CD102 PDF

Important safety instructions
Observe the general and press-specific safety

instructions in the operating manual.
At first start-up or after the exchange of
equipment or components check the correct
functioning of all safety equipment.
Control cabinet and machine housing have to be
locked while the press is in operation. They may
only be opened for repair purposes.
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.
If it is necessary to repair the press while it is
connected to the mains supply, please pay attention
to general safety precautions.
Never exchange components and units while the
press is connected to the mains supply.
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.
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.
Observe these handling instructions when

you replace electronic boards with electrostatically sensitive devices (ESDs)!
Attention:
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
Main drive
M1 Direct-current main motor
12
M1 Brushless main motor
17
Pile centering
17
Block diagram
19
11B10 Pile centering
21
11M9 Pile centering
28
11B55 Inactivating pile centering
31
Pile merging
31
11M8 Adjustment of pile support plate
39
Suction head height control
39
11M5 Suction head height adjustment
45
Size adjustment
45
Block diagram
47
11M4 Adjustment of format wheels
53
11M6 Suction head/format adjustment
59
11M11/11M12 Pile stops D.S./O.S.
67
1M4 Cover guide height adjustment
77
1M2/1M3 Print-free margin D.S./O.S.
85
1...nM5 Adjustment of printing pressure
96
1M7/1M8 Adjustment of pull lays
104
12M5 Sheet slowdown/format adjustment
110
12M6/12M7 Sheet joggers D.S./O.S.
1 438
Table of contents
119
Feeder pile control
119
Block diagrams
121
Layout
124
Overview of components
127
Function
140
11M1 Main pile motor (Preset)
143
11M1 Main pile motor (standard)
146
11M2 Auxiliary pile motor
149
11B11 Auxiliary pile detection
152
11B33 Upper main pile limitation
155
11B35 Automatic pile transport
158
11S34 Bottom main pile limitation
161
Delivery pile control
161
Block diagrams
163
Layout
166
170
Function
186
189
192
195
12B65 Changeover fast/slow
198
12B69 Pile height control
201
12B129 Delivery upper edge of pile
204
207
Sheet alignment
207
Block diagram
210
1B13/ 1B49 Sheet alignment control
223
1B9/1B10 Pull lay control
231
1B11 Double-sheet detector
238
11M3 Automatic sheet arrival control
241
11M3 Automatic sheet arrival control (standard version)
247
11M3 Automatic sheet arrival control (Preset version)
251
11M7 Automatic misalignment control
Table of contents
259
Sheet monitoring
259
1...nB48/ 1...nB48a Sheet travel monitor
267
Plate clamping device
267
Autoplate
271
1...nB53 Coarse register monitoring
275
Washup devices
275
Control by command Washup
276
Messages
278
Service display Washup
281
Blanket washup device (GTW)
286
Inking roller washup device (FWW)
292
Impression cylinder washup device (DZW)
296
M43, M50 ... M56 Washup brush motors
297
E9 Washup solution container
301
B1, B54, B55 Sensors at the washup solution container
303
1...nB43 Monitoring the ink blade
305
Inking unit
305
Servo-drive ink fountain roller
308
Servo-drive diagonal register 1...nM6
311
Servo-drive lateral register
314
Servo-drive circumferential register
317
Inking unit temperature control
318
E39 Inking unit temperature control
321
Dampening
321
1...nM1 Pan roller motors
322
1...nM45 Blower motor for dampening system
323
1...nB32 Sensor Dampening solution control
325
E40 Central dampening solution supply /

cooling and circulating unit
328
E41 Dampening solution mixing unit
Table of contents
329
Central lubrication
329
Basic concept
330
Service display
332
Fault messages
333
Grease lubrication
338
Oil lubrication
343
M44 Oil pump
345
12M47 Motor for grease lubrication
346
1F33 Pressure monitoring oil lubrication 1 bar
347
1F34 Pressure monitoring oil lubrication 12 bars
348
12B47 Lubrication monitoring 1 and

12B77 Lubrication monitoring 2
351
Pneumatic system
351
15Y11 Admission of pressure, pneumatic system
353
15B14 Pressure sensor Pneumatic system
355
E4 Pneumatic system compressor
357
Suction and blast air
357
1M9 Blast air regulation at the feeder
369
Other components
369
E4a Varnish supply unit
371
L-B32 Level in coating pan
373
12E2 Powder spray unit
377
12M35 Blower motor for powder spray device
379
12S68 Switch Powdering cycle
380
12S9, -a, -b, -c Monitoring the IR slide-in dryer
381
E8 Air supply cabinet
382
383
12E3 Static electricity eliminator
386
WSA Intercom
388
IDS Encoder
Table of contents
393
Location diagrams
393
ZSG Central control cabinet
408
ZSP Central control console
409
Position switches
411
Solenoid valves
413
Motors
415
Sensors
417
Control panels
423
Operators controls
429
ZSP Control panel of control console
431
Abbreviations
435
Equipment identification
437
Position codes
Table of contents
Main drive
Main drive
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

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
Make sure the motor is disconnected from

the power supply before working on it!
Attention:
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

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 a SIEMENS main motor

Terminal box of BAUMLLER main motor

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

Connecting cable 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 of the brake.
Loosen the fixing bolts
from the
of the brake.
Pull the brake off the main motor shaft.
Brake at main motor

Connecting cable 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.
of
uniformly.
Connect the connecting cable of the brake
to the terminal box .
Tighten the fixing bolts
Main motor with brake removed
Main drive
Removal/installation of carbon brushes

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.
on the
Disconnect the wires of the carbon brushes

from the terminals .
Note:
With certain motors it is necessary to turn the
brush-rocker ring for brush removal.
Before turning the brush-rocker ring , mark
its position in relation to the stator ( e.g.
colour line ) if no markings exist so far.
Layout of brush-rocker ring (example)
10
Loosen the retaining screws ( but do not

turn them out completely ) and turn the
brush-rocker ring ( see illustration on next
page).
Flip up the clamp-type brush holder and

take out all used carbon brushes .
Main drive

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.

Fastening the brush-rocker ring (example)
Insert the new carbon brushes and

connect them to the terminals. Close the
clamp-type brush holder .
Note:
The carbon brushes must rest correctly on
the commutator and run smoothly in the
brush boxes.
If the brush-rocker ring 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
again.
Note:
The ventilation slots in the ventilation covers
must point downward to maintain the type of
protection.
11
Main drive

Construction with terminal board (from 37kW)
Main motor M1 with terminal box

12
Motor shaft
Terminal box of main motor
Rotor position encoder
Plug of rotor position encoder
Lever for manual release of the brake
Main drive
Rotor position encoder

The rotor position encoder consists of three
components:
sensor,
rotating part,
adjusting ring.
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!
Attention:
Layout

Pin base X2 / connection to BLT4

Safety screws of adjusting ring
Sensor
Adjusting ring
Front view of rotor position encoder

Pin assignment
X2
2
1
X2
7
6
Pin
4
Plug connection to ZSG (BLT4)

Function
DC +15 V
15 V
Pin base X2, 7-pole
13
Main drive
Rotor position encoder of main motor M1

Motor casing / brake

Adjusting ring
End-float washers (not always provided)
Motor shaft
Rotating part
Connector M1-X2
Sensor part
Removal
1
2
3
4
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
14
Reinstall all parts and connect the rotor

position encoder.
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.

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
Pin and socket bases, 6-pole
Pin
Plug connection in motor terminal box

Function
Motor code 0
Motor code 1
Motor code
Temperature sensor
Brake +
Brake
15
Main drive
16
M1 Brushless main drive
Pile centering
Block diagram
Pile centering
Block diagram
The pile centering function comprises:
Pile centering
Inactivating
pile centering
11B10
11B55
the sensor Pile centering 11B10,
the sensor Inactivating pile centering 11B55,
the servo-drive Pile centering 11M9.
Pile centering
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.
11M9
SSM1
SSM1
SSK
EAK 1
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
SAK
ESK
REK1
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).
REK386
DSK
DNK
SVM
MID11
ZID
MID12
Displays
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.

18
Pile centering

The sensor 11B10:
11B10
senses the lateral pile edge (actual distance),
with the required distance = 130 2 mm.
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
1646 70
130 2 mm
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.
Plus button
The pushbuttons Main pile centering control the

servo-drive 11M9.
Maximum positioning range: +/ 30 mm in relation
to the centre of the feeder.
Minus button
Plus button
= movement towards D.S.
Minus button
= movement towards O.S.
Pushbuttons
Main pile centering
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

ON
Main pile control activated.
OFF
The pushbuttons Main pile centering control

the servodrive.
Maximum positioning range:

35mm in relation to the centre of the feeder.
Pushbuttons
Main pile centering
Plus button
Plus button =
Minus button =
Minus button
movement towards D.S.

movement towards O.S.
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
ON
Auxiliary pile control activated.
OFF
The pushbuttons Auxiliary pile centering

control the pile support frame.

35mm in relation to the centre of the feeder.
Pushbuttons
Auxiliary pile centering
Plus button

Minus button
Indication of position in MID
11
2 0
Indication of position of pile support frame
22
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.

Present position
Position code
Pile centering
11M9 Pile centering
11M9
Operator side
Technical data
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
23
Pile centering
11M9 Pile centering
Interconnection diagram
X5
X10
SSR
SSR X10
X11
X12
X3
X13
X4
X14
SSR X14
Backplane of servodrive plug-in unit SSR
11
11LVT1
2SSM1: X2
X3 X4
X1
2SSM1: X4
X2
X5
2SSM1
Servo-drive distributor
module 2SSM1
11M9: X1
4
5
11M9
Servo-drive 11M9
10V
0V
24

Pin 1
Pin 2
Pin 3
Pin 4

X5: C1
X5: C2
X5: C3
X5: C4
X2:
X2:
X4:
X4:
Pin 5
X5: C5
X4: 5
1
2
3
4

X10:
X10:
X14:
X14:
B14
D14
3
4
X14: 5
Pile centering
11M9 Pile centering

ON
OFF
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)
07
2048 2
1M9: X1
Fit the motor baseplate and gear wheel.

Connect plug 11M9: X1.
Set to 20482 inc.
26
Install the servo-drive.
Pile centering
11M9 Pile centering
Checking the operating range

Servo-drive Pile centering 11M9
Condition:
The pile support plate is in its central position
(2048 inc).
Input
Incremental value
35 mm
3686 " 23 inc
+ 35 mm
409 " 23 inc
Service display Values, incremental values servodrives
27
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
brown
black
11LVT1
FAM64
XE: 55
+1
1
blue
Check
0010
29
Pile centering
30
Pile merging
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
Pushbuttons
Plus button
Minus button
Pushbutton
Main pile down
Toggle switch in position Off

ON
OFF
Main pile control activated.
The pushbuttons Auxiliary pile centering control

the servodrive 11M8.
30 mm in relation to the centre of the feeder.
Plus button
Minus button


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)
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
Pushbuttons
Main pile centering
Plus button
Minus button
Toggle switch in position ON

ON
Auxiliary pile control activated.
OFF
The pushbuttons Auxiliary pile centering control

the servodrive 11M8.
30 mm in relation to the centre of the feeder.
Plus button
Minus button


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
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
33
Pile merging
X5
X10
SSR
SSR X10
X11
X12
X3
X13
X4
X14
SSR X13
11
11LVT1
2SSM1: X1
X3 X4
2SSM1: X3
X2
X1
X5
2SSM1
module 2SSM1
11M8: X1
4
5
11M8
Servo-drive 11M8
10V
0V
34

Pin 1
Pin 2
Pin 3
Pin 4

X5: B1
X5: B2
X5: B3
X5: B4
X1:
X1:
X3:
X3:
Pin 5
X5: B5
X3: 6
3
4
8
7

X10:
X10:
X13:
X13:
B12
D12
8
7
X13: 6
Pile merging

ON

OFF
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)
06
2048 2
1M8: X1
Mount the servo-drive on the motor baseplate.

Fit the gear wheel.
Set to 2048 inc.
36
Tighten the chain.
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
Service display Values, incremental values

servo-drives
Input
Incremental value
30 mm
3461 " 23 inc
+ 30 mm
634 " 23 inc
37
Pile merging
38

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.
Plus button
Minus button
= suction head moves up (+ 20 mm).

= suction head moves down ( 20 mm).
39
11M5
Preset feeder
Technical data
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
40
X5
X10
SSR
SSR X10
X11
X12
SSR X12
X3
X13
X4
X14
11
11LVT1
1SSM1: X1
X3 X4
1SSM1: X4
X2
X1
X5
1SSM1
module 1SSM1
11M5: X1
4
5
11M5
Servo-drive 11M5
10V
0V

Pin 1
Pin 2
Pin 3
Pin 4

X5: C1
X5: C2
X5: C3
X5: C4
X2:
X2:
X4:
X4:
Pin 5
X5: C5
X4: 5
1
2
3
4

X10:
X10:
X12:
X12:
B6
D6
3
4
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

Set to 2456 2 inc.

Servo-drive Suction head height adjustment

11M5
Input
Incremental value
20
880 " 4 inc
+ 20
3215 " 4 inc
Service display Values, incremental values servodrives
43
44
Size adjustment
Block diagram
Size adjustment
Block diagram
Adjustment of
format wheels
11M4
SSM
Sheet slowdown/
format adjustment
12M5
SSM
M
Adjustment of
pull lay D.S. 1M7
Suction head/
format adjustment
11M6
SSM
SSM
Adjustment of
pull lay O.S. 1M8
Pile stop D.S.

11M11
SSM
SSM
Cover guide height

adjustment 1M4
Pile stop O.S.

11M12
SSM
SSM
Adjustment of printing
pressure 1...nM5
Sheet jogger D.S.

12M6
SSM
SSM
M
M
Sheet jogger O.S.
12M7
SSM
M
SSK1/2/3
Displays
SAK
REK1
Legend:
Data line
ESK
REK386
SVM
MID11
MID12
DSK
DNK
ZID
Control lines
Block diagram size adjustment

45
Size adjustment
Block diagram
Command: PRESETTING

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
Command in control console display ZID
Suction head/format adjustment
Pile stops D.S. and O.S.
Adjustment of format wheels
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
46
Sheet slowdown/format adjustment
Sheet joggers D.S. and O.S.
Size adjustment

The servo-drive 11M4 positions the format wheels on
the feeder.
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
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.
Minus button
Plus button
= movement towards maximum format.
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
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
48
Size adjustment
X5
X10
SSR
SSR X10
X11
X12
SSR X11
X3
X13
X4
X14
11
11LVT1
1SSM1: X1
X3 X4
X2
X1
1SSM1: X3
X5
1SSM1
module 1SSM1
11M4: X1
4
5
11M4
Servo-drive 11M4
10V
0V

Pin 1
Pin 2
Pin 3
Pin 4

X5: B1
X5: B2
X5: B3
X5: B4
X1:
X1:
X3:
X3:
Pin 5
X5: B5
X3: 6
3
4
8
7

X10: B4
X10: D4
X11: 8
X11: 7
X11: 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.
50
Remove the servo-drive Adjustment of

format wheels 11M4.
Bring the format wheels into their central

position.
Size adjustment
.
Format wheels
.
Sheet of paper
Set the distance ( 722.5 mm ) between the front lays and format wheels.
02
11M4: X1
3871 2
Attach the gear wheel to the motor shaft.

Set to 3871 " 2 inc.
51
Size adjustment

Servo-drive Adjustment of format wheels

11M4
SM102:
Print-free margin: 10.00 mm
8.00 mm
Paper length:
720 mm
280 mm
Paper thickness:
1.50 mm
1.50 mm
Incremental value: 3876 2 inc
288 2 inc
CD102:

servo-drives
Print-free margin: 10.00 mm
8.00 mm
Paper length:
720 mm
280 mm
Paper thickness:
2.00 mm
2.00 mm
52
288 2 inc
Size adjustment

The servo-drive 11M6 positions the suction head to
the entered paper length.
is effected through the command Presetting;
depends on the entered sheet length.

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).

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,
Plus button
= to max. 730 mm.
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.
54

Run,
when one of the pushbuttons Suction head

format is actuated and the press is on Run.
Size adjustment
11M6
Preset feeder
Technical data
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
55
Size adjustment
X5
X10
SSR
SSR X10
X11
X12
SSR X12
X3
X13
X4
X14
11
11LVT1
1SSM1: X2
X3 X4
1SSM1: X4
X2
X1
X5
1SSM1
module 1SSM1
11M6: X1
4
5
11M6
Servo-drive 11M6
10V
0V
56

Pin 1
Pin 2
Pin 3
Pin 4

X5: D1
X5: D2
X5: D3
X5: D4
X2:
X2:
X4:
X4:
Pin 5
X5: D5
X4: 6
3
4
8
7

X10:
X10:
X12:
X12:
B8
D8
8
7
X12: 6
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

Set to 462 2 inc.
57
Size adjustment

Servo-drive Suction head/format adjustment

11M6
Paper length

servo-drives
58
Incremental value
280 mm
3634 " 2 inc
730 mm
389 " 2 inc
Size adjustment

The servo-drive 11M11 positions the pile stop on the
D.S.
The servo-drive 11M12 positions the pile stop on the
O.S.
is effected through the command Presetting,
depends on the inputs into CPTRONIC, such as:

sheet width,
off-centre position,
preselected pull direction.


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:
the off-centre position can be up to 50 mm,
Plus button
= to max. 1040 mm.
59
Size adjustment

Pile stop D.S.
The symbols appear in the display Feeder/Warning.

The symbols appear:
Pile stop O.S.
The symbols go off:

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.

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.
60
Symbol Prepiling
Size adjustment
11M12
11M11
Operator side
Technical data
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
61
Size adjustment
Interconnection diagram 11M11

X5
X10
SSR
SSR X10
X15
X16
SSR X15
X3
X17
X4
X18
Backplane of servo-drive
plug-in unit SSR
11
3SSM2: X1
11LVT1
3SSM1: X2
X2
X1
X3
3SSM2
module 3SSM2
11M11: X1
4
5
11M11
Servo-drive 11M11
10V
0V
62

Pin 1
Pin 2
Pin 3
Pin 4

X5: A1
X5: A2
X5: A3
X5: A4
X1:
X1:
X3:
X3:
Pin 5
X5: A5
X3: 5
1
2
3
4

X10:
X10:
X15:
X15:
B18
D18
3
4
X15: 5
Size adjustment

X5
X10
SSR
SSR X10
X15
X16
SSR X15
X3
X17
X4
X18
11
3SSM2: X1
11LVT1
3SSM2: X2
X2
X1
X3
3SSM2
module 3SSM2
11M12: X1
4
5
11M12
Servo-drive 11M12
10V
0V

Pin 1
Pin 2
Pin 3
Pin 4

X5: B1
X5: B2
X5: B3
X5: B4
X1:
X1:
X2:
X2:
Pin 5
X5: B5
X2: 6
3
4
8
7

X10:
X10:
X15:
X15:
B20
D20
8
7
X15: 6
63
Size adjustment
11M11
11M12
Remove the servo-drive Pile stop D.S.

11M11 or Pile stop O.S. 11M12.
D.S.
O.S.
O.S.
D.S.
D.S./O.S. = 180 mm
64
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.
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

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
Position the pile stops manually to the minimum
format (press the button Pile stops smaller format).

servo-drives
66

Size 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.
New desired position 1.9mm
Example 1
When the new desired position has been entered,

the servo-drive first positions to the reversal point
and then to the new desired position .
Example 2:
New desired
position
Actual position
1.9mm
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.
Example 2
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.
Actual value/coarse display, cover guide height

adjustment
68
Indication of the present value of the cover

guide height adjustment
Size adjustment
Printing unit 1 and feeder
Technical data
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
69
Size adjustment
X5
X10
SSR
SSR X20
X21
X22
X3
X23
X4
X24
SSR X23
plug-in unit SSR
1
1LVT1
2SSM1: X2
X3
X4
X1
2SSM1: X4
X2
X5
2SSM1
module 2SSM1
1M4: X1
1M4
Servo-drive 1M4
70
10V

1
2
4
5

X5: D1
X5: D2
X5: D3
X5: D4
X2:
X2:
X4:
X4:
0V
X5: D5
X4: 6
3
4
8
7

X20:
X20:
X23:
X23:
B12
D12
8
7
X23: 6
Size adjustment
Removal and installation of motor
1

0

15Q66
1M4
1M4
1M4
71
Size adjustment
brown
blue
red
1
2
2
black
1M4
1M4
15Q66
72
Size adjustment
Removal and installation of potentiometer
1
2
310 . 0
3
1
15Q66
1M4
2
1
73
Size adjustment
defective
new
5
1 M4: X1

beige
yellow
black
blue
black
red
15Q66
08
74
1016 4
Size adjustment
1M4
75
Size adjustment

Preset version:
Servo-drive Cover guide height adjustment

1M4
Paper thickness
Incremental value
0.01 mm
676 " 4 inc
1.00 mm
3260 " 4 inc

servo-drives
Standard version:

servo-drives
76
Servo-drive Cover guide height adjustment

1M4
Paper thickness
Incremental value
0.01 mm
676 " 4 inc
1.00 mm
3260 " 4 inc
Size adjustment

Running direction of paper
Front lays
2mm

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.
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
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
78
Size adjustment
X5
X10
SSR
SSR X10
X15
X16
X3
X17
X4
X18
SSR X18
1
1LVT1
1SSM1: X1
X3
X4
1SSM1 X3
X2
X1
X5
1SSM
1
module SSM 1
X3
X1
X3
X1
SSM3
X2
1M2
10V
0V
SSM3
X2
1M3

SSM3
X3: 1
X3: 2
X3: 3
X3: 4
SSM 1
X5: A1
X5: A2
X5: A3
X5: A4
X3: 5
X5: A5 X3: 5
X1:
X1:
X3:
X3:
1
2
3
4
SSR
X10:
X10:
X18:
X18:
B30
D30
3
4
X18: 5
Servo-drives 1M2 and

1M3

SSM3
X3: 1
X3: 2
X3: 3
X3: 4
SSM1
X5: B1
X5: B2
X5: B3
X5: B4
X3: 5
X5: B5 X3:6
X1:
X1:
X3:
X3:
3
4
8
7
SSR
X10: B32
X10: D32
X18: 8
X18: 7
X18: 6
79
Size adjustment
1
1
0
4
15Q66
1M2
(1M3)
24
1
1M2
(1M3)
80
2
3
24
Size adjustment
1
1
216 . 0
2
0
1
15Q66
3
1M2
(1M3)
24
2
1
81
Size adjustment
4
Pull rail

.

Front lay
defective
new
6

0
1
15Q66
82
Size adjustment
05
1M2
2048 6
06
1M3
2048 6
1
1M2
(1M3)
224
3
83
Size adjustment

Preset version:

Servo-drive Print-free margin D.S. 1M2

Servo-drive Print-free margin O.S. 1M3
Input
Incremental value
8 mm
3850 " 4 inc
10 mm
246 " 4 inc

servo-drives
Standard version:


servo-drives
84
Servo-drive Print-free margin D.S. 1M2

Servo-drive Print-free margin O.S. 1M3
Input
Incremental value
8 mm
3850 " 4 inc
10 mm
246 " 4 inc
Size adjustment

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.
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.

Explanation of the display

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)
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
86
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).
Size adjustment
1...nM5
L-M5
1...8M5
Operator side
Technical data
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
87
Size adjustment
Interconnection diagram for printing unit 1...nM5

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

PU3, PU5
PU2, PU4
SSR X20
PU6, PU7, PU8
SSR X30
PU2
PU3
PU4
PU5
PU6
PU7
PU8
PU9
=
=
=
=
=
=
=
=
SSR
SSR
SSR
SSR
SSR
SSR
SSR
SSR
X25
X26
X27
X28
X31
X32
X33
X34
X20
X25
X5
X30
SSR
X26
X3
X27
X4
X28
Backplane of servo-drive plug-in unit SSR

2..9
1SSM2: X1
2...9LVT1
2...9M5: X1
1SSM2 X2
X1
2...9M5: X1
X2
X3
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
6
X3: A5
2...9M5:X1 1SSM 2
10V
1
2
4
5
X3:
X3:
X3:
X3:
0V
X3: A5
A1
A2
A3
A4
X1:
X1:
X2:
X2:
1
2
3
4
X2: 5
X1:
X1:
X2:
X2:
1
2
3
4
X2: 5
SSR
PU2
X20:
X20:
X25:
X25:
X25:
SSR
PU6
X30:
X30:
X31:
X31:
B18
D18
3
4
PU3
X20:
X20:
X26:
X26:
X26: 5
X27: 5
X28: 5
B2
D2
3
4
PU7
X30:
X30:
X32:
X32:
PU8
X30:
X30:
X32:
X32:
PU9
X30:
X30:
X34:
X34:
X31: 5
B22
D22
3
4
B6
D6
3
4
X32: 5
PU4
X20:
X20:
X27:
X27:
B26
D26
3
4
B10
D10
3
4
X32: 5
PU5
X20:
X20:
X28:
X28:
B30
D30
3
4
B14
D14
3
4
X34: 5
89
Size adjustment
2
1
0
Switch off the press.

Open the guard on the O.S.
1...8M5 X1
Disconnect 1...8M5 X1.
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
brown
2
blue
blue
2
0
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.
92
Loosen the stud on the gear wheel.

Pull the gear wheel off the potentiometer.
Loosen the nut on the potentiometer.
Replace the potentiometer.
Turn the mechanism to the 0 value of the

scale by means of the hexagon.
Size adjustment
1...8M5 X1
1
blue
black
red
4
5
6
beige
yellow
black
2
0
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
94
Check the operating range: 1.20 = 3550 8 inc
Size adjustment

Preset version
Servo-drive Adjustment of printing pressure

1M5
Input
Incremental value
+ 0.30
616 " 8 inc
1.20
3550 " 8 inc

servo-drives
95
Size adjustment

The servo-drive 1M7 positions the pull lay on the D.S.
The servo-drive 1M8 positions the pull lay on the O.S.
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:
1M7
1M8
the pull lay in use to the sheet width entered,
the pull lay not in use 15 mm outside the

entered sheet width.
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
Servo-drives Adjustment of pull lays
96
during coarse positioning through the potentiometer in the servo-drive,
during precision positioning through the

potentiometer near the servo-drive.
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
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
98
Size adjustment

X5
X20
SSR
SSR X20
X21
X22
SSR X21
X3
X23
X4
X24
1
11LVT1
1SSM1: X2
X3
X4
1SSM1: X4
X2
X1
X5
1SSM1
module 1SSM1
1M7: X1
4
5
1M7
Potentiometer
(for precision adjustment)
Servo-drive 1M7
(with potentiometer for coarse adjustment)
+
10V
0V
Pin
Pin
Pin
Pin
1
2
3
4
Pin 5
X5:
X5:
X5:
X5:
C1
C2
C3
C4
X5: C5
X2:
X2:
X4:
X4:
1
2
3
4
X4: 5
X20:
X20:
X21:
X21:
B2
D2
3
4
X21: 5
X5: D3
X5: D4
X4: 8
X4: 7
X21: 8
X21: 7
X5: D5
X4: 6
X21: 6
99
Size adjustment

X5
X20
SSR
SSR X20
X21
X22
SSR X22
X3
X23
X4
X24
plug-in unit SSR
1
11LVT1
2SSM1: X1
X3 X4
2SSM1: X3
X2
X1
X5
2SSM1
module 2SSM1
3
1M8: X1
4
5
1M8
Potentiometer
(for precision adjustment)
Servo-drive 1M8
(with potentiometer for coarse adjustment)
+
10V
0V
100
Pin
Pin
Pin
Pin
1
2
3
4
Pin 5
X5:
X5:
X5:
X5:
A1
A2
A3
A4
X5: A5
X1:
X1:
X3:
X3:
1
2
3
4
X3: 5
X20:
X20:
X22:
X22:
B6
D6
3
4
X22: 5
X5: B3
X5: B4
X3: 8
X3: 7
X22: 8
X22: 7
X5: B5
X3: 6
X22: 6
Size adjustment
1Y47
Remove the servo-drive Adjustment of pull

lay D.S. 1M7 (or Adjustment of pull lay O.S.
1M8).

2
1
O.S.
Actuate the solenoid valve 1Y47 manually

and hold it in this position (pneumatic
clamping mechanism is open).
D.S.
3
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.

1M7 (D.S.) = set to 30552 inc.
1M8 (O.S.) = set to 30552 inc.
1020
1,00
102
720

format.
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

servo-drives
For 1M7: pulling towards D.S.

For 1M8: pulling towards O.S.
Minimum sheet width
Precision adjustment: 0.00 mm (2048 inc)
Sheet width: 420 mm
For 1M7: pulling towards D.S.
For 1M8: pulling towards O.S.
103
Size adjustment

The servo-drive 12M5 positions the sheet
slowdown at the delivery to the entered sheet
length.
depends on the entered sheet length.

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).

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
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,
Plus button
Minus button
Plus button
= to max. 730 mm.
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.

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
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
106
Size adjustment
X5
X10
SSR
SSR X10
X15
X16
SSR X16
X3
X17
X4
X18
plug-in unit SSR
12
12LVT1
X3 X4
1SSM1: X1
1SSM1: X3
X2
X1
X5
1SSM1
module 1SSM1
3
4
5
12M5: X1
12M5
Servo-drive 12M5
10V
0V
12M5:X1
Pin 1
Pin 2
Pin 3
Pin 4
1SSM 1
X5: B1
X5: B2
X5: B3
X5: B4
X1:
X1:
X3:
X3:
Pin 5
X5: B5
X3: 6
3
4
8
7
SSR
X10:
X10:
X16:
X16:
B24
D24
8
7
X16: 6
107
Size adjustment

Rear paper stop
Front paper stop
Remove the servo-drive Sheet slowdown /

format adjustment 12M5.
Set the distance between the front and rear

paper stops to 600 mm.
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.

Set to 1370 inc.
Size adjustment

Servo-drive Sheet slowdown / format

adjustment 12M5
Paper length Incremental value
280 mm
3540 " 3 inc
720 mm
556 " 3 inc
730 mm
498 " 3 inc

servo-drives
109
Size adjustment

The servo-drive 12M6 positions the sheet jogger on
the D.S.
The servo-drive 12M7 positions the sheet jogger on
the O.S.
depends on the inputs into CPTRONIC, such as:

sheet width, off-centre position.


reached,
when one of the pushbuttons Sheet jogger

D.S. or Sheet jogger O.S. is actuated.
Manual positioning
Pushbuttons
Sheet jogger D.S.
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.
Plus button
Minus button
Pushbuttons
Sheet jogger O.S.
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.
Plus button
Minus button
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,
Plus button = to max. 1040 mm.

110
Size adjustment

Sheet jogger D.S.
The symbols appear in the display Delivery/

Warning.
The symbols appear:
Sheet jogger O.S.
The symbols go off:

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
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
112
Size adjustment

X5
X10
SSR
SSR X10
X15
X16
X3
X17
X4
X18
SSR X17
plug-in unit SSR
12
12LVT1
X3 X4
1SSM1: X2
1SSM1: X4
X2
X1
X5
1SSM1
module 1SSM1
3
4
5
12M6: X1
12M6
Servo-drive 12M6
10V
0V
12M6:X1
Pin 1
Pin 2
Pin 3
Pin 4
1SSM 1
X5: C1
X5: C2
X5: C3
X5: C4
X2:
X2:
X4:
X4:
Pin 5
X5: C5
X4: 5
1
2
3
4
SSR
X10:
X10:
X17:
X17:
B26
D26
3
4
X17: 5
113
Size adjustment

X5
X10
SSR
SSR X10
X15
X16
X3
X17
X4
X18
SSR X17
plug-in unit SSR
12
12LVT1
1SSM1: X2
X3
X4
1SSM1: X4
X2
X1
X5
1SSM1
module 1SSM1
3
4
5
12M7: X1
12M7
Servo-drive 12M7
10V
0V
114
12M7:X1
Pin 1
Pin 2
Pin 3
Pin 4
1SSM 1
X5: D1
X5: D2
X5: D3
X5: D4
X2:
X2:
X4:
X4:
Pin 5
X5: D5
X4: 6
3
4
8
7
SSR
X10:
X10:
X17:
X17:
B28
D28
8
7
X17: 6
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)
12M6: X1
12M7: X1
13
704 2
14
704 2
Fit the gear wheel.

12M6 (D.S.) = set to 7042 inc.
12M7 (O.S.) = set to 7042 inc.
1020
720
1.00
116

format.
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
Sheet width: 420 mm

servo-drives
117
Size adjustment
118
Feeder pile control
Block diagrams
Feeder pile control

Block diagrams
Block diagram (Preset)
Pile
height
Switches and
sensors
Controls
SEK
Safety
circuit
EAK_11
Press control
REK2
ESK
Auxiliary drive
control
Main
pile
HAK_01
B
A
A
LTK500
BAK
B
B
HAK_02
B
STK1
11M1
11M2
Auxiliary
pile
Preset feeder with auxiliary pile
119
Feeder pile control
Block diagrams
Block diagram (Standard)
Pile
height
Switches and
sensors
Controls
SEK
Safety
circuit
EAK_11
Press control
REK2
ESK
Auxiliary drive
control
Main
pile
HAK_01
B
HAK_02
B
STK1
STK2
Auxiliary
pile
11M1
11M2
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
Processor board on board slot 2

(press control)
ESK
Input/output control board
HAK_01 Auxiliary drive board on board slot 1

STK1
Pile control board on board slot 1
STK2
BAK
Brake control board
LTK500
Power part board 500W
121
Feeder pile control
Layout
Press control
Inputs
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.
EAK_11
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)
Press control
Safety circuit
Inputs
SEK
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.
Safety circuit
122

Pile drive enabled
Pile up blocked
Pile down blocked
Feeder pile control
Layout
Safety circuit
HAK_01
Press control
HAK_02
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.
LT
LT
Drive
Control
section
Power part
Main pile
(Preset)
HAK01
Part A
BAK+LTK500
Part A
11M1
11M2
Main pile
(standard)
HAK01
Part A
STK1
Part A
Auxiliary pile
HAK01
Part C
STK2
Part A
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
Preset feeder
11M1
11S56
11S65
11S34
11M2
11S37
11S31
11B35
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
11M1
11M1
11M2
Function
Main pile drive (Preset)

Main pile drive (standard)
Auxiliary pile drive
Preset
with
nonstop
D
Standard
without
nonstop
D
with
nonstop
D
D
Remarks
without
nonstop
D
Brushless motor
Three-phase a.c. motor
Switches and sensors

Equipment
Function
11B11
11S31
11S32
11S33
11B33
11S34
11B35
11S35
11S36
11S37
Auxiliary pile detection

Suction head limitation
Upper pile safety
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)
11S39
11S56
11S65
126
with
nonstop
D
D
D
D
D
D
Preset
without
nonstop
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Standard
with
without
nonnonstop
stop
Remarks
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
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)
Sequence of main pile height control
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
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)

does not detect any paper (only during the
first 30 sheets in the closed loop 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
Switching points of the automatic main pile

height control
Automatic pile height control
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
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.

Pile up (by preset value)
Sequence of the automatic pile height control for

the main pile
128


switch (11S31)
actuation of the upper pile safety (11S32)

switch (11S33)

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)
Feeder pile control
Function
Automatic pile height control of auxiliary pile
11S65
11B35
Switching points of the automatic pile height

control of auxiliary pile
Pile up (by preset value)
Sequence of the automatic pile height control for

the 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.
The automatic pile height control at the feeder is


button (11S31)

(11S32)
actuation of the auxiliary pile down button

(11S29)
unloading the auxiliary pile detection sensor

(11B11)
(only with Preset)
(extra accessory)

does not detect any paper.
129
Feeder pile control
Function
Transport of main pile

Main pile up
11S24
The main pile can only be raised manually if the

automatic pile height control of the main pile is not
active.
11B33
fast
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
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
Sequence of main pile up
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.
interrupted under the following circumstances:

switch (11S31)

(11S32)

actuation of the main pile down button

(11S25)
(extra accessory)
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.
fast
11S39
slow
11S34
Switching points of main pile down

Main pile down
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
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.
interrupted if one of the following conditions is
met:
actuation of the lower end stop switch

(11S34)
actuation of the pile support plate limitation

switch (11S39)
actuation of the main pile up button (11S24)
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.
11S36
fast
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:
Switching points of auxiliary pile up

Auxiliary pile up
Permissible starting point
Auxiliary pile up
11S36
Auxiliary pile stop
Sequence of auxiliary pile up
132

switch (11S31)
actuation of the upper pile safety (11S32)
actuation of the auxiliary pile down button

(11S29)
sheeter is in operation
(extra accessory)

after the respective cause has been eliminated.
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
Switching points of auxiliary pile down

Auxiliary pile down

sensor (11B33)
(only in case of Preset with non-stop)
actuation of the auxiliary pile up button

(11S28)
sheeter is in operation
(extra accessory)
Permissible starting point


if the respective cause has been eliminated.
Auxiliary pile down

11S37
Auxiliary pile stop
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:
134
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.
Feeder pile control
Main pile
Function
Auxiliary pile
Automatic pile height control of main pile on
Automatic pile height control of auxiliary pile off
Inserting support rods
Pile transfer
11S27 auxiliary pile on

Auxiliary pile up, slow
11B11 damped
11B11 damped
Automatic pile height control of main pile off
Auxiliary pile stop
Awaiting starting point
Automatic pile height control of auxiliary pile on

11S39
Main pile stop
Centering main pile (automatically)
11S34
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
11S27 auxiliary pile off
Pile
merging
Removing support rods

11S29
Auxiliary pile down
11S37
Auxiliary pile stop
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
Pile transfer
11S28
Auxiliary pile up, slow
11S27 Auxiliary pile on
11S27 auxiliary pile on

11S25 (self-stopping mode)

11S39
Main pile stop
Pile change

11S34
Main pile stop (loading)
11S24
Main pile up, fast
Height of auxiliary pile reached
Main pile stop
Pile
merging
11S29
Auxiliary pile down
11S37
Auxiliary pile stop
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
(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).
(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
Place of installation of main pile motor (Preset)
Layout

Layout of main pile motor (Preset)
140
Motor electronics
Motor and brake
Gear unit
Male connector
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
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)
Technical specifications
141
Feeder pile control
Pin assignment
1
2
3
4
5
A B C
1
2
3
4
5
Pin assignment on main pile motor (Preset)
Pin
Function
A1
X1 motor line (slow)
B1
Y1 motor line (slow)
C1
Z1 motor line (slow)
A2
X2 motor line (fast)
B2
Y2 motor line (fast)
C2
Z2 motor line (fast)
C5
Brake (reference potential DC)
B5
Brake (DC +24 V)
B4
Hall 1
A5
Hall 2
B3
Hall 3
A4
Resistor code
A3
PTC (temperature monitoring)
C4
Auxiliary supply of motor electronics UH
C3
Ground auxiliary supply

PE conductor
142
Feeder pile control

11M1
Place of installation of main pile motor (standard)
Layout

Motor electronics
Motor and brake
Gear unit
Male connector
Layout of main pile motor (standard)
143
Feeder pile control
Task and function

and downwards by means of the pile chains.
A three-phase induction motor is used which
carries out the following functions:

Stopping and emergency braking by means

of the brake installed

monitoring:
Speed detection via Hall signals
Temperature detection via resistor
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
144
Feeder pile control
Pin assignment
Pin
Function
A1
Winding U1 (slow)
B1
Winding V1 (slow)
C1
Winding W1 (slow)
A2
Winding U2 (fast)
B2
Winding V2 (fast)
C2
Winding W2 (fast)
A3
N1, N2
B5
C5
Brake (DC +24 V)
B4
Hall 1
A5
Hall 2
C3
Resistor code
B3
C4
Auxiliary voltage of motor electronics UH
A4
Ground auxiliary voltage
A B C
pin assignment of main pile motor (standard)
PE conductor
145
Feeder pile control

11M2
11M2
Preset feeder
Standard feeder
Place of installation of auxiliary pile motor
Layout

Layout auxiliary pile motor

146
Motor electronics
Motor and brake
Gear unit
Male connector
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:


of the brake installed

monitoring:
Speed detection via Hall signals
Temperature detection via resistor
Output: 0.09/0.4 kW

265 V / 60 Hz

13.9/58.7 min1 (265V)
Ration: 57:1
Resistor code: 8 (56 kW)
147
Feeder pile control
Pin assignment
Pin
Function
A1
Winding U1 (slow)
B1
Winding V1 (slow)
C1
Winding W1 (slow)
A2
Winding U2 (fast)
B2
Winding V2 (fast)
C2
Winding W2 (fast)
A3
N1, N2
B5
C5
Brake (DC +24 V)
B4
Hall 1
A5
Hall 2
C3
Resistor code
B3
C4
Auxiliary voltage motor electronics UH
A4
A B C
Pin assignment main pile motor (standard)
PE conductor
148
Feeder pile control

11B11
Place of installation 11B11 (Preset feeder)
Layout

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
11B11
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: 1
black
signal
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
In its basic setting the sensor protrudes the base

plate by 14 mm (see figure).
14 0.2 mm
Setting 11B11
Checking the circuit state

EAK_11
E11
The output signal of the sensor 11B11 reaches the

EAK_11, input 11.
11B11
Signal flow
Position signal E11
The input signal E11 can be checked on the

service display EAK:
0:
The sensor detects no metal (the trip bar is

unloaded)
1:
The sensor detects metal (the trip bar is

loaded)
Service display, signal E11
151
Feeder pile control

11B33
Layout

152
Sensor
Cable
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
11B33
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: 1
black
signal
FEM64: XE33

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
The output signal of the sensor 11B33 reaches

EAK_11, input 33.
11B33
Signal flow
Position signal E33

154
0:
The sensor detects metal (the pile support

plate is located at level of the sensor)
1:
The sensor detects no metal (the pile support

plate is located below the sensor)
Feeder pile control

11B35
Layout

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.
Connection
11B35
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: 1
black
signal
FEM64: XE35

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

EAK_11, input 35.
11B35
Signal flow
Position signal E35

service display:
0:
The sensor does not detect an object (the

upper edge of pile is below the sensor)
1:
The sensor detects an object (the upper edge

of pile is at the level of the sensor)
157
Feeder pile control

11S34
11S34
Components
Preset feeder
Standard feeder
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
The output signal of the switch 11S34 reaches

EAK_11, input 34.
11S34
Signal flow
Position signal E34

0:
switch is actuated
1:
switch is not actuated
Note:
The signal is also displayed on the service display
SEK.
159
Components
Feeder pile control
160
Block diagrams

Block diagrams
Block diagram (Preset)
Pile
height
Switches and
sensors
Controls
SEK
Safety
circuit
Outputs
EAK_12
Press control
REK2
ESK
Auxiliary
drive control
HAK_01
B
A
A
LTK500
BAK
Main
pile
HAK_02
B
B
B
LTK50
12M1
12M2
Auxiliary
pile
Preset delivery with auxiliary pile
161
Block diagrams
Block diagram (standard)
Pile
height
Switches and
sensors
Controls
SEK
Safety
circuit
Outputs
EAK_12
Press control
REK2
ESK
Auxiliary
drive control
HAK_01
B
HAK_02
B
STK1
LTK50
12M1
12M2
Main
pile
Standard delivery with auxiliary pile
162
Auxiliary
pile
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
Processor board on board slot 2

(press control)
ESK

STK1
BAK
Brake control board
LTK500
LTK50
163
Layout
Press control
Inputs
Outputs
EAK_12
REK2
ESK
Press control
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:
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)
Safety circuit
Inputs
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.
SEK
The signals of the safety circuit take priority over
the signals of the press control.
Safety circuit
164

Pile drive enabled
Pile up blocked
Pile down blocked
Layout
Safety circuit
Press
control
HAK_01
HAK_02
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.
LT
LT
LT
Drive
Control
section
Power part
Main pile
(Preset)
HAK01
Part B
BAK+LTK500
Part B
Main pile
(standard)
HAK01
Part B
STK1
Part B
Auxiliary pile
(with auxiliary
pile at feeder)
HAK02
Part A
LTK50
Part A
Auxiliary pile
(no auxiliary
pile at feeder)
HAK01
Part C
LTK50
Part A
12M1 12M2 12M2
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
Operator side
12S130
12S55
12B69
12S56
12Y14/15
12S34
12S131
12S42
12S41
12B129a
12S33
12S35
12Y60/61
12S34b
12B129
12S42
12S117
12B65
Components on the operator side
166
12Y49
12Y11
12Y13
Drive side
12M1
12M2
12S39
12S55a
12S130a
12Y62
12S36
12S34a
12S38
Components on the drive side
167
Motors
Equipment
Function
12M1
12M1
12M2
Main pile drive (Preset)

Main pile drive (standard)
Auxiliary pile drive
with
nonstop
D
Preset
without
nonstop
D
Standard
with
without
nonnonstop
stop
Preset
without
nonstop
Standard
with
without
nonnonstop
stop
D
D
D
D
D
D
D
D
Remarks
Brushless motor
Three-phase a.c. motor
Switches and sensors

Equipment
Function
12S33
12S34
12S34a

D
D
D
D
12S34b
12S35
12S36
12S38
12S39
12S41
12S42
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
D
D
D
D
D
D
D
D
D
D
D
12S55
12S55a
Upper auxiliary pile limitation

Upper auxiliary pile limitation
D
D
12S56
12B65
12B69
12S117
D
D
D
D
12B129
12B129a
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
12S130
12S130a
Angular stop O.S.

Angular stop D.S.
D
D
D
D
D
D
D
D
12S131
Pile down, slow
168
with
nonstop
D
D
same function as
12S55
D
D
only with raised delivery, same function as

12S34
only with raised delivery, same function as
12S34
with board fitting

on D.S.
with rake fitting
on O.S.
D
D
D
D
D
Remarks
D
D
Receiver (light barrier)

Transmitter (light barrier)
same function as
12S130
Solenoid-operated valves
Equipment
Function
12Y11
12Y13
12Y14
12Y15
12Y49
12Y60
12Y61
12Y62
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
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
only with rake

only with rake
only with board
only with board
169
Function
Function
The automatic pile height control on the delivery is
automatically activated as soon as one of the
following conditions is met:
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)
12B69

Switching points of the automatic pile height control
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
slow
12S117/1
12B65

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.
fast
12S131
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)

(only if no non-stop operation)
Actuation of the main pile down button

(12S46)
slow
Switching points of main pile up (Preset)

Main pile up
Main pile up, slow
12S131
Main pile up, fast
12B65 or 12S117/1
The continuation of an interrupted pile transport is

only possible after elimination of the respective
cause.
Main pile up, slow

12B69 or 12S117/2
Main pile stop
Sequence of main pile up and passes through

all three speed levels (Preset)
171
Function
Main pile down

12S46 12S124
slow
12S117/1
12B65
fast

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).
12S131
slow
12S34
Switching point of main pile down (Preset)
Actuation of the main pile up button

(12S45)
Main pile down

12S46 (self-stopping mode after 1.5 s)
12B65 or 12S117/1
12S131
12S34
Main pile stop
Sequence of main pile down and passing

through all three speed levels (Preset)
172
The interrupted pile transport can only be

continued after elimination of the respective
cause.
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

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.
12S33
12B69

fast
Switching points of main pile up (standard)

Main pile up

(12S38)

or 12S36)

switch (12S39)

(12S130)

Actuation of the main pile down button

(12S46)

Main pile up, fast
12S33 or 12B69
Main pile stop

after elimination of the respective cause.
Sequence of main pile up (standard)
173
Function
Main pile down

12S46 12S124
fast
12S131
slow
12S34
Switching points of main pile down (standard)
Main pile down

12S46 (self-stopping mode after 1.5 s)
12S131
12S34
Main pile stop
Sequence of main pile down and passing

through both speed levels (standard)
174

controlled by means of the button main pile
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
Actuation of the main pile up button

(12S45)

Function
Transport of auxiliary pile

Auxiliary pile up
12S53
12S55
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

(12S38)

or 12S36)

switch (12S39)

(12S130)
Triggering of the sensor automatic pile

height control (12B69)

Actuation of the auxiliary pile down button

(12S54)
Switching points of auxiliary pile up

Auxiliary pile up
Auxiliary pile up
12S55
Auxiliary pile stop

Sequence of auxiliary pile up
175
Function
Auxiliary pile down

12S54

controlled by means of the button auxiliary pile
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.
12S56
Switching points of auxiliary pile down

Auxiliary pile down
Auxiliary pile down
12S56
Auxiliary pile stop
Sequence of auxiliary pile down
176

(12S130)
Actuation of the auxiliary pile up button

(12S53)

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
Main pile
Function
Auxiliary pile
12S42
Pile
separation

Pile change: 12S41 or 12B129
Rack: adjusted rack height
Main pile stop (insert rake/board)
45 mm paper on auxiliary pile
(insert rake/board)
45 mm paper on auxiliary pile
12S46 (self-stopping)
12S131
Pile change
(rack)

12S34
Main pile stop (unloading)
12S45
Main pile up, slow
12S131
Main pile up, fast
Pile
merging
Rake: 12B129
Rake: 12B129
Board: 12S41 free
Board: 12S41 free

(pull out rake/board)
Time delay 10 s
Automatic pile height control of auxiliary pile

off (pull out rake/board)
Rake: 12S42 free
Board: 12S10 actuated
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
12S42 12S41
Switching points for pile separation and pile

merging
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)
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) .
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
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)
Sequence of extending and retracting sheet

catcher
180
When inserting the rake/board (12S41), the

suction air is switched off (12Y62) and the sheet
catchers retract (12Y13).
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
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.
Extending and retracting supporting cross bar

Cross bar without delay time
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
12S41 and 12S42
Await time (3 s)
Extending cross bar (12Y14)
12S41 and 12S42 free
Retracting cross bar (12Y15)
Sequence of extending and retracting supporting cross bar (with delay time)
182
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).
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
12S10
Extending guide rail (12Y60)
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.

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
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.
Stop condition
Paper supply at feeder blocked
Sequence of paper blockage
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
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
Place of installation of main pile motor (Preset)
Layout

Layout of main pile motor (Preset)
186
Motor electronics
Motor and brake
Gear unit
Male connector
Task and function

and downwards via the pile chains.
A brushless motor is used which can execute the
Speed control

Electrical deceleration (controlled by the

corresponding power part)
Stopping or emergency braking by means of

installed brakes

functions for the purpose of control and monitoring:
Commutation and speed recording via Hall

signals
Temperature recording via resistor
Speed (gear unit): 5.7/40 min1
Ratio: 100:1
187
Pin assignment
1
2
3
4
5
A B C
1
2
3
4
5
Pin assignment of main pile motor (Preset)
Pin
Function
A1
X1 motor line (slow)
B1
Y1 motor line (slow)
C1
Z1 motor line (slow)
A2
X2 motor line (fast)
B2
Y2 motor line (fast)
C2
Z2 motor line (fast)
C5
B5
Brake (DC +24 V)
B4
Hall 1
A5
Hall 2
B3
Hall 3
A4
Resistor code
A3
C4
Auxiliary voltage motor electronics UH
C3

PE conductor
188

12M1
Place of installation of main pile motor (Standard)
Layout

Motor electronics
Motor and brake
Gear unit
Male connector
Layout of main pile motor (standard)
189
Task and function

and downwards by means of the pile chains.
A three-phase induction motor is used which can
execute the following functions:


of the installed brake

monitoring:
Speed recording via Hall signals
Temperature recording via resistor

265 V / 60 Hz

11.5/49.7 min1 (265V)
Ratio: 66:1
190
Pin assignment
Pin
Function
A1
Winding U1 (slow)
B1
Winding V1 (slow)
C1
Winding W1 (slow)
A2
Winding U2 (fast)
B2
Winding V2 (fast)
C2
Winding W2 (fast)
A3
N1, N2
B5
C5
Brake (DC +24 V)
B4
Hall 1
A5
Hall 2
C3
Resistor code
B3
C4
A4
A B C
Pin assignment of main pile motor (standard)
PE conductor
191

12M2
Place of installation of auxiliary pile motor
Layout

Layout of auxiliary pile motor
192
Gear unit
Motor
Motor electronics
Circular connector
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
Speed control
Electric deceleration (controlled by the

corresponding power part)
Deceleration through the self-locking gear

unit

monitoring:
Commutation and speed recording via Hall

signals
Output: 30 Watt
Speed (gear unit): 1 min1
Ratio: 2564:1
Resistor code: 5 (5.6 kW)
193
Pin assignment
Pin assignment auxiliary pile motor
Pin
Function
X motor line
Y motor line
Z motor line
Hall C
Hall B
Hall A
11
Resistor code
12
13
14
PE conductor
194

12B65
Place of installation 12B65
Layout

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
12B65
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: 1
black
signal
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

EAK_12, input E65 via the switch 12S117/switching point 1 (at the control lever).
12B65 12S117/1
Signal flow
Position signal E65

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)
1:
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)
197

12B69
Place of installation 12B69
Layout

198
Sensor
Cable
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.
Connection
12B69
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: 1
black
signal
12X2: 69

The sensor 12B69 is fixed to the support on the
sheet jogger shaft by means of a screw.
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
approx. 50 mm
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.
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

EAK_12, input 70 and the HAK control sections of
the main and auxiliary pile drive (exact assignment
see block diagram).
HAK_01
12B69
HAK_02
Signal flow
Position of signal E70

200
0:
The sensor detects no object (the pile is

below the sensor)
1:
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.

12B129a
12B129
Place of installation 12B129 and 12B129a
Layout

Sensor
Cable
12B129
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
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: 1
black
signal
FAM64:XA29
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: 1
12B129a
12B129a
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.
D.S.

room for the upward and downward movement of
the non-stop frame.
12B129a
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.
12B129

EAK_12
E77
12B129a
The output signal of the sensor 12B129 (receiver)

reaches EAK_12, signal E77.
12B129
Signal flow

0:
The light barrier is not interrupted
1:
The light barrier is interrupted
203

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

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
.
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
The output signal of the switch 12S34 reaches

EAK_12, input 34 via the switches 12S34a and
12S34b (if available).
12S34b
Signal flow

206
0:
at least one switch is actuated
1:
no switch is actuated
Sheet alignment
Block diagram
Sheet alignment
Block diagram
Double-sheet detector
SM74 / 52
O.S.
D.S.
1B66
Sheet alignment control
1B65
SM102/CD102
Pull lay control
D.S.
O.S.
D.S.
O.S.
1B13
1B49
1B9
1B10
1B11
RL12
RL12
SUM1
RL12
SUM1
RL12
DBE
1AUM1
Automatic misalignment control
Sheet stop finger
11M7
O.S
.
1Y15
Automatic sheet arrival control

SM102/CD102 = 11M3
SM74 = 1M7
Gripper opening
D.S
.
1Y46
1Y16
SSM1
M
SSM1
SSK
EAK 1
IDS
Displays
Legend:
SAK
ESK
REK1
REK2
Data line
SVM
MID11
MID12
DSK
DNK
ZID
Control lines
Block diagram of sheet alignment

207
Sheet alignment
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
Block diagram
Sheet alignment
Block diagram
Degree values relevant to sheet alignment
BAK
ZMK
DBE
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
Interrogation points
Feeder
OFF
SM52
SM74
SM102 CD 102
230_
285_
192,0_1 170,0_1
222,0_ 200,0_
303_
208,0_1 186,0_1
238,0_ 216,0_
20_
330_
336,0_ 313,0_
40_

330_
15_
311,0_
289,0_
42,5_
72_
3,0_
341,5_
1 only for presses with Preset feeder
209
Sheet alignment
1B13/1B49 Sheet alignment control

Block diagram
BAK
and 20_ ,
SM74 between 285_ and 40_ ,
SM102 between 222_ and 336_ ,
SM102 with Preset between 192_

and 336_ ,
CD102 between 200_ and 313_ ,
CD102 with Preset between 170_

and 313_ .
The optimum sheet arrival of the electric is as
FK
Front
lays
ANK
Paper
1B13/1B49

D.S.
O.S.
1B13
1B49
1 LVT1
1EVM4
MID12
MID11
ZID
EAK 1
for SM74 at 303_,
for SM102 at 238_,
for SM102 with Preset at 208_,
for CD102 at 216_.
for CD102 with Preset at 186_.
The following applies to the degrees listed (see block

diagram):
Displays
At and paper run:

the ANK must not detect paper.
At and paper run:

the ANK must detect paper.
DNK
ESK
SVM
REK2
Legend:
Data line
Control lines
Block diagram of sheet alignment control

210
SM52 between 240_
follows:
RL12
RL12
For correct sheet transfer from the feeder into the

first printing unit, the sheet must be placed against
the front lays as follows:
DSK
At and paper run:

to analyze the information provided by the pull
lay control (1B9/1B10) the ANK must detect
paper.
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
Note:
Speedmaster SM52 is only equipped with one sensor
(1B49) of the sheet alignment control.
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

O.S.
Circuit states displayed on the MID
FK display
(sensor for overshooting control)
ANK display
(sensor for sheet alignment control)
With the help of the MID on the control panel of the

feeder, the FK sensors and ANK sensors 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
sensor detects paper
Symbol not lit
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_
Paper (first sheet)
early sheets (first sheet),
late sheets (missing sheets),
misaligned sheets.
An early sheet exists if the first sheet of the sheet

stream already covers the ANK sensor at press
angle .
The feeder and press stop immediately. The
sheets are held back on the feed table.
Early sheet
BAK
SM52 20_
SM74 330_
SM102 336_
CD102 313_
A late sheet exists if none of the ANK sensors

detects paper at press angle .
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.
Late sheet
BAK
SM74 330_
SM102 336_
CD102 313_
O.S.
Paper
Misaligned sheet
212
Paper
D.S.
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 .
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.
Note:
On SM52 misalignment control is not required.
Sheet alignment
Sheet alignment error detected by the FK sensors

The FK sensors detect:
BAK
Paper
Overshooting sheet
SM52 20_
SM74 330_
SM102 336_
CD102 313_
overshooting sheets.
Given a continuous sheet flow, an overshooting sheet

exists if one of the FK sensors detects paper at
press angle .
The feeder and press stop immediately. The shingled
sheets remain on the feed table.
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)
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
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
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.
X2
ANK = sensor for sheet alignment control

FK = sensor for overshooting sheet control
X1
To 1LVT1
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.
Reflex sensor with amplifier
Pin assignment
ground
free
free
ANK
+24K
FK+
FK
ANK+
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.
216
Pull off the reflex sensor with the brass

block towards the front.
Remove the amplifier.
Sheet alignment
Disconnect the cable leading to 1LVT1.
Remove the reflex sensor.
8

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).
Turn the handwheel anticlockwise until the

end stop comes to rest on the cross bar.
Tighten the fixing bolt.
217
Sheet alignment
10
O.S.
Connect the cable coming from 1LVT1 to

the amplifier.
11
D.S.
Fasten the amplifier.
12
1.5 2.0 mm
218
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.
Sheet alignment
Adjustment
2
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.
MID
MID
D.S.
D.S.
O.S.
O.S.
Turn the adjusting screw until the ANK

symbol on the MID just lights up.
220
Place a sheet of paper of max. width

(102cm) and approx. 20cm length against
the front lays.
Turn the adjusting screw until the ANK symbol

on the MID just lights up.
Both ANK symbols on the MID must be lit.
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
10 mm
Front lay
MID
D.S.
O.S.
Paper
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
Service display Present input/output, input/output

board EAK
222
= sensor detects paper

= sensor does not detect paper
Sheet alignment

Block diagram
The pull lay control (ZMK) monitors the entire pull
procedure, i. e. the correct sheet infeed and the pull
end position.
ZMK
SM52 330_
SM74 15_
SM102 311_
CD102 289_
1B9/1B10
SM52 42.5_
SM74 72_
SM102 3_
CD102 341.5_
Paper
The following applies to the degrees listed (see

block diagram):
At and paper run:

the ZMK must not detect any paper.
At and paper run:

the ZMK and ANK must detect paper.
Pull lay control

D.S.
O.S.
1B9
1B10
Audible signal
device 12 H 55
SUM1
RL12
SUM1
RL12
Audible signal
device 11 H 55
1 LVT 1
1EVM4
12 LVT 1
12EVM4
11 LVT 1
11EVM4
EAK 1
EAK 12
EAK 11
At and no paper run:

the ZMK signal is not analyzed because the
sheet alignment control does not detect paper.
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.
ZID
The electronic control system evaluates the signals

of the signal conversion modules.
The signals from the amplifiers reach the processor
board REK2 via
DNK
the distribution box 1LVT1,
the input/output distributor module EVM

(SM52 only),
the input/ output board EAK,
the input/ output control board ESK.
Displays
MID12
ESK
MID11
SVM
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.
O.S.
Circuit states displayed on the MID
Circuit states of the ZMK sensors on the MID
Display of pull lay control
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
= sensor detects paper
Symbol not lit
= 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
Sheet infeed error
224
A sheet infeed error exists if the sheet is already

below the reflex sensor at the interrogation point.
The sensor detects paper.
Sheet alignment
ZMK
SM52 42.5_
SM74 72_
SM102 3_
CD102 341.5_
1B13/1B49
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.
1B9/1B10
Paper
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.
2
3
5
Adjustment of pull lays
a)
Pull direction of sheet of paper
b)
c) Edge for format adjustment
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.
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 .
Turn the knurled head screw clockwise,

until the green LED at the corresponding
signal conversion module goes off.
Turn the knurled head screw anticlockwise, until the green LED just lights up.
Turn the knurled head screw anticlockwise for another 10 notch positions
(= 0.3 mm; corresponds to approx. 1/4 rev.
of ).
Take out the sheet. The LED of the reflex

sensor goes off.
227
Sheet alignment

228
Adjust the spring pressure with the knurled

head screw . 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
prevents the pressure from changing once it
has been set.
Reflex sensor
Knurled head screw
Knurled head screw
Locking nut
Sheet alignment
Adjustment (standard version)

The adjustment must be made:
1 mm
when changing the printing material (paper)
Loosen the tommy bar screw and

position the pull lay so that it complies with
the sheet size at the feeder.
Move the magnet cover plate with

recess until it is approx. 1mm away from
the pull lay stop .
Note:
The pull lay stop must not lie on the magnet
cover plate while the paper is being pulled.
3
4
+ -
5
a)
Pull direction of sheet of paper
b)
c) Edge for format adjustment
6
7
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.
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 .
Loosen the knurled head screw
bit.
a little
Turn the knurled head screw clockwise,

until the green LED at the corresponding
signal conversion module goes off.
Turn the knurled head screw anticlockwise, until the green LED just lights up.
Turn the knurled head screw anticlockwise for another 14 notch positions
(= 0.4 mm; corresponds to approx. 1/4 rev.
of ).
229
Sheet alignment
q
w
e
Retighten the knurled head screw . 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 . 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
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:
The distance between the lower edge of the reflex

sensor
and the surface of the magnet cover
plate must be 4.5 5 mm. When fitting the reflex
sensor pay attention to this.
Sensing distance

230
Tommy bar screw

Magnet cover plate
Pull lay stop
Reflex sensor
Knurled head screw

Knurled head screw

Paper
Knurled head screw
Locking nut
Lower edge of reflex sensor
Sheet alignment

Block diagram
The double-sheet detector monitors sheet infeed at
the feeder. It detects multiple sheets and irregularities in the sheet flow and thus prevents malfunctions.
Optical
sensor system
Transmitter
1B11S
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.
Receiver
1B11E
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.
Control device
DBE
1LVT1
Shortly before the sheet enters the first printing

unit, the electronic control system checks the
amplitude of the signal supplied by the receiver.
Displays
MID12
MID11
Monitoring occurs at the following press angles:

ZID
EAK 1
DNK
ESK
SVM
REK2
Legend:
Data line
Control lines
Block diagram of double-sheet detector
DSK
336 _ (SM102),
313_ (CD102).
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.
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
Symbol
Electronic
double-sheet detector
Selection and symbol
232
Selection of the display Feeder / warning
The symbol Electronic double-sheet detector

appears if the sensor 1B65 or 1B66 detects a
double-sheet.
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

Control device of double-sheet detector

DBE with operators controls
1 B11 S
Transmitter with connecting cable and
fixing bracket
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.
234
The LED
lights up as soon as there are
two or more sheets.
Selector switch for adjustment of paper
thickness
1 B11 E
Receiver with connecting cable and
fastening element
Potentiometer for adjustment of sensitivity
Paper thick
Control device off
Paper thin
Sheet alignment
Connection and pin assignment
1LVT1 at
PU1
X1
X2
Control device
1B11 Transmitter
X3
1B11 Receiver
Connection principle
Pin assignment of connector X1:
Contact no. on X 1
Function
Core identification
Terminal in LVT
Ground 24 V
X2: 1
2
3
4
5
+24 V
Signal
+1
XE 11
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

236
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
Sheet alignment
Adjustment
The adjustment must be carried out:
Attention:
each time the printing material changes,
if printed sheets are printed on again.
Prerequisite for adjustment:
1
2
press ready to run,
paper run possible.
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:
Continue turning the potentiometer clockwise

for another 10 scale marks.
Continue with
8.
.. LED
5
6
7
does not go off:
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

possible sheet arrival
BAK
optimum
sheet arrival
285_
222_
192_
200_
170_
330_ SM74
336_ SM102
336_ SM102 with Preset
313_ CD102
313_ CD102 with Preset
303_
238_
208_
216_
186_
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

D.S.
O.S.
1B13
1B49
Displays
MID11
ZID
MID12
RL12
DNK
DSK
RL12
1LVT1
EAK
ESK
SSK
SAK
SVM
REK2
1SSM1
11M3
M
Automatic sheet arrival control
Legend:
Data lines
Control lines
Block diagram of automatic sheet arrival control
238
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.
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:
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
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
240
Sheet arrives at the front lays after

the optimum sheet arrival
Sheet alignment

(standard version)
11M3 Automatic sheet arrival control (standard version)

Technical data
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
241
Sheet alignment

(standard version)
X5
X10
SSR
SSR X10
X11
X12
SSR X11
X3
X13
X4
X14
11
plug-in unit SSR
11
11LVT1
1SSM2: X1
1SSM2: X2
X1
X3
X2
1SSM2
module 1SSM2
11M3: X1
4
5
11M3
Servo-drive 11M3
10V
0V
242

Pin 1
Pin 2
Pin 3
Pin 4

X5: A1
X5: A2
X5: A3
X5: A4
X1:
X1:
X3:
X3:
Pin 5
X5: A5
X3: 5
1
2
3
4

X10: B2
X10: D2
X11: 3
X11: 4
X11: 5

Motor +
Motor
10V
Tap
Sheet alignment

(standard version)
2
1
0
2
2
1
4
1
3
1
243
Sheet alignment

(standard version)
6
2
1 2 mm
8
1
3
1
22
5
4
244
Sheet alignment

(standard version)
10
11
12

245
Sheet alignment

(standard version)
13

Servo-drive Automatic sheet arrival control

11M3
Input
+ 18
2

servo-drives
246
Incremental value
3134 " 4 inc
963 " 4 inc
Sheet alignment

(Preset version)
11M3 Automatic sheet arrival control (Preset version)

11M3
Operator side
Technical data
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
247
Sheet alignment

(Preset version)
X5
X10
SSR
SSR X10
X11
X12
SSR X11
X3
X13
X4
X14
11
11LVT1
1SSM1: X1
X3 X4
1SSM1: X3
X2
X1
X5
1SSM1
module 1SSM1
11M3: X1
4
5
11M3
Servo-drive 11M3
10V
0V
248

Pin 1
Pin 2
Pin 3
Pin 4

X5: A1
X5: A2
X5: A3
X5: A4
X1:
X1:
X3:
X3:
Pin 5
X5: A5
X3: 5
1
2
3
4

X10: B2
X10: D2
X11: 3
X11: 4
X11: 5
Sheet alignment

(Preset version)
2
Remove the servo-drive Automatic sheet

arrival control 11M3.
2.0 mm
(approx. 1 rev.)
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

(Preset version)

Servo-drive Automatic sheet arrival control

11M3
Input
+ 10
10

servo-drives
250
Incremental value
205 " 4 inc
3891 " 4 inc
Sheet alignment

D.S.
O.S.
1B13
1B49
Displays
MID11
ZID
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:
MID12
RL12
DNK
DSK
RL12
the servo-drive 11M7,
the guide rail (D.S.) of the forwarding suckers

at the suction head.
The misalignment is registered:
1LVT1
by the ANK sensors on the D.S. and O.S.
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
SSK
ESK
SVM
SAK
If the misalignment exceeds three degrees, the

automatic control compensates for the deviation.
The automatic misalignment control does not
intervene in press control.
REK2
1SSM1
11M7
M
Automatic misalignment control
Legend:
Data lines
Control lines
Block diagram of automatic misalignment control

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

mechanical principle of the misalignment correction.
D.S.
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:
If the symbol is lit, the automatic misalignment

control is active.

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
252
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
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.
arrival D.S.
Mean value of the two
deviations
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

Misaligned sheet, O.S. advanced

253
Sheet alignment
11M7
Preset feeder
Technical data
Motor data
DC 24 V
5 W
Potentiometer data
DC 10 V
10 K
254
Sheet alignment
X5
X10
SSR
SSR X10
X11
X12
X3
X13
X4
X14
SSR X13
11
11LVT1
2SSM1: X1
X3 X4
2SSM1: X3
X2
X1
X5
2SSM1
module 2SSM1
11M7: X1
4
5
11M7
Servo-drive 11M7
10V
0V

Pin 1
Pin 2
Pin 3
Pin 4

X5: A1
X5: A2
X5: A3
X5: A4
X1:
X1:
X3:
X3:
Pin 5
X5: A5
X3: 5
1
2
3
4

X10:
X10:
X13:
X13:
B10
D10
3
4
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
Incremental value
10
1434 " 2 inc
+10
2662 " 2 inc

servo-drives
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
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.
Segment
disk
Impression
cylinder
LED
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.
Irregularity in paper run

No paper
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
1 LVT1
Signals in the case of irregularities in the paper

run (see illustration):
Displays
MID12
MID11
ZID
EAK 1
DNK
ESK
SVM
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.
DSK
REK2
Legend:
Data line
Control lines
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)
Service display EAK2_02 of PU2
2)
3)
4)
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 lit)
LED
0V
(LED not lit)
ca. 24V
3
1
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.
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
264
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).
Sheet monitoring
8
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
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.
Control panel
Pressing bar

Operator side of printing unit
Air supply, connections:

S
Control air, air supply
1
Opening the rear clamping bar
2
Opening the front clamping 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
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
Malfunctions in 2nd printing unit
268
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).
Autoplate
Block diagram
n Y7
E4
n S4
EAK15
EAKn
REK1
n Y 62
n Y 61
n S17
n S59
n H59
n Y 63
n S 25a /
n S 25b
SEK
ESK
Legend:
Parallel data line
DSK
REK2
Serial data line
DNK
ZID
SAK
Control line
Pneumatic line
Electronic control system
Block diagram Autoplate

E4
Pneumatic system compressor
n Y7
Pneumatic valve
n Y61
Pneumatic valve
n Y62
Pneumatic valve
n Y63
Pneumatic valve
n S4
Selector switch Safe
n S17
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
Plate
removal
Unclamping the
rear edge
of the plate
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
0.3 s
Opening the
front clamping bar
n Y62 actuated
1.0 s
2.0 s
Air supply
control air
n Y61 actuated
0.5 s
2.0 s
Enabling
main motor
0.5 s
Enabling
main motor
Enabling
main motor
0.5 s
1.8 s
n Y7 actuated
Press angle
270
264.8 _
322.6 _
297.5 _
0.5 s

B53
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.
Place of installation of sensor Coarse register

monitoring
Layout/connection

Sensor
Locking nut
Connecting cable
Core
Function
brown
DC 24V
blue
ground 24V
black
output signal
Layout of sensor Coarse register monitoring

1...nB53
271
Task/function

Sensor and positioning bolt
Positioning bolt
Sensor B53
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.
1.0 mm 0.5 mm

Positioning bolt
Sensor B53
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

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 .
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 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 becomes inactive.
The sensor has determined the zero position
and has passed it on to the press control
system.
273
274
Washup devices
Washup devices
Selection of functions
Command
Washup
Actual value
display
Service
display
Printing unit
selection
Printing unit
selection
The command
Washup can
be aborted any
time with the
button Delete.
Input
Only with
start-up
warning

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.
Dryer waiting time
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.
276
Washup devices
Not enough water
Messages
Not enough water in the washup solution container

E9:
-
Not enough washup solution
Not enough washup solution in the washup

solution container E9:
-
Inking roller washup device

monitoring of ink blade
Sensor B1 "Monitoring water" (blanket / inking

roller washup device).
Sensor B54 "Monitoring washup solution,

blanket washup device".
Sensor B55 "Monitoring washup solution,
inking roller washup device.
In the displayed printing unit the ink blade is not

fitted. The sensor nB43 is not damped.
277
Washup devices

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
Functions of the impression cylinder washup device DZW

Spraying with water

The washup brush motors M43, M50...M56 start up.

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
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
280
Mineral oil-based solution
Vegetable oil-based solution
Washup devices

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
Y55
Blanket, washup brush
E9
Washup solution container
Y56
Blanket, driving clutch
Y52
Blanket, washup solution
Y53
Blanket, washup blade
Y54
Blanket, water
281
Washup devices
Layout

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

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 cylinder revolutions
3 spray procedures
10
30%
Setting for washup solution:

3 spray procedures
40
30%
Flow chart:
Washing with washup solution and water
1.2 s
Water (nY54)
0.7 s (0.3 s if vegetablebased)
Washup solution (nY52)

0.3 s
Blanket
washup brush (nY55)
Blanket
driving clutch (nY6)
Blanket
washup blade (nY53)
Revolutions
0 4
40
99
104
102
Flow chart: Washing with washup solution and water
285
Washup devices

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
Y44
Inking rollers, water
E9
Y50
Inking rollers, washup solution
Y9
Inking form rollers
Y51
Ink blade
Y10
Ink ductor
Y11
Dampening rollers
286
Washup devices
Layout

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

Function
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

After the allocation the parameters can be changed
device again.

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%
one spray procedure every
28 revolutions

225
70%

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)
80% of preselected cylinder

revolutions if printing plate is
washed as well
Ink ductor (n Y10)

Ink blade
(n Y51)
66% of preselected cylinder revolutions if

printing plate is washed as well
Water (nY44)
Washup solution
(n Y50)
Revolutions
0.4 s 0.2 s
20
0.2 s
20
40
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)
as 1st section
above (without water)
Ink blade
(n Y51)
Water (nY44)
Washup solution
(n Y50)
0.4 s
0.4 s
0.2 s
x1
Revolutions
Preset spray procedures washup solution
Preselected cylinder revolutions

washup solution
x2
x2
Preset spray procedures water
40

water
Flow chart: Washing with mineral oil-based washup solution and water
290
30
20
30 20
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)
80% of preselected cylinder

revolutions if printing plate is
washed as well
Ink ductor (nY10)

Ink blade
(nY51)
66% of preselected cylinder revolutions if

printing plate is washed as well
Water (nY44)
Washup solution
(nY50)
Revolutions
0.4 s
8
0.4 s
0.2 s
0.4 s
0.2 s
x1
x1
x1
x1
Preset spray procedures

washup solution
Preselected cylinder revolutions washup solution
x2
x2
80
30 20
Preset spray procedures

water
Preselected
cylinder revolutions
water
Flow chart: Washing with vegetable oil-based washup solution and water
291
Washup devices

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
1...nY41
Impression cylinder, washup brush
E9
1...nY42
Impression cylinder, washup solution
1...nY43
Impression cylinder, water
M50 ... M56, M43 Washup brush motors
292
Washup devices
Layout

Impression cylinder
Spray tube for water
Washup brush motor
Washing trough
Spray tube for washup solution
Blade
Washup brush
Impression cylinder washup device
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.
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

After the allocation the parameters can be changed
device again.
Impression cylinder washup device selected

Enter the number of cylinder revolutions for water
and washup solution with the left-hand +/ buttons:
Water:
0 and 30
Washup solution:
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%
294
Change in basic pulse duration

0.5 s
0.4 s
L
0
L
+ 0.4 s
+ 0.5 s
Washup devices
Example
Setting for water:
0
50%
basic spray duration +/ 0 s

50
50%
spray duration 0 s
Flow chart:
Washing with washup solution and water
Washup brush motor

(M43, M50...M56)
Impression cylinder
washup brush
(n Y41)
3.0 s+/x
Spray duration
2.0 s+/x
1.0 s+/x
Water (nY43)
2.0 s+/x
0.7s+/x
0.7 s+/x
0.5 s+/x
1,0 s
Washup solution
(n Y42)
0.5 s
25
25
25
Revolutions
washup solution
25
15
15
30
Preselected
cylinder revolutions
water
Flow chart: Washing with washup solution and water
295
Washup devices
M43, M50...M56 Washup brush motors
M43, M50 ... M56 Washup brush motors

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
A B C
1
Function
A2
AC 400 / 480 V phase U
B3
AC 400 / 480 V phase V
C2
AC 400 / 480 V phase W
2
3
4
5
Plugs M43-X1, M50-X1 ... M56-X1
296
PE conductor
Washup devices

Block diagram

15K4M
M4
E9
F70
B1
B54
Pressure reducer with check valve

Safety valve
15K4M
Contactor, pneumatic system compressor
M4
B1
Sensor Monitoring water.
B54
Sensor Monitoring washup solution,

blanket washup device
B55
Sensor Monitoring washup solution,

inking roller washup device
E9
F70
Pressure switch
B55
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:
production run display,

display which appears after initiating the
command Washup,
fault display Entire press/warning.
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.
Not enough water
Not enough water in the washup solution

container E9.
Sensor B1 Monitoring water.
Insufficient pressure in the

container
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.
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).

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,
Sensor B1 Monitoring water
Sensor B54 Monitoring washup solution,
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
4
5
Pin
Function
1
2
3
4
DC 24 V
24 V
Monitoring water
Monitoring washup solution,
Monitoring washup solution,
Plug E9-X1
300
Washup devices
B1, B54, B55 Sensors at the washup

solution container
B1, B54, B55 Sensors at the washup solution container


B1 Monitoring water
B54 Monitoring washup solution,
B55 Monitoring washup solution,
Sensors at washup solution container
Connection
Input at EAK :
0 level too low
1 level OK
Pin assignment
Marking
Colour
Function
X1
white
signal
+1
brown
DC +24 V
301
Washup devices
B1, B54, B55 Sensors at the washup

solution container

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
Mounting position of sensor
302
Function
upward
NC contact
downward
NO contact
Symbol
Washup devices

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

Sensor
Nut and locking nut
Connecting cable
Sensor Monitoring the ink blade with nut and

locking nut
303
Washup devices
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
Function
brown
blue
black
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
4.0 mm

Blade
Sensor
Nut/locking nut
Side frame
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
Inking unit
The servo-drives for the ink fountain rollers 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 k
Terminal assignment
Terminal
black
yellow
beige
yellow/green
brown
blue
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
Terminal strip of servo-drive for ink fountain

roller
306
1
2
4
5
6
Function
DC 12 V (motor)
DC 10 V (potentiometer)
potentiometer
Potentiometer tap
Inking unit

Attention:
Small parts can fall into the press during

disassembly!
O.S.
Nut on servomotor
Gear wheel
Locking screw
Anti-rotation element
Retaining nut
1
2
3
4
5
Ink fountain roller O.S.
6
7
Zero position of ink fountain roller

Turn the threaded rod against the left stop
with the nut .
Disconnect the potentiometer from the
terminal strip.
Loosen the locking screw
potentiometer.
and take out the
Attach the anti-rotation element

potentiometer.
to the new
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 .
Correct the value by slightly turning the
potentiometer.
Check the value displayed on the central
control console.
307
Inking unit

The servo-drives for the diagonal register are
D.S.
O.S.
Place of installation of servo-drive for diagonal

register O.S.
Layout and task
Speedmaster SM 102
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 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 k
Pin assignment
Pin
Function
1
2
4
5
3
4
1
2
3
4
5
DC 24 V (motor)
Potentiometer tap
potentiometer
Plug of servo-drive of diagonal register
309
Inking unit

Attention:

disassembly!
Plug 1...nM6-X1
Fixing bolts
Hexagon nut
Block
Upper stop of eccentric sleeve
Eccentric bolt
Servo-drive
1
2
3
Eccentric sleeve
behind block
5mm
Servo-drive diagonal register, e.g. SM 102
310
Withdraw the plug
from the servo-drive .
Remove the servo-drive by loosening the four

fixing bolts .
Positioning the diagonal register to zero:
Turn the hexagon below the block until
the distance between the upper stop of the
eccentric sleeve O.S. and the eccentric bolt
is 5 mm.
Setting the central position for the new
servo-drive:
Connect the plug to the servo-drive . 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.
Note:
Do not loosen the eccentric bolt .
After loosening the eccentric bolt, the plate cylinder
and the dampening distributor must be adjusted
parallel to each other again.
Inking unit

The servo-drives for the lateral register are
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
Motor data
U = DC 12 V
Potentiometer data
U = DC 10 V
R = 10 k
Terminal assignment
Terminal
black
yellow
beige
yellow/green
brown
blue
6
5
4
3
2
1
6
5
4
3
2
1
black
red
blue
brown
blue
Terminal strip of servo-drive for lateral register
312
1
2
4
5
6
Function
DC 12 V (motor)
potentiometer
Potentiometer tap
Inking unit

Attention:
2.2...2.27 mm
2.2...2.27 mm

disassembly!
Nut
Gear wheel
Nut
Nut
Sleeve
Positioning the lateral register to zero:

Turn the gear wheel with the help of the nut
until the distance of 2.2...2.27 mm is
obtained.
Note:
Use a feeler gauge!
Lateral register O.S.
2
3
4
5
6
7
8
.
Loosen the nut .
Unscrew the nut
Take out the potentiometer and disconnect the

cable from the terminal strip.
potentiometer.
to the new
Connect and install the new potentiometer and

turn until the display on the central control
console indicates 0,00.
loosen the nut . To correct the value insert a
screw driver in the sleeve and turn the
potentiometer axis slightly. Check the value
displayed on the central control console.
313
Inking unit

The servo-drives for the circumferential register
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
Motor data
U = DC 12 V
Potentiometer data
U = DC 10 V
R = 10 k
Terminal assignment
Terminal
black
yellow
beige
yellow/green
brown
blue
6
5
4
3
2
1
6
5
4
3
2
1
black
red
blue
brown
blue
1
2
4
5
6
Function
DC 12 V (motor)
potentiometer
Potentiometer tap
Terminal strip of servo-drive for circumferential

register
315
Inking unit

Attention:

disassembly!
6.2...6.3 mm
6.2...6.3 mm
Nut
Gear wheel
Locking screw
Nut
Positioning the circumferential register to zero:

Turn the gear wheel with the help of the nut
until the distance of 6.2...6.3 mm is obtained.
Note:
Use a feeler gauge!
2
Circumferential register D.S.
3
4
5
6
7
316
Disconnect the potentiometer from the terminal

strip.
Loosen the locking screw
potentiometer.
and take out the

potentiometer.
to the new
Connect and install the new potentiometer and

turn until the display on the central control
console indicates 0,00.
loosen the nut . Correct the value by slightly
turning the potentiometer. Check the value
displayed on the central control console.
Inking unit

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)
on/off
317
Inking unit

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.

Connection of inking unit temperature control E39
Pin assignment E39-X1 (only model 3/8)

Pin
10

318
Function
Phase U
Phase V
Phase W
PE conductor
Remaining pins
Inking unit

(models 6/12; 6/16; 9/20 and 9/25)
Pin

Function
Phase U
Phase V
Phase W
PE conductor
Remaining pins
4pole
cable

319
Inking unit
320
Dampening
Dampening
Place of installation / plug connections
Connector 1...nM1-X3
( power supply )
1...nM1-X3
2M1
1M1
3M1
Pan roller motors 1...nM1 at PU/CU on D.S.
Pin assignment
7
Pin
4
3
9
14
10
11
12
Function
13
2
Connector 1...nM1-X3, pins in plug insert
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
10
11
Motor code
12
13
14
PE
321
Dampening

Place of installation and task
nM45
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.
Place of installation of blower motor for dampening

system
Pin assignment
Pin
1
2
3
Plug of blower motor for dampening system
322
Function
Enable message
Ground 24 V
DC 24 V
Dampening

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
Function
brown
DC 24 V
blue
ground 24 V
black
message
Sensor Dampening solution control
323
Dampening
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/

E40 Central dampening solution supply/cooling and circulating unit

Layout of central dampening solution supply
X1
X2
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
Central dampening solution supply Technotrans
X2
X1
Central dampening solution supply Baldwin, rear view
325
Dampening

Pin assignment X1, central dampening solution supply

Pin
10
Connector E40-X1, coming from the press
326
Function
3
7
9
Phase U
Phase V
Phase W
PE conductor
Remaining pins
*)
380...415 V " 15V

* ) AC
AC 460...500 V " 15V
at 50Hz
at 60Hz
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
Cooling and circulating unit
Pin assignment X1, cooling and circulating unit

Pin
2
4
1
10
Function
AC 230 V
Zero 230 V
PE conductor
Remaining pins
327
Dampening

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

Service display Oil lubrication
330
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.
Central lubrication
Service display
Grease lubrication
7
8
9
Service display Grease lubrication
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.
chain lubrication. After completion of lubrication
the counter is automatically zeroed.
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.
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
Grease lubrication not possible
Motor circuit-breaker Q 44
has tripped
The audible signal devices 11H55
and 12H55 give out a warning
332
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.
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.
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.
Central lubrication
Grease lubrication
Grease lubrication
Block diagram
15 Q 66
15 Q 47
12B47
15 K47 M
12M47
12Y78
12B77
11H55
12H55

Control line
Power supply
Grease line
Block diagram of grease lubrication

Pressure limiting valve (38 bars)
12M47
Motor Grease lubrication
Metering elements
12Y78
Changeover grease lubrication
15Q66
Main switch
12B47
Lubrication monitoring 1 (chains)
15Q47
Motor circuit-breaker
12B77
Lubrication monitoring 2 (bearings)
11H55
Audible signal device (audio alert feeder)
12H55
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

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
LED
Inductive sensors monitor the two lubrication

circuits. Each is equipped with an LED and can
assume two circuit states.
Sensor with LED monitoring the lubrication circuit
Pin of progressive distributor extended, sensor

damped:
LED is lit.
Pin of progressive distributor retracted, sensor
not damped:
LED is not lit.
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:

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
Even if the main switch is turned off, the press

is not voltage-free and there are currentconducting components in the central control
cabinet!
Attention:
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

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.
2 500
Lubrication cycle for delivery
5 000
30000
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

Control line
Power supply
Oil line
Block diagram of oil lubrication

Pressure relief valve (18 bars)
Y67
Changeover oil lubrication
Metering elements
1F33
Pressure monitoring (1 bar)
15Q66
Main switch
1F34
Pressure monitoring (12 bars)
15Q44
11H55
Audible signal device (audio alert feeder)
15X3
Plug
12H55
Audible signal device (audio alert delivery)
M44
Oil pump
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

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
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
Oil lubrication
Central lubrication
Oil lubrication
Triggering a lubrication process

Distributing lubrication is triggered:

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
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:
Filter unit
Green: filter cartridge okay
Red: change filter cartridge
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

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
Function
A2
B3
C2
A B C
1
2
3
4
5
Plug M44-X1
344
PE conductor
Central lubrication

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
3
1
2
PE
Pin
Function
DC 24 V
Grease lubrication delivery chains
PE
Plug 12M47-X1
345
Central lubrication
1F33 Pressure monitoring

oil lubrication 1bar
1F33 Pressure monitoring oil lubrication 1bar

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

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


Layout
The sensor 12 B47 for chain lubrication monitoring
and the sensor 12 B77 for bearing lubrication monitoring are of identical design.

LED
Sensor
Locking nut
Receptacle
Plug
Stop pin
Sleeve
Distributor

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
Colour
Function
47 or 77
black
signal
+1
brown
DC 24 V
blue
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
Pneumatic system
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
Pin assignment
Plug 15Y11-X1
1
3
PE
2
Plug 15Y11-X1
352
Pin
Function
DC 24 V
Signal 4 mA ... 20 mA
PE
Pneumatic system

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
Pin assignment
Plug 15B14-X1
3
1
2
PE
Pressure sensor and connector
354
Pin
Function
DC 24 V
Sensor signal 4 mA ... 20 mA
PE
Pneumatic system

Technical data
Technical data, see operating instructions 71.102.9100
Pin assignment
Pin
Function
A2
B3
C2
C4
DC 24 V
A5
Pressure switch F45
B5
Blow-off valve Y68
A B C
1
2
PE conductor
Plug E4-X1
355
Pneumatic system
356

Block diagram
Displays
MID11
ZID
MID12
DNK
The blast air pressure is regulated by servo-drive

1M9 which controls a relief valve.
DSK
The blast air pressure depends on two factors:
the thickness of the stock (e.g. paper

calliper);
the production speed (preset speed).
IDS
EAK
SSK
ESK
In the operator program of CPTronic the blast air

regulation can be switched on and off.
SVM
SAK
REK2
1SSM1
1M9
M
Blast air regulation
Legend:
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.
Data lines
Control lines
Block diagram: blast air regulation at the feeder
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.
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
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.

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
Manual change of the characteristiccurvedepen

dent blast air regulation
p [bar]
For a 0.05 mm thick paper the setting range for the

slope is as follows for SM 102 and CD 102:
1.0
Minimum:
0% (corresponds to the
0%-characteristic curve)
Maximum:100% (corresponds to the
100%-characteristic curve)
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]
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)
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

The setting range for SM 102 and CD 102 is as
follows:
p [bar]
Minimum: 20% (corresponds to 0.2 bar above

atmospheric pressure)
Maximum:100% (corresponds to 1.0 bar above
atmospheric pressure)
1.0
0.8
0.6
0.4
0.2
20
40
60
80
100
ZID display [%]

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:

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 k
Pin assignment
Contact
+
2
3
4
1
2
3
4
5
3
4
2
Assignment
Motor, + (DC 24 V)
Motor, (DC 24 V)
Potentiometer, + (DC 10 V)
Potentiometer wiper
Potentiometer, (DC 10 V)
Pin assignment: blast air regulation at the feeder
363
Attention:

disassembly!
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 .
and remove
(4)
4
(4)
364
Unscrew the connector 1M9X1 and

withdraw it from the servo-drive . Loosen
the four fixing bolts and remove the
servo-drive together with the sleeve .
Turn on the main switch (blast air is present).
7
8
9
Turn the threaded spindle manually

until the manometer measuring the
pressure above atmospheric at the feeder
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 with the new
servo-drive and tighten up the bolts.
Turn on the main switch.
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 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 on the threaded spindle .
365
Push the servo-drive onto the threaded

spindle so that the pin engages with
two slots of the sleeve .
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 .
with the four
Let the servo-drive 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)
366
Put the protecting cover back in place

and fasten it with the four fixing bolts .
Selecting the service display

Incremental values for the servo-drive
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
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
Other components
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.
E4a-X21
The varnish supply unit is remotely controlled with

a cable. This cable is connected to plug E4a-X22.
E4a-X22
The varnish supply unit is located under the

footboard on the D.S. of the coating unit.
E4a-X1
A manufacturers manual is available.
Varnish supply unit
Pin assignment
E4a-X1
Pin
A B C
1
2
3
4
5
Plug E4a-X1, coming from the control cabinet
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
369
Other components
E4a-X21
Pin
2
3
4
6
Plug E4a-X21, control lines
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
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

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
183 170 171
blk
br
L-B32
4
6
E4a-X2
Pin
Colour
brown
grey
yellow
green
DC 24 V
white
Ground
L-LVT1-X2
bl
Sensor
Function
DC 24 V (+1) for fault message
Fault message
Analog sensor signal:
0 ...5 V
Conductive level sensor
voltage for
sensor
Connection of sensor Level in coating pan
371
Other components
Layout, adjustment

108 mm
approx. 10 mm
Mounting dimensions of sensor Level in coating pan
372
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.
Other components

Place of installation, layout

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 device, powder tube and motor at

delivery
powder spray devices without serial interface,
powder spray devices with serial interface.
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

Function
A2
L2
B3
L1
C2
L3
A4
AC 230 V
C5
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
Switch Powder on 12S68,

switch contact 2 (not with
proximity switch)
A2
DC 24 V for test button
A3
AC 230 V
A4
Switch Powder on 12S68,

switch contact 1 (not with
proximity switch)
A5
Impression on ( AC 230 V)
B1
Test ( DC 24 V)
B2
Zero 230 V
B3
PE conductor
B4
Press turns ( AC 230 V)
B5
C1 C5
Plug 12E2X2, coming from the press, distribution

box at delivery
Function
PE
Pin assignment of proximity switch 12S68
3
4
5
Plug of proximity switch
374
2
1
Pin
Function
Ground
DC 24 V
Signal
Ground
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
Pushbutton Forward/
Backward
Set the selector switch Safe to Safe.
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.
Display of degree value
Indication on the MID while press is in inching mode
375
Other components
Service display Delivery
4
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 jumps back to
the standard degree value .

SM102
( CD102)
+ extended
+ coating unit
+ coating unit
High-pile delivery high-pile delivery + high-pile delivery + extended high-pile delivery
2 PUs
132 101 )
225 102
83 176
84 177
4 PUs
166 250
259 251
118 326
119 326
5 PUs
3 325
97 326
315 39
316 40
6 PUs
201 39
294 40
152 114
153 115
7 PUs
38 114
131 115
349 189
350 189
8 PUs
235 189
328 189
188 263
188 264 )
+ 74.6 74.6
for every further
coating unit
Degree values for the beginning of powdering SM102 (CD102)
376
+ 74.6 74.6
for every further
coating unit
Other components

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

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
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

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

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

Sensor
Openings for switching element
Switching element (fitted on slide-in dryer)
Marking
Function
21-22
13-14
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
380
1
0
IR dryer(s) inserted
IR dryer(s) removed
Other components

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

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.
10
382
Pin
Function
AC 230 V, phase U
AC 230 V, phase V
AC 230 V, phase W
PE
Other components
Attention:

Cut off the power supply before working on the
device!
Place of installation of static electricity eliminator

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

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

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

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
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:
388
motor regulation,
interrogation points of sensors,
positioning for plate change.
Other components
IDS Encoder
Function
Track A
Track B
Track 0
The encoder generates three pulse signals:
5V
track A,
0V
track B,
5V
track 0.
0V
Track B is staggered by 90 in relation to track A.
5V
Per revolution track 0 generates one zero pulse.
0V
The inverted signals are also available from all 3

tracks.
Pulse signals from the encoder
Tracks A and B each generate 1024 pulses per

revolution.
Pin assignment
M
J
A
K
Pin
Function
M, G, H
DC+5V
A, L, D
5V
Track A/
Track A
Track B/
Track B
Track 0/
Track 0
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
SM102 Perfector presses

IDS 2
1
1
1
1
1
1
1
4
4
4
4
4
4
4
IDS 1
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
Printing
Printing
Printing
Printing
Printing
Printing
Printing
Printing
Printing
Printing
Printing
Printing
Printing
Printing
Printing
Printing

2
Encoder IDS
390
1
2
3
Remove the plug.

Loosen the stud.
Remove the encoder.
unit
unit
unit
unit
unit
unit
unit
unit
unit
unit
unit
unit
unit
unit
unit
unit
IDS 2
1
1
1
1
1
1
1
1
1
1
1
1
4
1
4
5
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
Other components
IDS Encoder
Insert the gauge in printing unit 1.
Inserting the gauge
Line mark D
Positioning to zero
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.
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.
Note:
If the value 000.0 is not displayed in the MID,
continue with step q.
If the setting is correct, continue with r.
Adjustment of the encoder IDS
e
q
Loosen the locking nut.
Turn the adjusting screw until 000.0 is

displayed in the MID.
Tighten the locking nut.
Remove the gauge from PU 1.
Precision adjustment of the encoder IDS
Removing the gauge
392
Location diagrams
Location diagrams
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.

15M1
Fan Power components
15L1
Power choke - power converter
15R120
Load resistor
(only for presses with Preset)
15R48
Load resistor
(only for presses with auxiliary pile
at the delivery)
15F2
Semiconductor fuses
Armature circuit M1
15Q66
Main switch
15Z2
EMC filter
15F1
Semiconductor fuses Mains
15X1
Terminal strip
PE
PE conductor
15Z1
EMC filter
15T1
Control transformer

Equipment zone Power supply
394
Location diagrams
Equipment zone B Partition wall
SLT
GRM5
15Q61
15Q62
GRM24
15Q37
15K37M
15Q38
GRM48
Converter power part
GRM5
Rectifier module
GRM24
Rectifier module
GRM48
Rectifier module
GRM120-2
Rectifier module
15Q61
Flat switch
Transformer protection, secondary
15Q62
Flat switch
Transformer protection, secondary
15Q37
Circuit-breaker
Feeder / delivery main pile
(not for Preset version)
15Q38
Circuit-breaker
Feeder auxiliary pile
15K37M
Contactor Pile control

STK1 (without Preset) /
LSR (with Preset)
15K38M
Contactor
Pile control
STK1 (with Preset) /
STK2 (without Preset)
15K48A
Contactor Power supply

connecting part of power converter
15Q2
Air supply cabinet E 8
15Q65
Transformer protection, primary
GRM120-2
15Q65
15K48A
15K38M
SLT
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

395
Location diagrams
GRM Rectifier modules

The equipment zone B Partition wall contains four
rectifier modules.
F6
F8
F3
F4
F5
F7

GRM5
Rectifier module
GRM24
Rectifier module
GRM48
Rectifier module
GRM120-2 Rectifier module
The rectifier modules GRM24 and GRM48 are of

identical design and interchangeable.
Fuses:
F6, F7, F8 (GRM5)
Rectifier modules GRM
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 26 V
3 x ca. AC 100 V
ca. DC 36 V
ca. DC 120 V
ca. DC 33 V
ca. DC 50 V
Voltages at the rectifier modules GRM
396
F3 (GRM120)
32 A, slow-blowing
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
Q39
Q39a
Q40
K22M K33M K33aM K35M K39M
Q44
Q22a
Q80
IWM
K39M
Earth-leakage monitor
module
K22aM
K40M
K39M K39aM K46A K61A K50M K51M K52M K53M K54M K55M K56M K43M
Terminal amplifier module

Flat-cable output module
64 outputs
KVM
BAM
BKM
SPM
VSM
SVM
SVM
FAM 64
FEM 64
Flat-cable input module

64 inputs
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

15V1

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
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
Location diagrams
Equipment zone E Swing frame

Equipment of swing frame for presses with:
REE2
2 - 5 PUs, without Preset

REE2
Computer plug-in unit 2
EHE2
Input/output
auxiliary drive plug-in unit 2
LTE
Power part plug-in unit
SSE2 Servo-drive plug-in unit 2
EHE2
LTE
Swing frame for presses with 2- 5 PUs
2 - 5 PUs, with Preset

REE2
EHE2
Input/output
LTE
SSE2/LSE Servo-drive plug-in

unit 2/ power part plug-in unit for
brushless pile motors
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
REE2
EAE
HAE2
LTE
Swing frame for presses with 6- 8 PUs
6 - 7 PUs, without Preset

REE2
EAE
Input/output plug-in unit
HAE2
Auxiliary drive plug-in unit 2
LTE
SSE2 Servo-drive plug-in unit 2
6 - 7 PUs, with Preset,

8 PUs, with Preset, without non-stop
delivery
REE2
EAE
HAE2
LTE
SSE2/LSE Servo-drive plug-in

unit 2 / power part plug-in unit for
8 PUs, with Preset, with auxiliary pile at

the delivery
REE2
EAE
HAE2
LTE
SSE2/LSE2 Servo-drive plug-in

brushless pile motors 2
Note:
400
Location diagrams
REE2
EAE
EHE2
LTE
Swing frame for presses with 9 PUs
9 PUs, with Preset, without non-stop

delivery
REE2
EAE
EHE2
Input/output
LTE
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
Input/output
LTE


unit 2/ power part plug-in unit for
Note:
401
Location diagrams
Computer plug-in unit REE 2

Computer plug-in unit REE
NTK24 Power supply board

REK386 Processor board 386
ESK_2 Input/ output control board
SAK2 Memory analog 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.

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
The processor board REK 1 consists of the computer

motherboard RGP 2 and the EPROM module EPM.
Computer
motherboard
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

Input/output auxiliary drive plug-in unit for

presses with 9 printing units

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
Note:
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.
Input/output plug-in unit for

presses with 6 printing units


SEK
Safety input board
EAK2 Input/output board

from right to left for:
feeder,
delivery,
central control cabinet,
printing units 1 to 8.
Note:
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.

Auxiliary drive plug-in unit for presses with 6- 8
printing units
404

HAK2 Auxiliary drive board
Note:
boards NTK , auxiliary drive boards HAK 2). Boards
Location diagrams
Power part plug-in unit LTE
The power part plug-in unit LTE is required for all

presses.

Power part plug-in unit for presses with 7 printing

units, without Preset, with auxiliary pile at feeder
and delivery
Power part plug-in unit for presses with 8- 9 printing units, with 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
LTK500
Power part board
LTK50
Power part board
STK_2
Pile control board
STK_1
Pile control board
Note:
frame are identical in design (e.g. power part
boards LTK50, power part boards LTK500). Boards
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
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.
405
Location diagrams
Servo-drive plug-in unit SSE2

The servo-drive plug-in unit SSE2 is required for
presses with:
Servo-drive plug-in unit for a press with 2- 7 PUs,

without Preset
2 - 4 PUs, without Preset (only one SSK 2),
2 PUs, without Preset, without CPC,
5 - 7 PUs, without Preset,
NTK24
Power supply board
SSK2
Servo-drive control board
Note:
boards NTK , servo-drive control boards SSK 2).
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


SSK2 Servo-drive control board
BAK Brake control board
Note:
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

SSK2 Servo-drive control board
BAK Brake control board
Note:
407
Location diagrams

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
1S29
2S28
11S37
1S28
11S34
11S31
11S65
11S56
2S26
2S25
2S25a
2S25b
2S24
1S25
1S25a
1S25b
1S24
2S20
1S26
11S40
11S38
11S38a
1S40a
2S37
1S40
11S32
11S4
11S38b
11S36
2S31
11S39
Preset feeder, printing units 1 and 2
12S55
12S55a
3...9S28
12S40
12S44
12S56
12S38
12S35
12S36
12S422) 12S130a
12S41
12B129a
12B129
Version with rake
Version with board
12S37
12S34
12S130
12S421)
12S39
12S33
3...9S29
3...9S24
12S9
12S65a
3...9S20
12S117
12S34b
12S34a
3...9S37
12S43
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
12S55
12S55a
12S68
12S35
12S42
3...9S28
12S40
12S44
12S56
12S36
12S39
12S37
12S34
12S9
3...9S29
3...9S24
12S37a
12S65a
12S411)
12S412)
12S65
3...9S20
3...9S37
12S34b
12S34a
12S43
12S9c
Version with rake
Version with board
Extended delivery with coating unit

Legend:
Equipment O.S.
Equipment D.S.
410
12S9b
12S9a
Location diagrams
Solenoid valves
Solenoid valves
2Y56
1Y56
11Y74
1Y45
11Y66
11Y16
15Y11
1Y15
11Y15
2Y12
1Y12
1Y16
2Y48
2Y2
2Y9
2Y10
2Y11
2Y13
2Y53
1Y48
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
1Y44
1Y54
1Y43
front
or
back
1Y52
1Y55
1Y42
1Y54
1Y43
front

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

Legend:
Equipment O.S.
Equipment D.S.
412
3...9Y48
Location diagrams
Motors
Motors
2MD
1MD
11M11
1M45
2M45
Lateral register
11M2
11M12
11M1
Lateral register
11M6
2M1
2M6
1M1
1M6
1M4
11M7
11M5
1M8
2M5
Circumferential register
1M5
Circumferen1M7
tial register
11M3
M52
M51
1M4
1M2
1M3
11M9
11M8
1M9
12M2
12M5
12M7
12M6
3...9M2
12M1
12M3
12M47
M44

Legend:
Equipment O.S.
Equipment D.S.
413
Location diagrams
Motors
12M2
12M5
12M7
12M6
3...9M2
12M1
12M3
12M47

Legend:
Equipment O.S.
Equipment D.S.
414
M44
Location diagrams
Sensors
Sensors
2B43
2B32
1B43
1B32
15B14
11B10
11B35
1B11
1B13
2B48
1B48
2B48a
1B48a
11B55
1B9
1B10
HWI
1B49
11B33
11B11
3...9B32
12B129
12B69
12B129a
12B65
12B77
12B47

Legend:
Equipment O.S.
Equipment D.S.
415
Location diagrams
Sensors
3...9B32
12B129
12B69
12B129a
12B65
12B77

Legend:
Equipment O.S.
Equipment D.S.
416
12B47
Location diagrams
Control panels
Control panels
F
C
H
C
417
Location diagrams
Control panels
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
Dampening system control
Fan and dryer control
Preset version
422
Control panels
Location diagrams
Operators controls
Operators controls
Description
Feeder
Pushbutton Run
11S2
12S2
Pushbutton Stop
11S30
12S8
Pushbutton Production run
11S19
12S60
Emergency stop button
11S1
Compressor on/off
11S3
11H3
11S58
11H58
Feeder on/off
11S7
11H7
12S59
12H59
Paper run on/off
11S5
11H5
12S57
12H57
Pushbutton Fast
11S20
12S6
Pushbutton Slow
11S21
12S7
Pushbutton Forward
11S17
1...nS3 (O.S.)
1...nS6 (D.S.)
12S3
11S18
1...nS4 (O.S.)
1...nS7 (D.S.)
12S4
1...nS5 (O.S.)
1...nS8 (D.S.)
12S5
Pushbutton Backward
Signal lamp
Malfunction press
11H51
Signal lamp
Malfunction feeder
Malfunction delivery
Malfunction printing/coating unit
Malfunction dryer
11H1
Printing/coating
unit
1...nS1 (O.S.)
1...nS2 (D.S.)
Delivery
Remark
12S1
12H9
1...nH1
12H1
423
Location diagrams
Description
Operators controls
Feeder
Printing/coating
unit
Job counter on/off
12S63
12H63
Pushbutton
Crawl speed
1...nS23
Pushbutton Position
1...nS17
Plate mounting
1...nS59
1...nH59
Pushbutton Auxiliary pile down
11S29
12S54
Pushbutton Auxiliary pile up
11S28
12S53
Toggle switch
Auxiliary pile on/off
11S27
Pushbutton Main pile down
11S25
12S46
Pushbutton Main pile up
11S24
12S45
Pushbutton Pile stop
11S26
12S124
Pushbutton
Pile board on/off
12S10
12H10
Pushbutton Removal of
inspection sheet
12S11
12S11a
Press display MID

Inking form rollers on/off
424
Delivery
1...nS57
1...nS57
Remark
Location diagrams
Description
Operators controls
Feeder
Printing/coating
unit
Ink ductor on/off
1...nS58
1...nH58
Pushbutton
+ dampening
1...nS22
Delivery
Remark
12S17...
12S24
Washing dampening/varnishing
rollers
dampening
12S25...
12S32
Selector switch
Adjusting dampening rollers
1...nS21
Pushbuttons
Blast air regulation
11S117
11S118
Pushbuttons
Suction head height
11S44
11S44a
11S45
11S45a
Pushbuttons
Suction head format
11S46
11S47
Pushbuttons
Main pile centering
11S58
11S58a
11S59
11S59a
Pushbuttons
11S59
11S60
Pushbutton
Pile stops larger format
11S63
Pushbutton
Pile stops smaller format
11S62
Pushbutton Pile stops D.S.
11S9
Pushbutton Pile stops O.S.
11S10
Pushbuttons
Format wheels
11S48
11S57
Pushbuttons
Sheet slowdown format
12S68
12S69
425
Location diagrams
Description
Operators controls
Feeder
Delivery
Pushbuttons
Sheet slowdown speed
12S61
12S62
Pushbuttons
Sheet jogger D.S.
12S73
12S74
Pushbuttons
Sheet jogger O.S.
12S75
12S76
Potentiometer to
regulate the displayed fans
DSM5
Potentiometer to
DSM3
Potentiometer to
DSM6
Potentiometer to
DSM2
Potentiometer to
DSM1
Potentiometer to
DSM4
Pushbutton Dryer on/off
Selector switch for dryer
Potentiometer to
regulate dryer output
Volume controller
Intercom
Pushbutton
Lifting the sheet stop fingers
426
Printing/coating
unit
11S8
Remark
Location diagrams
Operators controls
Description
Feeder
Dampening rollers
11S6
11H6
Pushbutton Suction air for suction

tape +
11S41
Pushbutton Suction air for suction

tape
11S42
Illuminated pushbutton Turning

the ink fountain roller
Printing/coating
unit
Delivery
Remark
1...nS45
Varnish circulation
Varnish pump ON/OFF
Turning the pan roller
Draining the coating pan
Varnish flow rate to varnish pump
Spraying
Rinsing
Stopping the pan roller
Potentiometer Blast air at front

lays
2...nS57
2...nH57
11R1
427
Location diagrams
428
Operators controls
Location diagrams
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

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)
Adjustment buttons
429
Location diagrams
430
Abbreviations
Abbreviations
Abbreviation
Description
Abbreviation
Description
AEM
Drive extension module
EAE
ANZ
Display board
EAK
Input/output board
ATV
Display and key distribution

board
EAM
Input/output module
EAR
ASE
Job memory card unit
Backplane of input/output
plug-in unit
AUM
Analog signal distribution

module
EE
Electronic plug-in unit
EEM
AVM
Control and distributor module
Single-fault fail-safe
extension module
EGK
External equipment board
EHE
Auxiliary drive input/output

plug-in unit
EHR
Backplane of auxiliary drive

input/output plug-in unit
ELK
Mains discharge board
ELR
Backplane of electronic plug-in

unit
BAK
Brake control board
BAM
Brake control module
BEK
Control unit board
BFM
Filter module of brushless

power part
BKM
Brake/ clutch module
BLT
Brushless power part
EPM
EPROM module
BSM
Control unit interface module
ESG
Extension control cabinet
BVM
Control unit distributor module
ESK
ESM
Interference suppressor
module
EVG
Electronic ballast
EVK
Front-corner alignment control
CSM
CPC3 interface module
CVK
CPC3 distributor board
DAM
EVM
Input/output distributor module
Double-sheet indication
module
EWK
Extension board
DAK
Digital output board
EWM
Extension module
DAS
Speed ratio display system
EXK
External equipment supply

board
DBE
DGP
Display motherboard
DLW
Diskette drive
FAM
Flat-cable output module
DNK
Display power supply board
FCA
Adaptor between telediagnosis

board and CPC2S
DSK
Display control board
FCK
Flash memory controller board
DSM
Speed control module Fans
FDK
Telediagnosis board
431
Abbreviations
Abbreviation
Description
Abbreviation
Description
FEM
Flat-cable input module
LDM
Air pressure sensor module
FKK
Ink fountain board
LG
Light pen
FKV
Ink fountain distributor
LLM
Power logic module
FK
Sensor for overshooting-sheet

control
LPM
Varnish pump control module
LRM
Power part control module
FVM
Flat-cable connection module
LS
Light barrier
FZA
Ink zone display board
LSE
FZT
Distribution board for ink zone

keys
Power part plug-in unit for

LSM
Lamp control module
LSR
Backplane of power part plugin unit for brushless pile motors
GKM
Compact rectifier module
GRM
Rectifier module
LTE
GSM
Rectifier module with fuses
LTK
Power part board
LTM
Power part module
LTR
Backplane of power part plugin unit
HAE
Auxiliary drive plug-in unit
HAK
Auxiliary drive board
LUM
Interconnection module
HAR
Backplane of auxiliary drive

plug-in unit
LVM
Air distributor module
HLM
Auxiliary drive logic module
LVT
Distribution box
HSK
Main drive control board
HSQ
Sheeter
MAE
Motor drive plug-in unit
HTM
Auxiliary drive driver module
MAR
Motor drive backplane
HVK
Main current distributor board
MCM
Microcontroller module
HWI
Encoder
MEE
Motor drive/electronic plug-in

unit
MID
Press display
IDS
Encoder
MK
Measuring head
ITF
Terminal interface
MOT
Motor drive board
ITM
IGBT driver module
MRK
Motor regulation board
IWM
Earth-leakage monitor module
MRM
Measuring bar computer

module
KID
Compact information display
MSK
Motor control board
KKM
Heat sink module
MSM
Measuring bar sensor module
KLM
Compact power module
MWE
Measured-value acquisition
board
KNT
Compact power supply unit
MZK
State indication board
KOK
Communication board
KVM
Terminal amplifier module
KVT
Heat sink unit
432
Abbreviations
Abbreviation
Description
Abbreviation
Description
NAM
Mains connection module
SBM
Power bridge module
NEK
Electronics supply board
SDM
Servo-drive pushbutton module
NSM
Supplementary module of
power supply unit
SEK
Safety input board
SEM
Interface input module
NTE
Power supply plug-in unit
SIK
NTK
Power supply board
Actual current measuring

board
NTM
Power supply module
SLA
Suction air control
NTR
Power supply backplane
SLM
Pile power module
NVK
Mains supply board
SLT
NVM
NV-RAM module
SM
Stepper motor
NVTE
Power distributor of
electronic plug-in unit
SMM
Current measuring module
SMR
Stepper motor control board
SNT
Chopper-type power supply

unit
SPM
Memory analog board module
SPR
Voltage regulator
SPW
Voltage selector switch
PBK
Back-up battery board
PD
Printer
PEK
Extension board for plate

image reader
PRZ
Processor board
SRK
Power converter board
PRM
Plate position detection module
SSA
Serial interface adapter
PSL
Positioning lamps
SSE
Servo-drive plug-in unit
PSM
Profibus interface module
SSK
Servo-drive control board
PU
Printing unit
SSM
Servo-drive distributor module
SSR
Backplane of servo-drive plugin unit
STA
Interface adapter
STK
Pile control board
STL
Pile power part
STM
Pile control module
REE
Computer plug-in unit
REK
Processor board
REM
Register module
RER
Backplane of computer plug-in

unit
RGP
Computer motherboard
STS
Vacuum cleaner
RRM
RGP computer module
STT
RSK
Plug-on control board
Supporting element of power

converter
RSM
Plug-on control module
SUM
Signal conversion module
RWK
Backplane
SVK
Control voltage distributor

board
SVM
Interface distributor module
SVT
Connecting part of power

converter
SW
Voltage fluctuation relay
SWM
Setpoint module
SAK
Memory analog board
SAM
Interface output module
SAS
Busbar system
433
Abbreviations
Abbreviation
Description
Abbreviation
Description
TAM
Button and display module
ZRM
ZSK computer module
TEM
Tacho input module
ZSG
Central control cabinet
TLK
Transistor power board
ZSK
Central control board
TML
Terminal
ZSP
Central control console
TMP
Buttons for manual positioning

of measuring head
ZT
Zenith terminal
ZTK
Central control board
TRK
Transistor control board
TRM
Transistor control module
TSK
Driver/interface board
TSM
Dryer control module
TTK
Transistor driver board
TUM
Keyboard coding module
TVK
Key distributor board
TVM
Encoder distribution module
TVS
Tacho signal distribution

system
UFK
Filter board
USM
Interconnection module
UVM
Converter and distributor

module
VEN
Fan
VMM
Distributor for measuring

module
VP
Distributor board
VSM
Amplifier module
VTL
Distributor board for diskette

drives
VTR
Distributor board
VVK
Ballast supply board
WDM
Resistance decade module
ZID
Control console display
ZMM
Double current-measuring
module
434
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
LVT
PU1
Distribution box
1st distribution box

(main distributor)
Example 2: 1S3
1
Printing unit 1
Switch
here: pushbutton Forward
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
Printing unit 1
Printing unit 2 or coating unit
...
11
Feeder
12
Delivery
13
Central control console
14
Sheeter HSQ
15
Central control cabinet ZSG
16
Extension control cabinet ESG
20
Dryer
101
Control unit CPC1
10
Example:
Position codes on a Speedmaster
15
4
12
101
13
11
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
Technical data, 33
Adjustment of printing pressure 1...nM5, 85
Interconnection diagram for CU, 89
Interconnection diagram for PU, 88
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
Interconnection diagram 1M7, 99
Precision adjustment of pull lay, 97
Technical data, 98
Admission of pressure, pneumatic system 15Y11
Pin assignment, 352
Task, 351
Air supply cabinet E8, 381
Automatic misalignment control 11M7
Activation and inactivation, 252
Block diagram, 251
Graphical representation, 253
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

Block diagram, 238
Graphical representation, 240
Preset version, 247
Technical data, 247
Sheet arrival control, 239
Standard version, 241
Technical data, 241
Autoplate, 267
Block diagram, 269
Fault display, 268
Method of functioning, 267
Sequence of functions, 270
auxiliary pile detection 11B11
connection, 150
layout, 149
removal- and installation, 150
setting, 151
auxiliary pile motor 11M2
layout, 146
pin assignment, 148
Technical specifications, 147
auxiliary pile motor 12M2
layout, 192
pin assignment, 194
Task and function, 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
Layout and task, 362
Pin assignment, 363
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
setting, 159
bottom main pile limitation 12S34
setting, 205
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
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
Pressure relief valve of oil pump, 342
Triggering a lubrication process, 341
Service display, 330
changeover fast/slow 12B65
connection, 196
layout, 195
-Removal and installation, 196
Circumferential register SM/CD 102, 314
Coarse register monitoring, 271
Adjustment, 273
Connection, 271
Layout, 271

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
Printing unit/coating unit, 420
Cooling and circulating unit E40, 325
Cover guide height adjustment 1M4, 67
Positioning, 67
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
connection, 202
layout, 201
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
E
Encoder, Place of installation, 388
Encoder IDS, 388
Installation variants, 390
Pin assignment, 389
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
Pile stops 11M11/11M12, 59
Sheet joggers 12M6/12M7, 110
Sheet slowdown/format adjustment 12M5, 104
Suction head/format adjustment 11M6, 53
G
Grease lubrication, 333
Lubrication monitoring 1 12B47, 348
GRM Rectifier module, Central control cabinet ZSG,
396
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
L
Lateral register SM/CD 102, 311
Level in coating pan LB32, 371
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
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
technical specifications, 141
main pile motor (standard) 11M1
Layout, 143
pin assignment, 145
Index
main pile motor 12M1 (Preset)

layout, 186
pin assignment, 188
main pile motor 12M1 (standard)
layout, 189
pin assignment, 191
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
Task, 304
Monitoring the IR slidein dryer, Switches 12S9, a,
b, c, 380
Motor for grease lubrication
Pin assignment, 345
Motor terminal board, 15
Motors
Blower motor for powder spray device 12M35, 377
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
Operators controls, Location diagrams, 423
P
Pan roller motors 1...nM1, 321
Pile centering, 17
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
Technical data, 23
pile height control 12B69
connection, 199
Layout, 198
setting, 200
Pile merging, 31
Adjustment of pile support plate 11M8, 31
Fault message, 60
Prepiling, 60
Technical data, 61
Pin assignment
Servodrive diagonal register M4 SM/CD 102, 309
Coarse register monitoring, 271
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),
Pressure sensor pneumatic system 15B14
Pin assignment, 354
Printfree margin 1M2/1M3
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
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
Sensor Pile centering 11B10, 20
Check, 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
Level in coating pan LB32, 371
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 pile support plate 11M8, 33
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
Pile centering 11M9, 21, 23

Suction head height adjustment 11M5, 40
Servodrive diagonal register SM/CD 102, 308
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
Adjustment, 219
Block diagram, 210
Misalignedsheet display (trend display), 214
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
Fault message, 111
Technical data, 112
Sheet monitoring, 259
Sheet travel monitor 1...nB48/1...nB48a, 259
Sheet slowdown / format adjustment 12M5
Technical data, 106
Fault message, 105
Sheet travel monitor 1...9B48/1...9B48a, 259
Adjustment, 263
Components, 263
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

Suction head height adjustment 11M5, 39, 40
Technical data, 40
Suction head height control, 39
Suction head height adjustment 11M5, 39
Fault message, 54
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
Washup solution container, Warnings, 298
Block diagram, 297
Layout, 299
Pin assignment, 300
Sensors B1, B54, B55, 301
Task, 300
Warnings, 298
T
Temperature control, SM/CD 102. Siehe
FarbwerkTemperierung
U
upper main pile limitation 11B33
connection, 153
Layout, 152
removal and installation-, 153
setting, 154
V
Varnish supply unit E4a, 369
W
Washup brush motors M43, M50 ... M56, 296
Pin assignment, 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
Z
Zentralschmierung, Oil lubrication, Circular
lubrication, 340
Zero position
Servodrive diagonal register SM/CD 102, 310

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Important safety instructions

Observe the general and press-specific safety

Observe these handling instructions when

Handling and replacing electronic boards

Protective measures for ESDs

M1 Direct-current main motor

M1 Brushless main motor

11B10 Pile centering

11M9 Pile centering

11B55 Inactivating pile centering

11M8 Adjustment of pile support plate

Suction head height control

11M5 Suction head height adjustment

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.

Feeder pile control

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

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

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

1...nB48/ 1...nB48a Sheet travel monitor

Plate clamping device

1...nB53 Coarse register monitoring

Control by command Washup

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

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

Loosen the retaining screws ( but do not

If the brush-rocker ring was turned