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- 1 -Service / Error Messages at the ONLINE Processor
Are the covers in place and triggering theinterlock switches?
Is interlock switch ok?
Replace coverand switch on
Replace switch
NOTE: There are three interlock switches- processor lid- dryer cover- filter housing cover
no
yes
Is continuity present between interlock switches and pcb GCB?
Has fuse F510 blown?
yes
yes
yes
Replace pcb GCB
no
no
no
Replace wiring
Replace fuse 1.5A (S) 6.3 x 32mm
E00: Check Interlock on OLP
- 2 -Service / Error Messages at the ONLINE Processor
Lift conveyor cover: is there film inside?
Has the film reached the processor input sensor?
Inverstigate location of film in Herkules.
no
no
Has the film reached the input rollers of the sensor?
Are the input sensors seated correctly?
yes
yes
yes
no
yes
no
Are the rollers turning?
E01: Film Jam in Conveyor
Check the position of guides, rollersand grip of rollers.
Are input sensors operating correctly ? I.e... jammed.
Reseat sensors
continued onnext page
no yes
yes
no Replacesensors
no * *
- 3 -Service / Error Messages at the ONLINE Processor
Is input sensor electrical circuit operating correctly?Check by triggering sensors in service mode parameter 32 + 33. Does display status toggle onand off?
E01: Film Jam in Conveyor
Is 5 volts DC present across pcb GCB plug X201 and X202 when plug is removed?
Reconnect plug does voltage return to 0 volts?
Is there 5 volts DC at input sensor?
no
yes
no
no
Change wiring
yes
no
yes
yes
Change pcb GCB
Change sensor
Change pcb GCB
Change pcb GCB
- 4 -Service / Error Messages at the ONLINE Processor
E01: Film Jam in Conveyor
Cut and remove the film
Trigger interlock switch.Do the conveyor rollers rotate?
Check the position of therollers and look for worn belts
Has fuse F301 blown?
Is there 24 volts DC supplied to the conveyor?
Replace fuse 2A (S)
Change conveyor motor
Is there 24 volts across plug X301 on pcb OCM04?
Has the film been released by the Herkules?
Check wiring to conveyor motor
no
no
no
no
no
yes
yes
yes
yes
yes
Change pcb OCM04
no* *
- 5 -Service / Error Messages at the ONLINE Processor
E02: Film Jam in Processor
Is the processor exit sensor too high or dislodgedfrom its mounting and not being triggered by the film?
yes
yes
yes
yes
Is the processor output sensor being held up by a sheet of film?
Is the processor output sensor stuck in the up position?
Is the film stuck in the processor racks or in the bottom of the tanks?
a) ... all racks are located under the drive barb) ... missing worm geer clips causing loss of drive to the racksc) ... damaged geers causing loss of drive in racksd) ... correct location of guides and rollers in racks
no
continued onnext page
Reposition sensor
Remove film andempty basket
Release sensor arm and clean or replace sensor
Remove film and check for ...
no
no
no
- 6 -Service / Error Messages at the ONLINE Processor
E02: Film Jam in Processor
yes
yes
yes
no
no
Is the film stuck in the conveyor and triggering the processor input sensor?
Check speedcontrol timing
Remove the processor lid and trigger the interlock switch. Do the processor rollers turn?
Check for nongripping rollers
Is there power to the main drive motor? Change motor
Is there continuity of the wiring between pcb GCB and main drive motor?
Replace wiring
Change pcb GCB
yes
no
no
- 7 -Service / Error Messages at the ONLINE Processor
yesClose coverIs conveyor cover open?
no
no
no
yes
yes
Is interlock switch on conveyor ok? Replace switch
Replace wiringIs there continuity in the wiring through the interlock switch to plug X902 on pcb OCM04?
Replace pcb OCM04
E03: Conveyer Cover open
- 8 -Service / Error Messages at the ONLINE Processor
yesAddress errors
no
no
Replace cable
E04: Level Error Developer
Are errors E07, E10, E13 or E25 also displayed?
no
Is the levellow?
Does the devaccount = 500?
yes
no
yes Is the O-ring seal at the baseof the overflow pipe leaking?
no ja
Is there continuity in the wiring betweenpcb GCB plug X101 and the level sensor?
Replace pcb OCM04
Top up withwater
ReplaceO-ring
With plug X101 removed is there 24V AC at the output from the pcb GCB?
Check fuse F511
yesCheck pcb GCB
yes
no
- 9 -Service / Error Messages at the ONLINE Processor
yesAddress errors
no
no
E05: Level Error Fixer
Are errors E08, E11, E14 or E26 also displayed?
no
Is the levellow?
Does the fixaccount = 500?
yes
no
yes Is the O-ring seal at the baseof the overflow pipe leaking?
no yes
Is there continuity in the wiring betweenpcb GCB plug X102 and the level sensor?
Changepcb OCM04
Top up withwater
ReplaceO-ring
With plug X102 removed is there 24V AC at the output from the pcb GCB?
Check fuse F511
noReplace cable
yesCheck pcb GCB
yes
- 10 -Service / Error Messages at the ONLINE Processor
yes Follow flow diagramfor E15
no
no
E06: Level Error Wash (Applies only to Wash Tank 1)
Is E15 showing?
no
Is the level lowin wash tank 1
Is there continuity in the wiring betweenpcb GCB plug X103 and the level sensor?
With plug X103 removed is there 24V AC at the output from the pcb GCB?
Check fuse F511
noReplace wiring
yesCheck pcb GCB
yes
yes Follow flow diagramfor E15
- 11 -Service / Error Messages at the ONLINE Processor
yes
E07: Change Developer Replenisher Container
Is E10 alsodisplayed?
no
Follow flow diagramfor E13
Follow flow diagramfor E10
- 12 -Service / Error Messages at the ONLINE Processor
yes
E08: Change Fixer Replenisher Container
Is E11 alsodisplayed?
no
Follow flow diagramfor E14
Follow flow diagramfor E11
- 13 -Service / Error Messages at the ONLINE Processor
yesAre E06 or E15 also displayed?
yes
yes
no
no
no
Remove restriction
E09: Low Flow Mix- with-Fix Pump
Remove fixer replenisher fuse F507, pulse fixer rep button, is wash solution delivered to the fix tank?
Is there a restriction in the hose between the baseof wash tank 1 and the flow sensor?
Check mix- with-fix pumpusing replenisher pumpcheck guide
Follow flow diagramE6 or E15
Check mix- with-fix flow sensor using flow sensor guide
- 14 -Service / Error Messages at the ONLINE Processor
yes
no
yes
yes
yes
no
no
yes
noRemove restriction
E10: Dev Waste Container full
refit
Is the developer waste container full?
Is the dry break connector seated correctly?
Is the developer waste hose restricted?
Is the float sensor short circuit?
Change developer waste container and reset on Herkules panel
Investigate switch failure, possibly:- float stuck in up position- float dropped off spine
no
Is 18V AC supplied to the switch?
continued onnext page
- 15 -Service / Error Messages at the ONLINE Processor
E10: Dev Waste Container full
Is the power supply to pcb GCB correct?
no
yes
yes
no
Is fuse F18 blown?
Check transformer output voltage
Replace pcb GCB
Replace fuse 500 mA(F) 250V
- 16 -Service / Error Messages at the ONLINE Processor
E11: Fixer Waste Container full
Use flow diagram for E10 replacing fixer for developer.
- 17 -Service / Error Messages at the ONLINE Processor
E12: Wash Waste Container full
yes
noIs jumper plug X203 pin 1 to 3 in place? Install jumper
Replace pcb GBP01
- 18 -Service / Error Messages at the ONLINE Processor
no
no
yesRefit
E13: Dev Rep Container empty
continued onnext page
When arriving in this column clear error code by pulsing dev rep button.If error does not clear continue with process.
Is the developer replenisher container empty?yes
Is the dry break connector seated correctly?no
Change dev repcontainer
Has the rep bag collapsed over its exit?yes
Is the red dev rep hose restricted or is thefilter blocked?
yes
Release obstruction
Remove restriction
no
- 19 -Service / Error Messages at the ONLINE Processor
no
yes
yes
no
Is fuse F508 blown?
E13: Dev Rep Container empty
Does dev rep reach the tank when the repbutton is pressed?
Check flow sensor using flow sensor guide
Replace fuse 500 mA (F)6.3 x 32 mm
Check rep pump using rep pump guide
WARNING:the replenisher pumps will not work when the processor lid is removed unless the interlockswitch and daylight slot magnet is triggered.
- 20 -Service / Error Messages at the ONLINE Processor
E14: Fixer Replenisher Container empty
Use flow diagram for E13 replacing fixer for developer. Fixer replenisher hose is blue. Fixer fuse number is F507.
- 21 -Service / Error Messages at the ONLINE Processor
E15: Wash Replenisher Container empty
Use flow diagram for E13 replacing wash for developer. Wash replenisher hose is green. Wash fuse number is F18.
- 22 -Service / Error Messages at the ONLINE Processor
E16 / E17: Low / High Processing Speed
Check service parameters (green LED) 46 and 47or static data 10045 and 10046 on herkules panel.Do the values equal -3 and +3 respectively?Is service parameter 51, developer rack length330 mm?
yes
yes
Has OLP been switched off / on during film processing?
yes
no
Set service parameter 35 or static data ID 10034 = processing speed auto-calibrate to 0, and run afew films through the OLP.Observe value of auto-calibrate parameter.Does values stay between -10 and +10?
continued onnext page
Set to correct value
no Check adjustmentof film speed onpcb GCB
no Check adjustmentof film speed onpcb GCB
- 23 -Service / Error Messages at the ONLINE Processor
E16 / E17: Low / High Processing Speed
NOTE:The most likely source of this error is the "processing speed autocalibrate"system. This system measures the complete processing time for a film from input sensor to output sensor. For example:If a film is left in the machine at power off, and an additional film is sent through immediately after power on, the film arrives too soon, thus fooling the system. Normally the errors E16 and E17 are a combination of motor control maladjustment and technician / user interference with the system. The OLP calculates a "measured processing speed" based oninput-to-output time and machine length. The value can been seen in casual user parameter 26 (no LED) or measure data 10009 on the herkules interface panel.
- 24 -Service / Error Messages at the ONLINE Processor
E18: Total idle Time exceeded
no
yes
yes
noSet to default value.
noSet to 2.0
Check casual user parameters (no LED) 27 and 28,or measure data ID 10017 + 10018 (time on sincelast job and time off since last job measuredin minutes). Is the sum of these values large?I.e.... > 10000 minutes
Check service parameter (green LED) 52, or static data ID 10051 (alarm for total idle time).Does the value = 14400 min. (= 10 days)?
Check service parameter 66, or static data ID 10065 (idle on time scaling factor). Does the value = 2.0?
Carry out a system check to establish ifthe processor chemicals are exhausted.
yes
Carry out a system check to establish if the processorchemicals are exhausted.
- 25 -Service / Error Messages at the ONLINE Processor
yes
no
E20: Developer Filter blocked
no
yes
Change developer string filter, does error remain?
yes
Is pressure sensor open circuit?
On pcb GBP short circuit plug X104 pin 1 to 3.Does the error clear after 30 seconds?
Replace pcb GBP1
no Reset filter lifetime counter on Herkules panel
Replace pressure sensor
Check continuity of wiring between pressure sensorand pcb GBP plug X104
- 26 -Service / Error Messages at the ONLINE Processor
E21: Fixer Filter blocked
Follow flow diagram for E20 but use plug X105 pin 1 to 3 on pcb GBP.
- 27 -Service / Error Messages at the ONLINE Processor
E22: Wash 1 Filter blocked
Follow flow diagram for E20 but use plug X205 pin 1 to 3 on pcb GBP.
- 28 -Service / Error Messages at the ONLINE Processor
E23: Wash 2 Filter blocked
Follow flow diagram for E20 but use plug X206 pin 1 to 3 on pcb GBP.
- 29 -Service / Error Messages at the ONLINE Processor
E24: Biocide Container empty
Plumbed system:Follow flow diagram for E13 but use biocide in place of developer(there is no dedicated fuse for this pump). Plumbless system:Check that a jumper is installed on pcb GBP plug X204 pin 1 to 3.
- 30 -Service / Error Messages at the ONLINE Processor
E25: Dev Rep Container empty
Is E10 also displayed?
no
yes Follow flow diagramfor E10
Follow flow diagramfor E13
- 31 -Service / Error Messages at the ONLINE Processor
E26: Fixer Replenisher Container empty
Is E10 also displayed?
no
yes Follow flow diagramfor E11
Follow flow diagramfor E14
- 32 -Service / Error Messages at the ONLINE Processor
E27: Replace Fixer Filter
The fixer filter lifetime has elapsed. Replace with a new carbon filterand reset on the Herkules panel.
no
Does the error remainafter changing the filterand resetting on theHerkules panel?
Is fixer filter lifetimecounter serviceparameter 55 (green LED)set to the default value?
yes
System is now operable
noyes
Replacepcb OCM04
Reset todefault
- 33 -Service / Error Messages at the ONLINE Processor
E28: Replace Wash 1 Filter
Follow flow diagram for E27 replacing the carbon filter for a string filterand using service parameter 53.
- 34 -Service / Error Messages at the ONLINE Processor
E29: Replace Wash 2 Filter
Follow flow diagram for E27 and using service parameter 54.
- 35 -Service / Error Messages at the ONLINE Processor
no
no
yes
yes
no
yes
Wait until it comesup to temperature.
E30: Developer Temperature incorrect
Set to 35 °C.
Check recirculationinside dev tank.
Is the developer temperature set to 35°C?Check using casual user parameter 13 (no LED).
Is the developer temperature above 35°C?Check using casual user parameter 23.
Is the developer temperature below 35°C and not increasing?
Is E04 displayed on the processor panel?
no
Is fuse F504 (dev heat) blown?no
continued onnext page
yes
yes
Follow flow diagramfor E04.
Replace fuse 5A (F) 250V (6.3 x 32 mm).
- 36 -Service / Error Messages at the ONLINE Processor
no
yes
no
E30: Developer Temperature incorrect
Is 230V AC arriving at dev heater element? Has heater element thermofuse blown?
no ja
Replacethermofuse
Replace heaterelement
Is there 230V at the output from pcb GCB?Measure between plug X508 red wireand plug X507 black wire.
nein
Is the temperature probe resistance(ex. 1200 ohms approx.) in a similarrange to the other temperature probes?
yes
Check continuity of wiring between pcb GCB and heaterelement.
Replace temperature probe
yesReplace pcb GCB
- 37 -Service / Error Messages at the ONLINE Processor
E31: Fixer Temperature incorrect
Follow flow diagram for E30 replacing developer with fixer. Referring to fuse F503 5A (F) 250V 6.3 x 32 mm and measuringpcb GCS output voltage between plug X507 brown wire andplug X507 orange wire.
- 38 -Service / Error Messages at the ONLINE Processor
How to check a Replenisher Pump
NOTE:Replenisher pumps will not operate when:- The processor lid is removed unless the interlock switch and the daylight slot magnet switch is triggered.- When the corresponding replenisher account is equal to 500. Trigger the operation of the replenisher pump by:- Pulsing the rep button for FIX, DEF and MIX-WITH-FIX pump.- Using service parameters 16 (fix) or 17 (dev) on pcb gcb.- Dropping the level in wash tank 1 to operate the wash rep pump.
yesDoes the replenisher pump oscillate?
Is there 180 to 230 V AC supplied to the replenisher pump?Measure on the terminal block under the dryer rack.
no
nocontinued onnext page
yesReplace pump
Check internal popet valveand replace if damaged,if not replace pump.
- 39 -Service / Error Messages at the ONLINE Processor
yes
How to check a Replenisher Pump
Is the supply voltage at the output of the pcb GCB?
no
Check the continuity of thewiring between the pumpand the pcb GCB.
Has the corresponding fuse on the pcb GCB blown?
no
Replace pcb GCB
yesReplace fuse
- 40 -Service / Error Messages at the ONLINE Processor
How to check a Flow Sensor
Observe the replenishment accounts found in extended parameters (yellow LED).
Dev account parameter 12.Fix account parameter 13.Mix with fix account parameter 14.
Does the account change value when squeezing the online rubber gather next to the flow sensor.
no
Remove the plug connection from the flowsensor and connect an alternative plugfrom another flow sensor.Pump replenisher through the flow sensor and monitor the alternative account.Does the account change value?
no
yes
continued onnext page
no
NOTE
yes
Check the hose between the pumpand flow sensor, are there anyfloating obstructions?
yes
Carry outprocedure for calibratingflow sensors
Removeobstruction
Replaceflow sensor * *
- 41 -Service / Error Messages at the ONLINE Processor
How to check a Flow Sensor
no
yes
Replace wiringIs there continuity in the wiring between the flow sensor and pcb GBP?
Is there 10V DC between pin 1 and 3 of theflow sensor?
no
yes
Has fuse F19 blown?
no
Is there 18V AC at input to pcb GBP?
no
Check transformer supply
yes
yes
Replace pcb GBP
Replace fuse 500 mA(S) 250V
Replace pcb GBP
- 42 -Service / Error Messages at the ONLINE Processor
How to check a Flow Sensor
NOTE:The MIX-WITH-FIX flow sensor may malfunction due to a build upof black particles on its internal sensor. Removing the particles:- exchange MIX-WITH-FIX flow sensor.- pump fixer through the defective flow sensor. The flow sensor should start to operate after approx. 0.5 to 1 literof fixer has passed through it.
* *
General Remarks - 1 -
PcbsPrinted circuit boards must not be energized when being pulleout.Carry out operations on modules only when they are pulled outand not energized.
General Remarks - 2 -
Electrostatic Discharge (ESD)Observe ESD (Electrostatic-Sensitive Device) safety regulations! PCBs and semiconductor modules should remain as long as possible in their original packing. When shipped or stored, use either the original or adequate protective packing. Machines, soldering irons, work surfaces and persons should have the same potential as the semiconductor modules. Avoid static charge caused by synthetic floor coverings, synthetic clothing etc. at any cost to prevent destruction or damage of the semiconductor modules. Therefore:- When working on modules, wear a wristlet and establish a ground.- Use a grounded work surface.- Do not disconnect the ground before having finished all operations. For this purpose, use the ESD set (Order No. 02302683).
General Remarks - 3 -
Soldering OperationsFor soldering operations, only mains isolated low-voltage soldering irons equipped with leakage resistors may be used.E.g. WELLER soldering unit WECP 20 (Order number 02289245,Weller order number 52501199). While soldering, make sure the arising vapor does not get into contact with any optical parts.
General Remarks - 4 -
MeasurementsPrior to each measurement, make sure that electrical isolation exists, otherwise take respective measures, e.g. use isolating transformer.
General Remarks - 5 -
Optical PartsAvoid contact of the optical parts with any metal object.Do not leave any small parts on the glass panes.Clean optical parts according to "Cleaning Procedure (order No. 02064634)".
General Remarks - 6 -
Floppy DiskObserve the manufacturer´s instructions for handling floppy disks and drives.The following items are of special importance:- Always store floppy disks in clean protective covers.- Neither bend nor fold floppy disks.- Do not place heavy articles on floppy disks.- Protect floppy disks from magnetic influences and do not touch magnetic surfaces.
Copyright - 7 -
Copyright by Heidelberger Druckmaschinen Aktiengesellschaft, 24107 Kiel Adobe and Adobe Illustrator are registered trademarks of Adobe Systems Incorporated. Apple, Apple-Logo, AppleTalk, EtherTalk and Macintosh are registered trademarks of Apple Computer, Inc. Ethernet is a trademark of Xerox Corporation. LinoColor, Linotype, Linotronic, Linotype Library, Centennial, Helvetica and Times are registered trademarks of Heidelberger Druckmaschinen Aktiengesellschaft. PostScript is a registered trademark of Adobe Systems, Inc. Taxi is a registered trademark of AMD. We point out that companies, trademarks and product names mentioned in this manual fall within the regulations regarding protection of trademarks and patents.
No. Measure
No. MeasureThis FollowMe documentation corresponds to the hardware version indicated on the modification label with which the machine or the respective component is provided. Modification states are indicated by the number marked on the modification label. If the hardware has a different modification state, please refer to the respective Service Information.
No. Measure
No. Measure
Technical Data - 1 -
DimensionsHeight 930 mmWidth 780 mmDepth 1510 mm
WeightOperating weight ca. 500 kg
Technical Data - 2 -
Ambient ConditionsOperating temperature +18 ... +28 °CTransport temperature -10 ... +50 °CRelative humidity 45 - 80 % (not condensing)Atmospheric pressure 700 - 1060 mbarHeat dissipation ca. 3200 kJ/h
Technical Data - 3 -
Power RequirementsMains voltages 1 N PE AC 100 V, 110 V,
120 V, 127 V, 200 V,220 V, 230 V, 240 V
Connecting 115 V to 120 V Mains frequency 47 - 63 Hz Power consumption ca. 0.9 kW with
200 V ... 240 V
Technical Data - 4 -
FloorThe floor at the installation site must be level.As a rule, the floor (covering) must meet the following quality requirements: Permanently antistatic, i.e.Max. static charge <= 500 V/cmHalf-life period <= 30 sLeakage resistance <= 10 E9 ohmsVolume resistance <= 10 E10 ohms Abrasionproof and easy to clean with a smooth surface Indentation resistance = 80-100 N/mm²
Technical Data - 5 -
Operating Noise LevelOperating noise level < 55 dB (A)Emission value related to job area
System Configuration - 7 -
RS 232
ETHERNET
OPSVT 100(SERVICE)
TAXI
2x RIP 60
XA20 SpeedwayXA21 Speedway
Herkules -Extension
XB6
XA7 A02
A04
A08/A07
MAC MAC
RS 232
Transport, Packaging, Completeness - 1 -
Herkules must be installed firmly on the transport pallet during transport! Avoidance of condensation:- remove packaging only when the machine has been at the installation site for 24 hours Machine parts:- carefully remove from cardboards- check for transport damages- check for completeness against delivery note
General Notes - 2 -
General Notes
The appliance plug and/or the power outlets of the house installation must be easily accessiblesince the power plug must be pulled to disconnect the machine completely from the power supply, for example, in the case of emergencies. The mains connection is established using the delivered mains cable with the 3-pole plug. The machine may only be operated with the protective conductor connected. The mains connection and the fuses are at the rear of the machine. During installation, it must be ensured that there is sufficient distance between the side panels and the walls or other objects to guarantee an adequate ventilation. The dimensions are to be taken from the installation instructions. During installation, do also observe the notes in the technical data.
Removing the Transport Pallet - 3 -
Wooden screws (1) of the transport safeguard brackets:- remove Bolt (2):- insert into the square tubes Plates (3):- position as shown Screws (4):- screw into the bolts until the machine is raised off the pallet Pallet:- pull out parallel to the axis
Square tube
2
4x
3
4
1 (6x)
5 (4x)
Transportsafeguard bracket
Removing the Transport Pallet - 4 -
Machine feet:- unscrew slightly Screws (4):- unscrew Machine:- is lowered down and stands on the machine feet NOTE:The transport safeguard brackets must not make contact with the floor. Screws (5):- remove Transport safeguard bracket:- remove Machine feet:- insert
Square tube
2
4x
3
4
1 (6x)
5 (4x)
Transportsafeguard bracket
Removing the Transport Pallet - 5 -
Machine:- transport to installation site using the transporting rollers Machine feet:- unscrew until the transporting rollers are relieved Machine:- align in longitudinal and lateral direction (use spirit level) Alignment:- performed by rotating the machine feet NOTE:Store transport safeguard bracket and installation accessories.
Square tube
2
4x
3
4
1 (6x)
5 (4x)
Transportsafeguard bracket
- 6 -Installation Instructions (Advantage Option)
Select installation site according to the following criteria: No direct irradiation of the machine through:- sunlight- radiators installed in the room Do not install machine near air-conditioning equipment! Machine must be protected against humidity at the installation site!
- 7 -Installation Instructions (Advantage Option)
ON-LINE Operation
Side view
NOTE: All dimensions in mm
Transport channel
Recorder OnLine-ProcessorTyp 860
Collecting basket
Supplycassette
940
90
1020
1450
1100
115
760 345850475
25
- 8 -Installation Instructions (Advantage Option)
ON-LINE Operation
Top view
NOTE: All dimensions in mm
200 ca. 140
>700
265
1510
>700
1080
>1000
1230
>700
Film run
Power cablelength: 4 m Cable exit: - OnLine-Interface
- RIP-Interface
Recorder
OnLine-ProcessorTyp 860
>700
(establishshield)
- 9 -Installation Instructions (Advantage Option)
- 10 -Installation Instructions (Advantage Option)
- 11 -Installation Instructions (Advantage Option)
- 12 -Installation Instructions (Advantage Option)
Transport Safeguards - 13 -
Transport safeguards:- Remove only at the final location in the mentioned order!
Transport safeguards are marked with red varnish and/or a red adhesive label.Store removed transport safeguards for transport at a later time (Order No. 04587960).
i
1. Guide Panel and Film Exit Unit3. Spindle Motor
2. Trough
4. Carriage
6. Compr. Air Unit 5. Vacuum Pump
Transport Safeguards - 14 -
Machine cover:- remove Remove cable strap from the axle of the movable holders Foam strips between:- movable holders and guide panel- film exit unit and cast wall must be removed
Interior, Guide Panel and Film Exit UnitAdhesive foam tape
Transport Safeguards - 15 -
Remove the following components:- front cover- rear cover- large covers (right and left)- small covers (right and left)- EMC plates
Trough (left-hand side of machine)
Cover
Large cover
Small covers
Right
Left
Cover
EMC plate
Rear
Front
Transport Safeguards - 16 -
Remove the following components:- lock nuts (1), nuts (2) and washers (3)- screws (4) with strain washers (5)- plates (6)- screw (7) Screws (8) and sealing plates (9):- remove from the bag at the rack Sealing plates (9, 4x):- fasten with four screws (8) each time
4x
76
83
21
945
Transport Safeguards - 17 -
Fixing screws (1):- loosen Plates (2):- slide radially outside NOTE:Follow adjustment instructions on the adhesivelabel (3). Fixing screws (1):- tighten
Spindle Motor (interior)1 (4x)
2
2
3
Transport Safeguards - 18 -
Remove:- nut (1) with washer (2) Lock nut (3):- unscrew Remove screw (4) between spindle nut and hinge. Spacer (5):- remove from carriage
Carriage (interior)
X
1
2
Y
View Y
34
5
Transport Safeguards - 19 -
Carriage:- slide towards the spindle nut Four screws:- remove from the bag at the carriage Spindle nut and hinge:- connect with screws (6)
View X
X
6 (4x)
Transport Safeguards - 20 -
Remove six screws (1) with strainwashers (2).
Vacuum Pump, Base
1, 2 (6x each time)
Transport Safeguards - 21 -
Remove screws (1) with strain washers (2). Brackets (3, 4):- remove Screws (5):- unscrew from the base plate NOTE:The screws are secured with Loctite 222.
Compressed Air Unit, Base
X
View X
1, 2(2x each time)
1, 2(2x each time)
3
4
55
Transport Safeguards - 22 -
Attach covers and EMC plates.
Cover
Large cover
Small covers
Right
Left
Cover
EMC plate
Rear
Front
- 23 -SW Installation / Start-up
Switching on the machines:- Herkules- RIP- MAC(s) Test programs:- start, if necessary NOTE:For start-up and parameter setting, refer to the RIP dcumentation.
Mains Connection - 24 -
Factory settings:- 100, 115, 230 V NOTE:The set voltage is marked on the adhesive label next to the machine's power outlet. If another voltage is set, attach a corresponding label on top of the existing label. CAUTION:If the machine is switched off, the power supply is not interrupted. To separate the machine from the power supply, always pull out the power plug.
General Notes
Mains Connection - 25 -
Power Cables / Connector AdaptationConnection to 230 V: Delivered power cable:- must be used! NOTE:Power cable is designed for 230 V AC. CAUTION:If connections are established using power cables that were not provided by Heidelberg, or if connectors need to be adapted, the national regulations are to be observed. The power cables used in the USA and the Canada must at least be of the SJT type.
Mains Connection - 26 -
RegulationsCountry Connect.voltage
Plug type Cable type
North America125V 15A 110-120V
ANSI C73.11NEMA 5-15-P
IEC 83 Listed, Certified
Type SJT, 14AWG
Connection to 100-127 V AC
Use the following cable:
Mains Connection - 27 -
RegulationsCountry Connect.voltage
Plug type Cable type
North America250V 15A 240V
ANSI C73.20NEMA 6-15-PIEC 83UL 198.6
Listed, CertifiedType SJT, 14AWG
Europe250V 10/16A 230V
CEE(7).II.IV.VIIIEC 83IEC 127
<HAR> H05VV-F
United Kingdom240V 6A 220-240V
B.S. 1363IEC 83IEC 127
<HAR> H05VV-F
Australia240V 10A 240-250V A.S. C112
IEC 127 <HAR> H05VV-F
Connection to 200-240 V AC
Use one of the following cables in accordance with the national requirements:
Mains Connection - 28 -
RegulationsCountry Connect.voltage
Plug type Cable type
North America250V 15A 240V
ANSI C73.20NEMA 6-15-PIEC 83UL 198.6
Listed, CertifiedType SJT, 14AWG
Europe250V 10/16A 230V
CEE(7).II.IV.VIIIEC 83IEC 127
<HAR> H05VV-F
United Kingdom240V 6A 220-240V
B.S. 1363IEC 83IEC 127
<HAR> H05VV-F
Australia240V 10A 240-250V A.S. C112
IEC 127 <HAR> H05VV-F
Connection to 200-240 V AC
Use one of the following cables in accordance with the national requirements:
Mains Connection - 29 -
The cores in the mains lead are colored in accordance with the following codes:- green and yellow: earth- blue: neutral- brown: live Since the colors of the mains lead may not correspond to the colors identifying the terminals in your plug, proceed as follows:- Connect the green and yellow colored core to the terminal in the plug which is marked with the letter "E", or with the earth symbol, or which is colored green and yellow.- Connect the blue colored core to the terminal in the plug which is marked with the letter "N" or which is colored black.- Connect the brown colored core to the terminal in the plug which is marked with the letter "L" or which is colored red.
Note for Installations in the UK
Mains Connection - 30 -
Check by means of the label next to the machine's power outlet whether the machine is prepared for the local voltage. CAUTION:Only connect the mains cable, if the supplied and the preset voltages are identical.
100 V / 115 V / 230 V
Mains Connection - 31 -
Other VoltagesStrapping plug:- plug onto a corresponding jumper (X28...X35) 100 V -> X28 200 V -> X32110 V -> X29 220 V -> X33120 V -> X30 230 V -> X34127 V -> X31 240 V -> X35 Voltages not listed, e.g. 115 V:- select the connector for the next higher voltage (here 120 V -> X30) Plug jumper:- onto X5 (U <= 127 V)- onto X6 (U > 127 V) "LINK 110 V" jumper at the power supply:- plugged (U <= 127 V)- pulled (U > 127 V)
X5
X6
X32
X33
X34
X35
X31
X30
X29
X28
X7
Pcb AC-CONTROLLER (5.950)
Powersupply module
Mains Connection - 32 -
CAUTION:Machine must only be connected to the power supply if the F1 fuse is equipped correctly. F1 fuse:- in the case of U <= 127 V: T 15 A / 250 V- in the case of U > 127 V: T 6.3 A / 250 V NOTE: Fuses have different bayonet joints. Stick the label indicating the set voltage on top of the old one. Label Order No. 230 V 04137655115 V 04258673all other voltages 04258703
Checking Mains Input FuseF1
Label
Fuse F1 Order No.
T 6.3 A 00138215T 15 A 04188713
Cabling - 33 -
MAC
ETHERNET
Herkules
XA3
XB6
Speedway
RS 232
RS 232
RIP 60
MAC
TAXI
A04
A08
XA7
VT 100(SERVICE)
OPS
A02
CAUTION:To comply with the interferenceregulations, only shielded datacables must be used.
Cabling - 34 -
MAC
ETHERNET
Herkules
XA3
XB6
Speedway
RS 232
RS 232
RIP 60
MAC
TAXI
A04
A08
XA7
VT 100(SERVICE)
OPS
A02
Establish the following connections: XA3 pcb RIP-INTERFACE <--> TAXI RIP:- Speedway - pull off rear panel at the upper edge and lift out of lower guide - loosen clamp screw (below the nest) - unhook upper section of clamp - center dismantled cable 20 mm (Speedway) on lower section of clamp - hook upper section of clamp and set screw
Cabling - 35 -
MAC
ETHERNET
Herkules
XA3
XB6
Speedway
RS 232
RS 232
RIP 60
MAC
TAXI
A04
A08
XA7
VT 100(SERVICE)
OPS
A02
Optional OPS link:- XA7 Pcb MATERIAL-CONTROL <--> on-line processor RIP <--> MAC, ETHERNET:- EtherTalk phase 1 or- EtherTalk phase 2 or- TCP / IP RIP <--> MAC:- RS 232 Mains connection to:- RIP- Herkules- MAC
- 1 -Preventive Maintenance / Maintenance Control
It is possible to set and monitor up to 4 time intervals (dates for maintenance work) using the maintenance control.Parameter setting and checking takes place via the Service terminal.Output when reaching a date additionally takes place via the unit terminal. The maintenance control is available as of the following software versions:Herkules Pro 5.01.001
General
- 2 -Preventive Maintenance / Maintenance Control
The maintenance control is available via the Service terminal after password entry.
- Basic menu
1. speedway commands menue2. parameter menue3. test menue ... ... ...j. consumptionk. maintenance control
Machine xx ReleaseVersion: xxxDate: xx xx xx
(ON)(ON)
(ON)
General
PID list:PID 900-"Maintenance control" Off (0) / On (1)PID 901-Maintenance interval 1 (in days)PID 902- „-„ 2PID 903- „-„ 3PID 904- „-„ 4PID 905-Next service date 1 (in days)PID 906- „-„ 2PID 907- „-„ 3PID 908- „-„ 4 NOTEA maximum of 4 maintenance controls can be configured.
ATTENTIONPID 900 = 1 must be set in order to edit the "Maintenance control" menu.
- 3 -Preventive Maintenance / Maintenance Control
Start:- in basic menu Select "Maintenance control". MAINTENANCE CONTROL menu- Display of remaining days until next service- only those intervals are displayed which have been set to greater than 0.
- Basic menu > Maintenance control
1. Service task A is due in 29 days Interval A = 30 days2. Service task B is due in 179 days Interval B = 180 days3. Service task C is due in 359 days Interval C = 360 days4. Service task D is due in 719 days Interval D = 720 days e. set interval valuesq. quit maintenance console
MAINTENANCE CONTROL
to reset a interval counter, select key (1..4)
Start
- 4 -Preventive Maintenance / Maintenance Control
Output (terminal):- Output to the terminal (MAINTENANCE CONTROL menu) when exceeding a maintenance interval (Interval 1)- Intervals 3 and 4 are set to 0.
1. Since 5 days the service task A is overdue Interval A = 30 days2. Service task B is due in 145 days Interval B = 180 days
e. set interval valuesq. quit maintenance console
MAINTENANCE CONTROL
- Basic menu > Maintenance control
to reset a interval counter, select key (1,2)
Output
- 5 -Preventive Maintenance / Maintenance Control
Resetting the maintenance counter:- Enter the number of the corresponding maintenance interval in the MAINTENANCE CONTROL menu. NOTEResetting a higher-level maintenance interval also acknowledges the intervals with shorter periods of time. Respond to the alert message with "No" (n):- the maintenance intervals are output without change Respond to the alert message with "Yes" (y):- the maintenance intervals are output in an updated state- the parameters are stored to floppy disk and in the Touchmemory.
Please confirm, that the service task A has been completely executed.
y / n >
MAINTENANCE CONTROL
- Basic menu - maintenance control > e. set interval values
Reset
- 6 -Preventive Maintenance / Maintenance Control
Parameterizing the maintenance counter:- Press the e key in the MAINTENANCE CONTROL menu (e. set interval values)- Enter the line number to change an interval. Examples:- Set the interval to 90
> Enter line number1
< OutputMaintenace interval 1New Value =
> Enter value and acknowledge90 ENTER
- Set the interval to 720> Enter line number
4 etc...NOTEIntervals are stored in ascending order.0 values are stored after the interval with the highest parameter setting.
- Basic menu - Maintenance control > Reset an interval counter (..)
1. Maintenance interval A = 30 days2. Maintenance interval B = 180 days3. Maintenance interval C = 360 days4. Maintenance interval D = 0 days
q. quit
MAINTENANCE CONTROL
to set a new interval counter, select key(1..4)
Parameterize
- 7 -Preventive Maintenance / Maintenance Control
The MAINTENANCE CONTROL menu is displayed with the new values after changing. NOTEThe changed intervals are displayed with the current status (time since the last reset). ATTENTIONA slight time delay occurs after entering a new value for an interval, as the new value is stored in the Touchmemory and to diskette.
- Basic menu - Maintenance control
MAINTENANCE CONTROL
to reset a interval counter, select key (1..4)
1. Service time A has to become in 89 days Interval A = 90 days2. Service time B has to become in 179 days Interval B = 180 days3. Service time C has to become in 359 days Interval C = 360 days4. Service time D has to become in 720 days Interval D = 720 days e. set interval valuesq. quit maintenance console
Parameterize
Base - 1 -
Nest
Mains Distributor
Compressed Air Unit
Vacuum Unit
Control Unit
Pcb Configuration
Mains Input
Base / Pcb Configuration - 2 -
1
2
3
4
5
A 07
A 02
A 09
A 08
A 04
A 06
A 01
A 03
A 05
with modification 27 or 28
1 04578503 #VOLTAGE-REG - 5.970
2 04860160 #HERK-IF - 2081.524(for machine with mod. 27)
04859987 #HERK-IF - 2081.523(for machines with mod. 28)
3 04122119 #FEED-CONTROL - 5.941
4 05262569 #TOP_MAINCONTROL - 6.276 cpl.
00049356 #FD drive, FD235HF-7529
05241251 #Adapter, FDD - Data
05130247 #Adapter, FDD - power
Base / Nest - 3 -
1
2
34
5
with modification 40
6
E 1
7 (4x)
1 04577698 #H-MOTHERBOARD - 5.949
2 05318483 #Power supply unit
3 04591402 #TOUCH MEMORY 4KX1
4 04595467 #TOUCH MEMORY + TIME
5 04595874 #Fan, axial
6 05356393 #Encoding connector 10 kOhm(Herkules PRO)
05356407 #Encoding connector 6.81 kOhm(Herkules)
7 02133113 #Flex. loc-element
- 4 -Base / Mains Input
1
3
2
4
5*
6* (2x)
* only for 115V
78*
1 04597575 #Bayonet joint (USA/CND, Japan)
04597583 #Bayonet joint (Europe, UK)
2 00138215 #Fuse T 6.3 A (Europe, UK)
04602080 #Fuse T 15 A (USA/CND, Japan)
3 04597567 #Fuse holder
4 04597591Protective cover
5 04745469Bracket
6 02079836Screw - M3x8 DINEN 7045
Base / Mains Distributor - 5 -
1
2
3
10 (2x)
11
9 (2x)
8 (4x)7 (4x)
5 (4x)
6 (4x)
4
1 04575431AC-CONTROL - 5.950
2 04966708Mains filter
3 04720393 #Toroidal transformer, cpl.
4 04555597Transformer, cpl.
5 00146552Nut - M4 DINEN 24032
6 00219991Serrated washer - DI 4.1
7 02288400Washer - DI 6.4 DIN 6796
8 00166375Nut - M6 DINEN 24032
Base / Mains Distributor - 6 -
1
2
3
10 (2x)
11
9 (2x)
8 (4x)7 (4x)
5 (4x)
6 (4x)
4
9 00219991Serrated washer - DI 4.1
10 00160202Screw - M4x6 DIN 912
11 04551540Housing, cpl.
Base / Control Unit - 7 -
12 (2x)
3 (2x)
4
1 04596692 #Control unit for stepping motor
2 00044946Screw - M4x12 DIN 912
3 02288389Washer - DI 4.3 DIN 6796
4 00028004 #Fan
Base / Compressed Air Unit - 8 -
Frame
Compressor
Heat Sink
10
11
4
59
3
8
7 (without item 6)
6 (2x)
with modification 35
1 2
E 2
12
1 04771982 #Line filter - 0.2 µm
2 04857364 #Vacuum hose130 mm long
3 04717015 #Screw connection
4 04772652 #Prefilter - 25 µm
5 05012546Case
6 04716086 #Flex. loc-element
7 05012732 #Filter unit
8 04772660 #Microfilter - 0.1 µm
Base / Compressed Air Unit - 9 -
Frame
Compressor
Heat Sink
10
11
4
59
3
8
7 (without item 6)
6 (2x)
with modification 35
1 2
E 2
12
9 04571347 #Case
10 04307046 #Fan, axial
11 00136603Protective grille
12 04585666 #Compressed air chamber
Base / Compressed Air Unit / Frame - 10 -
1
23
5
6
4
10 (6x)11 (2x)
98
7
12 (4x)
14
13 (4x)
with modification 35
S 11
16 (2x)15
1 04186192 #Compressed air switch
2 00292788 #Gasket
3 04568982Frame, cpl.
4 04718100Collecting tray
5 00292788 #Gasket
6 04771532 #G-quick-fastening attachment
7 04857364 #Vacuum hose60 mm long
8 04717023 #T-plug-in connector
Base / Compressed Air Unit / Frame - 11 -
1
23
5
6
4
10 (6x)11 (2x)
98
7
12 (4x)
14
13 (4x)
with modification 35
S 11
16 (2x)15
9 04857364 #Vacuum hose390 mm long
10 01288148Screw - M4x6
11 02455765Setscrew - M6x35 DIN 916
12 00169498Screw - M3x20 DIN 912
13 04716086 #Flex. loc-element
14 04718194Plate, cpl.
15 05137497 #Splash guard
16 00127787Cable holder
Base / Compressed Air Unit / Heat Sink - 12 -
1 (2x)2 (2x)
3 (2x)
9
7
56 (4x)
4 (2x)
13
11
15 (2x)
21
16 (2x)
17
14
19
13
18
25 (2x)
2417
10
with modification 35
8
22 20
23 (2x)
12
1 00218979Nut - M4 DIN 917
2 02034077 #Pressure spring
3 00055301Washer - DI 4.3 DIN 9021
4 04219597Insulating bushing
5 04587707Insulating sleeve
6 00033605Screw - M3x8 DINEN 7045
7 04975790 #AIR-CONTROL - 6.165
8 05014085 #Temperature sensor, cpl.
Base / Compressed Air Unit / Heat Sink - 13 -
1 (2x)2 (2x)
3 (2x)
9
7
56 (4x)
4 (2x)
13
11
15 (2x)
21
16 (2x)
17
14
19
13
18
25 (2x)
2417
10
with modification 35
8
22 20
23 (2x)
12
9 04766652 #Peltier, cpl.
10 04973755 #Heat sink, cpl.
11 00938297Screw
12 04261976 #Sealing ring
13 04261976 #Sealing ring
14 04218337 #Screw, hollow
15 04219597Insulating bushing
16 00578762Screw - M4x50 DIN 912
Base / Compressed Air Unit / Heat Sink - 14 -
1 (2x)2 (2x)
3 (2x)
9
7
56 (4x)
4 (2x)
13
11
15 (2x)
21
16 (2x)
17
14
19
13
18
25 (2x)
2417
10
with modification 35
8
22 20
23 (2x)
12
17 01876910 #Quick-fatening attachment
18 04857364 #Vacuum hose230 mm long
19 04857364 #Vacuum hose220 mm long
20 05013658 #Magnetic valve
21 04857364 #Vacuum hose200 mm long
22 04857364 #Vacuum hose280 mm long
23 00033605Screw - M3x8 DINEN 7045
Base / Compressed Air Unit / Heat Sink - 15 -
1 (2x)2 (2x)
3 (2x)
9
7
56 (4x)
4 (2x)
13
11
15 (2x)
21
16 (2x)
17
14
19
13
18
25 (2x)
2417
10
with modification 35
8
22 20
23 (2x)
12
24 04662857Heat sink
25 01212729Screw - M4x16
Base / Compressed Air Unit / Compressor - 16 -
1
23 (4x)
8 (4x)
7 (4x)
5 (4x)
6 (4x)
4 (4x)
10 (2x)
11
9
12
with modification 35
13 1 04186206 #Compressor
2 04717007 #W- plug in connector
3 00964727 #Tension spring
4 00636738 #Tension spring
5 00044938Screw - M4x10 DIN 912
6 02288389Washer - DI 4.3 DIN 6796
7 00164909Screw - M4x20 DIN 912
8 02288389Washer - DI 4.3 DIN 6796
Base / Compressed Air Unit / Compressor - 17 -
1
23 (4x)
8 (4x)
7 (4x)
5 (4x)
6 (4x)
4 (4x)
10 (2x)
11
9
12
with modification 35
13 9 04857364 #Vacuum hose330 mm long
10 04179536Bracket
11 04179528Plate
12 04213343 #Piston
13 04204719 #Filter
Base / Vacuum Unit - 18 -
2
1
34
Vacuum Pump 1 01459678 #Compressed air hose580 mm long
2 01459678 #Compressed air hose210 mm long
3 01459678 #Compressed air hose720 mm long
4 04716795 #Non-return valve
Base / Vacuum Unit / Vacuum Pump - 19 -
13 (2x)
11
12 (2x)
10 (6x)9 (6x)
6 (3x)
7 (3x)8 (3x)
2 (3x)
3 (3x)4 (3x)
5 (3x)
1
14
S 1215
1 04596021 #Vacuum pump
2 00166375Nut - M6 DINEN 24032
3 02288400Washer - DI 6.4 DIN 6796
4 00055557Washer - DI 6.4 DIN 9021
5 04722299Bracket
6 04686098 #Shock absorber
7 00055557Washer - DI 6.4 DIN 9021
8 04899822Setscrew - M6x45 DIN 916
Base / Vacuum Unit / Vacuum Pump - 20 -
13 (2x)
11
12 (2x)
10 (6x)9 (6x)
6 (3x)
7 (3x)8 (3x)
2 (3x)
3 (3x)4 (3x)
5 (3x)
1
14
S 1215
9 00139335Screw - M5x8 DIN 912
10 02288397Washer - DI 5.3 DIN 6796
11 04765826 #Valve, cpl.
12 00207098Screw - M4x40 DIN 912
13 02288389Washer - DI 4.3 DIN 6796
14 04204638 #Piston
15 00281166 #Microswitch
Basic Machine (left) - 1 -
Loading Platform
Optics Head
Rotating Mirror Unit
Drive
ECC Carrier
Bottom Punch
Bottom Punch Adapter
Lateral Punch
Basic Machine (right) - 2 -
Top Punch
Punch Adapter
Film Exit Unit
Cutting Device
Loop Switch
Mains, Safety Switch
Basic Machine / ECC Carrier - 3 -
7
1 2 (5x)
3 (8x)4 (8x)
5
6
8
with modification 27
E 5
1 04743482Cover
2 02936038Screw - M4x10
3 00207047Screw - M3x6 DIN 912
4 02288370Washer - DI 3.2 DIN 6796
5 04896904 #EC-CONTR EXT - 6.125
6 04541707ECC carrier
7 04661478 #Cable guide
8 04743490 #Fan
Basic Machine / Drive - 4 -
1
23 (2x)
45
(2)
6
with modification 22
Polling Unit
Pcb MOD. CONNECT
Opto Switch
Stepping Motor
Spindle
Guide Panels
1 02172550 #Rubber buffer
2 04717058 #Bearing unit (SP set)
3 00045047Screw - M6x20 DIN 912
4 04852222 #Flywheel
5 04721659 #Ring, cpl.
6 04847741 #Ball screw
04852419 #Ball screw (Herkules - M)
Basic Machine / Drive / Spindle - 5 -
with modification 21
6
78 9
1 (4x) 34
5
10
2
14 (4x)15
(8)
11 (4x)
13 (2x)
12
1 00044989Screw - M5x16 DIN 912
2 04847741 #Ball screw
04852419 #Ball screw (Herkules - M)
3 04853156 #Flange
4 04772717 #Sliding bearing
5 04793471 #Hose
6 00079936Screw - M3x12 DIN 912
7 04852834 #Bushing, cpl.
Basic Machine / Drive / Spindle - 6 -
with modification 21
6
78 9
1 (4x) 34
5
10
2
14 (4x)15
(8)
11 (4x)
13 (2x)
12
8 04717058 #Bearing unit (SP set)
9 04551885Ring
10 01507133 #Thrust piece, resilient
11 00166790Screw - M6x30 DIN 912
12 04270355Holder
13 02253356 #Pressing screw - M8x12
14 00207314Screw - M5x35 DIN 912
15 04270452Holder
- 7 -Parts Catalog / Basic Machine / Drive / Stepping Motor
1 (4x)2
3 4 5
6
7 (4x)
89
1110
M 8 1 00044946Screw - M4x12 DIN 912
2 04745418 #Stepping motor
3 04721659 #Ring, cpl.
4 00044938Screw - M4x10 DIN 912
5 00409383Thrust piece
6 04212975 #Stop
7 00146552Nut - M4 DINEN 24032
8 04212975 #Stop
Basic Machine / Drive / Pcb MOD. CONNECT - 8 -
1 (4x)
2 (4x)3
1 00044938Screw - M4x10 DIN 912
2 02288389Washer - DI 4.3 DIN 6796
3 04575423 #MODULE CONNECT - 5.952
Basic Machine / Drive / Opto Switch - 9 -
1
2 (2x)3 (2x)
5 (2x)
64 (2x)
B 2
1 02343533 #Opto switch 1
2 00049158Screw - M4x8 DIN 912
3 02288389Washer - DI 4.3 DIN 6796
4 00045039Screw - M6x16 DIN 912
5 04188039Cable clamp
6 04270347Block
Basic Machine / Drive / Polling Unit (MAT-WIDTH I) - 10 -
1 (2x)2 (2x)
34
6 (2x)
5
7 (2x)8 (2x)
910 (2x)
1 00044938Screw - M4x10 DIN 912
2 02288389Washer - DI 4.3 DIN 6796
3 04662261 #Adapter X82-X87
4 04556054Bracket
5 04662342Bracket
6 02288389Washer - DI 4.3 DIN 6796
7 00049158Screw - M4x8 DIN 912
8 02944863Pressure spring
Basic Machine / Drive / Polling Unit (MAT-WIDTH I) - 11 -
1 (2x)2 (2x)
34
6 (2x)
5
7 (2x)8 (2x)
910 (2x)
9 04576497 #MAT-WIDTH I - 6.004
10 00079936Screw - M3x12 DIN 912
Basic Machine / Drive / Polling Unit (MAT-WIDTH II) - 12 -
1 (2x)
2 (2x)
34
6 (2x)5
7 (2x)
1 01288148Screw - M4x6
2 02288389Washer - DI 4.3 DIN 6796
3 04662261 #Adapter X82-X87
4 04764641Bracket
5 04700805 #MAT-WIDTH II - 6.063
6 02288389Washer - DI 4.3 DIN 6796
7 00049158Screw - M4x8 DIN 912
Basic Machine / Drive / Guide Panels - 13 -
for Machines with Lateral Punch
1
2 (2x)3 (2x)
4 (2x)
5
6 (2x)7 (2x)
8 (2x)
9 (6x)10 (3x)11 (6x)
1 04970527 #Guide panel
2 00207381Screw - M4x25 DIN 912
3 00055301Washer - DI 4.3 DIN 9021
4 00602981Pressure spring
5 04971590 #Cover "Bacher"
04971612 #Cover "Stösser"
04719247Cover "customer-specific systems"
6 00602981Pressure spring
Basic Machine / Drive / Guide Panels - 14 -
for Machines with Lateral Punch
1
2 (2x)3 (2x)
4 (2x)
5
6 (2x)7 (2x)
8 (2x)
9 (6x)10 (3x)11 (6x)
7 00055301Washer - DI 4.3 DIN 9021
8 00207381Screw - M4x25 DIN 912
9 00049638Nut - M3 DINEN 24032
10 04971620 #Mount
11 00577014Screw - M3x6 DINEN 7046
Basic Machine / Drive / Guide Panels - 15 -
1 (2x)2 (2x)
3 (2x) 4
65 (2x)
7 (2x)8 (2x)
9 (2x)11 (2x)
10
12
for Machines without Lateral Punch (without modification 25)
1 00207381Screw - M4x25 DIN 912
2 00055301Washer - DI 4.3 DIN 9021
3 00602981Pressure spring
4 04719344 #Guide plate
5 00156566Screw - M4x16 DIN 912
6 04663136Block
7 00602981Pressure spring
8 00055301Washer - DI 4.3 DIN 9021
Basic Machine / Drive / Guide Panels - 16 -
1 (2x)2 (2x)
3 (2x) 4
65 (2x)
7 (2x)8 (2x)
9 (2x)11 (2x)
10
12
for Machines without Lateral Punch (without modification 25)
9 00207381Screw - M4x25 DIN 912
10 04719344 #Guide plate
11 00156566Screw - M4x16 DIN 912
12 04663136Block
Basic Machine / Loading Platform - 17 -
3
5
2 (2x)
4
1 (4x)
2 (2x)
Guide Panels
Stepping MotorRewind Unit
1 04854209Screw - M4x20 DIN 912
2 04258193 #Elastic buffer
3 04552121 #Loading platform, cpl.(for machines without modification 90)
04766725 #Loading platform, cpl.(for machines with modification 90)
4 00094684 #Elastic buffer
5 04585208 #Polling unit
Basic Machine / Loading Platform - 18 -
3
5
2 (2x)
4
1 (4x)
2 (2x)
Guide Panels
Stepping MotorRewind Unit
Basic Machine / Loading Platform / Guide Panels - 19 -
1 (2x)
2 (2x)
4 (5x)6 (5x)
7 (5x)
5 (5x)
3
8
1 04588568 #Guide panel
2 04588657 #Antistatic rail
3 00051209 #Deep-groove ball bearing - DI 6
4 00206903Screw - M3x6 DINEN 7045
5 02288370Washer - DI 3.2 DIN 6796
6 00206903Screw - M3x6 DINEN 7045
7 02288370Washer - DI 3.2 DIN 6796
8 04081226 #Position indicator, cpl.
Basic Machine / Loading Platform / Stepping Motor - 20 -
1
2
3
11 (2x)
5
12 (2x)
10
9
8 (4x)
6 (4x)
7 (4x)4
M 6
1 04270215 #Pin
2 01318403 #Tension spring
3 02594129 #Stepping motor
4 04541014 #Pin
5 04148762 #Spur wheel
6 02080702Screw - M4x12 DIN 965
7 00049921Washer - DI 4.3 DIN 433
8 00146552Nut - M4 DINEN 24032
Basic Machine / Loading Platform / Stepping Motor - 21 -
1
2
3
11 (2x)
5
12 (2x)
10
9
8 (4x)
6 (4x)
7 (4x)4
M 6
9 04538978Bracket
10 00183989Lock washer - DI 6 DIN 6799
11 00213101Setscrew - M4x4 DIN 916
12 00213101Setscrew - M4x4 DIN 916
Basic Machine / Loading Platform / Rewind Unit - 22 -
2 (2x)
1
3
5
6
4
Rewind Motor
1 04685113 #Tension spring
2 01487531Screw - M3x10 DINEN 7045
3 04535367Rewind motor
4 04534301Bushing
5 00166499Lock washer - DI 5 DIN 6799
6 04768302Side panel
Basic Machine / Loading Platform / Rewind Unit / Rewind Motor - 23 -
4
1
2
3 M 5S 4
1 04148568 #Spur wheel
2 04078926 #Gear wheel
3 04186184 #Microswitch
4 04067282 #Motor w. gear unit
Basic Machine / Optics Head - 24 -
4 (4x)
1
3 (4x)2 (4x)
5 (4x)
67, 8
9 (2x)
10
1 04661397 #Optics head, cpl.
2 05000483Knurled screw - M4x35 DIN 653
3 00055301Washer - DI 4.3 DIN 9021
4 04114957Pressure spring
5 04586190Bushing
6 04718275Bracket
7 00049158Screw - M4x8 DIN 912
8 02288389Washer - DI 4.3 DIN 6796
Basic Machine / Optics Head - 25 -
4 (4x)
1
3 (4x)2 (4x)
5 (4x)
67, 8
9 (2x)
10
9 04222768 #Holder
10 04222571 #Plate
Basic Machine / Rotating Mirror Unit - 26 -
4 (4x)
1
3 (4x)2 (4x)
5 (4x)
7 (2x)
6
8
with modification 27
9
1 05126053 #Rotating mirror unit
2 05000483Knurled screw - M4x35 DIN 653
3 00055301Washer - DI 4.3 DIN 9021
4 04114957Pressure spring
5 04586190Bushing
6 04853091Fishplate
7 00044938Screw - M4x10 DIN 912
8 00164909Screw - M4x20 DIN 912
Basic Machine / Rotating Mirror Unit - 27 -
4 (4x)
1
3 (4x)2 (4x)
5 (4x)
7 (2x)
6
8
with modification 27
9
9 04771834 #W-quick fastening attachment
Basic Machine / Trough - 28 -
1
2
3
without modification 90
Y 2
Y 11
1 04244311 #Solenoid
2 04569962 #Retainer
3 00240982 #Tension spring
Basic Machine / Bottom Punch - 29 -
Solenoid, right
Punch Drive
Solenoid, left
Opto Switch
Pressure Rail
Punch Body
Basic Machine / Bottom Punch / Punch Drive - 30 -
1
2 (2x)
3 45
6
8 79 (2x)10 (2x)
11
8
8
M 191 04597443 #Motor with gear unit
2 00044903Screw - M3x10 DIN 912
3 04768493Clamp
4 04768752Eccentric
5 04768566Connecting rod
6 00101028 #Sleeve
7 04768655Pin
8 04883284 #Spare parts set -bottom punch-Customer-specific spare parts set acc. to customer sheet
Basic Machine / Bottom Punch / Punch Drive - 31 -
1
2 (2x)
3 45
6
8 79 (2x)10 (2x)
11
8
8
M 199 00213101Setscrew - M4x4 DIN 916
10 00164909Screw - M4x20 DIN 912
11 04768396Bar
Basic Machine / Bottom Punch / Punch Body - 32 -
1 2
3 4 (6x)
5 (6x)
7 (2x)
6
8 (2x)
13 (4x)
9 (2x)
10
11
12
1 05139597Bracket
2 04772474 #Reflection strip
3 04883284 #Spare parts set -bottom punch-Customer-specific spare parts set acc. to customer sheet
4 00049158Screw - M4x8 DIN 912
5 02288389Washer - DI 4.3 DIN 6796
6 04772474 #Reflection strip
7 00217662Screw - M3x25 DIN 912
Basic Machine / Bottom Punch / Punch Body - 33 -
1 2
3 4 (6x)
5 (6x)
7 (2x)
6
8 (2x)
13 (4x)
9 (2x)
10
11
12
8 00044946Screw - M4x12 DIN 912
9 02288389Washer - DI 4.3 DIN 6796
10 04767985Collecting try
11 02288389Washer - DI 4.3 DIN 6796
12 00044946Screw - M4x12 DIN 912
13 00207098Screw - M4x40 DIN 912
Basic Machine / Bottom Punch / Pressure Rail - 34 -
1
2
3 (2x)
4 (3x)
5 (3x)6
8 (2x)
7
9
10
11 (2x)
1 04768396Bar
2 04722132Plate
3 00183334Screw - M2x4 DINEN 1207
4 04765737Screw - M3x3x3.5
5 00055255Washer - DI 4.3 DIN 125
6 00240982 #Tension spring
7 04765168 #Pressure rail
8 00183334Screw - M2x4 DINEN 1207
Basic Machine / Bottom Punch / Pressure Rail - 35 -
1
2
3 (2x)
4 (3x)
5 (3x)6
8 (2x)
7
9
10
11 (2x)
9 00240982 #Tension spring
10 04722132Plate
11 00184241Straight pin - M6x10 DINEN 22338
Basic Machine / Bottom Punch / Opto Switch - 36 -
1 2 (2x)
34 (2x)
5 (2x)
6
B 19
1 04794028Bracket
2 01288121Screw - M3x6 DIN 965
3 02608588 #Opto switch
4 00391611Washer - DI 2.7 DIN 125
5 01212664Screw - M2.5x6
6 04768396Bar
Basic Machine / Bottom Punch / Solenoid, Left - 37 -
1
2
3
4 (2x)
5 (2x)7 (2x) 68 (2x)
Y 2
1 04244311 #Solenoid
2 00045330Setscrew - M3x4 DIN 916
3 04979834 #Sleeve
4 02288370Washer - DI 3.2 DIN 6796
5 00207047Screw - M3x6 DIN 912
6 04768485Bracket
7 02288389Washer - DI 4.3 DIN 6796
8 00044946Screw - M4x12 DIN 912
Basic Machine / Bottom Punch / Solenoid, Left - 38 -
1
2
3
4 (2x)
5 (2x)7 (2x) 68 (2x)
Y 2
Basic Machine / Bottom Punch / Solenoid, Right - 39 -
1
2
34
5 (2x)
7 (2x)
6 (2x)
8 (2x)
Y 1
1 00045330Setscrew - M3x4 DIN 916
2 04979834 #Sleeve
3 04244311 #Solenoid
4 04768477Bracket
5 02288389Washer - DI 4.3 DIN 6796
6 00044946Screw - M4x12 DIN 912
7 00207047Screw - M3x6 DIN 912
8 02288370Washer - DI 3.2 DIN 6796
Basic Machine / Bottom Punch / Solenoid, Right - 40 -
1
2
34
5 (2x)
7 (2x)
6 (2x)
8 (2x)
Y 1
Basic Machine / Bottom Punch Adapter - 41 -
Solenoid, right
Pressure Rail
Solenoid, left
Basic Machine / Bottom Punch Adapter / Pressure Rail - 42 -
12
3
4 (6x)
5 (6x)6 (2x)
8
7 9
14 (2x)
10 (4x)
11 (4x)
12
13
15 (3x)
16 (3x)18
17
1 04768299Bar
2 05139597Bracket
3 04772474 #Reflection strip
4 02288389Washer - DI 4.3 DIN 6796
5 00049158Screw - M4x8 DIN 912
6 00183334Screw - M2x4 DINEN 1207
7 00240982 #Tension spring
8 04722132Plate
Basic Machine / Bottom Punch Adapter / Pressure Rail - 43 -
12
3
4 (6x)
5 (6x)6 (2x)
8
7 9
14 (2x)
10 (4x)
11 (4x)
12
13
15 (3x)
16 (3x)18
17
9 04765168 #Pressure rail
10 02288389Washer - DI 4.3 DIN 6796
11 00156566Screw - M4x16 DIN 912
12 04767969Carrier
13 04722132Plate
14 00183334Screw - M2x4 DINEN 1207
15 04765737Screw - M3x3x3.5
16 00055255Washer - DI 4.3 DIN 125
Basic Machine / Bottom Punch Adapter / Pressure Rail - 44 -
12
3
4 (6x)
5 (6x)6 (2x)
8
7 9
14 (2x)
10 (4x)
11 (4x)
12
13
15 (3x)
16 (3x)18
17
17 00240982 #Tension spring
18 04772474 #Reflection strip
Basic Machine / Bottom Punch Adapter / Solenoid, Left - 45 -
1
2
3
4 (2x)
5 (2x)7 (2x)6
8 (2x)
Y 2
1 04244311 #Solenoid
2 00045330Setscrew - M3x4 DIN 916
3 04979834 #Sleeve
4 02288370Washer - DI 3.2 DIN 6796
5 00207047Screw - M3x6 DIN 912
6 04768485Bracket
7 02288389Washer - DI 4.3 DIN 6796
8 00044946Screw - M4x12 DIN 912
Basic Machine / Bottom Punch Adapter / Solenoid, Left - 46 -
1
2
3
4 (2x)
5 (2x)7 (2x)6
8 (2x)
Y 2
Basic Machine / Bottom Punch Adapter / Solenoid, Right - 47 -
1
2
3
45 (2x)
7 (2x)
6 (2x)
8 (2x)
Y 1
1 00045330Setscrew - M3x4 DIN 916
2 04979834 #Sleeve
3 04244311 #Solenoid
4 04768477Bracket
5 02288389Washer - DI 4.3 DIN 6796
6 00044946Screw - M4x12 DIN 912
7 00207047Screw - M3x6 DIN 912
8 02288370Washer - DI 3.2 DIN 6796
Basic Machine / Bottom Punch Adapter / Solenoid, Right - 48 -
1
2
3
45 (2x)
7 (2x)
6 (2x)
8 (2x)
Y 1
Basic Machine / Lateral Punch - 49 -
Punch Replacement Parts
2 (2x)1
1
1
2 (2x)
2 (2x)
3 (3x) 1 04718550Punch body
2 00207098Screw - M4x40 DIN 912
3 04715330Screw - M6x55 DIN 912
Basic Machine / Lateral Punch / Punch Replacement Parts - 50 -
5 (2x)
1
6
4 (2x)
6
6
6
2 (2x)3
1 04766520Holder
2 04715381Screw - M3x30 DIN 7984
3 04719182 #Punch head
4 01487825Screw - M4x8 DINEN 7046
5 00167339Screw - M3x16 DIN 7984
6 04882512 #Spare parts set "Bacher"Customer-specific spare parts set acc. to customer sheet
Lateral Punch "Bacher"
Basic Machine / Lateral Punch / Punch Replacement Parts - 51 -
5 (2x)
1
6
4 (2x)
6
6
6
2 (2x)3
Lateral Punch "Stösser"1 04766520Holder
2 04715381Screw - M3x30 DIN 7984
3 04719182 #Punch head
4 01487825Screw - M4x8 DINEN 7046
5 00167339Screw - M3x16 DIN 7984
6 04881710 #Spare parts set "Stösser"Customer-specific spare parts set acc. to customer sheet
- 52 -Parts Catalog / Basic Machine / Cutting Device
1 (2x)
2 (2x)
3 (2x)
4
Drive
Cutting Wheel
Cutting Rail
1 00055301Washer - DI 4.3 DIN 9021
2 00160202Screw - M4x6 DIN 912
3 00049158Screw - M4x8 DIN 912
4 04552040 #Cutting device
Basic Machine / Cutting Device / Drive - 53 -
1
2
3
15
16
17 (4x)
18 (4x)
1112
14
10
9
8
6
7
4 (2x)
5
19
M 4 13
1 04039203Knob
2 04295544 #Toothed belt
3 04081293 #Toothed belt pulley
4 00045292Setscrew - M4x8 DIN 915
5 04081838 #Ring
6 04081633Housing
7 04081226 #Position indicator, cpl.
8 00146552Nut - M4 DINEN 24032
Basic Machine / Cutting Device / Drive - 54 -
1
2
3
15
16
17 (4x)
18 (4x)
1112
14
10
9
8
6
7
4 (2x)
5
19
M 4 13
9 02288389Washer - DI 4.3 DIN 6796
10 04212428Axle
11 04086058Retaining disk
12 01111132 #Deep-groove ball bearing - DI 4
13 04086058Retaining disk
14 00055255Washer - DI 4.3 DIN 125
15 00062847Lock washer - DI 3.2 DIN 6799
16 04237900 #Motor w. gear unit
Basic Machine / Cutting Device / Drive - 55 -
1
2
3
15
16
17 (4x)
18 (4x)
1112
14
10
9
8
6
7
4 (2x)
5
19
M 4 13
17 02288370Washer - DI 3.2 DIN 6796
18 00044903Screw - M3x10 DIN 912
19 00422142 #Magnet
Basic Machine / Cutting Device / Cutting Rail - 56 -
1
2
3 (3x)
13
15
16
17 (6x)
10
1112 (2x)
9
8 (3x)7 (2x)
5
6 (2x)
14 (2x)
4
1819
1 00106178Adhesive label
2 04552210Cassette mount
3 01424238Screw - ST 2.9x13 DIN 7981
4 04534271Bracket
5 00049158Screw - M4x8 DIN 912
6 01424238Screw - ST 2.9x13 DIN 7981
7 01424238Screw - ST 2.9x13 DIN 7981
8 01424238Screw - ST 2.9x13 DIN 7981
Basic Machine / Cutting Device / Cutting Rail - 57 -
1
2
3 (3x)
13
15
16
17 (6x)
10
1112 (2x)
9
8 (3x)7 (2x)
5
6 (2x)
14 (2x)
4
1819
9 00049158Screw - M4x8 DIN 912
10 04552563Bracket
11 04295544 #Toothed belt
12 00051055 #Deep-groove ball bearing - DI 4
13 04551788 #Cutting rail
14 00045292Setscrew - M4x8 DIN 915
15 00226017Straight pin - 8x24 DINEN 22338
16 04551974 #Rail
Basic Machine / Cutting Device / Cutting Rail - 58 -
1
2
3 (3x)
13
15
16
17 (6x)
10
1112 (2x)
9
8 (3x)7 (2x)
5
6 (2x)
14 (2x)
4
1819
17 00049158Screw - M4x8 DIN 912
18 00103837Double-stick tape
19 05181259Gasket
Basic Machine / Cutting Device / Cutting Wheel - 59 -- 59 -
1
2
3
4
567
8
1 04082869 #CUT REED 2 - 5.894
2 04082869 #CUT REED 2 - 5.894
3 04209656Holder
4 00158135Cable holder
5 02079658Screw - M4x6 DINEN 7045
6 04144937 #Cutting wheel, cpl.
7 00055255Washer - DI 4.3 DIN 125
8 00164909Screw - M4x20 DIN 912
Basic Machine / Loop Switch - 60 -
4
1 2
3 (2x)
5 (2x)6 (2x)
S 2
1 04078551Plate
2 04661885Holder
3 00044946Screw - M4x12 DIN 912
4 04595890 #Microswitch, Hall
5 00143472Insulating washer - DI 3.2
6 02080095Screw - M2.5x16 DINEN 7045
Basic Machine / Film Exit Unit - 61 -
2 (10x)1
3 (10x)
4
with modification 32
Control Unit
Stepping Motor
Roller Drive
Gear Unit Motor, Solenoid
Diode HolderBlock
1 04542444 #Film exit unit, cpl.
2 00044946Screw - M4x12 DIN 912
3 02288389Washer - DI 4.3 DIN 6796
4 04847962 #Guide panel
Basic Machine / Film Exit Unit / Diode Holder - 62 -
1
23
45
7
89
10
1112
13 (2x)
1415 (3x)
16
17
18
19
6B 9
1 04766369Screw - M6x30
2 04661192Block
3 00233102Washer - DI 5.2
4 00409383Thrust piece
5 04588274 #Tapped plate
6 04661702 #Diode holder
7 04721594Guide
8 00441759Spacer
Basic Machine / Film Exit Unit / Diode Holder - 63 -
1
23
45
7
89
10
1112
13 (2x)
1415 (3x)
16
17
18
19
6B 9
9 00055352Washer - DI 3.2 DIN 9021
10 01424238Screw - ST 2.9x13 DIN 7981
11 04588703 #Toothed belt pulley
12 00552496 #Toothed belt
13 00206849Setscrew - M4x6 DIN 916
14 04081838 #Ring
15 00233102Washer - DI 5.2
16 00392006 #Deep-groove ball bearing - DI 5
Basic Machine / Film Exit Unit / Diode Holder - 64 -
1
23
45
7
89
10
1112
13 (2x)
1415 (3x)
16
17
18
19
6B 9
17 01359002Spacer
18 04661966 #Threaded rod
19 04661168 #Flat cable
Basic Machine / Film Exit Unit / Roller Drive - 65 -
1
2
34
7
65
810
11 (2x)
9
12
13
14 (2x)15
16
with modification 32
Stepping Motor
1 04542258 #Front guide panel
2 04662059 #Holder
3 00044938Screw - M4x10 DIN 912
4 00055301Washer - DI 4.3 DIN 9021
5 02288389Washer - DI 4.3 DIN 6796
6 00146552Nut - M4 DINEN 24032
7 00166499Lock washer - DI 5 DIN 6799
8 00051209 #Deep-groove ball bearing - DI 6
Basic Machine / Film Exit Unit / Roller Drive - 66 -
1
2
34
7
65
810
11 (2x)
9
12
13
14 (2x)15
16
with modification 32
Stepping Motor
9 04551796 #Roller
10 00051209 #Deep-groove ball bearing - DI 6
11 01212729Screw - M4x16
12 01430211Spacer
13 04081838 #Ring
14 00206849Setscrew - M4x6 DIN 916
15 00552496 #Toothed belt
16 04081293 #Toothed belt pulley
Basic Machine / Film Exit Unit / Roller Drive / Stepping Motor - 67 -
1 (2x)2 (2x)
3 (2x)4 (2x)
5 (2x)
6 (2x)
9
8 (2x)7
14
1012 (2x) 13
(2x)
11
15
16 (5x)
17
M 3
1 00044938Screw - M4x10 DIN 912
2 02288389Washer - DI 4.3 DIN 6796
3 00100811Spacer
4 00055379Washer - DI 5.3 DIN 9021
5 02288389Washer - DI 4.3 DIN 6796
6 00055891Screw - M4x10 DIN 6912
7 02594129 #Stepping motor
8 00206849Setscrew - M4x6 DIN 916
Basic Machine / Film Exit Unit / Roller Drive / Stepping Motor - 68 -
1 (2x)2 (2x)
3 (2x)4 (2x)
5 (2x)
6 (2x)
9
8 (2x)7
14
1012 (2x) 13
(2x)
11
15
16 (5x)
17
M 3
9 04081838 #Ring
10 00552496 #Toothed belt
11 04078373 #Toothed belt pulley
12 01288148Screw - M4x6
13 02288389Washer - DI 4.3 DIN 6796
14 00593745 #Sliding bearing - DI 8
15 04640829Washer
16 04662148 #Roller
Basic Machine / Film Exit Unit / Roller Drive / Stepping Motor - 69 -
1 (2x)2 (2x)
3 (2x)4 (2x)
5 (2x)
6 (2x)
9
8 (2x)7
14
1012 (2x) 13
(2x)
11
15
16 (5x)
17
M 3
17 04765621 #Vibration damper, cpl.
Basic Machine / Film Exit Unit / Control Unit - 70 -
1 (3x)
2 (6x)
3 (2x)4 (2x)
5
8
7
6
9 (5x)
10
S 16
Control Rollers 1, 2, 4
Rear Guide Panel Control Roller 3 1 04574451 #Magnetic lock
2 02079917Screw - M3x4 DINEN 7045
3 02288389Washer - DI 4.3 DIN 6796
4 01288148Screw - M4x6
5 04542517Block
6 00593745 #Sliding bearing - DI 8
7 04640829Washer
8 00099228 #Safety switch
Basic Machine / Film Exit Unit / Control Unit - 71 -
1 (3x)
2 (6x)
3 (2x)4 (2x)
5
8
7
6
9 (5x)
10
S 16
Control Rollers 1, 2, 4
Rear Guide Panel Control Roller 3 9 04662148 #Roller
10 04765621 #Vibration damper, cpl.
Basic Machine / Film Exit Unit / Control Unit / Control Rollers 1, 2, 4 - 72 -
1 (6x)2 (9x)
3 (6x)
4 (6x)5 (3x)
7 (3x)
6 (3x)
9 (3x)
8 (6x)
with modification 32
1 00100064Spacer
2 04587618 #Roller
3 00233064Adjusting washer - DI 5.2
4 00062847Lock washer - DI 3.2 DIN 6799
5 04085256Axle
6 04567927 #Holder
7 00510882 #Pressure spring
8 02080257Screw - M4x8 DIN 965
Basic Machine / Film Exit Unit / Control Unit / Control Rollers 1, 2, 4 - 73 -
1 (6x)2 (9x)
3 (6x)
4 (6x)5 (3x)
7 (3x)
6 (3x)
9 (3x)
8 (6x)
with modification 32
9 04947827 #Block
Basic Machine / Film Exit Unit / Control Unit / Control Roller 3 - 74 -
1 (2x)2 (3x)
3 (2x)
4 (2x)5
87
6
14
1312
11
10
15
9
20
17 (3x)
16
19
18 (3x)
with modification 32
M 14
1 00100064Spacer
2 04587618 #Roller
3 00233064Adjusting washer - DI 5.2
4 00062847Lock washer - DI 3.2 DIN 6799
5 04085256Axle
6 04567927 #Holder
7 00510882 #Pressure spring
8 02080257Screw - M4x8 DIN 965
Basic Machine / Film Exit Unit / Control Unit / Control Roller 3 - 75 -
1 (2x)2 (3x)
3 (2x)
4 (2x)5
87
6
14
1312
11
10
15
9
20
17 (3x)
16
19
18 (3x)
with modification 32
M 14
9 04947827 #Block
10 01338811Screw - M4x16 DINEN 7045
11 00051101 #Deep-groove ball bearing - DI 4
12 00102040Spacer
13 04661893Lever
14 00413216Setscrew - M6x6 DIN 916
15 04067282 #Motor w. gear unit
16 04567242Bracket
Basic Machine / Film Exit Unit / Control Unit / Control Roller 3 - 76 -
1 (2x)2 (3x)
3 (2x)
4 (2x)5
87
6
14
1312
11
10
15
9
20
17 (3x)
16
19
18 (3x)
with modification 32
M 14
17 00391611Washer - DI 2.7 DIN 125
18 00216534Screw - M2x6 DINEN 1207
19 04566459 #Block
20 00206849Setscrew - M4x6 DIN 916
Basic Machine / Film Exit Unit / Control Unit / Rear Guide Panel - 77 -
1
5 (2x)
6
7
8
9 (3x)
11
10 (3x)
2 3
4
1 00146552Nut - M4 DINEN 24032
2 02288389Washer - DI 4.3 DIN 6796
3 05132819Guide
4 01487477Screw - M3x6 DINEN 7045
5 00975427Screw - ST 2.9x6.5 DIN 7982
6 04662881 #Block
7 04767519 #Reflection strip
8 04848306 #Guide panel
Basic Machine / Film Exit Unit / Stepping Motor - 78 -
12 3 4 (3x)
5 (2x)6
9
8
714 (2x)
10 (2x)
12
13
11 M 2
15 (2x)
1 04661966 #Threaded rod
2 01359002Spacer
3 00392006 #Deep-groove ball bearing - DI 5
4 00233102Washer - DI 5.2
5 00206849Setscrew - M4x6 DIN 916
6 04081838 #Ring
7 04588703 #Toothed belt pulley
8 00552496 #Toothed belt
Basic Machine / Film Exit Unit / Stepping Motor - 79 -
12 3 4 (3x)
5 (2x)6
9
8
714 (2x)
10 (2x)
12
13
11 M 2
15 (2x)
9 02034441Spacer
10 00044938Screw - M4x10 DIN 912
11 04586956 #Stepping motor
12 04588703 #Toothed belt pulley
13 04081838 #Ring
14 00206849Setscrew - M4x6 DIN 916
15 00055379Washer - DI 5.3 DIN 9021
Basic Machine / Film Exit Unit / Gear Unit Motor, Solenoid - 80 -
1 (2x) 2 (3x)3 (3x)
4
5
6
8 (2x)
7 (2x)
with modification 32
9Y 10
M 1
1 00206849Setscrew - M4x6 DIN 916
2 00216534Screw - M2x6 DINEN 1207
3 00391611Washer - DI 2.7 DIN 125
4 04067282 #Motor w. gear unit
5 04148568 #Spur wheel
6 04244311 #Solenoid
7 02288370Washer - DI 3.2 DIN 6796
8 00207047Screw - M3x6 DIN 912
Basic Machine / Film Exit Unit / Gear Unit Motor, Solenoid - 81 -
1 (2x) 2 (3x)3 (3x)
4
5
6
8 (2x)
7 (2x)
with modification 32
9Y 10
M 1
9 04662245 #Sleeve
Basic Machine / Film Exit Unit / Block - 82 -
1
2
3 (2x)
1 04662881 #Block
2 04720512Leaf spring
3 00975427Screw - ST 2.9x6.5 DIN 7982
Basic Machine / Top Punch - 83 -
Punch Replacement Parts
Solenoid
Stepping Motor
Left Rollers
Right Rollers
Basic Machine / Top Punch / Solenoid - 84 -
1 (2x)
2 (4x)3 (4x)
4
8 9 (2x)
11
10 (2x)
12 (3x)
13 (3x)
12
14 (2x)
15 (2x)
Y 6Y 8
13
5 (2x) 7
(2x)
6B 17
Right Connecting Rod
1 04244311 #Solenoid
2 00207047Screw - M3x6 DIN 912
3 02288370Washer - DI 3.2 DIN 6796
4 04587251Side panel, cpl.
5 01212664Screw - M2.5x6
6 02608588 #Opto switch
7 00391611Washer - DI 2.7 DIN 125
8 04585305Bracket
Basic Machine / Top Punch / Solenoid - 85 -
1 (2x)
2 (4x)3 (4x)
4
8 9 (2x)
11
10 (2x)
12 (3x)
13 (3x)
12
14 (2x)
15 (2x)
Y 6Y 8
13
5 (2x) 7
(2x)
6B 17
Right Connecting Rod
9 02288389Washer - DI 4.3 DIN 6796
10 00044938Screw - M4x10 DIN 912
11 04721969Spacer hex.
12 02288389Washer - DI 4.3 DIN 6796
13 00044938Screw - M4x10 DIN 912
14 04979834 #Sleeve
15 00045330Setscrew - M3x4 DIN 916
Basic Machine / Top Punch / Solenoid / Right Connecting Rod - 86 -
1
2 34 5
6
8 (2x)7
12
10 (2x)11 (2x)
9
1314
15
1918 (3x)
17 (3x)
16 (3x)
20
22
21
23(13)
24 25
(6)
27
26
M 17
1 00167258Circlip - 8x0.8 DIN 471
2 00232882Washer - DI 8.1
3 02121492 #Sleeve
4 01181041Washer - DI 8.1
5 01763814 #Pin
6 04661257 #Connecting rod
7 04979826Flange
8 00206830Setscrew-M4x10 DIN 916
Basic Machine / Top Punch / Solenoid / Right Connecting Rod - 87 -
1
2 34 5
6
8 (2x)7
12
10 (2x)11 (2x)
9
1314
15
1918 (3x)
17 (3x)
16 (3x)
20
22
21
23(13)
24 25
(6)
27
26
M 17
9 00051578 #Deep-groove ball bearing - DI 10
10 00164909Screw - M4x20 DIN 912
11 02288389Washer - DI 4.3 DIN 6796
12 01764241 #Toothed belt pulley
13 04715535 #Toothed belt
14 04661354Motor plate
15 02121328 #Motor w. gear unit
16 00044938Screw - M4x10 DIN 912
Basic Machine / Top Punch / Solenoid / Right Connecting Rod - 88 -
1
2 34 5
6
8 (2x)7
12
10 (2x)11 (2x)
9
1314
15
1918 (3x)
17 (3x)
16 (3x)
20
22
21
23(13)
24 25
(6)
27
26
M 17
17 02288389Washer - DI 4.3 DIN 6796
18 04722043Spacer, hex.
19 04661265Bearing block
20 00167258Circlip - 8x0.8 DIN 471
21 00232882Washer - DI 8.1
22 02121492 #Sleeve
23 01181041Washer - DI 8.1
24 04720997 #Pin
Basic Machine / Top Punch / Solenoid / Right Connecting Rod - 89 -
1
2 34 5
6
8 (2x)7
12
10 (2x)11 (2x)
9
1314
15
1918 (3x)
17 (3x)
16 (3x)
20
22
21
23(13)
24 25
(6)
27
26
M 17
25 00408557Clamping pin - 2.5x14 DINEN 28752
26 01763652 #Toothed belt pulley
27 04585348Shaft
Basic Machine / Top Punch / Stepping Motor - 90 -
14 (3x)
131 (2x)
2 (4x)
3 (4x)
4 (2x)
5
6
9 (4x)
1012 11
8 (4x)7 (4x)
15 (3x)
16
A
1 (2x)17 (2x)
A
18 (2x)
Y 9
Y 7
M 7
Left Connecting Rod
1 04244311 #Solenoid
2 00207047Screw - M3x6 DIN 912
3 02288370Washer - DI 3.2 DIN 6796
4 00206849Setscrew - M4x6 DIN 916
5 04081838 #Ring
6 04078373 #Toothed belt pulley
7 00044946Screw - M4x12 DIN 912
8 02288389Washer - DI 4.3 DIN 6796
Basic Machine / Top Punch / Stepping Motor - 91 -
14 (3x)
131 (2x)
2 (4x)
3 (4x)
4 (2x)
5
6
9 (4x)
1012 11
8 (4x)7 (4x)
15 (3x)
16
A
1 (2x)17 (2x)
A
18 (2x)
Y 9
Y 7
M 7
Left Connecting Rod
9 00146552Nut - M4 DINEN 24032
10 02594129 #Stepping motor
11 00044938Screw - M4x10 DIN 912
12 02288389Washer - DI 4.3 DIN 6796
13 04721969Spacer hex.
14 02288389Washer - DI 4.3 DIN 6796
15 00044938Screw - M4x10 DIN 912
16 04585534Side panel, cpl.
Basic Machine / Top Punch / Stepping Motor - 92 -
14 (3x)
131 (2x)
2 (4x)
3 (4x)
4 (2x)
5
6
9 (4x)
1012 11
8 (4x)7 (4x)
15 (3x)
16
A
1 (2x)17 (2x)
A
18 (2x)
Y 9
Y 7
M 7
Left Connecting Rod
17 04979834 #Sleeve
18 00045330Setscrew - M3x4 DIN 916
Basic Machine / Top Punch / Stepping Motor / Left Connecting Rod - 93 -
2122
23
1
2
3 (2x)4 (2x)
5 (2x)
87
6 (2x)
9 (2x)
11 (2x)
12
10 (2x)
13 1415
161718
1920
(18)
1 04585348Shaft
2 00164828Circlip - 10x1 DIN 471
3 00164909Screw - M4x20 DIN 912
4 02288389Washer - DI 4.3 DIN 6796
5 02285908Screw - M4x5 DIN 58450
6 00055301Washer - DI 4.3 DIN 9021
7 04661265Bearing block
8 00051578 #Deep-groove ball bearing - DI 10
Basic Machine / Top Punch / Stepping Motor / Left Connecting Rod - 94 -
2122
23
1
2
3 (2x)4 (2x)
5 (2x)
87
6 (2x)
9 (2x)
11 (2x)
12
10 (2x)
13 1415
161718
1920
(18)
9 00055301Washer - DI 4.3 DIN 9021
10 02285908Screw - M4x5 DIN 58450
11 00206830Setscrew-M4x10 DIN 916
12 04979826Flange
13 01763814 #Pin
14 01181041Washer - DI 8.1
15 02121492 #Sleeve
16 00167258Circlip - 8x0.8 DIN 471
Basic Machine / Top Punch / Stepping Motor / Left Connecting Rod - 95 -
2122
23
1
2
3 (2x)4 (2x)
5 (2x)
87
6 (2x)
9 (2x)
11 (2x)
12
10 (2x)
13 1415
161718
1920
(18)
17 00232882Washer - DI 8.1
18 04661257 #Connecting rod
19 00167258Circlip - 8x0.8 DIN 471
20 00232882Washer - DI 8.1
21 02121492 #Sleeve
22 01181041Washer - DI 8.1
23 04720997 #Pin
Basic Machine / Top Punch / Stepping Motor / Left Connecting Rod - 96 -
2122
23
1
2
3 (2x)4 (2x)
5 (2x)
87
6 (2x)
9 (2x)
11 (2x)
12
10 (2x)
13 1415
161718
1920
(18)
Basic Machine / Top Punch / Right Rollers - 97 -
1 (2x)2 3 (2x)
4 5 (2x)6 (4x)
9 (2x)8 (2x)
7 (2x)
1 00166499Lock washer - DI 5 DIN 6799
2 04078918 #Tension spring
3 04084632 #Roller
4 04586271Plate
5 04533534Washer
6 00206849Setscrew - M4x6 DIN 916
7 04148762 #Spur wheel
8 04177398 #Deep-groove ball bearing - DI 7
Basic Machine / Top Punch / Right Rollers - 98 -
1 (2x)2 3 (2x)
4 5 (2x)6 (4x)
9 (2x)8 (2x)
7 (2x)
9 04794060 #Roller
Basic Machine / Top Punch / Left Rollers - 99 -
1 (2x)2 (2x)
3 (2x)
4 56
98
7 (2x)
14
10
1213 (2x) 11 (2x)
1516 (2x)
17 (2x)
18 19 (4x)
20 (3x)
21 (3x)
1 04794060 #Roller
2 00166499Lock washer - DI 5 DIN 6799
3 04177398 #Deep-groove ball bearing - DI 7
4 04588363Tube
5 04081293 #Toothed belt pulley
6 04715527 #Toothed belt
7 00206849Setscrew - M4x6 DIN 916
8 04081838 #Ring
Basic Machine / Top Punch / Left Rollers - 100 -
1 (2x)2 (2x)
3 (2x)
4 56
98
7 (2x)
14
10
1213 (2x) 11 (2x)
1516 (2x)
17 (2x)
18 19 (4x)
20 (3x)
21 (3x)
9 04533410Washer
10 04586271Plate
11 00166499Lock washer - DI 5 DIN 6799
12 04078918 #Tension spring
13 04084632 #Roller
14 04533534Washer
15 04553268Tube
16 00240982 #Tension spring
Basic Machine / Top Punch / Left Rollers - 101 -
1 (2x)2 (2x)
3 (2x)
4 56
98
7 (2x)
14
10
1213 (2x) 11 (2x)
1516 (2x)
17 (2x)
18 19 (4x)
20 (3x)
21 (3x)
17 04722132Plate
18 04765168 #Pressure rail
19 00183334Screw - M2x4 DINEN 1207
20 00055255Washer - DI 4.3 DIN 125
21 04765737Screw - M3x3x3.5
Basic Machine / Top Punch / Punch Replacement Parts - 102 -
1
2
3
4
5
5
55
5
1 00217662Screw - M3x25 DIN 912
2 00217662Screw - M3x25 DIN 912
3 04585054Plate
4 00169498Screw - M3x20 DIN 912
5 Spare parts set (standard)
04851129 # Bacher
04852540 # Stösser
04852370 # LHLTD Customer-specific spare parts set acc. to customer sheet
Basic Machine / Top Punch / Punch Replacement Parts - 103 -
1
2
3
4
5
5
55
5
Basic Machine / Top Punch / Punch Replacement Parts - 104 -
1
2
3
4
5
5
55
5
Basic Machine / Punch Adapter - 105 -
1
Holder
Drive
1 04719581 #Punch adapter
Basic Machine / Punch Adapter / Drive - 106 -
1 (4x)
2 (4x)
3 (2x)4 (2x)
5 (2x)
876 (2x)
13 (2x)
911
12
10
14 (2x)
1516 (2x)
1718
19
20 (2x)
21 (2x)
22 (4x)
23 (3x)
24 (3x)
25
26 27
28
29 (2x)
30 (2x)
Y 9Y 7
Stepping Motor1 00207047Screw - M3x6 DIN 912
2 02288370Washer - DI 3.2 DIN 6796
3 04244311 #Solenoid
4 00045330Setscrew - M3x4 DIN 916
5 04979834 #Sleeve
6 04722280Spacer - 26 mm, size 6
7 04588363Tube
8 04081293 #Toothed belt pulley
Basic Machine / Punch Adapter / Drive - 107 -
1 (4x)
2 (4x)
3 (2x)4 (2x)
5 (2x)
876 (2x)
13 (2x)
911
12
10
14 (2x)
1516 (2x)
1718
19
20 (2x)
21 (2x)
22 (4x)
23 (3x)
24 (3x)
25
26 27
28
29 (2x)
30 (2x)
Y 9Y 7
Stepping Motor9 04715470 #Toothed belt
10 00206849Setscrew - M4x6 DIN 916
11 04081838 #Ring
12 04533410Washer
13 00062847Lock washer - DI 3.2 DIN 6799
14 00166499Lock washer - DI 5 DIN 6799
15 04078918 #Tension spring
16 04084632 #Roller
Basic Machine / Punch Adapter / Drive - 108 -
1 (4x)
2 (4x)
3 (2x)4 (2x)
5 (2x)
876 (2x)
13 (2x)
911
12
10
14 (2x)
1516 (2x)
1718
19
20 (2x)
21 (2x)
22 (4x)
23 (3x)
24 (3x)
25
26 27
28
29 (2x)
30 (2x)
Y 9Y 7
Stepping Motor17 04722124Plate
18 04533534Washer
19 04553268Tube
20 00240982 #Tension spring
21 04722132Plate
22 00183334Screw - M2x4 DINEN 1207
23 04765737Screw - M3x3x3.5
24 00055255Washer - DI 4.3 DIN 125
Basic Machine / Punch Adapter / Drive - 109 -
1 (4x)
2 (4x)
3 (2x)4 (2x)
5 (2x)
876 (2x)
13 (2x)
911
12
10
14 (2x)
1516 (2x)
1718
19
20 (2x)
21 (2x)
22 (4x)
23 (3x)
24 (3x)
25
26 27
28
29 (2x)
30 (2x)
Y 9Y 7
Stepping Motor25 04765168 #Pressure rail
26 01487736Screw - M4x8 DINEN 7045
27 02288389Washer - DI 4.3 DIN 6796
28 04721853Bracket
29 00044946Screw - M4x12 DIN 912
30 02288389Washer - DI 4.3 DIN 6796
Basic Machine / Punch Adapter / Drive / Stepping Motor - 110 -
17 (2x)
13 (4x)
1 2 (6x)3 (6x)
45
6 (2x)
9
10
12 (4x)
11
8 (2x)
7 (2x)18 (2x)
14 (4x)
1516 (2x)
M 7
1 04722205Guide plate
2 01487736Screw - M4x8 DINEN 7045
3 02288389Washer - DI 4.3 DIN 6796
4 04720237Guide plate
5 04720431Side panel, cpl.
6 02288389Washer - DI 4.3 DIN 6796
7 00044938Screw - M4x10 DIN 912
8 00206849Setscrew - M4x6 DIN 916
Basic Machine / Punch Adapter / Drive / Stepping Motor - 111 -
17 (2x)
13 (4x)
1 2 (6x)3 (6x)
45
6 (2x)
9
10
12 (4x)
11
8 (2x)
7 (2x)18 (2x)
14 (4x)
1516 (2x)
M 7
9 04078373 #Toothed belt pulley
10 04715470 #Toothed belt
11 04081838 #Ring
12 00044946Screw - M4x12 DIN 912
13 02288389Washer - DI 4.3 DIN 6796
14 00146552Nut - M4 DINEN 24032
15 02594129 #Stepping motor
16 04177398 #Deep-groove ball bearing - DI 7
Basic Machine / Punch Adapter / Drive / Stepping Motor - 112 -
17 (2x)
13 (4x)
1 2 (6x)3 (6x)
45
6 (2x)
9
10
12 (4x)
11
8 (2x)
7 (2x)18 (2x)
14 (4x)
1516 (2x)
M 7
17 00166499Lock washer - DI 5 DIN 6799
18 04794060 #Roller
Basic Machine / Punch Adapter / Holder - 113 -
1 (2x)2
3 (2x)
4 (2x) 5 (2x)
6 (2x)
1413 (2x)
7 (2x)
8 (2x)9 (2x)10
11 12
Solenoid
1 00166499Lock washer - DI 5 DIN 6799
2 04078918 #Tension spring
3 04084632 #Roller
4 00062847Lock washer - DI 3.2 DIN 6799
5 04722035Spacer - 21.5 mm, size 6
6 00206849Setscrew - M4x6 DIN 916
7 04148762 #Spur wheel
8 00044946Screw - M4x12 DIN 912
Basic Machine / Punch Adapter / Holder - 114 -
1 (2x)2
3 (2x)
4 (2x) 5 (2x)
6 (2x)
1413 (2x)
7 (2x)
8 (2x)9 (2x)10
11 12
Solenoid
9 02288389Washer - DI 4.3 DIN 6796
10 04720881Bracket
11 01487736Screw - M4x8 DINEN 7045
12 02288389Washer - DI 4.3 DIN 6796
13 04533534Washer
14 04722124Plate
Basic Machine / Punch Adapter / Holder / Solenoid - 115 -
1 (2x)
2 (4x)
3 (4x)
4
5
6 (6x)
87 (6x)
9 (2x)
10 (2x)
13 (2x)
14 (2x)
11 (2x)
12 (2x)
Y 8Y 6 1 04244311 #
Solenoid
2 00207047Screw - M3x6 DIN 912
3 02288370Washer - DI 3.2 DIN 6796
4 04720261Side panel
5 04720237Guide plate
6 01487736Screw - M4x8 DINEN 7045
7 02288389Washer - DI 4.3 DIN 6796
8 04722205Guide plate
Basic Machine / Punch Adapter / Holder / Solenoid - 116 -
1 (2x)
2 (4x)
3 (4x)
4
5
6 (6x)
87 (6x)
9 (2x)
10 (2x)
13 (2x)
14 (2x)
11 (2x)
12 (2x)
Y 8Y 6 9 04794060 #
Roller
10 04177398 #Deep-groove ball bearing - DI 7
11 02288389Washer - DI 4.3 DIN 6796
12 00044938Screw - M4x10 DIN 912
13 04979834 #Sleeve
14 00045330Setscrew - M3x4 DIN 916
Basic Machine / Power Switch, Safety Switch - 117 -
1
23
4
S 18
S 14 S 1
S 151 02690764 #Safety switch
2 04313623 #Rocker-type switch
3 02690764 #Safety switch
4 01746073 #Key-operated switch
Supply Cassette - 1 -
CAUTION:This module is equipped with a Lithium battery.Observe Technical Remarks on Safety (chapter "General")!
1
Catch
Reel Holder
Rollers
1 04588282 #Supply cassette withoutreel holder and nut segment
Supply Cassette / Reel Holder - 2 -
1
65
7
8
14
1012
13
11 (2x)
15 (2x)
16
17 (2x) 18
19
2
9
3
4
2021
2223
1 04541332 #Reel holder, PRO
05003008 #Reel holder, offset foil (option)
05108667 #Reel holder, NP (option)
2 04720717 #Gear wheel
3 04541162 #Knurled screw - M5x15
4 04541065 #Cap
5 04686047PT. screw - 3x12
6 04142462 #Nut segment
Supply Cassette / Reel Holder - 3 -
1
65
7
8
14
1012
13
11 (2x)
15 (2x)
16
17 (2x) 18
19
2
9
3
4
2021
2223
7 04080106 #Vibration damper, cpl.
8 04162404Washer - DI 3.2
9 01487396Screw - M3x6 DINEN 7046
10 04586921 #Holder (TOUCH MEMORY)
11 00207985Screw - M4x8 DINEN 1207
12 04142195 #Transmission unit
13 00492302Setscrew-M4x12 DIN 916
14 04148762 #Spur wheel
Supply Cassette / Reel Holder - 4 -
1
65
7
8
14
1012
13
11 (2x)
15 (2x)
16
17 (2x) 18
19
2
9
3
4
2021
2223
15 00213101Setscrew - M4x4 DIN 916
16 04142616 #Bearing
17 04686039PT. screw - 3x10
18 02533871 #Adhesive foam tape
19 04662474Shaped plate
20 00051195 #Deep-groove ball bearing
21 00234397Circlip - 9,3x4 DIN 6799
22 00195677 #Sliding bearing
Supply Cassette / Rollers - 5 -
1
23
4
56 (2x)
9 (2x)
87
14 (2x)
10
12
13
11
15 (2x)
16 (2x)
17
18
1 05181305 #Gasket
2 04553101Guide
3 04588746 #Roller
4 01608959 #Pressure spring
5 02894289Plate
6 04242963Screw - M3x5 DINEN 7045
7 04013999 #Bearing
8 00052973 #Deep-groove ball bearing - DI 6
Supply Cassette / Rollers - 6 -
1
23
4
56 (2x)
9 (2x)
87
14 (2x)
10
12
13
11
15 (2x)
16 (2x)
17
18
9 01700758Screw - M3x12 DINEN 7045
10 04663160 #Roller
11 00052973 #Deep-groove ball bearing - DI 6
12 04013999 #Bearing
13 04148762 #Spur wheel
14 00213101Setscrew - M4x4 DIN 916
15 01700758Screw - M3x12 DINEN 7045
16 04242963Screw - M3x5 DINEN 7045
Supply Cassette / Rollers - 7 -
1
23
4
56 (2x)
9 (2x)
87
14 (2x)
10
12
13
11
15 (2x)
16 (2x)
17
18
17 04084845Segment
18 01608959 #Pressure spring
Supply Cassette / Catch - 8 -
1
2
3 4
1 04270061Catch
2 02288370Washer - DI 3.2 DIN 6796
3 04686039PT. screw - 3x10
4 00055352Washer - DI 3.2 DIN 9021
Supply Cassette (Small) - 9 -
CAUTION:This module is equipped with a Lithium battery.Observe Technical Remarks on Safety (chapter "General")!
1
Catch
Reel Holder
Rollers
1 04793307 #Supply cassette (small)
Supply Cassette (Small) / Reel Holder - 10 -
1
65
7
8
14
1012
13
11 (2x)
15 (2x)
16
17 (2x) 18
19
2
9
3
4
2021
2223
1 04079442 #Reel holder
2 04720717 #Gear wheel
3 04541162 #Knurled screw - M5x15
4 04541065 #Cap
5 01487736Screw - M4x8 DINEN 7045
6 04142462 #Nut segment
7 04080106 #Vibration damper, cpl.
8 04162404Washer - DI 3.2
Supply Cassette (Small) / Reel Holder - 11 -
1
65
7
8
14
1012
13
11 (2x)
15 (2x)
16
17 (2x) 18
19
2
9
3
4
2021
2223
9 01487396Screw - M3x6 DINEN 7046
10 04586921 #Holder (TOUCH MEMORY)
11 00207985Screw - M4x8 DINEN 1207
12 04142195 #Transmission unit
13 00492302Setscrew-M4x12 DIN 916
14 04148762 #Spur wheel
15 00213101Setscrew - M4x4 DIN 916
16 04142616 #Bearing
Supply Cassette (Small) / Reel Holder - 12 -
1
65
7
8
14
1012
13
11 (2x)
15 (2x)
16
17 (2x) 18
19
2
9
3
4
2021
2223
17 04242963Screw - M3x5 DINEN 7045
18 02533871 #Adhesive foam tape
19 04143353Shaped plate
20 00051195 #Deep-groove ball bearing
21 00234397Circlip - 9,3x4 DIN 6799
22 00195677 #Sliding bearing
23 00234397Circlip - 9,3x4 DIN 6799
Supply Cassette (Small) / Rollers - 13 -
1
23
4
56 (2x)
9 (2x)
87
14 (2x)
10
12
13
11
15 (2x)
16 (2x)
17
18
1 05181305 #Gasket
2 04148215Profil
3 04209540 #Roller
4 01608959 #Pressure spring
5 02894289Plate
6 04242963Screw - M3x5 DINEN 7045
7 04013999 #Bearing
8 00052973 #Deep-groove ball bearing - DI 6
Supply Cassette (Small) / Rollers - 14 -
1
23
4
56 (2x)
9 (2x)
87
14 (2x)
10
12
13
11
15 (2x)
16 (2x)
17
18
9 01700758Screw - M3x12 DINEN 7045
10 04086473 #Roller
11 00052973 #Deep-groove ball bearing - DI 6
12 04013999 #Bearing
13 04148762 #Spur wheel
14 00213101Setscrew - M4x4 DIN 916
15 01700758Screw - M3x12 DINEN 7045
16 04242963Screw - M3x5 DINEN 7045
Supply Cassette (Small) / Rollers - 15 -
1
23
4
56 (2x)
9 (2x)
87
14 (2x)
10
12
13
11
15 (2x)
16 (2x)
17
18
17 04084845Segment
18 01608959 #Pressure spring
Supply Cassette / Catch - 16 -
1
2
3 4
1 04270061Catch
2 02288370Washer - DI 3.2 DIN 6796
3 00215139Screw - M3x5 DIN 912
4 01733680Washer - DI 4.3
Supply Cassette (Middle) - 17 -
CAUTION:This module is equipped with a Lithium battery.Observe Technical Remarks on Safety (chapter "General")!
1
Catch
Reel Holder
Rollers
1 04886704 #Supply cassette (middle)
Supply Cassette (Middle) / Reel Holder - 18 -
1
65
7
8
14
1012
13
11 (2x)
15 (2x)
16
17 (2x) 18
19
2
9
3
4
2021
2223
1 04541332 #Reel holder, PRO
2 04720717 #Gear wheel
3 04541162 #Knurled screw - M5x15
4 04541065 #Cap
5 04686047PT. screw - 3x12
6 04142462 #Nut segment
7 04080106 #Vibration damper, cpl.
8 04162404Washer - DI 3.2
Supply Cassette (Middle) / Reel Holder - 19 -
1
65
7
8
14
1012
13
11 (2x)
15 (2x)
16
17 (2x) 18
19
2
9
3
4
2021
2223
9 01487396Screw - M3x6 DINEN 7046
10 04586921 #Holder (TOUCH MEMORY)
11 00207985Screw - M4x8 DINEN 1207
12 04142195 #Transmission unit
13 00492302Setscrew-M4x12 DIN 916
14 04148762 #Spur wheel
15 00213101Setscrew - M4x4 DIN 916
16 04142616 #Bearing
Supply Cassette (Middle) / Reel Holder - 20 -
1
65
7
8
14
1012
13
11 (2x)
15 (2x)
16
17 (2x) 18
19
2
9
3
4
2021
2223
17 04686039PT. screw - 3x10
18 02533871 #Adhesive foam tape
19 04662474Shaped plate
20 00051195 #Deep-groove ball bearing
21 00234397Circlip - 9,3x4 DIN 6799
22 00195677 #Sliding bearing
23 00234397Circlip - 9,3x4 DIN 6799
Supply Cassette (Middle) / Rollers - 21 -
1
23
4
56 (2x)
9 (2x)
8 7
14 (2x)
10
12
13
11
15 (2x)
16 (2x)
17
18
1 04141490 #Gasket
2 04553101Guide
3 04886631 #Roller
4 01608959 #Pressure spring
5 02894289Plate
6 04242963Screw - M3x5 DINEN 7045
7 04013999 #Bearing
8 00052973 #Deep-groove ball bearing - DI 6
Supply Cassette (Middle) / Rollers - 22 -
1
23
4
56 (2x)
9 (2x)
8 7
14 (2x)
10
12
13
11
15 (2x)
16 (2x)
17
18
9 01700758Screw - M3x12 DINEN 7045
10 04663160 #Roller
11 00052973 #Deep-groove ball bearing - DI 6
12 04013999 #Bearing
13 04148762 #Spur wheel
14 00213101Setscrew - M4x4 DIN 916
15 01700758Screw - M3x12 DINEN 7045
16 04242963Screw - M3x5 DINEN 7045
Supply Cassette (Middle) / Rollers - 23 -
1
23
4
56 (2x)
9 (2x)
8 7
14 (2x)
10
12
13
11
15 (2x)
16 (2x)
17
18
17 04084845Segment
18 01608959 #Pressure spring
Supply Cassette / Catch - 24 -
1
2
3 4
1 04270061Catch
2 02288370Washer - DI 3.2 DIN 6796
3 04686039PT. screw - 3x10
Collecting Cassette, Standard - 25 -
1
Cover
Housing
1 04662652 #Collecting cassette
Collecting Cassette / Housing - 26 -
1
2 (4x)
9 (2x)
8 (2x)
7 (2x)5 (2x)
6 (2x)
4 (2x)
13 15
1617
10 (2x)11 (2x)
12 (2x) 14 (2x)
18
19
320
1 04662555 #Reel
2 00213101Setscrew - M4x4 DIN 916
3 04766261 #Foil
4 01615912 #Tension spring
5 00225274Straight pin - 8x12 DINEN 22338
6 00611395Setscrew - M2.5x8 DIN 916
7 04640489Lever
8 00089893Washer - DI 6.1
Collecting Cassette / Housing - 27 -
1
2 (4x)
9 (2x)
8 (2x)
7 (2x)5 (2x)
6 (2x)
4 (2x)
13 15
1617
10 (2x)11 (2x)
12 (2x) 14 (2x)
18
19
320
9 04662792 #Handle
10 00054151Lock washer - DI 4 DIN 6799
11 04771990 #Pressure spring
12 04553055 #Shaft
13 00415790Sliding bearing w. shoulder - DI 6
14 00213101Setscrew - M4x4 DIN 916
15 04722108 #Gear wheel
16 00062847Lock washer - DI 3.2 DIN 6799
Collecting Cassette / Housing - 28 -
1
2 (4x)
9 (2x)
8 (2x)
7 (2x)5 (2x)
6 (2x)
4 (2x)
13 15
1617
10 (2x)11 (2x)
12 (2x) 14 (2x)
18
19
320
17 04586980 #Lock
18 04586891 #Pin
19 04662733Housing
20 05181259Gasket
Collecting Cassette / Cover - 29 -
1 (4x)
2 (4x)
3 (4x)
6 (4x)
4
5 (4x)
1 04640608 #Vibration damper
2 00478091Screw - M4x12 DINEN 7045
3 02288389Washer - DI 4.3 DIN 6796
4 04542304 #Cover
5 04661591 #Roller
6 04640136Block
Collecting Cassette, Middle (NP) - 30 -
1
Cover
Housing
1 05126126 #Collecting cassette, midlle (NP)
Collecting Cassette, Middle (NP) / Housing - 31 -
1
2
3 9
875
6
4
13 15
1617
1011
12 14
18
19
20
1 05126223 #Reel
2 00213101Setscrew - M4x4 DIN 916
3 05126274 #Foil
4 01615912 #Tension spring
5 00225274Straight pin - 8x12 DINEN 22338
6 00611395Setscrew - M2.5x8 DIN 916
7 04640489Lever
8 00991015 #Washer - DI 6.1
Collecting Cassette, Middle (NP) / Housing - 32 -
1
2
3 9
875
6
4
13 15
1617
1011
12 14
18
19
20
9 04662792 #Handle
10 00054151Lock washer - DI 4 DIN 6799
11 04771990 #Pressure spring
12 04553055 #Shaft
13 00415790Sliding bearing w. shoulder - DI 6
14 00213101Setscrew - M4x4 DIN 916
15 04722108 #Gear wheel
16 00062847Lock washer - DI 3.2 DIN 6799
Collecting Cassette, Middle (NP) / Housing - 33 -
1
2
3 9
875
6
4
13 15
1617
1011
12 14
18
19
20
17 04586980 #Lock
18 04586891 #Pin
19 05126134Housing
20 04848934 #Gasket
Collecting Cassette, Middle (NP) / Cover - 34 -
1
2
3
6
4
5
1 04640608 #Vibration damper
2 00478091Screw - M4x12 DINEN 7045
3 02288389Washer - DI 4.3 DIN 6796
4 05006155Cover
5 04661591 #Roller
6 04640136Block
Collecting Cassette, Short - 35 -
1
Cover
Housing
1 04794591 #Collecting cassette, short
Collecting Cassette, Small / Housing - 36 -
1
2 (4x)
39 (2x)
8 (2x)
7 (2x)5
6 (2x)
4
13 15
1617
10 (2x)11 (2x)
12 (2x) 14 (2x)
18
19
20
1 04846915 #Reel
2 00213101Setscrew - M4x4 DIN 916
3 04850416 #Foil
4 01615912 #Tension spring
5 00225274Straight pin - 8x12 DINEN 22338
6 00611395Setscrew - M2.5x8 DIN 916
7 04640489Lever
8 00991015 #Washer - DI 6.1
Collecting Cassette, Small / Housing - 37 -
1
2 (4x)
39 (2x)
8 (2x)
7 (2x)5
6 (2x)
4
13 15
1617
10 (2x)11 (2x)
12 (2x) 14 (2x)
18
19
20
9 04662792 #Handle
10 00054151Lock washer - DI 4 DIN 6799
11 04771990 #Pressure spring
12 04553055 #Shaft
13 00415790Sliding bearing w. shoulder - DI 6
14 00213101Setscrew - M4x4 DIN 916
15 04722108 #Gear wheel
16 00062847Lock washer - DI 3.2 DIN 6799
Collecting Cassette, Small / Housing - 38 -
1
2 (4x)
39 (2x)
8 (2x)
7 (2x)5
6 (2x)
4
13 15
1617
10 (2x)11 (2x)
12 (2x) 14 (2x)
18
19
20
17 04586980 #Lock
18 04586891 #Pin
19 04847253Housing
20 05181259Gasket
Collecting Cassette, Small / Cover - 39 -
1 (3x)
2 (3x)
3 (3x)
6 (3x)
4
5 (3x)
1 04640608 #Vibration damper
2 00478091Screw - M4x12 DINEN 7045
3 02288389Washer - DI 4.3 DIN 6796
4 04848942 #Cover
5 04661591 #Roller
6 04640136Block
- 1 -Barcode Reader Pen
Supply cassette flap open
1
2
1 04908872 #Barcode reader pen
2 04904605 #Cable, Advantage
Covers - 2 -
12 (2x)
45
3
6
7
8
A
11
109
A
1 04541529 #Cover
2 02339587Hinge
3 04244184 #Operating panel
4 04585917Front cover
5 04556356 #Signal lamp, cpl.
04596773 #Lamp - 28V 40MA
6 04991729 #Flap, cpl.
7 04768361 #Gas spring
Covers - 3 -
12 (2x)
45
3
6
7
8
A
11
109
A
8 05116155 #Cover
9 04574451 #Magnetic lock
10 04662059 #Holder
11 04640039 #Flap
Side Panels - 4 -
1 2 3
98
7
5
6
4
10
11
12
13 (4x)
14 (2x)
Mount
E 3E 4
15 (4x)16 (4x)
1 04775015 #Panel
2 04640330 #Panel
3 04556585 #Panel
4 04557298 #Panel
5 00440191 #Locking pin
6 04640446 #Panel
7 04557476 #Panel
8 04557557 #Panel
Side Panels - 5 -
1 2 3
98
7
5
6
4
10
11
12
13 (4x)
14 (2x)
Mount
E 3E 4
15 (4x)16 (4x)
9 04640330 #Panel
10 01700677 #Lock
11 04555953Front cover
12 04643291 #EMC plate
13 01927965 #Lock
14 04597451 #Fan, axial
15 04138589 #Roller
16 02968754 #Machine foot
Side Panels / Mount - 6 -
2 (5x)
1
4 (8x)3 (5x)
5 (8x)
1 04551532 #Mount
2 02115387Screw - M4x6 DINEN 7046
3 00220345Washer - DI 5
4 02115387Screw - M4x6 DINEN 7046
5 00220345Washer - DI 5
Parts Catalog / Overview - 1 -
Side Panels
Covers
Base
=>marked items are described in the Removal, Installation and Adjustment Instructions.
Basic Machine (right)Basic Machine (left)
Supply Cassette
Barcode Reader Pen
Collecting Cassette
- 2 -Notes on Parts Catalog
Further information on spare parts can be obtained from:
Siemenswall24107 KielGermany
Telephone (0431) 386-0Telefax (0431) 386-1502
Heidelberger DruckmaschinenAktiengesellschaft
Spare parts which are available for delivery are markedwith #.Certain parts not inlcuded in the classification system also appear in these lists, e.g. parts required for mounting, parts belonging to the vicinity of spare parts. If necessary, we also deliver spare parts not included in the spare parts program when to do so- is technically acceptable and- does not adversely affect the quality assurance after reviewing description of fault. For parts not represented the following specifications are required:- machine type / model / system component- locality in machine / in machine component / in module- documentation reference number(s)- further features / special features (e.g. combinations of numbers / letters)
- 3 -Notes on Parts Catalog
Further information on spare parts can be obtained from:
Siemenswall24107 KielGermany
Telephone (0431) 386-0Telefax (0431) 386-1502
Heidelberger DruckmaschinenAktiengesellschaft
Parts manufactured for Heidelberger Druckmaschinen Aktiengesellschaft, if not covered in the documentation provided by Heidelberger Druckmaschinen Aktiengesellschaft, can be found in the manufacturer's documentation. Spare parts must be ordered exclusively from
Heidelberger Druckmaschinen AktiengesellschaftCustomer Support Logistics (CSL)
if not, overall warranty and quality assurance are invalid.
- 1 -Preventive Maintenance / Maintenance Intervals
After every service, check the safety loop for proper funcitoning!
Check List
Maintenance Control
If required (by the customer)- Cleaning trough and loading platform- Cleaning the rubber rollers of the supply cassette; monthly When using photo material with a thickness of 0.18 mm; weekly- Cleaning the dust collecting roller of the supply cassette (option)- Cleaning the rubber rings of the collecting cassette; monthly
- 2 -Preventive Maintenance / Maintenance Intervals
After every service, check the safety loop for proper funcitoning!
Check List
Maintenance Control
Quarterly (by the service department)- Starting the test programs- Checking the compressed air, peltier control, drain valve- Cleaning trough, loading platform and interior- Cleaning the collecting trays for punching waste- Cleaning the rubber rollers of the supply cassette- Cleaning the dust collecting roller of the supply cassette (option)- Cleaning the rubber rings of the collecting cassette- Cleaning the rubber rollers- Checking the voltages- Test exposure
- 3 -Preventive Maintenance / Maintenance Intervals
After every service, check the safety loop for proper funcitoning!
Check List
Maintenance Control
Half-yearly (by the service department)- Starting the test programs- Checking the compressed air, peltier control, drain valve - Cleaning trough, loading platform and interior- Cleaning the collecting trays for punching waste- Cleaning the rubber rollers of the supply cassette- Cleaning the dust collecting roller of the supply cassette (option)- Cleaning the rubber rings of the collecting cassette- Cleaning the rubber rollers- Cleaning the prefilter case- Exchanging the compressor (after approx. 5000 operating hours)- Exchanging the line filter of the compressed air unit - Checking the voltages- Test exposure
- 4 -Preventive Maintenance / Maintenance Intervals
After every service, check the safety loop for proper funcitoning!
Check List
Maintenance Control
Yearly (by the service department)- Starting the test programs- Checking the compressed air, peltier control, drain valve - Checking the elastic buffers (Loading platform)- Checking the pressure rail (Bottom punch adapter)- Cleaning trough, loading platform and interior- Cleaning the collecting trays for punching waste- Cleaning the rubber rollers of the supply cassette- Cleaning the dust collecting roller of the supply cassette (option)- Cleaning the rubber rings of the collecting cassette- Cleaning the rubber rollers- Cleaning the foam and textile rollers- Clean mirror motor and optics (checking the geometry)- Exchanging the compressor (after approx. 5000 operating hours)- Exchange all filters in the compressed air unit - Checking the voltages- Test exposure
- 5 -Preventive Maintenance / Cleaning
Front panel
Flap (left)
Protective plate
Switch off machine, pull out power plug. Open (left) flap. Remove supply cassette. Remove front panel by pulling it out (direction of the arrow). Remove protective plate (loosen bayonet joints by turning through 90 degrees).
Trough, Loading Platform ans Interior
- 6 -Preventive Maintenance / Cleaning
TroughCollecting tray
CAUTION:Only use vacuum cleaner with plastic nozzle, otherwise, surface damages of the trough and/or spindle are possible. Clean trough and loading platform using a vacuum cleaner. Attach protective plate in such a way that the safety switch is actuated. Lock protective plate (lock bayonet joints by turning through 90 degree) in position. Insert front panel in guide and press it against themachine until it engages. Insert supply cassette. Close flap (left).
Trough, Loading Platform ans Interior
- 7 -Preventive Maintenance / Cleaning
Side panel
Protective plate
Stubs
Switch off the machine, pull out the power plug. Pull off right-hand side panel at the upper edge and lift out of the lower guide. Loosen screws of the protective plate (but do not unscrew), slide protective plate upwards a little and remove it. Use a vacuum cleaner to remove the punching waste from the 3 stubs. Hook protective plate into the screws, tighten screws. Insert right-hand side panel in lower guide and press against the machine until it engages.
Top Punch
- 8 -Preventive Maintenance / Cleaning
Front panel
Flap (left)
TroughCollecting tray
Switch off machine, pull out power plug. Remove front panel. Loosen bayonet joints of the protective plate by turning through 90 degrees. Remove protective plate. Use vacuum cleaner to remove the punching waste from the collecting tray. CAUTION:Do not damage cable leading to the punch heads Attach protective plate in such a way that the safety switch is actuated. Lock protective plate in position (lock bayonet joint by turning through 90 degrees)
Lateral Punch
Protective plate
- 9 -Preventive Maintenance / Cleaning
Front panel
Flap (left)
TroughCollecting tray
Insert front panel in guide and press against the machine until it engages.
Lateral Punch
Protective plate
- 10 -Preventive Maintenance / Cleaning
Side panelProtective plate
Pull off left-hand side panel at the upper edge andlift out of the lower guide. Loosen screws of the protective plate (but do not unscrew). Slide protective plate upwards a little and removeit. Use a vacuum cleaner to remove the punching waste from the stub. Hook protective plate into the screws, tighten screws. Insert left-hand side panel in the lower guide and press against the machine until it engages.
Bottom Punch
- 11 -Preventive Maintenance / Cleaning
1
2
3 (2x)4
3 (2x)5
Take the supply cassette out of themachine and open it. Clean rubber rollers [1] and [2] witha damp cloth (cleaner's naphtha).
Rubber rollers (supply cassette)
- 12 -Preventive Maintenance / Cleaning
1
2
3 (2x)4
3 (2x)5
NOTE:To clean the dust collecting roller, remove it from the cassette! Take the supply cassette out of themachine and open it. Unscrew screws [3]. Mount segment [4] and plate [5]. Remove the dust collecting roller from the supply cassette und cleanit under running water. Allow dust collecting roller to air-dry.
Dust collecting roller (option)
- 13 -Preventive Maintenance / Cleaning
1
2
3 (2x)4
3 (2x)5
CAUTION:Install dust collecting roller only if it is dry! Insert the dust collecting roller intothe supply cassette. Mount segment [4] and plate [5] and fasten with screws [3].
Dust collecting roller (option)
- 14 -Preventive Maintenance / Cleaning
Rubber ring
Reel
Clean the rubber rings on the collecting cassette reel if photo material with a thickness of 0.18 mm is used. Open flap, remove and open collecting cassette. Clean rubber rings with a cloth soaked in methylated spirit. When doing so, turn reel manually. Close collecting cassette and insert it. Close flap.
Rubber Rings (collecting cassette)
- 15 -Preventive Maintenance / Cleaning
Flap (right)
Flap (left)
Switch off machine, pull out power plug. Remove flap (right).
Rubber Rollers
- 16 -Preventive Maintenance / Cleaning
Control rollers (4x)Roller
5 rubber rollers in the film exit unit (4 x short = control rollers, 1 x long = roller) Clean rubber rollers with a cloth soaked in methylated spirit. When doing so, turn rollers manually. Close flap.
Rubber Rollers
- 17 -Preventive Maintenance / Cleaning
Flap (right)
Flap (left)
Supply cassette: Switch off machine, pull out power plug. Open flap (left), remove supply cassette and openit. Clean foam and/or textile rollers using a brush. Close and insert supply cassette. Close flap (left).
Foam and Textile Rollers
- 18 -Preventive Maintenance / Cleaning
Flap (right)
Flap (left)
Trough exit: Open flaps. Remove film exit unit and cutting device. (T1) Clean foam and/or textile rollers using a brush. Install film exit unit and cutting device. (T2) Close flaps.
Foam and Textile Rollers
- 19 -Preventive Maintenance / Cleaning
Remove filter unit. (T1) Unscrew filter case. Clean filter case in the area of the sensors. Screw on filter case. Install the filter unit. (T2)
Prefilter case
Compressed air filter
- 20 -Preventive Maintenance / Checking and Exchanging
The failure rate of the compressor increases afterapprox. 5000 operating hours.There is no indication of a failure in advance and thus results in a machine standstill. If the compressor has more than 5000 h (according to elapsed time meter), it should be exchanged. CAUTION:For quality analyses, the operating time of the exchanged compressor is required.Note the operating time on the return form.
Compressor
- 21 -Preventive Maintenance / Checking and Exchanging
Pull the hoses off the line filter. Exchange line filter. CAUTION:Observe installation position! Fit hoses.
Line filtersLine filterPull the hoses off the line filter. Exchange line filter. CAUTION:Observe installation position! Fit hoses.
Line filtersLine filter
- 22 -Preventive Maintenance / Checking and Exchanging
EMC plate
Front panel
Switch off machine, pull out power plug. Remove front panel by pulling it out (direction of the arrow). Remove EMC plate. The filter inserts of the following units must be exchanged: - line filter - prefilter (25 µm) - submicrofilter (0.01 µm) - compressor
Replacement of all filter inserts in the compressed air unit
- 23 -Preventive Maintenance / Checking and Exchanging
Pull the hoses off the line filter. Exchange line filter. CAUTION:Observe installation position! Fit hoses.
Line filtersLine filter
- 24 -Preventive Maintenance / Checking and Exchanging
Remove filter unit. (T1) Unscrew filter case. Disassemble filter element and exchange filter. Assemble filter element and screw in. Clean filter case in the area of the sensors. Screw on filter case. Install the filter unit. (T2)
Prefilter (25 µm)
Prefilter
- 25 -Preventive Maintenance / Checking and Exchanging
Unscrew case of the submicrofilter (0.01 µm). Exchange filter element. Clean and screw on case of the submicrofilter.
Submicrofilter (0.01 µm)
Submicrofilter
- 26 -Preventive Maintenance / Checking and Exchanging
Screw
Cover
Remove screw and washer. Remove cover. Exchange filter element (in the cover). Insert O-ring into the groove if necessary. CAUTION:Observe that the O-ring is correctly positioned! Mount cover and lock in position with screw.
Compressor
- 27 -Preventive Maintenance / Checking and Exchanging
1 (2x)
3
1 (2x)
31 (2x) 1 (2x)
620 mm
2
2 4
4
Check the condition and position of the elastic buffers [1] and [3]. The outer elastic buffers [1] must adhere to the profile [2], flush with the front and outside edges. The inner elastic buffers must be flush with the front and adjacent to the outer buffers. NOTE:If there is only one elastic buffer at each side, these must be removed!Two buffers must then be adhered to each side! The elastic buffer [3] must be flush with the rear edge of the guide plate [4] and 620 mm from the right-hand side.
Elastic buffer
- 28 -Preventive Maintenance / Checking and Exchanging
1
2
4 (3x)
3
Check that the fastening screws [4]sit firmly: Remove the bottom punch pdapter.[T1] Tighten the fastening screws [4]. Grease the slots for the pressure rail [1] and the screw shafts [4] with Arconal L78. Remove excess grease. Check the functionality of the pressure rail. Install the bottom punch pdapter. [T2]
Pressure rail, bottom punch adapter
- 29 -Preventive Maintenance / Checking and Exchanging
Test Exposure
Following the yearly maintenance, perform a test exposure. See operating manual RIP 50 or RIP 60.
- 30 -Preventive Maintenance / Checking and Exchanging
Check the Safety Loop
Switch on the machine and let it run up to operating speed. Move the carriage (material must not be loaded)- Press the following keys at the operating panel: The carriage must stop, when- opening the right-hand flap OR- removing the protective plate. The carriage must continue moving, when- the protective plate is returned AND- the right-hand flap is closed.
or
Front panelProtective plate
Flap (right)
- 1 -Removal, Installation, Adjustment
Input / Side Panels
Output
Exposure Unit
Punches (Option)
Lower Section
Prior to all service work:- switch off machine- pull out power plug NOTE:Before beginning the service work,remove corresponding side panels and EMC plates in accordance withmenu item "Side Panels". SAFETY LOOP:Upon completion of repair work, the safety loop function is to be checked by opening the dust cover!Check the protective covers for completeness while reassembling them and make sure that they show no cracks or other damage.
When performing service work to the upper section:Protect the trough against damage!
- 2 -Removal, Installation, Adjustment / Cable Guide
X78X77
X72, X79, X84, X85, X86
XA4
X58, X59, X69
1
Removal, Cable Guide
ECC carrier (1):- move to the middle of the machine- unscrew and remove cover Disconnect electrical connections:- pull coaxial connectors X77 and X78 off optics head- pull coaxial connectors X72 and X79 off pcb EC-CONTR.- pull flat cables X84, X85 and X86 off pcb EC-CONTR.- unscrew ground cable- pull coaxial connector XA4 off pcb RIP INTERFACE or HERK-IF (slot A08)- pull flat cables X58, X59 and X69 off pcb MODUL-CONNECT
- 3 -Removal, Installation, Adjustment / Cable Guide
1
4
2
3
XA4
X
View "X"
NOTE:The following work must be carried out in order to dismount the coaxial cable XA4 and the air hose. Coaxial cable:- unscrew nest (2) and pull it out for approx. 5 cm- open cable strap at cable duct (4)- remove bracket of cable duct (4)- pull coaxial cable (3) through cable duct (4) upwards Air hose:- loosen hose at compressed air unit (1)- pull hose through cable duct (4) upwards
- 4 -Removal, Installation, Adjustment / Cable Guide
1 2 (2x) 3
5
4 (2x)
6
X
View X
View Y
7
Y8 (2x)
Retainer (3):- remove screws (2)- remove retainer Flat cables (1):- tilt to the side CAUTION:During the following work, make sure that the tapped plate (5) does not fall down. Cable guide (7):- open cable strap (8)- remove screws (4, 6)- remove cable guide
- 5 -Removal, Installation, Adjustment / Cable Guide
1
2 (2x) 3
5
4 (2x)
6
Marking
X
View X
View Y
7
Y8 (2x)
Installation, Cable Guide
Cable guide (7):- insert in machine- screw screws (4) into tapped plate (5) and tighten- screw in and tighten screw (6)- attach cable strap (8) CAUTION:During the following step, align the flat cable in such a way that the marking of the flat cable coincides with the edge of the retainer! Retainer (3):- screw on loosely using screws (2)- align flat cable (1)- tighten retainer
- 6 -Removal, Installation, Adjustment / Cable Guide
1
4
2
3
XA4
X
View "X"
NOTE:The following work must be carried out in order to install the coaxial cable XA4 and the air hose. Air hose:- pull down hose through cable duct (4)- connect hose to compressed air unit (1) Coaxial cable:- pull down (3) through cable duct (4)- screw on bracket of cable duct (4)- attach cable strap to cable duct (4)- insert and screw on nest (2) CAUTION:After assembly, make sure that the cable duct is light-proof!
- 7 -Removal, Installation, Adjustment / Cable Guide
X78X77
X72, X79, X84, X85, X86
XA4
X58, X59, X69
1
Establish electrical connections:- plug flat cables X58, X59 and X69 onto pcb MODUL-CONNECT- plug coaxial connector XA4 onto pcb RIP INTERFACE or HERK-IF (slot A08)- screw on ground cable- plug flat cables X84, X85 and X86 onto pcb EC-CONTR.- plug coaxial connectors X72 and X79 onto pcb EC-CONTR.- plug coaxial connectors X77 and X78 onto optics head ECC carrier (1):- screw on cover
- 8 -Removal, Installation, Adjustment / Optics Head
A
B
C
X78X77
X74
2 1
5
6
X83
3
4
Optics Head RemovalCut cable straps A, B and C. Unscrew and remove cover [1] of ECC carrier [2]. Unscrew bracket [6]. Pull connectors X74, X77 and X78 off the optics head [5]. Pull X83 connector off pcb EC-CONTR.
- 9 -Removal, Installation, Adjustment / Optics Head
8 (4x)
5
7
9 (4x)
11
10 3
4
The laser diode must never be operated if the optics head is removed!
Loosen screws [4] and pull bracket [3] off the optics head. CAUTION:During the following work, make sure that the optics head [5] cannot fall down. Loosen screws [8] (do not unscrew). Lower the plate [7] until the optics head [5] can be moved. Remove the optics head from the machine.
Optics Head Removal
- 10 -Removal, Installation, Adjustment / Optics Head
8 (4x)
5
7
9 (4x)
11
10 3
4
The laser diode must never be operated if the optics head is removed! Optics Head Installation
CAUTION:Prior to installation, note down the value for I (max) which is shown on the optics head! Insert optics head [5] in the holder [10] and slide it up to the stop. CAUTION:The straight pin [11] of the optics head must be positioned in the guide groove of thecarrier! Tighten screws [8] until the optics head is securely positioned in the prism of the carrier. CAUTION:The bushings [9] (4x) must be positioned in the bore holes of the plate [7]. Press the bracket [3] onto the optics head and tighten screws [4].
- 11 -Removal, Installation, Adjustment / Optics Head
A
B
C
X78X77
X74
2 1
5
6
X83
3
4
Connect connector X74, X77 and X78 to the optics head. Connect connector X83 to pcb EC-CONTR. Attach cable straps A, B and C and tighten manually. CAUTION:Fasten coaxial cable in such a way that it is squeezed when the exposure unit moves. Screw on plate [6] (do not squeeze cable) Screw cover [1] onto ECC carrier [2]. Perform parameter set-up.
Optics Head Installation
- 12 -Removal, Installation, Adjustment / Rotating Mirror Unit
3
2
1
X71
4
5 (4x)
6
7
9
8
10 (2x)
6
11
Rotating Mirror Unit RemovalPull off connector X71. Pull off air duct [3]. Loosen stop screw [9]. Turn out screws [10] and remove fishplate [8]. CAUTION:During the following work, make sure that the rotating mirror unit [2] cannot fall down. Loosen screws [5] (do not unscrew). Lower plate [4] until the rotating mirror unit [2] can be moved. Remove the rotating mirror unit [2] from the machine. Remove straight pin [7].
- 13 -Removal, Installation, Adjustment / Rotating Mirror Unit
3
2
1
X71
4
5 (4x)
6
7
9
8
10 (2x)
6
11
Rotating Mirror Unit InstallationScrew in straight pin [7]. Insert rotating mirror unit [2] in the holder [6] and slide it up to the stop. CAUTION:The straight pin [7] of the rotating mirror unit must be positioned in the guide groove of the carrier [1]! Tighten screws [5] until rotating mirror unit is securely positioned in the prism of the carrier. CAUTION:The bushings [11] (4x) must be positioned in the bore holes of the plate [4]. Fasten fishplate [8] onto the carrier using screws.
- 14 -Removal, Installation, Adjustment / Rotating Mirror Unit
3
2
1
X71
4
5 (4x)
6
7
9
8
10 (2x)
6
11
Rotating Mirror Unit InstallationTighten stop screw [9] to a torque of 0.1 Nm. Fit connector X71. Fit air duct [3].
- 15 -Removal, Installation, Adjustment / Stepping Motor
4
8
1
2
3
M 8
Stepping Motor RemovalRemove covers and coverings. (T1) Remove transport safeguard [1] and distance plate [2].
- 16 -Removal, Installation, Adjustment / Stepping Motor
3
4
7
6 (4x)
8
5 6
9 (4x)
11
12
M 8
10
13 (2x)14
View X5
X
CAUTION:Do no loosen stopper [8 and 10] fixing screws [6 and 12]! Pull connector X143 off stepping motor. Loosen screws [13] until the ring [5] no longer jams the spindle end [14]. Pull the stepping motor [3] out of the spindle end [14] and stoppers [8 and 10]. Remove screws [6]. Remove lever [4] from stepping motor [3].
Stepping Motor Removal
- 17 -Removal, Installation, Adjustment / Stepping Motor
3
4
7
6 (4x)
8
5 6
9 (4x)
11
12
M 8
10
13 (2x)14
View X5
X
Y
0.5 mm
View Y
48 or10
Stepping Motor InstallationCAUTION:Do no loosen stopper [8 and 10] fixing screws [6 and 12]!Turn spindle [14] so that the spindle slot is in vertical position! Fasten lever [4] onto stepping motor [3] using screws, but do not tighten screws [6]. Place stepping motor with lever into the spindle end [14] and stoppers [8 and 10]. Tighten screws [6]. Set a distance of 0.5 mm between lever [4] and stopper [8 or 10] (View Y).
- 18 -Removal, Installation, Adjustment / Stepping Motor
3
4
7
6 (4x)
8
5 6
9 (4x)
11
12
M 8
10
13 (2x)14
View X5
X
Turn ring [5] until the ring slot is at an angle of 90° to the spindle slot. Tighten screw [13].
Stepping Motor Installation
- 19 -Removal, Installation, Adjustment / Stepping Motor
4
8
1
2
3
M 8
Mount distance plate [2] and transport safeguards [1]. Fit connector X143 onto stepping motor. Mount covers and coverings.
Stepping Motor Installation
- 20 -Removal, Installation, Adjustment / Flywheel
4
23
1
Flywheel Functions TestUse an adhesive tape to attach a thread to the flywheel [3]. Hook a spring balance into the thread, pull it in the direction of thearrow and measure the tractive force;tractive force 0.45 +0.1 N. If the tractive force is not achieved,exchange the flywheel.
- 21 -Removal, Installation, Adjustment / Flywheel
4
23
1
Flywheel RemovalRemove stepping motor [1]. (T1) Pull ring [2] off the spindle. Loosen the setscrew of the flywheel [3]. Pul flywheel off the spindle.
- 22 -Removal, Installation, Adjustment / Flywheel
4
23
1
Flywheel InstallationDegrease the spindle end. Slide flywheel [3] onto the spindle.Distance to nut [4]:0.2 mm. Tighten the setscrews of the flywheel. Install the stepping motor [1]. (T1)
- 23 -Removal, Installation, Adjustment / Spindle
A
CAUTION:Before installing the spindle, measure the diameter of the spindle passage A !The removal and installation of the spindle must be performed according to the diameter (46 mm or 49 mm)!
- 24 -Removal, Installation, Adjustment / Spindle
A = 46 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Remove covers and coverings. (T1) Protect the trough (e.g. cover with film). Remove pcb EC-CONTROL with box. (T2) Remove screws [1]. Turn spindle nut [2] out of the flange. Unscrew flange [5] from holder [14].
Spindle Removal
- 25 -Removal, Installation, Adjustment / Spindle
A = 46 mm
21
18
17
15
16
19
20
Remove flywheel [16] and steppingmotor [15]. (T3) Mark position of bearing [21]. Remove bearing.
Spindle Removal
- 26 -Removal, Installation, Adjustment / Spindle
A = 46 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Pull carriage with spindle [3] out ofthe bearing block. Pull ring [11] off the ball bearing [10]. Remove circlip [12]. Pull ball bearing [10] off the spindleand mark installation position. Loosen clamping screw [8]. Pull bushing [9], hose [7] and sliding bearing [6] off the spindle.
Spindle Removal
- 27 -Removal, Installation, Adjustment / Spindle
A = 46 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Move the carriage to the center. Move spindle in the direction of thefloating bearing until the spindle end has no longer contact with the fixed bearing side. Lift spindle end and take the spindle with the flange [5] out of the holder [14].
Spindle Removal
- 28 -Removal, Installation, Adjustment / Spindle
A = 46 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Mount flange [5] onto spindle [3]. Insert the spindle into the holder [14] and move it in the direction of the floating bearing until the spindle end has no longer contact with the fixed bearing side. Move spindle to the fixed bearing side. Move carriage to the fixed bearing side.
Spindle Installation
- 29 -Removal, Installation, Adjustment / Spindle
A = 46 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Mount sliding bearing [6], hose [7] and bushing [9] onto the spindle.Screw in clamping screw [8] but donot tighten it! Insert ball bearing [10] into the ring[11] exerting uniform pressure. CAUTION:Observe installation position! Place ring with ball bearing onto the spindle. Mount circlip [12]. Carefully slide the spindle with the ring [11] and ball bearing [10] into the bearing unit.
Spindle Installation
- 30 -Removal, Installation, Adjustment / Spindle
A = 46 mm
21
18
17
15
16
19
20
Mount bearing [21]. Observe installation position! Turn nut [17] onto the spindle and tighten to a torque of 9 ±1 Nm.Use an open-end wrench at the other end of the spindle to secure it against turning. Insert the protective plate in the bore hole of the nut [17] and tighten locking screw [18]. The labeling of the spindle and the marking of the spindle nut must face upward.
Spindle Installation
- 31 -Removal, Installation, Adjustment / Spindle
A = 46 mm
21
18
17
15
16
19
20
Spindle InstallationInstall flywheel [16] and stepping motor [15]. (T1)
- 32 -Removal, Installation, Adjustment / Spindle
A = 46 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
NOTE:The carriage must be at the fixed bearing side. Screw flange [5] onto the holder [14]. Press carriage with flange against the spindle nut. Use your hand to lightly tighten thebox nut of the flange. Fit metal needle (dia. of 2.5 mm) into a bore hole at the outside of the box nut.
Spindle Installation
- 33 -Removal, Installation, Adjustment / Spindle
A = 46 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Tighten box nut by 35° ±5° (angle distance of bore holes = 30°). This setting corresponds to a torque of 4.6 ±1 Nm. Tighten screw [4] to a torque of 0.4 ±0.05 Nm. Pull the carriage with the flange offthe spindle nut and then press carriage and flange against the spindle nut again.It must be possible to move the spindle nut into the flange and out of the flange smoothly and noiselessly. If necessary, loosen the screws [13] and tighten them again.
Spindle Installation
- 34 -Removal, Installation, Adjustment / Spindle
A = 46 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Move carriage to the center. Turn in the screws [1] and fasten the spindle nut onto the flange but do not tighten the screws. Move the carriage to the fixed bearing side. Tighten the upper screws of the spindle nut. Move the carriage to the center. Tighten the lower screws of the spindle nut. Loosen the clamping screw [8].
Spindle Installation
- 35 -Removal, Installation, Adjustment / Spindle
A = 46 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
X
86
A
Set distance Xbetween bushing [9] and ring [11] (see Ill. A): X = 62 - 0.5 mm (Herkules) X = 165 - 0.5 mm (Herkules M) Tighten clamping screws [8]. Move the carriage in both directions for 5 times and remove excess grease. Install pcb EC-CONTROL. (T2) Remove the trough protection. Mount coverings and covers.
Spindle Installation
- 36 -Removal, Installation, Adjustment / Spindle
A = 49 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Remove covers and coverings (T1). Protect the trough (e.g. cover with film). Remove screws [1]. Turn spindle nut [2] out of the flange.
Spindle Removal
- 37 -Removal, Installation, Adjustment / Spindle
A = 49 mm
21
18
17
15
16
19
20
Remove flywheel [16] and steppingmotor [15]. (T2) Mark position of bearing [21]. Remove bearing.
Spindle Removal
- 38 -Removal, Installation, Adjustment / Spindle
A = 49 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Pull carriage with spindle [3] out ofthe bearing block. Pull ring [11] off the ball bearing [10]. Remove circlip [12]. Pull ball bearing [10] off the spindleand mark installation position. Loosen clamping screw [8]. Pull bushing [9], hose [7] and sliding bearing [6] off the spindle.
Spindle Removal
- 39 -Removal, Installation, Adjustment / Spindle
A = 49 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Move carriage with spindle to the fixed bearing side. Take the spindle out of the machine through the bore hole at the front.
Spindle Removal
- 40 -Removal, Installation, Adjustment / Spindle
A = 49 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Move the carriage to the fixed bearing side. Carefully slide spindle [3] through the front bore hole, the flange [5] and the holder [14]. Mount sliding bearing [6], hose [7] and bushing [9] onto the spindle.Screw in clamping screw [8] but donot tighten it! Insert ball bearing [10] into the ring[11] exerting uniform pressure.
Spindle Installation
- 41 -Removal, Installation, Adjustment / Spindle
A = 49 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
CAUTION:Observe installation position! Place ring [11] with ball bearing [10] onto the spindle. Mount circlip [12]. Carefully slide the spindle with the ring and ball bearing into the bearing unit.
Spindle Installation
- 42 -Removal, Installation, Adjustment / Spindle
A = 49 mm
21
18
17
15
16
19
20
Mount bearing [21]. Observe installation position! Turn nut [17] onto the spindle and tighten to a torque of 9 ±1 Nm.Use an open-end wrench at the other end of the spindle to secure it against turning. Insert the protective plate in the bore hole of the nut [17] and tighten locking screw [18]. The labeling of the spindle and the marking of the spindle nut must face upward.
Spindle Installation
- 43 -Removal, Installation, Adjustment / Spindle
A = 49 mm
21
18
17
15
16
19
20
Spindle InstallationInstall flywheel [16] and stepping motor [15]. (T1)
- 44 -Removal, Installation, Adjustment / Spindle
A = 49 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
Move the carriage to the center. Press carriage with flange against the spindle nut. Turn in screws [1] and fasten the spindle nut onto the flange but do not tighten the screws. Move the carriage to the fixed bearing side. Tighten the upper screws of the spindle nut. Move the carriage to the center. Tighten the lower screws of the spindle nut. Loosen the clamping screw [8].
Spindle Installation
- 45 -Removal, Installation, Adjustment / Spindle
A = 49 mm
6
7
89
1 (4x)
34
5
10 11
2
12
13 (4x)14
X
86
A
Set distance Xbetween bushing [9] and ring [11] (see Ill. A): X = 62 - 0.5 mm (Herkules) X = 165 - 0.5 mm (Herkules M) Tighten clamping screws [8]. Move the carriage in both directions for 5 times and remove excess grease. Remove the trough protection. Mount coverings and covers.
Spindle Installation
- 46 -Removal, Installation, Adjustment / Pcb EC-CONTROL
1
2 (8x)
3 (8x)
4
56 (4x)
7
8
10
9 (4x)
RemovalManually move the carriage to the machine center. Remove the screws [4 and 6] from the cover [5]. Carefully lift the cover and pull the fan cable off pcb EC-CONTROL [1]. Remove the cover. Remove all connectors from pcb EC-CONTROL. Remove the screws [2]. Slide pcb EC-CONTROL under the cable and take it out of the machine.
- 47 -Removal, Installation, Adjustment / Pcb EC-CONTROL
1
2 (8x)
3 (8x)
4
56 (4x)
7
8
10
9 (4x)
RemovalUnscrew the cable guide [7] from the box [10]. Remove the flat cable [8] from the box. Screw out the screws [9] and remove the box.
- 48 -Removal, Installation, Adjustment / Pcb EC-CONTROL
1
2 (8x)
3 (8x)
4
56 (4x)
7
8
10
9 (4x)
InstallationMount box [10] onto the carriage. Clamp the flat cable [8] onto the box. Fasten the cable guide [7] onto the box using screws. CAUTION:The photo diode of pcb EC-CONTROL [1] must be fit into the centering of the ECC carrier! Position pcb EC-CONTROL in the box and screw on lightly. Plug all connectors onto the pcb.
- 49 -Removal, Installation, Adjustment / Pcb EC-CONTROL
X73 (SOL)
S2 (HS4)
max. amplitude
40 ... 90 µsecs
S2
X73
K3
PcbInstallationStart the diagnostic software DIAGHERK. Call up test program 49- Input: r49 Abort the test- Input: STOP Connect the oscilloscope to S2 and X73. Move the pcb until the signal to your left appears (max. symmetry amplitude). Tighten the screws of the pcb. Plug the fan cable onto the pcb and mount the cover.
- 50 -Removal, Installation, Adjustment / Pcb MAT-WIDTH I
6 ±0,2
58
910
Mount pressure spring [8] between bracket [5] and pcb MAT-WIDTH I [9]. Insert screw [10] with LOCTITE 222 and set a distance of 6 ±0.2 mm between pcb MAT-WIDTH I[9] and bracket [5]. Fit connector X 87. Perform alignment according to: Pcb MAT-WIDTH I Alignment (T1).
Installation
- 51 -
Order No. 04699629
R5
Pcb MAT-WIDTH I (6.004)
BARCODE
X2
X87
R6
Film material required:- Reference film (20% screen or transparent unexposed infrared film)- Black film (100% black). Remove loading platform (T1). Start test software (T2)Call up test 82 Input: r82[l,m] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>
Alignment
- 52 -
Order No. 04699629
R5
Pcb MAT-WIDTH I (6.004)
BARCODE
X2
X87
R6
Display:Bit sequence 7654 3210- Bit 4 = 1 > Film is in both opto switches- Bit 4 = 0 > Film is not in opto switches or only in one opto switche. Insert reference film in the trough in front of the two opto switches. CAUTION:Film must have the same position as with normal operation. Cover left-hand opto switch with the black film. So adjust right-hand pot (R6) that bit 4 changes from "0" to "1". Remove black film.
- 53 -
Order No. 04699629
R5
Pcb MAT-WIDTH I (6.004)
BARCODE
X2
X87
R6
Cover right-hand opto switch with the black film. So adjust left-hand pot (R5) that bit 4 changes from "0" to "1". Perform a test at the end positionsand in the middle of the travel:- without reference film > bit 4 = "0" - with reference film on both opto switches > bit 4 = "1". Install loading platform (T3). Note:If the setting is not possible alter the distance between pcb and carrier.
Starting the Test Software - 54 -
Preparations:- switch off machine Rear panel:- remove from upper edge- lift out of lower guide Mac, PC with terminal emulation or WYSE terminal:- connect using VT 100 connector (SERVICE) Insert floppy disk. Switch on Mac, PC with terminal emulation or WYSE terminal. Switch on Herkules. Input: R0 <ENTER> Check configuration.
- 55 -Removal, Installation, Adjustment / Pcb MAT-WIDTH II
5,5
1 ( 6x)
X87
X2
Mount pcb MAT-WIDTH II. Check that there is a distance of 5.5 mm between pcb and bracket; if necessary, turn screws (1). Fit connectors X2 and X 87. Perform alignment according to: Pcb MAT-WIDTH II Alignment (T1).
Installation
- 56 -
Order No. 04700805
Pcb MAT-WIDTH II (6.063)
R5
X2X87
R6
Film material required:- Reference film (20% screen or transparent unexposed infrared film)- Black film (100% black). Remove loading platform (T1). Displace carriage in such a way that the right-hand opto switch is positioned over the right-hand reflection strip. Start test software (V > 2.00) (T2)Call up test 82 Input: r82[l,m,r] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>
Alignment
- 57 -
Order No. 04700805
Pcb MAT-WIDTH II (6.063)
R5
X2X87
R6
Display:Bit sequence 7654 3210- Bit 4 = 1 > Film is in opto switch- Bit 4 = 0 > No film is in opto switch. Insert reference film in the trough in front of the right-hand opto switch. Caution:Film must have the same position as with normal operation. So adjust right-hand pot (R4) that bit 4 changes from "0" to "1". Caution:At the ends of the reflection strip, the film must be safely recognized.
- 58 -
Order No. 04700805
Pcb MAT-WIDTH II (6.063)
R5
X2X87
R6
Stop test 82 Input: stop <Enter> Position left-hand opto switch over the left-hand reflection strip. Call up test 82 Input: r82[l,m,l] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter> So adjust left-hand pot (R5) that bit 4 changes from "0" to "1". Caution:At the ends of the reflection strip, the film must be safely recognized.
- 59 -
Order No. 04700805
Pcb MAT-WIDTH II (6.063)
R5
X2X87
R6
Install loading platform (T3). Note:If the setting is not possible alter the distance between pcb and carrier.
Starting the Test Software - 60 -
Preparations:- switch off machine Rear panel:- remove from upper edge- lift out of lower guide Mac, PC with terminal emulation or WYSE terminal:- connect using VT 100 connector (SERVICE) Insert floppy disk. Switch on Mac, PC with terminal emulation or WYSE terminal. Switch on Herkules. Input: R0 <ENTER> Check configuration.
- 1 -Removal and Installation / Barcode Reader Pen
Supply cassetteflap
Supply cassette
AB
C
750
40
280
75
All dimension in mm
15°Barcode Reader Pen RemovalReader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. Cut cable straps A, B and C.
- 2 -Removal and Installation / Barcode Reader Pen
1
2 33
4 5
6XA7
D
E
Remove the rear panel. Disconnect the connectors [1]. Remove the reader pen from the holder. Lower cable: Unscrew the cable holder [2]. Do not remove thecable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side. Pull off the supply voltage connector [6].
Barcode Reader Pen Removal
- 3 -Removal and Installation / Barcode Reader Pen
1
2 33
4 5
6XA7
D
E
Pull off connector XA7. Pull the cable with the connector through cable passage D into the exposure compartment. Cut cable strap E. Disconnector connectors [1] and take out the cable.
Barcode Reader Pen Removal
- 4 -Removal and Installation / Barcode Reader Pen
Supply cassetteflap
Supply cassette
AB
C
750
40
280
75
All dimension in mm
15°Barcode Reader Pen InstallationReader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. If necessary, drill holes (3.6 mm) for the reader pen holder and mount the holder. Insert the reader pen into the holder. Attach cable straps A, B and C and tighten them(hand-tight).
- 5 -Removal and Installation / Barcode Reader Pen
1
2 33
4 5
6XA7
D
E
Remove the rear panel. Insert the cable from above into the exposure compartment. Connect connectors [1]: Lower cable: Unscrew the cable holder [2]. Do not take off thecable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side.
Barcode Reader Pen Installation
- 6 -Removal and Installation / Barcode Reader Pen
1
2 33
4 5
6XA7
D
E
Fit connector XA7. Fit the supply voltage connector [6]. Pull the cable with the connector through cable passage D into the exposure compartment. Attach cable strap E and tighten it (hand-tight). Connect connectors [1]. Fasten holding bracket [4] and [5] using screws. Insert the electronics rack and screw tight. Screw on the cable holder [2]. Attach the rear panel.
Barcode Reader Pen Installation
- 7 -Parameter Set-up of Advantage Option
Parameter PID 815 'Use ABC' Enabling/disabling the 'Advantage' option Parameter PID 837 'Use Barcode' Enabling/disabling the barcode reader pen
NOTE: After the parameter set-up, reset the recorder by switching it off and then on again.
Transferring the parameters to the recorder software via the service terminal.
- 8 -Parameter Set-up of Advantage Option
Parameter PID 527 'Use Online Processor' Switching on/switching off the online processor.Even if the 'Advantage' option is enabled (PID 815 'Use ABC' has value "1"), the online processor can be switched off in the case of an error.
NOTE: After the parameter set-up, reset the recorder by switching it off and then on again.
Transferring the parameters to the recorder software via the service terminal.
- 9 -Parameter Set-up of Advantage Option
Parameter PID 527 'Use Online Processor'Transfer parameter using the user software.
Return to "Edit Parameter" menu
Save the parameter
NOTE: After the parameter set-up, reset the recorder by switching it off and then on again.
- Press the following key at the operating panel:
- General imagesetter parameter set-up: If the parameter record is not "static data":
- Press the following keys to select the parameter:
- Press the following keys in succession to edit the parameter:
- To save the parameter after editing, press the following keys:
- To return to the main menu, press the following key repeatedly:
- 10 -Parameter Set-up of Advantage Option
General imagesetter parameter set-upSelect parameter record To jump to the level below the current one, press the following key: To select the parameter record, press the following key repeatedly: To jump to the next higher level, press the following key:
- 1 -Removal, Installation, Adjustment
Input / Side Panels
Output
Exposure Unit
Punches (Option)
Lower Section
Prior to all service work:- switch off machine- pull out power plug NOTE:Before beginning the service work,remove corresponding side panels and EMC plates in accordance withmenu item "Side Panels". SAFETY LOOP:Upon completion of repair work, the safety loop function is to be checked by opening the dust cover!Check the protective covers for completeness while reassembling them and make sure that they show no cracks or other damage.
When performing service work to the upper section:Protect the trough against damage!
- 2 -Removal, Installation, Adjustment / TOUCH MEMORY (Motherboard)
TOUCH MEMORY 4K x 1
TOUCH MEMORY + Timer
RemovalRemove pcb MAINCONTROLLER (slot A04/05) and pcb FEED-CONTROL (slot A06). NOTE:Before replacing any components, check whether the fault occurred due to bad pressure spring contact. Lift the pressure spring a little andremove the TOUCH MEMORY to the side. CAUTION:Do not bend the pressure spring.
- 3 -Removal, Installation, Adjustment / TOUCH MEMORY (Motherboard)
TOUCH MEMORY 4K x 1
TOUCH MEMORY + Timer
InstallationIf necessary, tension the pressure spring before installing it. Insert the TOUCH MEMORY from the side. CAUTION:Do not bend the pressure spring. Insert pcb MAINCONTROLLER (slot A04/05) and pcb FEED-CONTROL (slot A06). Perform parameter set-up.
- 4 -Removal, Installation, Adjustment / Vacuum Hoses
1
2 3
54
RemovalPress the flap [4] against the plug-in connector [1] and hold it. Pull the hose [5] out of the plug-in connector.
- 5 -Removal, Installation, Adjustment / Vacuum Hoses
1
2 3
54
InstallationCAUTION:Cut the hose [5] straight! Insert the hose into the plug-in connector [1] until you can feel the resistance of the collet [3]. Exert pressure to slide the hose through the O-ring [2] (approx. 2-3 mm). Slightly pull back the hose (flap [4] has a distance of approx. 1 mm to the plug-in connector).
- 1 -Removal, Installation, Adjustment
Input / Side Panels
Output
Exposure Unit
Punches (Option)
Lower Section
Prior to all service work:- switch off machine- pull out power plug NOTE:Before beginning the service work,remove corresponding side panels and EMC plates in accordance withmenu item "Side Panels". SAFETY LOOP:Upon completion of repair work, the safety loop function is to be checked by opening the dust cover!Check the protective covers for completeness while reassembling them and make sure that they show no cracks or other damage.
When performing service work to the upper section:Protect the trough against damage!
- 2 -Removal, Installation, Adjustment / Side Panels
Front panel
Large side panel
Small side panels
Right
Left
Rear panel
EMC plate
Side panels / rear panel / front panel:- remove by pulling them out NOTE:Remove large side panels before removing the small side panels. EMC plate:- loosen bayonet joint- remove EMC plate
General Notes
- 3 -Removal, Installation, Adjustment / Loading Platform
Loading Platform
Stepping Motor M6
Rewind Motor M5
Guide Panels, Antistatic Rails
Cassette Polling Unit
Caution:Remove the loading platform before exchanging individual components!
Removal, Installation, Adjustment / Loading Platform - 4 -
1 2
3
4
6, 7
5
Switch off the machine, pull out thepower plug. Remove supply cassette. Remove side panels [3, 4 and 5]. Remove rear panel [6] and EMC plate [7]. Open the dust cover [2]. Loosen the screw used to attach the gas spring [1] to the inner side of the dust cover. Swing dust cover to the rear.
Loading Platform Removal
Removal, Installation, Adjustment / Loading Platform - 5 -
9 10
8
11 (7x)
12 (7x)
PcbMODULE-CONNECT
Remove lateral screw [9] with washer [10]. Remove screws [11] with washers [12]. Lift the cassette mount [8] out of the machine. Pull connector X52 off pcb MODULE-CONNECT.
Loading Platform Removal
Removal, Installation, Adjustment / Loading Platform - 6 -
14 (4x)
13
CAUTION:Do not loosen the guide disks screws (the screws are secured with gray varnish)! Loosen the screws [14]. Lightly lift laoding platform, pull it to the rear and lift it out of the machine.Lift loading platform out of the machine.
Loading Platform Removal
Removal, Installation, Adjustment / Loading Platform - 7 -
14 (4x)
13
CAUTION:Do not loosen the guide disks screws (the screws are secured with gray varnish)! Insert the loading platform [13] in the machine.The guide disks must be positioned in the bore holes of the loading platform. Tighten screws [14].
Loading Platform Installation
Removal, Installation, Adjustment / Loading Platform - 8 -
9 10
8
11 (7x)
12 (7x)
PcbMODULE-CONNECT
Connect connector X52 to pcb MODULE-CONNECT. Insert cassette mount [8] in the machine. Turn in screws [9] and [11] with washers [10 and 12].
Loading Platform Installation
Removal, Installation, Adjustment / Loading Platform - 9 -
1 2
3
4
6, 7
5
Mount the gas spring [1] onto the inner side of the dust cover. Close dust cover [2]. Mount coverings [3...7]. Insert the supply cassette.
Loading Platform Installation
- 10 -Removal, Installation, Adjustment / Loading Platform / Guide Panels
View X
X
2
4
1 (5x)3 (5x)
RemovalNOTE:Antistatic rails [4] are found under the guide panels [2]. Guide panels [2]:- remove 5 fixing screws with washers [1] each time- remove Antistatic rails [4]:- remove 5 fixing screws with washers [3] each time- remove
- 11 -Removal, Installation, Adjustment / Loading Platform / Guide Panels
View X
X
2
4
1 (5x)3 (5x)
InstallationAntistatic rails [4]:- insert- screw in 5 fixing screws with washers [3] each time Guide panels [2]:- insert- screw in 5 fixing screws with washers [1] each time CAUTION:The brushes of the antistatic rails [4] must not become caught under the beading of the guide panels [2]!
- 12 -Removal, Installation, Adjustment / Loading Platform / Cassette Polling Unit
Cable, red
Cable, gray
Setscrew (2x)
RemovalCoverings:- remove Guide:-remove Cable (red, gray):- pull off Two setscrews:- loosen Polling unit:- slide in direction of the arrow- remove
- 13 -Removal, Installation, Adjustment / Loading Platform / Cassette Polling Unit
Cable, red
Cable, gray
Setscrew (2x)
318
InstallationPolling unit:- insert into the guide- slide in direction of the arrow CAUTION:Observe installation measure 318 mm (sensor center)! Two setscrews:- tighten manually Cable (red, gray):- plug on Guide:- insert Coverings:- mount
- 14 -Removal, Installation, Adjustment / Loading Platform / Stepping Motor M6
4x
8 (4x)
76
5
4
3
1
2
10
9
RemovalLoading platform:- remove Cable strap:- remove between X93 and stepping motor Connector X93:- pull off CAUTION:During the following work, make sure that the stepping motor [1] cannot fall down! Circlip [2]:- remove Spring [3]:- unhook on both sides
- 15 -Removal, Installation, Adjustment / Loading Platform / Stepping Motor M6
4x
8 (4x)
76
5
4
3
1
2
10
9
Stepping motor [1]:- pull with bracket [4] off pin [5] Nuts [6] with washers [7]:- remove Stepping motor [1]:- remove from bracket [4] Two setscrews [10]:- loosen Pin [9]:- pull off motor shaft with installed spur wheel [11] For the replacement of pin [9]:- dismount spur wheel [11] where necessary
Removal
- 16 -Removal, Installation, Adjustment / Loading Platform / Stepping Motor M6
6.5
PinStepping motor
Ill. A
M 6
InstallationSpur wheel [11]:- fasten to pin [9] where necessary Pin [9] with spur wheel [11]:- slide on the motor shaft Two setscrews [10]:- tighten NOTE:Observe installation measurement (Ill. A)! Stepping motor [1]:- fasten to bracket [4] with screws [8], washers [7] and nuts [6] CAUTION:Observe installation position of themotor!
- 17 -Removal, Installation, Adjustment / Loading Platform / Stepping Motor M6
6.5
PinStepping motor
Ill. A
M 6
Pin [5]:- grease slightly with Arcanol L78 Stepping motor [1] with bracket [4]:- slide on the pin [5] Circlip [2]:- slide on Spring [3]:- hook in on both sides Connector X93:- plug Cable strap:- fasten between X93 and stepping motor Loading platform:- install
Installation
- 18 -Removal, Installation, Adjustment / Loading Platform / Rewind Motor M5
1
1
4
2
4
3
RemovalSupply cassette:- remove where necessary Loading platform:- remove Two cables (gray, red):- unsolder from machine Cable strap:- remove Circlip [1]:- remove Spring [2]- unhook on both sides Rewind motor [3]:- pull out of bushing [4] in the direction of the arrow
- 19 -Removal, Installation, Adjustment / Loading Platform / Rewind Motor M5
1
2
3
4
Exchange defective parts:- spur wheel [1]- gear wheel [2]- microswitch [3]- DC motor with gear unit [4]
Removal
- 20 -Removal, Installation, Adjustment / Loading Platform / Rewind Motor M5
1
1
4
2
4
3
InstallationRewind motor [3]:- insert in bushing [4] contrary to the direction of the arrow Spring [2]:- hook in on both sides Circlip [1]:- mount
- 21 -Removal, Installation, Adjustment / Loading Platform / Rewind Motor M5
Capacitor
red gray+
When connecting, observe correct polarity!
Solder two cables onto the machine:- red, left side -> plus (see Ill.)- gray, right side -> minus Cable:- fasten with cable strap Loading platform:- install
Installation
- 22 -Removal, Installation, Adjustment / Bottom Punch
Bottom Punch Adapter
Solenoid, Left
Solenoid, Right
- 23 -Removal, Installation, Adjustment / Bottom Punch Adapter
1 (4x)
RemovalRemove the loading platform. (T1) Disconnect the connector X91. Remove the fixing screws [1]. Remove the bottom punch adapter from the machine.
- 24 -Removal, Installation, Adjustment / Bottom Punch Adapter
1 (4x)
InstallationInsert the bottom punch adapter in the machine. Use the screws [1] to fasten the bottom punch adapter onto the trough. Connect the connector X91. Install the loading platform. (T1)
- 25 -Removal, Installation, Adjustment / Bottom Punch Adapter / Solenoid, Left
1
2
3
4 (2x)
5 (2x)7 (2x) 68 (2x)
Y 2
RemovalPull the flat connector off the solenoid [1]. Turn out the screws [5] and remove the solenoid. Loosen the setscrew [2] and pull the sleeve [3] off the magnet armature.
- 26 -Removal, Installation, Adjustment / Bottom Punch Adapter / Solenoid, Left
1
2
3
4 (2x)
5 (2x)7 (2x) 68 (2x)
Y 2
InstallationSlide the sleeve [3] onto the magnearmature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 ±0.2 mm. Tighten the setscrew [2]. Fasten the solenoid onto the bracket [6] using screws. Connect the flat connector, observepolarity.
Install the bottom punch adapter and adjust the solenoid.
X
GY OG
- 27 -Removal, Installation, Adjustment / Bottom Punch Adapter / Solenoid, Left
B
AdjustmentLoosen the solenoid fixing screws. With the armature pushed back, slide the solenoid against the pressure rail [1] until the pressure rail can no longer be moved (Ill. A). Tighten the solenoid fixing screws. Release the armature: The pressure rail must push back the armature smoothly. Push back the aramture completely: There must be a gap between the armature and the pressure rail (Ill. B).
A
Gap
Armature pushed back
Armature pulled out
1
1
- 28 -Removal, Installation, Adjustment / Bottom Punch Adapter / Solenoid, Right
1
2
34
5 (2x)
7 (2x)
6 (2x)
8 (2x)
Y 1
RemovalPull the flat connector off the solenoid [3]. Turn out the screws [7] and remove the solenoid. Loosen the setscrew [1] and pull the sleeve [2] off the magnet armature.
- 29 -Removal, Installation, Adjustment / Bottom Punch Adapter / Solenoid, Right
1
2
34
5 (2x)
7 (2x)
6 (2x)
8 (2x)
Y 1
InstallationFit the sleeve [2] onto the magnet armature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 ±0.2 mm. Tighten the setscrew [1]. Fasten the solenoid onto the bracket [4] using screws. Connect the flat connector, observepolarity.
Install the bottom punch adapter and adjust the solenoid.
X
GYOG
- 30 -Removal, Installation, Adjustment / Bottom Punch Adapter / Solenoid, Right
B
AdjustmentLoosen the solenoid fixing screws. With the armature pushed back, slide the solenoid against the pressure rail [1] until the pressure rail can no longer be moved (Ill. A). Tighten the solenoid fixing screws. Release the armature: The pressure rail must push back the armature smoothly. Push back the aramture completely: There must be a gap between the armature and the pressure rail (Ill. B).
A
Gap
Armature pushed back
Armature pulled out
1
1
- 31 -Removal and Installation / Barcode Reader Pen
Supply cassetteflap
Supply cassette
AB
C
750
40
280
75
All dimension in mm
15°Barcode Reader Pen RemovalReader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. Cut cable straps A, B and C.
- 32 -Removal and Installation / Barcode Reader Pen
1
2 33
4 5
6XA7
D
E
Remove the rear panel. Disconnect the connectors [1]. Remove the reader pen from the holder. Lower cable: Unscrew the cable holder [2]. Do not remove thecable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side. Pull off the supply voltage connector [6].
Barcode Reader Pen Removal
- 33 -Removal and Installation / Barcode Reader Pen
1
2 33
4 5
6XA7
D
E
Pull off connector XA7. Pull the cable with the connector through cable passage D into the exposure compartment. Cut cable strap E. Disconnector connectors [1] and take out the cable.
Barcode Reader Pen Removal
- 34 -Removal and Installation / Barcode Reader Pen
Supply cassetteflap
Supply cassette
AB
C
750
40
280
75
All dimension in mm
15°Barcode Reader Pen InstallationReader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. If necessary, drill holes (3.6 mm) for the reader pen holder and mount the holder. Insert the reader pen into the holder. Attach cable straps A, B and C and tighten them(hand-tight).
- 35 -Removal and Installation / Barcode Reader Pen
1
2 33
4 5
6XA7
D
E
Remove the rear panel. Insert the cable from above into the exposure compartment. Connect connectors [1]: Lower cable: Unscrew the cable holder [2]. Do not take off thecable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side.
Barcode Reader Pen Installation
- 36 -Removal and Installation / Barcode Reader Pen
1
2 33
4 5
6XA7
D
E
Fit connector XA7. Fit the supply voltage connector [6]. Pull the cable with the connector through cable passage D into the exposure compartment. Attach cable strap E and tighten it (hand-tight). Connect connectors [1]. Fasten holding bracket [4] and [5] using screws. Insert the electronics rack and screw tight. Screw on the cable holder [2]. Attach the rear panel.
Barcode Reader Pen Installation
- 1 -Removal, Installation, Adjustment
Input / Side Panels
Output
Exposure Unit
Punches (Option)
Lower Section
Prior to all service work:- switch off machine- pull out power plug NOTE:Before beginning the service work,remove corresponding side panels and EMC plates in accordance withmenu item "Side Panels". SAFETY LOOP:Upon completion of repair work, the safety loop function is to be checked by opening the dust cover!Check the protective covers for completeness while reassembling them and make sure that they show no cracks or other damage.
When performing service work to the upper section:Protect the trough against damage!
- 2 -Removal, Installation, Adjustment / Film Exit Unit
Prior to removing components or parts, remove the complete film exit unit!
Film Exit Unit, cpl.
Stepping Motor M3
Roller
Front Guide Panel
Holder Assembly
Rear Guide Panel
Control Rollers
Motor M14
Stepping Motor M2
Threaded Rod
Motor M1
Diode Holder
Solenoid
- 3 -Removal, Installation, Adjustment / Film Exit Unit
2 (10x)1
3 (10x)
RemovalOpen flap. Remove collecting cassette where appropriate. Disconnect electrical connection X54. Remove 10 fixing screws [2]. Tilt film exit unit [1] slightly forward and pull it out carefully.
- 4 -Removal, Installation, Adjustment / Film Exit Unit
2 (10x)1
3 (10x)
InstallationCarefully insert film exit unit [1]. NOTE:Screw in marked screw (x) first! Loosely screw in fixing screws [2]. Tighten fixing screws [2]. If necessary, insert collecting cassette and close flap. Establish electrical connection X54.
x
- 5 -Removal, Installation, Adjustment / Film Exit Unit / Diode Holder
1
23
45
6 7
8
9B 9
RemovalCut the cable strap at the diode holder [6]. Pull off flat cable [9]. Loosen screw [1] (approx. 1 revolution). Move block [2] to the left across the assembly opening in the shaped strip [7]. CAUTION:Do not lose the washer [3]! Manually turn the threaded rod [8] until the diode holder [6] no longer touches the threaded rod.
- 6 -Removal, Installation, Adjustment / Film Exit Unit / Diode Holder
1
23
45
6 7
8
9B 9
Remove the diode holder through the assembly opening. Remove screw [4]. Remove tapped plate [5] from the diode holder.
Removal
- 7 -Removal, Installation, Adjustment / Film Exit Unit / Diode Holder
1
23
45
6 7
8
9B 9
InstallationInsert tapped plate [5] int diode holder [6] and secure in position using screw [4]. Insert the diode holder through theassembly opening of the shaped strip [7] and push it against the threaded rod [8]. Turn threaded rod into the tapped plate [5]. Place washer [3] onto the threaded rod shoulder. Push bearing block [2] against the threaded rod and tighten screw [1] (approx. 1 revolution).
- 8 -Removal, Installation, Adjustment / Film Exit Unit / Diode Holder
1
23
45
6 7
8
9B 9
Lightly grease threaded rod using LOSOID 1160B. Fit flat cable [9]. Fasten cable using cable straps. Perform parameter set-up.
Installation
- 9 -Removal, Installation, Adjustment / Film Exit Unit / Threaded Rod
1
23
45 6
7
89 10
1112
13 (2x)
14
15 (3x)
16
17
18
RemovalRemove the toothed belt [12] from the toothed belt pulley [11]. Cut the cable strap at the diode holder [6]. Disconnect the electrical connection. Loosen the screw [1] (approx. 1 revolution). Move the block [2] to the left acrossthe assembly opening in the shaped strip [7]. CAUTION:Do not lose the washer [3]! Manually turn the threaded rod [18] until the diode holder [6] no longer touches the threaded rod.
- 10 -Removal, Installation, Adjustment / Film Exit Unit / Threaded Rod
1
23
45 6
7
89 10
1112
13 (2x)
14
15 (3x)
16
17
18
Remove the screw [10] with the washer [9] and spacer [8]. Pull the threaded rod out of the film exit unit. Loosen the setscrew [13] by one revolution. Pull the toothed belt pulley [11] andthe ring [14] off the threaded rod. Pull the washers [15], ball bearing [16] and bushing [17] off the threaded rod.
Removal
- 11 -Removal, Installation, Adjustment / Film Exit Unit / Threaded Rod
1
23
45 6
7
89 10
1112
13 (2x)
14
15 (3x)
16
17
18
InstallationSlide the bushing [17], the ball bearing [16] and the washers [15] onto threaded rod [18]. Slide the ring [14] and the toothed belt pulley [11] and lock in positionusing setscrews [13]. Insert the threaded rod in the film exit unit. Insert the ball bearing [16] in the bore hole of the housing. Place the washer [9] and spacer [8]onto the screw [10]. Turn in the screw [10] using Loctite222 and tighten it slightly.
- 12 -Removal, Installation, Adjustment / Film Exit Unit / Threaded Rod
1
23
45 6
7
89 10
1112
13 (2x)
14
15 (3x)
16
17
18
Insert the diode holder [6] through the assembly opening of the shaped strip [7] and slide it up to the threaded rod [18]. Turn the threaded rod into the tapped plate [5]. Mount the washer [3] onto the sholder of the threaded rod. Slide the bearing block [2] against the threaded rod and tighten the screw [1] (approx. 1 revolution). Lightly grease the threaded rod using LOSOID 1160B. Establish the electrical connection.
Installation
- 13 -Removal, Installation, Adjustment / Film Exit Unit / Threaded Rod
1
23
45 6
7
89 10
1112
13 (2x)
14
15 (3x)
16
17
18
Fasten the cable using cable straps. Check axial backlash:- diode holder -> no backlash- threaded rod -> max. backlash 0.2mm Position the toothed belt [2] onto toothed belt pulley [11]. NOTE:It must be possible to easily press the toothed belt by approx. 9 mm centrally between the gear wheels on one side. Perform the paramter set-up.
Installation
- 14 -Removal, Installation, Adjustment / Film Exit Unit / Motor M1
View X
+
3
grayred
2
41
X
Side panel
When connecting, observe correct polarity!
5M 1
RemovalRemove cable strap. Unsolder red (+) and gray ( - ) cables. Spur wheel [1]:- loosen two setscrews [2]- pull spur wheel off the motor shaft CAUTION:Observe installation position of thestepping motor and, if necessary, mark it! Motor [3]:- remove three fixing screws [4] with washers [5]- remove motor
- 15 -Removal, Installation, Adjustment / Film Exit Unit / Motor M1
View X
+
3
grayred
2
41
X
Side panel
When connecting, observe correct polarity!
5M 1
InstallationMotor [3]:- insert in correct installation position- fasten with three fixing screws [4] and washers [5] Fixing screws [4]:- secure with Loctite 242 Spur wheel [1]:- slide onto the motor shaft- fasten with two setscrews [2] Solder on red (+) and gray ( - ) cables (see view X). Attach cable strap.
- 16 -Removal, Installation, Adjustment / Film Exit Unit / Stepping Motor M2
1
X92
2
3
4
5
1
6
7toX92
8
RemovalRemove cable strap. Remove screw [1]. Stepping motor [2]:- rotate in direction of the arrow NOTE:The toothed belt [3] is now released. Toothed belt [3]:- remove from toothed belt pulley [4] Stepping motor [2]:- remove fixing screw [5]- remove stepping motor [2]
- 17 -Removal, Installation, Adjustment / Film Exit Unit / Stepping Motor M2
1
X92
2
3
4
5
1
6
7toX92
8
InstallationToothed belt pulley [4] withring [6]:- slide on the motor shaft- tighten with two setscrews [7] Stepping motor [2]:- hold onto spacers [8]- tighten with fixing screw [5] Toothed belt [3]:- position onto toothed belt pulley [4] Stepping motor [2]:- rotate contrary to the direction of the arrow- fasten with screw [1]
- 18 -Removal, Installation, Adjustment / Film Exit Unit / Stepping Motor M2
1
X92
2
3
4
5
1
6
7toX92
8
NOTE:It must be possible to easily press the toothed belt [3] by approx. 9 mm centrally between the gear wheels on one side! If necessary, tension or release toothed belt [3]. Check whether the toothed belt runs straight. Attach cable strap.
Installation
- 19 -Removal, Installation, Adjustment / Film Exit Unit / Stepping Motor M3
RemovalRemove cable strap. Disconnect electrical connection X89. CAUTION:Observe installation position of thestepping motor and, if necessary, mark it! Remove screws [1] with washers [2]. Remove toothed belt [10] from toothed belt pulley [11]. Remove stepping motor [7]. Loosen setscrews [8] by one revolution.
>
- 20 -Removal, Installation, Adjustment / Film Exit Unit / Stepping Motor M3
InstallationSlide ring [9] with toothed belt pulley [11] on the shaft. Fasten setscrews [8]. Position toothed belt [10] on toothed belt pulley [11]. Position Stepping motor [7] onto spacer [3] in correct installation position. Fasten screws [1] with washers [2]. NOTE:It must be possible to easily press the toothed belt by approx. 9 mm centrally between the gear wheels on one side!
>
- 21 -Removal, Installation, Adjustment / Film Exit Unit / Motor M14
1
Axle
2
3
45
76
8
11
10 9
RemovalPreconditions:- front guide panel is dismounted. Remove two nuts [1] with washers [2]. Tilt motor [3]. Unsolder red (+) and gray ( - ) cables. NOTE:Observe polarity, if necessary, notedown! Loosen setscrew [4]. Remove block [5].
- 22 -Removal, Installation, Adjustment / Film Exit Unit / Motor M14
1
Axle
2
3
45
76
8
11
10 9
NOTE:Observe installation position, note down if necessary! Remove three screws [6] with washers [7]. Remove motor from bracket [8]. NOTE:Observe installation position of themotor, note down if necessary!
Removal
- 23 -Removal, Installation, Adjustment / Film Exit Unit / Motor M14
1
Axle
2
3
45
76
8
11
10 9
InstallationMotor M14 [3]:- use three screws [6] and washers [7] to fasten to bracket [8] in correct installation position Block [5]:- use setscrew [4] to fasten onto the motor shaft in correct installation position Solder on red (+) and gray ( - ) cables. CAUTION:The cables may not touch the strut [11]!
- 24 -Removal, Installation, Adjustment / Film Exit Unit / Motor M14
1
Axle
2
3
45
76
8
11
10 9
Motor [3]:- tilt and position in installation position- fasten with two nuts [1] and washers [2] CAUTION:When tilting the block [5], the ball bearing [9] always has to be remain in the grasp of the lever [10]! - mount front guide panel.
Installation
- 25 -Removal, Installation, Adjustment / Film Exit Unit / Holder Assembly
3 (2x)2 (2x)
5
1
4
6
RemovalNOTE:Observe installation position of block [1]! Block [1]:- loosen setscrew- pull off the axle Remove from both sides:- 2 screws [2]- washers [3] Holder assembly [4]:- pull out of milling [5]
- 26 -Removal, Installation, Adjustment / Film Exit Unit / Holder Assembly
3 (2x)2 (2x)
5
1
4
6
InstallationHolder assembly [4]:- insert into milling [5] On both sides:- fasten washer [6] with washers [3] and 2 screws [2] Block [1]:- slide onto axle in correct installation position- set in position with setscrew Perform holder adjustment.
- 27 -Removal, Installation, Adjustment / Film Exit Unit / Holder Assembly
58 ±1
1 +0.6
Guide panel
Holder
12
4
35
Pivot pointAdjustmentThe holders must reach the following measurements:- as far as the screw [1]: 58 ±1 mm- as far as the bracket [2]: 1 +0.6 mm Adjustment: Block [3]:- loosen setscrew [4] Holder:- use your hand to set to 58 ±1 mm Block [3]:- lightly press against screw [1] until it has contact- tighten setscrew [4]
- 28 -Removal, Installation, Adjustment / Film Exit Unit / Holder Assembly
58 ±1
1 +0.6
Guide panel
Holder
12
4
35
Pivot point Bracket [2]:- loosen fixing screw [5] by one revolution Holder:- set to 1 +0.6 mm using feeler gauge Bracket [2]:- lightly press against block [3] until it has contact- tighten fixing screws [5]
Adjustment
- 29 -Removal, Installation, Adjustment / Film Exit Unit / Solenoid
1
4 (2x)3 (2x)
2
RemovalRemove film exit unit. (T1) Remove front guide panel. (T2) Remove screws [4]. Remove solenoid [1] from the film exit unit.
- 30 -Removal, Installation, Adjustment / Film Exit Unit / Solenoid
1
4 (2x)3 (2x)
2
InstallationDegrease solenoid armature [1] in the adhering area. Note:Hold solenoid vertically and plug the sleeve [2] onto the armature from below! Adhere the sleeve with Loctite 638 to the armature. Screw the solenoid to the film exit unit. Grease the tip of the sleeve with Losoid 1160B. Check the holder adjustment. (T1)
- 31 -Removal, Installation, Adjustment / Film Exit Unit / Solenoid
1
4 (2x)3 (2x)
2
InstallationInstall the front guide panel. (T2) Install film exit unit. (T3)
- 32 -Removal, Installation, Adjustment / Film Exit Unit / Roller
Right:
Left:
11
10
9
8
5
2
1Side panel
Side panel
1067
M3
3
Left
11
4
RemovalRemove a fixing screw of the stepping motor M3. Swing stepping motor M3, remove toothed belt. Toothed belt pulley [1] with ring [3]:- loosen two setscrews [2] by one revolution- pull off roller shaft Spacer [4]:- pull off roller shaft Clamp [5]:- remove screw [6] with washer [7]- remove clamp [5]
- 33 -Removal, Installation, Adjustment / Film Exit Unit / Roller
Right:
Left:
11
10
9
8
5
2
1Side panel
Side panel
1067
M3
3
Left
11
4
Screw [8] and washer [9]:- remove Roller [10]:- remove Ball bearing [11]:- remove from both sides
Removal
- 34 -Removal, Installation, Adjustment / Film Exit Unit / Roller
Right:
Left:
11
10
9
8
5
2
1Side panel
Side panel
1067
M3
3
Left
11
4
InstallationBall bearing [11]:- slide on the roller axle on both sides Roller [10]:- insert Screw [8]:- attach with washer [9] Clamp [5]:- mount- fasten with screw [6] and washer [7] Spacer [4]:- slide on the roller shaft
- 35 -Removal, Installation, Adjustment / Film Exit Unit / Roller
Right:
Left:
11
10
9
8
5
2
1Side panel
Side panel
1067
M3
3
Left
11
4
Toothed belt pulley [1] with ring [3]:- slide onto the roller shaft as far as the stop- lock in position on the roller shaft using two setscrews [2] Toothed belt:- position on toothed belt pulley [1] and toothed belt pulley of the stepping motor M3 Stepping motor M3:- move into installation position- lock in position with fixing screw NOTE:It must be possible to press the toothed belt by approx. 9 mm centrally between the gear wheels on one side!
Installation
- 36 -Removal, Installation, Adjustment / Film Exit Unit / Front Guide Panel
1
2
RemovalPull the front guide panel [1] up from the screws.
- 37 -Removal, Installation, Adjustment / Film Exit Unit / Front Guide Panel
1
2
InstallationPlace the front guide panel [1] fromthe top onto the screws [2].
- 38 -Removal, Installation, Adjustment / Film Exit Unit / Rear Guide Panel
2
3
4 (3x)
1
5 (3x)
RemovalRemove front guide panel. (T1) Remove roller. (T2) Remove screws [5] with distance sleeve [4]. Remove rear panel [1] with guide panel [3].
- 39 -Removal, Installation, Adjustment / Film Exit Unit / Rear Guide Panel
2
3
4 (3x)
1
5 (3x)
InstallationScrew the rear guide panel [1] with the screws [5] and distance sleeves [4] loosely to the back panel of the film exit unit. CAUTION:Observe the installation position ofthe guide panel [3], upper rim mustpoint in the direction of the exit unit! Insert guide panel [3] and press on the middle screw, align horizontally and sidewards. Tighten screws [5].
- 40 -Removal, Installation, Adjustment / Film Exit Unit / Rear Guide Panel
2
3
4 (3x)
1
5 (3x)
InstallationWhen exchanging the guide panel [1] adhere strips [2] as follows:Edge "a" even with outer edgeEdge "b" 0.1 +0.15 mm lapping over the metal edge Mount front guide panel. (T1) Mount roller. (T2)
a
b
- 41 -Removal, Installation, Adjustment / Film Exit Unit / Control Rollers
Drive M14
Strut
Cable harness
1 2 3 4
M
GeneralOnly control roller 3 is moved with motor M14 (see Ill.). The other rollers are moved synchronously over struts around their pivot point. The force transmission from the motor to the control roller 3 is performed via lever impact. Prior to removing a control roller, remove the cable harness mountedonto it.
- 42 -Removal, Installation, Adjustment / Film Exit Unit / Control Rollers 1, 2, 4
1 (4x)2
3
RemovalRemove front guide panel. (T1) CAUTION:Do not loosen screws (3x) secured with Loctite from the strut [2] ! Remove circlip [1]. Remove strut [2] from the fork pins.
- 43 -Removal, Installation, Adjustment / Film Exit Unit / Control Rollers 1, 2, 4
5 (2x)6 (3x)
7 (2x)
89
10
12
11
13
4 (2x)
RemovalRemove fixing screws [4] on the back side. Remove entire unit. Pull the fork [11] out of the holder [13] and remove pressure spring [12]. Remove lock washer [8]. Carefully pull axle [9] out of the fork and rollers [6].
- 44 -Removal, Installation, Adjustment / Film Exit Unit / Control Rollers 1, 2, 4
5 (2x)6 (3x)
7 (2x)
89
10
12
11
13
4 (2x)
InstallationPack the rollers [6], distance sleeves [5] and washers [7] in the fork [11] together to one set. Thread the axle [9] into the fork and the roller set. Mount lock washer [8]. Mount pressure spring [12] onto the shaft of the fork. Grease shaft with Losoid 1160B. Insert fork into the holder [13].
- 45 -Removal, Installation, Adjustment / Film Exit Unit / Control Rollers 1, 2, 4
1 (4x)2
3
InstallationInstall the entire unit into the film exit unit. Check foam rubber stopper [3] andexchange, if required. CAUTION:Do not loosen screws (3x) secured with Loctite from the strut [2]! Set the complete strut [2] with boreholes onto the pins of the fork. Set circlip [1] onto the pins. Adjust control rollers. (T1)
- 46 -Removal, Installation, Adjustment / Film Exit Unit / Control Roller 3
1 (4x)2
3
RemovalRemove front guide panel. (T1) CAUTION:Do not loosen screws (3x) secured with Loctite from the strut [2] ! Remove circlip [1]. Remove strut [2] from the fork pins.
- 47 -Removal, Installation, Adjustment / Film Exit Unit / Control Roller 3
5 (2x)6 (3x)
7 (2x)
89
10
4 (2x)12
11
15
14
13
RemovalLoosen setscrew [15]. Remove level [14].
Remove fixing screws [4] on the back side. Remove entire unit. Pull the fork [11] out of the holder [13] and remove pressure spring [12]. Remove lock washer [8]. Carefully pull axle [9] out of the fork and rollers [6].
- 48 -Removal, Installation, Adjustment / Film Exit Unit / Control Roller 3
5 (2x)6 (3x)
7 (2x)
89
10
4 (2x)12
11
15
14
13
InstallationPack the rollers [6], distance sleeves [5] and washers [7] in the fork [11] together to one set. Thread the axle [9] into the fork and the roller set. Mount lock washer [8]. Mount pressure spring [12] onto the shaft of the fork. Grease shaft with Losoid 1160B. Insert fork into the holder [13].
Mount lever [14] centered to the fork.
- 49 -Removal, Installation, Adjustment / Film Exit Unit / Control Roller 3
1 (4x)2
3
InstallationInstall the entire unit into the film exit unit. Check foam rubber stopper [3] andexchange, if required. CAUTION:Do not loosen screws (3x) secured with Loctite from the strut [2]! Set the complete strut [2] with boreholes onto the pins of the fork. Set circlip [1] onto the pins. Adjust control rollers. (T1)
- 50 -Removal, Installation, Adjustment / Film Exit Unit / Control Rollers
Drive M14
Strut
Cable harness
1 2 3 4
M
Auxiliary tools
AdjustmentPrerequisites:1. Struts have to be fastened to thecontrol rollers!2. Struts are secured with the locking rings! Position tools with a flat surface onthe front of the control rollers. NOTE:Control rollers are aligned straight,if they have contact with the flat surface over the entire length of the auxiliary tools.
- 51 -Removal, Installation, Adjustment / Film Exit Unit / Control Rollers
Motor M14
Lever
Strut
Setscrew
Axle
Rollers CAUTION:The lever has to be adjusted in such a way that the rollers can be moved uniformly when starting at the zero position. The greatest allowable tolerance between the two rollers may be ±1°. Adjustment:- loosen setscrew- turn lever on axle- tighten setscrew Check adjustment. If necessary, repeat the adjustment. Install front guide panel. (T1)
Adjustment
- 52 -Removal, Installation, Adjustment / Cutting Device
Gear Unit Motor M4
Cutting Device
Before removing the cutting device, the film exit unit must be removed! Before removing individual components, remove the complete cutting device!
Cutting Wheel
Cutting Rail
- 53 -Removal, Installation, Adjustment / Cutting Device
3 (2x)
2 (2x)
1 (2x)
RemovalRemove the film exit unit. (T1) Pull off connector X55. Loosen screw [1] by one revolution. Remove the screw [2]. Remove the washer [3]. Remove the cutting device.
- 54 -Removal, Installation, Adjustment / Cutting Device
3 (2x)
2 (2x)
1 (2x)
InstallationInsert the cutting device into the machine. Tighten screw [1]. Tighten screw [2] with washer [3]. NOTE:The washer [3] must be positioned onto the shaped strip of the cuttingdevice. Fit connector X55. Install the film exit unit. (T1)
- 55 -Removal, Installation, Adjustment / Cutting Device / Gear Unit Motor M4
X
M4
+grayred
View X
1
2
3
45
6
789
Motor shaft
Setscrew
Flat surface
Ill. A
RemovalKnob [1]:- pull off motor shaft Cable strap [2]:- cut and remove Pull connector [3] off motor. NOTE:Observe installation position of motor [6], mark if necessary. Remove four fixing screws [4] with washers [5]. Motor [6]:- tilt- remove toothed belt from toothed belt pulley [7]
- 56 -Removal, Installation, Adjustment / Cutting Device / Gear Unit Motor M4
X
M4
+grayred
View X
1
2
3
45
6
789
Motor shaft
Setscrew
Flat surface
Ill. A
Two setscrews [8]:- loosen by one revolution at the ring [9] Toothed belt pulley [7] with ring [9]:- pull off motor shaft Remove gear unit motor [6].
Removal
- 57 -Removal, Installation, Adjustment / Cutting Device / Gear Unit Motor M4
X
M4
+grayred
View X
1
2
3
45
6
789
Motor shaft
Setscrew
Flat surface
Ill. A
InstallationGear unit motor [6]:- insert motor shaft through the bore hole Toothed belt pulley [7] with ring [9]:- slide on the motor shaft Screw in setscrew [8] so that it reaches the flat surface (Ill. A). Slide up toothed belt pulley [7] withring [9] until the setscrew [8] touches the end of the flat surface (Ill. A). In this position (Ill. A):- tighten both setscrews [8]
- 58 -Removal, Installation, Adjustment / Cutting Device / Gear Unit Motor M4
X
M4
+grayred
View X
1
2
3
45
6
789
Motor shaft
Setscrew
Flat surface
Ill. A
Motor [6]:- tilt- position toothed belt on toothed belt pulley [7] Gear unit motor [6]:- fasten with four fixing screws [4] and washers [5] Fit connector [3]. CAUTION:Observe polarity: red to +, gray to - ! Attach cable strap [2]. Knob [1]:- position on the motor shaft
Installation
- 59 -Removal, Installation, Adjustment / Cutting Device / Cutting Wheel
Assembly opening
1
2
Danger of being cut while removing orinstalling the cutting wheel!
3
4
RemovalPrecondition:Cutting device is removed. CAUTION:During the following procedure, press back the cutting wheel be means of an appropriate tool before reaching the assembly opening so that it does not slip off the cutting rail [2]! Cutting wheel [1]:- use the handwheel to move in the direction of the assembly opening as far as the stop- press axially- remove carefully
- 60 -Removal, Installation, Adjustment / Cutting Device / Cutting Wheel
Assembly opening
1
2
Danger of being cut while removing orinstalling the cutting wheel!
3
4
InstallationUse methylated spirit to clean the cutting wheel [1] and, if necessary, remove protruding burr with a grindstone. CAUTION:Cutting wheel [1] blade must not touch the cutting rail [2]! Cutting wheel [1]:- press axially- insert in assembly opening- press back; while the cutting wheel is pressed back, use the handwheel to move it in the direction of the arrow
- 61 -Removal, Installation, Adjustment / Cutting Device / Cutting Rail
1
3 (6x)
2 (2x)
RemovalRemove cutting wheel [1]. (T1) Turn out setscrews [2]. Loosen screws [3].
- 62 -Removal, Installation, Adjustment / Cutting Device / Cutting Rail
1
3 (6x)
2 (2x)
RemovalRemove cutting wheel [1]. (T1) Turn out setscrews [2]. Loosen screws [3].
- 63 -Removal, Installation, Adjustment / Cutting Device / Cutting Rail
4
5
2(2x)
3 (6x)
4A
A
InstallationUse methylated spirit to clean the cutting rail [4] and, if necessary, remove protruding burr with a grindstone. CAUTION:Observe the installation position ofthe cutting rail (bore holes for setscrews [2], s. Ill. A)! Slide cutting rail into the cutting device and screw tight.
- 64 -Removal, Installation, Adjustment / Cutting Device / Cutting Rail
1
3 (6x)
2 (2x) C
4 2
5
B
B
6
7 5
CLoosen setscrew [6] and remove tensioner [7]. Insert toothed belt [5], the setscrews [2] must engage in the first two gaps (s. Ill. C). Turn in setscrew against slight resistance. Mount tensioner [7]. Slightly tighten the toothed belt using the setscrew [6]. Insert cutting wheel [1] and install cutting device. (T1)
Installation
- 65 -
Punch Adapter
Stepping Motor M7
Solenoids
Solenoids
Removal, Installation, Adjustment / Punch Adapter
Removal, Installation, Adjustment / Punch Adapter - 66 -
112
RemovalHolder [1] and safety switch [2]:- loosen fixing screws- swing out of position Remove film exit unit and cutting device. Disconnect electrical connection X61:- punch adapter <->pcb MODULE CONNECT
Removal, Installation, Adjustment / Punch Adapter - 67 -
Three fixing screws:-loosen at the marked positions NOTE:Screws remain at the punch adapter. - Lift out punch adapter
Removal
Removal, Installation, Adjustment / Punch Adapter - 68 -
Installation- Insert punch adapter from above Punch adapter:- position in correct installation position at the trough (screws reach into the milling at the trough)- use three fixing screws to fasten at the marked positions
Removal, Installation, Adjustment / Punch Adapter - 69 -
112
Establish electrical connection X61:- punch adapter <->pcb MODULE CONNECT Install film exit unit and cutting device. Holder [1] and safety switch [2]:- swing into installation position- fasten with fixing screws
Installation
- 70 -
Film exit side
Y 8
Y 9
Trough sideY 6
Y 7
Removal, Installation, Adjustment / Punch Adapter / Solenoids
Installation, SolenoidsSolenoids:- fastened on each side with two screws and washers Set a corresponding distance X for each solenoid: X for the trough side: 2.5 mm X for the film exit side: 5.0 mm Sleeve [1]:- slide onto the solenoid- lightly press against the armature- set sleeve [1] into position with setscrew [2]
X
1 2
X
1 2
- 71 -Removal, Installation, Adjustment / Punch Adapter / Solenoids
Installation of the solenoids:- loosely fasten slenoids- position solenoids to measure 1 mm- tighten fixing screws
Installation, Solenoids
1 mm
1 mm
- 72 -Removal, Installation, Adjustment / Punch Adapter / Stepping Motor M7
Motor holder1
2
45
6
3
1.5 mm
RemovalRemove cable strap. Disconnect electrical connection X61. CAUTION:Observe installation position of thestepping motor, mark if necessary. Remove four nuts [1] with screws [2] and washers [3]. Remove toothed belt from toothed belt pulley [4]. Remove stepping motor.
- 73 -Removal, Installation, Adjustment / Punch Adapter / Stepping Motor M7
Motor holder1
2
45
6
3
1.5 mm
InstallationRing [5] with toothed belt pulley [4]:- slide onto the shaft- use two setscrews [6] to fasten onto motor shaft Position toothed belt on toothed belt pulley [4]. Stepping motor:- position in correct installation position at the motor holder- fasten with four nuts [1], screws [2] and washers [3] NOTE:It must be possible to easily press in the toothed belt by approx. 9 mmcentrally between the toothed belt pulleys on one side.
Observe the distance of 1.5 mm for the toothed belt pulley (4)!
- 74 -Removal, Installation, Adjustment / Collecting Cassette
1
X
2 (2x)View "X"
4
3
CAUTION:Prior to installing the collecting cassette [1], the following functions must be checked! Functions check of handles [2]:- it must be possible to press the handles easily and without resistance into the cassette [1]- when releasing the handles, they must be automatically pressed out of the cassette by means of the elastic force of their pressure springs
Adjustment
>
- 1 -Removal, Installation, Adjustment
Input / Side Panels
Output
Exposure Unit
Punches (Option)
Lower Section
Prior to all service work:- switch off machine- pull out power plug NOTE:Before beginning the service work,remove corresponding side panels and EMC plates in accordance withmenu item "Side Panels". SAFETY LOOP:Upon completion of repair work, the safety loop function is to be checked by opening the dust cover!Check the protective covers for completeness while reassembling them and make sure that they show no cracks or other damage.
When performing service work to the upper section:Protect the trough against damage!
- 2 -
The top punch is an option. If no top punch is installed, the punch adapter must be installed. The top punch may only be actuated if it is installed! After removal of the entire unit, remove and install individual parts.
Top Punch
Gear Unit Motor M17
Stepping Motor M7
Solenoids Solenoids
Removal, Installation, Adjustment / Top Punch
Punch Replacement Parts
Removal, Installation, Adjustment / Top Punch - 3 -
112
RemovalHolder [1] and safety switch [2]:- loosen fixing screws- swing out of position Remove film exit unit and cutting device. Disconnect electrical connection X61:- top punch <-> pcb MODULE CONNECT
Removal, Installation, Adjustment / Top Punch - 4 -
3
Fasten two long cable straps or a suitable tape at both sides as handles. CAUTION:Ensure, that pressure strip [3] is not twisted or damaged due to the handles! Loosen the three fixing screws at the marked positions. NOTE:Screws remain in the top punch! Hold top punch at the handles and lift out.
Removal
Removal, Installation, Adjustment / Top Punch - 5 -
3
InstallationFasten two long cable straps or a suitable tape at both sides as handles. CAUTION:Make sure that pressure strip [3] is not twisted or damaged due to the handles! Hold top punch at the handles and insert from above. Top punch:- position in correct installation position at the trough (screws reach into the milling at the trough)- use three fixing screws to fasten at the marked positions
Removal, Installation, Adjustment / Top Punch - 6 -
112
Establish electrical connection X61:- top punch <-> pcb MODULE CONNECT Manually move the pressure rail back and forth to check for easy movements. Install film exit unit and cutting device. Holder [1] and safety switch [2]:- swing into installation position- fasten with fixing screws Check and, if necessary, perform the parameter set-up.
Installation
- 7 -Removal, Installation, Adjustment / Top Punch / Gear Unit Motor M17
RemovalToothed belt pulley [1]:- loosen two setscrews [6] by one revolution- pull off motor shaft together with toothed belt [2] Unsolder two cables (red, gray). CAUTION:Observe installation position of thegear unit motor, mark if necessary. Remove nut [3]. Gear unit motor [5]:- take out of holder [4]
- 8 -Removal, Installation, Adjustment / Top Punch / Gear Unit Motor M17
RemovalToothed belt pulley [1]:- loosen two setscrews [6] by one revolution- pull off motor shaft together with toothed belt [2] Unsolder two cables (red, gray). CAUTION:Observe installation position of thegear unit motor, mark if necessary. Remove nut [3]. Gear unit motor [5]:- take out of holder [4]
- 9 -
Film exit side
Y 8
Y 9
Trough sideY 6
Y 7
Parts Catalog
Removal, Installation, Adjustment / Top Punch / Solenoids
Installation, SolenoidsSolenoids:- fastened on each side with two screws and washers Set a corresponding distance X for each solenoid: X for the trough side: 2.5 mm X for the film exit side: 5.0 mm Sleeve [1]:- slide onto the solenoid- lightly press against the armature- set sleeve [1] into position with setscrew [2]
Xa
1 2
Xm
1 2
- 10 -
Parts Catalog
Removal, Installation, Adjustment / Top Punch / Solenoids
Installation of the solenoids:- loosely fasten slenoids- position solenoids to measure 1 mm- tighten fixing screws
Installation, Solenoids
1 mm
1 mm
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 11 -
12
6
5
43
5
Cutting Plate RemovalNOTE:As a rule, punch needle, cutting plate and guide panel should be exchanged. Remove coverings. Cover the trough. Remove the film exit unit. (T1) Remove the cutting device. (T2) Remove the top punch. (T3) Cut the cable strap. Pull the connector off the punch motor.
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 12 -
12
6
5
43
5
Unhook the springs [6] (2x). Unscrew the screws [4] from the brackets [3]. Remove the screws [1] (6x) from the holding brackets [2] and [5]. Remove the holding brackets with the rollers from the top punch.
Cutting Plate Removal
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 13 -
6
78
1110
9
12
13 (3x)
14
15
Remove the screws [8] (5x). Remove the collecting tray [7]. Perform the following steps on both sides:- Remove the circlips [10] (2 at eachside) and washers [11] (2 at each side).- Remove the connecting rods [9] (2 x).- Remove the washers [12] (2 at each side). Remove screws [13] (3 x). Remove the pressure rail [14]. CAUTION:Do not unscrew the lever [15].
Cutting Plate Removal
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 14 -
17
16
16
18
Remove the screws [17] (3 x) and remove holding brackets [18]. Unscrew bearing blocks [16] (2 x) and take off the motor unit.
Cutting Plate Removal
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 15 -
19
20
2122
Remove the screws [19] (4 x). Remove the holder [22]. NOTE:Remove the securing varnish from the hexagon socket of the fixing screws [20] using a pointed device. Remove the fixing screws [20] and take the cutting plate [21] off the carrier.
Cutting Plate Removal
Install the cutting plate
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 16 -
19
20
2122
Cutting Plate InstallationCAUTION:Punch needle, cutting plate and guide panel fit together precisely.Components of different spare parts sets must not be mixed! Take the components included in the spare parts set out of the bag and degrease them. Mark installation positions and replacement parts accordingly. Distinctive feature of cutting plate or guide panel:Cutting plate = 4.8 mm thickGuide panel = 3.8 mm thick
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 17 -
19
20
2122
Insert cutting plate [21] and tightenscrews [20] slightly. Position the cutting plate:- lateral distance: 1 mm- distance to lower contact surface: 0.2 mm Tighten screws [20]. CAUTION:The screw ends must no protrude beyond the cutting plate. The position of the guide panels may be checked by mounting a register pin row.
A
A
1 mm1 mm
0.2 mm
Cutting Plate Installation
Remove punch needle and guide panel
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 18 -
2324
252627
28
3129
30
Punch Needle and Guide Panel RemovalRemove the screws [28] from the plate [24]. Swing bar [23] away. Remove the plate [24]. Pull the pin [26] out of the punch needle [25] and remove the punch needle from the guide panel [29]. NOTE:Remove the securing varnish from the hexagon socket of the fixing screws [30] using a pointed device.
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 19 -
2324
252627
28
3129
30
Punch Needle and Guide Panel RemovalUnscrew guide panel from holder [31].
Install punch needle and guide panel
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 20 -
2324
252627
28
3129
30
Punch Needle and Guide Panel InstallationCAUTION:Make sure, the punch needle, cutting plate and guide panel belong to the same set! Insert punch needle [25] in the guide. Insert pin [26]. Insert guide panel [29] and screw on loosely.It must still possible to move the guide panel. Push the punch needle into the guide panel.
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 21 -
19
20
2122
Carefully position the bar onto the carrier. CAUTION:The punch needle must not slip outof the guide panel. Insert the screws [19] (4x) into the carrier from below and tighten them slightly. The lateral surfaces of the holder [22] and of the carrier musut be flush with each other. Tighten the screws and check the position of the holder to the carrier.
Punch Needle and Guide Panel Installation
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 22 -
2324
252627
28
3129
30
Insert punch needle [25] through the guide panel [29] into the cuttingplate. Swing up bar. Install the punch in the machine. Press guide panel upward slightly, carefully press punch needle into the cutting plate and pull it out again. Tighten screws [30] of guide panel alternately and uniformly. Check the punch needle for smooth and easy movement (manually).
Punch Needle and Guide Panel Installation
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 23 -
2324
252627
28
3129
30
NOTE:If smooth and easy movement of the punch needle is not achieved by moving the guide panel, then check the position of the holder in relation to the carrier. Adjust all guide panels and screw tight. Remove the punch again. Insert new balls [27]. Lift punch needle and position plate [24] between holder and pin.
Punch Needle and Guide Panel Installation
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 24 -
2324
252627
28
3129
30
Position pin [26] centrally in the punch needle and press punch needle downward as far as the stop. Swing bar onto the holder. Insert screws [28], position plate [24] carefully and tighten screws.
Punch Needle and Guide Panel Installation
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 25 -
6
78
1110
9
12
13 (3x)
14
15
Observe installation position of pressure rails [14]! Mount pressure rail and tighten screws [13] (3x). Check pressure rail for smooth andeasy movement. CAUTION:The bar must touch the carrier!The punch needle must not slip outof the guide panel!
Punch Needle and Guide Panel Installation
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 26 -
17
16
16
18
Mount motor unit with blocks [16]. Mount holding bracket [18].
Punch Needle and Guide Panel Installation
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 27 -
6
78
1110
9
12
13 (3x)
14
15
Punch Needle and Guide Panel InstallationPerform the following steps on both sides:- Mount washers [12] (2 at each side). - Mount connecting rod [9] (2x). - Mount washers [11] (2 at each side). - Mount circlip [10] (2 at each side)
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 28 -
12
6
5
43
5
32
3334
35
35
GYOG+ -
Mount holding brackets with rollers.Check that the ball bearings (4x) in the guides are sitting correctly. NOTE:The slotted disk [34] must run centrally through the opto switch [32]. Hook in springs [6] (2x). Mount collecting tray. Plug connector onto the motor [33](observe polarity). Fasten cables onto the holder [35] using cable straps.
Punch Needle and Guide Panel Installation
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
Exchange the punch replacement parts in the specified order!
- 29 -
12
6
5
43
5
32
3334
35
35
GYOG+ -
Install the top punch and check theparameters. (T1) Install the cutting device. (T2) Install the film exit unit. (T3)
Punch Needle and Guide Panel Installation
- 30 -Removal, Installation, Adjustment / Top Punch / Stepping Motor M7
RemovalRemove cable strap. Disconnect electrical connection X61. CAUTION:Observe installation position of thestepping motor, mark if necessary. Remove four nuts [1] with screws [2] and washers [3]. Remove toothed belt from toothed belt pulley [4]. Remove stepping motor.
>
- 31 -Removal, Installation, Adjustment / Top Punch / Stepping Motor M7
RemovalRemove cable strap. Disconnect electrical connection X61. CAUTION:Observe installation position of thestepping motor, mark if necessary. Remove four nuts [1] with screws [2] and washers [3]. Remove toothed belt from toothed belt pulley [4]. Remove stepping motor.
>
- 32 -Removal, Installation, Adjustment / Lateral Punch
Punch Body
Lateral punch:- produced according to customer specifications- can be equipped with different numbers of punch bodies- is delivered as a pre-assembled module
Millings forfurther punch bodies(customer-specific)
Punch Replacement Parts
- 33 -Removal, Installation, Adjustment / Lateral Punch / Punch Body
2 (2x)1
1
1
2 (2x)
2 (2x)
RemovalRemove the front covering and the front cover. Disconnect electrical connections. Remove screws [2]. Remove punch body [1] from the machine.
- 34 -Removal, Installation, Adjustment / Lateral Punch / Punch Body
2 (2x)1
1
1
2 (2x)
2 (2x)
InstallationUse screws to fasten the punch body [1] onto the trough, but do not tighten screws [2]. Position the available (punched) film into the trough. Insert the punch needles of the punch bodies in the available punch holes. Tighten screws [2]. Establish electrical connections. Perform a functions test of the lateral punch and check the punch parameters.
- 35 -Removal, Installation, Adjustment / Lateral Punch / Punch Replacement Parts
2 (2x)
5 (2x)
1
6
3
7
8
94 (2x)
RemovalNOTE:As a rule, all punch needles, cutting plate and guide panel should be exchanged. Remove the punch body. (T1) Turn out the screws [4] and take the holder [1] out of the punch body. Remove the pin [6] from the punch needle [7]. Remove the punch needle from theholder. Remove the cutting plate [8] and the guide panel [9].
- 36 -Removal, Installation, Adjustment / Lateral Punch / Punch Replacement Parts
2 (2x)
5 (2x)
1
6
3
7
8
94 (2x)
0.2 ±0.01 mm
1
8
9
InstallationCAUTION:The punch needle, cutting plate andguide panel fit together precisely.Parts from different spare parts sets must not be mixed! Take the components out of the spare parts set and degrease them. Insert the cutting plate [8] in the holder [1] and lightly tighten the screws [5]. Position the cutting plate:- make sure the sides of the cutting plate are flush with the holder sides- distance to the front edge 0.2 ±0.01 mm
- 37 -Removal, Installation, Adjustment / Lateral Punch / Punch Replacement Parts
2 (2x)
5 (2x)
1
6
3
7
8
94 (2x)
0.2 ±0.01 mm
1
8
9
InstallationTighten the screws [5] and check the position of the cutting plate. Screw the guide panel [9] onto the holder, but do not tighten the screws [2]. Insert the punch needle [7] in the cutting plate and guide panel and insert the pin [6]. NOTES:While locking the guide panel in position, move the punch needle back and forth. Tighten the screws [2] alternately insteps of 1/2 revolution.
- 38 -Removal, Installation, Adjustment / Lateral Punch / Punch Replacement Parts
2 (2x)
5 (2x)
1
6
3
7
8
94 (2x)
0.2 ±0.01 mm
1
8
9
InstallationCheck the punch needle for smoothand easy movement. Insert the holder in the punch body [3]. Install the punch body and check the parameter set-up. (T1)
- 39 -
The bottom punch is an option. If no bottom punch is installed, the bottom punch adapter must be installed. The bottom punch may only be actuated if it is installed! After removal of the entire unit, remove and install individual parts.
Bottom Punch
Gear Unit Motor
Removal, Installation, Adjustment / Bottom Punch
Solenoid, Left
Solenoid, RightPunch Replacement Parts
- 40 -Removal, Installation, Adjustment / Bottom Punch
1 (4x)
RemovalRemove the loading platform. (T1) Pull off connectors X66 and X91. Screw out the fixing screws [1]. Remove the bottom punch from the machine.
- 41 -Removal, Installation, Adjustment / Bottom Punch
1 (4x)
InstallationInsert the bottom punch in the machine. Fasten the bottom punch onto the trough using screws [1]. Check the bottom punch for properfunctioning by turning the motor axle. Fit connectors X66 and X91. Install the loading platform. (T1) Perform the parameter set-up.
- 42 -Removal, Installation, Adjustment / Bottom Punch / Gear Unit Motor
1 2 (2x)3
4 (2x)
5 6
7 (2x)9
A
A
ORGY
+
-
8
10
M 19RemovalRemove the screws [2]. Remove the bracket [1] with the opto switch and carefully put it to the side. Pull the flat connector off the motor[3]. Remove setscrew [7]from the eccentric [6]. Pull the pin [9] out of the eccentric. Turn out the screws [4], remove theclamp [5]. Remove the motor with the connecting rod [8] and punch needle from the bottom punch.
- 43 -Removal, Installation, Adjustment / Bottom Punch / Gear Unit Motor
1 2 (2x)3
4 (2x)
5 6
7 (2x)9
A
A
ORGY
+
-
8
10
M 19RemovalPull the connecting rod off the eccentric. Loosen the setscrew position at the motor [7] and pull the eccentricoff the motor axle.
- 44 -Removal, Installation, Adjustment / Bottom Punch / Gear Unit Motor
1 2 (2x)3
4 (2x)
5 6
7 (2x)9
A
A
ORGY
+
-
8
10
M 19InstallationPlace the eccentric [6] onto the motor axle and turn it until the setscrew [7] positioned at the motor exerts pressure onto the milled area of the motor axle. Tighten the setscrew. Position the connecting rod [8] onto the eccentric. Insert the punch needle [10] in the guide panel, move motor [3] into installation position and fasten the clamp [5] using screws. Insert the pin [9] in the eccentric. Screw in the setscrew [7] but do not tighten it.
- 45 -Removal, Installation, Adjustment / Bottom Punch / Gear Unit Motor
1 2 (2x)3
4 (2x)
5 6
7 (2x)9
A
A
ORGY
+
-
8
10
M 19InstallationCAUTION:The switch lug of the pin [9] must run through the center of the opto switch. Mount the bracket [1] with the optoswitch. Turn the motor axle until the punchneedle is at its upmost position (setscrew [7] is at the top). Turn the pin [9] until the slot of the switching lug is in the opto switch. Tighten the setscrew. Fit the flat connector onto the motor, observe polarity.
- 46 -Removal, Installation, Adjustment / Bottom Punch / Solenoid, Left
1
2
3
4 (2x)
5 (2x)7 (2x) 68 (2x)
Y 2
RemovalPull the flat connector off the solenoid [1]. Turn out the screws [5] and remove the solenoid. Loosen the setscrew [2] and pull the sleeve [3] off the magnet armature.
- 47 -Removal, Installation, Adjustment / Bottom Punch / Solenoid, Left
1
2
3
4 (2x)
5 (2x)7 (2x) 68 (2x)
Y 2
InstallationSlide the sleeve [3] onto the magnetarmature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 ±0.2 mm. Tighten the setscrew [2]. Fasten the solenoid onto the bracket [6] using screws. Connect the flat connector, observepolarity.
Install the bottom punch and adjustthe solenoid.
X
GY OG
- 48 -Removal, Installation, Adjustment / Bottom Punch / Solenoid, Left
B
AdjustmentLoosen the solenoid fixing screws. With the armature pushed back, slide the solenoid against the pressure rail [1] until the pressure rail can no longer be moved (Ill. A). Tighten the solenoid fixing screws. Release the armature: The pressure rail must push back the armature smoothly. Push back the aramture completely: There must be a gap between the armature and the pressure rail (Ill. B).
A
Gap
Armature pushed back
Armature pulled out
1
1
- 49 -Removal, Installation, Adjustment / Bottom Punch / Solenoid, Right
1
2
34
5 (2x)
7 (2x)
6 (2x)
8 (2x)
Y 1
RemovalPull the flat connector off the solenoid [3]. Turn out the screws [7] and remove the solenoid. Loosen the setscrew [1] and pull the sleeve [2] off the magnet armature.
- 50 -Removal, Installation, Adjustment / Bottom Punch / Solenoid, Right
1
2
34
5 (2x)
7 (2x)
6 (2x)
8 (2x)
Y 1
InstallationFit the sleeve [2] onto the magnet armature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 ±0.2 mm. Tighten the setscrew [1]. Fasten the solenoid onto the bracket [4] using screws. Connect the flat connector, observe polarity.
Install the bottom punch and adjustthe solenoid.
X
GYOG
- 51 -Removal, Installation, Adjustment / Bottom Punch / Solenoid, Right
B
AdjustmentLoosen the solenoid fixing screws. With the armature pushed back, slide the solenoid against the pressure rail [1] until the pressure rail can no longer be moved (Ill. A). Tighten the solenoid fixing screws. Release the armature: The pressure rail must push back the armature smoothly. Push back the aramture completely: There must be a gap between the armature and the pressure rail (Ill. B).
A
Gap
Armature pushed back
Armature pulled out
1
1
Removal, Installation, Adjustment / Bottom Punch / Punch Replacement Parts - 52 -
Exchange the punch replacement parts in the specified order!
12
5
4 (3x)
3 (3x)
RemovalNOTE:As a rule, punch needle, cutting plate and guide panel should be exchanged. Remove coverings. Cover the trough. Remove the bottom punch. (T1) Unhook the springs [1] and [5]. Remove the pressure rail [2].
Removal, Installation, Adjustment / Bottom Punch / Punch Replacement Parts - 53 -
Exchange the punch replacement parts in the specified order!
6
7
11 10
9
8
Remove the collecting tray [11]. Remove bracket [8] with opto switch. Cut the cable strap at the gear unit motor, pull off the flat connector. Unscrew the cover plates [7] and [9]. Unscrew holding bracket with solenoids [6] and [10] and remove it from the punch. Remove the gear unit motor. (T2)
Removal
Removal, Installation, Adjustment / Bottom Punch / Punch Replacement Parts - 54 -
Exchange the punch replacement parts in the specified order!
17
16
19 (4x)
18
12 13 (2x)
14 15
2021 (2x)
Press pin [14] out of the connecting rod [15] and remove the punch needle [16]. Unscrew the carrier [20] from the bar [12]. Turn out the screws [21] and take the cutting plate [18] off the carrier. Turn out the screws [13] and remove the guide panel [17].
Removal
Removal, Installation, Adjustment / Bottom Punch / Punch Replacement Parts - 55 -
Exchange the punch replacement parts in the specified order!
17
16
19 (4x)
18
12 13 (2x)
14 15
2021 (2x)
CAUTION:The punch needle, cutting plate and guide panel fit together precisely.Components of different spare parts sets must not be mixed! Take the components included in the spare parts set out of the bag and degrease them. Insert cutting plate [18] and tightenscrews [21] lightly. Position the cutting plate:- distance parallel to the lower contact surface: 0.4 ±0.015 mm Tighten screws [21].
Installation
0.4 ±0.015 mm
1820
Removal, Installation, Adjustment / Bottom Punch / Punch Replacement Parts - 56 -
Exchange the punch replacement parts in the specified order!
17
16
19 (4x)
18
12 13 (2x)
14 15
2021 (2x)
CAUTION:The screw ends must not protrude beyond the cutting plate. Insert guide panel [17] and screw on loosely.It must be possible to move the guide panel. Carefully position the carrier [20] onto the straight pins of the bar [12]. Tighten the screws [19] (4x). Insert pin [14] in punch needle [16]. Carefully insert the punch needle through the guide panel [17] in the cutting plate [18].
Installation
Removal, Installation, Adjustment / Bottom Punch / Punch Replacement Parts - 57 -
Exchange the punch replacement parts in the specified order!
17
16
19 (4x)
18
12 13 (2x)
14 15
2021 (2x)
Install the punch in the machine. NOTE:The guide panel is locked in position step by step. Between the individual steps, the punch needle must be moved in both directions. Tighten the screws [13] of the guide panel alternately by 1/2 revolution. Check the punch needle for smoothmovement. Remove the punch. Remove the pin [14] from the punch needle. Insert the punch needle in the connecting rod [15].
Installation
Removal, Installation, Adjustment / Bottom Punch / Punch Replacement Parts - 58 -
Exchange the punch replacement parts in the specified order!
6
7
11 10
9
8
Insert the pin and secure it in position by tapping lightly on both sides using a center punch. Mount the holding bracket with solenoids [6] and [10]. Install the gear unit motor. (T1) Fasten the cable onto the motor using cable straps. Fasten the cover plates [7] and [9] using screws. Mount the collecting tray [11].
Installation
Removal, Installation, Adjustment / Bottom Punch / Punch Replacement Parts - 59 -
Exchange the punch replacement parts in the specified order!
12
5
4 (3x)
3 (3x)
InstallationObserve the installation position ofthe pressure rail [2]! Mount the pressure rail and tightenthe screws [3]. Check the pressure rail for smooth movement. Attach the springs [1] and [5]. Install the bottom punch and checkthe parameters. (T2) Adjust the solenoids.
- 1 -Adapter List, Exposure Unit
MODULE-CONNECT 5.952
X50 => B01 H-MOTHERBOARD 5.949Adapter 2081.1080200.0 04640047
X51 => C01 H-MOTHERBOARD 5.949
Adapter 2081.1080200.0 04640047 X59 => X85 EC-CONTR. 5.951
Flat cable 2081.1080000.0 04537335 X60 => X8 AC-CONTROLLER 5.950
Adapter 2081.1080300.0 04640144 X63 => X113 lateral punch A (option)
Adapter 2081.1081400.0 04556747 # X64 => X114 lateral punch B (option)
Adapter 2081.1081400.0 04556747 # X65 => X115 lateral punch C (option)
Adapter 2081.1081400.0 04556747 #
- 2 -Adapter List, Exposure Unit
MODULE-CONNECT 5.952
X66 => X116 lateral punch D (option)Adapter 2081.1081400.0 04556747 #
X68 => Safety switches S14, S15, S18
Wiring 2081.2060012.0 04661214 X98 => X90 loop monitoring
Cable 2081.1081500.0 04556488
- 3 -Adapter List, Exposure Unit
EC-CONTR. 5.951
X70 => X71 rotating mirrorAdapter 2081.1081001.0 04743598
X72/ => XA4 RIP-INTERFACE 5.976X79 X77/X78 optics head
Adapter 2081.1080100.0 04587162 X80 => X74 optics head
Flat cable 2083.1081500.0 04156951 X82 => X87 MAT.WIDTH I 6.004 or
MAT.WIDTH II 6.063Flat cable 2083.1081500.0 04156951
X84 => X69 MODULE-CONNECT 5.952
Flat cable 2081.1080000.0 04537335 X85 => X59 MODULE-CONNECT 5.952
Flat cable 2081.1080000.0 04537335 X86 => X58 MODULE-CONNECT 5.952
Flat cable 2081.1080000.0 04537335
- 4 -Adapter List, Exposure Unit
Optics head
X74 => X80 EC-CONTR. 5.951Flat cable 2083.1081500.0 04156951
X77/ => XA4 RIP-INTERFACE 5.976X78 X72/X79 EC-CONTR. 5.951
Adapter 2081.1080100.0 04587162
- 5 -Adapter List, Base
H-MOTHERBOARD 5.949
B01 => X50 MODULE-CONNECT 5.952Adapter 2081.1080200.0 04640047
C01 => X51 MODULE-CONNECT 5.952
Adapter 2081.1080200.0 04640047 X39 => Valve controller
Adapter 2081.2056218.0 04671511 X44 => X140 Berger controller
Adapter 2081.1080600.0 04641027 X47 => X147 operating panel
Adapter 2081.1080900.0 04640756 X48 => X13 AC-CONTROLLER 5.950
Adapter 2081.1080500.0 04640586 X49 => Fan E2
Adapter 2081.2056014.0 04569237
- 6 -Adapter List, Base
AC-CONTROLLER 5.950
X8 => X60 MODULE-CONNECT 5.952Adapter 2081.1080300.0 04640144
X13 => X48 H-MOTHERBOARD 5.949
Adapter 2081.1080500.0 04640586 X15 => Vacuum pump
Power cable 2081.2056216.0 04671422 X16 => Compressed air pump
Power cable 2081.2056012.0 04569156 X17 => S1, H1 mains, illuminated display
Adapter 2081.1080400.0 04640837 X20 => X142 Berger controller
Adapter 2081.1080800.0 04640667
- 7 -Adapter List, Base
XA4 => X72/X79 EC-CONTR. 5.951 X77/X78 optics headAdapter 2081.1080100.0 04587162
RIP-INTERFACE 5.976
XA4 => X72/X79 EC-CONTR. 5.951 X77/X78 optics headAdapter 2081.1080100.0 04587162
- 8 -Adapter List, Base
Berger controller
X140 => X44 H-MOTHERBOARD 5.949Adapter 2081.1080600.0 04641027
X141 => X143 stepping motor M8
Adapter 2081.1080701.0 04557182 X142 => X20 AC-CONTROLLER 5.950
Adapter 2081.1080800.0 04640667
Cleaning and Lubricating Agents, Adhesives, Varnish - 9 -
Cleaner's NaphthaCleaning Agents
Precision oil Clock 859 02098318 #Oil Tonna T 68 00593850Universal grease Arcanol L78 00129631 #Special-purpose grease LOSOID 1160B 02463253 #
Lubricating Agents
Varnish retouching pen light gray 04321928 #Varnish retouching pen gray 04321936 #
Varnish
Thermolube, e.g. Electrolube HTC 02722070Securing varnish, f. screws, gray 00129003Adhesive, Loctite 222 01169939 #Adhesive, Loctite 242 01169920 #Adhesive, cyanoacrylate (Sicomet 99) 02225360 #Adhesive, Loctite 572 04138856Adhesive, Loctite 638 02427052 Film material 150x30 mm
Sundries
Tools - 10 -
Screwdriver 00187119Hex. size 2 angled
Screwdriver, ball head 00349712Hex. size 3 T-handle
Screwdriver 02203294Hex. size 3 angled
Screwdriver 02203359Hex. size 3 T-handle
Screwdriver 02203251Hex. size 4 angled
Screwdriver, ball head 01276786Hex. size 4 angled
Screwdriver, ball head 01276778Hex. size 5 angled
Screwdriver 01167057Size 1 Pozidriv
Screwdriver 01234188Size 2 Pozidriv
Screwdrivers
Tools - 11 -
Open-end wrench set Combi. wrench set 02454769
Square ¼"Torque wrench 01760491
0.2-4 Nm ¼"
Wrenches
Tools - 12 -
Dial gauge 00576212Div. 0.01 meas. range 5 mm
Meas. tip f. dial gauge 02486725Meas. disk dia. 10 mm
Magnetic stand 02863286with prism guide
Contactor 00996521500 - 2000 g
Spring balance 04001745Div. 0.05 meas. range 0 - 5 N
Measuring Tools, Mechanical
Tools - 13 -
Oscilloscope 019125932 channels 100 MHz
Digital multimeter 013278524 1/2 digits
Adapter 1:1 f. Service PC 045365769-pin SUB-D max.10 m
Conv. adapter f. Service PC 042350459/25-pin
Adapter SMC/BNC 01959891 #1.5 m
Measuring Tools, Electrical
Tools - 14 -
Spring hook 00494534Rd 1.5 155 mm
Wrench for filter container 05914469 #
Sundries
Starting the Test Software - 1 -
Preparations:- switch off machine Rear panel:- remove from upper edge- lift out of lower guide Mac, PC with terminal emulation or WYSE terminal:- connect using VT 100 connector (SERVICE) Insert floppy disk. Switch on Mac, PC with terminal emulation or WYSE terminal. Switch on Herkules. Input: R0 <ENTER> Check configuration.
Error Messages - 2 -
Error messages are displayed on the operating panel display. Press the "?" key, the stored errors are displayed. Leaf through the messages using key.
- 3 -
EC-CONTR. (6.500)MODULE-CONNECT (5.952)
Pcb ConfigurrationNest
H-MOTHERBOARD (5.949)
AC-CONTROLLER (5.950)
MAT-WIDTH IMAT-WIDTH II
Overview
[only Herkules extension]
- 4 -
EC-CONTR. (5.951)MODULE-CONNECT (5.952)
Pcb ConfigurrationNest
H-MOTHERBOARD (5.949)
AC-CONTROLLER (5.950)
MAT-WIDTH IMAT-WIDTH II
Overview
Pcb MODULE CONNECT (5.952) - 5 -
X64 X63 X62
X57
X51
X52
X61 X98
X50
X54X55X53
X56
Order No. 04575423
X65X66
X69X58 X59
X60
X68
BARCODE
Pcb EC-CONTROL (5.951) - 6 -
X82
K3
X80 X83
S2
S3
S1
Order No. 04577736
X85X86X84
X3
X4 TP15
X72
X73
X70
X1
X38X79
TP15: Light Measurement, Test Program 41- Between 0 and 2.5V (10 mV are approx. 1 digit light value) Example: 200 LV = 2 V.
Pcb EC-CONTROL (5.951) - 7 -
X82
K3
X80 X83
S2
S3
S1
Order No. 04577736
X85X86X84
X3
X4 TP15
X72
X73
X70
X1
X38X79
Connector X3- Window signal for the SOL photo diode
Pcb EC-CONTROL (5.951) - 8 -
X82
K3
X80 X83
S2
S3
S1
Order No. 04577736
X85X86X84
X3
X4 TP15
X72
X73
X70
X1
X38X79
Connector X4
- 5 V for test purposes
Pcb EC-CONTROL (5.951) - 9 -
X82
K3
X80 X83
S2
S3
S1
Order No. 04577736
X85X86X84
X3
X4 TP15
X72
X73
X70
X1
X38X79
Connector X73
- SOL (analog) signal - Check of the direction of rotation, of the rotating mirror - In the case of incorrect direction of rotation actuate switch S1
Correct signal run
Wrong signal run
Pcb EC-CONTROL (5.951) - 10 -
X82
K3
X80 X83
S2
S3
S1
Order No. 04577736
X85X86X84
X3
X4 TP15
X72
X73
X70
X1
X38X79
Switch S2
- SOL window generation 60 µs per motor rotation
Pcb EC-CONTROL (6.500) [only Herkules Extension] - 11 -
X82
K3
X80 X83
S2
S3
S1
Order No. 04896904
X85X86X84
X3
X4 TP15
X72
X73
X70
X1
X38X79
TP15: Light Measurement, Test Program 41- Between 0 and 2.5V (10 mV are approx. 1 digit light value) Example: 200 LV = 2 V.
Pcb EC-CONTROL (6.500) [only Herkules Extension] - 12 -
X82
K3
X80 X83
S2
S3
S1
Order No. 04896904
X85X86X84
X3
X4 TP15
X72
X73
X70
X1
X38X79
Connector X3- Window signal for the SOL photo diode
Pcb EC-CONTROL (6.500) [only Herkules Extension] - 13 -
X82
K3
X80 X83
S2
S3
S1
Order No. 04896904
X85X86X84
X3
X4 TP15
X72
X73
X70
X1
X38X79
Connector X4
- 5 V for test purposes
Pcb EC-CONTROL (6.500) [only Herkules Extension] - 14 -
X82
K3
X80 X83
S2
S3
S1
Order No. 04896904
X85X86X84
X3
X4 TP15
X72
X73
X70
X1
X38X79
Connector X73
- SOL (analog) signal - Check of the direction of rotation, of the rotating mirror - In the case of incorrect direction of rotation actuate switch S1
Correct signal run
Wrong signal run
Pcb EC-CONTROL (6.500) [only Herkules Extension] - 15 -
X82
K3
X80 X83
S2
S3
S1
Order No. 04896904
X85X86X84
X3
X4 TP15
X72
X73
X70
X1
X38X79
Switch S2
- SOL window generation 60 µs per motor rotation
- 16 -
Order No. 04699629
R5
Pcb MAT-WIDTH I (6.004)
BARCODE
X2
X87
R6
Film material required:- Reference film (20% screen or transparent unexposed infrared film)- Black film (100% black). Remove loading platform (T1). Start test software (T2)Call up test 82 Input: r82[l,m] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>
Alignment
- 17 -
Order No. 04699629
R5
Pcb MAT-WIDTH I (6.004)
BARCODE
X2
X87
R6
Display:Bit sequence 7654 3210- Bit 4 = 1 > Film is in both opto switches- Bit 4 = 0 > Film is not in opto switches or only in one opto switche. Insert reference film in the trough in front of the two opto switches. CAUTION:Film must have the same position as with normal operation. Cover left-hand opto switch with the black film. So adjust right-hand pot (R6) that bit 4 changes from "0" to "1". Remove black film.
- 18 -
Order No. 04699629
R5
Pcb MAT-WIDTH I (6.004)
BARCODE
X2
X87
R6
Cover right-hand opto switch with the black film. So adjust left-hand pot (R5) that bit 4 changes from "0" to "1". Perform a test at the end positionsand in the middle of the travel:- without reference film > bit 4 = "0" - with reference film on both opto switches > bit 4 = "1". Install loading platform (T3). Note:If the setting is not possible alter the distance between pcb and carrier.
- 19 -
Order No. 04700805
Pcb MAT-WIDTH II (6.063)
R5
X2X87
R6
Film material required:- Reference film (20% screen or transparent unexposed infrared film)- Black film (100% black). Remove loading platform (T1). Displace carriage in such a way that the right-hand opto switch is positioned over the right-hand reflection strip. Start test software (V > 2.00) (T2)Call up test 82 Input: r82[l,m,r] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>
Alignment
- 20 -
Order No. 04700805
Pcb MAT-WIDTH II (6.063)
R5
X2X87
R6
Display:Bit sequence 7654 3210- Bit 4 = 1 > Film is in opto switch- Bit 4 = 0 > No film is in opto switch. Insert reference film in the trough in front of the right-hand opto switch. Caution:Film must have the same position as with normal operation. So adjust right-hand pot (R4) that bit 4 changes from "0" to "1". Caution:At the ends of the reflection strip, the film must be safely recognized.
- 21 -
Order No. 04700805
Pcb MAT-WIDTH II (6.063)
R5
X2X87
R6
Stop test 82 Input: stop <Enter> Position left-hand opto switch over the left-hand reflection strip. Call up test 82 Input: r82[l,m,l] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter> So adjust left-hand pot (R5) that bit 4 changes from "0" to "1". Caution:At the ends of the reflection strip, the film must be safely recognized.
- 22 -
Order No. 04700805
Pcb MAT-WIDTH II (6.063)
R5
X2X87
R6
Install loading platform (T3). Note:If the setting is not possible alter the distance between pcb and carrier.
Pcb AC-CONTROLLER (5.950) - 23 -
K3
L1
K5K1
K7
F7
K4K2
X2
X19
X18
F5
F6F4
Order No. 04575431
F2F3
X13X17
X3X20
X12X8
X15X16
X4
7X... 306
31
28
5
3533
3432 29X...
Pcb H-MOTHERBOARD (5.949) - 24 -
Order No. 04577698
X48
X47
X42
X46
X43X49 X39
X44
X500
X45
C01 B01
CAUTION:This module is equipped with a Lithium battery.Observe Technical Remarks on Safety (chapter "General")!
- 25 -
A 07
ERIAL-CONTROL (5.948)NCONTROLLER (5.933)ED-CONTROL (5.941)IF (2081.523 or 2081.524)VOLTAGE REG (5.970)
A 02
A 09
A 08
A 04
A 06
unoccupied A 01
unoccupied A 03
unoccupied A 05
Pcb Configuration, Nest
- 26 -
A 07
ERIAL-CONTROL (5.948)NCONTROLLER (5.933)ED-CONTROL (5.941)P INTERFACE(5.976)VOLTAGE REG (5.970)
A 02
A 09
A 08
A 04
A 06
unoccupied A 01
unoccupied A 03
unoccupied A 05
unoccupied
Pcb Configuration, Nest
- 27 -
Meas.Points,
DiagnosticConnector
KK1 XA3X1
BARCODE XB3
Pcb VOLTAGE REG (5.970) Slot 09
Order No. 04578503
- 28 -
Pin 010203040506070809101112131415161718
Diagnostic connector XA 3 on pcb VOLTAGE-REG (slot 09): measuring points
Signal MGND+ 5 V- 2 V B- 15 VREF P1 - P4REF TIGHT MOTSENSE FANREF GUI MOTPWR FANREF LOOP MOTMOT REG SPG CTRLREF B MOT+ 15 V+ 7.5 VMOT REG SPGEXT 2EXT 4+ 24 V
Meaning Supply logic unitfor RIP IF ECL logic unitSupply analog systemReference voltage, punches 1-4Reference voltage for M7Electronics frame fanReference voltage for M2+24 V electronics frameReference voltage for M3Mirror motorReference voltage for M5Supply, analog systemSOP supplyMirror motorn.c.n.c.Motors / solenoids supply
Block Diagrams, Overviews
- 29 -
Pin 19202122232425262728293031323334353637
Diagnostic connector XA 3 on pcb VOLTAGE-REG (slot 09): measuring points
Meaning GND of the 24 Vn.c.n.c.Reference voltage for M6ECL & Peltier element supplyfor ECL RIP IF logic unit+10 V of the DAC for stepping motorReference voltage for punches 5-6Supply, RS 232 (MAINCONTROLLER)S11 compressed air monitoring unitSupply, RS 232 (MAINCONTROLLER)Supply cassette motorCollecting cassette motorMirror motorReference voltage for M1Reference voltage for M15n.c.Opto switch B9 reference voltageSupply, mirror motor
Signal 0 VEXT 3EXT 6Ref SUP CAS- 5.2 V- 2 V ARef 10Ref P5-P6+ 12 VA SWI*- 12 VB MOT 1TA MOT 10 V MOT REG SPG CRTLRef TA MOTRef VVExt 5Ext 1+ 28 V
Block Diagrams, Overviews
Pcb HERK - IF (2081.523 or 2081.524) slot 07 / 08 - 30 -
X1
Order No. 04859987 (machines with mod. status 27)Order No. 04860160 (machines with mod. status 28)
X2 X1
XA4 X21 X20
Pcb RIP INTERFACE (5.976) Slot 08 - 31 -
XA4
X2
BARCODE
X1
XA3
XA7
Order No. 04576330
Pcb FEED-CONTROL (5.941) Slot 06 - 32 -
Order No. 04122119
X1X2
BARCODE
S1S2
XA3
Pcb MAINCONTROLLER (2081.526) Slot 04 - 33 -
X2
BARCODE
X1
V1V2S1
XA4
XC4
XB5
XA6 XB6
XA5
Order No. 05266521
FD drive
FD drive- FD235HF-7529
Pcb MATERIAL-CONTROL (5.948) Slot 02 - 34 -
XA7
X5 X2
BARCODE
X1
S1
Order No. 04576497
- 35 -
F1
Label
Fuse F1 Order No.
T 6.3 A 00138215T 15 A 04188713
Mains Connection
CAUTION:Machine must only be connected to the power supply if the F1 fuse is equipped correctly. F1 fuse:- in the case of U <= 127 V: T 15 A / 250 V- in the case of U > 127 V: T 6.3 A / 250 V NOTE: Fuses have different bayonet joints. Stick the label indicating the set voltage on top of the old one. Label Order No. 230 V 04137655115 V 04258673all other voltages 04258703
Checking Mains Input Fuse
- 36 -
K3
L1
K5K1
K7
F7
K4K2
X2
X19
X18
F5
F6F4
Order No. 04575431
F2F3
X13X17
X3X20
X12X8
X15X16
X4
7X... 306
31
28
5
3533
3432 29X...
Pcb AC-CONTROLLER (5.950)
F2 T 0.3 A 00138452F3 T 0.125 A 01468367
F4 MT 10 A 00240699F5 T 4 A 00442836F6 T 1.5 A 00138525F7 T 8 A 04188691
Fuse Order No.
Block Diagram - 37 -
XA3A08
X44A06
XB6 service
2081.526
XA7
5.948
XB3 C01
XA6
XA3A01
5.970
MATERIAL-CONTROL
MAIN-CONTROLLER
FEED-CONTROL
RIPINTERFACE
A04, 05
5.976 5.941
STEPPINGMOTOR
M8X143
X141X140
SOL, CLOCK, BIAS, VIDEO
A CPU Bus X100
B Priv.Wir X200
C Priv.Wir X500
VT 10019200 bauds8 bitsNo parity1 stop bitNo handshake
RIP 60REC-IF
Motherboard B01
C01
SENSORIKACTUATORS
SPEEDWAY
PcbMODULE
CONNECT
PcbEC-CONTR. /
OPTICS HEAD
AMPLIFIER
VOLTAGE-REG+7.5V SOP-2V A ECL-2V B ECL+28V MIRROR MOTOR
XA4
FDD
Block Diagram - 38 -
SOL, CLOCK, BIAS, VIDEO
X85
5.951 X72 X79 X80
X70
X84X82
X86
OPTICS HEADX78X74 X77
X87
X71
MAT-WIDTH
ROT. MIRRORUNIT
6.004
EC-CONTR.
MODULE CONNECT
RIP INTERFACE
Block Diagram - 39 -
X51
5.952
MODULE-CONNECT
SENSORSACTUATORS
X59X69 X58
X63X64X65X66
X50 X52
X54X55
X53
X61
X98
X68
X60
X57
X56
LOADING PLATFORM
EXPOSURE UNIT
FILM EXIT UNIT
CUTTING DEVICEX90 LOOP MONITORING UNIT
TOP PUNCH (OPTION)
SAFETY SWITCHESS14, S15, S18
(OPTIONS)
AC-CONTROLLER X8 (5.950)
DIAG SENSORS
DIAG ACTUATORSX113 LATERAL PUNCH A (1)X114 LATERAL PUNCH B (2)X115 LATERAL PUNCH C (3)X116 LATERAL PUNCH D (4)
EC-CONTR.
MOTHERBOARD
- 40 -
Pin 010203040506070809101112131415161718
Diagnostic connector XA 3 on pcb VOLTAGE-REG (slot 09): measuring points
Signal MGND+ 5 V- 2 V B- 15 VREF P1 - P4REF TIGHT MOTSENSE FANREF GUI MOTPWR FANREF LOOP MOTMOT REG SPG CTRLREF B MOT+ 15 V+ 7.5 VMOT REG SPGEXT 2EXT 4+ 24 V
Meaning Supply logic unitfor RIP IF ECL logic unitSupply analog systemReference voltage, punches 1-4Reference voltage for M7Electronics frame fanReference voltage for M2+24 V electronics frameReference voltage for M3Mirror motorReference voltage for M5Supply, analog systemSOP supplyMirror motorn.c.n.c.Motors / solenoids supply
Block Diagrams, Overviews
- 41 -
Pin 19202122232425262728293031323334353637
Diagnostic connector XA 3 on pcb VOLTAGE-REG (slot 09): measuring points
Meaning GND of the 24 Vn.c.n.c.Reference voltage for M6ECL & Peltier element supplyfor ECL RIP IF logic unit+10 V of the DAC for stepping motorReference voltage for punches 5-6Supply, RS 232 (MAINCONTROLLER)S11 compressed air monitoring unitSupply, RS 232 (MAINCONTROLLER)Supply cassette motorCollecting cassette motorMirror motorReference voltage for M1Reference voltage for M15n.c.Opto switch B9 reference voltageSupply, mirror motor
Signal 0 VEXT 3EXT 6Ref SUP CAS- 5.2 V- 2 V ARef 10Ref P5-P6+ 12 VA SWI*- 12 VB MOT 1TA MOT 10 V MOT REG SPG CRTLRef TA MOTRef VVExt 5Ext 1+ 28 V
Block Diagrams, Overviews
Block Diagram, Overviews - 42 -
Abbreviations M 1M 2M 3M 4M 5M 6M 7M 8M 9M10M11M12M13M14M15M16M17M18M19
Motors
Allocation Film Exit UnitFilm Exit UnitFilm Exit UnitCutting DeviceLoading PlatformLoading PlatformExposure UnitExposure UnitOptics HeadOptics HeadOptics HeadCompressed Air UnitVacuum UnitFilm Exit UnitVacuum UnitExposure UnitTop PunchLateral PunchBottom Punch
Component Collecting Cassette DriveStepping Motor, Lateral GuideStepping Motor, LoopCutter MotorRewind Motor, Supply CassetteStepping Motor, FeedStepping Motor, Loading UnitStepping Motor, Feed (Spindle)Stepping Motor, FocusStepping Motor, Filter WheelStepping Motor, ShutterCompressed Air PumpVacuum PumpFilm Guide DriveValve ControllerRotating Mirror DriveGear Unit Motor, Top PunchGear Unit Motor, Lateral PunchGear Unit Motor, Bottom Punch
Block Diagram, Overviews - 43 -
Abbreviations S 1S 2S 4S11S12S14S15S16S18
Switches
Allocation Control PanelFilm Exit UnitLoading PlatformCompressed Air UnitVacuum UnitBaseUpper SectionFilm Exit UnitBase
Component On/Off SwitchPolling Unit, LoopFilm End, RemainderPressure SwitchValve ControllerSafety SwitchSafety SwitchCollecting Cassette Polling UnitKey-operated Switch
Interface Recorder <--> Transport Channel / Processor - 44 -
RECORDER - READY
RECORDER - CUT
PROCESSOR - CONNECT
PROCESSOR - ON
PROCESSOR - WAIT
FRAME - GND (shield)
RECORDER Transportchannel / processor
...please refer to the next pages
For explanation on signal names
Interface Timing
Interface Recorder <--> Transport Channel / Processor - 45 -
RECORDER - READYThe recorder is switched on and ready for operation.Now the CUT signal can be evaluated.READY = between pins 1 and 9 24 volts are applied that are evaluated by an opto coupler.
Explanation on Signal NamesX69
READY
CUT
CONNECT
ON
WAIT
SHIELD
Opto coupler
Opto coupler
SUB - D 15-pinSUB - D 15-pin
+24V
+24V
+24V
+24V
Transportchannel
Interfacecable
Recorderinterface
XA7
+24V / max. 150mA
01
09
02
10
03
11
0412
05
13
09
0210
03
11
0412
0513
01
Sign.
Sign.
Sign.
Interface Recorder <--> Transport Channel / Processor - 46 -
RECORDER - CUTThe signal appears-> for the time the film is being cut in the recorder or-> at film end, the supply cassette as simulated signal between galley proof and the rest of the film which is not cut. During this time, the film may not be transported. CUT = between pins 2 and 10, 24 volts are not applied that can be evaluated by an opto coupler.
Explanation on Signal NamesX69
READY
CUT
CONNECT
ON
WAIT
SHIELD
Opto coupler
Opto coupler
SUB - D 15-pinSUB - D 15-pin
+24V
+24V
+24V
+24V
Transportchannel
Interfacecable
Recorderinterface
XA7
+24V / max. 150mA
01
09
02
10
03
11
0412
05
13
09
0210
03
11
0412
0513
01
Sign.
Sign.
Sign.
Interface Recorder <--> Transport Channel / Processor - 47 -
PROCESSOR - CONNECTInstead of the cassette, the transport channel is coupled with the recorder and connected via the interface cable.This coupling is ensured bysignal CONNECT.Dependent on this, the film unloading sequence is switched from cassette operation to on-line operation. Via pins 3 and 11, a ground cable is looped throughthe transport channel and polled in the recorder via 5 volts.CONNECT = ground loop closed. The cassette switch must not be actuated if the transport channel is coupled.
Explanation on Signal NamesX69
READY
CUT
CONNECT
ON
WAIT
SHIELD
Opto coupler
Opto coupler
SUB - D 15-pinSUB - D 15-pin
+24V
+24V
+24V
+24V
Transportchannel
Interfacecable
Recorderinterface
XA7
+24V / max. 150mA
01
09
02
10
03
11
0412
05
13
09
0210
03
11
0412
0513
01
Sign.
Sign.
Sign.
Interface Recorder <--> Transport Channel / Processor - 48 -
PROCESSOR - ONThe on-line processor and the transport channel are connected to the mains and switched on.ON = at pins 4 and 12, 24 volts areapplied which are evaluated in therecorder via opto couplers.
Explanation on Signal NamesX69
READY
CUT
CONNECT
ON
WAIT
SHIELD
Opto coupler
Opto coupler
SUB - D 15-pinSUB - D 15-pin
+24V
+24V
+24V
+24V
Transportchannel
Interfacecable
Recorderinterface
XA7
+24V / max. 150mA
01
09
02
10
03
11
0412
05
13
09
0210
03
11
0412
0513
01
Sign.
Sign.
Sign.
Interface Recorder <--> Transport Channel / Processor - 49 -
PROCESSOR - WAITFor the following reasons, the processorcan receive no galley proofs: -> The level regulations of the baths indicate an incorrect liquid level. -> The temperature sensors of the baths indicate an incorrect temperature (e.g. during the warm-up time after swiching on). -> There is still a galley proof in the transport channel or-> a malfunction in the processor makes it impossible to receive galley proofs.
Explanation on Signal NamesX69
READY
CUT
CONNECT
ON
WAIT
SHIELD
Opto coupler
Opto coupler
SUB - D 15-pinSUB - D 15-pin
+24V
+24V
+24V
+24V
Transportchannel
Interfacecable
Recorderinterface
XA7
+24V / max. 150mA
01
09
02
10
03
11
0412
05
13
09
0210
03
11
0412
0513
01
Sign.
Sign.
Sign.
Interface Recorder <--> Transport Channel / Processor - 50 -
WAIT = at pins 5 and 13, 24 volts are not applied that can be evaluated in the recorder via opto couplers.In the case of a contact error or line break, the error state or an uncritical state should always be entered.
Explanation on Signal NamesX69
READY
CUT
CONNECT
ON
WAIT
SHIELD
Opto coupler
Opto coupler
SUB - D 15-pinSUB - D 15-pin
+24V
+24V
+24V
+24V
Transportchannel
Interfacecable
Recorderinterface
XA7
+24V / max. 150mA
01
09
02
10
03
11
0412
05
13
09
0210
03
11
0412
0513
01
Sign.
Sign.
Sign.
Interface Recorder <--> Transport Channel / Processor - 51 -
PROCESSORCONNECT-L
RECORDERREADY
PROCESSORON
PROCESSORWAIT
RECORDERCUT
FILMLAUF
<---------->--------------->
5V
----------------->
CUT
0V
24V
24V
24V
24V
0V
0V
0V
0V
WAIT WAIT
Pin Interface connector
03
11
09
01
12
04
13
05
10
02
<-------------><-------><----------------->
Interface - Timing
Switch-on process of recorder and processor completed
Interface Recorder <--> Transport Channel / Processor - 52 -
PROCESSORCONNECT-L
RECORDERREADY
PROCESSORON
PROCESSORWAIT
RECORDERCUT
FILMLAUF
<---------->--------------->
5V
----------------->
CUT
0V
24V
24V
24V
24V
0V
0V
0V
0V
WAIT WAIT
Pin Interface connector
03
11
09
01
12
04
13
05
10
02
<-------------><-------><----------------->
Interface - Timing
The recorder did not transport the galley proof continuously through the transport channel due to loop controlling.
Interface Recorder <--> Transport Channel / Processor - 53 -
PROCESSORCONNECT-L
RECORDERREADY
PROCESSORON
PROCESSORWAIT
RECORDERCUT
FILMLAUF
<---------->--------------->
5V
----------------->
CUT
0V
24V
24V
24V
24V
0V
0V
0V
0V
WAIT WAIT
Pin Interface connector
03
11
09
01
12
04
13
05
10
02
<-------------><-------><----------------->
Interface - Timing
Galley proof is being cut, film transport not permissible
Interface Recorder <--> Transport Channel / Processor - 54 -
PROCESSORCONNECT-L
RECORDERREADY
PROCESSORON
PROCESSORWAIT
RECORDERCUT
FILMLAUF
<---------->--------------->
5V
----------------->
CUT
0V
24V
24V
24V
24V
0V
0V
0V
0V
WAIT WAIT
Pin Interface connector
03
11
09
01
12
04
13
05
10
02
<-------------><-------><----------------->
Interface - Timing
Galley proof is continuously transported at a speed of approx.140 mm / sec
Interface Recorder <--> Transport Channel / Processor - 55 -
PROCESSORCONNECT-L
RECORDERREADY
PROCESSORON
PROCESSORWAIT
RECORDERCUT
FILMLAUF
<---------->--------------->
5V
----------------->
CUT
0V
24V
24V
24V
24V
0V
0V
0V
0V
WAIT WAIT
Pin Interface connector
03
11
09
01
12
04
13
05
10
02
<-------------><-------><----------------->
Interface - Timing
The recorder is ready for exposure, galley proof is slowly transported into the processor
Interface Recorder <--> Transport Channel / Processor - 56 -
PROCESSORCONNECT-L
RECORDERREADY
PROCESSORON
PROCESSORWAIT
RECORDERCUT
FILMLAUF
<---------->--------------->
5V
----------------->
CUT
0V
24V
24V
24V
24V
0V
0V
0V
0V
WAIT WAIT
Pin Interface connector
03
11
09
01
12
04
13
05
10
02
<-------------><-------><----------------->
Interface - Timing
WAIT extinguishes only if the transport channel is empty and a new galley proof can be transported out of the recorder
Explanations on the Test Page - 57 -
BAR 2BAR 3
BAR 4
BAR 5BAR 6
BAR 9
BAR 7
BAR 1
BAR 8
BAR 10
BAR 11
BAR 12
Note
Explanations on the Test Page - 58 -
Introduction The setup of a technical test page (TTP 2083) is described.The data stock of this TTP 2083 is available as a Postscript file and it can be copied to Postscript imagesetter systems using a floppy disk.The file is protected by Heidelberger Druckmaschinen Aktiengesellschaft copyright. Application TTP 2083 can be used in all cases where the output quality of Postscript imagesetter systemsis checked and the output is evaluated.By means of this file, a test pattern in the form of a test page is exposed on photo material in the output format of the imagesetter.This test page is analyzed visually, by means of a microscope or by means of an automatic measuring device.REMARK:This test page is used exclusively for evaluating the exposure quality. Notes on possible error sources can only contribute coarsely to the error identification.
General
Explanations on the Test Page - 59 -
Structure of test page The test page consists of different test patterns, BAR 1 - BAR 12. Base fog Base fog:- can be measured on every unexposed position of the test page,- depends to a high degree on the photo material and on the set threshold value of the imagesetter. If the imagesetter is correctly adjusted, the following values are valid:0.3 - 0.5 density, orthochromatic0.5 - 0.8 density, ultraviolet Measuring instruments: Densitometer with a corresponding measuring range Possible error sourcesIf the base fog is too high, check the photo material, the developing processes,the storage and the handling of photo material.
General
Explanations on the Test Page - 60 -
Is there a pre-exposure?The imagesetter is adjusted by means of a light test including a threshold value adjustment.In the case of an incorrect adjustment of the threshold value, it may happen that the photo material is pre-exposed.
General
Explanations on the Test Page - 61 -
BAR 1, BAR 12 as well as the grid patterns between corner points A and K as well as C and Mare line images consisting of lines of identical width and spacing.With these grid patterns, the geometrical reproduction accuracy can be checked.This applies to page width, page height, diagonal, linearity, straightness, line width in FastScan and SlowScan directions.Evaluation should be performed with an automatic measuring instrument. A coarse, fast evaluation can be performed visually. REMARK:During evaluation of the absolute precision, it must be observed that an error-free calculationof the geometry data was performed by Postscript.Otherwise, only the determination of the repetition accuracy is possible. An enlargement or reduction of the test page is always performed symmetrically to the X- or Y-axis. The 50% and the 90% screen areas in the four corners are used to measure of screen homogeneity in comparison with the screen areas in BAR 7, 9 and 10. In addition, BAR 1 comprises:- the test page designation TTP 2083 and its version number- 3 register marks which are used to accurately position the test page in a punch
BAR 1 and BAR 12: Explanation
Explanations on the Test Page - 62 -
Geometry can be checked or measured using BAR 1 and BAR 12. Page lengthsAll four lengths (AC, KM, AK, CM) are compared with the lengths pre-set by the front-end system.Check the absolute deviation and the delta of the opposite side. Perpendicularityis the difference value between the diagonals (AM and CK). Linearityis the repetition accuracy of the partial distances of the lengths AC, KM, AK, CM. Length(actual) * partial length(set)Partial length(actual) = ---------------------------------------------------------- Length(set) Linearity error = Partial length(set) - partial length(actual) StraightnessThe lines AC, KM, AK, CM must be straight.
BAR 1 and BAR 12: Evaluation
Explanations on the Test Page - 63 -
Line widthThe lines AC, KM, AK, CM as well as all short horizontal lines must have the same width. The imagesetters offer a highly precise geometrical recording function.However, this is very strongly influenced by the photo materials. The photo materials in particular change under temperature, humidity and mechanical influences.Depending on the used photo material, different results are to be expected.
BAR 1 and BAR 12: Evaluation
Explanations on the Test Page - 64 -
A ruler (glass ruler) is suitable for coarse measurements.For precise measurements, an automatic measuring instrument is required. For a further simple and coarse evaluation, the test page is cut into halves at that X or Y axis.The two halves of the test page are put on top of each other with the emulsion sides facing each other and brought to coincidence at the corner points.Thus, page length, linearity, straightness and perpendicularity can be evaluated using a microscope (40- to 50-fold enlargement).
BAR 1 and BAR 12: Measuring instruments
Explanations on the Test Page - 65 -
Sharply focused exposure, but geometrical distortion-> Observe photo material handling, such as transport, temperature, humidity, development. Unsharpness and distortion-> Possible reason(s): photo material not fitting during exposure. Linearity error and page length error in FastScan direction-> Possible reason(s): drive failure of the rotating mirror. Linearity error and page length error in SlowScan direction-> Possible reason(s): drive failure of the exposure carriage. Straightness error: deflection of lines in FastScan direction-> Possible reason(s): deadjustment of the beam position. Straightness error: deflection of lines in SlowScan direction-> Possible reason(s): failures in the travel distance of the exposure carriage.
BAR 1 and BAR 12: Possible error sources
Explanations on the Test Page - 66 -
BAR 2 is a solid area density bar (100%).It is used to measure the solid area density during exposure in landscape and portrait format. The inserted recesses (bright rectangles) change the black and white information in such a way that possible density changes in large areas between different video dynamics can be detected. This only applies to FastScan direction. When changing the test page format, the bar height of 10 mm remains constant, the bar width changes symmetrically to the center axis.
BAR 2: Explanation
Explanations on the Test Page - 67 -
If the test page is exposed in landscape and portrait format, the solid area density lets and itshomogeneity can be measured at any point using a densitometer. The solid area density depends on the photo material and imagesetter specifications. At the bar recesses, the solid area density can be measured from transparency to black in FastScan direction, and vice versa.
BAR 2: Evaluation
Explanations on the Test Page - 68 -
Densitometer with measuring range in accordance with the selected solid area density.Microscope with 40- to 50-fold enlargement.
BAR 2: Measuring instruments
Explanations on the Test Page - 69 -
Continuous decline of density in FastScan direction and exceeding of the density tolerance-> Possible reason(s): excessive dirt accumulation of the rotating mirror. Continuous decline of density in FastScan and SlowScan directions-> Possible reason(s): interruption of the developing process, pre-exposure of photo material. Check material packing, cassette shutter, machine cover.
BAR 2: Possible error sources
Explanations on the Test Page - 70 -
In BAR 3, all page-specific parameters can be read off. The image parameters- width:... mm- height: ... mm- rotation: ... degand the screen system- DotShape: ...- Screensystem: ...- HFactor: ...- resolution: ... pixel / cm [dots / inch]- Screenangle: ... deg- Screenruling: ... screen lines / cm [lines / inch]are selected for exposure via operation. Specifications- Version: ...- Revision: ...- Serial No.: ...are system parameters and are output on every test page exposure.
BAR 3: Explanation
Explanations on the Test Page - 71 -
In addition to the company name and the copyright note, the following fields are available for entries:MATERIAL:DATE:TIME:SIGN.:TESTNO.: CAUTION:Prior to each evaluation of the test page, the parameters set for exposure must be checked inorder to avoid misinterpretations.
BAR 3: Explanation
Explanations on the Test Page - 72 -
The round test symbol is used for visual determination of the focus and the focus homogeneity. The size and the shape of the dark area in the center of the test symbol is a criterion for the focus evaluation. When changing the test page format, the size of the test symbol remains unchanged, their number, however, changes. The concentric rings are an aid for comparing the test symbols of an exposure.
BAR 4: Explanation
Explanations on the Test Page - 73 -
The smaller the black area in the center - assumung that the work density is constant - the sharper is the adjustment of the imagesetter.In the case of an error-free exposure of the test symbol, the centers of all symbols must be identical. This is applies to FastScan and SlowScan directions. The size of the black area is a coarse indication for the resolution selected for the exposure.Coarse resolution --> large black areaFine resolution --> small black area NOTE:When using photographic paper, the dark area is larger.
BAR 4: Evaluation
Explanations on the Test Page - 74 -
Evaluation is performed purely visually.
BAR 4: Measuring instruments
Explanations on the Test Page - 75 -
A large black area in all symbols indicates poor focusing or excessive density if photo material was exposed, e.g., in the saturation area.Uneven black area sizes in the test symbols indicate that the photo material did not fit during exposure. This is applies to FastScan and SlowScan directions.
BAR 4: Possible error sources
Explanations on the Test Page - 76 -
Various resolution symbols (micro character = M ) can be found in BAR 5 across the entire test page width.Their distances are 10 mm. The resolution symbol is can be found on further positions in the test page so that it is possible to compare the results. The resolution symbol is used to evaluate the resolution and further criteria using a microscope.The structure of the symbol allows the evaluation in FastScan and SlowScan directions.
BAR 5: Explanation
Explanations on the Test Page - 77 -
Resolution symbol (enlarged representation) in BAR 5
Explanations on the Test Page - 78 -
The essential evaluation criteria are:- repetition of lines- repetition of line spacings- geometry of the lines and line spacings- transitions between the lines or between spacings- fringing between transparency and solid density- density structure in the case of different line combinations- fine structure of the lines The repetition of the lines and the line spacings is especially important.This repetition (width and black density range) is strongly influenced by:- focus setting of the imagesetter- the selected resolution of the imagesetter- the used photo material
BAR 5: Evaluation
Explanations on the Test Page - 79 -
The evaluation of the criteria is performed using a microscope with 40- to 50-fold enlargement.A microdensitometer is required for more precise and objective evaluations.
BAR 5: Measuring instruments
Explanations on the Test Page - 80 -
The focus setting of the imagesetter is important. Different resolution symbols in the exposure positions-> Possible reason(s): photo material not fitting during exposure.
BAR 5: Possible error sources
Explanations on the Test Page - 81 -
This is a text bar with font sizes 1, 1.5 and 3 mm of all letters of the alphabet.It can be used to evaluate the repetition of the fonts, in particular the fine structure in the case of complex fonts.
BAR 6: Explanation
Explanations on the Test Page - 82 -
The large-area screen field in the 90% tone value is used to evaluate the area quality.
BAR 7: Explanation
Explanations on the Test Page - 83 -
The screen field must be a uniform 90% tone value area. It must be free of screen interferences, tone value changes and other patterns which can be detected by eyesight. This applies to exposure in landscape and portrait format.
BAR 7: Evaluation
Explanations on the Test Page - 84 -
Densitometer and visual evaluation.
BAR 7: Measuring instruments
Explanations on the Test Page - 85 -
Interferences (structures at periodic distances)-> Possible reason(s): defect in the feed system of the exposure carriage. Continuous tone value decline in FastScan direction-> Possible reason(s): excessive dirt accumulation of the rotating mirror, photo material not fitting during exposure. See also screen field with 90% tone value in BAR 1 and BAR 12.
BAR 7: Possible error sources
Explanations on the Test Page - 86 -
The vertical middle of the test page is between BAR 7 and BAR 8. If the page is cut horizontally in this position, the halves can be placed on top of each other for a visual check of the exposure geometry.
Note
Explanations on the Test Page - 87 -
These screen bars represent a total of a screen shading from 2% to 98%. BAR 8 includes graduations 60, 70, 80, 90, 92, 94, 96, 98%, that is, the shadow and middle ranges. BAR 11 includes graduations 2, 4, 6, 8, 10, 20, 30, 40%, that is, the highlights and middle ranges. BAR 10 represents the 50% tone value. By means of these screen bars, the following criteria are checked:- repetition of the screen tone value in %; all levels from 2% to 98% in the case of basic adjustment and with screen tone value correction performed (linearization)- recognition of interferences in shadow ranges >90%- determination of the screen homogeneity per screen bar- using the microscope, the increase and decline of the screen dot area
BAR 8, 10, 11: Explanation
Explanations on the Test Page - 88 -
The screen bars must be a uniform area according to the tone value. They must be free of screen interferences, tone value changes and other structures which are visible by eyesight. This applies to exposure in landscape and portrait format. In the case of a correct solid area density (depending on the film type), the exposed screen tone values only deviate slightly from the calculated ones (set input). However, depending on the selected resolution, differences are to be expected in the tone value repetitions.
BAR 8, 10, 11: Evaluation
Explanations on the Test Page - 89 -
Microscope with 40- to 50-fold enlargement.Densitometer and visual evaluation.
BAR 8, 10, 11: Measuring instruments
Explanations on the Test Page - 90 -
Interferences (structures at periodic distance)-> Possible reason(s): defect in the feed system of the exposure carriage. Continuous tone value decrease in FastScan direction-> Possible reason(s): excessive dirt accumulation at the rotating mirror, photo material not fitting during exposure. Linearizations which might have been set with regard to used photo material and developing processes must be observed.
BAR 8, 10, 11: Possible error sources
Explanations on the Test Page - 91 -
This sample consists of a screen area and bars. It is used to determine possible tone value changes in the 90% screen during video changes differing in time. For this purpose, the bar must run in FastScan direction.
BAR 9: Explanation
Explanations on the Test Page - 92 -
In the 90% screen field, no trailing strips in the rhythm of the"black -> screen" and "white -> screen" transitions may occur.
BAR 9: Evaluation
Explanations on the Test Page - 93 -
Evaluation is performed purely visually.
BAR 9: Measuring instruments
Explanations on the Test Page - 94 -
These screen bars represent a total of a screen shading from 2% to 98%. BAR 8 includes graduations 60, 70, 80, 90, 92, 94, 96, 98%, that is, the shadow and middle ranges. BAR 11 includes graduations 2, 4, 6, 8, 10, 20, 30, 40%, that is, the highlights and middle ranges. BAR 10 represents the 50% tone value. By means of these screen bars, the following criteria are checked:- repetition of the screen tone value in %; all levels from 2% to 98% in the case of basic adjustment and with screen tone value correction performed (linearization)- recognition of interferences in shadow ranges >90%- determination of the screen homogeneity per screen bar- using the microscope, the increase and decline of the screen dot area
BAR 8, 10, 11: Explanation
Explanations on the Test Page - 95 -
The screen bars must be a uniform area according to the tone value. They must be free of screen interferences, tone value changes and other structures which are visible by eyesight. This applies to exposure in landscape and portrait format. In the case of a correct solid area density (depending on the film type), the exposed screen tone values only deviate slightly from the calculated ones (set input). However, depending on the selected resolution, differences are to be expected in the tone value repetitions.
BAR 8, 10, 11: Evaluation
Explanations on the Test Page - 96 -
Microscope with 40- to 50-fold enlargement.Densitometer and visual evaluation.
BAR 8, 10, 11: Measuring instruments
Explanations on the Test Page - 97 -
Interferences (structures at periodic distance)-> Possible reason(s): defect in the feed system of the exposure carriage. Continuous tone value decrease in FastScan direction-> Possible reason(s): excessive dirt accumulation at the rotating mirror, photo material not fitting during exposure. Linearizations which might have been set with regard to used photo material and developing processes must be observed.
BAR 8, 10, 11: Possible error sources
Explanations on the Test Page - 98 -
These screen bars represent a total of a screen shading from 2% to 98%. BAR 8 includes graduations 60, 70, 80, 90, 92, 94, 96, 98%, that is, the shadow and middle ranges. BAR 11 includes graduations 2, 4, 6, 8, 10, 20, 30, 40%, that is, the highlights and middle ranges. BAR 10 represents the 50% tone value. By means of these screen bars, the following criteria are checked:- repetition of the screen tone value in %; all levels from 2% to 98% in the case of basic adjustment and with screen tone value correction performed (linearization)- recognition of interferences in shadow ranges >90%- determination of the screen homogeneity per screen bar- using the microscope, the increase and decline of the screen dot area
BAR 8, 10, 11: Explanation
Explanations on the Test Page - 99 -
The screen bars must be a uniform area according to the tone value. They must be free of screen interferences, tone value changes and other structures which are visible by eyesight. This applies to exposure in landscape and portrait format. In the case of a correct solid area density (depending on the film type), the exposed screen tone values only deviate slightly from the calculated ones (set input). However, depending on the selected resolution, differences are to be expected in the tone value repetitions.
BAR 8, 10, 11: Evaluation
Explanations on the Test Page - 100 -
Microscope with 40- to 50-fold enlargement.Densitometer and visual evaluation.
BAR 8, 10, 11: Measuring instruments
Explanations on the Test Page - 101 -
Interferences (structures at periodic distance)-> Possible reason(s): defect in the feed system of the exposure carriage. Continuous tone value decrease in FastScan direction-> Possible reason(s): excessive dirt accumulation at the rotating mirror, photo material not fitting during exposure. Linearizations which might have been set with regard to used photo material and developing processes must be observed.
BAR 8, 10, 11: Possible error sources
Explanations on the Test Page - 102 -
BAR 1, BAR 12 as well as the grid patterns between corner points A and K as well as C and Mare line images consisting of lines of identical width and spacing.With these grid patterns, the geometrical reproduction accuracy can be checked.This applies to page width, page height, diagonal, linearity, straightness, line width in FastScan and SlowScan directions.Evaluation should be performed with an automatic measuring instrument. A coarse, fast evaluation can be performed visually. REMARK:During evaluation of the absolute precision, it must be observed that an error-free calculationof the geometry data was performed by Postscript.Otherwise, only the determination of the repetition accuracy is possible. An enlargement or reduction of the test page is always performed symmetrically to the X- or Y-axis. The 50% and the 90% screen areas in the four corners are used to measure of screen homogeneity in comparison with the screen areas in BAR 7, 9 and 10. In addition, BAR 1 comprises:- the test page designation TTP 2083 and its version number- 3 register marks which are used to accurately position the test page in a punch
BAR 1 and BAR 12: Explanation
Explanations on the Test Page - 103 -
Geometry can be checked or measured using BAR 1 and BAR 12. Page lengthsAll four lengths (AC, KM, AK, CM) are compared with the lengths pre-set by the front-end system.Check the absolute deviation and the delta of the opposite side. Perpendicularityis the difference value between the diagonals (AM and CK). Linearityis the repetition accuracy of the partial distances of the lengths AC, KM, AK, CM. Length(actual) * partial length(set)Partial length(actual) = ---------------------------------------------------------- Length(set) Linearity error = Partial length(set) - partial length(actual) StraightnessThe lines AC, KM, AK, CM must be straight.
BAR 1 and BAR 12: Evaluation
Explanations on the Test Page - 104 -
Line widthThe lines AC, KM, AK, CM as well as all short horizontal lines must have the same width. The imagesetters offer a highly precise geometrical recording function.However, this is very strongly influenced by the photo materials. The photo materials in particular change under temperature, humidity and mechanical influences.Depending on the used photo material, different results are to be expected.
BAR 1 and BAR 12: Evaluation
Explanations on the Test Page - 105 -
A ruler (glass ruler) is suitable for coarse measurements.For precise measurements, an automatic measuring instrument is required. For a further simple and coarse evaluation, the test page is cut into halves at that X or Y axis.The two halves of the test page are put on top of each other with the emulsion sides facing each other and brought to coincidence at the corner points.Thus, page length, linearity, straightness and perpendicularity can be evaluated using a microscope (40- to 50-fold enlargement).
BAR 1 and BAR 12: Measuring instruments
Explanations on the Test Page - 106 -
Sharply focused exposure, but geometrical distortion-> Observe photo material handling, such as transport, temperature, humidity, development. Unsharpness and distortion-> Possible reason(s): photo material not fitting during exposure. Linearity error and page length error in FastScan direction-> Possible reason(s): drive failure of the rotating mirror. Linearity error and page length error in SlowScan direction-> Possible reason(s): drive failure of the exposure carriage. Straightness error: deflection of lines in FastScan direction-> Possible reason(s): deadjustment of the beam position. Straightness error: deflection of lines in SlowScan direction-> Possible reason(s): failures in the travel distance of the exposure carriage.
BAR 1 and BAR 12: Possible error sources
- 1 -Setting the Parameters
... of the Punches
... of the Optics Head
... of the TOUCH MEMORY (Motherboard)
... the Guide Opto Switch
Parameter Set-up ...
Modifying a Parameter (Example with Menu Description)
Modifying a Parameter (BriefDescription)
... of the TOUCH MEMORY (Supply Cassette)
... the Advantage Option
- 2 -Modifying a Parameter (Brief Description)
Starting with the basic menu: Enter the password, for this purpose- press key f Search a parameter, for this purpose- press key 2 Select the data record "static data", for this purpose- press key 1 Change to default, for this purpose- press key d Enter the PID or the parameter name, for this purpose- press key 1 Enter new value Save the value (on floppy disk), for this purpose- press key s
- 3 -Modifying a Parameter (Example with Menu Description)
1. speedway commands menu2. parameter menu3. test menu8. adjust tests9. external testsa. recorder informationb. recorder measurementc. quick set of geometry paramd. quick set of other parame. toggle recorder status linef. password
HERKULES Test Releaseversion: 2.01.xxxdate: xx xx xx
(ON)(ON)
(PF1)(PF2)(PF3)(PF4)(OFF)
Basic menu:After entering the password (for this purpose, press key f), parameters can be modified. To modify a parameter (here: Punch Configuration) press key 2.
- 4 -Modifying a Parameter (Example with Menu Description)
PARAMETER MENU - WORK DATAq. Quit1. static data2. application data3. action data4. material data5. measure data6. save machine configuration7. restore machine configuration8.
This menu contains only data records,as well as commands for saving andrestoring recorder-specific data.After selecting a data record(here: static data) you are ...
- 5 -Modifying a Parameter (Example with Menu Description)
WORK STATIC DATA - FIND & EDIT1. Find parameter2. Normal sorted list3. Pid sorted list4. Name sorted list
q. Quitd. Switch to Default
DEFAULT STATIC DATA - FIND & EDIT1. Find parameter2. Normal sorted list3. Pid sorted list4. Name sorted list
q. Quitw. Switch to Workr. Read parameterss. Save parameters
... immediately in the new parameter editor.Press key d to go to the default data record.If, e.g., key 1 is pressed, you can either ...
Description of the KEYSKEY 1Extended parameter search function.You can either search for PID or parameter names. It does not matter how the name is written. If no corresponding parameter is found, the search function suggests a similar parameter. KEY 2The parameters are listed according to their function (the most important parametersare shown in the first positions, the order corresponds to the one shown on the recorder display). KEY 3This list is sorted according to the PID numbers. KEY 4This list is sorted according to the parameter names.
- 6 -Modifying a Parameter (Example with Menu Description)
WORK STATIC DATA - FIND & EDIT1. Find parameter2. Normal sorted list3. Pid sorted list4. Name sorted list
q. Quitd. Switch to Default
DEFAULT STATIC DATA - FIND & EDIT1. Find parameter2. Normal sorted list3. Pid sorted list4. Name sorted list
q. Quitw. Switch to Workr. Read parameterss. Save parameters
... immediately in the new parameter editor.Press key d to go to the default data record.If, e.g., key 1 is pressed, you can either ...
KEY qQuits the parameter editor. KEY wChanges to work mode. Only temporary changescan be performed in the recorder. KEY dChanges to default mode. All changes are permanently effective (as soon as this data record is saved with "s"). KEY rThe data record is read from the recorder floppy disk (only possible in default mode). KEY sThe data record is written onto the floppy disk (only possible in default mode).
Description of the KEYS
- 7 -Modifying a Parameter (Example with Menu Description)
DEFAULT STATIC DATA Search PanchKonfugirDo you mean 'punch configur' like'Punch Configuration' ?(y)es, find this(n)o, continue with next proposal(q)uit
DEFAULT STATIC DATA - FIND & EDIT1. Find parameter2. Normal sorted list3. Pid sorted list4. Name sorted list
q. Quitd. Switch to Defaultr. Read parameterss. Save parameters
Continue with any key ...Enter an PID or Parameter name:PanchKonfugir
... enter the name or the PID. If the name is written incorrectly, a name as similar as possibleis suggested. It is also possible to enter a partial string (e.g. 'punch'). After pressing key y...
Description of the KEYSKEY yThe suggested parameter is correct.A list of all parameters containingthe specified names is drawn up. KEY nLooks for more common criteria. KEY qQuits the search function and return to the previous menu.
- 8 -Modifying a Parameter (Example with Menu Description)
DEFAULT STATIC DATA Search punch0. | Punch Shape P31. | Punch Shape P4..........9. | Punch Advance P0a. | Punch Advance P1.....e. .....
| PID= 83| PID= 84..........| PID= 110| PID= 111..........
| free| free..........| mm| mm..........
| 0| 0..........| 0| 0..........
(q)uit (p)rev (n)ext
... a list of all parameters containing thispartial string is displayed (here: 'punch' ).If the key for 'Punch Configuration' is pressed, ...
Description of the KEYSKEY qQuits the list. KEY pPrevious page of the list (key is only active if there is more than one page to be selected). KEY nNext page of the list (key is only active ifif there is more than one pageto be selected). KEYS 0 - eSelects the parameter to be edited.
- 9 -Modifying a Parameter (Example with Menu Description)
PARAMETER EDITParameter ClassParameter SetDescriptionIdent (PID)UnitTypeAccessMinimum ValueMaximum ValueCurrent Value
New value (?) help:
: DEFAULT PARAMETER: STATIC DATA: Punch Configuration: 766: free: UINT: User Read, Service Write: 0: 32: 16
... the PARAMETER EDIT menu is displayed (noalphabetical character string can be assignedto a numerical parameter). If default parametershave been modified, then they must be ...
Description of the KEYSKEY ?Call up parameter-sensitive ONLINE help.
- 10 -Modifying a Parameter (Example with Menu Description)
DEFAULT STATIC DATA - FIND & EDIT1. Find parameter2. Normal sorted list3. Pid sorted list4. Name sorted list
q. Quitd. Switch to Workr. Read parameterss. Save parameters
Continue with any key ...
Default parameter changed. Save (y / n) ?
... saved in the parameter editor with key s. If you exit the editor without saving the modifed values an appropriate message is displayed.
- 11 -Modifying a Parameter (Example with Menu Description)
DEFAULT STATIC DATA PID sorted parameter
(q)uit, (p)rev, (n)ext, (f)irst of list, (l)ast of list, (g)o to
Key | Name | PID | UNIT | VALUE
0. | SS2UZP1. | FS2UZP..........9. | SS2P2a. | Punch Link P2.....e. | FS2P4
| 3| 4..........| 17| 18.....| 22
| µm| µm..........| µm| free.....| µm
| 0| 0..........| 0| 0.....| 0
Example for a list sorted according to PID.
Description of the KEYSKEY qQuits the list KEY pPrevious page of the list KEY nNext page of the list KEY fFirst page of the list KEY lLast page of the list KEY gGo to a specific parameter (input options: PIDor name) and show the list from this positiononwards KEY 0 - eSelects the parameter to be edited
- 12 -Parameter Set-up of the Punches
NOTE:The parameter setting should be performed on a backup diskette. Precondition:- Switch off the punch on the RIP- Set the RIP to collect mode. At the service terminal:Input Explanation f PasswordInput check 2 Parameter menu d Set default data flag 1 Static parameter 3 Geometry 1 Recorder geometry b Changing SS SOP -34500 New value
Return to geometry
Lateral punches
Bottompunch
Arrangement of Punches
Top punches
Punch Type Punch Geometry Key Punch LinkLateral...
Bottom...Top...
1
12
5
56
PL0 = 1PL1 = 2PL2 = 4PL3 = 8PL4 = 8PL5 - 9= 16 each
Activating the Punches
- 13 -Parameter Set-up of the Punches
At the service terminal:Input Explanation
Punch configuration (PID 766) X Adding the punch links according to
the available lateral punches:1+2+4+8 = X (variable value)
16 Constant value of top punches Y = X (value of lateral punches) + 16 (const. value of top punches) Z = X (value of lateral punches)
+ 8 (const. value of bottom punches) + 16 (const. value of top punches)
Example of punch configuration:Z = 31 = (1+2+4) + (8) + (16)
lateral bottom top
Lateral punches
Bottompunch
Arrangement of Punches
Top punches
Activating the Punches
Punch Type Punch Geometry Key Punch LinkLateral...
Bottom...Top...
1
12
5
56
PL0 = 1PL1 = 2PL2 = 4PL3 = 8PL4 = 8PL5 - 9= 16 each
- 14 -Parameter Set-up of the Punches
Lateral punches
Bottompunch
Arrangement of Punches
Top punches
At the service terminal:Input Explanation Change punch links according to the list
For non-available punch linksenter value 0.
q return q return w save
Activating the Punches
Punch Type Punch Geometry Key Punch LinkLateral...
Bottom...Top...
1
12
5
56
PL0 = 1PL1 = 2PL2 = 4PL3 = 8PL4 = 8PL5 - 9= 16 each
- 15 -Parameter Set-up of the Punches
Exposing the Test Film
At the RIP terminal:- perform job ‘Punch-li.ps’. At the service terminal:Input Explanation 8 Adjust tests p Punching At the RIP terminal:- perform job ‘Punch-Help.ps’ (measuring template).
- 16 -Parameter Set-up of the Punches
Measuring the Test Film
At the service terminal:Input Explanation a Recorder information Values ‘Exposing window’:- note down 'FS to begin' and 'SS to begin' on the exposed test film. NOTE:The parameter determination for the lateral punches described in the following is meant as example.The parameters for the other punches are determined accordingly.For the arrangement and allocation of the respective punches, refer to the test film:- Lateral punch = Punch 0 to punch 3- Bottom punch = Punch 4- Top punch = Punch 5 to punch 9
Lateral punches
Bottompunch
Arrangement of Punches
Top punches
- 17 -Parameter Set-up of the Punches
Take measurements on the film using the exposed measuring template(do not interchange scales for Stoesser or Bacher punches). Determine lateral punch - 'Punch 0 FS':- Position the template on top of punch 0- The line reaching from the center of the punch hole to the two scales below the hole indicates the value 'b0' in mm- Calculate und enter 'Punch 0 FS'.
Template for 'b0'Punch hole 0Punch
Value 'b0'
Punch 0 FS = 'FS to begin' + 'b0' (all values in µm)
Measuring the Test Film
- 18 -Parameter Set-up of the Punches
Determine the lateral punch - ‘Punch 0 SS’:- Position the template on top of punch 0- Measure the line from the center of the punch hole to the ‘20mm measuring edge’ = value ‘a0’- Calculate und enter ‘Punch 0 SS’. Take the respective measurement and make the entries for all punches.
Template for 'b0'
Punch 0 SS = ‘a0’ + ‘SS to begin’ (all values in µm)
Punch hole 0Punch
20mm measuring edge
Measuring the Test Film
- 19 -Parameter Set-up of the Punches
Determine the lateral punch - ‘Punchend SS’:- Measure the black bar positioned opposit to punch hole 0 starting at ‘20mm measuring edge’ = value ‘y’- Value 'c' = 20000 - 'y'- Calculate und enter punchend SS.
Punchend SS = ‘c’ + ‘SS to begin’ (all values in µm)
Punch hole 0Punch
20mm measuring edge
yc
Measuring the Test Film
- 20 -Parameter Set-up of the Punches
Entering Punch Parameters
At the service terminal:Input Explanation 2 Parameter menu d Set default data flag 1 Static parameter 3 Geometry 5 / 6 Punch geometry 1 / 2
Enter the measured or calculated parameters and save them Space w
Enter and save value 'Punchend SS'. Reset the Herkules and wait for the message ‘Recorder ready’. At the RIP terminal:
Activate the punch Expose the job
Check the punch geometry and, if necessary, correct it.
- 21 -Parameter Set-up of the Optics Head
Start the diagnostic software Determine I(max) of the laser head:- Input: r 42 (The program asks for the approximate value of I(max))- Input: the noted down value for the optics head (After approx. 1.5 min., the determined value is displayed. Note down this value) Entries in the parameter list for the diagnostics:- Input: r 0 [c] > I(max) value of the laser diode: determined value Save value in the TOUCH MEMORY:- Input: r 0 [w] (determined value) Terminate the diagnostic software:- Input: ex Remove the floppy disk containing the diagnostic software. Insert the floppy disk containing the recorder software.
- 22 -Parameter Set-up of the Optics Head
Perform a RESET on slot A04. Transfer the determined parameter value ('Max Laser current') onto the recorder software. Transfer the parameters by means of the user software.- Press the following keys at the operating panel: Perform filter, light, focus tests and calibration. NOTES:- The data stocks in the TOUCH MEMORY and in the recorder software must be identical.- Update the backup floppy disks.- Enter the modified values in the machine manual.
'Max Laser current' (PID 563)
- 23 -Parameter Set-up of the TOUCH MEMORY (Motherboard)
Start the diagnostic software Format the TOUCH MEMORY:- Input: r 9 [w] (both TOUCH MEMORIES are created) Test the TOUCH MEMORY:- Input: r 9 (duration: approx. 2 minutes) Initialize the timer:- Input: r 9 [t, i] (The time, operating hours, number of switch-on processes are set to 0) Read the timer:- Input: r 9 [t, r] Enter the serial number (from the type label):- Input: r 0 [s, w] (for Herkules)- Input: r 0 [s, w, m] (for Herkules M)- Input: r 0 [s, w, n] (for Herkules NP)
- 24 -Parameter Set-up of the TOUCH MEMORY (Motherboard)
Read the serial number:- Input: r 0 [s, r] Entries in the parameter list for diagnosis:- Input: r 0 [c] > Peltier temperature: 135 > Hall-Selekt fore mirror motors: 4 > I(max) value of the laser diode: machine-specific parameter (TEST 42) > Light sensor type: 1 > Work. current of guide opto switch:machine-specific parameter (TEST 82) > Max. feed position (mm): 750 (for Herkules) or
550 (for Herkules M) Save values in the TOUCH MEMORY:- Input: r 0 [w] Terminate the diagnostic software:- Input: ex Remove the floppy disk containing the diagnostic software. Insert the floppy disk containing the recorder software.
- 25 -Parameter Set-up of the TOUCH MEMORY (Motherboard)
Perform a RESET on slot A04. Transfer the parameters by means of the user software.- Press the following keys at the operating panel: Check whether the floppy disk is being accessed. NOTES:- The data stocks in the TOUCH MEMORY and in the recorder software must be identical. - Update the backup floppy disks.- Enter the modified values in the machine manual.
- 26 -Parameter Set-up of the TOUCH MEMORY (Supply Cassette)
Prior to removing the TOUCH MEMORY ask for the values and note them down (material mustnot be loaded)- Press the following keys at the operating panel: Install new TOUCH MEMORY. Initialize TOUCH MEMORY:- Press the following keys at the operating panel: Enter the material-specific values:- For this purpose, see operating manual RIP 50, RIP 60 or operating manual delta technology online documentation NT-Utility NOTES:If the values of the old TOUCH MEMORY are unknown (TOUCH MEMORY defective),then test jobs must be run.For this purpose, see operating manual RIP 50, RIP 60 or operating manual delta technology onlinedocumentation NT-Utility
or
- 27 -Parameter Set-up of the Guide Opto Switch
Starting the Diagnostic Software Position the opto switch over the reflection foil:- Input: r 86 [g,d,75,300] Start the current measurement:- Input: r82 [r,l,0]- Output: current value XY in mA Entries in the parameter list for diagnosis:- Input: r 0 [c) > working current of guide opto switch : XY + 7 Save the current value in the TOUCH MEMORY:- Input: r 0 [w] Terminate the diagnostic software:- Input: ex Remove the floppy disk containing the diagnostic software. Insert the floppy disk containing the recorder software.
- 28 -Parameter Set-up of the Guide Opto Switch
Perform a RESET on slot A04. Transfer the parameter value XY + 7 ('Guide LB current') onto the recorder software. Transfer the parameters by means of the user software.- Press the following keys at the operating panel: NOTES:- The data stocks in the TOUCH MEMORY and in the recorder software must be identical. - Update the backup floppy disks.- Enter the modified values in the machine manual.
'Guide LB current' (PID 549)
- 29 -Parameter Set-up of Advantage Option
Parameter PID 815 'Use ABC' Enabling/disabling the 'Advantage' option Parameter PID 837 'Use Barcode' Enabling/disabling the barcode reader pen
NOTE: After the parameter set-up, reset the recorder by switching it off and then on again.
Transferring the parameters to the recorder software via the service terminal.
- 30 -Parameter Set-up of Advantage Option
Parameter PID 527 'Use Online Processor' Switching on/switching off the online processor.Even if the 'Advantage' option is enabled (PID 815 'Use ABC' has value "1"), the online processor can be switched off in the case of an error.
NOTE: After the parameter set-up, reset the recorder by switching it off and then on again.
Transferring the parameters to the recorder software via the service terminal.
- 31 -Parameter Set-up of Advantage Option
Parameter PID 527 'Use Online Processor'Transfer parameter using the user software.
Return to "Edit Parameter" menu
Save the parameter
NOTE: After the parameter set-up, reset the recorder by switching it off and then on again.
- Press the following key at the operating panel:
- General imagesetter parameter set-up: If the parameter record is not "static data":
- Press the following keys to select the parameter:
- Press the following keys in succession to edit the parameter:
- To save the parameter after editing, press the following keys:
- To return to the main menu, press the following key repeatedly:
- 32 -Parameter Set-up of Advantage Option
General imagesetter parameter set-upSelect parameter record To jump to the level below the current one, press the following key: To select the parameter record, press the following key repeatedly: To jump to the next higher level, press the following key:
- 1 -Service / Settings at the Power Supply Module
110 VLINKLNGND
25 AMPS 6A TOTAL12 AMPS 4 AMPS 7 AMPS
B EC DRP D
+S -S+5.2V 0V +36V 0V +24V 0V 0V0V+5.1V 0V
+15V +15V+S -S+S -S+S -S
Potentiometer
1 23 4
OV ADJ*)
V. ADJ
*)By newer power supply modules this potentiometer is no longeravailable for the over-voltage protection. The over-voltage protection will beguaranteed during the alignment of the output voltage. **)Jumper at:- 90 - 132 V AC to be screwed in - 180 - 264 V AC to be removed
Module
Settings at the module
**)
- 2 -Service / Settings at the Power Supply Module
Settings at DRP moduleProgrammable connectorPin 1: NCPin 2: NCPin 3: Prog inPin 4: 0 V
1: Power output2: 0 volt3: + ve sense4: - ve sense
1 2
3 4
1 2
3 4
DRP module
Table
| Resistance 0 ... 10 kOhms (see| table) between pins 3 and 4.
012345678910
12,014,416,819,221,624,026,428,831,233,636,0
R prog(kOhm)
U out(V)
Depending upon the desired output voltage, connect a resistor (see table) between pins 3 and 4.
Base / Nest - 3 -
1
2
34
5
with modification 40
6
E 1
7 (4x)
1 04577698 #H-MOTHERBOARD - 5.949
2 05318483 #Power supply unit
3 04591402 #TOUCH MEMORY 4KX1
4 04595467 #TOUCH MEMORY + TIME
5 04595874 #Fan, axial
6 05356393 #Encoding connector 10 kOhm(Herkules PRO)
05356407 #Encoding connector 6.81 kOhm(Herkules)
7 02133113 #Flex. loc-element
- 1 -Technical Remarks on Safety
Proper UseThe Herkules is a laser image setter for photo material and must only be used for this purpose in accordance with the operating instructions. Do not use the machine as a depository for any articles or fluids.Do not cover the ventilation slots.
- 2 -Technical Remarks on Safety
GeneralNon-observance of the safety regulations may result in the loss of accident insurance coverage. The mains plugs and the local supply sockets must be easily accessible because it may be necessary to disconnect the machine from the mains - for example, in an emergency - by unplugging the mains plug from the socket. The machine is connected to the mains using the supplied mains cable with a three-pole plug. The machine must not be used if the protective ground wire has been disconnected.The mains connector and the fuses are located at the rear of the machine. In order to provide proper ventilation, ensure that there is sufficient distance between the machine and the wall or between the machine sides and other equipment when the equipment is installed. Please refer to the chapters Installation and Technical Data when installing the machine.The machine must:- not be installed in the vicinity of air conditioning systems- be protected from direct sunlight or electric spotlights in the room- be protected from humidity
- 3 -Technical Remarks on Safety
CAUTION: Lithium BatteryVORSICHT:EXPLOSIONSGEFAHR BEI UNSACHGEMÄßEM AUSTAUSCH DER BATTERIE. ERSATZ NUR DURCH DENSELBEN ODER EINEN VOM HERSTELLER EMPFOHLENEN GLEICHWERTIGEN TYP.ENTSORGUNG GEBRAUCHTER BATTERIEN NACH ANGABEN DES HERSTELLERS. CAUTION: DANGER OF EXPLOSION IF BATTERIE IS INCORRECTLY REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER.DISCARD USED BATTERIES ACCORDING TO THE MANUFACTURER`S INSTRUCTIONS. ATTENTION: IL Y DANGER D´EXPLOSION S´IL Y A REPLACEMENT INCORRECT DE LA BATTERIE.REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU MŹME TYPE OU DŁN TYPE RECOMMANDÉPAR LE CONSTRUCTEUR. METTRE AU RÉBUT LES BATTERIES USAGÉES CONFORMÉMENT AUX INSTRUCTIONS DU FABRICANT.
- 4 -Technical Remarks on Safety
Mechanical HazardsCAUTION:If, in case of servicing, the dust cover is open and the key-operated switch has been actuated (safety switch is disabled), there is a danger of being squeezed in the carriage travel range!
- 5 -Technical Remarks on Safety
Laser SafetyDefinitions - Laser equipment: Equipment which includes a laser unit.- Laser unit: Laser with laser power pack General The laser imagesetter Herkules is a laser equipment of laser class 1. This means that the laser radiation generated in the machine is screened using protective covers. The laser unit installed in the Herkules corresponds to class 3B (5 ... 500 mW). Companies which have servicing performed in Germany must appoint a representative for laser safety in accordance with the Regulation for the Prevention of Accidents VBG 93 of the trade unions.
Servicing must only be performed by persons which have been instructed correspondingly by the appropriate representative for laser safety.
- 6 -Technical Remarks on Safety
Laser SafetyLaser Standards and Regulations The laser imagesetter Herkules complies with the valid safety regulations. It is manufactured in accordance with the Regulation for the Prevention of Accidents VBG 93 and the EN 60825, IEC 825 ("Radiation safety of laser equipment"), and 21 CFR 1040 (USA) standards. Service and Maintenance No laser adjustment should be performed at the Herkules since the modules have been adjusted atthe factory and are to be used without any additional adjustments. CAUTION:If, in case of servicing, the Herkules is operated in an open state, with the key-operated switch actuated, there is a danger of class 3B laser radiation if the laser beam is lead outside by reflectingmaterial. If necessary, a temporary laser area must be set up. The Regulation for the Prevention of Accidents VBG 93 ("Laser Radiation") as well as the implementation instructions for the VBG 93 must be met. In addition, the national safety regulations must be observed.
- 7 -Technical Remarks on Safety
Laser SafetyAfter repair work has been completed, correct functioning of the safety loop must be checked by opening the cover. During reassembly, the protective covers must be checked for completeness. It must be ensured that these covers do not show any cracks or other damages. CAUTION:If operating or a adjustment devices other than the ones mentioned are used, or if other procedures are applied, this may lead to dangerous exposure to radiation.
- 8 -Technical Remarks on Safety
Laser SafetyAdjusting goggles:- protective goggles with closed frame for wearers of glasses, order No. 02440628- protective goggles with standard frame, order No. 04161793
Laser LabelsSee the illustration of the labels
- 9 -Technical Remarks on Safety
Norms and StandardsThe machine meets the safety regulations of the standards listed below.
General - GSG - 73/23/EEC
(law regarding machine safety, Germany)(law regarding technical equipment)(low-voltage directive, Europe)
Mechanical Safety - EN 292 (Europe)- Accident prevention regulations for trade associations (Germany)
- 10 -Technical Remarks on Safety
Norms and StandardsElectrical Safety - EN 60950- IEC 950- UL 1950- CSA C22.2 No.950- EN 60204-1- IEC 204-1
(Europe)(international)(USA)(Canada)(Europe)(international)
Electromagnetic Compatibility (EMC) - EMVG- 89/336/EEC
Law regarding electromagnetic compatibility of devices (Germany) EMC directive of the European Council (Europe)
- 11 -Technical Remarks on Safety
Norms and StandardsInterference Emission (interference radiation and interference voltage) - EN 50081-1- EN 55022, limit B- CISPR 22 mod., limit B- FCC, Part 15, Subpart B, Class A- DOC, Radio Act SOR/88-475, Class A
(Europe)(Europe)(international)(USA)(Canada)
Interference Immunity - EN 50082-2- EN 60801-2- IEC 801-2/-3/-4
(Europe)(Europe)(international)
- 12 -Technical Remarks on Safety
Certifications and MarkingsGS certifiedUL E156891 (NWGQ)cUL E156891 (NWGQ 7)CE declaration of conformityCDRH applied
For labels see section "Schilder-Uebersicht" (label overview).
(Germany)(USA)(Canada)(Europe)(USA)
- 13 -Technical Remarks on Safety
PollutantsWhen using cleaning and lubricating agents, observe the manufacturer's instructions.If necessary, consider the safety data sheets, and for Germany the List of Threshold Values quotingthe maximum permissible concentrations (List of Threshold Values issued by the Federal Ministry of Labor and Social Affairs) as well as the appropriate local regulations.
- 14 -Technical Remarks on Safety
CleaningAlways disconnect the machine by pulling out the mains plug if liquid cleaning agents are used. The machine surface can be cleaned using a dry cloth. In the case of stubborn dirt, a dry cloth soaked in water with a cleaning agent and then wrung out may be used. Prevent water from reaching the machine interior and protect the connectors at the machine rear from the humidity. Do not use any abrasive detergents or solvents.
- 15 -Technical Remarks on Safety
in accordance with Council Directives 73/23/EEC relating to Electrical Equipment designed foruse within certain voltage limits, and 89/336/EEC relating to electromagnetic compatibility
Name des Herstellers / supplier`s name:Adresse / address:
Heidelberger Druckmaschinen AGSiemenswallD- 24107 Kiel, Germany
declares, that the product
Produktname / product name:Geräteart / product class:Typenbezeichnung / type designation:
conforms with the above mentioned Directives
CE-Declaration of Conformity
CE-Declaration of Conformity
HerkulesLaser Recorder2081
- 16 -Technical Remarks on Safety
Applicable Standards:
- EN 60950
- EN 50081-1- EN 55022, Klasse B- EN 50082-2
Safety of Information Technology Equipmentincluding electrical business equipmentEMC Generic Emission Standard
EMC Generic Immunity Standard
CE-Declaration of Conformity
Kiel,.......................................................................................................................................................Ort / place Datum / date gezeichnet / signed Stempel / stamp
20. October 1997
Heidelberger DruckmaschinenAktiengesellschaft
Siemenswall - D-24107 KielW. Boppel
Senior Vice President
- 17 -Technical Remarks on Safety