Operator Manual FSA 12 BMX V01 Ab 2007 207

Leitenacker 3
95326 Kulmbach
Tel: + 49 92 21 / 92 09-0
Fax: + 49 92 21 / 92 09-22
e-mail: info@
helmut-weiss-gmbh.de
Flap disc machine
FSA 12 BMX
Operator Manual
Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 1

Table of Contents
1 General note ......................................................................................................... 5
2 Warranty ............................................................................................................... 5
3 Function of the machine ....................................................................................... 6
4 Safety notes.......................................................................................................... 8
4.1 Intended use of the machine .............................................................................. 8
4.2 Impermissible alterations on the machine ............................................................ 8
4.3 Personnel ......................................................................................................... 8
4.4 Safety notes ..................................................................................................... 8
4.5 General safety notes for the operator .................................................................. 9
4.6 Special safety notes for the use of the machine ................................................... 9
5 Installation of the Machine .................................................................................. 10
5.1 How to put machine into place .......................................................................... 10
5.2 Installation of the additional units ...................................................................... 11
6 Buttons and Switches on the control boards....................................................... 14
6.1 Main power switch and Emergency button ......................................................... 14
6.2 Compressed air supply unit and valve terminal block .......................................... 15
6.3 Switches and buttons on the control cupboard ................................................... 17
6.4 Switches and buttons on the operator panel box ................................................ 19
6.5 Control board behind the machine .................................................................... 19
6.6 Operator Panel ............................................................................................. 21
6.7 Signal Lamps .................................................................................................. 22
7 Starting the machine ........................................................................................... 23
7.1 Starting the adhesive pump .............................................................................. 23
7.2 Starting the flap disc machine ........................................................................... 23
8 Switching the machine off ................................................................................... 24
9 Start the machine cycle ...................................................................................... 24
10 Stopping the machine cycle ................................................................................ 25

10.1 Emergency stop ........................................................................................... 25
10.2 Stop-button.................................................................................................. 25
10.3 “Machine go empty” switch ............................................................................ 25
11 Safety Installations.............................................................................................. 26
11.1 Service doors............................................................................................... 26
11.2 Safety light barrier ........................................................................................ 26
12 Operation messages on the Operator Panel ...................................................... 26

13 Error messages on the Operator Panel ................................................................ 27
14 Operation modes and their functions .................................................................. 27

14.1 Set up mode (1) ........................................................................................... 27
14.2 Jog mode (2) ............................................................................................... 27
14.3 Automatic mode (3) ...................................................................................... 28
15 Manual mode for index table .............................................................................. 28
16 Operator panel .................................................................................................... 29

16.1 How to navigate on the operator panel ........................................................... 29
16.2 Main menu .................................................................................................. 30
16.3 Select product (F9) ....................................................................................... 32
16.3.1 Recalling a product out of the memory of the Operator Panel ........................ 32
16.3.2 Add a new product to the memory of the Operator Panel .............................. 34
16.3.3 Alter a product, which is already saved in the memory of the Operator Panel .. 37
16.3.4 Delete a product off the memory of the Operator Panel ................................. 38
16.4 View product list ........................................................................................... 38
16.5 Counter (F10) .............................................................................................. 39
16.6 Changing parameters of the active program (F10) ........................................... 40
16.7 Parameters menu (F11) ................................................................................ 41
16.7.1 Machine parameters (F9) ........................................................................... 41
16.7.2 Function parameters (10) ........................................................................... 41
16.8 Set up mode ................................................................................................ 43
17 Password ............................................................................................................ 44
18 Changing to a different product .......................................................................... 46
19 Changing the abrasive ribbon ............................................................................. 49

19.1 Changing the ribbon during flap application (ribbon is empty) ........................... 49
19.2 Changing the ribbon after the last disc is finished (product change) .................. 49
20 Changing the adhesive container on the pneumatic pump ................................. 50
21 Emergency Stop ................................................................................................. 51
22 Reference run (Reset) ........................................................................................ 52
23 Service and maintenance ................................................................................... 53

23.1 Maintenance work list ................................................................................... 53
23.2 Materials for maintenance ............................................................................. 54
23.3 Other maintenance instructions ..................................................................... 54
23.4 Instruction for lubrication of the cutting head ................................................... 54
23.5 Replacing the seal set on the piston rod of the adhesive pump ......................... 56
23.6 Replacing the seal of the adhesive valve ........................................................ 58
24 Technical specifications ...................................................................................... 61
25 EG-Declaration of conformity .............................................................................. 62

26 Service address .................................................................................................. 63

1 General note
The users manual of the machine, as well as the manuals of the purchased parts must be
read and fully understood by the operator, before the machine gets started.
Not paying attention to this users manual can cause injury to the operator and service per-
sonnel as well as machine damage.
We ask you to inform the HELMUT WEISS GmbH, if there is any instruction, drawing, meas-
urement or picture found in this book that does not match with the machine.
All drawings in this manual are the intellectual property of the HELMUT WEISS GmbH. You
are not allowed to copy them, nor to pass them on to a third person.
2 Warranty
The warranty for the machine is 12 month, if not arranged different in an additional contract.
For purchased parts, we can only pass on the warranty given by the supplier
The warranty starts with the day of delivery.
Not covered by the warranty are:
• wearing parts such as seals, conveyor belts etc.

• damage caused by wrong handling of the machine.
• damage caused by lack of maintenance or structural alterations on the machine.
• damage caused by improper implemented adjustments
• damage caused by local power supply problems
• damage caused by natural forces such as fire, lightning, earthquake, floods etc.
In order to keep our warranty commitment valid, please follow all instructions for use and
maintenance of the machine.

3 Function of the machine
This machine is producing flap discs automatically, using backing discs, one compound ad-
hesive and abrasive strip off a roll.
The functions in the different stations are as follows:
Station 1 (loading)
Backing discs, which have to be stacked on pins on a rotary table by an operator, are auto-
matically loaded to the main rotary table on the machine. The magazine rotary table is capa-
ble of holding up to 1200 backing discs (depending on thickness of the discs).
Station 2
No function.
Station 3 (adhesive application)
The one compound adhesive , supplied by the pneumatic pump, is applied to the backing
discs. In order to achieve a perfect adhesive application, the following alterations can be
made:
• number of tracks per disc

• number of revolutions per track
• speed of revolution for each track
• adhesive flow through the valve
• pump pressure
• temperature of the heading system
• diameter of the adhesive nozzle (when changing the nozzle)
• distance of the adhesive nozzle to the backing disc surface
All these parameters will affect the amount of adhesive on the disc or the quality of adhesive
application onto the disc.
Stations 4 – 8
These stations are not used. The time that it takes the disc to reach station 9 allows the ad-
hesive to cool down a little in order to reach the right viscosity to hold the flaps.

Station 9 (flap application)
A drive system is pulling the abrasive ribbon off the reel and is supplying it to the cutting
head. A servo motor on the cutting head pulls the strip for exactly the length of a flap through
a guiding tunnel. On the end of that tunnel, we have the two cutting blades. One of them is
driven by means of another servo drive and cuts against the other as soon as the flap is in
position. The cutting head has to be adjusted in the accurate distance above the backing
disc, so that the flap sticks inside the adhesive tracks on the disc. The disc underneath the
cutting head will be turned synchronic with the movement of the cutting blade for exactly the
right angle to take the next flap in the right place. The following adjustments can be made on
the flap application system:
• Guide adjustment for different strip widths (manual).

• Flap length (automatic).
• Vertical distance from cutting head to backing disc (manual by means of set pieces).
• Horizontal position of the cutting head (Y-direction / manual).
• Horizontal position of the cutting head (X-direction / manual).
• Numbers of flaps per disc (automatic).
Station 10 (push over unit)
As the flap application unit leaves some flaps upright, this unit will push these flaps while the
disc gets rotated so that finally all flaps are tilted to allow a proper function of the pressing
head.
Station 11 (pressing)
A pressing head moves down over the disc to press the flaps into the adhesive and to give
the disc the final shape. Different pressing heads are used for different disc sizes and differ-
ent flap widths.
Station 12 (unloading)
A handling arm picks the discs off the main rotary table and drops them onto one of 6 pins on
a magazine rotary table. The disc can be unloaded of the magazine with the pins. Usually the
pins are used to press the discs and to bake them in an oven.

4 Safety notes
4.1 Intended use of the machine
This machine is designed, only for production of abrasive flap discs of the diameter 100mm
to 180mm.
All use beyond the above described is not recommended by the HELMUT WEISS GmbH.
The provider is not liable for damage caused by unintended use of the equipment. All risk is
on the users side.
4.2 Impermissible alterations on the machine
Alterations on the machine, as well as the use of spare parts other than the ones listed in the
parts list, should only be implemented when agreed by the HELMUT WEISS GMBH. The
HELMUT WEISS GMBH will not be liable for any damage caused by such actions.
4.3 Personnel
The machine should only be used by trained and authorized personnel. All competence in
using and maintaining the machine should be clearly defined in order avoid safety risks.
4.4 Safety notes
The following safety notes serve the personal safety of the operator as well as the safety of
the machine.
Caution!
Dangerous voltage.
Disregarding may cause severe hazards or death!
Attention!
Disregarding may cause personal injury or damage to the equipment!

4.5 General safety notes for the operator
• Never act in a way that could affect the safety of the machine. Never remove or disable
safety equipment of the machine.
The only exception in the case of maintenance is as follows:
Stop the machine as described in the Operator manual before beginning the maintenance
work.
All safety equipment must be fixed in place right after the end of maintenance work.
Check the function of all parts and replace all damaged parts.
The machine should only be started, if in faultless condition.
• Electrical equipment
Work on the electrical equipment of the machine should only be carried out by trained
personnel with all power supply disconnected
• Maintenance
In order to achieve a long term save function of the machine, all maintenance described in
the in the service and maintenance plan should be carried out in the recommended inter-
val
4.6 Special safety notes for the use of the machine
• Some functions of the machine can be activated using a two hand function with open front
door. In this case, it is important that no second person can reach into the danger area.
• Danger of bruising
Due to the general design of the pump, there is a remaining danger of being bruised es-
pecially when changing the drum and cleaning the pump.
Attention:
Imminent bruise danger when the following plate moves into the adhe-
sive drum. Take care that no one reaches between the following plate
and the drum!
Never reach under the following plate unless the pump is switched off and the air supply is
disconnected as otherwise the scoop plate can start moving at any time.

5 Installation of the Machine
5.1 How to put machine into place
Lifting of the machine should only be made with appropriate forklift (weight of machine and
pump see chapter “24 Technical specifications”.
• Lift the machine as shown in the following pictures from the pallet and place it into its final
position.
Move the forklift under the center of the machine until the forks reach the second horizontal
bar of the machine frame (see above pictures).
Attention: Take care that the forks don’t damage the motor of the lifting unit
as this is lower than the horizontal bar (see above pictures).
• Level the machine out using a spirit level. Therefore check that all three index tables are
well levelled. The necessary adjustment can be achieved using the adjustable machine
feet.
• Check that all machine feet have good contact to the floor and tighten the counter nut on
each foot.

5.2 Installation of the additional units
• Place the dust collector in it’s position and connect the electrical supply and the suction
hoses as shown below:
• Place the adhesive pump in it’s position and connect the electrical supply and the inter-
face wires of the adhesive pump as shown in below pictures:
30L adhesive pump 200L adhesive pump

One socket for electrical supply of the Two data transfer
water heating system, the second for connections to the
the pump control system flap disc machines
• Connect the air supply hose for the pump to the distributor
block an the right side of the flap disc machine.
Air hose from the pump
Main air supply to the machine
• Pull the adhesive hose from the pump to the machine

through the clearance of the right machine door.

• Fix the adhesive nozzle to the linear positioning system
using the two screws and connect the two air hoses as
well as the two water circulation hoses to the pneumatic
adhesive valve (check the marks on the hoses and on the
valve) as shown on the picture below.
Air connection
water connection
2 mounting screws
• Place the ribbon reel in its position

6 Buttons and Switches on the control boards
6.1 Main power switch and Emergency button
Emergency Stop button
The “Emergency Stop” button should only be used to stop

the machine in the case of an emergency situation (see
chapter 21 “Emergency Stop”).
There are two Emergency Stop button available on the

machine. One on the front of the machine on the left side
of the control cabinet, the other on the control board on the
backside of the machine.
Main power switch
Using the main power switch, the machine can be

switched of totally.
ATTENTION:
Some parts inside the control cabinet

as well as the sockets on the right of
the control cabinet are still under live
current even if the main power is
switched off.

6.2 Compressed air supply unit and valve terminal block
Valve terminal manual override switch
The valves can be manually activated using the manual override switches.

Main pressure regulator pressure control switch
(set to 6 bar)
In case of a low pressure (below 4 bar) the pressure switch gives a signal to the PLC.
main air supply valve
This valve will interrupt the air supply to the ma-

chine. This will help to reduce the air consump-
tion when the machine is not working.

6.3 Switches and buttons on the control cupboard
“lift cutting head” switch
This switch is needed to move the cutting head up and down in a manual
manner. This helps while adjusting the head in the proper position and it is
helpful when changing the cutting blades. Activate this switch and
press the “START” -button to move the cutting head
“ribbon drive” switch
This switch allows to deactivate the drive that pulls the

ribbon off the reel. In case your machine is equipped
with a double ribbon drive, you could select which drive
you want to use when working with only one ribbon.
“Loosen cutting head” switch

“ribbon “loosen “cut ribbon”
With this switch, the pneumatic holding cylinder for the drive” cutting switch
cutting head may be released to allow a adjustment of switch head”
the cutting head in horizontal position (Y-axis). switch
“cut ribbon” switch
This switch is necessary to cut the edge of the abrasive strip straight after feeding a new roll.
Activate this switch. Then hold the “STOP” button and press “START” at the same time (see
chapter 19.2 “Changing the ribbon after the last disc is finished (product change)”).
“STOP” button
The “STOP” button is primarily used to

stop the automatic run of the machine.
However there are some more functions
that use the “STOP”-button together with
other buttons.
“STOP” “START” “machine “RESET”
button button go empty” button
“START” button switch
The “START”-button starts the automatic run of the machine. Holding the stop button and
pressing the “START”-button once allows to cut and apply only one flap at the cutting head in
some kind of jog-mode.
“Machine go empty” switch
If this button is activated, the machine will stop loading discs and proceeds until all discs are
placed on the spindle (see chapter 10.3 “Machine go empty” switch).

RESET-button
With the RESET-button you are able to start the reference run to put the machine back into
initial position. This may be necessary in the case of an error in order to restart the machine
or after selection of a new product (see chapter 22 “Reference run (Reset)”).
“PRESS” button
This button will activate the pressing head for a manual

pressing of a disc in station 10. It is necessary to hold
the “STOP”-button and then press the “PRESS”-button
“Rotary table run” button

“Press” “Rotary “loosen
This button allows to rotate the main index table in a button table run” pressing
manual mode to the next station (see chapter 15 button head”
“Manual mode for index table”). button
“Loosen pressing head” button
This button may be used in order to release the electric magnet which holds the pressing
head in place.
“Adhesive stop” switch
The “Adhesive stop” switch allows to run the machine without adhesive applica-
tion. This may be useful when adjusting the height of the adhesive nozzle.
“Adhesive” button (located on the right side of the control cupboard)
The adhesive button enables the operator to manually drain adhesive in order to
achieve a good adhesive application quality for the first disc after the machine
was stopped for a while. When the production on the machine is interrupted for a
certain period there will a message appear on the display that ask to drain some
adhesive.
This button is only active when the nozzles are manually pulled away from the
application position.
ATTENTION: Don’t forget to place a cup or a piece of paper under the

glue nozzle before pressing the button!

6.4 Switches and buttons on the operator panel box
Operation mode selection switch
This switch allows the selection of the differ-

ent program modes (see chapter 14
“Operation modes and their functions”).
Manual mode buttons
These switches are used to activate or deac-

tivate the selected functions in the set up
mode(see chapter 16.8 “Set up mode”).
“Adhesive nozzle in activated position”-

button
This button moves the adhesive nozzles

down and up. This allows a comfortable adjustment of the adhesive nozzle po-
sition for the different discs.
6.5 Control board behind the machine
Emergency Stop
turn table St.12
turn table St.1
loosen Press head
move swivel arm
Start
Stop

“turn table St.12” button
When activating this button, the rotary table in St.12 will move one step. This allows an easy
change of the spindles on the magazine rotary table.
“turn table St.1” button
When activating this button, the rotary table in St.1 will move one step. This allows an easy
change of the spindles on the magazine rotary table.
“move swivel arm” button
When activating this button, the swivel arm of the pick up handling will move to the inside
position. This allows an easy change of the spindles on the magazine rotary table as well as
an easy change of the grippers.
Don’t forget to move arm back in initial position!
Functions of other buttons see above.

6.6 Operator Panel
The operator panel, allows to control and to set up the machine in a comfortable manner
(see chapter 16 “Operator panel”.
Function Display Function

keys keys
Input keys
TAB-key
Arrow keys
ESC-button
ACK-button
ENTER-button
Function
keys
Function keys
Using the function keys, a several different menus can be called up on the display. Within the
different menus, the keys will have different functions.
TAB-key
This button allows to change between different input fields within the different menu screens.
ESC-button
The “ESC”-button is used to selection boxes is you don’t want do confirm the new setting.
You need to press “ESC” if you want to leave the error message list.

ACK-button
All error messages that are currently shown on the display can be deleted of the display us-
ing the ACK-button (acknowledge). As long as the cause of the message is not solved, the
message will be still active and can be seen in the error message list.
ENTER-button
Every input using the input buttons has to be confirmed with the ENTER-button. If you don’t
confirm, the new value will not be valid.
The ENTER-button is the only way to leave the error message list.
Input buttons
All information can be programmed into the operator panel using the input buttons. Never
forget to confirm all entries with the ENTER-button!
Numbers can be entered just pressing the buttons. To enter letters, it is necessary to press
the button “A-Z” before entering.
6.7 Signal Lamps
A orange and a red signal lamp are located on

top of the operator panel.
The messages of these lamps are as follows:
Orange lamp:
• Drain some adhesive manually
Red lamp (Slow blinking signal):

• product counter is reached
• Machine stopped caused by an error
(The automatic mode will be interrupted after 60 seconds; the buzzer will go on and a
message will appear on the display)
Red lamp (fast blinking signal):

• Service door is open
Red and orange lamp:

• Abrasive ribbon is empty.

7 Starting the machine
7.1 Starting the adhesive pump
In order to achieve the best adhesive application quality, the adhesive pump should be heat-
ed up properly, before starting the flap disc machine. Heating the whole system to about
50°C will last approximately 30 minutes. Check the specifications of the adhesive supplier for
appropriate application temperature.
• Check the water level inside the water heating system.

• Switch on the water heating system.
• Wait until the application temperature is reached (approx. 30 minutes).
• Switch on the main power switch on the pump.
• Wait for about 10 seconds, them press the start button on the adhesive pump.
• The pressure displayed on the pressure sensor should increase and the start button
should show a steady signal.
 Pump is ready for production
7.2 Starting the flap disc machine
• Switch on the main air valve

• Check that the mode selection switch is in “automatic mode” position
• Switch on the main power supply
 Wait approx. 45 sec. until the “main menu” appears on the display with the notice “con-
firm emergency stop with “START”
• Press „START“-button, in order to confirm the emergency stop
• The message “Data not yet transferred to PLC” appears on the display
• Select a program and transfer it to the PLC (see chapter 16.3 “Select product (F9)”).
• The message “reference start” appears on the main menu display.
• Press “RESET” and then “START” in order to start the reference run which puts the ma-
chine into initial setting.
 The machine is now ready to start.

8 Switching the machine off
• Activate the „machine run empty“ switch.

 The machine will stop loading discs and proceeds until all discs are placed on the spin-
dle.
 Wait until the message “machine is empty” appears on the display.
• Switch off the main power supply of the flap disc machine and of the adhesive pump.
• Switch off the water heating system.
• Switch off the air supply.
Attention: In case you need to switch the machine on again shortly after
switching off, you must wait at least 20 seconds before switching
the main power supply again.
9 Start the machine cycle
Once the machine is switched on as described, the machine cycle can be started with the
“START”-button.
Once the first backing disc reaches station 8, the following message will show up on the dis-
play: “cut ribbon”.
Now it is necessary to cut the ribbon manually in order to achieve a good cut already with the
first flap on the disc. This should be done as follows:
• Activate the switch “Band change”

• Press the “START”-button once → the ribbon gets fed for one flap length
• Press the “START”-button again → the flap gets cut
(Take care that the cut piece of ribbon is removed from the holding fixture before the pro-
duction starts!)
• Now, you can cut another flap for measuring of the flap length
• Deactivate the “Band change” switch

10 Stopping the machine cycle
The machine may be stopped in one of the following ways.
10.1 Emergency stop
In the case of an emergency or of a serious malfunction, the machine should be switched off
using the emergency button (see chapter 21 “Emergency Stop”.
10.2 Stop-button
Is the „Stop“-button pressed during the machine cycle, only the already started movements
will be finished and the machine will stop shortly.
10.3 “Machine go empty” switch
Is this button activated, the machine will stop loading discs and proceeds until all discs are
placed on the spindle. The machine will stop when no disc is left on the main rotary table.

11 Safety Installations
11.1 Service doors
All doors may be opened at any time during production. All machine functions will stop im-
mediately except the adhesive dispense system. Once the doors are closed again, the ma-
chine needs to be restarted by pressing the “START”-button.
ATTENTION:
Some functions can be activated with open doors using two buttons at the
same time. In this case it is necessary to take care that no other person is
reaching into the machine while a function is activated.
11.2 Safety light barrier
When activating the safety light barrier during the production run of the machine, the flap
application in station 9 and the adhesive application in station 3 will not be stopped. All other
safety relevant movements will be prevented.
In order not to stop the machine during production, it is recommended to reach into the ma-
chine while the cutting head and the adhesive application is working.
12 Operation messages on the Operator Panel
The operation messages are shown in red letters in the third line of the main menu. These
messages give information about the current status of the machine operation.
Operation messages for example are: “abrasive ribbon empty”

“close doors”
“drain some adhesive”
“check error message”
etc.
It may happen that more than one operation messages are active. In this case press F13
“messages” to enter the message screen. Here you will find a list of all active operation mes-
sages.

13 Error messages on the Operator Panel
In case of an error on the machine (machine stops for an undefined reason) an operation
message will appear on the display (e.g. “time out on step sequences”). The buzzer and the
red signal lamp will go on.
Check the error messages as follows:
• Press the „STOP“-button to disable the automat-

ic mode and to stop the buzzer.
• Press F13 “messages” to change to the mes-
sage screen.
• Press F13 “messages” again to open the error
messages.
• A window in this picture will show all active error
messages.
• The different messages can be reached using
the arrow keys.
• The “ACK” button may be used to confirm the
error messages.
Error Number of
• The error message list (F9) saves the last 19 message active
error messages. window messages
Once the reason for the error is found, and the prob-
lem is solved, all error messages shall disappear.
To leave the error message list, press “ESC”.
Back to the main menu with F14
14 Operation modes and their functions
The machine allows the selection of three different operation modes. The different modes
may be selected using the mode selection switch (see chapter 6.4 “Switches and buttons on
the operator panel box”).
14.1 Set up mode (1)
The set up mode allows to activate the different actors (motors, cylinders, etc.) manually us-
ing “the manual mode”-buttons. The function which should be activated has to be selected on
the operator panel first. Please see full description for set up mode in chapter 16.8 “Set up
mode”
14.2 Jog mode (2)
With the jog mode selected the machine stops after each cycle so that each disc can be
checked before the index table turns.
• Prepare the machine for automatic production.

• Activate the jog mode using the mode selection switch

• Start the production run with the “START”-button
 The machine will start and then stop before the index table turns.
• Press “START” again to rotate the index table.
• Press “START” in order to start the next machine cycle.
• Deactivate the jog mode using the mode selection switch.
14.3 Automatic mode (3)
The automatic mode is the production mode of the machine. This is the only mode in which
the full production run is possible.
15 Manual mode for index table
This mode allows to rotate the index table manually with the machine front door open which
is helpful when changing the center pins on the holding fixtures of the index tables.
Activate manual mode:
• Check that the automatic mode is selected.

• Check that no discs remain on the index table (run machine empty).
• Start the reference run in order to put the machine into initial position (see chapter 22
”Reference run (Reset)”).
• Change to “main menu 2” (pict. 7) using F14.
• Press F11 “manual mode” to activate the manual mode for the index table
 The light inside the “Rotary table turn”-button will go on and a status message appears
on the display.
• Press “START” and “Rotary table turn”-button together and hold them until the rotation
is finished (button stops blinking).
ATTENTION:
Take care that no other person reaches into the machine while the index
table turns
Deactivate manual mode:
• Press “RESET”
 light in “Rotary table turn”-button goes off and screen changes to main menu.
• Activate front door using the key switch on the left side of the control cabinet.
 The machine is now back in automatic mode.

16 Operator panel
The operator panel allows to adjust all necessary parameters to run the different products on
the machine. Once the machine is switched on as described above, the main picture will ap-
pear on the display (see chapter 16.2 “Main menu” ).
16.1 How to navigate on the operator panel
Different menus can be reached using the soft key buttons (F9-F14). Within the menus, you
can select between several submenus using the same buttons.
The cursor may be moved within a picture using either the arrow keys or the “TAB”-key.
In most of the pages within the menus, it is possible to enter a value using the number but-
tons:
• Move the cursor to the line were you want to change.

• Enter the new value using the input keys.
• Confirm with the “ENTER” button.
Selection box
Select value
using the arrow keys
then press “ENTER”
In some menus it is necessary to select a setting out of a selection box:
• Move the cursor to the selection box were you want to change.
• Press “ENTER”.
• The selection box opens up and shows all possible settings.
 Select the new setting using the “TAB”-button.
• Confirm with enter.
If you want to leave the different menus, press the function key “F14” (“exit” or “pict. ”). It
may be necessary to press “F14” several times to get back to the main menu.

16.2 Main menu
The main menu contains actually two pictures.
To start the machine for the automatic run, the machine should show the main menu. Using
the function key “F14”, you will always find back to the main menu.
The first (pict. 6) shows the most important information about the currently selected product
and gives the possibility to enter some submenus.
The second (pict. 7) shows further information about the current product and allows to reach
some other not so important submenus.
Change between the two pictures using F14.
The very top line of the main picture shows the type and the name of the currently selected
program:
For example:
Recipe: F_115mm_T27 F: backing disc of fibre glass

115mm: disc diameter 115 mm
T27: type 27 disc (flat backing disc)
Data: 1154062 This is the free programmable name of the

specific product (20 digits are possible)
The second line shows the number of the picture currently displayed (e.g.: pict. 6) as well as
the current date and time.
The third line is used to show error messages. In case of a malfunction the message will ap-
pear in red letters.
All other information on the main picture are information about the currently produced prod-
uct.

Picture 6:
Production counter:
Production counter target: This is the lot size that shall be produced.
Production counter actual: This is the amount of discs already produced for the
current lot.
Ribbon width: (informative)

The width of the abrasive ribbon used with that product.
Number of flaps:
The number of flaps applied to the disc.
Flap length:
Length of the flaps.
Application pos. Y-axis:

Position in which the cutting head should be adjusted manually.
Picture 7:
Grit bottom: (informative)

The grit of the abrasive strip used with that product. Not used if only one strip is used
Abrasive material bottom: (informative)

The abrasive material used with that product. Not used if only one strip is used
Grit top: (informative)

The grit of the abrasive strip used with that product.
Abrasive material top: (informative)

The abrasive material used with that product.
Amount of adhesive: (informative)

Amount of adhesive that should be applied for the selected product.
Backing disc size:

Size or type of the backing disc which should be used for the selected product.
Activate Station 13:

Information whether Station 13 is on or off.

16.3 Select product (F9)
In order to understand the function of the data storage of the flap disc machine, it is essential
to understand that all the programs are stored inside the Operator Panel. To activate a pro-
gram on the machine, it is necessary to transfer this program from the operator panel
(memory) to the PLC (Process Logical Control) in the control cabinet (see chapter 16.3.1
Recalling a product out of the memory of the O).
Chapter 16.6 “Changing parameters of the active program (F10)” describes how programs,
that are currently running in the PLC, can be changed. A program which gets changed while
it is currently running in the PLC must be transferred back to the Operator Panel in order to
save the changed data. Otherwise, the new parameters which are only changed in the PLC
may be lost and the original data in the Operator panel will be valid again.
This architecture of the programming systems allows to alter programs in the operator panel
while an other program is running on the machine.
The “select product” menu allows to
• recall a product out of the memory of

the Operator Panel
• add a new product to the memory of
the Operator Panel
• change a product, which is already
saved in the memory of the Operator
Panel
• delete a product off the memory of the
Operator Panel
• view the list of already saved products
16.3.1 Recalling a product out of the memory of the Operator Panel
The programs for all products are saved in the memory of the Operator Panel. This memory
is divided into different recipes. Each chapter contains a list of products of a specific shape
and size (e.g. F_115_CO which are discs of fibre glass backings, 155mm in diameter and
conical shape). This makes the selection of a specific product out of a list of many different
programs much easier. Once the product is selected out of the memory, the program must
finally be transferred to the PLC.
Recall a program as follows (starting from the main menu):
• Enter the “select product” menu pressing F9 “select product”.

• Press “ENTER” to open the list of different disc sizes (recipes).
• Select the disc size using the arrow keys “” or “” and confirm with “ENTER”.
• Move the cursor to “data record name” using the arrow keys “” or “” and open the
product list with “ENTER”

• Select the product out of the list using the arrow keys “” or “” and confirm with “EN-
TER”.
 The name of the product is shown under “data record name” on the display.
• Transfer the program from the Operator Panel memory to the PLC by pressing the func-
tion key F11 “data → PLC”
• Enter the password (Level 5 / see chapter 17 ”Password”) and confirm with “ENTER”.
• Press F11 “data → PLC” again.
• Press “RESET” and then “START” in order to activate the new program.
 The screen changes to the main menu and the new product name is shown in the top
right corner of the display!
 The program is transferred to the PLC and the parameters for the new product are now
shown on the display.

16.3.2 Add a new product to the memory of the Operator Panel
For adding a new product to the memory of the machine, it may be helpful to use a already
existing program as base. Load the base program to the PLC as described in chapter
16.3.1.The benefit of using a already existing program, which is as similar as possible to the
new program, is that you don’t need to enter all parameters. You only need to alter some of
them.
If there is no program available that could be used as base, it is also possible to start right
away.
Add a new product as follows:

• Recall a existing program out of the memory, if possible (see chapter 16.3.1).
• Move the cursor to “data record name” using the arrow keys “” or “”.
• Use the Input Keys to enter the name of the new product.
• Press “ENTER” to confirm.
• Press F9 “data” to enter the product parameter menu
• Enter the password (Level 7/ see chapter 17 ”Password”) and confirm with “ENTER”.
• After entering the password it is necessary to press F9 again!
 A dialog box opens up asking if you want to save the new program into the recipe.
• Confirm with “ENTER” if the new program should be saved into the recipe.
 The product data menu appears on the display. This menu contains 7 pictures. It is pos-
sible to switch between the pictures using the function keys F9 (back) or F10 (forward).
These pictures list all the parameters that specify the new product.
• Enter the new parameter as described in chapter 16.1 “How to navigate on the operator
panel”.
Most of the parameters directly control automatic functions of the machine e.g. the glue track
position. Other parameters are only stored as adjustment information to help the operator to
adjust the manual functions of the machine in a proper way (e.g. turns to open adhesive
valve).
The parameters are as follows:
Picture 102
disc shape: shape of backing plate (T27 = flat or T29 = conical)

disc size: outside diameter of the finished disc
number of flaps: numbers of flaps per disc
flap length: length of flaps
backing disc size: specification for the backing disc

Picture 103
flap width: informative for adjusting the ribbon guides

Abrasive material bottom: informative, if different programs are used for same disc
with different material.
Grit bottom: grit of abrasive material
Abrasive material top: informative, if different programs are used for same disc
with different material. Only used if two strips are cut at
one time.
Grit top: grit of abrasive material. Only used if two strips are cut
at one time.
Picture 104
Application pos. Y-axis: horizontal position of the cutting head when flaps are
applied (manual adjustment on the hand wheel / manual
programming only for operator information)
It is necessary to change the horizontal position of the cutting head in order to place the flaps
in the right circumference on the backing disc according to the different disc diameters.
Flap application speed: This is the working speed of the cutting head in %.The
default value is 120%. This value should work well for all
standard flap lengths up to approx 22 mm. For longer
flaps, the speed should be reduced in order to allow a
longer time for flap feeding.
Picture 105
Rotation: Rotations per adhesive track
Speed: Rotation speed in % from the maximum speed
The adhesive track speed is affecting the amount of adhesive on the disc.
Picture 106
Pressure adhesive pump: pressure of the adhesive pump system.
Amount of adhesive: Amount of adhesive per disc

(only informative for the operator / has no effect on
the machine performance)

Picture 107
Application program: There are two different programs available:
NORMAL: Standard flap discs
SPECIAL: Flap discs with different gaps between the flaps

(small/large/small….)
Activate Station 13: disable or enable station 13 (die plate magazine)

This function is optional
To change one of the above settings, move the cursor into the relevant line, press ENTER
and select the setting using the arrow keys “” or “”. Confirm with “ENTER”.
Picture 109
Selection swivel cylinder

cutting head: Switch the lifting of the cutting head “ON” or “OFF”:
ON: The cutting head will move up before the main index table turns.
This may be necessary for some special types of discs (e.g.
very short flaps, very conical shape, big disc diameter) in order
to have enough clearance to avoid collision or damaged discs.
OFF: The cutting head will stay in it’s working position which results is
a shorter cycle time.
ATTENTION: Check carefully if position of the cutting head is

high enough to avoid collision when the main in-
dex table turns!
Start value reel 1: Starting speed of the motor which pulls the ribbon off the reel.
This value may need to be adjusted in order to achieve a
smooth and equal operation of the ribbon feeding system.
Start value reel 2: Same as above (only when a second reel drive is installed)

• Once all new parameters are entered and confirmed with “ENTER”, leave the menu with
F14 “exit”.
• Press F10 “save” in order to save the product parameters in the memory of the Operator
Panel.
• Enter the password (“Master” Level / see chapter 17 ”Password”) and confirm with “EN-
TER”.
• Confirm with “ENTER” that you want to override the existing program.
In case you want to proceed production with this new product you need to transfer it to the
PLC:
• Press F11 “Data → PLC” in order to transfer the new program to the PLC.
• Press “RESET” and then “START” in order to activate the new program.
 The screen changes to the main menu and the new product name is shown in the top
right corner of the display!
 The program is now transferred to the PLC and the parameters for the new product are
now shown on the display.
 Machine is ready to start.
16.3.3 Alter a product, which is already saved in the memory of the Operator Panel
Sometimes it is necessary to alter parameters in a program that is already existing in the

memory and save the program again. This can be done as follows:
• Recall the program of the memory (see chapter 16.3.1)

• Then follow instructions described in chapter 16.3.2 for adding a new program just to not
enter a new product name.

16.3.4 Delete a product off the memory of the Operator Panel
Delete a product of the product list as follows:
• Select the recipe in which the product is saved

• Select the data record name which you want to delete
• Press button F12 “delete product”.
 A dialog box will show up on the display.
• Press “ENTER” if you really want to delete the program.
 The program is deleted.
16.4 View product list
Check the product list as follows:

• Enter the “Change product” menu with F9
• Press “ENTER”
• Select the recipe which you want to check, using the arrow keys “” or “”.
• Confirm with “ENTER”
• Move the cursor to “data record name”, using the arrow keys “” or “”
• Press “ENTER”.
 A list of programs of the selected size shows up on the display.
 Scroll in the list using the arrow keys “” or “”
• Leave the list with “ESC”

16.5 Counter (F10)
This menu offers several different counter functions in four pictures.
picture 76
Product counter Target: You can program the batch size. The machine will au-
tomatically stop production when the number is reached.
Product counter Actual: The currently produced number of discs.
Delete this counter with pressing F13 for 1.5 seconds.
Daily product counter: This is an additional counter which allows to count for
example the daily production rate.
Delete this counter with pressing F12 for 1.5 seconds.
picture 77
Total number of cuts: This counter counts the cuts ever made by the cutting
head.
Target for changing blades: You can program the number of cuts after which the
cutting blades should be changed.
Actual number of cuts: This counter displays the number of cuts since the last
change of the cutting blades.
Delete this counter using F11 “delete counter”.
picture 78:
Length check of abrasive ribbon:
This picture allows a measuring of the length of the abrasive ribbons used on the machine.
• Fill the new ribbon to the reel

• Press F13 “measure” to start the measuring of the ribbon length.
The measuring will be automatically stopped when the ribbon end is detected by the optic
sensor on the cutting head.
The currently measured length is automatically transferred to the last measured length after
the ribbon is empty

picture 79:
Counter for spacer discs:
This counter allows to program the number of disc after which a spacer disc should be
placed onto the stack.
16.6 Changing parameters of the active program (F10)
This menu may be used to alter some parameters during production without saving them to
the memory. The changes are only valid until a different program is recalled unless the
changed program is saved manually.
• Press button F10 “product data” in the

main menu to enter the “product data”
menu.
• Enter the password (Level 5/ see chapter
17 ”Password”) and confirm with “EN-
TER”.
• After entering the password it is neces-
sary to press F10 again!
This menu contains the same pages of pa-

rameters as described in chapter 16.3.2.
However, only some of the parameters may
be changed in this menu.
All alterations are valid immediately after confirmation with “ENTER”.
Save the changed data as follows:
• Press F11 “SAVE” to store the data into the cache.

Status message “data not yet transferred to PLC” appears on the display.
• Press “PLC -> data”-button.
 A dialogue box appears on the display asking if you want to overwrite the existing data.
• Confirm with “ENTER”.
 The new parameter are now saved in the existing recipe.

16.7 Parameters menu (F11)
On the menu screen, the time and Date can be set to

the local setting.
The menu contains two submenus. Both contain pa-

rameters that are used to adjust the machine perfor-
mance.
16.7.1 Machine parameters (F9)
This menu is only accessible with a master password. It contains parameters which control
the basic functions of the machine.
Altering these parameters could cause problems and malfunctions of the machine as well as
excessive load to some machine parts. For this reason:
Do not alter settings in this menu,

if not recommended by the HELMUT WEISS GmbH
16.7.2 Function parameters (10)
This menu contains parameters which may help to improve the quality of the product.
Picture 154: Station 3: closing adhesive valve
This picture allows to control the closing of the adhesive valve. One can program a distance
for the adhesive track which the valve should close either before or after the whole rotation is
finished is finished.
Picture 157: Station 9: correction if feeding roll wears
This picture allows to enter a correction value which compensates the smaller circumference
in case the feeding roll is worn down. The entered value is not an exactly in Millimetres so
that the result should be controlled by measuring the corrected flap length.
Station 9: Distances
- Program “special” / angle for short distances
This parameter specifies the short angle for disc rotation in the program “special”.
- Rotation for flap fold over (Station 9)
Specifies the rotation angle for fold over of the flaps in Station 9

Picture 158: Station 10
- Rotation for flap fold over (Station 10)
Specifies the rotation time for fold over of the flaps in Station 10
Picture 159:
This picture allows to adjust the remaining ribbon length after the ribbon end sensors give a
signal. Using this function, the loss of ribbon can get optimized.
Picture 160:
The parameters in this picture allow to adjust the speed control of the motors that pull the
abrasive ribbon off the reels. The adjustment can be done for different speed ranges for both
reels (only for one in case there is only one motor installed). The values which one can enter
into the chart will change the acceleration of the driving motor in case the ribbon loop is get-
ting short.
Note: Please change these values only after consultation with Helmut
Weiss GmbH!

16.8 Set up mode
The mode gives the possibility to operate all pneumatic cylinders or motors using two buttons
on the operator panel.
This menu is protected by a password (see chapter 10 “Password”).
• Move to the picture 2/2 of the main menu using

the “pict. ” button.
• Press F10 “set up” to open the set up menu
• Select the Station in which you want to manually
activate a function.
Each menu contains the list of all possible functions

(left column) and shows the current status of these
functions.
IP = input signal for initial position

IPV = output signal for initial position
APV = output signal for activated position
AP = input signal for activated position
The signal numbers (e.g. E39.1) for each function will

be highlighted with a black bar if it has 1-Signal (high
potential).
• Select the demanded function using the function keys F1 or F7.

• The currently selected function is highlighted by a black bar.
• Activate the selected function using the “manual mode activated position”-button.
• Deactivate the selected function using the “manual mode initial position”-button.
ATTENTION:
All manual functions have to be performed with greatest care as it is pos-

sible to cause a crash (e.g. turn the index table when a disc holder cylinder
is down).

17 Password
Some of the menus and functions on the Operator Panel are protected by an password, as
alterations in these menus should only be made by well trained personnel or by service tech-
nicians of the HELMUT WEISS GmbH.
Once the function key was pressed, the following picture will appear on the display:
• Enter the user name

• Move the cursor to the next field using the “TAB”-key
• Enter the password
• Move the cursor to “OK” using the “TAB”-key
• Press “ENTER” to confirm the password
To reach the selected menu, it is necessary to press the related function key again.
Note: The preset user names and passwords are printed on the following
page. It is up to the customer to keep this password secret.
In case a different password than the preset one is necessary, please contact the Helmut
Weiss GmbH.

The passwords are as follows:
Menu Sub menu Password User
Select product Data 1808 master
Save 1808 master
Delete data 1808 master
Date -> PLC 1111 worker
Product data 1111 worker
Parameters Machine parameter ---- ----
Function parameter 1808 master
Counter Delete day counter 1808 master
Delete production counter 1111 worker
Set up 1808 master

18 Changing to a different product
This chapter explains how to change from one product to another. Not all of the described
actions may be necessary!
• Recall the program of the memory (see chapter 16.3.1)
Check the following:
• pins on magazine table station 1, 12 and 13

• backing disc in station 1
• position of adhesive nozzles
• vertical position of adhesive nozzles
• amount of adhesive

• type of abrasive ribbon (station 9)
• size of abrasive guide and width of abrasive guide (station 9)
loosen the guide bar adjust the guide bar approx. 1 mm wider than the
ribbon width
adjust the 2 ribbon guide blocks feed the ribbon as shown below:
in the appropriate position:

• horizontal position of cutting head (y-axis) (station 9)
loosen clamp lever: activate switch: adjust position:
• inclination of cutting head (station 9)
open clamp screw and adjust inclination

(use the special tool):
• position of fold over roll (station 9 +10)
vertical position
horizontal position
• position of abrasive ribbon reel (station 9)
• type of pressing head (station 11)

19 Changing the abrasive ribbon
There are two possible situations in which the abrasive ribbon can be changed:
19.1 Changing the ribbon during flap application (ribbon is empty)
In this case, the machine stops with the cutting head in application position right above the
disc. The yellow signal lamp will come on and a message will appear on the display.
The cutting blade is in activated position (feeding tunnel is closed).
• Press the “STOP”-button

• Remove the rest of abrasive ribbon off the cutting head.
• Take care that the edge of the new ribbon is cut straight and feed it into the tunnel until it
touches the backside of the cutting blade.
• Restart the machine with the “START”-button.
 The disc will be finished without any loss of material.
19.2 Changing the ribbon after the last disc is finished (product change)
In this case, the cutting head is in it’s starting position high above the disc. The machine is
stopped and the cutting blade is in initial position (feeding tunnel is open).
• Remove the abrasive ribbon off the cutting head

• Feed the new ribbon through the feeding tunnel until you can see the end coming out
between the cutting blades.
• Activate the “band change” –switch.
• Press and hold the “STOP”-button.
• Press the “START”-button while still holding the “STOP”-button in order to cut the begin-
ning of the ribbon straight.
• Deactivate the “band change”-switch.
• Restart the machine.

20 Changing the adhesive container on the pneumatic pump
In case the adhesive container is empty, the machine will stop adhesive application and will
show a message on the display.
Up position
Neutral position
Down position
valve for following

plate
Lever valve for drum airing
• Switch the hand lever valve to neutral position (0)

 The pressure onto the following plate will be released!
Attention : Switching the valve to the up position will lift the whole container.
This may cause damage to the pump!
• Replace the air relief pole of the following plate by the air connection pole.
• Use the hand lever valve for drum airing to blow air underneath the following plate in or-
der to lift it. Do not leave the valve on for the hole lifting process rather than switching it
on and of periodically to achieve a better control of the lifting movement, especially the
last millimetres before the plate leaves the container. Move the hand lever valve for
pump plate pressure now and then between the neutral position (0) and up position (1) in
order to ease the lifting process.
• Close the drum airing valve, when the plate left the container.
• Switch the hand lever valve to the up position (1) to move the following plate further up.
• Replace the adhesive container and take care the container is centred under the follow-
ing plate.
• Lubricate the silicon seal rings on the following plate with standard machine grease.
• Remove the air connection pole off the following plate.
• Move the hand lever valve for press plate pressure to the down position (2) and take care
the following plate moves centred into the container.
• Wait until the following plate reaches the surface of the adhesive and check that some
adhesive comes out of the air relief hole.
• Switch the hand lever valve to neutral position (0).
• Place the air relief pole on the following plate.
• Switch hand lever valve to down position (2)

• Wait for about 10 minutes until the adhesive underneath the following plate is heated up
to proper temperature.
 Adhesive pump is ready for restart.
Notice: In case of a pressure drop in the pump system, the flap disc machine will stop
adhesive application automatically.
Possible reasons for such a pressure drop are as follows:
• Adhesive container is empty and now adhesive can be lifted by the lifting cup.
• Air bubble inside the pump or the adhesive hose.
• Adhesive temperature is too low ( bad adhesive flow).
• Shelf time of adhesive is already passed ( bad adhesive flow).
Release the air in the pump as follows:
• Open the ball valve above the following plate (use some sheet of paper to avoid getting
the adhesive all over the pump) and release the air until some adhesive comes out.
Check that there are no more air bubbles in the adhesive.
• Close the ball valve.
• Press the “START”-button on the pump.
 Pump pressure should come up to normal.
• Restart the machine.
 The machine will automatically finish the interrupted adhesive application process on the
disc in station 3.
21 Emergency Stop
The “EMERGENCY STOP”-button should only be used in an emergency situation or in case

of a malfunction of the machine.
Restart the machine after an emergency stop as follows:
• Remove all discs off the main rotary table.

• Release the emergency stop button by turning the knob.
• Press “START”-button
• Press “RESET” and then “START” to start synchronisation
 All axles will move into initial position.
 Machine is ready for start.

22 Reference run (Reset)
In the case of an error or after a mechanical problem, it may be necessary to put the ma-
chine back into the initial status, as there is no other possibility to restart the machine. This is
called reference run.
• Always, press the “STOP”-button to disable the automatic mode before starting the syn-
chronisation.
• Activate the reference run with “RESET”-button.
• Start the reference run with “START”
 All axles and cylinders move into their initial position.
• Remove all discs of the main rotary table.
 Machine is ready for start.

23 Service and maintenance
ATTENTION!
Before doing any service or maintenance work on the machine, switch the
machine off and take care it’s not switched on again by mistake.
23.1 Maintenance work list
In the following list, you will find all necessary service and maintenance work regarding the
interval in which it should be carried out. In order to achieve a errorless and low wearing run
of the machine, take care that all works are done within the right time.
Interval Maintenance work adjust- Material

ment
Every day • Clean the whole machine using a vacuum or com-

pressed air gun.
• Check the dust exhaust system and clean if necessary.
• Check the main air pressure at the air supply unit. 6 bar
• Release the condensed water at the air supply unit if
necessary.
Every week • Clean all optical sensors with a soft and clean cloth.
Every month • Check the function of all pneumatic actors (Cylinders;

Grippers; etc.)
• Clean all linear guides, check their function and lubri-
cate them slightly.
• Lubricate the bearings on the cutting head as de- 1
scribed below
Every half • Clean or interchange mufflers on the pneumatic valve 2/3

year block and on all single valves.
• Remove the metal sheet cover on the cutting head and
clean the linear guides
Approx. eve- • Get the cutting head reconditioned from Helmut Weiss
ry 2 years GmbH

23.2 Materials for maintenance
No. Supplier Term
1 Fuchs H443 HD88

2 Festo Muffler for valve terminal CPA 14 ; CPA 14-U-EP (173 969)
3 Riegler Mufflers G1/8“ 566-1
23.3 Other maintenance instructions
See manuals of purchased parts.
Part Supplier
Pneumatic rotor Sommer Automatic
Electro-mechanical index table Weiss
Maintenance instructions of the above listed suppliers must be obeyed unrestrictedly.
Maintenance instructions of other suppliers may be found in the same chapter as well.
23.4 Instruction for lubrication of the cutting head
The bearings on the cutting head needs to get lubricated in the above listed interval. There
are two different areas which need to be lubricated.
Lubricating the needle roller bearing on the crank shaft:
• Activate the “Emergency stop”-button in order to cut off the power supply to the driving
motors.
• Remove the screws in the middle of the lid
• Remove the screw plug which covers the lubrication nipple
• Use the supplied grease gun with the above listed grease and connect it to the lubrication
nipple inside the whole.
• Press only one stroke of grease into the nipple while rotating the crank shaft using an
Allen key. This way, the grease will be distributed evenly within the whole bearing.
• Replace the screw plug
• Replace the screw in the middle of the lid

Ball type lubrication nipple
Hexagonal socket screw on the crank shaft

(inside)
Lubricating the friction bearing:
Use the supplied grease gun with the

above listed grease and connect it to the
lubrication nipple on the rear side of the
cutting head
Make only one stroke with the grease gun
lubrication nipple

23.5 Replacing the seal set on the piston rod of the adhesive pump
head cap screws
¾“ nut
seal tightening nut
seal package housing
• Check that the pump piston is in the upper end position, otherwise drain some adhesive
using the “Adhesive” button (Attention: Use some paper to avoid getting the adhesive all
over the machine).
• Unscrew the socket head cap screws (M8)
• Unscrew the ¾” nut at the top end of the piston rod
• Press the green “Adhesive” button at the control cupboard of
the machine and hold it until the pump piston reaches the down position.
• Still hold the “Adhesive” button and switch off the pump´s main
power switch when the piston reaches the top position. Then release the “Adhesive” but-
ton.
• Open the ball valve above the following plate and release some
adhesive until the pressure is totally released (wait 1 – 2 minutes
after the adhesive flow stopped).
• Switch the hand lever valve to neutral (position 0) in order to
release the pressure of the following plate.
• Switch off the water heating system.
• Loosen the seal tightening nut a little bit.
• Unscrew the seal package housing out of the pump and clean the
whole system.
• clean the piston rod

• Assemble the seal system and tighten it slightly.
• Fills some oil into the seal tightening nut.
• Tighten the three socket head cap screws (M8)
• Switch the water heating system on
• Switch hand lever valve to position “2”, remove the air relief rod
and replace it if all air left the system
• Switch on the main switch on the pump
• Restart the adhesive pump
Important: Clean the pist on rod of the pump every day and check
if the seal package is tightened. The pump should not
be under pressure when tightening the seal package.

23.6 Replacing the seal of the adhesive valve
1. Remove the pneumatic hoses from the valve cylinder

2. Demount the valve cylinder (4 head cap screws)
3. Demount the cylinder base plate (4 head cap screws) - not compulsory!
4. Unscrew the 4 distance bolts – not compulsory!
5. Unscrew the cap nut and the counter nut from the valve needle and remove the
washer and the spring.
6. Unscrew the seal cover (4 head cap screws)
7. Remove the seal out of the seal housing
8. Clean all parts before reassembling
9. Cover the new seal and the mounting surfaces with some grease
10. Place the seal onto the valve needle and into the seal housing
11. Place the seal cover over the valve needle and tighten the 4 screws for the cover
12. Place the spring and the washer over the valve needle and screw the counter nut all
the way down.
13. Screw the cap screw all the way down on the valve needle and tighten it with the
counter nut
14. Reassemble the cylinder base plate onto the distance bolts.
15. Reassemble the valve cylinder and connect the pneumatic hoses
Attention: The press head on the pneumatic cylinder needs to be adjusted

in order to achieve a clearance of approx. 0,1-0,3 mm when the
piston rod is in it’s upper position. This setting should be
checked every week.

to 1. and 2.) 4 head cap screws
Valve cylinder
Pneumatic hoses
to 3. and 4.) 4 head cap screws
cylinder base plate
4 distance bolts
to 5. und 6.)
cap nut
counter nut
spring
seal cover

to 7. to 10.)
seal
to 15.)
Clearance adjustment 0,1 – 0,3 mm

24 Technical specifications
• Size of the machine: Length: 3500 mm

Width: 1900 mm
Height: 2000 mm
• Weight of the machine: approx. 750 kg
• Size of the pump (200L) : Length: 1100 mm

Width: 900 mm
Height max: 2400 mm
• Weight of the pump: approx. 250 kg
• Electrical system:
Main power supply: 400 V / 3 Phase
Control Voltage: 24 V DC
Current: 16 A
Frequency: 50 Hz
Attention: The earth connection of the machine has to be made

properly by the purchaser.
• Pneumatic system:
Air pressure: 6 bar
Supply hose: DN 9
Air consumption: approx. 200 L/min
The supplied air must be:
- dehydrated
- filtered
- oil free

Leitenacker 3
95326 Kulmbach
Tel: + 49 92 21 / 92 09-0
Fax: + 49 92 21 / 92 09-22
e-mail: info@
helmut-weiss-gmbh.de
25 EG-Declaration of conformity
In terms of EG-guidelines machines 98/37/EG, appendix II A
With this we declare, that the machine as described, confirm with the appropriate regulation.
Type: Flap disc machine FSA 12 BMX
Machine-number: 2007 207
Year of construction: 2007
Guidelines:
Machine-guidelines: 98/37/EG
Low-voltage-guidelines: 73/23/EWG
EMV-guidelines: 89/336/EWG
Harmonised standards:
Safety of machines: EN ISO12100 / Part 1 + 2
Safety-distance
at machines: EN 294
Emergency-stop-equipment: EN 418
Electrical equipment
of machines: EN 60204-1
Kulmbach, 10.11.2023
_________________________ __________________________
Ulrike Weiß, General Manager Reiner Weiß, General Manager

26 Service address
HELMUT WEISS GMBH

-Automatisierungstechnik-
Leitenacker 3
D-95326 Kulmbach
Tel.: +49 92 21 / 92 09-0
Fax: +49 92 21 / 92 09-22
e-mail: info@helmut-weiss-gmbh.de
We need the following information in the case of a problem:
1. Type of equipment
2. Machine number
3. Symptoms of the error

Operator Manual FSA 12 BMX V01 Ab 2007 207

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Leitenacker 3

Flap disc machine

Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 1

1 General note ......................................................................................................... 5

3 Function of the machine ....................................................................................... 6

9 Start the machine cycle ...................................................................................... 24

10 Stopping the machine cycle ................................................................................ 25

Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 2

14 Operation modes and their functions .................................................................. 27

16 Operator panel .................................................................................................... 29

18 Changing to a different product .......................................................................... 46

19 Changing the abrasive ribbon ............................................................................. 49

21 Emergency Stop ................................................................................................. 51

22 Reference run (Reset) ........................................................................................ 52

23 Service and maintenance ................................................................................... 53

25 EG-Declaration of conformity .............................................................................. 62

Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 3

Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 4

The warranty starts with the day of delivery.

Not covered by the warranty are:

• wearing parts such as seals, conveyor belts etc.

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The functions in the different stations are as follows:

Station 3 (adhesive application)

• number of tracks per disc

Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 6

• Guide adjustment for different strip widths (manual).

Station 10 (push over unit)

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4.1 Intended use of the machine

4.2 Impermissible alterations on the machine

4.4 Safety notes

Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 8

The only exception in the case of maintenance is as follows:

The machine should only be started, if in faultless condition.

4.6 Special safety notes for the use of the machine

Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 9

5.1 How to put machine into place

Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 10

30L adhesive pump 200L adhesive pump

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Air hose from the pump

Main air supply to the machine

• Pull the adhesive hose from the pump to the machine

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• Place the ribbon reel in its position

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6.1 Main power switch and Emergency button

Emergency Stop button

The “Emergency Stop” button should only be used to stop

There are two Emergency Stop button available on the

Main power switch

Using the main power switch, the machine can be

Some parts inside the control cabinet

Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 14

Valve terminal manual override switch

Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 15

main air supply valve

This valve will interrupt the air supply to the ma-

Kopie von Operator Manual FSA 12 BMX V01 ab 2007 207.doc 16

“lift cutting head” switch

“ribbon drive” switch