LS40P Electrical Manual en

Automatic perfecting
conversion device
ELECTRICAL MANUAL
English Version
Contents
I. Introduction/Safety
Introduction...................................................................................................................................... I-I
Safety Precautions ......................................................................................................................... I-II
1. Configuration
Configuration ................................................................................................................................. 1-1
1-1 Outline ................................................................................................................................................. 1-1
1-2 Perfecting electrical parts .................................................................................................................... 1-2
2. Operating Instruction
Operating Instruction .................................................................................................................... 2-1
2-1 Perfecting conversion operating buttons ............................................................................................. 2-1
Description of the control buttons ................................................................................................... 2-2
Procedures for automatic perfecting conversion ............................................................................ 2-4
2-2 Manual operation switches for perfecting conversion.......................................................................... 2-8
Description of manual operation switches ...................................................................................... 2-8
Description of manual conversion operation switches.................................................................. 2-13
Manual conversion procedure ...................................................................................................... 2-14
2-3 Perfecting maintenance switches ...................................................................................................... 2-16
2-4 Perfecting conversion operation monitor (without extended delivery specifications)......................... 2-18
2-5 Perfecting conversion operation monitor (for extended delivery specifications)................................ 2-19
2-6 Perfecting conversion error monitor................................................................................................... 2-20
3. Perfection Conversion Operation Flow

Perfection Conversion Operation Flow (without extended delivery specifications) .............. 3-1
3-1 Single-sided → perfecting conversion ................................................................................................. 3-1
3-2 Perfecting → single-sided conversion ................................................................................................. 3-3
3-3 Sheet size conversion during perfecting printing ................................................................................. 3-5
3-4 Sheet size conversion during single-sided printing.............................................................................. 3-7
Perfection Conversion Operation Flow (for extended delivery specifications) ...................... 3-9
3-1 Single-sided → perfecting conversion ................................................................................................. 3-9
3-2 Perfecting → single-sided conversion ............................................................................................... 3-11
3-3 Sheet size conversion during perfecting printing ............................................................................... 3-13
3-4 Sheet size conversion during single-sided printing............................................................................ 3-15
4. Problems and Remedies

Problems and Remedies............................................................................................................... 4-1
4-1 About the perfecting conversion problems and remedies.................................................................... 4-1
[Problem 1] Perfecting conversion does not start.......................................................................... 4-3
[Problem 2] “Aux. Motor Gear Trouble” lights up........................................................................... 4-9
[Problem 3] “Turning Cylinder Brake Trouble” lights up .............................................................. 4-10
[Problem 4] “Turning Cylinder Gripper-A Lock Pin Trouble” lights up ......................................... 4-12
[Problem 5] “Turning Cylinder Gripper-A Lock/Release Trouble” lights up ................................. 4-15
[Problem 6] “W-Gear Conclude/Release Trouble” lights up ........................................................ 4-17
[Problem 7] “Suction Cylinder Release Cam Gear Trouble” lights up ......................................... 4-19
LS40P-GFH EN EO 0410 06 ANSI

[Problem 8] “Suction Cylinder Brake Trouble” lights up............................................................... 4-21
[Problem 9] “Suction Head Hook Trouble” lights up .................................................................... 4-24
[Problem 10] “Suction Head Lock/Release Trouble” lights up....................................................... 4-27
[Problem 11] “Aux. Motor Trouble” lights up.................................................................................. 4-29
[Problem 12] “Double Size Cylinder Phase Encoder Trouble” lights up ........................................ 4-35
[Problem 13] “Turning Cylinder Blower Over Load” lights up ........................................................ 4-37
[Non-central cabinet specifications] ......................................................................... 4-38
[Central cabinet specifications] ................................................................................ 4-38
[Problem 14] “Home Position Trouble” lights up............................................................................ 4-39
[Problem 15] “Double Size Cylinder Position Trouble” lights up.................................................... 4-41
[Problem 16] “Suction Cylinder Release Cam Position Trouble” lights up .................................... 4-42
[Problem 17] “Perfecting Manual Push Button” lights up............................................................... 4-43
[Problem 18] “Gripper-A Lock/Release Position Trouble” lights up ............................................... 4-44
[Problem 19] “Perfecting Manual Change Push Button” is lit ........................................................ 4-45
[Problem 20] “Suction Head Position Trouble” lights up................................................................ 4-46
[Problem 21] “Perfecting Manual Return Select Push Button” is lit ............................................... 4-47
[Problem 22] “Perfecting Stop Push Button” lights up ................................................................... 4-48
[Problem 23] “Correction Turn Stop Push Button” lights up .......................................................... 4-49
[Problem 24] A gripper shaft operation error is displayed (Touch panel section).......................... 4-50
[Problem 25] The encoder setting [SET] position is displayed (Touch panel section)................... 4-51
[Problem 26] A sheet decurler ON/OFF stop position error is displayed (Touch panel section)
(for extended delivery specifications)....................................................................... 4-52
[Problem 27] A sheet decurler operation error is displayed (Touch panel section)
(for extended delivery specifications)....................................................................... 4-53
[Problem 28] Perfecting conversion return operation does not start ............................................. 4-54
5. Perfecting Conversion Return Function

Perfecting Conversion Return Function ..................................................................................... 5-1
5-1 Purpose of this function ....................................................................................................................... 5-1
5-2 Outline and functions ........................................................................................................................... 5-1
5-3 Configuration ....................................................................................................................................... 5-2
Operation Procedure..................................................................................................................... 5-3
5-1 Automatic return to single-sided mode when trouble occurs during single-sided →
perfecting conversion........................................................................................................................... 5-3
5-2 Automatic return to perfecting mode when trouble occurs during perfecting →
single-sided conversion ....................................................................................................................... 5-4
5-3 Automatic return to perfecting mode (original sheet size) when trouble occurs during perfecting →
perfecting (sheet size) conversion ....................................................................................................... 5-5
5-4 Automatic return to single-sided mode (original sheet size) when trouble occurs during single-sided →
single-sided (sheet size) conversion.................................................................................................... 5-6
5-5 Return Conversion Operations Using STEP FORWARD (step by step) ............................................. 5-7
Perfecting Conversion Step Monitor ........................................................................................... 5-9
5-1 Return conversion operation display monitor ...................................................................................... 5-9
5-2 Trouble Step Check Monitor .............................................................................................................. 5-10
6. Maintenance
Maintenance................................................................................................................................... 6-1
6-1 Encoder home calibration (Double-size cylinder phase encoder) ....................................................... 6-1
Configuration .................................................................................................................................. 6-1
Procedure ....................................................................................................................................... 6-3
Home calibration operation flow ..................................................................................................... 6-3
6-2 Controlled single-sided recovery ......................................................................................................... 6-4
Procedure ....................................................................................................................................... 6-5

0Introduction/Safety
I
Introduction
CAUTION
This section contains important caution information for using this device. Be sure to read this section
and understand it thoroughly before using this device.
Purpose of This Device
This unit automatically switches between single-sided to double-sided printing or double-sided to double-sided
printing (paper size change) to conserve energy. To perform the change operation, enter the paper size at the
PQC unit’s touch panel screen, select single-sided or double-sided, press the CONFIRMATION button, and then
just press the delivery unit’s operation panel AMR button to make the change.
Scope of Warranty and Warranty Exclusions
Operation and maintenance of this press and equipment will be carried out by the customer/user, in accordance
with the operation, inspection and maintenance procedures explained in this manual. Should problems occur
after delivery, Komori will repair the press in accordance with the terms of the purchase contract only in cases
when the press has been inspected by Komori and judged to have a defect for which Komori is responsible.
However, accidents or damage due to the following causes are outside the scope of any contract coverage. All
repair work or parts needed because of the following causes will be provided at the customer's expense.
(1) Komori will accept no responsibility, and will not be liable, for accidents or damage due to the use of the
device and equipment in ways other than those specified in “Purpose of This Device” above.
(2) Komori will accept no responsibility, and will not be liable, for accidents or damage due to operation or use by
the customer/user in ways contrary to the operation procedures and instructions included in this manual.
(3) Komori will accept no responsibility, and will not be liable, for accidents or damage due to modifications or
changes made by or on behalf of the customer/user or at the customer/user's own discretion.
(4) Komori will accept no responsibility and will not be liable for accidents or damage resulting from the use of
products (accessories, electrical parts, mechanical parts, printing materials, software, etc. of other
manufacturers) other than those manufactured by Komori or products of other manufacturers installed by
Komori or under Komori's direction.
(5) In accordance with Komori's copyright, it is prohibited to copy, reproduce, reprint or to transfer or show this
manual to a third party other than for the safety and warning purposes and operation/maintenance
procedures set forth in this manual.
Purpose and General Outline of This Manual
Operators and maintenance personnel should read through this operation manual before proceeding to operate
or maintain the press. In addition to this manual, the instruction manuals issued by the manufacturers of the
peripheral devices are packed separately with the press and should be read as well.
Do not operate or maintain the machine if you do not fully understand the procedures involved.
Follow the instructions in the operation manual concerned to operate and maintain the machine.
Keep the manual in a safe place where it can be referred to at any time.
Warning of Changes Made of Product Specifications
Komori is continually improving and refining its technology and, as such, the exterior, mechanisms and
accessories of this press and its devices are subject to change. For this reason, Komori may make changes to
specifications, etc. without prior warning.
II
Safety Precautions
WARNING
Cautions concerning safety are important for safe use of this device. Be sure to read and fully understand
all safety precautions before using this device.
This device is equipped with two types of safety devices: those which protect the safety of the operator/maintainer,
and those which maintain optimum press performance. This device has been designed and manufactured with full
consideration for safety. To ensure maximum safety, always check the locations and functions, and be familiar with
the operation of the safety devices before operating, or performing maintenance on, the device.
Safety Precautions in This Manual
Precautions concerning operational safety are given along with the mark urging safety on the upper right
hand side of each page and in the text. Observe these precautions and operate/maintain the device safely.
Personal Protection
Loose articles of clothing, rings, dangling jewelry, wiping rags, tools, or long hair can easily become entangled in
moving machinery. To avoid serious personal injury, never operate equipment with loosely fitting clothes,
exposed shirt-tails, dangling ties or similar loose fitting clothes. Wearing clothes properly suited to the operation
is essential for safe operation. All jewelry should be removed and kept away from machinery.
Great care should be taken when using wiping rags to avoid contact with moving machine parts. Tools should be
kept away from machinery when they are not being used. Long hair can be a serious hazard if not properly
restrained or covered. Avoid wearing gloves or wrapping a cleaning rag around your hand.
Using the Safety Devices
(1) This device is equipped with many safety guards and safety devices to protect the operator and persons
performing maintenance. Do not remove these safety guards, and do not disengage the safety devices or
interlock switches. Ignoring safety precautions, failing to inspect safety signals, valves and switches, or
disengaging safety devices could result in unnecessary risk that may lead to serious injury to the worker and
other co-workers who are unaware of the danger. In addition, removing or modifying a safety guard or safety
device could cause the press to stop or malfunction.
(2) Frequently inspect the safety guards and systems to ensure that they function properly. The operation safety
device check should be part of the daily inspection and performed before operating the press. Do not
operate or maintain the press with a safety guard removed or with a safety device disengaged. If a lost,
disengaged, damaged or defective safety guard or system is discovered, report it immediately to the
foreman.
Safety Precautions during Daily Work
(1) Only one person should operate switches at any given time. If more than one person operates the switches,
the press may operate in unexpected ways, resulting in accidents.
(2) Warn other nearby operators and persons and check for safety before operating the press.
(3) A warning horn is sounded to warn that the press is about to start operating. For your safety, move away
from operating parts or the press itself whenever you hear the horn.
(4) To ensure safe footing, promptly wipe up any oil or water spilled on the footboards or floor.
Always keep the press’ work environment clean.

III
(5) When performing any work with the guards, safety covers, footboards, or other protective devices opened,
first stop the press and other related equipment and press the ADJUSTMENT button before opening the
covers. If performing adjustment or maintenance that could put you in contact with the press’ moving parts,
be sure to always press in and lock the red STOP button.
(6) If any safety covers or footboards protecting the operator from rotators or mechanical operating parts are
opened to perform adjustments, etc., be sure to set them back to their original position promptly after
completing the adjustment.
(7) Do not leave any tools or cleaning implements on any part of the press, as operators/maintainers may trip
over them and be injured, and the tool or cleaning implement may fall inside, causing the press to stop or
damaging it.
Be sure to store tools and cleaning implements in their proper place after using them.
(8) Arrange the power cords and cables properly to ensure safe footing.
Safety Precautions during Maintenance, Inspection and Adjustment
(1) Before entering inside a safety guard, cover, footboard or working under the press for maintenance,
inspection, or adjustment, first press and lock the EMERGENCY STOP button, turn off the main power
disconnect switch on the main switchboard, place your lock and identification tag on the disconnect switch
and lock the power off to avoid the danger of serious injury to yourself and other workers. After locking off all
electrical power, bleed off all hydraulic and pneumatic systems, secure all parts that can fall and take other
specific precautions required for the job being performed. Warn operators and others in proximity that you
are working on the press.
(2) Before performing any electrical maintenance, inspection or adjustment in which the terminal box,
switchboard may be opened and terminals or wires can be touched, turn off the main power disconnect
switch on the switchboard or turn off power from the factory power supply to the press, and lock and tag the
switch in the off position. Bleed or discharge all capacitors, and always test for the absence of electricity
before contacting electrical parts. All electrical wiring should be considered live until it is tested by a qualified
worker.
CAUTION
BECAUSE OF THE POTENTIAL FOR AN ELECTRICAL SHOCK, NEVER USE A WET RAG WHEN CLEANING
AROUND ELECTRICAL EQUIPMENT. DO NOT PERMIT FLUIDS OF ANY KIND TO LEAK INTO ELECTRICAL
CIRCUITS OR DEVICES.
(3) Power supplied to the press may in some cases be supplied not only to the press’ main switchboard but also
to accessory devices. In addition, in some cases control signals are also input to such devices from the
press’ switchboard, so turn off both the main power switch on the press’ switchboard and the power supply
from the factory to these devices when performing maintenance and inspections on these devices.
(4) In some cases control signals are also input to the main switchboard in from accessory devices, so turn off
both the main power switch on the press’ switchboard and the power supply from the factory to these
devices when performing maintenance and inspections on the main switchboard.
(5) Never make any modifications to the control devices or inside switchboards. Doing so is dangerous as this
may disable the device or result in malfunction, leading to accidents and serious injuries.
(6) Maintenance and inspection operations should be carried out only by experienced mechanics and
electricians who are properly trained with respect to the press and equipment and familiar with the
instructions and precautions contained in this manual.

IV
Corrective Measures
If you should discover any irregularity in this device, stop operation immediately.
Correct the cause for the irregularity as described in [Troubleshooting] and perform and check the
countermeasures work. Never restart the press before it has been restored to its normal operating status.
If it cannot be restored to its normal operating status contact a Komori service representative immediately.
Touch Panel Handling
(1) If the LCD touch panel surface becomes dirty, wipe it carefully with a soft dry cloth moistened with a slight
amount of ethanol.
CAUTION
NEVER LET THE TOUCH PANEL CONTACT WITH WATER, NEUTRAL DETERGENT, COMMON WINDOW
POLISH OR ORGANIC SOLVENT DIRECTLY AS THIS MAY DAMAGE THE TOUCH PANEL.
(2) Turn off the press (or device) power when wiping the touch panel. Not doing so could cause a malfunction.

V
Warning Labels
Locations of high-power voltage and rotators or other mechanical operating parts are indicated by warning labels.
Pay careful attention when performing operations at these locations.
Also, make sure that these warning labels are always clearly visible. If a label should peel off or become dirty or
damaged, replace it.
Two types of labels are used on this press to ensure safety:
1. General safety labels: These include general precautions on use of the press.
2. Warning labels: These indicate the presence of danger, the level of danger, and ways to avoid the danger for
safety matters which cannot be avoided through normal press operation.
(1) Basic format of warning labels

The warning labels on the press have the following basic format:
Danger level indication (warning symbol)
Danger element pictogram (symbol)
Explanation on how to avoid danger (text message)
(2) Classification of danger levels

The danger level is classified in three categories according to the level of damage which could occur. This
danger level is indicated along with the mark at the top of the warning label. The warning labels on the
press indicate the danger element and the degree of danger.
DANGER This indicates a level of danger which could lead to serious injury.
WARNING This indicates a level of danger which could lead to major injury.
CAUTION This indicates a level of danger which could lead to minor injury.

1
1Configuration
Configuration 1–1
Configuration
1-1 Outline
Perfecting conversion mechanism section
Delivery panel
Perfecting control panel
Perfecting manual operation switches

(Box)
Touch panel
Perfecting maintenance switches
Perfecting conversion operating screen
Perfecting conversion operation monitor

screen
Perfecting conversion error monitor screen

Configuration 1–2
1-2 Perfecting electrical parts

<Drive side>
(This illustration shows the perfecting configuration .)
5 6
Transfer
cylinder
Turning
cylinder
2C Impression Suction
cylinder cylinder
1 2 3 4 7 8 9
1) Auxiliary motor
2) Auxiliary motor gear ON sensor

Auxiliary motor gear OFF sensor
3) Suction cylinder release cam gear ON sensor

Suction cylinder release cam gear OFF sensor
4) W-gear release (ON) sensor

W-gear conclude (OFF) sensor
5) Suction cylinder release cam limit sensor

<Mounted on the inside>
6) Gripper shaft motion detector

7) Reflecting-type sheet drop detector

<Mounted in the middle on the inside>
8) Sheet guide (turning cylinder lower) motor

<Mounted inside on the operation side, in the middle, and inside on the drive side>
9) Sheet guide (turning cylinder lower) motor potentiometer


Configuration 1–3
<Operation side>
(This illustration shows the perfecting configuration .)
9” Turning cylinder 6” 7” 8” Solenoid valve unit box
11” 11”
1” 2” 3” 10” 4” 5”
Suction cylinder Transfer cylinder
1”) Rear unit phase encoder
2”) Turning cylinder A gripper pin ON sensor

Turning cylinder A gripper pin OFF sensor
Solenoid valve unit box
3”) Turning cylinder A gripper lock/release sensor
Turning cylinder A gripper lock set sensor Suction cylinder brake ON/OFF
W gear release/conclude
4”) Suction cylinder brake ON sensor
Suction cylinder brake OFF sensor Suction cylinder release cam ON/OFF
Suction head release/lock
5”) Double-size cylinder phase encoder
Turning cylinder brake ON/OFF
6”) Turning cylinder brake ON sensor Suction head hook ON/OFF
Turning cylinder brake OFF sensor
Turning cylinder A gripper lock/release
7”) Suction head hook ON sensor Turning cylinder A gripper pin
Suction head hook OFF sensor
Sheet drop air purge
8”) Suction head release sensor
Suction head lock sensor
9”) Turning cylinder home positioning sensor

<Deceleration sensor>
10”)Turning cylinder operation side cover
11”)Turning cylinder unit footboard


Configuration 1–4
<Drive side>
• This illustration shows the perfecting configuration with extended delivery specifications.
• Only the electrical parts added for extended delivery specifications are indicated.
(E) (B) (A)
(D) (C)
(A) Transport belt drive motor
(B) Sheet decurler ON/OFF solenoid valve
(C) Sheet decurler ON sensor

Sheet decurler OFF sensor
(D) Sheet guide (delivery) motor

(E) Sheet guide (delivery) motor potentiometer


Configuration 1–5
<Operation side>
• This illustration shows the perfecting configuration with extended delivery specifications.
• Only the electrical parts added for extended delivery specifications are indicated.
Transport belt encoder
Extended delivery panel

2
2Operating Instruction
Operating Instruction 2–1
Operating Instruction
2-1 Perfecting conversion operating buttons
1
(Delivery control panel)
SAFE
(Perfecting conversion operating screen)
For extended delivery

specifications
For extended delivery
specifications

Description of the control buttons
Item Description
Sheet length setting Input the vertical length of the sheet for perfecting printing.
mm
Current sheet length value When conversion to perfecting printing is finished, the current vertical length of
the sheet is displayed.
During single-sided printing, “0” is displayed.
mm
Paper width check [Only for extended delivery specifications.]

The current lateral sheet size is displayed.
During conversion to perfecting printing, the delivery paper guides move to this
mm paper width position.
Sheet guide (delivery) status [Only for extended delivery specifications.]

Lights up when the extended delivery sheet guides are retracted.
Sheet decurler status [Only for extended delivery specifications.]

Lights up when the sheet decurler is ON.
Sheet decurler status [Only for extended delivery specifications.]

Lights up when the sheet decurler is OFF.
Press status Lights up during single-sided printing.

Flashes during conversion from perfecting printing to single-sided printing.
Press status Lights up during perfecting printing.

Flashes during conversion from single-sided printing to perfecting printing, and
perfecting printing to perfecting printing.
Selector Selector button and indicator for conversion to single-sided printing.

When the button is pressed, it lights up. When it is pressed again, it goes out.
When the button is pressed, it goes out when the conversion is finished.
Selector Selector button and indicator for conversion to perfecting printing.

When the button is pressed, it lights up. When it is pressed again, it goes out.
When the single-sided selector indicator or the perfecting selector indicator is lit,
and this button is pressed, it lights up. When it is pressed again, it goes out.

Item Description
When the single-sided selector indicator or the perfecting selector indicator is lit,
and this button is pressed, it lights up. When it is pressed again, it goes out.
When conversion to single-sided printing or perfecting printing is selected and

the Suction Head Pad Check button and Suction Head Valve Check button are
pressed, the Make-ready Finished indicator lights up and perfecting conversion
operation is enabled.
The Make-ready Finished indicator goes out when perfecting conversion
operation is started.
Pressing this button displays the perfecting conversion operation non-start
conditions.
Operation is possible by resolving the displayed conditions.
Return When an error occurs during perfecting conversion operation and the Release
Error button is pressed, the error is canceled and the button lamp lights.
When the perfecting conversion operation is restarted or the perfecting
conversion return operation is completed, the button lamp goes out.
Return When the Return Preparation button is pressed while the Release Error button
lamp is lit, the perfecting conversion return preparations are completed and the
button lamp lights.
When the Return Preparation button is pressed again or when the perfecting
conversion return preparations are completed while the button lamp is lit, the
button lamp goes out.
Return When the Release Error button and the Return Preparation button are pressed,
the Ready indicator lights and the perfecting conversion return operation is
enabled.
When the perfecting conversion return operation is started, the Ready indicator
goes out.
Return Pressing this button displays the perfecting conversion return operation
non-start conditions.
Operation is possible by resolving the displayed conditions.

Procedures for automatic perfecting conversion

a) Conversion from single-sided printing to perfecting printing ( → )
Step Operations State

Input the sheet length and sheet size
1 settings.
mm
Press the double-sided printing selector button.

2 Lights up
Suction head pad check button ON.

3 Lights up
Suction head valve check button ON.

4 Lights up
The Make-ready Finished indicator lights up.

5 Lights up
Press and hold down the delivery panel [AMR] switch (1)
6 for 3 seconds. (An alarm sounds for 3 seconds. Release
the [AMR] switch when the alarm stops.)
Delivery panel [AMR] switch (1) ON. AMR
7 Lights up
Conversion to perfecting printing starts.

8 Flashes
Conversion to perfecting printing finished. *1

9 Lights up
*1 For extended delivery specifications.

b) Conversion from perfecting printing to single-sided printing ( → )

1 settings.
mm
Press the single-sided printing selector button.

2 Lights up

3 Lights up

4 Lights up

5 Lights up
7 Lights up
Conversion to single-sided printing starts.

8 Flashes
Conversion to single-sided printing finished. *1 *1

9 Lights up
*1 For extended delivery specifications.

c) Sheet size conversion during perfecting printing ( → )

1 settings.
mm
Press the perfecting printing selector

2 button. Lights up

3 Lights up

4 Lights up

5 Lights up
7 Lights up
Conversion to perfecting printing starts.

8 Flashes
Conversion to perfecting printing finished.

9 Lights up

d) Sheet size conversion during single-sided printing ( → )

1 settings.
mm
Press the single-sided printing selector button.

2 Lights up

3 Lights up

4 Lights up

5 Lights up
7 Lights up
Conversion to single-sided printing starts.

8 Flashes
Conversion to single-sided printing finished.

9 Lights up
<Precautions during perfecting conversion>

1) Inputting the sheet size value using the sheet length setting button
Check the vertical length of the printing sheets and input the sheet size data.
2) Temporary stop and restart

If you want to stop the perfecting conversion for some reason once it has been started, a temporary stop is
possible.
When the emergency stop switch or some other stop switch on the press is pressed, or when a cover, footboard,
etc. is opened, or when some other safety device is activated, the conversion stops temporarily. (During the
temporary stop, the melody changes to an alarm signal.)
To restart the perfecting conversion, release the above stop switch or safety device, and then press the AMR
button (1) on the delivery panel.
* When using extended delivery specifications, perfecting conversion will not restart even if the safety device is
released and the [AMR] button (1) on the delivery panel is pressed under the following conditions.
– If perfecting conversion is temporarily stopped by a safety device other than a stop switch (press safety
cover, footboard, etc.)
– If the extended delivery sheet guides are operating at this time.
To restart the perfecting conversion, wait until the extended delivery sheet guide operation is completed and
then press the AMR button (1) on the delivery panel, or press a stop switch to stop the extended delivery sheet
guides and then press the AMR button (1) on the delivery panel.
3) When the perfecting conversion is finished

The perfecting conversion cannot be stopped partway.
Be sure to finish the conversion first.

2-2 Manual operation switches for perfecting conversion

Description of manual operation switches
These buttons are used to perform the perfecting conversion procedure step manually by step. They are only used
when a problem occurs during perfecting conversion or for fine-tuning the perfecting conversion. Please make sure
that you understand each part of the conversion mechanism before you proceed.
Button shape
Operating conditions <*1> Function
and name
When this switch is pressed,
stepwise perfecting conversion is
MANUAL ON
enabled. When this switch is
MANUAL pressed, it stays depressed and
ON
the indicator lights up. When this
switch is pressed again, the
manual operation mode is
released, and the indicator goes
out.
AUX.MOTOR • Manual operation switches When this switch is pressed, the

GEAR ON [ON] switch indicator lights up, and
auxiliary motor gear ON
AUX.MOTOR GEAR operation is performed. When
ON
this switch is pressed again, the
switch indicator goes out, and the
auxiliary motor gear is
disengaged.
SUCTION • Manual operation switches When the conditions to the left

HEAD HOOK [ON] are met and this switch is
ON • The preceding unit phase pressed, the switch indicator
position is within the range lights up, and suction cylinder
SUCTION HEAD between the smallest sheet hook ON operation is performed.
HOOK ON
size (360 mm) and the largest When this switch is pressed
sheet size (720 mm). again, the switch indicator goes
<*2> out, and the suction cylinder hook
is released.
SUCTION • Manual operation switches When this switch is pressed, the
HEAD [ON] switch indicator lights up, and
RELEASE suction head release operation is
performed. When this switch is
SUCTION HEAD
RELEASE pressed again, the switch
indicator goes out, and the
suction head is fixed.
SUCTION • Manual operation switches When this switch is pressed, the

CYLINDER [ON] switch indicator lights up, and
RELEASE suction cylinder release cam gear
CAM ON operation is performed.
When this switch is pressed
SUCTION
CYLINDER again, the switch indicator goes
RELEASE CAM
out, and the suction cylinder
release cam gear is released.

Button shape
and name
• Manual operation switches When the conditions to the left
[ON] are met and this switch is
• Conversion is at home position pressed, the switch indicator
SUCTION (home stop timing ON) lights up, and suction cylinder
CYLINDER + brake ON operation is performed.
BRAKE • When the preceding unit's When this switch is pressed
phase position is set to the again, the switch indicator goes
SUCTION
CYLINDER BRAKE single-sided position out, and the suction cylinder
(single-sided enabled timing brake is released.
ON), or the preceding unit's
phase position is set to the
minimum sheet size (360 mm)
position.
<*2>
TURNING • Manual operation switches When the conditions to the left

CYLINDER [ON] are met and this switch is
BRAKE • Conversion is at home position pressed, the switch indicator
(home stop timing ON) or lights up, and turning cylinder
TURNING turning cylinder gripper-A brake ON operation is performed.
CYLINDER BRAKE
return/release stop position When this switch is pressed
(gripper-A return/release timing again, the switch indicator goes
ON). out, and the turning cylinder
<*2> brake is released.
[ON] are met and this switch is
A-GRIPPER • When the turning cylinder brake pressed, the switch indicator
PIN ON is ON (the ON sensor is ON) lights up, and the gripper-A pin
A-GRIPPER PIN + ON operation is performed.
ON
• The turning cylinder is at the When this switch is pressed
gripper-A return /release stop again, the switch indicator goes
position. (Gripper-A return/ out, and the gripper-A pin is
release timing ON). released.
<*2>
A-GRIPPER • Manual operation switches When this switch is pressed, the

LOCK [ON] switch indicator lights up, and the
RELEASE turning cylinder gripper-A lock is
A-GRIPPER LOCK
released. When this switch is
RELEASE pressed again, the switch
indicator goes out, and turning
cylinder gripper-A returns.
DOUBLE • Manual operation switches When the conditions to the left

GEAR [ON] are met and this switch is
RELEASE • Conversion is at home position pressed, the switch indicator
DOUBLE GEAR
(home stop timing ON) lights up, and W-gear release
RELEASE + operation is performed. When
• The turning cylinder brake is this switch is pressed again, the
ON (the ON sensor is ON). switch indicator goes out, and the
<*2> W-gear concludes.

Button shape
and name
[ON] are met, this switch is used to
• Inching is possible under the inch the press using the auxiliary
following conditions. motor. Press this switch once
INCH and then release it. (The normal
(PERFECTING) 1) During only auxiliary motor operation alarm sounds and the
gear ON operation Make-ready/Running indicator
INCH
(PERFECTING) 2) Auxiliary motor gear ON flashes.)
+ When the alarm stops (while the
Turning cylinder brake ON Make-ready/Running indicator is
+ flashing) and this switch is
W-gear released pressed again, the press starts
+ moving (in the perfecting phase
Turning cylinder release cam direction). As soon as the switch
gear ON is released, the press stops.
3) Auxiliary motor gear ON
When the conditions to the left
+
are met, this switch is used to
Turning cylinder brake ON
inch the press backwards using
+
the auxiliary motor. Press this
W-gear released
switch once and then release it.
+
(The reverse operation alarm
REVERSE Turning cylinder release cam
sounds and the Make-ready/
gear ON
REVERSE Running indicator flashes.)
+
When the reverse alarm stops
Suction cylinder hook ON
(while the Make-ready/Running
+
indicator is flashing) and this
Suction head released
switch is pressed again, the
4) Auxiliary motor gear ON
press starts moving backwards
+
(in the single-sided phase
Suction cylinder hook ON
direction). As soon as the switch
+
is released, the press stops.
Suction head released

Button shape
and name
When the conditions to the left
are met, this switch causes a
move to the switch over home
position using the auxiliary drive
motor. Press this switch once
and then release it. (The normal
HOME
operation alarm sounds and the
POSITION
Make-ready/Running indicator
flashes.)
When the alarm stops (while the
Make-ready/Running indicator is
flashing) and this switch is
pressed again, the press starts
moving forward and stops at the
switch over home position.

[ON] are met, this switch causes a
• The operation is possible move to the A-gripper engage/
under the following conditions. release position using the
auxiliary drive motor. Press this
1) During only auxiliary motor switch once and then release it.
gear ON operation (The normal operation alarm
sounds and the Make-ready/
Running indicator flashes.)
A-GRIPPER When the alarm stops (while the
LOCK Make-ready/Running indicator is
POSITION flashing) and this switch is
pressed again, the press starts
moving forward and stops at the
A-gripper engage/release
position.
(Moving forward causes a move
to the near side’s A-gripper
engage/release position. To
move to the opposite A-gripper
engage/release position,
execute the same operation
again.)

Button shape
Function
and name
When the press starts operating, an alarm sounds and this
indicator starts flashing as a warning.
After the alarm stops, the indicator continues flashing for 3 more
seconds, during which time the press can be started. Start
operation during this time.
If you do not do anything within 3 seconds, the indicator lights up
as a warning.
This indicator lights up when the stop button is locked, the
manual handle inserted, a main motor error has occurred, or
there is some other problem that means that the press cannot be
started.
When this switch is pressed while the press is at any stage from
make-ready to fast printing, or during perfecting conversion, the
press immediately stops, and the perfecting conversion stops
temporarily.
This switch is of a push-lock type that stays depressed once it is
pressed. Turn the switch clockwise to release the lock and enable
press operation or perfecting conversion.
<*1>
The following conditions must be met for all conversion steps.
• The press is stopped.
• All safety devices are OFF.
• The feeder is ON with the cylinders disengaged.
• No other functions (e.g. APC, ink clutch) are operating.
<*2>
Conversion stop position angles
Conversion home Double-size cylinder phase

Gripper-A return/
Perfecting mechanism position standard — min. sheet size to max. sheet size —
release standard angle
angle position standard angle
Between 1C and 2C 221° 321° 55° – 192°
Between 2C and 3C 309° 49° 143° – 280°
Between 3C and 4C 37° 137° 231° – 8°
Between 4C and 5C 125° 225° 319° – 96°
Between 5C and 6C 213° 313° 47° – 184°
Between 6C and 7C 301° 41° 135° – 272°
• The above angles are the standard position angles for each conversion stop position, however, a deviance of ±2°
from the standard value is acceptable.
• Check the conversion home angle on the degree display for the following unit [on the timing device (DE-TG2)
inside the feeder control panel].
• Check the gripper-A return/release angle and the double-size cylinder phase — min. sheet size to max. sheet size
— angle on the degree display for the preceding unit.
• These angles may be different during perfecting conversion tune-up or for configurations with optional units.

Description of manual conversion operation switches

Perfecting conversion operation can be performed one step at a time by manual operation.
When a problem occurs, these procedures can be used to check each step of the conversion operation once the
problem has been fixed. Normally, however, they are not used.
Please make sure you understand the contents of each description before you proceed.
MANUAL SWITCHING This switch enables manual perfecting conversion. When this switch is
ON
pressed, the switch indicator lights up, and the single-sided button, the
perfecting button, and the step button are enabled. When this switch is
pressed again, the indicator goes out, and the above button is
disabled. When manual conversion is enabled, automatic conversion
operation is not possible. When the conversion is finished, press the
switch to turn it off.
NORMAL
When this switch is pressed, the switch indicator lights up, and
conversion to single-sided printing is selected. When this switch is
pressed again, the indicator goes out. When the conversion is finished,
press the switch to turn it off.
PERFECTING
When this switch is pressed, the switch indicator lights up, and
conversion to perfecting printing is selected. When this switch is
pressed again, the indicator goes out. When the conversion is finished,
press the switch to turn it off.
STEP FORWARD When this switch is pressed, an alarm sounds for 2.5 seconds, and
then the perfecting conversion operation is performed step by step.
For each step during the conversion operation, the switch indicator
lights up, and when each step is finished it goes out again.

Manual conversion procedure
a) Conversion from single-sided printing to perfecting printing ( → )
Step Operations
1 Sheet length setting (Touch panel conversion screen)
2 [MANUAL SWITCHING ON] switch ON
3 [PERFECTING] selector ON
4 [STEP FORWARD] switch ON
5 One step of the conversion to perfecting printing is performed.
6 Keep the [STEP FORWARD] switch ON until the conversion to perfecting printing is finished.
7 Conversion to perfecting printing finished.
b) Conversion from perfecting printing to single-sided printing ( → )
Step Operations
3 [NORMAL] (Single-sided) selector ON
5 One step of the conversion to single-sided printing is performed.
6 Keep the [STEP FORWARD] switch ON until the conversion to single-sided printing is finished.
7 Conversion to single-sided printing finished

c) Sheet size conversion during perfecting printing ( → )
Step Operations
3 [PERFECTING] selector ON
5 One step of the conversion to perfecting printing is performed.
6 Keep the [STEP FORWARD] switch ON until the conversion to perfecting printing is finished.
7 Conversion to perfecting printing finished.
d) Sheet size conversion during single-sided printing ( → )
Step Operations
3 [NORMAL] (Single-sided) selector ON
5 One step of the conversion to single-sided printing is performed.
6 Keep the [STEP FORWARD] switch ON until the conversion to single-sided printing is finished.
7 Conversion to single-sided printing finished

2-3 Perfecting maintenance switches

These switches are only used for perfecting tune-up or when an error occurs. Normally, they are not used.
Please make sure you understand the state of the press and the contents of each explanation before you proceed to
use these switches.
Perfecting control
panel
DECELERATION
POSITION DECELERATION POSITION
SINGLE-SIDE RETURN READY CORRECTION TURN CORRECTION SINGLE-SIDE SIGLE-SIDE RETURN CORRECTION CANCEL
OFF(O) ON (I) STOP ON BUTTON RESET ON
SINGLE-SIDE RETURN READY

OFF(O) ON (I)
When this key switch is turned to [ON], the [SINGLE-SIDE RETURN ON]
switch is enabled. The [SINGLE-SIDE RESET] switch is also enabled.
[Caution]
Do not use this switch except when performing single-sided recovery.
Normally, the switch should be set to the [OFF] position with the key
removed.
SINGLE-SIDE RETURN
ON
When the [SINGLE-SIDE RETURN READY] key switch is turned to [ON] and
this switch is pressed, the switch indicator lights up and the [SINGLE-SIDE
RESET] switch is enabled. When this switch is pressed again, the indicator
goes out.
[Caution]
Do not use this switch except when performing single-sided recovery.
SINGLE-SIDE If for some reason the perfecting conversion is interrupted (for example by an
RESET
error) that cannot be circumvented, the press can be reset manually to
single-sided printing, but it can also be reset to single-sided printing using the
control circuits by pressing this switch. When the [SINGLE-SIDE RETURN
READY] key switch is turned to [ON], the [SINGLE-SIDE RETURN ON]
switch is ON, and this switch is pressed, the [SINGLE-SIDE RETURN ON]
switch indicator goes out after 5 seconds and the reset is finished.
[Caution]
Do not use this switch except when performing single-sided recovery. Make
absolutely sure that the press is set to single-sided printing before you use
this switch.

DECELERATION POSITION
CORRECTION CANCEL
When this key switch is turned ON (the key is inserted and turned clockwise),
the encoder home position data are reset.
[Caution]
Normally, the position data stored in the memory are adjusted at the factory,
and should not be changed.
Do not use this switch except when the encoder has been replaced or
removed, or when the transformer has been replaced.
DECELERATION
POSITION
CORRECTION
ON BUTTON
When this switch is pressed, the encoder values are stored as home position
data. Since these values are factory-adjusted, this operation is normally not
necessary. If the encoder has been replaced or removed, or the transformer
has been replaced, see page 6-1 [6-1 Encoder home calibration (Double-size
cylinder phase encoder)].
CORRECTION TURN
STOP
When this switch is pressed, it stays ON, and the home position calibration
operation is temporarily stopped. When this switch is pressed again, the
temporary stop is released.

2-4 Perfecting conversion operation monitor (without extended delivery

specifications)
The progress of the perfecting conversion operation is displayed on this monitor.
x
(Single-sided sheet size conversion

(Single-sided operation monitor screen) operation monitor screen)
(Perfecting sheet size conversion

(Perfecting operation monitor screen) operation monitor screen)

2-5 Perfecting conversion operation monitor (for extended delivery

specifications)
The progress of the perfecting conversion operation is displayed on this monitor.
x
(Single-sided sheet size conversion

(Single-sided operation monitor screen) operation monitor screen)
(Perfecting sheet size conversion

(Perfecting operation monitor screen) operation monitor screen)

2-6 Perfecting conversion error monitor

Operation states, operation errors, control errors and other contents that occur during the perfecting conversion
operation are displayed on this monitor.
x
(Error display monitor screen)
• When an error occurs, the error location lights up red.

• Contents that indicate operation states light up orange.
• If an error is displayed on the monitor, see the corresponding [Problems and Remedies] item.

3
3Perfection Conversion
Operation Flow
Perfection Conversion Operation Flow 3–1
Perfection Conversion Operation Flow

(without extended delivery specifications)
3-1 Single-sided → perfecting conversion
(Touch panel section)
Sheet length setting Input sheet size
Select the perfecting printing button ( ) Perfecting button indicator lights up
Suction head pad check button ON Suction head pad check button indicator lights up
Suction head valve check button ON Suction head valve check button indicator lights up
“Make-ready finished” lights up
Press and hold down the [AMR] switch (delivery panel) for 3
Ready alarm
seconds.
The alarm sounds for 3 seconds. Release the [AMR] switch

when the alarm stops.
[AMR] switch ON (delivery panel) AMR switch indicator lights up
Turning cylinder gripper-A release air cylinder

The double-sided ( ) indicator operation
flashes
Melody ON
Turning cylinder gripper-A lock air cylinder operation
Press brake OFF “Make-ready finished”
indicator goes off
Auxiliary motor gear ON operation 1
Auxiliary motor inch 2

Gear ON sensor ON
Auxiliary motor accelerates
Home position return (stopping at home position) 3

Home stop timing ON
Turning cylinder brake ON operation 4
Turning cylinder brake OFF operation 5 (Perfecting printing operation monitor screen)
Turning cylinder face-A gripper-A release positioning 6

1 2 3 4 5
Turning cylinder brake ON operation 7 6 7 8 9 10 11
12 13 14 15
Turning cylinder face-A gripper-A lock pin ON operation 8
Turning cylinder face-A gripper-A release operation 9
Turning cylinder face-A gripper-A lock pin disengage operation 10
Turning cylinder brake OFF operation 11
Turning cylinder face-B gripper-A release positioning 12
Gripper-A return side operation (return) 14
Turning cylinder face-B gripper-A lock pin ON operation 15
(A)

(A)
Turning cylinder face-B gripper-A release operation 16
Turning cylinder face-B gripper-A lock pin disengage operation 17
Home position return (stopping at home position) 19 (Perfecting printing operation monitor screen)
Home stop timing ON
W-gear conclude/release operation 21

16 17 18
Suction cylinder release cam gear ON operation 22
19 20
21 22 23 25 26
Single-sided printing suction head positioning 23
28 29 30 29’ 30’
Suction head hook ON operation 25 31 32
Suction head release operation 26
Double-size cylinder phase positioning (Transfer to the

specified sheet size position) 28
W-gear conclude ON 29 Suction head set operation 29’
Suction cylinder release cam gear OFF operation 30 Suction head hook OFF operation 30’
Auxiliary motor gear OFF operation 32
Melody OFF
The perfecting ( ) indicator lights
up
AMR button indicator goes out
Perfecting button indicator
goes out
Press brake ON
Suction head pad check button
indicator goes out
Suction head valve check
button indicator goes out
Perfecting conversion finished

3-2 Perfecting → single-sided conversion

Single-sided button ( ) select Single-sided button indicator lights up
Ready alarm
seconds.

The single-sided ( ) indicator Turning cylinder gripper-A lock air cylinder operation
flashes Melody ON
operation
indicator goes off

Gear ON sensor ON

Home stop timing ON
Suction head hook ON operation 6 (Single-sided printing operation monitor screen)

1 2 3 4
5 6 7 8 9
11 12 14 15
Suction head set operation 11
Suction head hook OFF operation 12
Double-size cylinder phase positioning (Move to the single-sided

printing position) 14
Suction cylinder brake ON operation 15
(B)

(B)
W-gear conclude ON 16
Suction cylinder release cam gear OFF operation 17

(Single-sided printing operation monitor screen)
Suction cylinder brake OFF operation 19
Turning cylinder face-A gripper-A return positioning 20 16
17 18 19
20 21 22 23 24 25
Turning cylinder face-A gripper-A lock pin ON operation 22 26 27 28 29 30 31
32 33
Turning cylinder face-A gripper-A return operation 23
Turning cylinder face-A gripper-A pin disengage operation 24
Turning cylinder face-B gripper-A return positioning 26
Gripper-A release side operation (return) 28
Turning cylinder face-B gripper-A return operation 30
Turning cylinder face-B gripper-A pin disengage operation 31
Melody OFF
The single-sided ( ) indicator
lights up
Single-sided button indicator goes
out
Press brake ON
indicator goes out
Single-sided conversion finished

3-3 Sheet size conversion during perfecting printing

Select the perfecting printing button ( ) Double-sided button indicator lights up
Ready alarm
seconds.

The perfecting ( ) indicator

flashes
Melody ON
Press brake OFF “Make-ready finished” indicator goes off
Auxiliary motor gear ON operation 1 (Perfecting sheet size conversion operation monitor screen)

1 2 3 4
Gear ON sensor ON

Home stop timing ON
(C)

(C)
W-gear conclude/release operation 5 Suction head hook ON operation 5’
Suction cylinder release cam gear ON operation 6 Suction head release operation 6’

Turning cylinder W-gear conclude ON 8 Suction head set operation 8’

(Perfecting sheet size conversion operation monitor screen)
Melody OFF
lights up
AMR button indicator goes out 5 6 5’ 6’
Perfecting button indicator 7 8 9 8’ 9’

goes out
10 11
Press brake ON
indicator goes out

3-4 Sheet size conversion during single-sided printing

Ready alarm
seconds.
The alarm sounds for 3 seconds. Release the [AMR]

switch when the alarm stops.

flashes Melody ON
(Single-sided sheet size conversion operation monitor screen)
Press brake OFF "Make-ready finished"
indicator goes off
1 2 3 4 5
6 7 8 9 10 11
Auxiliary motor inch 2 12
Gear ON sensor ON

Home stop timing ON
Suction head positioning for old sheet size 6
Suction head hook ON operation 7
Suction head positioning for new sheet size 9
(D)

(D)
Melody OFF
lights up
out
Press brake ON
indicator goes out
Suction head valve check button
indicator goes out
Single-sided sheet size conversion finished

Perfection Conversion Operation Flow

(for extended delivery specifications)
3-1 Single-sided → perfecting conversion
Select the perfecting printing button ( ) Perfecting button indicator lights up
Ready alarm
seconds.


The double-sided ( ) indicator operation
flashes
Melody ON
Turning cylinder gripper-A lock air cylinder operation
indicator goes off

Gear ON sensor ON
Sheet decurler ON/OFF positioning 3
Sheet decurler OFF operation 4

Sheet decurler ON indicator goes out
Extended delivery sheet guide movement starts Sheet decurler OFF indicator lights up

Home stop timing ON
Turning cylinder brake OFF operation 7 (Perfecting printing operation monitor screen)
Turning cylinder face-A gripper-A release positioning 8

1 2 3 4 5 6 7
Turning cylinder brake ON operation 9 8 9 10 11 12 13
14
Turning cylinder face-A gripper-A lock pin ON operation 10
Turning cylinder face-A gripper-A release operation 11
Turning cylinder face-A gripper-A lock pin disengage operation 12
Turning cylinder face-B gripper-A release positioning 14
(A)

(A)
Gripper-A return side operation (return) 16
Turning cylinder face-B gripper-A release operation 18
Turning cylinder face-B gripper-A lock pin disengage operation 19
Home position return (stopping at home position) 21 (Perfecting printing operation monitor screen)
Home stop timing ON
15 16 17 18 19 20
21 22
Single-sided printing suction head positioning 25 23 24 25 27 28
30 31 32 31’ 32’
Suction head hook ON operation 27 33 34
35

W-gear conclude ON 31 Suction head set operation 31’
Extended delivery sheet guide movement complete 35
Melody OFF
The perfecting ( ) indicator lights
up
Perfecting button indicator
goes out
Press brake ON
indicator goes out

3-2 Perfecting → single-sided conversion

Ready alarm
seconds.

The single-sided ( ) indicator Turning cylinder gripper-A lock air cylinder operation
flashes Melody ON
operation
indicator goes off

Gear ON sensor ON
Extended delivery sheet guide movement starts

Home stop timing ON
Suction head hook ON operation 6 (Single-sided printing operation monitor screen)

1 2 3 4
W-gear conclude/release operation 8 5 6 7 8 9
11 12 14
Double-size cylinder phase positioning (Move to the single-sided

printing position) 14
(B)

(B)
Suction cylinder brake ON operation 15
W-gear conclude ON 16
Suction cylinder release cam gear OFF operation 17

(Single-sided printing operation monitor screen)
Suction cylinder brake OFF operation 19
Turning cylinder face-A gripper-A return positioning 20 15 16
17 18 19
20 21 22 23 24 25
Turning cylinder face-A gripper-A lock pin ON operation 22 26 27 28 29 30 31
32 33 34 35
Turning cylinder face-A gripper-A return operation 23
36
Turning cylinder face-A gripper-A pin disengage operation 24
Turning cylinder face-B gripper-A return positioning 26
Gripper-A release side operation (return) 28
Turning cylinder face-B gripper-A return operation 30
Turning cylinder face-B gripper-A pin disengage operation 31
Sheet decurler ON/OFF positioning 33
Extended delivery sheet guide retraction complete 36
Sheet decurler ON operation 34

Sheet decurler OFF indicator goes out
Auxiliary motor gear OFF operation 35 Sheet decurler ON indicator lights up
Melody OFF
lights up
out
Press brake ON
indicator goes out
Single-sided conversion finished

x

3-3 Sheet size conversion during perfecting printing

Select the perfecting printing button ( ) Double-sided button indicator lights up
Ready alarm
seconds.


flashes
Melody ON
Press brake OFF “Make-ready finished” indicator goes off
Auxiliary motor gear ON operation 1 (Perfecting sheet size conversion operation monitor screen)

1 2 3 4
Gear ON sensor ON
Extended delivery sheet guide movement starts

Home stop timing ON
(C)

(C)
W-gear conclude/release operation 5 Suction head hook ON operation 5’
Suction cylinder release cam gear ON operation 6 Suction head release operation 6’

Turning cylinder W-gear conclude ON 8 Suction head set operation 8’
Extended delivery sheet guide movement complete 12

(Perfecting sheet size conversion operation monitor screen)
Melody OFF
lights up
AMR button indicator goes out 5 6 5’ 6’
Perfecting button indicator 7 8 9 8’ 9’

goes out
10 11
Press brake ON
indicator goes out
12

3-4 Sheet size conversion during single-sided printing

Ready alarm
seconds.
The alarm sounds for 3 seconds. Release the [AMR]

switch when the alarm stops.

flashes Melody ON
(Single-sided sheet size conversion operation monitor screen)
Press brake OFF "Make-ready finished"
indicator goes off
1 2 3 4 5
6 7 8 9 10 11
Auxiliary motor inch 2 12
Gear ON sensor ON

Home stop timing ON
Suction head positioning for old sheet size 6
Suction head hook ON operation 7
Suction head positioning for new sheet size 9
(D)

(D)
Melody OFF
lights up
out
Press brake ON
indicator goes out
Suction head valve check button
indicator goes out
Single-sided sheet size conversion finished

4
4Problems and Remedies
Problems and Remedies 4–1
Problems and Remedies

CAUTION
Be sure to read and fully understand the “Safety Precautions” before operation.
4-1 About the perfecting conversion problems and remedies

For various problems that may occur during perfecting conversion operation, the cause, checkpoints and remedies
are listed. If a problem occurs, make sure that you understand all safety precautions and warnings, and also how
each operation is performed and its function, before you proceed with the checks and remedies.
The addresses mentioned in this manual refer to the sequencer input/output addresses (numbers). Check these
indicators to resolve the problem.
<Sequencer structure>
Input/output module
Power supply module

<How to read the sequencer input/output>
Seal no. Seal no.

(Address no.) (Address no.)
X50 X52
Indicator no. Indicator no.
Selector switch
(Example) (Example)
When checking the indicator for address X50.0007 When checking the indicator for address
• Seal no. ........................................X50 X52.0007
• Display toggle switch....................0 side • Seal no. .............................X52
• Indicator no. .................................Look at 7 • Indicator no. ......................Look at 7
(Example)
When checking the indicator for address X50.0017
• Seal no. ............................ X50
• Display toggle switch ........ 1 side
• Indicator no....................... Look at 7

[Problem 1] Perfecting conversion does not start
Check the following items after also checking the press “Electric Operation Instructions” Chapter 2 Press
Configuration “How to Read the Interlock Information.”
Points to check Remedies
If the ready alarm does not sound, refer to
“[Phenomenon 2] Ready alarm does not sound” on page
Does the ready alarm sound?
3-3 of “3. Troubleshooting” in the main press Electrical
Manual.
Perfecting interlock information: Is “TUNE UP button on” Check the lamp on the TUNE UP button (1). If the lamp
displayed in the “Perfecting conversion start not is lit or flashing, press the button (1) of the location that
possible” screen? is flashing to cancel it.
Perfecting interlock information: Is “Feeder on” The feeder is turned on. Operate the machine at low
displayed in the “Perfecting conversion start not speed (button lamp flashes) and press the FEEDER
possible” screen? ON/TRIP button (2) to turn off the feeder.
If the IMPRESSION ON button (3) lamp is lit, operate
Perfecting interlock information: Is “Cylinders engaged”
the press at low speed (the button lamp flashes) and
displayed in the “Perfecting conversion start not
then press the FEEDER ON/TRIP button (2) to
possible” screen?
disengage the cylinders.
Perfecting interlock information: Is “Reverse operation
Reverse operation is in progress.
in progress” displayed in the “Perfecting conversion
Press the NORMAL STOP button (4) to stop the press.
start not possible” screen?
Perfecting interlock information: Is “Press operation in
The press is operating.
progress” displayed in the “Perfecting conversion start
not possible” screen?
Perfecting interlock information: Is “INCH button on” The INCH button (5) is pressed.
displayed in the “Perfecting conversion start not (Pressing both at the same time is prohibited.)
possible” screen? Check the wiring of the INCH button (5).
Perfecting interlock information: Is “REVERSE INCH The REVERSE INCH button (6) is pressed.
button on” displayed in the “Perfecting conversion start (Pressing both at the same time is prohibited.)
not possible” screen? Check the wiring of the REVERSE INCH button (6).
Perfecting interlock information: Is “SLOW button on” The SLOW SPEED button (7) is pressed.
displayed in the “Perfecting conversion start not (Pressing both at the same time is prohibited.)
possible” screen? Check the wiring of the SLOW SPEED button (7).
The LOW SPEED/HIGH SPEED button (8) is pressed.
Perfecting interlock information: Is “LOW SPEED/HIGH
(Pressing both at the same time is prohibited.)
SPEED button on” displayed in the “Perfecting
Check the wiring of the LOW SPEED/HIGH SPEED
conversion start not possible” screen?
button (8).
Perfecting interlock information: Is “REVERSE button The REVERSE button (9) is pressed.
on” displayed in the “Perfecting conversion start not (Pressing both at the same time is prohibited.)
possible” screen? Check the wiring of the REVERSE button (9).
Perfecting interlock information: Is “Sheet in press”
A sheet remains in the press. Remove the sheet from
the press.
possible” screen?
Perfecting interlock information: Is “RESERVATION The AMR RESERVATION button (10) is pressed.
button on” displayed in the “Perfecting conversion start Press the RESERVATION button (10) to turn it off
not possible” screen? (button lamp off).
Perfecting interlock information: Is “Perfecting home not The perfecting home has not been corrected. The home
corrected” displayed in the “Perfecting conversion start correction setting operation is required, so please
not possible” screen? consult Komori technical service.


The Select (single-sided) button (12) or
Perfecting interlock information: Is “Change Single/ (perfecting) button (13) on the touch panel (11) has not
Double side not selected” displayed in the “Perfecting been selected.
conversion start not possible” screen? Select the Select (single-sided) button (12) or
(perfecting) button (13).
The Suction head pad check button (14) on the touch
Perfecting interlock information: Is “Suction head pad
panel (11) has not been pressed (OFF).
check is not completed” displayed in the “Perfecting
Press the Suction head pad check button (14) to turn it
ON.
The Suction head valve check button (15) on the touch
Perfecting interlock information: Is “Suction head valve
panel (11) has not been pressed (OFF).
check is not completed” displayed in the “Perfecting
Press the Suction head valve check button (15) to turn it
ON.
Perfecting interlock information: Is “Inker clutch
The inker clutch is operating. Check the AMR button
operating” displayed in the “Perfecting conversion start
lamp (16) and wait for the operation to complete.
not possible” screen?
Product operation is in progress.
Perfecting interlock information: Is “Product operation in If the PRODUCT START/STOP button (17) lamp is
progress” displayed in the “Perfecting conversion start flashing, press the PRODUCT START/STOP button
not possible” screen? (17) to cancel the product operation, then press the
EMERGENCY STOP button (18) and stop the press.
Perfecting interlock information: Is “Timing device error” If the message is displayed, turn the power off and wait
displayed in the “Perfecting conversion start not 30 sec before turning it on again. If the message
possible” screen? appears again, consult Komori technical service.
Perfecting interlock information: Is “Register solenoid If the message is displayed, lower the circuit breaker
power outage” displayed in the “Perfecting conversion (CP-FG) (19) or (CP-SG) (20) lever inside the main
start not possible” screen? control panel and then raise it again (set to ON).
The APC MANUAL ON/OFF button (21) is pressed
Perfecting interlock information: Is “APC manual”
(ON).
Press the APC MANUAL ON/OFF button (21) to cancel
possible” screen?
manual mode. (The button lamp goes off.)
Check the operation of the sucker bar drive section and
Perfecting interlock information: Is “Plate changing C
the position and wiring of the sensor.
Sucker bar error” displayed in the “Perfecting
Check the air pressure.
(The air pressure is 0.6 MPa (6 kgf/cm2).)
Perfecting interlock information: Is “Perfecting Manual The MANUAL ON button (22) is pressed.
Push Button” displayed in the “Perfecting conversion Press the MANUAL ON button (22) to turn it OFF
start not possible” screen? (button lamp off).
Perfecting interlock information: Is “Perfecting Manual The MANUAL SWITCHING ON button (23) is pressed.
Change Push Button” displayed in the “Perfecting Press the MANUAL SWITCHING ON button (23) to turn
conversion start not possible” screen? it OFF (button lamp off).
The CORRECTION TURN STOP button (24) is
Perfecting interlock information: Is “Correction Turn Stop
pressed.
Push Button” displayed in the “Perfecting conversion
Press the CORRECTION TURN STOP button (24) to
turn it OFF.
Press the Perfecting Cylinder Sheet Drop Detection
Perfecting interlock information: Is “Perfecting cylinder
RESET button (25) to display and cancel the alarm.
sheet drop detector (reflective sensor)” displayed in the
Then remove the dropped sheet from inside the
“Perfecting conversion start not possible” screen?
machine.


Perfecting interlock information: Is “Perfecting cylinder RESET button (25) to display and cancel the alarm.
sheet drop sensor error” displayed in the “Perfecting Then stop (lock) the press and wipe clean the light
conversion start not possible” screen? emitting surface and reflective plate of the sheet drop
sensor (26).
Perfecting interlock information: Is “Perfecting error If the message is displayed, check the error details and
monitor screen” displayed in the “Perfecting conversion perform the procedures for the appropriate
start not possible” screen? Troubleshooting item in this section.
Perfecting interlock information: Is “Sheet guide The sheet guide (delivery) axis is not selected.
(delivery) axis not selected” displayed in the “Perfecting Press the Sheet Guide (Delivery) axis select buttons
conversion start not possible” screen? (27) to select the axis.

[Problem 1] Perfecting conversion does not start (Continued)
Circuit breaker
(19) CP-FG (20)CP-SG (17)
(18)
(3)
(1) (2)
(For U.S. (For non-U.S. (1) (8)

(6)
specifications) specifications)
(5)
(4) (5) (7) (18)
Touch panel
(11)
(18)
(16) (18) (6)

(5)
(1)
(17) (1) (5) (7) (8) (9) (4)

Touch panel
(11)
(26)Turning cylinder sheet drop

detection sensor
Turning cylinder sheet

drop detection sensor
Cylinder
Reflection plate
(12) (13) (14) (15)
(25) (27)

Touch panel
(11)
[APC manual operation panel]
(21)
[Perfecting conversion manual

operation panel]
(22)
(24)
(23)
(10)

[Problem 2] “Aux. Motor Gear Trouble” lights up
Problem Normal condition

(Condition) Contents Address Indicator
The gears did not Is the auxiliary motor gear Auxiliary X51.0000 Lights up If sensor input (X51.0000)
engage during ON sensor OFF? motor gear is not lit, check the
auxiliary motor gear ON sensor condition of the air
ON operation. cylinder and the sensor.
Auxiliary Y54.0010 Lights up
motor gear
ON
The gears did not Is the auxiliary motor gear Auxiliary X51.0001 Lights up If sensor input (X51.0001)
disengage during OFF sensor OFF? motor gear is not lit, check the
auxiliary motor gear OFF sensor condition of the air
OFF operation. The cylinder and the sensor.
Auxiliary Y54.0011 Lights up
gear OFF position is
motor gear
wrong.
OFF
Auxiliary motor
Auxiliary motor gear

ON/OFF air cylinder

ON sensor
OFF sensor

[Problem 3] “Turning Cylinder Brake Trouble” lights up

During turning cylinder Is the turning cylinder Turning X51.0010 Lights up If sensor input (X51.0010)
brake ON operation, brake ON sensor OFF? cylinder is not lit, check the
the brake is not brake ON condition of the air
engaged. sensor cylinder and the sensor.
Turning Y54.000E Lights up
cylinder
brake ON
During turning cylinder Is the turning cylinder Turning X51.0011 Lights up If sensor input (X51.0011)
brake OFF operation, brake OFF sensor OFF? cylinder is not lit, check the
the brake is not brake OFF condition of the air
released. The turning sensor cylinder and the sensor.
cylinder is not at the
Turning Y54.000F Lights up
brake OFF position.
cylinder
brake OFF
The turning cylinder Is the brake ON sensor Turning Y54.000F Lights up If sensor input (X51.0010)
brake ON sensor or ON during turning cylinder cylinder is lit, check the condition
brake OFF sensor is brake OFF operation? brake OFF of the air cylinder and the
short-circuited. operation of the sensor,
Turning X51.0010 Not lit
and also check the wiring.
cylinder
brake ON
sensor
Is the brake OFF sensor Turning X51.0011 Not lit If sensor input (X51.0011)
ON during turning cylinder cylinder is lit, check the condition
brake ON operation? brake OFF of the air cylinder and the
sensor operation of the sensor,
cylinder
brake ON
The turning cylinder Is the cylinder stopped at Home stop X52.000D Lights up If the stop angle is correct
brake ON operation the conversion home timing but the indicator is not lit,
does not start. position? Check the stop check the wiring.
angle.
<*1>
Is the turning cylinder Gripper-A X52.000F Lights up If the stop angle is correct
stopped at the gripper-A lock/Release but the indicator is not lit,
return/release position? timing check the wiring.
Check the stop angle.
<*2>

[Problem 3] “Turning Cylinder Brake Trouble” lights up (Continued)
Turning cylinder brake OFF sensor
Turning cylinder brake ON/OFF air cylinder Turning cylinder brake ON sensor
(Turning cylinder brake OFF)
(Turning cylinder brake ON)

Turning cylinder
(O)
Cam
<*1> Conversion home position
Conversion home position

Perfecting mechanism
standard position angle
Between 1C and 2C 221°
• The angles listed to the left are the conversion home position standard position angles. A deviation of ±2° from the standard
value is acceptable.
• Check the angle on the following unit's timing display [on the timing device (DE-TG2) inside the feeder control panel].
<*2> Turning cylinder gripper-A return/release position
Gripper-A return/release
standard position angle
• The angles listed above are the standard position angles for the turning cylinder gripper-A return/release position. A deviation
of ±2° from the standard value is acceptable.

[Problem 4] “Turning Cylinder Gripper-A Lock Pin Trouble” lights up

During turning cylinder Is the turning cylinder Turning X51.000C Lights up If sensor input
gripper-A lock pin ON gripper-A pin ON sensor cylinder (X51.000C) is not lit,
operation, the pin does OFF? gripper-A pin check the condition of the
not go in. ON sensor air cylinder and the
sensor.
Turning Y54.001C Lights up
cylinder A
gripper pin
ON
During turning cylinder Is the turning cylinder Turning X51.000D Lights up If sensor input
gripper-A lock pin OFF gripper-A pin OFF sensor cylinder A (X51.000D) is not lit,
operation, the pin does OFF? gripper pin check the condition of the
not go out. The OFF sensor air cylinder and the
cylinder is not at the sensor.
Turning Y54.001C Not lit
pin OFF position.
cylinder A
gripper pin
ON
Turning cylinder Is the gripper-A pin ON Turning Y54.001C Not lit If sensor input
gripper-A pin ON sensor ON during turning cylinder A (X51.000C) is lit, check
sensor or the gripper-A cylinder gripper-A pin OFF gripper pin the condition of the air
pin OFF sensor is operation? ON cylinder and the operation
short-circuited. of the sensor, and also
Turning X51.000C Not lit
check the wiring.
cylinder
gripper-A pin
ON sensor
Is the gripper-A pin OFF Turning Y54.001C Lights up If sensor input
sensor ON during turning cylinder (X51.000D) is lit, check
cylinder gripper-A pin ON gripper-A pin the condition of the air
operation? ON cylinder and the operation
of the sensor, and also
Turning X51.000D Not lit
check the wiring.
cylinder
gripper-A pin
OFF sensor

[Problem 4] “Turning Cylinder Gripper-A Lock Pin Trouble” lights up (Continued)

Turning cylinder Is the turning cylinder Turning Y54.000E Lights up If sensor input (X51.0010)
gripper-A pin ON brake ON? Is the turning cylinder is not lit, turn ON the
operation does not cylinder stopped at the brake turning cylinder brake.
start. gripper-A return/release
Turning X51.0010 Lights up
position? Check the stop
cylinder
angle.
brake ON
<*1>
sensor
Gripper-A X52.000F Lights up If the stop angle is correct
lock/release but the indicator is not lit,
enabled check the wiring.
timing

[Problem 4] “Turning Cylinder Gripper-A Lock Pin Trouble” lights up (Continued)
Turning cylinder (O)
(Release)
Gripper-A lock pin ON/OFF air cylinder

(Set) Gripper-A release/return air cylinder
(Pin OFF) (Pin ON)
Turning cylinder gripper-A pin OFF sensor Turning cylinder gripper-A pin ON sensor
Gripper-A return/release standard

position angle

[Problem 5] “Turning Cylinder Gripper-A Lock/Release Trouble” lights up

During turning cylinder Is the turning cylinder Turning X51.000E Lights up If sensor input (X51.000E)
gripper-A release gripper-A lock/release cylinder is not lit, check the
operation, gripper-A is sensor OFF? gripper-A condition of the air
not released. lock/release cylinder and the sensor.
sensor
cylinder
gripper-A
lock/release
During turning cylinder Is the turning cylinder Turning X51.000F Lights up If sensor input (X51.000F)
gripper-A return gripper-A lock set sensor cylinder is not lit, check the
operation, the gripper OFF? gripper-A condition of the air
does not return. The lock set cylinder and the sensor.
cylinder is not at the sensor
gripper-A return
Turning Y54.001F Lights up
position.
cylinder
gripper-A
lock set
The turning cylinder Is the gripper-A lock/ Turning Y54.001F Lights up If sensor input (X51.000E)
gripper-A lock/release release sensor ON during cylinder is lit, check the condition
sensor or the turning turning cylinder gripper-A gripper-A of the air cylinder and the
cylinder gripper-A lock lock set operation? lock set operation of the sensor,
set sensor is and also check the wiring.
Turning X51.000E Not lit
short-circuited.
cylinder
gripper-A
lock/release
sensor
Is the gripper-A lock set Turning Y54.001E Lights up If sensor input (X51.000F)
sensor ON during turning cylinder is lit, check the condition
cylinder gripper-A lock/ gripper-A of the air cylinder and the
release operation? lock/release operation of the sensor,
Turning X51.000F Not lit
cylinder
gripper-A
lock set
sensor

[Problem 5] “Turning Cylinder Gripper-A Lock/Release Trouble” lights up (Continued)
Turning cylinder (O)
Turning cylinder gripper-A lock/

(Release)
release sensor
Turning cylinder gripper-A lock
set sensor
Gripper-A lock pin ON/OFF air cylinder
(Set) Gripper-A release/return air cylinder
(Pin OFF) (Pin ON)

[Problem 6] “W-Gear Conclude/Release Trouble” lights up

W gear is not released Is the W-gear release W-gear X51.0002 Lights up If sensor input (X51.0002)
during the W gear sensor OFF? release is not lit, check the
release operation. sensor condition of the air
cylinder and the sensor.
W-gear Y54.0012 Lights up
release
During W-gear Is the W-gear conclude W-gear X51.0003 Lights up If sensor input (X51.0003)
conclude operation, sensor OFF? conclude is not lit, check the
the W-gear does not sensor condition of the air
conclude. cylinder and the sensor.
W-gear Y54.0013 Lights up
conclude
The W-gear release Is the W-gear release W-gear Y54.0013 Lights up If sensor input (X51.0002)
sensor or the W-gear sensor ON during W-gear conclude is lit, check the condition
conclude sensor is conclude operation? of the air cylinder and the
W-gear X51.0002 Not lit
short-circuited. operation of the sensor,
release
sensor
Is the W-gear conclude W-gear Y54.0012 Lights up If sensor input (X51.0003)
sensor ON during W-gear release is lit, check the condition
release operation? of the air cylinder and the
W-gear X51.0003 Not lit
operation of the sensor,
conclude
sensor
W-gear conclude/ Is the cylinder stopped at Home stop X52.000D Lights up If the stop angle is correct
release does not start. the conversion home timing but the indicator is not lit,
position? Check the stop check the wiring.
angle.
<*1>
Is the turning cylinder Turning Y54.000E Lights up If sensor input (X51.0010)
brake ON? cylinder is not lit, turn ON the
brake ON turning cylinder brake.
Turning X51.0010 Lights up
cylinder
brake ON
sensor

[Problem 6] “W-Gear Conclude/Release Trouble” lights up (Continued)
(W-
gea
r rele
ase
)
(W-
gea
r co
nclu
d e)
W-gear release sensor
W-gear conclude sensor

Turning cylinder (D)
W-gear conclude/release air cylinder
Conversion home position standard

position angle
• The angles listed above are the conversion home position standard position angles. A deviation of ±2° from the standard value
is acceptable.

[Problem 7] “Suction Cylinder Release Cam Gear Trouble” lights up

During suction cylinder Is the suction cylinder Suction X51.0004 Lights up If sensor input (X51.0004)
release cam gear ON release cam gear ON cylinder is not lit, check the
operation, the gear sensor OFF? release cam condition of the air
does not engage. gear ON cylinder and the sensor.
sensor
Suction Y54.0014 Lights up
cylinder
release cam
gear ON
release cam gear OFF release cam gear OFF cylinder is not lit, check the
operation, the gear sensor OFF? release cam condition of the air
does not disengage. gear OFF cylinder and the sensor.
sensor
cylinder
release cam
gear OFF
The suction cylinder Is the suction cylinder Suction Y54.0015 Lights up If sensor input (X51.0004)
release cam gear ON release cam gear ON cylinder is lit, check the condition
sensor or the suction sensor ON while the release cam of the air cylinder and the
cylinder release cam suction cylinder release gear OFF operation of the sensor,
gear OFF sensor is cam gear is OFF? and also check the wiring.
Suction X51.0004 Not lit
short-circuited.
cylinder
release cam
gear ON
sensor
Is the suction cylinder Suction Y54.0014 Lights up If sensor input (X51.0005)
release cam gear OFF cylinder is lit, check the condition
sensor ON while the release cam of the air cylinder and the
suction cylinder release gear ON operation of the sensor,
cam gear is ON? and also check the wiring.
cylinder
release cam
gear OFF
sensor

[Problem 7] “Suction Cylinder Release Cam Gear Trouble” lights up (Continued)
Suction cylinder
(D)
Suction cylinder release cam gear Suction cylinder release cam gear OFF sensor
ON sensor
(Release cam gear ON) (Release

cam gear
OFF) Suction cylinder release cam gear ON/OFF
air cylinder

[Problem 8] “Suction Cylinder Brake Trouble” lights up

brake ON operation, brake ON sensor OFF? cylinder is not lit, check the
the brake does not brake ON condition of the air
lock. sensor cylinder and the sensor.
cylinder
brake ON
brake OFF operation, brake OFF sensor OFF? cylinder is not lit, check the
the brake is not brake OFF condition of the air
released. The turning sensor cylinder and the sensor.
cylinder is not at the
brake OFF position.
cylinder
brake OFF
The suction cylinder Is the brake ON sensor Suction Y54.0017 Lights up If sensor input (X51.0006)
brake ON sensor or ON during suction cylinder cylinder is lit, check the condition
the suction cylinder brake OFF operation? brake OFF of the air cylinder and the
brake OFF sensor is operation of the sensor,
short-circuited. and also check the wiring.
cylinder
brake ON
sensor
Is the brake OFF sensor Suction Y54.0016 Lights up If sensor input (X51.0007)
ON during suction cylinder cylinder is lit, check the condition
brake ON operation? brake ON of the air cylinder and the
operation of the sensor,
cylinder
brake OFF
sensor

[Problem 8] “Suction Cylinder Brake Trouble” lights up (Continued)

Suction cylinder brake Is the cylinder stopped at Home stop X52.000D Lights up If the stop angle is correct
ON operation does not the conversion home timing but the indicator is not lit,
start. position? Check the stop check the wiring.
Single-sided X52.0005 Lights up
angle.
enabled
<*1>
timing
Is the cylinder stopped at If the position is incorrect,
the min. sheet size please contact our
(360 mm) position? Check — — — customer service.
the scale in the turning
cylinder gear section.

[Problem 8] “Suction Cylinder Brake Trouble” lights up (Continued)
Suction head lock/release air cylinder

(Suction head hook OFF) Suction
cylinder
gear Suction cylinder brake ON sensor
(Suction head hook ON)
(Cam) Suction cylinder brake OFF sensor
(Suction cylinder brake ON) (Suction cylinder Suction cylinder brake ON/OFF air cylinder
brake OFF)
<Turning cylinder gear>
The illustration to the left shows the perfecting

360 mm position.

position angle
is acceptable.

[Problem 9] “Suction Head Hook Trouble” lights up

Suction head hook ON Is the suction head hook Suction head X51.0008 Lights up If sensor input (X51.0008)
operation does not ON sensor OFF? hook ON is not lit, check the
start. sensor condition of the air
cylinder and the sensor.
Suction head Y54.0018 Lights up
hook ON
During suction head Is the suction head hook Suction head X51.0009 Lights up If sensor input (X51.0009)
hook OFF operation, OFF sensor OFF? hook OFF is not lit, check the
the hook is not sensor condition of the air
released. The cylinder cylinder and the sensor.
Suction head Y54.0019 Lights up
is not at the hook OFF
hook OFF
position.
The suction head hook Is the suction head hook Suction head Y54.0019 Lights up If sensor input (X51.0008)
ON sensor or the ON sensor ON during hook OFF is lit, check the condition
suction head hook suction head hook OFF of the air cylinder and the
Suction head X51.0008 Not lit
OFF sensor is operation? operation of the sensor,
hook ON
short-circuited. and also check the wiring.
sensor
Is the suction head hook Suction head Y54.0018 Lights up If sensor input (X51.0009)
OFF sensor ON during hook ON is lit, check the condition
suction head hook ON of the air cylinder and the
Suction head X51.0009 Not lit
operation? operation of the sensor,
hook OFF
sensor
Suction cylinder brake Is the cylinder stopped at If the position is incorrect,
ON operation does not a position between the please contact our
start. min. sheet size (360 mm) customer service.
and the max. sheet size
— — —
(720 mm)?
Check the scale in the
turning cylinder gear
section.

[Problem 9] “Suction Head Hook Trouble” lights up (Continued)
Suction head hook ON sensor
Suction head hook OFF sensor
Suction head hook ON/OFF air cylinder

(Suction head hook OFF) Suction
cylinder

(Cam)
(Suction cylinder brake ON) Suction cylinder brake ON/OFF air

(Suction cylinder
brake OFF)
cylinder

[Problem 9] “Suction Head Hook Trouble” lights up (Continued)
The illustration to the left shows the

perfecting 360 mm position.

[Problem 10] “Suction Head Lock/Release Trouble” lights up

During suction head Is the suction head Suction head X51.000A Lights up If sensor input
release operation, the release sensor OFF? release (X51.000A) is not lit,
suction head is not sensor check the condition of the
released. air cylinder and the
Suction head Y54.001A Lights up
sensor.
released
During suction head Is the suction head set Suction head X51.000B Lights up If sensor input
set operation, the sensor OFF? set sensor (X51.000B) is not lit,
suction head is not set. check the condition of the
Suction head Y54.001B Lights up
The suction head is air cylinder and the
set
not at the set position. sensor.
The suction head Is the suction head Suction head Y54.001B Lights up If sensor input
release sensor or the release sensor ON during set (X51.000A) is lit, check
suction head set suction head set the condition of the air
Suction head X51.000A Not lit
sensor is operation? cylinder and the operation
release
short-circuited. of the sensor. Also check
sensor
the wiring.
Is the suction head Suction head Y54.001A Lights up If sensor input
release sensor ON during released (X51.000B) is lit, check
suction head release the condition of the air
Suction head X51.000B Not lit
operation? cylinder and the operation
set sensor
of the sensor. Also check
the wiring.

[Problem 10] “Suction Head Lock/Release Trouble” lights up (Continued)
Suction head
release sensor
(Suc
t
head ion Suction head
Suction head hook ON/OFF set)
(S u c
air cylinder t
relea ion head
set sensor
se)
(Suction head hook OFF)

Suction
cylinder
(Cam)
(Suction cylinder brake ON) Suction cylinder brake ON/OFF air

(Suction cylinder
brake OFF) cylinder

[Problem 11] “Aux. Motor Trouble” lights up
Normal condition
Problem (Condition) Points to check Remedies
Contents Address Indicator
An auxiliary motor amp Is the auxiliary motor error Auxiliary X52.000C Lights up Press the error RESET
error has been detected. input OFF? Check if an error motor button to cancel the error. If
code is displayed in the error pressing the RESET button
motor status display screen. does not cancel the error,
turn the power off and wait
30 sec before turning it on
again. If the error occurs
again, check the error code
and consult Komori
technical service.

[Problem 11] “Aux. Motor Trouble” lights up (Continued)
Touch panel
Press to display the motor status display screen.
Conversion auxiliary motor error

code display
(See the separate sheet for the
error details.)
Error RESET button
Button for returning to the original

screen
(Conversion trouble display
Monitor screen)

[Problem 11] “Aux. Motor Trouble” lights up (Continued)
Display Operation at Cancel

Item LCD display Description
code occurrence method
1-0 IPM error IPM ERR. The cables U, V, W between earth or the Motor free Press the
controller and the motor has been RESET button
short-circuited or earthed, causing a
power overflow in the main circuit
transistors. Else, the power element
cooling heat sink is overheated.
1-1 Control voltage UNDRVOLT1 The control voltage (+5 V, +15 V) has Motor free Press the
power drop dropped. RESET button
error DC+5 V : below approx. +4.75 V
DC+15 V : below approx. +13.5 V
1-2 Control voltage UNDRVOLT2 The power of the main circuit DC bus Motor free Press the
power drop has fallen below 180 [90] V. The value in RESET button
error brackets is the value for 100 V
specifications. (This alarm appears when
a main power stand-alone controller is
used.)
1-3 Power surge OVER VOLT The load inertia is over the upper limit, Motor free Press the
error exceeding the regenerative capacity RESET button
during motor stop or slow-down, so that
the main circuit DC voltage has surged
above approx. 400 [200] V. The value in
brackets it the value for 100 V
specifications.
1-4 Overspeed error OVERSPEED The motor speed exceeds 130% of the Motor free Press the
set speed. RESET button
1-5 Overload error OVER LOAD The internal thermistor has been Motor free Press the
activated due to overload, or too high RESET button
tolerance repeat frequency.
1-6 IPM overload IPM O.L. An excessive load was applied to the Motor free Press the
error unit power elements. RESET button
Current of 180% or more of the rated
current for the motor or the unit flowed
for the prescribed time or longer.
1-7 Regenerative RG.O.L. The regenerative power produced by Motor free Press the
resistance deceleration of the load inertia, etc. RESET button
overload error exceeds the allowable range for the
regenerative resistance power
connected to the device.
1-8 AC interrupt AC DOWN The AC power has fallen below approx. Motor free Press the
error 60 [30] V for more than 50 ms. (A RESET button
temporary power cut has occurred.)
The value in brackets it the value for
100 V specifications.
2-0 Motor type not MOTRTYPE1 The [P000: Motor type] setting is “000”. Motor free Set the motor
set type, then turn
the power off
and then on
again.
2-1 Incorrect motor MOTRTYPE2 The motor set at [P000: Motor type] does Motor free Set the correct
type not correspond to the controller. motor type,
then turn the
power off and
then on again.


3-0 Encoder error ENCODER (1)Encoder error Motor free Turn the power
(2)The encoder cable has been cut off or off and then on
is not connected, or the connector again.
has been disconnected.
(3)Incorrect encoder selection among
the parameter settings or some other
error has occurred.
3-1 Motor axis error PW.ON ENC When the power was turned on, the Motor free Turn the power
during power on motor axis was rotating or vibrating. If off and then on
the motor axis is rotating or vibrating again.
when the power is turned on, the
encoder cannot be initialized.
4-0 Deviation OVERFLOW The position deviation exceeds the value Motor stops Press the
overflow set in [P207: Overflow detection pulse]. immediately RESET button
then free
4-1 Deviation error VARI.OVER The position deviation exceeds the value Motor stops Press the
set in [P208: Deviation error detection immediately RESET button
pulse]. then servo
locked
5-0 Forward +HARD OT. A forward direction overtravel signal Motor stops Move in the
direction (FOT) has been detected. immediately reverse
overtravel then servo direction.
locked
5-1 Backward -HARD OT. A backward direction overtravel signal Motor stops Move in the
direction (ROT) has been detected. immediately forward
overtravel then servo direction.
locked
5-2 Forward +SOFT OT. The current position exceeds the value Motor stops Move in the
direction set at [P306: Forward direction soft immediately reverse
software limit overtravel limit]. then servo direction.
locked
5-3 Reverse -SOFT OT. The current position exceeds the value Motor stops Move in the
direction set at [P307: Backward direction soft immediately forward
software limit overtravel limit]. then servo direction.
locked
6-0 Address setting ADDR ERR. An attempt has been made to execute a Motor servo Set the correct
error command with an address outside the locked address and
range from 0 to 279. press the
RESET button.
6-1 Positioning time TIME OUT Positioning did not finish within the time Motor stops Press the
out set at [P203: Positioning time out]. immediately RESET button
then servo
locked
6-2 Positioning data DATA OVER An attempt has been made to perform Motor servo Set the
overflow easy continuous positioning continuous locked continuous
operation with a distance outside the operation
range from 2147483647 to distance within
–2147483647. the specified
range and
press the
RESET button.
6-3 One-turn data P305 ERR. An attempt has been made to execute Motor servo Set the correct
not set an indexing positioning command or a locked value and
spin command with [P305: Rotor press the
position range] still set to “0”. RESET button.


6-4 Program end PEND.ERR. A command for a group other than group Motor stops Correct the
command not 0 was executed without the PEND immediately program and
set command having been set, so that the then servo press the
address became 280. locked RESET button.
6-5 Subroutine call CALL OVER An attempt has been made to execute 9 Motor servo Correct the
nesting over subroutine calls without returning from locked program and
the subroutines. press the
RESET button.
6-6 Subroutine PET ERR. An attempt has been made to execute a Motor servo Correct the
Incorrect return subroutine return without executing a locked program and
previous subroutine call. press the
RESET button.
6-7 Illegal address JUMP ERR. An attempt has been made to execute a Motor servo Set the correct
jump command with a jump address or locked address and
subroutine call address outside the press the
range from 0 to 279. RESET button.
6-8 Spin command SPN.ERR. An attempt was made to execute an Motor stops Correct the
incorrect unrecognizable command. (This occurs immediately program and
when an illegal command is registered then servo press the
by the communication.) locked RESET button.
6-9 Incorrect ODIV.ERR. An attempt was made to divide using a Motor servo Set the correct
division divisor of 0. locked divisor and
press the
RESET button.
6-A Positioning POS OVER An attempt has been made to execute a Motor servo Set the correct
amount error positioning command with a positioning locked data and press
amount exceeding the value set for the the RESET
parameter [P308: Forward direction button.
positioning amount, maximum value] or
[P309: Backward direction positioning
amount, maximum value].
6-b Incorrect CMND.ERR. An attempt has been made to execute Motor servo Set the correct
command an unrecognized command. (This error locked data and press
appears when an incorrect command the RESET
has been registered because of incorrect button.
communications.)
6-C Indirect data IXNO.ERR. An attempt has been made to execute a Motor servo Set the correct
number command with an indirect data number locked data and press
incorrect outside the range from 0 to 99 specified. the RESET
(This error may appear when an indirect button.
data number offset is used, or when an
incorrect indirect data number has been
registered because of incorrect
communications.)
6-d Continuous CONT ERR. While executing a continuous control Motor stops Set the correct
control command, an attempt was made to immediately data and press
command error execute a command other than then servo the RESET
continuous control without waiting for the locked button.
continuous control end command
(CEND).
7 Data storage DATA The stored data is corrupted. Motor free Set the data
error again and
press the
RESET button.


9-0 SQB error SQB ERR (1)There has been no access from the Motor free Turn the power
SQB for over 10 seconds after off and then on
power-on, or for over 1 second during again.
normal operation.
(2)The self-diagnosis mode, forced
inching mode etc. has been
disengaged.
9-1 Remote NET IC ER The control IC for remote sequence Motor free Consult
sequence control communications has Komori
control IC malfunctioned. technical
malfunction service.
9-2 Remote NET ERR. The remote sequence control Motor free Turn the power
sequence communications failed. off and then on
control This also happens if the power to the again.
communications sequence controller is turned OFF first.
interrupted
A-0 Expansion RAM BATT. The voltage of the battery used to hold Motor free Press the
Memory battery data in the expansion memory (option) RESET button
voltage drop has dropped. (This is detected and an or replace the
alarm is sounded only once when the expansion
power is on.) memory.
A-1 EEPROM WR.EEPROM Data could not be written in the Motor stops Press the
(Electrically controller’s internal EEPROM. immediately RESET button
Erasable then servo
Programmable locked
Read-Only
Memory) write
error
A-2 Incorrect STD.SPD.1 The standard motor speed set with Motor free Press the
standard speed [P303, P304: Electronic gear ratio] and RESET button
command 1 [P310: Machine transfer quantity] has
exceeded 40M (setting unit/sec).
A-3 Incorrect STD.SPD.2 The standard motor speed set with Motor free Press the
standard speed [P303, P304: Electronic gear ratio] and RESET button
command 2 [P310: Machine transfer quantity] was
below 100 (setting unit/sec).
A-4 Servo control M.COMM.ER Communication was cut off during servo Motor free Press the
communication control communication. RESET button
cut off error
A-5 Servo control BCC.ERR A communication error occurred during Motor free Press the
communication servo control communication. RESET button
cut off error

[Problem 12] “Double Size Cylinder Phase Encoder Trouble” lights up
Normal condition
The double-size cylinder Is the encoder ready Encoder X50.0010 Lights up If the indicator is not lit, turn
phase encoder wiring has output not lit? ready off the power, and then turn
been cut. it back on again after 30
There is a malfunction with seconds. If the error
the encoder itself or the reoccurs after restarting,
encoder transformer. please contact our customer
service.
Double-size cylinder phase encoder

[Problem 12] “Double Size Cylinder Phase Encoder Trouble” lights up (Continued)
<Double-size cylinder phase encoder transformer>
Home calibration SET key switch
(1)
Lit green: RUN condition
Flashing red: Error condition
Lit orange: Key switch [SET] position

[Problem 13] “Turning Cylinder Blower Over Load” lights up

The turning cylinder Is the turning cylinder Turning X52.0009 Not lit If the indicator is lit,
blower, suction blower overload input lit? cylinder release the overload by
cylinder blower, or blower OL pressing the RESET
suction cylinder lower button on the thermal
blower is overloaded. relays (1) (CVP1), (2)
(CVP2), (3) (CVP3), (4)
(CHV1) and (5) (CHV2)
inside the perfecting
control panel or central
blower panel (for central
cabinet specifications).

[Problem 13] “Turning Cylinder Blower Over Load” lights up (Continued)
[Non-central cabinet specifications]
Thermal relay
(1) CVP1 (4) CHV1

(2) CVP2 (5) CHV2
(3) CVP3
Check if this reset button has

popped out. If the reset button has
popped out, press it back in.
[Central cabinet specifications]
Thermal relay
(1) CVP1 (4) CHV1

(2) CVP2 (5) CHV2
(3) CVP3
Check if this reset button has

popped out. If the reset button has
popped out, press it back in.

[Problem 14] “Home Position Trouble” lights up

During home position Is the home stop timing Home stop X52.000D Lights up If the stop angle is correct
return operation, the OFF? Check the timing but the indicator is not lit,
home stop position is conversion home angle. check the wiring.
wrong. <*1>
During home position At the home position Turning X51.0013 Lights up at If the stop angle is correct
return operation, the return cam hole position, cylinder the detection but the indicator is not lit,
cylinder does not stop is the adjacent switch home return hole position check the wiring.
at the home stop indicator not lit? sensor
position.
If the press is adjusted to Home stop X52.000D Lights up
the conversion home timing
angle position, is the
home stop timing OFF?
<*1>
The unit following the Check the conversion Home stop X52.000D Lights up If it is incorrect, please
turning cylinder is home angle on the timing contact our customer
rotating during following unit. service.
double-size cylinder <*1>
phase transfer
operation.

[Problem 14] “Home Position Trouble” lights up (Continued)
<Turning cylinder section>
Turning cylinder home return sensor
Cam Home return detection hole

position angle
is acceptable.

[Problem 15] “Double Size Cylinder Position Trouble” lights up

During double-size Is the single-sided Single-sided X52.0005 Lights up If the input (X52.0005) is
cylinder phase enabled timing input OFF? enabled not lit, please contact our
operation, the Check the position on the timing customer service.
single-sided stop scale in the turning
Home stop X52.000D Lights up
position is incorrect. cylinder gear section.
timing
During double-size Is the perfecting enabled Perfecting X52.0006 Lights up If the input (X52.0006) is
cylinder phase timing input OFF? enabled not lit, please contact our
operation, the position Check the position on the timing customer service.
is below the min. sheet scale in the turning
Home stop X52.000D Lights up
size or above the max. cylinder gear section.
timing
sheet size position.
The illustration to the The illustration to the left

left shows the shows the single-sided
perfecting 360 mm condition.
position.

[Problem 16] “Suction Cylinder Release Cam Position Trouble” lights up

The suction cylinder Is the suction cylinder Suction X51.0012 Lights up If it is not lit, please
release cam is beyond release cam limit sensor cylinder contact our customer
the max. sheet size input OFF? release cam service.
position. Check the position on the limit sensor
The suction cylinder scale in the suction
release cam is beyond cylinder section.
the single-sided
position.
Suction cylinder release cam limit sensor

(Mounted inside the frame)

[Problem 17] “Perfecting Manual Push Button” lights up

The perfecting manual Is the Perfecting Manual Manual X50.0012 Not lit If the indicator is lit, press
operation ON switch Operation ON switch (1) button the Manual Operation ON
(1) has been pressed. indicator lit? switch (1) so that the
indicator goes out.
<Perfecting manual operation switches>
(1)

[Problem 18] “Gripper-A Lock/Release Position Trouble” lights up

The gripper-A release Is the turning cylinder Gripper-A X52.000F Lights up If the indicator is not lit,
stop position is stopped at the gripper-A lock/Release turn off the power, and
incorrect. The return/release position? timing then turn it back on again
gripper-A return stop Check the stop angle. after 30 seconds. If the
position is incorrect. <*1> error reoccurs after
restarting, please contact
our customer service.
Gripper-A return/release standard

position angle

[Problem 19] “Perfecting Manual Change Push Button” is lit

The manual switching Is the manual switching MANUAL Y54.000A Not lit If the indicator is lit, press
ON switch (1) among ON switch (1) indicator lit? SWITCHING the Manual Switching ON
the perfecting manual ON button switch (1) so that the
operation switches has lamp indicator goes out.
been pressed.
(1)

[Problem 20] “Suction Head Position Trouble” lights up

During suction head Is the perfecting enabled Perfecting X52.0006 Lights up If the input (X52.0006) is
positioning operation, timing input OFF? enabled not lit, please contact our
the position is timing customer service.
incorrect.

[Problem 21] “Perfecting Manual Return Select Push Button” is lit

Press the single-side Is the single-side return Single-side Y54.0009 Not lit If the indicator is lit, press
return ON switch (1). ON switch (1) indicator lit? return ON the single-side return ON
indicator switch (1) so that the
indicator goes out.
DECELERATION
POSITION
SINGLE-SIDE RETURN READY CORRECTION TURN CORRECTION SINGLE-SIDE SIGLE-SIDE RETURN
(1)

[Problem 22] “Perfecting Stop Push Button” lights up

Press the stop switch Is the perfecting stop Perfecting X52.0008 Not lit If the indicator is lit,
(1) among the switch input ON? stop button release the stop switch
perfecting manual (1).
operation switches.
(1)

[Problem 23] “Correction Turn Stop Push Button” lights up

The correction stop Is the correction stop Calibration X51.001C Lights up If it is not lit, press the
switch (1) that is used switch input OFF? stop home calibration stop
for home calibration switch (1) to release it.
operation has been
pressed.
DECELERATION
POSITION
(1)

[Problem 24] A gripper shaft operation error is displayed (Touch panel section)
Normal condition
During conversion to Check if there is a path Gripper X51.001F Lights up If there is a path where the
perfecting printing, turning where the gripper-A roller shaft gripper-A roller can pass by
cylinder gripper-A is not passes the gripper shaft operation the sensor, please contact
released. operation detector section. detector our customer service.
[Caution]
During conversion to
NEVER restart the device
single-sided printing
in this condition!
operation, turning cylinder
gripper-A does not return.
<Inside the drive side frame>
Gripper shaft operation detector
Turning cylinder Gripper shaft roller

[Problem 25] The encoder setting [SET] position is displayed (Touch panel section)
Normal condition
After home calibration Is the key switch in the Home X50.0011 Not lit If the key switch is at the
operation is finished, the double-size cylinder calibration [SET] position, turn it to the
key switch in the phase encoder key switch [RUN] position.
double-size cylinder phase transformer section ON
encoder transformer turned to the [SET]
section has not been position?
turned to the [RUN]
position.
<Double-size cylinder phase encoder transformer>
Home calibration SET key switch
Lit green: RUN condition

Flashing red: Error condition
Lit orange: Key switch [SET] position

[Problem 26] A sheet decurler ON/OFF stop position error is displayed (Touch panel section) (for extended
delivery specifications)
Normal condition
During sheet decurler ON/ Is the sheet decurler ON/ Sheet X03.000A Lights up If the stop angle is correct
OFF position operation, the OFF position timing decurler (Sequencer but the indicator is not lit,
sheet decurler ON/OFF OFF? ON/OFF inside the check the wiring.
positioning is offset. Check the conversion position main control
home position angle.*1 timing panel)
*1 Sheet decurler ON/OFF position

• The angles listed to the left are the sheet decurler ON/
Sheet decurler ON/OFF position
Unit configuration OFF position standard position angles. A deviation of
standard position angle ±15° from the standard value is acceptable.
3 units 114° • Check the angle on the following unit's timing display:
[on the timing device (DE-TG2) inside the feeder
4 units 202° control panel].
• These angles may be different during perfecting
5 units 290°
conversion tune-up or for configurations with optional
6 units 18° units.
7 units 106°
8 units 194°
9 units 282°
10 units 10°
11 units 98°
12 units 186°

[Problem 27] A sheet decurler operation error is displayed (Touch panel section) (for extended delivery
specifications)
Normal condition
During conversion to Is the sheet decurler OFF Sheet X52.0001 Lights up If sensor input (X52.0001)
perfecting printing, the sensor OFF? decurler is not lit, check the
sheet decurler does not OFF sensor operation of the air cylinder
turn OFF. and the condition of the
Sheet Y54.0008 Lights up
sensor.
decurler
OFF
During conversion to Is the sheet decurler ON Sheet X52.0000 Lights up If sensor input (X52.0000)
single-sided printing, the sensor OFF? decurler is not lit, check the
sheet decurler does not ON sensor operation of the air cylinder
turn ON. and the condition of the
Sheet Y54.0007 Lights up
sensor.
decurler
ON
The sheet decurler OFF Is the sheet decurler ON Sheet Y54.0008 Lights up If sensor input (X52.0000)
sensor or the sheet sensor ON when the decurler lights up, check the
decurler ON sensor is sheet decurler is OFF? OFF operation of the air cylinder
short-circuited. and the condition of the
Sheet X52.0000 Not lit
sensor.
decurler
ON sensor
Is the sheet decurler OFF Sheet Y54.0007 Lights up If sensor input (X52.0001)
sensor ON when the decurler lights up, check the
sheet decurler is ON? ON operation of the air cylinder
and the condition of the
Sheet X52.0001 Not lit
sensor.
decurler
OFF sensor
<Inside the operation side frame>
Sheet decurler OFF sensor
Sheet decurler ON sensor
Sheet decurler ON/OFF air cylinder

[Problem 28] Perfecting conversion return operation does not start
Check the following items after also checking the press “Electric Operation Instructions” Chapter 2 Press
Configuration “How to Read the Interlock Information.”
If the ready alarm does not sound, refer to
“[Phenomenon 2] Ready alarm does not sound” on page
Does the ready alarm sound?
3-3 of “3. Troubleshooting” in the main press Electrical
Manual.
Perfecting interlock information: Is “TUNE UP button on” Check the lamp on the TUNE UP button (1). If the lamp
displayed in the “Perfecting conversion return start not is lit or flashing, press the button (1) of the location that
possible” screen? is flashing to cancel it.
Perfecting interlock information: Is “Feeder on” The feeder is turned on. Operate the machine at low
displayed in the “Perfecting conversion return start not speed (button lamp flashes) and press the FEEDER
possible” screen? ON/TRIP button (2) to turn off the feeder.
If the IMPRESSION ON button (3) lamp is lit, operate
Perfecting interlock information: Is “Cylinders engaged”
the press at low speed (the button lamp flashes) and
displayed in the “Perfecting conversion return start not
then press the FEEDER ON/TRIP button (2) to
possible” screen?
disengage the cylinders.
Perfecting interlock information: Is “Reverse operation
Reverse operation is in progress.
in progress” displayed in the “Perfecting conversion
return start not possible” screen?
Perfecting interlock information: Is “Press operation in
The press is operating.
progress” displayed in the “Perfecting conversion return
Perfecting interlock information: Is “INCH button on” The INCH button (5) is pressed.
displayed in the “Perfecting conversion return start not (Pressing both at the same time is prohibited.)
possible” screen? Check the wiring of the INCH button (5).
Perfecting interlock information: Is “REVERSE INCH The REVERSE INCH button (6) is pressed.
button on” displayed in the “Perfecting conversion return (Pressing both at the same time is prohibited.)
start not possible” screen? Check the wiring of the REVERSE INCH button (6).
Perfecting interlock information: Is “SLOW button on” The SLOW SPEED button (7) is pressed.
displayed in the “Perfecting conversion return start not (Pressing both at the same time is prohibited.)
possible” screen? Check the wiring of the SLOW SPEED button (7).
The LOW SPEED/HIGH SPEED button (8) is pressed.
Perfecting interlock information: Is “LOW SPEED/HIGH
(Pressing both at the same time is prohibited.)
SPEED button on” displayed in the “Perfecting
Check the wiring of the LOW SPEED/HIGH SPEED
conversion return start not possible” screen?
button (8).
Perfecting interlock information: Is “REVERSE button The REVERSE button (9) is pressed.
on” displayed in the “Perfecting conversion return start (Pressing both at the same time is prohibited.)
not possible” screen? Check the wiring of the REVERSE button (9).
Perfecting interlock information: Is “Sheet in press”
A sheet remains in the press. Remove the sheet from
the press.
possible” screen?
Perfecting interlock information: Is “Perfecting Perfecting conversion return is not possible, so return to
conversion return not possible” displayed in the the single-sided printing mode manually and consult
“Perfecting conversion return start not possible” screen? Komori technical service.
Perfecting interlock information: Is “Perfecting
The Release Error button (14) on the touch panel (11) is
conversion error Reset button not pressed” displayed in
not pressed. Press the Release Error button (14) to turn
the “Perfecting conversion return start not possible”
it ON (button lamp lights).
screen?


Perfecting interlock information: Is “Perfecting
The Return Preparation button (15) on the touch panel
conversion return Ready button not pressed” displayed
(11) is not pressed. Press the Return Preparation button
in the “Perfecting conversion return start not possible”
(15) to turn it ON (button lamp lights).
screen?
Perfecting interlock information: Is “Inker clutch
The inker clutch is operating. Check the AMR button
operating” displayed in the “Perfecting conversion return
lamp (16) and wait for the operation to complete.
Product operation is in progress.
Perfecting interlock information: Is “Product operation in If the PRODUCT START/STOP button (17) lamp is
progress” displayed in the “Perfecting conversion return flashing, press the PRODUCT START/STOP button
start not possible” screen? (17) to cancel the product operation, then press the
EMERGENCY STOP button (18) and stop the press.
Perfecting interlock information: Is “Timing device error” If the message is displayed, turn the power off and wait
displayed in the “Perfecting conversion return start not 30 sec before turning it on again. If the message
possible” screen? appears again, consult Komori technical service.
Perfecting interlock information: Is “Register solenoid If the message is displayed, lower the circuit breaker
power outage” displayed in the “Perfecting conversion (CP-FG) (19) or (CP-SG) (20) lever inside the main
return start not possible” screen? control panel and then raise it again (set to ON).
The APC MANUAL ON/OFF button (21) is pressed
Perfecting interlock information: Is “APC manual”
(ON).
Press the APC MANUAL ON/OFF button (21) to cancel
possible” screen?
manual mode. (The button lamp goes off.)
Check the operation of the sucker bar drive section and
Perfecting interlock information: Is “Plate changing C
the position and wiring of the sensor.
Sucker bar error” displayed in the “Perfecting
Check the air pressure.
conversion return start not possible” screen?
(The air pressure is 0.6 MPa (6 kgf/cm2).)
Perfecting interlock information: Is “Perfecting Manual The MANUAL ON button (22) is pressed.
Push Button” displayed in the “Perfecting conversion Press the MANUAL ON button (22) to turn it OFF
return start not possible” screen? (button lamp off).
Perfecting interlock information: Is “Perfecting Manual The MANUAL SWITCHING ON button (23) is pressed.
Change Push Button” displayed in the “Perfecting Press the MANUAL SWITCHING ON button (23) to turn
conversion return start not possible” screen? it OFF (button lamp off).
The CORRECTION TURN STOP button (24) is
Perfecting interlock information: Is “Correction Turn Stop
pressed.
Push Button” displayed in the “Perfecting conversion
Press the CORRECTION TURN STOP button (24) to
return start not possible” screen?
turn it OFF.
Perfecting interlock information: Is “Perfecting cylinder
RESET button (25) to display and cancel the alarm.
sheet drop detector (reflective sensor)” displayed in the
Then remove the dropped sheet from inside the
“Perfecting conversion return start not possible” screen?
machine.
Perfecting interlock information: Is “Perfecting cylinder RESET button (25) to display and cancel the alarm.
sheet drop sensor error” displayed in the “Perfecting Then stop (lock) the press and wipe clean the light
conversion return start not possible” screen? emitting surface and reflective plate of the sheet drop
sensor (26).
Is the perfecting conversion error indicator lit? If the message is displayed, check the error details and
Check the perfecting conversion error monitor and the perform the procedures for the appropriate
message display contents. Troubleshooting item in this section.
Perfecting interlock information: Is “Sheet guide The sheet guide (delivery) axis is not selected.
(delivery) axis not selected” displayed in the “Perfecting Press the Sheet Guide (Delivery) axis select buttons
conversion return start not possible” screen? (27) to select the axis.

[Problem 28] Perfecting conversion return operation does not start (Continued)
Circuit breaker
(19) CP-FG (20)CP-SG (17)
(18)
(3)
(1) (2)
(For U.S. (For non-U.S. (1) (8)

(6)
specifications) specifications)
(5)
(4) (5) (7) (18)
Touch panel
(11)
(18)
(16) (18) (6)

(5)
(1)
(17) (1) (5) (7) (8) (9) (4)

Touch panel
(11)
(26)Turning cylinder sheet drop

detection sensor
Turning cylinder sheet

drop detection sensor
(14) Cylinder
(15) Reflection plate
(25) (27)

[APC manual operation panel]
(21)

operation panel]
(22)
(24)
(23)

5
5Perfecting Conversion
Return Function
Perfecting Conversion Return Function 5–1
Perfecting Conversion Return Function

5-1 Purpose of this function
This function performs the return conversion operation to return the device to the status before perfecting
conversion in order to avoid a situation where perfecting conversion stops (press stops) due to perfecting
conversion trouble. This is an emergency measure to allow press operation.
Note that this function does not eliminate the cause of the trouble, so after the return conversion operation is
completed, consult Komori technical service and inspect, adjust and check the device.
5-2 Outline and functions

This function makes it possible to avoid trouble and perform the return conversion operation when trouble occurs
during perfecting conversion operation.
(1) When trouble occurs, the trouble is avoided so that perfecting conversion operation can be restarted
(continued).
(2) When trouble occurs and perfecting conversion cannot be continued, the automatic return conversion
operation can be performed to return to the status before perfecting conversion.
Single-sided → Restarted but the trouble Automatic return to

Trouble occurs
perfecting occurs again single-sided mode
Perfecting → Restarted but the trouble Automatic return to

Trouble occurs
single-sided occurs again perfecting mode
Perfecting →
perfecting Restarted but the trouble Automatic return to
Trouble occurs
(Sheet size occurs again perfecting mode
conversion)
Single-sided →
single-sided Restarted but the trouble Automatic return to
Trouble occurs
(Sheet size occurs again single-sided mode
conversion)
CAUTION
Notes on the perfecting conversion return function
(1) Depending on the trouble contents, it may not be possible to avoid the trouble or perform the return
conversion operation.
(2) If the trouble cannot be avoided and the return conversion operation cannot be performed, consult Komori
technical service.

5-3 Configuration
[Delivery control panel] AMR button (4)
[Manual operation switches for

perfecting conversion]
[Perfecting conversion
operating screen]
Return Ready Release Error Return Preparation

indicator (3) button (1) button (2)

Operation Procedure
5-1 Automatic return to single-sided mode when trouble occurs during
single-sided → perfecting conversion
Perfecting conversion Perfecting ( ) indicator
operation in progress flashes
Conversion trouble occurs
Release Error button (1) lamp

Release Error button (1) ON
lights up
The step currently in progress

The trouble is avoided
stops (OFF).
Restart (continue) the

Operation conversion operation.
goes out
can be Press the AMR button (4).
restarted
any Trouble occurs again
number of
times. Release Error button (1) lamp
lights up

stops (OFF).
Return Preparation button Return Preparation button (2)

(2) ON lamp lights up
Ready indicator (3) lights up

*1
Press and hold down the AMR
“3. Perfection Conversion Operation Flow”
button (4) for 3 seconds.
Steps 29 and later of the “3-1 Single-sided →
perfecting conversion” processes on pages 3-1
The alarm sounds for 3 seconds. Release the
and 3-9 are the perfecting forced end
AMR button (4) when the alarm stops.
operation.
Press the AMR button (4).
*1
Single-sided return Perfecting ( ) indicator Perfecting conversion
conversion starts goes out forced end
Single-sided ( ) indicator
Perfecting ( ) indicator
flashes
lights up
Ready indicator (3) goes out
Single-sided return Single-sided ( ) indicator

conversion finished lights up

5-2 Automatic return to perfecting mode when trouble occurs during

perfecting → single-sided conversion
Single-sided conversion Single-sided ( ) indicator
operation in progress flashes

lights up

stops (OFF).

goes out
restarted
number of
lights up

stops (OFF).


*2
Steps 32 and later of the “3-2 Perfecting →
single-sided conversion” processes on pages
3-3 and 3-11 are the single-sided forced end
operation.
*2
Perfecting return conversion Single-sided ( ) indicator Single-sided conversion
starts goes out forced end
Perfecting ( ) indicator Single-sided ( )

flashes indicator lights up
Perfecting return conversion Perfecting ( ) indicator

finished lights up

5-3 Automatic return to perfecting mode (original sheet size) when trouble
occurs during perfecting → perfecting (sheet size) conversion
Perfecting (sheet size
Perfecting ( ) indicator
change) conversion
flashes
operation in progress

lights up

stops (OFF).

goes out
restarted
number of
lights up

stops (OFF).


*3
Steps 8 and later of the “3-3 Sheet size
conversion during perfecting printing”
processes on pages 3-5 and 3-13 are the
perfecting forced end operation.
*3
Perfecting (sheet size) return Perfecting ( ) indicator Perfecting conversion
conversion starts flashes forced end
Ready indicator (3) goes out Perfecting ( ) indicator

lights up
Perfecting return conversion Perfecting ( ) indicator
finished lights up

5-4 Automatic return to single-sided mode (original sheet size) when

trouble occurs during single-sided → single-sided (sheet size)
conversion
Single-sided (sheet size
Single-sided ( ) indicator
change) conversion
flashes
operation in progress

lights up

stops (OFF).

goes out
Operation
can be
restarted Trouble occurs again
goes out
any
number of
times. The step currently in progress
stops (OFF).


*4
The alarm sounds for 3 seconds. Release the “3. Perfection Conversion Operation Flow”
AMR button (4) when the alarm stops. Steps 10 and later of the “3-4 Sheet size
conversion during single-sided printing”
processes on pages 3-7 and 3-15 are the
Press the AMR button (4). single-sided forced end operation.
*4
Single-sided (sheet size) Single-sided ( ) indicator Single-sided conversion
return conversion starts flashes forced end
Single-sided ( )
indicator lights up
Single-sided return Single-sided ( ) indicator

conversion finished lights up

5-5 Return Conversion Operations Using STEP FORWARD (step by step)

Conversion operation in [Perfecting conversion operating screen]
progress

Same as
automatic
return
conversion Trouble occurs again
operation up to
this point Release Error button (1) ON
(3) (1) (2)
Return Preparation button
(2) ON
MANUAL SWITCHING ON The AMR button does not need to be pressed.

button (5) ON (Automatic conversion operation is not possible.)
STEP FORWARD button (6)

ON
One step is performed each time the STEP
FORWARD button is pressed.
One step of the return
conversion operation is
performed.
Return conversion finished

operation panel]
(5) (6)

CAUTION
Notes on perfecting conversion return operation.
(1) Return conversion operation enabled range

When trouble occurs, press the Release Error button to stop (OFF) the operation currently in progress, and
then press the Return Preparation button. The return conversion operation is enabled when the Ready
indicator lights.
When the Release Error button is pressed by the trouble is not canceled, or when the Ready indicator does
not light, the return conversion operation is disabled.
(2) Temporary stop and restarting

When a safety device operates during return conversion operation, the return conversion operation is
temporarily stopped.
To restart the return conversion operation, return the safety device to the normal status, then press the AMR
button on the delivery control panel.
(3) When trouble occurs during return conversion

When trouble occurs during return conversion operation, the Release Error button is disabled.
The return conversion operation can be restarted by removing (canceling) the trouble contents.
If the trouble continues or occurs again, the press must be returned to the single-sided mode by manual
operation, so consult Komori technical service.

Perfecting Conversion Step Monitor

5-1 Return conversion operation display monitor
The progress conditions can be checked at this monitor even for individual return conversion operation steps.
Select the return conversion step currently being performed to check the conversion operation conditions.
Example: Checking the progress conditions at the perfecting display monitor during single-sided → perfecting
conversion
[Perfecting operation display monitor screen]
Perfecting selector button
When an error occurs and single-sided return conversion operation is started, the single-sided return
conversion operation progress conditions can be checked by selecting the single-sided ( ) selector
button.
[Single-sided operation display monitor screen]
Single-sided selector button

5-2 Trouble Step Check Monitor

When trouble occurs during perfecting conversion operation, the indicators for conversion operation steps that
were completed light up, and the indicators for steps after the location where the trouble occurred remain off.
Select the conversion step monitor and press the Check button to check the conversion operation step where
the trouble occurred.
[Single-sided operation display monitor screen]
Press the Check button to check the conversion operation conditions when an error occurs. Press
the Check button again to return the screen to the original status.
Operations were completed

for locations with lit
indicators.
Trouble occurred in this next conversion operation step.
CAUTION
The conversion operation conditions cannot be checked while the perfecting conversion operation is in
progress, even by pressing the Check button.
The Check Monitor is valid when perfecting conversion operation is not in progress.

6
6Maintenance
Maintenance 6–1
Maintenance
CAUTION
Be sure to read and fully understand the “Safety Precautions” before operation.
6-1 Encoder home calibration (Double-size cylinder phase encoder)

Encoder home calibration is performed at the factory before shipping, so this normally never needs to be adjusted.
However, in the following cases, re-calibrate according to the procedure described below.
1. If the encoder or encoder amp has been replaced due to an encoder error.
2. If the encoder has been removed from the press and the reattached.
3. After home stop position (home stop timing) adjustment.
Configuration
Double-size cylinder phase encoder
DECELERATION
POSITION DECELERATION POSITION
SINGLE-SIDE RETURN READY CORRECTION TURN CORRECTION SINGLE-SIDE SIGLE-SIDE RETURN CORRECTION CANCEL
(2) Key switch
(3) DECELERATION (1) DECELERATION Double-size cylinder phase

POSITION POSITION encoder transformer
CORRECTION CORRECTION CANCEL

Maintenance 6–2
Drive side internal view Turning cylinder gear
Pointer
Single-sided
Single-sided
position scale
position scale
Pointer
Suction cylinder grip release cam gear

Maintenance 6–3
Procedure Home calibration operation flow

Set the press to single-sided printing. (Check that [DECELERATION POSITION
pointers on the scale in the turning cylinder gear CORRECTION] switch ON
section and on the suction cylinder grip release
Step 1 cam scale point to single-sided printing.)
Ready alarm
Auxiliary motor gear ON operation

Insert the key in the [DECELERATION
POSITION CORRECTION CANCEL] key switch Auxiliary motor rotates.
Step 2
(1) and turn it ON. (Insert the key and turn it
clockwise to turn it ON.) (The press starts moving.)
Once the key is turned ON, return it to the original Stopping at home position<*1>
Step 3 position and remove it.
Turning cylinder brake ON operation

Step 4 Check whether the press is in runable condition.
Encoder home calibration
Turn the double-size cylinder phase encoder
transformer key switch (2) to [SET]. (When the Turning cylinder brake OFF operation
Step 5 key is turned to SET, the [STATUS] indicator
lights up orange.)
Auxiliary motor gear OFF operation
Press the [DECELERATION POSITION Home calibration operation finishing

CORRECTION] switch (3). alarm
• Home calibration is performed.
(The operation proceeds as in the flow-chart at
Step 6 Completion
right.)
When the home calibration operation is
finished, an alarm (perfecting conversion error)
sounds for a set time. <*1>
Check the home stop position angle.

Please refer to the table [Conversion
Return the double-size cylinder phase encoder
transformer key switch (2) to the [RUN] position. stop position angles] on page 2-12.
Step 7 (When the switch is returned to RUN, the
[STATUS] indicator lights up green.)
This completes the adjustment.

Maintenance 6–4
6-2 Controlled single-sided recovery

If during perfecting conversion some problem (e.g. an error) occurs that cannot be circumvented, the press must be
restored to single-sided printing using the manual operation switches. This section describes the procedure for
controlled recovery to single-sided printing.
CAUTION
Never used this procedure except for single-sided recovery. If the press is set to perfecting printing and
single-sided recovery is performed, the press can be seriously damaged. Make absolutely sure that the
press is set to single-sided printing before starting the single-sided recovery procedure.
In addition, make sure that the suction head position is the smallest sheet size position before pressing the
SINGLE-SIDE RESET button.
Never use the SINGLE-SIDE RESET button when the suction head position is not the smallest sheet size
position.
DECELERATION
POSITION
(1) SINGLE-SIDE RETURN (3) SINGLE-SIDE (2) SINGLE-SIDE RETURN

READY RESET ON
OFF (O) ON (I)

Maintenance 6–5
<*1> Conversion home position Procedure

Perfecting Conversion home Check if the press has returned to the
mechanism position standard angle Step 1 single-sided state.
Between 3C and 4C 37° Set the press at the conversion home
position angle.
Between 4C and 5C 125° Step 2
<*1>
Insert the key into the [SINGLE-SIDE
RETURN READY] key switch (1), and
Step 3
turn it to the [ON] position.
Press the [SINGLE-SIDE RETURN ON]

switch (2), so that the switch indicator
Step 4
lights up and manual single-sided
recovery is enabled.
When the [SINGLE-SIDE RESET] switch

(3) is pressed, an alarm (perfecting
conversion error) sounds for 5 seconds,
Step 5 and the [SINGLE-SIDE RETURN ON]
switch (2) indicator goes out. (When the
indicator goes out, the single-sided
recovery is finished.)
Turn the [SINGLE-SIDE RETURN

Step 6 READY] key switch (1) to [OFF] and
remove the key.
This completes the single-sided recovery process.

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Automatic perfecting

3. Perfection Conversion Operation Flow

4. Problems and Remedies

LS40P-GFH EN EO 0410 06 ANSI

5. Perfecting Conversion Return Function

LS40P-GFH EN EO 0410 06 ANSI

Purpose of This Device

Scope of Warranty and Warranty Exclusions

Purpose and General Outline of This Manual

Warning of Changes Made of Product Specifications

Safety Precautions in This Manual

Using the Safety Devices

Safety Precautions during Daily Work

LS40P-GFH EN EO 0410 05 ANSI

Safety Precautions during Maintenance, Inspection and Adjustment

LS40P-GFH EN EO 0410 05 ANSI

Touch Panel Handling

LS40P-GFH EN EO 0410 05 ANSI

Two types of labels are used on this press to ensure safety:

(1) Basic format of warning labels

Danger level indication (warning symbol)

Danger element pictogram (symbol)

Explanation on how to avoid danger (text message)

(2) Classification of danger levels

LS40P-GFH EN EO 0410 05 ANSI

Perfecting conversion mechanism section

Perfecting control panel

Perfecting manual operation switches

Perfecting conversion operating screen

Perfecting conversion operation monitor

Perfecting conversion error monitor screen

LS40P-GFH EN EO 0410 03 ANSI

1-2 Perfecting electrical parts

2) Auxiliary motor gear ON sensor

3) Suction cylinder release cam gear ON sensor

4) W-gear release (ON) sensor

5) Suction cylinder release cam limit sensor

6) Gripper shaft motion detector

7) Reflecting-type sheet drop detector

8) Sheet guide (turning cylinder lower) motor

9) Sheet guide (turning cylinder lower) motor potentiometer

LS40P-GFH EN EO 0410 03 ANSI

9” Turning cylinder 6” 7” 8” Solenoid valve unit box

1”) Rear unit phase encoder

2”) Turning cylinder A gripper pin ON sensor

9”) Turning cylinder home positioning sensor

10”)Turning cylinder operation side cover

11”)Turning cylinder unit footboard

LS40P-GFH EN EO 0410 03 ANSI

(E) (B) (A)

(A) Transport belt drive motor

(B) Sheet decurler ON/OFF solenoid valve

(C) Sheet decurler ON sensor

(D) Sheet guide (delivery) motor

(E) Sheet guide (delivery) motor potentiometer

LS40P-GFH EN EO 0410 03 ANSI

Transport belt encoder

Extended delivery panel

LS40P-GFH EN EO 0410 03 ANSI

(Perfecting conversion operating screen)

For extended delivery

LS40P-GFH EN EO 0410 06 ANSI

Description of the control buttons

Conversion to single-sided printing finished. 1 1