01 P40s Alfons Haar Complete Manual

Machine values
Eccentric Press
Type: CNC-DF3-P40s Mk5.1
Machine No. 4113
Year of Construction 2006
Simmons
Machine values
Table of Contents
1 MACHINE CODINGS 3
2 TECHNICAL DATA 3
2.1 CAPACITY 3
2.2 RAM 3
2.3 ENERGY SUPPLY 4
2.4 SOUND LEVEL MEASUREMENT 4
2.4.1 NO-LOAD OPERATION 4
2.4.2 CREAKS OF THE GEAR 4
2.4.3 LOAD OPERATION 4
2.5 WEIGHTS AND MEASURES 5
2.5.1 W EIGHTS 5
2.5.2 MEASURES OF THE PRESS 5
3 SETTINGS 6
3.1 MACHINE PARAMETERS 6

3.2 SWITCHING POINTS 8
3.3 SYNCHRONIZATION VALUES 9
3.4 ADVANCE 9
3.5 DIES 10
3.6 SHEET LUBRICATION 10
3.7 DISPLAY 10
3.8 SERVICE DISPLAY 10
4 PRESSURE VALUES 11
5 ASI-SLAVE-LAYOUT 12
5.1 ASI-SLAVE KEY PLAN 12

5.2 LIST OF ALL INSTALLED ASI-SLAVES 13
5.3 LIST OF ALL INSTALLED BRIDGES 14
4113 - 2
Machine values
1 Machine codings
Machine No.: 4113
Type of machine: DF3-P40s
Control program: Mk5.1
Program version / Date: ADEFRTC Mk5.1-1.000 / 07.04.2006
Year of construction: 2006
Edition:
2 Technical data
2.1 Capacity
Compressive force: 400 kN
Speed: 240 strokes/min
Drive rating: 15 kW
Type of drive: AC
2.2 Ram
Length of ram stroke: 120 mm
Range of ram adjustment: +25 mm
4113 - 3
Machine values
2.3 Energy supply
Pressure: 6 bar minimum
Supply line diameter: ¾“ , inside diameter
Voltage: 3x400 V
Frequency: 60 Hz
Type of current: 3-phase AC
Fuse, supply side: 100 A
2.4 Sound level measurement
2.4.1 No-load operation
Sound power level: 97 dB(A)
Measuring surface sound level: 76 dB(A)
2.4.2 Creaks of the gear
2.4.3 Load operation
4113 - 4
Machine values
2.5 Weights and measures
2.5.1 Weights
Structural component Weight [kg]
P40s 13500
Advance system DF3 2000
Loading table DF 400
Control cabinet 630
2.5.2 Measures of the press
Height [mm]: 3050
Length [mm]: 4160
Width [mm]: 1700
4113 - 5
Machine values
3 Settings
3.1 Machine parameters
Parameter Description Value

01 Machine coding 06
02 Language 001
03 Rotational direction of resolver 11
-1
04 Maximum speed [min ] 250
05 Motor type 14
06 Negative speed correction at max. speed 11
07 Jam check, sensitivity 100
08 Jam check, restart 200
09 Safety bar / backgear 10
10 Central lubrication, monitoring time 115
11 Central lubrication, high-pressure period 05
12 Central lubrication, pause 60
13 Lower destacker suction cups 120
14 Destacker suction cups, fixing 100
15 Lower pre-destacking suction cups 070
16 Pre-destacking suction cups, fixing 050
17 Sheet destacking nozzles, blowing time 150
18 Sheet transit monitoring 05
19 Sheet setting 100
20 Ejector correction 30
21 Synchronisation correction 50
22 Pitch L-axis 40.96
23 Pitch X-axis 40.96
24 Pitch Y-axis 40.96
25 Software limit L+ 1520.00
26 Software-limit X+ 0315.00
27 Software-limit Y+ 0945.00
28 L-zero position 106.00
29 X-zero position 000.00
30 Y-zero position 000.00
31 Toothed rack 000.00
32 Delay swing in / Drawing compound coating, drive 01
33 Operating mode, back-up (JAM) 000
34 Unit of measurement 1
35 Draw cushion lubrication 005
36 Magnetic strip destacking 0
4113 - 6
Machine values

37 Pallet changer 0
38 Temperature monitoring / Die fixation monitoring 000
39 Operation mode: empty pallet 0
40 Operation mode: External control, option 00
41 Number of dies 0
42 DNC-interface, ON / OFF 0
43 Operation mode DNC-interface 0
44 Velocity Y- axis 1
45 Overload MIN 07.0
46 Overload MAX 40.0
47 Offset Overload 000000
48 Factor Overload 088357
49 Correction of swivel grippers 000
50 Delay time opening of the loading grippers 30
51 Blowing time of the nozzles while swivelling 040
52 Delay time between blowing and swivelling 000
53 Pressure marking sensor / Alignment repetition 00
54 Take off servo valve 050
55 Pallet fork to bottom 10
56 Pallet fork lowered free 03
57 Varnish inspection 011
58 Reserve 000
59 Reserve 000
60 Proximity switch of baffle plate / Alignment of sheet block 0
61 Auxiliary insert rail correction 000
62 Lubrication of sheet advance 100
63 reserve 000
64 Adjusting dynamics of the axis 0000
65 Reserve 000
66 Reserve 000
67 Zero parameter 00000000
4113 - 7
Machine values
3.2 Switching points
Cap distributor sheets

Cap distributor strokes
Upper dead center
0°
Ventilation OFF
Die safety device
Knock out OFF
Clutch STOP
Blow out
Ventilation ON
Vacuum pump top die
OFF
270° 90°
Knock out ON
Vacuum pump top die

ON
Die opens Die closes
180°
Bottom dead center

Cap distributor
Ventilation top die
Universal output 1 ON
4113 - 8
Machine values
3.3 Synchronization values

-1
Speed [min ] 240
Die safety device 030
Die closes 150
Die opens 210
Blow out 330
Knock out ON 157
Knock out OFF 203
Ventilation ON 320
Ventilation OFF 020
Vacuum pump top die ON 130
Vacuum pump top die OFF 180
Clutch stop 330
Blowing time [ms] 040
Cap distributor 180
Cap distributor strokes 0
Cap distributor sheets 0
Ventilation top die 350
Blowing time ventilation upper die 000
[ms]
Universal output 1 ON 180
Signal length universal output 1 180
3.4 Advance
Number of program 01
Punches X 02
Punches Y 07
Start position X 0065.00
Start position Y 01000.00
Step X 110.00
Step ½X 055.00
Step Y 090.00
Start position L 0750.00
X transfer correction 0.00
Misprints 0
4113 - 9
Machine values
3.5 Dies
Number of dies 5
Pressure preset 40
3.6 Sheet lubrication
Sheet lubrication 01
Varnish inspection 1
Relevel 0.3
Pallet changer -
Sheet brake 095
3.7 Display
Start Synchro L
Synchro L strokes
L-Vmax
X-Vmax
Y-Vmax
Hours system 147
Hours press 19
3.8 Service display
Type ADEFRTC MK5:1- 1.000

Date 07.04.06
4113 - 10
Machine values
4 Pressure values
System pressure
Pressure switch system pressure
Counter balance cylinder
Pressure switch counter balance cylinder
Sheet alignment X
Sheet alignment Y
Pressure separation cylinder
Vacuum separation cylinder
Pressure pre separation cylinder
Vacuum pre separation cylinder
Blow out product
Blow out product front side
Blow out product back side
Stripper
Ejector
Ventilation upper die
Vacuum upper die
Ventilation lower die
Pressure draw cushion
Pressure switch - draw cushion
Advance gripper monitoring device
Loading gripper monitoring device
Sheet brake
Advance gripper close
Advance gripper swing in
Overload safety device - hydraulic
Overload safety device - pneumatic
Loading aid lift, left
Loading aid lift, right
Blow-out nozzle auxiliary insert rail, left
Blow-out nozzle auxiliary insert rail, right
Open skeleton transport
Close skeleton transport
Pressure holding gripper
Pressure lining
Pressure switch lining
Pressure destacking cylinder
Pressure pulsed waste ejector
Vacuum sucking pad alignment
Clearing air sheet stops
4113 - 11
Machine values
5 ASi-Slave-Layout
5.1 ASi-Slave key plan
201 202
108
107
106
109
114
113
115
203
101 205
102 204
116
103
117
104
118
105
119 120
110
121
4113 - 12
Machine values
5.2 List of all installed ASi-slaves
Liste der installierten ASi-Slaves

List of all installed ASi-Slaves
Kunde:
Customer: Simmons. 4113
Name: Datum:
Name: CNC-DF3-P25 Mk5.0 Date:
IO ID Typ IO ID Typ IO ID Typ IO ID Typ
X SLAVE 101 7 0 S X SLAVE 109 7 F L X SLAVE 117 7 F L SLAVE 125
X SLAVE 102 7 0 S SLAVE 110 7 0 S X SLAVE 118 7 F L SLAVE 126
X SLAVE 103 7 0 S SLAVE 111 SLAVE 119 7 F L SLAVE 127
X SLAVE 104 7 0 S SLAVE 112 X SLAVE 120 7 0 S SLAVE 128
X SLAVE 105 7 0 S X SLAVE 113 7 F L X SLAVE 121 7 0 S SLAVE 129
X SLAVE 106 7 F L X SLAVE 114 7 F L X SLAVE 122 SLAVE 130
X SLAVE 107 7 F L X SLAVE 115 7 F L X SLAVE 123 SLAVE 131
X SLAVE 108 7 F L X SLAVE 116 7 F L SLAVE 124 SLAVE 132
X SLAVE 201 7 F L SLAVE 209 SLAVE 217 SLAVE 225
SLAVE 206 SLAVE 214 SLAVE 222 SLAVE 230
Doppelslaves / double- slaves

Adresse 1/Addr.1 Adresse 2/Addr. ASI- Kreis/circle Adresse 1/Addr. Adresse 2/Addr. ASI- Kreis/circle
2 1 2
...................... ...................... ...................... ...................... ...................... ......................
...................... ...................... ...................... ...................... ...................... ......................
...................... ...................... ...................... ...................... ...................... ......................
...................... ...................... ...................... ...................... ...................... ......................
4113 - 13
Machine values
5.3 List of all installed bridges
Liste der installierten Brücken

List of all installed Bridges
Kunde:
Customer: Simmons 4113
Name: Datum:
Name: CNC-DF3-P40s Mk5.1 Date:
Nr. Feldgeräte- Kennzeichen Eingang (Slave)
element designation input (slave)
1 A 103 103E1
2 A-106 106E6
3 A 107 107E2
4 A 107 107E3
5 A-203 203E3
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
4113 - 14
Operation Manual
Introduction
Introduction
This documentation is created for authorized specialists. It applies to the product named in the title, which
may only be installed and operated in accordance with this documentation.
Possible changes to the product by the user are not subject to the manufacturer’s inspection. It is
therefore recommended to check the correspondence of the specifications in this documentation with the
actual product prior to operation or intervention. If deviations or ambiguities are detected, we kindly ask
you in your own interest to notify Alfons Haar immediately.
The pre-requisite for operation or intervention is the strict observance of current national, local and user-
based safety regulations.
These documents are copyrighted. They are intended for personal information only and may not be
copied, duplicated, distributed or made accessible to third parties. Manufacture on the basis of these
documents without express authorization is also not permitted.
The product names used in this documentation are in part brand names, trademarks or registered
trademarks of the specific owner.
Subject to change without notice.
2
Introduction
Table of Contents
1 CD-ROM DOCUMENTATION 4
1.1 SCOPE OF DOCUMENTATION 5

1.2 COPYRIGHT 6
2 PREFACE 7
3 DESIGNATED USE 8
4 SAFETY 9
4.1 SYMBOLS 9
4.2 OPERATING INSTRUCTIONS 11
4.3 SAFETY DEVICES 12
4.3.1 MASTER SWITCH 12
4.3.2 EMERGENCY OFF BUTTON 13
4.3.3 PROTECTIVE COVERS AND SCREENS 14
4.4 WORKING WITHOUT SAFETY EQUIPMENT 16
4.5 SOURCES OF RISK 17
4.6 INSTRUCTIONS FOR MAINTENANCE AND SERVICE 18
4.7 OBSERVING ENVIRONMENTAL PROTECTION REGULATIONS 20
5 INSTALLATION 21
5.1 DELIVERY 21
5.2 TRANSPORT 22
5.3 REQUIRED SPACE 23
5.4 SET UP SURFACE 23
5.5 ASSEMBLY INSTRUCTIONS 24
5.5.1 INSTALLATION OF THE PRESS 24
5.5.2 INSTALLATION OF THE ADVANCE TABLE 26
5.5.3 CONNECTIONS 27
6 CHECKLIST FOR PUTTING INTO OPERATION 28
3
Introduction
1 CD-ROM documentation
The documentation from Alfons Haar Maschinen is generally

supplied on CD-ROM. All documents are stored on this CD-ROM.
The CD-ROM was optimized for the operating systems

MICROSOFTä WINDOWS 95, 98, NT, ME.
Use of the CD-ROM requires a PLUG-IN Internet browser (such as
MS Internet Explorerä or Netscape Communicatorä) and the
software ADOBE ACROBAT READERä. If the viewing software
has not yet been installed on the computer, the installation files can
be found on the CD-ROM in the subdirectory /SOFTWARE/.
The CD-ROM documentation can also be run under other operating
systems such as Linuxä, Unixä, Macä. The software required for
viewing, however, is not contained on the CD-ROM.
STARTING THE CD-ROM The CD-ROM will start automatically after insertion. If the AUTO-
START function for WINDOWSä is deactivated or another
operating system is used, the file START.HTM must be opened
from the main directory of the CD-ROM. Click on the AH logo on
the opened page.
NAVIGATION To navigate within the CD documentation the mouse pointer must

be placed on the desired menu items or symbols. Click on the left
mouse button when the mouse pointer is on the desired location.
The submenu or the desired file will open automatically.
Additional information on navigation in the Internet browser can be

found in the ONLINE ASSISTANT for the specific software.
PRINTING PDF FILES Every individual PDF file can be printed on any WINDOWS system
printer for internal use.
The drawings on the CD-ROM have all been optimized to a

maximum format of DIN-A3. This makes it possible to print out
large drawings on A4 and A3 printers. Because the PDF format can
be adjusted to any page size, it is also possible to make printouts
on larger paper formats.
NOTE:
When printing with a resolution of more than 300dpi, the printing

resolution should be reset to no more than 300dpi in the printer
driver to print out drawings. This will ensure that the lines on the
printout are darker.
4
Introduction
1.1 Scope of documentation
The following documents are supplied:
On CD-ROM:
· Operating instructions
· Parts lists and drawings of the mechanical components
· Parts lists and drawings of the electrical components
· Documentation of add-on equipment from other manufacturers
· CE conformity statement (for deliveries within the EU)
Optional on CD:
· Documentation of sequential machinery (such as video

inspection systems, furnaces, etc.), if ordered from Alfons Haar
and the manufacturer’s documents are available in a format
compatible with CD-ROM.
On paper:
· 1 folder with operating instructions

· 1 folder with electrical diagrams
· 1 folder with pneumatic diagrams
Optional on paper:
· Documentation of add-on equipment from other manufacturers

if they are not available in a format that is compatible with a CD-
ROM.
· Documentation on sequential machinery (such as video
inspection systems, furnaces, etc.) if ordered from Alfons Haar
and the manufacturer’s documents are NOT available in a
format compatible with CD-ROM.
5
Introduction
1.2 Copyright
The supplied documents on CD-ROM are copyrighted. They are

intended for personal information only and may not be distributed
or made accessible to third parties. Manufacture on the basis of
these documents without express authorization of AH is not
permitted.
Making copies of the CD-ROM or the data contained within is

permissible for internal use.
PROVIDING THE CD DATA In general it is possible to copy the data from the CD-ROM on a
IN AN INTERNAL NETWORK network or INTRANET server for internal use. Making local copies
OR INTRANET at workstations without a network link is also permitted.
To make the data available, the entire contents from the CD-ROM
subdirectory /DOKU/ must be copied in an empty directory on the
server or the internal hard drive. The menu support system can
then be started by calling up the file START.HTM.
6
Introduction
2 Preface
This manual follows the principle of the machine concept. This

concept is one of a modular structure and hybrid technology -
hybrid in the sense of a complete integration of mechanics and
electronics.
Each chapter of the manual describes the entire operation of each
machine module, without subdividing it according to its mechanical
and electronic functions. Setting up, maintenance and, where
appropriate, the programming of the module are all described in
the same chapter.
Consequently, the chapter on the control system is confined to the
technical details of the components used and to their adjustment.
The description of the control panel does not fit into this pattern. It
is the interface between man and machine and is linked to all the
parts of the machine. Therefore all the possible functions are
summarised again in that chapter.
7
Introduction
3 Designated Use
The CNC controlled sheet-feed press is designed for the

automated cutting and drawing of ends, cups and lug-caps.
DANGER:
If the machine is used contrary to its designated use, personal

injury or damage to property can occur.
The user is obliged to operate the machine only when it is in good

working order.
Unauthorised conversions or modifications of the machine are not

permitted.
The admissible load parameters must not be exceeded.
8
Introduction
4 Safety
4.1 Symbols
The following symbols are used in the operating manual to draw

attention to text of special note.
DANGER:
This symbol indicates the possible risk of death, injury and/or

property damage.
CAUTION:
This symbol indicates a possible risk to the machine, material and

the environment.
DANGER:
This symbol indicates the possible risk of death, injury and/or

property damage while working on the electrical system.
CAUTION:
This symbol indicates a possible risk to the machine, material and

the environment while working on the electrical system.
ADJUSTMENT:
Indicates mechanical adjustment.
NOTE:
Additional information and tips.
9
Introduction
The most important aim of the safety instructions is the prevention

of personal injury.
n The word “Danger“ above safety instructions indicates risk of

personal injury. The possibility of risks to the machine, material
and environment cannot be excluded.
n The word “Caution“ above safety instructions indicates that
there is no direct risk of personal injury.
The symbols used here cannot replace the text of the safety
instructions. The text must always be read completely!
10
Introduction
4.2 Operating instructions
The press was designed and built on the basis of a risk analysis
and the careful selection of the harmonised standards that must be
observed, as well as other technical specifications. It complies with
the current state of the art and permits a high degree of safety
during operation.
However, machine safety can only be implemented in actual
practice when all required measures are taken. It is subject to the
due care and diligence of the operator of the machine to schedule
these measures and to ensure they are carried out.
Qualification The operation, adjustment and maintenance of these machines may

be carried out by trained personnel only. Specialised knowledge must
be obtained by training at regular intervals.
Our specialised mechanics are available on request for repair and

service work. This makes it possible to avoid errors that may
occur as a result of improper work.
Safety Operators, setters and service personnel must receive instruction

regularly from the operator on all safety matters concerning the
machine, with special emphasis on current safety regulations.
This also applies to safety regulations that only apply for the user and
which are not specified in this manual.
Required personal safety equipment must be made available to and
worn by all operating, maintenance and repair personnel.
Supervisory duty The operator must report any changes affecting safety without delay to
supervisors. In addition, the operator must ensure that no
unauthorised persons remain in the area of the machine.
Noise protection The operation of the eccentric press can result in very high noise
levels. Appropriate noise protection measures should be taken.
11
Introduction
4.3 Safety devices
The safety devices are part of the standard equipment of this

machine.
They serve to protect health and life. Anyone who disables the
standard safety devices does so at his own risk.
PLEASE NOTE:
All protective safety devices should be inspected at regular

intervals for proper function, condition and completeness. These
inspections should be carried out once a week.
4.3.1 Master Switch
Hauptschalter The power supply of the machine is turned on and off by means of
an individual master switch.
0 The master switch is always located on the left side wall when the
machine is viewed from the operating side of the control cabinet.
This master switch can be locked in the O-position (OFF) with a
padlock to protect it from being turned on inadvertently.
PLEASE NOTE:
When working at dangerous areas of the machine, always turn

the master switch of the machine to "OFF" and lock the switch
with a padlock so that it cannot be turned on again.
DANGER:
Even when the master switch is turned off, individual parts in the
interior of the control cabinet are still live. This involves, among
other things, the mains cable from the electric power supply to the
master switch as well as the capacitors of the advance drive.
12
Introduction
4.3.2 Emergency OFF Button
This machine is equipped with one emergency OFF switchs. It is

located at the control cabinet.
In accordance with regulations, the emergency OFF switch is a red

switches with self-stopping positions on a yellow background.
Upon activation of the emergency OFF function, all drive motors of

the machine (main drive, forward feed drives etc.) are immediately
cut off from the current supply.
DANGER:
The flywheel is not braked when the emergency OFF function is

activated. For this reason, the access doors in the protective
screens cannot be opened after the emergency OFF button has
been pressed. See the section "Protective Covers and Screens"
below for more information on this point.
Activation of the emergency OFF To activate the emergency OFF function the red button must be
function. pressed until it snaps into the emergency OFF position.
PLEASE NOTE:
In order to reverse the emergency OFF function, the emergency

OFF button must be pulled out until it snaps into position audibly.
As an option, the machine can also be equipped with an

emergency OFF button with a key lock. In this case, the button
cannot be unlocked without a key.
Modules and machine components which are not operated or

controlled by means of the AH MICROGUIDE control unit of this
machine are not connected to the emergency OFF button circuit!
In case of systems which include more than one AH machine,
each individual machine has its own emergency OFF button circuit.
Activating the emergency OFF button of any machine does not
stop the other machines.
13
Introduction
4.3.3 Protective Covers and Screens
Protective covers and screens protect the persons using the unit
from incurring bodily injury at dangerous machine areas.
The following types of protective covers and screens are used with
this machine:
Protective covers and screens: Protective covers and screens are permanently attached to the
machine or its components. Some of these protective safety
devices are also attached permanently to the machine base by
means of anchoring bolts.
Adjustment and maintenance work on the machine does not

require protective safety devices.
Maintenance openings: Maintenance openings are any dismantling of protective covers and
screens which need be opened or removed only for specific
adjustment and maintenance work. It is not necessary to open or
remove those protective safety covers during normal operation of
the machine.
Proper tools are required to open or remove these protective

covers. Door locks with keys are mounted on some of the
protective screen doors. The proper key must be used to open
these doors.
The maintenance door at the advance system is locked with a

safety lever which is closed from outside only and which cannot be
opened from inside the advance cage (drawing M-9108). The
machine can only be operated, if the lever is locked; if the lever is
unlocked during operation, the machine is stopped at once.
DANGER:
The master switch of the machine should always be turned off

and locked in the 0-position with a padlock before these
protective safety devices are opened or removed.
Access openings with safety control Access openings or protective screen doors which can be opened
systems: by the operator during normal operation of the system in order to
correct errors are equipped with a safety switch. Opening these
protective safety devices immediately switches off all drive motors
in the respective access area.
It is not possible to turn on the drive mechanisms when the
protective safety devices are open.
PLEASE NOTE:
Even though opening the access doors automatically turns off the
drives, the main drive and the forward feed drives should
nevertheless always be turned off beforehand.
14
Introduction
Access openings with safety control Access openings and screens in the pestle and tool area which can
systems and mechanical door blocks: be opened by the user during normal operation in order to correct
errors have a safety switch with an automatic door block.
These safety devices are monitored by Schmersal switches which

use a safety contact and a mechanical block for each door (Figure
1).
Fig. 1: Schmersal Safety Switch
The mechanical door block can only be released when the main
drive has been stopped. It is thus impossible to open the doors
when the machine is operating.
To ensure this safety status, the control system is equipped with a

stop sensor which detects rotation of the flywheel.
DANGER:
It is not possible to open safety covers which are equipped with

mechanical door blocks after the emergency OFF button has
been pressed. Access to the tool space is not permitted after the
emergency OFF button has been pressed, since this does not
brake the flywheel!
In case of emergency, however, the mechanical door block can
be overcome by exerting increased physical force. The locking
bolt is equipped with a predetermined breaking point for this
purpose. However, opening it by force destroys the protective
safety switch.
15
Introduction
4.4 Working without safety equipment
DANGER:
When safety equipment is taken out of operation, the work to be

performed holds an especially high risk. It is of utmost importance
to note that switching off the machine or bypassing safety
equipment is not normal operating mode.
n Carry out a technical risk assessment before starting work.

n Ensure that additional protective measures are taken which are
appropriate to protect the health and life of all those present
(e.g. barriers, blockades, warning devices, protective insulation,
etc.).
n After conclusion of work check all safety equipment for
completeness and proper function.
n Conduct a trial run to obtain release for normal operation.
16
Introduction
4.5 Sources of risk
DANGER:
Careless behaviour creates dangerous situations in all machine

areas and materials.
Control cabinet Even if the main switch has been turned off, some lines in the control
cabinet are still live. These lines are hazardous. Observe all warning
signs.
Inside area Only authorised persons may open the doors to the inside of the
machine.
Compressed air The supply of compressed air does not stop when the machine is
switched off. The supply lines and consumers are still under pressure.
Advance drives These drives are characterised by highly dynamic performance.
Drives, general Risk to all motorised machine parts, especially when the machine is
stopped and has not been switched off.
17
Introduction
4.6 Instructions for maintenance and service
Observe all inspection and maintenance intervals specified in

the Operating Manual!
Follow maintenance and repair instructions for the individual
components included in this Operating Manual!
Our specialised mechanics are available by request for

repair and maintenance work. This makes it possible to
avoid errors that may occur as a result of improper work.
Block all access to the machine work area to unauthorised

persons before carrying out maintenance or repair work! Post
notice or sign that draws attention to the maintenance or repair
work!
Prior to the maintenance or repair work, turn off the main switch
to the power supply and secure with a padlock! The key to the
padlock must remain with the person who carries out the
maintenance or repair work!
When replacing heavy machine parts, only use appropriate and
faultless lifting devices and fastening materials!
Environmentally unsafe lubricants, coolants or cleaning agents

must be disposed of properly!
18
Introduction
Repair work to the machine’s electrical systems may only be

carried out by trained electricians!
· Inspect electrical equipment regularly!

· Fasten loose connections!
· Replace damaged lines/cables immediately!
· Keep control cabinet shut at all times! Access is permitted
only for authorised persons with key/tool!
· Never clean control cabinets and other electrical equipment
housings by spraying with a water hose!
Maintenance and repair work to the hydraulic and pneumatic

equipment should only be carried out by specially trained
personnel!
· Prior to carrying out maintenance and repair work release

pressure from the machine’s pneumatic and hydraulic
equipment!
· Replace hoses at regular intervals as a means of preventive
maintenance, even if no damage is detected! (Follow
manufacturer’s instructions!)
· Following maintenance or repair work test the tightness of
screw connections before start-up.
· Replace any covers screens and filters that have been
removed.
Following maintenance or repair work and prior to resuming

production, ensure that all
· materials
· tools
· other equipment
· escaped fluids
required for the execution of maintenance or repair work have

been removed from the work area. Ensure that all safety
equipment functions faultlessly!
19
Introduction
4.7 Observing environmental protection regulations
The statutory specifications for the avoidance of waste and

proper recovery/disposal must be followed during all work on
and with the machine.
Specifically: during installation, repair and maintenance work,

water-polluting substances such as
· Lubricating greases and oils

· Hydraulic oils
· Coolants
· Cleaning fluids that contain solvents
may not pollute the soil or enter the sewer system!

These substances must be stored, transported, collected and
disposed of in appropriate containers!
20
Introduction
5 Installation
DANGER:
From unpacking to setting the machine into operation staff of the

company Alfons Haar should always be present.
NOTE:
When the machine is unpacked and transported, handle the

components with care to avoid damage.
5.1 Delivery
After having been tested at AH the machine is disassembled in

single modules. With the exception of the press support, these
single modules are packed in wodden boxes. Further the single
modules are shrink-wraped into protective film to protect them
against corrosion. The press support shrink-wraped into protective
film is put on wodden beams.
The delivery is executed by trucks (European Continent) or in
several containers (delivery by ship).
In case of delivery, the customer of the machine must keep ready

for unloading suitable means of transport as cranes, fork lifters,
conveyor rollers etc.
On arrival of the machine you should check before unloading

whether there are damages due to the transport.
21
Introduction
5.2 Transport
DANGER:
Select the appropriate means of transport and slings for the

weights to be transported.
Make sure that the weight is evenly distributed!
Informationens about the sling points and the center of gravity of

the single modules can be found on the transport drawings which
are includes on the CD-documentation. They are located in the
menu structure under „DRAWINGS AND SPARE PART LISTS“/
„LAYOUT“ or „TRANSPORT DRAWINGS“.
22
Introduction
5.3 Required Space
The dimensions of the machine can be seen in the PROJECT

LAYOUT which can be found on the CD-ROM. The space required
by the machine is about 15 x 10 m. The layout is located in the
menu structure under „DRAWINGS AND SPARE PART LISTS“/
„LAYOUT“.
5.4 Set Up Surface
n The surface where the machine is to be set up must be level.

n The surface where the machine is to be set up must be able to
support its weight.
23
Introduction
5.5 Assembly instructions
NOTE:
The machine should be installed and assembled by staff of the

company Alfons Haar.
When installing and aligning the machine, accurate and careful

work is of utmost importance.
The most important criterion to obtain the stamping accuracy

guaranteed is to mind the tolerance range with respect to angular
deviations as well as for deviations from parallelism when the
different modules of the machine, such as press and advance
table, are connected.
5.5.1 Installation of the press
The press is mounted on three adjustable vibration dampers. Two

of the dampers are on the left and on the right side (955 mm from
the press centre). The other one is in the middle on the advance
table.
Before the press frame is placed on the vibration dampers, the

dampers should be adjusted to a height of 70 mm. When this is
done, the press is placed on the dampers.
When aligning the machine, make sure that the tolerated deviation,
measured at two points of the fixing plate with a spirit level, does
not exceed 1/100 mm per meter.
position water level

2nd measurement
position water level

1st measurement
Fig. 2: Measuring points on the fixing plate
24
Introduction
For aligning, turn the adjusting screws of the vibration dampers

clockwise or anticlockwise, depending on the deviation. The
construction of these dampers allows fine adjustment in the 1/100
mm range. Self-locking ensures that the position will not shift due
to vibratory stresses. The maximum adjustment range is 10 mm.
Type : PK3-B H
Load daN/damper. : 2000
L mm : 200
B
B mm : 95
H mm in centre position : 64
L
Range of adjustment : 10
Fig. 3: Vibration damper
25
Introduction
5.5.2 Installation of the advance table
For mounting and fixing the advance table place it on the surface
cut into the fixing plate and bolt it.
To ensure exact centring of the advance table with respect to the

press's centre, the table has been pinned in the fixing plate before
dismounting. Therefore it is unnecessary to centre the table again
when the machine is installed.
NOTE:
It should be checked with a feeler gauge that the advance adapter

is in exact alignment with the surface cut into the fixing plate in
both directions.
Angular deviation of the axes in production direction as well as an
inclined position of the advance table can thus be excluded.
After bolting, the advance table must only be levelled out by means
of an adjustable foot under the Y-axis. For doing so, one of the
guide rails of the Y-axis should be used as a measuring surface.
Afterwards, the alignment of the press should be checked once

more and readjusted if necessary.
26
Introduction
5.5.3 Connections
Establish the pneumatic connections between the advance unit

and the loading table to the pneumatic unit. Connect the pneumatic
unit to the compressed air supply system.
Operate all valves manually to check their function.
Control cabinet Install the control cabinet and place the cables inside the cabinet.
Take care that the cables run neatly.
DANGER:
Only allow authorised electrical personnel to make electrical

connections of the machine.
DANGER:
Before the machine is switched on, all safety devices must be

mounted and their function must be checked.
Function check Check the function of all input signals (proximity switches, limit
switches, guard doors).
27
Introduction
6 Checklist for Putting into Operation
Safety n All coverings are closed.

n No people or work devices in the area of the dies or of advance
system.
Supply n Electric connection functioning.

n Pneumatic pressure for system pressure (6 bar) present, shut-
off valve is open.
n All connections checked.
Operating state n Rotation speed adjusted.

n Error-free start of control after main switch has been switched
on.
Lubrication n Oil filled in.

n Manual lubrication points lubricated.
n Central lubrication ready for operation.
Connections n Performance parameters adjusted.

n Machines connected on the input and output sides ready for
operation.
Tools n Adjusted to the product.

n Dies in work position.
n Upper and lower dies are aligned relative to another and to
feeder.
Finally, the comprehensive functioning of the system must be

checked by running the whole system without sheets at full speed.
The controller internally simulates the signals that are normally
triggered by sheets.
All errors that occur unexpectedly during the test run must be
immediately examined and eliminated.
If no errors occur, production can be started now.
28
I. Operation
I. Operation
Content
1 CONTROL AND DISPLAY DEVICES 4
1.1 CONTROL CABINET 4

1.2 CONTROL AND DISPLAY PANEL 5
2 COMMISSIONING 7
2.1 SWITCHING ON THE CONTROL UNIT 7

2.2 START UP SEQUENCE 8
2.3 SWITCHING OFF THE CONTROL UNIT 12
3 FUNCTIONS OF THE HARDKEYS 13
3.1 MAIN DRIVE AND CLUTCH 13

3.1.1 SWITCHING ON THE MAIN DRIVE 14
3.1.2 NORMAL DRIVE MODE 14
3.1.3 SINGLE STROKE MODE 15
3.1.4 CRAWL GEAR (TURN MODE) 16
3.1.5 SWITCHING OFF THE MAIN DRIVE 18
3.2 ADVANCE DRIVES 19
3.3 DISCHARGE 20
3.4 FEEDING 21
3.5 ACKNOWLEDGEMENT / CLEAR 22
3.6 LANGUAGE 22
3.7 HELP 23
3.8 DIAGNOSIS 24
4 SET UP MODE 25
4.1 SOFTKEY-FUNCTIONS MENU 1 (SET UP MODE) 27

4.1.1 MACHINE TYPE AF-PX 27
4.1.2 MACHINE TYPE DF-PX 29
4.1.3 MACHINE TYPE E-P(V)X, EF-PX 31
4.1.4 MACHINE TYPE OF(2G)-PX 32
4.2 SOFTKEY-FUNCTIONS MENU 2 (MANUAL ADVANCE) 34
4.2.1 MACHINE TYPE AF-PX 34
4.2.2 MACHINE TYPE DF-PX 35
4.2.3 MACHINE TYPE E-P(V)X AND EF-P(V)X 36
4.2.4 MACHINE TYPE OF(2G)-PX 37
5 AUTOMATIC MODE AND SOFTKEY FUNCTIONS 38
5.1 MACHINES TYPE AF-PX, DF-PX, EF-PX, OF(2G)-PX 38

5.2 MACHINE TYPE E-P(V)X 40
I-2
I. Operation
6 DISPLAY MODE 42
6.1 MONITOR 42
6.2 SOFTKEY FUNCTIONS 43
6.3 MENU STRUCTURE DISPLAY MODE 45
6.3.1 MENU STRUCTURE FOR AF-PX-MACHINES 45
6.3.2 MENU STRUCTURE FOR DF-PX-MACHINES 46
6.3.3 MENU STRUCTURE FOR E-P(V)X-MACHINES 47
6.3.4 MENU STRUCTURE FOR EF-PX-MACHINES 48
6.3.5 MENU STRUCTURE FOR OF(2G)-PX-MACHINES 49
7 DATA INPUT MODE 50
7.1 PROCEDURE 50
7.2 SOFTKEY-FUNCTIONS DATA INPUT MODE 52
7.3 MENU STRUCTURE DATA INPUT MODE 54
7.3.1 MENU STRUCTURE DATA INPUT MODE AF-PX 54
7.3.2 MENU STRUCTURE DATA INPUT MODE DF-PX 56
7.3.3 MENU STRUCTURE DATA INPUT MODE E-P(V)X 58
7.3.4 MENU STRUCTURE DATA INPUT MODE EF-PX 59
7.3.5 MENU STRUCTURE DATA INPUT MODE OF(2G)-PX 60
7.4 MACRO OPERATION 61
7.4.1 MACRO-FUNCTIONS 62
7.4.2 ACCESS TO MACRO-FILES BEFORE THE ADVANCE TEST 63
7.4.3 ACCESS TO MACRO-FILES AFTER THE ADVANCE TEST IN SET UP MODE 64
7.5 INPUT OF MACHINE PARAMETERS 66
8 INTEGRATION OF THE LINE 67
8.1 JAM MONITOR 67

8.2 EXTERNAL CONTROL 70
I-3
I. Operation
1 Control and Display Devices
1.1 Control Cabinet
Pos.: Function:
1 Mainswitch (lockable with pad-lock)
2 Emergency Stop
3 Control and Display unit
4 Aircondition unit (optional)
I-4
I. Operation
1.2 Control and Display Panel
HARDKEYS
Help Main drive ON Clutch START
1
Diagnosis Crawl gear * Clutch STOP
3
Keyswitch *
Display mode Main drive OFF
Manual clutch operation
Keyswitch
Data input mode Single stroke mode
Data input
Advance drive
Service language ENTER Acknowledge input
(SERVOS)
2
Automatic mode Feeder drives * CLEAR Delete input
Set up mode Discharge drives ð MORE
Acknowledge
(Reset) ï BACK / RETURN
SOFTKEYS
F1 F2 F3 F4 F5 F6
1
* = inactive on 15 t-presses
2
* = function only available on redraw and trimming presses
3
* = inactive on 15 t-presses / Keyswitch manual clutch operation is mounted on the press frame
I-5
I. Operation
The keys of the control panel are divided into so-called

HARDKEYS and SOFTKEYS.
HARDKEYS HARDKEYS are labeled with pictograms representing their

function. Most HARDKEYS have LEDs in the keys which light up
when the key is active.
SOFTKEYS SOFTKEYS are labeled with characters F1 to F6. The function is

defined by the software and changes according to the machine
operating mode. The actual functions of these keys are displayed
along the bottom of the screen. The SOFTKEYS are not provided
with LEDs. However, when their activation is shown on the display
by invertio. When the key is inverted, the characters appear dark
against a light background, whereas normally they are light against
a dark background.
NOTE:
All keys of the keyboard are components of the AH-Microguide

and therefore they not parts of the electrical drawings.
I-6
I. Operation
2 Commissioning
2.1 Switching on the control unit
DANGER:
Only trained personnel is allowed to switch on the control unit.
The following points should be checked before the control unit is

switched on.
Before the control unit is switched on the following points have to

be checked:
Checklist for commissioning:
n All safety devices must be in place and secured. Missing safety

guards must be installed prior to commissioning.
n No persons are permitted inside the safety guards.
n Remove all parts (sheets, screws, tools, dirt) from the die area
and the sheet guiding surface.
n The advance axes must be in their normal travel range. It is
necessary to push the axes back to the normal travel range if
one of them is located on one of the limit switches.
n Compressed air must be supplied to the press. The pressure
must be at least 6 bar.
I-7
I. Operation
2.2 Start up sequence
SWITCH OFF MAIN SWITCH ON MAIN

SWITCH SWITCH
KEYBOARD
TEST
TEST
AH-MICROGUIDE
FAULT MESSAGE
ON DISPLAY
SERVOS SWITCH ON
F1
DISPLAY MODE F2
F3
CRAWL GEAR F4
F5
F6
START ADVANCE
TEST
START
F1
ADVANCE TEST IN
OPERATION
SET UP MODE
F1 F2 F3 F4 F5 F6
I-8
I. Operation
Switch on The equipment is started up by closing the main switch at the side
of the control cabinet. In response the background light of the
display screen is seen to come on. This light is supplied by the 24V
supply of the machine. This is no indication that the control unit is
being started up.
After switching on the control cabinet the CPU is booting and

performing several self tests before showing the ALFONS HAAR
icon and being ready for use. This booting procedure takes
approximately 90 seconds.
This message is displayed on the screen for a few seconds.
I-9
I. Operation
After a successful boot up sequence the operator will requested to

SWITCH ON SERVOS.
SWITCH ON SERVOS
Switch on Servos The SWITCH ON SERVOS request in CNC machines serves to

test the advance system, which must be done before any other
operation. Before this test is carried out, only the crawl gear of the
press drive and the display functions are active. When the request
has been met and the advance drives have been switched on
without malfunction, the ADVANCE TEST request is displayed.
At the same time the softkey-menu is presented, offering only the

F1 START function key. The advance test is carried out on
pressing the SOFTKEY START and the message TEST
RUNNING is shown on the display.
I-10
I. Operation
START ADVANCE TEST
START
TEST RUNNING
After the test has been completed the message READY is

displayed, i.e. SET UP MODE.
Fault:
At CNC-machines the corresponding FAULT MESSAGE is shown
on the display.
NOTE:
The machine can only be operated by personnel who have a

precise knowledge of the functions available on the control field.
I-11
I. Operation
2.3 Switching off the control unit
Before the main switch of the control unit is switched off it is

necessary to check the following points:
n The clutch of the press is disengaged.

n All drive units must be switched off.
n The flywheel has stopped, the LED in the Hardkey MAIN DRIVE
OFF is solid.
n The machine is in SET UP MODE.
NOTE:
There must be a delay of at least five seconds between switching

the control unit off and back on again. Otherwise the system may
appear to hang after a new switch-on procedure as not all units
(control system, operating panel, drivers) have been properly
reset by the voltage drop.
If the control does not start propperly after switching on, it shall be
switched off for at least 30 seconds.
I-12
I. Operation
3 Functions of the HARDKEYS
3.1 Main drive and clutch
DANGER:
Severe injuries can occur if you attempt to cancel the safety

devices.
This machine is equipped with a three-phase motor to drive the

flywheel. The connection between the flywheel and the crankshaft
is made by a clutch / brake unit. If the clutch / brake unit is not
activated (no pressure) the crankshaft is connected by the brake
unit with the press frame. In this case the flywheel runs free on the
crankshaft. If the clutch is activated the crankshaft is connected to
the flywheel by the clutch / brake unit.
There are two different clutch / brake systems used on HAAR

presses. Depending on the size and the force of the machine the
clutch / brake unit is activated by pneumatic or hydraulic pressure.
n Presses with a maximum force of 400 kN are equipped with a

pneumatic clutch / brake unit.
n Presses with a force of more than 400 kN are equipped with a
hydraulic clutch / brake unit.
For the operation of the press the sort of clutch is of no importance

as the operation steps are the same.
With the exception of the manual turn mode and the crawl mode of
the crankshaft the operation of the main drive and the clutch /
brake unit is done by the control panel which is mounted at the
front side of the control cabinet. The operations “manual turn mode
and crawl mode“ are executed using the twin hand buttons which
are mounted at the press frame.
NOTE:
The main drive can only turn in one direction. Only in the crawl
mode of the crankshaft it is possible to reverse the rotation
direction of the motor.
I-13
I. Operation
3.1.1 Switching on the main drive
There are three diffrent operation modes of the main drive:
n Normal drive mode

n Single stroke mode
n Crawl gear
3.1.2 Normal drive mode
The following requirements must be met to switch on the main

drive:
n The control unit is switched on.

n The machine is in SET UP or AUTOMATIC MODE.
n All safety devices are closed and locked.
n The flywheel is fully stopped.
The main drive can be started as described below if all of the

above mentioned requirements are met.
Switch on the main drive by pressing the HARDKEY MAIN DRIVE

ON. During the accelaration of the flywheel the LED on of the
HARDKEY is flashing. Once the drive reaches its programmed
speed the LED becomes solid.
It is not possible to activate the clutch while the LED is flashing.
Activate the clutch by pressing the HARDKEY CLUTCH START.

The clutch will stay engaged as long as there is no fault which will
disengage the clutch automatically or the clutch is disengaged
manually by pressing the HARDKEY CLUTCH STOP.
NOTE:
It is not possible to engage the clutch if the crankshaft is stopped

between 180° and 340°. In this case the crankshaft must be
turned to the area of UDC-position (upper dead center) for using
crawl gear mode.
I-14
I. Operation
3.1.3 Single stroke mode
The following requirements must be met to switch on the switch on

the main drive in single stroke mode:

n The machine is in SET UP or AUTOMATIC MODE.
n All safety devices are closed and locked.
n The flywheel is fully stopped.
n The advance axes are in their START-POSITIONs.
n The crankshaft position is between 340° and 180°.
The main drive can be started as described below if all of the

above mentioned requirements are met.
Press HARDKEY SINGLE STROKE MODE to activate the single

stroke function of the machine. The LED must be illuminated to
operate the clutch in single stroke mode.
Switch on the main drive by pressing the HARDKEY MAIN DRIVE

ON. During the accelaration of the flywheel the LED on of the
HARDKEY is flashing. Once the drive has reached its
programmed speed the LED becomes solid.
It is not possible to activate the clutch while the LED is flashing.
Activate the clutch by pressing the HARDKEY CLUTCH START.

The clutch is disengaged automatically when the press reaches
the UDC-position.
NOTE:
The clutch cannot be engaged at a crankshaft position between

Zwischen 180° and 340°. To engage the clutch, the ram must be
turned in turn mode up to upper dead center (UDC).
The single stroke function can be activated and deactivated at all

times as long as the clutch is disengaged.
I-15
I. Operation
3.1.4 Crawl gear (turn mode)
There are two different operation sequences for turning the

crankshaft manually:
n Turn mode by hand

1
n Turn mode with motor support *
NOTE:
The turn mode with motor support is only available at presses

with a force of 250 kN and more. The presses with 150 kN are not
equipped with the motor support for the turnmode.
The following requirements must be met to switch on the main

drive in single stroke mode:

n The machine is in SET UP MODE.
n The flywheel is fully stopped, the main drive is switched OFF.
The main drive can be started as described below, if all of the

requirements above mentioned are met.
Turnmode by hand To move the crankshaft by hand the following operations must be
carried out:
Turn the KEYSWITCH MANUAL CLUTCH to activate the manual

clutch button on the press frame. It is not possible to switch on
the main drive or the advance drives, as long as the KEYSWITCH
is activated.
Open the flywheel cover or the cover of the crankshaft access.

Use a TURNBAR or the special TURNKEY to move the
crankshaft while the clutch is engaged. The clutch can be
engaged by pressing the TWIN-HAND-BUTTONS which are
mounted in the tool area of the press.
NOTE:
There are no TWIN-HAND-BUTTONS on presses with a force of

150 kN. These presses are equipped with a single CLUTCH
BUTTON to activate the clutch.
1
* = This function is not available at presses with a force of 150 kN (15 t)!
I-16
I. Operation
Turnmode with motor support To move the crankshaft with motor support the following
operations must be carried out:
Turn the KEYSWITCH MANUAL CLUTCH to activate the manual

clutch button on the press frame. It is not possible to switch on
the main drive or the advance drives as long as the KEYSWITCH
is activated.
Activate the HARDKEY CRAWL MODE. The LED of the

HARDKEY must be illuminated. The flywheel cover must be
closed to activate the motor support.
The clutch can be engaged by pressing the TWIN-HAND-

BUTTONS which are mounted in the tool area of the press. The
-1
flywheel is turning with a speed of approx. 5 min as long as the
TWIN-HAND-BUTTONS are pressed.
The rotation direction of the flywheel can be changed by turning

the switch TURN DIRECTION which is mounted nearby the
TWIN-HAND-BUTTONS:
n Switch turned 45° clockwise = Turn direction forward

n Switch horizontal = Turn direction backward
NOTE
The turn mode with motor support is only available at presses

with a force of 250 kN and more. The presses with 150 kN are not
equipped with the motor support for the turn mode.
I-17
I. Operation
3.1.5 Switching off the main drive
The main drive is switched off as discribed below:
Disengage the clutch by pressing the HARDKEY CLUTCH STOP.

It is important to disengage the clutch before the main drive is
switched off. The clutch is disengaged immediately, if the press
drive is switched off while the clutch is engaged.
Switch off the main drive by pressing the HARDKEY

MAIN DRIVE OFF. While the flywheel is decelerated the LED of
the HARDKEY is flashing; it becomes solid at the standstill.
The safety guards of the advance and die area may not be
opened before the LED is solid.
NOTE:
The main drive must be switched off, before the press is switched
off with the main switch; the LED in the HARDKEY MAIN DRIVE
OFF must be solid.
I-18
I. Operation
3.2 Advance drives
The HARDKEY switches the advance drives on and off. This

HARDKEY is only operational in CNC machines.
Pre-conditions:
n All safety devices in the advance unit and die area are closed.
n Clutch disengaged.
n Main drive not in MANUAL OPERATION MODE, key switch
CLUTCH MANUAL turned off.
Status:
n LED solidly illuminated = advance drives activated

n LED off = advance drives are idle
LED flashing = settling time of the
drives
(approx. 3 sec to 9 sec.)
NOTE:
The HARDKEY ADVANCE DRIVES is only used on presses with

numerical controlled advance systems.
I-19
I. Operation
3.3 Discharge
The HARDKEY switches the discharge drives on and off, e.g. the
transport systems which remove the products from the press.
Pre-condition:
CNC-machines This button can only be used when the clutch is disengaged.
The discharge unit is started up automatically when the clutch is

engaged during AUTOMATIC OPERATION.
RT-machines The discharge unit must be switched on manually on RT machines.

Here switching on the discharge unit is a requirement for engaging
the clutch. (SET UP and AUTOMATIC MODE)
Status:
n LED solidly illuminated = discharge activated

n LED off = discharge disactivated
I-20
I. Operation
3.4 Feeding
This HARDKEY FEEDING is only operational in RT machines.
The HARDKEY switches the feeding drives on and off, that is the
transport systems for feeding.
Pre-condition:
RT-Machines This button can only be used when the clutch is disengaged.
Switching on the feeding unit is a requirement for engaging the

clutch (SET UP and AUTOMATIC-MODE).
Status:
n LED solidly illuminated = feeding activated

n LED off = feeding desactivated
I-21
I. Operation
3.5 Acknowledgement / Clear
The HARDKEY ACKNOWLEDGEMENT is used to acknowledge

all messages displayed by the control unit outside the display file
and data input file. As long as these messages are not
acknowledged the control panel remains blocked in the main.
Exception:
n disengage the clutch

n shut down the main drive
n some display functions (for example help texts)
The LED in the key indicates a message which requires

acknowledgement.
NOTE:
On acknowledging a message the operator takes responsibility

for ensuring that appropriate measures are taken to solve the
reported problem. For example, if the operator acknowledges the
message DIE SAFETY he must ensure that no pieces of sheet
metal remain in the die area.
3.6 Language
The HARDKEY LANGUAGE is used to switch between languages

on the display screen. The display language is that of the operator
language. However on each control unit the service language is
available, too. The key switches to and fro between the operator’s
language and the service language.
NOTE:
The languages GERMAN, ENGLISH and FRENCH are available

as service languages. The service language is set with the
machine parameter 2.
I-22
I. Operation
3.7 Help
The HARDKEY HELP switches over to a more extensive

commentary of the actual display. If more than one message is on
the screen at the time, the commentary to the message in the top
line is displayed. To get back into the standard display mode press
the key again.
Availability HELP can always be called.
The display is blocked as long as the help text is displayed. It is

released after switching back to standard operation. There is no
actual help text existing, if no help text is displayed when the key is
pressed.
Helptext No. A number is assigned to each help text which is displayed at the
beginning of each help text.
In case of requests to the Alfons Haar service department, please
signalize this number to specify the problem.
I-23
I. Operation
3.8 Diagnosis
In case of machine interrupts for unknown reasons the hardkey

DIAGNOSIS can be pressed to get further informations about the
reasons for the interrupt.
This HARDKEY displays the contents of the diagnosis memory on

the screen. This memory contains all operations commanded by
the control unit which were not registered as finished at the time of
display.
Format The format is: TEXT 1 or 0 / NAME.
Format Function
Digit The digit 1 or 0 refers to the expected status of the
sensor to indicate that the function has been
completed.
Name The NAME gives the name of the sensor expected

to deliver this message.
Text The TEXT describes the function which was not

registered as being finished.
I-24
I. Operation
4 SET UP MODE
The HARDKEY SET UP MODE switches the machine into the

SET UP MODE, indicated by the solid LED of this hardkey.
Pre-condition:
n only available in AUTOMATIC MODE

n clutch disengaged
Status:
n LED solidly illuminated = SET UP MODE
There are two different screens (Menu 1 and Menu 2) assigned to

ð the HARDKEY SET UP MODE. Menu 1 is named as SET UP
MODE, Menu 2 is named MANUAL ADVANCE. Use the
HARDKEYs MORE (ð) and RETURN (ï) to switch between
ï these two screens.
READY
SET UP MODE MORE>

WITH ZERO ADV.- FEEDER DESTAC DOSING
SHEET SYSTEM TONGS TONGS KING IMPULS
Display panel for AF- and OF2(G)-Px -machines
I-25
I. Operation
READY
SET UP MODE MORE>

WITH ZERO ADV.- FEEDER DESTAC SHEET
SHEET SYSTEM TONGS TONGS KING TRANSF
Display panel for DF-P(V)x -machines
READY
SET UP MODE MORE>

WITH ZERO ADV.-
SHEET SYSTEM TONGS
Display panel for E-P(V)x- and EF-P(V)x-machines
I-26
I. Operation
4.1 Softkey-functions Menu 1 (SET UP MODE)
4.1.1 Machine type AF-Px
It is significant for machines of the type AF-PX in the set-up-mode:
WITH SHEET The SOFTKEY WITH SHEET switches on and off the vacuum
pump on (optional). This defines whether the machine is operated
with or without sheets. Without the vacuum pump all functions of
automatic operation are carried out with the sheets being
simulated. This operation is used to trace faults.
During automatic operation this SOFTKEY WITH SHEET cannot
be activated; the selection must be made before switching to
automatic operation.
If the SOFTKEY WITH SHEET is activated in the set up mode, the
succer is connected to vaccum for 15 sec. That way a basic
adjustment of the alignment succer for speed and pressure can be
made. For that purpose there must be a sheet in the alignment
station.
ZERO POSITION The SOFTKEY ZERO POSITION brings all axes into the ZERO
POSITION to get the machine ready for automatic operation. This
button must always be pressed before switching to the automatic
mode. Only at the end of the advance test the machine is ready to
start without activating ZERO POSITION.
ADVANCE TONGS The SOFTKEY ADVANCE TONGS opens and closes the advance
tongs.
FEEDER TONGS The SOFTKEY FEEDER TONGS opens and closes the loader
tongs.
I-27
I. Operation
DESTACKING The SOFTKEY DESTACKING has a double function. Alignment

and destacking operation is executed in a 10s-cycle.
Alignment:
The sucker moves in Y-direction. After 4 s it moves in X-direction.
After further 4 s the sucker moves back in the starting position.
This cycle does not end before the SOFTKEY F5 is switched off.
When the SOFTKEY F1 WITH SHEET is actuated, the sucking
while moving in X- and Y-direction is switched on, too and it is
switched off before returning. This way the movement of an
inserted sheet can be observed.
Destacking:
The destacking operation is switched as in AUTOMATIC mode with
the variety that no swivelling is executed. This cycle runs down in a
10 s-cycle until SOFTKEY F5 is switched off.
operation is also switched on and a sheet is destacked, too. At the
end of destacking the vacuum is switched off, and the sheet falls
off.
DOSING IMPULSE The SOFTKEY DOSING IMPULSE initiates a dosing process for
coating the sheets with drawing compound. This function is used
when the machine has not been operated for some time.
I-28
I. Operation
4.1.2 Machine type DF-Px
It is significant for machines of the type DF-PX in the set-up-mode:
WITH SHEET The SOFTKEY WITH SHEET switches the vacuum pump on and
off. This determines whether the machine is operated with or
without sheets. With the vacuum pump switched off all the
functions of automatic operation are carried out, the sheets being
simulated. This mode serves to trace faults. Normally of course the
machine is operated with sheets, i.e. with the vacuum pump
switched on.
During automatic operation this SOFTKEY WITH SHEET is not
offered. The selection must therefore be made before switching to
succer is impinged on vaccum for 15 sec. That way a basic
made. For that purpose the sheet must be in the alignment station.
tongs.
FEEDER TONGS The SOFTKEY FEEDER TONGS opens and closes the load slide
tongs.
I-29
I. Operation
DESTACKING The SOFTKEY DESTACKING that is switched in inverse function

has a double function. Alignment and destacking operation is
executed in a 10s-cycle.
Alignment:
Destacking:
off.
SHEET TRANSFER The SOFTKEY SHEET TRANSFER switches the solenoid valves
of the swing system, the advance tongs and the loading aids. The
use of this key facilitates the alignment of the sheet.
I-30
I. Operation
4.1.3 Machine type E-P(V)x, EF-Px
It is significant for machines of the type E-P(V)X and EF-Px in the

set-up-mode:
WITH SHEET The SOFTKEY WITH SHEET switches the vacuum pump on and
off. This determines whether the machine is operated with or
without sheets. With the vacuum pump switched off all the
functions of automatic operation are carried out, the sheets being
simulated. This mode serves to trace faults. During automatic
operation this SOFTKEY WITH SHEET is not offered, therefore the
selection must be made before switching to automatic operation.
ZERO SYSTEM The SOFTKEY ZERO POSITION brings all axes into the ZERO
tongs.
I-31
I. Operation
4.1.4 Machine type OF(2G)-Px
It is significant for machines of the type OF(2G)-Px in the set-up-

mode:
WITH SHEET The SOFTKEY WITH SHEET switches on and off the vacuum
pump on (optional). This defines whether the machine is operated
with or without sheets. Without the vacuum pump all functions of
automatic operation are carried out with the sheets being
simulated. This operation is used to trace faults.
During automatic operation this SOFTKEY WITH SHEET cannot
be activated; the selection must be made before switching to
succer is connected to vaccum for 15 sec. That way a basic
made. For that purpose there must be a sheet in the alignment
station.
tongs.
FEEDER TONGS The SOFTKEY FEEDER TONGS opens and closes the load slide
tongs.
I-32
I. Operation
DESTACKING The SOFTKEY DESTACKING has a double function. Alignment

and destacking operation is executed in a 10s-cycle.
Alignment:
Destacking:
off.
DOSING IMPULSE The SOFTKEY DOSING IMPULSE initiates a dosing process for
I-33
I. Operation
4.2 Softkey-functions Menu 2 (MANUAL ADVANCE)
4.2.1 Machine type AF-Px
It is significant for machines of the type AF-Px:
FEEDER FORWARD The SOFTKEY switches on the loader slide drive to move to the
sheet transfer station. If this direction is already selected at the time
of actuating the key, the whole drive of the loader slide is switched
off. This way the slide can be moved manually.
FEEDER BACKWARD The SOFTKEY switches on the loader slide drive to move to the
sheet alignment station. If this direction is already selected at the
time of actuating the key, the whole drive of the loader slide is
switched off. This way the slide can be moved manually.
MANUAL X+,X-,Y+,Y- This key moves the axis at crawl gear speed. The motion continues
as long as the key is pressed. The current positions of all axes are
shown on the screen.
CAUTION:
In manual operation the press can be engaged in any position of

the advance-axis. The advance grippers must never collide with
the die when engaging.
READY
MANUAL ADVANCE RETURN<

FEEDER FEEDER MANUAL MANUAL MANUAL MANUAL
FORWRD BACKWD X+ X- Y+ Y-
I-34
I. Operation
4.2.2 Machine type DF-Px
It is significant for machines of the type DF-Px:
MANUAL L+, L-, X+, X-, Y+, Y- This key moves the axis at crawl gear speed. The motion continues
CAUTION:
When the feed is under manual operation the press can be

engaged in any position of the feed. You should always make
sure that the feed tongs never collide with the die during the
engaging procedure.
READY

MANUAL MANUAL MANUAL MANUAL MANUAL MANUAL
L+ L- X+ X- Y+ Y-
I-35
I. Operation
4.2.3 Machine type E-P(V)x and EF-P(V)x
It is significant for machines of the type E-P(V)x and EF-P(V)x:
MANUAL X+,X-,Y+,Y- This key moves the axis at crawl gear speed. The motion continues
CAUTION:

engaging procedure.
READY

MANUAL MANUAL MANUAL MANUAL
X+ X- Y+ Y-
I-36
I. Operation
4.2.4 Machine type OF(2G)-Px
It is significant for machines of the type OF(2G)-Px:
MANUAL L+,L-,Y+,Y- This key moves the axis at crawl gear speed. The motion continues
CAUTION:

engaging procedure.
ROLLER The SOFTKEY moves the sheet which is currently in the feed
station into the alignment station. On account of the improved
accessibility it is a good idea under setting-up mode for a sheet to
be in the feed station as this since it must be removed before it is
possible for you to switch over into automatic mode. The rollers can
only be moved when the initiator "SHEET IN PRE-ALIGNMENT
STATION" is dampened.
LOADER UP/DWN The SOFTKEY swings the loader tongs downwards or returns them
to their working position. This is a toggle key, which means each
time it is pressed the inactive of the two functions is activated.
READY

MANUAL MANUAL ROLLER LOADER MANUAL MANUAL
L+ L- UP/DWN Y+ Y-
I-37
I. Operation
5 AUTOMATIC MODE and softkey functions
5.1 Machines type AF-PX, DF-Px, EF-Px, OF(2G)-Px
It is significant for machines of the type AF-Px, DF-Px, EF-Px,

OF(2G)-Px:
The HARDKEY AUTOMATIC MODE switches the machine into

the AUTOMATIC MODE.
The solidly illuminated LED of this hardkey indicates that the

machine is in AUTOMATIC MODE.
Pre-condition:
n only available in SET UP MODE

n clutch disengaged
n Advance axes in STANDARD-POSITION
Status:
n LED solidly illuminated = AUTOMATIC MODE
There is one screen assigned to the HARDKEY AUTOMATIC

MODE. This Menu is called AUTOMATIC MODE.
READY
AUTOMATIC MODE
AD- FEEDER ALIGN LUB- DOSING
VANCE AGAIN ROLLER IMPULS
I-38
I. Operation
Softkey functions:
ADVANCE This SOFTKEY ADVANCE switches on the advance logic after

switch-over to AUTOMATIC mode. On initial activation and after
program changes affecting the initial punch position, the loader axis
feeds in the sheet for measuring purposes when the key is
actuated. At the dual-coordinate advance, the time between the last
punch position and the sheet transfer position is determined. The
number of dummy strokes involved in each sheet change is
determined from this time.
The key also has an additional function. If it is switched off after the
sheet has been taken over and the loader or advance tongs have
been closed, the relevant tongs open and the appropriate advance
returns to the ZERO POSITION or START POSITION. The sheet
left behind can now be removed. This means that the sequence
can be interrupted without leaving AUTOMATIC mode.
This function is only available when the clutch is disengaged.
FEEDER The SOFTKEY FEEDER switches the sheet separator on and off. It
can be operated at all times and serves to start up and close down
production.
ALIGN AGAIN The SOFTKEY ALIGN AGAIN serves to repeat the alignment of
the sheet in the sheet alignment station. If it is used after
acknowledging the message SHEET ALIGNMENT then the
alignment is carried out again. If the sheet alignment stopped
without displaying an error message then pressing this key displays
the error message. By acknowledging this message and then
pressing this key once again the sheet alignment is repeated. As
soon as the alignment has been carried out successfully the
automatic operation continues. It is therefore not necessary to
leave the AUTOMATIC mode.
LUB. ROLLERS The SOFTKEY LUB. ROLLERS starts and stops the rollers of the
sheet coating system. This function is used when the machine has
not been operated for some time.
DOSING IMPULS The SOFTKEY DOSING IMPULS initiates a dosing process for
I-39
I. Operation
5.2 Machine type E-P(V)x
It is significant for machines of the type E-P(V)x:
The HARDKEY AUTOMATIC MODE switches the machine into

the AUTOMATIC MODE.

machine is in AUTOMATIC MODE.
Pre-condition:
n only available in SET UP MODE

n clutch disengaged
n advance axes in NORM-POSITION
Status:
n LED solidly illuminated = AUTOMATIC MODE
There is one screen assigned to the HARDKEY AUTOMATIC

MODE. This Menu is named AUTOMATIC MODE.
READY
AUTOMATIC MODE
AD- AUTO
VANCE START
I-40
I. Operation
Softkey functions:
ADVANCE The SOFTKEY ADVANCE switches on the advance logic after

switch-over to AUTOMATIC mode. On initial activation and after
program changes affecting the initial punch position, the loader axis
feeds in the sheet for measuring purposes when the key is
actuated. At the dual-coordinate advance, the time between the last
punch position and the sheet transfer position is determined. The
number of dummy strokes involved in each sheet change is
determined from this time.
The key also has an additional function. If it is switched off after the
sheet has been taken over and the loader or advance tongs have
been closed, the relevant tongs open and the appropriate advance
returns to the ZERO POSITION or START POSITION. The sheet
left behind can now be removed. This means that the sequence
can be interrupted without leaving AUTOMATIC mode.
This function is only available when the clutch is disengaged.
AUTO START The SOFTKEY AUTO START switches the clutch on and off, when
both axis have reached their first stamping position. The key can be
operated at any time and is used to start and terminate the operational
production mode.
I-41
I. Operation
6 Display mode
The HARDKEY DISPLAY MODE switches the machine into the

DISPLAY MODE.

machine is in DISPLAY MODE.
6.1 Monitor
Availability This function is available at any time as long as the control unit is
switched on.
Display To check the readings press the desired SOFTKEY which is

named with the corresponding machine modul. Scroll through the
list by pressing the HARDKEY ENTER to read out the different
ENTER
values.
Leave the DISPLAY MODE Close all files and press the HARDKEY RETURN (ï) to leave
the DISPLAY MODE .
ï
READY
DISPLAY MODE RETURN<

PRESS AD- SER- COUNT- I/O- HOURS
VANCE VICE ER STATUS
AF-Px,- DF-Px-, E-Px-, EF-Px-, OF(2G)-Px-machines
I-42
I. Operation
6.2 Softkey functions
As can be seen from the Menu structure, most display data and/or
parameters are entered via the different SOFT KEY FUNCTIONS.
Detailed parameter descriptions relating to the individual
parameters are to be found in the appropriate chapter.
PRESS Displays the present orientation of the crankshaft, the

measured speed of rotation of the press, the synchronization
switching positions of the crankshaft and the actual pressures of
the overload safety device.
ADVANCE Displays the current positions of the advance axes and their
maximum speed of rotation.
SERVICE Displays the machine model, the date and the machine software
version. This function is only available for the service by pushing
the hardkey "LANGUAGE".
If the hardkey is not pressed, the die safety device data are
displayed.
COUNTER The SOFTKEY opens the file for the COUNTERS. These count the
number of sheets and stampings passing through the monitoring
systems such as die safety and the double sheet monitor without
malfunction being registered. On overflow the counters return to
zero and continue counting. The counters are erased by overwriting
them with zeros. If the voltage supply is interrupted the EEPROM
stores the contents of the counters.
Softkey Function
Piece counter Displays the number of pieces produced.
Sheet counter Displays the number of sheets fed to the

press.
Preselect Input of the preselect counter for the target

value of the number of pieces.
I-43
I. Operation
I/O STATUS This machine is equipped with an ASI-BUS system. All signal
connections between the control system and the input and output units
take place via the so-called ASI-SLAVE MODULE. More detailed
information on the design of the ASI-BUS system is found in the
chapter CONTROL UNIT.
Every slave module has four (4) input and four (4) output connections.
The SOFTKEY F5 is provided in the display menu to check the status

of the input and outputs on the control panel.
Four slaves are always shown in the display field at the same time
when the status is being checked.
The display contains the following information:
Output: OUT 4, OUT 3, OUT 2, OUT 1
Input: IN 4, IN 3, IN 2, IN 1
Slave no.
Slave 100 0000 1100

Slave 101 0110 1000
Slave 102 1001 0101
Slave 103 0100 1101
PRESS AD- SERVICE COUN- I/O HOURS

VANCE TER STATUS
HOURS Displays the number of operating hours of the control unit and of
the engaged clutch of the press.
I-44
I. Operation
6.3 Menu structure DISPLAY MODE
6.3.1 Menu structure for AF-Px-machines
F1 F2 F3 F4 F5 F6
PRESS ADVANCE SERVICE COUNTER I/O HOURS

MODE
RAM POSITION X - POSITION PIECE COUNT SLAVE 100 ... HOURS
Y - POSITION SLAVE 101 ... MACHINE
SLAVE 102 ...
SLAVE 103 ...
SPEED / RPM X - VMAX SHEET COUNT SLAVE 104 ... HOURS PRESS
Y - VMAX SLAVE 105 ...
SLAVE 106 ...
SLAVE 107 ...
START SYNCHRO START MODE PRESET SLAVE 108 ...

X SLAVE 109 ...
START SYNCHRO SLAVE 1101 ...
Y SLAVE 111 ...
X-SYNCH LUBRICATION ...

STROKES ...
Y-SYNCH ...
STROKES ...
SLAVE 128 ...

SLAVE 129 ...
SLAVE 130 ...
SLAVE 131 ...
...
...
...
...
* SLAVE 200 ...
PRESS LOAD
SLAVE 201 ...
SLAVE 202 ...
SLAVE 203 ...
PRESS LOAD ...

* ...
MAX
...
...
SLAVE 228 ...

SLAVE 229 ...
SLAVE 230 ...
SLAVE 231 ...
*
only with overload safety device (machine parameter 45/46)
I-45
I. Operation
6.3.2 Menu structure for DF-Px-machines
F1 F2 F3 F4 F5 F6
PRESS ADVANCE COUNTER I/O HOURS

MODE
RAM POSITION L - POSITION PIECE COUNT SLAVE 100 ... HOURS
X - POSITION SLAVE 101 ... MACHINE
Y - POSITION SLAVE 102 ...
SLAVE 103 ...
SPEED / RPM X - VMAX SHEET COUNT SLAVE 104 ... HOURS PRESS
L - VMAX SLAVE 106 ...
SLAVE 107 ...
START SYNCHRO L PRESET SLAVE 108 ...

SLAVE 109 ...
L - SYNCHRO
SLAVE 1101 ...
STROKES
SLAVE 111 ...
* SHEET ...
PRESS LOAD
LUBRICATION ...
*
PRESS LOAD MAX ...
...
SLAVE 128 ...

SLAVE 129 ...
SLAVE 130 ...
SLAVE 131 ...
...
...
...
...
SLAVE 200 ...

SLAVE 201 ...
SLAVE 202 ...
SLAVE 203 ...
...
...
...
...
SLAVE 228 ...

SLAVE 229 ...
SLAVE 230 ...
SLAVE 231 ...
*
I-46
I. Operation
6.3.3 Menu structure for E-P(V)x-machines
F1 F2 F3 F4 F5 F6

STATUS
RAM POSITION X - POSITION PIECECOUNT SLAVE 100 ... HOURS
SLAVE 102 ...
SLAVE 103 ...
SPEED / RPM X - VMAX SHEETCOUNT SLAVE 104 ... HOURS PRESS

SLAVE 106 ...
SLAVE 107 ...
* PRESET SLAVE 108 ...
PRESS LOAD
SLAVE 109 ...
*
PRESS LOAD MAX SLAVE 1101 ...
SLAVE 111 ...
...
...
...
...
SLAVE 128 ...

SLAVE 129 ...
SLAVE 130 ...
SLAVE 131 ...
...
...
...
...
SLAVE 200 ...

SLAVE 201 ...
SLAVE 202 ...
SLAVE 203 ...
...
...
...
...
SLAVE 228 ...

SLAVE 229 ...
SLAVE 230 ...
SLAVE 231 ...
*
I-47
I. Operation
6.3.4 Menu structure for EF-Px-machines
F1 F2 F3 F4 F5 F6

STATUS
RAM POSITION X - POSITION PIECECOUNT SLAVE 100 ... HOURS
SLAVE 102 ...
SLAVE 103 ...
SPEED / RPM X - VMAX SHEETCOUNT SLAVE 104 ... HOURS PRESS

SLAVE 106 ...
SLAVE 107 ...
* PRESET SLAVE 108 ...
PRESS LOAD
SLAVE 109 ...
*
PRESS LOAD MAX SLAVE 1101 ...
SLAVE 111 ...
LUBRICATION ...
...
...
...
SLAVE 128 ...

SLAVE 129 ...
SLAVE 130 ...
SLAVE 131 ...
...
...
...
...
SLAVE 200 ...

SLAVE 201 ...
SLAVE 202 ...
SLAVE 203 ...
...
...
...
...
SLAVE 228 ...

SLAVE 229 ...
SLAVE 230 ...
SLAVE 231 ...
*
I-48
I. Operation
6.3.5 Menu structure for OF(2G)-Px-machines
F1 F2 F3 F4 F5 F6
PRESS ADVANCE SERVICE COUNTER I/O- HOURS

STATUS
RAM POSITION L - POSITION PIECE COUNT SLAVE 100 ... HOURS
Y1 - POSITION SHEET COUNT SLAVE 101 ... MACHINE
SPEED / RPM
Y2 - POSITION PRESET SLAVE 102 ...
Y3 - POSITION SLAVE 103 ...
START SYNCHRO.L L-VMAX LUBRICATION SLAVE 104 ... HOURS PRESS

R-VMAX SLAVE 105 ...
L-SYNCHRO
Y1 - VMAX SLAVE 106 ...
STROKES
Y2 - VMAX SLAVE 107 ...
PRESS LOAD DSL1-L SLAVE 108 ...

DSL1-R SLAVE 109 ...
PRESS LOAD MAX
DSL2-L SLAVE 1101 ...
DSL2-R SLAVE 111 ...
...
...
...
...
SLAVE 128 ...

SLAVE 129 ...
SLAVE 130 ...
SLAVE 131 ...
...
...
...
...
SLAVE 200 ...

SLAVE 201 ...
SLAVE 202 ...
SLAVE 203 ...
...
...
...
...
SLAVE 228 ...

SLAVE 229 ...
SLAVE 230 ...
SLAVE 231 ...
I-49
I. Operation
7 DATA INPUT mode
7.1 Procedure
The HARDKEY DATA INPUT MODE switches the machine into

the DATA INPUT MODE.
The solidly illuminated LED of this hardkey is indicating that the

machine is in DATA INPUT MODE.
Availability The DATA INPUT MODE is available in all operation modes.
The functions of the SOFTKEY´s are available at all times.
Programmation / changing values It is only possible to change values in the DATA INPUT MODE
while the clutch is disengaged. It is necessary to activate the
KEYSWITCH DATA INPUT to modify values. It is not possible to
change any value without the KEY!
A few values inside the ADVANCE program are specially

protected. To change one of these values the machine must be
switched to SET UP MODE.
Display To check the programmed values press the desired SOFTKEY

which is named with the corresponding machine modul. Scroll
through the list by pressing the HARDKEY ENTER to read out the
ENTER
different values.
Data input To change a value it is importend to enter the correct number of

digits before you press the HARDKEY ENTER (including leading
ENTER zero´s). if you type a new value it will appear below the old value.
The new vaulue is accepted and programmed if you press the
HARDKEY ENTER. It is possible to correct incorrect entered
CLEAR values by pressing the HARDKEY CLEAR
No comma input (“,”) is accepted.
I-50
I. Operation
READY
DATA INPUT MODE RETURN <

MACRO SYNCH AD- DIES SHEET COUNT-
VANCE LUB. ER
Display for AF-Px , DF-Px, EF-Px, OF(2G)-Px- machines
READY
DATA INPUT MODE RETURN<

MACRO SYNCH AD- DIES COUNT-
VANCE ER
Display for E-P(V)x-machines
Switch off No data file must remain open when the main switch is turned
off. When a file is closed the check digit is calculated for data
protection. This operation cannot be performed if the main switch is
turned off. In this case the malfunction message CONTROL DATA
would appear on the display.
NOTE: INTERNAL CONTROL
Plausibility tests are performed on the data both during inputing

and when the file is closed. If errors are found the display either
returns to the parameter in question or to the beginning of the file
after the message has been acknowledged. In this case the
mistake must be taken care of immediately. Defective files cannot
be closed! The control unit is blocked until the input error has
been corrected.
I-51
I. Operation
7.2 Softkey-functions DATA INPUT mode
As can be seen from the menu structure, most display data and/or
parameters are entered via the different SOFT KEY FUNCTIONS.
Detailed parameter descriptions relating to the individual
parameters are to be found in the appropriate chapter and in
Appendix C „Machine values“.
ADVANCE The SOFTKEY opens the Data file containing details of the
advance program.
SYNCH The SOFTKEY opens the data file containing details of the
synchronization program. These are the switching positions of
the Z-axis which provide the synchronisation between the press
and the other systems which make up the machine. The first
parameter in this file determines the rotational speed of the press.
DIES The SOFTKEY opens the file containing the data for the DIE
PROGRAM.
SHEET LUB. For AF-Px-machines:

not available for E-P(V)x
The SOFTKEY opens the file containing the program data for
coating the sheets with drawing compound and monitoring the
varnish.
COUNTER The SOFTKEY COUNTER opens the file for the COUNTERS.
These count the number of sheets and stampings passing through
the monitoring systems such as die safety and the double sheet
monitor without malfunction being registered. On overflow the
counters return to zero and continue counting. The counters are
erased by overwriting them with zeros. If the voltage supply is
interrupted the EEPROM stores the contents of the counters.
I-52
I. Operation
Softkey Funktion
Piece counter Displays the number of pieces produced.
Sheet counter Displays the number of sheets fed to the

press.
Preselect Input of the preselect counter for the target

value of the number of pieces. Input means
overwriting the previous value. If it is set to
zero the counter is disenabled.
When the preset value is reached the clutch is
disengaged and the message PRESET is
displayed on the screen.
Pressing the HARDKEY ENGAGE CLUTCH
the clutch is engaged again and the preset
value is loaded into the preselect counter
again.
Clear by input of 00000
I-53
I. Operation
7.3 Menu structure DATA INPUT MODE
7.3.1 Menu structure DATA INPUT MODE AF-Px
F1 F2 F3 F4 F5 F6
MACRO SYNCH AD- DIES SHEET COUN-

VANCE LUB. TER
STORE MACRO SPEED / RPM PROGRAM- NO OF DIES LUBRICATION PIECE COUNT
NUMBER
CALL MACRO DIE SAFETY PUNCHES X PRESSURE VARNISH SHEET COUNT

DEVICE PRESET INSPECTION
DELETE MACRO DIE CLOSES PUNCHES Y RELEVEL [S] PRESET
DIE OPENS STARTPOS X PALLET CHANGE RESELECTION S1
BLOW OFF STARTPOS Y SHEET BRAKE RESELECTION S2

[MS]
KNOCK OUT ON STEP X
KNOCK OUT OFF STEP ½ X
VENTILATION STEP Y
ON
VENTILATION STEP YD
OFF
VACUUM PUMP TAKE-OVER POS

ON
VACUUM PUMP START POS L

OFF
CLUTCH OFF X-TRANSFER

CORR
BLOW-OFF TIME MISPRINTS

[MS]
I-54
I. Operation
F1 F2 F3 F4 F5 F6

VANCE LUB. TER
CAP DISTRIBUTOR POS MISPRINT
CAP DISTRB.
STROKES
CAP DISTRB.
SHEETS
VENTILATION TOP
DIE ON
VENTILATION TIME
TOP DIE
UNIV. OUTPUT 1 ON
UNIV. OUT 1 OFF
I-55
I. Operation
7.3.2 Menu structure DATA INPUT MODE DF-Px
F1 F2 F3 F4 F5 F6
MACRO SYNCH ADVANCE DIES SHEET COUNTER

LUB.
STORE MACRO SPEED / RPM PROGRAM- NO OF DIES LUBRICATION PIECE COUNT
NUMBER
CALL MACRO DIE SAFETY PUNCHES X PRESSURE VARNISH SHEET COUNT

DEVICE PRESET INSPECTION
DELETE MACRO DIE CLOSES PUNCHES Y RELEVEL [S] PRESET
DIE OPENS STARTPOS X PALLET CHANGE RESELECTION S1
BLOW OFF STARTPOS Y SHEET BRAKE RESELECTION S2

[MS]
KNOCK OUT ON STEP X
KNOCK OUT OFF STEP ½ X
VENTILATION STEP Y
ON
VENTILATION TAKE-OVER POS

OFF
VACUUM PUMP START POS L

ON
VACUUM PUMP X-TRANSFER

OFF CORR
CLUTCH OFF MISPRINTS
BLOW-OFF TIME POS MISPRINT

[MS]
I-56
I. Operation
F1 F2 F3 F4 F5 F6

LUB.
CAP DISTRIBUTOR
CAP DISTRB.
STROKES
CAP DISTRB.
SHEETS
VENTILATION TOP
DIE ON
VENTILATION TIME
TOP DIE
UNIV. OUTPUT 1 ON
UNIV. OUT 1 OFF
I-57
I. Operation
7.3.3 Menu structure DATA INPUT MODE E-P(V)x
F1 F2 F3 F4 F5 F6

LUB.
STORE MACRO SPEED / RPM PROGRAM- NO OF DIES PIECE COUNT
NUMBER
CALL MACRO DIE SAFETY DEVICE PUNCHES X SHEET COUNT
DELETE MACRO DIE CLOSES PUNCHES Y PRESET
DIE OPENS STARTPOS X
BLOW OFF STARTPOS Y
CLUTCH OFF STEP X
BLOW-OFF TIME STEP ½ X

[MS]
KNOCK OUT ON STEP Y
1)
KNOCK OUT OFF STEP YD
VENTILATION ON TAKE OVER X
VENTILATION OFF TAKE OVER Y
IDLE PUNCHES
2)
IDLE POSITIONS
MISPRINTS
3)
POS. MISPRINT
1)
not displayed, if - - program-No. < 4
- program-No.
= 22
- program-No. = 27
2)
only if IDLE POSITIONS <> f
3)
only if POS. MISPRINT <> f
I-58
I. Operation
7.3.4 Menu structure DATA INPUT MODE EF-Px
F1 F2 F3 F4 F5 F6
MACRO SYNCH ADVANCE DIES COUNTER

STORE MACRO SPEED / RPM PROGRAM- NO OF DIES PIECE COUNT
NUMBER
CALL MACRO DIE SAFETY PUNCHES X SHEET COUNT

DEVICE
DELETE MACRO DIE CLOSES PUNCHES Y PRESET
DIE OPENS STARTPOS X
BLOW OFF STARTPOS Y
CLUTCH OFF STEP X
BLOW-OFF TIME STEP ½ X

[MS]
KNOCK OUT ON STEP Y
1)
KNOCK OUT OFF STEP YD
VENTILATION ON TAKE OVER X
VENTILATION OFF TAKE OVER Y
IDLE PUNCHES
2)
IDLE POSITIONS
MISPRINTS
3)
POS. MISPRINT
1)
not displayed, if - - program-No. < 4
- program-No.
= 22
- program-No. = 27
2)
only if IDLE POSITIONS <> f
3)
only if POS. MISPRINT <> f
I-59
I. Operation
7.3.5 Menu structure DATA INPUT MODE OF(2G)-Px
F1 F2 F3 F4 F5 F6

VANCE LUB. TER
CALL MACRO SPEED / RPM PUNCHES L FRONT DIES LUBRICATION PIECECOUNT
STORE MACRO DIE SAFETY START POS L REAR DIES VARNISH SHEETCOUNT
DEVICE INSPECTION
DELETE MACRO DIE CLOSES PUNCHES Y DIE SPACING RELEVEL [S] PRESET
DIE OPENS START POS Y1 PRESSURE PALLET CHANGE

PRESET
BLOW OFF START POS Y2
KNOCK OUT ON START POS Y3
KNOCK OUT OFF STEP
VENTILATION TAKE-OVER POS

ON
VENTILATION IDLE STROKES

OFF
CLUTCH STOP SHEET EDGE

MONITOR.
PARAMETER
DETERM.
BLOW - OFF TIME WEB SETPOINT

[MS]
RAMP 2 ON ACTUAL WEB

FRONT LEFT
RAMP 0 - 3 OFF ACTUAL WEB

FRONT RIGHT
WEB SETPOINT
REAR
ACTUAL WEB
REAR LEFT
ACTUAL WEB
REAR RIGHT
I-60
I. Operation
7.4 Macro operation
MACRO The softkey MACRO gives access to the background memory.

Complete user programs called macros can be stored in this
memory and loaded from it.
A macro is made up of all program data for a product, i.e. all

synchronization-, advance-, and lubrication data. The macros
belonging to a special product are given numbers starting from 01.
Storing and deleting a macro is possible after the advance
test, in set-up mode, but not in automatic mode, although the
macro-functions are displayed there, too.
I-61
I. Operation
7.4.1 MACRO-functions
The MACRO-File has got three functions which are STORE

MACR, CALL MACRO and DELETE MACR. The functions of this
file can be called up using the ENTER key; here the macro number
must be 00 to continue switching.
Macro function Explanation

STORE MACRO NN When a number not equal 00 is entered, the user programme in
the main memory is stored in the background memory under the
number entered, provided this has not already be assigned to
another macro.
If it has already been assigned an appropriate message is
displayed.
For reasons of safety all macro labels are classified as assigned
when the machine is delivered. They must be deleted before
macros can be stored.
CALL MACRO NN When a number not equal 00 is entered, the macro stored in the
background memory under that number is recalled into the main
memory when the ENTER key is pressed.
The data in the main memory at the time are overwritten. The
procedure is completed when ERASE MACRO is displayed.
DELETE MACRO NN When a number not equal 00 is entered, the macro stored in the
background memory under that number is erased. This space is
then available for storing a new user program.
I-62
I. Operation
7.4.2 Access to macro-files before the advance test
1. Switch on the main switch.
2. After the control has run up, press Emergency stop.
3. Press the hardkey ACKNOWLEDGE.
4. Press the hardkey DATA INPUT.
F1 5. Press the softkey F1 “MACRO“.

The three functions of the MACRO-file are displayed each
time after pressing the ENTER-button:
STORE MACRO 00
ENTER leads to
CALL MACRO 00
ENTER leads to
DELETE MACRO 00
ENTER leads to
mask “Data input“
I-63
I. Operation
7.4.3 Access to macro-files after the advance test in set up mode
1. After the execution of the advance test pressing the hardkey

SET UP changes the operation to SET UP MODE.
2. Press the hardkey DATA INPUT.
The screen looks like follows, with softkey F5 SHEET LUB. being
empty for E-advance systems.
READY
DATA INPUT MODE RETURN <

VANCE LUB. ER
3. Now the data input of program values can start for:
synchronization F2
F2 F3 F4 F5 advance F3
dies F4
lubrication (not for E-advance systems) F5
Any one time the ENTER-button is used to move further, and with
ENTER the last ENTER pressing the section is left.
I-64
I. Operation
Now the macro storage can follow.

Before the storage of a macro, for example as MACRO 01, the
macro must be deleeted.
4. Press softkey F1 “MACRO.

F1 The three functions of the MACRO-file are displayed each
time after pressing the ENTER-button:
STORE MACRO 00
ENTER leads to
CALL MACRO 00
ENTER leads to
DELETE MACRO 00
ENTER leads to
mask “Data input“
I-65
I. Operation
7.5 Input of machine parameters
The definition of the machine parameters is assigned to each

machine according to the design and designation. Some of these
parameters can be changed by the operator, others shall not be
changed. You can look at all machine parameters. The machine
parameters have nothing to do with the macros.
You get access to the machine parameters in data input mode.
Procedure:
1. The main switch of the control cabinet must be switched

off. While the unit is off circuit, press the EMERGENCY
STOP. Then switch on the control cabinet. The message
EMERGENCY OFF appears on the screen.
2. Press the ACKNOWLEDGE-button. In the meantime the

message EMERGENCY STOP will remain on the screen.
3. Now press the hardkey DATA INPUT and delect the

F1 function MACRO F1 from the softkey menu. The
message PARAMETER and the value 11 are displayed.
4. Turn the key switch to release the data input. Then

00 ENTER overwrite the value 11 with 00 and press the ENTER-
button.
5. Now the file MACHINE PARAMTER is open, and the first

parameter is displayed as PARAMETER 01. By pressing
ENTER
the ENTER-button you can scroll through die individual
parameters. Parameters can be changed here, too, as far
value as this is allowed. Thus the displayed value is overwritten
ENTER ENTER
and there is the possibility to move to the next parameter
pressing ENTER. The programmed precision for data
input must be observed.
6. To close the list of parameters scroll to the end of the list

with the ENTER-button or press F1. Press the left arrow
key above the number pad to leave the data input.
7. Switch off the controll with the main switch.
8. Tear out again the EMERGENCY STOP-button.
I-66
I. Operation
8 Integration of the line
The control allows beside the DNC-interface also a simplified

adaptation of the down stream line (back end) behind the press.
The integration of the line includes two functions:
n Jam monitor
n External control
8.1 Jam monitor
Purpose This device serves the safety of the stampings flow off.
Cups or cans passing a sensor make it only deliver a short signal

on each passage. In case of a jam the product remains below the
sensor; the signal becomes solid. Using this principle the control
recognizes jams in the discharge.
ADJUSTMENT:
DISCHARGE JAM MONITOR Contact Maker
The input monitors the discharge flow of stampings. In each

discharge channel an inductive or for aluminum a capacitive
proximity switch is installed. If several switches are installed they are
connected in parallel to the input. This way the switches are to
design and to adjust, that also on slow motion of cans in line, a
continious signal is given.
105Exi,i ={3, 4} (E1Axi, i = 6, 7}) Exit jam monitor channel xi,i ={1, 2)
Sensitivity The sensitivity of the jam monitor is programmable in the

MACHINE PARAMETER DISCHARGE JAM MONITOR.
The parameter defines the signal length from which on the signal
is interpreted as jam.
Jam detection If a jam is detected in the described way, the message JAM is
displayed on the screen.
I-67
I. Operation
READY
JAM
AUTOMATIC MODE
AD- DEST- ALIGN LUB- DOSING
VANCE ACKER AGAIN ROLLER IMPULS
I-68
I. Operation
Reaction:
n Clutch of the press is switched off.
n The supply of the next sheet is interrupted. In that case, the
press runs on idle.
The reaction of the machine depends on the MACHINE

PARAMETER LINE-JAM.
As long as this message is displayed all other functions besides

CLUTCH STOP of the panel are blocked.
Clear Jam Jam is automatically cleared as soon as the correspondant sensor

is set free again.
Key CLUTCH STOP
Automatical restart:
As long as the message JAM is displayed, the clutch is engaged

automatically or sheet feeding will start again. This is achieved by
releasing the appropriate switch after a delay time defined with
machine parameter JAM RESTART.
Acknowledgement There is no acknowledgement of the error message „JAM“ by

pressing the HARDKEY ACKNOWLEDGEMENT as usual.
To acknowledge the message the HARDKEY CLUTCH STOP
must be pressed. Thus an automatic restart of the press is
prevented. Instead the clutch must be engaged manually after the
jam is resolved is prevented.
I-69
I. Operation
8.2 External control
This monitor function serves an in time reaction of the machine on

interruptions of operation within the downstream production line.
Normaly a potentialfree contact of a down stream machine or a
manual switch is connected into the circuit. For operation of the
press a 0-signal on the input 103E3 (E1B7) is required. In case of
interruption LINE JAM 1 or 2 is shown on the screen.
Identification When a line faults occur the MESSAGE "EXTERNAL CONTROL"

appears.
READY
EXTERNAL CONTROL
AUTOMATIC MODE
AD- DEST- ALIGN LUB- DOSING
VANCE ACKER AGAIN ROLLER IMPULS
As defined with machine parameter EXTERNAL CONTROL the

clutch of the press is disengaged.
As long as this message is displayed, the panel is blocked for
other functions except CLUTCH STOP.
Clear Jam Jam is automatically enabled as soon as the correspondant

sensor is set free again.
Automatical restart:
As long as the message „EXTERNAL CONTROL“ is displayed, the

clutch is engaged automatically, as soon as the port EXTERNAL
CONTROL is supplied with + 24V.
Engaging itself is delayed for about 5 seconds, to let the machine
behind work out some products.
Acknowledgement There is no acknowledgement of the error message „EXTERNAL

CONTROL“ by pressing the HARDKEY ACKNOWLEDGEMENT
as usual. To acknowledge the error message the HARDKEY
CLUTCH OFF must be pressed. Thus an automatic restart of the
press is prevented. Instead the clutch must be engaged manually
after the jam is resolved is prevented.
I-70
II. Eccentric Press P40s
II. Eccentric Press P40S
Table of Contents
1 USE 4
2 OPERATION 4
2.1 COMMISSIONING 4
2.2 NORMAL OPERATION 6
2.3 SET UP MODE 7
2.3.1 TURN MODE (CRAWLING GEAR) 7
2.3.2 MANUAL OPERATION 9
2.4 SAFETY DEVICES 10
2.5 SWITCHING OFF 11
3 ADJUSTMENT 12
3.1 PROGRAMMABLE VALUES 13

3.1.1 SPEED 13
3.1.2 CRANKSHAFT ANGLE FOR CLUTCH ON/OFF 14
3.1.3 CENTRAL LUBRICATION SYSTEM 15
3.1.4 OVERLOAD SAFETY DEVICE 16
3.1.5 MONITORING WITH ANALOGUE PRESSURE SENSOR 17
3.2 ADJUSTMENT OF THE PNEUMATIC EQUIPMENT 19
3.2.1 RAM COUNTERWEIGHT 20
3.2.2 CLUTCH PRESSURE 22
3.3 ADJUSTMENT OF THE HYDRAULIC EQUIPMENT 23
3.3.1 OVERLOAD SAFETY DEVICE FEHLER! TEXTMARKE NICHT DEFINIERT.
3.3.2 KICKBACK DAMPER 26
3.4 MECHANCAL RAM ADJUSTMENT 27
4 DIES 28
4.1 PROGRAMMING 28
4.2 DIE CHANGING 29
4.2.1 DIE INSTALLATION 30
4.2.2 DIE REMOVAL 34
4.3 DIE CUSHIONS 35
4.4 EJECTOR 36
4.4.1 EJECTOR WITH SPRING CONTROL 36
4.4.2 EJECTOR WITH PNEUMATIC CONTROL 37
5 MAINTENANCE 38
5.1 LUBRICATION 38
5.1.1 LUBRICATION OF THE RAM WEIGHT COMPENSATION CYLINDERS 39
5.1.2 LUBRICATION OF THE AIR OPERATED DIE CUSHIONSS 39
5.1.3 FLYWHEEL BEARING 39
II-2
5.2 DRIVE 40
5.2.1 THREE-PHASE CURRENT MOTOR AND SPEED REGULATOR 40
6.2.2 CLUTCH 41
5.2.3 BEARINGS 42
5.2.4 TRANSMISSION BELT 44
5.2.5 RAM 45
5.2.6 OVERLOAD SAFETY DEVICE 46
5.2.7 DIE CUSHIONS 48
Presse P40S m5 04 06
II-3
1 Use
The press „P40S“ is suitable for the manufacture of flat caps and
cups of high number. With a die stroke of 120 mm and a maximum
number of 240 strokes per minute at a force of the press of 40 t
max., up to eleven stampings per stroke may be produced
according to the blank diameter.
Combined with the advance system DF running without idle
strokes is possible.
2 Operation
2.1 Commissioning
The working area of the press is locked up against the outside by

safety devices. Once all admittance doors are locked, the press
can be put into operation. The „set up mode“ forms an exception;
in this mode it is possible to execute careful movements of the
press even with open safety devices in view of special safety
measures.
Opening the safety devices during operation causes the

immediate emergency cut off of the machine. This may provoke
undefined conditions of the system leading to problems when re-
engaging the line.
DANGER:
Severe injuries can occur if you attempt to circumvent the safety

devices or to bridge them mechanically or electrically.
To set the press to work the supply of power and pressure air
must be guaranteed.
The pressure air is switched on at the main valve at the machine

frame. With main swith at the control cabinet the machine is made
operational.
First the auxiliary devices must start up to vreate the different
working pressures in the pneumatic and hydraulic circles. Not
before the working pressures are attained, the working of the
press is released by the control via electric control devices.
All machines are equipped with electronically adjustable DC or

three-phase AC main drive motors The drive of the press results
from an electronically adjustable AC-drive via a four-quadrant
speed control device. This device is used to adjust the speed, to
start and stop the flywheel and to run in slow mode (turn mode) in
both senses of rotation.
II-4
On the operating panel there are three HARDKEYS (wired keys)

with pictograms to control the drive.
Drive ON
Turn mode
Drive OFF
The following modes are possible:
Normal operation
Set up mode
Turn mode (crawling gear)
Manual operation
II-5
2.2 Normal operation
Preconditions for normal operation are:
All safety devices are closed.
The flywheel is stationary, the LED of the key PRESS DRIVE

OFF is shining steadily.
The keyswitch „Turn mode“ is not on.
Air pressure and hydraulic pressure in the overload safety

device are sufficient.
When all preconditions are met, use the HARDKEY MAIN DRIVE
ON to start the main drive of the press.
Pressing this key switches on the drive's main contactor K102A1
(A1A2) PRESS DRIVE and the drive is accelerated up to the
programmed speed. The key's LED blinks while the drive is
accelerating. Once the adjusted speed is reached, the LED shines
continuously. Not before this stage the clutch can be engaged and
the press set to work.
Pressing the green button, the clutch is engaed and the press and
the coordinated working sequences of the supply and auxiliary
devices are started.
Pressing the red button, the clutch is disengaged in controlled
motion and the sequence is stopped.
The drive is stopped with the key DRIVE OFF, the flywheel is
slowed down and stopped with the drive control. After successful
standstill the LED lights up in the key and the drive contactor
separates the electrical connection to the motor.
DANGER:
The main switch at the control cabinet may not switched off
before the flywheel comes to a standstill. As long as the flywheel
is running the systems is supplied with power that cannot be
converted in a controlled way so that it may cause damages at
the control device or activate the cut-outs!
II-6
2.3 Set up mode
To install dies and other system components the press must be

taken to defined positions. Therefor the set up mode is used.
The press can only be moved slowly in this mode, as the

operation must takes place while the safety devices are open. As
the crankshaft is held when the clutch is switched off, it must be
activated to turn the crankshaft. This is executed in the crawling
gear („Turn“ mode) with the two-hand button right at the press
frame. At hte same time, with this button the drive in mesh is
started.
To this, the press can also be moved by hand. For this, the clutch
must be activated with both buttons, too.
2.3.1 Turn mode (crawling gear)
Preconditions for crawling gear are:
The clutch is disengaged.
The press must be set to operate in SET-UP MODE:
The flywheel is stationary.

The key switch S102E1 (E1A4) CLUTCH MANUAL is
switched on.
The flywheel clap is closed.
This function is also available when the safety devices are open.
Pressing the crawling gear button the press drive is switched in

the operating mode CRAWL. The main contactor of the drive
switches the speed setting value to zero, that means that the drive
is controlled stationary.
With that the preparation for the ram’s movement in crawling gear
is done. This state is indicated by the LED in the hardkey.
There are two hand buttons at the press frame, SLOW MOTION
S102E2 (E1A5) and S102E3 (E1A6), installed ad fixed distance to
another. A movement is only executed, if both buttons are pressed
at the same time. The distance between the buttons ensures that
they can only be pressed with both hands.
II-7
When both keys are pressed simultaneously, the drive begins to

turn at crawling speed and the clutch is engaged by means of the
double solenoid valves Y101A1 (A1A0) PRESS CLUTCH
CHANAL 1 and Y102A1 (A1A1) PRESS CLUTCH CHANAL 2.
The direction of rotation is determined by the selector switch
S106E3 (E1A7) SLOW MOTION TURN DIRECTION which is
assigned to one of the keys of the two-hand trip guard. Die The
movement continues as long as the keys are pressed.
In order to enable turning the pressure should be taken off the die
cushions as the power during crawling operation is not enough to
overcome the back pressure of the die cushions.
The crawling gear speed is programmed as a MACHINE

PARAMETER separately for each direction of rotation.
Releasing the keys the clutch is switched off and thus the
crankshaft is fasten again. Simultaneously the drive speed is set
to zero again and the motor is stopped.
Before this, to switch off the control cabinet the drive must be
switched off again with the key drive OFF.
II-8
2.3.2 Manual operation
Preconditions for manual operation are:
The clutch is disengaged.
The drive is switched off with the HARDKEY DRIVE OFF.
The flywheel is stationary.
The press must be set to operate in SET-UP MODE.
The key switch S102E1 (E1A4) CLUTCH MANUAL is switched

on.
The flywheel clap is open.
This function is also available when the safety devices are open.
If the ram is to be moved manually (e.g. when exchanging the

dies), turn the key-switch DRIVE OFF to isolate the drive from the
mains power supply.
When the two-trip guard SLOW MOTION is pressed, only the

clutch is engaged. The ram can be moved upwards and
downwards by turning the flywheel with the turn bar put into the
contact bores. These can be reached though the flywheel clap.
This operation requires two operators.
NOTE:
All functions are interlocked against EMERGENCY OFF.
II-9
2.4 Safety devices
The following safety devices are attached to the press:
the die area cover
advance protection grid
the flywheel clap
The safety devices are movable and held with an electromagnetic

bar in the safe working position. For opening the safety devices
the unlatching switches nearby must be actuated. Those release
the bars only in a safe working mode of the machine, i. e. when
the drive is at a standstill. As soon as one of the bars is open, the
mashine is only movable in set up mode.
If one of the unlatching switches is opened with forced rupture,
emergency stop is released, i. e. the machine is disengaged
immediately and all drives are stopped. Thereby a non-
coordinated state results from the last moves of the line. This state
must be changed before a normal restart.
II-10
2.5 Switching off
The drive may only be stopped using the PRESS DRIVE OFF key.
Both shut-down from normal operation and shut-off of the crawling
gear are controlled by the key.
When it is pressed, the drive is braked and the rotational energy is

fed back into the circuit. Once the drive is stationary, the drive's
main contactor is turned off and the LED in the key comes on. The
drive is now disconnected from the power supply circuit.
The main switch of the control unit may only be turned on or off
when the flywheel is stationary. Otherwise the semiconductor
fuses may blow. In unfavourable circumstances the speed
regulator may be damaged.
NOTE:
If the sequence is not followed, an unwanted fault message will

appear on the display.
DANGER:
No guard door must ever be opened until all components have

come to a complete standstill. All components must be switched
off before a guard element is opened.
The fact that the drives are switched off when a guard door is
opened is irrelevant as far as this safety regulation is concerned
as undefined conditions can occur which can lead to problems on
restart.
II-11
3 Adjustment
To adjust the press some MACHINE PARAMETERS, some

mechanical adjustments and adjustments concerning the hydraulic
and pneumatic systems must be taken into account.
The adjustments are made in the factory or while mounting the
press by the works mechanic installer. They are written down in
the lists of machine values forming part of this documentation. In
some cases it is necessary to correct the machine values
according to the die in use, but most of the values shouls not be
changed without consultation with the constructor.
The most important machine values for the press are:
speed of the crankshaft (MACHINE PARAMETER according to

the specific product)
Cycles of the central lubrication unit (MACHINE PARAMETER

according to the machine)
working pressure of the clutch
working pressure of the ram counterweight (according to the

die)
working pressure of the safety overload device
operating values of the safety overload device (MACHINE

PARAMETER according to the die)
working pressure of the kickback damper
crank angle for the start (programme value)
crank angle for the stop (programme value)
crank angle for the die safety device (programme value)
height adjustment of the crankshaft
II-12
3.1 Programmable values
The programmable values are available with the keys of the

control panel bearing the pictogram for DATA INPUT. When the
key is pressed, the softkey-menu for data input is displayed on the
screen.
The softkey labelled with SYNCHRO opens the file containing the
data for the synchronisation programme. The data can only be
changed with the clutch disengaged.
3.1.1 Speed
The first parameter of the SYNCHRO file is SPEED. This

parameter gives the rotational speed of the press in revolutions ( =
strokes) per minute.
The maximum speed of the press is determined by the mechanical
parts. The depth of drawing and the advance distances required
for the individual products are decisive factors here The depth of
drawing determines the opening time of the die and hence the
time available to the advance system for moving the sheet.
II-13
3.1.2 Crankshaft angle for clutch ON/OFF
The crankshaft angles for starting and stopping are further

program values of the file SYNCHRO.
As the clutch starts very sudden and as the bearings are less
strong for the upwards movement than for the stamping direction,
the engaging is bocked in angle positions before the upper dead
center (UDC) in order to prevent the bearings from wear when
tearing up the heavy ram. Therefore in normal operation the clutch
can only be switched on out of the „forbidden area“. If the press
stops unscheduled within the „forbidden“ angle, then it must be
first moved in the crawling mode to the normal operation area to
be strarted again.
In normal operation and with the stop button the clutch is

disengaged in a preselected crankshaft angle CLUTCH STOP.
Thus the press stop with opened dies in normal operation in safe
positions, where it can be restarted without problems.
The discharge of products is monitored by indicating devices. A

product that fails in a die station for a stroke is interpreted by the
control as a discharge failure, i.e. a stamped product still being in
the die. That produces a case of die safety device. In that case
the press is disengaged at a preselected angle DIE STOP. At this
angle on one hand the failed discharge is surely noticed, on the
other hand the die is not yet completely dipped.
After this fault the press can be normally started again; possibly an
adjustment in the crawling gear is necessary, if, for example, the
drive from the short starting distance is not enough to run through
the bottom dead center (BDC).
II-14
3.1.3 Central lubrication system
The central lubrication system provides all bearings and moving

parts with oil ( exceptions are desrcribed in the annex “
Maintenance“). The lubrication is lead out in cycles, means, in the
supply line the oil pump establishes pressure in regular intervals,
thus piston-type dosing units at each position which needs
lubrication, are activated to apply a defined quantum of oil to their
referring bearing.
The portion of oil in every cycle is assigned from design by the
dimension of the dosing units, the overall dose is defined by the
cycle frequence programmed in the control. The cycle times can
differ from press to press, during test operation in the factory, the
best values are evaluated and set up ( machine parameters
10,11,12 )
The lubrication is observed by pressure switches ( 108E1 – low

pressure near the supply device / 109E1 - high pressure at the
end of the common supply line ), means, the increase as well as
the dropping of the pressure after switching off the pump is
indicated. If one of the cycle events is missing, an error message
is generated and the machine is stopped. Thus greater bearing
damages shal be avoided.
Machine parameter 10 defines the standby time, the control is

waiting for a status change of the switches and generates the
error “CL”, if one of the switches has failed
( Pressure not increased leakage or lock up of the
supply line on the way to the end
-- pressure not dropped recharging of the dosing units
disturbed
machine parameter 11 defines the time, the pressure is kept high
in the line, during this time the dosing units squeeze out the oil
they have stored
machine parameter 12 defines the time between 2 high pressure
pulses, this time the dosing units need for regeneration and
recharging with new oil
Flywheel The „P40S“- Presses have a separate flywheel bearing at the

Frame, not on the shaft as the standard presses. Thus, the
flywheel bearing is moving permanently and not only during press
stop. Lubrication is provided here by a permanent oil flow ( without
pressure ) so the pump has to run permanently here, the normal
bearings are supplied in cycles in the same way as in the standard
presses by means of solenoid valve 108A2 which switches over
the pressure for the programmed cycle time to the oil supply line
of the bearings.
Balancing cylinders / The balance cylinders as well as the draw cushion pistons need a
draw cushion: least oil supply to avoid dry running of the seals. Therefore an -
other solenoid valve (109A1) splits off the oil pressure to the
specific dosing units at the cylinders and the cushions after a
programmed number of press strokes ( machine parameter 35 –
lubrication of drawing cushion )
II-15
3.1.4 Overload safety device
The presse is equipped with a hydraulic overload safety device to

avoid in case of a serious fault bigger damages of bearings and
dies. A pressure sensor is connected to the hydraulic system to
record the actual charge of the press. Due to this values, a
beginning overload event can be recognized and resisted in time
by an error message or by stopping the machine.
The following machine parameters / program values form part of

the overload safety devices:
Machine parameter Function
Overload MIN: control of the pressure in the overload

Parameter 45 safety device.
The reaching of this presure values is
precondition to start the machine.
Overload MAX: Appointment of a limit pressure beneath

Parameter 46 the threshold of the hydraulic pressure
control.
Exceeding this value causes an error
message and the stop of the machine.
Die pressure Appointment of a limit pressure beneath

Preset: „Overload MAX“, corresponding to the
Program value charge tolerance of the die. Exceeding this
value causes an error message and the
stop of the machine.
This program value is used for products
that require a special force built-up.
Offset overloed This parameters are provided for

device calculation of the press force from the
Parameter 17 hydraulic pressure values, they are set
Factor Overload during the initial setting of the machine and
device installed by the manufacturer, For detailled
Parameter 18 informations refer to App. C.
Over and above that the ultimate pressure values during one
stroke are recorded. These can be extracted by the control to
watch the charge of the press during operation.
II-16
3.1.5 Monitoring with analogue pressure sensor
The load on the press is mirrored in the current internal pressure

of the cylinder. Consequently the load of the press is supervised
with the relevant internal pressure of the overload safety valve.
The MICROGUIDE takes the current pressure with an analogue
pressure sensor in the pressure supply of the overload safety
device and responds on preselected limit values defined as
machine parameters:
pressure 1
2
x
time
Fig. 1: Pressure values vs time
Pos. Observed value Machine parameter
1 Release pressure overload safety valve

2 Overload MAX 21
3 Die pressure
4 Die pressure MAX
5 Overload MIN 20
x Die pressure preset program value „Die“
Release pressure overload safety The release pressure of the overload safety valve (1)
valve is pretensioning pressure (die pressur (3)) + 30 %.
When reaching this values the overload valve opens and the oil
disengages depressurized from the overload safety device.
OVERLOAD MIN OVERLOAD MIN (5) monitors the minimum pressure in the
Machine parameter 45 overload safety cylinder required for functioning.
II-17
The value must be input at approximately 30 - 40 bar below the

base pressure set, for of the pressure can differ due to dynamic
stress during operation.
As long as this pressure is not reached after engaging the press

the message „Overload MIN“ is displayed and engaging is barred.
If the pressure value remains under the minimum pressure, what
indicates a leakage in the overload device, the machine is
disengaged immediately and an error message is displayed.
OVERLOAD MAX OVERLOAD MAX (2) monitors the maximum permissible pressure
Machine parameter 46 in the overload safety cylinder and thus the maximum permissible
press force.
If this pressure is exceeded, the clutch is switched off immediately

and the error message OVERLOAD MAX is displayed.
The pick-up pressure which should be set is approximately 10 bar

below the triggering pressure of the overload valve.
The die-related limit value DIE PRESSURE PRESET (x) is defined

as application parameter under the softkey DIE. This value
indicates the die-related maximum pressure of the press. If this is
exceeded, the clutch is disengaged when the CLUTCH STOP
point is reached and the error message OVERLOAD PRESET
appears on the screen.
In order to obtain a guide value for the programme value DIE

PRESSURE PRESET two additional items of information can be
called up by pressing the hardkey DISPLAY under the softkey
PRESS.
DIE PRESSURE The value DIE PRESSURE (3) indicates the current pressure
which has just been set at the unit for operation. The so-called
base pressure (P2) is created by the pneumatically powered
hydraulic unit. The oil pressure is set by setting a corresponding
pneumatic pressure at the pressure controller.
DIE PRESSURE MAX The value DIE PRESSURE MAX (4) indicates the maximum
pressure which occurs during a stroke.
II-18
3.2 Adjustment of the pneumatic equipment
The pneumatic preconditions to guarantee the readiness for

working as for ex. the minimum pressure are monitored by the
control.
The following adjustments are not set with the control, but are
made directly on the press with the according fittings and control
valves. The manual entries and the actual values are observed
with the installed display units.
II-19
3.2.1 Ram counterweight
To relieve mainbearing and drive the ram hangs on two pneumatic

cylinders which get compressed air from the lower piston side.
That way they can bear the ram weight. The cylinders are
connected to reservoirs that offer a bigger volume in comparison
with the working volume so that light variations of pressure are
admissible.
The upper side of the cylinder is open to the atmosphere. The
lighting of dust is prevented by filter at the air admission.
Procedure:
In the TURN MODE bring the ram / crankshaft in the 270° and
90° positions.
Call up the current resolver position in the menu DISPLAY

using the key PRESS.
270° 90°
Fig. 2: Zero point adjustment
When the ram is in the specified position, the flywheel flap is

opened. Thus the drive is disconnected from the system.
When the clutch is reengaged, the ram may no longer move when
the correct pressure is set, i.e. the air pressure in the cylinders
compensates the weight at the crankshaft.
If the pressure is too low, the ram will move downwards.
If the pressure is too high, it will be pulled upwards by the

compensation cylinders.
A manometric switch B107E1 (E1D1) PRESSURE MONITORING

WEIGHT COMPENSATION makes sure that a minimum pressure
exists at all times. The press cannot start without a pressure
sufficient for the balancing cylinders.
II-20
The seals of the ram counterweight cylinders and the seals of the
drawing cushions are lubricated to avoid wear caused by friction.
The lubrication intervals are specified in machine parameter 35
(AF, DF),. The lubrication oil accumulates in the tanks and must
be let off from time to time.
II-21
3.2.2 Clutch pressure
The clutch on the main shaft is actuated with compressed air of 6

bar. Declutching and braking occurs by spring pressure. The
brake spring must be overcome by the pressure. Too low clutch
pressure can effect that the brake is detached while the clutch is
only insufficiently engaged or not engaged at all, so that the
crankshaft is not moved or only moved weakly. The results are
higher wear of the clutch and products of low quality.
As the clutch needs for a short time a big airflow for connecting
which in case of long feeding pipes could lead to pressure drops
and, consequently, to unstable engaging, this actual air
requirement is supplied by an accumulator series connected to the
control valve of the clutch.
II-22
3.3 Adjustment of the hydraulic equipment:Overload safety device
All hydraulic equipment systems are supplied from the oil stock of
the central lubrication system. That prevents oil of different
classes in case of leakage to enter through the internal oil
recirculation to get into the central lubrication system.
The central lubrication system is a preset system that feeds oil in
cycles into the supply net according to the rates from the control.
NOTE:
At a change of the oil type also the overload device has to be

evacated and refilled with the new type. Otherwise the new oil will
be one by one mixed up with theold type and degrade with the
time
DANGER:
Maintenance, setting and repair work to the hydraulic equipment

should only be carried out by specially trained personnel!
Pay attention to the safety instructions ginven in the intruduction

of this manual.
The hydraulic overload safety device connects the ball socket to

the ram and transfers the force from the drive to the ram through
an oil pad.
The oil pad is under pressure to keep the requisite stamping
forces while maintaining an adequate mechanical stiffness, but,
controlled by a pressure control valve it can yield, if the force
increases excessively due to a too low adjustment of the ram or
on account of any obstruction in the working area so that damages
at the press might occur.
The overload safety device works with a pick-up pressure of up to

225 bar, according to the designed force of 400 kN. This value of
pressure is only reached when the overload safety device already
energizes. The preload pressure is about 77% of the pick-up
pressure, due to the construction of the pressure control valve.
The pressure control valve is a proportional valve with a pick-up
proportion 1:1.3. That means that generally the stamping force
can be limited by adjusting the overload safety device, if this is of
use to the quality of the products.
Normally it is sufficient to monitor the stamping force by the
machine parameters of the control and to keep the adjustment of
the hydraulic equipment as it was adjusted in the company, for
changing the hydraulic adjustment is only necessary in case of
emergency.
II-23
The overload safety device is supplied by a pneumatic-hydraulic

multiplicator („booster“), that pumps by the normal compressed air
oil from the central lubricating system into the pressure circle of
the overload safety device with a pick-up proportion 1:42 of
compressed air to oil. This multiplicator is mounted on the tank of
the central lubricating system. The oil pressure is controlled by the
pick-up proportion on the air side. The prestress pressure is
limited on the oil side upward by a safety valve. This safety valve
was adjusted on 180 bar in the company and leaded.
As the oil is caged in the overload safety device by check valves,

the pressure in the overload safety device must be let off, before a
lower pressure can be adjusted. This is made by a solenoid valve
( Y2 ) in the pressure supply which is actuated in common with the
valve for the air pressure ( Y1 ) manually with the switch „S1“. This
switch is mounted beside the assembling opening for the ram
adjustment, because also for this adjustment the overload safety
device must be set depressurized.
The solenoid valve releases the pressure from the external
pressure circuit, so the limiting valve gets less preset pressure and
the pressure in the inner circuit exceeds the release factor of the
valve which open at once, which can be heard as a “pop” – noise.
For the setting of the air pressures for several Reaction- and
pretensioning pressures refer to the label near the device on the
press frame
.
II-24
φ10x1.5
p2
p3
4,6 bar
i = 1:1.3
1:38
p1
Fig. 3: Hydraulic plan for the overload safety device
The set-points for the compressed air supply for various pick-up
pressures and prestress pressures can be taken out from a board
aside from the device at the press support.
F [kN] p1 [bar] p2 [bar] p3 [bar]
100 56 43 1.02
150 84 65 1.6
200 112 86 2.1
250 141 108 2.6
300 169 130 3.1
350 197 152 3.6
400 225 173 4.1
Fig. 4: Table of pressure relationships
II-25
3.3.2 Kickback damper
According to the adjustment of the preload pressure regularly it

occurs that the overload safety device is actuated as a result of
pressure forces at the operate margins. Because of that the back
of the ram hardly kicks against the head of the overload safety
device when the ram is raised again.
The stroke is softened by the kickback damper while an opposed
piston is floatingly held by the pressure oil in the kickback damping
system against the overload safety device piston and follows it in
its spring system movement. On the way back the stroke is
damped while the pressure oil in this system must be displaced
through a throttle by the opposed piston.
So that the opposed piston can quickly enough follow the main
piston, an adequate pressure must be held in the system. The
pressure in the kickback damper is derived from the pressure of
the overload safety device and reduced to 70 bar by a pressure
reducing valve. This pressure does not even change when the
overload safety pressure is reduced, for otherwise the opposed
piston cannot follow the overload safety piston quickly enough.
to connection 4
overload safety device to the ram
pressure control valve

to return connection 5
pressure limiting valve overload safety device
Fig. 5: Kickback damper and control plate (backe)
II-26
3.4 Mechancal ram adjustment
The ram height adjustment is provided for the precise adjustment

of the die contact. For this, either the connecting rod length or the
position of the connecting rod bearing in the ram can be changed.
Here the position of the connecting rod bearing in the ram is
changed. This function is integrated in the overload safety device.
The upper stop of the overload safety device piston is adjusted by

a spindle nut. Thus the piston is pressed more or less up by the
pressure oil; according to this, the ram is fixed to the connecting
rod in various heights. The height adjustment reduces the
available overstroke of the overload safety device. Therefore it is
limited to 20 mm. Bigger height divergences caused by the design
of the die, must be compensated with adequate intermediate
layers.
The adjustment of the spindle nut is made by a driving worm and a

worm toothed wheel work. The worm can be reached through a
mounting opening at the feeding side.
For this the ram is turned to the convenient height in the crawling
gear. Aside from the mounting opening is the switch to let off the
pressure of the overload safety device. This switch must be
actuated, otherwise turning the spindle nut is impossible because
of the big pressing force.
Blowing off the overload safety device pressure results in an error

message „OVERLOAD MIN“. This message must be
acknowledged.
Now the ram position can be adjusted with a socket wrench. The
ram height cannot exactly enough be measured in this time,
because the working design is not set without the prestress of the
overload safety device. For this, the pressure in the overload
safety device must be rebuilt again, before the ram adjustment
can te tested in contact.
II-27
4 Dies
The dies are always arranged in one row..

According to the blank diameter more than ten dies can be used.
production direction
...
1 2 3 4 5 6 ...
channels
Fig. 6: Die arrangement
4.1 Programming
To gain access to programming the dies use the key DIES in the
key group DATA INPUT.
The parameter NUMBER OF DIES indicates the number of dies.
This defines the number of die channels monitored by the die
safety device.
If a number less than existings dies, then the supernumery dies
work without monitoring.
This parameter must be zero to let the machine run without

sheets. Before the feeder starts with sheets, this parameter is
tested to see whether it is set to zero. If the value is zero at this
time, the start is not executed and instead of this a message is
shown on the display.
This file is available in any mode of operation. Data can only

be changed in the SET-UP mode.
II-28
4.2 Die changing
Before starting the installation the the surfaces of the fixing plate,
at the ram and at the die must be cleaned and smoothed if
necessary. The fixing plate of the dies and the die stop cylinders
must be cleaned as well.
After releasing the die is placed on the rails. The die can be pulled
out of the press across an insulating air cushion emerged from
compressed air blown out of nozzles in the die bed.
After that the die can be raised from the suppots with a cran.
Another possiblity is to lift the die using a special elevating
platform and drive it out of the machine area.
The exact positioning of the die in the machine is obtained with

three stop at the ram and at the fixing plate as well. There are two
stop points for the top die and for the bottom in the direction of the
insertion of the die die and one stop point across this direction.
The precise close fitting of the die to the stop points is
acknowledged during the mounting with a LED indication.
mounting direction
spring loaded contact
pressure screw
die stop cylinder
Fig. 7: Schematic diagram: stops
II-29
4.2.1 Die installation
Before starting the installation the the surfaces of the fixing plate,
at the ram and at tthe die must be cleaned and smoothed if
necessary. The fixing plate of the dies and the die stop cylinders
must be cleaned as well.
upper die plate ram

lateral stop
front stop
spacer support
clamping plate
Fig. 8: Die stops
Installation sequence:
The rails for die changing are mounted.
The ram must be turned by hand to the upper dead point
position (UDP). The plug of the display device is connected to
the socket at the ram.
Top die and bottom die are locked by spacer supports.
Together they are pushed in the machine on the insulating air
cushion. Because of the blocking the upper stops is the first to
be fitted closely, while there is still some space between the
bottom die and the bottom stops.
II-30
transport support transport support top die
spacer support
air connection
floating
bottom die plate
Fig. 9: Transport condition of the die
NOTE:
Die stops are not simple stoppers but high-precision contact

devices.
The entire die is provisionally hung on the ram with the fastening
screws and it is lifted. The die changing rails are removed.
turn button floating rail
die in lifted position
transport support
Fig. 10: Die removal
II-31
Top die:
The ram is moved down by hand and the die starts floating.
The die is pushed against the stops with the aid of the spring-
loaded printing screws. The precise pressing force is obtained,
when the printing screws are driven in.
The spacer supports are removed.
The top die is fixed crosswise with fastening screws from the
center outwardly. Pay attention to the moment of torsion.
7 1 3 5
top die
6 4 2 8
Fig. 11: Die screwing sequence
The position of the top die must be checked. The position is

correct, when all three LEDs are lightening.
LED
connection to the socket button for LED test
v2 v1
v3
Fig. 12: Display for the die stops
II-32
Bottom die:
The plug of the indicating element is connected to the socket at
the fixing plate.
The bottom die is foating. Now the die is pushed against the
stops with the aid of the spring-loaded printing screws. The
precise pressing force is obtained, when the printing screws
are driven in.
The bottom die is fixed crosswise with fastening screws from
the center outwardly. Pay attention to the moment of torsion.
The position of the bottom die must be checked. The position is
correct, when all three LEDs are lightening.
When the dies are first-time installed, the die clearance at the
die stations must be steadily aligned.
NOTE:
Before the first stroke the die cuts should generally be checked
and readjusted if necessary.
Swing in scrap skeleton ejector and arrest it.

Put in blow-out rail.
Admit die cushions with pressure (s. table pressure values in
appendix).
Connect die cushions lubrication (quick acting closure).
Connect ejector, stripper, vacuum to air on thefixing plate.
Swing in discharge flap and adjust it.
Adjust ejector with consideration of the appropriate control
cam.
II-33
4.2.2 Die removal
The die should be cleaned before the die removal can take place.
Screw the spacer supports on the die fixing plate and turn
down the ram by hand until the die upper plate lies on the
spacer supports. The connection between top die and bottom
die is completed, when all screws are tightened. It is necessary
for the screws to be suitable to tear the bottom die a bit away
from the stops.
Release the bottom die and turn up the ram with the whole die
by hand.
Screw the die change system respectively the transport

support on the fixing plate for to be able afterwards to put on
the floating rails as far as they exist. This is, however, only
possible, when top die and bottom die have been lifted.
Now the die con be deposited on the floating rails in manual

operation.
Now the die can be detached from the ram plate. Afterwards
the ram should be turned up so that the die can be pulled out
troublefree.
Now it is possible to pull the die out of the machine over an

insulating air cushion by impinging on the air nozzles with
pressure imbeded in the die fixing plate. Now the further
transportation of the die can be made with a crane or a special
lift truck.
II-34
4.3 Die Cushions
The die cushions used are all gas-operated. In this way the sheet
retaining force can be numerically adjusted and horizontal
characteristics can be achieved even for deep drawing.
If possible, namely for working pressure p < 20 bar, air-operated
die cushions are used. In some applications it is necessary to use
nitrogen which is applicable up to working pressures of more than
100 bar.
The die cushions may be integrated in the clamping plate or in the
lower plate of the die. The pressure supply and the lubrification
are directly connected to the die.
For pressures up to 6 bar the compressed-air die cushions are

supplied directly from the system pressure. For higher pressures
boosters are employed achieving pressures up to 15 bar and
more. The sheet retaining force is then a result of the diameter of
the die cushion.
ADJUSTMENT:
PRESSURE MONITORING, DRAWING CUSHION

B108E4 (E1D4)
Contact maker
The pneumatic manometric switch monitors the pre-pression of

the drawing cushions. The manometric switch shall be adjusted
about 0.5 bar beneath the adjusted working pressure.
During maintenance works, the re-engagement of the pressure
may be forgotten.
All cushions are of the single-stage variety.

The equilibrium volume needed for each die cushion is added
below each cylinder, thus avoiding problems due to flux and the
heating effects associated with this.
The die cushions are annexed to the central lubrication system

and, in regular intervals, are connected by a solenoid valve to the
lubrication supply; that means that the die cushions are supplied
according to a preselected number of lubrication cycles.
The values of the lubrication cycles is adjusted with machine
parameters 10, 11, 12 and 60.
II-35
4.4 Ejector
The press has not got a mechanical ejection device of its own.
The ejector is part of the die.
According to the intended use machines of this line can be
provided with two different ejection devices:
with spring control

with pneumatic control
4.4.1 Ejector with spring control
The die intergrated ejector is activated by spring power, i.e. when

the die is open the ejector is always even with the punch. Only
when dipping into the bottom die the ejector is inserted into the top
die to fabricate the product.
Thereby the product is pressed out of the top die as soon as the
die opens. Now it is just to care that the cup is transported
upwards, i.e. that it keeps hanging on the top die until the height
necessary for blowing out is reached.
II-36
4.4.2 Ejector with pneumatic control
The pneumatically operated ejector is a function of the

MICROGUIDE control system.
Presence of a minimum pressure is monitored by a manometric
switch.
ADJUSTMENT:
PRESSURE MONITORING EJECTOR

B106E2 (E5A1)
contact maker
The pneumatic manometric switch monitors the pressure in the

die ejector system. It is connected in series with the manometric
switches which monitor the system pressure and the pressure of
the machine's compensation cylinders. The manometric switch
prevents the clutch engaging when pressure at the ejector is too
low. The manometric switch should be set to a pressure 0.5 bar
below the preset working pressure.
This system consists entirely of a mechanism inside the die which

is actuated by the control system via a solenoid valve. The usual
ejector cap of the tool takes the form of a double-acting cylinder.
The solenoid valve is actuated by the control system as a function
of the crankshaft position. This causes the pressure in the double-
acting cylinder to be reversed and the ejector extended. However,
the ejectors within the die continue to move in synchrony with the
ram. The system is thus comparable with cam control.
The ejector is programmed with the softkey SYNCHRO and with

the program values EJECTOR ON and EJECTOR OFF. The
solenoid valve Y106A4 (A1B6) EJECTOR TOP DIE is switched on
respectivly off at the crankshaft positions [°] fed in
It is only possible to change the data when the clutch is switched
off.
This function can also be used to control the vacuum in the top
die. In this case vacuum is put to the top die when the valve is
switched off to hold products safely in the top die during the
upward stroke. When the valve is switched on, it is either possible
to use the atmosphere for ventilation or to blow in compressed air.
II-37
5 Maintenance
5.1 Lubrication
The press is equipped with an automatic central lubrication

system which is monitored by the MICROGUIDE control system.
The lubrication system is a closed circuit. Excess oil is collected
and returned to the oil reservoir tank.
The oil reservoir tank and the pump system make up a single
aggregate which is mounted at the base of the press. The tank is
equipped with a float switch B108E3 (E1B5) CENTRAL
LUBRICATION OIL LEVEL which monitors the minimum
permissible oil level. This is a fail-safe closed circuit which is
broken by the float switch when the oil level falls below the
minimum.
The oil fill amountzs to 10 liters. Type B is used (see lubricants
table). The first oil change for the central lubrication system should
be carried out after 1000 hours of operation. Subsequently the oil
should be changed every 4000 hours of operation or at least once
a year.
At the beginning of each lubrication process the pump is switched

over by the solenoid valve Y103A2 (A1B2) from supplying the
flywheel bearing to the dosing and distribution system.
The aggregate has a fine filter on the pressure side whose
differential pressure, and thus the degree of contamination, is
monitored by a differential pressure switch B108E2 (E1B2)
CENTRAL LUBRICATION FILTER.
The manometric switches for monitoring lubrication are switches
with a fixed, non-adjustable triggering pressure. The triggering
pressure is engraved in the switch casing on one face of the key
hexagon.
In addition to the single function monitoring devices described in

the following sections the system also has a total cycle monitor.
The total cycle is composed of the pressure rise, the high pressure
period and the following pause period. The monitoring period is
defined as machine parameter 10.
Before the lubrication pulse starts a check is made by means of

the manometric switch B108E1 (E1B1) CENTRAL LUBRICATION
LOW PRESSURE that the pressure of the previous pulse has
been reduced completely. The manometric switch is realized as a
break switch with a fixed triggering pressure of 2 bar. Pressure
reduction between lubrication pulses is essential if the dosing
distributor is to be operated reliably. To prevent the pressure line
from running empty, a pressure retainer valve with an operating
pressure of 0.5 bar is fitted.
Before the start of the lubrication pulse a check is also made that
the manometric switch B109E2 (E1B3) CENTRAL LUBRICATION
CON ROD HOSE is at zero pressure.
II-38
After the start of the lubrication pulse, switching on of the

manometric switch B109E1 (E1B0) CENTRAL LUBRICATION
HIGH PRESSURE is expected. This manometric switch has a
fixed triggering pressure of 12 bar. From this moment onwards the
HIGH PRESSURE PERIOD is running. It is defined as machine
parameter 11. This period of time is long enough for all dosing
distributors to be able to carry out a dosing stroke.
The manometric switch B109E2 (E1B3) CENTRAL
LUBRICATION CON ROD HOSE must actuate; this way leakage
in the hose is found.
5.1.1 Lubrication of the Ram Weight Compensation Cylinders
These cylinders are connected to the central lubrication system.

Oil is supplied from above through the non-pressure part of the
cylinder. Frequency of lubrication is controlled by a stroke counter.
The number of strokes between two lubrication pulses is defined
as 35.
Usually adjustment: one lubrication pulse in 5.000 - 10.000
strokes.
As soon as this counter reaches the programmed number of

strokes, lubrication is initiated by the control system. First of all the
next high-pressure phase of the central lubrication system is
awaited. Then the solenoid valve Y109A1 (A1A7) LUBRICATION
RAM COUNTERWEIGHT is actuated. This synchronization
ensures that oil is fed in during the descent of the ram. This
prevents oil from blowing out with the escaping air during the
upward movement of the ram.
5.1.2 Lubrication of the air operated die cushionss
The die cushions are lubricated in parallel to the lubrication of the

weight compensation cylinders. To simplify the line routing a
second solenoid valve is however fitted at the second solenoid
valve Y109A1 (A1A7) LUBRICATION RAM COUNTERWEIGHT.
5.1.3 Flywheel bearing
The flywheel bearing is directly connected to the central lubrication

unit.
II-39
5.2 Drive
5.2.1 Three-phase current motor and speed regulator
The three-phase current motor is pipe-ventilated. The windings of

the three-phase current motor are provided with a temperature
safety device; ist reaction is monitored on the display. The contact
is connected to the control input K109E4 (E1D2) MAIN DRIVE
TEMPERATURE MONITORING as a break contact.
The speed regulator is provided at the primary side with very fast
semiconductor cut-outs to protect the semiconductors of the line,
in addition the recirculation in the DC-interstage circle is protected
with a semiconductor cut-out. The specification of these cut-outs
must be observed in case of exchange, otherwise damages at the
power unit of the speed regulator may occur.
A detailed manual for the speed regulator made by the supplier

forms part of this documentation. The device has got a number of
LED indicators for state monitoring and error diagnostics.
The speed regulator consists of separated modules conntected to

one another by distributors with shield grids.
The powersupply is situated on the left side, the speed regulator is
situated on the right side. Both devices have got LEDs for state
monitoring and error diagnostics. The microguide control is
connected with the speed regulator by a serial interface. The
communication between microguide control and speed regulator is
executed via this serial interface.
It is not necessary to adjust the actual speed after changing the

controller.
II-40
6.2.2 Clutch
The clutch in this production series is a pneumatic single-disc

clutch and brake combination. The clutch is engaged using
compressed air, it is disengaged and simultaneously braked by
spring pressure.
The clutch is directly activated by the double solenoid valve
Y101A1 (A1A0) PRESS CLUTCH CHANNAL 1, Y101A2 (A1A1)
PRESS CLUTCH CHANNAL 2. This double valve is provided
with a pressure balance as safety device. If both valves do not
switch simultanously, the pressure balance comes into action and
blocks the valve. This state is not shown outside the valve. It is
only visible that the clutch does not engage in spite of the action of
both magnet coils. This is visible by the LEDs assigned to each of
the coils.
It is only possible to unlock the pressure balance in state of
complete pressure suppression. Switching off the main switch is
not sufficient. In addition the caged pressure must be released by
opening the stop valve.
The clutch features wear, i. e. the transmittable moment abates by

the time, the friction lining must be renewed after a certain working
period. To control the clutch trip and to change the linings, please
observe the manufacturere’es advuces.
NOTE:
The clutch in use is not the manufacturer's standard design,

certain adaptations to the integration to the press are necessary,
therefore wearing parts can only ve ordered directly from the
manufacturer!
The clutch needs a light lubrication, supplied as oil mist with the
working. To this the oil tank at the valve unit is used. Pay attention
to a sufficient filling of this tank and use oil of Typ C (see
lubricants table).
II-41
5.2.3 Bearings
The backgear shaft and the crankshaft are equipped with roller
bearings. Only the connecting rod uses split plain bearings.
The special instructions of the manufacturers must be observed
when assembling the roller bearings. Special tools and equipment
are also needed.
Fig. 13: Crankshaft bearing
Each bearing is lubricated via a direct pipe and individual dosing

units are assigned to each bearing. Based on the standard dosing
frequency, the dosing volume is 1.5 cm3 per bearing.
II-42
The connecting rod bearing gets lubricated with an arc-shaped

hose from above that follows the movements of the connecting
rod. Because of the moving leakages of the hose may occur,
therefore its closeness is observed with a manometric switch
located right aside the feeding point. Thus the course of the
increase and decrease of pressure during one lubrication cycle is
reported. An unusual course due to a leakage causes an error
message and the stop of the machine.
The oil runs down from the connecting rod bearing along the
connecting rod into the ball socket which thereby get lubricated.
NOTE:
To avoid grat bearing damage, see that there is no rough dirt or

dust above the press, that might fall into the ball socket and be
washed in with the oil.
.
II-43
5.2.4 Transmission belt
The transmission belt is mounted and prestressed in the factory.

The belt tension should be periodically controled.
The transmission belt of the main drive is tensed in the following
way:
Put the belt on the pulley, stain the tensing device until the belt
can be pressed down ca. 20 mm with normal manual force to
set the belt to the pulley.
Then release the tension again.
When the belt lies removable on the pulley, mark (with chalk or
tape) a distance of 1000 mm on the back of the belt. At the
new attempt of pressing down the belt shall extend for ca. 10
mm within the marked distance; after multiple turnings of the
drive, when the tension is spread over the whole length, the
measured distance shall be still 5 mm longer.
After the tensioning fasten the screws on the tensing device
again.
For inspetion the final tension must be measured again after the
slack. Therefore the slack of one end of rope is measured with a
weight and noticed. With the same weight the tension of the belt
can be controlled; this control shall be made half-yearly. If the
slack grows too much (>30%), te-tensing is necessary according
to the description above.
For a new belt a higher pre-tension of about +30% is

recommended to compensate the initial elongation. Therefore
retensing after the first slack test will be necessary.
Tighten screws and nuts after the tensing process.
Torque Ma = 200 Nm
Drive in the nut on the feed rod
Torque Ma = 360 Nm
II-44
5.2.5 Ram
The ram is made of a cast body with fully-hardened guide rails

mounted on it. The preloaded shoes of the linear roller bearing run
in these rails.
The ram is connected to the drive of the press via the ball socket.
This ball socket is fixed to a piston which moves in one of the
cylinders of the overload safety device.
The ram is guided by preloaded linear roller bearings. A total of 16
roller bearings, 8 above and 8 below, hold and guide the ram
without play.
Pretensioning is achieved using wedges on which half of the
shoes are adjustably mounted.
Fig. 14: Ram with ram guidance
The linear roller bearings are lubricated via individual pipes.

Individual dosing units are assigned to each shoe. Based on the
standard dosing frequency, the dosing volume is 1.5 cm3 per
shoe.
II-45
The roller shoes are designed for a normal machine’s life-time.

According to the press forces and to adjustment variations of the
die unbalanced overload of the ram guidancees may occur that
reduces similar to the influence of dirt the life-time of the
guidances.As the guide rails are covered, a damage of the ram
guidance is not directly seen in the beginning. The surfaces of the
guidances only may be examined during maintenance or
adjustment works, when the oil sampling device is taken away. If
in the course of this reliefs in the area of the traces are
recognized, the changing of the guidances is recommended.
5.2.6 Overload safety device
The hydraulic overload safety device protects the press and the
die.
Essentially it consists of a hydraulic cylinder built into the ram. The
ball socket which transmits the power from the drive to the ram is
mounted on the piston in this cylinder.
Fig. 15: Overload safety device
The adjustment of the overload safety device is described in the

chapter „Adjustment: Hydraulic overload safety device“.
II-46
The overload safety device is provided with highly burdened seals

which, due to the special use of the press, may wear out. The
beginning of a seal failure is indicated by increasing pumping of
the pressure intensifier which must level out the deficiency caused
by the leak. At that occasion it is to be watched how many strokes
the pressure intensifier needs to reach the final pressure when
switching on the machine.
If the adjusted pressure is not reached in the long run, this can not
be recognized in the beginning by the values of the control,
because the minimum pressure adjusted is sharply lower. Only
with the manometer can be checked whether the pressure do not
rise sufficiently while currently pumping.
In this case the overload safety device needs to be checked.
Mostly a new value spare part can be ordered. An autonomous
exchange of the seals is not recommended.
II-47
5.2.7 Die cushions
The die cushions operate in seals that suffer from wear.

In the event of leaks, but in any case not later than after approx.
6000 operating hours, the seals and guide belts should be
replaced.
Here, the lubrication oil lines must be disconnected. When refitting
them, make sure that the entire oil line, right up to the outlet at the
die cushions, is full of oil. If this is not the case, due to the small
dosing quantity, temporary dry running may occur with
impermissible heating of the lower die. Special attention should be
paid to the long riser within the die cushion housing.
The temperature of the die cushions and the temperature of the
lower die plate must be checked regularly during operation.
NOTE:
If the lubrication system fails, the temperature will rise rapidly and
this may lead to longitudinal expansion of the lower die plate.
This in turn will lead to wear on the cutting parts of the die.
Replacing the seals
To change the seals a special device (fitting cone and calibration

sleeve) matching the diameter of the piston must be used.
The fitting cone is required for expanding the sealing rings. The
rings must then be shrunk back with the aid of the calibration
sleeve in order to prevent damage to the O-ring and TURCON-
GLYD ring when they are fitted over the piston.
NOTE:
If the seals are not lifted using a matched devoce of fitting cone
and Sizing sleeve, the they will be overstretched and will only
have a short service life.
II-48
Mounting instruction to remove the piston
Remove the old seals and guiding rings

Warm up the TURCON-GLYD ring in 80° - 100°C hot water
Place the fitting cone over the die cushion piston
Slide the O-ring over the cone.
Fig. 16: Replacing the seals
Id. no Function
1 Fitting cone
2 TURCON-GLD-ring
3 O-ring
Pull the heated TURCON ring over the fitting cone so that it
can be stretched without damage.
Insert the guiding rings of the piston
After that use the calibration sleeve to shrink back the
expanded TYRCON-GLYD ring.
If necessary, temper again TYRCON-ring and piston.
In the cours of this the die cushion piston is pressed through
the sizing sleeve. The sizing sleeve should be over the
TURCON-GLYD-ring until the ring is inserted again into the die
cushion cylinder
II-49
1
3
2
4
5
Fig. 17: Replacing the seals
Id. no Function
1 Die cushion piston
2 guiding ring
3 TURCON-GLD-ring
4 Sizing sleeve
5 Die cushion cylinder
II-50
III. Z-Axis
upper dead
center
ventilation OFF 0°
ejector OFF
vacuum STOP OFF
blow off die safety device
clutch STOP
vacuum STOP ON 270° 90°
ejector ON
ventilation ON
die opens die closes
180° cap distributor
bottom dead
center
III. Z-Axis
Table of Contents
1. SWITCHING POINTS OF THE Z-AXIS 3
2. MEASURING SYSTEM AND ADJUSTMENT OF ZERO POSITION 4
3. PROGRAMMING CALLING UP 5
4. PROGRAM VALUES MANUAL INPUT 6
4.1 PROGRAM VALUES PRESS 6

4.1.1 SPEED 6
4.1.2 DISENGAGE CLUTCH 6
4.2 PROGRAM VALUES ADVANCE 8
4.2.1 DIE OPENS 8
4.2.2 DIE CLOSES 9
4.3 PROGRAM VALUES DIE / PRODUCT RELATED 10
4.3.1 BLOW OUT 10
4.3.2 BLOWING TIME 11
4.3.3 DIE SAFETY SYSTEM 12
4.3.4 EJECTOR ON/OFF 14
4.3.5 VACUUM / VENTILATION THE UPPER DIE 14
4.3.6 VENTILATION LOWER DIE 15
4.3.7 END CONVEYOR POINT 15
4.3.8 END CONVEYOR POINT COUNTER 15
5 PROGRAM VALUES WITH AUTOMATIC ADAPTATION 16
5.1 LOADER ADVANCE 17

5.2 SYNCHRONISATION MONITORING 18
5.3 OPEN ADVANCE TONGS 19
5.4 OPEN LOADING TONGS 20
5.5 SCRAP SKELETON EJECTOR 20
III-2
III. Z-Axis
1. Switching points of the Z-axis
DANGER:
When performing setting or adjustment work of any kind, dis-

abling the safety devices may result in physical injury to persons.
The crankshaft is equipped with a measuring system to permit its

position to be synchronised with the other systems that make up
the machine. For control purposes the crankshaft is interpreted as
a simplified NC-axis. Following common practice it is called the Z-
axis.
The Z-axis can be interpreted as a cam-operated switching device

with programmable cam positions. It is also called the SYNCHRO
AXIS.
Types of switching positions:
Manually programmed These are described in the chapter 4 on DATA INPUT.
Automatically calculated These are automatically calculated by the control unit and are de-
scribed in the chapter 5 on ADAPTATION.
upper dead
center
ventilation OFF 0°
ejector OFF
vacuum STOP OFF
blow off die safety device
clutch STOP
vacuum STOP ON 270° 90°
ejector ON
ventilation ON
die opens die closes
180° cap distributor
bottom dead
center
Fig. 1: Synchropoints for one turn of the crankshaft
Z-Achse DF 04 06
III-3
III. Z-Axis
2. Measuring System and Adjustment of Zero Position
The measuring system used is a resolver. A resolver is an ana-

logue measuring system whose signal is only digitised in the con-
trol unit. The system is absolute within a single cycle, each posi-
tion of the rotor with respect to the stator corresponds to a distinct
output signal. This means there is also a distinct zero position.
The top dead centre of the crankshaft corresponds to 0 degrees.

Therefore the resolver must be adjusted such that its zero position
is reached at top dead centre.
Proceed as follows:
Move the crankshaft exactly to TOP DEAD CENTRE.

Call up the actual position of the resolver. This is displayed on
the screen using the PRESS key of the DISPLAY menu.
Finally rotate the resolver until 000 degrees is displayed on the
screen.
4 3
Fig. 2: Zero point adjustment
Position Function
1 Ram
2 Upper die
3 Lower die
4 Gauge
III-4
III. Z-Axis
3. Programming calling up
Precondition Availability in all operating modes and in any machine state.
The data can however only be changed with the clutch disen-
gaged.
Access The key group on the control panel for DATA INPUT allows you to
programme the Z-axis.
After pressing that key the line with the softkeys for data input ap-
pear. One of them is labelled SYNCHRO.
This key opens the data file of the SYNCHRO and Z-AXIS
PROGRAMMES.
SPEED RPM 200
DATA INPUT MODE RETURN<

VANCE LUB. ER
Fig. 3: Display of the control panel
Programming The values used should be given in degrees of the CRANKSHAFT.
Associated parameters, such as TIMES, are given in millisec-

onds.
Data input The individual switching positions are best found by moving the
ram to the appropriate positions in the turn mode.
The corresponding orientations of the crankshaft can be read off

from the screen using the PRESS key in the DISPLAY MODE.
The value 000 may not be used.
Z-Achse DF 04 06
III-5
III. Z-Axis
4. Program values manual input
4.1 Program values Press
4.1.1 Speed
The speed of the press and thus that of the Z- Axis is set here. It
deals with the scheduled speed, how the main drive is controlled
for, there is no feedback control. Evident deviations due to load
reasons at the real achieved speed can be corrected by the ma-
chine Parameter 06
4.1.2 Disengage Clutch
The press is provided with a brake/clutch disc combination. There

is no declutching position determined by the clutch. It can be dis-
engaged at any time during the crankshaft cycle.
For the press to operate together with the other parts of the ma-
chine it is important that declutching positions are defined.
Undefined declutching points: Defined declutching points (program values):
1. OVERLOAD SAFETY DEVICE 1. Die safety device

2. EMERGENCY STOP 2. Clutch STOP
3. SAFETY ( DOOR- ) SWITCHES
0°
10°
clutch STOP
270° 90°
180°
Fig. 7: Switchpoint "Disengage Clutch"
III-6
III. Z-Axis
Adjustment The switching position DISENGAGE CLUTCH should be chosen

such that the ram comes to a halt shortly beyond the top dead cen-
tre.
The switching point DIE SAFETY cannot be set before successful

blow out, but shall be set as far as possible before the angle where
the die closes again, for the press will stop before. The angle be-
tween switching point and real stop point will be somehow larger,
than for clutch stop, as the downgoing ram has to be decelerated
too.
It is necessary to allow for the difference in stopping distance be-

tween single stroke and continuous stroke operation. If the switch-
ing position is set too early, it will be difficult to remove the stamp-
ings. The stopping distance also depends on the speed of rotation
of the press. If the speed is significantly altered, it will be neces-
sary to readjust the switching position accordingly.
Z-Achse DF 04 06
III-7
III. Z-Axis
4.2 Program values Advance
4.2.1 Die Opens
The advance motion from one punching position to the next is

quite independent of the rotation of the crankshaft. The switching
position DIE OPENS only determines the point at which this mo-
tion begins.
Adjustment The switching position should be adjusted such that the upper and
lower die are only just still in contact.
First switching position: Die opens
Fig. 4: Die opens
Position Function
1 Ram
2 Upper die
3 Lower die
III-8
III. Z-Axis
4.2.2 Die Closes
As the advance movement is controlled independent from the

crank angle it is needed to check if the scheduled position has
been achieved in real during the time since die opened. Therfor
the advance control responds a ready message, which is re-
quested at the moment when the die closes
If the ready message of the advance is not present at this mo-
ment, the error message “SYNCHRO ADVANCE” is generated
and the press stopped at the switching point CLUTCH STOP:
One reason why this might not be the case is malfunction, but an-
other explanation could be that the time between the positions for
DIE OPENS and DIE CLOSES is too short for the axes to move to
the next position.
Adjustment The switching position should be adjusted such that the upper and
lower die are only just still in contact.
Second switching position: Die closes
Fig. 5: Die closes
Position Function
1 Ram
2 Upper die
3 Lower die
Z-Achse DF 04 06
III-9
III. Z-Axis
4.3 Program values die / product related
4.3.1 Blow Out
The stampings are generally blown out using compressed air. The
point at which blowing out begins is determined by the switching
position BLOW OUT.
Pay attention for: the RESPONSE TIME between operating the

solenoid valve Y106A3 (A1A4) BLOW OUT and the air being ex-
pelled from the nozzles.
This time lies between 30 and 50 milliseconds depending on the

unit. This fixed period is independent of the speed of rotation, i.e. it
does not change automatically when the speed is changed.
Hence, at high speeds the position must be advanced further than
at low speeds. Therefore if the speed of the press is altered ap-
preciably, this switching position must be adjusted accordingly.
1
5
4
3
Fig. 6: Remove stampings
Position Function
1 Ram
2 Upper die
3 Lower die
4 Nozzle
5 Cover
Adjustment The switching position should be adjusted such that the stamping
is exactly in front of the nozzle when completely pushed out of the
upper die.
The switching position is then advanced step by step to compen-

sate for the response time until good results are obtained. The
steps should not be greater than 5 degrees at a time.
NOTE:
When carrying out these fine adjustments it is advisable to use

the SINGLE STROKE mode.
III-10
III. Z-Axis
Aid for adjustment of the blow The mechanical setup as well as the air supply and the adjustment
out system of the switching points for blowing take influence on the time
needed to get the product out.
As the process is to fast to get it watched by eye, it is desired to
have measured values for comprarision. There is an aid provided
with the µGuide. In the DISPLAY- Mode under the softkey
„SERVICE“ the values of the die safety from the last stroke are
found.
Within one block are presented the number of the die station, the
state of reaction, the crank angle where the die safety did respond
and the time it was “ON”.
With the crank angle and the ON- time it can be estimated, if the
adjustment has been improved, means, the blow out time has got
shorter and the output speed higher. Even the balance of reaction
between the channels can thus be evaluated..
Check of Die Safety Sensors When the switching position BLOW OUT is reached, the die safety
sensors are checked. All should be clear at this time, i.e. switched
off.
If a malfunction is discovered during this process, the message
DIE SAFETY MALFUNCTION appears on the screen.
Example:
DIE SAFETY MALFUNCTION 00000010
Thereby means:
All trouble-free sensors indicate 0.
All faulty sensors indicate 1.
Causes for malfunctions may be:

Stamping has been left in the sensor field
Malfunction of the sensor
Inductive sensors may be activated by nearby pieces of metal.
Optical sensors may be dirty.
4.3.2 Blowing Time
While the switching position BLOW OUT triggers the blowing at a

particular position of the crankshaft, the BLOWING TIME is inde-
pendent of the crankshaft orientation. It is independent of the
speed of rotation and so does not need to be adjusted if the speed
is altered.
The instant the stamping is released from the die, its further re-
moval is independent of the motion of the crankshaft.
Adjustment The blowing time should be as short as possible.
It should lie in the range of 50 to 150 milliseconds. Short blow-

ing times are only possible if the time at which blow out com-
mences is exactly right. Long blowing times often just serve to
compensate for inaccurately set blow out positions.
Z-Achse DF 04 06
III-11
III. Z-Axis
4.3.3 Die Safety System
The die safety system monitors whether the stampings have been
successfully removed. It is not only important that the parts are
removed, but also that this occurs rapidly. Only if blowing out
commences in time and the speed of blowing out is great enough
can the decision to disengage the clutch because of malfunction
be made in time for the die not to close.
Assignment A SENSOR IS ASSIGNED TO EACH DIE.
Standard version: Up to 8 sensors are possible.
Extended version: With the additional input board up to 16 sensors can be monitored.
The appropriate MACHINE PARAMETER must be programmed

accordingly in this case.
From the time that blowing out begins until the crankshaft reaches
the DIE SAFETY position the control unit stores the signals at the
input ports 201Exi, i = {1, 2, 3, 4} and 202Exi, i = {1, 2, 3, 4}
(E1Cxi, i = {0, 1, 2, ..., 7}. When the turn on point position DIE
SAFETY is reached the signals stored until that moment are
evaluated. This analysis is based on the number of dies specified
under the softkey DIE. The inputs are checked with reference to
the number programmed in this parameter, starting with channel
1. For example, if the number of dies is programmed as 3, input
channels 1, 2 and 3 are monitored.
ADJUSTMENT:
DIE SAFETY Contact Maker
Depending on the type of stampings, different kinds of sensors

are employed. Non-optical systems are generally preferred be-
cause they are less subject to malfunction. Nevertheless this unit
is equipped with optical sensors. It must be made sure that the
signal lasts for at least 5 ms. It may therefore be necessary to in-
crease the pulse length if the parts are small and flat. Many sen-
sors are designed with built-in delays to reduce interference.
Such a delay can reduce the duration of a signal that is short to
begin with to an unacceptable level. Furthermore it is important
that the entire area through which the stamping may pass is cov-
ered. In the case of adjustable sensors this means adjusting
them to maximum sensitivity.
III-12
III. Z-Axis
NO MALFUNCTION Signals have been recorded at the monitored inputs at the time of
polling.
MALFUNCTION One or several signals are absent at the time of polling.
CONSEQUENCE The CLUTCH is DISENGAGED.
The fault message DIE SAFETY is displayed.
Example:
DIE SAFETY 00011001
Thereby means:
All trouble-free sensors indicate 0.

All faulty sensors indicate 1.
Reset 1:
Acknowledgement of the fault message
Consequence:
The clutch can be reengaged in this crankshaft position.
As the drive is not switched off , this can be done , ONLY WHEN
THE REASON FOR THE STOP IS EVIDENT AND CAN BE
CLEARED SAFELY WITHOUT OPENING OF THE SAFETY
DOORS.
Reset 2:
Before you acknowledge the fault message, switch off the press
drive.
Consequence:
If the message DIE SAFETY is acknowledged while the flywheel is

stationary, the ram is automatically returned to top dead centre, for
example to allow the die to be inspected or stampings to be re-
moved. During automatic operation the machine can be started
again from this position if the drive of the press is first started up
again.
NOTE:
The second fault correction method cannot be used if any safety

guard has been opened!
Z-Achse DF 04 06
III-13
III. Z-Axis
4.3.4 Ejector ON/OFF
This switching point allows various functions to be switched via the

solenoid valve EJECTOR Y106A4 (A1B6).
Normally, in the upper die a piston is activated which pushes the

product out of the punch by respective pin pushers.
The time when the air is provided for this issue, is determined by
the program value EJECTOR ON
In the most dies, the ejector is pushed back again, when the die
closes, therefore the valve has to be switched back in time for the
piston can respirate at diving back again. In some cases the knock
out has to be retracted actively by providing compressed air to the
lower side of the piston. Both cases are programmed by the value
EJECTOR OFF.
Adjustment To carry out this adjustment it should be proceeded in the same

way as with the switching point BLOW-OFF when compensating
for the reaction time.
4.3.5 Vacuum / Ventilation the upper die
When the lid is lifted on the one hand an overpressure is created

in the upper die which must be discharged, and on the other hand,
when the stamping is removed, an underpressure is created which
also ultimately has to be prevented
The respective pneumatic circuits combines a vacuum pump with

an air suplly line which are mutually switched on the upper die
For respiration during dive in and holding the product during com-
ing up, the vacuum is switched on by the valve 107 A2, the other
post of this valve is connected to the air supply, thus, in the same
moment, when vacuum is switched off, immediately air is supplied
to the upper die to release the product with the least delay.
This moment is defined by the program value
VENTILATION TOP DIE ON
This value has to be coordinated with the value EJECTOR ON
As long as the product did not get clear off the die, the supporting
air should be kept on, this is defined by the value BLOWING TIME
VENTILATION TOP DIE
The injector type vacuum pump also needs air supply for opera-
tion, this is provided by the separate valve 107A1, the time to
switch this valve on and off is defined separately by the values
VACUUM PUMP TOP DIE ON / VACUUM PUMP TOP DIE OFF
A delay has to be mentioned for reaction of the valve from activat-

ing as well as the time, the injector needs to establish the vacuum.
III-14
III. Z-Axis
4.3.6 Ventilation lower die
The product drawn into the lower die has to be pushed out by the
drawing cushion. During this process the drawing core has to be
respired by air inlets to prevent the effect of underpressure which
could damage the product or even tear off the product from the
upper die too early.
In addition, sometimes air support is needed to achieve a proper
attaching of the product to the upper die
This is managed by the valve 106A2, the respective program val-
ues are VENTILATION ON / VENTILATION OFF
4.3.7 End Conveyor Point
The end conveyor point ensures that the stampings from the cen-
tral die are evenly distributed between the two channels when an
uneven number of dies is used.
It is switched pneumatically by means of the solenoid valve

Y201A1 (A1B5) END CONVEYOR POINT.
Programming The parameter END CONVEYOR POINT programmes the crank-

shaft position at which switching takes place.
Adjustment The switching position should be chosen such that the previous
part has safely left the distributing guide and the next part has not
yet reached it
4.3.8 End Conveyor Point Counter
The END CONVEYOR POINT COUNTER determines the number

of strokes or the number of sheets as well performed before the
distributing guide is switched over. For this purpose different pro-
gram values „DISCHARGE POINT STROKES“ and „DISCHARGE
POINT SHEETS“ are available with the softkey "SYNCHRO".
Z-Achse DF 04 06
III-15
III. Z-Axis
5 Program values with automatic adaptation
The switching positions determined by the control unit are auto-

matically adapted to the current rotational speed of the press.
These positions therefore need not and cannot be accessed.
The switching positions are displayed for the purpose of servicing.

They are recalculated every time operation is resumed. The fixed
value 359 is displayed if they have not yet been calculated.
The key on the control panel bearing the pictrogram for display
gives access to the Z-axis display. When this key is pressed, the
softkey menu for the display comes up. One of the softkeys is la-
belled PRESS. This softkey opens the file for the press or Z-axis
displays. The file can be accessed from all operating modes and
in any machine state.
The values displayed are given in degrees.
III-16
III. Z-Axis
5.1 Loader Advance
Feeding the sheet from the sheet positioning station to the first
punching position marks the transition from the asynchronous po-
sitioning process to the synchronous punching process. The diffi-
culty lies in the fact that there is no link between the path from the
zero position of the loader axis to the first punching position on the
one hand and the path between individual stamping events of the
sheet processing on the other. The control unit therefore deter-
mines the displacement-time diagram of the feeding process by
taking a measurement. Whenever the machine is switched on or
the relevant data is altered, the forwarding distance is measured
again and the appropriate switching positions are recalculated.
The results are displayed.
START SYNCHRO L This parameter specifies the crankshaft position at which the
loader axis is started for feeding the sheet from the positioning sta-
tion. If the sheet has not been received when this position is
reached, the axis only starts at the next stroke with the ram in the
same position.
L-SYNCHRO STROKES This parameter indicates at which stroke the loader axis starts to
feed the sheet. When the forwarding distance is long, i.e. the
sheets are small, a single stroke may not leave enough time. In
this case this parameter takes on a non-zero value.
Specially on DF-systems, the following situation as an exception
may occur. If for some reason the advance in two coordinates
comes to a standstill in the last or in the next-to-last row with a die
safety device message, the loader axle that has already started is
stopped on the way to the first stamping position. Then the control
switches internally to single stroke mode. After elimination of that
failure the sheet being in the two coordinates advance must be
achieved in single stroke mode and the sheet in the loader axle
must be passed into the first stamping position in single stroke
mode. Then you can change again to continuous operation.
Z-Achse DF 04 06
III-17
III. Z-Axis
5.2 Synchronisation Monitoring
The performance of the automatic sheet feeding press is deter-

mined by the cut diameter and the drawing depth of the produced
piece (please also see capacity diagram of advance system). It is
only within that part of the stroke where the sheet can be freely
moved between upper and lower die that the advance system is
able to cover the distance of both - cut diameter plus bridge.
This time share varies depending on the drawing depth, i.e. a lar-
ger cut requires more advancing time than a smaller one. For this
reason the press speed must be set according to the capacity dia-
gram.
In order to monitor this correlation with a certain margin of safety,

the machine is equipped with a SYNCHRONISATION MONITOR.
At every stroke it checks whether the advance drives have

reached their position at the time of die entry.
Malfunctions:
1. The clutch is disengaged.

2. The ram comes to a halt in the standard position, i.e. shortly
behind its top dead centre.
3. Simultaneously the SYNCHRO messages appear on the dis-
play.
Remedy:
1. If L-SYNCHRO ADVANCE or Y-SYNCHRO ADVANCE are

shown, the speed of the eccentric press must be reduced in
accordance with the capacity diagram.
2. Is the speed correctly set, please check first the following
things:
2.1 Maximum speed of the advance motors
2.2 Proportional amplification
2.3 Speed of the main drive motor
2.4 Synchro-points die opens and die closes
2.5 Resolver adjustment of the top dead centre
If, however, L-SYNCHRO START is displayed, this means that

the automatic determination of the starting point to feed in the
sheet is not correct. If X-SYNCHRO START or Y-SYNCHRO
START are displayed, this means that the automatic determina-
tion of the starting points for returning to the X and Y starting
points, respectively, is not correct.
In this case the machine should be restarted in order to generate

new, correct starting points.
III-18
III. Z-Axis
Display of moving times The times where the evaluation of the starting points of the loader
and advance axes are based on, can be displayed in the
„DISPLAY“ Mode:
Press DISPLAY and then „LANGUAGE“, then activate Softkey
„SERVICE“ ( F3 ).
The last 3 rows of the display contain the values of the axes
he last column
L LZ xxxx,xxxx
X.... LX xxxx
Y LY xxxx,xxxx
The number following the comma shows the time stored during-
the test run which is base of the calculated starting time,
The number leading the comma shows the time needed for the
last step lead out. If this time is significant higher than the stored
time, the trouble may be caused by the advance.
5.3 Open Advance Tongs
The advance tongs usually open as the die closes for the last
punch of the sheet. Only after the die has closed does the ad-
vance unit no longer need to hold the sheet. A response time
passes between inactivating the valve Y112A1 (A1A6) ADVANCE
TONGS and the actual loss of gripping power, this time being
made up of the valve's switching time and the power losses of the
compressed air due to flux. The valve is closed 30 milliseconds
before the switching position DIE CLOSES is reached to compen-
sate for this response time. The appropriate switching position is
calculated in degrees with respect to the current drive speed. Its
value is not displayed.
Both the closing and the opening movement are part of the sheet
changing time and hence critical processes. This is why the signal
"ADVANCE TONGS OPEN" is checked within a specified time
(100 ms). If the signal of the advance tong monitor is not deacti-
vated during that time (signal = 0), the fault message "F: V-OPEN
TONGS" is displayed and the clutch of the press is disengaged.
If the DIE SAFETY switching position is too late and the ram only
comes to a halt shortly before the die closes, then the switching
position for opening the advance tongs may already have been
reached. When the machine is started up again, the tongs will
then open before the die closes.
Z-Achse DF 04 06
III-19
III. Z-Axis
5.4 Open Loading Tongs
The loading tongs open with a slight delay as the die closes for the
first punch of the sheet. This delay time can be varied by means of
a machine parameter. Only after the die has closed does the
loader axis no longer need to hold the sheet. In this position, i.e.
when the die closes, the advance tongs are closed, thus transfer-
ring the sheet.
5.5 Scrap Skeleton Ejector
The ejector has a driven and an undriven roller. The rollers are
closed to eject the scrap skeleton. A cylinder switch monitors the
rollers' closed position.
ADJUSTMENT:
SKELETON EJECTOR CLOSED Contact Maker
The cylinder switch is mounted on the cylinder that closes the

scrap ejector. It must be adjusted very precisely to the closed po-
sition of the rollers. To achieve this, the rollers are closed manu-
ally by operating the solenoid valve CLOSE SCRAP EJECTOR.
The switch is now pushed against the piston in the opposite di-
rection to that in which the piston moves until the switch is flicked,
as indicated by its LED. To obtain a safety margin, it is moved a
further 0.5 mm and then fixed in this position. The safe operation
is checked by operating the scrap ejector manually a number of
times. Finally, the main switch must be turned off and then on
again, since the response time is measured during the advance
test.
During the advance test the ejector is closed once in order to

measure the response time between operating the solenoid valve
Y106A1 (A1B1) and the rollers being closed. The ejector must be
in its operating position for this test, i.e. not lowered as is usually
the case when dies are changed.
Attention should also be paid to the working pressure of the clos-

ing cylinder. It should lie in the range of 3 to 4 bar. It must not be
altered once the response time has been measured. Otherwise
the main switch must be turned off and on again to repeat the
measurement of the response time.
The switching position calculated from the response time meas-

urement is displayed in the parameter EJECTOR.
The position is calculated so that the rollers are closed about 10

degrees after the switching position DIE OPENS is reached. Dur-
ing operation the result is checked for each ejection process. If the
deviations are too great, an appropriate message is displayed on
the screen. In this case it is advisable to repeat the advance test
to obtain a new measurement of the response time.
III-20
III. Z-Axis
Z-Achse DF 04 06
III-21
IV. Sheet advance system DF3M
Table of Contents
1 FUNCTION 3
2 ADVANCE DRIVES - LINEAR MOTORS 5
3 LINEAR GUIDANCES 7
4 ADVANCE TONGS 8
4.1 DESCRIPTION OF THE GRIPPING SYSTEM 8

4.2 ADVANCE GRIPPER MONITORING 10
5 LOADER AXIS AND LOADING TONGS 11
5.1 LOADER AXIS 11

5.2 LOADING TONGS 12
6 CONTROL 14
6.1 SPEED CONTROL CIRCUIT 14

6.1.1 SPEED MATCHING 15
6.2 POSITION CONTROL 16
6.2.1 MEASURING SYSTEMS 16
6.2.2 SETTING THE ZERO POINTS 17
6.2.3 SETTING OF AXES TRAVEL 17
7 PROGRAMMING, 18
7.1 CALLING UP 18
7.2 DATA INPUT 19
7.2.1 PROGRAM NUMBER 19
7.2.2 PUNCHES X 22
7.2.3 PUNCHES Y 22
7.2.4 START POSITION X 22
7.2.5 START POSITION Y 23
7.2.6 STEP X 23
7.2.7 STEP ½X 23
7.2.8 STEP Y 23
7.2.9 STEP YD 23
7.2.10 SHEET CLAMPING POSITION 24
7.2.11 START POSITION L 24
7.2.12 X-TRANSFER CORRECTION 24
8 LUBRICATION 25
9 SCRAP EJECTOR 26
9.1 TILTING OF THE SCRAP EJECTOR 26
IV-2
1 Function
The sheet advancing system of the DF-system consists of the
movement axes X ( lateral ) and Y ( lengthwise guiding towards
the press ) , and the loader axis (L-axis) parallel to Y.
The axis X is located on the carriage of the Y- axis and contains
the clamping system with the shiftable advance grippers.
The loader axis (L-axis) is built similar to the Y- axis, but located in
a lower level, the carriage supports the support of the loading
tongs and their swivelling device
The loader axis has to move behind the alignment station of the
feeder table to catch the sheet in its alignment position. Therefor
the tongs are swivelled backwards down while they run backwards
below the sheet coming in from the sheet lubrication, and
swivelled up again to grip the rear edge of the sheet after this has
been aligned properly. Then, the sheet is guided by the loader
axis into the first punching position, synchronised to the press,
where the sheet is taken over by the advance grippers during the
die is engaged in the first punch. This takeover is supported by
means located to the feeding table, which is described in the
chapter V – sheet alignment station.
At this type of advance the loader axis leads out the first
positioning of the sheet in the die, the timing of this movement is
calculated from the running time of the axis ( evaluated during
initial test run after start ), a correcting value ( provided as
machine parameter 21 ) and the programmed press speed.
After the takeover, the two-coordinate advance with X- and Y- axis

guides the sheet through the whole following punch positions. This
movement of the advance is sychronized to the press by the
program values of the Z- axis ( SYNCHRO ) “die opens / die
closes “
The dynamic performance of the advance is the limiting parameter
of the feasible press speed depending on the required step length
and the time available during the “die open” period.
The punch positions are approached “on the fly”, any correction or
machine stop at a wrong positioning is not possible, but after the
die has closed the actual position is compared to the scheduled
and in case of a misprint the press is stopped at regular “clutch
Stop”.
Vorsch DF3M5 03 06
IV-3
L-axis Y-axis
1 22
linear motor
3
X
direction of production 4
Fig. 1: Sheet advance system DF3
Item Function
1 Sheet clamping system left
2 Sheet clamping system right
3 Tong support
4 Loading tong
IV-4
2 Advance drives - Linear motors
DANGER:
Linear induction motors are used to drive the advance axes. The
guide tracks for these axles are equipped with strong permanent
magnets.
• People wearing cardiac pacemakers must keep away from the

feed axle area. The risk to these people is potentially fatal.
• There is a more acute risk of injury as a result of ferromagnetic
materials (e.g. tools, measuring equipment, implants, etc.) being
attracted and held.
• Quartz watches, credit cards and other magnetic storage media
may be destroyed by the magnetic field.
The drive axes Y and L are lead out with single sided linear
motors. The active- primary – part is moving on the respective
drive carriage, the machine frame carries strong permanent
magnets with the effective side upwards, these magnets form the
passive – secondary side / reaction rail for the linear motor.
The magnets are protected against dirt and small parts by a rolling
cover blind. Unless, they will attract strongly any iron parts which
would hold down the cover and damage it during the movement of the
axis.
.
The linear motor of the X-axis runs in an U-shaped double

magnetic rail
In case of motor damage the primary part must be replaced. Local

repair of the primary part is not possible. Only original primary
parts supplied by AH-Hamburg may be used.
The permanent magnets can be replaced as needed with the

same type of magnet modules. The proper orientation of the
magnetic field (north-south) must be verified.
Vorsch DF3M5 03 06
IV-5
The temperature of the motor may reach a maximum of 125°C. It

is monitored by a thermostat in the coils. The motors of the X- and
the Y-axis are connected to a heat exchanger for cooling. The
splitting of the cooling water stream is shown by the inspection
glasses of the levelling valves.
Flow counter > 2 l/min for X

> 6 l/min for Y
Cooling fluid:
The cooling medium is water with an additive for corrosion
protection based on Ethandiol- ( appr.1,5 l / tank volume)
It is recommended to use demineralised water.
The motor of the L-axis is less loaded and does not need a water
cooling system.
ADJUSTMENT:
After assembly and maintenance work on the primary parts at the

carriage and the magnet modules it is absolutely necessary to
check the air gap between the primary part and the magnets.
Remove the protective cover from the carriage and check the air
gap along the entire travel path with a feeler gauge.
SET-POINT min.: 0.4 mm

SET-POINT max.: 0.8 mm
There should be 0.5 mm clearance.
IV-6
3 Linear guidances
Each of the linear guidances of the L- and the Y-axis consist of a
ball rail guidance with integrated magnetic scale and a roller
guidance for support.
The X-axis needs only a ball rail guidance.
These linear guidances cannot be replaced by other linear

guidances. Only linear guidances supplied by AH-Hamburg shall
be installed.
NOTE:
Maintenance works at these linear guidances should only be

carried out by educated AH personel.
Vorsch DF3M5 03 06
IV-7
4 Advance tongs
4.1 Description of the gripping system
The advance tongs are opened and closed by an integrated

double-action pneumatic cylinder. The tension pressure is
adjusted between 3 and 5 bar. The gripping force is too low at a
pressure below 3 bar, a higher pressure could damage the gripper
on the long run.
Fig. 2: Advance gripper
The pneumo-controlled valves ADVANCE TONGS CLOSE are

directly mounted at the advance grippers, the pre-control valves
Y203A1 and Y203A2 are close behind.
Both the closing and the opening actions are elements of the
sheet changing time and therefore time sensitive procedures. The
air supply installation takes account of this and should therefore
not be changed.
The gripping faces of the grippers are hardened. Nevertheless

wear occurs here, particularly when working on TFS sheets. Worn
or broken grippers must be replaced. Because of the overall heigt
and the requirement that the upper and lower halves of the
grippers be parallel it is not recommended to attempt a repair.
It is most important that the tongs do not touch the table surface in
any advance position. The result would be the destruction of the
gripper and excessive wear of the slide guidance.
IV-8
The top edge of the lower part of the gripper must be at the same
level as the cut edge in the die-plate. After resharpening the die-
plates has to be relevelled by shims if necessary.
Both grippers of this double action advance system are pivoted.

The swivelling device is moved by a pneumatic cylinder which is
operated by system pressure. The control valves ADVANCE
TONGS TURN, LEFT Y203A3 and ADVANCE TONGS TURN,
RIGHT Y203A4 are directly mounted at each advance gripper.
This swivelling movement is decelerated by a hydraulic damper.
The swivelling of the grippers enables the introduction of the sheet

into the bit of tongs during the travel of Y or L. After reaching the
gripping position only gripping is allowed. ( refer to chapter V –
Alignment station )
Vorsch DF3M5 03 06
IV-9
4.2 Advance gripper monitoring
The gripper jaws are pierced, from the upper jaw air is supplied
which can escape through the hole in the lower jaw, as long as the
gripper has no sheet clamped. When the sheet is clamped
properly, the air outlet is closed and a counter pressure is
established in the supply line which activates a pressure switch,
thus responding the successful clamping.
In the same manner the swivelling of the grippers is monitored, an

air nozzle is integrated at the swivelling device which is closed by
the swivelling lever in its end position.
Both swivelling levers as well as both grippers are observed by the
programmable pressure switch B203E1 ADVANCE GRIPPERS
CLOSED means, all nozzles have to be closed, otherwise a
gripper error “ADVANCDE GRIPPERS 203E1” is generated and
the further proceeding is stopped. In this case all 4 gripper states
have to be checked
The gripper monitos is provided with a constant working pressure,

supplied by a fine pressure regulator mounted at the base of the
Y-axis carrier near the cable support chain. It supplies both the
advance as well as the loading gripper monitor. The pressure
switch is located on the gripper carrier, combined with a
connection block. It contains throttles in line to establish the flow
sensitivity of the pressure, and the connectors for the supply- and
feedback lines for 2 grippers. Aside, one outlet is closed by a plug,
it serves for function test. The pressure switch is equipped with a
digital display and an small keypad.
For adjustment of the switch refer to the supplier’s manual
The switching point of the pressure switch is set to 0,5 bar, the
hysteresis to 0,05 bar
For Adjusmetn and testing the grippers are swivelled in an closed,
using a piece of sheet to close the nozzles. The loader tong shall
be opened in this moment.
The pressure is adjusted by the fine regulator following the display
of the switch ( operating mode Æ display shows actual pressure )
to 0,57 bar. For testing the plug can be removed, thus simulating a
open sensing nozzle, at this moment, the pressure shall drop
below the trigger level of the switch which shall respond.
IV-10
5 Loader axis and loading tongs

5.1 Loader axis
The loader axis takes the sheet from the alignment station to the
first punch. During this first punch, the sheet is passed to the
advance grippers.
The run from the alignment station to the takeover position needs
more than 1, up to 4 press strokes.
The starting time of the loader axis is calculated by the
MICROGUIDE according to the dynamic values evaluated during
the initial advance test, the programmed press speed and the
SYNCHRO- values for the die. The calculated value is referred to
a crank angle compareable to the programmed SYNCHRO-
Values. The result can be inquired in the Menu DISPLAY under
the softkey PRESS in (°) as “START SYNCHRO L”
Due to charge caused speed deviations of the press in relation to

the programmed set value, the arrival of the sheet in the die can
be too early ( collision with still closed die ) or too late ( error
message SYNCHR-L ADVANCE ). This is adjusted by the
machine parameter 21 “Synchronazation correction “
Vorsch DF3M5 03 06
IV-11
5.2 Loading tongs
The loading tongs are opened and closed by an integrated double-

action pneumatic cylinder. Full system pressure of 6 bar is used.
clamping piece
air connection
Fig. 3: Loading tong
Heere, too, the control valves LOADER TONGS OPEN, left

Y204A2 and LOADER TONGS OPEN, right Y204A3 are directly
mounted at the loading tongs to reduce the reaction periods.
The loading tongs shall be levelled according to the advance

grippers. The adjustment is carried out by inserting spacer disks
underneath the loading tong.
The loading tongs are monitored in the same manner for
successful clamping of the sheet as the advance grippers. The
pliers are pierced and the upper supplied with nozzles which are
closed by the clamped sheet. An equal switch unit B204E1
LOADER TONGS CLOSED responds the status, in case of failure
the error message “LOADING GRIPPERS 204E1” is generated,
the loading run is cancelled
The air is supplied from the same fine regulator which supplies the
advance gripper monitor.
The pressure switch is also set to 0,5 bar, the pressure is the
result of the adjustment of the advance grippers. For testing here
the advance grippers shall be open and swivelled out.
IV-12
For each sheet changing process, i.e. on the way back from the
the transfer station to the positioning station, the loading tongs are
swivelled away to prevent collision with the next sheet. When the
loader axis has arrived at its zero position, the tongs are raised
again. This is monitored by a proximity switch LOADING TONGS
UP B204E2 by means of a signal contact arm at the tong support.
The swivelling movement is carried out by a double-action

pneumatic cylinder operated at full system pressure. It is actuated
by the solenoid valve LOWER LOADING TONGS Y204A1. In
both end positions the tong support is decelerated by hydraulic
dampers. The adjustment of the hydraulic dampers is shown in the
concerned dokumentation drawing.
ADJUSTMENT
LOADING TONGS UP Contact Maker

B204E2
The proximity switch monitors the loading tong position in the

sheet positioning station by means of a signal contact arm. The
tong support is pressed against a fixed stop. The adjustment
should be made such that the signal is switched off as soon as
possible when the tongs swing out. If the signal was deactivated
too late, the return movement of the loader axis would be
delayed.
Vorsch DF3M5 03 06
IV-13
6 Control
The advance motion is controlled by means of a cascade control
system using closed control circuits.
µ-Guide
Positions- 1
setpoint
table Advance -
Servo module motor
Speed
control
Position- speed
control
Position 2
3
sensor-
head 4
Fig. 4: Control circuit of the servo modules

1: linear scale
2: axis zero ( programmed )
3: axis zero ( hardware reference )
4: end position initiator
The speed control is a task of the servo drive module, the power
control that supplies the motor. The positioning control is a task of
the MICROGUIDE control system.
6.1 Speed control circuit
The speed control devices are preset, respectively have to be

initialized at exchange by the control. Refer to chapter VIII Control.
IV-14
6.1.1 Speed matching
There is no manual adjustment of the speed foreseen. The control

evaluates the topmost feasible speeds during the test run after
switching on the machine and sets the control parameters
accordingly.
A significant change of these values allows conclusions upon the

status of the axes, thus the speed values are filed during the
assembly / Setup of the machine to be available for comparision
L - VMAX 1712
Y - VMAX 2408
X - VMAX 2416
DISPLAY MODE RETURN<
PRESS AD- SER- COUN- I/O- HOURS

VANCE VICE TER STATUS
Fig. 5: Display in DISPLAY mode
This screen is shown in the DISPLAY menu with the softkey

ADVANCE in mm/s. The display is only correct, if the machine
parameters PITCH ( 22,23,24 ) are set to 40,96, which the control
interpretes as linear gauge.
In regular setting the advance axes run with the utmost feasible
acceleration, thus the shortest positioning times are achieved.
In special applications ( thin and large sheets ) the standard
settings may lead to flopping of the loose – not clamped by the
grippers – side of the sheet. In this case, the dynamic of the
advance can be reduced within the limits of the allowable
positioning times, means the starting- and braking accelerations
are reduced to values, where the sheets still keep smooth during
movement. These values are evaluated and set during the
assembly tests and programmed under machine parameter 64 –
axis dynamics correction
Vorsch DF3M5 03 06
IV-15
6.2 Position control
No need for adjument of control parameters of closed loop

position control. These parameters are found automatically during
the test run.
6.2.1 Measuring systems
The measuring unit of the X-, Y- and L-axis is directly integrated in

the liner bearing of the axis carriage. The measuring unit is made
of magnetic scales with 1 mm scale division.
As the scales are pure counter- gauges, the zero reference has to
be searched for at first after switchin on the machine. The scales
are provided with a special mark at one end which is recognized
as Zero by the sensor head.
Therefor the advance travels with low speed towards the rear end
position until the end position indicator is activated.
As soon as the initiator responds, the advance is stopped and

moves now forward with the same low speed as before. After
dropping the signal of the initiator the zero reference is ecxpected.
Thus, the initiator has to be placed sufficiently far behind this
mark, there are even set positions to be approached – with
negative sign – between zero reference and final rear position.
During the slow forward movement the sensor head recognizes
the zero mark and resets the scale counter. The advance runs on
without further delay to the programmed start position for the
dynamic test.
IV-16
6.2.2 Setting the zero points
The programming of the advance reference positions refers to a

coordinate system oriented to the press center, where the die
geometry is also referred to. The position of the hardware- zero
points in this coordinate system is varying at each machine due to
dimension tolerances. Thus, the software zero points of the axes
have to be set in the program according to these deviations.
These values are defined by the machine parameters 28 ( L- axis
),
29 ( X- axis ), 30 ( Y- axis ) measured in mm referred to the
hardware- axis zero
The axes zero points have to be distincted from the start positions,
these are program values to be defined for different sheet formats.
As the advance axes return to the set zero ( standard position )

points at initialization and return to the start position these points
are set as far as possible to the rear end of the axes to get the
grippers in either case located outside the sheet perimeter. I tma y
be, the zero point will be located even behind the hardware zero
as long as the travel end initiator is far away enough.
As all other coordinate values of the sheet programs refer to these

zero points, they have to be initialized by new again, when the
measuring system or a guide rail or a complete drive axis was
changed.
6.2.3 setting of axes travel
The advance axes are able to produce extreme acceleration

forces, only by the program they can be stopped in time without
damage before the mechanical stops are approached. This
requires the axes lengths to be set in the control for reference.
The maximum allowed axes travels are set with the machine
parameters 25 – 27 during assembly testing.
Vorsch DF3M5 03 06
IV-17
7 Programming,
7.1 calling up
CAUTION:
With program changes of any kind, improper inputting of program

values can cause serious damage.
There is access to advance programming with the button of the

operation panel labelled with the pictogram for data input. After
actuating this button the softkey menu line DATA INPUT is
displayed. One of the softkeys is labelled “ADVANCE“. This
softkey opens the file of the advance menu data. There is access
to this file in every operation mode and at any state of the
machine.
Changing data is only possible when the clutch is off and the
advance must be in STANDARD POSITION.
The advance distance and positions can be indicated in

millimeters or in inches. The concerned operation mode is defined
by machine parameter 34.
IV-18
step ½X
7.2 Data input 1
x − step = 2 ⋅ x − step
2
7.2.1 Program number step Y
In combination with the DF – advance the

standard programs 1, 2, 4
are in application, in addition the respective
strip programs 11, 12, 14
The program number indicates the kind of sheet = 1st punch

pattern. The
sheet pattern is the arrangement of cuts on the sheet. There are 5
standard sheet patterns. Of these, the the pattern of number 0 - 3
is staggered and the pattern of number 4 is aligned.
Sequence of steps P1: step Xmotion ofstep ½X

the sheet
relative to the die
3 dies step Y
Æ 2 punches, 1 X- Step :
Program No. 2
X Æ Y,-X/2 Æ -X Æ Y,X/2
2 dies: 1 step ½X
− step = 22 X-
Æ 3 xpunches, ⋅ Steps
x − step
2
XÆXÆY,-X/2 Æ-XÆ-XÆY,X/2 Program No. 0 Program No. 1
step Y
Sequence of steps P2:
X Æ Y,X/2 Æ -X Æ Y,-X/2
Program No. 2 Program No. 3

= 1st punch
motion of the sheet

relative to the die Program No. 4
Fig. 6: Standard sheet patterns
Program No. 1
The programs 0 and 3 are feasible with single dies only, this is not
compatible with the DF advance.
The number of punches in X is depending from the die equipment.
The entry of 1 for the number of punches in X means no X step
the same programs can be run for sheets with turned punch
pattern ( turned sheet / turned pattern ), where only diagonal steps
are lead out. The programming of the X step has to be done any
way by the double value of the now required lateral step.
Vorsch DF3M5 03 06
IV-19
Fig. 7: Sheet patterns for rotated punch patterns ( turned sheet /

turned pattern )
These punch patterns allow smaller die distances, thus the

working range of the press can be used more efficiently for
specific punch formats.
IV-20
The Strip programs are assigned to program numbers added 10

to the pattern corresponding standard program numbers.
step X step ½X
step YD
step Y
Program No. 14
Fig. 8: Strip sheet patterns
Strip programs are for printed sheet patterns, which where initially
foreseen for application on double- die strip automatons
For strip operation the sheets are cut in strips. Therefore the webs
between the punches in the strip cut area are larger than the other
webs. The result is a sheet pattern with two different but regularly
arranged distances of rows. The first row distance is small, the
second one is large. The odd numbered row distances are all
smaller than the even numbered row distances.
Such printed sheet can be processed on AH presses without
cutting, as here the different steps can be programmed.
This additional program value YD is only displayed, if a program
number in the range of 10 - 15 is programed. For multi-die
operation only the program numbers 11, 12 and 14 are used.
Vorsch DF3M5 03 06
IV-21
7.2.2 Punches X
This parameter specifies the number of punches per row that each
die must perform. This definition is valid for single-die as well as
multi-die applications.
For sheets that are rotated by 90 degrees for processing the value
1 should be specified.
7.2.3 Punches Y
This parameter specifies the number of rows to be punched.
For sheets that are rotated by 90° for processing each punch is
regarded as an independent row. According to this, this program
value must define the number of punches per sheet for every die.
7.2.4 start position X
This program value specifies the start position of the sheet in the
X direction where the advance tongs are closed, i.e. where the
sheet is taken over from the loader axis. The start position is the
axis position where the initial punch is carried out. This position
must be chosen so that the clamped sheet shurely covers the
sensing nozzles in the advance tongs. Additionally, it must be
ensured that the advance tongs do not collide with the die when
the outside punches in the last row are made.
Startposition X
Startposition Y
Startposition
Fig. 9: Start positions for the X-axis and Y-axis
IV-22
7.2.5 Start position Y
This program value specifies the start position of the sheet in the
Y direction where the advance tongs are closed, i.e. where the
sheet is taken over from the loader axis. The start position is the
axis position wherer the initial punch is carried out. This position
must be chosen so that the clamped sheet shurely covers the air
nozzles in the advance tongs. Additionally, it must be ensured that
the advance tongs do not collide with the die when the outside
punches in the last row are made
7.2.6 Step X
This program value defines the advance distance in the X-

direction from one punch to the next within a row. It is made up of
the punch diameter plus the width of the web.
7.2.7 Step ½X
This program value defines the advance distance in the X-

direction from one punch to another when moving to a new row.
This only applies in the case of staggered sheet partitionings,
program numbers ending in digits 0 - 3. This program value is
calculated automatically when the program value STEP X is
specified and is always half that value. If the value is to be
changed, this can be done by entering a new value. The changed
value will be retained after switch-off of the control system.
When rotated sheets are processed, only the ½X-step is available.

In this case twice the length must be specified for STEP X, for the
correct value to be calculated as ½X-step.
7.2.8 Step Y
This program value defines the advance distance in the Y-

direction from one row to the next for the standard programs 0 - 5.
For the strip programs 10 - 15 this value defines the advance
distance between even numbered rows and odd numbered rows,
i.e. from row 2 to row 3, row 4 to row 5 etc. This is the larger of the
two row distances.
7.2.9 Step YD
This program value defines the advance distance in Y-direction

between an odd numbered row and an even numbered row for the
strip programs 10 - 15. That means the advance distance between
row 1 and row 2, and between row 3 and row 4 etc. This is the
shorter one of the two different row distances.
Vorsch DF3M5 03 06
IV-23
7.2.10 sheet clamping position
The position of the loader axis, where it grips the sheet in the
alignment station is the same as the Zero position.
7.2.11 Start position L
This program value specifies the start position for the run of the
loading axis with the sheet from the alignment station. The start
position is the axis position where which the initial punch is carried
out. In this position the sheet is taken over by the two-coordinate
advance unit.
Start position L = Sheet takeover pos.
Sheet clamping
Y X
Fig. 10: Start positions of the loader axis
7.2.12 X-Transfer correction
With the sheet takeover from loader axis to advance axes

systematic shitfing may occur. This program value causes the first
X- step to be effected shorter or longer according to the
determined shifting of the sheet between the positioning of the first
punch lead out by the loader axis, and the second punch
positioned by the advance after takeover.
IV-24
8 Lubrication
Lubrication of the advance system is only necessary in the area of
the rail guidances. The rail guidances are equipped with a long-
duration greasing where re-greasing is necessary every 6 months
is necessary.
Refer to app. B –Maintenance
Vorsch DF3M5 03 06
IV-25
9 Scrap ejector
After the last punch the scrap must be extracted from the die
synchronuously to the press. The scrap ejector has to be assigned
to the advance by its function, but is attached direwctly to the
press on the side opposing to the advance.
The function of the scrap ejector is controlled depending on the
sheet program by the SYNCHRO values from the Z- axis
The scrap ejector consists of the two roller which are rotating
permanently but kept in distance during standby, so the scrap can
move easily between. For ejection, the rollers are closed, thus
gripping the scrap and drawing it out.
The closed position is observed by a cylinder switch
Adjustment: Scrap ejector closed B106E1 (E1D7)

Shutter contact
The cylinder switch is attached to the cylinder, which closes the

scrap ejector. It has to be adjusted quite precisely to the closed
state of the rollers.
.Therefor the rollers are closed by manual activation of the
solenoid valve Y106A1 CLOSE SCRAP EJECTOR. Now, the
switch is moved in revers direction of the piston stroke against
the piston, until the switch responds, indicated by it’s LED,.To be
sure, the switch should be pushed on appr. 0,5 mm before it is
fixed in this position.
9.1 tilting of the scrap ejector
For die change, the scrap ejector has to be tilted down. This
movement is supported by a pneumatic cylinder which draws the
ejector frame upwards and is permanently supplied with an
adjustable air pressure
This pressure shall be set to 4 bar.
In operating position the ejector frame is locked aganinst the press

frame by two locking bolts left and right. These can be retracted
for unlocking by two spring countered pneumatic cylinders.
Therefor a pneumatic pushbutton is provided.
At the following tilting down of the frame, the captured air in the
support cylinder escapes by the regulating valve..
At tilting back, the cylinder is ventilated against the atmosphere,

the pushbutton needs not to be activated, as the lockers fall back
to the fixing position by lifting wedges in the frame., thus achieving
an automatic locking.
IV-26
V. Sheet Alignment Station DF
V. Sheet alignment DF
Table of Contents
1 STRUCTURE 3
2 STANDARD VERSION OF THE DF SYSTEM 4
3 SHEET ALIGNMENT STATION 8
3.1 SHEET ORIENTATION 8

3.2 ALIGNMENT FOR TURNED SHEET-INSTALLATION 12
3.3 SHEET BRAKE 13
4 SHEET TRANSFER 16
4.1 BLOWING NOZZLES 19

4.2 HAND OVER AIDS (SUPPORT FINGERS) 20
4.3 SWIVELING TONGS 23
4.4 ADJUSTING THE SHEET TRANSFER 24
4.4.1 ADJUSTMENT 24
4.4.2 FUNCTION TEST 28
V-2
1 Structure
The sheet alignment station consists of the alignment suction cup,

revolving on a pneumatic compound slide, and three sheet stops
whose positions determine the sheet's final alignment.
Directly after alignment in this station, the sheet is taken over by a
third axis designated the loader axis and conveyed to the sheet
transfer position.
If printed sheets are being used, the sheet stops must be set so
that their points of contact with the sheet correspond to those used
by the printing machine when aligning the sheet. All three sheet
stops can be moved accordingly.
The side stop, called the X-stop, can be used on either side.
If the stop is transferred to the other side, the X-advance direction
of the compound slide must be switched, too. To do so, the air
couplings connected to the throttle of the speed regulator for this
purpose must be switched.
The alignment suction cup can be switched by the control system
between vacuum and air supply. The air supply serves to release
the suction cup quickly when the alignment has been completed
and to create a layer of air between the suction cup and the sheet.
This layer of air protects the fragile lips of the suction cup from
damage while the sheet is being removed from the station. A
throttle regulates the amount of air supplied.
Fehler! Textmarke nicht definiert. SETTING:
A gentle stream of air must escape at the alignment extractor in

alignment operation. The air stream is used to create an air
cushion between the extractor and the sheet.
The quantity of air is set with a throttle valve on the vacuum
extractor valve.
If the stream of air is set too low or is switched off completely this
will cause extreme wear to the extractor.
V-3
2 Standard Version of the DF System
This version is characterised by the position of the sheet with

respect to the direction of production flow.
4 3
Fig. 1: Configuration of the sheet alignment station
Item Function
1 Hand over aids 3x
2 Sheet brake
3 Stop in X direction
4 Stops in Y direction
5 Positioning extractor
6 Initiator "Sheet in alignment station“
V-4
Before the sheet enters the station, the X-stop is extended.
The suction cup is in its rest position and the air supply is switched
on.
As the speed at which the sheet is fed is very high due to the high
frequency at which the sheets are changed, the sheet is
decelerated by the sheet brake when it leaves the coating system.
As soon as the switch registers that a sheet has arrived, a double

sheet test is carried out. If a double sheet is discovered, an
appropriate message is displayed on the screen and the process is
interrupted.
In this case, both sheets must be removed manually before the

message is acknowledged. This is necessary because when a
lubricant coating machine is connected the insides of the sheets
will not have been coated with a drawing lubricant.
If no double sheet is detected, the sheet will be stopped by the

sheet brake when it arreves at a distance of about 10 - 20 mm
away from the stop. The arrival of the sheet in the alignment
station is monitored by the proximity switch B114E2 (E2B6)
SHEET IN ALIGNMENT STATION.
ADJUSTMENT:
SHEET IN ALIGNMENT STATION 114E2 (E2B6)
Contact Maker
The inductive proximity switch is built in at table level. It indicates

the arrival or presence of a sheet in the alignment station. It
should be right behind the transport or application rollers so that it
is only activated when the trailing edge of the sheet falls onto the
table, i.e. the entire sheet is lying on the table.
As soon as the proximity switch registers that a sheet has arrived,

the suction cup of the alignment station changes from blast air
mode to vacuum mode. The meantime is used as
STABILISATION TIME OF THE SHEET. The length of time is
specified by the corresponding machine parameter 19.
At the end of this period, the actual alignment process begins. First
the solenoid valve Y114A2 (A2B5) SHEET REGISTRATION Y
starts moving the suction cup in the Y-direction. The force and the
speed of the motion can be influenced. The force is regulated by
means of the air pressure at the corresponding pressure regulator.
The speed is adjusted by means of the amount of air passing
through the appropriate throttle.
V-5
The pressure and the speed of the motion should be kept as low
as possible so as to avoid deforming the sheet and reducing the
alignment tolerance. The pressure depends on the sheet's weight
and should not exceed 1-1.5 bar. However, the Y-pressure should
be approx. 0.5 bar greater than the X-pressure.
The Y-motion brings the sheet up against one sheet stop, rotating
it then until it is in contact with the second one. This edge of the
sheet is now parallel to the X-axis of the advance unit. Sometimes
the print on printed sheets is not aligned with this edge. In this case
the lefthand Y-sheet stop can be moved by some tenths of a
millimetre in Y-direction so that the sheet is rotated. The angular
error of the printing process can be compensated in this way.
The shape of the sheet stops prevents the edge of the sheet from
being deflected upwards as it is pressed against the stops.
The sheet stops are provided with switches which monitor whether
the edge of the sheet is in contact with them.
ADJUSTMENT:
POSITION CONTROL Contact Maker
Y-RIGHT B115E1(E2C0),
Y-LEFT B115E2(E2C0),
X B115E3(E2C0)
The inductive proximity switches are operated by the levers of the

sheet stops. Once the lever's displacement has been adjusted by
means of the screw provided for this purpose and the screw has
been fixed, the switches are set. To do this, the lever is pressed
against its stop and the proximity switch is shifted towards it until
it is just triggered. It is then fixed in that position. This method
prevents the switching hysteresis from affecting the switch.
As soon as the switches in both Y-stops register contact with the

sheet, the solenoid valve Y114A1 (A2B4) SHEET REGISTRATION
X switches on the X-motion of the suction cup. With the suction
cup still exerting a force in the Y-direction, the sheet is now moved
along the Y-stops in the X-direction.
When the edge of the sheet comes up against the X sheet stop, a
torque is applied which acts to pull the sheet off the Y-stop nearest
to the X-stop. The Y-pressure is about 0.5 bar greater than the X-
pressure so as to counteract this effect. This is particularly
important because switching hysteresis effects make it impossible
for the switch on the Y-stop to detect small movements.
V-6
When the sheet is in contact with all three stops, the machine
again waits for the length of the SHEET STEADYING PERIOD
before the loading tongs are closed. When the manometric switch
LOADING TONGS CLOSED has been reached, the X-stop is
lowered by switching off the solenoid valve Y115A2 (A2B7) „X-
REGISTER STOPS EXTEND“.
Otherwise the message „SHEET ALIGNMENT“ is displayed on

the screen.
V-7
3 Sheet alignment
3.1 Sheet alignment station
3.1.1. Alignment sucking pad
3.1.2 Sheet positioning stops
The Alignment stops consist of a flute as insertion guide, the

proper stop itself, stated out as a carbide milling insert and the
optical stop sensor, which is blinded when the sheet edge aligns
correctly and transmits this to the control.
The X- stop can be shifted by pneumatic to get it off the sheet
edge after aligning to avoid wear or damage during the movement
of the sheet along.
One of the Y-stops can be fine adjusted to arrange the sheet edge
rectangular to the advance axis.
The setting of the three sheet stops determines the orientation of

the sheets with respect to the die.
If printed sheets are processed, the sheet stops must be set such
that the points at which they contact the sheet correspond to those
which the printing machine uses to position the sheets. All three
sheet stops are correspondingly adjustable.
The X-stop thus can be mounted to both sides, mounting faces
and connections for electrics and pneumatics are provided.
With the change of the stop side the X- advance of the cross slide
of the sucking pad has to be inverted, This is lead out by changing
the air connections at the throttle unit for speed adjustement.
Since transfer of the sheet from the loader axis to the two-
coordinate advance unit takes place in the sheet transfer position,
the orientation of the sheet in X-direction must be correct from the
start, since the loader axis cannot perform an X-movement.
For setting the X-stop this means:
1. Advance the loader axis together with the transferred sheet in

the crawling mode until the sheet's leading edge in the Y-
direction is positioned above the cutting rings of the die. Thus,
also a measure for the start position of the loader axis is
obtained which can be read off directly at the control cabinet.
Afterwards, this value only needs to be programmed under the
softkey "ADVANCE" in the programming mode.
2. Using the softkey "OPEN LOADER TONGS" open the tongs.
The sheet now being released can be positioned so that the
right-hand edge of the sheet extends beyond the cutting ring of
the right-hand die by the width of the bridge specified in the
sheet layout.
3. Use the softkey "CLOSE LOADING TONGS" to transfer the
sheet to the desired position with the loading tongs.
V-8
4. To check the resulting bridge width, a single stroke is

performed in this position.
5. Step 2, 3 and 4 should be repeated until the specified bridge
width is obtained.
DANGER:
Observe safety devices.
6. When the correct bridge width is obtained, move the loader axis
with the sheet backwards in the crawling mode.
7. The X- sheet stops are now adjusted mechanically against the
edge of the sheet. This means that the stop lever of the stop
should be in its end position when the sheet is in this position -
in other words, pressing against the stop.
Fix the adjustment.
8. After completion of the adjustment, a check should always be
made.
9. The orientation of the Y-stops results from the parallelism of the
bridge widths at the front of the sheets.
V-9
3.1.2.1 optical monitored alignment stops
Function The alignment of the sheet to the stop is monitored by the

electrical survey of the blinding of the light slot which is formed
between the sheet edge and the round stop insert
To avoid dirt blinding, smooth air is blown through the inlet
channels.
Due to lack of space the light is guided by fiber optic cables from
the sensor/amplifier device to the stop and back, concentrated by a
lens and deflected by an 90°- prism head.
The tolerated gap between sheet edge and stop insert is adjusted
by the sensitivity of the sensor/amplifier device.
For this task, a standard gauge is provided. It consists of a guiding
frame and a special shaped sheet to define a reference edge.
In normal use the sheet edge will rest in contact to the stop.
Depending on raughness and planarity of the sheet, torque effects
can occur during the adjustment movement, leading to a loss of
contact to one of the stops, which equals a bad alignment. He
optical monitored stops allow a dedicated adjustment of the
tolerated alignment deviation between 0,1 and 0,5 mm.
The gauge is shaped in such manner, that it contacts the

cylindrical insert plate with two 30° - angled edges left and right
from the light beam and a straight edge between which keeps off
the insert in the range of the light beam with 0,1 mm.
Other gauges can be made for different gaps, they will be marked
with referring numbers.
V-10
Evaluation / Adjustment
required equipment :
n Turck / Banner light conductor sensor type D12SP6FPYQ
n Lower light conductor with lens
n Upper light conductor with angled ( prism- ) lens
n Licht conducting cable, diameter 1,5 mm
n Adjustment gauge
Adjustment of the light sensor / amplifier:
1. set turnswitch for switching speed ( frequency ) to range 500

2. insert adjustment gauge for 0,1 gap at the stop head in the
hole therefore provided
3. search for the switching limits by turning the sensitivity
regulator ( yellow LED on / off ), mention referring slot angles
(à switching hysteresis )
4. a) turn regulator to increase sensitivity ( LED lights )
b) turn back until LED is off
c) smoothly increase again for ¼ - ½ of the switching range
determined before
5. releave gauge from the stop head. The yellow LED will light,
insert gauge again, LED shall extinguish, if not press gauge
slightly in. If LED still keeps on, start with 3 again,
Sensitivity regulation
LED green
LED yellow
Switching frequ.
LED-Strip red
Fig. 2 Adjustment elements of optical fiber sensor / amplifier
Thus, the Sensor / amplifier is adjusted for a gap of 0,1 mm and

ready for operation.
V-11
3.2 Alignment for Turned sheet-installation
In standard case the sheet is conducted through the die with

interchanging transverse and inclined punches according to the
sheet layout with rows staggered in X-direction.
Y In case of rows arranged in Y-direction with offset the dies can be
put closer together; for that the sheet is only conducted through the
die with inclined punches. Here "Turned sheet" and "Turned
pattern" must be distinguished.
In case of "Turned pattern" sheet is printed in a way that the
alignment on the loading table does not differ from the alignment in
not turned pattern case. On the other hand, for "Turned sheet" the
printed sheet is handled in the same way as for the normal
advance run, but turned with dies put closer together.
For this, the alignment device must be turned 90°. According to
this the loading table must be arranged. Either the alignment
station is only installed in this position or a second alignment
Turned sheet station is provided for both operation modes.
As now the "Y"-stops work in X-direction, the alignment sucker

must moved futher from the feeding edge. For this a retractable
alignment sucker is used to avoid damages caused with front edge
of the sheet while running in. The lowering and lifting movement is
executed simultaneously with the switching from blast air to
vacuum.
The two "Y"-stops now arranged parallel with the loading axis,
must be displaceable, too. This way they can be torn out of the
area of the sheet edge during fast movements of the sheet. The
single “X“-stop, now working in Y-direction, can be a fixexd one.
Turned pattern Otherwise the operation process corresponds to the process
without Turned sheet. Accessory control devices are not needed,
the cables and hoses are changed from normal to traverse
direction, when processing in this mode.
The control does not distinguish Turned-sheet operation from

normal operation, i.e. the messages keep talking about two "Y"-
stops and one “X“-stop. Remenber that the "Y"-stops work in “X“-
direction and the “X“-stop in Y-direction!
V-12
3.3 Sheet brake
The sheet brake is integrated directly in the alignment station. It

consists of a speed-controlled drive roller with motor. Two
pressurized pressure rollers are used to press the sheet against
die turning drive roller from below. The adjustable pressure is set
at the same time for both pressure rollers at a pressure control
valve. The speed is regulated from the software via a frequency
converter which is installed directly in the control cabinet next to
the servo boosters.
Fig. 12: Sheet brake
Function: Before the sheet is inserted into the alignment station, the X-stop is
extended and the sheet brake is activated. The positioning vacuum
is in the basic position and the blowing air is switched on.
As soon as the sheet is swiveled inwards by the destacking

cylinder (1-signal to B117E2 (E2B2) SHEET DESTACKER
CYLINDERS SWUNG IN), the motor will run with the synchronous
speed of the coating unit. The pressure rollers are lifted at the
beginning of the outwards swiveling movement of the destacking
cylinder. If the loading axis is still traveling forwards, the sheet will
be swiveled inwards only when the loader has arrived at the
transfer position.
At the beginning of the sheet alignment, i.e. as soon as the
alignment in the Y-direction begins, the pressure rollers are
lowered again in order to permit the alignment of the sheet. The
actual adjustment of the sheet brake downwards begins after a
programmed delay and as soon as the rear edge of the sheet has
generated a 0-signal at the initiator B116E1 (E2D0) SWITCH ON
SHEET BRAKE (availability of the initiator after passing the rear
edge of the sheet). This delay is defined as a programmed value
SHEET BRAKE. This programmed value makes it possible to
influence the time at which the sheet is braked.
V-13
SHEET BRAKE 060
DATA INPUT MODE BACK<

MACRO SYN- AD- DIES COAT- COUN-
CHRO VANCE ING TER
Fig. 13: Programming of sheet brake
V-14
PREMATURE BRAKING: Premature braking will result in the sheet not being transported into
the sheet alignment station. The rear edge of the sheet remains on
the insertion plate and cannot be positioned.
LATE BRAKING: Late braking will result in the sheet slipping too far during insertion.
Because the cross slide of the positioning vacuum has only a
limited distance, there should be a residual path of no more than 25
mm until the sheet stops. If the sheet slips too far, it will not be
possible to transport the sheet to the sheet stops due to the limited
path of the positioning vacuum.
As soon as the next sheet has been brought into position, i.e. the
output for swiveling the destacking cylinder inwards has been
activated, the drive roller is again adjusted up to the synchronous
speed of the coating rollers.
ADJUSTMENT:
SWITCH ON SHEET BRAKE

B116E1 (E2D0) Make contact
The proximity initiator is installed on the lower level of the guide

plate, directly behind the lower discharge roller. It is used to shift
the braking motor down during deactivation by the rear edge of
the sheet (signal is 0). It cannot be adjusted.
NOTE:
This adjustment must be performed in accordance with the

given format.
V-15
4 Sheet transfer
In the case of the DF advances the sheet is transferred from the

loading tongs to the advance tongs during the first stamping. The
first stamping is therefore approached from the loading axis. While
the die in the first stamping is shut, i.e. when the top cutting bell
has dipped into the cutting ring, the sheet is collected by the outer
advance tongs. The loading axis returns to the alignment station
after the sheet transfer has been completed to collect a new sheet.
Fig. 2: Sheet transfer
Item Function
1 Sheet plate (shown transparent)
2 Stamping die
3 First stamping position
4 Advance tongs (shown swiveled inwards)
5 Hand over aids
V-16
The advance tongs can be swiveled in order to minimize the time

needed to change the sheet. When the Y-axis is returned to the
sheet transfer position the advance tongs are swiveled in order to
grasp the new sheet. It is necessary to lift the edges of the sheet to
the advance tong level. The advance tongs and the loading tongs
are located at the same height. Because the sheet guide level is
approximately 5 mm lower than its gripping level, the sheet which
is placed on the guide level at the outer edges must be lifted.
There are three devices for carrying out the sheet transfer:
n Blowing nozzles to lift the sheet

n Support fingers to support the sheet
n Swing system for the advance tongs
1
2
Fig. 3: Sheet transfer aids
Item Function
1 Advance tong
2 Blowing nozzles
3 Support finger
V-17
In addition, a distinction is made between two separate sheet

transfer time points:
STATIC SHEET TRANSFER The static transfer of the sheet takes place, for example, when the
first sheet is inserted after a stop in production. The following
conditions are required for static transfer:
n The advance tongs are already in the transfer position during

the swiveling process.
n During the swiveling process the sheet is moved forwards from
the loading axis.
DYNAMIC SHEET TRANSFER The dynamic sheet transfer takes place during normal production
with sheet plate. The following features are present during dynamic
transfer:
n During the swiveling process the advance tongs are returning

from the last stamping position and moving to the transfer
position.
n During the swiveling process the sheet is moved forwards from
the loading axis.
NOTE:
In the case of certain sheet formats it may be possible that only

static transfer takes place, since the advance tongs reach the
transfer position faster than the loading tongs.
The sheet must therefore be lifted at various positions, regardless

of the time of transfer. To ensure this occurs, the sheet transfer is
equipped with two blowing nozzles for each advance tong.
The time for blowing the sheet upwards and the upward swiveling
movement of the hand over aids is programmed as follows:
The sheet is blown upwards when the distance of the axes Y and L
is less than twice the programmed Y-step. This means that the
blowing time depends solely on the Y-step that is entered for the
given sheet format. A modification changing the concerning
machine parameter is possible.
The swiveling procedure for the advance tongs is started at the

same time as the sheet is blown upwards. The swiveling
movement itself, however, can be delayed via machine parameter
50.
V-18
4.1 Blowing nozzles
Compressed air is blown under the sheet through two nozzles in

order to lift the outer edges of the sheet. These nozzles are
controlled independently from the solenoid valves Y113A2 (A1C3)
"AIR NOZZLES, SHEET HAND OVER AID". The blowing nozzle
Item 2 / Fig. 4 is used to lift the sheet during static transfer, while
the blowing nozzle Item 3 / Fig. 4 is used to lift the sheet during
dynamic transfer.
The compressed air supplied to the blowing nozzles must be

adjusted to the given weight of the sheet edges.
The outer edges of the sheet are lifted as the blowing nozzles are
activated and placed onto the top sheet guidance. The top sheet
guidance is bolted flush with the top advance tongs bit. When the
advance tongs are swiveled in the sheet is placed into the bit of the
tongs by the guide plate.
4 1
3 2
Fig. 4: Blowing nozzles
Item Function
1 Advance tongs
2 Blowing nozzle - static transfer
3 Blowing nozzle - dyn. transfer
4 Top sheet guidance
The blowing period can be programmed via machine parameter

49. The blowing period must be programmed slightly longer than
the actual duration of the swiveling process. The blowing period
should be approx. 60 ms.
NOTE:
If the swiveling process is delayed via machine parameter 50 it

may be necessary to select a longer blowing period, since this
may cause the sheet to fall onto the sheet guidance level again
before the swiveling starts. This would prevent the sheet from
being transferred into the bit of the tongs.
V-19
4.2 Hand over aids (Support fingers)
Support fingers are lifted on the left, right and center to support the
transfer of the sheet to the dual-coordinate advance.
1 3 2
4 6 5
Fig. 5: Hand over aids
Item Function
1 Support finger, left
2 Support finger, right
3 Support finger, center
4 Advance tongs, left
5 Advance tongs, right
6 Loading tongs
The hand over aids are designed as swiveling strips whose sheet
supports fingers serve as a rest for the rear edge of the sheet. It is
necessary to support these support fingers because the sheet
guidance level in the area of the sheet transfer is located at a lower
level than the sliding level of the positioning table. The lower level
of the sheet guidance level is necessary to ensure that the
advance tongs never come in contact with the guidance level at
any position of the advance.
The support fingers fold down again following the completion of the
sheet transfer from the loading tongs to the advance tongs.
V-20
CONTROL The support fingers are moved with a dual-action pneumatic

cylinder.
The support fingers are controlled with three solenoid valves
Y113Exi, i = {1, 2, 3} (E5Bxj, j = {1, 2, 3}) "Fold back INSERTION
AID, right, center, left".
MONITORING The support fingers are each monitored with an initiator in the
lowered position. This monitoring is intended to avoid the automatic
movement of the axes when the support fingers are in the raised
position.
4 1
Fig. 6: Layout of hand over aids
Item Function
1 Sheet supports
2 Swivel frame with adjustment for sheet support
3 Fastening frame
4 Sheet support rails
The hand over aids can be shifted in the direction of production in

accordance with the transfer position. When the sheet format is
changed, it may be necessary to move the hand over aids aids
across the direction of production in order to compensate for the
changed position of the advance tongs. In addition, it is also
possible to adjust position of the sheet supports laterally. Individual
sheet supports may need to be removed if they might collide with
the advance tongs when returning to the transfer position from the
last stamping position.
V-21
NOTE:
The support fingers are not used to lift the sheet to the advance
tongs. The support fingers should only be used to help prevent
the sheet from hanging down between the advance and loading
tongs. The actual lifting of the sheet is performed with the blowing
nozzles.
V-22
4.3 Swiveling tongs
The swiveling tongs are a component of the advance table.
The following conditions must be met in order to guarantee the

sheet transfer to the sheet transfer position:
n The advance tongs must be able to grip the sheet securely on

both sides in the swiveled "in" position.
n In the swiveled "out" position the advance tongs must be
located to the side and next to the outer edge of the sheet. The
top sheet guidance (plate angle) must always be above the
sheet.
Fig. 7: Advance tongs swivelled in Fig. 8: Advance tongs - swivelled out
Item Function
1 Advance tongs
2 Top sheet guidance
3 Sheet plate
NOTE:
The top sheet guides may not be bent or disassembled.

The sheet transfer cannot function without these top guides.
V-23
4.4 Adjusting the sheet transfer
4.4.1 Adjustment
CAUTION:
Noncompliance with this basic setting can lead to damage to the

hand over aid or advance tongs.
The following basic conditions must be met before adjusting the

sheet transfer:
BASIC CONDITIONS n The spacing of the advance tongs has been adjusted with
regard to the required tong spacing has been adjusted in the
swiveled "in" position.
n The machine is in automatic mode.
n One sheet was separated from the pallet block and positioned in
the alignment station.
n The sheet was transferred correctly to the alignment station by
the loading tongs and moved to the first stamping position in
single-stroke action. The main drive and the advance drives are
switched off in this position.
n The sheet is positioned correctly above the die with the first
stamping position in X- and Y-direction. A deviation of 2 mm is
acceptable.
The following sequence is used to adjust the sheet transfer:
ADJUSTMENT OF THE n Push Y-axis by hand in the area of the sheet transfer. Stop
ADVANCE TONGS approx. 5 to 10 mm before the rear edge of the sheet.
n Push the X-axis by hand until the advance tongs are centered
with respect to the outer edges of the sheet.
n Push the Y-axis by hand until the advance tongs grip approx. 6
to 8 mm above the rear edge of the sheet. The edges of the
sheet must be placed in the advance tongs by hand. In this
position the sheet must cover both openings in the lower bit of
the advance tongs.
n Read and record the advance position of the X- and Y-axis in
the display mode of the machine. These values must be
programmed later as the START POSITION X and START
POSITION Y in the data input mode.
V-24
ADJUSTMENT OF THE n The supports for the support fingers are bolted to the sheet
AUXILIARY INSERT RAILS guidance level from below. Loosen the individual fastening bolts
and push the hand over aid into position below the sheet in
accordance with the adjusting dimensions (10 - 15 mm) shown
in Fig. 9. Tighten the fastening bolts in this position.
» 10 - 15 mm
Fig. 9: Position of support fingers
n Adjust the sheet supports to the sheet. When adjusting the

sheet supports care must be taken to ensure freedom of
movement of the supports (Fig 10/Item 1) with respect to the
support strips and the thrust angles. The supports may not be
hindered when the hand over aids are swung away.
V-25
1 3 4
Fig. 10: Adjusting the hand over aids
Item Function
1 Support finger
2 Adjustment block
3 Auxiliary insert rail
4 Thrust angle
· It may be necessary to remove or add single sheet supports

when changing formats. The complete sheet support must be
installed or removed including the adjustment block (see Fig.
10).
CAUTION:
In general no sheet supports may be installed in the Y-approach

area of the advance tongs, since this would cause the advance
tongs to collide with the already raised auxiliary insert rails on
their return to the sheet transfer position from the last stamping
position. This would result in damage to the hand over aids and
advance tongs.
V-26
ADJUSTMENT OF · Position blowing nozzles beneath the sheet according to Fig. 11.
BLOWING NOZZLES The position of the blowing nozzles can be shifted along slots.
Both blowing nozzles must be approx. 10 mm below the side
edge of the sheet.
Þ The blowing nozzle (Fig.11/item 1) is used for static transfer of
the sheet and must therefore be positioned in alignment with the
sheet supports.
Þ The blowing nozzle (Fig. 11/item 2) is used for dynamic transfer
of the sheet and must therefore be positioned in the swiveling
area of the advance tongs when returning from the last
stamping position in the transfer of the sheet. This point
corresponds approximately to ½ Y-step in the direction of
production, behind the blowing nozzle (Fig.11/item 1).
» 0.5 × Y - step
1 3
Fig. 11: Adjusting the blowing nozzles
Item Function
1 Blow-out nozzle 1
2 Blow-out nozzle 2
3 Auxiliary insert rail
V-27
4.4.2 Function Test
A function test must be carried out after adjustment is complete.

The following tests are required:
FUNCTION - BLOWING NOZZLE Switch the machine to set-up mode. Scale the axes and switch off
the servos. Place a single sheet in the transfer position. The
position of the sheet should approximate the its position during
transfer.
· Switch solenoid valve of the blowing nozzles manually. The

special die "auxiliary manual activation 157600 / FESTO“ must
be used.
Þ The sheet must then be blown upwards against the top guides
which are installed at the advance tongs (bracket). If the sheet
is not blown upwards correctly, conduct the following tests:
· Is the opening in one of the blowing nozzles plugged? If

necessary, remove and clean the blowing nozzle.
· Has one of the hoses become unconnected or kinked?
If necessary, connect hose or replace with new part.
· Does the valve switch properly? The valve may be
defective or dirty => replace valve.
· Are the blowing nozzles too far from the outer edge of
the sheet? If the blowing nozzles are too far from the
side outer edges the sheet cannot be lifted correctly.
Move the blowing nozzles further under the sheet if
necessary.
· Is the height of the blowing nozzles correct? If the
distance from the blowing nozzle opening to the sheet is
too large or too small, the sheet will not be lifted
correctly. The distance of the nozzles to the sheet
should be approx. 2 - 5mm. Adjust height of nozzles if
necessary.
V-28
FUNCTION - SWIVELING TONGS Conduct a function test of the blowing nozzles as described above
and do not switch off the valve for the blowing nozzles. The sheet
must be blown upwards to the top guides (brackets).
· Use the hardkey F6 to swivel in the advance tongs in set-up

mode (the insertion aids also fold up at the same time as
swiveling inward).
Þ The sheet must be placed in the tongs. Conduct the following

tests if the sheet is not placed correctly in the tongs or the sheet
is shifted during the swiveling process:
· Check the adjustment of the top guide at the tongs. The
bracket must be flush with the lower edges of the top bit
of the advance tongs and must be corrected if
necessary.
· Check function of blowing nozzles again.
V-29
VI. Sheet Lubrication
Station
VI. Sheet Lubrication Station
Table of Contents
1 STRUCTURE 3
2 VARNISH INSPECTION 4
2.1 FUNCTION 4
2.2 PROGRAMMING 8
3 LUBRICANT COATING SYSTEM 9
4 DOSING 10
4.1 OPERATION 10
4.2 PROGRAMMING 12
5 GUIDANCE OF THE LUBRICANT 14
6 DOUBLE SHEET MONITOR 16
VI-2
1 Structure
The sheet presentation station is an independent module within the

complete machine. In the sense of the operation it is installed be-
tween the feeder and the sheet alignment station. The operational
integration of the modules is made exclusively by the control sys-
tem.
This station comprises:
n the roller frame and the sheet transport unit to move the sheet
from the destacker into the sheet alignment station;
n this roller frame can be equipped with a varnish inspection
device. This device is optional;
n all components for the lubricant coating system. This device
is also optional;
n instead of the lubricant coating system a spraying system for
hot wax can be installed;
n furthermore the vacuum supply for the destacker and the
sheet alignment station in the form of an air injector is part of
this station;.
With the DF system the coating installation is adjustable as fitted.

The entire roller frame can be moved vertically in either direction
by means of an adjustment spindle. This is necessary in order to
put the sheet into the optimum discharge position for the position-
ing which follows once it has passed through this station.
The inlet position should be such that no time is lost during posi-
tioning of the sheet for the X movement.
Besch_DF_M5_04_06
VI-3
2 Varnish Inspection
2.1 Function
Location This device (1) is an option installed in the roller frame between
catching (2) and transport and application rollers (3). If the roller
frame is completely equipped for lubricant coating, the varnish in-
spection becomes a standard.
3 2 1
Fig. 1: Varnish inspection
Position Function
1 Varnish inspection
2 Catching roller
3 Transport and application rollers
Function The function of this device is to check the sheet's upper and lower
surface for varnish. For this purpose the fact is used that varnish is
a bad conductor, whereas the sheet material - metal - is a good
conductor.
VI-4
Function The only function of the device is to check whether the sheet is not
varnished at all or not over the full width in some areas. This hap-
pens when partially overlapping or full double sheets pass through
the varnish coater.
For this purpose two isolated fixed pairs of contact rollers on the
Uñ upper and the lower side of the sheet are sufficient. The rollers are
sheet made of ball bearings pressed on by springs. They are arranged in
such a way that neither the unvarnished edge of the sheet nor the
rollers on the opposite side can trigger a fault signal.
u(t) Both rollers of each pair are connected to the poles of an alternat-
ing current circuit, each with low voltage. When the rollers of a pair
are connected conductively, current flows. This can only happen
through an unvarnished sheet. In this arrangement the flow of cur-
Uñ rent is the signal that a totally or partially unvarnished sheet is
passing the inspection device (see also the terminal diagram).
Fig. 2: Terminal diagram
The trigger level for the detection of an unvarnished sheet is ad-

justable on the control device K104E, which is installed at the back
of the control cabinet. This device sends the digital signal obtained
to the input K104E1 of the MICROGUIDE control system.
Thereby means:
n 1-signal which is +24V-level means interruption of the sensing

circuit.
n 0-signal in contrast means current flow in the sensing circuit
and hence passing of an unvarnished sheet.
This description makes it clear that if only fully varnished sheets

pass the device, no current will ever flow within the sensing circuit.
Therefore, to verify the operation of the device, an unvarnished
sheet must be fed through it from time to time. This also applies for
adjustment.
Besch_DF_M5_04_06
VI-5
Setting the control unit There are two ways to make settings for the varnish inspection unit.
n Adjustment at the control unit A 104E1 (MRU 800)

n Adjustment at the mounting plate AR1, 2, 3.
Adjustment 1:
The MRUL 400 has three rotary buttons which have the following
factory settings:
n U at 35%
n Hyst. at 10 %
n sec at 0,2 - 2,5
LED yellow A1 11 M
MRUL 400-10
U
35%
0,2-0,5
LED green
sec
Hyst.
10%
E1 E2 E3
14 12 A2
Fig. 3: Control unit MRUL 400 for varnish inspection unit
VI-6
Adjustment 2:
In the standard setting on the mounting bracket A R1,2,3 the

jumpers are set across 5 and 7 and 13 and 15.
This setting is used for standard layers of varnish.
If especially thin layers of varnish are applied which are not to be

detected as faults, the jumpers across 5 and 7 and across 13 and
15 must be removed.
Instead, the jumpers must be set across 1 and 3 and across 13
and 17as shown by a dashed line in the wiring diagram.
CAUTION:
Inexpert changing of the adjustment or changing of the jumpers

may cause troubles during production.
NOTE:
This setting may only be made by employees of Alfons Haar or

after consultation with the company Alfons Haar.
Besch_DF_M5_04_06
VI-7
2.2 Programming
Access This file can be accessed from all operating modes at disengaded
clutch.
Precaution is the setting of “varnish control present” in machine
parameter 57 ( last digit )
Data input The control panel key marked with the DATA INPUT pictogram
gives access to program the varnish inspection data. After pressing
this key the softkey headline DATA INPUT MODE is displayed.
Softkey F5 is marked as Sheet LUB.(rication). This softkey gives
access to the program data for the lubricant coating device. By
pressing the ENTER key all parameters in this file can be displayed
one after the other. The name of this program value is VARNISH
INSPECTION.
Status The program value VARNISH INSPECTION can take the values 0
and 1.
n 1 means operation with varnished sheets.

n 0 means operation with unvarnished sheets, but not deacti-
vation of the device.
In this mode, the control system expects the control device

K104E1 to issue the "Unvarnished sheet"-signal whenever a
sheet passes through. If this signal in the form of a switch-over
from +24V to 0V does not appear the control system concludes
that in contrast to the mode parameter 57, the unit is operated with
varnished sheets and that one forgot to adjust the programme pa-
rameter to this mode.
So, whith each sheet, the error message “varnish contro” will ap-
pear until the parameter 57 is set according to the operated sheet
type.
To switch off the device in case of malfunction or in case the de-

vice is not installed at all, parameter 57 VARNISH INSPECTION
needs to be set to 0. In that case the program value VARNISH IN-
SPECTION will be ignored at all.
VI-8
3 Lubricant Coating System
This device is an option installed in the roller frame which is always

part of the station.
There are three different versions:
First version The standard version is equipped with dosing and distribution on
the upper side. But the sheet passes an upper and lower applica-
tion roller so that the lower side of the sheet is lubricated, too, with
a smaller volume however.
The lower roller is supplied from the upper roller in the times be-
tween the passes of the sheets. This way of distribution of the lu-
bricant to the upper and lower side of the sheet has proven itself
for the production of drawn cans. This is also valid for the produc-
tion of standard lids.
Second version As an extension of the standard version the roller frame can be
additionally or exclusively equipped with a dosing and distribution
system on the lower side of the sheet passing level.
Third version As an extension of the standard version the roller frame can be The
third version is used for the production of lids whose lower side is
afterwards fitted with lining.
The required adhesion of the sealing compound does not allow

any lubricant on the lower surface of the sheet. In this case a gap
is set between upper and lower application roller so that no lubri-
cant can be transferred from the upper to the lower roller. To guar-
antee the separation of both rollers, smooth, ground surfaces are
used.
Besch_DF_M5_04_06
VI-9
4 Dosing
4.1 Operation
For even distribution over the complete roller width volumetric dos-
ing devices (1) are installed at distances.
The dosing devices are pneumatically operated piston pumps. The

delivered volume can be adjusted with a screw from zero to maxi-
mum volume. This way it is possible to keep the areas of the roll-
ers dry which do not have contact with the passing sheet.
In the application area the dosing volume should be as low as pos-

sible. Ideal is the adjustment on the basis of one sheet only, which
means that a dosing pulse is given on each sheet passing through.
Fig. 4: Dosing
Supply The liquid lubricant is supplied by gravity from a storage tank in-
stalled above. For the first start-up or after the pipe system was
empty the pipe needs to be vented at its end.
Activation The pneumatically operated dosing devices are activated via the
solenoid valve Y116A2 ( upper side ) or Y116A3 ( lower side ) . The
control unit pulses this solenoid valve with a fixed pulse length.
With each pulse the full dosing volume set at the dosing unit is de-
livered.
VI-10
Adjustment Each dosing unit has an adjustment screw. This screw has only a
stop on the right. This position delivers the maximum volume. By
turning the screw to the left, the delivered volume is reduced.
Volume adjustment of the dosing devices:
Maximum volume 30 mm3

3
1 turn left 25 mm
3
2 turns left 20 mm
3
3 turns left 15 mm
3
4 turns left 10 mm
3
5 turns left 5 mm
3
6 turns left 3 mm
Besch_DF_M5_04_06
VI-11
4.2 Programming
Availability This file can be accessed from all operating modes and in any ma-
chine state.
Programming of the lubricant coating system is accessed using the

key marked with the pictograph DATA INPUT. After activating the
key, the DATA INPUT MODE menu is displayed. Softkey F5 is
marked with “SHEET LUB.(rication)“.
This softkey gives access to the data file of the lubricant coating
programme. By pressing the ENTER key all program values in this
file can be displayed one after the other. The name of this program
value is SHEET LUB.(rication).
Precaution is the setting of the Machine parameter 57 VARNISH

INSPECTION where the leading digit defines the coating opera-
tion, whether more lubrication pulses per sheet are applied:
Format: X Y Z
0 = without varnish control

1 = with varnish control
0 = coating on both sides

1 = coating on the upper side
2 = coating on the lower side
0 = normal coating
( = 1 coating only)
1 = multiple coating
performance of 100/300 ms
VI-12
Function The control system counts the sheets which actually pass through
the coating system. On the basis of the count the number of
sheets passing per dosing pulse can be programmed. This is
carried out by the program value Sheet lubrication.
In this file the ACTUAL VALUE is shown for check of the function.
Switching on the control the counter is loaded with the pro-
grammed value to be counted down by the passing sheets. When
the value zero is reached, the dosing pulse is given and the
counter is reset to the preselcted value.
The number of dosing pulses per sheet is programmed with the
program value “Sheet lubrication“.
The input is made according to the following model:
Coating Parameter 57 Program value

Sheet Lubrication
1 time per sheet 0yz 01
1 time per 2 sheets 0yz 02
... ... ...
1 time per 5 sheets 0yz 05
... ... ...
1 time per n sheets 0yz nn
1 time per sheet 1yz 01

2 times per sheet 1yz 02
3 times per sheet 1yz 03
... ... ...
n times per sheet 1yz nn
Besch_DF_M5_04_06
VI-13
5 Guidance of the Lubricant
As dosing is effected by a finite number of dosing units, their dis-

charge openings are spaced in a certain distance to each other
which must not be neglected. To evenly distribute the punctually
applied lubricant, the first roller, the so-called distributor roller
(Fig.4, 1) oscillates with an amplitude higher than the distance of
the dosing units. This roller by its oscillation distributes the lubri-
cant on the following transfer roller (Fig. 4, 2).
Fig. 4: Lubricant coating
Standard version In the standard version, the distributor roller is covered by a soft
hose whereas the transfer roller is not covered.
In the version for single side lubrication, the distributor roller has no
cover whereas the transfer roller is covered. The reason for this ar-
rangement is the surface of the application roller which has in this
case a smooth surface.
The transfer roller passes on the lubricant, which is evenly distrib-
uted on it, to the application roller which in turn applies it on the
sheet surface.
VI-14
In the standard version, both the upper and lower roller are cov-
ered with a soft hose. The softness of the surface allows the rollers
to be adjusted to each other in such a way that during the period
no sheet passes, lubricant is transferred from the upper to the
lower application roller.
Double coating In the version with a double dosing and distribution system two
dosing units, distributor rollers and transfer rollers are installed. The
control of both systems is synchronous. If a different lubrication
volume is to be applied to the upper and lower sheet surface, the
dosing units themselves must be adjusted accordingly.
Besch_DF_M5_04_06
VI-15
6 Double Sheet Monitor
Double sheet detectors are used for monitoring sheet feeding on

sheet metal processing machines. They prevent 2 (double sheet)
or more sheets being fed in and thus protect the machines and
dies from being damaged or destroyed. The sheet being fed to the
machine is subjected to scanning by sensors directly after it has
passed through the lubrication station.
Sensor heads
Fig. 5: Double sheet monitor
Function The sensors are connected by a multicore cable to a switching am-

plifier which can be mounted either directly on the machine or
separate from it.
The switching amplifier operates with the signal. In case of double

sheet transfer the positioning of the sheet is switched off and a
corresponding "DOUBLE SHEET" message is displayed. Even if
the error is acknowledged, it will not be possible to simply continue
with production. It is absolutely essential that the double sheet be
removed from the alignment station first, which will also be dis-
played by the corresponding message "REMOVE SHEET FROM
ALIGNMENT STATION".
VI-16
The sheet thickness can be adjusted by means of setting control-

lers and when the set figure is exceeded the output relay of the
switching amplifier is triggered. Moreover, the switching amplifier is
so designed that the output relay will go into the "DOUBLE
SHEET" position as well if the power supply to the switching ampli-
fier fails.
Setting Adjustment is carried out at the setting controller of the switching

amplifier which is mounted on the machine itself.
For this purpose switch on the power supply and release the
"sheet thickness" setting controller.
Fig. 6: Sheet sensing
Doppelblechdetektor
Netz Power
Double Sheet Detactor
Doppelblech Double sheet
Relais Contact
Sheet
Blechdicke
thickness
Jungmichel
j Industrieelektronik
Fig. 7: Compensation Type IT 01EZ
Besch_DF_M5_04_06
VI-17
Proceeding:
1. Place two sheets of those in use at disposal. The edge of these

sheets should be more than > 200 mm.
2. Determination of the1st peak position (sensitivity to high):
While one sheet is held between the sensors, increase the
sensitivity turning the setting controller until „double sheet“ is in-
dicated.
st
3. Note the 1 peak position.
4. Determination of the 2nd peak position (sensitivity to low):
While two sheets are held between the sensors, decrease the
sensitivity until no „double sheet“ is indicated.
nd
5. Note the 2 peak position.
6. Middle the setting controller betwwen the thwo peak positions
and lock it.
7. Test the adjustment with single sheets and with double sheet;
during the test runs the sheets may be moved in any way be-
tween the sensors.
No error message may occur!
VI-18
VII. Sheet transport and feeding
system
AF, DF, OF(G)
VII. Sheet transport and feeding system AF, Df, OF(G)
Table of Contents
1 ROLLER CONVEYOR (OPTION) 4
1.1 FUNCTION 4
1.2 OPERATION OF THE ROLLER CONVEYOR 5
2 PALLET CHANGING HANDOPERATED 6
2.1 PALLET CHANGING UNIT 6

2.2 ORDER OF PALLET CHANGING BY HAND 7
3 PALLET CHANGER WITH EMPTY PALLET FORK (OPTION) 10
3.1 FUNCTION 10
3.2 PROGRAMMING 10
3.3 AUTOMATICAL PALLET CHANGING PROCEDURE 11
3.4 MANUAL FUNCTIONS IN SET-UP MODE 13
3.4.1 ROLLER CONVEYOR 13
3.4.2 FORK ROLLER CONVEYOR 13
3.4.3 EMPTY PALLET FORK 14
3.5 PALLET LIFT DOOR 15
3.6 CHARGING THE ROLLER CONVEYOR 15
3.7 REMOVAL OF THE EMPTY PALLET 15
3.8 HELPTEXTS 16
4 2-MINUTES-PALLET CHANGER TYPE 2K (OPTION) 17
4.1 DESIGN AND FUNCTION 17

4.2 INPUT CONDITIONS 17
4.3 OPERATION 18
4.4 PALLET CHANGING OPERATION WITH THE 2-MINUTES PALLET CHANGER WITH EMPTY PALLET
STACKER STATION 18
5 PALLET LIFT 20
5.1 FUNCTION 20
5.2 OPERATION 24
5.2.1 LOWERING 24
5.2.2 LIFTING 25
5.2.3 LIFTING FROM THE LOWEST POSITION 26
5.2.4 LEVEL CONTROL DURING AUTOMATIC OPERATION 27
5.2.5 TRANSVERSE SHEAR FOR PALLET LIFT 2K (OPTION) 28
5.3 MAINTENANCE INSTRUCTIONS 29
5.3.1 RACK AND PINION DRIVE AND COMBI-ROLLERS 29
5.3.2 HYDRAULIC UNIT AND HYDRAULIC CYLINDERS 30
VII-2
VII. Sheet transport and feeding system
6 SHEET DESTACKER 31
6.1 FUNCTION 31
6.2 PRELIMINARY SHEET DESTACKING (AF, DF, OF) 33
6.3 SHEET DESTACKING (AF, DF, OF) 35
6.4 ADJUSTING THE SHEET DESTACKER 39
VII-3
VII. Sheet transport and feeding system AF, DF, OF(G)
1 Roller conveyor (Option)
1.1 Function
DANGER:
Before moving the roller conveyor make sure that there is no

person left in the working area of the pallet lift or on the roller
conveyor. There are no safety devices at the roller conveyor. If
this is not observed, the result may be grave and irreversible
physical injury.
The rollers of the roller conveyor are run by chains, the main drive
is protected by a slip clutch. The roller conveyor is operated by
hand buttons in the operation unit of the pallet lift.
There is a catch preventing rolling back at the front end of the
roller conveyor, the so-called loader side. This catch preventing
rolling back has to prevent rolling down of the pallets from the roller
conveyor.
For lateral alignment of the pallet there is a pallet stop above on
the roller conveyor. This pallet stop has to support the touching
down of the new pallet in the right position.
During the adjustment of the pallet guidance it has to be cared for
the guiding angle to be fixed in a slanting position (approx. 1 - 3°).
The guiding angle has to point away from the middle of the
conveyor, seen in conveying direction. By that the pallet is
positioned exatly enough, but cannot get stuck while conveyed.
The fork stacker driver can pre-align the sheet block with the catch
preventing rolling back.
pallet lift
roller conveyor
1 - 3° drive unit of the

roller conveyor
pallet stop
catch preventing
rolling back
Fig. 1: Pallet lift with roller conveyor
VII-4
1.2 Operation of the roller conveyor
DANGER:

physical injury.
The roller conveyor can be moved using the operation unit at the
pallet lift. With the two buttons above the pallet is driven forward
roller conveyor and back. The machine must be in the set up mode for to switch
forward
on the drive of the roller conveyor. In the automatic mode the
function of the operation unit are desactivated with the exception of
the emergency stop.
The roller conveyor itself has no limit switch. The sheet block can
roller conveyor be moved up to the coating system respectively up to the catch
backward preventing rolling back. The motor will not stop as long as the
corresponding button is pressed. To prevent damaging of the
drive, the drive chain is armed with a slip clutch. When reaching
the end position that one will slip and prevents blocking and
overheating of the motor.
VII-5
2 Pallet changing handoperated
2.1 Pallet changing unit
If there is no automatic pallet changer, the ancient empty pallet is

to be taken off by hand before putting in a new pallet with sheets.
DANGER:

physical injury.
pallet lift
roller conveyor
drive unit of the

roller conveyor
pallet stop
catch preventing
rolling back
Fig. 2: Pallet changing unit
NOTE:
The new pallet should always be laid down on the sheet-feed

station in front of the pallet changer in time to avoid loosing time
while changing pallets.
VII-6
2.2 Order of pallet changing by hand
The pallet change by hand is to be daone as soon as the wodden

pallet on the pallet lift fork is empty.
This can be noticed by sight or with the help of the message

DESTACKER TROUBLE.
NOTE:
Message DESTACKER TROUBLE
The passage of the sheet through the machine is supervised by

the control. If the sheet has not been recognized by the initiator
B114E2 (AF/DF) SHEET IN ALIGNMENT STATION or B103E4
(OF) SHEET IN PRESENTATION STATION after a time
programmed with machine parameter 18 (AF/DF) or 15 (OF)
SHEET TRANSIT MONITORING, this is regarded as a transit
malfunction at destacking station, lining station, alignment station
or for reason of an empty pallet.
To insert a new pallet with sheets into the destacking station, the
machine must be switched back by the hardkey SET UP to the set
up mode. In automatic mode the keys of the operation panel are
pallet lift down desactivated with the exception of EMERGENCY STOP.
Now the empty pallet must be lowered. Lowering is started by

activating the button S120E2 PALLET LIFT DOWNWARD,
described by a vertical arrow in downward direction.
Downward movement can be stopped at any time by releasing the
hand key button S120E2 PALLET LIFT DOWNWARD.
After the empty pallet has been completely lowered, it has to be

taken off by the operator. For that purpose, convenient safety
gloves are necessary.
Please, check before transporting a new pallet:

Before the new pallet is taken onto the lifting forks, the sheet block
has to be pre-aligned with the lateral stop of the catch preventing
rolling back.
VII-7
roller conveyor Now the new pallet may be transported on the lifting forks. For
move on thisthe pallet can be moved on the roller conveyor by using the
buttons CONVEYOR FORWARD and CONVEYOR REVERSE.
The new pallet has to be moved forward up to the baffle plate at
the coating unit. A touching of the sheet block is unproblematic, as
the drive track of the rolls is furnished by a slip clutch. The
roller conveyor travelling motion may be interrupted at any time by releasing the
move back prevailing button.
Advance Switch unit Function
AF3, DF2 122A1 (A3C0) conveyor drive forward

OF2 122A1 (A3C1) conveyor drive forward
AF3, DF2 122A2 (A3C1) conveyor drive reverse
OF2 122A2 (A3C2) conveyor drive reverse
VII-8
The lateral position of the sheet block, i.e. x-direction, depends on

the position in the alignment station where the sheet has already
been pre-aligned. The edge of the sheet block shall be situated
more about 5 - 10 mm to the middle than the lateral stop in the
alignment station. That guarantees that the sheet does not move
against the stop when coming in.
Now the sheet block can be lifted. By pressing the button PALLET
pallet lift up
LIFT UP the new pallet can be moved into its working position, i.e.
the separation station.
The lifting movement is executed by pressing the button S120E1
PALLET LIFT UP, which is marked with a vertical arrow in
upwards direction. The lifting movement lasts on as long as the
button is pressed; it can be interrupted at any time by releasing the
button.
transverse shear right For lateral correction there is the option to set the sheet block in
(option, not available for lift 1K) lateral direction by using the pallet lift hand buttons TRANSVERSE
SHEAR RIGHT respectively TRANSVERSE SHEAR LEFT. The
motion only remains as long as the button is pressed.
The option „Transverse shear right/left“ is not available for lift

transverse shear right 1K.
(option, not available for lift 1K)
When the hand button S120E1 PALLET LIFT UP is activated, the

three destacking cylinders come out completely. Then, at the same
time when the elevating platform is lifting up, the suckers touch
down on the surface of the sheet block. They are pushed down
until the switch S118E4 PALLET LIFT LEVEL CONTROL is
activated.
When this switch is activated, the pallet stops automatically. The

pallet changing is finished when the level is reached, and the sheet
F2 sepraration to provide the machine may be switched on again. For
that, the mode must be changed to AUTOMATIC and the softkey
FEEDER on the operation panel must be pressed.
VII-9
3 Pallet changer with empty pallet fork (Option)
3.1 Function
The automatic paleet changing device is used for uninterrupted

sheet feeding of machines with fast advance systems.
The pallets are conveyed on the roller conveyor. The pallet
changer with the travel line of the auxiliary fork is above the roller
conveyor. The stillage is lifted by the pallet lift into the arm sweep
of the destacking unit and it is relifted. In the last lifting position the
auxiliary fork is moved under the pallet across the pallet lift. The
auxiliary fork keeps the pallet in its position, while the lift moves
back in the receiving position to take a new stillage under the pallet
that is actually destacked. When the last sheet has been
destacked, the empty pallet is only drawn aside with the auxiliary
fork for pallet changing and the new stillage is lifted up to the
destacking unit.
The empty pallet must be moved by hand before the lift reaches
the top position, so that the auxiliary fork is free again for the next
pallet.
3.2 Programming
Input conditions:
The following machine parameters and program values must be
set for pallet changing operation:
Machine parameters:
n machine parameter 37 = 4, i.e. pallet changer with empty
pallet fork
n machine parameter 39 = 1, i.e. with empty pallet sensor
Program values:
n Lubrication / Pallet changer = 1
VII-10
3.3 Automatical pallet changing procedure
When the lift has reached during relifting the proximity switch
PALLET LIFT UPPER LIMIT, 123E1 = 1, the automatical pallet
changing operation starts, if the following conditions are fulfilled:
1. The pallet door must be closed, 121E2 =1, error message

F:089.
2. The empty pallet fork must be in the removal station, 125E4 =1
or in the free-running position, 128E2 = 1, error message
F:488.
3. The empty pallet depository station must be free, 125E1 = 0,
error message F:231.
4. A stillage can stand in the loading station, 125E3 = 1, or in the
transfer station, 125E2 = 1.
The empty pallet fork moves forward to take over the pallet with
the residual sheets. Simultaneously, the transfer station being
empty, the roller conveyor moves a stillage out of the loading
station forward. When the fork has taken over the pallet, the flift
moves down and takes over the next stillage. When all sheets are
worked off, the lift moves up into the working position with the new
pallet.
This kind of automatical pallet changing is now described step by

step:
n The status light PALLET CHANGING lights up, 121A2 = 0 aund

125A2 = 0. After 5 s waiting time the empty pallet fork runs in,
125A3 = 1 and 125A4 = 1.
Simultaneously, the transfer station being empty, 125E2 = 0,
and one Pallet in the Loading station, 125E3 =1, the forwad
movement continues (122A1 = 1), as long as the loading station
PALLET IN TRANSFER STATION 125E2 = 1 indicates, that
the stillage is ahead, diagnosis essage D:499.
n When the fork has reached the proximity switch EMPTY
PALLET FORK IN TAKE-OVER STATION, 128E1 = 1, the lift
moves down, 120A2 = 1, D:299, F:358. If the fork has not run in
after 20 s, the change is interrupted, F:503.
n In the meantime the residual sheets on the pallet have been
worked off. The end is indicated by the empty pallet sensor
117E4 = 0. The lateral guiding plate is swivelled up, 126A1 = 1,
D:490, F:491.
n The proximity switch LATERAL GUIDING PLATE SWIVELLED
UP (126E4 = 1) starts the return of the empty pallet fork, 125A3
= 1, 125A4 = 0, D:493, F:492.
n When the fork has reached the proximity switch FORK FREE,
128E2 = 1, The guiding plate is lowered again, 126A1 = 0, and
the fork is stopped, 125A3 = 0, D:494, F:491. After the coasting
of the fork the proximity switch EMPTY PALLET FORK FREE,
128E2 = 1, must still be surely activated.
n The lowered guiding plate, 126E4 = 0, indicates that the next
stillage can move up into the working position.
VII-11
n At the end of the downward movement the lift reaches the

proximity switch PALLET LIFT ON TAKING PALLET LEVEL,
123E3 = 1. That starts the running-in of a stillages from the
roller conveyor.
If the roller conveyor is empty, 125E3 = 0 and 125E2 = 0, the lift
stops and the light PALLET CHANGING is switched off. When
all sheets on the empty pallet fork are worked off, the fork
moves back as described above, F:256.
n Now the roller conveyor, 122A1 = 1, and the fork roller
conveyor, 122A3 = 1, move forward, D:495, F:254.
n When the pallet leaves the roller conveyor, 125E2 = 0, the fork
roller conveyor keeps moving on, D:496. The driving gear of the
roller conveyor is switched off, 122A1 = 0, if no more pallets are
on the roller conveyor. Otherwise the driveing gears keeps
runing on until the second pallet has reached the transfer
station, 125E2 = 1, D:499.
n On the fork roller conveyor the stillage reaches the proximity
switch PALLET FED, 126E1 = 1, and switches off the driving
gear after a 2 s delay, 122A3 = 0.
If the stillage is not yet fed after 30 s, the changing is
interrupted, F:504.
n When the empty pallet fork has reached the removal station,
125E4 = 1, the destacking suckers lower and the lift moves up,
120A1 =1, until reaching the proximity switch PALLET LIFT
LEVEL CONTROL, 118E4 = 1. Then the suckers are lifted
again and the sheet destacking starts.
If the lift has been stopped in the intermediate position, this
cycle goes off, when the guiding plate is lowered, 126E4 = 0.
n The automatical pallet change is finished, and the status light is
switched off, 121A2 = 0 and 125A2 = 0.
VII-12
3.4 Manual functions in set-up mode
3.4.1 Roller conveyor
By hand key the roller conveyor can be moved forward (122E1)

and backward (122E2), when the door of the pallet lift is closed
(F:089).
n The roller conveyor moves backward, until a pallet has

reached the loading station, 125E3 = 1.
n The roller conveyor stops forward, when a pallet has reached
the tranfer station, 125E2 = 1.
It is only possible to move on from the transfer station, when the lift
is down (123E3 =1) and empty (126E1 = 0). Then automatically
with the forward moving of the roller conveyor the fork roller
conveyor is switched on, too. When the pallet has left the roller
conveyor, 125E2 = 0, both drives stop. The movement continuation
must be carried out with the fork roller conveyor.
3.4.2 Fork roller conveyor
By hand keys the fork roller conveyor can be moved forward

(122E3) and backward (122E4), when the door of the pallet lift is
closed and the lift is down (F: 485). The fork roller conveyor only
moves backwards, when the loading station is free, 127E1 = 0
and 127E2 = 0. When the stillage reaches the transfer station,
125E2 = 1, additionally the backward roller advance is switched
ont, 122A2 = 1. When a pallet leaves the transfer station, 125E2 =
0, both drives are switched off.
VII-13
3.4.3 Empty pallet fork
By hand key 128E4 the fork roller conveyor can be moved

forward and backward, when the door of the pallet lift is closed. If
the pallet is in the removal station, 125E4 = 1, the guiding plate is
swivelled up and afterwards the fork is moved ahead. In every
other position the empty pallet fork is always moved backwards
with the lifting of the guiding plate. The guiding plate is lowered,
when the fork has reached a final position. With the hand key
128E3 at the loading station the empty pallet fork can be driven
back out of the central position to pick an empty pallet after a pallet
change. Afterwards the fork can be driven again with the same key
up to the central position.
VII-14
3.5 Pallet lift door
When opening the pallet lift door (121E2 = 0) all functions of the lift
and of the roller conveyor are interrupted, F:089.
3.6 Charging the roller conveyor
The roller conveyor can be charged at any time, if the status light
PALLET CHANGE is not on. The stillage must be deposited in the
loading station in a way that the light barrier is interrupted, 125E3 =
1.
n Empty roller conveyor

A deposited stillage can be moved forward in the set-up mode.
For pallet changing an aligned stillage is automatically driven
into the removal station.
n One pallet in the removal station
Now a second pallet can be deposited in the loading station.
3.7 Removal of the empty pallet
The wooden pallet can be removed from the pallet fork at any time,
if the status signal PALL ETTE CHANGE is not on.
VII-15
3.8 Helptexts
089 DOORS DESTACKER
231 EMPTY PALLET DEPOSIT OCCUPIED
256 NO STILLAGE
299 PALLET LIFT FORK LOWER 123E3
358 F: PALLET LIFT FORK, LIMIT DOWN
485 PALLET LIFT NOT IN BOTTOM POSITION
486 LOADING STATION OCCUPIED
487 PALLET LIFT OCCUPIED
488 EMPTY PALLET FORK UNDEFINED
489 PALLET FORK IN TAKE-OVER STATION
490 GUIDE PLATE IN TOP POSITION
491 F: GUIDE PLATE
492 F: EMPTY PALLET FORK
493 EMPTY PALLET FORK FREE
494 GUIDING PLATE LOWERED
495 DIAGNOSIS: PALLET IN TAKE-OVER STATION
496 PALLET INFEED
499 PALLET IN TAKE-OVER STATION
503 EMPTY PALLET FORK
504 PALLET INFEED
VII-16
4 2-minutes-pallet changer type 2K (Option)
4.1 Design and function
The 2-minutes-pallet changer is a simple sytem to carry out the

procedure of laying down the empty pallet and picking up the full
pallet using the travelling motions of the pallet lift. Therefore the
pallet lift has got a horizontal operating radius of 1900 mm. To
avoid collision between pallet lift mast and sheet destacking frame
a power driven lifting device is added to the latter.
Thepallets are put down on a two level stillage, the empty ones up,
the full ones below. The movements of the lift are controlled by
initiators. The positions of these initiators must be set according to
the application, because the legths of brake path depend on the
weight of the pallet.
The sensor plan is shown in drawing A-5734.
4.2 Input conditions
The following machine parameters and program values must be

set for the operation of the 2-minutes pallet changer with an AF- or
DF-system:
Machine parameters:
n machine parameter 37 = 1, i.e. pallet changer without
roller conveyor
n machine parameter 39 = 1, i.e. with empty pallet sensor
n machine parameter 58 = 1, i.e. pallet in position with
proximity switch in baffle plate
(proximity switch of baffle plate)
Program values:
n Lubrication / Pallet changer = 1
VII-17
4.3 Operation
There is no more operation at the Microguide control unit, when

the machine parameters and the program values are set.
The empty pallet must be removed. A full pallet must be put in

place, well aligned, so that the cycle can occur troublefree. That
means that the side with the front edge of the sheet (sheet nose)
must be pushed towards the unit and that the position of the right
pallet edge (where the forks of the lift enter) must tie in with an
accurancy of +/- 5 mm. This dimension must be observed!
4.4 Pallet changing operation with the 2-minutes pallet changer

with empty pallet stacker station
The automatic pallet change starts with the lighting up of the lamp
PALLET CHANGE (121A2 = 1), when the proximity switch EMPTY
PALLET 117E4 signals that the pallet has been completely worked
off. And when a new stillage lies in the retainer 125E2 (message
“NO PALLET“).
n The sheet guiding frame is folded up (104A1 = 1).

n The pallet lift rises (120A3 = 1, 103A4 = 1, 120A1 = 1) when the
switch SHEET FRAME LIFTED 116E4 is actuated.
n When the proximity switch PALLET LIFT UPPER LIMIT
B123E1 signals arrival, the lift stops (120A1 = 0) and the lift
mast moves backwards (121A3 = 1).
n The mast stops when it has reached the proximity switch
PALLET LIFT MAST LIMIT BACKWARDS 124E2 and the fork
is lowered (120A2 = 0, 120A3 = 0, 103A4 = 0, 120A2 = 1).
n The lowering operation stops (120A2 = 0), when the proximity
switch PALLET LIFT CONTROL UPPER LEVEL 123E2 has
been reached. Now the empty pallet must be safely placed on
the stacker, because the lift mast will move forward next
(120A3 = 1, 103A4 = 1, 121A1 = 1).
n The proximity switch PALLET LIFT MAST LIMIT FORKS
LOWERABLE 124E1 stops the run and starts the lowering
operation of the forks (120A3 = 0, 103A4 = 0, 120A1 = 0,
120A2 = 1).
n The lowering operation stops (120A2 = 0), when the proximity
switch PALLET LIFT PALLET PICK UP LEVEL 123E3 has
been reached and the lift mast moves backwards (120A3 = 1,
103A4 = 1, 121A3 = 1).
n When the proximity switch PALLET LIFT MAST LIMIT
BACKWARDS 124E2 has been reached, the lift mast stops
(121A3 = 0), and the forks lifts for one second (120A1 = 1) to
take the new stillage. After that the lift mast moves forward with
the new stillage (121A1 = 1, 120A3 = 1, 103A4 = 1).
VII-18
n The proximity switch PALLET LIFT MAST IN WORKING

POSITION 123E4 stops (121A1 = 0, 120A3 = 0, 103A4 = 0). If
the proximity switch PALLET LIFT MAST LIMIT FORWARD
124E3 has been reached at the same time, the sheet guide
frame is lowered (104A2 = 1). If 124E3 has not been reached,
the automatic pallet change is stopped with the message “X-
ALIGNMENT OF THE PALLET NOT FOUND“.
n If the sheet guide frame has reached his working position
(117E3), the new stillage is lifted (120A3 = 1, 103A4 = 1, 120A1
= 1), and the destacking suckers are lowered (117A1 = 1).
n The level control 118E4 stops the lowering operation (120A3 =
0, 103A4 = 0, 120A1 = 0), and the light PALETTENWECHSEL
is out (121A2 = 0). The automatic pallet change is finished.
VII-19
5 Pallet Lift
5.1 Function
The basic version consists of the lift mast, the guide frame - which
forms part of the coating system - the lift slide (1), the fork arms (2)
and the hydraulic unit (3).
1 3
Fig. 3: Pallet lift
Item Function
1 lift slide
2 fork arms
3 hydraulic unit
4 plunger cylinder
The hydraulic unit is a compact unit where the pump case

accommodates the components of a radial piston pump as well as
stator and armature of the drive motor. The ribbed oil tank is
pressed onto the case. The heat generated by the stator coil is
dissipated by metallic heat conduction directly to the ribs without
passing through the oil. The heat generated in the system by
hydraulic losses is also conducted by the oil through the tank wall
to the ribs. Through a large fan the heat is dissipated from the ribs
to the environment.
The hydraulic unit is therefore suitable for the modes of operation

continuous duty S1 under nominal capacity or continuous
operation periodic duty S6 as defined in VDE 0530. In the latter
case, utilization can be up to 1.5 times nominal capacity.
As a standard the motor is rated for 380/220V Y 50 Hz. It can be

connected to 50 and 60 Hz mains and operated at a wide voltage
range.
VII-20
The compact hydraulic unit with and the flow control valve
(proportional valve) Y120A3 (A1C1) is used to control the
positioning movements of 2K-lifts.
The working pressure of the pallet lift is approx. 130 bar. This
value is set at the pressure-limiting valve of the compact hydraulic
unit. To set the pressure required, the pump must be switched on,
and the flow control valve Y120A3 must be activated.
VII-21
plunger cylinder
Y120A1 Y120A2
P
A
line break
0 - 250 bar safety device
A B
1 2 Y121A1
Y120A3
K103A4 M
P p = 15 bar
Y121A3
R p = 130 bar
compact hydraulic unit
Fig. 4: Hydraulic diagram of the pallet lift
VII-22
The flow control valve Y120A3 ensures that all movements are
smooth enough that the sheets keep lying on the pallet and that
the pallet keeps lying on the forks.
The valve Y120A3 is open in the no-flow state; it has been set to
the nominal flow by the manufacturer. This adjustment must not be
changed.
Adjustment of the servo-valve: The adjustment of the servo-valve is described in detail in the
electrical diagrams. Make sure that the resistance and capacitor
values specified are observed.
The control unit for the servo-valve is situated in the terminal box
at the backside of the pallet lift.
The load is lifted by a single-acting plunger cylinder working

directly on the lift slide (load stroke = cylinder stroke). It only
requires a hydraulic delivery line for the upward and downward
movements.
For all movements, with the exception of braking the transverse

feed, the pump, flow control valve Y120A3 and control valve
Y121A1 / Y121A3 will be switched off simultaneously.
When braking the lateral advance the flow control valve Y120A3 is
taken off first. That means that there is a delay time between
taking off the flow control valve Y120A3 and taking off the pump or
control valve Y121A1 / Y121A3. That causes by opening the by-
pass a ramp leaded descent of pressure in the system resulting in
soft braking.
The delay time can be programmed as a machine parameter.
Advance Parameter: Take off servor valve,

value: 0,5 s
AF Parameter 52
DF Parameter 52
OF2 Parameter 41
OF2G Parameter 40
The corresponding command devices (push-buttons) are fitted

directly to the lift (operation unit) or to the sound-insulated cabin.
VII-23
5.2 Operation
5.2.1 Lowering
Lowering is initiated by pressing the button S120E2 PALLET LIFT

DOWN, which is represented by a downwards-pointing arrow.
Pressing button S120E2 PALLET LIFT DOWN actuates the

solenoid seat valve Y120A2 thus enabling the oil to flow back via
the filter into the tank. A line break safety device is fitted directly to
the cylinder connection and if a defined lowering speed is
pallet lift down exceeded, it closes off the return flow of the oil (e.g. when a hose
ruptures).
The solenoid seat valve on the cylinder has the function to keep
the load constant in the raised position. This device also contains
an adjustable lowering brake valve to control the speed of lowering
and also an emergency outlet (in the event of power failure).
The lowering movement can be interrupted at any time by

releasing the PALLET LIFT DOWN button.
VII-24
5.2.2 Lifting
The lifting movement is basically dependent on one condition and

that is that during lifting the sheet guide frame must be in the
correct position,i.e. in its working position.
pallet lift up
The lifting movement is initiated by pressing the button S120E1
PALLET LIFT UP, which is represented as a vertical arrow
pointing upwards.
By pressing the button S120E1 the pump is switched on. By

means of the secondary elements of the hydraulic system the
lifting cylinder is triggered to extend.
The lifting movement can be interrupted at any time by releasing

the button PALLET LIFT UPD.
VII-25
5.2.3 Lifting from the Lowest Position
When the sheet stack is lifted the first time after the change, the
machine's reaction depends on the contents of machine parameter
PALLET CHANGER.
Advance Parameter: Pallet changer

AF Parameter 37
DF Parameter 37
OF2 Parameter 32
OF2G Parameter 34
n 0 = without pallet changer

n 1 = with pallet changer without roller conveyor
(pallet lift travel 1900 mm)
n 2 = with pallet changer with roller conveyor
Input = 0 If the input is 0, the sheet stack, when lifted the first time during
manual lifting, must be lifted so far from the first that the switch
B118E4 PALLET LIFT, LEVEL CONTROL is activated. For this
purpose, the upper edge of the sheet stack should be lifted until it
reaches the relevant mark before separating is started.
Input = 1 If the input is 1, the pallets will be changed automatically by a pallet

changer with a long travel, but the lifting procedure starting from
the lowest position must be so executed as described in section
„Input=0“.
Input = 2 If the input is 2, the pallets will be changed automatically by a pallet

changer with a lateral roller conveyor including the lifting from the
lowest position.
Adjustment of the pallet lift level control:
The proximity switch B118E4 is attached to the middle destacking

clamp cylinder with a clamp. By this proximity switch the pallet lift working
level is defined.
118E4 While extending the piston activates the proximity switch. Working
the sheet stack the piston travel increases and from that the time
intervals of the sheet transports towards the press. To avois idle
strokes of the press, the pallet lift re-lifts before reaching the
critical piston travel. The critical piston travel depends on the sheet
and on the punching program. It is taken into account by the
position of this proximity switch attached to the destacking cylinder.
VII-26
5.2.4 Level Control during automatic operation
Level control in automatic mode is performed by the switch 118E4

PALLET LIFT LEVEL CONTROL. During sheet destacking the
nozzles are extended to the top of the stillage edge. The position of
the piston of the destacking cylinder is the indication of the actual
level of the top of the stillage edge. If the piston of the central
destacking cylinder goes so far down that it reaches the switch
PALLET LIFT LEVEL CONTROL, this will start the relifting
process. The relifting distance is time-controlled and programmed
with the menu DATA INPUT under the softkey SHEET LUB. The
program value in question is RELEVEL.
RELEVEL S 0,3
DATA-INPUT RETURN <

MACRO SYN- AD- DIES SHEET COUNT-
CHRO VANCE LUB. ER
Fig. 5: Display of the control panel
VII-27
5.2.5 Transverse Shear for Pallet lift 2K (Option)
Transverse shear is used for the lateral adjustment of the sheet

support frame on the transfer carriage. The travel movements are
deadened by the flow control valve Y120A3 to avoid that the
sheets might not slip on the pallet.
The position of the sheet support frame crosswise, that is along

the x axis, depends on the position of the in the alignment station
where the sheet already has been pre-aligned. The edge of the
sheet support frame should be positioned approximately 5 - 10 mm
further in towards the centre than the lateral stop in the alignment
station. This will ensure that when it runs into the alignment station
transverse shear
the sheet will not come to a halt at the x stop.
right
As an option the transverse movement is carried out by pressing
the hand-button S121E1 SHEET GUIDE FRAME UP/DOWN.
A hydraulic motor drives the carriage via chain and gear rack.
Here, pressing the button S121E3 or S121E4 PALLET LIFT,
TRANSVERSE SHEAR RIGHT or LEFT will actuate either
solenoid valve Y121A1 or solenoid valve Y121E1.
transverse shear
left In order to prevent drifting out of the neutral position, the hydraulic
motor is hydraulically clamped on both sides by a double non-
return valve which, however, is automatically released upon
actuation being received on one side.
The pressure working on the hydraulic motor is limited by the

pretensioning valve. To prevent that the hydraulic motor builds up
excessive internal pressure due to external forces (for example,
inertial forces when the drive is switched off), it is protected by the
two shock valves.
WARNING:
Pressure settings are made in the factory and must not be

changed.
Control is by means of buttons on the operation unit of the pallet

lift. Movement will only continue for as long as the button is kept
pressed down.
VII-28
5.3 Maintenance instructions
The load-bearing parts should be inspected once a year. Nuts and

bolts should be checked to see that they are tight, especially on
chain studs, chain roller fixings and cylinder holders.
Keep the running surfaces of the profiles clean and occasionally

regrease them to prevent corrosion.
5.3.1 Rack and pinion drive and combi-rollers
Depending on the ambient conditions provide the rack and pinion

drive and the combi-rollers with a sufficient amount of grease once
a month up to every six months. For reasons of space no
lubrication nipple can be provided in the inside masts, so that the
grub screw must be unscrewed and an AM6 lubrication nipple
screwed in instead. After lubrication work, the nipple is to be
replaced by the grub screw again.
The stop pins must be controlled by sight referring to wear and

corrosion. If necessary, the whole chain including the pins and
connecting parts must be replaced; for order, please indicate
number of links)
VII-29
5.3.2 Hydraulic unit and hydraulic cylinders
DANGER:
Only qualified persons are allowed to maintenance works at the

hydraulic unit. Before starting work please move the lifting fork to
the lower end. The main switch at the switch cabinet must be set
to 0 and fixed in this position. If necessary, pallets with sheets
must be removed from the lifting forks and from the roller
conveyor.
Change the hydraulic oil once a year. At the upper end, the
cylinders are fitted with a vent screw with inspection glass.
Check the hydraulic cylinders for leaks; the piston rod must almost
be dry and free from damage. In the case of greater leakage after
a certain service time, a new set of seals must be fitted. Check
hydraulic lines and hoses for damage and leaks. Bent hoses must
be replaced.
NOTE:
When ordering please specify the tube length.
VII-30
6 Sheet Destacker
6.1 Function
Two versions of this unit exist.

The standard version consists of 3 pneumatic cylinders with
suction cups, the destacking cylinders (1), suspended from a
swivelling axis. This version is used for sheets made of magnetic
materials, i.e. materials in which destacking can be assisted by
separating magnets (2).
Fig. 6: Sheet destacking with separating magnets
The second version includes two additional separating nozzles for

the back edge of the sheet built in, the so-called pre-destacking
unit. By these pre-separating nozzles blast air is time controlled
blown in the right moment between the sheets to support the sheet
separation.
This version is applicable for sheets made of nonmagnetic
material.
Pre-destacking is used whenever the sheet sequence is done in

short time intervals of less than 6 s. In this carse there is no time
left for an unsuccessful attempt.
Working with Al-sheets the pre-destacking is generally used to
increase the operatability. Furthermore, blowing nozzles at the side
of the baffle plate to manage the separating and faning out of the
sheets under the main separating suckers are part of the Al-sheet
equipment.
VII-31
Fig. 7: Destacking station with pre-destacking cylinders
Item Function
1 pre-destacking cylinder
2 sheet guiding plate
The control unit is standardly fitted with both variants. The

standard version and the expansion stage with the two separating
nozzles do not differ as far as control systems are concerned. The
sequence of functions does not change. The only difference is
whether the additional separating nozzles are fitted or not.
The functional sequence of destacking is primarily governed by

time without feedback from the pneumatic cylinders. Only the
position of the swivelling axis and the raised position of the
destacking suction cups hanging from it are monitored by cylinder
switches.
VII-32
6.2 Preliminary sheet destacking (AF, DF, OF)
Machines with fast advance systems such as DF and OF are

furnished with a preliminary sheet destacking unit. The same
applies for AF-lines fitted for special sheets.
The preliminary destacking cylinders should be located as far to

the outside as possible, so that the sheets can fan out. The air
nozzles should be arranged in between the cylinders. They should
blow air at the raised sheet in such a way that the sheet flutters.
The destacking process begins with the lowering of the two

preliminary destacking suction cups located at the rear. They are
controlled by the solenoid valve Y119A1 LOWER PRELIMINARY
DESTACKING SUCTION CUPS. The lowering is time controlled.
Its duration can be programmed as the machine parameter
LOWER PRELIMINARY DESTACKING SUCTION CUPS. The
speed and duration of lowering must be chosen such that when the
suction cups are switched from blowing out to suction, the suction
pads rest securely on the top sheet. By observing the LED in the
plug of the solenoid valve Y119A2 BLOW OFF PRELIMINARY
DESTACKING SUCTION CUPS it is possible to check that this
condition is being met. This valve is shut the moment the suction
cups are switched to vacuum.
The lowering motion is carried out at reduced pressure so as to

limit the pressure exerted on the sheet by the suction cups. The
pressure to be used can be read off from the corresponding
pneumatic plan.
Advance Parameter: Lower preliminary Value

destacking suction cups
AF Parameter 15 0,7 s
DF Parameter 15 0,7 s
OF2 Parameter 15 0,8 s
OF2G Parameter 15 0,8 s
When the lowering time is over, the suction cups are switched
from blowing out to suction. This is achieved by closing the
solenoid valve Y119A2 BLOW OFF PRELIMINARY
DESTACKING SUCTION CUPS. This valve will have been opened
at the beginning of the lowering motion at the latest.
For a vacuum to form between the suction cups and the sheet a
further period is programmed as a machine parameter. The time
period PRELIMINARY DESTACKING SUCTION CUPS, FIXING,
delays lifting the suction cups after the vacuum is switched on.
VII-33
Advance Parameter: Preliminary Value

destacking suction cups, fixing
By closing the solenoid valve Y119A1 LOWER PRELIMINARY

DESTACKING SUCTION CUPS the suction cups are raised at the
end of this time. While raising them, the cylinders are operated at
unreduced system pressure. The speed at which they are raised is
adjusted by throttles on each individual cylinder.
At the same time air is blown in by sheet destacking nozzles at the

rear. The air supply is regulated by the solenoid valve Y 116A1
SHEET DESTACKER NOZZLES. The blowing time is
programmable as the machine parameter DESTACKER
BLOWING TIME.
Advance Parameter: Sheet separator Value

nozzles, blow out
VII-34
6.3 Sheet Destacking (AF, DF, OF)
Without the additional cylinders the effect is like a delay in starting

up. This delay is necessary in any case to remove a destacked
sheet before the destacking cylinders can be lowered. This is
essential to prevent the descending destacking suction cups from
colliding with the sheet below. When optimising this delay it should
be noted that it consists of two time periods, the lowering time and
the lifting time of preliminary destacking.
When the two time periods have expired, i.e. when the preliminary
destacking suction cups begin to rise, if present, the 3 destacking
suction cups are lowered. They are controlled by the solenoid
valve Y117A1 LOWER DESTACKER SUCTION CUPS.
Lowering is time controlled. The time period is programmed as the

machine parameter LOWER DESTACKER SUCTION CUPS. The
speed and duration of the lowering must be chosen such that when
the suction cups are switched from blowing out to suction, the
suction pads rest securely on the top sheet. By observing the LED
in the plug of the solenoid valve Y118A1 DESTACKER SUCTION
CUPS SUCK it is possible to check that this condition is being met.
This valve is shut the moment the suction cups are switched to the
vacuum.
The lowering motion is carried out at reduced pressure so as to

limit the pressure exerted on the sheet by the suction cups. The
pressure to be used can be read off from the corresponding
pneumatic plan.
Advance Parameter: Lower destacker Value

suction cups
When the lowering time is over, the suction cups are switched
from blowing out to suction. This is achieved by closing the
solenoid valve Y118A1 SHEET DESTACKER SUCTION CUPS,
SUCK. This valve will have been opened at the beginning of the
lowering motion at the latest.
For a vacuum to form between the suction cups and the sheet a
further period is programmed as a machine parameter. The time
period DESTACKER SUCTION CUPS FIXING delays lifting the
suction cups after the vacuum is switched on.
VII-35
Advance Parameter: Destacker suction Value

cups, fixing
By closing the solenoid valve Y117A1 LOWER DESTACKER

SUCTION CUPS and addressing the solenoid valve Y118A1
DESTACKING SUCTION CUPS SUCK the suction cups are
raised. While raising them, the cylinders are operated at
unreduced system pressure. The speed at which they are raised is
adjusted by throttles on each individual cylinder
The lifting speed of the three cylinders should be adjusted such

that the middle one is delayed, thus deforming the sheet. This
assists separation.
At the same time air is blown in again at the sheet destacking

nozzles. The air supply is regulated by the solenoid valve Y116A1
SHEET DESTACKER NOZZLES. The blowing time is
programmable as the machine parameter 17 DESTACKER
BLOWING TIME. The air nozzles are generally only set up in
machines used for sheets made of non-magnetic metal.
Advance Parameter: Sheet separator Value

nozzles, blow out
Switches in each of the three cylinders monitor when the destacker

suction cups reach the raised position.
ADJUSTMENT:
DESTACKER SUCTION B118E1
CUPS UP 3 Contact makers in series
Cylinder switches in all three destacker cylinders monitor when

they reach the final position. They are connected in series to their
control input port B118E1. This is to prevent a collision between
the guide sheet and the suction cups while swivelling.
VII-36
As soon as the three suction cups have reached the top position
and all three switches have been triggered the destacking
sequence is complete. As soon as the adjoining alignment station
permits, the sheet is swung round into the interception rollers of
the sheet remover or the sheet coating system for applying the
drawing compound.
A double-action pneumatic cylinder carries out the swinging

motion. Both final positions are monitored by cylinder switches.
During destacking the destacking cylinders are vertical. In this
position they are said to be swung out.
ADJUSTMENT:
DESTACKER CYLINDERS B117E1
SWUNG OUT Contact Maker
The position of the cylinder switch is not critical. It ensures that

the suction cups extended for destacking do not collide with the
guide plate of the interception rollers.
The speed at which the sheet is swung in must match the speed at
which the interception rollers draw it in so as to avoid the sheets
being strained when their leading edge touches the interception
rollers.
In fact the swinging motion should be somewhat slower than the
speed of the rollers. This adjustment is carried out using throttles
located directly at the swinging cylinders. The throttles affect the
amount of air entering, so that the swivelling axis can follow the
acceleration of the sheet as it is gripped by the interception rollers
without inertial forces being exerted.
If the speed of swinging in exceeds that of the rollers, the speed

cannot be adjusted in this way and the sheet's leading edge is
strained.
Once the sheet is securely held by the rollers, the switch B117E2
DESTACKING CYLINDERS SWUNG IN must be triggered.
ADJUSTMENT:
DESTACKER CYLINDERS B117E2
SWUNG IN Contact Maker
The cylinder switch identifies the position at which the suction cup
is switched from suction to compressed air and the swinging out
motion sets in. It should be adjusted such that some 5mm of the
sheet's leading edge have already passed the interception rollers.
VII-37
The suction cups are switched from suction to compressed air to

facilitate quick separation from the sheet. The amount of air blown
out is adjusted by a throttle and must be sufficient to prevent the
sheet from being warped during transfer to the rollers.
Function Valve
AF DF OF2
Sheet destacking suction cups lower Y117A1 (A2A6) Y117A1 (A2A6) Y117A1 (A2A6)
Tafelvereinzelungszylinder absenken + abblasen Y118A1 (A2A7) Y118A1 (A2A7) Y118A1 (A2A7)
Sheet destacking nozzles, front Y116A1 (A2B2) Y116A1 (A2B2) Y116A1 (A2B2)
Function Switch
Kind of AF DF OF2
switch
Sheet destacker suction cups on top, contact B118E1 (E2B0) B118E1 (E2B0) 118E1 (E2B0)
left maker
Sheet destacker suction cups on top, contact B118E2 (E5B4) B118E2 (E5B4) B118E2 (E5B4)
center maker
Sheet destacker suction cups on top, contact B118E3 (E5B5) B118E3 (E5B5) B118E3 (E5B5)
right maker
Sheet destacker cylinder vertical contact 117E1 (E2B1) 117E1 (E2B1) 117E1 (E2B1)
maker
Sheet destacker cylinder swung in contact 117E2 (E2B2) 117E2 (E2B2) 117E2 (E2B2)
maker
VII-38
6.4 Adjusting the Sheet Destacker
Proceed as follows for adjusting the sheet destacker:
1. Transversal sheet destacking alignment
The transverse position of the guide is dependent on the position

of the X-stop in the sheet alignment station, i.e. X-axis.
2. Level control
Level control is carried out with the aid of the second cylinder
switch on the middle destacking cylinder B118E4 PALLET LIFT,
LEVEL CONTROL. The varying mechanical differences in the
different machine versions must be taken into account when
adjusting the work level.
2.1 Level determination without preliminary

destacking cylinder for operation with magnetic
materials
In this case the middle cylinder switch should be adjusted so that

the upper edge of the sheet stack (1) comes to a halt when lifting
takes place in the pick-up area of the separation magnets (2).
Fig. 8: Sheet destacker for magnetic materials
VII-39
2.2 Level determination with preliminary destacking

cylinder for operation with nonmagnetic materials
With this version the maximum stroke length of the preliminary

destacking cylinders is all important. During the automatic
operation, the suction cups of these cylinders (1) should be in
contact with the upper surface of the sheet stack (2) at all times.
Here the correct assembly of the cylinder retainer (3) should be
carried out carefully, i.e. the cylinder retainer angle should be in the
indicated position.
max. 80 mm 1
Fig. 9: Sheet destacker for nonmagnetic materials
3. Sheet guides
The sheet guides secured to the guide frame must be matched to

the transverse position of the sheet stack. They should be
mounted in such a way that they can dodge when pressure is
exerted from the bottom.
VII-40
4. Position of the destacking and preliminary

destacking cylinders
The distance of the cylinders to the edges of the sheets is set as

indicated in the drawing for rectangular sheets; whereby a certain
deviation in the settings is permissible for scrolled sheets. Note
that the position of the individual cylinders must always be adjusted
in relation to the scrolled laps.
approx. 30 mm
Fig. 10: Sheet destacker for magnetic materials
approx. 50 mm
VII-41
5. Position of the nozzles for operation with

nonmagnetic materials
5.1. Height setting
The height setting of nozzle (1) must be set so that the

compressed air jet emitted by the nozzle is at the same level as
sheet guide surface (2). This ensures that as the sheet is lifted, air
is blown between the sheets to separate them as the uppermost
sheet is raised.
5.1. Distance to sheet stack
The nozzles should be set at approx. 5 mm from the edge of the

sheet guide. In addition it is also advantageous when the lateral
space between the nozzles and the destacking cylinder is kept,
where possible, small.
3
10 mm 1 2
Position Funktion
1 nozzle
2 sheet guide surface
3 retainer
VII-42
6. Retainer
Reatainers are used for sheets made of magnetic and

nonmagnetic material. The retainers are designed to prevent
several sheets clinging together when the sheets are being
separated.
Sucking the upper sheet it is pressed down at the outer bachward
edges. The sharing strain resulting from this fault is sufficient to
separe the lower sheet from the upper one.
Retainers are used for pre-destacking of the very fast advance
systems DF and OF as well as for AF-machines used for sheets
made of magnetic material.
destacking cylinder
retainer
Fig. 13: Pre-destacking with retainers
VII-43
7. Destacking cylinder speed setting
To limit the pressure applied by the suction cup to the sheet the
lowering motion is carried out at reduced speed. The destacking
cylinder pressure should be set in the region of 2-3 bar. The
pressure of the pre-destacking cylinders is abaout ~ 1 bar. Due to
this pressure setting the lowering speed of the cylinder is, as it
were, obtained.
The cylinder lifting motion is carried at full pressure. For this

reason the lifting speed of each cylinder must be regulated
independently of the others on the restrictors, located on each
cylinder.
The two pre-destacking cylinders should move up at the same
speed. The three pre-destacking cylinders should be adjusted so
that the middle cylinder moves upwards more slowly; this causes
the sheet being lifted to deform, and thus assists in the sheet
separation process.
VII-44
Appendix A
General Informations
ordering spare parts
repair
reply
disposal
Appendix A
Contents
1 LUBRICATOR TABLE 3
1.1 POSSIBLE SUPPLIERS OF ALL SPECIFICATIONS 4
2 DISPOSAL 6
3 REPLY 7
4 AH SERVICE 9
4.1 ORDERING SPARE PARTS 9

4.2 RETURN PARTS TO ALFONS HAAR HAMBURG 12
A-2
Appendix A
1 Lubricator Table
ID Comments Specification
A Light transmission oil CLP + HLP CLP 46 (DIN 51517 Part 3)

HLP 46 (DIN 51524 Part 2)
B Miedium transmission oil CLP CLP 150 (DIN 51517 Part 3)
C Hydraulic oil HL HL 32 (DIN 51524 Part 1)

Hydraulic oil HLP HLP 32 (DIN 51524 Part 2)
D Hydraulic oil HL < 50°C HL 22 (DIN 51524 Part 1)

Hydraulic oil HL 50°C-60°C HL 32 (DIN 51524 Part 1)
Hydraulic oil HL > 60°C HL 46 (DIN 51524 Part 1)
E Hydraulic oil HL HL 68 (DIN 51524 Part 1)
Hydraulic oil HLP HLP 68 (DIN 51524 Part 2)
F Multi purpose grease K2K-30 Lithium soponified
G Special grease
H Medium transmission oil CLP CLP 220 (DIN 51517 Part 3)
I Heavy transmission oil CLP CLP 320 (DIN 51517 Part 3)
J Special grease K2K-30
K Special grease KP1K-30
L Special grease GP00G-10
M Transmission oil CLPPG 68 (DIN 51517 Part 3)
N Transmission oil HLP HLP 100 (DIN 51524 Part 2)
O Temperature transfer oil Q (DIN 51522)
P Chain grease Klüber Lubrification Structovis BHD
Q Linear guidance grease KP2K (DIN 51825)

consistency NLG 12 according to DIN
51818
A-3
Appendix A
1.1 Possible Suppliers of all Specifications
SHELL
A SUMUROL CM46 ENERGOL NUTO H 46 MOBIL DTE 25 KLÜBER SUMMIT TELLUS 46
HLP 46 S (HLP 46) HySyn FG-46
B DEGOL BG 150 ENERGOL SPATAN EP 150 Mobilgear 629 KLÜBEROIL OMALA 150
GEM 1-150
GR-XP 150
C VITAM GF 32 TURBINOL 32 TERESSO 32 MOBIL LAMORA TELLUS 32

DTE OIL Light HLP 32
ENERGOL NUTO H 32
HLP-HM 32 MOBIL DTE 24
D KOSMOL TF32 TURBINOL 32 TERESSO 32 MOBIL CRUCOLAN 22 MORLINA 22

VELOCITE OIL
KOSMOL TF 46 TURBINOL 46 TERESSO 46 No. 10 CRUCOLAN 32 MORLINA 46
MOBIL DTE OIL CRUCOLAN 46

Light
MOBIL DTE OIL
Medium
E VITAM GF 68 TURBINOL 68 TERESSO 68 DTE OIL LAMORA TELLUS 68

Heavy Medium HLP 68
ENERGOL NUTO H 68
HLP-HM 68 DTE 26
F ARALLUB HL 2 ENERGREASE BEACON 2 MOBILUX 2 KLÜBERPLEX ALVANIA Fett R2

LS 2 BEM 41-132
G ISOFLEX LDS 18
SPECIAL A
H DEGOL BG 220 ENERGOL SPARTAN EP 220 MOBILGEAR 630 KLÜBEROIL OMALA 220
GEM 1-220
GR-XP 220
I DEGOL BG 320 ENERGOL SPARTAN EP 320 MOBILGEAR 632 KLÜBEROIL OMALA 320
GEM 1-320
GR-XP 320
J ENERGREASE UNIREX N2 MOBILGREASE KLÜBERPLEX RETINAX LXZ

LS2 HP222 BEM 41-132
K MICROLUBE ALVANIA
GL 261 EP (LF) 1
L ARALUB FDF 00 ENERGREASE FIBRAX EP 370 MOBILUX EP MICROLUBE ALVANIA

HT-EP 00 004 GB 00 GL 00
FIBRAX 370
ENERGREASEFG (GPBM-20)
00-EP
M GLYGOYLE 11 SYNTHESO
D 68 EP
N ENERGOL KLÜBER-
HLP-HM 100 SUMMIT HYSYN
FG100
O FAROLIN T TRANSCAL LT THERMALÖL S MOBILTHERM KLÜBERSYNTH THERMIA ÖL A

594 UH1 4-18
P Klüber Lubrifica-
tion Structovis
BHD
A-4
Appendix A
SHELL
Q Klueber Microlu-
be GL 251 / GL
262
A-5
Appendix A
2 Disposal
The machine or machine groups do not contain any raw materials

or additional materials that must be handled as dangerous mater-
ials during disposal.
During disposal, the individual materials must be sorted and deliv-

ered to a recycling plant; disposal can also be carried out accord-
ing to the normal regional requirements.
Oil Drain, collect and dispose of transmission oils together as used oil.
Electric and electronic compo- These parts are to be collected separately and disposed of accord-
nents ing to the local regulations
Metal parts Steel, cast iron and non-iron metal parts are to be collected sepa-
rately and brought to the appropriate recycling plant.
Plastic Plastic parts are to be collected separately and disposed of accord-

ing to the local regulations. Plastic parts must not be incin-erated.
A-6
Appendix A
3 Reply
We have attempted to design the documentation so that it is as

user-friendly as possible.
Comments and criticisms fro4m our clients can also lead to an im-
provement in the documentation. If you have any suggestions,
please fill out the following reply and send it to:
Alfons Haar GmbH

Dokumentation Maschinenbau
Fangdieckstraße 67
Postfach 530 160
D-22531 Hamburg
GERMANY
A-7
Appendix A
Reply
Company name: Machine type:
Machine number: Year of construction:
The documentation could be improved as follows (please give precise details):
Evaluation of the documentation (please mark with an “X”, 1 = negative, 10 = positive):
Quality of the translation of the operating instructions
1 2 3 4 5 6 7 8 9 10
Understandability of the operating instructions
1 2 3 4 5 6 7 8 9 10
Structure of the operating instructions/documentation
1 2 3 4 5 6 7 8 9 10
Optical representation of the operating instructions
1 2 3 4 5 6 7 8 9 10
A-8
Appendix A
4 AH Service
4.1 Ordering Spare Parts
NOTE:
We can only assure a fast and correct delivery of spare parts if

we have all the requestes informations available on the spare part
order form.
When ordering spare parts please give the following informa-

tions:
Your company name
Machine No. and Machine Typ
Drawing No. in which the requested part is included
Modification level of the drawing
Alfons Haar GmbH Name of the drawing / modul

Serviceabteilung
Postfach 530 160
Fangdieckstraße 67
Fax: 040 83 391 260
D-22531 Hamburg Name of the requested part
Position No. of the requested part (from the drawing)
Ordering No. of the requested part
Ammount of the requested parts
A-9
Appendix A
Item
Version No.
Designation
Drawing No.
Fig. 1: Drawing informations
A-10
Appendix A
Name of the requested part
Item
Material number
Fig. 2: Spare part list information
Please give as many informations as possibel in your spare part

order form and send these informations to our next SERVICE
DEPARTMENT.
Missing information will delay our technical support or could end in

the delivery of the incorrect parts.
THANK YOU VERY MUCH FOR YOUR SUPPORT !
A-11
Appendix A
4.2 Return Parts to Alfons Haar Hamburg
To ensure a fast reply on returned parts to Alfons Haar Service

please print out or copy the form on the next page, fill in the re-
quested information and send the form together with the returned
parts to:
Alfons Haar GmbH

Service Department / VMK
Hellgrundweg 112
D-22525 Hamburg
GERMANY
or sent it via fax to:
Alfons Haar GmbH

Service Department / VMK
FAX: +49 40 83391 260
NOTE:
Required information should be provided within seven (7) days af-

ter delivery of the goods, otherwise this remain property of cus-
tomer. Part will be checked and repaired if required. The AH-
Company will not take any responsability for any damage arising
later on for damage due to insufficient description of failure or
lake of information from customer.
A-12
Appendix A
CUSTOMER REFERENCES
FOR ANY RETURN OF ALFONS HAAR PARTS
SENDER-Details:
Company Machine No.:
Phone-No.: Mr. / Ms.:
Delivery Note No.: Fax-No.:
DESCRIPTION OF PART:
AH-Ordering-No.: Part No. (ETN):
Description: or serial No.

(SN):
DETAILED DESCRIPTION OF FAILURE:

if more space is required please attach another sheet of paper
REASON FOR RETURN: PLEASE MARK ACCORDINGLY !!!
covered by garnty Exchange Repair Others

A new part must or will be Goods remains custom- i.e. non required parts in re-
sent. The returned part be- ers'property. Send an es- turn, failure in delivery
comes property of AH. In ca- timation for reparation be- etc. please specify:
se of repair, you will receive a fore repairing: ................................................
credit note equivalent to ................................................
1 rd
/3 of the price for a new YES ................................................
part. NO ................................................
................................................
................................................
______________________________
Place, Date Signature with Company stamp
A-13
Appendix B /
Maintenance + Lubrication Routine
Appendix B
Table of Contents
1 LUBRICATION 3
1.1 ECCENTRIC PRESS P(V)40(S) 3

1.2 ADVANCE SYSTEM DF3 5
1.3 COATING SYSTEM 6
1.4 PALLET LIFT 7
2 MAINTENANCE WORKS 8
2.1 PRESS P(V)40(S) 9

2.2 ADVANCE DF3 M 12
2.3 LOADING SYSTEM DF 14
2.4 SHEET LUBRICATION SYSTEM 15
2.5 SHEET DESTACKING DEVICE 16
2.6 PALLET LIFT / ROLLER CONVEYOR 17
2.7 DISCHARGE SYSTEM / JET SYSTEM 18
B-2
Appendix B
1 Lubrication
1.1 Eccentric press P(V)40(s)
Module Specification Amount / Frequency Position:
Central lubrication P(V)40(s) Class B 50.000 ml / yearly
air inlet clutch A Class F 8 ml / 4000 h

C
drip oiler B Class A 1drop / 100 engagements
flywheel bearing C Class J 600 h

( not needed with P40S) A
B-3
Appendix B
Main drive motor P(V)40(s) Class F Yearly
B-4
Appendix B
1.2 Advance system DF3
The advance system is equipped with guiding slide and long-time lubrication. Manual re-lubrication has to be made every 6 months with grease class Q.
The track of the Y-axis shall be wetted with grease. It may not be wiped dry. The bearings of the pulleys are permanently lubricated.
X-axis right Slide Y
Slide L X-axis left
B-5
Appendix B
1.3 Coating system
Swiveling drive / mechanics Class F Manual lubrication /

monthly
Gear box / gear wheels Class F Manual lubrication /

monthly
NOTE:
It is necessary to remove the safety covers to reach the

obove shown lubrication points.
B-6
Appendix B
1.4 Pallet Lift
Oiltank of hydraulic pump 1 Class E fill up to MAX level /

anually
3
Combination rollers of 2 Class F monthly
horizontal movement
Combination rollers of Class F monthly 1

3
lifting movement
Rack and pinion drive of 4 Class F monthly

horizontal movement
2 2
NOTE:
Only refill the tank when the forks are in their lowest possible
position. There is a risk of overfloating, if the tank is filled up
to MAX when the forks are not completely lowered.
B-7
Appendix B
2 Maintenance works
SYMBOL: MAINTENANCE WORK: SYMBOL: MAINTENANCE WORK:

Oil change: Visual Check:
Drain old oil, clean the oil container and refill with new oil. Control each build group for operation, missing parts, general
condition and replace missing or worn part if applicable.
Manual grease lubrication: Wearing parts replacement:

Using a hand grease pump, apply grease through the grease nipples, Remove wearing parts and replace with new parts.
clean off excess grease. Warning: apply only the correct grease volume.
Filter change: Cleaning:

Remove filter of the unit and swap with new identical filter. Oil circuit Clean the machine by hand.
must be bled of all air.
Various liquid level control: Liquid leaks:

Oil, drawing lubrication or cooling fluids are to be filled to the MAX-Level. Check all hoses and fittings for leaks, if applicable stop leak by
replacing defect hose or seals.
Manual oil lubrication: Air leaks:

Apply oil by hand to the areas to be lubricated. Check all hoses and fittings for air leaks, if applicable stop air leak by
replacing defect hose, fittings or seals.
Central lubrication unit: Set up:

Control the operation of the central lubrication system and all Check basic set up and if required make corrections. Information to the basic
dosing distributors. set up can be found in the instruction manual and in the attached drawings.
Moving surfaces: Surface wear / Cracking:

Moving surfaces on the spindle, linear guide rails and bearing to Parts to be checked for surface wear and / or cracks.
be checked for damage.
Inspection for play:

Play between two parts to be checked and compared to the
required value.
B-8
Appendix B
2.1 Press P(V)40(s)
Pos. Module: Substructure: daily weekly monthly every 3 months every 6 months every 12 months
1.1 Safety equipment Emergency stop
1.2 Safety guards
1.3 Safety switches
2.1 Main drive Main drivebelt
2.2 Flywheel
2.3 Main driving motor
3.1 Clutch Rotating connection
3.2 Clutch / brake pads
3.3 Oil distributor
3.4 PNE Clutch
Oil change Filter change Manual grease lubrication Visual check Cleaning
Manual oil lubrication Various liquid level control Central lubrication unit Wearing parts replacement Liquid leaks
Moving surfaces Surface wear Inspection for play Set up Air leaks
B-9
Appendix B
4.1 Central lubrication Oiltank
4.2 Oil - hoses / pipes
4.3 Dosing distributor
5.1 Ram Ram guidance
5.2 Recirculating roller shoes
6.1 Drawing cushion Drawing cushion

lubrication
6.2 PNE Drawing cushion
6.3 Drawing cushion piston
B-10
Appendix B
7.1 Die set Springs inside tool
7.2 Guiding bands
NOTE:
The wearing parts of the die set are having an aprox. Life
time of about 30 Mio strokes. Due to that it is not possible to
give a timing for the replacement of the wearing parts.
B-11
Appendix B
2.2 Advance DF3 M
1.1 X-axis Linear motor
1.2 Linear guidances
1.3 Water cooling
2.1 Y-axis Linear motor
2.3 Water cooling
3.1 Advance gripper PNE - Advance gripper
3.2 Advance gripper
3.3 Swing system
B-12
Appendix B
4.1 L-axis Linear motor
4.3 Swing system
4.4 Shock absorber (swinging)
5.1 Loading grippers PNE Loading gripper
5.2 Loading gripper
5.3 Locking piston / Upper

part loading gripper
B-13
Appendix B
2.3 Loading system DF
1.1 Loading system Sheet guidance
1.2 PNE - Sheet fixation
1.3 Register points (3x)
1.4 Cross sled
1.5 Sheet stopping pins
1.6 Double sheet device
4.1 Pneumatic All pneumatic devices

equipment
B-14
Appendix B
2.4 Sheet lubrication system
1.1 Lubrication rollers Clothing of lubrication

rollers
1.2 Bearing of the rollers
2.1 Main drive Index belt drive
2.1 Gear box / Gear wheels
2.2 Swivelling drive
3.1 Drawing Lubricant tank

compound
distributor
3.1 Dosing distributor
4.1 Pneumatic PNE - Lubrication

equipment
B-15
Appendix B
2.5 Sheet destacking device
1.1 Sheet destacking Separating cylinders

device
1.2 Proximity switches
1.3 Suction heads
2.1 Sheet guidance Sheet guidance

frame
2.2 Safety switches for frame
3.1 Pneumatic All pneumatic devices

equipment
B-16
Appendix B
2.6 Pallet lift / Roller conveyor
1.1 Hydraulic Pump / Oiltank

equipment
1.2 Lifting cylinder
2.1 Horizontal Combination rollers

movement class F
2.2 Rack and pinion drive
class F
3.1 Vertical movement Combination rollers
class F
4.1 Load capacity Load capacity test (3t)
5.1 Roller conveyor Bearings of the rollers
Friction safety clutch
Anti retour locking device
B-17
Appendix B
2.7 Discharge system / Jet system
1.1 Jet rails Top guidance / Lateral

guidance
1.2 Ventilation
1.3 Throttle valve
1.4 Cup brake
2.1 Die safety device Proximity switches

Blow out Change valves
monitoring
2.2 Top guidance / Lateral

guidance
B-18
Appendix C
Machine values legend
CNC- DF(Z)3-Px Mk5.3
Software: DFH ADEFRTC Mk5.3-4.008
App C DFH ADEFRTC 4008 Mk53
Table of Contents
1 GENERAL INSTRUCTIONS 3
2 MACHINE VALUES 5
3 PROGRAM VALUES 24
3.1 SYNCHRONIZATION VALUES 24

3.2 ADVANCE 26
3.3 DIES 28
3.4 DISPLAY DIE SAFETY 28
3.5 LUBRICATION 29
3.6 DISPLAY 30
3.7 SERVICE DISPLAY 30
C-2
1 General instructions
DANGER:
Only authorized, trained personnel are permitted access to the

machine parameters.
Errors during programming can result in serious physical injury or
mechanical damage.
The definition of the machine parameters is coordinated with each

machine upon delivery. Normally these parameters may be
changed only with prior approval from HAAR.
Changes must be reported to HAAR SERVICE.
NOTE:
Changes are entered in the relevant machine files at HAAR.

However, some selected parameters can be changed by the user
without risk. The function of these parameters are explained in
the introduction and are marked in the following list of
parameters, as follows:
This parameter may be changed by the

machine operator. Notes in the relevant chapter
of the operating manual must be observed.
____________________________________________________
This parameter may not be changed by the operator, it

represents the basic machine configuration and is related
to the actual program version.
____________________________________________________
This parameter shall not be changed by the operator

Any change to a parameter marked in this way is
permissibly only A. Haar staff or following
instructions issued by the AH Service
Department (Hamburg)!

C-3
Access to the file MACHINE PARAMETERS is protected with

various security measures in order to prevent access by
unauthorized persons.
Access First switch off the main switch to the control cabinet. Press the
EMERGENCY STOP while unit is off.
⇒ Switch on the control system and wait for the message

emergency OFF to appear on the screen.
⇒ Acknowledge error message(s). The error message

"EMERGENCY OFF" will remain on the screen.
⇒ Press the hard key DATA INPUT MODE and select the
F1 function MACRO in the appropriate soft key menu.
PARAMETER and the value 11 will appear on the screen.
⇒ Activate the key DATA ENTRY. Write over the value 11 with
00 ENTER 00 and press ENTER.
The file MACHINE PARAMETERS is now open and the first

parameter will be displayed as PARAMETER 01. Pressing the
ENTER key will make it possible to page through the individual
parameters. Changes to the parameters can also be made.
Changing parameter values ⇒ Search for the parameters to be changed. Page through the
list to view the individual parameters using the ENTER key.
⇒ Write over the old value with the new value and confirm by
ENTER value ENTER pressing ENTER. Ensure that the number of digits is correct.
If necessary, several parameters can be changed consecutively.
Closing the parameter list ⇒ Go to the end of the list by pressing the ENTER key, or press
F1.
⇒ Press the left arrow key above the number pad to leave the
data entry.
⇒ Switch off the control system via main switch.
⇒ Pull out EMERGENCY STOP.
NOTE:
After changing the machine parameters the file MACHINE

PARAMETERS must be closed before switching off the control
system.
C-4
2 Machine values
Param Format Description Unit

No
ASI
Chg?
01 xx Machine coding
Indicates the type of machine the software is able to control. This parameter
cannot be changed with standard control systems, since only the
implemented software version can be activated. However, there are
combined control systems with multiple firmware versions for various
machine series. When using these control systems, the current firmware
version is selected using this parameter. The parameter must therefore
contain the type for the machine series that is to be controlled.
02 X00 Service Language
The first number indicates the service language This is the language to
display messages on the screen, when the language key is activated ( LED
on )
The language is preselected here. A change precaution is the upload of the
respective language version on the system..
The service language is activated using the hard key LANGUAGE on the
control panel. Selectable are:
0?? = German
1?? = English
2?? = French
0xx Operator language
Die two trailing digits indicate the Operator language. This is the language to
display messages on the screen, when the language key is disactivated (
LED off ) By this parameter the uploaded language version is checked
during startup of the machine. Usually, except the service language only the
particular customer's language is provided in the data memory.
The following languages can be selected:
?00 = German
?01 = English
?02 = French
?03 = Dutch
?04 = Spainish
?05 = Italian
?06 = Danish
?07 = Czech
?08 = Portuguese
?09 = Schwedish
?10 = Norwegian
?11 = Slowene
?12 = Russian
?13 = Polnish
?18 = Brasilian-portuguese

C-5

No
ASI
Chg?
03 X0 standstill monitoring
0? = standstill monitoring with one initiator at ASI

1? = standstill monitoring with two initiators with evaluation device
0x Rotational direction of resolver
?0 = clockwise
?1 = counter clockwise
04 Xxx Maximum speed spm
This parameter determines the maximum possible speed of the press in

[strokes/min]..
05 xx Motor type
This parameter specifies the main drive motor and combination of motor and
frequency converter.
AC motor: Press
12 = PV 40-
13 = P30-
14 = P40S-
15 = DRMTPV 50-
16 = P40-
17 = P125
20 = P25-
21 = P15-
22 = PV15-
23 = P25D-
24 = P25d
25 = PV15 1:4
26 = P40HN w. backgear
06 xx negative speed correction 1/min
Three-phase motor (AC): negative speed correction at max. speed

[min-1]
This parameter specifies the negative speed correction refered to the

maximum speed of the press (machine parameter 4).
If the measured (actual) speed differs from the programmed (nominal)
speed (synchronization value “speed“), the programmed speed must be
increased or reduced according to the divergence. The divergence is
programmed here.
C-6

No
ASI
Chg?
07 Xxx Jam check, sensitivity 1/100s
* Indicates the sensitivity of the input JAM CHECK. If the 1-signal is present at
the input for more than the set time, this will be interpreted as a jam. Value
100 corrsponds to 1.00 s decimal
08 Xxx Jam check, restart 1/100s
& Indicates the restart delay after input JAM CHECK switches back to zero.
09 X0 Distance blocks
, This parameter indicates whether the press is provided with safety distance
blocks (P40/PV40) .
0? = with Distance blocks

1? = without Distance blocks
0x Backgear
This parameter specifies the lubrication mode of a backgear (P40/PV40/

DRMTPV ).
?0 = without backgear or dry or oilbath lubrication

?1 = with backgear and active lubrication (PV40, RTPV40)
10 xxx Central lubrication, monitoring time s
& specifies the total cycle monitoring time of the central lubricating system.
At last after this time a signal form the high- pressure sensor and afterwards
one from the low pressure sensor is expected.
11 xx Central lubrication, high-pressure period s
* Indicates the high-pressure period of the lubrication impulse for the

centralized lubrication. In the time between the high pressure switch is on.
For presses the value is: high-ressure period = 5 s.
12 xx Central lubrication, pause s
* Indicates the pauses between two lubrication impulses for the central
lubrication.
The complete time for one lubrcation cycle is the total of machine
parameters "high-pressure" and "pause"

C-7

No
ASI
Chg?
13 xxx Lower destacker suction cups 1/100s
specifies the lowering time of the sheet destacking suction cups (rear in 117A1
production direction) in hundreths of a second.
This time elapses as soon as the output signal "Sheet destacker suction
cup lower" has switched through. At the end of this time period the suction
time of the destacking cylinders starts..
14 xxx Destacker suction cups, fixing 1/100s
specifies the sucking time of the sheet destacking suction cups in hundreths 118A1/
of a second. 119E1
This time elapses as soon as the output signal "Sheet destacker suction
cup suck" has switched. At the end of this time period the destacking
cylinders are moved up again. Here the solenoid valve "Sheet destacker
nozzles front" is activated for the period of time which has been
programmed.
15 xxx Lower pre-destacking suction cups 1/100s
specifies the lowering time of the optional sheet pre-destacking suction cups 117E2
in hundreths of a second.
This time elapses as soon as the output signal "Sheet destacker cylinders
swung in" has switched. At the end of this time period the suction time of the
pre-separation cylinders starts
16 xxx Pre-destacking suction cups, fixing 1/100s
specifies the initial sucking time of the preliminary sheet destacking suction 119A2
cups in hundreths of a second.
This time elapses as soon as the output signal "Sheet destacker presuction
cups suck" has switched. At the end of this time period the pre-separation
cylinders are moved up again. Here the solenoid valve "Sheet destacker
nozzles front" is activated for the period of time which has been programmed
17 x000 Position Sheet destacking nozzles
l nnn= 0nnn = nozzle location behind baffle plate

l nnn= 1nnn = nozzle location sidewards diagonal direction
0xxx blow time Sheet destacking nozzles 1/100s
?mmm specifies the blowing time of the sheet separator nozzles n 116A1
hundredths of a second.
C-8

No
ASI
Chg?
18 xx Sheet transit monitor s
specifies the maximum transit time in seconds for a sheet from the
destacking station to the alignment station. When operating without a
PALLET EMPTY sensor, exceeding this time is interpreted as PALLET
EMPTY.
19 xxx Sheet setting 1/100s
specifies the time allowed for the sheet to settle in the alignment station, in
hundredths of a second.
20 xx Ejector correction °
As part of the advance test the reaction time of the scrap skeleton ejector is 106E1
measured up to the point when the scrap skeleton ejector is closed. The
closing is detected by the initiator "scrap skeleton ejector closed".
In case of malfunctions the switching point calculated with the response time
measurement can be delayed with this parameter..
21 xx Synchronisation correction [ms]
specifies a modification of the automatically generated synchronization point

which starts the advance moving of the sheet into the die.
It is meant only in operation mode “Automatic“:
The approach of the sheet into the die when actuating the softkey “Advance“
is carried out for testing purpose at the first actuation of the softkey
“Advance“ or after program changes concerning the first stamping position.
The bigger the correction value the earlier starts the departure. If the
synchronisation value “Die closes“ is right and if the speed of the press is
the speed of input, then machine parameter 21 is corrected as follows
The sheet arrived too early, if it runs against the closed die, therefore
machine parameter 21 must be decreased.
If the error „SYNCHRO ADVANCE X“ or „SYNCHRO ADVANCE Y“ ( AF )
resp. „SYNCHRO ADVANCE L“ (DF) occurs, it arrived too late, therefore
machine parameter 21 must be increased..
22 xx.xx Pitch L-axis [mm]
specifies the pitch / counting cycle of the positioning system of the L-axis.
For linear drive: 40.96 mm
23 xx.xx Pitch X-axis [mm]
specifies the pitch / counting cycle of the positioning system of the

X-axis ( wormscrew = 1 rev ) = 32 mm ) . ( AF )
( Linear ) 1 cylcle = 40,96 mm ( DF )
..( rack. cycle = 1 rev ) = 62,83 mm

C-9

No
ASI
Chg?
24 xx.xx Pitch Y-axis [mm]
specifies the pitch / counting cycle of the positioning system of the

Y-Axis ( wormscrew = 1 rev = 1 U ) = 32 mm ) . ( AF )
( Linear ) cylcle = 40,96 mm ( DF )
25 xxxx.xx Software-limit L+ [mm]
specifies the maximum range of movement of the L-axis in [mm]. This value
is depending on the advance configuration.
This value must be set to a position behindthe last stamping position.
26 xxxx.xx Software-limit X+ [mm]
specifies the maximum range of movement of the X-axis in [mm].

This value must be set to a position before the carriage activates the
hardware limit switch.
This value is depending on the advance configuration.
27 xxxx.xx Software-limit Y+ [mm]
specifies the maximum range of movement of the Y-axis in [mm].

This value must be set to a position before the carriage activates the
hardware limit switch.
This value is depending on the advance configuration.
28 xxx.xx L-zero position [mm]
Specifies the L-zero position. The L-zero position is the position that the L-
axis approaches after a successful advance test.
If a negative value is required, a "1" is entered as a minus sign.
Example:
020.00 = + 20 mm
120.00 = - 20 mm
29 xxx.xx X-zero position [mm]
Based on the hardware- Zero position, which is defined by the resolver

measuring system and the hardware- end switch X-, the operating zero point
can be shifted by this parameter.
Example:
015.00 = + 15 mm
115.00 = - 15 mm
C-10

No
ASI
Chg?
30 xxx.xx Y-zero position [mm]
Based on the hardware- Zero position, which is defined by the resolver

measuring system and the hardware- end switch Y-, the operating zero point
can be shifted by this parameter.
Example:
025.00 = + 25 mm
125.00 = - 25 mm
31 000.0x rack
Specifies, if the advance is .moved by a rack drive
000.00 = no rack
000.01 = witht rack
32 X00 /X0 Start predestacking
States, if the pre- destacking is started simultanouosly or after finishing the

infeed of the sheet.
0?? = Start after swivel in of the sheet
1?? = Start together with swivel in of the sheet
0X0 Delay swing in
A sheet sticking at the sucked up sheet is split off by the separating nozzles,
this may need more time at the first sheet separated, so the sheet is swung
in together, causing a double sheet error. By delay of the swing in after
picking up a pause is awaited before the swivel movement. At continuous
operation this pause will occur automatically, as the clearign of the alignment
station has to be awaited.
?0? = no swing in delay

?1? = with swing in delay
00x / 0x sheet lubricant, drive
specifies the operational mode of the drive for the drawing compound
coating system
??0 = continuous operation

??1 = timed shut-down
Timed shut-down means that after a fixed time whithout a sheet having
passed, the drive is shut down. This mode of operation is particularly
important for plants including mechanically driven dosing pumps for
emulsion. It prevents the spreading rollers from being overlubricated.
The drive starts up again when the next sheet enters the station.

C-11

No
ASI
Chg?
33 xxx Operating mode, jam
Defines the reaction in the event of a jam downstream of the press:
The value must be entered in three digits:
0mn = The press reengages automatically after release of the jam.

1mn = The press must be reengaged manually after release
of the jam.
l0n = Switch off clutch

l1n = Stop feed of next sheet to die
lm0 = Discharge conveyor without stop

lm1 = Discharge conveyor stops immediately
lm2 = Discharge conveyor stops after 2 seconds
...
34 x Unit of measurement
specifies the display and data input mode:
0 = inch
1 = metric ( mm )
( only concerning the display on the screen, the data are always stored and
processed in mm, Inputs and displayed values are converted in Inch- mode,
no new input of data required )
35 xxx Draw cushion lubrication 1000
specifies the number of strokes, in [ mmm ⋅ 1000 strokes ], for the lubriction
intervals for the ram weight compensating cylinders and the the air-operated
draw cushions..
36 x Magnetic belt destacking
Defines the operating mode with or without magnetic belt destacking. In

case of magnetic belt destacking the sheet moves upwards to a horizontal
magnetic belt without any swivelling movement of the destacking cylinders.
0 = without magnetic belt separation

1 = with magnetic belt separation
C-12

No
ASI
Chg?
37 x Pallet changer
Defines whether the machine is operated with or without pallet changer:
0= without pallet changer

In this case, the program value "PALLET CHANGER" under the
softkey LUBRICATION must also be set to 0.
1= with pallet changer without roller conveyor
2= with pallet changer and pallet changing system
3= with hydraulic lift
4= with pallet changer and empty pallet fork
6= Twin destacker with 2 roller conveyors
38 x00 Monitoring cooling
defines whether the machine operates with monitoring of die cooling
0xx = without die cooling flow indicator

1xx = with die cooling flow indicator
0x0 Monitoring die temperature
defines whether the machine operates with monitoring of die temperature

?0? = without temperature monitoring
?1? = witht temperature monitoring
00x die fixation
defines whether the machine operates with monitoring of die fixation

??0 = without hydraulic die fixation system
??1 = without hydraulic die fixation system
??2 = with hydraulic die fixation system
n must be “2“, if the tool is provided with a hydraulic die fixation system with
permanent pressure supply for operation
39 x Operating mode: Empty pallet
specifies the way in which an empty pallet is recognized on the pallet lift.
This choice only exists when operating without a pallet changer. If a pallet
changer is used, the mode with sensor must be chosen to detect the empty
pallet.
0 = without sensor, i.e. using Sheet Transit Time Monitoring

1 = with sensor
2= with sensor, last sheet not to beprocessed !

C-13

No
ASI
Chg?
40 xx Operating mode: External control
specifies the reaction of external control 103E1 “External control“:
0? = disengage clutch and re-engage automatically

1? = interrupt sheet infeed, press keeps idling
2? = disengage clutch without re-engaging automatically
?0 = No stop of discharge conveyor

?1 = immediate stop of discharge conveyor
?2 = 2 sec. delayed stop of discharge conveyor
...
41 x Maximal Number of dies
specifies the maximum number of dies of the safety system: ( equipment

with in-/ outputs for die safety / Blowout nozzles)
0 = max 8 dies
1 = max 16 dies
42 X00 Collision free
0?? Advance grippers may collide with loading grippers due to

lateral stroke travel
1?? Lateral travel / gripping width without collision risc with loading
grippers
( L- and X axis need not to be coordinated in movement )
0xx Reduction of idle strokes ms
at larger diving depth and low speed this is used for sparing time for the
calculation of the loader start, in order to get less idle strokes.
? 00 without closing time delay
? mm mm ms delay for closing time delay
43 xxx Proceeding survey / Sheet feeding
At machines, which are not permanently observed, a failure in sheet feeding

may cause the press to run idle some time, which may affect the die. With
the proceeding survey active, the press is stopped after mmm seconds,
when no sheet was fed to the lubrication station.
000 = no observaton / press stop
mmm = observation / Stop after mmm s without sheet feeding
C-14

No
ASI
Chg?
44 xxx Y-Return observation
The moment for the arrival of the new sheet in the first punch position is
calculated in reference to loader speed, press speed and die – open- time.
On the other side, the returning of the Y- axis must be finished at the same
moment, other wise an additional idle stroke must be spent. This parameter
serves as safety offset to mention variations of the real parameters during
operation compared to the parameters programmed and evaluated during
test run
45 xxx.x Overload MIN [t]
The least required preload pressure of the overload protection device for
operating the press, recalculated to force ( tons ).
Input with 1 decimal after the decimal point.
MP 45 = 000 and MP 46 = 000 no monitoring.
MP 45 = 000 and MP 46 > 000 electronical overload monitor, strain
sensor on the frame, no hydraulic device.
46 xxx.x Overload MAX [t]
specifies the maximum allowed force of pressure of the press in tons.

Input with 1 decimal after the decimal point.
MP 45 = 000 and MP 46 = 000 no monitoring.
MP 45 = 000 and MP 46 > 000 electronical overload monitor, strain
sensor on the frame, no hydraulic device.
47 xxxxxx Offset overload safety device
refer to „Factor...“ !
with use of a signal converter 0-10V this value shall be 0
at direct connection of the pressure transducer ( 4 – 20mA ) at 0 bar an
offset is returned, which has to be mentioned in the force calculation. This
value is entered here, where Param 48 has to be mentioned
( = o*a/c – refer to table at param 48 )
after calibration ( rate evaluation ) of the tension transducer ( ref. to
param 48 ) a calculated force offset will be left at 0 V this value in tons
multiplied by 1000 has to be set here. ( f.e. 0,27 t -_> 000270 )

C-15

No
ASI
Chg?
48 xxxxxx Factor overload safety device
This factor is used for calculation of the press force ( F ) from the returned
digital output signal ( DAC ) of the pressure transducer, resp. the tension
transducer of the overload monitor of P(V)15…P125
Bei hydraulischer ÜLS

max. Output limit of the Sensor:( 500 bar ) =>10V=> 655350000 DAC
( do). Offset,if used=>2V=>131070000 DAC ( o) c = ( do – o ) / 500..
Output value of the sensor xxxx DAC ( d ) piston crosssection (cm²) P25:
113,1 / P40: 176,7 / P100: 380,1 ( a) F = ( d - o ) * (a/c ) Factor...“ ! =
a/c*109 :
0-10V 4-20 mA “Offset”
P25: 086288 107860 014137
P40:…134825 168531 022089
P100 290023 362528 047517
Tension transd.
Force measuring with hydraulic jack ( P(V)15:
Sensor-Reset – introduce force – read out voltage ( U) – release force..
...repeat with increasing forces up to 15 t.
Force measuring with hydraulic OLD:

lower ram on kissblocks or respective distance posts ( insert appr. 1 mm of
lining ), release OLD and turn crank to LDC Sensor reset – pump up OLD
with specific pressure – read voltage ( U) release OLD … repeat with
increasing pressure up to recalculated nominal press load
Evaluate rate for force related to voltage referred to 10 V:

c = diff(F)/diff(U) * 10 V ) Factor = c / 655350*109
49 xxx Correction of swiveling grippers
Swiveling in of the advance grippers during return to the sheet takeover

position is triggered at a distance between loader- and advance grippers of
90% of the programmed Y- step. This parameter enlarges or reduces this
distance ( in mm )
Values between 0xx and 099 reduce , the swiveling starts later
Values between 1xx and 199 enlarge the swiveling starts earlier
50 xx Delay time for the opening of the loading grippers [ms]
The advance grippers close when the die closes for the first stroke. The
loading grippers open with delay time with respect to this time. The delay
time is indicated in milliseconds.
If the value is 00, the loading grippers open simultaneously with the closing
of the advance grippers..
C-16

No
ASI
Chg?
51 xxx Blowing time of the nozzles while swivelling in [ms]
The blowing time of the insert aid nozzles before the swivelling in of the
grippers is indicated in [ms].
52 mmm Delay time between blowing and swinging [ms]
The operation of swinging in starts when the nozzles are activated. If this
parameter is 000, the advance gripper swing in when blowing starts.
Otherwise there is a delay of swinging in according to the choosen value in
milliseconds..
53 x0 Print marking sensor
indicates whether the machine is provided with a print marking sensor.
0? = without pressure marking sensor

1? = with pressure marking sensor
0x/0x0 Alignment repetition
Defines the number of sheet alignment repetition in case of failure
?n_ = repeat alignment n times maximum
54 mmm Take off servo valve 1/100s
Pallet lift 120A3

While braking the lateral advance the servo valve is taken off first. This
effects gentle braking via a ramp control. After the ramp time of the valve
Y120A3 , see drawing A-3599, of 50 ms the directional control valve must be
switched off, too. This time is defined with machine parameter 54
55 x0 Misprint ejection time
Switch on- time of misprint ejection output

0? = 50ms
1?= 100ms
2? = 150ms
3? = 200ms
4? = output kept "ON" until next pulse of cap detector
0x Misprint ejection
Picking out of bad products in discharge ( preprogrammed misprints )
?0 = lateral deflection of misprints

?1 = longitudinal deflection, all channels of a punch
?2 = longitudinal deflection, individual channel selection
( only without redraw press )

C-17

No
ASI
Chg?
56 no Function
57 x00/ lubrication ( pulses )

x0
Defines, if multiple lubrication pulses shall be spent per sheet:
0?? = normal lubrication ( = 1 time per cyclus )
1?? = multiple lubrication in 500-ms-rhythm
Furthermore, the amount of lubrication pulses is defined by the program

value “Lubrication”.
For input mention the following combination pattern:
Lubrication Parameter 57 Program value

"Lubrication"
1 time every sheet 0?? 01

1 for each 2 sheets 0?? 02
... ... ...
1 for each 5 sheets 0?? 05
... ... ...
1 for each m sheets 0?? mm
1 time per sheet 1?? 01

2 times per sheet 1?? 02
3 times per sheet 1?? 03
... ... ...
m times per sheet 1?? mm
The dosing items in use only allow 2 - 3 impulses per sheet
0x0 lubrication ( side )
Defines, if the lubrication shall be applied to preferred sides of the sheet

?0? = lubrication on both sides / rollers
?1? = lubrication onla upside
?2? = lubrication only down side
00x/ Varnish inspection

0x
specifies, if the machine is provided with varnish check resp. this shall be
active
??0 = no varnish control
??1 = with varnish control
58 Reserve
C-18

No
ASI
Chg?
59 xxx Sheet swing in after loader start
In normal operation a new sheet is swivelled in the sheet lubricator not

before the loader has returned to its starting position. At short processing
time the new sheet can be swung in already when the loader has started
with the aligned sheet to the first punch, so the alignment can begin already
while the loader returns with the grippers sviwelled down below the sheet.
So idle strokes can be reduced
Input 0 normal operation

1 swivel in earlier
60 X Proximity switch of baffle plate / Alignment of stillage
indicates the mode of the proximity switch in the baffle plate while waiting for
the lateral alignment of the sheet stillage.
0= the stillage stops when the signal changes from 0 to 1

1= the stillage stops when the signal changes from 1 to 0
61 xxx Auxiliary insert support correction [mm]
defines the distance covered by the loader after which the lifting of the
auxiliary insert supports or the loading aids is triggered.
000 = The loading aid is assigned to the swinging in of the

advance gripper (standard).
nnn = The lifting of the auxiliary insert supports / loading aid is
triggered after nnnn mm loading distance.
62 xyy Lubrification of sheet advance
0nn = lubrication every nn * 1000 strokes

100 = no lubrication, sheet advance bearings with lifetime lubrication
Indicates the number of strokes for the lubricating of the sheet advance
system in mm.
63 xx,x Speed increase for idling speed of flywheel [%]
The inertia masses to be accelerated ( crank drive, ram and upper die ) at
the moment of engagement of the clutch may lead to a significant drop of
speed during the first stroke, thus causing timing problems with the advance
in some cases. So, for extraordinary heavy dies, this parameter allows to
define a speed increase for the idling speed of the flywheel, thus
compensating the momentum loss at starting the machine and running
through the first stroke with the preprogrammed speed already.
Input in % of programmed speed

C-19

No
ASI
Chg?
64 x0000 Straighten sheet
Defines movement of the advance grippers:

The 1. digit defines, if the right gripper is swivelled out again 20 ms after
seizing the sheet, in order to pull the rear sheet edge straight:
0???? = run sheet „normally“, no swivel out again
( AF: Standard )
1???? = straighten sheet resp. swivel out again
0xxxx Adjusting the dynamics of the axes
the last 4 digits describe the adaptation to the axis dynamics. To the
advance steps. Depending on sheet rigidity and punch pattern a reduction of
the acceleration of the advance axes in the particular moving states may be
needed.
Standard setting ?0000 means accelerations of

- 100 % in X full step and Y return to takeover position
40% acc./ 70% brake for X half step,
60% acc / brake for Y full step.
Other setting individually after testing,which proves correct sheet guiding.

Setting only with help of AH Service dep't.
65 Die temperature control °C
Maximum tolerable temperature difference between upper and lower die,

input in ° C ( only, if MP 74 is set to 2, 5 or 6 )
66 Die change position °Kw
Ram position in 1/10 ° of crankshaft, where the release / take over of the
upper die is performed for the rapid die change procedure. This position is
approached automatically in SETUP mode on demand
67 00000000 Param 00
0
68 xxx,xxx Nominal current main drive
The control evaluates and sets the steering parameters in coordination with
the drive control device automatically and stores reference values for the
next startup. As preset start values for the initial setting to work or after an
exchange of drive components, the nominal data from the type label of the
main drive motor are entered.
C-20

No
ASI
Chg?
69 xxx,xx Nominal voltage main drive
70 xxx,xxx Nominal frequency main drive
71 xxxx,xxx Nominal speed main drive
72 x,xxx Cos φ main drive – effective power factor
73 xx,xxx Nominal power main drive

C-21

No
ASI
Chg?
74 x Periperal device
Existence / type of a proceeding peripheral device with autonomuous

process control, which is also influenced by the control or status values are
inquired from for specific control functions. Asi- Ports have to be provided
which establish the connection to the peripheral device. Parameter values
are not transmitted.
0 = no peripheral device to respect

1 = Curler
2 = die cooling, mixing reservoir cold water
5 = die cooling system, heat radiator, one mixer valve
6 = die cooling system, heat radiator, two mixer valves upper/ lower die
7 = discharche system with product deflectors from twin destacker
75 NC- X- stop Zero position 1/100

mm
Reference value for the start position of the automatically adjustable X- stop
at the alignment station. Here, the distance of the Zero position of the stop
after its scale initialization ( setup procedure in "COMMISIONING" ) to the
machine - / die center axis is entered. Then, the target values can be
programmed like readable from the sheet layouts. If 0 is kept here, the target
values must be recalculated form the difference to the said distance.
76 Die temperature control P- component
Parameter for regulating the water temparature of the die cooling, direct
amplification
77 Die temperature control I component
Parameter for regulating the water temparature of the die cooling, time
related
78 mmm H- Axis zero position mm
Start position of the horizontal axis of the twin sheet destacking system,
equals the pick- up position for sheets from the stack "A" ( viewn left in
production direction ). The value refers to the hardware- zero position after
the advance test, has to be adapted in case of changes at the axis drive
79 mmm V- Axis zero position mm
Start position of the vertical axis of the twin sheet destacking system, equals
the transport level position for the sheets above the feeding table. The value
refers to the hardware- zero position after the advance test, has to be
adapted in case of changes at the axis drive
C-22

No
ASI
Chg?
80 mmmm H- Axis pick sheet "B" mm
2. pick- up position of the horizontal axis of the twin sheet destacking system
equals the pick up position for sheets from the stack "B" ( viewn right in
production direction ). The value refers to the software- zero position ( MP78
81 mmmm V- axis position palet mm
Maximal travel of the vertiacal axis downwards, equls the height of the
empty palet on the roller conveyour. The value refers to the the software-
zero position ( MP79 )

C-23
3 Program values
3.1 Synchronization values
Function Format Description

Speed [min-1] mmm Selection of operation speed, limited by machine
parameter 4.
Die safety device [°crankshaft] mmm defines the crankshaft position to check whether
each of the die safety device sensors 201Ex and
202Ex did respond a signal since blowing out. If
there is no signal, the clutch is disengaged. Values
between 15° and 30° are standard.
The value is to high for the planned use, if the top die
dips into the bottom die after a die safety stop.
Die closes [°crankshaft] mmm Examination, whether the advance systems have
reached their positions.
Turned-sheet equipment: the ramps in the die
covering are lowered.
Test output 101A4 is switched on (only for test
functions).
Die opens [°crankshaft] mmm The advance systems are started.

Turned-sheet equipment: during the first stroke
(each sheet) the ramps in the die covering are lifted.
Test output 101A4 is switched off (only for test
functions).
Blow out [°crankshaft] mmm When operating in AUTOMATIC mode WITH SHEET
the output Y106A3 BLOW OUT is switched on for the
duration of the blowing time.
The output 131A1 is switched, if misprints are
programmed actually for this stamping. ( lateral
deflection )
Dark control, that means examination of the die
safety device initiators K201Ex and K202EX
(assignement according to the number of dies): no
initiator may be actuated.
Ejector ON [°crankshaft] mmm switches on Y106A4 EJECTOR TOP DIE and

Y107A2 VACUUM TOP DIE.
Ejector OFF [°crankshaft] mmm switches off Y106A4 EJECTOR TOP DIE and
Y107A2 VACUUM TOP DIE.
Ventilation ON [°crankshaft] mmm switches on Y106A2 VENTILATION BOTTOM DIE.
Ventilation OFF [°crankshaft] mmm switches off Y106A2 VENTILATION BOTTOM DIE.
Vacuum pump top die ON mmm switches on Y107A1 VACUUM PUMP TOP DIE.
[°crankshaft]
Vacuum pump top die OFF mmm switches off Y107A1 VACUUM PUMP TOP DIE.
[°crankshaft]
C-24

Clutch stop [°crankshaft] mmm For a regular stop of the press the press safety valve
101A1 and 101A2 is switched off here.
The point should be selected so that the conveyance
of the products is terminated in the die area (Vacuum
stop, ventilation ON, Ventilation top die, blow out), so
that the error detection of these operation steps has
already effects in this stroke.
The point should be selected so that the slowing is
finished short after the upper dead center.
This value must be accommodated when changing
the speed.
Blow out time [ms] mmm Duration of blowing during blowing out. After passing
of the time the output Y106A3 is switched off again.
Cap distributor [°crankshaft] mmm defines the crankshat position to switch the cap
distributor.
Cap distributor strokes m defines the number of strokes after which the cap
distributor is switched to the other direction.
Cap distributor sheets m defines the number of sheets after which the cap
distributor is switched to the other direction.
Ventilation top die [°crankshaft] mmm switches on Y107A3 VENTILATION TOP DIE for the
duration of the time programmed with “Blowing time
ventilation top die” [ms].
Blowing time ventilation top die mmm Duration of blowing during the ventilation. After the
[ms] passing of time the output Y107A3 is switched off
again.
Universal output 1 ON [°crankshaft] mmm switches on Y107A4 UNIVERSAL OUTPUT 1.

Output for free use by the customer.
Signal time universal output 1 [ms] mmm time [ms], while Y107A4 UNIVERSAL OUTPUT 1
Y107A4 is switched. After the passing of this time the
output Y107A4 is switched off again.

C-25
3.2 Advance

Program No. mm The advance value Program No. the way in which the sheet is
partitioned. Partitioning refers to the arrangement of the cuts
on the sheet.
Punches X mm The advance value Punches X specifies the number of

punches per row that each die must perform in X-direction.
For sheets that are rotated through 90° for processing the
value 1 should be specified.
Punches Y mm The advance value Punches Y specifies the number of rows

to be punched.
For sheets that are rotated through 90° for processing each
punch is seen as a row. This value should then be equal to the
number of punches each die performs per sheet.
Start position X mmm.mm The advance value Start position X specifies the start
position of the sheet in the X direction in which the advance
tongs are closed. The start position is the axis position in
which the initial punch is carried out.
Start position Y mmm.mm The advance value Start position Y specifies the start
position of the sheet in the Y-direction in which the advance
tongs are closed. The start position is the axis position in
which the initial punch is carried out.
Step X mmm.mm The advance value Step X specifies the advance

displacement in the X-direction from one punch to the next
within a row. It is made up of the punch diameter plus the
width of the bridge.
Step ½ X mmm.mm The advance value Step ½ X specifies the advance

displacement in the X-direction from one punch to another
when moving to a new row. This only applies in the case of
staggered sheet partitionings.
When sheets that are rotated through 90° are processed, only
the advance value Step ½ X is available.
Step Y mmm.mm The advance value Step Y specifies the advance

displacement in the Y-direction from one row to the next for
the standard programs.
For the strip programs it specifies the advance displacement
from even numbered rows to odd numbered rows, i.e. from
row 2 to row 3, row 4 to row 5 etc. This is the larger of the two
row separations.
C-26

Start position L [mm] mmmm.mm The advance value Start position L indicates an absolute
position of the loader axis referred to the axis zero position
and defines the start position of the loader axis from the
alignment station. The start position is the position of the axis,
where the first punch is executed. In this position the sheet is
taken over by the two-coordinate advance system. All other
punch positions of the Y-axis in Y-direction are based on this
position.
X-transfer correction m.mm With the advance value X-transfer correction a correction of
[mm] the X-step from the first to the second punching position is
executed. This way an offset in the punching pattern is
corrected.
Misprints m The advance value Misprints specifies whether there are

misprints or not.
0 = no misprints
1 = There are misprints.
Misprints positions Mm Input of the particular position of the misprints on the sheet. In
punch direction, zig – zag from row to row, the individual prints
on the sheet are counted, and the misprints programmed here.
The control recalculates the related punch number and
activates the waste deflection accordingly.
X- Stop Target position mmmm.mm Input of the target position of the automatically adjeustable X-
stop of the alignment station:
If the MP 75 was set to the real distance to the die center, here
directly the dimension from the center of the first punch to the
sheet edge is read from the sheet layout and entered.
Otherwise the layouts new / old are compared and the
preceeding value increased resp. reduced about the difference
of the distances form the sheet egdes to the center.

C-27
3.3 Dies

Number of dies (m)m The die value Number of dies specifies the number of dies.
Pressure preset mmm The die value Pressure preset specifies the preselected
pressure. The value “Pressure preset“ must be less the
maximum pressure. When the actual pressure exceeds the
preselected limit defined with Pressure preset, the clutch
stops at the position defined with CLUTCH STOP and the
error message “OVERLOAD PRESET“ is displayed.
3.4 Display die safety

Readout of the response values of the die safety in the mode
DISPLAY – SERVICE ( Language key inactive )
Note the highest and the least value of the particular die
stations as reference for the result of adjustment of the blow-
out nozzles, the activation times and pressures for blow out.
Angle min / max Readout of the crank angles, where the particular die safety
sensors are activated.
Is a reference value for the balance of the synchro values for
knockout / blow out
Time min / max Readout of the time, which the particular sensors where
activated by the passing-by product.
Is a reference for the blow out speeds influenced by the setting
of the nozzles, the blow time and the blow pressure.
C-28
3.5 Lubrication

Sheet lubrication mm The lubrication value Sheet lubrication defines the
frequency of lubrication pulses.
Accessory defined by the actual value for machine parameter
57, the input is made according to the following model:
Coating Parameter 57 Lubrication value

1 time per sheet 0 01
1 time per 2 sheets 0 02
... ... ...
1 time per 5 sheets 0 05
... ... ...
1 time per mm sheets 0 mm
1 time per sheet 1 01

2 times per sheet 1 02
3 times per sheet 1 03
... ... ...
mm times per sheet 1 mm
Varnish inspection m The lubrication value Varnish inspection defines, whether the
sheets are to be checked for being covered with varnish while
passing through the rollers.
Thereby means:
0 = processing with unvarnished sheets,

but no deactivation of the device
1 = processing with varnished sheets
To switch off the device, the parameter 57 “Varnish inspection“

must be set to “0“. It is set to “0“ as well, if the device is not
installed at all.
Relevel [ms] m.m The lubrication value Relevel defines the time for releveling
the pallet lift (pallet lift level control).
Pallet changer m The lubrication value Pallet changer is used to switch on and
off the pallet changer without changing the value of the
machine parameter 37 “Pallet changer“.
Sheet brake mmm The lubrication value Sheet brake defines the delay time in
[ms], after which the sheet brake is slowed down.
Drop position sheet A mmmm Position of the horizontal axis of the twin sheet destacking
system, where the sheet from stack "A" is laid down on the
feeding table. The sheet shall arrive finally with its alignment
edge close enough to the alignment stop X on the alignment
station.
The value refers to the the software- zero position ( MP78 )
Drop position sheet B mmmm Position of the horizontal axis of the twin sheet destacking
system, where the sheet from stack "B" is laid down on the
feeding table. The sheet shall arrive finally with its alignment
edge close enough to the alignment stop X on the alignment
station.
The value refers to the the software- zero position ( MP78 )

C-29
3.6 Display

Start Synchro L mmm The display value Start Synchro L indicates the crankshaft
[°crankshaft] position where the L-axis starts.
Synchro L strokes m The display value Synchro L strokes indicates the number of
(idle) strokes that are executed in the time until the L-axis has
reached the die. Possibly the previous sheet is then still in
phase of operation.
mm mmmm The display value L - Vmax indicates the maximum speed of the
L - Vmax [ ] L-axis found with the advance test.
s
mm mmmm The display value X - Vmax indicates the maximum speed of
X - Vmax [ ] the X-axis found with the advance test.
s
mm mmmm The display value Y - Vmax indicates the maximum speed of
Y - Vmax [ ] the Y-axis found with the advance test.
s
Hours system [h] mmmmmm The display value Hours indicates how long the control device
was on (display of elapsed time).
Hours press [h] mmmmmm The display value Hours press indicates how long the press
clutch was engaged (display of elapsed time).
3.7 Service Display

Type ADEFRTC MK5.1- m.mmmm The display value Type indicates the software version.
Date: mm.mm.mm The display value Date indicates the date of the software
version.
C-30
Appendix D Slave-List
Input / output list
CNC-DF Mk5.x
Appendix D
Content
1 1 MARKING SYSTEM...................................................................................................................3
1.1 1.1 MARKING OF THE INPUT / OUTPUT UNITS...........................................................................................3

1.2 1.2 MARKING OF SLAVE-MODULES.......................................................................................................4
2 2 I/O-LIST.....................................................................................................................................5
D-2
Anhang D
11 Marking system
The input- / output-list in this chapter gives a summary of all input and
output connections to the slave modules in this machine. This list is
only available in the two languages GERMAN and ENGLISH.
The I/O-list is about all elements in numerical order. The list of cross
references shows the connections between actual and former
markings.
Actually, the terms for inputs and outputs are the same as for the
element indications.
1.11.1 Marking of the input / output units
All electrical units such as solonoid valves, motors, proximity switches

for this machine are marked with yellow labels. Every label is
connected with straps to the electrical wire of the unit. This prevents
the label on the wire from being lost.
106A2
Fig. 1: Label for electrical units
A plan of all IO-positions is in this manual. This plan is to support you

finding the refering IO-units on the machine.
NOTE:
If you have to remove the wires during maintenance of the ma-

chine take care that all the labels are fitted back on the new wires.
NOTE:
On pneumatic hoses you will find the same labels as in fig. 1 in

white color. These labels are indicating the drawing No. and posi-
tion No. of pneumatic devices.
DF_Mk5.x_M7365_13
D-3
Appendix D
1.21.2 Marking of slave-modules
All slave modules are marked with a yellow label, too. There are two
kinds of informations on the slave modules:
Label of the slave module The marking on slave modules is for example:
101 or EA-101 (example)
where
 (EA-)101 is the marking for a slave in the 1st slave circuit,

 (EA-)101 is marking the slave No. 01 in this circuit.
Label of the I/O-connections The I/O-connections are marked in the same way, for example:
Inputs:
101E2
Outputs: 101A2
where E means input, A means output
NOTE:
if you have to change a slave module take care that you transfer
the labels to the new modul !
There is an advice for the changing sequence of Slave modules in

the chapter AH MICROGUIDE Mk4.
D-4
Anhang D
22 I/O-list
NOMENKLATUR ( Typ Steuer / Meldegerät ):

MS MotorSchütz NI NäherungsInitiator
MV MagnetVentil GT GrenzTaster
KT KonTakt HT HandTaster
ML MeldeLeuchte ST SchlüsselwahlTaster
WT WahlTaster
HD HydraulikDruckschalter
PD PneumatikDruckschalter
SS SchwimmerSchalter
KT KonTakt eines Schaltgerätes
OS Optoelektronischer Schalter
ZS Zylinder Schalter
FS Fußschalter
/Ö Öffner, sonst Schließer
NOMENCLATURE: ( Type actuator / indicator )

MC Motor Contactor PS Proximity Switch
EV Electro Valve LS Limit Switch
CT ConTact KY KeY, manual
SL Signal Lamp KS Key Switch
SS Selector Switch
MH Manometric Hydraulic Switch
MP Manometric Pneumatic Switch
FS Float Switch
CT ConTact of a Electric Device
OS Optoelectronic Switch
CS Cylinder Switch
FS Foot Switch
/B Break, others Make Con-
tacts
DF_Mk5.x_M7365_13
D-5
Appendix D
Bem./Bed. Type Funktion Ausgang Einbauort- SLAVE Location Funktion Eingang Type Bem./Bed.
cond. / rem. Function actuator A E Function indicator cond. / rem.
Schaltschrank 101 control cabinet

MV Pressenkupplung Kanal 1 1 Not- Aus HT/Ö
EV press clutch channel 1 emergency stop KY/B
KT Freigabe Netz Haupt- und Vorschubantriebe Pressenkupplung Kanal 2 KT
CT release of power main and advance drives
2 press clutch channel 2 CT
KT Reset elektronische ÜLS (DSRT) 3 Werkzeugraumabdeckung GT/Ö
CT reset electronic overload protection (DSRT) die area enclosure LS/B
KT Testausgang Vorschubraumabdeckung GT/Ö
CT test output
4 advance area enclosure LS/B
MV Pressenkupplung Kanal 2 1 Kupplung Hand ST
EV press clutch channel 2 clutch manual KS
MS Vorschubkühlung Pressenkupplung Kanal 1 KT
MC advance cooling
2 press clutch channel 1 CT
MS Ziehmittelbeschichtung, Antrieb 3 Turnen Tipp, Taster 1 HT
MC drawing compound coater, drive slow motion, push button 1 KY
KT Sammelstörmeldung Turnen Tipp, Taster 2 HT
CT collective fault signal
4 slow motion, push button 2 KY
MS Abtransportantrieb 1 Externe Steuerung KT
MC exfeed conveyor drive external control CT
MS Zentralschmierung Sicherungsautomaten, Schaltschrank KT/Ö
MC central lubrication of press
2 thermal cut outs, control cabinet CT/B
MS Restgitterauswerferantrieb 3 Stillstandsüberwachung Schwungrad KT
MC scrap ejector drive Flywheel stop control CT
MS Palettenlift, hydr. Pumpe Schwungradabdeckungsklappe GT/Ö
MC pallet lift, hydr. pump
4 flywheel enclossure flap LS/B
MS Palettenlift, Tafelführungsrahmen anheben 1
MC pallet lift, sheet guiding fram lift x
MS Palettenlift, Tafelführungsrahmen absenken Servo bereit, Tafelbremse KT
MC pallet lift, sheet guiding fram down
2 servo ready, sheet brake CT
3 Werkzeugtemperaturwächter KT
x monitoring die temperature CT
KT Hydraulikpumpe Werkzeugspanner Tafelseparierung nicht erlaubt KT
CT hydraulic pump die clamping
4 sheet separation not allowed CT
KT Vakuumpumpe 1 Störmeldung, Klimagerät Steuerschrank KT/Ö
CT vacuum pump fault indication, air condition control cabinet CT/B
KT Tafelbremse Temperaturüberwachung, Netzdrossel KT/Ö Only for P25d
CT sheet brake
2 temperature monitoring, line chocke CT/B & P(v)40
KT Deckelzählimpuls für RT 3
CT ends count impulse for RT x
KT Presse in Produktion
CT press in production
4 x
Presse 106 Press
MV Restgitterauswerfer schließen 1 Restgitterauswerfer geschlossen NI
EV scrap ejector close scrap ejector closed PS
MV Belüftung Werkzeug Drucküberwachung, Auswerfer (Werkzeug) PD
EV ventilation of die
2 pressure monitoring, ejector (tooling) PS
MV Ausblasen 3 Turnen Drehrichtung WT
EV blow off slow motion turn direction SS
MV Auswerfer, Oberwerkzeug Werkzeug gespannt KT
EV knock out, upper tooling
4 die locked CT
Presse 107 Press
MV Vakuumpumpe, Oberwerkzeug 1 Drucküberwachung, Gewichtsausgleich PD
EV vacuum pump, upper tooling pressure monitoring, weight compensation PS
MV Vakuum, Oberwerkzeug Drucküberwachung, Abstreifer (Werkzeug) PD
EV vacuum, upper tooling
2 pressure monitoring, stripper (tooling) PS
MV Belüftung Oberwerkzeug 3 Ziehkissen, Temperaturüberwachung KT/Ö
EV ventilation upper tooling draw cushions, overtemperature monitoring CT/B
-- Universalausgang Drucküberwachung, Einspeisedruck PD
-- universal output
4 pressure monitoring, supply pressure PS
D-6
Anhang D
Presse 108 Press

MV Schmierung Ziehkissen 1 Zentralschmierung, Niederdruck HD/Ö
EV lubrication of draw cushions central lubrication, low pressure MH/B
MV Zentralschmierung Umschaltventil Zentralschmierung, Filter HD/Ö
EV central lubrication, change- over valve
2 central lubrication, low pressure MH/B
3 Zentralschmierung, Füllstand Vorratsbehälter SS/Ö
x central lubrication, tank level MH/B
MV Werkzeugrampe 0 Drucküberwachung, Ziehpuffer HD
EV die ramp 0
4 pressure monitoring, draw cushion MH
Presse 109 Press
MV Schmierung, Stößelgewichtsausgleich 1 Zentralschmierung, Hochdruck HD
EV lubrication, ram mass compensation central lubrication, high pressure MH
MV Schwungradbremse Zentralschmierung, Pleuelschlauch HD
EV Flywheel brake
2 central lubrication, connection rod hose MH
3 Zentralschmierung, Ölbadniveau, Vorgelege HD/SS
x central lubrication, oil bath level, gear MH/FS
Drucküberw.,Überlastsicherungsdruck PD
x
4 pressure monitoring, overload pressure PS
Austragssystem 110 Discharge conveyor system
MV Düsen am Jet 1 Ausgangsstauüberwachung Kanal 1 NI
EV nozzles at the jet exit jam monitor channel 1 PS
MV Düsen am Deckelwender Ausgangsstauüberwachung Kanal 2 NI
EV nozzles at the cupturner
2 exit jam monitor channel 2 PS
3 Ausgangsstauüberwachung Kanal 3 NI
x exit jam monitor channel 3 PS
Ausgangsstauüberwachung Kanal 4 NI
x
x
x
Presse 112 Press
1 Distanzblock/Stößelsicherung in Aufnahme, NI
x spacers for ram safety in pockets, right PS
x 2 x
x 3 x
x 4 x
Ladesystem 113 Loading System
Einlegehilfe abgesenkt, links NI
x
1 auxiliary insert rail, left PS
MV Düsen, Einlegehilfe 2
EV air nozzles, sheet transfer service x
MV Einlegehilfe absenken Einlegehilfe abgesenkt, rechts NI
EV sheet transfer service, lower
3 auxiliary insert rail, right PS
x 4 x
Ladesystem rechts 114 Loading System right
MV Tafelausrichtung X 1 Druckmarken Kontrolle KT/Ö
EV sheet registration X control printed mark CT/B
MV Tafelausrichtung Y Tafel in Ausrichtstation NI
EV sheet registration Y
2 sheet in register station PS
MV Tafelausrichtsauger, ansaugen 3
EV sheet register suction cup, suck x
x
4 x
DF_Mk5.x_M7365_13
D-7
Appendix D
Ladesystem links 115 Loading System left

MV Tafelbremse, Andruckrollen anheben 1 Lagekontrolle Y-rechts/gedreht: X-vorne NI
EV sheet brake, lift up pressure rollers registration Y-right/turned: X-front PS
NI X-Anschläge ausfahren Lagekontrolle Y-links/gedreht: X-hinten NI
PS X-register stops extend
2 registration Y-left/turned: X-rear PS
3 Lagekontrolle X-links/gedreht: Y NI
x registration X-left/turned: Y PS
Lagekotrolle X-rechts/gedreht: Y NI
x
4 registration X-right/turned: Y PS
Tafelvereinzelungssystem 116 Destacker System
MV Tafelvereinzelungsdüsen, vorne 1 Tafelbremse einschalten NI
EV sheet destacker nozzles, front switch on sheet brake PS
MV Ziehmittelbeschichtung, Dosierung, oben Ziehmittel, Vorratsbehälterfüllstand SS/Ö
EV sheet lubrication, dosing puls, top
2 drawing compound, tank level MH/B
MV Ziehmittelbeschichtung, Dosierung, unten 3 Doppelblechkontrolle KT/Ö
EV sheet lubrication , dosing puls, bottom double sheet monitor CT/B
Tafelführungsrahmen angehoben GT
x
4 sheet guiding frame up LS
MV Tafelvereinzelungssauger, absenken 1 Tafelvereinzelungszylinder ausgeschwenkt ZS
EV sheet destacker suction cups, lower sheet destacker cylinders vertical CY
Tafelvereinzelungszylinder eingeschwenkt ZS
x
2 sheet destacker cylinders swung in CY
MV Tafelvereinzelungszylinder einschwenken 3 Tafelführungsrahmen in Arbeitsposition NI
EV sheet destacker cylinders swing in sheet guide frame in operation position PS
Palette nicht leer NI
x
4 pallet not empty PS
MV Tafelvereinzelungssauger, ansaugen 1 Tafelvereinzelungssauger, oben, links ZS
EV sheet destacker suction cups, suck sheet destacker suction cups, on top, left CY
Tafelvereinzelungssauger, oben, Mitte ZS
x
2 sheet destacker suction cups, on top, center CY
3 Tafelvereinzelungssauger, oben, rechts ZS
x sheet destacker suction cups, on top, right CY
Palettenlift, Niveausteuerung ZS
x
4 pallet lift, level control CY
MV Tafelvorvereinzelungssauger, absenken 1 Tafelvereinzelungssauger, Vakuum ZS
EV shett destacker presuction cups, lower sheet destacker presuction cups, vacuum CY
MV Tafelvorvereinzelungssauger, ansaugen Tafelvorvereinzelungssauger, Vakuum ZS
EV sheet destacker presuction cups, suck
2 sheet destacker presuction cups, vacuum CY
3 Tafelvereinzelungssauger, Vakuum abschalten ZS
x sheet destacker presuction cups, vacuum off CY
MV Tafelvereinzelungsdüsen, hinten
EV sheet destacker nozzles, at the rear
4 x
Palettenlift, Schaltkasten 120 pallet lift, control box XL 4.1
MV Palettenlift aufwärts 1 Palettenlift aufwärts HT
EV pallet lift upward pallet lift upward KY
MV Palettenlift abwärts Palettenlift abwärts HT
EV pallet lift downward
2 pallet lift downward KY
MV Palettenlift, Servoventil 3
EV pallet lift, servovalve x
MS Palettenlift, hydr. Pumpe Hydraulikölstand Hubanlage SS
MC pallet lift, hydr. pump
4 hydraulic- oil level, pallet lift FS
MV Palettenlift, Mast vorwärts 1 Tafelführungsrahmen auf/ab HT
EV pallet lift, mast forward sheet guide frame lift/lower KY
ML Palettenwechsel 1 Palettenlift, Türen geschlossen GT
SL palletchange 1
2 pallet lift, enclosure doors closed LS
MV Palettenlift, Mast rückwärts 3 Palettenlift, Querschub rechts (vorwärts) HT
EV pallet lift, mast backward pallet lift, crosswise sdvance right (forward) KY
x Palettenlift, Querschub links (rückwärts) HT
4 pallet lift, crosswise advance left (backward) KY
D-8
Anhang D

KT Antrieb Rollenbahn, vorwärts 1 Rollenbahn, vorwärts ein HT
MP37=4 MP37=4
CT conveyor drive, forward conveyor, forward KY
KT Antrieb Rollenbahn, rückwärts Rollenbahn, rückwärts ein HT
MP37=4
CT conveyor drive, reverse
2 conveyor, reverse KY
MP37=4
KT Gabelrollenbahn, vorwärts 3 Gabelrollenbahn, vorwärts HT
MP37=4 MP37=4
CT fork roller conveyor, forward fork roller conveyor, forward KY
KT Gabelrollenbahn, rückwärts Gabelrollenbahn, rückwärts HT
MP37=4
CT fork roller conveyor, reverse
4 fork roller conveyor, reverse KY
MP37=4

1 Palettenlift, Endlage oben NI
MP37=1,2,4
x pallet lift, upper limit PS
Palettenlift, Niveauregelung oben NI/Ö
x
2 pallet lift, leveling upper level PS/B
MP37=1,2
3 Palettenlift, Palettenaufnahmeniveau NI/Ö

MP37=1,2,4
x pallet lift, pallet pick up level PS/B
Palettenlift, Hubmast, Arbeitsposition NI
x
4 pallet lift, mast, operation position PS
MP37=1,2
Palettenwechsler 124 Pallet changer

1 Palettenlift,Hubmast, Endlage Gabel absenkbar NI
MP37=1,2
x Pallet lift, mast, limit forks lowerable PS
Palettenlift, Hubmast, Endlage rückwärts NI
x
2 pallet lift, mast, limit backward PS
MP37=1,2
3 Palettenlift, Hubmast, Endlage vorwärts NI

MP37=1,2
x pallet lift, mast, limit forward PS
Palettenlift, Tür offen NI
x
4 pallet lift, door open PS
MP37=1,2

MS Antrieb Rollenbahn, oben 1 Leerpalettenablagestation belegt OS/Ö
MP37=2 MP37=2,4
MC top conveyor drive empty pallet fork occupied OS/B
KT Antrieb Rollenbahn, unten, vorwärts Palette in Aufnahmestation OS/Ö
MP37=2
CT bottom conveyor drive, forward
2 pallet in pickup station OS/B
MP37=2
ML Palettenwechsel 2 2 Palette in Übergabestation OS
MP37=4 MP37=4
SL palletchange 2 pallet in takeover station OS
KT Antrieb Rollenbahn, unten, rückwärts Leerpalettenentnahmestation belegt OS/Ö
MP37=2
CT bottom conveyor drive, reverse
3 empty pallet fork occupied OS/B
MP37=2
MV Leerpalettengabel fahren 3 Palette in Ladestation OS
MP37=4 MP37=4
EV move empty pallet fork pallet in loading station OS
KT Antrieb Rollenbahn, Schleichgang Palettenvorlagestation belegt OS
MP37=2
CT conveyor drive crawl speed
4 pallet presentation station occupied OS
MP37=2
MP37=4 MV Leerpalettengabel vorfahren 4 Leerpalettengabel in Entnahmestation NI MP37=4
EV empty pallet fork, forward empty pallet fork in taking out station PS
MV Seitliches Führungsblech einschwenken Schleichgang einschalten KT
MP37=4
EV swing in, side guiding plate
1 switch on crawl speed CT
MP37=2
1 Palette eingefahren NI
MP37=4
pallet fed PS
ML Palettenwechsel 2 Rollenbahn oben ein HT
MP37=2
SL palletchange 2
2 top conveyor on top KY
MP37=2
3 Rollenbahn unten, rückwärts ein HT

MP37=2
x bottom conveyor, forward KY
Rollenbahn unten, vorwärts ein HT
x
4 bottom conveyor, reverse KY
MP37=2
4 Seitliches Führungsblech hochgeschwenkt NI MP37=4

lateral sheet plate raised PS
DF_Mk5.x_M7365_13
D-9
Appendix D

1 Sicherungsbügel oben, geschlossen GT
MP37=2
x safety loop on top, closed LS
Leerpalettengabel in Übernahmestation NI
1 empty pallet fork in transfer station PS
MP37=4
2 Sicherungsbügel unten, geschlossen GT

MP37=2
x safety loop bottom, closed LS
Leerpalettengabel freigefahren NI
2 empty pallet fork free PS
MP37=4
3 Leerpalettengabel freifahren HT
MP37=4
x clear empty pallet fork KY
Leerpalettengabel vor / zurück HT MP37=4
x
4 empty pallet fork, forward / backward KY
Presse 129 Press
1 Temperatur Vorlaufwasser, Oberwerkzeug AS
MP74=2,5,6
x temperature, water forward run, upper die AS
Temperatur Oberwerkzeug AS
x
2 temperature, upper die AS
MP74=2,5,6
3 Temperatur Unterwerkzeug AS
MP74=2,5,6
x temperature, lower die AS
Temperatur Vorlaufwasser, unterwerkzeug AS
x
4 temperature, water forward run, lower die AS
MP74=2
Presse 130 Press

1 Temperatur Ständer AS
MP74=2
x temperature, frame AS
Temperatur Stößel AS
x
2 temperature, ram AS
MP74=2
x 3 x
x 4 x
Presse 131 Press
KT Freigabe Peripherie- Gerät / Curler 1 Durchflußwächter, WZ-Kühlung PD
MP74=1,2,6 MP74=0
CT disengaging peripheral devices / Curler flow control unit, die cooling system MP
MV Rücklaufmischer Kühlung Oberwerkzeug Peripherie- Gerät bereit / Curler KT
MP74=5
EV return mixing valve cooling upper die
1 peripheral devices ready / curler CT
MP74=1,2,5,6
MV Aussortierer, Ausblasen 2 Stau Curler NI
MP74=0,1,2,6 MP74=1
EV reject station, blow out jam Curler PS
Durchflußwächter / Schwimmerschalter, WZ-
2 Kühlung PD /S
MP74=5 MP74= 2,5,6
MV Rücklaufmischer Kühlung Unterwerkzeug flow control unit / float switch, die cooling sys- S
EV return mixing valve cooling lower die tem MP/FS
KT Zählimpuls 3 Aussortierer, Deckelsensor NI MP74=0,1,2,5
MP74=0,1
CT counter pulse reject station, ends- sensor PS ,6
MV Oberwerkzeug Kühlwasser
MP74=2
EV upper die cooling water
3
KT Kaltwassermischer Auf (mehr kühlen) 3
MP74=5,6
CT cold water mixing open (more cooling)
MV Unterwerkzeug Kühlwasser Arbeitsdruck Werkzeugspanner PD MP74=0,1,2,5
MP74=2
EV lower die cooling water
4 operating pressure die clamping MP ,6
KT Kaltwassermischer Zu (weniger kühlen) 4
MP74=5,6
CT cold water mixing shut (less cooling)
Austragssystem
201 Discharge conveyor system
NI/OS
MV Deckelweiche
1 Werkzeugsicherung Kanal 1
Special connection
M-7109-031A-3
EV end conveyor point die safety channel 1 PS/OS
NI/OS
Special connection
M-7109-031A-3
x die safety channel 2 PS/OS
NI/OS
Special connection
M-7109-031A-3
NI/OS
Special connection
M-7109-031A-3
D-10
Anhang D

NI/OS
MV Bremsdüse Kanal 5
Special connection
M-7109-031A-3
EV brake jet, channel 5 die safety channel 5 PS/OS
NI/OS
Special connection
M-7109-031A-3
NI/OS
Special connection
M-7109-031A-3
NI/OS
Special connection
M-7109-031A-3
Vorschubsystem 203 Advance system
MV Vorschubzangen schließen, links 1 Vorschubzangen geschlossen PD
EV advance tongs close, left advance tongs closed PS
MV Vorschubzangen schließen, rechts Zentralschmierung, Zahnstange KT
EV advance tongs close, right
2 central lubrication, gear bar CT
MV Vorschubzangen schwenken, links 3 Endlage X- Achse + NI
EV advance tongs turn, left limit switch X-axle + PS
MV Vorschubzangen schwenken, rechts Endlage X-Achse - NI
EV advance tongs turn, right
4 limit switch X-axle - PS
Ladeschlitten 204 Loading carriage
MV Laderzangen absenken 1 Laderzangen geschlossen PD
EV feeder tongs lower feeder tongs closed PS
MV Laderzangen öffnen, links Laderzangen angehoben NI
EV feeder tongs open, left
2 feeder tongs up PS
MV Laderzangen öffnen, rechts 3 Zentralschmierung, Ladeachse PD
EV feeder tongs open, right central lubrication, loader axle PS
Durchflußwächter PD
x
4 flow control unit PS
Vorschubsystem 205 Advance system
MV Zentralschmierung, Vorschubsystem 1 Endlage L-Achse + NI
EV central lubrication, advance system limit switch L-axle + PS
Endlage L-Achse - NI
x
2 limit switch L-axle - PS
3 Endlage Y-Achse + NI
x limit switch Y-axle + PS
Endlage Y-Achse - NI
x
4 limit switch Y-axle - PS
MV Bremsdüse Kanal 1 1
EV brake jet, channel 1 x
EV brake jet, channel 2
2 x
MV Bremsdüse Kanal 3 3
EV brake jet, channel 3 x
EV brake jet, channel 4
4 x
1 Werkzeugsicherung Kanal 9 (hinten) NI/OS Special connection
x die safety channel 9 (at the rear) PS/OS M-7109-031A-3
Werkzeugsicherung Kanal 10 (hinten) NI/OS Special connection
x
2 die safety channel 10 (at the rear) PS/OS M-7109-031A-3
DF_Mk5.x_M7365_13
D-11
Appendix D

x
x
MV Ausschleuseeinheit Kanal 1 1 Deckel in Ausschleuseeinheit Kanal 1 NI
EV to discharge unit channel 1 cap in discharge unit channel 1 PS
MV Ausschleuseeinheit Kanal 2 Deckel in Ausschleuseeinheit Kanal 2 NI
EV to discharge unit channel 2
2 cap in discharge unit channel 2 PS
Ladesystem 213 Loading System
KT NC- X- Anschlag, Spannungsversorgung 1 NC- X- Anschlag, Endlage - NI
CT NC- X- arrester, power suply NC- X- arrester, limit switch - PS
KT NC- X- Anschlag, Drehrichtung NC- X- Anschlag, Endlage + NI
CT NC- X- arrester, rotating direction
2 NC- X- arrester, limit switch + PS
KT NC- X- Anschlag, Schleichgang 3 NC- X- Anschlag, Encoder Hauptsignal KT
CT NC- X- arrester, inching NC- X- arrester, encoder main signal CT
KT NC- X- Anschlag, Eilgang NC- X- Anschlag, Encoder Quadratursignal KT
CT NC- X- arrester, quick motion
4 NC- X- arrester, encoder quadrature signal CT
D-12
Machine values
Date: 12.04.06
Name:
Machine No.: 4113
Customer: Simmons.
Machine type: CNC-DF3-P40s Mk5.1
Name of product:
SOFTWARE version: ADFHRTC 1.000

SOFTWARE date: 07.04.06
Machine values:
01 Machine coding 06
02 Language 001
03 Rotational direction of resolver 11
-1
04 Maximum speed [min ] 250
05 Motor type 14
06 Negative speed correction at max. speed 11
07 Jam check, sensitivity 100
08 Jam check, restart 200
09 Safety bar / backgear 10
10 Central lubrication, monitoring time 115
11 Central lubrication, high-pressure period 05
12 Central lubrication, pause 60
13 Lower destacker suction cups 120
14 Destacker suction cups, fixing 100
15 Lower pre-destacking suction cups 070
16 Pre-destacking suction cups, fixing 050
17 Sheet destacking nozzles, blowing time 150
18 Sheet transit monitoring 05
19 Sheet setting 100
20 Ejector correction 30
21 Synchronisation correction 50
22 Pitch L-axis 40.96
23 Pitch X-axis 40.96
24 Pitch Y-axis 40.96
25 Software limit L+ 1520.00
26 Software-limit X+ 0315.00
27 Software-limit Y+ 0945.00
28 L-zero position 106.00
29 X-zero position 000.00
30 Y-zero position 000.00
#41131
31 Toothed rack 000.00
32 Delay swing in / Drawing compound coating, drive 01
33 Operating mode, back-up (JAM) 000
34 Unit of measurement 1
35 Draw cushion lubrication 005
36 Magnetic strip destacking 0
37 Pallet changer 0
38 Temperature monitoring / Die fixation monitoring 000
39 Operation mode: empty pallet 0
40 Operation mode: External control, option 00
41 Number of dies 0
42 DNC-interface, ON / OFF 0
43 Operation mode DNC-interface 0
44 Velocity Y- axis 1
45 Overload MIN 07.0
46 Overload MAX 40.0
47 Offset Overload 000000
48 Factor Overload 088357
49 Correction of swivel grippers 000
50 Delay time opening of the loading grippers 30
51 Blowing time of the nozzles while swivelling 040
52 Delay time between blowing and swivelling 000
53 Pressure marking sensor / Alignment repetition 00
54 Take off servo valve 050
55 Pallet fork to bottom 10
56 Pallet fork lowered free 03
57 Varnish inspection 011
58 Alingment monitor 000
59 Reserve 000
60 Proximity switch of baffle plate / Alignment of sheet block 0
61 Auxiliary insert rail correction 000
62 Lubrication of sheet advance 100
63 Reserve 000
64 Adjusting dynamics of the axis 0000
65 Reserve 000
66 Reserve 000
67 Zero parameter 00000000
#4113/ 2
Synchronization: Advance:
Speed [min-1] 240 Program No. 01
Die safety device 030 Punches X 02
Die closes 150 Punches Y 07
Die opens 210 Start position X 0065.00
Blow out switches Y106A3 330 Start position Y 01000.00
Ejector ON switches 157 Step X 110.00
Y106A4/Y107A2
Ejector OFF 203 Step ½ X 055.00
Ventilation ON switches Y106A2 320 Step Y 090.00
Ventilation OFF 020 Start position L 0750.00
Vacuum pump top die switches Y107A1 130 X transfer correction 0.00
ON
Vacuum pump top die 180 Misprints 0
OFF
Clutch STOP 330
Blowing timet [ms] 040
Cap distributor switches Y201A1 180
Cap distributor strokes 0
Cap distributor sheets 0
Ventilation top die switches Y107A3 350
Blowing time ventilation 000
top die
Universal output 1 ON switches Y107A4 180
Signal time universal 180
output 1
Lubrication: Dies:
Sheet lubrication 01 Number of dies 5
Varnish inspection 1 Pressure preset 40
Relevel 0.3
Pallet changer -
Sheet brake 095
Display: Service display:

Start Synchro L Type ADEFRTC MK5.1 1.000
Synchro L strokes Date 07.04.06
L-Vmax
X-Vmax
Y-Vmax
Hours system 147
Hours press 19
#4113/ 3
Pressure values:
System pressure
Pressure switch system pressure
Counter balance cylinder
Pressure switch counter balance cylinder
Sheet alignment X
Sheet alignment Y
Pressure separation cylinder
Vacuum separation cylinder
Pressure pre separation cylinder
Vacuum pre separation cylinder
Blow out product
Blow out product front side
Blow out product back side
Stripper
Ejector
Ventilation upper die
Vacuum upper die
Ventilation lower die
Pressure draw cushion
Pressure switch - draw cushion
Advance gripper monitoring device
Loading gripper monitoring device
Sheet brake
Advance gripper close
Advance gripper swing in
Overload safety device - hydraulic
Overload safety device - pneumatic
Loading aid lift, left
Loading aid lift, right
Blow-out nozzle auxiliary insert rail, left
Blow-out nozzle auxiliary insert rail, right
Open skeleton transport
Close skeleton transport
Pressure holding gripper
Pressure lining
Pressure switch lining
Pressure destacking cylinder
Pressure pulsed waste ejector
Vacuum sucking pad alignment
Clearing air sheet stops
#4113/ 4

01 P40s Alfons Haar Complete Manual

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Machine values

3.1 MACHINE PARAMETERS 6

5.1 ASI-SLAVE KEY PLAN 12

Machine No.: 4113

Type of machine: DF3-P40s

Control program: Mk5.1

Program version / Date: ADEFRTC Mk5.1-1.000 / 07.04.2006

Year of construction: 2006

Compressive force: 400 kN

Speed: 240 strokes/min

Length of ram stroke: 120 mm

Range of ram adjustment: +25 mm

2.3 Energy supply

Pressure: 6 bar minimum

Supply line diameter: ¾“ , inside diameter

Type of current: 3-phase AC

Fuse, supply side: 100 A

2.4 Sound level measurement

2.4.1 No-load operation

Sound power level: 97 dB(A)

Measuring surface sound level: 76 dB(A)

2.4.2 Creaks of the gear

Sound power level: 101 dB(A)

Measuring surface sound level: 122 dB(A)

2.4.3 Load operation

Sound power level: 124 dB(A)

Measuring surface sound level: 103 dB(A)

2.5 Weights and measures

Structural component Weight [kg]

Advance system DF3 2000

Loading table DF 400

Control cabinet 630

2.5.2 Measures of the press

Height [mm]: 3050

Length [mm]: 4160

Width [mm]: 1700

3.1 Machine parameters

Parameter Description Value

Parameter Description Value

3.2 Switching points

Cap distributor sheets

Knock out OFF

Vacuum pump top die

Bottom dead center

3.3 Synchronization values

3.6 Sheet lubrication

3.8 Service display

Type ADEFRTC MK5:1- 1.000

5.1 ASi-Slave key plan

5.2 List of all installed ASi-slaves

Liste der installierten ASi-Slaves

X SLAVE 102 7 0 S SLAVE 110 7 0 S X SLAVE 118 7 F L SLAVE 126

X SLAVE 103 7 0 S SLAVE 111 SLAVE 119 7 F L SLAVE 127

X SLAVE 104 7 0 S SLAVE 112 X SLAVE 120 7 0 S SLAVE 128

X SLAVE 105 7 0 S X SLAVE 113 7 F L X SLAVE 121 7 0 S SLAVE 129

X SLAVE 106 7 F L X SLAVE 114 7 F L X SLAVE 122 SLAVE 130

X SLAVE 107 7 F L X SLAVE 115 7 F L X SLAVE 123 SLAVE 131

X SLAVE 108 7 F L X SLAVE 116 7 F L SLAVE 124 SLAVE 132

X SLAVE 201 7 F L SLAVE 209 SLAVE 217 SLAVE 225

X SLAVE 202 7 F L SLAVE 210 SLAVE 218 SLAVE 226

X SLAVE 203 7 F L SLAVE 211 SLAVE 219 SLAVE 227

X SLAVE 204 7 F L SLAVE 212 SLAVE 220 SLAVE 228

X SLAVE 205 7 F L SLAVE 213 SLAVE 221 SLAVE 229

SLAVE 206 SLAVE 214 SLAVE 222 SLAVE 230