Z51508-01 M600 CPTronic - Troubleshooting Guide

Heidelberg Web Press SA
Square H. Marinoni BP 70149

60761 MONTATAIRE Cedex
FRANCE
Tel : +33 (0)3 44 29 40 00
Fax : +33 (0)3 44 27 40 73
It is strongly recommended not to operate this machine, or to adjust or service it,

before having carefully read and understood the instructions given in this manual.
M − 600
CPTronic
Troubleshooting guide
Z51508 March 1986
The information contained in this document is subject to change without notice. No part of this manual may be
reproduced or transmitted for whatever reason and by whatever means, without the written consent of Heidelberg Web
Press.
1. Start - up
2. Function and
Components
3. Diagnostic
1. Start - up Table of contents
General
1.1 Equipment identification

1.2 Position codes
1.4 Abbreviations
1.6 Wiring principle
1.7 Identification of the cable ducts
1.9 Danger signs and indicator plats
HEIDELBERG HARRIS 03.96

1. Start - up Table of contents

General Equipment identification
General
Equipment identification
Position code Identification letter or Number

Abbreviation
To distinguish equipment
Where on the machine ? What on the machine ?
of the same type
Example 1: 23 LVT1
23 LVT 1
Folder Distribution box No. 1
Example 2: 023Q18
023 Q 18
0 : in the control cabinet Power switchgear; in this case: No. 18

23 : for the folder motor overload switch (turner bar blower)
For the general electro−technical equipment we use

the standardized abbreviations.
B Measuring converters
E Miscellany
F Protective devices (e.g. fuses)
H Signalling devices (e.g. lamps)
K Relays, contactors
L Inductors
M Motors
N Amplifiers, controllers
Q Power switchgear
R Resistor
S Switches
T Transformers
X Terminals, connectors, sockets
Y Electrically actuated mechanisms
(e.g. pneumatic valves)
Note:
You will find a list of position codes and abbrevi−
ations on the next pages.
− 1.1 −
General Position codes
Post − Unit section
Dryer section
Dampening washer
preparation unit.
Ink distributor temperature
control
CPTronic section
Post − Unit section

Three − phase
power section
Imprinting unit section

position codes
− 1.2 −
General Position codes
Position codes Overview of position codes:

The position code indicates in which unit of the 0 Control cabinet
press the equipment in question is located. 1...12 Printing unit 1.... printing unit 12
Position codes starting with 0 (control cabinet) 13, 14 Splicer 1, 2
may receive asecond figure indicating the unit, the 15, 16 Infeed unit 1, 2
equipment. 17, 18 Dryer 1, 2
19, 20 Chill rollers 1, 2
21,22 superstructure 1,2
The chapter covering position code 0 is divided in (in the wiring diagram is meaning:
two sections in the wiring diagram: Y1 − bottom superstructure JF50 / JF50s
− Control cabinet Printing Unit Y2 − top superstructure JF50 / JF50s
− Control cabinet Post−Unit Y3 − bottom superstructure JF44
Y4 − top superstructure JF44)
When counting the PUs "electrically" make sure to 23, 24 Folder 1, 2
count from the web catcher to the infeed. (in the wiring diagram is meaning:
Z0 − JF50
Z1 − JF50s
Z2 − JF44)
25 Sheeter
26 Main control console Master−CPTRONIC
27,28 Main control console Post−Unit−CPTRONIC 1,2
29, 30 Main drive printing units 1, 2
33 Main drive Post−Unit
39, 40 Ink distributor temperature control
41, 42 Dampening water preparation unit
43, 44 Compressed air supply
45 gluing device
59, 60 Web catcher
63 Imprinting unit
65 Perforating unit
66 Four page module on the first folder
67 Four page module on the second folder
68, 69 Blanket wash−up device
70 additionaly web edge control
80 Cooling water supply unit
90, 91 Standard interface 1, 2 Post−Unit
96, 97 Standard interface 1, 2 Master
HEIDELBERG HARRIS 03 − 96
− 1.3 −
General Abbreviations
Abbreviations
A.S. Drive side of the press HAE Auxiliary drive plug−in unit
AAM Analogue output module HAK Auxiliary drive board
HAR Backplane of auxiliary drive plug−in unit
BAM Brake control module HWI Encoder
BBF Silicon applicator
BBS Web break detector IWM Earth−leakage monitor module
BFV Web catcher
BKR Web edge control KOK Communication board
BTV Web severing device KSK Bridging board
KW Chill rollers
CPC Computer Print Control KWZ Cooling water supply unit
DDW Double printing unit LTE Power part plug−in unit

DGP Basic display board LTK Power part board
DNK Display power supply board LTM power part module
D.S. Drive side of the machine LTR Backplane of power part plug − in unit
DSK Display control board LVT Distribution box
EAE Input/output plug−in unit MID Press display

EAK Input/output board MSS Motor overload switch
EAR Backplane of input/output plug−in unit MZS Machine status signal
EDW Imprinting unit
EHE Auxiliary drive input/output plug−in unit NTK Power supply board
EHR Backplane of auxiliary drive input/output
plug − in unit O.S. Operator side of the machine
ENM Infeed power supply module
EPM EPROM module PU Printing unit
ERE Infeed computer plug−in unit PW Perforating unit
ERK Infeed control board
ERR Infeed backplane of computer REE Computer plug−in unit
plug−in unit REK Computer board
ESK Input/output control board RER/M Backplane of computer plug−in unit,
EUM Safety module Post−Unit−CP TRONIC
EXK Copy monitoring RER/M1 Backplane of computer plug−in unit,
EZW Infeed Master−CPTRONIC
RER/M2 Backplane of computer plug−in unit,
FA Folder Printfunction1−CPTRONIC
FAM Flat cable output module RGP Basic computer p.c.b.
FAZ Dampening water preparation unit RL Round cable
FDK Telediagnosis board RQ Sheeter
FEM Flat cable input module RW Splicer
FKM Flat cable module
FLK Flat cable SAK Memory analog board
FRT Ink distributor temperature control SBM Power bridge module
FRR Color register control SAM Interface output module
FVM Flat cable connection module SEK Safety input board
SEM Interface input module
GFM Synchronization module SLT Power converter power part
GLK Synchronization control board SPM Memory analog board module
GRM Rectifier module SRK Power converter board
GTW Blanket wash−up device SRR Cut−off register control
− 1.4 −
General Abbreviations
STS Vacuum cleaner

SSE Servo drive plug−in unit
SSK Servo drive control board
SSM Servo drive control module
SSR Backplane of servo drive plug−in unit
SVM Interface distributor module
SVT Connecting part of the power converter
SZM Interface hardwire module
TR Dryer
TVK Key distributor board
TVM Encoder distribution module
TVS Encoder distribution system
VSM Amplifier module
ZAR Double drive adapter backplane

ZID Control console display
− 1.5 −
General W iring principle
On delivery, almost all cables between the control

Wiring principle cabinets and the machine units or optional
equipment are connected to the control cabinet
sections and located in the upper cable ducts from
where they are led to the different press units.
At the end of each cable an inscription gives you

the position code or the name of the device the
cable has to be led to.
Connect these cables to the corresponding units.
Cable identification
The abbreviations used in the tables are included The number of connections to be made makes it
in the list of abbreviations at the beginning of this necessary to show the routing and connection of
chapter. the cables in the form of a table which looks as
follows:
Connector
Connector
S tarting point Type of cable, Destination Routing
Single
Single
cores
cores
cable
designation
EAR1.2: 11X1A D X 20FLK, 1EA1 1LVT1FAM64 − 1: 1X1A X BC
Cable routing is indicated in the last column. The

letters in this column are the result of the division
of the cable ducts into certain sections, as shown
on the next two pages.
If the cable in question is a flat cable, you find the

abbreviation "FLK in the column "Type of cable,
cable designation, and "RL" for a round cable.
If, on delivery of the machine, the cables are

already connected up at the starting point or
destination, you will find the sign " D " in the
corresponding column. In this case, this end of
the cable does not have to be connected.
The Table for connections of the press, are

enclosures of the wiring diagram.
− 1.6 −
General
Connection point
Connection point
63 LVT1
X LVT1 3 LVT1 2 LVT1 1 LVT1
15
LVT1
HEIDELBERG HARRIS
- 1.7 -
Control cabinets
E
A
B Connection F
Connection point
point
Identification of the cable ducts

C C
Imprintin
Splicer Infeed g Unit PU PU PU PU Dryer
D
Web-
catcher
console
03.96
General
23 LVT4 23 LVT3 24 LVT3
19 LVT1
23 LVT1 23 LVT2 24 LVT2
HEIDELBERG HARRIS
24 LVT1
− 1.8 −
E
K
Identification
H
N
Chill I O
Dryer rollers
L
Folder
G
of
the
M
cable
ducts
03.96
General Danger signs and indicator plates
Danger signs and indicator plates

On the control cabinet of the M600 are mounting
diferent danger signs and indicator plates.
Nameplate:
press model
X
X serial number
XXXXXX
XXX V X XX Hz
main supply voltage, voltage system,
XXX A / XXX kW
frequency
XXX A
nominal current/nominal power
xx.xxx.xxxx
recommended back - up fuse
ACHTUNG!
Alle Schrauben im Schaltgerät müssen bei Inbetriebnahme
1. SCHALTSCHRANK BEIM LAUF DER MASCHINE IMMMER
der Maschine nachgezogen werden.
VERSCHLIESSEN.
2. KEINE ZUSÄTZLICHEN ELEKTROGERÄTE IM SCHALT-

All screws in the control box must be tighened befor the
SCHRANK ANSCHLIESSEN.
machine is being put into operation.
BEI NICHTBEFOLGEN ERLISCHT DIE FABRIK-GARANTIE

Toutes les vis dans la boite de commande doivent être bien
FÜR DIE ELEKTRISCHE EINRICHTUNG.
serrées avant de mettre la machine en fonction.
Todos los tornillos en la caja de mandos tienen que volver

a atornillarse bien antes de meter la mãquina en marcha.
Tutte le viti nel impianto di commando devono essere

strinti bene prima di mettere la macchina in funzione.
ACHTUNG! Alle elektrischen Kontakte in diesem Schaltschrank haben

eine Silberkadmium-Oxid-Oberfläche, die nicht zu reinigen ist. Kein
Kontaktfett benutzen!
ATTENTION! All conact in this control box are equipped with a silver
cadmium surface requiring no maintenance. Do not use contact sprays
or contact lubricats!
ATTENTION! Tous les contacts dans cette armoir de commande

possèdent une surface en cadmiumargent qui ne doît jamais être
nettoyée. Ne pas utiliser des graisses ou liquides etc. de nettoyage pour
contacts!
- 1.9 -
General Danger signs and indicator plates
Fixing points of the danger signs and indicator plates
0Q1 0Q2
0Q1 0Q2
Main switch cabinet Print-Unit
0Q1
0Q1
Transformer cabinet Post-Unit
- 1.10 -
2. Components and function Table of contents
2.1 General
2.2 Main drives
2.3 Servo drives
2.4 Voltage supply
2.5 Oil supply
2.6 Location diagram
− 1.0 −
2. Components and function Table of contents
− 1.1 −
2.1 General Table of contents
2.1 General
2.1.1 CPTRONIC overview

2.1.2 Overview CPTRONIC control
2.1.3 Infeed CPTRONIC
2.1.4 Imprinting unit CPTRONIC
2.1.5 Master CPTRONIC (standard and guiding press)
2.1.6 Master CPTRONIC plug-in units (standard and guiding press)
2.1.7 Master CPTRONIC plug-in units (two-web configuration)
2.1.8 Master CPTRONIC plug-in units (Duplex following press)
2.1.9 Printfunction CPTRONIC
2.1.10 Plug-in units Printfunction CPTRONIC1/Printfunction CPTRONIC2
2.1.11 Post-Unit CPTRONIC (standard configuration)
2.1.12 Plug-in units Post Unit CPTRONIC (standard configuration)
2.1.13 Post-Unit CPTRONIC (special configuration)
2.1.14 Plug-in units Post Unit CPTRONIC (special configuration)
2.1.15 Ideograms of the operator panel infeed and printing unit
2.1.16 Ideograms of the operator panel chill roller and folder

2.1 General Table of contents

2.1 General CPTRONIC overview
General
CPTRONIC overview
For machine control different control groups are The various control systems are in the control
combined: cabinets (see ”Start-up/General”).
- The Infeed CPTRONIC for closed-loop control of The CPTRONIC control system is of modular design. It
the infeed unit drive. comprises different function blocks which have been
- The Imprinting -Unit CPTRONIC for closed-loop developed for certain tasks (e.g. servo drives, digital
control of the imprinting-unit drive. inputs/outputs etc.).
- The Master CPTRONIC for closed-loop control of Each control group on the M 600 therefore is a
the printing unit drive and of all functions not configuration of function blocks designed to meet its
directly attributable to printing - from the splicer special requirements.
to the web severing device and web catcher.
- The Printfunction CPTRONIC for open-loop The present chapter gives an overview of the
control of all printing-related functions. different configurations, and the subsequent chapters
- The Post-Unit CPTRONIC for the drives at the describe the individual function blocks.
chill rollers, folder and superstructure and for
open-loop control of all installations existing
there.
Infeed Imprinting-Unit Master Printfunction Post-Unit

CPTRONIC CPTRONIC CPTRONIC CPTRONIC CPTRONIC
Main drive Imprinting-Unit Main drive Main drive

drive
Infeed Unit Imprinting Printing-Units Chill Folder

Unit rollers
Machine control diagram

Apart from the Infeed CPTRONIC, all control
systems need a swing frame to accommodate the
individual plug-in units. Into each of these plug-in
units electronic boards are inserted, arranged in
groups.
− 2.1.1 −
EUM EUM
2.1 General
Interface adapter
Dampening Ink distributor
Infeed cabinet Master Printfunction
water preparation temperature
CPTRONIC CPTRONIC CPTRONIC Dryer Post−Unit
GTW Main connection unit control
CPTRONIC
HWI
HD
HWI
Chill rollers HWI
Ink Ink WEB Dryer
HEIDELBERG HARRIS
Splicer Infeed
LVT zones LVT zones catcher
BKS HWI FE FE
BKS servo
drive
ÖT ÖT
SR UR FA SR UR FA
SchR SchR BKR cutt − off
BKR register
LVT Web
GR GR tension
− 2.1.2 −
Web measurem
ent LVT
MID tension FA SR UR SchR FA SR UR SchR
measurem Silico n
ent applicat Folder
FE FE or
BE Ink LVT Ink LVT CPC
zones zones 4-W LVT LVT
Abbreviations:
BE Web up device
Overwiew CP
BKR Web edge control
BKS Web edge searching device
FA Ink fountain roller motors CPTRONIC CPTRONIC
console console
CPC1 lower Web CPC1 upper Web
FE Dampening ductor motors
GR Unit − to − unit register
TRONIC
HD Harmonic Drive
HWI Encoder
LVT Cable distributor
− control
MID Display
Inputs/Outputs, digital, analogue, serial
ÖT Oil temperature
Servo drives
SchR Diagonal register
Auxillary drives
SR Lateral register
Other connections
03.96
UR Circumferential register
2.1 General Infeed CPTRONIC
Infeed CPTRONIC
The Infeed CPTRONIC is located in the infeed cabinet.
The infeed computer plug-in unit ERE contains the
following boards.
REK REK NTK 5: Power supply board 5V DC

NTK5
ERK SRK ERK SRK ERK : Infeed control board
REK : Processor board
SRK : Power converter board
two - web The Infeed CPTRONIC controls the speed of the draw
roller of the infeed.
There are two different operating modes of the
Plug-in unit ERE infeed:
In operating mode 1 the draw roller of the infeed runs
at a lower speed than the printing unit group
(Master). This builds up web tension. Speed is
indicated by an encoder HWI fitted at the draw roller.
For operating mode 1 the speed information provided
by the HWI of the printing unit group is used in
addition. With this information from the HWI,
proportional running of the main drives is achieved
which, in turn, regulates the speed.
In operating mode 2 it is not directly the speed of the
draw roller which is regulated, but through the draw
roller (draw roller as controlling element) the position
HWI signal PU of the double dancer is controlled (position deter-
mination by means of potentiometer). Thus the
preset web tension is kept constant (see chapter
ERE ”Main drives”/Web tension control). Presetting is
achieved by means of the air pressure for the
M Main drive SEK pneumatic cylinder acting on the double dancer.
− SLT
control
Switching over between operating mode 1 and
Master EAK operating mode 2 takes place
HWI
1 - if the contact pressure roller is on,
Potentiometer - if the web tension is 50N
feedback - and if the main drive of the printing unit and
web tension the main drive of the Post-Unit run in syn-
chronism as far as speed and angle
are concerned.
Switching over is carried out by the Master CPTRONIC.
Central
control
The Infeed CPTRONIC is connected with the Master
Commu−
nication via the serial interface. Additionally, there is a parallel
with Master− interface (EAK and SEK signals) to the Master
CPTRONIC CPTRONIC.
All main motors (EZW, DDW, Post-Unit) are in

general decelerated electrically. Should there be an
emergency, a mechanical brake is integrated in the
motor which decelerates the motor in case of failure
Infeed CPTRONIC diagram of the electronics.
− 2.1.3 −
2.1 General Imprinting - Unit CPTRONIC
Imprinting-unit CPTRONIC
The imprinting-unit CPTRONIC is located in the
imprinting-unit cabinet. The plug-in unit contains the
following boards.
MSK NTK 5: Power supply board 5V DC

NTK5 TPK : Transputer board
TPK TPK
MSK : Motor control board
The imprinting-unit CPTRONIC controls and

monitorings the speed of the imprinting-unit drive.
The imprinting-unit drive speedy the respective
printing unit (top or down) to the press speed.
Plug-in unit TPE Speed is indicated by an encoder HWI fitted at each
printing unit. The printing unit speed be compared to
the press speed.
The imprinting-unit motor is a brushless D.C.motor,

which is in general decelerated electrically. Only at
standstill of the imprinting-unit drive and an
emergency, a mechanical brake is integrated in the
motor which decelerates the motor.
The imprinting-unit CPTRONIC is connected with the

Master via the serial interface. Additionally, there is a
parallel interface (EAK signals). Here is the operating
HWI Signal PU status (incing, run) pretended.
TPE
M drive
− BLT
control
HWI
1
HWI
2
central
control
Communica
tion with
Master−CPT
RONIC
Master EAK
Imprinting-unit CPTRONIC diagram
− 2.1.4 −
2.1 General Master CPTRONIC
Master CPTRONIC (Standard and Guiding press)

The Master CPTRONIC holds a special position The pushbuttons and lamps of those machine
within the control system. operating panels and valves which are not directly
Via the serial interface the Master CPTRONIC keeps printing-related are read in or controlled via the
in touch with the other CPTRONICs. The Master input/output boards of the Master CPTRONIC (see
determines and actively performs the exchange of chapter "Digital inputs/outputs”).
information.
The EAKs in the plug-in unit 1.1 are responsible
The Master CPTRONIC controls the speed of the for the buttons and lamps of the console, for the
printing unit groups or can position the printing contactors, auxiliary contacts and parallel
units at a certain circumferential angle (plate interfaces to the other control systems. Further,
mounting position). This is carried out by the the infeed, splicer and web catcher are connected.
function block of the main drives which comprises
a part of the REE/M1 and which, with the help of The EAKs in the plug-in unit EAE 1.2 are
the converter power part SLT and the d.c. motor responsible for the operator control elements not
with brushes, controls the speed of the printing unit directly involved in the printing process (e.g. crawl
group (see chapter " Main drives" ). Speed and speed, run, safe) and for the safety limit switches
position are indicated by an encoder (HWI) at the and valves of the pneumatic clutches at the
printing unit in front of the dryer. The signals of this printing units (see chapter "Digital inputs/out-
HWI are additionally passed to the Infeed, puts”).
Post-Unit and Printfunction CPTRONIC.
The safety limit switches at the guards and the
Via the function block of the Master CPTRONIC the EMERGENCY STOP buttons are connected to
servo drives, the web edge sensors and the web the EAKs and, redundantly, to the safety input
infeed device at the infeed are positioned. This boards SEK in the two input/output plug-in units
positioning is effected by means of d.c. motors with EAE 1.1 and EAE 1.2.
brushes which are connected to the servo drive
plug-in unit (see chapter ”Servo drives”). The function blocks of the digital inputs/outputs
and the encoder HWI are connected to the
The CPTRONIC control console for machine processing part. The console electronics, the
operation is connected to the Master CPTRONIC function block of the servo drives and of the main
(see chapter ”CPTRONIC console”). drive are directly connected with the central
control.
REE/M1 EAE 1.1

M SLT Main Safety inputs 1
−
drive
control
HWI TVM Input/output 1
1 Input/output con−
EZW CPTRONIC trol 1
Post−Unit CPTRONIC
Follower press
Master and Post − Unit
EAE 1.2
CPTRONIC
console Central con− Safety inputs 2
Communication with trol
other CPTRONICs SSE 1.1 PU’s
Input/output 2
SSK
1−3 Input/output con−
trol 2
Master CPTRONIC diagram (Guiding press)
− 2.1.5 −
2.1 General Master CPTRONIC plug-in units
Master CPTRONIC plug -in units (Standard and guiding press)

The Master CPTRONIC is located in the CPTRONIC
section. It comprises several plug-in units.
NTK5
The input/output plug-in units EAE 1.2/1.1 contain
EAE 1.2 EAK12 EAK1
the following boards (for allocation of boards see
SEK2
”Digital inputs/outputs”):
SEK 1/2 Safety input board

NTK24
SAK REK2 ESK1 SRK NTK5 Power supply board 5V DC
REE/M1 EAE 1.2:
REK3 ESK2 REK1 KSK
NTK5 EAK 1 ... 12: Input/output board depending on
the number of DDW
EAE 1.1:
EAK1 EAK 1: CPTRONIC console
NTK5
NTK5 EAK11
EAK2
EAK 2: control cabinet, board 1
EAE 1.1 EAK12 EAK3 EAK 3: control cabinet, board 2
SEK1 EAK4 EAK 4: Splicer/Infeed
EAK11: Parallel-Bus -Communication (only at
Duplex)
EAK12: General press functions
NTK24/1
SSE 1.1 SSK3 SSK1
The computer plug-in unit REE/M1 contains the
NTK24/2 SSK2
following boards:
KSK Bridging board

SRK Power converter board
NTK24/1
SSE 2.1 SSK3 SSK1 REK 1 Processor board 1
(to Printfunction NTK24/2
SSK2 ESK 1 Input/output control board 1
CPTRONIC)
ESK 2 Input/output control board 2
REK 2 Processor board 2
Master CPTRONIC plug-in units SAK Memory analog board
NTK5/24 Power supply boards 5V/24V DC
The servo drive plug-in units SSE 1.1/2.1 contain the

following boards (for allocation of boards see ”Servo
drives”):
SSK 1 ... 3 Servo drive control board

NTK24 Power supply boards 24V DC
Because of the functions is has to fulfill and

because of its wiring (servo drive control for
diagonal and unit-to -unit registers, oil
temperature of the printing units), the SSE 2.1
belongs to the Printfunction CPTRONIC.
− 2.1.6 −
Master CPTRONIC plug -in units (two -web configuration)

NTK5
EAE 1.2 EAK12 EAK1
SEK2

NTK24 ZAR
SAK REK2 ESK1 SRK1
NTK5 Power supply board 5V DC
REE/M1 EAE 1.2:
REK3 ESK2 REK1 SRK2
the number of DDW
EAE 1.1:
EAK5 EAK1 EAK 1: CPTRONIC console
NTK5
NTK5 EAK2
EAK6 EAK 2: control cabinet, board 1
EAK 5: control cabinet, board 3 (two-web)
EAK 6: Splicer/Infeed (two-web)
NTK24/1
SSE 1.1 SSK3 SSK1
NTK24/2 SSK2
following boards:
ZAR Double drive adapter backplane

SRK1 Power converter board (drive 1)
NTK24/1
SSE 2.1 SSK3 SSK1 SRK2 Power converter board (drive 2)
SSK2 REK 1 Processor board 1
CPTRONIC)
Master CPTRONIC plug-in units REK 3 Processor board 3
SAK Memory analog board
NTK5/24 Power supply boards 5V/24V DC

drives”):


− 2.1.7 −
Master CPTRONIC plug -in units (Duplex follower press)

NTK5
EAE 1.2 EAK12 EAK1
SEK2

NTK24
SAK REK2 ESK1 SRK NTK5 Power supply board 5V DC
REE/M1 EAE 1.2:
REK3 ESK2 REK1 GLK
the number of DDW
EAE 1.1:
EAK5 EAK1 EAK 1: CPTRONIC console
NTK5
NTK5 EAK2
EAK6 EAK 2: control cabinet, board 1
EAK11: Parallel-Bus -Communication
NTK24/1
SSE 1.1 The computer plug-in unit REE/M1 contains the
SSK3 SSK1
following boards:
NTK24/2 SSK2
GLK Synchronization control board

NTK24/1
SSE 2.1 SSK3 SSK1 ESK 1 Input/output control board 1
SSK2 ESK 2 Input/output control board 2
CPTRONIC)
Master CPTRONIC plug-in units NTK5/24 Power supply boards 5V/24V DC

drives”):


− 2.1.8 −
2.1 General Printfunction CPTRONIC
Printfunction CPTRONIC
The Printfunction CPTRONIC controls all printing-re- The auxiliary drive boards HAK in plug-in unit HAE
lated functions of the M-600. 2.1 are used for speed control of the dampening
ductors. One HAK can control max. three motors.
For operation and control of the ink zones, of the The power part boards LTK500 (in the LTE
circumferential and lateral registers, for operation 2.1/2.2) convert the control information provided by
of the diagonal register and for setting the ink the HAKs into the energy required by the
fountain roller and dampening ductor per cent brushless dampening ductor motors.
values, the two CPC 1 are connected. Each LTK500 can control up to two motors with a
maximum continuous rating of 500W.
The diagonal and unit-to -unit registers are
operated and controlled from the CPTRONIC The ink fountain roller speed is controlled via the
console. The servo motors of these registers are HAK in plug-in unit HAE 2.2. As power parts for
positioned via the servo drive plug-in unit SSE 2.1 the ink fountain rollers the power part modules
(Master CPTRONIC cabinet). LTM1000 are, however, used. Each LTM can
control one brushless ink fountain roller motor with
Via the EAK in the input/output plug-in unit 2.2 the a max. continuous rating of up to 1000W.
printing-related buttons and lamps (e.g. "Impres-
sion on") of the operating panels as well as the Via the input/output control, the function blocks of
valves of the printing-related pneumatic cylinders the digital inputs/outputs and of the auxiliary drives
(e.g. "Plate inking rollers on") are read in or are connected to the central control (processing
controlled. part of the Printfunction CPTRONIC). The CPC 1
consoles and the function block of the servo drives
The Auxiliary drive boards HAK in the plug-in unit are directly connected with the central control.
HAE2.1 serve for speed control of the dampening
ductors. The Printfunction CPTRONIC is connected to the
Master via the serial interface only.
REE/M2 HAE 2.1 LTE 2.1/2.2

M
−
Input/output Auxiliary drives
control 1 Auxiliary drives
power part
control part 1 M−
LTK
Communication with
other CPTRONICs
Sensor Sensor
bottom top
Central
CPC4W
control
bottom top
EAE 2.2
CPC 1 CPC 1 Input/output 2

bottom top
HAE 2.2
SSE 2.1
Auxiliary
SSK Input/output Auxiliary drives drives
1−3 control 2 control part 2 power part M−
(LTM)
Printfunction CPTRONIC diagram
− 2.1.9 −
2.1 General Printfunction CPTRONIC plug-in units
Plug-in units Printfunction CPTRONIC 1 / Printfunction CPTRONIC 2
Printfunction CPTRONIC 1: The Printfunction CPTRONIC 1/2 is located in the

CPTRONIC section. The Printfunction CPTRONIC 1
comprises several plug-in units:
EAE2.2 EAK12
NTK5 EAK1
The input/output plug-in unit EAE 2.2 contains the
following boards (for allocation of boards see chapter
NTK24
SAK REK2 ESK1
EAK1 ... 12 Input/output boards
REE/M2 NTK5 REK3 ESK2 (one per Print-Unit)

following boards:
LTK500/5 LTK500/4 LTK500/3 LTK500/2 LTK500/1
LTE2.1
ESK1 Input/output control board 1
ESK2 Input/output control board 2
REK2 Processor board 2
HAK10 HAK7 HAK4 HAK1 REK3 Processor board 3
NTK24
HAE2.1 HAK9 HAK6 HAK3 SAK Memory analog board
NTK5
HAK8 HAK5 HAK2 NTK5/24 Power supply board 5/24V DC
The power part plug-in units 2.1/2.2 contain the

power part boards LTK 500 for the dampening ductor
LTK500/5 LTK500/4 LTK500/3 LTK500/2 LTK500/1 motors.
LTE2.2 The auxiliary drive plug-in unit HAE 2.1 contains the
”Auxiliary drives”):
HAK 1 ... 10 Auxiliary drive boards

Printfunction CPTRONIC 2:
NTK 5/24 Power supply boards 5/24V DC
HAK10 HAK7 HAK4 HAK1

NTK24 The Printfunction CPTRONIC 2 cabinet only contains
HAE 2.2 HAK9 HAK6 HAK3
one plug-in unit.
NTK5
HAK8 HAK5 HAK2 The power part modules LTM1000 and their voltage
supply with a GRM250 are screwed to the back
panel of the cabinet.
LTM LTM LTM LTM
1000 1000 1000 1000
PU 4 PU 3 PU 2 PU 1 The auxiliary drive plug-in unit HAE 2.2 contains the
top top top top
LTM LTM
”Auxiliary drives”):
1000 1000
PU 6 PU 5
top top HAK1 ... 10 Auxiliary drive boards
GRM
250 NTK5/24 Power supply boards 5/24V DC
LTM LTM
1000 1000
PU 6 PU 5
bot- bot-
tom tom
LTM LTM LTM LTM

1000 1000 1000 1000
PU 4 PU 3 PU 2 PU 1
bot- bot- bot- bot-
tom tom tom tom
Max. 24 LTMs for 12 DDW
− 2.1.10 −
2.1 General Post-Unit CPTRONIC
Post-Unit CPTRONIC (Standard configuration)

When the machine is on impression, the Post-Unit This board directly processes the HWI signals for
drive is controlled as follower drive of the printing determination of the press speed (Post-Unit drive)
unit drive. In this case we speak of a ”clutched and is capable of compensating the wide speed
condition”. control range of 30-6000 rpm (see chapter ”Servo
In this condition the main drive of the Post-Unit drives”)
runs in synchronism with the printing unit group The servo drives of the Post-Unit are controlled by
as far as speed and angle are concerned. The the servo drive control boards SSK in the servo
HWI signals of the Post-Unit HWI and of the drive plug-in unit. They are responsible for format
printing unit HWI are used. changes and turner bar readjustment.
The machine can be operated from the two
CPTRONIC control consoles. Via the input/output control, the input/output boards
It may be necessary to turn the Post-Unit drive EAK and the safety input board and the safety
independently of the printing unit drive. This is input board as well as the function block of the
called the ”unclutched condition”. auxiliary drives are connected to the processing
In this case the HWI signals are used. The part.
Post-Unit group works separately from the printing
unit group and can only be operated from the Via an encoder distribution module TVM, the signal
Post-Unit CPTRONIC control console. of the HWI1 is also passed to the input/output
control.
Via the EAK all buttons, limit switches, lamps and Apart from this, it is led to the input/output auxiliary
valves are read in or controlled. The signals from drive plug-in unit EHE, where the signal is
the safety switches are passed in addition, i.e. processed on the HAK2.
redundantly, to the safety input board SEK. The EHE can accommodate max. six HAKs or
The silicone applicator motors are controlled via HAK2 as well as up to nine EAK2 and one SEK.
power part boards LTK50 for a maximum
continuous rating of 50W. The Harmonic Drive The Post-Unit CPTRONIC is connected to the Master
motor is controlled via an LTK500. via a parallel and serial interface and via a safety
Speed control of the silicone applicator motors is bus.
performed means of an auxiliary drive board HAK.
The Harmonic Drive motor is controled of an
auxiliary drive board HAK2.
Master HWI signal

REE
M
− SLT Main drive EHE
control
Safety
inputs
HWI TVM
trol Input/output
Post EHE
Unit
LTE
Con− M
sole
Auxiliary drives Auxiliary drives
−
control part power part
Communication with
M
−
other CPTRONICs Central
SSE control
SSK
1−3
Encoder signal (HWI1)
from the TVM
Post-Unit CPTRONIC diagram
− 2.1.11 −
2.1 General Post-Unit CPTRONIC plug-in units
Post-Unit CPTRONIC plug -in units (Standard configuration)

The Post-Unit CPTRONIC is located in the Post-Unit
section. It consists of several plug-in units.
The computer plug-in unit REE/M contains the
following boards:

NTK24
SAK REK2 ESK1 SRK
REE/M ESK 2 Input/output control board 2
NTK5 REK3 ESK2 REK1 GLK REK 2 Processor board 2
NTK5 EAK9 EAK5 EAK1
NTK5/24 Power supply board 5/24V
HAK
HAK2 EAK8 EAK4
EHE 1-6 HAK The input/output auxiliary drive plug-in unit EHE
EAK7 EAK3
SEK
EAK6 EAK2 contains the following boards (for allocation of the
EAKs see chapter ”Digital inputs/outputs”):
EAK1 ... 9 Input/output boards

LTK500
LTE LTK50 SEK Safety input board
HAK2 Auxiliary drive board 2
(without Encoder processing)
HAK Auxiliary drive board
(with Encoder processing)
NTK24/1
SSK3 SSK1 NTK5 Power supply board 5V DC
SSE
NTK24/2 SSK2
The power part plug-in unit LTE contains one
LTK500 for the Harmonic Drive and one LTK50 for
the silicone applicator.
Post-Unit CPTRONIC plug-in units The servo drive plug-in unit SSE contains the
following boards (for allocation of the EAKs see
chapter ”Digital inputs/outputs”):
SSK1 ...3 Servo drive control board

− 2.1.12 −
2.1 General Post-Unit CPTRONIC
Post-Unit CPTRONIC (Special configuration)

If with a special configuration be required more
than nine input/output boards is an additionally
plug-in unit necessary in the Post-Unit CPTRONIC.
Additionally a second ESK (input/output control
board) is located in the computer plug-in unit, by
that the additionally EAE be conducted.
The new input/output plug-in unit is controled
from the ESK 1. The input/output part from the
EHE (input/output auxiliary drive plug-in unit) is
controled from the additionally ESK 2.
Master HWI signal

REE
M
− SLT Main drive EAE
control
Safety
inputs
HWI TVM
trol Input/output
Post EHE
Unit
LTE
Con− M
sole
Auxiliary drives Auxiliary drives
−
control part power part
Communication with
M
−
other CPTRONICs Central con−
SSE trol
SSK Encoder signal

1−3 from the TVM
EHE
Safety
inputs
Input/output con−
Post HWI
Unit trol 2
2 Input/output
Post-Unit CPTRONIC diagram
− 2.1.13 −
2.1 General Post-Unit CPTRONIC plug-in units
Post-Unit CPTRONIC plug -in units (Special configuration)

The Post-Unit CPTRONIC is located in the Post-Unit
NTK5
section. It consists of several plug-in units.
SEK The computer plug-in unit REE/M contains the
EAE EAK12 EAK1 following boards:

NTK24
SAK REK2 ESK1 SRK
REE/M ESK 1 Input/output control board 1
NTK5 REK3 ESK2 REK1 GLK ESK 2 Input/output control board 2
NTK5 EAK9 EAK5 EAK1
HAK
EAK8 EAK4
NTK5/24 Power supply board 5/24V
EHE HAK2
EAK7 EAK3
SEK
1-6 HAK
EAK6 EAK2 The input/output auxiliary drive plug-in unit EHE
contains the following boards (for allocation of the
EAKs see chapter ”Digital inputs/outputs”):
LTK50
LTK500 LTK500 EAK1 ... 9 Input/output boards
LTE LTK50
SEK Safety input board
HAK Auxiliary drive board
NTK24/1
SSK3 SSK1
The power part plug-in unit LTE contains one
SSE LTK500 for the Harmonic Drive and one LTK50 for
NTK24/2 SSK2
the silicone applicator.
The servo drive plug-in unit SSE contains the

following boards (for allocation of the SEK see
chapter ”Servo drives”):
Post-Unit CPTRONIC plug-in units
(Special configuration) SSK1 ...3 Servo drive control board
− 2.1.14 −
2.1 General Ideograms of the operator panel Infeed and PU’s
Ideograms
Ideograms of the operator panel on the press

Infeed Printing Units and Imprinting Unit
stop forward
crawl speed backward
footboard upon damping
footboard down ink ductor off
center web wash - up damping rollers
web - up device safe
trolley damping +
damping -
ink rollers
footboard upon
footboard down
impression on/off
blade on
position
- 2.1.15 -
2.1 General Ideograms of the operator panel chill rollers and folder
chill rollers
sheet stop
stop
product delivery height
cleaning blade on/off

trolley
crawl speed
clutch superstructure
center web
clutch chill rollers
trolley
clutch cylider part
faster
folder
slower
stop
grooved direction
tape guide
crawl speed
tape tension
centre slitting
trolley top
edge trimming
trolley bottom
tape tension quaterfold
longitudial perforation
safe
backward
forward
- 2.1.16 -
2.2 Main drives Table of contents
2.2 Main drives
Main drives
2.2.1 Replacing the brake at the main motor of the infeed
2.2.2 Replacing the brake at the main motor of the printing
units/Post-Unit
2.2.3 Replacing the carbon brushes at the main motor of
the infeed
2.2.4 Replacing the carbon brushes at the main motor of the
printing units/Post-Unit
Encoder HWI
2.2.5 Location
2.2.6 Method of functioning
2.2.7 Encoder distribution module TVM
2.2.9 Connector pin assignment
2.2.10 Installation of the HWI
2.2.11 Coarse adjustment
2.2.12 Mechanical zero position
Web tension
2.2.13 Overview
2.2.14 Web tension control at the Infeed
2.2.15 Web tension in the Post-Unit

2.2 Main drives Table of contents

2.2 Main drives Replacing the brakes
Main drives
Replacing the brake at the main motor of the infeed
Caution: Switch off the main switch of the three-phase

power section!
Removing the defective brake:
Disconnect the supply cable from the

terminal box of the brake
Loosen the mounting bolts at the brake
Pull the brake off the shaft of the main motor
Brake of main motor infeed
Installing the new brake:
Push the brake against the square driver of

the main motor shaft.
Tighten the mounting bolts uniformly.
Connect the supply cable leading to the

brake to the terminal box
Any dust produced must not enter the machine and

must be blown off!
Square driver
- 2.2.1 -
2.2 Main drives Replacing the brakes
Replacing the brake at the main motor of the printing units / Post-Unit
Caution: Switch off the main switch of the three-

phase power and Post-Unit sections!
Removing the defective brake:
Disconnect the supply cable from the

terminal box of the brake
ÅÅ Loosen the mounting bolts at the brake
ÅÅ
ÅÅ Pull the brake off the shaft of the main motor
Brake of main motor printing units / Post-Unit
Installing the new brake:
ÅÅ
Push the brake against the square driver of
the main motor shaft
ÅÅ
ÅÅ
Tighten the mounting bolts uniformly
Connect the supply cable leading to the

brake to the terminal box
Any dust produced must not enter the machine and

must be blown off!
Square driver
- 2.2.2 -
2.2 Main drives Replacing the carbon brushes
Replacing the carbon brushes of the main motor of the infeed

power section!
ÎÎÎ Remove the covers on the installation side
ÎÎÎ
ÎÎ of the brake
ÎÎ
ÎÎ
ÎÎ
Motor infeed
ÎÎ
ÎÎ
Î
Remove the connection of each carbon brush
Î
at the terminal
(4x one brush, 90°offset on the carbon brush
Î support)
Flip up the terminal clamp and take out the

used carbon brushes
Insert the new carbon brushes, connect them to

the terminals and flip the terminal clamp down
Important:
The carbon brushes must run smoothly in the car-
bon boxes and rest on the commutator! Any dust
produced must not enter the machine and must be
View carbon brush support blown off.
ÎÎÎ
ÎÎÎ
Î
To reach the upper carbon brushes and those
Î
at the back loosen the holding screws (but
do not turn them out entirely) and turn the
carbon brush support accordingly.
Important:
If the manufacturer has not provided any markings,
mark the position of the carbon brush support in
relation to the stator (colour marking) before turning
the carbon brush support!
After replacement of the carbon brushes the

carbon brush support must be locked
exactly in its original position.
Directions of rotation carbon brush support
- 2.2.3 -
2.2 Main drives Replacing the carbon brushes
Replacing the carbon brushes of the main motor of the printing units /
Post-Unit

power and Post-Unit sections!
Remove the covers on the installation side of

the brake
ÅÅ
ÅÅ
ÅÅ
Motor printing units / Post-Unit
Remove the connection of each carbon brush
ÅÅ
at the terminal (4x three brushes, 90° offset
ÅÅ
on the carbon brush support)
Flip up the terminal clamp and take out the

used carbon brushes
Insert the new carbon brushes, connect them to

the terminals and flip the terminal clamp down
Important:
The carbon brushes must run smoothly in the car-
bon boxes and rest on the commutator! Any dust
produced must not enter the machine and must be
blown off.
View carbon brush support
ÅÅ
To reach the upper carbon brushes and those
at the back loosen the holding screws (but
ÅÅ do not turn them out entirely) and turn the

carbon brush support accordingly.
Important:
If the manufacturer has not provided any mark-
ings, mark the position of the carbon brush sup-
port in relation to the stator (colour marking)
before turning the carbon brush support!
After replacement of the carbon brushes the

carbon brush support must be locked exactly in
Directions of rotation carbon brush support its original position.
- 2.2.4 -
2.2 Main drives HWI, location
Encoder HWI
Encoders HWI are located at the infeed (O.S.),at

the imprinting unit, at the ”electrical” last printing
unit (after the infeed D.S.).
The major components of the encoder HWI are a

light source, an optical sensor and a light-transmit-
ting disc divided into a multitude of segments. The
encoder converts one rotation of the press
(corresponding to 360 degrees into 1024 sections.
The optical sensor detects the signals and converts
them into electrical pulses.
The pulses the electronic control system receives

from the HWIs serve to recognize the machine
angle (position sensing), the speed and the
direction of rotation.
Locations
Drive side M-600
- 2.2.5 -
2.2 Main drives HWI, Method of functioning
Method of functioning
The HWI generates 3 pulse signals: track A, track B
5V and track 0. Track B is offset against track A by 90°.
Track A Track 0 contains the zero pulse which is generated
0V once during each rotation. On all 3 tracks the
inverted signals are also available. During each
5V rotation 1024 pulses are generated on tracks A and
Track B B each. They are passed to the backplanes of the
0V computer plug-in units and from there to the ESKs.
There the 1024 pulses of tracks A and B are XOR
5V connected, thus producing 4096 pulses:
Track 0
0V
Pulse signals of the HWI
Track A Track B XOR
SLT
0 0 0
1 0 1
1 1 0
Printing Units SRK 0 1 1
0 0 0
HWI
REK 1
The angular resolution resulting from 4096 pulses
is: 360°
ESK 0,1°
4096
RER/M1 The processor boards 1 compare the pulses/time

with the reference value and control the drives
accordingly.
TVM
Electronic boards guarantee synchronous run of
the drives of the infeed, printing units and Post-
ERR RER/M Unit.
These boards receive control signals from the
processor board and additionally the HWI signals
ERK GLK from the encoder distribution module TVM.
REK 1 SRK The power converter board controls the converter

REK1 power parts which, in turn, control the correspond-
HWI
ing main motors.
SLT
SRK ESK
SLT HWI
Infeed Post Unit
Block diagram HWI signals
- 2.2.6 -
2.2 Main drives Encoder distribution module TVM
Encoder distribution module TVM

The encoder distribution module TVM multiplies the
arriving HWI signals and simultaneously provides
electrical isolation (optocoupler).
Voltage supply
+5V DC ground M5
X1
X3
Electrical
isolation
HWI and
X4
outputs signal multiplication
X5 X2 HWI input
Principle of the TVM
The encoder distribution modules are located at the

X1 back panel of the Master CPTRONIC cabinet.
The encoder distribution modules 0TVM1...3 are
located at the backpanel of the Post Unit CPTRONIC -
cabinet.
X3
3 Connector pin assignment X1:
2
1
1 +5V
X4 2 not assigned
3 Ground
X5
X2
- 2.2.7 -
2.2 Main drives
Infeed 1 Infeed 2 Master Printfunction X6 Post-Unit
CPTRONIC CPTRONIC CPTRONIC CPTRONIC CPTRONIC
ERR ERR RER/M1 RER/M2 RER/M
X5
X6 X8 X11 X9 X14 X17 X14 X17 EHR
X14 X12 X17
X3 X4 X5 if X3 X4 X5 bei
0TVM1.4 required Bedarf CPC4-W2
0TVM2.4
X2 web X2 web
catcher ( catcher (
1)
imprinting 2)
imprinting
X3 X4 X5 unit (1)
HEIDELBERG HARRIS
X3 X4 X5 unit (2) X3 X4 X5
0TVM1.3 0TVM2.3 0TVM3
CPC4-W X3 X4
X2 X2 X2 0TVM1
X2
X3 X4 X5 X3 X4 X5 X3 X4 X5
- 2.2.8 -
0TVM1.2 0TVM2.2 0TVM2

X2 X2 X2
X3 X4 X5 23
HWI1
M
0TVM1.1

X2 M M X3 X4 X5 HWI2
0TVM2.1
HWI X2
chill
roller1
HWI infeed 2 M Folder
PU PU
PU PU (two-w (two-w HWI chill
HWI infeed 1 M eb) eb) roller2
Connecting the TVMs on the M-600

03.96
Note: The figures ”2” or ”3” behind the abbreviation indicates that it is two-web variant.
2.2 Main drives HWI, connector pin assignment, removal
Connector pin assignment

Connection Assignment
Connector HWI Connector RER-X5
A Ground
B Track A
C Track A
D Ground
E Track B
F Track B
G +5V±20%
H +5V±20%
I Track 0
K Track 0
L Ground
M +5V±20%
Removing the HWI
Caution: Interrupt the main supply voltage before

performing any work!
Loosen the screw and the nut (dotted in fig.) of

the adjusting unit.
Adjusting unit
Remove the screw connection and

loosen the screw.
Take off the plug connector.
Encoder
- 2.2.9 -
2.2 Main drives HWI, Installation of the HWI
Installation of the HWI When the encoder is installed it is important that it is

in a certain position to the corresponding unit (zero
position of the corresponding unit, see chapter
”mechanical zero position)).
This does not apply to the installation of the encoder

in the infeed. Points 1, 3, 6 below thus only refer to
the encoder of the 1st printing unit and the encoder
at the main drive Post Unit
The opposite CPTRONIC -display is necessary to the

adjustment of the encoder.
Caution! The degree display is necassary in the
Master CPTRONIC -console for the encoder
at the Printing Unit and in the Post Unit
CPTRONIC -console for the encoder at the
Post Unit.
actual value display
selector button: Global press

CPTRONIC-Display
selector button group: Global press
Set the corresponding unit to the mechanical

zero position (see sheet ”Mechanical zero
position”).
Connect the encoder which has been removed

from the press and switch on the machine.
Hold the housing of the HWI tight. Rotate the

shaft of the HWI in the printing direction of the
machine (see arrow in fig.) until ”000.0” apears
in the display of the CPTRONIC console.
Reverse side of the encoder
Align the HWI in such a way that the metal pin

is positioned above the recess of the adjusting
unit.
Push the encoder, without turning it, onto the

shaft and fasten it by means of the screw. While
doing this, make sure that the metal pin stays
approximately in the centre of the recess of the
adjusting unit.
When step is carried out, the indication

”000.0” in the display of the CPTRONIC console
may change slightly. Precise setting is obtained
by the coarse and fine adjustments described
Encoder below.
- 2.2.10 -
2.2 Main drives HWI, coarse adjustment
Coarse adjustment
The coarse and fine adjustments do not have to be
made for the encoder in the infeed.
Should a coarse adjustment be necessary the

two cheese-headed screws can be loosened
(dotted in fig.).
Adjusting unit
The adjusting unit can be pushed to the right or

left; then the screws have to be retightened.
Adjusting unit
Fine adjustment
For fine adjustment turn the stop screw against
the metal pin of the encoder until the indication
”000.0” appears in the display of the CPTRONIC
console.
Lock the stop screw using the hexagon nut.
The spring must rest on the metal pin of the

Adjusting unit encoder so that the metal pin always contacts
the stop screw.
After one rotation compare the adjustment of

the encoder once more with the mechanical
zero position.
- 2.2.11 -
2.2 Main drives HWI, mechanical zero position
Mechanical zero position
Infeed The infeed does not have a reference position and

therefore no mechanical zero position.
Printing units
To adjust the encoder of the printing unit the printing
units have to be inched to the mechanical zero posi-
tion.
In this position the channel of the upper blanket cylin-
der of the 1st printing unit (before the dryer) is in
horizontal position.
(in the display: encoder = 0o)
1st printing unit (before the dryer)
Folder
For adjustment of the encoder at the folder the
folder has to be turned to the mechanical zero
position.
For this purpose insert the crank handle in the
opening provided and turn it clockwise until the
adjusting disc indicates ”0”.
(JF50 in the display: encoder = 0o, when the folder
8 − , 16 − or 32 − pages − configuration
the encoder = 300o, when the folder 12 − or
24 − pages − configuration)
Only turn the crank handle clock-

wise; otherwise mechanical dam-
age may occur!
Folder paper outlet
- 2.2.12 -
2.2 Main drives Web tension, overview
Web tension
Overview
Infeed CPTRONIC Infeed

Double dancer
Hand-
wheel Potentiometer
air pres- dancer position
sure
ERK
REK 1 SRK SLT M

Main drive
Master - CPTRONIC Distribution box
Load cells
SAK FLK10 0N1 15B1
15
Converter Amplifier LVT2
15B2
Web tension
display
REK 1 ESK SVM 15MID1
Printing units Main drive
REK 1 SRK SLT M
Post -Unit Auxiliary

HAK 2 LTK 500 M
drive
Post-Unit - CPTRONIC Harmonic

Drive
Main
drive
REK 1 SRK SLT M
2.2.13
2.2 Main drives Web tension, infeed
Web tension control

at the infeed
In the infeed the web tension is adjusted by means Dynamic web tension fluctuations are compensated
of a pressure gauge. by the double dancer.
The web tension is generated through differential When the machine starts running both main motors
speeds between the infeed drive and the printing run in synchronism until the contact pressure roller
unit drive. For this purpose, the infeed drive is in the infeed is thrown on and all printing units are
controlled in such a way that the double dancer is on impression.
always in the middle of its range of travel. The
position of the double dancer is recognized by The web tension is measured at the roller located at
means of a potentiometer. The air pressure set at the paper outlet of the infeed. At both ends, load
the pressure gauge is applied to the double dancer cells are located under the roller which measure the
and acts against the web tension. If the web web tension. The web tension is indicated in a
tension is to be increased, the air pressure at the digital display on the operating panel of the infeed.
pressure gauge must be increased, if it is to be The measurement and display of the web tension is,
decreased the air pressure must be reduced. however, completely independent from the control
The position of the double dancer determines procedure.
whether the way the paper has to travel is longer
or shorter, and the double dancer thus makes up
for web tension fluctuations.
Measuring roller web tension
Double dancer
Infeed roller
Contact pressure roller
Infeed
2.2.14
2.2 Main drives Web tension, Post-Unit
Web tension in the Post-Unit The web tension in the Post-Unit builds up
automatically and can be influenced by means of
the Harmonic Drive.
The Harmonic Drive is a variable speed gear

allowing precision adjustment which, with the help
M of an auxiliary drive (naux) enables changes in the
output speed (nout) versus the input speed (nin).
naux The lag or advance of the output versus the input
lies in the range from -1‰ to +3‰.
nin Harmonic nout= nin ± ...‰

M Drive
Harmonic Drive
CPTRONIC controls the auxiliary drive proportionally

to the current machine speed.
Speed
It is possible to change this advance or lag from the
auxiliary drive Advance
CPTRONIC console.
Harmonic Drive
+4‰
100 Adjustment in 0 − direction means to increase
+3‰ the web tension in the folder, adjustment in the
direction of 100 means to decrease it.
+2‰
100 +1‰ Within the shaded area all zero-point straight lines
46 are possible (0 to 100 per cent). Each straight line
0 corresponds to a certain advance or lag.
46 -1‰
100 If the set value is between 40 and 60 per cent, it will
-2‰ be maintained when the machine is switched on
0 Lag again. If not, the value will be set to 46 per cent after
0
Speed switching on (corresponds to an advance of 0.84‰).
drive
Diagram Harmonic Drive at the chill roller
2.2.15
2.3 Servo drives Table of contents
2.3 Servo drives

2.3.1 Overview
2.3.3 Init − Test SSK
2.3.5 Dyn − Test SSK
2.3.6 Servo drive control module SSM
2.3.7 Procedure to check an SSK board (master)
2.3.10 Servo drives infeed, chill rollers
2.3.12 Register motors, overview
2.3.13 Register motors,Terminal strip, connector for lateral register
and circumferential register
2.3.14 Replacing the potentiometers of the lateral registers
2.3.16 Replacing the potentiometers of the circumferential registers
2.3.19 Replacing the potentiometer of the unit−to−unit register
2.3.22 Replacing the potentiometers of the diagonal registers
2.3.24 Procedure to check an SSK board (post − unit)
2.3.28 Servo drives folder
2.3.29 Replacing the potentiometers of the turner bar 1 upper/lower
2.3.31 Replacing the potentiometers of the grripper fold
1st/2nd cross fold
2.3.33 Replacing the potentiometers of the cross perforation
2.3.35 Replacing the potentiometer of the 1st cut − off register 1/1, 1/2
2.3.37 Replacing the potentiometers of the former position

2.3 Servo drives Table of contents

2.3 Servo drives Overview
Servo drives
Overview
All servo drives on the machine are d.c. drives with Folder: gripper fold, 1st cross fold
brushes equipped with potentiometers providing gripper fold, 2nd cross fold
position feedback. With their help mechanical units cross perforation
are moved into certain positions. phase, 2nd longitudinal fold
Superstructure: former position
The following servo drives are available: former slant
1st cut − off register 1/1
Infeed: web edge detector D.S. 1st cut − off register 1/2
web edge detector O.S. turner bars 1 top
web infeed motor turner bars 1 bottom
Printing unit: upper/ lower lateral registers Additionally for folder on two web machine:
upper/ lower circumferential
registers 2nd cut − off register 1/1
upper/ lower diagonal registers 2nd cut − off register 1/2
unit−to−unit registers turner bars 2 top
turner bars 2 bottom
Chill roller group:
web edge detector D.S.
web edge detector O.S.
The servo drive control board SSK controlled max.

16 servo drives with a power to 50W. The potentio −
meter providing position feedback of the servo
drives.
A 24V power supply unit is provided for the motor
voltage and a 5V power supply unit is provided for
the supply of the logic on the SSK.
The 24V power supply unit is located in same
plug − in unit, in which are located the boards. The
5V power supply unit is located in the computer
plug − in unit.
servo drive control board SSK
In a servo drive plug − in unit (SSE) may be

located three servo control boards (SSK) and two
power supply boards 24V (NTK24).
NTK24/1
SSK3 SSK1
NTK24/2
SSK2
servo drive plig-in unit SSE
− 2.3.1 −
2.3 Servo drives Overview
The SSK consists of three function blocks:

SSK
motor control: This part is able to control 16
motor motor con- dc − motors with a current up to 3A in two
1...16 trol directions.
computer The current limit is variable and protects
10V analog part
resistor part smaller motors, too. When the current limit will
1...16 (measured be passed, the motor becomes switched off
value acqisi- and in the Init − /Dyn − test appears an error
tion) message.
analog part: The feedback of the servo drive

position is realized with a variable resistor (10
SAK
revolutions, max. value 10 kW).
The supply voltage amounts 10V and is
generated on the SSK.
computer part: The computer part controls the

REK voltage on the SSK. When a malfunction is
reckognized all motors become switched off.
REE
block diagram SSK
Á
SSK1
ÁÁ
Á
X10 SSK2
Á Á
X20 SSK3
Á Á
X30
Á
X5
ÁÁ
Á
ÁÁ
Á Á
ÁÁÁ Á
ÁÁÁ Á
Á
ÁÁ
Á Á Á Á Á Á
ÁÁ
Á
ÁÁ
Á Á
ÁÁÁ Á
ÁÁÁ
ÁÁ
Á ÁÁ ÁÁ
Á 24V DC
ground 24 X4
Á X11
ÁÁÁ
ÁÁ
X12
ÁÁÁ
ÁÁ Á X22
Á
X32
Á Á
Á ÁÁÁ
ÁÁ ÁÁ
ÁÁ Á Á Á Á
X3
X21 X31
ÁÁÁÁÁ Á ÁÁÁ
ÁÁÁÁÁÁ
ÁÁ Á Á Á
X1 X2
X13 X14 X24 X34
ÁÁÁÁ Á ÁÁÁ
ÁÁ
X23
ÁÁÁ
Á Á X33
Á Á Á
ÁÁ Á X15
ÁÁÁ
ÁÁ
X16
ÁÁÁ
ÁÁ Á X26
Á
X36
Á Á
Á Á
ÁÁÁ
Á
ÁÁ
ÁÁÁÁÁ
Á
ÁÁ
Á
ÁÁ
X25 X35
Á
Á ÁÁ ÁÁ
Á Á Á Á
X17 X18 X28 X38
M5 M5
SSK1
X27
SSK2
X37
SSK3
Á
Backplane of servo drive plug − in unit SSR
− 2.3.2 −
2.3 Servo drives INIT − Test SSK
INIT − Test SSK

After switching on the press all servo drives ans SSKs are tested during the initial phase. in the
Init − Test "SSK" the results are stored. With following push button sequence it is posiible to get into the
Init−Test:
left
push buttons sequence
time level
general variables motor variables
In the Init − Test 12 − 14 "SSK" are 16 motor

variables and one general variable indicated in
t= 0 hex − code on every SSK. The motor variables are
connected with one servo motor, the genaral
variable is connected with the whole SSK.
01 02 03 04
06 07 08
05 Every fault is stored in the variables and when the
09 10 11 12
press is switched on again indicated in the time
13 14 15 16
level t= − 1. The actual variable is indicated in the
t
time level t=0. Altogether there are 6 time levels
(t=0 ... t=5). It is possible to change the time
levels with the right +/ − push button.
Init −Test SSK
Motor variables:
Following tests are conveyd, the rest is covered D Test control electronics:
with 0. When the test is good X = 1. When it’s not This test is convegd first and test the control
good, X = 0 electronics for the stepper motor.
0000 000X 0000 00XX D Test stepper motor:

test This is the second test and rekognizes if there
steppermotor is a stepper motor connected. There for the
test resistor current limit is decreused until the motor is not
able to turn. is there a current, a motor is
test control connected, is there no current, no motor is
electronics connected.
− 2.3.3 −
2.3 Servo drives INIT − Test SSK
D Test resistor: The underlagd, flashing display means a fault.

In the last test the motor is checked first clock Is according to the configuration no motor
wise then anticlock wise. The feedback of the connected, the variable 0100 is displayed at the
resistor has to go into right direction and corresponding place.
value.
There are only four variables, because the tests are variable possibilities to clear malfunctions
executed in the described sequence and if one test
fail then the following tests are not executed. 0000 a) changing the board (SSK)
These variables are:
0000, 0100, 0101, 0103
0100 / a) checking the motor and the
0000 : electronics for the stepper motor on the 0101 resistor connection
SSK is defect b) changing the motor
0100 : electronics for the stepper motor is o.k., c) changing the cables
but no motor reckognized d) checking the interface
0101 : electronics for the stepper motor is o.k., e) changing the interface module
the motor is reckognized but motor or
resistor turn into wrong direction or are
defect
0103 : electronics for the stepper motor is o.k.,
the motor and the resistor is reckognized
with the right direction
General variables:
Following tests are convegd, the rest is convered
with 0.
0000 0000 0000 0XXX
test A/D−converter,
voltage supply
variable possibilities to clear malfunctions
test D/A−converter
0000 a) checking the power supply and
test serial to the ground at the backplane
interface 0005 b) changing SSK and SAK
0006 a) checking the power supply and

0007 : everything is o.k. the ground at the backplane
0006 : A / D−converter or power supply has a fault b) changing SSK
(fault 1)
0005 : D / A−converter has a fault (fault 2)
0004 : fault 1 and fault 2
0003 : serial interface has a fault (fault 3)

0000 : fault 1 and fault 2 and fault 3 or
fault in the initializing or
fault in the data transmission
− 2.3.4 −
2.3 Servo drives DYN − Test SSK
DYN − Test SSK
The Dyn − Test runs cyclic and checks the logic of

the resistor feedbacks. The results are stored in the
Dyn − Test.
With following push button sequence it is possible
to get into the DYN−Test:
left
push button sequence
In the Dyn − Test "SSK" 16 motor variables and one

time level
motor variable general variable are indicated. The motor variables
ggggeneral variable
are connected with one servo motor, the general
variable is connected with the whole SSK.
An underlagd, flashing display means a fault.

t= 0
Is according to the configuration no motor

connected, FFFF is displayed. Every fault is stored
01 02 03 04
in the variables and when the press is switched on
05 06 07 08
10 11 12
again indicated in the time level t= − 1. The actual
09
13 14 15 16
variable is indicated in the time level t=0.
Altogether there are 6 time levels (t=0 ... t= − 5). It
t is possible to change the time levels with the right
+/ − push buttons.
Dyn− Test SSK
Motor variable General variable
FFFF : everything o.k. FFFF : everything o.k.

7FFE : motor can not turn to position 7FFB : low voltage or stroke to electronics for the
stepper motor has a fault
7F7F : data transmission fault

7FFE a) removing mechanical clamp or
heavyness
b) changing the stepper motor 7FFB a) changing the SSK
c) changing the connection cables 7F7F b) changing the SAK
d) changing the interface module c) changing SSK and SAK
− 2.3.5 −
2.3 Servo drives Servo drive control module
Servo drive control module SSM

Function
The servo drive control module SSM is a
passive module distributing the wires from
terminal strip X5 to the connectors X1, X2, X3
and X4.
At the SSM the potentiometers of the servo

motors are connected to terminal strip X5.
Contrary to sheet fed presses the motor cables
are not led via the SSM, but via the connectors
supplying voltage to the individual machine
units.
The distribution boxes of the printing units and

of the chill rollers are equipped with one SSM
each. The distribution box of the folder has 6
SSMs.
Design
Connections:
X3 1 2 3 4 5 6 7 8 9 10
3 4 9 X5 − − A3 A4 A5 B5 B4 B3 − −
10 9 10
X1 8 7 8 7
1 2 5
6 5 6
4 3 4 3 X4 1 2 3 4 5 6 7 8 9 10
2 1 2 1
3 4
X2 X5 − − C3 C4 C5 D5 D4 D3 − −
1 2
X3 X4
A1 A2 A3 A4 A5 C1 C2 C3 C4 C5
X5
B1 B2 B3 B4 B5 D1 D2 D3 D4 D5
Servo drive control module
− 2.3.6 −
2.3 Servo drives S SK (Master)
Procedure to check an SSK board

Master CPTronic : Infeed web edge control (position and sensor)
NTK
2 SSK
SSK1 allocations
SSK1 Function Init test Dyn test Display Setting Setting value (potentiometer)
range position
01 Web edge control 0103 FFFF Limit DS 3892
Infeed web guide
DS
02 Sensor DS Infeed 0100 FFFF 0 to 4095
03 Web edge control 0103 FFFF Limit OS 190
Infeed web guide
OS
04 Sensor OS Infeed 0100 FFFF 0 to 4095
05 Web up chain 0103 FFFF
infeed
06 FFFF
07 Web edge control 0103 FFFF Limit DS 3892
2nd Infeed web
guide DS
08 Sensor DS2nd 0100 FFFF 0 to 4095
Infeed
SSK1 Function Init test Dyn test Display Setting Setting value (potentiometer)
range position
09 Web edge control 0103 FFFF Limit OS 190
2nd Infeed web
guide OS
10 Sensor OS 2nd 0100 0 to 4095
Infeed
− 2.3.7 −
PRINT FUNCTION CPTRONIC

Diagonal Registers (Top And Bottom) For Each Unit
Phasing Registers For Each Unit
Oil Temperature For Each Unit
NTK
2 SSK
+
Then, by using " you obtain the SSK2 and SSK3 (if used)
−
SSK1 allocations
SSK1 Function Init Dyn Display Setting Setting value Lower value Higher value
test test range position (potentiometer) (console (console
display) display)
01 Diagonal register 0103 FFFF +/ − 0,3 Middle of the 2048
Top U1 mechanical
setting.
Bottom U1 mechanical
setting.
03 Phasing register 0103 FFFF +/ − Middle of the 2048
U1 3mm mechanical
range.
04 Oil temprature U1 0100 FFFF
Top U2 mechanical
setting.
setting.
U2 3mm mechanical
range.
− 2.3.8 −
SSK1 Function Init Dyn Display Setting Setting value Lower value Higher value
test test range position (potentiometer) (console (console
display) display)
Top U3 mechanical
setting.
setting.
U3 3mm mechanical
range.
Top U4 mechanical
setting.
setting.
U4 3mm mechanical
range.
SSK2 (SSK3) are used only if the configuration of the press is higher than 4 printing units (8 printing units).
− 2.3.9 −
2.3 Servo drives Infeed, chill rollers
Servo drives infeed, chill rollers

Replacing the servo motors Remove the mounting bolts of the motor and
pull out the motor.
Measure and write down the clearance d

between the mounting plate and the sleeve.
3)
Loosen the lateral set screw and place the

gear wheel on the new motor and fasten it.
Make sure the clearance "d" remains the
d 2) same.
sixteen − page web offset press

M − 600 Push the sensor O.S. manually to the stop on
the operator side.
Push the sensor D.S. manually to the stop on
the drive side.
However the stop balls be may no pushed in.
− 2.3.10 −
2.3 Servo drives Infeed, chill rollers
Infeed: Infeed:
Potentiometer D.S. Potentiometer O.S. On the CPTRONIC − console Master the following
Sensor D.S. Sensor O.S. buttons actute:
Push the group button "Global press", the
display button "Service display", the selector
button "Service 2" and the function button
"Analog values SSK". Use the left−hand "+"
button to leaf through the different displays until
the menu "SSK 1" appears.
NTK
SSk
NTK Chill rollers:

SSk
On the Post − unit CPTronic console (folder),

check the "analog valves SSK" on the SSK2
with the same procedure.
Connect the motor and turn it until the

motor potentiometer indicates the value
shown in the table.
M − 600 web offset press
Motor potentiometer Incremental value
O.S. 190 ± 2
D.S. 3892 ± 2
Position and fasten the motor without changing

the potentiometer setting.
− 2.3.11 −
2.3 Servo drives Register motors
Register motors
Overview Each double printing unit is equipped with 7 register

motors:
− 2 motors for the lateral registers and two

motors for the diagonal registers on the
operator side.
− 2 motors for the circumferential registers
and 1 motor for the unit−to−unit register
on the drive side.
The circumferential and lateral registers are

controlled by the electronics in the CPC1 console
whereas the diagonal and unit−to−unit registers are
controlled by the CPTRONIC in the control cabinet.
Diagonal
register top Circumferential register top
Lateral register top Unit−to−unit register
Lateral register bottom

Circumferential register bottom
Diagonal
register bottom
Operator side Drive side

Double printing unit
DC motors Location Potentiometer Voltage for Electrical

with brushes potentiometer setting range
Lateral register max.24VDC(12VDC) O.S. 10 turn, 10KW 10V 3V .....7V
Circumferential 10V 1V .....9V
register max.24VDC(12VDC) D.S. 10 turn, 10KW
Diagonal register 24V DC O.S. 10 turn, 10KW 10V 3,4V .....6,6V
Unit−to−unit register 24V DC D.S. 10 turn, 10KW 10V 2V .....8V
− 2.3.12 −
2.3 Servo drives Register motors
Terminal strip
The terminal strips are identical for all register
motors and located directly at the corresponding
+ registers.
blue blue
brown
brown
− green − yellow
blue beige
10V DC yellow
red
black
black
Terminal strip for register motors
Connectors for lateral and circumferential registers
The connector shown opposite is connected at

A B C the reverse side of the CPC console. The
connector pin and socket assignment is the same
1
for all printing units.
2
3
4
5
Connector
6
pin assign− Core color Function
7 ment
8
A1 black Wiper potentiometer
9 A2 yellow 10V DC circumferential
A3 beige register
A4 black Wiper potentiometer
A5 yellow 10V DC lateral
A6 beige register
B2 brown 12V DC motor
B3 blue circumferential
register
B4 brown 12V DC motor
B5 blue lateral register
B8 green − yellow Ground
C1 green − yellow Ground
C2 green − yellow Ground
− 2.3.13 −
2.3 Servo drives Lateral registers
Replacing the potentiometers In order to explain how to replace the potentiometers

of the lateral registers, we have chosen the lower
of the lateral registers lateral register as an example. Replacement on the
upper lateral register is performed in the same way.
The printing units have to be on "Impression off" and
clutched.
Loosen the screws of the terminal strip cover

and take the cover off. Loosen the poten−
tiometer connections 4 blue, 5 red and 6
black and remove the potentiometer.
Note:
Make sure the machine is turning while
the lateral register is displaced!
Start up the machine and turn it at crawl

speed.
Bring the lateral register against the
mechanical stop using a wrench.
Turn the lateral register back by approx. 2½

rotations.
Continue turning to the teeth marked by means

of a punch. Thus the lateral register is in its
center position.
For checking purposes, you can measure the
lateral clearances between the plate cylinders
and the side frames. They must be identical.
Stop the machine.
2½ rotations
− 2.3.14 −
2.3 Servo drives Lateral registers
Connect the new potentiometer to 10V DC and

set the wiper to 5V DC.
Place the potentiometer on the gear wheel

red without changing the setting and tighten the
nut.
black 10V DC 5V DC
blue
After replacing all parts, check if the register is

moving manually :
S Start the press in crawl speed.
S From the CPC console (top web on the right side,
bottom web on the left side), select the printing
unitwhere you have a problem with the push button
1, 2, ..., 6 or B, C, ..., Z(label 1 on the picture).
3 S Then, move the registerby an action on the push
1 button (+) or ( − ) (label 2).
Nota : Maximum values display for the lateral register
are +/ − 2mm (label 3)
− 2.3.15 −
2.3 Servo drives Circumferential registers
Replacing the potentiometers of the For the following instructions a power supply
unit is required!
circumferential registers
The printing unit must be set to "Impression off"
and being cluched.
Loosen the lateral setscrew.
Take off the gear wheel.
Loosen the hexagon socket head screws of

the protective plate above the terminal strip
and take off the plate.
Loosen the screws of the terminal strip cover

and take off the cover. Loosen the potentiome−
ter connections 4 (blue), 5 (red) and 6 (black)
at the terminal strip.
Loosen the hex head cap screws of the cover

plate and take off the plate. Remove the
potentiometer from the cover plate.
− 2.3.16 −
Note:
Make sure the machine is turning while
the circumferential register is displaced.
1 2 3 4 5 6
Remove the connections 1 (blue) and 2
(brown) on the CPTRONIC side.
Start up the machine and turn it at crawl speed.
Connect the power supply unit to terminal
V connections 1 and 2. Turn the motor against

the mechanical stop with a voltage of 12V. The
direction is irrelevant. Set the current limitation
12V DC to a minimum value just allowing the motor to
turn. This protects the motor against overload.
Reverse the voltage at the power supply unit,

mark the gear wheel (e.g. by means of tape)
and turn back by approx. 3¼ rotations. It can
happen that the motor and the register are
"stuck". In this case, turn manually at first.
Reduction of the voltage of the power supply

unit allows to exactly turn the gear wheel. The
gear wheel is turned until the teeth marked by
means of a punch mesh. Disconnect the
power supply unit and establish connections 1
3¼ rotations (blue) and 2 (brown) again.
Stop the machine.
Attach the new potentiometer to the cover

plate, connect it to 10V DC and set the wiper
to 5V DC.
red
Place the cover plate on top without turning
black 10V DC 5V DC the potentiometer and tighten the screws
slightly.
blue
Connect the potentiometer connections blue to
terminal connection 4, red to 5 and black to 6
and tighten the terminal strip cover.
− 2.3.17 −
Place the gear wheel on top without turning

the potentiometer.
Fasten the gear wheel using the lateral

setscrew.
Move the cover plate with the gear wheel

laterally until the gear wheel engages properly
with the other gear wheel, allowing a slight
amount of play. Tighten the hex head cap
screws of the mounting plate.
Replace the protective plate of the terminal

strip and tighten the screws.

moving manually :
unitwhere you have a problem with the push button
1, 2, ..., 6 or B, C, ..., Z(label 1 on the picture).
3 S Then, move the registerby an action on the push
1 button (+) or ( − ) (label 2).
Nota : Maximum values display for the lateral register
are +/ − 4mm (label 3)
− 2.3.18 −
2.3 Servo drives Unit−to−unit register phasing
Replacing the potentiometer for For the following instructions a power supply
unit is required!
unit−to−unit register
The printing unit must be set to "Impression off".
Loosen the lateral setscrew and take off the
gear wheel.
Loosen the potentiometer connections 4
(blue), 5 (red) and 6 (black) at the terminal
strip.
Remove the potentiometer.
Remove the connections 1 (blue) and 2

(brown) on the CPTRONIC side and connect
the power supply unit to terminal connections
1 and 2 instead. Turn the motor against the
mechanical stop with a voltage of 24V DC.
The direction is irrelevant. Set the current
1 2 3 4 5 6 limitation to a minimum value just allowing the
motor to turn.
24V DC
Caution: Never turn the motor against the mechanical

stop while the potentiometer is connected.
This will damage the potentiometer!
Reverse the voltage at the power supply unit,

mark the worm shaft (e.g. adhesive tape) and
Worm shaft
turn it back by approx. 100 rotations.
100 rotations
− 2.3.19 −
Connect the new potentiometer to 10V DC

10V DC and set the wiper to 5V DC. Place the poten−
red tiometer on the mounting plate and fasten it
slightly without changing the setting.
black
blue
5V DC
Position the gear wheel at the potentiometer

and fasten it in such a way that it is centered
with the worm shaft. Displace the potentiome−
ter so that the clearance between the gear
wheel and the worm shaft is as small as pos−
sible.
− 2.3.20 −

moving manually :
S From the printing unit CPTronic console, select the
"actual display" (label 1).
S Select the "printing unit section" (label 2).
S Select the faulty print unit by the numbers 1 to 8
maximum on the left side of the display (label 3).
S Then, you can move the unit to unit
registerphasing by an action on the push button
(+) or ( − ) (label 4).
S The maximum values are +/ − 3 mm (label 5).
− 2.3.21 −
2.3 Servo drives Diagonal registers
Replacing the potentiometers of To replace the potentiometer of a diagonal register

the drive block must be removed completely.
the diagonal registers
Loosen the connections at the terminal strip on

the CPTRONIC side, unscrew the screws of the
diagonal register and lift out the entire block.
Drive block diagonal register
Block Loosen the lateral setscrew of the shaft and

Potentio − remove the potentiometer.
meter
Shaft
Lateral
hexagon
socket−head Holder
screw
1.6 mm 1.6 mm Displace the block by turning the shaft so the

clearance between the holder and the stop
Block Holder screw is 1.6 mm on each side.
Shaft
Stop
screw
Caution: The stop screws have been preset at the

manufacturer and must not be readjusted!
− 2.3.22 −
2.3 Servo drives Diagonal registers
Connect the potentiometer to 10VDC and set

the wiper to 5VDC. Place the potentiometer
on the mounting plate, place the nut on top,
red tighten the lateral set screw of the shaft and
fasten the potentiometer by means of the nut.
black 10VDC 5VDC
blue
Insert the block into the opening of the plate

cylinder and push the drive block into the
mounting recesses. Tighten the mounting
bolts.

moving manually :
unit where you have a problem with the push
button 1, 2, ..., 6 or B, C, ..., Z (label 1 on the
picture).
1 S Select the diagonal registers push button (label 2).
S Then, move the register by an action on the button
(+) or ( − ) (label 3).
S The display will appear at the same place than the
lateral register. The maximum values are +/ −
0.3mm (label 4)
− 2.3.23 −
2.3 Servo drives S SK (Post − unit)
Procedure to check an SSK board

NTK
2 SSK
+
Then, by using " you obtain the SSK2 and SSK3 (if used)
−
SSK1 allocations
SSK1 Function Motor Init Dyn Display Setting position Setting value Lower value Higher value
number Test Test 11 range (potentiometer) (console (console
11 display) display)
01 Folder lap 1 M1 0103 FFFF +/ − 12mm Mechanical zero 2048 348 3748
first folder or with paper.
02 Folder lap 2 M2 0103 FFFF +/ − 12mm Mechanical zero 2048 348 3748
first folder or with paper.
03 Perforation M3 0103 FFFF +/ − Mechanical zero 2048 348 3748
first folder 4,2mm or with paper.
04 Chopper M4 0103 FFFF 0 to 100% Cut − off:630mm: 2048 2700 tabloid 3548
phasing Paper at 60mm
first folder from the chopper 578 other 1426
end fold
05 Cut − off: 2048 2700 tabloid. 3621
598,5mm:
398 other 1319
Paper at 60mm fold.
from the chopper
end
06 Cut − off: 2048 2700 tabloid. 3479
577,85mm:
754 other 1533
Paper at 60mm fold.
from the chopper
end.
− 2.3.24 −
SSK1 allocations (continue)

number Test Test 11 range (potentiometer) (console (console
07 Cut − off: 2048 2700 tabloid. 3691
546,10mm:
paper at 60mm 222 other 1213
from the chopper fold.
end.
08 Former first M16 0103 FFFF 0 to Middle range. 2048 248 3848
folder +170mm
09 Angle manual 0100 FFFF 69_ to 71_ Mechanical zero 2048 342 3754
triangle first
folder
10 First angle M12 0103 FFFF +/ − 136 mm from 2048 1352 2744
bar top 116mm gear side frame.
11 First angle M11 0103 FFFF +/ − 218 mm from 2048 848 3248
bar bottom 200mm operator side
frame.
12 FFFF
13 FFFF
14 First M14 0103 FFFF +/ − Middle range 2048 1117 2979
cut − off 180mm
web 1/1
15 First M15 0103 FFFF +/ − Middle range. 2048 1117 2979
cut − off 180mm
web 1/2
16 4p cut − off 0103 FFFF Middle range. 2048
1/1
4p cut − off 0103 FFFF Middle range. 2048
1/2
Folder lap 1 0103 FFFF +/ − 12mm Mechanical zero. 2048 348 3748
stacked
folder
Folder lap 2 0103 FFFF +/ − 12mm Mechanical zero. 2048 348 3748
stacked
folder
− 2.3.25 −
SSK2 allocations
SSK2 Function Motor Init Dyn Display Setting postion Setting value Lower value Higher value
number Test test 12 range (potentiometer) (console (console
01 Web guide 0103 FFFF Limit gear side 3892
chill roll 1
gear side
02 Sensor 0100 FFFF 0 to 4095 Paper front edge 0 4095
web guide
chill roll 1
03 Web guide 0103 FFFF Limit operator 190
chill roll 1 side
op.side
web guide
chill roll 1
05
06
07 Web guide 0103 FFFF Limit gear side 3892
chill roll 2
gear side
08 Sensor 0100 FFFF 0 to4095 Paper front edge 0 4095
web guide
chill roll 2
gear side
09 Web guide 0103 FFFF Limit operator 190
chill roll 2 side
op.side
web guide
chill roll 2
op.side
11 Optional 0103 FFFF limit gear side 3892
web guide
gear side
optonal
web guide
gear side
13 Optional 0103 FFFF Limit operator 190
web guide side
op.side
optional
web guide
op.side
15
16
− 2.3.26 −
SSK3 allocations
number test test 13 range (potentiometer) (console (console
01 Fold lap1 M1 0103 FFFF +/ − 12mm 2048
2nd folder
02 Fold lap2 M2 0103 FFFF +/ − 12mm 2048
2nd folder
03 Perforation M3 0103 FFFF +/ − 2048
2nd folder 4,2mm
04 Chopper M4 0103 FFFF 0 to 100%
phasing
2nd folder
05 Former 2nd M16 0103 FFFF 0 to 2048
folder 170mm
06 Angle Manual 0103 FFFF 69_ to 71_ 2048
triangle 2nd
folder
07 2nd angle M12 0103 FFFF +/ − 2048
bar top 116mm
08 2nd angle M11 0103 FFFF +/ − 2048
bar bottom 200mm
09 Angle bar 0103 FFFF +/ − 2048
top 2nd 116mm
folder
10 Angle bar 0103 FFFF +/ − 2048
bottom 2nd 200mm
folder
11 2nd cut − off M14 0103 FFFF +/ − 2048
web 1/1 180mm
12 2nd cut − off M15 0103 FFFF +/ − 2048
web 1/2 180mm
13 Cut − off 0103 FFFF +/ − 2048
web 1/1 180mm
2nd folder
14 Cut − off 0103 FFFF +/ − 2048
web 1/2 180mm
2nd folder
15 Fold lap1 M15 0103 FFFF +/ − 12mm 2048
stacked
folder
16 Chopper M16 0103 FFFF 0 to 100%
phasing
stacker
folder
− 2.3.27 −
2.3 Servo drives Folder
Servo drives Folder
At the folder there are 10 servo drives (two web

contro lrange variant: 14). The motors are 24V dc - motors, the
0 10 revolutions 10 same as the cocking and unit - phasing motors.
0 4096 increments 4096
When the servo drive is in the middle of its range,
the display must show 2048 increments. The
adjusting range control range of the resistors is 4096 steps. This is
0,5 9 revolutions 9,5 according with 10 revolutions of the rsistor, but
3686 increments only 9 revolutions are used (3686 increments).
205 3891
The limits are commited by the sotfware, in a way
that the first and the laast 205 increments are not
used.
control range, adjusting range of the resistors
Terminal for servo drive with one resistor.

coarse
servo drive with one resistor
- 2.3.28 -
2.3 Servo drives Turner bar 1 upper/lower
Changing the resistor at the turner bar 1 upper/lower

For the foolowing advices a power supply is
required!
The servo drives of the turner bars has one

resistor.
The following advices are connected with the
coarse resistor.
turner bar 1,
top
ÀÀ
ÍÍÍ
resistor,
coarse
resistor,
coarse
turner bar 1,
bottom
Remove resistor connections 4 (blue), 5 (red)

resistor coarse (without and 6 (black).
slicling clutch)
Remove the thread bolt at the resistor.
Remove the resistor.
Connect the power supply to terminal 1 and 2.
- +
V
24V DC
- 2.3.29 -
2.3 Servo drives Turner bars 1 upper/lower
Drive the turner bars to the shown position

paper infeed with max. +24V dc. Adjust the current
218 136 limitation to a min. value, which even allows
the turning of the motor.
So the motor is protected against overload.
turner bar 1 bottom:
distance: 218 mm
side frame O.S. - left edge of the saddle
turner bar 1, turner bar 1 top:
turner bar 1, top
bottom distance: 136 mm
side frame D.S. - right edge of the saddle
Increments Turner bar 1 upper display

O.S. D.S.
1352 - 116 mm
2048 0 mm
2744 + 116 mm
Increments Turner bar 1 lower display
paper outlet
848 - 200 mm
2048 0 mm
3248 + 200 mm
turner bars, top view
Connect the new resistor to 10V dc and

adjust the wiper to 5V dc. Fix the resistor to
the strap, without changing the adjustment.
red
black
10V DC 5V DC
blue
Connect the rsistor connections 4 (blue), 5

(red) and 6 (black) to the terminals.
- 2.3.30 -
2.3 Servo drives Gripper fold 1st/2nd cross fold
Changing the register at gripper fold 1st/2nd cross fold

For the following advices a power supply is
required!
Remove the resistor connections 4 (blue), 5

(red) and 6 (black).
- +
V
24V DC
Adjust the gripper fold to 0 mm with max.

+24V dc. Adjust the current limitation to a
min. value, which even allows the turning of
the motor.
- 2.3.31 -
2.3 Servo drives Gripper fold 1st/2nd cross fold
Connect the new resistor to 10V d.c. and

adjust the wiper to 5V (according to 2048
increments in the CPTRONIC display).
rt Fix the resistor to the strap, without changing
blaxk the adjustment. The connection with the
10V DC 5V DC number ot the increments and gripper fold in
mm is shown in the diagram beneath.
blue
Connect the resistor connections 4 (blue), 5

increments
resistor
3940
3500
142
number of increments = 2048 +
gripper fold in mm 3000
142
2500
1
− 14 − 12 − 10 −8 −6 −4 −2
gripper fold
in mm
2 4 6 8 10 12 14
1500
increments gripper fold
1000 60 - 14mm
2048 0
500 2190 1mm
4036 14mm
160
0
diagram gripper fold 1st cross fold
- 2.3.32 -
2.3 Servo drives Cross perforation
Changing the resistor Cross perforation

required!

- +
V
24V DC
Adjust the shift of the perforation knife to 0

mm with max. 24V DC.
Adjust the current limitation to a min. value,
which even allows the turning of the motor.
- 2.3.33 -
2.3 Servo drives Cross perforation
Connect the new resistor to 10V DC and

adjust the wiper to 5V DC (according to 2000
increments in the CPTRONIC display).
red Fix the resistor to the strap, without changing
black the adjustment. The connection with the
10V DC 5V DC number of the increments and the shift of the
perforation knife in mm is shown in the
blue diagram beneath.

increments
resistor
4000
3500
405
number of increments = 2048 +
shift in mm 3000
405
2500
−4 −3 −2 −1 1
shift of the perforation
knife in mm
1 2 3 4
1500
increments shift
1000 28 - 4mm
2048 0
500 2453 1mm
4068 4mm
diagram Cross perforation
- 2.3.34 -
2.3 Servo drives 1st cut - off register 1/1, 1/2
Changing the resistor of the 1st cut - off register 1/1, 1/2

required!
The servo drives 1st cut - off register 1/1 and 1/2
has each one resistor.
The following advices are connected with the
coarse resistor.

resistor coarse (without (red) and 6 (black).
sliding clutch)
Drive the control slide into the middle of the
Ç
Ç ÉÉ
ÉÉ ÇÇÇ
ÇÇÇ
range with the CPTronic console or by hand
due to the unpossibility to use +/ − 24V like the
Ç ÉÉ ÇÇÇ
other servo motors. This motor is driven by a
ÉÉ
Weko electronic or an other supplier. The
distance from the stop to the middle of the
control slide is 202 mm.
ÇÇ
Ç
Ç
ÇÇ
ÇÇ ÉÉÉ
ÉÉÉ
404
- 2.3.35 -
2.3 Servo drives 1st cut - off register 1/1, 1/2

adjust the wiper to 5V DC.
Fix the resistor to the strap, without changing
red the adjustment.
black
10V DC 5V DC
blue

(red) and 6 (black) to the terminal.
Increments Cut - off register display (1/1 or 1/2)

1117 - 180 mm
2048 0 mm
2979 + 180 mm
- 2.3.36 -
2.3 Servo drives Former position
Changing the resistor for former position

required!

- +
V
24V DC
Adjust the former slant to 20°. Drive the

folding table until the distance from the for-
mer nose to the side frame is 320 mm with
max. 24V DC.
Adjust the current limitation to a value, which
even allows a turning of the motor.
former So the motor is protected against overload.
20°
side frame
folder, superstructure
- 2.3.37 -
2.3 Servo drives Former position

adjust the wiper to 5V DC (according to 85
mm or 2048 increments in the CPTRONIC
red display).
black Fix the resistor to the strap, without changing
10V DC 5V DC the adjustment.
blue Connect the resistor connections 4 (blue), 5

(red) and 6 (black) to the terminal.
- 2.3.38 -
2.4 Voltage supply Table of contents
2.4 Voltage supply
2.4.1 Rectifier modules GRM

2.4.2 GRM voltages
2.4.3 Power supply boards NTK5/NTK24
2.4.4 Memory analog board module SPM
Infeed power supply module ENM
2.4.5 Measuring amplifier 0N1
2.4.6 Earth leakage monitor module IWM

2.4 Voltage supply Table of contents

2.4 Voltage supply Rectifier modules GRM
Rectifier modules GRM
auxiliary
LTK drives
auxiliary
GRM LTM drives
Supply Trans−
voltage former
Electronic
NTK boards
Brakes + field
main drives
Principle of voltage supply

Rectifier modules GRM convert the alternating GRM24 and GRM48 are of identical design and
voltage coming from the transformers into direct interchangeable.
voltage.
This direct voltage supplies the power parts, The modules are in the converter power part
power supply boards and the components of the cabinets of the CPTRONIC and Post−Unit sections
main drives (field and brakes). and in the Printfunction CPTRONIC − cabinet.
GRM5 GRM24 /GRM48
fuses on the GRM5: 15AF/ 250V fuses on the GRM24/GRM48: 20A/ 250V
GRM120 GRM250
fuses on the GRM120: 30A / 250V fuses on the GRM250: 16AT / 250V
Rectifier modules
− 2.4.1 −
2.4 Voltage supply GRM, voltages
The voltages of the rectifier modules are applied

GRM−voltages to the fastening screws of the modules (exception
GRM250).
The permissible tolerance for the output and input
voltages is ± 15%.
GRM5 Output voltages:

U1 = U2 = U3 = 34V DC
U1 U2 U3
U4 U5 U6 Input voltages:
U4 = U5 = U6 = 24V AC
GRM24 Output voltage:

U1 = 37V DC
U1
Input voltages:
U2 U3 U2 = U3 = U4 = 26V AC
U4
U1 = 52V DC
U1
Input voltages:
U2 U3 U2 = U3 = U4 = 37V AC
U4

U1 = 127V DC
U1
Input voltages:
U2 U3 U2 = U3 = U4 = 90V AC
U4
GRM250 U1
Output voltage:
U1 ...... U12 = 251V DC
U13 U14 Input voltages:

U15 U13 = U14 = U15 = 185V AC
U12
− 2.4.2 −
2.4 Voltage supply Power suppy boards
Power supply boards

NTK5/NTK24
The power supply boards receive their input
voltages from the rectifier modules (NTK24 from
GRM24 and NTK5 from GRM5). The respective
power supply board reduces the input voltage to
an output voltage of approx. 24V DC or approx.
5,2V DC.
The power supply boards are slot coded, i.e. only
in its board slot the NTK obtains, by means of a
reference voltage, the information which output
voltage is to be generated.
The boards are of identical design and inter−

changeable.
Plug X1 F1
16AT
Power supply board
The input voltage tolerances may be max.

± 15%.
The output voltage tolerances are max. ± 1%.
NTK5
Input voltage UI = 34V DC Output voltage UO= 5,2V DC
Plug X1 Plug X1
− UI D30 − UO D26
+UI Z32 +UO D22
NTK24
Input voltage UI = 37V DC Output voltage UO= 24V DC
Plug X1 Plug X1
− UI D30 − UO D26
+UI Z32 +UO D22
− 2.4.3 −
2.4 Voltage supply SPM/ENM
Memory analog board module SPM

Memory analog board modules are in the Printfunc−
tion CPTRONIC 1 cabinet and in the Post−Unit
X1 CPTRONIC cabinet.
approx. 1
18V AC 2 From an
approx. 3 SPM − input voltage of approx. 21V AC (X1/5, X1/6)
18V AC 4 they generate an
5 − output voltage of approx. 18V AC (X1/1, X1/2,
approx. X1/3, X1/4) as well as of 20V DC (X2/1, X2/2).
21V AC 6
X2 The AC output voltage is required on the memory
1 analog board SAK to generate the supply voltage
approx. 2 for the digital−analog converters.
20V DC 3 The direct voltage can be used to supply sensors
connected to the SAK.
At the moment no sensors are connected; plug X2
remains free.
Fuse:
1.6AT/250V
Memory analog board module
Infeed power supply module ENM

The infeed power supply modules ENM are in
the infeed CPTRONIC cabinet (2 modules) and in
Heat sink the Post−Unit CPTRONIC cabinet (2 modules).
From an input voltage of 15V AC or 18V AC they

generate the supply voltage for the infeed control
Si: board ERK3 and the synchronization control
1.6AT/250V board GLK2. Depending on the backplane
coding these are 12V DC or 15V DC.
ENM
Connector pin assignment X1
Si:
1.6AT/250V 1 +U supply voltage
2 − U supply voltage
3 switchable input for 12V DC/15V DC
4 ground
Plug X1 5 voltage monitoring (5V against ground)
6 not assigned
Infeed power supply module 7
8
Inputs for 15V AC or 18V AC
9
10
− 2.4.4 −
2.4 Voltage sopply Module for measuring amplifier
Voltage supply module for measuring amplifier

The voltage supply module 0E1 rectifies the a.c.
voltage coming from the transformer OT9 and
passes the direct voltage to the measuring
X1 X1
amplifier 0N1 (web tension control).
1 7 +15V DC
26V AC 2
5 Ground
Fuse: 0.5A 3 -15V DC
9
26V AC
10
Fuse: 0.5A
Voltage supply module for measuring amplifier
voltage supply
0E1 Module 0E1
SAK FEM10 0N1 15B1

15 web tension
load cells
LVT2
Measuring
amplifier 0N1 15B2
REK 1 ESK 15MID1

SVM
diagramm of the modules and the measuring amplifier
allocation of the terminal strip X2:
X2 terminal strip
15a +15V DC
19c Masse
16a -15V DC
measuring amplifier 0N1
− 2.4.5 −
2.4 Voltage supply IWM, location
Earth leakage monitor IWM

Location and function One earth leakage monitor is located
- at the back panel of the three-phase current
cabinet in the three-phase current section,
- at the back panel of the CPTRONIC cabinet in
the Post-Unit section.
Three-phase current section Post-Unit section

LT PT
Location of the earth leakage monitor modules
Main power
source
U
Measuring voltage 20V
Measuring signal approx. 20V / 0.1 Hz
220V AC Output
to CPTRONIC
10s t
A2 A3 11 E B2 B1
Evaluating electronics
Setpoint transmitter LT PT
(set to 100kW)
green red
14
24 V DC
Function chart / earth leakage monitor module

- the IWM monitors the insulation resistance of the - the monitoring function of the IWM is indicated by
main power source by permanent measurements the green LED (IWM active)
- the set insulation resistance
is 100kW - red LED at the IWM is lit
- output 11: 24V DC, if insulation resistance - if insulation resistance <100kW :
100 kW - yellow signal lamp ”Production run error” on the
- output 11: 0V, if insulation resistance CPTRONIC console is flashing
<100kW (ground fault)
Functional test (ground fault simulation)

The green LED shows that the earth leakage Note: The English inscription for ”LT” and ”PT” is ”RB”
monitor is in operation. (Reset Button) and ”TB” (Test Button)!
- press the test button ”PT” for at least 10 seconds
- the red LED signals a fault and is lit
- press the reset button ”LT” for at least 10 seconds
- the red LED goes out
− 2.4.6 −
2.5 Oil supply Table of contents
2.5 Oil supply
2.5.1 Oil circuit printing units

2.5.2 Central lubrication
2.5.4 Circular lubrication
2.5.8 Oil circuit Post−Unit
2.5.9 Switches, sensors
2.5.11 EAK input/output assignment Post−Unit

2.5 Oil supply Table of contents

Oil circuit printing units
Oil supply
2.5 Oil supply

Worm flow 12 bar
control switch pressure switch
Dryer Central lubrication (O.S.+D.S.)
Web catcher
Circular lubrication
(D.S.)
Oil reservoir with

water detector
Drive shaft
HEIDELBERG HARRIS
Central lubrication
float switch (O.S.)
(D.S.)
Central 3~
− 2.5.1 −
lubricationReturn
flow pump
Capacitive Main
sensor drive Temperature
sensor
Central lubrication
oil pressure switch Oil
oil filter cooling
valve Relief
Oil valve
pressure
switch
Oil reservoir Oil filter
Oil
Central float switch circular
lubrication 3~ 3~ 3~ 3~ lubrication 3~
Circular
pump
circuit
lubrication
pump
printing
Oil circuit printing units
units
03.96
2.5 Oil supply Oil circuit central lubrication
Central lubrication:
The central lubrication system provides cyclic oil If the pressure of 12 bars is not reached within two
supply to the slide bearings on the operator and minute, the pump continues running until a pressure
drive sides. of 12 bars is reached. An error message is output,
however (Yellow lamp).
When the main switch is turned on, the central If the pressure of 12 bars is not reached after one
lubricating pump (flow rate = 0.5 l/min) starts hour, the machine goes to stop (red lamp).
running. If an oil pressure of 12 bars is reached The auxiliary contact of the motor overload switch
within 2 minutes, the pump continues to run for for the pump is constantly interrogated, and if it
another 15 seconds before shutting down. The responds the pump is also shut down by the
waiting period for the next lubricating cycle then software. An error message is output.
begins. At 50000 imp/h it lasts 10 minutes, at
standstill 60 minutes. In between, the function is The functions explained are shown in the flow
linear. The reference value is the maximum press diagram below.
speed between 2 lubricating intervals.
Main switch Oil pressure OK

"ON"
Pump on;
Error message;
delete error message; Oil pressure of 12 bars not reached interrogation MSS
interrogation MSS and pressure
and pressure
switch;
switch
start waiting period of 2 minutes
Error
Oil pressure o.k. motor over−
load switch
Pump off;
15 seconds of lubrication;
Error motor overload switch error message;
interrogation MSS and pressure
interrogation
switch
MSS
Lubricating
period
over
Pump off;
start waiting period (10 − 60min) for Error motor overload switch
the next lubricating cycle;
interrogation MSS
Waiting period over
Flow diagram central lubrication
− 2.5.2 −
Oil reservoir with water detector
capactive The collecting vessel on the operator side collects

oil flow
sensor oil. The oil flows into the oil reservoir with the
water detector situated at a lower level. At a
intermediate certain level the oil is pumped back into the
tank central oil reservoir until the "min" float switch
responds. In order to prevent water from entering
oil pump
the oil circuit in case of lackage of the cooling
system for the distributor roller or ink fountain
roller, a capacitive sensor permanently measures
the water content of the oil. This sensor is
calibrated to a water content of 5%.
float switch The setting screw must not be readjusted! If the
sensor responds, the red LED lights up and the oil
pump is stopped immediately.
A pump in operation is shut down and a pump at
standstill cannot be started up again. The source
of the derangement must located and must
drain plug redresses. The sensor is activ and machine at
stand still, the machine con not be started up
again.
Oil reservoir with water detector The oil reservoir and the intermediate tank must
be drained. For this purpose, remove the drain
plug from the oil reservoir and disconnect the
supply line from the intermediate tank.By this it is
possible the intermediate tank to turn top. The oil
in the intermediate tank runs turn in the oil tank.
Here can the oil let off. Also the oil, in the line
between collecting vessel (printing unit O.S.) and
oil tank, is let off. The oil is according to fills in the
corresponding printing unit, until the oil in the tank
is not vollutes.
Atfter the elimination of the derangement the
machine can start up per push button acknowl−
edgement.
Oil filter (central lubrication)
The oil filter comprises a pressure switch and a

pressure relief valve. If the filter cartridge is dirty,
the oil flow is reduced, the oil pressure behind the
filter cartridge goes down and the pressure switch
responds. Simultaneously, the oil pressure in front
of the filter cartridge rises and the relief valve
opens the bypass. This ensures that although the
oil filter is dirty the oil flow is not interrupted. The
oil is, however, no longer filtered and the cartridge
has to be replaced.
Oil filter
− 2.5.3 −
2.5 Oil supply Oil circuit circular lubrication
Circular lubrication The corresponding SSKs are in the SSE 2.1

(Printfunction). The following inputs are assigned on
printing units: the following SSKs:
The circular lubrication system lubricates gear

Input Input Input Input
wheels, worm gears and the drive block.
4 8 12 16
Oil temp. Oil temp. Oil temp. Oil temp.
Each double printing unit is equipped with a
SSK1 PU1 PU2 PU3 PU4
pump having a capacity of 18 l/min.
At power − up, the oil pumps start running and
wait until all flow control elements report "OK". If
this does not happen within 10 minutes, an error
message will be produced. The oil pumps
continue running, however.
If the "OK" comes from all flow control elements,
the pumps are shut down for 10 minutes. After The measuring converter has the following connections:
this, the pumps run for 1 more minute and are
then shut down again for 10 minutes. As soon as 24V
6 0V 1
the machine turns, this cycle is interrupted and
the oil pumps remain on. 5 0...10V 2
When the machine stops, the lubrication system
remains switched on for 5 minutes and then the 4 0°C ....100°C 0V 3
cycle "10 minutes off, 1 minute on" starts again.
The exact function is shown in the flow diagram
on the next page.
Oil temperature control The exact function of the oil temperature control is
shown in the flow diagram on the page after next.
A temperature sensor PT100 measures the
temperature of the oil from the circular lubrication
system which is pumped into the printing unit. The Oil temperature rise
measuring converter is located in the distribution
box of the printing unit and converts the measured On power − up of the machine, the oil might at
value of 0 to 100°C into a voltage between 0 and first be too cold and thus too thick to be
10V. The supply voltage for the converter is 24V. pumped to the outlet openings of the circular
lubrication system which are situated at a higher
level. The pressure in the piping below rises. As
a result of this, the relief valve opens and the oil
flows back into the oil reservoir through the
bypass. The oil temperature rises and more and
X5
0 24V more oil escapes through the outlet openings of
SSR the circular lubrication system. As a result of this,
PT100 5
2 0 ...10V D4 the oil pressure in the piping drops. The relief
DC SSK valve closes again and all the oil pumped flows
4
3 D5 out of the outlet openings.
SSM
Measuring converter Float switch
SAK
If the oil level drops below a certain value,
the float switch responds and the yellow button
"Error production run" starts flashing.
REK
− 2.5.4 −
Flow control elements
The worm gears and drive block require constant

lubrication (cooling and lubrication). Any response
by the flow control elements therefore leads to an
emergency stop of the machine.
The machine can decontrolled with the button
"acknowledgment" on the console after elimina−
tion of the fault.
Oil filter circular lubrication
The oil filter is equipped with a pressure switch.

When the filter cartridge is dirty less oil flows
through, the oil pressure behind the filter cartridge
drops and the pressure switch responds. The
yellow lamp in the CPTRONIC console starts to
flash. The filter has to be replaced. But contrary to
the oil filter of the central lubrication system, there
is no by pass. Less and less oil will flow, the flow
control element will respond and the machine will
stop.
− 2.5.5 −
2.5 Oil supply Oil circuit circular lubrication
Main switch
"ON"
Error eliminated
Test motor overload switch Error message test flow
and flow control elements control elements
Error flow control elements
no errors
Flow control Error eliminated Error message, test motor

Pump on;
elements OK overload switch, block drive,
test motor overload switch
pump off
and flow control elements
Error motor overload switch
Error
flow control elements
Cylinders Error motor overload switch
are turning
10 minutes of lubrication Lubricating time has elapsed
Error message, test motor

overload switch and flow
control elements, if error
block drive
Pump shutdown for
10 minutes Error eliminated
Cylinders Time has

Lubricating time has elapsed
are elapsed
turning Error flow control elements
1 minute of intermediate lubrica−
tion Error motor overload switch
Cylinders
are turning
Error flow control elements

Pump on;
test motor overload switch
and flow control elements
no errors
Machine is running; Error flow control elements

monitor MSS and flow control
elements;
unblock drive
Machine at standstill
Cylinders
are turning Error flow control elements
After machine stop still 5
Time has minutes of lubrication; block
elapsed drive
Flow diagram for circular lubrication printing

units
− 2.5.6 −
2.5 Oil supply Oil temperature control
Main switch ”ON”
Oil flow (flow control element o.k.")

Cooling off
Cooling off (water valve closed)
no oil flow
Oil temperature < 25°C

Oil temperature > 40°C during operation
Oil temperature < 30°C
during standstill
no oil flow Cooling on

(water valve open)
delete warning
Oil temperature > 55°C Oil temperature < 52°C
Output warning
(yellow button Error
no oil flow production" is flashing)
Take the machine off Stop"
Oil temperature > 60°C Oil temperature < 57°C
Stop the machine

(red button Error machine"
no oil flow is lit)
Flow diagram for oil temperature control − circular lubrication
− 2.5.7 −
2.5 Oil supply Oil circuit Post−Unit
Oil circuit Post − Unit
Gear block
superstructure
Flow control Switch grease lubrication

element minimum
Switch Grease lubrication

"Grease solenoid valve
lubrication
finished"
Chill rollers
gear block
Oil pressure
switch
oil filter Float
switch
3~
Circular lubrication
oil reservoir
Diagram oil circuit Post − Unit
Circular lubrication Grease lubrication

The circular lubrication system of the Post − Unit Grease lubrication is triggered every 500000 copies
lubricates the gear wheels of the folder as well as (gross counter) or on command from the CPTRONIC
the gear block in the superstructure and in the chill console. The switch "Grease lubrication finished"
rollers. This function is basically identical to the monitors lubrication and during each lubricating cycle
circular lubrication of the printing units. Only the it is switched on or off by means of a cam.
temperature control and the cooling valve are
missing. You will find the description of these
functions in the chapter "Circular lubrication−
printing units".
− 2.5.8 −
2.5 Oil supply Switches, sensors
Switches, sensors The drawings always show the switches in their

normal state, i.e. when the power is not applied.
D Worm flow control element (XS58), NO − contact:
1 3 Oil flow below minimum

1 (= emergency stop of the
machine)
1 3 Oil flow OK
3
D Circular lubrication oil filter (XS64), NC − contact:
1 3 Oil filter clogged

1 (=oil pressure in oil fil−
ter too high)
1 3 Oil filter OK
3 (=oil pressure in oil filter
OK)
D Central lubrication oil filter (1S125, only PU1), NC − contact:
1 3 Oil filter clogged

too low)
1 3 Oil filter OK
OK)
D Oil reservoir float switch (1S63, only PU1), NO − contact:
Float switch below

1 2
1 minimum
(=oil level too low)
1 2 Float switch OK
2 (=oil level OK)
− 2.5.9 −
2.5 Oil supply Switches, sensors
D Float switch central lubrication (1S122/123, only PU1), changeover contact:

3
1
Float switch minimum
1 (=pump stop return flow
2 central lubrication)
3 Float switch maximum

1
2 3 (=pump start return flow
central lubrication)
2
D Capacitive sensor (1B124, only PU1):
red
adjusting LED
srew Output 24 V No water in the oil
Output 0 V Water in the oil

(=pump return flow
central lubrication blocked)
D 12bar pressure switch (XS121, only last PU), NO − contact:
1 2
1 Oil pressure central lubrication
<12 bars
1 2 Oil pressure central lubrication

3 >12 bars
D Temperature sensor, measuring converter:
6 0V 24V 1
5 0...10V 2
4 0°C ....100°C 0V 3
− 2.5.10 −
2.5 Oil supply EAK input/ output assignment
Post −Unit
EAK input/output assignment Post−Unit

EAK1_05:
− input 27: flow control element

− input 28: float switch
NTK5 EAK9 EAK5 EAK1
EAK12 EAK8 EAK4
− input 29: oil pressure switch oil filter
EAE EAK11 EAK7 EAK3
− input 30: switch grease lubrication minimum
SEK1 EAK10 EAK6 EAK2 − input 31: switch grease lubrication finished
− output 31: solenoid valve grease lubrication

− output 32: valve oil cooling
EHE in the CPT R O N IC −cabinet Post−Unit
− 2.5.11 −
2.5 Oil supply EAK input/ output assignment
Post −Unit
− 2.5.12 −
2.6 Location diagram Table of contents
2.6.1 Control cabinet sections

2.6.5 Legend
Infeed 2.6.6 Infeed drive side

2.6.7 Infeed operator side
2.6.8 Infeed paper outlet
2.6.9 Infeed operation panels
2.6.10 Infeed distribution boxes
Imprinting unit 2.6.11 Imprinting unit drive side

2.6.12 Imprinting unit operator side
2.6.13 Imprinting unit paper infeed
2.6.14 Imprinting unit paper outlet
2.6.15 Imprinting unit operation panels D.S.
2.6.16 Imprinting unit operation panls O.S.
2.6.17 Imprinting unit distribution boxes
Printing units 2.6.18 Printing units drive side

2.6.19 Printing units operator side
2.6.20 Printing units paper infeed
2.6.21 Printing units paper outlet
2.6.22 Printing units operation panels D.S.
2.6.23 Printing units operation panels O.S.
2.6.24 Printing units distribution boxes
Web catcher 2.6.25 Operator panel web catcher
Chill rollers 2.6.26 Chill rollers operator side

2.6.27 Chill rollers drive side
2.6.28 Chill rollers paper outlet
2.6.29 Chill rollers operation panels
2.6.30 Chill rollers distribution boxes

Folder JF50s 2.6.31 Guards on the folder JF50s, lower module

2.6.32 Guards on the folder JF50s, upper module
2.6.33 Folder JF50s paper infeed
2.6.34 Folder JF50s paper outlet
2.6.35 Folder JF50s, O.S.
2.6.36 Folder JF50s, D.S.
Folder JF50 2.6.37 Guards on the folder JF50

2.6.38 Folder JF50 paper infeed
2.6.39 Folder JF50 paper outlet
2.6.40 Folder JF50, O.S.
2.6.41 Folder JF50, D.S.
Folder JF44 2.6.42 Guards on the folder JF44

2.6.43 Folder JF44 paper infeed
2.6.44 Folder JF44 paper outlet
2.6.45 Folder JF44, O.S.
2.6.46 Folder JF44, D.S.
Distribution boxes/ 2.6.47 Distribution box Z.0LVT1

operation panels
JF50 2.6.48 Distribution box Z.0LVT2
2.6.49 Operation panels DS1, DS2
2.6.50 Operation panel DS3

operation panels
JF50s 2.6.53 Distribution box Z.1LVT2
2.6.54 Distribution box Z.LVT3
2.6.55 Distribution box Z.1LVT4

Distribution boxes/ 2.6.62 Distribution box Y.1LVT1

operation panels
superstructure 2.6.63 Operation panel DS5
JF50/JF50s 2.6.64 Operation panels DS11, DS12, DS12
2.6.65 Operation panels DS4, DS14, DS15, DS17

operation panels
JF44 2.6.67 Operation panels DS1, DS2
Distribution boxes/ 2.6.70 Distribution box Y.3LVT1

operation panels
superstructure JF44 2.6.71 Operation panels DS11, DS12, DS13
Imprinter -cabinet 2.6.73 Imprinter - cabinet

2.6.74 Imprinter - back panel
2.6.75 Imprinter - right-hand side frame
2.13.76 Imprinter - inside upper
Infeed-cabinet 2.6.77 Infeed - cabinet

2.6.78 Infeed - back panel
2.6.79 Infeed - right-hand side frame
2.6.80 Infeed - inside upper
Three phase power 2.6.81 Three phase power cabinet - cabinet

cabinet
2.6.82 Three phase power cabinet - back panel
2.6.83 Three phase power cabinet - hinged mounting plate
Interface adapter 2.6.84 Interface adapter cabinet - cabinet

cabinet
2.6.85 Interface adapter cabinet - back panel
2.6.86 Interface adapter cabinet - right-hand side frame

Cable entry cabinet 2.6.87 Cable entry cabinet - cabinet

2.6.88 Cable entry cabinet - left-hand side frame
Main switch 2.6.89 Main switch cabinet - cabinet

cabinet
2.6.90 Main switch cabinet - power distribution
Transformer 2.6.91 Transformer cabinet - cabinet

cabinet
2.6.92 Transformer cabinet - left-hand side frame
2.6.93 Transformer cabinet - transformer rack
2.6.94 Transformer cabinet - (Two web)
2.6.95 Transformer cabinet - (Two web)- left-hand side frame
2.6.96 Transformer cabinet - (Two web) - transformer rack
Converter power part 2.6.97 Converter power part cabinet - cabinet

cabinet
2.6.98 Converter power part cabinet - left-hand side frame
2.6.99 Converter power part cabinet - back panel
2.6.100 Converter power part cabinet (Two web) - cabinet
2.6.101 Converter power part cabinet - left-hand side frame (Two web)
2.6.102 Converter power part cabinet - back panel (Two web)
Master 2.6.103 Master CPTRONIC -cabinet - cabinet

CPTRONIC -caninet
2.6.104 Master CPTRONIC-cabinet - back panel
2.6.105 Master CPTRONIC-cabinet - swing frame
Printfunction 2.13.106 Printfunction CPTRONIC 1-cabinet - cabinet

CPTRONIC 1-cabinet
2.6.107 Printfunction CPTRONIC 1-cabinet - back panel
2.6.108 Printfunction CPTRONIC 1-cabinet - swing frame
Printfunction 2.6.109 Printfunction CPTRONIC 2-cabinet - cabinet

CPTRONIC 2-cabinet
2.6.110 Printfunction CPTRONIC 2-cabinet - back panel
2.6.111 Printfunction CPTRONIC 2-cabinet - swing frame

Post-Unit
Transformer 2.6.112 Transformer cabinet Post-Unit - cabinet

cabinet Post-Unit
2.6.113 Transformer cabinet Post-Unit - left-hand side frame
2.6.114 Transformer cabinet Post-Unit - back panel
2.6.115 Transformer cabinet Post-Unit - right-hand side frame
Converter power part 2.6.116 Converter power part cabinet Post-Unit - cabinet
cabinet Post-Unit
2.6.117 Converter power part cabinet Post-Unit - left-hand side frame
2.6.118 Converter power part cabinet Post-Unit - back panel
2.6.119 Converter power part cabinet Post-Unit - right-hand side frame
Post-Unit
CPTRONIC -cabinet
2.6.120 Post-Unit CPTRONIC-cabinet - cabinet
2.6.121 Post-Unit CPTRONIC-cabinet Post-Unit - back panel
2.6.122 Post-Unit CPTRONIC-cabinet Post-Unit - right-hand side frame
2.6.123 Post-Unit CPTRONIC-cabinet Post-Unit - inside upper
2.6.124 Post-Unit CPTRONIC-cabinet Post-Unit - swing frame


2.6 Location diagram Control cabinet sections
Control cabinet sections

The control cabinet for the M600 is divided into The following cabinet sections are electrically
different groups. isolated towards each other:
On delivery of the machine the control cabinet
comes in six different sections:
Three − phase power section
CPTRONIC section
Imprinting unit section
Three−phase power section
electrical isolation
CPTRONIC section Post−Unit section
Post−Unit section
Dryer section
Dampening water preparation unit, Dryer section
ink distributor temperature control
Dampening water prepara−

The individual cabinets contain the mentioned
tion unit, ink distributor tem−
electronic plug−in units whose abbreviations are perature control
included in the list of abbreviations.
Each section has its own voltage supply.
Depending on the system voltage and frequency,

matching transformers are provided for the voltage
supply to the CPTRONICs (see "Start−up/Connec −
tions").
Three−phase power section
TPE ERE
Imprinter Infeed cabi− Interface Main

cabinet net adapter switch cabinet
Three−phase cabinet
power
cabinet Cable entry
cabinet
− 2.6.1 −
CPTRONIC section
EAE 1.2 EAE 2.2 HAE 2.2

REE / M1 REE / M2
EAE 1.1 LTE 2.1
SSE 1.1 HAE 2.1
SSE 2.1 LTE 2.2
Trans−
former Master Print function
cabinet CPTRONIC CPTRONIC 2 cabinet
Converter cabinet Print function
power part CPTRONIC 1
cabinet cabinet
Post−Unit section
Post-Unit-section with Post-Unit-section with

one folder two folders
- EAE
REE / M REE / M
EHE EHE
LTE LTE
SSE SSE
Transforme CPTRONIC -c Transforme

r cabinet Converter Converter CPTRONIC -c
power part abinet r cabinet abinet
power part
cabinet cabinet
− 2.6.2 −
Dryer section
Depending on the manufacturer, up to three
control cabinet sections are required.
Dryer Dryer Dryer

cabinet 3 cabinet 2 cabinet 1
Dampening water preparation unit, ink distributor temperature control

The dampening water preparation unit and the ink
distributor temperature control are located
between the control cabinets CPTRONIC section
and dryer section.
Dampening water Ink distributor tem−

preparation unit perature control
− 2.6.3 −
The single control cabinet sections are arranged as

follows:
Post − Unit
section
Dryer
section
Dampening water
preparation unit, ink
distributor temperature
control
CPTRONIC sec−
tion
Print-Unit-section
Three phase
power section
Arrangement of control cabinet sections
Imprinting
Unit
section
− 2.6.4 −
2.6 Location diagram Legend
Explanation of the different views

The views in the following location diagrams are
identical with the arrows shown below.
This way of looking at the machine is particulary
important for the folder!
Drive side
Paper infeed Paper outlet

RW EZW DDWs BFV TR KW FA
Operator side
Viewing diagram
When counting the printing units electrically

make sure to count from the web catcher to
the infeed.
− 2.6.5 −
2.6 Location diagram Infeed, D.S.
Infeed drive side
Paper outlet Paper infeed
Fan motor 15 M9
Infeed main motor

I15 M1
15 M 18
Web infeed drive
− 2.6.6 −
2.6 Location diagram Infeed, O.S.
Infeed operator side
Paper outlet
Operating
panel
15 R 1
Dancer position resistor
15 HWI 1 15 BKR 1
Power 15 BKR 2
electronics Evaluating
electronics
Paper infeed
operating
panel
15S 7 Contact
pressure roller
ON / OFF
15 LVT1 15 LVT2
15Y7
15Y37 15Y38
Solenoid valves:
15Y7 − Contact pressure roller

15Y37 − Infeed deck UP
15Y38 − Infeed deck DOWN
− 2.6.7 −
2.6 Location diagram Infeed, paper outlet
Infeed paper outlet
O.S. D.S.
15 B 2
ÁÁ ÁÁ
15 B 1
Load cell 15 BBS 1 Load cell
ÁÁ ÁÁ
Web break sensor
15 BKR 1
Web edge control
M M
15 BKR O.S. 15 BKR D.S.
Swivel frame motor
15 B 37
top
Centre−position Infeed deck sensors

sensor
15 B 38
bottom
15 B 31
WEB−infeed
sensor
− 2.6.8 −
2.6 Location diagram Operator panel infeed
Operator panel infeed

Paper infeed D.S. Paper outlet O.S.
15H42 15S42
15S33
Fault Stop
E−STOP
15S43
Crawl speed
15S41
E−STOP 15H2 15S2
Fault Stop
15S39/15H39
Footboard swing up
15S3
15S40/15H40
Footboard swing down Crawl speed
15MID1
15S17/15H17
Center web 15S8/15H8
Trolleys
15S5/15H5
Web − up device
15S1
E−STOP
− 2.6.9 −
2.6 Location diagram Infeed, distribution box
Infeed distribution box LVT1, operator side
FVM SEM SSM FEM 10 FAM 64 FEM 64
X2 X3,X4
X4A X1A X1E X4E
X1
X3A X2A X2E X3E
X5
15/16 LVT 1
X2
X1
SAM Terminal strip X1
Infeed distribution box LVT2, operator side

This LVT does not have a terminal strip.
Its function is to distribute the load cell signals.
15/16 LVT 2
X1
X3
X2
− 2.6.10 −
2.6 Location diagram Imprinting unit, D.S.
Imprinting unit D.S.

63Y357
63Y358
Solenoid valves for
ink feed
Upper ink
fountain roller
63M1
Paper outlet Pape infeed

Upper dampening Upper
ducktor 63M2 circumferential
register
acceleration motor
63M10
Unit − to −
unit Denture clutch
register 63Y5 Multiple − disk
clutch
63Y5
Worm flow control

element 63S58
Printing unit clutched

63B53
Printing unit
declutched 63B54
Multiple − disk
clutch
63Y8
Denture clutch
63Y7 Lower
dampe − ning
ductor
63M3
Lower ink
fountain roller
63M4
Lower
circumferential
register
Pump circular PT100

lubrication Monitoring of
63M3X the oil
temperature
63R1 12 bars pressure switch
Central lubrication
63S121
63Y49
Solenoid valve: Central lubrication oil

filter 63S64
63Y49 − Oil cooling
On
− 2.6.11 −
2.6 Location diagram Imprinting unit, O.S.
Imprinting unit O.S.

Paper outlet
Outlet inking unit top

Paper infeed
XY337
XY340
XY336
XY334
XY338
XY333
XY335
XY339
guard 63S40
Magnetventile XLVT1
XY339 − Wash − up blade
Infeed inking Outlet
XY335 − Dampening rollers On
unit top dampening
XY333 − Metering rollers
63S33 unit top guard
XY338 − Dampening roller
thrown on inking roller 63S36
XY334 − Dampening fountain roller
XY336 − Inking roller1
XY340 − Inking rollers 2+3
XY337 − Ink ductor On XY343
XY343 − Dampening rollers On XY341 Top diagonal

XY341 − Metering rollers XY346 register
XY346 − Dampening roller XY342
thrown on inking roller Top infeed
XY342 − Dampening fountain roller XY344 guard
XY344 − Inking roller 1 XY348 63S39
XY345 − Ink ductor On XY345
XY347 − Wash − up blade XY347
XY33 − Bearer guard Down Top lateral register
XY53 − Clutch Printing unit XY33
XY54 − Declutch printing unit XY53 XY54 Middle infeed
XY9 − Printing unit deck Up guard
XY10 − Printing unit deck Down XY9 XY10
63S35
XY349 − Impression On/Off
XY350 − Impression On/Off XY350 063HWI1
XY349 063HWI2
Botoom
infeed guard Bottom lateral
63S36 register
Outlet guard
bottom 63S41
Infeed dampening
unit bottom guard Bottom
63S36 diagonal
register
Outlet floor
guard 63S42
Infeed inking
unit bottom
guard 63S38
− 2.6.12 −
2.6 Location diagram Imprinting unit, paper infeed
Imprinting unit, paper infeed
A.S. B.S.
Paper infeed top operating

panel
63LVT3
Bottom inking/dampening
system vibrator
clutched/declutched 63B310 Bottom
63S344 dampening water
control
63S345
Paper infeed bottom

operating panel
− 2.6.13 −
2.6 Location diagram Imprinting unit, paper outlet
Imprinting unit, paper outlet
B.S. A.S.
Paper outlet
operating panel
63B309 Top dampening
water control 63S341
Top inking/dampening
system vibrators
63BBS1 Web break sensors
clutched/declutched
63S342
63B9 Printing
unit deck up
63B10 Printing
unit deck down
− 2.6.14 −
2.6 Location diagram Operation panels Imprinting unit D.S.
Operation panels imprinting unit, D.S.

Paper infeed, D.S., top Paper outlet, D.S., bottom
63S25 63S306/H306
E−STOP Damping
63S305/H305
63S26
Clean damping rollers
Forward
63S331/H331
63S27
Ink fountain roller On
Safe
63S28 63S24/H24
Backward Plate cylinder
posioning
63S302/H302 63S30
Damping Forward
63S323/H323 63S31
Ink fountain roller On Safe
63S23/H23 63S32
Plate cylinder Backward
posioning
63S29
E−STOP
− 2.6.15 −
2.6 Location diagram Operation panel Imprinting unit O.S.
Operation panel imprinting unit, O.S.
Paper outlet
63S1
E−STOP
63S318, Dampening + + 63S4

Forward
63S319, Dampening − −
63S320/H320, Dampening 63S5

Safe
63S321/H321, Ink rollers
63S6
63S322/H322, Ink ductor On
Backward
63S301/H301 Clean dampening rollers
63S324/H324, Throw the ink blade on
63S7/H5, Plate cylinder positioning
63H1, Fault 63S2

Stop
63S11/H11, Footboard swing up
63S12/H12, Footboard swing down 63S3

Crawl speed
63S312/H312, Impression On
63S326, Dampening + +
63S327, Dampening − −
63S18
63S328/H328, Dampening
Forward
63S329/H329, Ink rollers
63S19
63S330/H330, Ink ductor On
Safe
63S332/H332, Throw the ink blade on
63S21/H6, Plate cylinder positioning 63S20

Backward
63S17
E−STOP
− 2.6.16 −
2.6 Location diagram Distribution box imprinting unit
Imprinting unit, distribution box LVT 1
FEM64 − 1
X4E X1A
X1 X3E X2A
FAM64 − 1
X2E X3A
X1E X4A
X1
FEM10
X5 X2 SSM1
X5E XES X3
Measuring X4
converter
PT100
Terminal strip Terminal strip
X1E X4A
X2E X3A
FEM64 − 2 FAM64 − 2
X3E X2A
X4E X1A
− 2.6.17 −
2.6 Location diagram Printing unit, D.S.
Printing unit drive side
XY358 XY357
Upper ink fountain roller Solenoid valves for

Buzzer 0 H1 pressure switch X M1 ink feed
(above BFV) 0 S28 (above BFV)
Upper dampening ductor

X M2
Upper circumferential
Unit−to− register
unit
register
Worm flow control

element X S58
HWI
HWI1 1 X4
(only
(onlyPU1)
PU1)
Printing unit clutched X B53
Printing unit declutched X B54
Solenoid valves: Lower circumfer−

ential register
XY49 − Oil cooling ON
XY357 − Ink feed bottom Lower dampening
XY358 − Ink feed top ductor X M3
Lower ink foun−

tain roller X M4
Central lubrication−
Central return flow pump
lubrication 1 M19 Oil reservoir float
float switch switch
1 S122/123 1 S63 (only PU1)
Pump circular
lubrication 12 bars pressure switch
X M3X X S121 (only last PU)
Main drive 29M1

Water level detector Fan motor 29M4
1 B124 Brake 29Y1
XY49
Water pan only Central lubrication Central lubrication oil filter

PU1 pump 1 M14 (only 1 S125 (front, only PU1)
PU1)
Circular lubrication oil fil−
ter X S64 (back)
− 2.6.18 −
2.6 Location diagram Printing unit, O.S.
Printing unit operator side
Outlet inking unit top

guard X S40
XY339
XY335
XY333
XY338
XY334
XY336
XY340
XY337
Solenoid valves top:
X LVT1
XY335 − Dampening rollers ON Guard infeed
XY333 − Metering rollers
XY338 − Dampening roller thrown on
top X S33 Guard outlet
inking roller top X S36
XY334 − Dampening fountain roller
XY336 − Inking roller 1
XY337 − Ink ductor ON
Top diagonal
register
Bearer guard X
S42
Top lateral regis−

ter
Outlet bottom
guard X S38
Bottom lateral
register
Solenoid valves bottom:
XY343 − Dampening rollers ON

XY341 − Metering rollers Infeed bottom
XY346 − Dampening roller thrown on
inking roller guard X S34 Diagonal reg−
XY342 − Dampening fountain roller ister bottom
XY344 − Inking roller 1 XY343
XY349
XY345 − Ink ductor ON XY341

XY33 − Bearer guard DOWN XY346
XY53 − Clutch printing unit
XY54 − Declutch printing unit
XY342
XY9 − Printing unit deck UP XY359 XY344
XY10 − Printing unit deck DOWN
XY349 − Impression ON/OFF XY360 XY348
XY359 − Wash inking rollers Infeed inking Outlet floor
top unit top guard X XY345 guard X S41
XY360 − Wash inking rollers S35
bottom XY347
XY33
XY53 XY54
XY9 XY10
− 2.6.19 −
2.6 Location diagram Printing unit, paper infeed
Printing unit, paper infeed
D.S. O.S.
Paper infeed top operating
panel
X LVT 3
X S341
Top inking / dampening system

vibrators clutched / declutched
X S342
X B309 Top
dampening water
control
X S344
X B310 Bottom
Bottom inking / dampening system vibrator dampening water
clutched / declutched control
X S45
Paper infeed bottom oper−

ating panel
X LVT 4
− 2.6.20 −
2.6 Location diagram Printing unit, paper outlet
Printing unit, paper outlet
O.S. D.S.
Paper outlet
operating panel
X BBS 1 Web break sensors
X B9 Printing unit
deck up
X B10 Printing
unit deck down
− 2.6.21 −
2.6 Location diagram Operation panels printing units D.S.
Operating panels printing units, D.S.

Paper infeed, D.S., top Paper infeed, D.S., bottom
XS25 XS306/H306
E−STOP Damping
XS305/H305
XS26
Forward
XS331/H331
XS27
Ink fountain roller On
Safe
XS30
XS28
Forward
Backward
XS31
XS302/H302
Safe
Damping
XS32
XS301/H301 Backward
XS29
E−STOP
− 2.6.22 −
2.6 Location diagram Operation panel printing units O.S.
Operation panel printing units, O.S.

Paper outlet
XS1
E−STOP
XS318, Dampening + + XS4

Forward
XS319, Dampening − −
XS320/H320, Dampening XS5

Safe
XS321/H321, Ink rollers
XS6
XS322/H322, Ink ductor run
Backward
XS323/H323, Ink ductor On
XS7/H5, Plate cylinder positioning
XH1, Fault XS2

Stop
XS11/H11, Footboard swing up
XS12/H12, Footboard swing down XS3

Crawl speed
XS312/H312,Impression On
XS326, Dampening + +
XS327, Dampening − −
XS18
XS328/H328, Dampening
Forward
XS329/H329, Ink rollers
XS19
XS330/H330, Ink ductor On
Safe
XS21/H6, Plate cylinder positioning XS20

Backward
XS17
E−STOP
− 2.6.23 −
2.6 Location diagram Distribution box printing units
Printing unit, distribution box LVT 1
FEM64 − 1
X4E X1A
X1 X3E X2A
FAM64 − 1
X2E X3A
X1E X4A
X1
FEM10
X5 X2 SSM1
X5E XES X3
measuring X4
converter
PT100
Terminal strip Terminal strip
X1E X4A
X2E X3A
FEM64 − 2 FAM64 − 2
X3E X2A
X4E X1A
− 2.6.24 −
2.6 Location diagram Operation panel web catcher
Operation panel web catcher
59H23 59S23
Fault Stop
59S24
Crawl speed
59S22
E−STOP
− 2.6.25 −
2.6 Location diagram Chill rollers, O.S.
Chill rollers operator side
ÁÁ
19 B 1/2
ÁÁ
ÁÁ
Load cells 19 LVT1
19 BKR 1
Power
Paper infeed electronics
operating
panel
15 BKR 2
Evaluating
19M 2 electronics
Blade
Paper outlet
operating
19 BBS 1 panel
Web break sensor
− 2.6.26 −
2.6 Location diagram Chill rollers, D.S.
Chill rollers drive side
19M 67 Harmonic Drive motor
19Y7
19 HWI1 19S 7
19Y6
19S 6
19S 6 − Flow control element 1 Solenoid valves :

19S 7 − Flow control element 2
19Y 6 − Cooling water valve 1
19Y 7 − Cooling water valve 2
− 2.6.27 −
2.6 Location diagram Chill rollers, paper outlet
Chill rollers paper outlet
O.S. D.S.
ÁÁ ÁÁ
ÁÁ 19 B 1 19 B 2
ÁÁ 19Y11
ÁÁ ÁÁ
Load cell Load cell 19Y12
19Y32 19Y31
19Y9
19 BKR 3
Sensor for BKR O.S. sensor cross bar Sensor for BKR D.S. 19Y13
M M
M Stepper motor
for swivel − type frame
Center position sensor
19 BBS 1
Web break sensor
Solenoid valves:
19Y 9 − Blade
19Y 11 − Silicone applicator top
19Y 12 − Silicone applicator bottom
19Y 13 − Contact pressure rollers
19Y 31 − Clutch cylinder part ENGAGED
19Y 32 − Clutch cylinder part DISENGAGED
− 2.6.28 −
2.6 Location diagram Operation panels chill rollers
Operation panels chill rollers

Operation panel paper infeed, O.S. Operation panel paper outlet, O.S.
19H1 19S2
Fault Stop 19H2 19S26
Fault Stop
19H4 19S3
19S4 Crawl speed 19S27
Blade Crawl speed
On/Off
19S1
E−STOP
19S17 / 19H17 19S5 / 19H5

Center web Trolley
15S1
E−STOP
− 2.6.29 −
2.6 Location diagram Chill rollers, distribution box
Chill rollers distribution box LVT 1
Terminal strip
X1A X1E
X2A X2E
FAM64 FEM64
X3A X3E
X4A X4E
FEM10
SSM1 X5S X5E
X2
X1
Chill rollers distribution box LVT2, operator side

This distribution box has no terminal strip. It
distributes the load cell signals.
19 LVT 2
X1
X3
X2
− 2.6.30 −
2.6 Location diagram F older , protection grid JF50s
Protection grid at the folder JF50s, lower module

For the allocation of the protection grids to the
corresponding limit switches please refer to the
next pages.
Please note the view of the folder shown below!
Chill rollers
Paper infeed
Operator side
ÇÇ Drive side
ÇÇ ÇÇÇ
SG18
ÇÇ
SG14
ÇÇ
ÇÇÇ
ÇÇ
ÇÇÇ SG12
ÇÇÇ SG17
ÇÇÇ
ÇÇ
ÇÇÇ
ÇÇÇ ÇÇ
ÇÇÇ
ÇÇÇ ÇÇ ÇÇÇ
SG16
SG11
ÇÇÇ ÇÇ
ÇÇ
SG13
ÇÇ
ÇÇ
ÇÇ
ÇÇ
SG15
Paper outlet
Top view folder
− 2.6.31 −
2.6 Location diagram F older , protection grid JF50s
Protection grid at the folder JF50s, upper module

next pages.
Chill rollers
Paper infeed
Operator side
ÇÇ Drive side
ÇÇ ÇÇÇ
SG8
ÇÇ SG4
ÇÇ
ÇÇÇ
ÇÇ
ÇÇÇ SG2
ÇÇÇ ÇÇÇ
SG5
SG7
ÇÇÇ
ÇÇ
ÇÇÇ
ÇÇÇ ÇÇ
ÇÇÇ
ÇÇ ÇÇ ÇÇÇ
SG6
ÇÇ
ÇÇ
SG1 ÇÇ
ÇÇ
SG3
Paper outlet
Top view folder
− 2.6.32 −
2.6 Location diagram F older , paper infeed JF50s
DS11
A.S. B.S.
limit switch SG4

Z.1S141
M3
M1 V8 DS3
V5
limit switch
V6 SG4
Z.1LVT1 M4
Z.1S351
Z.1S107
M2
Z.1LVT3 V17 Z.1S108
Z.1S106
DS23
V50
M15 Z.1S105 M16
− 2.6.33 −
2.6 Location diagram F older , paper outlet JF50s
Scanner SSR
DS13
B.S. A.S.
SG3 V19
V7
DS1 V3
V12
SG1 V14 V13
V4
V15
V10 V9
V2 Z.1LVT2
V58
V1
SG13
SG11
DS5
limit switch
DS25 SG3
Z.1S253
V51 Limit switch
main crank
Z.1S232
V52 Limit switch

grease lubrication
Limit switch Z.1S231
jam control (from the D.S.
Z.1S142 accessible) Z.1LVT4
(DS4 and
LVT2 from
the D.S.
accessible)
− 2.6.34 −
DS12 DS13
Y.1M16
Cut − off register control Former position
Y.1SRR1.1, power electronics,
HEIDELBERG HARRIS
Y.1SRR2.1, evaluating electronics,

cut − off register motor Limit switch
Y.1M11 SG5
Top turner bar DS4
Z.1S152
DS11 adjustment Y.1BBS3
Paper DS15 Y.1BBS4
Distribution box Limit switch
infeed
− 2.6.35 −
SG17
Z.1S153
V10
Y.1M12 Y.1LVT1
Bottom turner bar
adjustment
Cut − off register control cut − off register motor
DS24
DS17
V11 V5
F older , JF50s, O.S.

Limit switch
SG17
23S153
V10 23M13
2nd longitudinal fold
vacuum pump motor
03.96
Paper
infeed
Paper
outlet
DS2
Limit switch SG2
Z.1S150
HEIDELBERG HARRIS
DS14
− 2.6.36 −
Top silicone
Limit switch SG12 applicator
Z.1S350 19M65
DS22
Grease lubrication Bottom
min. Z.1S230 silicone
Z.1S231, lubrication applicator
cycle completed 19M66
Main drive 33M1 Blower
F older , JF50s, D.S.

Limit switch Motor fan 33M4 for turner
SG6Z.13S 254 Brake 33Y1 bars Blower
23M18 for Dampening
Oil level float switch
former solution pump
Z.1Y231 Z.1S228
23M19 for silicone
Grease Ölpumpe 23M6 Oil filter pressure applicator
lubrication switch 19M7
Z.13S229
Oil flow control element

03.96
Z.1S227
2.6 Location diagram F older , protection grid JF50
Protection grid at the folder JF50

next pages.
Chill rollers
Paper infeed
Operator side
ÇÇ Drive side
ÇÇ ÇÇÇ
SG8
ÇÇ SG4
ÇÇ
ÇÇÇ
ÇÇ
ÇÇÇ SG2
ÇÇÇ ÇÇÇ
SG5
SG7
ÇÇÇ
ÇÇ
ÇÇÇ
ÇÇÇ ÇÇ
ÇÇÇ
ÇÇ ÇÇ ÇÇÇ
SG6
ÇÇ
ÇÇ
SG1 ÇÇ
ÇÇ
SG3
Paper outlet
Top view folder
− 2.6.37 −
DS11
D.S. O.S.
DS16
HEIDELBERG HARRIS
Clutch for 2nd

V3 longitudinal fold Limit switch SG4
Z0Y325
Z0Y329
Z0Y326
Z0Y330
Z0Y327
Change − over crank Z.0S117 Z.03S151
Solenoid valves: Z.0S124 limit switch
Z0Y120 Z0Y121
− 2.6.38 −
Z.0Y325 Trolleys, draw roller1

Z.0Y326 Center slitting, draw roller1 Z.0M3 Cross Z0Y110 Z0Y109
Z.0Y327 Edge trimming, draw roller1 perforation
Z.0Y328 Creaser1 Z0Y112 Z0Y111
Z.0Y329 Trolleys, draw roller2
Z.0Y330 Center slitting, draw roller2 Z0Y104 Z0Y103
DS3 Z0Y102 Z0Y101
Inductive proximity switches at pneumatic Jam detector
Z.0M1 Gripper fold V5 limit switch
cylinder:
1st cross fold Z.0M4 Phase 2nd Z.03S141
V3 Folding blade s Z.0S122
V5 V6 longitudinal fold
(gripper cam) r Z.0S123
V5 Segment clutch s Z.0S105 Copy
(1st cross fold) r Z.0S106 V6
V6 Segment clutch s Z.0S107
monitoring
F older , paper infeed JF50

(2nd cross fold) r Z.0S108 Z.0S148
V17 Clutch s Z.0S115
(cylinder part) r Z.0S116
Z.0LVT1
Solenoid valves:
Z.0Y101 s Delivery height V11

Z.0Y102 r
Z.0M2 Gripper fold Z.0Y103 s Tape guide(2nd cross fold) V12
2nd cross fold z.0Y104 r
Z.0Y109 s Up(2nd longitudinal fold) V9
Z.0Y110 r
Z.0Y111 s Stop(2nd longitudinal fold) V10
Z0Y107 Z.0Y112 r
V17 Z0Y105 Z.0Y120 s Tape tension(2nd longitudinal V18
Z.0Y121 r fold)
Z.0Y105 Segment clutch(1st cross fold) V5
Z.0Y107 Segment clutch(2nd cross fold) V6
03.96
DS13 Scanner SRR
O.S. D.S.
DS16
Inductive proximity switches at
pneumatic cylinder:
HEIDELBERG HARRIS
Clutch V1 Pin cam s Z.0S217

2nd r Z.0S218
Linmit switch SG1 longitudinal V7 V2 Cover cam, s Z.0S219
Z.0S149 fold (1st cross fold) r Z.0S220
Z.0S117 V4 Gripper opening s Z.0S221
V4 V14 cam r Z.0S222
− 2.6.39 −
DS1 V7 Tape separation s Z.0S223

(2nd cross fold) r Z.0S224 1
V9 Up(2nd longitu − s Z.0S109
V9 V12 dinal fold) r Z.0S110
DS5 DS6 V12 Tape guide s Z.0S103
(2nd cross fold) r Z.0S104
Z.0S143 V14 Longitudinals s Z.0S225
Copy monitoring perforation r Z.0S226
Z.0S146 Grease lubrication limit Solenoid valves(accessible from D.S.):
Jam detector switch 23S231
DS4 limit switch (accessiblr from D.S.) Z.0Y229 s Contact pressure V16
Z.0S142 Z.0Y230 r roller (top)
F older . paper outlet JF50

Z.0Y227 s Contact pressure V15
V2
Z.0Y228 r roller (bottom)
Z.0Y225 s Longitudinal V14
Z.0Y226 r perforation
Z.0Y223 s Tape guide V7
Z.0Y224 r (2nd cross fold)
Z.0Y217 s Pin / gripper opening V1
V1 Z.0Y218 r cam
Z.0LVT2
Limit switch (LVT2 Z.0Y219 s Cover cam fold V2
Main crank SG3 Z.0S253 accessibl Z.0Y220 r gripper opening
limit switch Z.0S232 e from
D.S.)
03.96
Paper Cut − off register control Distribution box DS12 DS13 Paper
Y.1SRR1.1, power electronics, Cut − off register motor
infeed DS11 Y.1SRR2.1, evaluating electronics, outlet
DS15 Y.1BBS3
Y.1M11
Top turner bar Y.1BBS4
adjustment
Y.1M12
Bottom turner
bar adjustment
Cut − off register motor Y.1LVT3
Cut − off register control

HEIDELBERG HARRIS
Y.1M16
Former position
Limit switch SG 5
Z.0S152
− 2.6.40 −
Limit switch SG7 DS4

Z.0S153
DS17
Copy monitoring
23S146 23S147
V10
pneumatic cylinder:
V10 Stop (2nd s Z.0S111

longitudinal fold)r Z.0S112 23M13
F older JF50, O.S.

V11 Delivery height s Z.0S101 vacuum pump motor
r Z.0S102
V11 V11′
03.96
Scanner SRR
Paper Paper
outlet infeed
DS14
HEIDELBERG HARRIS
Solenoid valves: top silicone

Limit switch SG2 applicator 19M65
Z.0S150 Z.0Y113 Cut − off knife
DS2 Z.0Y115 s Clutch cylinder V17
Z.0Y116 r V17
Solenoid valves, Z.0Y118 s Tape tension V19
behind cover Z.0Y119 r (2nd cross fold) Bottom silicone
V19
− 2.6.41 −
Z.0Y157 r Antibacklash 1 V8 applicator 19M66

Z.0Y158 s Antibacklash 2 V8
Z.0Y159 s Antibacklash B V8
Z.0Y160 r V8
V8 Inductive proximity switches at

pneumatic cylinder:
Grease lubrication Z.0BBS1 Z.0BBS2
V8 Antibacklash s Z.0S157
min. Z.0S230
m Z.0S158
Z.0S231, lubrication r Z.0S159
cycle completed
Limt switch SG6

Z.0S 254 Dampening solution
23LVT2 Main drive 33M1 pump for silicone
F older JF50, O.S.

Oil level float switch Motor fan 33M4 Blower for Blower for applicator 19M7
Z.0S228, Brake 33Y1 turner bars former 23M19
Z0Y231
Oil filter 23M18
Grease oil pump 23M6 pressure
lubrication switch
Z.0S229
Oil flow control

element
03.96
Z.0S227
2.6 Location diagram F older , protection grid JF44
Protection grid at the folder JF44

next pages.
Chill rollers
Paper infeed
ÇÇ
ÇÇ SG2
Operator side
ÇÇ ÇÇ Drive side
ÇÇ
ÇÇ SG6
ÇÇ
ÇÇ
ÇÇÇ SG1
ÇÇÇ ÇÇÇ ÇÇ
SG4
SG7
ÇÇÇ ÇÇ
SG3
ÇÇ
ÇÇ
ÇÇ
SG5
Paper outlet
Top view folder
− 2.6.42 −
DS11
D.S. O.S.
DS16
HEIDELBERG HARRIS
Clutch for 2nd

V3 longitudinal fold Limit switch SG4
Change − over crank Z.2S117 Z.2S151
Z.2S124 limit switch
− 2.6.43 −
Z.2M3 Cross
perforation
DS3
Inductive proximity switches at pneumatic Jam detector
Z.2M1 Gripper fold V5 limit switch
cylinder:
1st cross fold Z.2M4 Phase Z.2S141
V17 Clutch, s Z.2S115
V5 V6 2nd longitudinal
(cylinder part) r Z.2S116
fold Copy
V6 monitoring
F older
Z.2S148
JF44,
Z.2M2 Gripper
fold 2nd cross
fold
paper
Z2Y107
V17 Z2Y105
infeed
03.96
DS13
B.S. 23BBS3 A.S.
23BBS4
DS16
Inductive proximity switches at pneumatic
cylinder:
HEIDELBERG HARRIS
V9 Up (2nd longi − s Z.2S147

Clutch 2nd tudinal fold) r Z.2S148
Limit switch SG1 longitudinal fold
Z.2S149 Z.2S117
− 2.6.44 −
DS1 1
DS5
V9
Grease lubrication limit

switch Z.2S231
Jam detector (accessible from D.S.)
limit switch
F older
Z.2S142
JF44,
paper
Limit switch
Main crank SG3 Z.2S253
limit switch Z.2S232
outlet
03.96
Paper Cut − off register control DS12 DS13 Paper
23SRR1.1, power electronics,
infeed DS11 23SRR2.1, evaluating electronics, outlet
DS15 23BBS3
23M11
Top turner bar 23BBS4
adjustment
23M12
Bottom turner
bar adjustment
Z.2LVT3
HEIDELBERG HARRIS
Z.2M16
Former position
Limit switch SG 5
Z.2S152
− 2.6.45 −
Limit switch SG7 DS4

Z.2S153
DS17
V10
pneumatic cylinder:
V10 Stop (2nd s Z.2S111

longitudinal fold)r Z.2S112 Z.2M13
F older JF44, O.S.

V11 Delivery height s Z.2S101 vacuum pump motor
r Z.2S102
V11 V11′
03.96
Paper Paper
outlet infeed
DS14
HEIDELBERG HARRIS
Soleonoid valves: Tor silicone

Limit switch SG2 applicator 19M65
Z.2S150 23Y113 Cut − off knife V8
DS2 23Y115 s Clutch cylinder
23Y116 r
Bottom silicone
− 2.6.46 −
applicator 19M66
V8
Grease lubrication
min. Z.2S230
Z.2S231, lubrication
cycle completed
Limit switch SG6

Z.2S 254 Dampening solution
23LVT2 Main drive 33M1 pump for silicone
F older JF44, D.S.

Motor fan. 33M4 applicator 19M7
Blower 23M18
Z2Y107 Brake 33Y1
Grease
lubrication
03.96
2.6 Location diagram ’Distribution box 1, JF50
Folder JF50, distribution box Z.0LVT 1
X1 X3
X1A
X2A
FAM64
X3A
X4A X2.2 X2.1 Terminsl strip
X4E
X3E
FEM64
X2E
X1E
X1
X5 X2 SSM1
FEM10 X5E X5S
X3
X4
− 2.6.47 −
2.6 Location diagram Distribution box 2 JF50
Folder JF50, distribution box LVT 2
X4A X4E
X3A X3E
FEM64
FAM64 X2
X2A X2E
X1A X1E
X5S X5E FEM10
Terminal strip
− 2.6.48 −
2.6 Location diagram Operation panels JF50 DS1, DS2
Operation panel JF50, DS1
Z.0H233 Z.0S234
Fault Stop
Z.0S238 / Z.0H238
Z.0S235
Tape guide
Crawl speed
( 2nd cross fold)
Z.0S240 / Z.0H240 Z.0S236

2nd cross fold Forward
Tape tension
Z.0S237
Safe
Z.0S233
E−STOP
Operation panel JF50, DS2
Z.0H201 Z.0S202
Fault Stop
Z.0S208 / Z.0H208 Z.0S203

Contact pressure roller (top) Crawl speed
Z.0S206 / Z.0H206
Longitudinal perforation
Z.0S207 / Z.0H207 Z.0S204
Contact pressure roller (bottom) Forward
Z.0S205
Safe
Z.0S201
E−STOP
− 2.6.49 −
2.6 Location diagram Operation panel JF50 DS3
Operation panel folder JF50, DS3
Z.0H125 Z.0S126
Fault Stop
Z.0S136 / Z.0H136 Z.0S127

Sheet stop (2nd longitudinal fold) Crawl speed
Z.0S137 / Z.0H137
Product delivery height
Z.0S132 / Z.0H132 Z.0S128
Reset Forward
Z.0S138 / Z.0H138 Z.0S129

2nd longitudinal fold Safe
Tape tension
Z.0S139/ Z.0H139 −1− Z.0S130

Clutch chill rollers Faster
Z.0S135 / Z.0H135
Clutch chill rollers
Z.0S134 / Z.0H134 Z.0S131
Clutch superstructure Slower
Z.0S133 / Z.0H133
Clutch cylinder part
Z.0S125
E−STOP
−1− only 2nd chill rollers
− 2.6.50 −
2.6 Location diagram Operation panel JF50 DS4 DS16
Z.0H241 Z.0S242
Fault Stop
Z.0S243
Crawl speed
Z.0S244
Forward
Z.0S245
Safe
Z.0S241
E−STOP
Z.0S211
Stop
Z.0S212
Crawl speed
Z.0S210
E−STOP
− 2.6.51 −
2.6 Location diagram Distribution box 1 JF50s
Folder JF50s, distribution box Z.1LVT 1
X1 X3
X1A
X2A
FAM64
X3A
X4A X2.2 X2.1 Terminal strip
X4E
X3E
FEM64
X2E
X1E
X1
X5 X2 SSM1
FEM10 X5E X5S
X3
X4
− 2.6.52 −
X4A X4E
X3A X3E
FEM64
FAM64 X2
X2A X2E
X1A X1E
X5S X5E FEM10
Terminal strip
− 2.6.53 −
X1
SSM1 X2 X5
X3 X5S X5E FEM10
X4
X4A X4E
X3A X3E
FEM64
FAM64 X2
X2A X2E
X1A X1E
Terminal strip
− 2.6.54 −
X4A X4E
X3A X3E
FEM64
FAM64 X2
X2A X2E
X1A X1E
X5S X5E FEM10
Terminal strip
− 2.6.55 −
2.6 Location diagram Operation panels JF50s DS1, DS2
Operation panel folder JF50s, DS1
Z.1H233 Z.1S234
Fault Stop
Z.1S238 / Z.1H238
Z.1S235
Tape guide (2nd cross fold)
Crawl speed
Z.1S239 / Z.1H239
Tranfer − module (paper guiding piece)
Z.1S240 / Z.1H240 Z.1S236
2nd cross fold Forward
Tape tension
Z.1S237
Safe
Z.1S233
E−STOP
Operation panel JF50s, DS2
Z.1H201 Z.1S202
Fault Stop
Z.1S208 / Z.1H208 Z.1S203

Contact pressure roller (top) Crawl speed
Z.1S206 / Z.1H206
Longitudinal perforation
Z.1S207 / Z.1H207 Z.1S204
Contact pressure roller (bottom) Forward
Z.1S205
Safe
Z.1S201
E−STOP
− 2.6.56 −
2.6 Location diagram Operation panel JF50s DS3
Z.1H125 Z.1S126
Fault Stop
Z.1S136 / Z10H136 Z.1S127

Sheet stop (2nd longitudinal fold) Crawl speed
Z.1S137 / Z.1H137
Z.1S138 / Z.1H138 Z.1S128
2nd longitudinal fold Forward
Tape tension
Z.1S132 / Z.1H132 Z.1S129

Reset Safe
Z.1S125
E−STOP
− 2.6.57 −
2.6 Location diagram Operation panels JF50s DS4 DS16
Z.1H241 Z.1S242
Fault Stop
Z.1S243
Crawl speed
Z.1S244
Forward
Z.1S245
Safe
Z.1S241
E−STOP
Z.1S211
Stop
Z.1S212
Crawl speed
Z.1S210
E−STOP
− 2.6.58 −
2.6 Location diagram Operation panels JF50s DS21, DS22
Z.1H433 Z.1S434
Fault Stop
Z.1S438 / Z.1H438
Z.1S435
Tape guide (2nd cross fold)
Crawl speed
Z.1S436
Forward
Z.1S437
Safe
Z.1S433
E−STOP
Z.1H401 Z.1S402
Fault Stop
Z.1S403
Crawl speed
Z.1S404
Forward
Z.1S405
Safe
Z.1S401
E−STOP
− 2.6.59 −
2.6 Location diagram Operation panel JF50s DS23
Z.1H301 Z.1S302
Fault Stop
Z.1S312 / Z.1H312 Z.1S303

Sheet stop ( 2nd longitudinal fold) Crawl speed
Z.1S313/ Z.1H313
Z.1S314/ Z.1H314 Z.1S304
2nd longitudinal fold Forward
Tape tension
Z.1S308/ Z.1H308 Z.1S305

Reset Safe
Z.1S315/ Z.1H315 −1−

Z.1S311/ Z.1H311
Z.1S310/ Z.1H310 Z.1S306
Clutch superstructure Faster
Z.1S309/ Z.1H309
Z.1S316/ Z.1H316 Z.1S307
Clutch cylinder part Slower
Z.1S317/ Z.1H317
Clutch Tranfer − module
Z.1S301
E−STOP
− 2.6.60 −
2.6 Location diagram Operation panels JF50s DS24 DS25
Z.1H425 Z.1S426
Fault Stop
Z.1S427
Crawl speed
Z.1S428
Forward
Z.1S429
Safe
Z.1S425
E−STOP
Z.1H417 Z.1S418
Fault Stop
Z.1S422/ Z.1H422 Z.1S419

Tranfer − module (paper guide piece) Crawl speed
Z.1S423/ Z.1H423
Tranfer − module (tape tension/outside)
Z.1S424/ Z.1H424 Z.1S420
Tranfer − module (tape tension/inside) Forward
Z.1S421
Safe
Z.1S417
E−STOP
− 2.6.61 −
2.6 Location diagram Distribution box 1 superstructure JF50/JF50s
Superstructure distribution box Y.1LVT 1
X1
X2
SSM1.1
X3
X4
SSM1.3 SSM1.2
X2 X2
Terminal strip
X5S X5E FEM10
X4A X4E
FEM64
X3A X3E
FAM64
X2A X2E
X1A X1E
− 2.6.62 −
2.6 Location diagram Operation panel superstructure JF50/50s DS5
Operation panel superstructure JF50/JF50s DS5
Y.1S135/Y.1H135
Edge trimming D.S. /O.S.
Y.1S138/ Y.1H138
Centre slitting 2
Y.1S134/ Y.1H134
Centre slitting 1
Y.1S137/Y.1H137
Trolleys former
Y.1S133/ Y.1H133
Trolleys superstructure
− 2.6.63 −
2.6 Location diagram Operation panels superstructure JF50/50s
DS11 DS12 DS13
Y.1H104 / Y.1S104 Y.1S102

Trolleys Stop
Y.1H301/Y.1 S106
Edge trimming D.S. /O.S.
Y.1H05 /Y.1 S105 Y.1S103
Centre slitting Crawl speed
Y.1S101
E−STOP
Y.1H109 Y.1S110
Fault Stop
Y.1S111
Crawl speed
Y.1S109
E−STOP
Y.1S122/ Y.1H122 −1− Y.1S118

Trolleys former Stop
Y..1S120 / Y.120
Trolleys former
Y.1S121 / Y.1H121 Y.1S119
Centre slitting Crawl speed
Y.1S117
E−STOP
−1− only 2nd web
− 2.6.64 −
2.6 Location diagram Transformer cabinet two web
0M27
Fan
A
E E
A EQUIPMENT ZONE ’LEFT − HAND SIDE FRAME’
E EQUIPMENT ZONE ’TRANSFORMER RACKS’
− 2.6.94 −
Operation panels superstructure JF50/50s
DS14, DS15, DS17
Y.1S126
Stop
Y.1S127
Crawl speed
Y.1S125
E−STOP
Y.1S130
Stop
Y.1S131
Crawl speed
Y.1S129
E−STOP
Y.1H157 Y.1S158
Fault Stop
Y.1S159
Crawl speed
Y.1S157
E−STOP
− 2.6.65 −
PE bar
− 2.6.95 −
2.6 Location diagram Distribution box 1 folder JF44
Folder JF44, distribution box Z.2LVT 1
FEM10 X5E X5S
X1A
X2A
FAM64
X3A
X4A
X2 Terminal strip
X4E
X3E
FEM64
X2E
X1E
− 2.6.66 −
E EQUIPMENT ZONE ’TRANSFORMER RACK’
E E
0T1
0T2
0T3.1 0T3.2
− 2.6.96 −
2.6 Location diagram Operation panels JF44 DS1, DS2
Z.2H101 Z.2S102
Fault Stop
Z.2S103
Crawl speed
Z.2S104
Forward
Z.2S105
Safe
Z.2S101
E−STOP
Z.2H109 Z.2S110
Fault Stop
Z.2S111
Crawl speed
Z.2S112
Forward
Z.2S113
Safe
Z.2S109
E−STOP
− 2.6.67 −
2.6 Location diagram Converter power part
A B
B EQUIPMENT ZONE ’BACK PANEL’
− 2.6.97 −
2.6 Location diagram Operation panel JF44 DS3
Z.2H117 Z.2S118
Fault Stop
Z.2S119
Crawl speed
Z.2S120
Forward
Z.2S12 4/ Z.2H124 Z.2S121

Reset Safe
Z.2 − S129/ Z.2H129 −1−

Z.2S128/ Z.2H128 Z.2S122
Clutch chill rollers Faster
Z.2S127 / Z.2H127
Clutch superstructure
Z.2S126/ Z.2H126 Z.2S123
Clutch 2nd longitudinal fold Slower
Z.2S125 / Z.2H125
Z.2S117
E−STOP
− 2.6.68 −
GRM GRM GRM

120/3 48/1 120/4
(24)
029
X2
029BAM1
0X3
029U1
− 2.6.98 −
2.6 Location diagram Operation panel JF44 DS4 DS16
Z.2H133 Z.2S134
Fault Stop
Z.2S135
Crawl speed
Z.2S136
Forward
Z.2S137
Safe
Z.2S133
E−STOP
Z.2S139
Stop
Z.2S140
Crawl speed
Z.2S138
E−STOP
− 2.6.69 −
029F2
029SLT1
029F1
Fans
power
components
0M31
Power choke
Power converter
0 29 L1
− 2.6.99 −
2.6 Location diagram Distribution box 1 superstructure Jf44
Superstructure JF44, distribution box Y.3LVT 1
X4E X4A
X3E X3A
FAM64
FEM64
X2E X2A
X1E X1A
FEM10 X5E X5S
X2 X2
Terminal strip
X4
X1
X3
SSM1.2 X2 X2
SSM1.3
X3
X1
X4
SSM1.1
− 2.6.70 −
2.6 Location diagram Converter power part, two web
A B
− 2.6.100 −
2.6 Location diagram Operation panels JF44 DS11 DS12 DS13
Y.3S102
Stop
Y.3S103
Crawl speed
Y.3S101
E−STOP
Operation panel folder FJ44, DS12
Y.3H109 Y.3S110
Fault Stop
Y.31311
Crawl speed
Y.3S109
E−STOP
Y.3S118
Stop
Y.3S119
Crawl speed
Y.3S117
E−STOP
− 2.6.71 −
GRM GRM GRM

120/3 48/1 120/4
(24)
GRM GRM
GRM
120/5 48/2
48/2
029BAM1 030BAM1
0X3
029U1 030U1
− 2.6.101 −
2.6 Location diagram Operation panels superstructure JF44
DS15, DS16
Operation panel superstructure JF44, DS14
Y.3S126
Stop
Y.3S127
Crawl speed
Y.3S125
E−STOP
Operation panel superstructure JF44, DS15
Y.3S130
Stop
Y.3S131
Crawl speed
Y.3S129
E−STOP
− 2.6.72 −
2.6 Location diagram Imprinting unit
C
D
C EQUIPMENT ZONE ’RIGHT − HAND SIDE FRAME’
D EQUIPMENT ZONE ’INSIDE UPPER’
− 2.6.73 −
030F2 029F2
030SLT1 029SLT1
030F1 029F1
0M31
0 30 L1 0 29 L1
− 2.6.102 −
2.6 Location diagram Master CPT R O N IC cabinet
F EQUIPMENT ZONE ’SWING FRAME’
− 2.6.103 −
2.6 Location diagram Imprinting unit cabinet

B
063 063
K5 K6
063 063
K7 K8
ÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍ
063X4 / 063XM
ÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍ
063SLT1 063 063 063
ÍÍÍÍÍÍÍÍÍ
FEM FEM K11
10 − 1 10 − 2
ÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍ ÍÍ
ÍÍ
063 063 063
ENM 063
Q32 F1 T2
1
ÍÍ
ÍÍ
ÍÍ
063 063 063
Q29 Q30 Q31
063Q28
063M32
063R12
ÍÍ ÍÍÍÍ
063R11
ÍÍ
ÍÍÍÍ
ÍÍÍÍ
ÍÍ
0 63 T1 0 63 L1 063L2
− 2.6.74 −

B
0 ÈÈ
ÈÈ 0 0 0 0 0 0 ÈÈÈ
ÈÈÈ 0
ÈÈ ÈÈÈ
TVM TVM TVM TVM TVM TVM TVM TVM
1.1 1.2 1.3 1.4 2.1 2.2 2.3 2.4
ÍÍÍ
ÍÍÍÍÈÈ
ÍÍÍ
ÍÍÍÍÈÈ
0 0 0 0 0
ÍÍÍ
ÍÍÍÍÈÈ
SVM SVM EUM SVM ESM
3 4 1 6 1 AAM
ËËË
ËËË 0 0
ËËË
0 0 0
SZM SZM SZM EUM ESM AAM
1 2 3 2 2
ÍÍ
ÍÍ only for two web version
ÈÈ
0SVM4 only imprinter1 or imprinter2
0SZM2 only imprinter1 or imprinter2
ÉÉ
ÈÈ
ÉÉ
only if required
only for Duplex

0ESM2 only 2nd main drive
− 2.6.104 −
C EQUIPMENT ZONE ’RIGHT − HAND SIDE FRAME’ C
PE bar
− 2.6.75 −
5 4 3 2 1
502
EAK for printing units
NTK5 SEK 2 EAK 12 EAK

EAK11
EAE1.2
241 503
and
221
REE/M1 SAK REK2 ESK1 SRK
NTK24 NTK5
REK3 ESK2 REK1 KSK
electrical cabinet
501
Splicer
infeed unit
EAE1.1 NTK5 SEK 1 EAK 12 EAK 1
control console
standard interfaces
244
SSE1.1 NTK24/1 NTK24/2 SSK3 SSK1
SSE2.1
NTK24/1 NTK24/2 SSK3 SSK1
− 2.6.105 −
TPR
TPE NTK5
MSK
TPR
− 2.6.76 −
2.6 Location diagram Infeed
C
D
− 2.6.77 −
2.6 Location diagram Printfunction CPT R O N IC 1 cabinet
− 2.6.106 −

B
ÍÍÍÍ
ÍÍÍÍÍÍÍÍÍ ÍÍÍÍ
16F2 15F2
ÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍ ÍÍ
ÍÍÍÍ
ÍÍ
ÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍ
016SLT1
ÍÍÍÍÍÍÍÍÍ
15X2 / 015XM
ÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍ 0T4
0 0
ENM ENM
1 2
ÍÍÍÍ
ÍÍ 16F1 15F1
ÍÍÍÍ
ÍÍ
ÍÍÍÍ
ÍÍ
ÍÍÍÍ
ÍÍ
015SLT1
ÍÍ
ÍÍ
ÍÍ
016 015 015
Q11 Q60 Q9
Power chokes
Power converters
ÍÍÍÍÍÍ
ÍÍ ÍÍ
ÍÍ
ÍÍÍÍÍÍ
0 16 L1 0 15 L1
ÍÍ
ÍÍ
* only on two web version
− 2.6.107 −

B
ÈÈ
ÈÈ ÈÈ
ÈÈ 0 0
ÈÈ ÈÈ
0 0Q 0Q 0Q 0Q 0Q 0Q 029 0 SPM
Q25 26/1 26/2 30/1 30/2 30/3 32 Q31 Q29 SPM
1 2
0X1
ÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉ
0X1 M5 M24 PE
ÍÍ
− 2.6.107 −
PE bar
− 2.6.108 −
2.6 Location diagram Printfunction CPTRONIC 1 cabinet
EQUIPMENT ZONE ’SWING FRAME’
5 4 3 2 1
505
NTK5 EAK 12 EAK1 1

EAK
EAE2.2
222 506
REK2 ESK1
SAK
NTK24 NTK5
ESK2
REE/M2 REK3
Power modules for dfr

LTK500/5
LTK500/3 LTK500/3 LTK500/2 LTK500/1 Printing Units 1 − 5
LTE2.1
PU5 PU4 PU3 PU2 PU1
4 3 2 1
242 507
NTK24 NTK5 HAK10 HAK1

HAE2.1
LTK500/5
LTK500/3 LTK500/3 LTK500/1
LTE2.2
PU10 PU9 PU8 PU7 PU6
− 2.6.108 −
B
F
− 2.6.109 −
REK REK
ERE NTK5
SRK SRK
ERK ERK
Two web
− 2.6.110 −
2.6 Location diagram Three − phase power cabinet
F EQUIPMENT ZONE ’HINGED MOUNTING PLATE’
− 2.6.111 −
GRM GRM GRM GRM GRM GRM

5/3 24/4 5/1 24/5 24/1 120/1
GRM GRM GRM GRM GRM

24/6 5/2 24/3 24/2 120/2
ÍÍÍ
ÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍ
ÍÍÍ
ÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍ
ÍÍÍ
ÍÍÍÍÍÍ
LTM LTM LTM LTM LTM LTM LTM LTM
1000 1000 1000 1000 1000 1000 1000 1000
PU 4 PU 3 PU 2 PU 1 PU 4 PU 3 PU 2 PU 1
ÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍ
ÍÍÍ ÍÍÍÍ
top top top top top top top top
ÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍ LTM LTM
ÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍ
1000 1000
PU 5 PU 5
top top
ÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍ
GRM GRM
250 250
ÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍ
LTM LTM
1000 1000
ÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍ
ÍÍÍ ÍÍÍÍ
PU 5 PU 5
down down
ÍÍÍÍÍÍÍÍ
ÍÍÍ
ÍÍÍÍ
LTM
ÍÍ LTM LTM LTM LTM LTM LTM LTM
ÍÍÍÍÍÍÍÍ
ÍÍÍ
ÍÍÍÍÍÍ
1000 1000 1000 1000 1000 1000 1000 1000
PU 4 PU 3 PU 2 PU 1 PU 4 PU 3 PU 2 PU 1
ÍÍÍÍÍÍÍÍ
down down down down down down down down
0M32
ÍÍ
− 2.6.110 −
2.6 Location diagram Three phase power cabinet

B
ÍÍÍ
Í
Í
ÍÍÍ 0Q 0Q 0Q 0Q 0Q 0Q
Í
ÍÍÍ
63 59 123 45 58 57
ÍÍÍ
ÍÍÍ
ÍÍÍ
ÍÍÍ
041Q52 013Q50 0Q122 0Q121
042Q53 014Q51 040Q55 039Q54
035 069 060 068 059

Q21 Q62 Q22 Q56 Q23
ÍÍ
ÍÍÍÍ
010ÍÍ
ÍÍ
ÍÍÍÍ
ÍÍ09 08 07 06 05 04 03 02 01
ÍÍÍÍ
ÍÍÍÍ
Q42 Q41 Q40 Q39 Q38 Q37 Q36 Q35 Q34 Q33
ÍÍÍÍ
ÍÍÍÍ
010
K42
09
K41
08 07
K40 K39
06
K38
05
K37
04
K36
03
K35
02
K34
01
K33
ÍÍÍÍ
ÍÍÍÍ
ÍÍÍÍ
ÍÍÍÍ
ÍÍÍÍ
ÍÍÍÍ
012 011 0x 0x 01 01 030 029 096 097
Q44 Q43 Q20 Q15 Q19 Q14 Q6 Q4 Q16 Q32
ÍÍÍÍ
ÍÍÍÍ
ÍÍÍÍ
ÍÍÍÍ
012 011 0x 0x 01 01
K44 K43 K20 K15 K19
*
K14
ÍÍ
ÍÍ only on two web version
− 2.6.111 −
0M30.2
502
NTK24 NTK5 HAK 10 EAK

HAK11
HAE2.2
− 2.6.111 −
2.6 Location diagram Three phase power cabinet
F EQUIPMENT ZONE ’HINGED MOUNTING PLATE’
Telediagno
sis board
0FDK1
0
X5
control
transformer
control device
Blanket wash
TX2 TX4 TX5 TX6
device
TX7 TX8 TX9 TX10 TX11 TX12 TX14
− 2.6.112 −
2.6 Location diagram Tranformer cabinet Post−Unit
B
A
− 2.6.112 −
2.6 Location diagram Interface adapter cabinet
− 2.6.113 −
2.6 Location diagram Transformer cabinet Post−Unit
0Q1
− 2.6.113 −

B
0FEM64 − 0FAM64 − 0FEM64 − 0FAM64 −

1XE 1XA 2XE 2XA
0FEM64 − 0FAM64 − 0FEM64 − 0FAM64 −

3XE 3XA 4XE 4XA
ÍÍ
ÍÍ
ÍÍ
ÍÍ
0 0 0 015 0 0
FEM FEM FEM FEM 0 0
Q16 Q16 0IWM1
10 10 − 2 10 − 3 10 Q64 Q124
−1 −2
ÍÍ
ÍÍ
ÍÍ
015 016
0 SAM1.5 0 SVM1.1 0 SEM2.1 0 SEM2.2 BAM BAM 0E1 0N1 0N2
ÍÍ
1 1
0 SEM1.1 0 SEM1.2 0 SEM1.3 0 SEM1.4 0 SEM1.5 0 SEM1.6
ÍÍ
ÍÍ ÍÍ ÍÍ
ÍÍÍÍ
ÍÍ ÍÍ
ÍÍ
ÍÍÍÍÍÍ ÍÍÍÍ
ÍÍÍÍ
0 0 0 0 019 039 041 059 068 068
K1 K2 K13 K22 K21 K23 K24 K17 K9 K33 0T9
ÍÍ
ÍÍÍÍ
ÍÍÍÍÍÍÍÍ
ÍÍÍÍ ÍÍ
ÍÍ
ÍÍÍÍ
ÍÍÍÍÍÍÍÍ
ÍÍÍÍ ÍÍ
068 068 068 080 096 096 096 096 096 096 096 096 097 018 018
K34 K35 K36 K16 K1 K2 K3 K4 K5 K6 K7 K8 K20 K2 K6
ÍÍ
ÍÍÍÍ
ÍÍÍÍÍÍÍÍ
ÍÍ
ÍÍ
ÍÍÍÍ
ÍÍÍÍÍÍÍÍ
ÍÍ
069 060 060 060 017 018 018 0 0
K12 K17 K18 K19 K8 K13 K8 K23 K24
− 2.6.114 −

B
0Q 0Q 0Q
8 10 30
0Q15
PE bar
0T1
− 2.6.114 −
C
C
EQUIPMENT ZONE ’RIGHT − HAND SIDE FRAME’
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
030X2/040X2/042X2/044X2
0X1a
0X1a
0X2/026X2/029X2/039X2/041X2/043X2
PE − bar
PE − bar
− 2.6.115 −
0T2
0T3
− 2.6.115 −
2.6 Location diagram Cable entry cabinet
D EQUIPMENT ZONE ’LEFT − HAND SIDE FRAME’
− 2.6.116 −
2.6 Location diagram Converter power part cabinet Post − Unit
A B
− 2.6.116 −
2.6 Location diagram Cable entry cabinet
D EQUIPMENT ZONE ’LEFT − HAND SIDE FRAME’
01X1 02X1 03X1 04X1 05X1 06X1 D
ÍÍÍ ÍÍ
07X1
ÍÍÍ Í08X1 09X1 010X1 011X1 012X1
ÍÍÍ ÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍ Í
Í
015X1 016X1
Í
Í
0XV1 0XU1
026X1
0XS1.1 0XS1.2 0XS1.3
0XT1
ÍÍÍ
ÍÍÍ
0XT2 0XV2
ÍÍÍ
ÍÍÍ
ÍÍ
ÍÍ only on two web version
− 2.6.117 −
2.6 Location diagram Converter power part cabinet Post−Unit
GRM GRM GRM GRM

120/1 24/1 48/1 5/1
GRM GRM GRM GRM

120/2 24/2 24/3 5/2
− 2.6.117 −
2.6 Location diagram Main switch cabinet
E EQUIPMENT ZONE ’POWER DISTRIBUTION’
− 2.6.118 −
033F2
033SLT1
033F1
Fans
Power
components
033M9
Power choke
Power converter
0 33 L1
− 2.6.118 −
2.6 Location diagram Main switch cabinet
E EQUIPMENT ZONE ’POWER DISTRIBUTION’
Cable pull relief bar
PE bar
Bar system
0Q1 0Q2
Main switch
PE bar
Cable pull relief bar
− 2.6.119 −
ÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍ
022 022 022
K47 K46 K41
ÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍ
ÍÍ
021 021 021
ÍÍÍÍÍÍÍ
K19 K23 K24
ÍÍÍÍÍ
ÍÍ
ÍÍÍÍÍ
ÍÍ
ÍÍÍÍÍ
ÍÍ
021 021 021
K18 K20 K21
0X3
− 2.6.119 −
2.6 Location diagram Transformer cabinet
0M27
Fan
E
A A
− 2.6.120 −
PE bar
− 2.6.121 −

E
0T1
0T2
0T3.1
− 2.6.122 −
2.6 Location diagram Post −Unit CPT R O N IC cabinet
C
D
− 2.6.120 −

B
0XM
0X1 033X2
0 0
FEM FEM
0FEM64 − 3 0FEM64 − 2 0FEM64 − 1 10 10−2
0
0FAM64 − 3 0FAM64 − 2 0FAM64 − 1
FEM
10−3
090 090 090 090 090 090 090 090 091 025 025
K1 K2 K3 K4 K5 K6 K7 K9 K20 K1 K2 0IWM1
070SSM1 0 SEM2 0 SEM3 0 SEM4
0 SAM1 0 SEM5 0 SEM6 0 SEM7
0 0 0 0 0 0 0033
TVM TVM TVM SPM EUM ESM ENM
BAM
1 2 4 1 2 1 1
0 0 0 0 0 0
ENM ENM SVM SVM SVM SVM 0E1 0N1 0N2
1 2 1 2 1 2
− 2.6.121 −
C EQUIPMENT ZONE ’RIGHT−HAND SIDE FRAME’ C
ÍÍÍÍ
ÍÍÍ
ÍÍ
ÍÍÍÍ
ÍÍÍ
ÍÍ
020 024 024 024
Q3 Q42 Q43 Q45
ÍÍ
ÍÍÍÍ
ÍÍÍ
ÍÍÍ
ÍÍ
ÍÍÍ
ÍÍÍ
020 024 024 024
K3 K42 K43 K45
ÍÍÍÍ
ÍÍÍ
ÍÍÍÍ
ÍÍÍÍÍ
ÍÍ
019 019 023 023 023
ÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍ
Q2 Q7 Q6 Q13 Q44
ÍÍÍÍ
ÍÍÍ
ÍÍÍ
ÍÍÍÍ
ÍÍÍ
ÍÍÍ
019 019 023 023 023
K2 K7 K6 K13 K44
ÍÍÍÍÍÍÍ
ÍÍ
ÍÍÍÍÍÍÍ
ÍÍ
ÍÍÍÍÍÍÍ
ÍÍ
033 0 021 021 022
Q4 Q14 Q18 Q19 Q41
ÍÍ
ÍÍÍÍÍ
ÍÍ
ÍÍ
ÍÍÍÍÍ
ÍÍ
090 091 025 045 019
Q16 Q32 Q31 Q1 Q16
ÍÍÍÍ
ÍÍ
ÍÍÍÍ ÍÍ
ÍÍÍÍ
ÍÍÍÍ
ÍÍÍÍ
0 0 0 0 033 0
Q27 Q26 Q12 Q11 Q9 Q32
ÍÍÍÍ
ÍÍÍÍÍÍ
ÍÍÍÍ
ÍÍÍÍÍÍ
066 067 024 021.1 022.1 023 023
K30 K31 K34 K15 K33 K16 K1
0T5 0T4
− 2.6.122 −
D EQUIPMENT ZONE ’INSIDE UPPER’ D
024X1
024X7
022.2X1 021.2X1
023X7
067X1 021.1X1
0XU1
066X1 019X1 023X1
028X1 020X1 027X1
− 2.6.123 −
0M30.2
SAK REK2 ESK1 SRK

NTK24 NTK5
REE/M
REK3 REK1 GLK
502
HAK 2 HAK HAK 2
EHE NTK5 1 − 6 HAK SEK EAK 9 EAK 1
Í
LTK50
BBFu
Í
ÅLTK500
Å
LTE BBFo
NTK24/1 NTK24/2 SSK3 SSK1

SSE
− 2.6.124 −
3. Diagnostic Table of contens
3. Diagnostic
3.1. Press Data messages
3.2 Error messages
3.3 Modules status
3.4 Failure cases
- 1.0 -
3. Diagnostic Table of contens
- 1.1 -
3.1 Press Data messages Table of contens
3.1 Press Data Messages
3.1.1 Procedure to accede to the Press Data messages

3.1.1 Signficant messages

3.1 Press Data messages Table of contens

Press Data Messages
S These messages can be read if the failure appeares during a press production.
S These messages are corresponding to the first reason of failure.
S These messages are only displayed in case of furtive failure.
S These messages can be obtained even if the error messages are displayed on the CPTronic console
screen.
Procedure to accede to the Press Data Messages

Use the following icons :
Significant messages
Press Data Messages Action
#0 No error detected Release of error
#1 No run (e_stop) See error message #101
#2 No run (sheeter guard) See error message #102
#4 No run (JF50/JF44 guard) See error message #104
#5 No run (JF50/JF44 crank) See error message #105
#6 No run (JF50/JF44 lubrication) See error message #106
#7 Blower drive cabinet See error message #107
#8 No run (unit lubrication) See error message #108
#9 No run (unit guard) See error message #114
#10 Blanket/blanket guard Status
#12 Guard/jam JF50/JF44 Status
#14 No crawl speed (unit guard) See error message #114
#16 No run (web break) See error message #116
#17 no run (int.mess. REK1_B) See error message #117
#18 No run (int.message REK1_H) See error message #118
#19 No run (web catcher guard) See error message #119
#20 No run (damp./ink clutch) See error message #120
#21 No run (centr.lubrication) See error message #121
#22 flaps bearer guards Status
#23 no crawl speed (REK1_T) See error message #123
#24 No run (JS50/JS44 guard) See error message #124, 127
#25 No run (JS50/JS44 crank) See error message #125
− 3.1.1 −

#26 No run (JS50/JS44 lubrication) See error message #126
#27 Guard/jam JS50/JS44 Status
#33 Configuration folder See error message #135
#34 Clutch main shaft units See error message #139
#35 Error flying imprinter See error message #143
#36 SEK no run See error message #141
#37 SEK no movement See error message #141
#39 Compressed air supply See error message #62, 149
#40 Line shaft off Status
#43 No positionning (unit guard) See error message #122, 193
#44 No run APC on Status
#100 No emergency stop Release of e_stop
#101 e_stop main operator panel See error message #77
#102 e_stop splicer See error message #78
#103 e_stop infeed See error message #79
#105 e_stop chill rolls See error message #81
#109 e_stop JF50/JF44 See error message #85
#110 e_stop JS50/JS44 See error message #136
#111 e_stop PIO See error message #86
#112 e_stop printing units See error message #87
#113 e_stop web catcher See error message #88
#114 e_stop parallel See error message #134
#115 e_stop jam folder
#118 e_stop el.jam detector See error message #92
#119 e_stop web break See error message #93
#120 e_stop communication See error message #94
#121 e_stop caused by command See error message #95
#122 e_stop internal (HW1) See error message #96
#123 e_stop internal (HW3) See error message #96
#124 e_stop (test DYN) See error message #98
#125 e_stop internal (RW_N) See error message #96
#127 e_stop other press See error message #147
#199 e_stop parallel See error message #134
#200 No stop Release of stop
#201 Stop operation panel Status or see error message #77
#202 Stop air pressure Status or see error message #62, 149
#203 Stop dampening − water level Status
#204 Stop (lubrication 12bars) Status or see error message #121
− 3.1.2 −

#205 stop oil temp1st web Status or see error message #108
#206 Stop oil temp 2nd web Status or see error message #108
#207 Stopcontrol console Status
#208 Stop auto production Status
#209 Stop by command See error message
#300 infeed ok
#301 Stop infeed 1 Status
#302 Stop infeed 2 Status
#303 No movement infeed 1
#304 No movement infeed 2
#305 Blanket wash Status
#306 No run (PIO guard)
#402 Power off Status
#900 New production Printer input
#901 Wait for plate Printer input
#902 Maintenance Printer input
#903 Service Printer input
#904 shift start Printer input
#905 Shift end Printer input
#906 Shift change Printer input
#907 Report Printer input
#990 Power on Status
− 3.1.3 −
3.2 Error messages Table of contens
3.2 Error messages
3.2.1 Presentation
3.2.3 Master CPTronic console
3.2.21 Post unit CPTronic console

3.2 Error messages Table of contens

3.2 Error messages Presentation
Error messages
Presentation
The CPTronic integrates a control system to help the printers in case of failure.This system indicates the
problem through two kinds of message:
S Literal message
S Symbol message
The CPTronic can also inform if this problem is dangerous for the people working on the press or/and if this
trouble can damage the press.
If the problem is minor, the yellow indicator located on the CPTronic console (Printing unit or Post − unit
section) is flashing and the press stays in production. In this case, the CPTronic indicates an ERROR
PRODUCTION".
If the problem is major, the red indicator located on both CPTronic consoles is lighting − up (Printing unit and
Post − unit in case of production), and the press stops as soon as possible. In this case, the CPTronic
indicates a PRESS ERROR".
If the blue indicator is lighting − up on one of the CPTronic console (Printing unit or Post − unit), this indicates
a FAULT CONSOLE". The press is not able to run until the fault is clear.
Literal message
The literal error messages are translated into five different languages. All of these translations are incluted
into the CPTronic : German, English, French, Spanish and Portuguese.
These translations are diplayed in the fault menu" (global press section).
One of this language is installed by default after each system power − on.
The first kind of literal message includes also a number at the end of the message :
Example : e_stop JF50/JF44 ...............#85"
The second literal message type is used like an indication of one circuit − breaker fault:
Example : 029Q4"
Nota : There is no message for circuit − breaker OQ1, OQ2, OQ45, OQ121, OQ122, OQ123 (Master cabinet)
and OQ1, OQ15 (Post − unit cabinet).
You will find a signification of this error message inside the Wiring diagramm" delivered with each press.
For the above example 029Q4" tell us that the circuit − breaker of the blower of the printing unit main motor
is trip − out.
To know exactly where this one is located inside the cabinet, use the location section of this manual.
− 3.2.1 −
3.2 Error messages Presentation
Symbol message
The symbol message of the CPTronic is a graphic representation of the fault in the press.This kind of
message gives more explanation to the operator after a literal message :
How to acceede to this symbol message ?
− Select the fault menu"
− Check if one block under the different press section (Infeed,Printing unit,Chill,Folder) is flashing.
− Push on one of this push button, and look the picture. One symbol message appeares.
Example : e_stop JF50/JF44 ..............#85 with a Folder section flashing.
The symbol message showed in the Folder unit section is :
The symbol of the fault is : Emergency stop actuated on the gear side of the folder
− 3.2.2 −
3.2 Error messages Master CPTronic Console
Error messages
Master CPTronic Console
N° Message Description / Reaction Action
#001 0Q64 Supply the 220VAC for CPC S Check if the CPC consoles are still working.
consoles.The yellow light on S If not, switch on the circuit breaker inside the
the CPT console is flashing. interface cabinet located in the master cabinet
section.
S If good, check the connection of the input E64
(OK=1) of the EAK1 − 02.
#002 0Q25 Supply the 21VAC for the S This message will not be displayed if the circuit
CPTronic console and for breaker is really Off.
the web tension S If you have a darkÿ" screen , check if the circuit
measurement.the yellow breakers 0Q59 and 0Q25 are switch on.
light on the CPT console is S If good, check the power supply 21VAC inside the
flashing. cabinet (0X1 − 215/N13).
#003 039Q54 Supply the Ink distribution S If the power supply is switch off, the message
temperature control 1 (FRT1) #060 will be also displayed.
with 380VAC.The yellow light S In this case switch − on the circuit breaker.
on the CPT console is S If not, check the connection until the input E54
flashing. (OK=1) of the EAK1 − 02.
#004 040Q55 Supply the Ink distribution S If the power supply is switch off, the message #
temperature control 2 (FRT2) will be also displayed.
with 380VAC in case of more S In this case switch the circuit breaker on.
than 6 units.The yellow light S If not, check the connection until the input E55
on the CPT console is (OK=1) of the EAK1 − 02.
flashing.
#005 041Q21 Supply the ink supply S Switch − on the cicuit breaker (035Q21).
equipment with 380VAC.The S If the time elapsed is too long, a low level ink will
yellow light on the CPT be displayed in the printing unit fault screen.
console is flashing. S If the circuit breaker is on, check the connection
until the input E21 (OK=1) of the EAK1 − 02.
#006 042Q22 Supply the second S The system is not operating anymore.
web − catcher equipment S Switch − on the circuit breaker (060Q22).
with 380VAC.The yellow light S If good, check the connection until the input E22
flashing.
#007 041Q52 Supply the central S If the power supply is off, you will find a
dampening water system 1 communication error message in the FAZ display.
(FAZ1) with 380VAC.The S In this case, switch the circuit breaker on.
yellow light on the CPT S If it is on, check the connection until the input E52
console is flashing. (OK=1) of the EAK1 − 02.
#008 042Q53 Supply the central S If the power supply is off, you will find a
dampening water system 2 communication error message in the FAZ display
(FAZ2) with 380VAC in case when the 2nd web is selected..
of more than 6 units. The S In this case, switch the circuit breaker on.
yellow light on the CPT S If it is on, check the connection until the input E53
console is flashing. (OK=1) of the EAK1 − 02.
− 3.2.3 −

#009 068Q56 Supply the blanket washing S When the circuit breaker is switch − off, it is not
device 1 (GTW1) with possible to use the wash" menu from the CPT
380VAC when console.
integrated.The yellow light S Switch it on.
on the CPT console is S If good, check the connection until the input E56
flashing. (OK=1) of the EAK1 − 02.
#012 OQ26/1 Power supply (21VAC) for ???????????????????????????
or the LTR 2.1,2.2) racks.The
OQ26/2 yellow light on the CPT
console is flashing.
#016 029Q4 Supply the fan of the main S Check if the fan is turning.
motor for the printing units S If not, switch on the circuit breaker.
with 380VAC.The red light S If it is on, check the connection until the input E4
on the CPT console is on (OK=1) of the EAK1 − 02.
and the press is stopped.
The message #107 is also
displayed.
#017 030Q6 Supply the fan of the second S Check if the fan is turning.
motor of the printing units S If not, switch on the circuit breaker.
(nearest the dryer) with S If it is on, check the connection until the input E6
380VAC if more than 6 (OK=1) of the EAK1 − 02.
units.Only the red light on
the CPT console is on.
#018 029Q31 Supply the fan located on S Make sure circuit breaker is switch − on.
the back of the cabinet for S Check the connection until the input E31 (OK=1)
the printing units power of the EAK1 − 02.
converter with 220VAC.The
red light on the CPT console
is on and the press is
stopped.The message #107
is also displayed.
#019 015Q9 Supply the fan of the infeed S Check if the fan is turning.
motor with 380VAC. The red S If not, switch − on the circuit breaker.
light on the CPT console is S If it is on, check the connection until the input E9
on and the press is (OK=1) of the EAK1 − 02.
stopped.The message #107
is also displayed.
#020 016Q11 Supply the fan of the second S Check if the fan is turning.
infeed motor, in case of two S If not, switch on the circuit breaker.
web press,with 380VAC. S If it is on, check the connection until the input E11
Only the red light on the (Ok=1) of the EAK1 − 02.
CPT console is on.
#021 0Q32 Supply the fan of the Ink S Make sure circuit breaker is switch − on.
motors power part (LTM) S Check the connection until the input E32 (OK=1)
with 220VAC. Only the red of the EAK1 − 02.
light on the CPT console is
on.
− 3.2.4 −

#022 0Q30 Supply the Fan of the S Check if the three circuit breakers 0Q30/1, 0Q30/2,
electrical cabinets with 0Q30/3 are switch − on.
220VAC.The red light on the S If good, check the connection until the input E30
CPT console is on and the (OK=1) of the EAK1 − 02, thru the 3 auxiliairies
press is stopped.The contacts of the circuit breakers.
message #107 is displayed.
#023 0Q16/1 Supply the lights of the CPC S Check if the CPC lights are Off.
or consoles with 220VAC.The S If yes, switch on the circuit breaker 0Q16/2.
0Q16/2 yellow light on the CPT S If not Off, check the connection until the input
console is flashing. E16(Ok=1), thru the auxiliaries conctacts of 0Q16/1
and 0Q16/2.
S If the display is working well, check the connection
until the input E25 (OK=1) of the EAK1 − 02.
#024 0xQ33 Supply the oil pump motor S Check if the oil pump is runing.
of the printing unit 1 (start S If not , switch the circuit breaker on.
counting from the dryer) with S If runing, check the connection until the input E33
380VAC.The press is (OK=1) of the EAK1 − 02.
stopped and the red light on S Reset the fault after each test in the general
the CPT console is printing unit fault screen by the function touch F1
flashing.The message #108 (push button lights).
is also displayed. S If more than one oil pump circuit breaker are
displayed, the reset is possible only when all
cleared.
of the printing unit 2 (start S If not, switch the circuit breaker on.
cleared.
counting from the dryer) with S If runing,check the connection until the input E35
cleared.
− 3.2.5 −

cleared
cleared
cleared
cleared
cleared
− 3.2.6 −

cleared
cleared
cleared
cleared.
#036 01Q19 Supply the oil pump return S Check if the circuit breaker is switch − on.
flow of the 12bars lubrication S If good, check the connection until the input E19
system (operator side) with (OK=1) of the EAK1 − 02.
380VAC the yellow light on S Make a reset of the fault in the general printing unit
the CPT console is flashing fault screen by the function touch F1(push button
and when the high level of highlighted).
the tank is detected the
press is stopped, the red
on and the message #121 is
also displayed.
− 3.2.7 −

#037 0xQ20 Supply the oil pump return S Check if the circuit breaker is switch − on.
flow of the 12bars lubrication S If good, check the connection until the input E20
system (operator side) with (OK=1) of the EAK1 − 02.
380VAC,in case of more S Reset the fault after each test in the general
than 6 printing units.The printing unit fault screen by the function touch F1
yellow light on the CPT (push button lights).
console is flashing and S If more than one oil pump circuit breaker are
when the high level of the displayed, the reset is possible only when all is
tank is detected the press is cleared.
stopped, the red light on the
CPT console is on and the
message #121 is also
displayed.
#038 013Q50 Supply the first splicer with S Check the controle panel of the splicer.
380VAC.The yellow light on S If no power switch − on the circuit breaker.
the CPT console is flashing. S If powered, check the connection until the input
E50 (OK=1) of the EAK1 − 02.
#039 014Q51 Supply the second splicer S Check the controle panel of the second splicer.
with 380VAC.The yellow light S If no power switch − on the circuit breaker.
on the CPT console is S If powered, check the connection until the input
flashing. E51 (OK=1) of the EAK1 − 02.
#040 0Q45 Supply the 380VAC for the S Switch − on the circuit breaker.
complete Infeed drives.The S If it trip − out immediatly, switch − off 015Q9,
yellow light on the CPT 016Q11, 015Q60 and swicth − on again, one by
console is flashing. one.
S If good, and the error message does not clear,
check the connection until the input E45 (OK=1) of
the EAK1 − 02.
S The reason of the switch − off could be a failure
inside the electronic of the drive :
S Check if an error is detected in the Init/dyn tests of
the infeed by looking in the maintenance 2 screen.
#044 0Q58 Supply the transformator S When this circuit breaker is switch off, a lot of
0T3.2 with 380VAC.It is used trouble are on the press like the error message
in case of more than 6 #55, no light between printing units and it is
printing units.The yellow possible to start the press without horn signal...
light on the CPT console is S If nothing happen, check the connection until the
flashing. input E63 (OK=1) of the EAK1 − 02.
#045 0Q57 Supply the 380VAC power S If not ,check the connection until the input E57
supply for the transfomator (OK=1) of the EAK1 − 02 .
0T1. S If the circuit breaker is switch off, the CPTronic
The CPT console screen is system is not working. A reason of the trouble
locked. the yellow light on must be checked by an electrician:
the CPT console is flashing. S Check if the transformer is not grounded.
S After switch on the circuit breaker, a complete
power reset of the cabinet is nedeed.
#046 015Q60 Supply the transformator S The infeed motor will not run synchrone with the
0T4 used to powered one press, if the cicuit breaker is Off.
part of the infeed drive.The S If not, check the connection until the input E60
yellow light on the CPT (OK=1) of the EAK1 − 02.
− 3.2.8 −

#047 0Q59 Supply the transformator S If this message is displayed, check the connection
0T3.1 with 380VAC.The until the input E59 (OK=1) of the EAK1 − 02.
press is stopped, the red S If you have a dark" screen, switch on the circuit
light on the CPT console is breaker and make a complete power reset of the
on and the yellow light is cabinet.
flashing.
#048 01Q14 Supply the oil pump motor S Check if the circuit breaker is switch − on.
for the 12bars lubrication S If good, check the connection until the input E14
system (gear and operator (OK=1) of the EAK1 − 02.
side) with 380VAC.The press
is stopped after a repetition
of the fault and the message
#121 is displayed.
#049 0xQ15 Supply the oil pump motor S Check if the circuit breaker is switch − on.
for the 12bars lubrication S If good, check the connection until the input E15
system (gear and operator (OK=1) of the EAK1 − 02.
side) with 380VAC if more
than 6 printing units. The
press is stopped after a
repetition of the fault and the
message #121 is displayed.
#050 059Q23 Supply the first S The system is not operating anymore. Switch − on
web − catcher equipment the circuit breaker.
with 380VAC.The yellow light S If good, check the connection until the input E23
flashing.
#051 brush This indicated that the S Make sure micro − switches are free (no dust
monitorin carbon brushes of the main between the switch and teh bracket).
g main motor 1(nearest of the infeed S Control if the carbon brushes are not to small.
drive 1 in case of 2 motors) are not S If good, check the connection until the input E5
good to drive it correctly.The (OK=1) of the EAK2.
yellow light on the CPT
#052 brush This indicate that the carbon S Make sure micro − switches are free (no dust
monitorin brushes of the second main between the switch and teh bracket).
g main motor (nearest of the dryer) S Control if the carbon brushes are not to small.
drive 2 are not good to drive it S If good, check the connection until the input E7
correctly.The yellow light on (OK=1) of the EAK2.
the CPT console is flashing
monitorin brushes of the infeed motor between the switch and teh bracket)
g infeed (lower) are not good to drive S Control if the carbon brushes are not to small.
drive 1 it correctly.The yellow light S If good, check the connection until the input E10
on the CPT console is (OK=1) of the EAK2.
flashing
− 3.2.9 −

monitorin brushes of the second between the switch and teh bracket)
g infeed infeed motor (Upper in case S Control if the carbon brushes are not to small.
drive 2 of 2 web press) are not S If good,check the connection until the input E12
good to drive it correctly.The (OK=1) of the EAK2.
console is flashing
#055 earth This message indicate an S Check if the red light of the IWM module in the
leakage isolation fault on the power master cabinet is on.
monitor supply of the CPTronic S If yes, try to reset the fault by pushing at least 10
cabinets: a ground is seconds on the LT" button on the IWM.
connected tothe 24VDC or S If the fault does not dissappear or come back, you
5VDC.the yellow light of the need to find the isolation failure (example : cable
CPT console is flashing until damaged, motor grounded.... )
the first control of the ÿfault S If not, make sure that power is going to the input
screenÿ". E28 (OK=1).
#056 dew This message indicate an S Empty the tank of the compressor.
point high level of water detected S If done and the message does not clear, check the
refrigerat in the compressor connection until the input E24 (OK=0) of the
or dryer equipment. EAK2.
The yellow light on the
master CPTronic console is
flashing.
#057 safety This indicate that one input S Check the SEK1 inputs following the procedure
input of the electronic board SEK1 SEK status".
signal (1) is not corresponding to the S If not correct, check the connection of the
normal logic status to put highlighted indication.
the press in revolution. S If correct check the Init test or/and the Dyn test of
the SEK1 board.
signal (2) is not corresponding to the S If not correct, check the connection of the
the press in revolution. S If correct check the Init test or/and the Dyn test of
the SEK2 board.
#060 ink This message indicate that a S Go to the FRT and look at the display panel
distributi problem is detected in the located in the front of the cabinet.
on FRT equipment S If a red light is on under a low level symbol, fill the
temperat :Temperature regulator for system with water.
ure error the printing unit. S If the actual temperature is not equal to the
The yellow light on the presseted , check the stability of the input
master CPTronic console is temperature of the system.
flashing. S If good, check the connection until the input E1
(OK=0) of the EAK2 for the FRT1,change the
module 0SEM1.2.
S Check the input E2 (OK=0) of the EAK2 for the
FRT2, change the module 0SEM2.2.
− 3.2.10 −

#061 central This message indicate that a S Check the Dampening status display for more
damp. problem is detected in the information.
water FAZ equipment :Temperature S If only the fault symbol is displayed the
supply regulator for the printing unit communication between the FAZ and the CPTronic
Dampening solution. is interrupted.
The yellow light on the S Make a power reset.
master CPTronic console is S If not good check the serial cable, change the
flashing. 0SVM1.1 module in the cabinet.
#062 compres This message indicate a S Check if the compressor is operating.
sed air fault on the air pressure S Look the display of the regulated valve on the
supply supply of the printing unit first printing unit" (nearest to the dryer) gear
part. side top.
The yellow light on the S If more than 3 bars, check the pressure switch.
master CPTronic console is S Change it if faulty.
flashing and 1minute after S Check the input E28 (OK=1) of the EAK2.
the press is stopped with the
red light On: the message
#149 is displayed.
#077 e_stop this error message indicate S Check if the red circle push button is activated.
main that the e_stop push button S If not, check the connection until the input E63
operator is activated on the CPT (OK=1) of the EAK1.
panel console.
The red light on the CPT
console is on and the blue
light is flasing.The press is
stopped.
#078 e_stop This error message indicate S After checking the fault screen, control if the red
splicer that an e_stop push button push button on the splicer drive station is not
is activated on the splicer. activated.
The red light on the master S If not correct, check the input status E57 (OK=1)
CPTronic console is on and on the EAK4.
the press is stopped. S Check the module 15SEM1 located in the infeed
the message #101 is also distribution box between the points 10,11 (contact
displayed. closed).
S If good, check if the point E1 of this module
(24VDC=OK).
S If not,change the module SEM.
S If good check the cable connection.
#079 e_stop This error message indicate S After checking the fault screen, control if one red
infeed that an e_stop push button push button on the infeed drive station is not
is activated on the infeed. activated.
The red light on the master S If not, check the input status on the EAK4:
CPTronic console is on and E1/E33 (OK=1) for the outlet e_stop button.
the press is stopped. E41 (OK=1) for the inlet e_stop button.
the message #101 is also S If one of this inputs is not correct,check the
displayed. connection until the EAK.
− 3.2.11 −

#087 e_stop This error message indicate S After checking the fault screen, control if one red
printing that an e_stop push button push button on the printing unit drive station is not
unit is activated on one printing activated.
unit. S If not, check the input status on the EAK2 − XX
The red light on the master (XX=unit number , start to count from the dryer):
CPTronic console is on and E1 (OK=1) Upper, operator side.
the press is stopped. E17 (OK=1) Lower, operator side.
the message #101 is also E25 (OK=1) Upper, gear side.
displayed. E29 (OK=1) Lower, gear side.
S If one of this inputs is not correct, check the
connection until the right EAK.
web that an e_stop push button push button on the web catcher drive station is not
catcher is activated on the web activated.
catcher. S If not,check the input status E22 (OK=1) on the
The red light on the master EAK3.
CPTronic console is on and S If not correct, check the connection between the
the press is stopped. drive station and the EAK.
the message #101 is also
displayed.
#093 e_stop This message indicate a S Check if there is a real break of paper.
web web break of the paper. S If not, check which sensor detect the break, control
break This is associated with a that it is not located on the edge of the paper,
display on the CPT console control the quality of the paper.
used for location of the first S If good, check the sensor with the help of the
detection . web break"screen on the CPT console: when
The press is stopped sensor see paper there is a small square symbol
displayed.
S If not, change the sensor and check the
connection until the right EAK.
S If the defective sensor is located at the infeed or
the last printing unit it is not possible to cross the
speed of 3300IPH until the clearance of the fault.
then the message#185 or #186 is displayed.
#094 e_stop This message is displayed S Check if the power supply of the master cabinet is
communi when the serial not swicth off.
cation communication between the S Check if there is a dynamique fault in the Dyn
master cabinet and the test1" screen of the maintenance 1 display on
post − unit cabinet is not both CPT consoles.
correct S Check if the flat cables RER/M1:X21 of the master
The red light on the CPT CPTronic and RER/M:X21 of the post − unit cabinets
console is on and the press are correctly locked.
is stopped. S If good, replace the module 0SZM1 or/and the
0SVM in the master cabinet.
S If not good, check the power supply of this module
and change it if necessary.
− 3.2.12 −

#096 e_stop This kind of message is a S Check if all the cables between this racks are good
internal result of an internal error inserted, not damaged.
(HW1) detected between the S Check all connections by screws....
Input/output racks(EAE) and S Check if the power supply 5VDC and
the computer rack(RER). 24VDC(NTK85) are not to low.
The red light on the CPT S Change the boards if nedeed.
console is on and the press S Change the SEK board located in the EAE or EHE
is stopped. rack.
S Change the ESK board in the RER/M rack.
S Check the output voltage of the GRM5 and GRM24
modules.
S Change it if nedeed.
S Control all power supply and look for mechanical
failure on the boards.
S Check if there is not electrical disturbance on the
power supply.
S Change the REK2 board.
#097 e_stop same kind of fault as #096
internal
(HW3)
#098 e_stop This message appear when S Check for a Dynamic failure in the maintenance 1
dynamic the CPTronic detect a major menu on the CPT console: Dyn test 1 until Dyn test
test fault of the electronic boards 6.
during the press running. S Note the fault.
the red light on the CPT S If an SPO or SPU fault flash (00"), check the
console is on and the press connection of all flat cables between the faulty EAK
stopped. and the press.
S If an other board code flash, switch power − off on
the press and look the Init test 1 (until 6) in the Init
test menu after the power − on.
S Note the fault, and constact your technical agency.
#099 e_stop same kind of fault as #096
internal
(RW_N)
#101 no run This message is a result of S Control the fault display at the CPT console for
(e_stop) an emergency stop activated more information.
on the press.
console is on and the press
is stopped.
#107 no run The message indicate that S Check wich circuit breaker is linked to this fault :
(blower one blower of the CPTronic S if 0Q32(swing frame) go to error #022.
drive/cab cabinets is not powered. S if 033Q9(power converter) go to error #014.
inet) The red light on the CPT
is stopped.
− 3.2.13 −

#108 no run This message is displayed S Check in the printing unit fault menu for wich kind
(unit after an oil fault detected on of fault is displayed:
lubricatio the printing unit.The press is S Circular lubrication fault (1 bar):
n) stopped and it is not * Circuit breaker : switch on (fault #024 until
possible to run without reset #037).
of the fault. * Oil flow fault: Check the pressure switch XS58
and the connection until the input E58 (OK=1)
of the right EAK of the Master CPTronic.
S Check if the temperature is not to high.
S In this case check the output A49 (XY49) of the
right EAK (Cooling On =1).Check the
electro − valve and clean it.
S Check if the oil filter is not durty, check the input
E64 (OK=1) of the right EAK.
#110 no revers This message is displayed S Check the printing unit fault screen for more
inching when the safety guard informations.
(blanket/ between blankets on the S If the guard is closed, check the input E42 (Ok=1)
blanket printing unit section is open. on the right EAK of the Master CPTronic.
guard) The red light on the S If not good, check the limit switch adjustement of
CPTronic console is On and the faulty guard.
the press is stopped.
#114 no crawl This message is displayed S Check the printing unit fault screen for more
speed when one safety guard in informations.
(unit the printing unit section is S If all guards are closed, check the following inputs:
guard) open. E33,E34,E35,E36,E38,E40,E41,E42 (Ok=1) on the
The red light on the right EAK of the Master CPTronic.
CPTronic console is On and S If not good, check the limit switch adjustement of
the press is stopped. the faulty guard.
#116 no run This message is displayed S Clear the web detection in the actual web break
(web after a web break detection display : action on the function push button lighted
break) if the fault is no cleared in (F8).
the web sensor screen.
The yellow light on the CPT
console is flashing and the
press is not able to run up
to 600IPH.
#117 no run This message is displayed S Check the Dynamique test: Dyn test1"and note
(internal when the CPTronic detect an all blinking codes as well as the board
message hardware fault on the main reference(SVT,SBM...)
REK1_B) drive of the press section. S If it is not possible to start, switch power off, wait
The red light on the CPT for at least 30 seconds, and switch power on.
console is on and the press S Check if there is Initialisation fault by looking now
is stopped. the Init test1" screen.
− 3.2.14 −

#118 no run This mesage is displayed S Check the Dynamique test:"Dyn test1" and note
(internal when the CPTronic detect a all blinking codes as well as the board reference.
message fault on the main drive when (REK,MOT,HWI...).
REK1_H) the press is running. S Reset the fault by the green button Enter" on
The press is stopped and the CPT console(Version higher than 3.0).
the yellow light on the CPT S This kind of fault is most of the time an external
console is flashing. problem, like: belt not tighted, gap in the encoder
gear,overload (brake)....
S This is always possible to start but the press will be
stopped at the next fault detection (if the problem
is not fixed).
S Check if the master motor is running well alone.
S Do the same test with the post − unit motor. By this
tests, the control of each encoder is made,
S Then check if the signal from the encoder master is
received by the post − unit CPTronic:
S Check all encoder connectors, change 0TVM1 (2)
module, change the encoder.
S If this error happend when you clutch the
post − unit to the printing units,make sure the
Drive initalisation" symbol is cleared and replace
by the crawl speed" symbol.
S If not,check the power supply modules 0ENM1 and
2, change the 0TVM2 module.
#119 no run This message is displayed S Close the guard.
(web when the safety guard on S Check the input E18 (Ok=1) of the EAK3.
catcher the web catcher is open. S If not good , check the limit switch adjustement of
guard) The red light on the the web catcher safety guard and the cable
CPTronic console is On and connection to the cabinet.
#120 no run This message is displayed S Check the printing unit fault screen for more
(damp./i when one Ink/Dampening information.
nk system on the printing unit is S Then, make sure the position of the handle of the
clutch) not correct clutch. Ink/Damp.
The yellow light on the CPT S Clutch on the faulty unit is correct.
console is flashing, and the S If good, check the inputs E41,E42 for the upper
press is stopped. and E44, E45 for the lower unit on the right Print
It is not possible to switch CPTronic EAK, following the list: E41=0, E42=1 for
the print functions on the the top ink/damp. clutch status; E44=0, E45=1 for
faulty unit. the lower inK/damp. clutch status.
#121 no run This message is displayed S Check in the printing unit fault menu for wich kind
(central after an oil fault detected on of fault is displayed:
lubricatio the printing unit.The press is S Central lubrication fault (12 bars):
n) stopped and it is not * Circuit breaker : switch − on (fault #48/49)
possible to run without reset * Flow fault: check the pressure switch XS121
of the fault. located on the last printing unit gear side (near
the Infeed) and the connection until the input
E121 (A57 on the EAK display).The input is on
(OK=1) when the 12 bars pressure is detected.
S Check if the filter mounted on the first oil tank
(near the dryer), used for the central lubrication is
not durty and check the connection until the input
E125 (OK=1).
− 3.2.15 −

#122 no
positionn
ing (unit
bearer
guard)
#123 no crawl This message isdisplayed S Check the Dynamique test:"Dyn test1" and note
speed when the CPTronic detect a all blinking code as well as the board
(internal fault on the main drive when reference.(REK , MOT, HWI...)
message the press is at crawl speed. S Reset the fault by the green button Enter" on
REK1_T) The press is stopped and the CPT console (version higher than 3.0).
the yellow light on the CPT This kind of fault is most of the time an overload on
console is flashing. the line shaft of the post − unit : declutch part by
part to identify the overloaded section.
#134 e_stop this message is displayed in S Check the printing unit CPT console for more
parallel the post − unit console when details
the printing unit section is
clutch to the post − unit,and
one fault or an emergency
stop is coming from the
printing unit section
#139 only
crawl
speed
(inter unit
clutch)
#140 only
crawl
speed
SEK
#141 no run
SEK
#143 error
flying
imprinter
#146 e_stop
communi
cation /
duplex
#147 e_stop This error message indicate
other that an e_stop push button
press is activated on the splicer.
The red light on the master
CPTronic console is on and
the message #101 is also
displayed.
#148 0Q30
#149 no run
(air
pressure)
− 3.2.16 −

#150 no run
(duplex
mode,
main
shaft)
#151 inadmissi Thisis not really an error S Release the safe button.
ble message but only an S If done, and the message does not clear, the
comman indication for the operator contact of the push button is not operating good.
d (safe that the press is already
operation under control.In this case is
) not possible to safe a new
area.
#152 inadmissi Thisis not really an error S Release the push button.
operation indication for the operator contact of the push button is not operating good.
(backwar that the press is already
d under control.In this case is
inching) not possible to inch
backward.
#153 inadmissi This is not really an error S Release the push button.
d that the press is already
(forward under control.In this case is
inching) not possible to inch forward.
#154 inadmiss Thisis not really an error S Release the push button.
ble message but only an S If done,and the message does not clear, the
d that the press is already
(positioni under control.In this case is
ng) not possible to run.
d (crawl that the press is already
speed) under control.In this case is
not possible to run.
d (stop) that the press is already
under control.In this case is
d (fast) that the press is already
− 3.2.17 −

d (slow) that the press is already
d (stop that the press is already
main under control.In this case is
console) not possible to run.
duplex) under control.In this case is
speed under control.In this case is
duplex) not possible to run.
#177 0Q29
#178 063Q28
#179 063Q29
#180 063Q30
#181 063Q30
#182 063Q32
#183 no incr.of This not really an error S Release the push button until the main shaft is
speed message but only an clutched.
(main indication for the operator
shaft) that the press is already
not possible to drive it.
#184 no incr.of This not really an error S Release the push button until the printing unit is
speed message but only an clutched.
(clutch indication for the operator
printing that the press is already
unit) under control.In this case is
− 3.2.18 −

#185 no incr.of This message is displayed S If it is not possible to speed up the press above
speed after a web break detection 3300 IPH, check if the sensors at the infeed, the
(web and a restart without reset of last printing unit, and at the chill roller detect the
break the status in the web break paper (full square in the web break screen).
control) screen. S If not, adjust it with the web width of paper, change
the sensor, check the connection until you have the
good display.
S If it not possible to speed up above 800 IPH, check
if the folder sensors do not detect always a belt
(sensor before and under the chopper fold).
#186 no preset This message is displayed S If it is not possible to speed up the press above
of speed after a web break detection 3300 IPH, check if the sensors at the infeed, the
(web and a restart with a last printing unit, and at the chill roller detect the
break preseting of the speed paper (full square in the web break screen).
control) without reset of the status in S If not, adjust it with the web width of paper, change
the web break screen. the sensor, check the connection until you have the
good display.
S If it not possible to speed up above 800 IPH, check
if the folder sensors do not detect always a belt
(sensor before and under the chopper fold).
#187 no incr.of This is not really an error S Release the faster function and wait the end of the
speed message but only an clutch sequence.
shaft/ that the press is already
not possible to drive it faster.
#188 no incr.of This is not really an error S Release the function.
speed message(in duplex press)
(following but only an indication for the
press) operator that the press is
already under control.In this
case is not possible to drive
it from the slave press.
#189 no incr.of This is not really an error S Release the function
speed message (in duplex mode)
(leading but only an indication for the
it from the master press.
#193 no
positioni
ng (unit
guard)
− 3.2.19 −

#194 no run This is not really an error S Wait for the end of the sequence.
(APC) message but only an
indication for the operator
that the automatic plate
changer sequence is
engaged.
#195 no incr. This is not really an error S Release the function and/or wait the end of the
of speed message but only an splice sequence.
(splicer) indication for the operator
that the splice is
imminent.In this case is not
possible to drive faster.
− 3.2.20 −
3.2 Error messages Post unit CPTronic console
Error messages
Post unit CPTronic Console

#001 0Q26 Supply the 220VAC for S Make sure that circuit breaker is switch − on.
external devices S If the breaker is Off the fault #55 will be also
The yellow light at the CPT displayed.
console is flashing S Check the connection until the input E26 (OK=1)
of the EAK2.
#002 0Q12 Supply the 21VAC for all S The display is not active but all push button are
interface module (SEM) and always in function (except the red from the
for the CPT console display. keypad).
#012 0Q11 Supply the rack LTR for the S Make sure that circuit breaker is switch − on.
silicon and harmonic − drive S If not, all of this motor are not runing and you will
motors.The yellow light at find a Dyn Test 7" fault like 7FFB" flashing.
the CPT console is flashing S If good, check the connection until the input E11
and the red light on. (OK=1) of the EAK2
#013 033Q4 Supply the fan of the S Make sure that the circuit breaker is switch − on.
post − unit main motor with S Check the connection until the input E4 (OK=1) of
380VAC.The press will the EAK2.
stopped and the red light at
the CPT console is on.This
fault is linked with the
message #107.
#014 033Q9 Supply the fan located on S Make sure that circuit breaker is switch − on.
the back of the cabinet for S Check the connection until the input E9 (OK=1) of
the post − unit power the EAK2.
converter with 220VAC.
stopped.This fault is linked
to the message #107.
monitorin brushes of the main motor between the switch and the bracket) and control if
g main are not good to drive it the carbon brushes are not to small.
drive correctly.The yellow light of S If good, check the connection until the input E5
post − uni the CPT console is flashing. (OK=1) of the EAK2
t.
#022 0Q32 Supply the fans of the S Make sure that circuit breaker is switch − on.
cabinets with 220VAC. S Check the connection until the input E32 (OK=1)
The press will stopped and of the EAK2.
the red light at the CPT
console is on.This fault is
linked with the message
#107.
#023 0Q27 Supply the folder lights with S Make sure that the circuit breaker is switch on.
220VAC S Check the connection until the input E27 (OK=1)
The yellow light of the CPT of the EAK2.
− 3.2.21 −

#044 0Q08 Supply the transformator S If the circuit breaker trip − out, folder lights are Off
0T3 with 380VAC.The yellow and the error #055 is also displayed.
light on the CPT console is S Switch the breaker On. If good, check the
flashing. connection until the input E8 (OK=1) of the EAK2.
#045 0Q10 Supply the 380VAC power S CPTronic system is not operating.
for the transformator 0T1.
#055 earth This message indicate an S Check if the red light of the IWM module in the
leakage isolation fault on the power post − unit cabinet is on.
monitor supply of the CPTronic S If yes, try to reset the fault by pushing at least 10
cabinets: a ground is seconds on the LT" button on the IWM module
connected to the 24 or inside the post − unit cabinet.
5VDC S If the fault do not dissappear or come − back, you
The yellow light of the CPT need to find the isolation failure.
console is flashing until the S For example: cable damaged, motor grounded....
first control of the Fault S If not red, make sure that power is going to the
screen". input E28 (OK=1) of the EAK2.
signal(1) is not corresponding to the S If not correct, check the connection of the
the press in revolution. S If correct, check the Init test or/and the Dyn test of
the SEK1 board.
#062 compres This message indicate an air S Check if the air supply system give more than 3
sed air pressure fault in the bars or if it is not swictch off.
supply post − unit.The yellow light of S If good, check if the pressure switch mounted in
the CPTronic console is the post − unit section is closed, and check the
flashing 1 minute after the connection until the input E25 (OK=1) of the EAK2.
press is stopped and the red
light is on.
#063 045Q01 Supply for the gluing S Check if the circuit breaker is switch on.
equipment with 380VAC S If good, check the connection until the input E1
The yellow light on the CPT (OK=1) of the EAK2.
#064 019Q2 Supply the chill roll sqeege 1 S The pneumatic function is still working only if the
(motor) with 380VAC. oscillation of the sqeege is not working.
the yellow light on the CPT S Check if the circuit breaker is switch − on.
console is flashing. S If good, check the connection until the input E2
(OK=1) of the EAK2.
#065 020Q3 Supply the chill roll sqeegee S Check if the circuit breaker is switch − on.
2 with 380VAC. S If good,check the connection until the input E3
the yellow light on the CPT (OK=1)of the EAK2.
#066 021.1Q0 Supply the blower motor for S Check if the circuit breaker is switch − on .
3 the angle bars 1 with S If good, check the connection until the input E18
380VAC.The yellow light on (OK=1) of the EAK2.
the CPT console is flashing.
#067 022.1Q4 Supply the blower motor for S Check if the circuit breaker is switch − on.
1 the angle bars 2 with S If good, check the connection until the input E41
− 3.2.22 −

#068 023Q19 Supply the blower motor for S Check if the circuit breaker is switch − on .
the folder former with S If good, check the connection until the input E19
#069 023Q13 Supply the suction motor S Check if the circuit breaker is swicth − on.
used for the chopper table. S If good,check the connection until the input E13
with 380VAC on the first (OK=1) of the EAK2.
folder.The yellow light on the
CPT console is flashing.
#070 024Q43 Supply the suction motor S Check if the circuit breaker is switch − on.
used for the chopper table S If good,check the connection until the input E43
with 380VAC on the second (OK=1) of the EAK2.
folder or on the lower folder
in case of JF50stacked.The
#071 0Q14 Supply the transformer 0T4 S Check if the circuit breaker is switch − on.
with 380VAC used for supply S If good, check the connection until the input E14
the ENM modules .The (OK=1) of the EAK2.
synchronisation board (GLK)
between the printing units
main motor and the post
unit motor will not working
properly.
#072 0Q15 Supply the distribution bar S Check if the circuit breaker is switch − on.If off, a lot
with 380VAC. of motors in the post − unit section are not working
The yellow light of the CPT (blower,....). If it tripp − out all the time, switch − off
console is flashing. all circuit breakers and switch − on again, one by
one.
S If good, check the connection until the input E15
(OK=1) of the EAK2.
#073 019Q16 Supply the silicon mixing S Check if the cicuit breaker is switch − on.
unit motor with 380VAC.The S If good, check the connection until the input E16
yellow light on the CPT (OK=1) of the EAK2.
#074 025Q31 Supply the sheeter with S Check the connection of the input E31 (OK=1) of
380VAC. the EAK2.
The yellow light on the CPT S If they are more fault displayed,like"sheeter
console is flashing. e − stop" with the red light on the CPT console,
S Check if the circuit breaker is switch − on.
#075 023Q06 Supply the oil pump motor S Check if the circuit breaker is switch − on and make
of the folder1. a reset in the folder fault display.
The red light on the CPT S Check the connection of the input E6 (OK=1) of
console is on and the press the EAK2.
is stopped.
This fault is linked with a
symbol displayed in the
folder fault screen and the
fault #106.
− 3.2.23 −

#076 024Q42 Supply the oil pump motor S Check if the circuit breaker is switch − on and make
of the folder2. a reset in the folder fault display.
the red light on the CPT S Check the connection of the input E42 (OK=1) of
console is on and the press the EAK2.
is stopped.
This fault is linked with a
symbol displayed in the
folder fault screen and the
fault #126 and #132.
#077 e_stop This error message indicate S Check if the red circle push button is activated.
main that the e_stop push button S If not, check the connection until the input E63
operator is activated on the CPT (OK=1) of the EAK1.
panel console.
The red ligh on the CPT
console is on and the blue
light is flasing.The press is
stopped.
chill rolls that an e_stop push button push button on the chill drive station is not
is activated on the chill roller activated.
section . S If not, check the input status on the EAK3:
The red light on the CPT E1(OK=1) bottom inlet e_stop push button.
console is on and the press E25 (OK=1)bottom outlet e_stop push button.
is stopped.This is linked with E33 (OK=1) top inlet e_stop push button.
a symbol in the chill fault E57 (OK=1) top outlet e_stop push button.
screen. S If one of this inputs is not correct, check the
The message #101 will be connection until the EAK3.
also displayed.
#082 e_stop This error indicate that an
perforato e_stop push button is
r activated on the perforator
unit.
is stopped.
The message #101 will be
also displayed.
− 3.2.24 −

#085 e_stop This error indicate that an S If all e_stop push button are released, take the
JF50/JF4 e_stop push button on the Input/output list of your press
4 first folder is activate.The red S Look at the input E25 (OK=1) of the JF50 part
light on the CPT console is 1"list, at the inputs E1, E10, E33, E41 (OK=1) of
on and the press is stopped. the JF50 part2" list.
This message is linked with S If you have a JF50stacked folder,
a location symbol display on * take the JF50s part 1" list and,
the folder fault screen.The * check the input E1(OK=1);
blue light of the drive station * take the JF50s part 2" list and check the inputs
is flashing. E1, E17, E25, E33 (OK=1).
The message #101 will be S If you have a JF44 folder,
also displayed. * take the JF44" list and,
* check the inputs E1, E9, E17, E33, E38 (OK=1).
S If you have a 4 pages Module,
* check the inputs E1, E17, E20 from the 4 page
module" list.(OK=1)
S If one input is not correct, control the connection
until the right EAK board.
#086 e_stop This indicate that an e_stop S Check if all e_stop push button of additionnal
PIO push button of an equipments are released.
(addition additionnal drive station is S If correct, check the connection until the inputs E1,
al activate.The red light on the E17 (OK=1) of the right EAK (9 or 12) following the
equipme CPT console is on and the Input/output list.
nt) press is stopped.There is No
location symbol in fault
screen because this is free
customer inputs.
The message #101 will be
displayed.
#092 e_stop This message appear to S Check the location of the fault.
product indicate a jam detection in S Make sure that the paper cross correctly the
control the folder.The press is sensor light; timing between two copies; quality of
folder. stopped and a manual reset the paper.
of the fault is nedeed at the S If good, check the faulty" sensor with a real copy:
CPT console in the folder Monobloc type (Weko):
fault screen or from the * sensor see paper, the small light is on;
folder station. * no paper detected, the light is off.
The fault is display by a S Emetter/receiver type:
picture: @". * sensor see paper, the light is off;
* no paper detected, the light is on.
S If one jam sensor is not working correctly it is not
possible to cross the speed of 3000IPH and the
message #185 or #186 is displayed.
− 3.2.25 −

#093 e_stop This message indicate a S Check if there is a real break of paper.
web web break of the paper. S If not,
break This is associated with a * check which sensor detect the break,
display on the CPT console * control that it is not located on the edge of the
used for location of the first paper,
detection . * control the quality of the paper.
The press is stopped. S If good,
* check the sensor with the help of the web
break" screen on the CPT console: when sensor
see paper, there is a small square symbol
displayed.
S If not,
* change the sensor,
* check the connection until the right EAK.
S If the defective sensor is located at the chill roll it is
not possible to cross the speed of 3300IPH until
the clearance of the fault, then the message #185
or #186 is displayed.
#094 e_stop This message is displayed S Check if the power supply of the master cabinet is
communi when the serial not swicth off.
cation communication between the S Check if there is a dynamique fault in the Dyn
master cabinet and the test1" screen of the maintenance 1 display on both
post − unit cabinet is not CPT console.
correct S Check if the flat cables RER/M1:X21 of the master
The red light on the CPT CPTronic and RER/M:X21 of the post − unit cabinets
console is on and the press are correctly locked.
is stopped S If good, replace the module 0SZM1 or/and the
0SVM in the master cabinet.
S If not good,
* check the power supply of this module and,
* change it if necessary.
#095 e_stop Check the location of the
caused e_stop action.
by
comman
d
#096 e_stop This kind of message is a S Check if all the cables between this racks are good
internal result of an internal error inserted, not damaged.
(HW1) detected between the S Check all connections by screws....
Input/output racks(EAE) and S Check if the power supply 5VDC and 24VDC
the computer rack(RER). (NTK85) are not to low.
The red light on the CPT S Change the boards if nedeed.
console is on and the press S Change the SEK board located in the EAE or EHE
is stopped. rack
S Change the ESK board in the RER/M rack.
S Check the output voltage of the GRM5 and GRM24
modules,
S Change it if nedeed.
S Control all power supply and look for mechanical
failure on the boards.
S Check if there is not electrical disturbance on the
power supply.
S Change the REK2 board.
− 3.2.26 −

#097 e_stop Same kind of fault as #096
internal
(HW3)
#098 e_stop This message appear when S Check for a Dynanique failure in the maintenance 1
dynamic the CPTronic detect a major menu on the CPT console: Dyn test 1 until Dyn test
test fault of the electronic boards 6.
during the press running. S Note the fault.
The red light on the CPT S If an SPO or SPU fault flash (00"), check the
console is on and the press connection of all flat cables between the faulty EAK
stopped. and the press.
S If an other board code flash,
* switch power − off on the press and
* look the Init test 1 (until 6) in the Init test menu
after the power − on.
S Note the fault, and constact your technical agency.
#099 e_stop Same kind of fault as #096.
internal
(RW_N)
#101 no run This message is a result of S Control the fault display at the CPT console for
(e_stop) an emergency stop activated more information.
on the press.
is stopped.
#102 no run One safety guard on the S Check if all the guards are closed and take the
(sheeter sheeter is open or the paper out of the sheeter.
guard or sheeter jam detection see S Check if the blue light of the sheeter panel is
jam) an accumulation of paper. flashing.
The red light on the CPT S If yes, check the connection until the input
console is on and the press E21(OK=1) of the sheeter EAK.
is stopped. S Check the power supply and the output E6 of the
module 0SEM5 of the post − unit cabinet.
S Change it if faulty.
#104 no run One safety guard of the first S Check the folder fault menu for more information.
(JF50/JF folder(JF50, JF50s or S If all guards are closed, check if the limit switch of
44 JF44,4p module) is open. the faulty guard is free when the guard is closed.
guard) The red light on the CPT S If good, check if the connection to the distribution
console is on and the press box in the folder are correct: (OK=24VDC).
is stopped. JF50:LVT1/E53 and LVT2/E54.
JF50stacked: idem as JF50 added LVT3/E53 and
LVT4/E54
JF44:LVT1/E51, 55.
4 page module: LVT1/E25,27.
− 3.2.27 −

#105 no run The message is diplayed S Check on the first folder where is this tool inserted;
(JF50/JF when one crank (folder tool) there is two place for the crank on the JF50 folder:
44 crank) is inserted to move the one operator side, one gear side.
folder manualy. S Check if the limit switches are released when not
The press must be already inserted.
stopped. S If good, check the connection to the distribution
The red light on the CPT box:
console is on. JF50:LVT1/E24,LVT2/E32 ,
JF50stacked added LVT4/E56
JF44:LVT1/E30,31,32.
(OK=24VDC)
#106 no run The message is displayed S Check the folder fault screen.
(JF50/JF when a lubrication flow S If it is an oil flow fault, there are more than one fault
44 fault.of the first folder is displayed.
lubricatio detected. S Look for the message #075 (circuit breaker
n) The red light on the CPT 023Q6),
console is on and the press S For the filter durty indication (ZxS229), then change
is stopped. it.
More information are S For an oil low level, then fill the oil tank.
displayed in the folder fault S If no more fault is displayed check the 380VAC
menu. power supply coming from the circuit breaker
The fault must be reseted. 023Q6 and, check the cable connection on the oil
pump motor.
S If good check, the oil flow indicator Z1S227
(LVT2/E27) for the JF50, or Z2S106 (LVT1/E6) for
the JF44.
(OK=24VDC).
S If it is a grease fault, check if the tank is not empty.
S Check the switch ZxS230 (LVT2/E30) for JF50, or
Z2S107 (LVT1/E7) for JF44.) (OK=24VDC).
S Do not forget to reset the fault between each test.
#107 no run The message indicate that S Check wich circuit breaker is linked to this fault :
(blower one blower of the CPTronic * if 0Q32 (swing frame) go to error #022.
drive/cab cabinets is not powered. * if 033Q9 (power converter) go to error #014.
inet) The red light on the CPT
is stopped.
#112 no crawl The message indicate that S Check the folder 1 fault menu to have more
speed one safety guard is open.It information.
(JF50/JF is only possible to inch the S If the guard displayed is closed, check if is limit
44 press from the nearest drive switch is released.
guard/ja station where the guard is S If good, check the connection to the distribution
m) open. box.
JF50: LVT1/E49,50,51,52,54 and LVT2/E53.
JF50stacked:LVT1/E50,51,52, LVT2E/49,53,
LVT3/E49,50,51,52,54, LVT4/E53.
JF44: LVT1/E49,50,52,53,54.
4p module:LVT1/E26.
(OK=24VDC).
− 3.2.28 −

#116 no This message is displayed S Clear the web detection in the actual web break
run(web after a web break detection display: action on the function push button lighted
break) if the fault is no cleared in (F8).
the web sensor screen.
console is flashing and the
press is not able to run up
to 600IPH.
#117 no run This message is displayed S Check the Dynamique test: Dyn test1" and note
(internal when the CPTronic detect an all blinking codes as well as the board
message hardware fault on the main reference(SVT,SBM...).
REK1_B) drive of the press section. S If it is not possible to start, switch power off, wait
The red light on the CPT for at least 30 seconds, and switch power on.
console is on and the press S Check if there is Initialisation fault by looking now
is stopped. the Init test1" screen.
#118 no run This mesage is displayed S Check the Dynamique test:"Dyn test1" and note
(internal when the CPTronic detect a all blinking codes as well as the board reference.
message fault on the main drive when (REK,MOT,HWI...).
REK1_H) the press is running. S Reset the fault by the green button Enter" on
The press is stopped and the CPT console(Version higher than 3.0).
the yellow light on the CPT S This kind of fault is most of the time an external
console is flashing. problem, like: belt not tighted, gap in the encoder
gear,overload (brake)....
S This is always possible to start but the press will be
stopped at the next fault detection (if the problem
is not fixed).
S Check if the master motor is running well alone.
S Do the same test with the post − unit motor. By this
tests, the control of each encoder is made.
S Then check if the signal from the encoder master is
received by the post − unit CPTronic:
S Check all encoder connectors,
S Change 0TVM1 (2) module,
S Change the encoder.
S If this error happend when you clutch the
post − unit to the printing units, make sure the
Drive initalisation" symbol is cleared and replace
by the crawl speed" symbol.
S If not, check the power supply modules 0ENM1
and 2, change the 0TVM2 module, change the
GLK2 board in the rack RER/M.
#123 no crawl This message isdisplayed S Check the Dynamique test:"Dyn test1" and note
speed when the CPTronic detect a all blinking code as well as the board
(internal fault on the main drive when reference.(REK ,MOT,HWI...).
message the press is at crawl speed. S Reset the fault by the green button Enter" on the
The press is stopped and CPT console (version higher than 3.0).
the yellow light on the CPT S This kind of fault is most of the time an overload on
console is flashing. the line shaft of the post − unit : declutch part by
part to identify the overloaded section.
− 3.2.29 −

#124 no run One safety guard of the 2nd S Check the folder fault menu for more information.
(2nd folder(JF50 or JF44) is open. S If all guards are closed, check if the limit switch of
JF50/JF4 The red light on the CPT the faulty guard is free when the guard is closed.
4 guard) console is on and the press S If good, check if the connection to the distribution
is stopped. box on the folder are correct:JF50:LVT1/E53 and
LVT2/E54, JF44:LVT1/E51,55.
4 page module:LVT1/E25,E27.
(OK=24VDC),
#125 no run The message is diplayed S Check on the 2nd folder where is this tool inserted;
(2nd when one crank (folder tool) there is two place for the crank on the JF50 folder:
JF50/JF4 is inserted to move the 2nd one operator side, one gear side.
4 crank) folder manualy. S Check if the limit switches are released when not
The press must be already inserted.If good check the connection to the
stopped. distribution box: JF50:LVT1/E24,LVT2/E32.
The red light on the CPT JF44:LVT1/E30,31,32.
console is on. (OK=24VDC)
#126 no run The message is displayed S Check the folder fault screen.
(2nd when a lubrication flow S If it is an oil flow fault, there are more than one fault
JF50/JF4 fault.of the 2nd folder is displayed.look for the message #075 (circuit
4 detected. breaker 024Q6),for the filter durty indication
lubricatio The red light on the CPT (ZxS229),then change it,for a oil low level,then fill
n) console is on and the press the oil tank.
is stopped. S If no more fault is displayed, check the 380VAC
More information are power supply coming from the circuit breaker
displayed in the folder fault 024Q6 and check the cable connection on the oil
menu. pump motor.
The fault must be reseted. S If good, check the oil flow indicator Z1S227
(LVT2/E27) for the JF50 or Z2S106 (LVT1/E6) for
the JF44.(OK=24VDC).
S If it is a grease fault check if the tank is not empty.
S Check the switch ZxS230 (LVT2/E30) for JF50 or
Z2S107 (LVT1/E7)for JF44.)
(OK=24VDC).
S Do not forget to reset the fault between each test.
#127 no crawl The message indicate that S Check the folder 2 fault menu to have more
speed(2n one safety guard is open on information.If the guard displayed is closed,check if
d JF50/ the second folder.It is only is limit switch is released.If good,check the
JF44 possible to inch the press connection to the distribution box.
guard/ja from the nearest drive JF50: LVT1/E49,50,51,52,54 and LVT2/E53.
m) station where the guard is JF44: LVT1/E49,50,52,53,54.
open. 4p module:LVT1/E26.
(OK=24VDC).
#134 e_stop This message is displayed in S Check the printing unit CPT console for more
parallel the post − unit console when details.
the printing unit section is
clutch to the post − unit,and
one fault or an emergency
stop is coming from the
printing unit section.
− 3.2.30 −

#135 stop This message is displayed S Check in the folder fault screen wich air cylinder is
configura when CPTronic does not faulty or by the maintenance menu select the
tion identify the configuration of function VEN" (version lower or equal to 2.9) or by
folder the folder. the folder change − over menu select the function
The yellow light on the CPT VEN" (version 3.X).
console is flashing and the S With this information, check if Only one light of the
press is stopped. 2 detectors mounted on the air cylinder is lit
(Except V8: 3 detectors):
S If not (display: Vx = on/....... or Vx= off /..........
highligted),
* Check if the cylinder is at the correct
end − position, then check the power supply of
the detector (24VDC),change the detector,
* Check the connection until the distribution box
LVT.
S If good, control if the status of the air cylinder is
corrected for the actual job running : this is the
message displayed.
For example : when the printer opens the guide of
the second folder cylinder (V7,V12) after a jam (Vx
= on/set or off/retract but highlited)
#136 e_stop This error indicate that an S If all e_stop push button are released, take the
JS50/JS4 e_stop push button on the Input/output list of your press and look at the input
4 second folder is E25 (OK=1) of the JF50 part 1" list, at the inputs
activated.The red light on E1, E10 ,E33 ,E41 (OK=1) of the JF50 part2" list.
the CPT console is on and (OK=1).
the press is stopped. S If you have a JF44 folder,
This message is linked with * Take the JF44" list and,
a location symbol display on * Check the inputs E1, E9, E17, E33, E38 (OK=1).
the folder fault screen,and S If you have a 4 pages Module, check the inputs
the blue light of this drive E1, E17, E20 from the 4 page module" list.
station is flashing. S If one input is not correct,control the connection
The message #101 will be until the right EAK board.
also displayed.
#137 019Q7 This circuit breaker supply S Make sure that the circuit breaker is switch − on.
the silicon pump motor with S Check the connection until the input E7 (OK=1) of
380VAC. the EAK2
the yellow light on the CPT
#140 only This message is display S Control the SEK status in the maintenance screen
crawl when one limit − switch 1 and check which number is higlighted. Then
speed (second contact) of one check inside the electrical drawings to know where
SEK safety guard is closed when is located the wrong switch.
the guard is closed.The S It is also possible to take a safety function of one
yellow light on the CPT drive station (one at each time) and try to inch the
console is flashing. press, then the wrong switch is in this same area.
S Check the wrong switch connected to the input
module FEM10 (points 3 and 8 = 0VDC when
good) located on each distribution box LVT.
S Change the faulty actuator.
− 3.2.31 −

#141 no run This message is displayed S Control the SEK status in the maintenance screen
SEK when the redundant 1 and check which number is highlited. The
conctact of safety guard, electrical drawings show the location of the wrong
folder crank or emergency actuator (or push button).
push button give a wrong S Check the connection in the distribution box LVT
signal.The red light on the on the input module FEM10 (points 1 and 6
CPT console is on and the =24VDC when good).
press is locked.
#144 023Q44 Supply the second suction S Make sure circuit breaker is switch − on. Check the
motor of the stacked folder overload adjustment.
with 380VAC. S If good, check the connection of the input E44
The yellow light on the CPT (OK=1) of the EAK2.
#147 e_stop This message is displayed S Check the CPT console from the other press for
other when the press is in more information.
press duplex/triplex and an
emergency stop push button
is activated.The red light on
the CPT console is on and
the press is locked.
#148 0Q30 Supply the tranformer 0T2 S Make sure the circuit breaker is switch − on.
with 380VAC used for the S Check the overload setting.
post_unit clutches S If good, chek the connection until the input E30
(Superstructure).The yellow (Ok=1) of the EAK2.
flashing.
#149 no run This error message is S Check the air supply.
(air − pres displayed 1 minute after the S Look the error message #062.
ure) message #062.
Now the red light on the
CPT consoe is on and the
press is stopped.
#150 no run This is not really an error S Wait until the duplex shaft is finished to clutch.
(duplex message but only an
mode,ma indication for the operator
in shaft) that the press is already
under control.Sequencer in
progress.
#151 inadmissi This is not really an error S Release the safe button.
d(safe that the press is already
operation under control.In this case is
) not possible to safe a new
area.
#153 inadmissi This is not really an error S Release the inch push button.
comman indication for the operator contact of the push button is not operating well.
d(forwar that the press is already
d under control.In this case is
inching) not possible to inch forward.
− 3.2.32 −

#155 inadmissi This is not really an error S Release the crawl speed push button.
speed) under control.In this case is
not possible to run higher
than 600IPH.
#156 inadmissi This is not really an error S Release the stop push button.
ble message but only an S If done,and the message does not clear, the
d (stop) that the press is already
not possible to stop.
#157 inadmissi This is not really an error S Release the +" push button.
d (fast) that the press is already
not possible to run faster.
#158 inadmissi This is not really an error S Release the − " push button.
d (slow) that the press is already
under control.(stand still).In
this case is not possible to
slow down.
#159 inadmissi This is not really an error S Release the stop push button on the console.
main under control.(stand still)In
console) this case is not possible to
slow down.
d(run that the press is already
unit main under control.In this case is
console) not possible to drive it.
speed under control.In this case is
duplex) not possible to drive it.
− 3.2.33 −

#183 no incr.of This is not really an error S Release the push button.
speed message but only an
shaft) that the press is already
#184 no incr.of This is not really an error S Release the push button.
speed message but only an
(clutch indication for the operator
printing that the press is already
unit) under control.In this case is
#185 no incr.of This message is displayed S Make a reset of the web break detectors and
speed after a web break and a speed up the press.
(web restart until 3300IPH without S If not possible, check if the infeed, printing unit
break reset of the sensor status in near the dryer and the chill roll sensors see paper
control) the actual web break (full square in the web break screen). If not, check
detector display. the connections, change the sensor and make a
reset until you have the good display.
#186 no preset This message is displayed Make a reset of the web break detectors and
of speed after a web break and a speed up the press.
(web automatic restart without S If not possible, check if the infeed, printing unit
break reset of the sensor status in near the dryer and the chill roll sensors see paper
control) the actual web break (full square in the web break screen). If not, check
detector display.The press the connections, change the sensor and make a
run until 3300IPH maximum. reset until you have the good display..
#187 no incr.of This is not really an error S Release the faster function and wait the end of the
speed message but only an clutch sequence.
shaft/ that the press is already
#188 no incr. This is not really an error S Release the function.
of speed message (in duplex press)
(following but only an indication for the
it from the slave press.
#189 no incr. This is not really an error S Release the function.
of speed message (in duplex mode)
(leading but only an indication for the
it from the master press.
− 3.2.34 −
3.3 Modules status Table of contens
3.3 Modules status
3.3.1 Infeed
3.3.3 Master Init test
3.3.7 Print function init test
3.3.10 Print function dynamic test
3.3.13 Post -unit dynamic test
3.3.16 SEK status

3.3 Modules status Table of contens

3.3 Modules status Infeed
Modules status
The following displays allow you to know each module status. Call your Heidelberg Harris service
representative to be driven on you problem.
Procedure to check the infeed status
NTK
2 SSK
+
"
−
− 3.3.1 −
3.3 Modules status Infeed
+
"
−
+
"
−
− 3.3.2 −
3.3 Modules status Master Init Test
Procedure to check the master init test
+
"
−
− 3.3.3 −
+
"
−
+
"
−
− 3.3.4 −
+
"
−
+
"
−
− 3.3.5 −
+
"
−
− 3.3.6 −
3.3 Modules status Print function init test
Procedure to check the print function init test
+
"
−
− 3.3.7 −
+
"
−
+
"
−
− 3.3.8 −
+
"
−
+
"
−
− 3.3.9 −
3.3 Modules status Print function dynamic test
Procedure to check the print function dynamic test
+
"
−
− 3.3.10 −
+
"
−
+
"
−
− 3.3.11 −
+
"
−
+
"
−
− 3.3.12 −
3.3 Modules status Post − unit dynamic test
Procedure to check the post -unit dynamic test
+
"
−
− 3.3.13 −
+
"
−
+
"
−
− 3.3.14 −
+
"
−
+
"
−
− 3.3.15 −
3.3 Modules status SEK status
Procedure to check the SEK status (Master console)

Master CPTronic : SEK1
+
"
−
1
LIST OF THE INPUTS :

N_ 1: Emergency stop main Cptronic console
N_11 until 20 : Communication between Master and Post − unit CPTronic
N_ 21 : Emergency stop web catcher 1 drive station
N_ 22 : Emergency stop web catcher 2 drive station
N_ 31 : Emergency stop infeed
N_ 32 : Emergency stop splicer
N_ 111 : Emergency stop (PIO) drive station 1
N_ 116 : Emergency stop (PIO) drive station 2
− 3.3.16 −
Master CPTronic : SEK2
LIST OF THE INPUTS: (example)
N_1 to N_10 :First printing unit (start count from the Dryer)
N_1: Emergency stop (xS1,xS17,xS25,xS29)

N_2: Safety guards top inlet (xS33,xS40)
N_3: Safety guards bottom inlet (xS34,xS35)
N_4: Safety guard top outlet (xS36)
N_5: Safety guards bottom outlet (xS38,xS41)
N_6: not used
N_7: not used
N_8: not used
N_9: Safety bearer guard (xS42)
N_10: Printing unit declutch (xB54)
N_11 to N_20 : Second printing unit

N_6: not used
N_7: not used
N_8: not used
− 3.3.17 −
N_21 to N_30 : Third printing unit

N_6: not used
N_7: not used
N_8: not used
N_31 to N_40 : Fourth printing unit

N_6: Flying Imprinter upper clutch (063K5)
N_7: Flying Imprinter lower clutch (063K7)
N_8: not used
N_41 to N_50 : Fifth printing unit (or Flying Imprinter)

N_6: Flying Imprinter upper clutch (063K5)
N_7: Flying Imprinter lower clutch (063K7)
N_8: not used
− 3.3.18 −
Procedure to check the SEK status (Post -unit console)
+
"
−
1
Post-unit CPTronic : SEK1
LIST OF THE INPUTS : (example)
N_1: Emergency stop of the post − unit console

N_11 to N_20 : Communication between Post − unit and Master CPTronic
N_21: Emergency stop chill roll (19S1, 19S25)
N_26: Emergency stop cill roll 2 (20S33, 20S57)
N_31 until N_120 depend of the Post − unit Input/Output board configuration:
JF − 50 group Z.0 (LVT1)

X1 : Emergency stop DS3 (ZOZ125)
X2 : Safety guard SG7 (ZOS 153)
X3 : Safety guard SG2, SG4, SG5, SG8, (ZOS150, ZOS151, ZOS152, ZOS154)
X4 : Not used
x5 : Folder decluched (Z0S115)
x6 : Jumper to 24VDC
x7 : Folder change over crank (Z0S124)
x8 : Not used
x9 : Not used
X10 : Folder declutched (Z0S115)
− 3.3.19 −
JF − 50 group Z.0 (LVT2)

x1 : Emergency stop DS1, DS2, DS16 (Z0S233, Z0S201, Z0S210)
x2 : Safety guard SG6 (Z0S254)
x3 : Safety guard SG1, SG3 (Z0S149, Z0S253)
x4 : not used
x6 : Emergency stop DS4 (Z0S241)
x7 : Main crank (Z0S232)
x8 : Not used
x9 : Not used
x10 : Folder declutched (Z0S115)
JF − 50 Stacked group Z1 (LVT1)

x3 : Safety guard SG2, SG4, SG5, SG8 (Z0S150, Z0S151, Z0S152)
X4 : Not used
X5 : Folder decluched (Z0S115)
x6 : Jumper to 24 VDC
x7 : Folder change over crank (Z0S124)
X8 : Not used
x9 : not used
X10 : Folder declutched (Z0S115)
JF − 50 Stacked group Z1 (LVT2)

x1 : Emergency stop DS1, DS2, DS16 (Z0233, Z0S201, Z0S210)
x3 : Safety guard SG1, SG3 (Z0S149, Z0S253)
X4 : not used
x7 : Main crank (Z0S232)
x8 : Not used
x9 : not used
JF − 50 Stacked group ZI (LVT3)

x1 : Emergency stop DS23 (ZIS301)
X2 : Safety guard SG17 (Z1S353)
x3 : Safety guards SG12, SG14, SG18 (Z1S350, Z1S351, Z1S354)
x4 : Not used
x6 : Jumper to 24 VDC
x7 : not used
x8 : safety guards SG11, SG15 (Z1S349, Z1S353)
x9 : not used
− 3.3.20 −
JF − 50 Stacked group ZI (LVT4)

x1: Emergency stop DS22 (ZIS401)
x3 : Safety guards SG13 (Z1S253)
x4 : not used
x5 : Folder declutched
x6 : Emergency stop DS
x7 : Not used 21, DS24, DS25 (Z1S433, Z1S425, Z1S417)
x8 : Not used
x9 : Not used
x10 : Folder declutched
JF − 50 group Y1 (Superstructure 1)
x1 : Emergency stop DS11, DS12, DS13 (Y1S101, Y1S109, Y1S117)
x6 : Emergency stop DS14, DS15, DS17 (Y1S125, Y1S129, Y1S157)
JF − 50 group Y1 (Superstructure 2)
x1 : Emergency stop DS11, DS14, DS15. If Duplex, then DS20 (Y2S101, Y2S129, Y2S153)
x6 : Emergency stop DS12, DS13 (Y2S109, Y2S117)
JF − 44 group Z2 (LVT1)
x1 : Emergency stop DS1, DS2, DS3, (Z2S101, Z2S109, Z2S117)
x2 : Safety guards SG1, SG7 (Z2S151, Z2S155)
x3 : Safety guards SG1, SG2 (Z2S149, Z2S150)
x4 : Not used
x5 : not used
x6 : Emergency stop DS4, DS16 (Z2S133, Z2S138)
x7 : Folder crank / guard CR1, CR2, CR3 (Z2S130, Z2S131, Z2S132)
x8 : Safety guard SG4, SG5, SG6 (Z2S152, Z2S153, Z2S154)
x9 : not used
x10 : not used
4 Pages Module group 66

x1 : Emergency stop DS41, DS42, DS43, (66ß101, 66S217, 66S120)
x2 : Safety guards SG41, SG43 (66S125, 66S127)
x3 : Safety guard SG42 (66S126)
x4 : not used
x5 : Module declutched (66K130/131)
x6 : Jumper to 24VDC
x7 : Not used
x8 : Not used
x9 : Not used
x10 : not used
− 3.3.21 −
Sheeter group 25
x1 : Emergency stop DS1
x6 : jumper to 24 VDC
Standart interface (PIO) group 90/91

x1 : Emergency stop DS1
X2 : Emergency stop DS2
− 3.3.22 −
3.4 Failure cases Table of contens
3.4 Failure cases
3.4.1 General
3.4.2 Infeed
3.4.3 Printing unit
3.4.4 Chill rollers
3.4.5 Folder

3.4 Failure cases Table of contens

3.4 Failure cases
Failure cases
This section gives various failure cases and help you to solve the problem in making a check − list.
General
The press does not start
S Look at the error message display on each CPTronic console (Master and Post − unit) for more information.
S If one message is displayed,used the list include in this manual to have more information of the problem.
S Then check the Init/Dyn test 1 on the maintenance menu.
Example : You may have the following message :
SLT CON=7F9F mean no field current or
SRK=012F mean no power supply for the field regulator.
The press start a short time and stop
S Look at the press status on the Cptronic console for more information.
S If one message is displayed,used the list include in this manual to have more information of the problem.
S If no message displayed, declutch the post − unit section to the master section and start each separate
section:
The master drive is faulty:
S The master section continue to stop.
S Declutch the infeed drive and start again.
S Look at the Dyn test menu 1 (Init test menu 1) and compare to the list in the manual.
S This kind of menu give one indication of the part faulty.
For example the DYN test :
HWI=7F7F means no release of the motor break.
HWI=7D7F means encoder faulty
MOT=7FFD means transmition trouble like belt not tigted or encoder gearing faulty.
The master drive run when the infeed dive is declutch:
S Look at the Dyn test menu of the infeed section (Init test menu) and compare to the list in the manual.
The post − unit drive is faulty:
S Declutch each part of the post − unit and try to run the motor alone.
S Look at the Dyn test menu 1 (Init test menu 1) on the post − unit console and compare to the list in the
manual.
For example the DYN test :
HWI=7F7F mean no release of the motor break.
HWI=7D7F mean encoder faulty
MOT=7FFD mean transmition trouble like belt not tigted or encoder gearing faulty.
S Check the encoder signal from the master cabinet, change the TVM module,change the GLK2 board.
S Check if the input E58 of the EAK1 − 02 of the post − unit Cptronic change of status when the press start.
− 3.4.1 −
3.4 Failure cases
INFEED
WEB GUIDE
No movement possible
S Check if the guide is not in a mechanical limit.
S Check if the CPTronic does not display one limit (0=OK):
S Contol the inputs E19,E20,E23,E24 of the EAK1 − 04 for the first infeed web guide (EAK1 − 06 for the
second infeed) on the master CPTronic console.
S Check if the motor is powered.(the motor is normaly Hot);
S Change the Weko contoller if needed
S Check the motor coupling.
No Automatic mode
S Check if the speed of the press is higher than the web guide speed point (default value=3600 IPH).
S Check if the guide is not outside the mechanical range;check the manual mode.
S Check if the Automatic mode" is enable:
S Check the output A24 (0=OK) of the EAK1 − 04 (EAK1 − 06 for the second infeed) on the master console.
One Web − edge sensor does not working
S Make sure both sensors are enable (check the preselection menu) from the master Cptronic console.
S Try to move the servo − motor by hand.
S Check the Init/Dyn status of the servo − motor with the procedure SSK status"
S Restart one web edge detection" :
If the motor stop before the detection of the paper, clean the sensor and the reflector and start again.
If the motor does not stop when the paper is under the sensor, change the sensor, check the feedback
to the SSK board. Change the Weko electronic box if no feedback.
WEB TENSION
S Make sure that the mechanic of the dancer is smooth, check the setting of the nip roller.
S Adjust the pressure of the dancer.
S Check the outputs signal from the master CPTronic to the infeed : EAK1 − 03/ A57, EAK1 − 03/ A58.
If A57=0 and A58=0
S This mode is correct after power up and the press at standstill of the press.
S When the press start the infeed system must switch to the proportionnel mode.
S If not, check the Init/dyn test of the Infeed Cptronic following the procedure include in this manual.
S Change the EAK1 − 03 of the master Cptronic inside the rack EAE1.1.
S Change the ERK3 board inside the ERR rack.
If A57=1 and A58=0: (proportionnal mode)
S Make sure that the nip roll come on the roller when the speed is higher than 800IPH
(adjustable speed point).
S Check the feedback to the Cptronic on the EAK1 − 04/ E7 (OK=1).
S Check the web tension display (local or on the master console); to switch the web tension mode the
system need a tension higher than 50Newtons.
S Check the dancer potentiometer as well as the mechanical coupling.
S Check if the chill roll is clutch in.
If A57=1 and A58=1: (web tension mode)
S Check the dancer potentiometer as well as the mechanical coupling.

S Check the encoder signal.
S Check if the infeed motor belts are tighted.
S Ckeck the infeed Init/Dyn test following the procedure include in this manual and compare the displays.
− 3.4.2 −
3.4 Failure cases
PRINTING UNITS
Impression goes Off:
S Check if no dryer fault.(look also on the dryer fault screen).
S Check the input E1(OK=1) of the EAK1 − 03 on the master console (E2 for a second dryer):
S Check the connection if the input is faulty.
S Change the SEM module.
Ink motor does not start:
S Check the Init/dyn test display on the master console (tests 8/9):
S All tests of the HAK2 boards must be equal to FFFF if used.Compare with the list include in this manual.
(Init/dyn tests of the Print − function Cptronic).
For example :
7F7F is a communication fault.
7FF1 is output not used.
7FF5 is no motor detected.
S Check if the motor cable is not disconnected.
S Check if the motor installed is correct. (the Ink fountain roller motor is longer than the Dampening motor).
S Check if the outputs voltage of the GRM250/1 (GRM250/2) are correct.(250VDC)
S Change the faulty power module (LTM1000).See the chapter locations" of the elements for more
details.
Dampening motor does not start:
S Check the Init/dyn test display on the master console (tests 6/7):
S All tests of the HAK2 boards must be equal to FFFF if used.Compare with the list include in this manual.
(Init/dyn tests of the Print − function Cptronic).
For example :
7F7F is a communication fault.
7FF1 is output not used.
7FF5 is no motor detected.
S Check if the motor cable is not disconnected.
S Check if the motor installed is correct. (the Dampening motor is shorter than the Ink fountain roller motor).
S Check if the output voltage of the GRM120/1 (GRM120/2) is correct.(120VDC)
S Change the faulty power module (LTK500).
Ink form roller not working
S Check if the Ink distribution is clutch.Check the handle on the print unit.
S If not correct: the printing function are not displayed at the master console:
S Control the inputs E41,E44 (OK=0),E42,E45 (OK=1) of the EAK2 − XX (XX=printing unit number)
S Check if the Ink distribution is preselected in the printing unit menu on the master console.
S Check the output signal A36 (top),A44 (bottom) of the Ink form roller (OK=1) on the same EAK board.
S Check if the pneumatic is correct,change the air − cylinder,change the valve.
S Ckeck the solenoid of the valve,change − it.
− 3.4.3 −
3.4 Failure cases
Dampening form roller not working

S Check if the Dampening distribution is clutch.Check the handle on the print unit.
S If not correct: the printing function are not displayed at the master console:
S Control the inputs E41,E44 (OK=0),E42,E45 (OK=1) of the EAK2 − XX (XX=printing unit number)
S Check if the Dampening distribution is preselected in the printing unit menu on the master console.
S Check the output signal A35 (top), A43 (bottom) of the Dampening form roller (OK=1) on the same EAK
board.
S Check the water level sensor mounted inside the Dampening pan, check the feedback on the input E9
(top), E10 (bottom) of the same EAK board.
S Check if the pneumatic is correct,change the air − cylinder,change the valve.
S Ckeck the solenoid of the valve,change − it.
CHILL ROLLERS
WEB GUIDE
No movement possible
S Check if the guide is not in a mechanical limit.
S Check if the CPTronic does not display one limit (0=OK):
S Control the inputs E19, E20, E23, E24 of the EAK1 − 03 for the first Chill − roll web guide
(inputs E43,E44,E47,E48 for the second) on the Post − unit CPTronic console.
S Check if the motor is powered.(the motor is normaly Hot);
S Change the Weko contoller if needed
S Check the motor coupling.
No Automatic mode:
S Check if the speed of the press is higher than the web guide speed point (default value=3600 IPH).
S Check if the guide is not outside the mechanical range;check the manual mode.
S Check if the Automatic mode" is enable:
S Check the output A23 (0=OK) of the EAK1 − 03 (A47 for the second web guide) on the post − unit console
One Web − edge sensor does not working:
S Make sure both sensors are enable (check the preselection menu) from the Cptronic console.
S Try to move the servo − motor by hand.
S Check the Init/Dyn status of the servo − motor with the procedure SSK status"
S Restart one web edge detection" :
If the motor stop before the detection of the paper,clean the sensor and the reflector and start again.
If the motor does not stop when the paper is under the sensor, change the sensor,check the feedback
to the SSK board. Change the Weko electronic box if no feedback.
WEB TENSION
S Check if the chill roll is clutch.
S Check the Init/Dyn test 6 ( HAK1 − 01) at the Post − unit console and compare to the procedure include in
this manual.
S If the result is good, check if the Harmonic drive at the Chill roll is turning.
S If not, make sure nothing stops the motor (check the mechanic) ,disconnect the belt and try without
mechanic.
S Look the LTK500 inside the the rack LTR of the post − unit.The motor is powered if the small Led mounted
on the board is switch − off.(top for the motor 1,bottom for the motor 2).
S Check if the power coming from the GRM120/1 (120VDC) is correct on the backplane LTR.
S Check the encoder signal used for the drive.
S Change the HAK2 board located inside the rack EAE or EHE.
S Change the board LTK500.
− 3.4.4 −
3.4 Failure cases
FOLDER
CHANGE − OVER
S Before using the change − over function make sure that the folder is clean (no glue on the fold cylinder).
S Make sure that no fault is displayed.
S Select the change − over menu and use the automatic sequence.
S In case of trouble, after a certain time one fault is displayed on this menu.
S If it is possible to repair it without open a safety guard, do it, and push the green push − button to finish
the sequence.
S If not, repair the trouble and finish the sequence manually by using the menu VEN" inside the
maintenance menu (or the change − over menu) following the list :
8P 16P 32P 32P 12P 24P 2X8P

V1 Off/R Off/R Off/R Off/R On/S On/S Off/R
V2 On/S On/S Off/R Off/R Off/R Off/R On/S
V4 Off/R Off/R Off/R Off/R On/S On/S Off/R
V5 Off/R Off/R Off/R Off/R Off/R Off/R Off/R
V8S Off/S Off/S Off/S Off/S Off/M Off/M Off/S
V8R Off/S Off/S Off/S Off/S Off/M Off/M Off/S
V8B Off Off Off Off Off Off Off
V9 On/S Off/R On/S Off/R On/S Off/R Off/R
V10 On/S Off/R On/S Off/R On/S Off/R Off/R
V11 On Off/R On Off/R On Off/R Off/R
V12 On/S On/S On/S On/S On/S On/S On/S
E2 Off On Off On Off On On
V50 On/S On/S On/S On/S On/S On/S Off/R
V51 On/S On/S On/S On/S On/S On/S On/S
V55 Off/R Off/R without transfert Off/R Off/R without transfert Off/R Off/R without tansfert On/S
On/S with transfert On/S with transfert On/S with transfert
V58 Off/R Off/R without transfert Off/R Off/R without transfert Off/R Off/R without transfert On/S
On/S with transfert On/S with transfert On/S with transfert
V59 On/S On/S On/S Off/R
Reasons of trouble
S No movement of the V8 air − cylinder due to durst on the fold cylinder.
In this case put some oil inside the lubrication system with the manual pump delivered with the press.
(See instructions inside the Operator Manual" of the folder).
S Not possible to have the retract" signal of the air − cylinder V5 or V6 because due to the bad setting of
the fold lap (motor M1 for V5 / motor M2 for V6)
S A feedback of one sensor is not correct (display type: Vx = On/........ or Off/.........).
First make sure that the mechanical position is correct and change the sensor if necessary.
S On air − cylinder is not operating.
First check the pneumatic function and change the valve and the solenoid if necessary.
Check the output of the right EAK board (display type: Vx = ...../set or Vx = ..../retract)
− 3.4.5 −
3.4 Failure cases
− 3.4.6 −

Z51508-01 M600 CPTronic - Troubleshooting Guide

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Heidelberg Web Press SA

Square H. Marinoni BP 70149

It is strongly recommended not to operate this machine, or to adjust or service it,

1.1 Equipment identification

HEIDELBERG HARRIS 03.96

HEIDELBERG HARRIS 03.96

Position code Identification letter or Number

Folder Distribution box No. 1

0 : in the control cabinet Power switchgear; in this case: No. 18

For the general electro−technical equipment we use

HEIDELBERG HARRIS 03.96

Post − Unit section

Post − Unit section

Imprinting unit section

HEIDELBERG HARRIS 03.96

Position codes Overview of position codes:

DDW Double printing unit LTE Power part plug−in unit

EAE Input/output plug−in unit MID Press display

HEIDELBERG HARRIS 03.96

STS Vacuum cleaner

VSM Amplifier module

ZAR Double drive adapter backplane

HEIDELBERG HARRIS 03.96

On delivery, almost all cables between the control

At the end of each cable an inscription gives you

Connect these cables to the corresponding units.

EAR1.2: 11X1A D X 20FLK, 1EA1 1LVT1FAM64 − 1: 1X1A X BC

Cable routing is indicated in the last column. The

If the cable in question is a flat cable, you find the

If, on delivery of the machine, the cables are

The Table for connections of the press, are

HEIDELBERG HARRIS 03.96

Identification of the cable ducts

Danger signs and indicator plates

2. KEINE ZUSÄTZLICHEN ELEKTROGERÄTE IM SCHALT-

BEI NICHTBEFOLGEN ERLISCHT DIE FABRIK-GARANTIE

Todos los tornillos en la caja de mandos tienen que volver

Tutte le viti nel impianto di commando devono essere

ACHTUNG! Alle elektrischen Kontakte in diesem Schaltschrank haben

ATTENTION! Tous les contacts dans cette armoir de commande

HEIDELBERG HARRIS 03.96

Fixing points of the danger signs and indicator plates

Main switch cabinet Print-Unit

Transformer cabinet Post-Unit

HEIDELBERG HARRIS 03.96

2.2 Main drives

2.3 Servo drives

2.4 Voltage supply

2.5 Oil supply

2.6 Location diagram

HEIDELBERG HARRIS 03.96

HEIDELBERG HARRIS 03.96

2.1.1 CPTRONIC overview

HEIDELBERG HARRIS 03.96

HEIDELBERG HARRIS 03.96

Infeed Imprinting-Unit Master Printfunction Post-Unit

Main drive Imprinting-Unit Main drive Main drive

Infeed Unit Imprinting Printing-Units Chill Folder

Machine control diagram

HEIDELBERG HARRIS 03.96

REK REK NTK 5: Power supply board 5V DC

All main motors (EZW, DDW, Post-Unit) are in

HEIDELBERG HARRIS 03.96