at the washup solution container Place of installation 1 2 3
B1 Monitoring water B54 Monitoring washup solution, blanket washup device B55 Monitoring washup solution, inking roller washup device
Sensors at washup solution container
Connection
Input at EAK : 0 level too low 1 level OK
Pin assignment
Marking X1 +1 Colour white brown Function signal DC +24 V
301
Washup devices
B1, B54, B55 Sensors at the washup solution container
Removal and installation 1 2 3

Float Sensor Width across flats 27 with marking
All three sensors are of identical design. For removal loosen the thread and unscrew the sensor. For installation introduce the sensor into the threaded hole, position the thread carefully and screw it in. The sensor is sealed up by the tapered thread and the Teflon sealing tape around it. Tighten the sensor with 5 Nm.
Sensor at the washup solution container
Adjustment
The mounting position of the sensor determines its switching function. Pay attention to the arrow on the flat face of the screw. Direction of arrow upward downward Function NC contact NO contact Symbol
Mounting position of sensor
302
Washup devices
1...nB43 Monitoring the ink blade
1...nB43 Monitoring the ink blade Place of installation

The inductive sensor is located on the inside of the side frame on the O.S. It is fitted in each printing unit at the paper outlet.
Sensor Monitoring the ink blade
Layout 1 2 3
Sensor Nut and locking nut Connecting cable
Sensor Monitoring the ink blade with nut and locking nut
303
Washup devices
1...nB43 Monitoring the ink blade
Task
The inductive sensor Monitoring the ink blade" 1...nB43 monitors the correct installation of the ink blade. When the ink blade is not fitted, automatic washing of the inking rollers is not possible.
Connection
Core brown blue black Function DC 24 V 24 V signal
Pin assignment
Input 43 of EAKn: (n = corresponding printing unit) 0 1 ink blade not fitted ink blade fitted
Removal and installation 1 2 3 4

Blade Sensor Nut/locking nut Side frame
4.0 mm
When fitting the sensor, screw it so far in the holder that the distance between ink blade and sensor is 4.0 mm. Tighten the nut and locking nut.
Installation of sensor "Monitoring the ink blade
304
Inking unit
Servo-drive ink fountain roller
Inking unit
Servo-drive ink fountain roller Place of installation
The servo-drives for the ink fountain rollers 1 are located on the operator side of the printing units.
D.S.
O.S.
Place of installation of servo-drive for ink fountain roller O.S.
Layout and task

The servo-drive for the ink fountain roller is a dc motor with brushes and potentiometer for position feedback. It is used for adjustment of the ink fountain roller stroke. Thus the ink stripe width can be influenced.
305
Inking unit
Technical data
Motor data U = DC 12 V Potentiometer data U = DC 10 V R = 10 kW
Terminal assignment
Terminal
black yellow beige yellow/green brown blue
Function DC 12 V (motor) DC 10 V (potentiometer) potentiometer Potentiometer tap
6 5 4 3 2 1
6 5 4 3 2 1
black yellow beige yellow/green brown blue
6 5 4 3 2 1
6 5 4 3 2 1
black blue red black red
1 2 4 5 6
Terminal strip of servo-drive for ink fountain roller
306
Inking unit
Removal and installation Attention:

Small parts can fall into the press during disassembly!
1
O.S.
Nut on servomotor Gear wheel Locking screw Anti-rotation element Retaining nut
2 3 4 5 1 2 3 4 5
Zero position of ink fountain roller Turn the threaded rod 2 against the left stop with the nut 1 . Disconnect the potentiometer from the terminal strip. Loosen the locking screw potentiometer.
3 and take out the 4 to the new
Attach the anti-rotation element potentiometer.
Ink fountain roller O.S.
Connect the new potentiometer and turn until the display on the central control console indicates 0,00. Install in reverse sequence. If you want to make a precision correction, loosen the retaining nut 5. Correct the value by slightly turning the potentiometer. Check the value displayed on the central control console.
6 7
307
Inking unit
Servo-drive diagonal register 1...nM6
Servo-drive diagonal register 1...nM6 Place of installation

The servo-drives for the diagonal register 1 are located on the operator side of the printing units.
D.S.
O.S.
Place of installation of servo-drive for diagonal register O.S.
Layout and task

The servo-drive for the diagonal register is a dc motor with brushes and potentiometer for position feedback. It is used for cocking the plate cylinder.
Speedmaster SM 102
Speedmaster CD 102
Servo-drive diagonal register on SM 102 and CD 102

308
Inking unit
Technical data
Motor data U = DC 24 V
Potentiometer data U = DC 10 V R= 10 kW
Pin assignment
Pin
1 2 3 4 5 2 1 3 4 5
Function DC 24 V (motor) DC 10 V (potentiometer) Potentiometer tap potentiometer
1 2 3 4 5
Plug of servo-drive of diagonal register
309
Inking unit

1 2 3 4 5 6 7 1 2 3
Plug 1...nM6-X1 Fixing bolts Hexagon nut Block Upper stop of eccentric sleeve Eccentric bolt Servo-drive
Withdraw the plug
1 from the servo-drive 7.
Remove the servo-drive by loosening the four fixing bolts 2. Positioning the diagonal register to zero: Turn the hexagon 3 below the block 4 until the distance between the upper stop 5 of the eccentric sleeve O.S. and the eccentric bolt 6 is 5 mm. Setting the central position for the new servo-drive: Connect the plug 1 to the servo-drive 7. Set the diagonal register display to 0,00 on the central control console. Alternatively, it is possible to set the variable voltage of the potentiometer to 5V at the servo-drive conversion module SSM in the distribution box of the printing unit. Installing the servo-drive: When installing the servo-drive, the backlash (flank clearance) is of no importance and can be neglected. When tightening the fixing bolts, pull the servo-drive outwards (away from the PU). Thus the backlash of the two pinions is adjusted.
Eccentric sleeve behind block
5mm
Servo-drive diagonal register, e.g. SM 102
Note: Do not loosen the eccentric bolt 6. After loosening the eccentric bolt, the plate cylinder and the dampening distributor must be adjusted parallel to each other again.
310
Inking unit
Servo-drive lateral register
Servo-drive lateral register Place of installation

The servo-drives for the lateral register 1 are located on the operator side of the printing units.
D.S.
O.S.
Place of installation of servo-drive for lateral register O.S.
Layout and task

The servo-drive for the lateral register is a dc motor with brushes and potentiometer for position feedback. It is used for adjustment of the plate cylinder in lateral direction.
311
Inking unit
Technical data
Potentiometer data U = DC 10 V R = 10 kW
Terminal assignment
Terminal black yellow beige yellow/green brown blue black red blue brown blue 1 2 4 5 6 Function DC 12 V (motor) DC 10 V (potentiometer) potentiometer Potentiometer tap
6 5 4 3 2 1
6 5 4 3 2 1
Terminal strip of servo-drive for lateral register
312
Inking unit

1 2
2.2...2.27 mm
Nut Gear wheel Nut Nut Anti-rotation element Sleeve
3 4 5 6
2.2...2.27 mm
Positioning the lateral register to zero: Turn the gear wheel 2 with the help of the nut 1 until the distance of 2.2...2.27 mm is obtained.
Lateral register O.S.
Note: Use a feeler gauge!
2 3 4 5 6 7 8
3. Loosen the nut 4.

Unscrew the nut Take out the potentiometer and disconnect the cable from the terminal strip. Attach the anti-rotation element potentiometer.
5 to the new
Connect and install the new potentiometer and turn until the display on the central control console indicates 0,00. Install in reverse sequence. If you want to make a precision correction, loosen the nut 4. To correct the value insert a screw driver in the sleeve 6 and turn the potentiometer axis slightly. Check the value displayed on the central control console.
313
Inking unit
Servo-drive circumferential register
Servo-drive circumferential register Place of installation

The servo-drives for the circumferential register 1 are located on the drive side of the printing units.
O.S.
D.S.
Place of installation of servo-drive for circumferential register D.S.
Layout and task

The servo-drive for the circumferential register is a dc motor with brushes and potentiometer for position feedback. It is used for adjustment of the plate cylinder in circumferential direction.
Servo-drive for circumferential register D.S.
314
Inking unit
Technical data
Potentiometer data U = DC 10 V R = 10 kW
Terminal assignment
Terminal black yellow beige yellow/green brown blue black red blue brown blue 1 2 4 5 6 Function DC 12 V (motor) DC 10 V (potentiometer) potentiometer Potentiometer tap
6 5 4 3 2 1
6 5 4 3 2 1
Terminal strip of servo-drive for circumferential register
315
Inking unit

6.2...6.3 mm 6.2...6.3 mm
1 2 3 4 5 1
Nut Gear wheel Locking screw Anti-rotation element Nut
Positioning the circumferential register to zero: Turn the gear wheel 2 with the help of the nut 1 until the distance of 6.2...6.3 mm is obtained.
Note: Use a feeler gauge!
2
Circumferential register D.S.
Disconnect the potentiometer from the terminal strip. Loosen the locking screw potentiometer.
3 4 5 6 7
3 and take out the 4 to the new
Attach the anti-rotation element potentiometer.
Connect and install the new potentiometer and turn until the display on the central control console indicates 0,00. Install in reverse sequence. If you want to make a precision correction, loosen the nut 5. Correct the value by slightly turning the potentiometer. Check the value displayed on the central control console.
316
Inking unit
Inking unit temperature control
Inking unit temperature control Activation and inactivation

The inking unit temperature control can be activated and inactivated at the central control console. Power supply is effected via plug E39-X1. On 7- and 8-colour presses, the required second inking unit temperature control is switched on and off via plug E39a-X1.
Actual value/fine display of control console display (ZID) Inking unit temperature control on/off
317
Inking unit
E39 Inking unit temperature control
E39 Inking unit temperature control Connection

Different models are available which differ in power. 7- and 8-colour presses require two inking unit temperature controls (E39 and E39a). The power supply for the unit(s) comes from the printing press. The illustration opposite is an example. The units differ in cabinet height and width.
E39-X1
Connection of inking unit temperature control E39
Pin assignment E39-X1 (only model 3/8)

Pin 3 7 1 2 3 4 5 6 7 8 9 10 Remaining pins PE conductor 9 Function Phase U Phase V Phase W
Plug E39X1 ( power supply )
318
Inking unit
Pin assignment E39-X1 (models 6/12; 6/16; 9/20 and 9/25)

Pin
1 3 5 7 9
Function Phase U Phase V Phase W PE conductor
1
2 4 6 8 10
2 3
Remaining pins
4pole cable Plug E39X1 ( power supply )
319
Inking unit
320
Dampening
1...nM1 Pan roller motors
Dampening
1...nM1 Pan roller motors Place of installation / plug connections 1
Connector 1...nM1-X3 ( power supply )
1...nM1-X3
1M1
2M1
3M1
Pan roller motors 1...nM1 at PU/CU on D.S.
Pin assignment
7 1 9 10 11 12 13 2 14 8 6 Pin 5 4 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 X motor line Y motor line Z motor line Hall-effect sensor, signal C Hall-effect sensor, tacho signal Hall-effect sensor, signal B DC 15 V Hall-effect sensor, signal A Ground of DC 15 V Motor code PE 321 Function
Connector 1...nM1-X3, pins in plug insert
Dampening
1...nM45 Blower motor for dampening system
1...nM45 Blower motor for dampening system Place of installation and task
The blower combination with the motor 1...nM45 is located under the guard of the inking and dampening rollers. The motor is a dc motor with brushes. It is integrated in the middle of the blower bar and drives a cross-flow fan.
nM45
Place of installation of blower motor for dampening system
Pin assignment
Pin 1 2 3
1 2 3
Function Enable message Ground 24 V DC 24 V
Plug of blower motor for dampening system
322
Dampening
1...nB32 Sensor Dampening solution control
1...nB32 Sensor Dampening solution control Place of installation

The capacitive sensor is located on the paper infeed side, D.S., in the dampening solution fountain.
nB32
Place of installation of sensor Dampening solution control
Layout/connection
Core brown blue black Function DC 24 V ground 24 V message
Sensor Dampening solution control
323
Dampening
1...nB32 Sensor Dampening solution control
Task/function
The capacitive sensor 1...nB32 monitors the level of the dampening solution in the fountain. The sensor works correctly when its sensing area is immersed in the dampening solution. With its sensing area immersed, the sensor is actuated. If the level of the dampening solution drops, the sensor will only change its circuit state if its sensing area is no longer in contact with the water film. The sensor is supplied with a stabilized direct voltage of DC 24 V.
324
Dampening
E40 Central dampening solution supply/ cooling and circulating unit
E40 Central dampening solution supply/cooling and circulating unit Layout of central dampening solution supply
The central dampening solution supply is in a separate cabinet. Generally, this cabinet is in the proximity of the central control cabinet. It is connected to the CP Tronic control system via a serial interface. The power supply and circuitbreakers are in the control cabinet of the printing press. For details please refer to the manufacturers manual. E40-X1: power supply E40-X2: serial interface
X1
X2
Central dampening solution supply Technotrans
X2
X1
Central dampening solution supply Baldwin, rear view
325
Dampening
Pin assignment X1, central dampening solution supply

Pin 3 7 9 Function Phase U Phase V Phase W PE conductor
1 2 3 4 5
6 7 8 9 10
*)
Remaining pins
Connector E40-X1, coming from the press
380...415 V " 15V * ) AC AC 460...500 V " 15V
at 50Hz at 60Hz
326
Dampening
Layout of cooling and circulating unit

The cooling and circulating units have no serial interfaces. The power supply and circuit-breakers are in the control cabinet of the printing press. A manufacturers manual is available. E40-X1: power supply
E40-X1
Cooling and circulating unit
Pin assignment X1, cooling and circulating unit

Pin 2 4 1 2 3 4 5 6 7 8 9 10 Remaining pins PE conductor Function AC 230 V Zero 230 V
327
Dampening
E41 Dampening solution mixing unit
E41 Dampening solution mixing unit

The dampening solution mixing unit is an additional unit for cooling and circulating devices without integral additive-mixing units. It admixes additives to the dampening solution. Power supply comes directly from the mains and not from the press. For details please refer to the manufacturers documentation.
Dampening solution mixing unit
328
Central lubrication
Basic concept
Central lubrication
Basic concept Distinction
Two lubrication systems supply the press with lubricant: grease lubrication system (for the delivery), oil lubrication system (for the printing units, feeder and bearings on the D.S. and O.S. of the delivery chain sprocket shaft).
The grease lubrication system is divided into: lubrication circuit 1 (chain lubrication), lubrication circuit 2 (bearing lubrication).
The oil lubrication system is divided into: the circular lubrication system (drive side), the distributing lubrication system (operator side and some lubricating points on the drive side).
329
Central lubrication
Service display
Service display
Button sequence
Oil lubrication 1 2 3 4 5
Service display Oil lubrication
Pressure monitoring 1bar, 1F33 (flashes if the pressure switch was not actuated). Pressure monitoring 12bars, 1F34 (flashes if the pressure switch was not actuated). Oil pump M44 (flashes if motor circuit-breaker 15Q44 has responded). Number of cylinder revolutions since the last distributing lubrication. After completion of lubrication the counter is automatically zeroed. Distributing lubrication initiated manually (only when press is on Run). Number of cylinder revolutions at which automatic oil lubrication is initiated.
330
Central lubrication
Service display
Grease lubrication 7 8 9 q w e r t
Sensor Lubrication monitoring 2 12 B77 (bearing lubrication) (flashes if sensor is not actuated). Sensor Lubrication monitoring 1 12 B47 (chain lubrication) (flashes if sensor is not actuated). Motor grease lubrication 12M47. Number of cylinder revolutions since the last chain lubrication. After completion of lubrication the counter is automatically zeroed. Number of cylinder revolutions since the last bearing lubrication. After completion of lubrication the counter is automatically zeroed. Chain lubrication initiated manually (lubrication circuit 1); (only when press is on Run). Bearing lubrication initiated manually (lubrication circuit 2); (only when press is on Run). Number of cylinder revolutions at which bearing lubrication is initiated automatically. Number of cylinder revolutions at which chain lubrication is initiated automatically.
Service display Grease lubrication
331
Central lubrication
Fault messages
Fault messages Display Entire press/warning

Button sequence
Dependent on the press model, the fault display Entire press / Warning shows the fault symbols of the grease lubrication or oil lubrication system:
Oil lubrication not possible
Oil lubrication has not occurred. After main switch On and changeover between circular and distributing lubrication, the oil pressure has not been built up within 3 minutes. Pressure switch 1F33 (1 bar) or pressure switch 1F34 (12 bars) not actuated. Filter unit clogged.
Grease lubrication not possible
Chain or bearing lubrication has not occurred. The sensor Lubrication monitoring 1 12 B47 or the sensor Lubrication monitoring 2 12 B77 has not responded within 10 minutes. Solenoid valve 12 Y78 defective. Changeover between chain and bearing lubrication is not possible. Motor for grease lubrication 12 M 47 defective.
Motor circuit-breaker Q 44 has tripped The audible signal devices 11H55 and 12H55 give out a warning
The motor circuit-breaker has tripped. Oil pump M 44 not ready to run. While lubrication is in progress, a warning signal sounds if the printing speed is u 3 000 i.p.h.
332
Central lubrication
Grease lubrication
Grease lubrication Block diagram
15 Q 66 15 Q 47 12B47 15 K47 M 12M47 12Y78 12B77
11H55
12H55
Electronic control system Control line Power supply Grease line
Block diagram of grease lubrication
1 2
15Q66 15Q47
Pressure limiting valve (38 bars) Metering elements Main switch Motor circuit-breaker
12M47 12Y78 12B47 12B77 11H55 12H55
Motor Grease lubrication Changeover grease lubrication Lubrication monitoring 1 (chains) Lubrication monitoring 2 (bearings) Audible signal device (audio alert feeder) Audible signal device (audio alert delivery)
15K47M Contactor
333
Central lubrication
Grease lubrication
The motor for grease lubrication is located on the D.S. of the last printing unit. The sensors Lubrication monitoring are fitted at the first progressive distributor behind the motor.
Layout 1 2 3 4 5 6 7
Motor Grease lubrication 12 M 47 Grease reservoir Pressure relief valve Lubrication monitoring 212 B77 (bearing lubrication) Lubrication monitoring 112 B47 (chain lubrication) Progressive distributor Changeover grease lubrication 12 Y78 (between bearing and chain lubrication)
Components of the grease lubrication system
Function
When the press is switched on, the grease lubrication system is ready for operation. The motor for grease lubrication 12M47 delivers the lubricant to the progressive distributors via solenoid valve 12 Y78. Depending on the position of the solenoid valve, either the chains in the delivery (lubrication circuit 1) or the bearings (lubrication circuit 2) are supplied with lubricant. The progressive distributors pass the lubricant to the lubricating points via pistons. The progressive distributors are sequence-controlled and thus all pistons move uniformly. For this reason, only the movement of one piston is monitored per lubrication circuit.
334
Central lubrication
Grease lubrication
Monitoring the lubrication system

Inductive sensors monitor the two lubrication circuits. Each is equipped with an LED and can assume two circuit states. Pin of progressive distributor extended, sensor damped: LED is lit. Pin of progressive distributor retracted, sensor not damped: LED is not lit.
LED
Sensor with LED monitoring the lubrication circuit
On presses with standard delivery, the sensor 12 B47 (chain lubrication) is actuated twice while lubrication is in progress and three times on presses with extended delivery. The sensor 12 B77 (bearing lubrication) is actuated once while lubrication is in progress. If the sensors do not switch within 10 minutes after a lubrication process was triggered, the electronic control system shuts the motor for grease lubrication down. The warning Grease lubrication not possible appears.
335
Central lubrication
Grease lubrication
Triggering a lubrication process

When the press is switched on, the grease lubrication system is ready for operation. Lubrication is triggered either automatically:
1 2
chain lubrication every 2 500 to 30 000 cylinder revolutions; (after a basic initialization, the cycle is preset to 20 000 cylinder revolutions), bearing lubrication every 200 000 cylinder revolutions,
or manually by actuating the function button Manual chain or bearing lubrication.
Central lubrication selected, press on Run
Setting the lubrication cycle for lubrication circuit 1 (chain lubrication)

Button sequence
Number of cylinder revolutions for automatic chain lubrication (lubrication circuit 1). The cylinder revolutions can be set in the range from 2 500 to 30 000 in steps of 2 500.
Note: To set the lubrication cycle an additional button must be fitted on the EAM (input/output module). Before fitting or removing this button, turn off the main switch 15 Q 66 on the central control cabinet ZSG! Number of cylinder revolutions set to 20000
336
Central lubrication
Grease lubrication
Attention:
Even if the main switch is turned off, the press is not voltage-free and there are currentconducting components in the central control cabinet! The input/output module EAM is on the underside of the central control console. Plug the additional button into slot 7 of the EAM - X12.
EAM
EAM-X12
Group
1 2 3
Turn off the main switch 15Q66. Fit the button. Turn on the main switch 15Q66.
Now press the button you just fitted plus group button 2 on the central control console. Set the cylinder revolutions with the left-hand + / buttons.
Lubrication cycle for delivery 30000
2 500 5 000 L 25 000 30 000
Remove the button from slot 7 of the EAM - X12. Then check the cylinder revolutions for chain lubrication (lubrication circuit 1) in the service display Central lubrication on the central control console.
Changing the lubrication cycle Note: The value for bearing lubrication (lubrication circuit 2) is set to 200 000 cylinder revolutions and is non-adjustable.
Pressure relief valve of the motor

The motor for grease lubrication is protected by a pressure relief valve. In the case of malfunctions, this valve prevents the building up of impermissible high pressures in the lubrication system and opens at a pressure of 150 bars.
337
Central lubrication
Oil lubrication
Oil lubrication Block diagram
15 Q 66 15 Q 44 1F33 15X3 M44 Y67 1F34
11H55
12H55
Electronic control system Control line Power supply Oil line
Block diagram of oil lubrication
1 2
15Q66 15Q44 15X3 M44
Pressure relief valve (18 bars) Metering elements Main switch Motor circuit-breaker Plug Oil pump
Y67 1F33 1F34 11H55 12H55
Changeover oil lubrication Pressure monitoring (1 bar) Pressure monitoring (12 bars) Audible signal device (audio alert feeder) Audible signal device (audio alert delivery)
338
Central lubrication
Oil lubrication
The oil reservoir with oil pump M44, filter unit, solenoid valve Y67 and pressure relief valve is located on the D.S. under the footboard (on presses with up to 5 units at the last unit, with 6 or more units in the middle). On presses with coating unit the guard serves as oil reservoir and contains the oil pump, filter unit and valves. The two pressure switches, 1 F 33 and 1 F 34, are fitted at the first printing unit under the feeder.
Layout 1 2 3 4 5 6 7
Oil pump M 44 Filter unit Oil lubrication press Y 67 (changeover between circular lubrication and distributing lubrication) Pressure relief valve (18 bars) Pressure switch 1F34 (12 bars) Pressure switch 1 F 33 (1 bar) Oil reservoir
Components of the oil lubrication system
339
Central lubrication
Oil lubrication
Function
Switching on the press activates oil lubrication, i.e. the circular lubrication system is active and continuously lubricates the gears on the D.S. For the changeover to distributing lubrication the solenoid valve Y67 must be actuated. This is effected either automatically or with the function button Manual distributing lubrication. The distributing lubrication system supplies the bearings on the D.S. and O.S. with oil. After every changeover between distributing and circular lubrication, the oil pressure must build up within 3 minutes; otherwise the electronic control system outputs a fault message. Circular lubrication The oil is continuously fed to the lubricating points via the oil riser and drip pan. The circular lubrication system works at an oil pressure y 1 bar. The oil pressure is monitored by pressure switch 1 F 33 (1 bar). The oil flowing back down the side frames on the D.S. is returned to the lubrication circuit. Through a return line the oil flows either into the oil reservoir or into the coating unit guard. The return line is fitted above the cable duct on the D.S. Distributing lubrication The distributing lubrication system supplies the lubricating points through piston distributors. The oil pressure in the system is y 12 bars and monitored by pressure switch 1 F 34 (12 bars). On SM102-presses the residual oil is collected in the bases and can be drained off through a drain cock on the O.S. On CD102-presses the residual oil is collected in a reservoir on the D.S. which can be emptied.
340
Central lubrication
Oil lubrication
Triggering a lubrication process

Distributing lubrication is triggered:
1 2
automatically every 45 000 cylinder revolutions or by actuating the function button Manual distributing lubrication.
For activation the printing press must be on Run (3 000 i.p.h.).
Central lubrication selected, press on Run
Filter unit 1 2
Optical differential pressure indicator Filter housing with cartridge
The filter unit is fitted between the pump and the solenoid valve. The optical differential pressure indicator shows the degree of soiling of the filter cartridge: Green: filter cartridge okay Red: change filter cartridge
Filter unit
If the filter cartridge is soiled, the oil pressure between the oil pump and filter unit rises. The relief valve in the filter unit opens the bypass and the oil flows to the lubricating points without having been filtered. Change the filter at least every 6 months.
341
Central lubrication
Oil lubrication
Changing the filter
Changing the filter
Optical differential pressure indicator
The tightening torque for the filter housing must be 120 Nm +/ 15 Nm.
Pressure relief valve of the oil pump

A pressure relief valve is installed to protect the oil pump. In the case of malfunctions, this valve prevents the building up of impermissible high pressures in the lubrication system. It opens at a pressure of 18 bars and the oil flows back into the coating unit guard or the oil reservoir.
342
Central lubrication
M44 Oil pump
M44 Oil pump Place of installation

On presses with coating unit, the oil pump is located on the D.S. of the coating unit, below the footboard.
Location of oil pump on presses with coating unit, D.S.
On presses without coating unit, the oil pump is installed at the oil reservoir. The oil reservoir is located on the D.S. under the footboard (on presses with up to 5 printing units at the last printing unit).
Location of oil pump on presses with up to 5 PUs
343
Central lubrication
M44 Oil pump
On presses with 6 or more units, the oil reservoir is bigger and located in the middle of the press, under the footboard on the D.S.
Location of oil pump on presses with 6 or more PUs
Pin assignment
Pin A2
A B C 1 2 3 4 5
Function AC 400 / 480 V phase U AC 400 / 480 V phase V AC 400 / 480 V phase W PE conductor
B3 C2
Plug M44-X1
344
Central lubrication
12M47 Motor for grease lubrication
12M47 Motor for grease lubrication Place of installation

The motor for grease lubrication 12M47 is located on the D.S. of the delivery.
Motor for grease lubrication with grease reservoir
Pin assignment
Plug 12M47-X1 Pin 3 1 2 PE 1 2 3 PE Function DC 24 V Grease lubrication delivery chains
Plug 12M47-X1
345
Central lubrication
1F33 Pressure monitoring oil lubrication 1bar
1F33 Pressure monitoring oil lubrication 1bar Place of installation

The pressure switch Pressure monitoring oil lubrication 1 bar 1F33 is located on the drive side of the first printing unit, under the sheet alignment system. It is accessible through the door between the feeder and first printing unit on the O.S.
Place of installation Pressure monitoring oil lubrication 1 bar, 1F33
346
Central lubrication
1F34 Pressure monitoring oil lubrication 12bars
1F34 Pressure monitoring oil lubrication 12bars Place of installation

The pressure switch Pressure monitoring oil lubrication 12 bars 1F34 is located on the O.S. of the first printing unit, under the feeder. It is accessible through the door between the feeder and first printing unit on the O.S.
Place of installation Pressure monitoring oil lubrication 12 bars, 1F34
347
Central lubrication
12B47 Lubrication monitoring 1 12B77 Lubrication monitoring 2
12B47 Lubrication monitoring 1 and 12B77 Lubrication monitoring 2 Layout

The sensor 12 B47 for chain lubrication monitoring and the sensor 12 B77 for bearing lubrication monitoring are of identical design.
1 2 3 4 5 6 7 8
LED Sensor Locking nut Receptacle Plug Stop pin Sleeve Distributor
12B47 Lubrication monitoring 1 and 12B77 lubrication monitoring 2
Connection
Input 47 or 77 at EAK 12: 0 sensor not damped (LED off) 1 sensor damped (LED lit)
348
Central lubrication
Pin assignment
Marking 47 or 77 +1 1 Colour black brown blue Function signal DC 24 V
Sensor Lubrication monitoring

To fit the sensor screw the receptacle into the sleeve using a copper disk and tighten it up. In doing so, align the receptacle in such a way that the sensor can be screwed in parallel to the longitudinal axis of the distributor. Screw the sensor manually into the receptacle until it contacts the stop pin and secure it with the locking nut. Then close the threaded hole of the receptacle from the bottom using the plug.
349
Central lubrication
350
Pneumatic system
15Y11 Admission of pressure, pneumatic system
Pneumatic system
15Y11 Admission of pressure, pneumatic system Place of installation
The solenoid valve Admission of pressure, pneumatic system 15Y11 is fastened to the side frame on the O.S. of the feeder and accessible through the protecting door.
15Y11
Admission of pressure, pneumatic system 15Y11 with plug
Task
When the pressure has been built up ( u5 bars ), the solenoid valve switches the pneumatic energy through the piping.
351
Pneumatic system
15Y11 Admission of pressure, pneumatic system
Pin assignment
Plug 15Y11-X1 Pin 1 1 3 PE 2 2 3 PE Function DC 24 V Signal 4 mA ... 20 mA
Plug 15Y11-X1
352
Pneumatic system
15B14 Pressure sensor Pneumatic system
15B14 Pressure sensor Pneumatic system Place of installation
The pressure sensor Pneumatic system 15B14 is located at the side frame on the O.S. of the feeder where it measures the air pressure in the pneumatic piping.
15B14
Place of installation of pressure sensor Pneumatic system 15B14
353
Pneumatic system
15B14 Pressure sensor Pneumatic system
Pin assignment
Plug 15B14-X1 Pin 1 2 PE 2 3 PE Function DC 24 V Sensor signal 4 mA ... 20 mA
3 1
Pressure sensor and connector
354
Pneumatic system
E4 Pneumatic system compressor
E4 Pneumatic system compressor Technical data

Technical data, see operating instructions 71.102.9100
Pin assignment
Pin A2
A B C 1 2 3 4 5
Function AC 400 / 480 V phase U AC 400 / 480 V phase V AC 400 / 480 V phase W DC 24 V Pressure switch F45 Blow-off valve Y68 PE conductor
B3 C2 C4 A5 B5
Plug E4-X1
355
Pneumatic system
E4 Pneumatic system compressor
356
Suction and blast air
1M9 Blast air regulation at the feeder

1M9 Blast air regulation at the feeder Block diagram
Displays MID11 MID12 ZID DNK DSK IDS
The blast air regulation at the feeder adapts the blast air pressure at the suction head to the press speed and ensures that the printing material is fanned. The blast air pressure is regulated by servo-drive 1M9 which controls a relief valve. The blast air pressure depends on two factors: the thickness of the stock (e.g. paper calliper); the production speed (preset speed). In the operator program of CPTronic the blast air regulation can be switched on and off. Automatic blast air regulation switched on means: characteristic-curve-dependent blast air regulation. The blast air pressure is automatically adapted by the CPTronic operator program on the basis of the entered paper thickness and the preset press speed. By pressing the right-hand +/ buttons on the control console the characteristic curve stored in the CPTronic control system can be modified manually. Automatic blast air regulation switched off means: manual blast air setting. The blast air pressure is set independently of the paper thickness and preset speed. It can be modified with the right-hand +/ buttons on the control console. The blast air regulation at the feeder does not intervene in the press control.
EAK
ESK
SVM
SSK
SAK
1SSM1
REK2
1M9
M Blast air regulation
Legend:
Block diagram: blast air regulation at the feeder
357
Characteristic-curve-dependent blast air regulation
Selection of the characteristic-curve-dependent blast air regulation

Function button Blast air regulation at the feeder on / off 1 If the background of the symbol is light, the characteristiccurvedependent blast air regulation is switched on. The characteristic curves are stored in the CPTronic operator program. The operator program automatically selects a suitable characteristic curve dependent on the thickness of the stock and the press speed. Preselection/coarse display
358
Selection: manual change of characteristic-curvedependent blast air regulation

Function button Changing the slope
When you switch over to the actual value display and the background of the symbol is light, you can set the slope of the characteristic curves manually (and thus deviate from the CPTronic-values). The setting is made at the control console with the right-hand +/ buttons.
Manual change of the characteristiccurvedepen dent blast air regulation p [bar] 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0 3000 6000 9000 12000 15000 n [sheets / h] For a 0.05 mm thick paper the setting range for the slope is as follows for SM 102 and CD 102: Minimum: 0% (corresponds to the 0%-characteristic curve) Maximum:100% (corresponds to the 100%-characteristic curve)
Field of characteristic curves for a printing paper with a thickness of 0.05 mm (corresponds to a paper weight of approx. 50 g/m2)
359
Manual blast air setting
Selection: changing the manual blast air setting

Function button Manual setting of blast air at feeder actuated (ON) 3 The manual blast air setting is activated automatically when the characteristic-curve-dependent blast air regulation is switched off. It does not depend on the paper thickness or preset speed. In this mode you can enter a percent value which is displayed on the control console display ZID. The setting is made at the control console with the right-hand +/ buttons. Changing the manual blast air setting The setting range for SM 102 and CD 102 is as follows: Minimum: 20% (corresponds to 0.2 bar above atmospheric pressure) Maximum:100% (corresponds to 1.0 bar above atmospheric pressure)
p [bar] 1.0
0.8
0.6
0.4
0.2 20 40 60 80 100 ZID display [%]
Characteristic curve of the manual blast air setting
360
The blast air regulation is located on the bottom crossbar of the feeder in direction of the drive side (D.S.).
O.S.
D.S.
Blast air regulation at the feeder
361
Layout and task

Dependent on the thickness of the printing material and the production speed, the blast air regulation at the feeder adapts the blast air pressure at the suction head and thus ensures that the printing material is fanned. The blast air regulation at the feeder consists of the following components:
1 2 3 4
Servo-drive 1M9 with dc motor with brushes, flange-mounted gear unit and potentiometer for position feedback. Motor bracket with protecting cover and threaded spindle inside Adjustable relief valve Manometer measuring the pressure above atmospheric (at feeder frame)
The servo-drive and relief valve are connected with each other by means of a mechanical coupling.
Servo-drive with adjustable relief valve
Manometers at feeder frame for pressure above atmospheric and low pressure
362
Technical data
Motor data U = DC 24 V P=5W Potentiometer data U = DC 10 V R = 10 kW
Pin assignment
Contact
+ 1 2 3 4 5 3 4 2 1 5
Assignment Motor, + (DC 24 V) Motor, (DC 24 V) Potentiometer, + (DC 10 V) Potentiometer wiper Potentiometer, (DC 10 V)
1 2 3 4 5
Pin assignment: blast air regulation at the feeder
363
Attention:
1 2 3
Inch the press until all blast air ducts at the rotary valve in the suction head are closed. Turn off the main switch. Loosen the four fixing bolts the protecting cover 2.
1 and remove
(4)
4
(4)
Unscrew the connector 1M9X1 3 and withdraw it from the servo-drive 4. Loosen the four fixing bolts 5 and remove the servo-drive together with the sleeve 6. Turn on the main switch (blast air is present).
364
Turn the threaded spindle 7 manually until the manometer measuring the pressure above atmospheric at the feeder 8 indicates 0.6 bar. Check whether all blast air ducts at the rotary valve in the suction head are closed. Turn off the main switch. Connect the connector 3 with the new servo-drive 9 and tighten up the bolts. Turn on the main switch.
7 8 9
Switch off the automatic blast air regulation (this activates the manual blast air setting).
Note: Also refer to the section Manual blast air setting.
Operate the servo-drive 9 with the right-hand +/ buttons at no-load until the value 60% is indicated on the control console display ZID.
Note: While doing this, do not place the servodrive 9 on the threaded spindle 7.
365
Push the servo-drive 9 onto the threaded spindle 7 so that the pin engages with two slots of the sleeve 6.
Note: Take care that the pin of the threaded spindle is not turned more than "90 while doing this.
(4)
Fasten the servo-drive fixing bolts 5.
9 with the four
Let the servo-drive 9 run over the entire operating range with the right-hand +/ buttons (i.e. from 20% to 100%).
Note: See also the next section Checking the operating range.
t
(4)
Put the protecting cover 2 back in place and fasten it with the four fixing bolts 1.
366
Selecting the service display

Incremental values for the servo-drive 1M9 Blast air regulation at the feeder
Operating range for SM 102 and CD 102: Incremental value [n] 768 (min.) 2048 3328 (max.) ZID display Air pressure [%] [bar] 20 0.2 60 0.6 100 1.0
Service display
Note: The incremental values may differ from the displayed percent values / air pressure by up to "4 increments.
When you have finished checking, switch on the characteristic-curve-dependent blast air regulation.
367
368
Other components
E4a Varnish supply unit
Other components
E4a Varnish supply unit Connections
The varnish supply unit receives 3AC 380 V and AC 230 V from the printing press. Both voltages pass through plug E4a-X1. The varnish sensor is located at the coating pan on the O.S. of the coating unit. It is connected to the distribution box at the coating unit. From there a cable leads to the varnish supply unit, plug E4a-X21. The varnish supply unit is remotely controlled with a cable. This cable is connected to plug E4a-X22. The varnish supply unit is located under the footboard on the D.S. of the coating unit. A manufacturers manual is available.
E4a-X21
E4a-X22 E4a-X1
Varnish supply unit
Pin assignment
E4a-X1 Pin A B C 1 2 3 4 5 A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 C1 C2 C3 C4 C5 Function Phase L1 AC 230 V Phase L2 Phase L3 Zero 230 V PE conductor
Plug E4a-X1, coming from the control cabinet
369
Other components
E4a Varnish supply unit
E4a-X21 Pin 2 6 1 5 3 4 1 2 3 4 Function DC 24 V (+1) for fault message Fault message Analog sensor signal: 0 ... 5 V Conductive level sensor DC 24 V Ground voltage for sensor
Plug E4a-X21, control lines
5 6
Fault messages
If the sensor Level in coating pan B32 detects that the level is too low and if the operating mode Varnish circulation has been selected for the coating unit, a fault message is transmitted to the CPTronic control system and the audible signal devices 11H55 and 12H55 output a warning. It is possible that the fault message is caused by the height adjustment of the level controller ( coating pan insert ).
Sensor Level in coating pan and level controller
370
Other components
L-B32 Level in coating pan
L-B32 Level in coating pan Place of installation

The sensor Level in coating pan is located at the coating pan on the O.S. of the coating unit.
Sensor Level in coating pan
Connection, pin assignment

Plug E4a-X2: 3 2 1 6 4 E4a-X2 5 2 3 183 170 171 L-LVT1-X2 4 blk br bl Sensor 5 6 green white grey yellow Pin 1 Colour brown Function DC 24 V (+1) for fault message Fault message Analog sensor signal: 0 ...5 V Conductive level sensor DC 24 V Ground voltage for sensor
L-B32
Connection of sensor Level in coating pan
371
Other components
L-B32 Level in coating pan
Layout, adjustment 1 2 3 4 5 6
108 mm Coating pan Pan roller Sensor Sensor holder Level controller Adjusting screws
Adjust the sensor so that the distance between the upper edge of the sensor and the upper edge of the sensor holder is 108 mm. The height of the level controller can be regulated by means of the adjusting screws. This influences the level in the coating pan. The immersion depth of the pan roller in the varnish should be approx. 10 mm.
approx. 10 mm
Mounting dimensions of sensor Level in coating pan
372
Other components
12E2 Powder spray unit
12E2 Powder spray unit Place of installation, layout 1 2 3

Powder spray device Powder tube Blower motor with suction filter
The powder spray device is located on the O.S. of the delivery. The motor is fitted on the O.S. of the delivery, on the inside of the press. Different types of powder spray devices can be connected to the printing press. We distinguish between: powder spray devices without serial interface, powder spray devices with serial interface.
Powder spray device, powder tube and motor at delivery
In the case of powder spray devices with serial interface, the motor is connected directly to the control box of the powder spray device.
Powder spray device with serial interface

Pin assignment 12E2-X1 Pin A2 B3 C B A 1 2 3 4 5 C2 A4 C5 Function L2 L1 L3 AC 230 V Zero 230 V PE
Plug 12E2-X1, coming from the press
373
Other components
Powder spray device without serial interface

Pin assignment 12E2-X2 The plug 12E2-X2 is at the distribution box of the delivery. Instead of the mechanical switch 12S68 a proximity switch can be fitted in the feeder (e.g. Betatronic powder sprayers). This switch is then connected directly to the powder spray device and is not led via the distribution box or plug 12E2-X2. Pin A1 Function Switch Powder on 12S68, switch contact 2 (not with proximity switch) DC 24 V for test button AC 230 V Switch Powder on 12S68, switch contact 1 (not with proximity switch) Impression on ( AC 230 V) Test ( DC 24 V) Zero 230 V PE conductor Press turns ( AC 230 V) PE
C B A 1 2 3 4 5
A2 A3
Plug 12E2X2, coming from the press, distribution box at delivery
A4
A5 B1 B2 B3 B4 B5 C1 C5
Pin assignment of proximity switch 12S68 Pin 3 4 5 2 1 1 2 3 4 5 Function Ground DC 24 V Signal Ground
Plug of proximity switch
374
Other components
Correcting the beginning of powdering

Settings The following settings are only required for powder spray devices with serial interface. Control panel at last printing unit / coating unit Selector switch Safe
Set the selector switch Safe to Safe.
Pushbutton Forward/ Backward
Inch the press until the front edge of the sheet is below the spray nozzles of the powder tube.
Sheet of paper
Required position of front edge of sheet
Positioning the sheet of paper

Control panel at delivery Press display MID
Read off the degree value indicated on the press display MID.
1
Indication on the MID while press is in inching mode
Display of degree value
375
Other components
Service display Delivery
4 1
Variable degree can be changed by entering another degree value.
Standard degree cannot be changed depends on the press model.
Service display Delivery

Entering the degree value
With the right-hand " buttons the degree value read off at the press display MID under 3 can be entered. When the function button is pressed, the variable degree 2 jumps back to the standard degree value 3.
Standard beginning of powdering
SM102 ( CD102) 2 PUs 4 PUs 5 PUs 6 PUs 7 PUs 8 PUs
+ extended + coating unit + coating unit High-pile delivery high-pile delivery + high-pile delivery + extended high-pile delivery 132 ( 101 ) 166 ( 250 ) 3 ( 325 ) 201 ( 39 ) 38 ( 114 ) 235 ( 189 ) 225 ( 102 ) 259 ( 251 ) 97 ( 326 ) 294 ( 40 ) 131 ( 115 ) 328 ( 189 ) 83 ( 176 ) 118 ( 326 ) 315 ( 39 ) 152 ( 114 ) 349 ( 189 ) 188 ( 263 ) + 74.6 ( 74.6 ) for every further coating unit 84 ( 177 ) 119 ( 326 ) 316 ( 40 ) 153 ( 115 ) 350 ( 189 ) 188 ( 264 ) + 74.6 ( 74.6 ) for every further coating unit
Degree values for the beginning of powdering SM102 (CD102)
376
Other components
12M35 Blower motor for powder spray device
12M35 Blower motor for powder spray device Place of installation, filter change
The motor is located at the delivery. It is mounted on the baseplate on the inside of the side frame, on the O.S. To change the suction filter, open the hinged cover above the footboard.
12E2-X1
Blower motor for powder spray device at delivery
Layout 1 2 3 4 5 6 7 8
Suction filter Air hose leading to powder spray device Plug connection M35-X1 Baseplate Casing cover with rotor vanes underneath Compressed-air cooler Hood for motor fan Pressure relief valve
Compressor motor M35
377
Other components
12M35 Blower motor for powder spray device
Changing the rotor vanes

Remove the casing cover of the compressor motor M35.
Note: When you loosen the lower fixing bolts of the casing cover, the compressed-air cooler becomes loose as well. Hold it tight.
The rotor vanes are accessible. If they are shorter than 27 mm (min. permissible length), they must be replaced.
27mm min.
Rotor vanes in motor 12M35
378
Other components
12S68 Switch Powdering cycle
12S68 Switch Powdering cycle Place of installation

The switch Powdering cycle 12S68 is located on the D.S. of the delivery. In the case of Betatronic from Grafix, Weko T 77Cs and Weko Ionomat Cs, the switch is connected directly to the powder spray device. With all other powder spray devices the switch is connected to the distribution box at the delivery.
Place of installation of switch Powdering cycle, 12S68
379
Other components
12S9, -a, -b, -c Monitoring the IR slide-in dryer
12S9, -a, -b, -c Monitoring the IR slide-in dryer Place of installation

Each IR slide-in dryer is equipped with a safety switch with NC and NO contacts. When the IR dryer is inserted, the switching element provided on the slide-in dryer actuates the safety switch on the drive side. Printing presses with several IR slide-in dryers (extended delivery) have 4 switches (12S9, 12S9a, 12S9b, 12S9c). The NC contacts of the safety switches are connected in series and the NO contacts in parallel.

Place of installation of safety switch Monitoring the IR slide-in dryer
Layout and connection 1 2 3

Sensor Openings for switching element Switching element (fitted on slide-in dryer) Marking 21-22 13-14 Function NC contact NO contact
NC contact ( s ) at input 9 of EAK12: 0 1 IR dryer(s) inserted IR dryer(s) removed
NO contact ( s ) at input 9 of SEK:
Sensor Monitoring the IR slide-in dryer
1 0
IR dryer(s) inserted IR dryer(s) removed
380
Other components
E8 Air supply cabinet
E8 Air supply cabinet Connections

The air supply cabinet receives 2 AC 380 V and the control signal Compressor on from the printing press. A thermostat in the control cabinet signals excessive temperatures to the CP Tronic control system. All cables are connected directly to terminal strips and are not led via plugs. For the exact terminal connections please refer to the circuit diagram and technical instructions of the manufacturer. Cable entries
Air supply cabinet, rear view
381
Other components
E39 Inking unit temperature control Layout

The supply voltage for the inking unit temperature control comes from the control cabinet and is connected via plug E39-X1. A manufacturers manual is available. E39-X1: power supply
Inking unit temperature control
Pin assignment E39-X1

Pin 6 7 8 9 10 1 2 3 4 5 3 7 9 Function AC 230 V, phase U AC 230 V, phase V AC 230 V, phase W PE
382
Other components
12E3 Static electricity eliminator
Attention:
Observe the circuit diagram! Cut off the power supply before working on the device!
Place of installation of static electricity eliminator
1 2 3 4
Power supply for static electricity eliminator (D.S.) Neutralizer bar Ion blowers Air-supported neutralizer bar
The static electricity eliminator consists of a power supply unit with high-voltage transformer, a neutralizer bar at the feeder and an air-supported neutralizer bar at the delivery. Two ion blowers can be additionally attached to the suction head (optional).
Note: The static electricity eliminator is optional and therefore not fitted on all presses.
For subsequent installation, threads are provided in the side frame as standard.
383
Other components
Layout 1 2 3 4 5 6
Mains switch Pilot lamp Power supply unit Power cable AC 230 V Ion blowers at feeder Neutralizer bar at delivery
Note: 2 different versions are available. Differences in the housing design do not affect the functions.
Static electricity eliminator 12E3 (ELTEX)
Static electricity eliminator, version 2 (SIMCO) 384
Other components
Task
The unit consisting of the power supply with high-voltage transformer plus connected neutralizer bars and ion blowers eliminates static charges on the sheets of paper.
385
Other components
WSA Intercom
WSA Intercom Layout 1 2 3 4

Loudspeaker Microphone Volume controller Illuminated pushbutton
The WSA consists of one intercom at the control panel at the feeder and one at the control panel at the delivery. Each intercom has a microphone, loudspeaker, illuminated pushbutton, volume controller and two electronic boards (main and secondary boards). The electronic boards are directly in the intercom.
Intercom at feeder
Intercom at delivery
386
Other components
WSA Intercom
Function 1 2 3 4 5 6 7
Secondary board with terminal strip 11WSA-X2/ 12WSA-X2 Main board Connection for volume controller Connection for microphone Connection for secondary board 11WSAX1/ 12WSA-X1 Connection for illuminated pushbutton Changeover switch main/secondary intercom
The intercom is set in such a way that the main intercom (H) is at the delivery and the secondary intercom (N) at the feeder. When the illuminated pushbutton is pressed at the delivery, speaking at the feeder is interrupted. The priority between the two intercoms can be reversed any time by means of the changeover switch on the main board. The setting of the switch must then be changed at both intercoms.
Electronic boards of intercom
387
Other components
IDS Encoder
IDS Encoder Place of installation
Encoder IDS
Place of installation of encoder in 1st PU
Task
The encoder is the basis for all speed- and degree-dependent functions. Examples of speed- and degree-dependent functions: motor regulation, interrogation points of sensors, positioning for plate change.
388
Other components
IDS Encoder
Function
Track A 5V 0V 5V 0V 5V 0V The encoder generates three pulse signals: track A, track B, track 0.
Track B
Track B is staggered by 90 in relation to track A. Per revolution track 0 generates one zero pulse. The inverted signals are also available from all 3 tracks. Tracks A and B each generate 1024 pulses per revolution.
Track 0
Pulse signals from the encoder
Pin assignment
Pin
G F M J A K B L E
Function DC+5V 5V Track A/ Track A Track B/ Track B Track 0/ Track 0
M, G, H A, L, D
D
C B
C
F E K J
Encoder plug
389
Other components
IDS Encoder
Installation variants
For presses with more than five printing units and sheet turning device a second encoder IDS is used. This IDS is used for closed-loop control of the main drive. The mechanical installation and removal of both IDS is identical (steps 1, 2, 3 and 6, 7, 8).
For the installation of the 2nd IDS (main drive regulation) the zero point adjustment is not required.
CD 102 Straight-printing presses On CD102 presses the IDS is always fitted in the 1st printing unit. SM102 Straight-printing presses IDS 1 SM1022 SM1022+L SM1023 SM1023+L SM1024 SM1024+L SM1025 SM1025+L SM1026 SM1026+L SM1027 SM1027+L SM1028 SM1028+L Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing unit unit unit unit unit unit unit unit unit unit unit unit unit unit 1 1 1 1 1 1 1 4 4 4 4 4 4 4 IDS 2 SM1022 SM1022+L SM1023 SM1023+L SM1024 SM1025 SM1025+L SM1026 SM1026+L SM1027 SM1027+L SM1028 SM1028 P5 SM1028+L SM1028+L P5 SM1028+L SM102 Perfector presses IDS 1 Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing unit unit unit unit unit unit unit unit unit unit unit unit unit unit unit unit 1 1 1 1 1 1 1 1 1 1 1 1 4 1 4 5 IDS 2 Printing Printing Printing Printing Printing Printing Printing
unit unit unit unit unit unit
4/5 4/5 4/5 4/5 4/5 4/5/6
unit 4/5
Removal and installation 2 1 2 3

Remove the plug. Loosen the stud. Remove the encoder.
Encoder IDS
390
3 1
Other components
IDS Encoder
Insert the gauge in printing unit 1.
Inserting the gauge
Line mark D
Positioning to zero
5 6 7 8
Use the crank handle to turn the impression cylinder to the zero position (line mark D). Fit the new encoder. Connect the encoder. Turn on the main switch 15Q66.
8 6
15Q66
Fitting the new encoder IDS
391
Other components
IDS Encoder
Turn the shaft of the encoder until 000.0 is displayed in the MID. Tighten the stud.

Adjustment of the encoder IDS
Note: If the value 000.0 is not displayed in the MID, continue with step q. If the setting is correct, continue with r.
e q
q w e
Loosen the locking nut. Turn the adjusting screw until 000.0 is displayed in the MID. Tighten the locking nut.
Precision adjustment of the encoder IDS
Remove the gauge from PU 1.
Removing the gauge
392
Location diagrams
ZSG Central control cabinet
Location diagrams
ZSG Central control cabinet Location and layout
Equipment zone E Swing frame Equipment zone A Power supply Equipment zone B Partition wall Equipment zone D Flat cable mounting plate Equipment zone C Mounting rack / control devices
Layout of central control cabinet

393
Location diagrams
Equipment zone A Power supply

This equipment zone contains the components necessary for connection to the power supply. The chapter Control systems describes how the press is connected to the power mains.
1 2 3 4 5 6 7 8 9 q w
15M1 15L1 15R120 15R48
Fan Power components Power choke - power converter Load resistor (only for presses with Preset) Load resistor (only for presses with auxiliary pile at the delivery) Semiconductor fuses Armature circuit M1 Main switch EMC filter Semiconductor fuses Mains Terminal strip PE conductor EMC filter Control transformer
15F2 15Q66 15Z2 15F1 15X1 PE 15Z1 15T1
Equipment zone Power supply
394
Location diagrams
Equipment zone B Partition wall

SLT GRM5 GRM24 GRM48 GRM120-2
SLT
Converter power part Rectifier module Rectifier module Rectifier module Rectifier module Flat switch Transformer protection, secondary Flat switch Transformer protection, secondary Circuit-breaker Feeder / delivery main pile (not for Preset version) Circuit-breaker Feeder auxiliary pile Contactor Pile control STK1 (without Preset) / LSR (with Preset) Contactor Pile control STK1 (with Preset) / STK2 (without Preset) Contactor Power supply connecting part of power converter Motor circuit-breaker Air supply cabinet E 8 Motor circuit-breaker Transformer protection, primary
15Q61 15Q62 15Q37
15Q38
GRM5 GRM24 GRM48 GRM120-2
15K37M
15K38M
15K48A
15Q61 15Q37 15K37M 15K48A 15Q65
15Q2 15Q65
15Q62 15Q38 15K38M 15Q2
Equipment zone Partition wall
SLT Converter power part The converter power part SLT contains the power electronics for driving the main drive. The chapter Control systems, subchapter Direct-current main drive lists the components of the converter power part.
SLT
Converter power part

395
Location diagrams
GRM Rectifier modules The equipment zone B Partition wall contains four rectifier modules.
F6 F8 F7 F5 F4 F3
1 2 3 4
GRM5 GRM24 GRM48
Rectifier module Rectifier module Rectifier module
GRM120-2 Rectifier module
The rectifier modules GRM24 and GRM48 are of identical design and interchangeable. Fuses:
Rectifier modules GRM
F6, F7, F8 (GRM5)
15 A, quick-acting, 6.3 x 32 mm
F5, F4 (GRM24 / GRM48) 20 A, quick-acting, 6.3 x 32 mm ca. AC 24 V 3 x ca. AC 35 V 3 x ca. AC 100 V F3 (GRM120) 32 A, slow-blowing
3 x ca. AC 26 V
ca. DC 36 V ca. DC 33 V
ca. DC 120 V
ca. DC 50 V
Voltages at the rectifier modules GRM
396
Location diagrams
Equipment zone C Mounting rack / control devices
Q.... Motor circuit-breakers

Q2a Q4 Q4a Q22 Q24 Q28 Q33 Q33a Q35 Q39
K....M Main contactors

22M K22M K33M K33aM K35M K39M
Q39
Q39a
Q40
Q44
Q22a
Q80 IWM
Earth-leakage monitor module
K39M
K40M
K22aM
K39M K39aM K46A K61A K50M K51M K52M K53M K54M K55M K56M K43M
Terminal amplifier module Flat-cable output module 64 outputs

KVM FAM 64 FEM 64
Flat-cable input module 64 inputs
BAM
BKM
SPM
VSM
SVM
SVM
ESM FEM10 AUM
Optocoupler 15U2
15X4
Terminal strips
15X3
Analog conversion module Flat-cable input module 10 inputs Interference suppressor module Interface distributor module Amplifier module Memory analog board module Brake coupling module Brake control module
Equipment zone Mounting rack / control devices

397
Location diagrams
Equipment zone D Flat cable mounting plate 1

15V1 The rectifier reduces the voltage from the power supply board NTK 24 (in the REE) to the supply voltage (22 V) for the signal lamps. Leading to the swing frame: backplane of input/output plug-in unit EAR / input/output auxiliary drive plug-in unit EHR From each press unit, input and output cables lead to the swing frame. The input/output cables are fastened on the flat cable mounting plate. Cable routing as shown in the sketch opposite. Fixing clips
2
I/O 1 I/O 2 I/O 3 I/O 4
13,15 5, 6 3, 4 1, 2 11,12 Flat cables from the press units
Equipment zone Flat cable mounting plate
398
Location diagrams
Equipment zone E "Swing frame

Equipment of swing frame for presses with:

REE2 EHE2 LTE
2 - 5 PUs, without Preset REE2 EHE2 LTE Computer plug-in unit 2 Input/output auxiliary drive plug-in unit 2 Power part plug-in unit SSE2 Servo-drive plug-in unit 2
1
REE2 EHE2 LTE
2 - 5 PUs, with Preset Computer plug-in unit 2 Input/output auxiliary drive plug-in unit 2 Power part plug-in unit SSE2/LSE Servo-drive plug-in unit 2/ power part plug-in unit for brushless pile motors
Swing frame for presses with 2- 5 PUs
Note: The electronic boards must be in their respective board slots. They must be correctly connected to the connectors of the backplane. In front of each plug-in unit the safety crossbar must be fitted.
399
Location diagrams
Swing frame for presses with 6- 8 PUs

REE2 EAE HAE2 LTE
Equipment of swing frame for presses with: 6 - 7 PUs, without Preset REE2 EAE HAE2 LTE Computer plug-in unit 2 Input/output plug-in unit Auxiliary drive plug-in unit 2 Power part plug-in unit SSE2 Servo-drive plug-in unit 2
6 - 7 PUs, with Preset, 8 PUs, with Preset, without non-stop delivery REE2 EAE HAE2 LTE Computer plug-in unit 2 Input/output plug-in unit Auxiliary drive plug-in unit 2 Power part plug-in unit SSE2/LSE Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors
8 PUs, with Preset, with auxiliary pile at the delivery REE2 EAE HAE2 LTE Computer plug-in unit 2 Input/output plug-in unit Auxiliary drive plug-in unit 2 Power part plug-in unit SSE2/LSE2 Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors 2
400
Location diagrams
Swing frame for presses with 9 PUs

REE2 EAE EHE2 LTE
Equipment of swing frame for presses with: 9 PUs, with Preset, without non-stop delivery REE2 EAE EHE2 LTE Computer plug-in unit 2 Input/output plug-in unit Input/output auxiliary drive plug-in unit 2 Power part plug-in unit SSE2/LSE Servo-drive plug-in unit 2/ power part plug-in unit for brushless pile motors
9 PUs, with Preset, with auxiliary pile at the delivery REE2 EAE EHE2 LTE Computer plug-in unit 2 Input/output plug-in unit Input/output auxiliary drive plug-in unit 2 Power part plug-in unit SSE2/LSE2 Servo-drive plug-in unit 2/ power part plug-in unit for brushless pile motors 2 SSE2/LSE2 Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors 2
1 1
401
Location diagrams
Computer plug-in unit REE 2
Computer plug-in unit REE
1 2 3 4 5 6 7 8
NTK24 Power supply board NTK5 Power supply board REK386 Processor board 386 ESK_2 Input/ output control board SAK2 Memory analog board ESK_1 Input/ output control board REK1 Processor board SRK Power converter board
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , input / output control boards ESK 2). Boards of the same type are interchangeable.
ESK_2 Input/ output control board The input/ output control board ESK_2 is required for presses with 9 printing units.
REK386 Processor board 386 EPROM module Computer motherboard The processor board 386 REK 386 consists of the computer motherboard RGP 3, the EPROM module EPM and the RGPcomputer module RRM.
RGPcomputer module
Layout of computer unit RGP3+RRM

REK1 Processor board EPROM module Computer motherboard The processor board REK 1 consists of the computer motherboard RGP 2 and the EPROM module EPM.
Layout of processor board REK1
402
Location diagrams
Input/output auxiliary drive plug-in unit EHE 2 The input/output auxiliary drive plug-in unit EHE 2 is required for presses with: 2 - 5 printing units, 9 printing units.
Input/output auxiliary drive plug-in unit for presses with 2- 5 printing units
1 2 3 4
NTK5 Power supply board HAK2 Auxiliary drive board SEK Safety input board
EAK2 Input/output board from right to left for: feeder, delivery, central control cabinet, printing units 1 to 5. EAK2 Input/output board for printing unit 9
Input/output auxiliary drive plug-in unit for presses with 9 printing units
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , auxiliary drive boards HAK 2, input/ output boards EAK 2). Boards of the same type are interchangeable.
Input/output plug-in unit EAE The input/output plug-in unit EAE is required for presses with: 6 printing units.
1 2 3
NTK5 Power supply board SEK Safety input board
Input/output plug-in unit for presses with 6 printing units
EAK2 Input/output board from right to left for: feeder, delivery, central control cabinet, printing units 1 to 8.
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , input / output boards EAK 2). Boards of the same type are interchangeable.
403
Location diagrams
Auxiliary drive plug-in unit HAE 2 The auxiliary drive plug-in unit HAE 2 is required for presses with: 6 - 8 printing units.
1 2
Auxiliary drive plug-in unit for presses with 6- 8 printing units
NTK5 Power supply board HAK2 Auxiliary drive board
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , auxiliary drive boards HAK 2). Boards of the same type are interchangeable.
404
Location diagrams
Power part plug-in unit LTE
The power part plug-in unit LTE is required for all presses.
1 2 3 4
LTK500 LTK50 STK_2 STK_1
Power part board Power part board Pile control board Pile control board
Power part plug-in unit for presses with 7 printing units, without Preset, with auxiliary pile at feeder and delivery
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power part boards LTK50, power part boards LTK500). Boards of the same type are interchangeable.
LTK50 Power part board The power part board LTK50 is only used for presses with: 2 - 7 printing units, with Preset, with auxiliary pile at the delivery, 7 printing units, without Preset, with auxiliary pile at the delivery
Power part plug-in unit for presses with 8- 9 printing units, with Preset, with auxiliary pile at the feeder
STK_1 Pile control board The pile control board STK_1 is used for all presses except for those with: 8 - 9 printing units, with Preset, without auxiliary pile at the feeder.
STK_2 Pile control board The pile control board STK_2 is only used for presses: without Preset, with auxiliary pile at the feeder.
Power part plug-in unit for presses with 8- 9 printing units, with Preset, without auxiliary pile at the feeder
405
Location diagrams
Servo-drive plug-in unit SSE2 The servo-drive plug-in unit SSE2 is required for presses with: 1 2 - 4 PUs, without Preset (only one SSK 2), 2 PUs, without Preset, without CPC, 5 - 7 PUs, without Preset,
Servo-drive plug-in unit for a press with 2- 7 PUs, without Preset
NTK24 SSK2
Power supply board Servo-drive control board
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , servo-drive control boards SSK 2). Boards of the same type are interchangeable.
Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors SSE 2/ LSE

Servo-drive plug-in unit/power part plug-in unit for brushless pile motors for presses with 6- 7 PUs, with Preset
The servo-drive plug-in unit / power part plug-in unit for brushless pile motors SSE 2/ LSE is required for presses with: 2 - 5 PUs, with Preset (only one NTK 24 and two SSK 2s), 2 PUs, with Preset, without CPC, 6 - 7 PUs, with Preset, 8 - 9 PUs, with Preset, without non-stop delivery
1 2 3 4
NTK24 Power supply board SSK2 Servo-drive control board LTK500 Power part board BAK Brake control board
406
Location diagrams
Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors SSE 2/ LSE

Servo-drive plug-in unit/power part plug-in unit for brushless pile motors 2 for presses with 8 - 9 PUs, with Preset, with auxiliary pile at the delivery
The servo-drive plug-in unit / power part plug-in unit for brushless pile motors SSE 2 / LSE2 is required for presses with: 8 - 9 PUs, with Preset, with auxiliary pile at the delivery
1 2 3 4 5
NTK24 Power supply board SSK2 Servo-drive control board LTK50 Power part board LTK500 Power part board BAK Brake control board
407
Location diagrams
ZSP Central control console
ZSP Central control console Layout
Fixing bolts for console plate
Console plate
Display control board DSK
Input / output module EAM Display unit consisting of: display power supply board DNK display support plate control console display ZID
Support plate for: A transformer 13T1 B connector 13X1 C terminal strip 13X2
Hinged cover with opening for cables Casing of central control console
Door
Overall view
408
Location diagrams
Position switches
Position switches
2S29 2S28 1S28 1S29 11S37 11S34 11S31 11S65 11S56 2S25 2S25a 2S25b 2S24 2S26 1S25 1S25a 1S25b 1S24 2S20 2S31 2S37 1S26 11S40 11S38 11S38a 1S40 11S38b 11S36 11S32 11S4
1S40a
11S39
Preset feeder, printing units 1 and 2
12S55
12S55a 12S40 3...9S28 12S39 12S33 12S130 12S41 12S117 12S34b 12S34a 12S43 12S37 3...9S24 12S9 3...9S20 3...9S37
12S44 12S38 12S56 3...9S29 12S35 12S36 12S422) 12S130a 12S421) 12B129a 12B129
12S34 12S65a
1 2
Version with rake Version with board
Delivery with coating unit

Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.
409
Location diagrams
Position switches
12S44
12S68

12S55 12S55a 12S40 3...9S28 12S35 12S42 12S56 12S36 12S39 12S37 3...9S29 12S34 12S9 12S37a 3...9S24 12S65a 12S34b 12S34a 3...9S20 12S411) 12S412) 12S65 12S43 12S9c 12S9b 12S9a Version with rake Version with board
3...9S37
1 2
Extended delivery with coating unit

410
Location diagrams
Solenoid valves
Solenoid valves
2Y56
1Y56
11Y74 1Y45 1Y15 15Y11
11Y66 11Y16
11Y15 2Y12 2Y48 1Y12 1Y16 1Y48
2Y2 2Y9 2Y10 2Y11 2Y13 2Y53
2Y63 2Y62 2Y61 2Y7 2Y51 2Y39/2Y40
1Y2 1Y9 1Y10 1Y11 1Y13 1Y53 1Y47
back 1Y63 1Y62 1Y61 1Y7 1Y51 1Y39/1Y40 1Y50 1Y52 1Y55 1Y42 front or back 1Y52 1Y55 1Y42 1Y54 1Y43 1Y44 1Y54 1Y43
front

411
Location diagrams
Solenoid valves
12Y14/ 12Y15 12Y60/ 12Y61 12Y11 12Y49 12Y13 12Y4 12Y78 12Y62 4...9Y67 3...9Y48 3...9Y12
12Y60/ 12Y61

12Y14/ 12Y15 12Y11 12Y49 12Y13 12Y4 3...9Y12 4...9Y67 3...9Y48 12Y78 12Y62

412
Location diagrams
Motors
Motors
2MD 1MD 11M11 2M45 Lateral register 2M1 Lateral register 11M6 2M6 2M5 Circumferential register M52 1M6 1M1 1M4 1M8 1M5 Circumferen1M7 tial register 11M3 M51 1M4 1M2 1M3 11M9 11M8 1M9 11M7 11M5 1M45 11M2 11M12 11M1
12M2 12M5 12M7 12M6 12M3 12M47 M44 12M1 3...9M2

413
Location diagrams
Motors

12M2 12M5 12M1 3...9M2 12M7 12M6 12M3 12M47 M44

414
Location diagrams
Sensors
Sensors
2B43
2B32
1B43
1B32
15B14 11B35 1B11 1B13 2B48 2B48a 1B48 1B48a 1B9
11B10 11B55
1B10 HWI 1B49
11B33 11B11
3...9B32 12B129 12B69 12B129a 12B65 12B77 12B47

415
Location diagrams
Sensors

3...9B32 12B129 12B69 12B129a 12B65 12B77 12B47

416
Location diagrams
Control panels
Control panels
F C D C D
H C G F
417
Location diagrams
Control panels

H C F G
418
Location diagrams
Control panels
Feeder
Press control
Pile control
Preset feeder
419
Location diagrams
Control panels
Printing unit/coating unit

C
Printing unit control O.S.
Printing unit/ coating unit control D.S.
Dampening system control
Coating unit control D.S.
Printing unit/coating unit
420
Location diagrams
Control panels
Delivery
H
Press control
Pile control
Press display MID
Preset version
421
Location diagrams
Control panels
Dampening system control
Fan and dryer control
Preset version
422
Location diagrams
Operators controls
Operators controls
Description
Feeder
Printing/coating unit
Delivery
Remark
Pushbutton Run
11S2
12S2
Pushbutton Stop
11S30
12S8
Pushbutton Production run
11S19
12S60
Emergency stop button
11S1
1...nS1 (O.S.) 1...nS2 (D.S.)
12S1
Illuminated pushbutton Compressor on/off Illuminated pushbutton Feeder on/off Illuminated pushbutton Paper run on/off Pushbutton Fast
11S3 11H3 11S7 11H7 11S5 11H5 11S20
11S58 11H58 12S59 12H59 12S57 12H57 12S6
Pushbutton Slow
11S21
12S7
Pushbutton Forward
11S17
1...nS3 (O.S.) 1...nS6 (D.S.) 1...nS4 (O.S.) 1...nS7 (D.S.) 1...nS5 (O.S.) 1...nS8 (D.S.)
12S3
Selector switch Safe
11S18
12S4
Pushbutton Backward
12S5
Signal lamp Malfunction press Signal lamp Malfunction feeder Malfunction delivery Malfunction printing/coating unit Malfunction dryer
11H51
12H9
11H1
1...nH1
12H1
423
Location diagrams
Operators controls
Description
Feeder
Delivery
Remark
Illuminated pushbutton Job counter on/off Pushbutton Crawl speed Pushbutton Position 1...nS23
12S63 12H63
1...nS17
Illuminated pushbutton Plate mounting
1...nS59 1...nH59
Pushbutton Auxiliary pile down
11S29
12S54
Pushbutton Auxiliary pile up
11S28
12S53
Toggle switch Auxiliary pile on/off Pushbutton Main pile down
11S27
11S25
12S46
Pushbutton Main pile up
11S24
12S45
Pushbutton Pile stop
11S26
12S124
Pushbutton Pile board on/off Pushbutton Removal of inspection sheet Press display MID Illuminated pushbutton Inking form rollers on/off 1...nS57 1...nS57
12S10 12H10 12S11 12S11a
424
Location diagrams
Operators controls
Description
Feeder
Delivery
Remark
Illuminated pushbutton Ink ductor on/off Pushbutton + dampening Washing dampening/varnishing rollers Illuminated pushbutton dampening Selector switch Adjusting dampening rollers Pushbuttons Blast air regulation Pushbuttons Suction head height 11S117 11S118 11S44 11S44a 11S45 11S45a 11S46 11S47 11S58 11S58a 11S59 11S59a 11S59 11S60 11S63 11S62 11S9 11S10 11S48 11S57
1...nS58 1...nH58 1...nS22 12S17... 12S24
12S25... 12S32 1...nS21
Pushbuttons Suction head format Pushbuttons Main pile centering
Pushbuttons Auxiliary pile centering Pushbutton Pile stops larger format Pushbutton Pile stops smaller format Pushbutton Pile stops D.S. Pushbutton Pile stops O.S. Pushbuttons Format wheels Pushbuttons Sheet slowdown format
12S68 12S69
425
Location diagrams
Operators controls
Description
Feeder
Delivery
Remark
Pushbuttons Sheet slowdown speed Pushbuttons Sheet jogger D.S. Pushbuttons Sheet jogger O.S. Potentiometer to regulate the displayed fans Potentiometer to regulate the displayed fans Potentiometer to regulate the displayed fans Potentiometer to regulate the displayed fans Potentiometer to regulate the displayed fans Potentiometer to regulate the displayed fans Pushbutton Dryer on/off
12S61 12S62 12S73 12S74 12S75 12S76 DSM5
DSM3
DSM6
DSM2
DSM1
DSM4
Selector switch for dryer
Potentiometer to regulate dryer output Volume controller
Illuminated pushbutton Intercom Pushbutton Lifting the sheet stop fingers 11S8
426
Location diagrams
Operators controls
Description
Feeder
Delivery
Remark
Illuminated pushbutton Dampening rollers Pushbutton Suction air for suction tape + Pushbutton Suction air for suction tape Illuminated pushbutton Turning the ink fountain roller Varnish circulation
11S6 11H6 11S41
11S42
1...nS45
Varnish pump ON/OFF
Turning the pan roller
Draining the coating pan
Varnish flow rate to varnish pump
Spraying
Rinsing
Stopping the pan roller
2...nS57 2...nH57 11R1
Potentiometer Blast air at front lays
427
Location diagrams
Operators controls
428
Location diagrams
ZSP Control panel of control console
7 4 1
8 5 2 0
9 6 3
CPC
Control panel of central control console ZSP
Selector buttons Unit (from left to right): Entire press Delivery Printing unit Feeder Preselection display Actual value display Fine display of preselection/actual value display Fault display: Press not ready to run Warning Service display: Central lubrication Service 1 Service 2 Colour buttons Function buttons Adjustment buttons
q w
Emergency stop button Button Stop Command buttons (from left to right): Presetting Job change Progressives (colour separations) Washup Command control buttons Signal lamps (from left to right): Malfunction press (red) Malfunction control console (blue) Malfunction production run (yellow) Button Page up/down in the display Control console display Numeric keypad CPC keys (for presses without CPC equipment)
2 3 4 5 6
e r
7 8 9
t z u i
429
Location diagrams
430
Abbreviations
Abbreviations
Abbreviation Description Drive extension module Display board Display and key distribution board Job memory card unit Analog signal distribution module Control and distributor module EGK EE EEM Abbreviation Description Input/output plug-in unit Input/output board Input/output module Backplane of input/output plug-in unit Electronic plug-in unit Single-fault fail-safe extension module External equipment board Auxiliary drive input/output plug-in unit Backplane of auxiliary drive input/output plug-in unit Mains discharge board Backplane of electronic plug-in unit EPROM module Extension control cabinet Input/output control board Interference suppressor module Electronic ballast Front-corner alignment control Input/output distributor module Extension board Extension module External equipment supply board
AEM
ANZ ATV ASE AUM AVM
EAE
EAK EAM EAR
BAK
BAM BEK BFM BKM BLT BSM BVM
Brake control board Brake control module Control unit board Filter module of brushless power part Brake/ clutch module Brushless power part Control unit interface module Control unit distributor module
EHE EHR ELK ELR EPM ESG ESK ESM
CSM
CVK
CPC3 interface module CPC3 distributor board
EVG EVK EVM
DAM
DAK DAS DBE DGP DLW DNK DSK DSM
Double-sheet indication module Digital output board Speed ratio display system Double-sheet detector Display motherboard Diskette drive Display power supply board Display control board Speed control module Fans
EWK EWM EXK
FAM
FCA FCK FDK
Flat-cable output module Adaptor between telediagnosis board and CPC2S Flash memory controller board Telediagnosis board
431
Abbreviations
Abbreviation
Description Flat-cable input module Ink fountain board Ink fountain distributor Sensor for overshooting-sheet control Flat-cable connection module Ink zone display board Distribution board for ink zone keys
Abbreviation
Description Air pressure sensor module Light pen Power logic module Varnish pump control module Power part control module Light barrier Power part plug-in unit for brushless pile motors Lamp control module Backplane of power part plugin unit for brushless pile motors Power part plug-in unit Power part board Power part module Backplane of power part plugin unit Interconnection module Air distributor module Distribution box
FEM
FKK FKV FK FVM FZA FZT
LDM
LG LLM LPM LRM LS LSE LSM LSR
GKM
GRM GSM
Compact rectifier module Rectifier module Rectifier module with fuses LTE LTK LTM
HAE
HAK HAR HLM HSK HSQ HTM HVK HWI
Auxiliary drive plug-in unit Auxiliary drive board Backplane of auxiliary drive plug-in unit Auxiliary drive logic module Main drive control board Sheeter Auxiliary drive driver module Main current distributor board Encoder
LTR LUM LVM LVT
MAE
MAR MCM MEE MID
Motor drive plug-in unit Motor drive backplane Microcontroller module Motor drive/electronic plug-in unit Press display Measuring head Motor drive board Motor regulation board Measuring bar computer module Motor control board Measuring bar sensor module Measured-value acquisition board State indication board
IDS
ITF ITM IWM
Encoder Terminal interface IGBT driver module Earth-leakage monitor module
MK MOT MRK MRM MSK MSM MWE MZK
KID
KKM KLM KNT KOK KVM KVT
Compact information display Heat sink module Compact power module Compact power supply unit Communication board Terminal amplifier module Heat sink unit
432
Abbreviations
Abbreviation
Description Mains connection module Electronics supply board Supplementary module of power supply unit Power supply plug-in unit Power supply board Power supply module Power supply backplane Mains supply board NV-RAM module Power distributor of electronic plug-in unit
Abbreviation SBM SDM SEK SEM SIK SLA SLM SLT SM SMM SMR SNT
Description Power bridge module Servo-drive pushbutton module Safety input board Interface input module Actual current measuring board Suction air control Pile power module Converter power part Stepper motor Current measuring module Stepper motor control board Chopper-type power supply unit Memory analog board module Voltage regulator Voltage selector switch Power converter board Serial interface adapter Servo-drive plug-in unit Servo-drive control board Servo-drive distributor module Backplane of servo-drive plugin unit Interface adapter Pile control board Pile power part Pile control module Vacuum cleaner Supporting element of power converter Signal conversion module Control voltage distributor board Interface distributor module Connecting part of power converter Voltage fluctuation relay Setpoint module
NAM
NEK NSM NTE NTK NTM NTR NVK NVM NVTE
PBK
PD PEK PRZ PRM PSL PSM PU
Back-up battery board Printer Extension board for plate image reader Processor board Plate position detection module Positioning lamps Profibus interface module Printing unit SPM SPR SPW SRK SSA SSE SSK SSM SSR
REE
REK REM RER RGP RRM RSK RSM RWK
Computer plug-in unit Processor board Register module Backplane of computer plug-in unit Computer motherboard RGP computer module Plug-on control board Plug-on control module Backplane
STA STK STL STM STS STT SUM SVK SVM
SAK
SAM SAS
Memory analog board Interface output module Busbar system
SVT SW SWM
433
Abbreviations
Abbreviation
Description Button and display module Tacho input module Transistor power board Terminal Buttons for manual positioning of measuring head Transistor control board Transistor control module Driver/interface board Dryer control module Transistor driver board Keyboard coding module Key distributor board Encoder distribution module Tacho signal distribution system
Abbreviation ZRM ZSG ZSK ZSP ZT ZTK
Description ZSK computer module Central control cabinet Central control board Central control console Zenith terminal Central control board
TAM
TEM TLK TML TMP TRK TRM TSK TSM TTK TUM TVK TVM TVS
UFK
USM UVM
Filter board Interconnection module Converter and distributor module
VEN
VMM VP VSM VTL VTR VVK
Fan Distributor for measuring module Distributor board Amplifier module Distributor board for diskette drives Distributor board Ballast supply board
WDM ZID
ZMM
Resistance decade module
Control console display Double current-measuring module
434
Equipment identification
To be able to clearly identify the electrical equipment, the following equipment identification is used:
Press model Position code Where on the press ... ? Identification letter or abbreviation Which equipment ... ? Number Distinguishes equipment of the same type
Example 1: 1LVT1
1 PU1
LVT Distribution box
1 1st distribution box (main distributor)
Example 2: 1S3
1 Printing unit 1
S Switch here: pushbutton Forward
3 Consecutive number of switch on PU 1
Example 3: E4
Blank Cannot be allocated to any unit
E Other equipment: motor / pneumatic system compressor
4 Consecutive number
Note: If a field of the equipment identification is not required or not defined, it is left blank.
In most cases the consecutive number corresponds to the inputs or outputs of the associated EAK.
435
436
Position codes
Position codes
Overview of position codes
The position code indicates on which unit of the press the equipment in question is located. The position codes 1 to 10 are reserved for the printing units or the coating unit.
1 2 3 4 5 11 12 13 14 15 16 20 101
Printing unit 1 Printing unit 2 or coating unit Printing unit 3 or coating unit Printing unit 4 or coating unit
...
10
Feeder Delivery Central control console Sheeter HSQ Central control cabinet ZSG Extension control cabinet ESG Dryer Control unit CPC1
Example: Position codes on a Speedmaster
15 4 12 101 13 11 3 2 1
Speedmaster SM102
437
Position codes
438
Index
Index
A
Abbreviation, 435 Abbreviations, 431 Adjustment of format wheels 11M4, 47 Checking the operating range, 52 Fault message, 47 Interconnection diagram, 49 Place of installation, 48 Removal and installation, 50 Technical data, 48 Adjustment of pile support plate 11M8, 31, 33 Checking the operating range, 37 Interconnection diagram, 34 Place of installation, 33 Removal and installation, 35 Technical data, 33 Adjustment of printing pressure 1...nM5, 85 Checking the operating range, 95 Interconnection diagram for CU, 89 Interconnection diagram for PU, 88 Place of installation, 87 Removal and installation of motor, 90 Removal and installation of potentiometer, 92 Technical data, 87 Adjustment of pull lays 1M7/1M8, 96 Automatic positioning, 96 Checking the operating range, 103 Interconnection diagram 1M7, 99 Interconnection diagram 1M8, 100 Place of installation, 98 Precision adjustment of pull lay, 97 Removal and installation, 101 Technical data, 98 Admission of pressure, pneumatic system 15Y11 Pin assignment, 352 Place of installation, 351 Task, 351 Air supply cabinet E8, 381 Automatic misalignment control 11M7 Activation and inactivation, 252 Block diagram, 251 Checking the operating range, 257 Graphical representation, 253 Interconnection diagram, 255 Place of installation, 254 Removal and installation, 256 Sheet alignment, 251 Technical data, 254 automatic pile transport 11B35 checking the circuit state, 157 connection, 156 Layout, 155 place of installation, 155 -removal and installation, 156 task and function, 156
Automatic sheet arrival control 11M3 Activation and inactivation, 239 Block diagram, 238 Graphical representation, 240 Preset version, 247 Checking the operating range, 250 Interconnection diagram, 248 Place of installation, 247 Removal and installation, 249 Technical data, 247 Sheet alignment, 238 Sheet arrival control, 239 Standard version, 241 Checking the operating range, 246 Interconnection diagram, 242 Place of installation, 241 Removal and installation, 243 Technical data, 241 Autoplate, 267 Block diagram, 269 Fault display, 268 Method of functioning, 267 Sequence of functions, 270 auxiliary pile detection 11B11 checking the circuit state, 151 connection, 150 layout, 149 place of installation, 149 removal- and installation, 150 setting, 151 task and function, 150 auxiliary pile motor 11M2 layout, 146 pin assignment, 148 place of installation, 146 task and function, 147 Technical specifications, 147 auxiliary pile motor 12M2 layout, 192 pin assignment, 194 place of installation, 192 Task and function, 193 Technical specifications, 193
B
Blanket washup device GTW, 281 Blast air regulation at feeder 1M9, Manual blast air setting, 360 Blast air regulation at the feeder 1M9 Block diagram, 357 Characteristiccurvedependent blast air regulation, 358 Checking the operating range, 367 Layout and task, 362 Pin assignment, 363 Place of installation, 361 Removal and installation, 364 Technical data, 363 Block diagram, Sheet alignment, 207 Blower bar, see blower motor for dampening system, 322
Index
Blower motor for dampening system M45, 322 Blower motor for powder spray device 12M35, 377 bottom main pile limitation 11S34 checking the circuit state, 159 place of installation, 158 setting, 159 task and function, 158 bottom main pile limitation 12S34 checking the circuit state, 206 place of installation, 204 setting, 205 task and function, 204 Brushless main motor from 37KW, 12
C
Central control cabinet ZSG, 393 Equipment zone A Power supply, 394 Equipment zone B Partition wall, 395 Equipment zone C Mounting rack / control devices, 397 Equipment zone D Flat cable mounting plate, 398 Equipment zone E Swing frame, 399 GRM Rectifier module, 396 Location and layout, 393 Central dampening solution supply E40, 325 Central lubrication, 329 Basic concept, 329 Fault messages, 332 Grease lubrication Block diagram, 333 Function, 334 Layout, 334 Monitoring the lubrication system, 335 Motor for grease lubrication 12M47, 345 Place of installation, 334 Pressure relief valve of the motor , 337 Settings, 336 Triggering a lubrication process, 336 Oil lubrication Block diagram, 338 Changing the filter, 342 Distributing lubrication, 340 Filter unit, 341 Function, 340 Layout, 339 Place of installation, 339 Pressure relief valve of oil pump, 342 Triggering a lubrication process, 341 Service display, 330 changeover fast/slow 12B65 checking the circuit state, 197 connection, 196 layout, 195 place of installation, 195 -Removal and installation, 196 task and function, 196 Circumferential register SM/CD 102, 314 Coarse register monitoring, 271 Adjustment, 273 Connection, 271 Layout, 271
Place of installation, 271 Removal and installation, 272 Coarse register monitoring 1...nB48, Task/function, 272 Coating unit, Position code, 437 Control console Layout, 408 Location diagrams, 408 Control panel ZSP, Location diagrams, 429 Control panels Delivery, 421 Feeder, 419 Location diagrams, 417 Printing unit/coating unit, 420 Cooling and circulating unit E40, 325 Cover guide height adjustment 1M4, 67 Checking the operating range, 76 Interconnection diagram, 70 Place of installation, 69 Positioning, 67 Removal and installation of motor, 71 Removal and installation of potentiometer, 73 Technical data, 69
D
Dampening, 321 Dampening solution mixing unit E41, 328 Dampening system Blower motor, 322 Dampening solution sensor, 323 Delivery, Position code, 437 delivery pile control automatic pile height control, 170 auxiliary drive control, 165 block diagram (Preset), 161 block diagram (standard), 162 nonstop operation, 177 overview (Layout), 163 overview of components (drive side), 167 overview of components (operator side), 166 overview of motors, 168 overview of solenoidoperated valves, 169 overview of switches and sensors, 168 paper blockage, 185 press control, 164 removal of sample sheet, 184 safety circuit, 164 Transport of auxiliary pile, 175 transport of main pile (Preset), 171 transport of main pile (standard), 173 delivery upper edge of pile 12B129 checking the circuit state, 203 connection, 202 layout, 201 place of installation, 201 -removal and installation, 203 task and function, 202 Diagonal register SM/CD 102, 308 Doublesheet detector 1B11 Adjustment, 237 Block diagram, 231
Index
Connection, 235 Fault messages, 232 Layout, 234 Pin assignment, 235 Place of installation, 233 Removal and installation, 236 Sheet alignment, 231
I
Identification letter, 435 Impression cylinder washup device DZW, 292 Block diagram, 292 Inactivating pile centering 11B55, 28 Ink blade, Sensor monitoring the ink blade 1...nB43, 303 Ink fountain roller motor SM/CD 102, 305 Inking roller washup device FWW, 286 Inking unit temperature control, 382 SM/CD 102, 317 Inking unit temperature control E39, E39a, SM/CD 102, 318 Intercom WSA Function, 387 Layout, 386 IR slidein dryer, Switches monitoring the IR slidein dryer 12S9, a, b, c, 380
E
Encoder, Place of installation, 388 Encoder IDS, 388 Installation variants, 390 Pin assignment, 389 Removal and installation, 390 Equipment identification, 435 Extension control cabinet ESG, 437
F
Feeder, Position code, 437 Feeder pile control block diagram (Preset), 119 block diagram (Standard), 120 Overview of components (Standard), 125 feeder pile control automatic pile height control of auxiliary pile , 129 automatic pile height control of main pile (standard), 128 auxiliary drive control, 123 nonstop operation (Preset), 134 nonstop operation (standard), 137 overview (layout), 121 Overview of components (Preset), 124 overview of motors, 126 overview of switches and sensors, 126 pile height control of main pile (Preset), 127 press control, 122 safety circuit, 122 transport of auxiliary pile, 132 Transport of main pile, 130 Format adjustment Adjustment of format wheels 11M4, 47 Adjustment of printing pressure 1...nM5, 85 Cover guide height adjustment 1M4, 67 Pile stops 11M11/11M12, 59 Sheet joggers 12M6/12M7, 110 Sheet slowdown/format adjustment 12M5, 104 Suction head/format adjustment 11M6, 53
L
Lateral register SM/CD 102, 311 Level in coating pan LB32, 371 Location diagrams, 393 Control panel ZSP, 429 Control panels, 417 Delivery, 421 Feeder, 419 Printing unit/coating unit, 420 Motors, 413 Operators controls, 423 Position switches, 409 Sensors, 415 Solenoid valves, 411 ZSP Central control console, 408 Location diagrams , Central control cabinet ZSG, 393 Lubrication monitoring 1 12B47, 348 Lubrication monitoring 2 12B77, 348
M
M1 Directcurrent main motor, 7 Main drive Brushless main motor from 37KW, 12 Directcurrent main motor, 7 Motor terminal board, 15 Replacing the brake, 9 Replacing the carbon brushes, 10 Rotor position encoder, 13 main pile motor (Preset) 11M1 layout, 140 pin assignment, 142 place of installation, 140 task and function, 141 technical specifications, 141 main pile motor (standard) 11M1 Layout, 143 pin assignment, 145 place of installation, 143 task and function, 144 Technical specifications, 144
G
Grease lubrication, 333 Lubrication monitoring 1 12B47, 348 Lubrication monitoring 2 12B77, 348 GRM Rectifier module, Central control cabinet ZSG, 396
Index
main pile motor 12M1 (Preset) layout, 186 pin assignment, 188 place of installation, 186 Task and function, 187 Technical specifications, 187 main pile motor 12M1 (standard) layout, 189 pin assignment, 191 place of installation, 189 Task and function, 190 technical specifications, 190 Malfunctions in printing unit, 268 Misalignment control 11M7, Misalignment control, 252 Monitoring the ink blade, sensor 1...nB43, 303 Connection, 304 Layout, 303 Pin assignment, 304 Place of installation, 303 Removal and installation, 304 Task, 304 Monitoring the IR slidein dryer, Switches 12S9, a, b, c, 380 Motor for grease lubrication Pin assignment, 345 Place of installation, 345 Motor terminal board, 15 Motors Blower motor for powder spray device 12M35, 377 Location diagrams, 413 Washup brush motors M43, M50 ... M56, 296 Motors / functional units, Servodrive diagonal register SM/CD 102, 308 Motors / motordriven units Servodrive circumferential register SM/CD 102, 314 Servodrive ink fountain roller SM/CD 102, 305 Servodrive lateral register SM/CD 102, 311
N
Number, 435
O
Oil lubrication, 338 Pressure monitoring oil lubrication 1F33 (1 bar), 346 Pressure monitoring oil lubrication 1F34 (12 bars), 347 Oil pump M44, 343 Pin assignment, 344 Place of installation, 343 Operators controls, Location diagrams, 423
P
Pan roller motors 1...nM1, 321 Pile centering, 17 Activation and inactivation, 18 Block diagram, 17 Sensor Inactivating pile centering 11B55, 28 Sensor Pile centering 11B10, 19
Sensor 11B10, 20 Sensor 11B55, 29 Servodrive Pile centering 11M9, 21 Pile centering 11M9, 23 Checking the operating range, 27 Interconnection diagram, 24 Place of installation, 23 Removal and installation, 25 Technical data, 23 pile height control 12B69 checking the circuit state, 200 connection, 199 Layout, 198 place of installation, 198 -removal and installation, 199 setting, 200 Task and function, 199 Pile merging, 31 Adjustment of pile support plate 11M8, 31 Pile stops 11M11/11M12, 59 Checking the operating range, 66 Fault message, 60 Interconnection diagram 11M11, 62 Interconnection diagram 11M12, 63 Place of installation, 61 Prepiling, 60 Removal and installation, 64 Technical data, 61 Pin assignment Servodrive circumferential register SM/CD 102, 315 Servodrive diagonal register M4 SM/CD 102, 309 Servodrive ink fountain roller SM/CD 102, 306 Servodrive lateral register SM/CD 102, 312 Coarse register monitoring, 271 Plate clamping device Autoplate, 267 1...nB53 Coarse register monitoring, 271 Pneumatic system, Admission of pressure, pneumatic system 15Y11, 351 Pneumatic system compressor E4 Pin assignment, 355 Technical data, 355 Position code, 435 Position codes, 437 Position switches, Location diagrams, 409 Potentiometer, 308 Powder spray unit 12E2, 373 Powdering cycle switch 12S68, 379 Pressure monitoring oil lubrication 1F33 (1 bar), Place of installation, 346 Pressure monitoring oil lubrication 1F34 (12 bars), Place of installation, 347 Pressure sensor pneumatic system 15B14 Pin assignment, 354 Place of installation, 353 Printfree margin 1M2/1M3 Checking the operating range, 84 Interconnection diagram, 79 Place of installation, 78 Removal and installation of motor, 80 Removal and installation of potentiometer, 81 Technical data, 78 Printfree margin D.S./O.S. 1M2/1M3, 77
Index
Printing unit, Position code, 437 Pull lay control 1B9/1B10 Block diagram, 223 Checking the sensing distance, 230 Place of installation, 226 Sheet alignment, 223 Sheet infeed error/pull error, 224 Preset version, Adjustment, 227 Standard version, Adjustment, 229
R
Rotor position encoder, 13 Layout, 13 Pin assignment, 13
S
Sensor Inactivating pile centering 11B55 Adjustment, 29 Check, 29 Place of installation, 29 Sensor Pile centering 11B10, 20 Check, 20 Place of installation, 20 Removal and installation, 20 Sensor for dampening solution control B32, 323 Sensors Admission of pressure, pneumatic system 15Y11, 351 at the washup solution container B1, B54, B55, 301 Adjustment, 302 Connection, 301 Pin assignment, 301 Place of installation, 301 Removal and installation, 302 Level in coating pan LB32, 371 Location diagrams, 415 Monitoring the ink blade 1...nB43, 303 Sensors/switches, 1...nB53 Coarse register monitoring, 271 Service display Grease lubrication, 331 Oil lubrication, 330 Service display Washup, 278 Functions of the blanket washup device, 278 Functions of the impression cylinder washup device, 278 Functions of the inking roller washup device, 279 Servodrive Adjustment of format wheels 11M4, 47 Adjustment of pile support plate 11M8, 33 Adjustment of printing pressure 1...nM5, 85 Adjustment of pull lays 1M7/1M8, 96 Automatic misalignment control 11M7, 251 Automatic sheet arrival control 11M3 Preset version, 247 Standard version, 241 Blast air regulation at the feeder 1M9, 357 Cover guide height adjustment 1M4, 67 Pile centering 11M9, 21, 23
Pile stops 11M11/11M12, 59 Sheet joggers 12M6/12M7, 110 Sheet slowdown/format adjustment 12M5, 104 Suction head height adjustment 11M5, 40 Suction head/format adjustment 11M6, 53 Servodrive circumferential register SM/CD 102, 314 Servodrive diagonal register SM/CD 102, 308 Servodrive ink fountain roller SM/CD 102, 305 Servodrive lateral register SM/CD 102, 311 Sheet alignment, 207 Automatic misalignment control 11M7, 251 Automatic sheet arrival control 11M3, 238 Block diagram, 207 Degree values, 209 Doublesheet detector 1B11, 231 Pull lay control 1B9/1B10, 223 Sheet alignment control, 210 Sheet alignment control Adjustment, 219 Block diagram, 210 Misalignedsheet display (trend display), 214 Sheet alignment, 210 Sheet alignment error ANK sensors, 212 FK sensors, 213 Sheet alignment control 1B13/1B49, 215 Checking the circuit state, 222 Layout and task, 215 Pin assignment, 215 Place of installation, 215 Removal and installation, 216 Sheet joggers 12M6/12M7, 110 Checking the operating range, 117 Fault message, 111 Interconnection diagram 12M6, 113 Interconnection diagram 12M7, 114 Place of installation, 112 Removal and installation, 115 Technical data, 112 Sheet monitoring, 259 Sheet travel monitor 1...nB48/1...nB48a, 259 Sheet slowdown / format adjustment 12M5 Checking the operating range, 109 Interconnection diagram, 107 Place of installation, 106 Removal and installation, 108 Technical data, 106 Sheet slowdown/format adjustment 12M5, 104 Fault message, 105 Sheet travel monitor 1...9B48/1...9B48a, 259 Adjustment, 263 Components, 263 Place of installation, 262 Service display, 261 Size adjustment, 45 Block diagram, 45 Command Presetting, 46 Printfree margin D.S./O.S. 1M2/1M3, 77 Solenoid valves, Location diagrams, 411 Static electricity eliminator 11E3, Task, 385 Static electricity eliminator 12E3 Layout, 384
Index
Place of installation, 383 Suction head height adjustment 11M5, 39, 40 Checking the operating range, 43 Interconnection diagram, 41 Place of installation, 40 Removal and installation, 42 Technical data, 40 Suction head height control, 39 Suction head height adjustment 11M5, 39 Suction head/format adjustment 11M6, 53 Checking the operating range, 58 Fault message, 54 Interconnection diagram, 56 Place of installation, 55 Removal and installation, 57 Technical data, 55 Switches Monitoring the IR slidein dryer 12S9, a, b, c, 380 Powdering cycle 12S68, 379
Settings, 294 Inking roller washup device FWW Additional washing of printing plate and ink fountain roller, 289 Block diagram, 286 Example, 289 Flow chart, 290 Function, 287 Layout, 287 Settings, 288 Messages, 276 Selection of functions, 275 Service display, 278 Washup solution container, Warnings, 298 Washup solution container E9 Block diagram, 297 Layout, 299 Pin assignment, 300 Place of installation, 299 Sensors B1, B54, B55, 301 Task, 300 Warnings, 298
T
Temperature control, SM/CD 102. Siehe FarbwerkTemperierung
Z
Zentralschmierung, Oil lubrication, Circular lubrication, 340 Zero position Servodrive circumferential register SM/CD 102, 316 Servodrive diagonal register SM/CD 102, 310 Servodrive ink fountain roller SM/CD 102, 307 Servodrive lateral register SM/CD 102, 313
U
upper main pile limitation 11B33 checking the circuit state, 154 connection, 153 Layout, 152 place of installation, 152 removal and installation-, 153 setting, 154 task and function, 153
V
Varnish supply unit E4a, 369
W
Washup brush motors M43, M50 ... M56, 296 Pin assignment, 296 Place of installation, 296 Washup devices Blanket washup device GTW Block diagram, 281 Example, 285 Flow chart, 285 Function, 282 Layout, 282 Settings, 284 Control by command, 275 Impression cylinder washup device DZW, 292 Example, 295 Flow chart, 295 Function, 293 Layout, 293

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Important safety instructions

Handling and replacing electronic boards

Protective measures for ESDs to be observed when replacing electronic boards

DISCHARGE static charges.

UNPACK from the protective container for ESDs.

REPLACE electronic boards.

PACK into the protective container for ESDs.

M1 Direct-current main motor

Representation of a dc main motor M1

M1 Direct-current main motor

Terminal box of BAUMLLER main motor

M1 Direct-current main motor

Removal and installation of brake 1 2 3 4 1 2 3 4

Pull the brake off the main motor shaft.

Main motor with brake removed

M1 Direct-current main motor

Removal/installation of carbon brushes 1 2 3 4 5

Removal of carbon brushes

Note: Always replace all carbon brushes of the main motor.

Ventilation covers of main motor

Disconnect the wires of the carbon brushes from the terminals 2.

M1 Direct-current main motor

M1 Brushless main motor

M1 Brushless main motor Construction with terminal board (from 37kW)

Main motor M1 with terminal box

M1 Brushless main motor

Rotor position encoder

Pin assignment 2 3 7 6 4 5 6 7 X2 Plug connection to ZSG (BLT4) Function DC +15 V 15 V

Pin base X2, 7-pole

M1 Brushless main motor

Reinstall all parts and connect the rotor position encoder.

M1 Brushless main motor

Pin and socket bases, 6-pole

M1 Brushless main drive

Pile centering 11M9

Data line Control lines

Block diagram for pile centering

Activating and inactivating pile centering

Selecting the display

Symbol Pile centering on / off

If the symbol is lit, pile centering is active.

Preselection/coarse display, pile centering

11B10 Pile centering

11B10 Pile centering

Where? approx. 25 mm below the upper edge of the pile.

Required distance for pile centering

No automatic control: within the tolerance limits of the required distance.

Output signal of sensor 11B10: analog voltage, digitization on the SSK1.

11B10 Pile centering

PU1 and Preset feeder

Removal and installation

11M9 Pile centering

11M9 Pile centering Automatic positioning

Manual positioning for feeder without NON-STOP facility:

11M9 Pile centering

Toggle switch Auxiliary pile on / off

Pushbuttons Main pile centering Plus button Minus button

Plus button = Minus button =

Indication of position in MID

Indication of position of pile support frame

Present position Position code

11M9 Pile centering