Pre PrensaComunidad Emagister 25141 25141

Important safety instructions
Observe the general and press-specific safety

instructions in the operating manual.
At first start-up or after the exchange of

equipment or components check the correct
functioning of all safety equipment.
Control cabinet and machine housing have to be

locked while the press is in operation. They may
only be opened for repair purposes.
Make sure that the main power switch is turned

off and that there is no voltage applied to the press
before you open the control cabinet or the machine
housing.
If it is necessary to repair the press while it is

connected to the mains supply, please pay attention
to general safety precautions.
Never exchange components and units while the

press is connected to the mains supply.
Safety equipment must not be modified. Do not

remove earth conductors. If it is necessary to
disconnect these conductors, please remember to
reconnect them after you are finished.
If extra accessories not corresponding to

Heidelberg specifications are installed or mounted,
Heidelberg does not accept any liability whatsoever.
In each case these accessories must be controlled
or locked in a way that no hazards can arise when
the press and its devices are operated.
Observe these handling instructions when
Attention: you replace electronic boards with electro-
statically sensitive devices (ESDs)!
Handling and replacing electronic boards
+80°C
–25°C
Storage: ALWAYS NEVER NEVER

NEVER below –25°C pack into the protec- replace when power is use force to insert.
NEVER above +80°C tive container for on.
ESDs.
Protective measures for ESDs

to be observed when replacing electronic boards
DISCHARGE UNPACK REPLACE PACK

static charges. from the protective electronic boards. into the protective
container for ESDs. container for ESDs.
2. Speedmaster CD102 Table of contents
2. Speedmaster CD 102 1 – 438
7 Main drive
7 M1 Direct-current main motor
12 M1 Brushless main motor
17 Pile centering
17 Block diagram
19 11B10 Pile centering
21 11M9 Pile centering
28 11B55 Inactivating pile centering
31 Pile merging
31 11M8 Adjustment of pile support plate
39 Suction head height control

39 11M5 Suction head height adjustment
45 Size adjustment
45 Block diagram
47 11M4 Adjustment of format wheels
53 11M6 Suction head/format adjustment
59 11M11/11M12 Pile stops D.S./O.S.
67 1M4 Cover guide height adjustment
77 1M2/1M3 Print-free margin D.S./O.S.
85 1...nM5 Adjustment of printing pressure
96 1M7/1M8 Adjustment of pull lays
104 12M5 Sheet slowdown/format adjustment
110 12M6/12M7 Sheet joggers D.S./O.S.
1
119 Feeder pile control

119 Block diagrams
121 Layout
124 Overview of components
127 Function
140 11M1 Main pile motor (Preset)
143 11M1 Main pile motor (standard)
146 11M2 Auxiliary pile motor
149 11B11 Auxiliary pile detection
152 11B33 Upper main pile limitation
155 11B35 Automatic pile transport
158 11S34 Bottom main pile limitation
161 Delivery pile control

161 Block diagrams
163 Layout
166 Overview of components
170 Function
186 12M1 Main pile motor (Preset)
189 12M1 Main pile motor (standard)
192 12M2 Auxiliary pile motor
195 12B65 Changeover fast/slow
198 12B69 Pile height control
201 12B129 Delivery upper edge of pile
204 12S34 Bottom main pile limitation
207 Sheet alignment

207 Block diagram
210 1B13/ 1B49 Sheet alignment control
223 1B9/1B10 Pull lay control
231 1B11 Double-sheet detector
238 11M3 Automatic sheet arrival control
241 11M3 Automatic sheet arrival control (standard version)
247 11M3 Automatic sheet arrival control (Preset version)
251 11M7 Automatic misalignment control
2
259 Sheet monitoring

259 1...nB48/ 1...nB48a Sheet travel monitor
267 Plate clamping device

267 Autoplate
271 1...nB53 ”Coarse register monitoring”
275 Washup devices

275 Control by command ”Washup”
276 Messages
278 Service display ”Washup”
281 Blanket washup device (GTW)
286 Inking roller washup device (FWW)
292 Impression cylinder washup device (DZW)
296 M43, M50 ... M56 Washup brush motors
297 E9 Washup solution container
301 B1, B54, B55 Sensors at the washup solution container
303 1...nB43 Monitoring the ink blade
305 Inking unit

305 Servo-drive ink fountain roller
308 Servo-drive diagonal register 1...nM6
311 Servo-drive lateral register
314 Servo-drive circumferential register
317 Inking unit temperature control
318 E39 Inking unit temperature control
321 Dampening
321 1...nM1 Pan roller motors
322 1...nM45 Blower motor for dampening system
323 1...nB32 Sensor ”Dampening solution control”
325 E40 Central dampening solution supply /
cooling and circulating unit
328 E41 Dampening solution mixing unit
3
329 Central lubrication

329 Basic concept
330 Service display
332 Fault messages
333 Grease lubrication
338 Oil lubrication
343 M44 Oil pump
345 12M47 Motor for grease lubrication
346 1F33 Pressure monitoring oil lubrication 1 bar
347 1F34 Pressure monitoring oil lubrication 12 bars
348 12B47 Lubrication monitoring 1 and
12B77 Lubrication monitoring 2
351 Pneumatic system

351 15Y11 Admission of pressure, pneumatic system
353 15B14 Pressure sensor ”Pneumatic system”
355 E4 Pneumatic system compressor
357 Suction and blast air

357 1M9 Blast air regulation at the feeder
369 Other components

369 E4a Varnish supply unit
371 L-B32 Level in coating pan
373 12E2 Powder spray unit
377 12M35 Blower motor for powder spray device
379 12S68 Switch ”Powdering cycle”
380 12S9, -a, -b, -c Monitoring the IR slide-in dryer
381 E8 Air supply cabinet
382 E39 Inking unit temperature control
383 12E3 Static electricity eliminator
386 WSA Intercom
388 IDS Encoder
4
393 Location diagrams

393 ZSG Central control cabinet
408 ZSP Central control console
409 Position switches
411 Solenoid valves
413 Motors
415 Sensors
417 Control panels
423 Operator’s controls
429 ZSP Control panel of control console
431 Abbreviations
435 Equipment identification
437 Position codes
5
6
Main drive M1 Direct-current main motor
Main drive
M1 Direct-current main motor
Layout
The dc main motor is a dc shunt motor. Its layout
varies depending on the manufacturer, motor
power and type of construction.
The illustration below shows one example of the
components of the main motor M1.
Representation of a dc main motor M1
Installation area of fan impeller

Ventilation cover
Terminal box for main motor M1
( contains all connections for M1 )
Hoop for manual release of brake
Terminal box of brake
Brake Y1
Installation area of carbon brushes and
commutator
Motor support rails or motor baseplate
7
Attention: Make sure the motor is disconnected from

the power supply before working on it!
Make certain to leave a minimum gap of
6 mm in the terminal box between neighbour-
ing conducting parts carrying different
potentials!
Shut the terminal box tight!
Terminal box of ”SIEMENS” main motor

Entries for motor connecting cables
Connection PE conductor
Connection armature circuit + / A1
Connection armature circuit – / A2
Connection field circuit + / F1
Connection field circuit – / F2
Connector X1 / connection to optocoupler
module 15U5 (monitoring of carbon brushes)
and brake control module BAM ( BAM-X1)
Connector X2 / connection to interference
suppressor module ESM ( motor coding )
Connecting cable to brake Y1
Terminal box of a ”SIEMENS” main motor
Terminal box of ”BAUMÜLLER” main motor

Connection PE conductor
Connector X1 / connection to optocoupler
module 15U5 (monitoring of carbon brushes)
and brake control module BAM ( BAM-X1)
Connector X2 / connection to interference
suppressor module ESM ( motor coding )
Connection field circuit – / F2
Connection field circuit + / F1
Connection armature circuit + / A1
Connection armature circuit – / A2
Entries for motor connecting cables
Terminal box of a ”BAUMÜLLER” main motor
8
Removal and installation of brake

Connecting cable of brake
Fixing bolts of brake
Brake of main motor M1
Removal of defective brake

Turn off the main switch on the central control
cabinet ZSG and make sure no-one can turn
the power back on.
Disconnect the connecting cable from the
terminal box of the brake.
Loosen the fixing bolts of the brake.
Pull the brake off the main motor shaft.
Brake at main motor
Connecting cable of brake

Fixing bolts of brake
Brake of main motor M1
Square driver of motor shaft
Installation of the new brake

Place the new brake on the square driver of
the motor shaft.
uniformly.
Tighten the fixing bolts
Connect the connecting cable of the brake
to the terminal box .
Main motor with brake removed
9
Removal/installation of carbon brushes

Ventilation covers of main motor
Terminals of carbon brushes
Carbon brushes
Clamp-type carbon brush holder
Brush-rocker ring
Removal of carbon brushes
Note:
Always replace all carbon brushes of the
main motor.
All carbon brushes should be from the same set of
spare parts to guarantee that they are all from the
same material.
Ventilation covers of main motor 1 Turn off the main switch on the central
control cabinet ZSG and make sure no-one
can turn the power back on.
2 Remove all ventilation covers on the
installation side of the brake.
3 Disconnect the wires of the carbon brushes
from the terminals .
Note:
With certain motors it is necessary to turn the
brush-rocker ring for brush removal.
Before turning the brush-rocker ring , mark
its position in relation to the stator ( e.g.
colour line ) if no markings exist so far.
4 Loosen the retaining screws ( but do not
turn them out completely ) and turn the
brush-rocker ring ( see illustration on next
page).
5 Flip up the clamp-type brush holder and
take out all used carbon brushes .
Layout of brush-rocker ring (example)
10
Carbon brush connections

Carbon brushes
Clamp-type carbon brush holder
Brush-rocker ring
Fixing bolts for brush-rocker ring
Installation of new carbon brushes

When replacing a set of carbon brushes, clean all
the cooling-air paths, e.g. with dry, oil-free
compressed air. Any deposits of carbon dust on
the insulating parts of the commutator and the
brush-rocker ring must be removed completely,
e.g. by cleaning these parts with a non-linting
cloth.
Insert the new carbon brushes and

connect them to the terminals. Close the
clamp-type brush holder .
Fastening the brush-rocker ring (example)
Note:
The carbon brushes must rest correctly on
the commutator and run smoothly in the
brush boxes.
If the brush-rocker ring was turned
before, it must be brought back in its initial
position and locked after replacement of the
carbon brushes. Pay attention to the
markings!
Screw down the covers again.
Note:
The ventilation slots in the ventilation covers
must point downward to maintain the type of
protection.
11
Main drive M1 Brushless main motor
M1 Brushless main motor
Construction with terminal board (from 37kW)
Á
Á
Main motor M1 with terminal box
Motor shaft
Terminal box of main motor
Rotor position encoder
Plug of rotor position encoder
Lever for manual release of the brake
12
Rotor position encoder

The rotor position encoder consists of three
components:
– sensor,
– rotating part,
– adjusting ring.
Attention: Do not loosen the safety screws of the adjusting

ring of the rotor position encoder!
Displacement of the adjusting ring results in
displacement of the rotor position encoder in
relation to the actual position of the rotor of the
main motor.
If the adjusting ring is not in its normal position
or defective, the main motor must be replaced!
Layout
Pin base X2 / connection to BLT4
Safety screws of adjusting ring
Sensor
ÁÁÁÁ Adjusting ring
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
Front view of rotor position encoder
Pin assignment
X2 2 X2 Plug connection to ZSG (BLT4)
1 3
7 Pin Function
6 4
5 6 DC +15 V
7 15 V
Pin base X2, 7-pole
13
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Rotor position encoder of main motor M1
Motor casing / brake

Adjusting ring
End-float washers (not always provided)
Motor shaft
Rotating part
Connector M1-X2
Sensor part
Removal
1 Turn off the main switch and make sure
no-one can turn the power back on.
2 Remove connector X2.
3 Remove the sensor (four fixing bolts).
4 Replace the sensor or rotating part.
Note:
Put the end-float washers back in place
between the rotating part and motor.
Installation
5 Reinstall all parts and connect the rotor
position encoder.
14
Connection
Main motors with < 37 kW are connected by
means of prefabricated plugs.
For EMC reasons, main motors with 37 KW or
more are connected via a terminal board.
PE conductor connection
Motor winding W (threaded bolt M12)
Motor winding V (threaded bolt M10)
Motor winding U (threaded bolt M8)
PE conductor connection
Plug for motor code, brake and tempera-
ture sensor
Terminal box of main motor BAUMÜLLER 37KW
Please note:
The terminal studs of the motor terminal board
and the eye rings of the connecting cables have
different diameters. Thus the cables cannot be
mixed up.
Terminal N is used for measuring purposes only.
Pin assignment
X1 Plug connection in motor terminal box
Pin Function
1 5 2 6
1 Motor code 0
2 Motor code 1
3 Motor code
1 5
2 6 4 Temperature sensor
5 Brake +
Pin and socket bases, 6-pole 6 Brake –
15
Main drive M1 Brushless main drive
16
Pile centering Block diagram
Pile centering
Block diagram
The pile centering function comprises:
Pile centering Inactivating
11B10 pile centering – the sensor ”Pile centering” 11B10,
11B55 – the sensor ”Inactivating pile centering” 11B55”,
– the servo-drive ”Pile centering” 11M9”.
Pile centering
The pile centering function compensates for the
11M9
lateral displacement of the paper pile at the feeder.
The sensor ”Pile centering” 11B10 senses the lateral
edge of the pile. The required distance between the
M
sensor and the lateral pile edge is 130 " 2 mm. If
the difference between the required and actual
distance exceeds the tolerance limits, the electronic
SSM1 SSM1 control system corrects the position of the paper pile
through the servo-drive ”Pile centering” 11M9”.
If the pile support plate reaches the sensor ”Inactivat-

ing pile centering” 11B35 during its upward move-
SSK EAK 1 ment, the electronic control system stops the
automatic control.
Automatic control is resumed as soon as

– the pile support plate is below the sensor 11B35
and
SAK ESK
– the sensors 11B10 and 11B35 detect paper or
– the pile support plate lies on the floor
(position switch 11S34 actuated).
REK1 REK386
DSK
DNK SVM
MID11 MID12
ZID
Displays
Legend: Data line

Control lines
Block diagram for pile centering
17
Pile centering Block diagram
Activating and inactivating pile centering
Selecting the display
Symbol ”Pile centering on / off”

Activating and inactivating pile centering:
– in the preselection display,
– by means of the function button.
If the symbol is lit, pile centering is active.

18
Pile centering 11B10 Pile centering
11B10 Pile centering

The sensor 11B10:
– senses the lateral pile edge (actual distance),
– with the required distance = 130 ± 2 mm.
Á 11B10
Á
Where?
Á
– approx. 25 mm below the upper edge of the pile.
Á Automatic control through the electronic control
Á system:
Á
130 ± 2 mm
– if the difference between the required distance
and actual distance exceeds the tolerance limits,
– by activating the servo-drive ”Pile centering”
Required distance for pile centering 11M9.
No automatic control:
– within the tolerance limits of the required
distance.
Output signal of sensor 11B10:

– analog voltage,
– digitization on the SSK1.
Signal flow:
– Sensor 11B10
– Servo-drive distributor module (11LVT: 2SSM1)
– backplane SSR: X14
– servo-drive control board SSK1.
19
Pile centering 11B10 Pile centering
Place of installation
11B10
PU1 and Preset feeder
Removal and installation
11LVT1
black
2SSM1
X5: D4
X2: +8
X2: –8
blue
brown
Check
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1646 ± 70
130 2 mm
20
Pile centering 11M9 Pile centering
11M9 Pile centering
Automatic positioning
Condition:
Automatic pile centering is switched on in the
preselection display.
The servo-drive 11M9 positions the pile support

frame at the feeder.
The sensor 11B10 senses the lateral edge of the

pile. If the difference between the required distance
and the actual distance exceeds the tolerance
limits, the servo-drive control board SSK regulates
the servo-drive 11M9.
If the pile support plate reaches the sensor 11B35

while moving up, the electronic control system
stops the automatic control.
Manual positioning for feeder without

NON-STOP facility:
Condition:
Automatic pile centering is switched off in the
preselection display.
Pushbuttons The pushbuttons Main pile centering control the

”Main pile centering” servo-drive 11M9.
Maximum positioning range: +/– 30 mm in relation
Plus button to the centre of the feeder.
Minus button Plus button = movement towards D.S.

Minus button = movement towards O.S.
21
NON-STOP feeder
The positioning of the pile support plate by means
of pushbuttons depends on the position of the
toggle switch ”Auxiliary pile on/off”.
ÁÁÁ

ÁÁÁ
Toggle switch
ON - Main pile control activated.
ÁÁÁ
”Auxiliary pile on / off”
OFF - The pushbuttons ”Main pile centering” control
the servoĆdrive.
Pushbuttons – Maximum positioning range:
”Main pile centering” ± 35mm in relation to the centre of the feeder.
Plus button Plus button = movement towards D.S.
Minus button
The pile support frame and pile support plate can
move max. 35 mm in the same direction together.
Toggle switch in position ”ON”:

Toggle switch ON – Auxiliary pile control activated.
OFF – The pushbuttons ”Auxiliary pile centering”
control the pile support frame.
Pushbuttons
”Auxiliary pile centering” – Maximum positioning range:
± 35mm in relation to the centre of the feeder.
Plus button
Minus button
Indication of position in MID

During manual positioning, the electronic control
system indicates the present position of the pile
support frame in the press display MID. The
displayed value represents the absolute position in
11 2 0
relation to the centre of the feeder.
Present position
Indication of position of pile support frame Position code
22
11M9
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
23
Interconnection diagram
X5
X10 SSR
SSR X10
X11 X12
X3 X4
X13 X14
SSR X14
Backplane of servo-
11 drive plug-in unit SSR
11LVT1
2SSM1: X2
X3 X4
X1
2SSM1: X4
X2
X5
2SSM1
Servo-drive distributor
module 2SSM1
11M9: X1 3 4
5
2 1
11M9
Servo-drive 11M9

+ Pin 1 X5: C1 X2: 1 X10: B14
– Pin 2 X5: C2 X2: 2 X10: D14
10V Pin 3 X5: C3 X4: 3 X14: 3
Pin 4 X5: C4 X4: 4 X14: 4
0V Pin 5 X5: C5 X4: 5 X14: 5
24

ON

OFF
06 2048 ± 2
– Set the toggle switch ”Auxiliary pile ON/OFF” – Remove the servo-drive ”Pile centering”
to ”OFF”. 11M9.
– Select the service display ”SSK1”.
– Bring the pile support plate into its central
position (set to 2048±2 inc).
– Set the distance between the side frame and

the pile support frame to 83 mm.
25

4)
07 2048 ± 2
1M9: X1
– Fit the motor baseplate and gear wheel.

– Connect plug 11M9: X1.
– Set to 2048±2 inc.
– Install the servo-drive.
26
Checking the operating range

Servo-drive ”Pile centering” 11M9
Condition:
The pile support plate is in its central position
(2048 inc).
Input Incremental value
– 35 mm 3686 " 23 inc
+ 35 mm 409 " 23 inc
Service display ”Values, incremental values servo-

drives”
27
Pile centering 11B55 Inactivating pile centering
11B55 Inactivating pile centering
If the pile support plate reaches the sensor 11B55

during
11B55
– ”Production run” or
– ”Paper run”,
the electronic control system switches the pile
centering function off. The remaining sheets on the
pile are still printed. For the pile change, the operator
lowers the pile support plate and places paper on it.
If the sensors
– ”Automatic pile transport 11B35” and
– ”Inactivating pile centering 11B55”
detect the paper, the preselected pile centering
function is active again.
Sensor 11B55
28
11B55
Adjustment
brown
black
blue
FAM64
XE: 55
+1
–1
11LVT1
Check
0010
29
30
Pile merging 11M8 Adjustment of pile support plate
Pile merging
11M8 Adjustment of pile support plate

The servo-drive 11M8 is only installed at the
NON–STOP feeder of Preset presses.
The servo-drive 11M8 positions the pile support

plate at the feeder.
The positioning of the pile support plate depends on

the position of the toggle switch ”Auxiliary pile
on/off”.
Toggle switch in position ”Off”
ÁÁ – Main pile control activated.

Toggle switch
ÁÁ ON
The pushbuttons ”Auxiliary pile centering” control
ÁÁ
OFF the servoĆdrive 11M8.
Maximum positioning range:

Pushbuttons ± 30 mm in relation to the centre of the feeder.
”Auxiliary pile centering”
Minus button
Pushbutton When the pile support plate reaches the position

”Main pile down” switch 11S39 ”Pile support plate limitation” while
moving down, the electronic control system
positions
– the pile support plate (through 11M8)
– the pile support frame (through 11M9)
relative to the centre of the feeder.
During positioning, the function ” Main pile down” is

blocked. Approx. 30 seconds after the beginning of
positioning, the electronic control system releases
the function ”Main pile down” again.
31
Toggle switch in position ”ON”
ÁÁ
Toggle switch – Auxiliary pile control activated.
ON
ÁÁ
The pushbuttons ”Auxiliary pile centering” control
OFF the servoĆdrive 11M8.
Maximum positioning range:
Pushbuttons ± 30 mm in relation to the centre of the feeder.
”Main pile centering”
Minus button
During the downward movement, the servo-drive

11M8 positions
Pushbutton
– the pile support plate
”Main pile down”
relative to the centre of the feeder.
As soon as the pile support plate lies on the ground

(position switch 11S34 actuated), this function is
stopped. The pile support plate cannot be posi-
tioned anymore.
NON-STOP mode:
When pile centering is active, the electronic control
system regulates the pile support frame. To ensure
that the pile support plate keeps its position on the
floor, it is displaced by the same value as the pile
support frame, however in the opposite direction.
32
11M8
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
33
X5
X10 SSR
SSR X10
X11 X12
X3 X4
X13 X14
SSR X13
Backplane of servo-
11LVT1
2SSM1: X1
X3 X4
X2 2SSM1: X3
X1 X5
2SSM1
module 2SSM1
11M8: X1 3 4
5
2 1
11M8
Servo-drive 11M8

+ Pin 1 X5: B1 X1: 3 X10: B12
– Pin 2 X5: B2 X1: 4 X10: D12
10V Pin 3 X5: B3 X3: 8 X13: 8
Pin 4 X5: B4 X3: 7 X13: 7
0V Pin 5 X5: B5 X3: 6 X13: 6
34

ON

OFF
07 2048 ± 2
– Set the toggle switch ”Auxiliary pile ON/OFF” – Remove the servo-drive ”Adjustment of pile
to ”OFF”. support plate” 11M8.
– Select the service display ”SSK1”.
– Bring the pile support frame into its central
position (set to 2048±2 inc).
Frame
.
Guide
– Set the distance between the pile support
plate guide and the pile support frame to
31.5 mm.
35

4)
06 2048 ± 2
1M8: X1
– Mount the servo-drive on the motor baseplate.

– Fit the gear wheel.
– Set to 2048 inc.
– Tighten the chain.
36

Servo-drive ”Adjustment of pile support plate”
11M8
Condition:
The pile support frame is positioned in the centre
of the feeder.
Off-centre position: 00

– 30 mm 3461 " 23 inc
Service display ”Values, incremental values + 30 mm 634 " 23 inc

servo-drives”
37
38
Suction head height control 11M5 Suction head height adjustment
Suction head height control
11M5 Suction head height adjustment

The servo-drive 11M5 positions the suction head
vertically. The servo-drive can be controlled with the
pushbuttons ”Suction head height”.
Pushbuttons ”Suction head Actuation of one of the pushbuttons:

height”
– suction head positions vertically,
Plus button
– positioning range +/– 20 mm,
Minus button
– indication of position in feeder MID.
Plus button = suction head moves up (+ 20 mm).
Minus button = suction head moves down (– 20 mm).
39
11M5
Preset feeder
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
40
X5
X10 SSR
SSR X10
X11 X12
SSR X12 X3 X4
X13 X14
Backplane of servo-
11LVT1
1SSM1: X1
X3 X4
1SSM1: X4
X2
X1 X5
1SSM1
module 1SSM1
11M5: X1 3 4
5
2 1
11M5
Servo-drive 11M5

+ Pin 1 X5: C1 X2: 1 X10: B6
– Pin 2 X5: C2 X2: 2 X10: D6
10V Pin 3 X5: C3 X4: 3 X12: 3
Pin 4 X5: C4 X4: 4 X12: 4
0V Pin 5 X5: C5 X4: 5 X12: 5
41
1 2
20 mm
– Remove the servo-drive ”Suction head height – Set the distance (20 mm) at the suction head
adjustment” 11M5. guide rail.
4)
03 2456 ± 2
11M5: X1

– Set to 2456 ±2 inc.
42

Servo-drive ”Suction head height adjustment”
11M5

– 20 880 " 4 inc
+ 20 3215 " 4 inc
Service display ”Values, incremental values servo-

drives”
43
44
Size adjustment Block diagram
Size adjustment
Block diagram
Adjustment of Sheet slowdown/

format wheels format adjustment
11M4 SSM SSM 12M5
M M
Suction head/ Adjustment of

format adjustment pull lay D.S. 1M7
11M6 SSM SSM
M M
Pile stop D.S. Adjustment of

11M11 pull lay O.S. 1M8
SSM SSM
M M
Pile stop O.S. Cover guide height

11M12 adjustment 1M4
SSM SSM
M M
Sheet jogger D.S. Adjustment of printing

12M6 pressure 1...nM5
SSM SSM
M M
Sheet jogger O.S.

12M7
SSM
M
SSK1/2/3
Displays
SAK ESK
SVM MID11 MID12
REK1 REK386 DSK DNK ZID
Legend: Data line Control lines
Block diagram size adjustment
45
Size adjustment Block diagram
Command: ”PRESETTING”
To avoid damage to the press, make sure nothing is

in the way of the following servo-drives when the
command ”Presetting” is active:
– suction head,
– pile stops D.S. and O.S.,
– format wheels,
– pull lays D.S. and O.S.,
– sheet slowdown,
– sheet joggers D.S. and O.S.
Selecting the command
As a result of the inputs in this command mode,

various servo-drives on the press are positioned
automatically.
1020 After command enabling the electronic control system

positions the following servo-drives:
On the feeder
720 – Suction head/format adjustment

1.00
– Pile stops D.S. and O.S.
– Adjustment of format wheels
Command in control console display ZID On printing unit / coating unit
– Adjustment of pull lays D.S. and O.S.
– Cover guide height adjustment
– Adjustment of printing pressure
On the delivery
– Sheet slowdown/format adjustment
– Sheet joggers D.S. and O.S.
46
Size adjustment 11M4 Adjustment of format wheels
11M4 Adjustment of format wheels

The servo-drive 11M4 positions the format wheels on
the feeder.
Automatic positioning:
– is effected through the command ”Presetting”;
– depends on inputs into CPTRONIC, such as:
paper length,
paper thickness,
front lay adjustment (smallest value);
– depends on inputs into CPC1-04, such as:
coating unit register.
Positioning accuracy: ± 0.25 mm.
End of automatic positioning:

– when the new desired position has been
reached,
– when one of the pushbuttons
”Format wheels” is actuated.
Pushbuttons ”Format wheels”
Manual positioning
Actuation of one of the pushbuttons ”Format wheels”:
Plus button
– the format wheels are repositioned irrespective
Minus button of the preset format,
– indication of the position in the feeder MID,
– when the command ”Presetting” is active,
automatic positioning is stopped immediately.
Plus button = movement towards maximum format.
Minus button = movement towards minimum format.
Fault message in the ZID

Adjustment of format wheels The symbol appears in the display ”Feeder/Warning”.
The symbol appears:

– during positioning while the press is on ”Run”.
The symbol goes off:
– when positioning is over and the press is on
”Run”,
– when one of the pushbuttons ”Format wheels”
is actuated and the press is on ”Run”.
47
11M4
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
48
X5
X10 SSR
SSR X10
X11 X12
SSR X11 X3 X4
X13 X14
Backplane of servo-
11LVT1
1SSM1: X1
X3 X4
X2 1SSM1: X3
X1 X5
1SSM1
module 1SSM1
11M4: X1 3 4
5
2 1
11M4
Servo-drive 11M4

+ Pin 1 X5: B1 X1: 3 X10: B4
– Pin 2 X5: B2 X1: 4 X10: D4
10V Pin 3 X5: B3 X3: 8 X11: 8
Pin 4 X5: B4 X3: 7 X11: 7
0V Pin 5 X5: B5 X3: 6 X11: 6
49
1 2
9.00
9.00
1020
720
1.00
– Enter the paper thickness (1.0 mm).

– Enter the paper width (1020 mm).
– Enter the paper length (720 mm).
– Set the print-free margin to 9 mm. – Enable the command ”Paper size adjustment”.
3 4
ÁÁÁ
ÁÁÁ
ÁÁÁ
– Remove the servo-drive ”Adjustment of – Bring the format wheels into their central
format wheels” 11M4. position.
50
Format wheels
.
Sheet of paper
– Set the distance ( 722.5 mm ) between the front lays and format wheels.
ÁÁÁÁÁÁÁÁÁÁÁ
02
3871 ± 2
11M4: X1
– Attach the gear wheel to the motor shaft.

– Set to 3871 " 2 inc.
51

Servo-drive ”Adjustment of format wheels”
11M4
SM102:
Print-free margin: 10.00 mm 8.00 mm
Paper length: 720 mm 280 mm
Paper thickness: 1.50 mm 1.50 mm
Incremental value: 3876 ± 2 inc 288 ± 2 inc
CD102:
Service display ”Values, incremental values Print-free margin: 10.00 mm 8.00 mm
servo-drives”
Paper length: 720 mm 280 mm
Paper thickness: 2.00 mm 2.00 mm
Incremental value: 3886 ± 2 inc 288 ± 2 inc
52
Size adjustment 11M6 Suction head/format adjustment
11M6 Suction head/format adjustment

The servo-drive 11M6 positions the suction head to
the entered paper length.
– is effected through the command ”Presetting”;
– depends on the entered sheet length.
Automatic positioning range:

– max. 720 mm,
– min. 500 mm because of danger of collision with
the lateral pile stops,
– in the case of sheet lengths below 500 mm, the
suction head stops at the lower limit (500 mm),
– manual positioning if the sheets are shorter (less
than 500 mm).

reached,
– when the lower limit (500 mm) of the positioning
range has been reached,
– when one of the pushbuttons
”Suction head format” is actuated.
Manual positioning
Pushbuttons Actuation of one of the pushbuttons ”Suction head
”Suction head format” format”:
– the servo-drive ”Suction head/
Plus button format adjustment” 11M6 is controlled,
Minus button – the suction head positions irrespective of the
preset format,
– automatic positioning is stopped immediately.
Plus button = to max. 730 mm.

Minus button = to min. 280 mm.
53
Suction head/format The symbol appears in the display ”Feeder/Warning”.

adjustment
The symbol appears:
– during positioning while the press is on ”Run”,
– when the lower limit is reached during
automatic positioning.

”Run”,
– when one of the pushbuttons ”Suction head
format” is actuated and the press is on ”Run”.
54
11M6
Preset feeder
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
55
X5
X10 SSR
SSR X10
X11 X12
SSR X12 X3 X4
X13 X14
Backplane of servo-
11LVT1
1SSM1: X2
X3 X4
X2
1SSM1: X4
X1 X5
1SSM1
module 1SSM1
11M6: X1 3 4
5
2 1
11M6
Servo-drive 11M6

+ Pin 1 X5: D1 X2: 3 X10: B8
– Pin 2 X5: D2 X2: 4 X10: D8
10V Pin 3 X5: D3 X4: 8 X12: 8
Pin 4 X5: D4 X4: 7 X12: 7
0V Pin 5 X5: D5 X4: 6 X12: 6
56
Á Front
sheet stop
Governor
foot
Marking
3
2
1
– Remove the servo-drive ”Suction head/format Note:
adjustment” 11M6. To compensate for the backlash, the 720 mm
– Set the distance between the front sheet stop must be set from the max. possible distance.
and the marking on the governor foot to
720 mm.
4)
11M6: X1
04 462 ± 2
11M6: X1

– Set to 462 ±2 inc.
57

Servo-drive ”Suction head/format adjustment”
11M6
Paper length Incremental value

280 mm 3634 " 2 inc
730 mm 389 " 2 inc
Service display ”Values, incremental values

servo-drives”
58
Size adjustment 11M11/11M12 Pile stops D.S./O.S.
11M11/11M12 Pile stops D.S./O.S.

The servo-drive 11M11 positions the pile stop on the
D.S.
The servo-drive 11M12 positions the pile stop on the
O.S.
– is effected through the command ”Presetting”,
– depends on the inputs into CPTRONIC, such as:
sheet width,
off-centre position,
preselected pull direction.

reached,
– when one of the pushbuttons ”Pile stops larger
format” or ”Pile stops smaller format” is
actuated.
Manual positioning
Pushbutton Actuation of pushbutton ”Pile stops larger format”:
”Pile stops larger format”
– Control of servo-drives ”Pile stop D.S.” 11M11
and ”Pile stop O.S.” 11M12,
– irrespective of the preset format, the pile stops
position to a larger format.
Actuation of pushbutton ”Pile stops smaller format”:
Pushbutton – Control of servo-drives ”Pile stop D.S.” 11M11
”Pile stops smaller format” and ”Pile stop O.S.” 11M12,
– irrespective of the preset format, the pile stops
position to a smaller format.
Actuation of one of the pushbuttons:

– the off-centre position can be up to ± 50 mm,
59

The symbols appear in the display ”Feeder/Warning”.
Pile stop D.S.
The symbols appear:
Pile stop O.S. – during positioning while the press is on ”Run”.
The symbols go off:

”Run”,
– when one of the pushbuttons ”Pile stop D.S.” or
”Pile stop O.S.” is actuated and the press is on
”Run”.
Prepiling
This function can only be activated in the preselec-

tion display. To inactivate it, press the correspond-
ing button once more.
The lateral pile stops move together when
– the pile support plate moving down is stopped
by means of the button ”Pile stop”
and
– the pile support plate is in front of the position
switch ”Pile support plate limitation” 11S39.
The distance between the stops is:

sheet width entered + 5 mm O.S.,
+ 5 mm D.S.
The ”5 mm O.S. + 5 mm D.S.” are added to the
entered value by the electronic control system.

The lateral pile stops move apart when
– the pile is raised.
The distance between the stops is:

sheet width entered + 25 mm O.S.,
+ 25 mm D.S.
The ”25 mm O.S. + 25 mm D.S.” are added to the
entered value by the electronic control system.
Symbol ”Prepiling”
60
11M12
11M11
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
61
Interconnection diagram 11M11
X5
X10 SSR
SSR X10
X15 X16
SSR X15 X3 X4
X17 X18
Backplane of servo-drive
11 plug-in unit SSR
3SSM2: X1 11LVT1
3SSM1: X2
X2
X1 X3
3SSM2
module 3SSM2
3 4
11M11: X1 5
2 1
11M11
Servo-drive 11M11

+ Pin 1 X5: A1 X1: 1 X10: B18
– Pin 2 X5: A2 X1: 2 X10: D18
10V Pin 3 X5: A3 X3: 3 X15: 3
Pin 4 X5: A4 X3: 4 X15: 4
0V Pin 5 X5: A5 X3: 5 X15: 5
62
X5
X10 SSR
SSR X10
X15 X16
SSR X15 X3 X4
X17 X18
Backplane of servo-
3SSM2: X1 11LVT1
3SSM2: X2
X2
X1 X3
3SSM2
module 3SSM2
11M12: X1
3 4
5
2 1
11M12
Servo-drive 11M12

+ Pin 1 X5: B1 X1: 3 X10: B20
– Pin 2 X5: B2 X1: 4 X10: D20
10V Pin 3 X5: B3 X2: 8 X15: 8
Pin 4 X5: B4 X2: 7 X15: 7
0V Pin 5 X5: B5 X2: 6 X15: 6
63
11M11
ÁÁÁ
ÁÁÁ
ÁÁÁ
11M12
ÁÁÁ ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
– Remove the servo-drive ”Pile stop D.S.”
11M11 or ”Pile stop O.S.” 11M12.
D.S.
O.S.
O.S.
Á
ÁÁ
D.S.
D.S./O.S. = 180 mm
– Set the distance between the side frame D.S. (or
side frame O.S.) and the pile stop D.S. (or pile
stop O.S.) to 180 mm.
64
09 3015 ± 2 10 1072 ± 2
11M11: X1
11M12: X1
– Fit the motor baseplate and gear wheel.

– Connect plug 11M11: X1 (or 11M12: X1).
– 11M11 (D.S.) = set to 3015±2 inc.
11M12 (O.S.) = set to 1072±2 inc.

1020
720
1,00
– Install the servo-drive. – Select the command ”Presetting”.

– Press the button ”Input”.
– The servo-drives position to the displayed
format.
65

Servo-drive ”Pile stop D.S.” 11M11
Servo-drive ”Pile stop O.S.” 11M12
Position the pile stops manually to the maximum

format (press the button ”Pile stops larger format”).
Incremental value for 11M11: 3231 ± 2 inc
Position the pile stops manually to the minimum

format (press the button ”Pile stops smaller format”).
servo-drives” Incremental value for 11M12: 3304 ± 2 inc
66
Size adjustment 1M4 Cover guide height adjustment
1M4 Cover guide height adjustment

For cover guide height adjustment a servo-drive is
installed on the operator side of the 1st printing unit.
With this servo-drive the cover guides (gripper
opening) on the transfer gripper are adjusted. By
means of a mechanical device (eccentric bush)
gripper opening can be adjusted within a range from
0.1 mm to 1.9 mm.
Positioning
The new desired position is always approached
from the direction of the widest gripper opening
(1.9 mm).
Example 1:
Actual position Reversal point
The new desired position is larger than the actual
position.
When the new desired position has been entered,

0 New desired position 1.9mm the servo-drive first positions to the reversal point
and then to the new desired position .
Example 1
Example 2:
New desired
position Actual position The new desired position is smaller than the actual
position.
When the new desired position has been entered,

0 1.9mm the servo-drive moves to the new desired position.
Example 2
Entering the paper thickness When the command ”Presetting” has been
enabled, the electronic control system positions the
cover guides on
CD102 and SM102 (only with REK386):

– to twice the paper thickness entered plus
0.1 mm (max. 1.9 mm),
SM74 and SM52:

– to twice the paper thickness entered (max.
1.9 mm).
67
Manual positioning
After actuating the button ”Cover guide height
adjustment”, the operator can make adjustments
Selecting the display with the left-hand +/– buttons.
Indication of the present value of the cover

guide height adjustment
Actual value/coarse display, cover guide height

adjustment
68
ÁÁÁÁ ÉÉÉ
ÉÉ
ÉÉÉ
ÉÉ
ÉÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
Printing unit 1 and feeder
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
69
X10 X5
SSR
SSR X20
X21 X22
X3 X4
X23 X24
SSR X23
1 plug-in unit SSR
2SSM1: X2 1LVT1
X3 X4
X1 2SSM1: X4
X2
X5
2SSM1
module 2SSM1
1M4: X1
1M4
Servo-drive 1M4

+ 1 X5: D1 X2: 3 X20: B12
– 2 X5: D2 X2: 4 X20: D12
10V 4 X5: D3 X4: 8 X23: 8
5 X5: D4 X4: 7 X23: 7
0V 6 X5: D5 X4: 6 X23: 6
70
Removal and installation of motor
1
ÉÉÉ
ÉÉ
É
ÉÉÉ
ÉÉ
É

ÉÉÉ
0 1 ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉ 1M4
15Q66
ÉÉ
ÉÉ
2
ÉÉÉ
ÉÉÉÉ
ÉÉÉÉ
ÉÉÉ
1M4
ÉÉÉ
½

ÉÉÉ
ÉÉ
É
ÉÉÉ
ÉÉ
É
ÉÉÉ
ÉÉÉ
1M4
ÉÉÉ
71
4
ÉÉ
ÉÉ
É
ÉÉ
ÉÉ
É
ÉÉ 1
ÉÉÉ
1M4
red
ÉÉ
brown
1
blue 2 2
black
ÉÉÉÉ 3
ÉÉÉÉ
ÉÉÉ
1M4 0 1
ÉÉÉ
1 15Q66
72
Removal and installation of potentiometer
1
2 310 . 0
3
1 0 1
15Q66
ÉÉÉ
É
ÉÉÉ
É
3 ÉÉÉ 1M4
ÉÉÉ
2
1
3
ÉÉÉÉ
ÇÇ
ÉÉÉÉ
ÇÇ
ÉÉÉÉ
ÇÇ
ÉÉÉ
2 ÉÉÉÉ
ÇÇ
ÉÉÉ ÉÉÉÉ
ÇÇ
1
ÉÉ ÉÉÉÉ
73
defec- new
tive
1 M4: X1
0 1
blue
beige
yellow black
black
red
15Q66
08 1016 ± 4
74
ÉÉÉ
É
ÉÉÉ
É
ÉÉÉ
É

ÉÉÉ
ÉÉÉ
ÉÉÉ
É
ÉÉÉ
É
ÉÉÉ
É
ÉÉÉ
1M4
ÉÉÉ

75

Preset version:
Servo-drive ”Cover guide height adjustment”
1M4
Paper thickness Incremental value

0.01 mm 676 " 4 inc
1.00 mm 3260 " 4 inc

servo-drives”
Standard version:
Servo-drive ”Cover guide height adjustment”
1M4
Paper thickness Incremental value

0.01 mm 676 " 4 inc
1.00 mm 3260 " 4 inc

servo-drives”
76
Size adjustment 1M2/1M3 Print-free margin D.S./O.S.
1M2/1M3 Print-free margin D.S./O.S.

The print-free margin on the sheet is adjusted by
Running direction of paper means of two servo-drives. These servo-drives
change the position of the front lay stop. The front
lays are fitted on a shaft which, for adjustment of
the print-free margin, can be adjusted parallel or at
Front lays an angle (to the feed table).
For this purpose, one servo-drive is installed on the
2mm drive side and one on the operator side. With these
two servo-drives the front lays can be influenced in

such a way that the print-free margin measures

between 10 mm and 12 mm. The adjustment is
made at the central control console.
Graphical representation in the ZID
Graphical representation ”Print-free margin”
Minimum value
Maximum value
Current value D.S.

Current value O.S.
To adjust the print-free margin, press the

Actual value/fine display ”Print-free margin” corresponding function button. Then make the
adjustment within a range from 10.0 mm to
Print-free margin O.S.
12.0 mm by means of the left-hand +/– buttons.
Print-free margin D.S.

and O.S.
Print-free margin D.S.
77
ÁÁÁÁ
1M2 = D.S.
1M3 = O.S.
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
78
X5
X10 SSR
SSR X10
X15 X16
X3 X4
X17 X18
SSR X18
Backplane of servo-
1SSM1: X1 1LVT1
X3 X4
1SSM1 X3
X2
X1
X5
1SSM
1
module SSM 1
X3 SSM3 X3 SSM3
X1 X2 X1 X2
1M2 1M3 Servo-drives 1M2 and

1M3

SSM3 SSM 1 SSR SSM3 SSM1 SSR
+ X3: 1 X5: A1 X1: 1 X10: B30 X3: 1 X5: B1 X1: 3 X10: B32
– X3: 2 X5: A2 X1: 2 X10: D30 X3: 2 X5: B2 X1: 4 X10: D32
10V X3: 3 X5: A3 X3: 3 X18: 3 X3: 3 X5: B3 X3: 8 X18: 8
X3: 4 X5: A4 X3: 4 X18: 4 X3: 4 X5: B4 X3: 7 X18: 7
0V X3: 5 X5: A5 X3: 5 X18: 5 X3: 5 X5: B5 X3:6 X18: 6
79
1
1
0 1
15Q66
1M2
(1M3) 2 3 2–4
1M2
(1M3)
2 2–4
80
1
1 216 . 0
2
0 1
15Q66
1M2
(1M3) 2 2–4
2
1
81
4
Pull rail

Front lay
defec- new
tive
0 1
15Q66
82
1M2 1M3
05 2048 ± 6 06 2048 ± 6
1M2
(1M3)
22–4
3
83

Preset version:
Servo-drive ”Print-free margin D.S.” 1M2
Servo-drive ”Print-free margin O.S.” 1M3

8 mm 3850 " 4 inc
10 mm 246 " 4 inc

servo-drives”
Standard version:
Servo-drive ”Print-free margin D.S.” 1M2
Servo-drive ”Print-free margin O.S.” 1M3

8 mm 3850 " 4 inc
10 mm 246 " 4 inc

servo-drives”
84
Size adjustment 1...nM5 Adjustment of printing pressure
1...nM5 Adjustment of printing pressure

The servo-drive ”Adjustment of printing pressure”
changes the gap between blanket cylinder and
impression cylinder. The rotation of the drive is
transmitted to the blanket cylinder via a worm gear
and a gear segment. The operator thus influences
the pressure exerted on the print sheet during the
printing process.
When the paper thickness is entered under the
command ”Presetting”, the servo-drive automati-
cally positions to the value:
paper thickness – 0.1 mm = pressure.
Examples:
0.07 –0.1 = –0.03 ! –0.03 x –1 = 0.03
0.50 –0.1 = 0.40 ! 0.40 x –1 = –0.40
The correction factor (–1) ensures that the result is
shown correctly in the ”Actual value display”.
Paper thickness entered

Symbol for the paper thickness entered
Upper adjustment limit for the printing
pressure (max. gap between blanket cylinder
and impression cylinder).
SM102 = – 0.75 mm,
CD102, CU on SM102 = – 1.20 mm.
Graphical representation of the printing
pressure
Present value of the printing pressure
Explanation of the display ”0” position of the printing pressure
Lower adjustment limit (0.3 mm) for the
printing pressure (min. gap between blanket
cylinder and impression cylinder)
85
Manual positioning
Graphical representation of the adjustment of

the printing pressure
The servo-drive can be positioned manually with the
right-hand +/– buttons. If no printing unit has been
selected in the ”Printing unit/actual value display”, all
drives respond. If only one drive is to be positioned,
the corresponding printing unit must be selected
before.
Note:
The software limits the maximum pressure to 0.55.
The max. pressure is composed of
Actual value/coarse display, adjustment of printing
pressure – the automatic positioning value (0.10) and
– the manual positioning value (max. 0.45).
86
1...nM5
L-M5 1...8M5
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
87
Interconnection diagram for printing unit 1...nM5
PU1, PU3, PU5

X5
PU2, PU4 SSR X20 X20 X30 SSR
PU6, PU7, PU8 SSR X30
PU1 = SSR X24

X25 X26
PU2 = SSR X25
PU3 = SSR X26 X3 X4
PU4 = SSR X27
X27 X28
PU5 = SSR X28
PU6 = SSR X31
PU7 = SSR X32
PU8 = SSR X33
Backplane of servo-drive plug-in unit SSR

1...8
1SSM2: X1 1...8LVT1
1...8M5: X1
1SSM2 X2
X1 1...8M5: X1
X2
X3
Servo-drive 1...8M5
1SSM2
module 1SSM2
1...8M5:X1 1SSM 2 SSR

PU1 PU2 PU3 PU4
+ 1 X3: A1 X1: 1 X20: B14 X20: B18 X20: B22 X20: B26
– 2 X3: A2 X1: 2 X20: B14 X20: D18 X20: D22 X20: D26
10V 4 X3: A3 X2: 3 X24: 3 X25: 3 X26: 3 X27: 3
5 X3: A4 X2: 4 X24: 4 X25: 4 X26: 4 X27: 4
0V 6 X3: A5 X2: 5 X24: 5 X25: 5 X26: 5 X27: 5
1...8M5:X1 1SSM 2 SSR
PU5 PU6 PU7 PU8
+ 1 X3: A1 X1: 1 X20: B30 X30: B2 X30: B6 X30: B10
– 2 X3: A2 X1: 2 X20: D30 X30: D2 X30: D6 X30: D10
10V 4 X3: A3 X2: 3 X28: 3 X31: 3 X32: 3 X32: 3
5 X3: A4 X2: 4 X28: 4 X31: 4 X32: 4 X32: 4
0V 6 X3: A5 X2: 5 X28: 5 X31: 5 X32: 5 X32: 5
88
Interconnection diagram for coating unit 2...nM5
PU3, PU5
X5
PU2, PU4 SSR X20 X20 X30 SSR
PU6, PU7, PU8 SSR X30
PU2 = SSR X25

X25 X26
PU3 = SSR X26
PU4 = SSR X27 X3 X4
PU5 = SSR X28
X27 X28
PU6 = SSR X31
PU7 = SSR X32
PU8 = SSR X33
PU9 = SSR X34
Backplane of servo-drive plug-in unit SSR

2..9
1SSM2: X1 2...9LVT1
2...9M5: X1
1SSM2 X2
X1 2...9M5: X1
X2
X3
Servo-drive 2...9M5
1SSM2
Servo-drive control
module 1SSM2
2...9M5:X1 1SSM 2 SSR

PU2 PU3 PU4 PU5
+ 1 X3: A1 X1: 1 X20: B18 X20: B22 X20: B26 X20: B30
– 2 X3: A2 X1: 2 X20: D18 X20: D22 X20: D26 X20: D30
10V 4 X3: A3 X2: 3 X25: 3 X26: 3 X27: 3 X28: 3
5 X3: A4 X2: 4 X25: 4 X26: 4 X27: 4 X28: 4
0V 6 X3: A5 X2: 5 X25: 5 X26: 5 X27: 5 X28: 5
2...9M5:X1 1SSM 2 SSR
PU6 PU7 PU8 PU9
+ 1 X3: A1 X1: 1 X30: B2 X30: B6 X30: B10 X30: B14
– 2 X3: A2 X1: 2 X30: D2 X30: D6 X30: D10 X30: D14
10V 4 X3: A3 X2: 3 X31: 3 X32: 3 X32: 3 X34: 3
5 X3: A4 X2: 4 X31: 4 X32: 4 X32: 4 X34: 4
0V 6 X3: A5 X2: 5 X31: 5 X32: 5 X32: 5 X34: 5
89
1 2
1
0 1
2 1...8M5 X1
– Switch off the press. – Disconnect 1...8M5 X1.

– Open the guard on the O.S.
3 4
– Loosen the fixing bolts on the motor. – Remove the defective motor.
90
5 6
– Install the new motor. – Tighten the fixing bolts.
7 8
1 brown brown
1
2
blue blue
2 1...8M5 X1
0 1
... 0.30
...-1.20
– Connect the motor. The value on the display changes in

– Start the press. positive direction (0.30).
The value on the display changes in
negative direction (–1.20).
91
1 2
1
0 1
1...8M5 X1
– Switch off the press. – Disconnect the potentiometer from 1...8M5 X1.
– Open the guard on the O.S.
3 4 4
1
2
– Loosen the stud on the gear wheel. – Turn the mechanism to the ”0” value of the
– Pull the gear wheel off the potentiometer. scale by means of the hexagon.
– Loosen the nut on the potentiometer.
– Replace the potentiometer.
92
5 6
1...8M5 X1
1
blue 4 beige
black 5 yellow
red 6 black
2
0 1
– Connect the new potentiometer. – Select service display 2.

– Start the press.
7 8
1
PU1 ... PUn =
1234 ± 8 inc 2
– Set the potentiometer to 1234 ± 8 inc. – Fasten the potentiometer.

– Put the gear wheel back in place and fasten
it with the stud.
93
... 0.30
– Check the operating range: 0.30 = 616 ± 8 inc
10
...-1.20
– Check the operating range: –1.20 = 3550 ± 8 inc
94

Preset version
Servo-drive ”Adjustment of printing pressure”
1M5

+ 0.30 616 " 8 inc
– 1.20 3550 " 8 inc

servo-drives”
95
Size adjustment 1M7/1M8 Adjustment of pull lays
1M7/1M8 Adjustment of pull lays

The servo-drive 1M7 positions the pull lay on the D.S.
The servo-drive 1M8 positions the pull lay on the O.S.
– depends on the inputs into CPTRONIC, such as
sheet width, off-centre position, pull direction,
precision adjustment of pull lay.
After actuation of the input button, the electronic

control system positions:
– the pull lay in use to the sheet width entered,
– the pull lay not in use 15 mm outside the
entered sheet width.
A pneumatic clamping mechanism locks the pull lay

1M7 in position. The pneumatic clamping mechanism
opens after actuation of the input button for the
command ”Presetting”.
1M8
The pneumatic clamping mechanism closes:
– when the pull lay is in the new position,
– if the new position is not reached in less than
4 minutes (fault message 7FFF in Dyn-test).
The electronic control system determines the

position of each pull lay via two potentiometers:
Potentiometer for
– during coarse positioning through the poten-
precision adjustment
tiometer in the servo-drive,
– during precision positioning through the
potentiometer near the servo-drive.
Servo-drives ”Adjustment of pull lays”
96
Precision adjustment of pull lay
Symbol and indication of the current value for

the precision adjustment of the pull lay
The symbol shows the active pull lay:
Arrow pointing up = pull lay on D.S. active
Arrow pointing down = pull lay on O.S. active
With the right-hand +/– buttons the active pull lay
can be precision-adjusted. Adjustment is possible
within a range of ± 5 mm in relation to the preset
format.
Actual value/coarse display, ”Adjustment of pull lays”
97
1M7
1M8
1Y47
Potentiometer for
precision adjustment
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
98
X5
X20 SSR
SSR X20
X21 X22
SSR X21 X3 X4
X23 X24
Backplane of servo-
11LVT1
1SSM1: X2
X3 X4
X2
1SSM1: X4
X1 X5
1SSM1
module 1SSM1
3 4
1M7: X1 5
2 1
1M7
Servo-drive 1M7 Potentiometer

(with potentiometer for coarse adjustment) (for precision adjustment)
+ Pin 1 – X5: C1 X2: 1 X20: B2

– Pin 2 X5: C2 X2: 2 X20: D2
10V Pin 3 X5: C3 X4: 3 X21: 3 X5: D3 X4: 8 X21: 8
Pin 4 X5: C4 X4: 4 X21: 4 X5: D4 X4: 7 X21: 7
0V Pin 5 X5: C5 X4: 5 X21: 5 X5: D5 X4: 6 X21: 6
99
X5
X20 SSR
SSR X20
X21 X22
SSR X22 X3 X4
X23 X24
1 plug-in unit SSR
11LVT1
2SSM1: X1
X3 X4
X2 2SSM1: X3
X1 X5
2SSM1
module 2SSM1
3 4
1M8: X1 5
2 1
1M8
Servo-drive 1M8 Potentiometer

(with potentiometer for coarse adjustment) (for precision adjustment)
+ Pin 1 X5: A1 X1: 1 X20: B6

– Pin 2 X5: A2 X1: 2 X20: D6
10V Pin 3 X5: A3 X3: 3 X22: 3 X5: B3 X3: 8 X22: 8
Pin 4 X5: A4 X3: 4 X22: 4 X5: B4 X3: 7 X22: 7
0V Pin 5 X5: A5 X3: 5 X22: 5 X5: B5 X3: 6 X22: 6
100

1Y47
– Remove the servo-drive ”Adjustment of pull – Actuate the solenoid valve 1Y47 manually
lay D.S.” 1M7 (or ”Adjustment of pull lay O.S.” and hold it in this position (pneumatic
1M8). clamping mechanism is open).
D.S.
1
2
2
1 3
O.S. 3
– Set the distance between the side frame D.S. Note:

(or O.S.) and the inside of the pull lay stop to Because of the backlash, the distance between
55 mm. the side frame and pull lay stop must first be
– Let go of the solenoid valve 1Y47. smaller than 55 mm.
Then the correct value of 55 mm must be set.
101
01 3055 ± 2 03 3055 ± 2
1M7: X1
1M8: X1

– 1M7 (D.S.) = set to 3055±2 inc.
– 1M8 (O.S.) = set to 3055±2 inc.

1020
1,00 720
– Install the servo-drive. – Select the command ”Presetting”.

format.
102

Servo-drive ”Adjustment of pull lay D.S.” 1M7
Servo-drive ”Adjustment of pull lay O.S.” 1M8
Only compare the new servo-drive with the

indicated values.
Maximum sheet width

Precision adjustment: 0.00 mm (2048 inc)
Sheet width: 1040 mm
Service display ”Values, incremental values For 1M7: pulling towards D.S.
servo-drives”
Incremental value: 3155 ± 4 inc
For 1M8: pulling towards O.S.
Minimum sheet width

Precision adjustment: 0.00 mm (2048 inc)
Sheet width: 420 mm
For 1M7: pulling towards D.S.
For 1M8: pulling towards O.S.
103
Size adjustment 12M5 Sheet slowdown/format adjustment
12M5 Sheet slowdown/format adjustment

The servo-drive 12M5 positions the sheet
slowdown at the delivery to the entered sheet
length.
– is effected through the command ”Preset-
ting”,
– depends on the entered sheet length.
Positioning range:
– max. 720 mm,
– min. 500 mm (because of danger of collision
with the sheet joggers),
– in the case of sheet lengths below 500 mm,
the suction head stops at the lower limit
(500 mm),
– manual positioning if the sheets are shorter
(less than 500 mm).

reached,
– when the lower limit (500 mm) of the
positioning range has been reached,
– when one of the pushbuttons ”Sheet
slowdown format” is actuated.
Manual positioning
Pushbuttons Actuation of one of the pushbuttons ”Sheet
”Sheet slowdown format” slowdown format”:
– the sheet slowdown positions irrespective of
Plus button the preset format,
– indication of the position in the delivery MID,
Minus button
104

Sheet slowdown/format The symbol appears in the display ”Delivery/
adjustment Warning”.
The symbol appears:

– during positioning while the press is on ”Run”,
– when the lower limit is reached during
automatic positioning.

”Run”,
– when one of the pushbuttons ”Sheet slowdown
format” is actuated and the press is on ”Run”.
105
12M5
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
106
X5
X10 SSR
SSR X10
X15 X16
SSR X16 X3 X4
X17 X18
12
plug-in unit SSR
12LVT1
1SSM1: X1 X3 X4
1SSM1: X3
X2
X1 X5
1SSM1
module 1SSM1
3 4
5
12M5: X1
2 1
12M5
Servo-drive 12M5
12M5:X1 1SSM 1 SSR

+ Pin 1 X5: B1 X1: 3 X10: B24
– Pin 2 X5: B2 X1: 4 X10: D24
10V Pin 3 X5: B3 X3: 8 X16: 8
Pin 4 X5: B4 X3: 7 X16: 7
0V Pin 5 X5: B5 X3: 6 X16: 6
107
Rear paper stop

1 2
3
1
2
Front paper stop
– Set the distance between the front and rear

paper stops to 600 mm.
Note:
To compensate for the backlash, the 600 mm must
– Remove the servo-drive ”Sheet slowdown / be set from the max. possible distance.
format adjustment” 12M5.
12M5: X1
12 1370
Coupling part
– Mount the coupling part.

– Set to 1370 inc.
108

Servo-drive ”Sheet slowdown / format
adjustment” “ 12M5
Paper length Incremental value

280 mm 3540 " 3 inc
720 mm 556 " 3 inc
730 mm 498 " 3 inc

servo-drives”
109
Size adjustment 12M6/12M7 Sheet joggers D.S./O.S.
12M6/12M7 Sheet joggers D.S./O.S.

The servo-drive 12M6 positions the sheet jogger on
the D.S.
The servo-drive 12M7 positions the sheet jogger on
the O.S.
– depends on the inputs into CPTRONIC, such as:
sheet width, off-centre position.

reached,
– when one of the pushbuttons ”Sheet jogger
D.S.” or ”Sheet jogger O.S.” is actuated.
Manual positioning
Pushbuttons Actuation of one of the pushbuttons ”Sheet jogger
”Sheet jogger D.S.” D.S.”:
– the servo-drive ”Sheet jogger D.S.” 12M6 is
Plus button controlled,
– the sheet jogger on the D.S. positions irrespec-
Minus button
tive of the preset format.
Pushbuttons Actuation of one of the pushbuttons ”Sheet jogger

”Sheet jogger O.S.” O.S.”:
– the servo-drive ”Sheet jogger O.S.” 12M7 is
Plus button controlled,
Minus button – the sheet jogger on the O.S. positions irrespec-

tive of the preset format.
Actuation of one of the pushbuttons ”Sheet jogger”:
– indication of the position in the delivery MID,
– the off-centre position can be up to ± 50 mm,
110

Sheet jogger D.S. The symbols appear in the display ”Delivery/
Warning”.
The symbols appear:

Sheet jogger O.S. – during positioning while the press is on ”Run”.
The symbols go off:

”Run”,
– when one of the pushbuttons ”Sheet jogger
D.S.” or ”Sheet jogger O.S.” is actuated and
the press is on ”Run”.
111
D.S. = 12M6
O.S. = 12M7
Delivery
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
112
X5
X10 SSR
SSR X10
X15 X16
X3 X4
X17 X18
SSR X17
12
plug-in unit SSR
12LVT1
1SSM1: X2 X3 X4
1SSM1: X4
X2
X1 X5
1SSM1
module 1SSM1
3 4
5
12M6: X1
2 1
12M6
Servo-drive 12M6
12M6:X1 1SSM 1 SSR

+ Pin 1 X5: C1 X2: 1 X10: B26
– Pin 2 X5: C2 X2: 2 X10: D26
10V Pin 3 X5: C3 X4: 3 X17: 3
Pin 4 X5: C4 X4: 4 X17: 4
0V Pin 5 X5: C5 X4: 5 X17: 5
113
X5
X10 SSR
SSR X10
X15 X16
X3 X4
X17 X18
SSR X17
12
plug-in unit SSR
12LVT1
X3 X4
1SSM1: X2
1SSM1: X4
X2
X1 X5
1SSM1
module 1SSM1
3 4
5
12M7: X1
2 1
12M7
Servo-drive 12M7
12M7:X1 1SSM 1 SSR

+ Pin 1 X5: D1 X2: 3 X10: B28
– Pin 2 X5: D2 X2: 4 X10: D28
10V Pin 3 X5: D3 X4: 8 X17: 8
Pin 4 X5: D4 X4: 7 X17: 7
0V Pin 5 X5: D5 X4: 6 X17: 6
114

Cam follower
Control cam
– Remove the servo-drive ”Sheet jogger D.S.” – Inch the press until the cam follower of the
12M6 (or ”Sheet jogger O.S.” 12M7). sheet jogger has reached the highest point of
the control cam.
– Set the distance between the sheet jogger

D.S. (or O.S.) and the side frame D.S. (or
O.S.) to 55 mm.
115

4)
12M6: X1
12M7: X1
13 704 ± 2 14 704 ± 2

– 12M6 (D.S.) = set to 704±2 inc.
12M7 (O.S.) = set to 704±2 inc.

1020
720
1.00
– Select the command ”Presetting”.

– Install the servo-drive. format.
116

Servo-drive ”Sheet jogger D.S.” 12M6
Servo-drive ”Sheet jogger O.S.” 12M7
The indicated values are valid for both servo-

drives.
Sheet width: 1040 mm
Sheet width: 420 mm

servo-drives”
117
118
Feeder pile control Block diagrams
Feeder pile control
Block diagrams
Block diagram (Preset)
Pile Switches and Controls

height sensors
Safety SEK EAK_11 Press control

circuit
REK2
ESK
Auxiliary drive HAK_01 HAK_02

control A B C A B C
A LTK500 B
A STK1 B
A BAK B
Main Auxiliary
M M
pile pile
11M1 11M2
Preset feeder with auxiliary pile
119
Feeder pile control Block diagrams
Block diagram (Standard)
Pile Switches and Controls

height sensors

circuit
REK2
ESK
Auxiliary drive HAK_01 HAK_02

control A B C A B C
A STK1 B A STK2 B
Main Auxiliary
M M pile
pile
11M1 11M2
Standard feeder with auxiliary pile
120
Feeder pile control Layout
Layout
Overview
The pile control of the feeder is used to control the
main pile and auxiliary pile. It consists of the
following functional units:
– Press control: Detection and evaluation of
input signals for controlling the pile drives
– Safety circuit: Detection and evaluation of
safety signals for the emergency shutdown of
pile drives
– Auxiliary drive control: Control of pile motors
The following components are part of the pile

control:
SEK Safety input board
EAK_11 Input/output board on board slot 11
(signal acquisition feeder)
REK2 Processor board on board slot 2
(press control)
ESK Input/output control board
HAK_01 Auxiliary drive board on board slot 1
STK1 Pile control board on board slot 1
BAK Brake control board
LTK500 Power part board 500W
121
Press control
The press control detects the signals of the
switches and sensors on the feeder via the inputs
Inputs
of EAK_11. REK2 evaluates these signals and
generates control signals for the pile motors. The
control signals for pile motors are passed on to
the auxiliary drive control via the ESK.
EAK_11
The ESK is provided with the following operation
set for controlling the individual pile motors:
– Pile stop (pile height control off)
REK2
– Pile up (slow)
– Pile down (slow)
ESK – Pile up, fast (at main pile only)
– Pile down, fast (at main pile only)
– Pile height control on
Auxiliary drive control – Rack mode (parameter: rack height)
Press control
Safety circuit
The SEK registers the signals of those switches
on the feeder which are relevant to safety. It
Inputs
evaluates these signals and if necessary it
generates control signals for the emergency
shutdown of the pile drives. These control signals
are directly passed on to the auxiliary drive
SEK control.
The signals of the safety circuit always take

priority over the signals of the press control.
Auxiliary drive control
Safety circuit – Pile drive enabled
– Pile up blocked
– Pile down blocked
122
The auxiliary drive control conditions the control

signals of SEK and ESK and regulates the
Safety circuit Press control
individual pile drives.
Each drive is assigned with a control section

(component of a HAK) and a power part (depen-
dent on the motor used). Depending on the press
version, the assignments listed in the following are
HAK_01 HAK_02 possible - see also ”block diagrams”.
Control
LT LT Drive section Power part
Main pile HAK01 BAK+LTK500

M M (Preset) Part A Part A
11M1 11M2 Main pile HAK01 STK1

(standard) Part A Part A
Auxiliary pile HAK01 STK2
Part C Part A
The signal of the governor foot for controlling the

pile heights is conditioned in the power parts of
the main pile and of the auxiliary pile. Both power
parts pass the conditioned signal to the relevant
control section.
See chapter ”Control systems / auxiliary drive

control” for further information on auxiliary drive
control.
123
Feeder pile control Overview of components
Overview of components
Preset feeder
11M1 11S56
11S34 11S65
11M2
11S37
11S31
11B35
11S32
11S36
11B33
11B11
11S39
Components on the Preset feeder
124
Standard feeder
11M1 11S33
11M2
11S34
11S37
11S36
11S32
11S65
11S31
11S35
11S39
Components on the standard feeder
125
Motors
Equip- Function Preset Standard Remarks
ment
with without with without
non- non- non- non-
stop stop stop stop
11M1 Main pile drive (Preset) D D Brushless motor
11M1 Main pile drive (standard) D D Three-phase a.c. motor
11M2 Auxiliary pile drive D D
Switches and sensors

ment with without with without
non- non- non- non-
stop stop stop stop
11B11 Auxiliary pile detection D
11S31 Suction head limitation D D D D
11S32 Upper pile safety D D D D
11S33 Upper main pile limitation D D
11B33 Upper main pile limitation D D
11S34 Bottom main pile limitation D D D D
11B35 Automatic pile transport D D
11S35 Automatic pile transport D D
11S36 Upper limitation of auxiliary pile D D
11S37 Bottom limitation of auxiliary D D
pile
11S39 Pile support plate limitation D D D D
11S56 Switching off the auxiliary pile D
11S65 Pile height control D D D D
(governor foot)
126
Feeder pile control Function
Function
Pile height control of main pile (Preset)

The automatic pile height control of the main pile
on the feeder is activated as soon as one of the
following conditions is met:
11S65
11B35 – The sensor ”automatic pile transport” (11B35)
detects paper when raising the main pile
(actuation of the button ”main pile up”,
11S24)
– The press turns, the feeder is engaged and
the sensor ”automatic pile transport” (11B35)
detects paper
With the automatic pile height control, the pile is

controlled so that the upper edge is always at the
level of the governor foot (11S65) - with governor
Switching points of main pile height control foot in vertical position. As soon as the sensor
detects too little paper on the pile, the pile is
moved upwards by a presettable height (the ”pile
Pile height control lift increment at the feeder” can be adjusted
between 0.5 mm and 2.5 mm on the ZID). The
Governor foot is positioned vertically
position of the governor foot can be altered by
11S65 detects too little paper means of the suction head height control.
Pile up (by the value set) The automatic pile height control on the feeder is
stopped under the following circumstances:
Sequence of main pile height control – actuation of an emergency stop switch
– actuation of the ”suction head limitation”
switch (11S31)
– actuation of the ”upper pile safety” switch
(11S32)
– actuation of the ”upper main pile limitation”
switch (11B33)
– actuation of the ”upper auxiliary pile limita-
tion” switch (11S36)
(only in case of non-stop)
– actuation of the ”pile stop” button (11S26)
– actuation of the ”main pile down” button
(11S25)
– Sheeter in operation
(extra accessory)
– The sensor ”automatic pile transport” (11B35)
does not detect any paper (only during the
first 30 sheets in the closed loop control)
127
Automatic pile height control of main pile (standard)

The automatic main pile height control on the
feeder is activated as soon as one of the following
conditions is met:
11S65
11S35 – The sensor ”automatic pile transport” (11S35)
detects paper when raising the main pile
(actuation of the button ”main pile up”,
11S24)
– The press turns, the feeder is engaged and
the switch ”automatic pile transport” (11S35)
detects paper
The pile is controlled by the automatic pile height

control so that its upper edge is always at the
level of the governor foot (11S65) - with vertically
Switching points of the automatic main pile positioned governor foot. As soon as the sensor
height control detects too little paper on the pile, the pile is
raised by the adjustable height (the ”pile lift
increment on the feeder” can be set between
Automatic pile height control
0.5 mm and 2.5 on the ZID). The position of the
Governor foot is positioned vertically
governor foot can be adjusted (manually) via the
suction head height control.
11S65 detects too little paper
The automatic pile height control on the feeder is
Pile up (by preset value) stopped under the following circumstances:
– actuation of an emergency stop switch
Sequence of the automatic pile height control for
the main pile
switch (11S31)
– actuation of the ”upper pile safety” (11S32)
switch (11S33)
– actuation of the ”main pile down” switch
(11S25)
– sheeter in operation
(extra accessory)
– The sensor ”automatic pile transport” (11S35)
does not detect any paper (only during the
first 30 sheets in the closed-loop control)
128
Automatic pile height control of auxiliary pile

The automatic pile height control of auxiliary pile
on the feeder is activated as soon as the toggle
switch is in position ”auxiliary pile on” (11S27) and
11S65 the sensor/switch ”automatic pile transport”
11B35
(Preset: 11B35, standard: 11S35) detects paper.
The pile is controlled by the automatic pile height

control so that the upper edge of the pile is always
at the level of the governor foot (11S65) - with
governor foot positioned vertically. As soon as the
sensor detects too little paper on the pile, the pile
is raised by an adjustable height (the ”pile lift
increment on the feeder” can be adjusted between
0.5 mm and 2.5 mm on the control console
display ZID). The position of the governor foot can
Switching points of the automatic pile height be altered via the suction head height control.
control of auxiliary pile
The automatic pile height control at the feeder is

Automatic pile height control stopped under the following circumstances:
Governor foot is positioned vertically – actuation of an emergency stop switch
11S65 detects too little paper – actuation of the ”suction head limitation”
button (11S31)
Pile up (by preset value)
(11S32)
Sequence of the automatic pile height control for
the auxiliary pile
– actuation of the ”auxiliary pile down” button
(11S29)
– unloading the ”auxiliary pile detection” sensor
(11B11)
(only with Preset)
(extra accessory)
– The sensor ”automatic pile transport” (11B35)
does not detect any paper.
129
Transport of main pile

Main pile up
11S24
The main pile can only be raised manually if the
automatic pile height control of the main pile is not
active.
The upwards movement of the main pile is

11B33 controlled via the button ”main pile up” (11S24) on
the feeder operation panel. If one of the following
circumstances is met upon actuation of the button,
the main pile moves upwards:
fast – The toggle switch (11S27) is in position
”auxiliary pile on”
– The sensor ”auxiliary pile detector” (11B11) is
damped
(only in case of non-stop with Preset)
– The toggle switch is in position ”auxiliary pile
Switching points of main pile up off” (11S27) and the ”automatic pile transport”
(Preset: 11B35, standard: 11S35) detects no
paper
Main pile up
When the pile support plate reaches the ”upper
Permissible start condition main pile limitation” (Preset: 11B33, standard:
11S24 (keep pressed) 11S33) or when the ”automatic pile transport”
(Preset: 11B35, standard: 11S35) detects paper,
Main pile up, fast the transport of the main pile stops.
– Preset: 11B33 or 11B35
– Standard: 11S33 or 11S35 interrupted under the following circumstances:
Main pile stop – actuation of an emergency stop switch
Sequence of main pile up switch (11S31)
(11S32)
– actuation of the ”main pile down” button
(11S25)
(extra accessory)
The pile transport can only be continued if the

respective cause has been eliminated.
130
Main pile down

11S25 11S26
The downward movement of the main pile is
controlled via the button ”main pile down” (11S25)
on the feeder operation panel. The speed is
changed (slow/fast) depending on the position of
the main pile.
The button ”main pile down” (11S25) is furnished

with a self-stopping mode. If the button is
actuated, the main pile moves downwards at fast
speed. When it reaches the ”pile support plate
fast limitation” (11S39), the main pile stops.
In case of the preset version, the pile support
plate is automatically centered in this position
11S39 (maximum duration: 25 s). During this centering
slow process, the control does not respond to the
11S34 actuation of the ”main pile down” button (11S25).
Switching points of main pile down
If the ”main pile down” button (11S25) is actuated
again, the main pile (without self-stopping) moves
further downwards at slow speed. When it reaches
Main pile down
the ”bottom main pile limitation” (11S34), the main
Permissible start condition pile stops.
11S25 (self-stopping mode) The downward movement of the main pile is

interrupted if one of the following conditions is
Main pile down, fast
met:
11S39
– Preset: main pile stop and automatic – actuation of the ”lower end stop” switch
centering of the pile support plate (11S34)
– Standard: main pile stop
– actuation of the ”pile support plate limitation”
switch (11S39)
11S25 (no self-stopping mode)
Main pile down, slow
– actuation of the ”main pile up” button (11S24)
11S34
An interrupted pile transport can only be continued
Main pile stop after elimination of the cause.
Sequence of main pile down and passing both

speed ranges
131
Transport of auxiliary pile

Preconditions
The auxiliary pile can only be transported if the
switch ”switching off the auxiliary pile” (11S56) is
clear.
(Only with Preset)
Auxiliary pile up
11S28
The auxiliary pile can only be moved up manually,
if the automatic pile height control of the auxiliary
pile is not active.
The upwards movement of the auxiliary pile is

11S36 controlled via the button ”auxiliary pile up” (11S28)
on the feeder operation panel. The auxiliary pile
moves upwards at a constant speed. When it
fast reaches the ”upper auxiliary pile limitation”
(11S36), the transport mechanism of the auxiliary
pile stops.
The upwards movement of the auxiliary pile is

interrupted if one of the following conditions is
met:
Switching points of auxiliary pile up – actuation of the ”suction head limitation”
switch (11S31)
Auxiliary pile up – actuation of the ”upper pile safety” (11S32)
Permissible starting point

– actuation of the ”auxiliary pile down” button
11S28 (keep pressed)
(11S29)
Auxiliary pile up – sheeter is in operation
11S36 (extra accessory)
Auxiliary pile stop An interrupted pile transport can only be continued

after the respective cause has been eliminated.
Sequence of auxiliary pile up
132
Auxiliary pile down

11S29
The downwards movement of the auxiliary pile is
controlled via the button ”auxiliary pile down”
(11S29) on the delivery operation panel. The
auxiliary pile moves downwards at a constant
speed. When it reaches the ”bottom auxiliary pile
limitation” (11S37), the transport mechanism of the
auxiliary pile stops.
fast The downward movement of the auxiliary pile is

stopped if one of the following conditions is met:
11S37
sensor (11B33)
(only in case of Preset with non-stop)
Switching points of auxiliary pile down – actuation of the ”auxiliary pile up” button
(11S28)
Auxiliary pile down – sheeter is in operation

(extra accessory)
Permissible starting point
if the respective cause has been eliminated.
Auxiliary pile down
11S37
Auxiliary pile stop
Sequence of auxiliary pile down
133
Non-stop operation (Preset)

Preconditions
The non-stop operation on the Preset feeder
requires the following preconditions:
– The press is in production mode
– The toggle switch (11S27) is in position
”auxiliary pile off”
– The non-stop bar is unhinged so that the
switch ”switching off the auxiliary pile”
(11S56) is clear
– The non-stop bar is at the level of the pile
board (starting position for inserting the
support rods)
Basic function
The non-stop operation on the Preset feeder
consists of the following sub-steps:
– Transfer of pile:
Inserting the support rods creates main and
auxiliary pile. The auxiliary pile takes over the
automatic pile height control
– Pile change:
The (empty) main pile moves downwards.
There it is loaded and moves back up to the
auxiliary pile
– Pile merging:
Main and auxiliary pile are merged by pulling
out the support rods. The main pile takes
over the automatic pile height control again.
134
Main pile Auxiliary pile
Automatic pile height control of main pile on Automatic pile height control of auxiliary pile off
Inserting support rods Inserting support rods

Pile transfer 11S27 auxiliary pile on
Auxiliary pile up, slow
11B11 damped 11B11 damped
– Automatic pile height control of main pile off – Auxiliary pile stop
– Awaiting starting point – Automatic pile height control of auxiliary pile on
– Main pile down, fast
11S39
– Main pile stop

– Centering main pile (automatically)
11S34
Pile change Main pile stop (loading)
11S24
Main pile up, fast
– Main pile stop

– Aligning main pile (manually)
11S24
Main pile up, fast
11B11 not damped
Automatic pile height control of main pile on
11S27 auxiliary pile off
Automatic pile height control of auxiliary pile off
Removing support rods Removing support rods

Pile
merging 11S29
Auxiliary pile down
11S37
Auxiliary pile stop
Sequence of non-stop operation (Preset)
135
Pile transfer
The support rods are inserted (manually) and the
toggle switch (11S27) is brought into the position
”auxiliary pile on”. The auxiliary pile moves
upwards until the sensor ”auxiliary pile detection”
(11B11) is damped. This activates the automatic
pile height control on the auxiliary pile and
deactivates it on the main pile.
When reaching the starting point (dependent on

the automatic pile height control of the auxiliary
pile), the main pile moves automatically down-
wards.
Pile change
The main pile stops when reaching the ”pile
support plate limitation” (11S39). In this position,
the pile support plate is automatically centered
(max. duration: 25 s).
When actuating the button ”main pile down”

(11S25), the main pile moves further downwards
at slow speed. When reaching the ”bottom limit
position” (11S34), the main pile stops and can be
loaded.
When actuating the button ”main pile up” (11S24),

the pile moves back upwards. The main pile must
be aligned manually just before it reaches the
auxiliary pile.
Pile merging
When reaching the auxiliary pile, the sensor
”auxiliary pile detection” (11B11) is no longer
damped, whereupon the automatic pile height
control of the main pile is activated again.
The toggle switch is put into the position ”auxiliary

pile off” (11S27), this deactivates the automatic
pile height control on the auxiliary pile. The
support rods are pulled out (manually). Upon
actuation of the button ”auxiliary pile down”
(11S29) the non-stop bars move downwards.
When reaching the ”bottom auxiliary pile limitation”
(11S37), the non-stop bars stop (starting position).
136
Non-stop operation (standard)

Preconditions
The non-stop operation on the standard feeder
requires the following preconditions:
– The press is in production mode.
– The toggle switch is in position ”auxiliary pile
off” (11S27)
– The non-stop bar is at the level of the pile
support board (starting position for inserting
the support rods)
Basic function
The non-stop operation on the standard feeder
consists of the following sub-steps:
– Pile transfer:
Inserting support rods creates main and
auxiliary pile. The auxiliary pile takes over the
automatic pile height control
– Pile change:
The (empty) main pile moves downwards.
There it is loaded and moves back up to the
auxiliary pile
– Pile merging:
Main and auxiliary pile are merged by pulling
out the support rods. The main pile takes
over the automatic pile height control again.
137
Inserting support rods Inserting support rods

Pile transfer 11S28
Auxiliary pile up, slow
11S27 Auxiliary pile on 11S27 auxiliary pile on
Automatic pile height control of main pile off Automatic pile height control of auxiliary pile on
11S25 (self-stopping mode)
11S39
Main pile stop
Pile change Main pile down, slow
11S34
Main pile stop (loading)

11S24
Main pile up, fast
Height of auxiliary pile reached
Main pile stop
11S27 auxiliary pile off 11S27 auxiliary pile off
Removing support rods Removing support rods
Pile 11S29
merging
Auxiliary pile down
11S37
Auxiliary pile stop
Sequence of non–stop operation (standard)
138
Pile transfer
The support rods are inserted (manually). Through
actuation of the ”auxiliary pile up” button (11S28),
the non-stop bars are moved upwards (until the
support rods are slightly lifted). The toggle switch
(11S27) is brought into position ”auxiliary pile on”,
this activates the automatic pile height control on
the auxiliary pile and deactivates it on the main
pile.
Pile change
(11S25), the main pile moves in self-stopping
mode downwards at fast speed. The main pile
stops when reaching the ”pile support plate
limitation” (11S39).

(11S25) once more, the main pile (without
self-stopping mode) moves downwards at slow
speed. When reaching the ”bottom limitation”
(11S34) the main pile stops and can be loaded.
When actuating the button ”main pile up” (11S24),

the main pile moves upwards at fast speed. The
main pile must be moved up to the auxiliary pile,
so that the auxiliary pile is relieved.
Pile merging
The toggle switch is put into position ”auxiliary pile
off” (11S27), this reactivates the automatic pile
height control on the main pile and deactivates it
on the auxiliary pile. The support rods are pulled
out (manually). When actuating the button
”auxiliary pile down” (11S29), the non-stop bars
move downwards. When reaching the ”bottom
limitation of auxiliary pile” (11S37), the non-stop
bars stop (starting position).
139
Feeder pile control 11M1 Main pile motor (Preset)
11M1 Main pile motor (Preset)
11M1
Place of installation of main pile motor (Preset)
Layout
Motor electronics
Motor and brake
Gear unit
Male connector
Layout of main pile motor (Preset)
140
Task and function

The main pile motor moves the main pile upwards
and downwards by means of pile chains.
A brushless motor is used which can perform the

following functions:
– Speed control
– Changeover between two different speed
levels (”fast” and ”slow”)
– Electric deceleration (controlled by the
respective power part)
– Stopping or emergency braking by means of
the brake installed
The motor is provided with the following internal

functions for the purpose of controlling and
monitoring:
– Commutation and speed detection by means
of Hall signals
– Temperature detection through resistor
Technical specifications
– Output: 0.18/0.36 kW
– Power supply: DC 120 V
– Speed (gear unit): 5.7/40 min–1
– Ratio: 100:1
– Resistor code: 2 (560 W)
141
Pin assignment
Pin Function
A1 X1 motor line (slow)
A B C B1 Y1 motor line (slow)
1 1
C1 Z1 motor line (slow)
2 2
3 3 A2 X2 motor line (fast)
4 4 B2 Y2 motor line (fast)
5 5 C2 Z2 motor line (fast)
C5 Brake (reference potential DC)
B5 Brake (DC +24 V)
B4 Hall 1
A5 Hall 2
Pin assignment on main pile motor (Preset) B3 Hall 3
A4 Resistor code
A3 PTC (temperature monitoring)
C4 Auxiliary supply of motor electronics UH
C3 Ground auxiliary supply
PE conductor
142
Feeder pile control 11M1 Main pile motor (standard)
11M1 Main pile motor (standard)
11M1
Place of installation of main pile motor (standard)
Layout
Motor electronics
Motor and brake
Gear unit
Male connector
Layout of main pile motor (standard)
143
Task and function

and downwards by means of the pile chains.
A three-phase induction motor is used which

carries out the following functions:
– Stopping and emergency braking by means
of the brake installed

monitoring:
– Speed detection via Hall signals
– Temperature detection via resistor
– Output: 0.13/0.42 kW
– Power supply: 220 V / 50 Hz
265 V / 60 Hz
– Speed (gear unit): 9.5/41.5 min–1 (220V)
11.5/49.7 min–1 (265V)
– Ratio: 66:1
144
Pin assignment
Pin Function
A1 Winding U1 (slow)
B1 Winding V1 (slow)
A B C
1 C1 Winding W1 (slow)
2 A2 Winding U2 (fast)
3 B2 Winding V2 (fast)
4 C2 Winding W2 (fast)
5 A3 N1, N2
B5 Brake (reference potential DC)
C5 Brake (DC +24 V)
B4 Hall 1
pin assignment of main pile motor (standard) A5 Hall 2
C3 Resistor code
B3 PTC (temperature monitoring)
C4 Auxiliary voltage of motor electronics UH
A4 Ground auxiliary voltage
PE conductor
145
Feeder pile control 11M2 Auxiliary pile motor
11M2 Auxiliary pile motor
11M2
11M2
Preset feeder Standard feeder
Place of installation of auxiliary pile motor
Layout
Motor electronics
Motor and brake
Gear unit
Male connector
Layout auxiliary pile motor
146
Task and function

The auxiliary pile motor moves the auxiliary pile
upwards and downwards by means of the pile
chains.
A three-phase induction motor is used which can

execute the following functions:
of the brake installed

monitoring:
– Speed detection via Hall signals
– Temperature detection via resistor
– Output: 0.09/0.4 kW
265 V / 60 Hz
13.9/58.7 min–1 (265V)
– Ration: 57:1
– Resistor code: 8 (56 kW)
147
Pin assignment
Pin Function
A B C
5 A3 N1, N2
C5 Brake (DC +24 V)
B4 Hall 1
Pin assignment main pile motor (standard) A5 Hall 2
C3 Resistor code
C4 Auxiliary voltage motor electronics UH
PE conductor
148
Feeder pile control 11B11 Auxiliary pile detection
11B11 Auxiliary pile detection
11B11
Place of installation 11B11 (Preset feeder)
Layout
Sensor
Cable
Sensor 11B11 with cable
149
Task and function

The inductive sensor 11B11 monitors whether the
non-stop bar is loaded.
In case of a loaded non-stop bar, the auxiliary pile

presses a trip bar downwards. The sensor detects
the trip bar (metal).
Switching output: normally open contact
Connection
Core colour Function Terminal
11B11 brown + 24V DC 12X2: +1
blue 24V DC 12X2: –1
black signal FEM64: XE11
Cable end sensor 11B11
The sensor is screwed down to a base plate

which is located at the non-stop bar.
Removal and installation 11B11
150
Setting
In its basic setting the sensor protrudes the base
ÁÁÁ
plate by 14 mm (see figure).
ÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁÁ
14 –0.2 mm
ÁÁÁÁÁÁÁÁ
ÁÁÁ
Setting 11B11
Checking the circuit state

The output signal of the sensor 11B11 reaches the
EAK_11 EAK_11, input 11.
E11
11B11
Signal flow
Position signal E11
The input signal E11 can be checked on the

service display EAK:
0: The sensor detects no metal (the trip bar is
unloaded)
1: The sensor detects metal (the trip bar is
loaded)
Service display, signal E11
151
Feeder pile control 11B33 Upper main pile limitation
11B33 Upper main pile limitation
11B33
Layout
Sensor
Cable
152
Task and function
The inductive sensor 11B33 monitors whether the

pile support plate has reached the uppermost
position.
The sensor detects the pile support plate (metal).
Switching output: normally closed contact
Connection
11B33 brown + 24V DC 12X2: +1

The sensor is screwed down to the non-stop bar.
153
Setting
In its normal position the sensor protrudes the

non-stop bar by 24 mm (see figure).
24 mm
Setting 11B33

The output signal of the sensor 11B33 reaches
E33
11B33
Signal flow
Position signal E33

0: The sensor detects metal (the pile support
plate is located at level of the sensor)
1: The sensor detects no metal (the pile support
plate is located below the sensor)
154
Feeder pile control 11B35 Automatic pile transport
11B35 Automatic pile transport
11B35
Layout
Sensor
Cable
155
Task and function

The capacitive sensor 11B35 detects whether the
upper edge of the pile (paper) is at the respective
height.
Connection
11B35 brown + 24V DC 12X2: +1

The sensor 11B35 is screwed down to the pile
support frame in a special holder.
When installing the cable make sure that no

moveable parts are touched (risk of wearing
through). The tape driving shaft is particularly
critical.
156

E35
11B35
Signal flow
Position signal E35

service display:
0: The sensor does not detect an object (the
upper edge of pile is below the sensor)
1: The sensor detects an object (the upper edge
of pile is at the level of the sensor)
157
Feeder pile control 11S34 Bottom main pile limitation
11S34 Bottom main pile limitation
11S34
11S34
Preset feeder Standard feeder

Components
Place of installation 11S34
Task and function
The position switch 11S34 deactivates the pile

drive when the main pile has reached its lowest
position.
There is a trip cam at the pile change which

actuates the position switch via a shifter mecha-
nism.
158
Setting
To set the ”bottom main pile limitation”, the main

pile chains must be shortened or lengthened
accordingly. The position switch 11S34 must not
be changed.
Basically the following procedure for shortening or

lengthening the main pile chains applies.
Furthermore, the instructions and safety hints of
the ”service manual for the mechanics” are to be
obeyed.
Lower the pile support plate of the feeder
until the pile support plate rests on the floor
or on an elevation (e.g. pallets) and the pile
chains are relaxed
Lengthen or shorten the main pile chains
accordingly

The output signal of the switch 11S34 reaches
E34
11S34
Signal flow
Position signal E34

0: switch is actuated
1: switch is not actuated
Note:
The signal is also displayed on the service display
SEK.
159
Components
160
Delivery pile control Block diagrams
Delivery pile control
Block diagrams
Block diagram (Preset)
Pile Switches and Controls Outputs

height sensors
SEK EAK_12
Safety Press control
circuit
REK2
ESK
HAK_01 HAK_02
Auxiliary A B C A B C
drive control
A LTK500 B
A LTK50 B
A BAK B
Main M M Auxiliary
pile pile
12M1 12M2
Preset delivery with auxiliary pile
161
Delivery pile control Block diagrams
Block diagram (standard)
Pile Switches and Controls Outputs

height sensors

circuit
REK2
ESK
HAK_01 HAK_02
Auxiliary A B C A B C
drive control
A STK1 B A LTK50 B
Main Auxiliary
M M
pile pile
12M1 12M2
Standard delivery with auxiliary pile
162
Delivery pile control Layout
Layout
Overview
The pile control of the delivery is used to control
main pile and auxiliary pile and other outputs
(solenoid-operated valves). It consists of the
following functional units:
– Press control: recording and evaluating input
signals for controlling the pile drives and
outputs
– Safety circuit: recording and evaluating
safety-relevant signals for emergency
shutdown of pile drives
– Auxiliary drive control: control of pile motors
The following components are part of the pile

control:
EAK_12 Input/output board on board slot 12
(signal acquisition delivery)
REK2 Processor board on board slot 2
(press control)
ESK Input/output control board
163
Press control
The press control records the signals of the
switches and sensors on the delivery and the
Inputs Outputs
delivery controls via the inputs of EAK_12. REK2
evaluates these signals and generates control
signals for the pile motors and solenoid-operated
valves. The solenoid-operated valves are
EAK_12 controlled via the outputs of EAK_12. The control
signals for the pile motors are passed on to the
auxiliary drive control via the ESK.
REK2 The ESK has the following operation set for

controlling the individual pile motors:
– Pile stop (pile height control off)
ESK – Pile up (slow)
– Pile down (slow)
– Pile up, fast (only for main pile)
Auxiliary drive control – Pile down, fast (only for main pile)
– Pile height control on
Press control
– Rack mode (parameter: rack height)
Safety circuit
The SEK detects the signals of the safety-relevant
switches on the delivery. It evaluates these signals
Inputs
and if necessary it generates control signals for
the emergency shutdown of pile drives. These
control signals are passed on directly to the
auxiliary drive control.
SEK
The signals of the safety circuit take priority over
the signals of the press control.

– Pile drive enabled
Safety circuit
– Pile up blocked
– Pile down blocked
164
The auxiliary drive control prepares the control

signals of SEK and ESK and controls the
Safety circuit Press
individual pile drives.
control
Each drive is assigned with a control section
(component of a HAK) and a power part (depen-
dent on the motor used). Depending on the press
version, the assignments listed below are possible
HAK_01 HAK_02 - see also ”block diagrams”.
Control
LT LT LT Drive section Power part
Main pile HAK01 BAK+LTK500

M M M (Preset) Part B Part B
12M1 12M2 12M2 Main pile HAK01 STK1

(standard) Part B Part B
Auxiliary pile HAK02 LTK50
(with auxiliary Part A Part A
pile at feeder)
Auxiliary pile HAK01 LTK50

(no auxiliary Part C Part A
pile at feeder)
The signal of the capacitive sensor for the

automatic pile height control is prepared in the
power part of the main pile. The prepared signals
is passed on to the power part of the auxiliary
pile. Both power parts pass the signal on to the
corresponding control section.
See chapter ”control systems / auxiliary drive

control” for further details about the auxiliary drive
control.
165
Delivery pile control Overview of components
Overview of components
Operator side
12S130
12S56 12S33
12S55 12Y14/15
12B69
12S34
12S131 12Y49
12S42
12S41 12S35
12B129a
12Y60/61 12Y11
12S34b 12Y13
12B129
12S42
12S117
12B65
Components on the operator side
166
Drive side
12M1
12M2
12S39
12S55a
12S130a
12Y62
12S36
12S34a
12S38
Components on the drive side
167
Motors
non- non- non- non-
stop stop stop stop
12M1 Main pile drive (Preset) D D Brushless motor
12M1 Main pile drive (standard) D D Three-phase a.c. motor
12M2 Auxiliary pile drive D D
Switches and sensors

non- non- non- non-
stop stop stop stop
12S33 Upper main pile limitation D D
12S34 Bottom main pile limitation D D D D
12S34a Bottom main pile limitation D D D D only with raised deli-
very, same function as
12S34
12S34b Bottom main pile limitation D D D D only with raised deli-
very, same function as
12S34
12S35 Sheet jogger 1 D D D D
12S36 Sheet jogger 2 D D D D
12S38 Overshooting control D D D D
12S39 Monitoring suction drum D D D D
12S41 Pile rake stop D D
12S42 Pile rake down D D – with board fitting
on D.S.
– with rake fitting
on O.S.
12S55 Upper auxiliary pile limitation D D
12S55a Upper auxiliary pile limitation D D same function as
12S55
12S56 Bottom auxiliary pile limitation D D
12B65 Changeover fast/slow D D
12B69 Pile height control D D D D
12S117 – switching point 1: D D
changeover fast/slow
– switching point 2:
upper main pile limitation
12B129 Upper edge of pile at delivery D D Receiver (light barrier)
12B129a Upper edge of pile at delivery D D Transmitter (light bar-
rier)
12S130 Angular stop O.S. D D D D
12S130a Angular stop D.S. D D D D same function as
12S130
12S131 Pile down, slow D D D D
168
Solenoid-operated valves
non- non- non- non-
stop stop stop stop
12Y11 Sheet stop D D D D
12Y13 Sheet catcher D D D D
12Y14 Supporting cross bar on D D only with rake
12Y15 Supporting cross bar off D D only with rake
12Y49 Locking of sheet stops D D D D
12Y60 Rack delivery on D D only with board
12Y61 Rack delivery off D D only with board
12Y62 Suction air sheet catcher D D D D
169
Delivery pile control Function
Function
Automatic pile height control

The automatic pile height control on the delivery is
automatically activated as soon as one of the
following conditions is met:
– The height control for the main pile at the
feeder is on
12B69
– The automatic pile height control for the
auxiliary pile control on the feeder is on
– The paper run is switched on
– The sheeter is in operation
(extra accessory)
The automatic pile height control on the feeder is

stopped under the following circumstances:
Switching points of the automatic pile height control – Actuation of the ”pile stop” button (12S124)
– Actuation of the ”main pile up” (12S45) or
Automatic pile height control ”main pile down” (12S46) button
(main pile only)
Permissible start condition
– Actuation of the ”auxiliary pile up” (12S53) or
12B69 detects paper ”auxiliary pile down” (12S54) button
(auxiliary pile only)
Pile down (by 2 mm)
– Opening of the sheet stop (12Y11)
Sequence of automatic pile height control Under normal circumstances the automatic pile
height control refers to the main pile. In addition,
the automatic pile height control at the auxiliary
pile is activated and deactivated in non-stop
operation (see chapter ”non-stop operation”).
The automatic pile height control controls the pile

in such a way that the upper edge is always at the
level of the sensor ”automatic pile height control”
(12B69). As soon as the sensor detects the upper
edge of the pile (paper), the pile is lowered by
2 mm.
In case the sensor ”automatic pile height control”

(12B69) fails to work, an emergency control is
automatically activated. With this emergency
control, the delivery pile is moved downwards
synchronously to the feeder pile.
170
Transport of main pile (Preset)

On the Preset version, the main pile is driven by a
brushless motor by means of which three speed
levels are passed.
Main pile up
12S45
controlled by means of the button ”main pile up”
(12S45) on the delivery operation panel. Depend-
ing on the position of the main pile, the speed is
changed (fast/slow). When reaching the ”upper
main pile limitation” (12S117/switching point 2) or
12S117/2 the ”automatic pile transport” (12B69), the
12B69 transport mechanism of the main pile stops.
slow
12S117/1
12B65 The upwards movement of the main pile is
interrupted under the following circumstances:
fast
– Actuation of an emergency stop switch
12S131 – Actuation of the ”overshooting control” switch
slow (12S38)
– Actuation of the ”sheet jogger” switch (12S35
Switching points of main pile up (Preset) or 12S36)
– Actuation of the ”monitoring suction drum”
switch (12S39)
Main pile up
– Actuation of the ”angular stop” switch
Permissible start condition (12S130)
12S45 (keep pressed) – Opening of the sheet stop (12Y11)
(only if no non-stop operation)
Main pile up, slow
– Actuation of the ”main pile down” button
12S131 (12S46)
Main pile up, fast The continuation of an interrupted pile transport is
12B65 or 12S117/1 only possible after elimination of the respective
cause.
Main pile up, slow
12B69 or 12S117/2
Main pile stop
Sequence of main pile up and passes through

all three speed levels (Preset)
171
Main pile down

12S46 12S124
controlled by means of the button ”main pile
down” (12S46) on the delivery operation panel.
Depending on the position of the main pile, the
speed is changed (fast/slow).
The button ”main pile down” (12S46) is equipped
with a self-stopping mode. If the button was
slow
actuated for more than 1.5 s, the main pile moves
12S117/1 down to the ”bottom main pile limitation” (12S34).
12B65 The self-stopping mode can be interrupted by
means of the button ”pile stop” (12S124).
fast

12S131 interrupted under the following circumstances:
slow
12S34 – Actuation of an emergency stop switch
– Actuation of the ”pile stop” button (12S124)
Switching point of main pile down (Preset)
– Actuation of the ”main pile up” button
(12S45)
Main pile down
The interrupted pile transport can only be
Permissible start condition continued after elimination of the respective
12S46 (self-stopping mode after 1.5 s)
cause.
12B65 or 12S117/1
12S131
12S34
Main pile stop
Sequence of main pile down and passing

through all three speed levels (Preset)
172
Transport of main pile (standard)

On the standard version the main pile is driven by
a three-phase a.c. motor, by means of which two
speed levels are passed.
Main pile up
12S45
controlled by means of the button ”main pile up”
(12S45) on the delivery operation panel. The main
pile moves upwards at a constant speed (fast).
When reaching the ”upper main pile limitation”
(12S33) or the ”automatic pile transport” (12B69),
12S33
the transport mechanism of the main pile stops.
12B69
fast – Actuation of an emergency stop switch
– Actuation of the ”overshooting control” switch
(12S38)
or 12S36)
Switching points of main pile up (standard) – Actuation of the ”monitoring suction drum”
switch (12S39)
Main pile up – Actuation of the ”angular stop” switch
(12S130)
12S45 (keep pressed) (only if no non-stop operation)
Main pile up, fast – Actuation of the ”main pile down” button
(12S46)
12S33 or 12B69
Main pile stop
after elimination of the respective cause.
Sequence of main pile up (standard)
173
Main pile down

12S46 12S124
controlled by means of the button ”main pile
Depending on the position of the main pile, the
speed is changed (fast/slow). When reaching the
”bottom limit position” (12S34), the transport
mechanism of the main pile stops.
The button ”main pile down” (12S46) is provided

with a self-stopping mode. If the button was
fast actuated for more than 1.5 s, the main pile moves
down to the ”bottom main pile limitation” (12S34).
The self-stopping mode can be interrupted by
12S131 means of the button ”pile stop” (12S124).
slow
12S34 The downward movement of the main pile can be
Switching points of main pile down (standard)
– Actuation of the ”pile stop” button (12S124)
Main pile down – Actuation of the ”main pile up” button
(12S45)
12S46 (self-stopping mode after 1.5 s) An interrupted pile transport can only be continued
12S131
12S34
Main pile stop
Sequence of main pile down and passing

through both speed levels (standard)
174
Transport of auxiliary pile

Auxiliary pile up
12S53
The upward movement of the auxiliary pile is
controlled by means of the button ”auxiliary pile
up” (12S53) on the delivery operation panel. The
auxiliary pile moves upwards at a constant speed.
When reaching the ”upper auxiliary pile limitation”
(12S55), the transport of the auxiliary pile stops.
12S55 The upward movement of the auxiliary pile is

– Actuation of the ”overshooting control” switch
(12S38)
or 12S36)
– Actuation of the ”monitoring suction drum”
Switching points of auxiliary pile up switch (12S39)
Auxiliary pile up (12S130)
– Triggering of the sensor ”automatic pile
height control” (12B69)
Auxiliary pile up
(only if no non-stop operation)
12S55
– Actuation of the ”auxiliary pile down” button
(12S54)
Auxiliary pile stop
Sequence of auxiliary pile up
175
Auxiliary pile down

12S54
The downward movement of the auxiliary pile is
controlled by means of the button ”auxiliary pile
The auxiliary pile moves downwards at a constant
speed. When reaching the ”bottom auxiliary pile
limitation” (12S56), the transport mechanism of the
auxiliary pile stops.
The downward movement of the auxiliary pile is

12S56 – Actuation of an emergency stop switch
(12S130)
– Actuation of the ”auxiliary pile up” button
(12S53)
Switching points of auxiliary pile down An interrupted pile transport can only be continued
Auxiliary pile down
Auxiliary pile down
12S56
Auxiliary pile stop
Sequence of auxiliary pile down
176
Non-stop operation
Basic function
The separation of pile occurs in non-stop
operation by means of rake or board in the main
pile and auxiliary pile. The auxiliary pile takes over
the automatic pile height control, the main pile
executes a pile change or a rack formation. After
that the two piles are remerged.
The rack function is a special version of the

non-stop operation which is selected and adjusted
(if available) by means of the control console.
Besides main and auxiliary pile further compo-

nents are involved in the non-stop operation:
– Sheet catcher
– Sheet stop front edge
(only with rake)
– Supporting cross bar
(only with rake)
– Guide rails
(only with board)
177
Permissible start condition Permissible start condition
12S42

Pile
separation – Pile change: 12S41 or 12B129
– Rack: adjusted rack height
Main pile stop (insert rake/board) (insert rake/board)
45 mm paper on auxiliary pile 45 mm paper on auxiliary pile
Automatic pile height control of main pile on Automatic pile height control of auxiliary pile on
12S46 (self-stopping)
12S131

Pile change
(rack) 12S34
Main pile stop (unloading)
12S45
Main pile up, slow
12S131
Main pile up, fast
– Rake: 12B129 – Rake: 12B129

– Board: 12S41 free – Board: 12S41 free
Automatic pile height control of main pile off Automatic pile height control of auxiliary pile
Pile (pull out rake/board) off (pull out rake/board)
merging
Time delay 10 s – Rake: 12S42 free
– Board: 12S10 actuated
Automatic pile height control of main pile on Auxiliary pile up
12S55 (starting position)
Auxiliary pile stop
Sequence of non-stop operation
178
Note:
The following must be observed with the
sequence of the non-stop operation (see figure):
– The steps for unloading are omitted with the
rake function
– Not all speed alterations are executed in
case of the standard version
Pile separation
When putting on the rake/board (12S42), the main
pile moves downwards at fast speed. The main
pile stops under the following circumstances:
12S41 – Pile change: Inserting the rake/board (12S41)
12B129
or lowering the upper edge of pile until it is at
the level of the light barrier (12B129)
– rake: When reaching the preset rake height
(the rake height can be adjusted on the ZID
between 20 mm and 300 mm in increments
of 10 mm)
As soon as 45 mm of paper are placed on the

auxiliary pile, main and auxiliary pile execute pile
12S42 12S41 height regulations.
Switching points for pile separation and pile Pile change

merging The main pile moves downwards in self-stopping
mode by pressing the button ”main pile down”
(12S46, for more than 1.5 s). After the main pile
has been emptied it moves back to the level of the
auxiliary pile when actuating the button ”main pile
up” (12S45).
When moving upwards and downwards the main

pile runs through the same speed levels as
described in the paragraph ”Transport of main
pile”.
Rack
After positioning the rack, the main pile moves
back to the level of the auxiliary pile by actuation
of the button ”main pile up” (12S45) .
179
Pile merging
The main pile moves upwards until the corre-
sponding condition is met.
– Rake: the upper edge of the pile has reached
the height of the light barrier (12B129)
– Board: the main pile lifts the board from
underneath (12S41 free)
The automatic pile height control for main and

auxiliary pile is interrupted for 10 seconds. Within
this period, the rake/ board can be pulled out.
Then the main pile takes over the automatic pile
height control again. The auxiliary pile frame
moves upwards back into its basic position.
In case of the version with board, the guide rails

must be retracted in addition - see paragraph
”guide rails”.
Sheet catcher
When separating the pile, the sheet catchers
retain the paper coming from above, this activity is
supported by suction air activated in addition.
When putting on the rake/board (12S42), the main

pile moves downwards (see ”pile separation”). If
the preset moment of application is reached, the
sheet catchers extend (12Y13) and the suction air
is switched on (12Y62). The moment of applica-
tion can be adjusted on the ZID within a range of
1 to 9 press rotations.
When inserting the rake/board (12S41), the

Extending and retracting sheet catcher suction air is switched off (12Y62) and the sheet
catchers retract (12Y13).
Sheet catcher
12S42
Main pile down
Moment of application reached
– Extending sheet catcher (12Y13)

– Suction air on (12Y62)
12S41
– Suction air off (12Y62)

– Retracting sheet catcher (12Y13)
Sequence of extending and retracting sheet

catcher
180
Front edge sheet stop (with rake)

The front edge sheet stop is locked during the
entire non-stop operation with rake. The locking
facility can also be operated manually on the
control console.
After putting on the rake (12S42), the locking

facility is switched on (12Y49). When pulling out
the rake (12S42 free), the locking facility is
switched off again (12Y49).
Front edge sheet stop
Front edge sheet stop
12S42
Sheet stop locked (12Y49)
12S42 free
Sheet stop released (12Y49)
Sequence of front edge sheet stop
181
Supporting cross bar (with rake)

The supporting cross bar is needed for the
non-stop operation with rake to put on the rods of
the rake. Dependent on the press-specific version,
there are two different options for controlling the
supporting cross bar.
– Without time delay:

When putting on the rake (12S42), the
supporting cross bar extends (12Y14). When
pulling out the rake (12S41 and 12S42 free)
the supporting cross bar retracts again
(12Y15).
Extending and retracting supporting cross bar – With time delay:

When inserting the rake (12S41 and 12S42)
the supporting cross bar extends after
Cross bar without delay time 3 seconds (12Y14). When pulling out the
rake (12S41 and 12S42 free) the supporting
Permissible start condition cross bar retracts again (12Y15).
12S42
Extending cross bar (12Y14)
Pile change or forming a rack
12S41 and 12S42 free
Retracting cross bar (12Y15)
Sequence of extending and retracting support-

ing cross bar (without delay time)
Cross bar with delay time
12S41 and 12S42
– Await time (3 s)
– Extending cross bar (12Y14)
12S41 and 12S42 free
Retracting cross bar (12Y15)
Sequence of extending and retracting support-

ing cross bar (with delay time)
182
Guide rails (with board)

12S10
The guide rails are needed for the non-stop
operation with board to act as a lateral support of
the board.
By pressing the button ”pile board on/off” (12S10)

the guide rails extend (12Y60). After that the
board can be inserted in the guide rails. After
completion of the unloading process or after
insertion of spacer angles for a rack, the main pile
moves back to the height of the auxiliary pile
(12S41 becomes clear). By pressing the button
”pile board on/off” (12S10) the guide rails retract
(12Y61).
Extending and retracting guide rails
Guide rail
12S10
Extending guide rail (12Y60)
12S41 free and 12S10
Retracting guide rail (12Y61)
Sequence of extending and retracting guide rails
183
Removal of sample sheet

The removal of sample sheet is controlled by
12S11 means of the button ”sample sheet removal”
(12S11) on the delivery operation panel.
When the button is actuated, the automatic pile

height control is interrupted. The sheet catchers
extend (12Y13), for reason of better adhesion it is
possible to additionally activate suction air
(optional) (12Y62). The stop shaft swings up
(12Y11) and the sheet can be removed. Actuating
the button ”sample sheet removal” (12S11) again,
cancels the removal of sample sheet, the pile
executes the automatic pile height control.
When removing a sample sheet the locking of the

front edge sheet stop (12Y49) is deactivated if it
was activated beforehand.

12S11
– Extending sheet catcher (12Y13)
– Suction air on (12Y62) - optional
– Swinging up stop shaft (12Y11)
12S11
– Suction air off (12Y62) - optional
– Retracting sheet catcher (12Y13)
– Swinging back stop shaft (12Y11)
Sequence of sample sheet removal
184
Paper blockage
In case of a paper blockage, the paper supply is
Paper blockage blocked at the feeder. To trigger a paper blockage,
either main pile or auxiliary pile must meet one of
the following stop conditions.
Stop condition
Main pile:
Paper supply at feeder blocked
(Only if the delivery is not in non-stop operation)
Sequence of paper blockage – Switch ”pile down slow” (12S131) overshot

– Switch ”bottom main pile limitation” (12S34)
reached
Auxiliary pile:
– Switch ”bottom auxiliary pile limitation”
(12S56) reached
– Maximum paper height in non-stop operation
reached (depending on paper thickness
between 1500 and 4000 sheets)
The paper blockage is only cancelled after
elimination of the respective cause.
185
Delivery pile control 12M1 Main pile motor (Preset)
12M1 Main pile motor (Preset)
12M1
Place of installation of main pile motor (Preset)
Layout
Motor electronics
Motor and brake
Gear unit
Male connector
Layout of main pile motor (Preset)
186
Task and function

and downwards via the pile chains.
A brushless motor is used which can execute the

– Speed control
– Electrical deceleration (controlled by the
corresponding power part)
– Stopping or emergency braking by means of
installed brakes

functions for the purpose of control and monitoring:
– Commutation and speed recording via Hall
signals
– Temperature recording via resistor
– Output: 0.18/0.36 kW
– Speed (gear unit): 5.7/40 min–1
– Ratio: 100:1
187
Pin assignment
Pin Function
A1 X1 motor line (slow)
A B C B1 Y1 motor line (slow)
1 1
C1 Z1 motor line (slow)
2 2
3 3 A2 X2 motor line (fast)
4 4 B2 Y2 motor line (fast)
5 5 C2 Z2 motor line (fast)
C5 Brake (reference potential DC)
B5 Brake (DC +24 V)
B4 Hall 1
A5 Hall 2
Pin assignment of main pile motor (Preset) B3 Hall 3
A4 Resistor code
A3 PTC (temperature monitoring)
C4 Auxiliary voltage motor electronics UH
C3 Ground auxiliary voltage
PE conductor
188
Delivery pile control 12M1 Main pile motor (standard)
12M1 Main pile motor (standard)
12M1
Place of installation of main pile motor (Standard)
Layout
Motor electronics
Motor and brake
Gear unit
Male connector
Layout of main pile motor (standard)
189
Task and function

and downwards by means of the pile chains.
A three-phase induction motor is used which can

execute the following functions:
of the installed brake

monitoring:
– Speed recording via Hall signals
– Temperature recording via resistor
– Output: 0.13/0.42 kW
265 V / 60 Hz
11.5/49.7 min–1 (265V)
– Ratio: 66:1
190
Pin assignment
Pin Function
A B C
5 A3 N1, N2
C5 Brake (DC +24 V)
B4 Hall 1
Pin assignment of main pile motor (standard) A5 Hall 2
C3 Resistor code
C4 Auxiliary voltage of motor electronics UH
PE conductor
191
Delivery pile control 12M2 Auxiliary pile motor
12M2 Auxiliary pile motor
12M2
Place of installation of auxiliary pile motor
Layout
Gear unit
Motor
Motor electronics
Circular connector
Layout of auxiliary pile motor
192
Task and function

The auxiliary pile motor moves the auxiliary pile
upwards and downwards by means of the pile
chains.
A brushless motor is used which can execute the

– Speed control
– Electric deceleration (controlled by the
corresponding power part)
– Deceleration through the self-locking gear
unit
monitoring:
– Commutation and speed recording via Hall
signals
– Output: 30 Watt
– Speed (gear unit): 1 min–1
– Ratio: 2564:1
– Resistor code: 5 (5.6 kW)
193
Pin assignment
Pin Function
1 X motor line
2 Y motor line
3 Z motor line
4 Hall C
6 Hall B
7 Auxiliary voltage of motor electronics UH
8 Hall A
9 Ground auxiliary voltage
11 Resistor code
12 –
Pin assignment auxiliary pile motor 13 –
14 –
PE conductor
194
Delivery pile control 12B65 Changeover fast/slow
12B65 Changeover fast/slow
12B65
Place of installation 12B65
Layout
Sensor
Cable
195
Task and function
The ultrasonic sensor 12B65 monitors whether the

upper edge of the pile (paper, pallet or pile
support plate) is at the corresponding height.
The output signal is used to change the speed to

fast/slow.
Switching output: normally closed contact
Connection
12B65 brown + 24V DC 12X2: +1
black signal 12X2: 116
The sensor 12B65 is fixed to the control lever by

means of two screws.
When installing the cable there must be enough

room for the rotary movement of the lever.
196

EAK_12 EAK_12, input E65 via the switch 12S117/switch-
E65 ing point 1 (at the control lever).
12B65 12S117/1
Signal flow
Position signal E65

0: The sensor 12B65 detects an object (the pile
is at the level of the sensor) or 12S117/
switching point 1 is actuated (the pile support
plate presses the control lever upwards)
1: The sensor 12B65 does not detect any object
(the pile is below the sensor) or
12S117/switching point 1 is not actuated (the
control lever is not actuated)
197
Delivery pile control 12B69 Pile height control
12B69 Pile height control
12B69
Place of installation 12B69
Layout
Sensor
Cable
198
Task and function
The capacitive sensor 12B69 monitors whether

the upper edge of the pile (paper) is level with the
sheet stop. Based on this sensor signal, the
control systems regulates the position of the
delivery pile.
Connection
12B69 brown + 24V DC 12X2: +1
black signal 12X2: 69

The sensor 12B69 is fixed to the support on the
sheet jogger shaft by means of a screw.

room for the rotary movement of the stop shaft
and for the adjustment of the sensor at the
support.
The cable must not be fixed to movable parts
(except for the sheet jogger shaft). These are in
particular the following points:
– Sheet catcher hose
– Non-stop frame
199
Setting
In the normal position the sensor is fixed in the
bottom third of the oblong hole (see figure) and
the rack height is adjusted to 70 mm. Depending
on the condition of the pile or the printing material,
approx. 50 mm this position can be altered.
Note:
A repositioning of the sensor needs to be
considered in non-stop operation for the rack
height (adjustable on the control console)
Normal setting

EAK_12 EAK_12, input 70 and the HAK control sections of
E70 the main and auxiliary pile drive (exact assignment
see block diagram).
HAK_01
12B69
HAK_02
Signal flow
Position of signal E70

0: The sensor detects no object (the pile is
below the sensor)
1: The sensor detects an object (the pile is
located at the level of the sensor)
Note:
The signal is also displayed as status signal on the
Service display, signal E70 service display of the two respective HAK control
sections.
200
Delivery pile control 12B129 Delivery upper edge of pile
12B129 Delivery upper edge of pile
12B129a
12B129
Place of installation 12B129 and 12B129a
Layout
Sensor
Cable
12B129
12B129a
Sensor 12B129 and 12B129a with cable
201
Task and function
The light barrier 12B129 monitors whether the

upper edge (paper, pallet or pile support plate) of
the main pile is located at the respective level
underneath the auxiliary pile. By means of this
sensor signal, the separation and merging of the
pile is controlled in non-stop operation with board.
The light barrier consists of a transmitter

(12B129a) and a receiver (12B129).
Switching output: dark switching
Connection
12B129
12B129 Core colour Function Terminal
brown + 24V DC 12X2: +1
black signal FAM64:XA29

12B129a
12B129a Core colour Function Terminal
brown + 24V DC 12X2: +1
Cable end sensor 12B129a
202

Transmitter and receiver of the light barrier are
screwed down to the support (metal plate). Both
D.S. supports can be relocated in height through the
oblong holes. Both supports must be at the same
level.

12B129a room for the upward and downward movement of
the non-stop frame.
O.S. In its normal position, the light barrier should be

set as high as possible to prevent a lowering of
the pile below the rear edge stop.
12B129

The output signal of the sensor 12B129 (receiver)
EAK_12 reaches EAK_12, signal E77.
E77
12B129a 12B129
Signal flow

0: The light barrier is not interrupted
1: The light barrier is interrupted
203
Delivery pile control 12S34 Bottom main pile limitation
12S34 Bottom main pile limitation
12S34
Place of installation 12S34
Task and function
The position switch 12S34 switches the main pile

drive off when the main pile has reached its
lowest position.
There is a pin on the pile chain which actuates the

position switch via a shifter mechanism.
Principle of operation: normally closed contact
204
Setting
Lower the pile support plate of the delivery

until the pile support plate rests on the floor
and the pile chains are relaxed.
Slacken the fixing bolt at the control plate
.
Adjust the control plates so that the position
switch 12S34 is actuated in this position of
the delivery pile support plate.
Position switch 12S34
Mounting plate with (actuated) position switch
205

The output signal of the switch 12S34 reaches
EAK_12 EAK_12, input 34 via the switches 12S34a and
E34 12S34b (if available).
12S34 12S34a 12S34b
Signal flow

0: at least one switch is actuated
1: no switch is actuated
206
Sheet alignment Block diagram
Sheet alignment
Block diagram
Double-sheet detector Sheet alignment control Pull lay control Double-sheet detector
SM74 / 52 SM102/CD102
D.S. O.S. D.S. O.S. D.S. O.S.
1B66 1B65 1B13 1B49 1B9 1B10 1B11
SUM1 SUM1
RL12 RL12 RL12 RL12 DBE
1AUM1
Automatic misalignment control Sheet stop finger Gripper opening

11M7 O.S D.S
. .
Automatic sheet arrival control 1Y15 1Y46 1Y16
SM102/CD102 = 11M3
M SM74 = 1M7
SSM1
M
SSM1
SSK EAK 1
IDS
Displays
SAK ESK
SVM MID11 MID12
REK1 REK2 DSK DNK ZID
Legend: Data line Control lines
Block diagram of sheet alignment
207
The sheet alignment system consists of:

– the sheet alignment control BAK,
– the pull lay control ZMK,
– the double-sheet detector DBE,
– the automatic sheet arrival control BAR
(not on SM52),
– the automatic misalignment control
(only on SM102 with Preset and CD102).
As a result of mechanically controlled sequences of

motions, the sheet is aligned with the sheet alignment
system before it enters the first printing unit. At the
same time, the electronic control system:
– registers the point of time of sheet arrival,
– monitors sheet infeed,
– detects double-sheets.
From different sensors the electronic control system

receives information from the area of the front lays at
certain interrogation points.
The sensor signals are processed on the processor
board 2 (REK2). The REK2 shows the result of the
evaluation on the control console display ZID and the
press displays MID. Simultaneously, the electronic
control system activates various actuators (drives,
valves etc.) in the press.
208
Degree values relevant to sheet alignment
The illustration opposite shows the different

interrogation points in the area of the front lays.
BAK The relation between the degree values and the
processes in the press is explained in more detail
ZMK on the next pages. To make the relation clear, the
illustration shows the operation points ”Feeder ON”
and ”Feeder OFF”.
DBE
Table of degree values:
SM52 SM74 SM102 CD 102

Feeder Feeder
ON OFF 230_ 285_ 192,0_1 170,0_1
222,0_ 200,0_
Interrogation points
303_ 208,0_1 186,0_1
238,0_ 216,0_
20_ 330_ 336,0_ 313,0_
40_
330_ 15_ 311,0_ 289,0_
42,5_ 72_ 3,0_ 341,5_
1 only for presses with Preset feeder
209
Sheet alignment 1B13/1B49 Sheet alignment control
1B13/1B49 Sheet alignment control
Block diagram
For correct sheet transfer from the feeder into the

BAK first printing unit, the sheet must be placed against
the front lays as follows:
FÜK
– SM52 between 240_ and 20_ ,
– SM74 between 285_ and 40_ ,
Front
lays
ANK Paper
– SM102 between 222_ and 336_ ,
1B13/1B49 – SM102 with Preset between 192_
Interrogation points and 336_ ,
– CD102 between 200_ and 313_ ,
Sheet alignment control – CD102 with Preset between 170_

D.S. O.S.
and 313_ .
1B13 1B49 The optimum sheet arrival of the electric is as

follows:
– for SM74 at 303_,
RL12 RL12 – for SM102 at 238_,
– for SM102 with Preset at 208_,
– for CD102 at 216_.
– for CD102 with Preset at 186_.
1 LVT1 The following applies to the degrees listed (see block
1EVM4 Displays diagram):
MID12 MID11 – At and paper run:

the ANK must not detect paper.
ZID – At and paper run:

EAK 1 the ANK must detect paper.
– At and paper run:
DNK to analyze the information provided by the pull
lay control (1B9/1B10) the ANK must detect
paper.
ESK SVM DSK
The sensors (1B13 and 1B49) of the sheet alignment
control register at which point of time the sheets
arrive at the front lays. Each sensor housing contains
an ANK and FÜK sensor.
REK2 ANK = sensor for sheet alignment control

FÜK = sensor for overshooting-sheet control
Legend: Data line Note:

Control lines Speedmaster SM52 is only equipped with one sensor
(1B49) of the sheet alignment control.
Block diagram of sheet alignment control
210
The signals of the sensors are transmitted to the

amplifiers (RL12) where they are amplified.
The signals from the amplifiers reach the processor

board REK2 via
– the distribution box 1LVT1,
– the input/output distributor module EVM (only
SM52),
– the input/ output board EAK and
– the input/output control board ESK.
The REK2 analyzes the signals of the sheet
alignment control. The evaluated signals are required
for the following functions of the printing press:
– sheet alignment at the front lays,
– misaligned-sheet display (trend display),
– automatic sheet arrival control (servo-drive
11M3/1M7),
– automatic misalignment control (servo-drive
11M7).
The REK2 shows the result of the evaluation on the

control console display ZID and the press displays
MID.
Circuit states of the ANK and FÜK sensors in the

D.S. MID
FÜK display
(sensor for overshooting control)
O.S.
ANK display
(sensor for sheet alignment control)
Circuit states displayed on the MID
With the help of the MID on the control panel of the
feeder, the FÜK sensors and ANK sensors can
be adjusted and monitored. The MID reflects the
circuit state of the corresponding sensor on the drive
side and on the operator side.
Symbol lit = sensor detects paper
Symbol not lit = sensor does not detect paper
The FÜK and ANK displays are visible when the

switch ”Safe” on the control panel of the feeder is set
to ”Safe” and the printing speed is x 3500 i.p.h.
Note:
On Speedmaster SM52 the symbols of two sensors
are displayed, even though only one sensor if fitted.
211
Sheet alignment errors detected by the ANK sensors
The ANK sensors detect:

BAK
– early sheets (first sheet),
SM52 240_
SM74 285_ – late sheets (missing sheets),
SM102 222_
SM102 with Preset 192_ Paper (first sheet) – misaligned sheets.
CD102 200_
CD102 with Preset 170_ An early sheet exists if the first sheet of the sheet
stream already covers the ANK sensor at press
angle .
The feeder and press stop immediately. The
sheets are held back on the feed table.
Early sheet
A late sheet exists if none of the ANK sensors

detects paper at press angle .
BAK
The feeder stops and the remaining sheets are held
SM52 20_
SM74 330_
back on the feed table. The sheets inside the press
SM102 336_ are printed and transported to the delivery. The
SM102 with Preset 336_ press speed is then reduced to 3 000 i.p.h.
CD102 313_
CD102 with Preset 313_
Late sheet
A misaligned sheet exists if only one of the ANK

BAK sensors – either on the drive side or on the operator
SM74 330_ side – detects paper at press angle .
SM102 336_ The feeder stops and the remaining sheets are held
SM102 with Preset 336_ back on the feed table. The sheets inside the press
CD102 313_
are printed and transported to the delivery. The press
CD102 with Preset 313_
speed is then reduced to 3 000 i.p.h.
O.S. Paper Paper D.S.

Note:
On SM52 misalignment control is not required.
Misaligned sheet
212
Sheet alignment error detected by the FÜK sensors

The FÜK sensors detect:
BAK – overshooting sheets.

SM52 20_
SM74 330_ Given a continuous sheet flow, an overshooting sheet
SM102 336_ exists if one of the FÜK sensors detects paper at
Paper
SM102 with Preset 336_ press angle .
CD102 313_
The feeder and press stop immediately. The shingled
sheets remain on the feed table.
Note:
The press can be started again from the feeder even
if the FÜK sensor still detects the sheet of paper after
the fault message ”Overshooting sheet”. The press
stops as soon as the pushbutton ”Production run” or
the illuminated pushbutton ”Feeder ON” is pressed.
Overshooting sheet
Extended functions
The extended functions are only active with the
inductive double-sheet detector of SM52 and
SM74.
During paper transport:

The control system monitors the paper transport
on the feed table. For this purpose, the control
system needs the signal from the FÜK sensor
and the measuring result of the double-sheet
detector.
If during paper run the FÜK sensors do not

detect a sheet being fed in although the
double-sheet detector has registered a good
sheet (no double-sheet), the control system
switches the feeder off. There is probably a
paper jam on the feed table.
In the case of a double-sheet:

The control system stops the press immediately
(emergency stop) if the FÜK sensors detect
paper in the case of a double-sheet. Thus no
multiple sheets are fed into the press.
213
Misaligned-sheet display (trend display)

During paper run or production run, the misaligned-
sheet display appears on the MID. This display
changes permanently and is a trend indication for
the operator. The misaligned-sheet display does
not intervene in press control.
The ANK sensors of the sheet alignment control
detect the misaligned sheet at the front lays. This
misalignment between the drive side (D.S.) and
operator side (O.S.) is determined and converted
Display of misaligned sheet. Drive side advanced. into a degree value.
The degree value is represented as a line symbol
on the MID (see ill.).
The display is only visible if no
Good sheet
Optimum sheet arrival – settings and adjustments,
– fault messages,
Misaligned sheet, D.S. advanced
Display of misalignment up to max. 18° – malfunctions
– or other information
Misaligned sheet, O.S. advanced
Display of misalignment up to max. 18° are indicated on the MID.
Note:
The fault message ”Misaligned sheet” and the
misaligned-sheet display are not identical.
214
The sensors of the sheet alignment control are

located at the front lays.
1B13
1B49
Place of installation of sheet alignment control
Layout and task

The reflex sensors on the drive side and operator
Running direction of side of the sheet alignment system serve for paper
paper detection. Each reflex sensor has two optical
FÜK
ANK sensors – ANK and FÜK – monitoring the sheet
Amplifier alignment.
Reflex sensor
The FÜK and ANK sensors are fitted in a housing.
Viewed in the running direction of the paper, the
paper first covers the ANK sensor.
X2
ANK = sensor for sheet alignment control
FÜK = sensor for overshooting sheet control
In the amplifier of the reflex sensor, the sensor

signals are amplified and transmitted to the
X1
electronic control system. The amplifiers of the two
reflex sensors are located at the side frame on the
To 1LVT1
O.S., under the feed table.
Reflex sensor with amplifier
Pin assignment
ground
free free
+24K ANK–
FÜK+ FÜK–
ANK+
Pin assignment 1B49:X1/1B13:X1
215
1 2
1/2–1
– Position the press:

SM102: 100 ± 3 degrees – Loosen the fixing bolt on the brass block
CD102: 70 ± 3 degrees (1/2–1 rev.).
3 4
O.S. D.S.
– Pull off the reflex sensor with the brass – Remove the amplifier.
block towards the front.
216
5 6
– Disconnect the cable leading to 1LVT1. – Remove the reflex sensor.
7 8
– Slide the new reflex sensor into the guide

of the holder.
Note:
To fix the reflex sensor in position, carefully
tighten the fixing bolt (tightening torque approx.
– Turn the handwheel anticlockwise until the
1 Nm).
end stop comes to rest on the cross bar.
– Tighten the fixing bolt.
217
9 10
O.S. D.S.
– Connect the cable coming from 1LVT1 to – Fasten the amplifier.

the amplifier.
11 12
1.5 – 2.0 mm
– Push the reflex sensor and brass block on the – Tighten the fixing bolt on the brass block.
guide pins through to the stop.
– Check the distance (1.5 – 2.0 mm).
218
Adjustment
1 2
3 2
ÁÁÁÁ
– Bring the bending in the ”0” position. – Press the pushbutton ”Forward” until the
sheet stop fingers are raised.
3 4
– Position the press: – Turn the handwheel anticlockwise until the

SM102: 333 ± 1 degree end stop comes to rest on the cross bar.
CD102: 310 ± 1 degree
219
5 6
– Turn the handwheel back by one revo- – Place a sheet of paper of max. width
lution. (102cm) and approx. 20cm length against
the front lays.
7 8
MID MID
D.S. D.S.
O.S. O.S.
– Turn the adjusting screw until the ANK – Turn the adjusting screw until the ANK symbol
symbol on the MID just lights up. on the MID just lights up.
– Both ANK symbols on the MID must be lit.
220
9 10
2 1/6
– Turn the handwheel clockwise for 1.3 mm – Both ANK symbols must be lit. The FÜK
+/–0.1 mm (2 1/6 revs), using the scale as a symbols must not be lit.
reference.
11
1.3 mm +/– 0.1 mm
FÜK Front lay
ANK
MID
10 mm D.S.
O.S.
Paper
– – Check the distance between the front lays

and ANK sensor.
221

1B13 in the service display of the EAK:
Input 13 = ANK (O.S.)
Input 15 = FÜK (O.S.)
1B49 in the service display of the EAK:

Input 49 = ANK (D.S.)
Input 51 = FÜK (D.S.)
1 = sensor detects paper

0 = sensor does not detect paper
Service display ”Present input/output, input/output

board EAK”
222
Sheet alignment 1B9/1B10 Pull lay control
1B9/1B10 Pull lay control
Block diagram
The pull lay control (ZMK) monitors the entire pull
procedure, i. e. the correct sheet infeed and the pull
ZMK end position.
SM52 330_ SM52 42.5_
SM74 15_ SM74 72_ The following applies to the degrees listed (see
SM102 311_ SM102 3_
CD102 289_ CD102 341.5_
block diagram):
At and paper run:
1B9/1B10 Paper
–
the ZMK must not detect any paper.
– At and paper run:
the ZMK and ANK must detect paper.
Interrogation points
– At and no paper run:
the ZMK signal is not analyzed because the
sheet alignment control does not detect paper.
Pull lay control
D.S. O.S.
The reflex sensors on the drive and operator sides
serve for paper detection. Depending on the pull
1B9 1B10 direction only one of the two reflex sensors is
Audible signal
necessary for monitoring.
device 12 H 55 The pull direction is entered under the command
”Presetting”. Only the reflex sensor of the active pull
SUM1 SUM1
Audible signal lay is interrogated.
RL12 RL12
device 11 H 55
In the signal conversion modules SUM 1 the signals
of the reflex sensors are amplified. The circuit state
1 LVT 1 12 LVT 1 11 LVT 1 of each sensor is signalled by an LED on the
1EVM4 12EVM4 11EVM4
corresponding SUM 1
(LED is lit = reflex sensor detects paper).
EAK 1 EAK 12 EAK 11
SM52 only:
On SM52 the signals are amplified by the amplifiers
of the reflex sensors RL12.
Displays The electronic control system evaluates the signals

of the signal conversion modules.
MID12 MID11 ZID
The signals from the amplifiers reach the processor
board REK2 via
ESK SVM DNK – the distribution box 1LVT1,
– the input/output distributor module EVM
DSK (SM52 only),
REK2 – the input/ output board EAK,

– the input/ output control board ESK.
Legend:
Data line Control lines
Block diagram of pull lay control
223
The REK2 analyzes the signals of the pull lay

control. In the case of a pull or sheet infeed error, it
passes the fault message to the control console
display ZID, the press displays MID and the audible
signal devices 11H55 and 12H55.
For an acoustic fault message to be output, the

function ”Audible signal device / pull lay control” must
be switched on in the central control console.
Circuit states of the ZMK sensors on the MID

D.S.
Display of pull lay control
With the help of the MID on the control panel of the
feeder, the reflex sensors 1 B9 and 1 B10 can be
monitored.
O.S. The MID reflects the circuit state of the correspond-
ing sensor.
Circuit states displayed on the MID
Symbol lit = sensor detects paper
Symbol not lit = sensor does not detect paper
The circuit states of the reflex sensors are visible

when the switch ”Safe” on the control panel of the
feeder is set to ”Safe” and the printing speed is
x 3500 i.p.h.
When does a sheet infeed error/pull error exist?

A sheet infeed error exists if the sheet is already
ZMK
below the reflex sensor at the interrogation point.
SM52 330_
SM74 15_ The sensor detects paper.
SM102 311_
CD102 289_
Paper
Sheet infeed error
224
A pull error exists if, at the interrogation point:

ZMK
SM52 42.5_ – the ANK sensors (1B13/1B49)
SM74 72_ detect the print sheet and
SM102 3_
CD102 341.5_ – the ZMK sensor does not detect
1B13/1B49 the print sheet.
1B9/1B10
Paper
Pull error
225
The pull lays with the reflex sensors are fitted on

two cross bars in front of the transfer gripper
drum. One pull lay is fitted on the operator side
(1B10) and one on the drive side (1B9).
1B9
1B10
Place of installation of pull lays
Signal conversion modules SUM1
Under the feed table, the two signal conver-

sion modules SUM1 are fitted on a support
bar. Each is allocated to one of the pull lays.
Place of installation of signal conversion modules
226
Adjustment (Preset version)

The adjustment must be made:
– for the first start-up
– when changing the printing material (paper)
– in the case of frequent fault messages.
1 Enter the required sheet width in the

command mode ”Presetting”. After com-
mand enabling, the control system positions
the pull lay to the entered format.
2 Set the selector switch ”Safe” on the control

panel at the feeder to ”Safe”.
3 Press the illuminated pushbutton ”Feeder”,
so that the button is lit. Press the pushbut-
ton ”Forward” until the sheet stop fingers
are raised.
4 Press the pushbutton ”Forward” until the

pull lay stop is below the upper edge of the
sheet metal plate. The pull rail must not
have grabbed the sheet yet. The sheet can
still be moved.
5 Pull the sheet against the pull lay stop; the

paper must be under the reflex sensor .
6 Turn the knurled head screw clockwise,

Adjustment of pull lays until the green LED at the corresponding
signal conversion module goes off.
a) Pull direction of sheet of paper
b) Running direction of paper 7 Turn the knurled head screw anticlock-
wise, until the green LED just lights up.
c) Edge for format adjustment 8 Turn the knurled head screw anticlock-
wise for another 10 notch positions
(= 0.3 mm; corresponds to approx. 1/4 rev.
of ).
9 Take out the sheet. The LED of the reflex

sensor goes off.
227
Adjust the spring pressure with the knurled

head screw . The pressure the pull roll
exerts on the printing material must be so
strong that each sheet is pulled reliably to
the pull lay stop. The locking nut
prevents the pressure from changing once it
has been set.
Reflex sensor
Knurled head screw
Knurled head screw
Locking nut
Adjustment of pull lays
228
Adjustment (standard version)
1 mm The adjustment must be made:

– when changing the printing material (paper)
a
1 Loosen the tommy bar screw and

b position the pull lay so that it complies with
the sheet size at the feeder.
2 Move the magnet cover plate with

recess until it is approx. 1mm away from
the pull lay stop .
Note:
The pull lay stop must not lie on the magnet
cover plate while the paper is being pulled.
3 Set the selector switch ”Safe” on the control

panel at the feeder to ”Safe”.
4 Press the illuminated pushbutton ”Feeder”,

+ - so that the button is lit. Press the pushbut-
c ton ”Forward” until the sheet stop fingers
are raised.
5 Press the pushbutton ”Forward” until the

pull lay stop is below the upper edge of the
Adjustment of pull lays sheet metal plate. The pull rail must not
have grabbed the sheet yet. The sheet can
a) Pull direction of sheet of paper still be moved.
b) Running direction of paper 6 Pull the sheet against the pull lay stop; the
paper must be under the reflex sensor .
c) Edge for format adjustment
7 Loosen the knurled head screw a little
bit.
8 Turn the knurled head screw clockwise,

until the green LED at the corresponding
signal conversion module goes off.
9 Turn the knurled head screw anticlock-

wise, until the green LED just lights up.
ß Turn the knurled head screw anticlock-

wise for another 14 notch positions
(= 0.4 mm; corresponds to approx. 1/4 rev.
of ).
229
q Retighten the knurled head screw . The

LED of the corresponding reflex sensor
must still be lit.
w Take out the sheet. The LED of the reflex

sensor goes off.
e Adjust the spring pressure with the knurled

head screw . The pressure the pull roll
exerts on the printing material must be so
strong that each sheet is pulled reliably to
the pull lay stop. The locking nut
prevents the pressure from changing once it
ÉÉÉÉÉÉÉÉÉÉÉÉÉ has been set.
Pull lay
Checking the sensing distance of

the reflex sensors
This check must be carried out:
The distance between the lower edge of the reflex

. sensor
and the surface of the magnet cover
plate must be 4.5 – 5 mm. When fitting the reflex
sensor pay attention to this.
Sensing distance
Tommy bar screw Knurled head screw

Magnet cover plate Paper
Pull lay stop Knurled head screw
Reflex sensor Locking nut
Knurled head screw
Lower edge of reflex sensor
230
Sheet alignment 1B11 Double-sheet detector
1B11 Double-sheet detector
Block diagram
The double-sheet detector monitors sheet infeed at
Optical the feeder. It detects multiple sheets and irregulari-
sensor system ties in the sheet flow and thus prevents malfunc-
tions.
Transmitter
1āBā11āS An optical sensor system consisting of a transmitter
(1 B11 S) and a separate receiver (1 B11 E)
Receiver transmits light through the paper. The receiver
1āBā11āE supplies a signal. The amplitude of the signal
depends on the thickness and nature of the printing
material.
The control device DBE supplies the optical sensor

Control device system with operating voltage. Apart from this, the
DBE control device helps to process the sensor signal
and to adjust the double-sheet detector to the
printing material used.
1āLVTā1
Shortly before the sheet enters the first printing
Displays unit, the electronic control system checks the
amplitude of the signal supplied by the receiver.
MID12 MID11
Monitoring occurs at the following press angles:
EAK 1
ZID – 336 _ (SM102),
– 313_ (CD102).
DNK
If the light does not pass through the paper at this
point, there are two or more sheets.
The signal reaches the processor board REK2 via

ESK SVM DSK
– the distribution box 1 LVT1,
– the input / output board EAK,
– the input / output control board ESK.
REK2 The REK 2 analyzes the signals from the double-
sheet detector. If there is a double-sheet, REK 2
stops the feeder. The electronic control system
Legend: Data line reduces the press speed to 3 000 i.p.h. Simulta-
neously, REK 2 transmits a fault message to the
Control lines
control console display ZID and the press
Block diagram of double-sheet detector displays MID.
231
Fault messages in the case of a double-sheet

Press display MID
The fault symbol # appears under the pictogram for
double-sheet.
MID after detection of a double-sheet
Control console display ZID

Selection
Selection of the display ”Entire press”
(production run display).
Symbol ”Double-sheet detector” The symbol ”Double-sheet detector” appears if the

sensor 1B65 or 1B66 detects a double-sheet.
Selection and symbol
Selection of the display ”Feeder / warning”

Selection
Symbol The symbol ”Electronic double-sheet detector”

”Electronic appears if the sensor 1B65 or 1B66 detects a
double-sheet detector” double-sheet.
Selection and symbol
232
The control device of the double-sheet detector

is fitted near the signal conversion modules at
the sheet alignment system.
Control device
Control device of double-sheet detector
The sensor is fitted on the press centreline in the

area of the front lays.
Sensor of double-sheet detector
Sensor of double-sheet detector
233
Layout
Components of double-sheet detector
Control device of double-sheet detector The LED lights up as soon as there are
DBE with operator’s controls two or more sheets.
1 B11 S Selector switch for adjustment of paper
Transmitter with connecting cable and thickness
fixing bracket
1 B11 E
Receiver with connecting cable and
fastening element
Cable to distribution box 1LVT1 at PU 1.
It comprises: Paper thick Control device off Paper thin
– the power supply for the control device
DBE (+ 24 V)
– the signal line from the control device DBE
to the electronics.
Potentiometer for adjustment of sensitivity
234
Connection and pin assignment
X1 1LVT1 at
PU1
Control device X2 1B11 Transmitter
X3
1B11 Receiver
Connection principle
Pin assignment of connector X1:
Contact no. on X 1 Function Core identification Terminal in LVT
1 Ground 24 V –1 X2: – 1
2 +24 V +1 X2: +
3 – – 1 –
4 Signal XE 11 FEM 64 XE 11
5 – – –
235

The transmitter and receiver are each screwed to
the fastening elements with one screw.
Each fastening element is held in place by two

screws.
The distance between transmitter and receiver

must be between 8 mm – 12 mm.
Note:
The upper edge of the receiver 1 B11 E must be
flush with the table edge.
The transmitter and receiver must be in perfect
alignment, i.e. arranged on the same centreline.
The control device is screwed to the fixing

bracket with 3 screws.
The fixing bracket is screwed to the press with

two screws.
Components of double-sheet detector
Receiver – 1 B11 E
Transmitter – 1 B11 S
Fastening element for receiver
Fastening element for transmitter
Screws for fastening element
Fixing bracket for control device
Screws for fixing bracket
236
Adjustment
The adjustment must be carried out:

Attention:
– each time the printing material changes,
– if printed sheets are printed on again.
Prerequisite for adjustment:

– press ready to run,
– paper run possible.
1 Check the distance between the transmitter and

receiver: required distance 8 – 12 mm. The
receiver does not jut out from the table edge.
2 Position the press to a press angle of 281 ± 1

degrees (CD102) or 304 ± 1 degrees (SM102)
and place a sheet of maximum width against
the front lays and pull lay stop.
3 Set the selector switch for paper thickness

0 to and turn the potentiometer
anticlockwise to the stop.
The LED is lit.
4 Turn the potentiometer slowly clockwise and

watch the LED :
if..
.. LED goes off: .. LED does not go off:
5 Continue turning the potentiometer clockwise 5 Set the selector switch 0 to

for another 10 scale marks. and turn the potentiometer anticlockwise to
the stop.
Continue with 8.
6 Turn the potentiometer clockwise until the
LED goes off.
7 Continue turning the potentiometer clockwise

for another 10 scale marks.
8 Check the functioning of the double-sheet

detector with a simulated double-sheet.
237
Sheet alignment 11M3 Automatic sheet arrival control
11M3 Automatic sheet arrival control

The automatic sheet arrival control influences the
possible sheet arrival transport of the sheets to the front lays. It regulates
the shingle stream in such a way that the individual
BAK sheets are positioned against the front lays at a
optimum certain press angle (see illustration). By means of a
sheet arrival servo-drive (11M3) the drive chain of the feeder is
adjusted. Thus the point of time of sheet arrival is
285_ 303_ 330_ SM74 controlled.
222_ 238_ 336_ SM102
192_ 208_ 336_ SM102 with Preset
200_ 216_ 313_ CD102
170_ 186_ 313_ CD102 with Preset
Point of time of sheet arrival
The ANK sensors (1B13/1B49) register when the

Sheet alignment control Displays sheets arrive at the front lays. On the basis of the
D.S. O.S. ANK signals the computer on the processor board
MID11 ZID
1B13 1B49 REK2 determines the point of time of sheet arrival.
If there is a deviation from the optimum sheet
MID12 DNK arrival, the shingle stream at the feeder must be
regulated. REK2 passes the new reference values
RL12 RL12 DSK for sheet arrival to the servo-drive control board
SSK. The SSK controls the servo-drive 11M3. If the
automatic sheet arrival control reaches the end of
its control range in the process, the symbol ”End of
positioning range” appears on the press displays
1LVT1
MID and on the control console display ZID
(production run display). The press control is not
affected by this.
EAK ESK SVM
SSK SAK REK2
1SSM1
11M3
Automatic sheet arrival control
Legend: Data lines

Control lines
Block diagram of automatic sheet arrival control
238
The symbol ”End of positioning range” will,

however, only disappear when the operator
repositions the servo-drive manually.
This can be done at the control console by means
of the ”Sheet arrival control” function.
”End of positioning range” displayed on the

press display MID
Activating and inactivating the automatic sheet arrival control
Selecting the automatic sheet arrival control
Symbol ”Automatic sheet arrival control

on / off”
Inactivating and activating the automatic sheet
arrival control:
If the symbol is lit, the automatic sheet arrival

control is active.
Preselection/coarse display
Sheet arrival control

The sheet arrival control is automatically activated
when the operator switches off the automatic sheet
arrival control.
Symbol of the sheet arrival For the sheet arrival control the operator enters a
control in the ... fixed value.
The setting is made at the control console by means
actual value / coarse display of the right-hand +/–buttons.
Press model Setting range

Standard Preset
actual value / fine display version version
SM102 –2 to +18 –10 to +10
CD102 –10 to +10
SM74 –4 to +16
239
Graphical representation of sheet arrival

The graphical representation of sheet arrival is
only visible during paper run.
Selecting the fine display
Deviation from optimum sheet

arrival D.S.
Mean value of the two

deviations

arrival O.S.
Note:
The display is updated with a delay.
Actual value/fine display
The misaligned-sheet display on the MID gives the

operator information about sheet arrival.
Optimum sheet arrival
Sheet arrives at the front lays before

the optimum sheet arrival
Misaligned-sheet display Sheet arrives at the front lays after
the optimum sheet arrival
240
(standard version)
11M3 Automatic sheet arrival control (standard version)
ÁÁÁ
ÁÁÁ
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
241
(standard version)
X5
X10 SSR
SSR X10
X11 X12
SSR X11 X3 X4
X13 X14
11
11 plug-in unit SSR
1SSM2: X1 11LVT1
1SSM2: X2
X1 X2
X3
1SSM2
module 1SSM2
3 4
11M3: X1
5
2 1
11M3
Servo-drive 11M3

+ Pin 1 X5: A1 X1: 1 X10: B2 Motor +
– Pin 2 X5: A2 X1: 2 X10: D2 Motor –
10V Pin 3 X5: A3 X3: 3 X11: 3 10V
Pin 4 X5: A4 X3: 4 X11: 4 Tap
0V Pin 5 X5: A5 X3: 5 X11: 5
242
(standard version)
1 2
1
0 1
2
2
3 4
1
1
3
1 2
243
(standard version)
5 6
1 – 2 mm
7 8
1 3
2 1
22
5
4
0 1
244
(standard version)
9 10
11 12

245
(standard version)
13

Servo-drive ”Automatic sheet arrival control”
11M3

+ 18 3134 " 4 inc
–2 963 " 4 inc

servo-drives”
246
(Preset version)
11M3 Automatic sheet arrival control (Preset version)
11M3
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
247
(Preset version)
X5
X10 SSR
SSR X10
X11 X12
SSR X11 X3 X4
X13 X14
Backplane of servo-
11LVT1
1SSM1: X1
X3 X4
X2 1SSM1: X3
X1 X5
1SSM1
module 1SSM1
3 4
11M3: X1
5
2 1
11M3
Servo-drive 11M3

+ Pin 1 X5: A1 X1: 1 X10: B2
– Pin 2 X5: A2 X1: 2 X10: D2
10V Pin 3 X5: A3 X3: 3 X11: 3
Pin 4 X5: A4 X3: 4 X11: 4
0V Pin 5 X5: A5 X3: 5 X11: 5
248
(Preset version)
1 2
2.0 mm
(approx. 1 rev.)

– Remove the servo-drive ”Automatic sheet – Turn the mechanism against the upper stop.
arrival control” 11M3. – Set the distance ( 2.0 mm ).
01 3891 ± 2
11M3: X1
– Fasten the servo-drive to the mounting plate.

– Insert plug 11M3: X1.
– Set to 3891"2 inc.
249
(Preset version)

Servo-drive ”Automatic sheet arrival control”
11M3

+ 10 205 " 4 inc
– 10 3891 " 4 inc

servo-drives”
250
Sheet alignment 11M7 Automatic misalignment control
11M7 Automatic misalignment control
The automatic misalignment control influences the

Sheet alignment control Displays position of the sheets in such a way that they
D.S. O.S. arrive parallel to the front lays.
MID11 ZID
1B13 1B49
Automatic control is effected through:
MID12 DNK
– the servo-drive 11M7,
RL12 RL12 DSK – the guide rail (D.S.) of the forwarding suckers
at the suction head.
The misalignment is registered:
– by the ANK sensors on the D.S. and O.S.
1LVT1
The deviation between the registered values is an
indication of the misalignment of the sheets in
relation to the front lays (not to the feed table).
EAK ESK SVM
If the misalignment exceeds three degrees, the
automatic control compensates for the deviation.
The automatic misalignment control does not

intervene in press control.
SSK SAK REK2
1SSM1
11M7
Automatic misalignment control
Legend: Data lines

Control lines
Block diagram of automatic misalignment control
Position of guide rail D.S. at Position of sheet The graphical representation on the left shows the
suction head mechanical principle of the misalignment correc-
Front lays
tion.
O.S. D.S.
Principle of the misalignment correction
251
Activating and inactivating the automatic misalignment control
Selecting the automatic misalignment control
Symbol ”Automatic misalignment control

on / off”
Inactivating and activating the automatic misalignĆ
ment control:
If the symbol is lit, the automatic misalignment

control is active.

Misalignment control
The misalignment control is automatically activated
when the operator switches off the automatic
misalignment control.
Symbol of the misalignment For the misalignment control the operator enters a
control in the ... fixed value.
The setting is made at the control console by means
actual value/coarse of the right-hand +/– buttons.
display Press model Setting range
actual value/fine display SM102 –10 to +10

CD102 –10 to +10
252
Graphical representation of sheet arrival
Selecting the fine display
The graphical representation of sheet arrival also

gives the operator information about the misalign-
ment of the sheets during paper run.

arrival D.S.
Mean value of the two

deviations

arrival O.S.
Actual value/fine display
Note:
The display is updated with a delay.
During paper run or production run, the misaligned-

sheet display appears in the MID.
This display changes permanently and is a trend
indication for the operator.
Good sheet
optimum sheet arrival
Misaligned sheet, D.S. advanced
Display of misalignment up to max. 18°

Misaligned sheet, O.S. advanced
Display of misalignment up to max. 18°
253
11M7
Preset feeder
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
254
X5
X10 SSR
SSR X10
X11 X12
X3 X4
X13 X14
SSR X13
Backplane of servo-
11LVT1
2SSM1: X1
X3 X4
X2 2SSM1: X3
X1 X5
2SSM1
module 2SSM1
11M7: X1 3 4
5
2 1
11M7
Servo-drive 11M7

+ Pin 1 X5: A1 X1: 1 X10: B10
– Pin 2 X5: A2 X1: 2 X10: D10
10V Pin 3 X5: A3 X3: 3 X13: 3
Pin 4 X5: A4 X3: 4 X13: 4
0V Pin 5 X5: A5 X3: 5 X13: 5
255
1 2
O.S.
O.S. D.S.
D.S.
Guide rails
– Remove the servo-drive ”Automatic – Position the guide rails of the forwarding
misalignment control” 11M7. suckers parallel to each other.
4)
05 2048 ± 2
11M7: X1
– Insert plug 11M7: X1.

– Set to 2048 ±2 inc.
256

Servo-drive ”Automatic misalignment control”
11M7

–10 1434 " 2 inc
+10 2662 " 2 inc

servo-drives”
257
258
Sheet monitoring 1...nB48/1...nB48a Sheet travel monitor
Sheet monitoring
1...nB48/1...nB48a Sheet travel monitor

The sheet travel monitor
Paper run – monitors the paper run,
Reflex sensor Paper Control switch – is fitted in each printing unit,
1...9B48 1...9B48a
– consists of:
the reflex sensor 1...9B48,
Segment the control switch 1...9B48a,
disk the segment disk for the control switch.
The reflex sensor detects the front edge of the paper

Impression
at the impression cylinder.
cylinder
LED
The control switch and the segment disk determine
the point of time of the interrogation.
The signals from the reflex sensor and control switch
Irregularity in paper run are combined in the reflex sensor and transmitted to
the control system.
No paper
Signals during paper run (see illustration):
– The segment disk is within the operating range
of control switch 1...9B48a.
– At the same time, the reflex sensor 1...9B48
LED detects the front edge of the paper.
– The LED on the reflex sensor 1...9B48 is lit.
– No signal to the control system.
1 LVT1
Displays Signals in the case of irregularities in the paper
MID12 MID11
run (see illustration):
ZID
EAK 1 – The segment disk is within the operating range
of control switch 1...9B48a.
DNK
– At the same time, the reflex sensor 1...9B48
does not detect paper.
– The LED on the reflex sensor 1...9B48
ESK SVM DSK is not lit.
– Signal to control system.
– REK2 intervenes in press control.
REK2
Legend: Data line
Control lines
Block diagram of sheet travel monitor
259
The electronic control system analyzes the signals

from the reflex sensor as long as there is paper in
the press. Via the input/output board EAK of the
corresponding printing unit and the input/output
control board ESK the signals are transmitted to the
processor board REK2. In the case of a fault, REK2
intervenes in press control and triggers various
processes:
– press and feeder stop,
– dampening systems and inking units are
thrown off,
– impression throw-off,
– display of fault at printing unit, in press
displays MID and control console display ZID.
In the MID, the position code of the corresponding

printing unit appears under the fault symbol.
Fault display in MID
Fault display in In the ZID (production run display), the fault

production run display (ZID) symbol appears with the corresponding position
code.
Symbol ”Blanket control Simultaneously, the symbol ”Blanket control
detects paper” detects paper” appears in the fault display. The
(fault display in ZID) fault can be acknowledged and deleted by
pressing the button allocated to the symbol.
The fault is eliminated:

– after removing the sheet from the base or
– after removing the piece of sheet from the
blanket and
– after lifting the guard ”Plate cylinder”.
The electronic control system allows the press to
continue running.
260
Service display
To check the input 48, select the service display
”Present input/output” (e.g. EAK2_02) of the corre-
sponding printing unit.
Buttons to be pressed for this selection:
1) 2) 3) 4)
Circuit state of input 48:

1 = reflex sensor detects paper,
no signal to the control system.
Service display ”EAK2_02” of PU2
0 = reflex sensor does not detect paper,
signal to control system.
Input 48 (sheet travel monitor 1...9B48)
261
1...nB48 1...nB48a
(middle of press) (operator side)
Impression cylinder
in printing unit
Speedmaster CD –operator side–
262
Components
Reflex sensor 1...nB48
Reflex sensor 1...nB48

detects does not
paper detect paper
ca. 24V
24V 0V 3 2
LED (LED lit) (LED not lit)

4 1
0V
Reflex sensor
Control switch 1...nB48a
Control switch
Adjustment
Adjustment of reflex sensor 1...nB48
1 4 + 7 9
Adjustment of control switch 1...nB48a
3 9
263
1 2
1...nB48
70 ± 1 mm
– Remove reflex sensor 1...nB48. – Fit the reflex sensor and insert the plug.
– Set the distance (70 ± 1 mm) between the
reflex sensor and impression cylinder.
3 4
1.0_
LED
LED
LED
– Turn the impression cylinder in the direction – Turn the impression cylinder back by 1.0°
of printing (see arrow) so that the LED just (see arrow).
lights up (reflex sensor detects cylinder – The LED is not lit.
surface).
5 6
1...nB48a
1...nLVT1
– Remove control switch 1...nB48a. – Fit the control switch and connect it with the
– Withdraw the plug from 1...nB48. reflex sensor (see circuit diagram).
264
7 8
1...nB48a
Segment disk
0.8 – 1.0 mm
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ = =
ÁÁÁÁÁÁÁ
– ÁÁÁÁÁÁÁ
The segment disk must run in the middle of
the recess and must not contact the control
switch. – Select the service display ”Present input/
– Pay attention to both segments. output” of the corresponding printing unit.
9 Direction of printing
2)
1
1)
– Loosen the segment disk.
– Turn the segment disk in the direction of
printing until input 48 changes from ”1” to ”0”.
– Fasten the segment disk.
– Check the adjustment.
265
266
Plate clamping device Autoplate
Plate clamping device
Autoplate
Method of functioning
The main components of Autoplate are:
– a modified plate cylinder with air supply and two
pneumatic bars to open the front and rear
clamping bars,
– a pressing bar which is brought into contact with
the plate cylinder by two cylinders,
– two position switches which monitor the position
of the pressing bar,
– four pneumatic valves which actuate the pneu-
matic bars, the two cylinders of the pressing bar
and the control air for the air supply.
For actuation of the cylinders an operating pressure
of approx. 6 bars is required. This pressure is
generated by the pneumatic system compressor E4
and is kept at a constant level by the maintenance
unit. The compressor is switched on after ”Main
switch on”.
Air supply, connections:

S – ”Control air, air supply”
1 – ”Opening the rear clamping bar”
2 – ”Opening the front clamping bar”
1
2 S Control panel
Pressing bar
Position switch ”Finger guard 2”:

n S 25 a – ”Monitoring the pressing bar D.S.”
n S 25 b – ”Monitoring the pressing bar O.S.”
Pneumatic valves from top to bottom:

n Y7 – ”Pressing bar on / off”
n Y 61 – ”Control air, air supply”
n Y 62 – ”Opening the front clamping bar”
n Y 63 – ”Opening the rear clamping bar”
Note:
Before the rear or front clamping bar is opened,
control air must be admitted to the air supply facility
in the plate cylinder. For this purpose, the plate
cylinder must be at standstill; otherwise the gaskets
could become subject to abrasion. This, in turn,
could cause unintentional venting of the control line.
Then the rear and front clamping bars cannot be
Operator side of printing unit opened anymore.
267
Fault display
Button sequence
The pressing bar and / or the upper finger

protecting bar was actuated.
The following position switches can be actuated:
– ”Monitoring the pressing bar”
n S 25 a (drive side)
n S 25 b (operator side),
– Monitoring finger guard 2”
n S 25 (operator side).
Malfunctions in 2nd printing unit
268
Block diagram
n Y7 n Y 61 n Y 62 n Y 63
E4
n S59 n S 25a /
n S4 n S17 n H59 n S 25b
EAK15 EAKn SEK
REK1 ESK Legend:
Parallel data line

DSK REK2
Serial data line
DNK SAK
Control line
ZID Pneumatic line

Electronic control system
Block diagram Autoplate
E4 – Pneumatic system compressor

n Y7 – Pneumatic valve
”Pressing bar on / off”
”Control air, air supply”
”Opening the front clamping bar”
”Opening the rear clamping bar”
n S4 – Selector switch ”Safe”
n S17 – Pushbutton ”Position”
n S59 / n H59 – Illuminated pushbutton ”Plate clamping”
n S25 a / b – Position switch
”Monitoring the pressing bar D.S./O.S.”
269
Sequence of functions
The indicated press angles are valid for printing
unit 1.
From unit to unit these values differ as follows:
Speedmaster SM 102 – 74.57_ ,
Speedmaster CD 102 – 197.28 _.
Condition:
The plate cylinder will only turn to the correct
position for plate clamping/unclamping, if the coarse
register is set to zero or if the coarse register
sensor n B53 has acquired the current press angle
(see also chapter ”Coarse register monitoring”).
Position- Unclamping the Plate Unclamp- Plate Clamping the

ing the rear edge removal ing / clamping insertion rear edge
plate of the plate the front edge of of the plate
cylinder the plate
Actuation of
operator’s controls:
0.3 s 0.3 s
”Opening the
rear clamping bar”
n Y63 actuated
2.0 s
0.3 s
”Opening the 1.0 s
front clamping bar”
n Y62 actuated
2.0 s 0.5 s 2.0 s 0.5 s Enabling

”Air supply main motor
Enabling Enabling
control air” main motor main motor
n Y61 actuated
0.5 s
1.8 s 0.5 s
”Pressing bar on / off”
n Y7 actuated
Press angle 264.8 _ 322.6 _ 297.5 _
270
Plate clamping device 1...nB53 ”Coarse register monitoring”
1...nB53 ”Coarse register monitoring”
The sensor ”Coarse register monitoring” B53 is

fitted in each printing unit.
B53 It is located behind the servo-drive of the
circumferential register where it is screwed to a
fixing angle.
Place of installation of sensor ”Coarse register

monitoring”
Layout/connection
Sensor
Locking nut
Connecting cable
Core Function
brown DC 24V
blue ground 24V
black output signal
Layout of sensor ”Coarse register monitoring

1...nB53”
271
Task/function
Positioning bolt
Sensor B53
The inductive sensor 1...nB53 registers the
manual coarse adjustment of the circumferential
register.
After each coarse adjustment of the circumferen-
tial register, the operator must turn the press at
crawl speed for at least one full revolution. Only
then can the sensor register the adjustment and
pass the corresponding adjustment value on to
the press control system.
While the press turns at crawl speed, the sensor
sees the positioning bolt rotating past it.
Sensor and positioning bolt The zero position of the plate cylinder serves as a
reference point for the sensor. If the sensor
detects a deviation from the reference point with
the help of the positioning pin, the value is passed
on to the press control system. The deviation
corresponds to the coarse adjustment of the
register. The press control system determines the
press angle on the basis of the adjustment value.
Thus exact positioning of the plate cylinder is
possible again (e.g. important for the function
”Autoplate”).
Note:
To ensure that the sensor recognizes the manual
coarse adjustment of the register, the press must
turn at crawl speed for min. 1 revolution after
every adjustment.
Positioning bolt
1.0 mm ± 0.5 mm Sensor B53
The sensor must be installed in such a way that

there is a distance of 1 mm ± 0.5 mm between the
positioning bolt and the sensor.
Tighten the sensor with the locking nut and carry
out the ”Adjustment” (see next page).
Fitting the sensor

”
272
Adjustment
Note:
The adjustment is necessary after every:
– installation and removal of the sensor,
– exchange of the software,
– exchange of the processor boards REK 1 / 2 and
of the display control board DSK,
– basic initialization of REK 1 / 2 and DSK,
– first start-up.
1 Set the circumferential register on all printing

units manually to ”0”.
Insert the positioning bolt at 52 mm .
Also refer to the operating manual, chapter C
Printing unit, circumferential register ”Setting
to zero” .
2 Set the circumferential register to zero on

CPC 1-04 (precision setting).
Also refer to the operating manual for
CPC 1-04.
3 Set perfector presses to straight printing.
4 Turn the press at crawl speed.
5 Select the function ”Coarse register

adjustment value” for each printing unit
at the control console (”Service display”,
”Printing unit”). The corresponding symbol
lights up.
The symbol cannot be deactivated anymore.
The operator guidance disappears.
The reference-point run starts.
6 After the zero position of the coarse register

has been detected by the sensor, the
function becomes inactive.
The sensor has determined the zero position
and has passed it on to the press control
system.
273
274
Washup devices Control by command ”Washup”
Washup devices
Control by command ”Washup”
Selection of functions
Command
”Washup”
Actual value Service

display display
Printing unit
selection
Printing unit
selection
The command
”Washup” can
be aborted any
time with the
button ”Delete”.
Only with
Input start-up
warning
Control by command ”Washup”
275
Washup devices Messages
Messages
Faults at print start and during printing
Messages
Press not ready to run Fault in the press. Washing cannot be carried out.
Note:
Terminate the command ”Washup” with the button
”Delete”.
To locate the fault select ”Entire press” and the fault
display.
Paper in the press On command initiation there is still paper in the

press. Washing can only be carried out when the
paper has been transported out of the printing units
into the delivery.
Dryer waiting time – Only applies to presses with UV dryer –

The blanket and inking rollers may only be washed
180 s after the last drying. If the command is
enabled earlier, the symbol will light up and the
remaining waiting time will be indicated. The washup
programme only starts after the waiting time.
276
Washup devices Messages
Not enough water Not enough water in the washup solution container
E9:
- Sensor B1 "Monitoring water" (blanket / inking
roller washup device).
Not enough washup solution Not enough washup solution in the washup
solution container E9:
- Sensor B54 "Monitoring washup solution,
blanket washup device".
- Sensor B55 "Monitoring washup solution,
inking roller washup device”.
Inking roller washup device In the displayed printing unit the ink blade is not
monitoring of ink blade fitted. The sensor nB43 is not damped.
277
Washup devices Service display ”Washup”
Service display ”Washup”
Functions of the blanket washup device GTW

Button sequence
With the help of the ”Service display”, spray

procedures with water and washup solution can be
initiated. Apart from this, the washup blades can be
thrown on/off.
All functions can be activated during standstill of the
press or during ”Run”. The functions can be
activated either printing unit by printing unit or for all
units simultaneously. The corresponding solenoid
valves are then actuated in the printing units.
Functions of the washup devices
Spraying with water Solenoid valve 1...nY54 actuated.
Spraying with washup solution Solenoid valves 1...nY52 and 1...nY55 actuated.
Washup blade on/off Solenoid valve 1...nY53 actuated.
Functions of the impression cylinder washup device DZW

The washup brush motors M43, M50...M56 start up.
Spraying with washup solution Solenoid valve 1...nY42 actuated.

The washup brush motors M43, M50...M56 start up.
278
Functions of the inking roller washup device FWW

Button sequence
With the help of the ”Service display”, spray

procedures with water and washup solution can be
initiated. Apart from this, the ink blades can be
thrown on/off.
All functions can be activated during standstill of the
press or during ”Run”. The functions can be
activated either printing unit by printing unit or for all
units simultaneously. The corresponding solenoid
valves are then actuated in the printing units.
Functions of the washup devices
Spraying with washup solution Solenoid valve 1...nY50 actuated.
Ink blade on/off Solenoid valve 1...nY51 actuated.
279
Selecting the washup solution

Button sequence
If you press the button ”Entire press” in the ”Service

display”, you can choose between washing with
mineral oil-based and vegetable oil-based washup
solution. After a change, the parameters will be reset
to default values.
Choosing between mineral oil-based and vegetable

oil-based washup solution
Selectable functions Mineral oil-based solution Vegetable oil-based solution
Washing the blanket
Washing the inking rollers
Washing the impression cylinder
280
Washup devices Blanket washup device (GTW)
Blanket washup device (GTW)
Block diagram
1...nY54 1...nY52 1...nY55 1...nY53 1...nY56
E4
E9
EAK
Parallel data line

Serial data line
DSK REK2 ESK Control line
Washup solution or
water conduit
DNK2
Pneumatic line
ZID
Block diagram ”Washing the blanket”
E4 Pneumatic system compressor Y55 Blanket, washup brush

E9 Washup solution container Y56 Blanket, driving clutch
Y52 Blanket, washup solution
Y53 Blanket, washup blade
Y54 Blanket, water
281
Layout
Blanket cylinder
Rubber roller
Rider roller
Drop tubes for water and washup solution
Wiper roller
Washup blade
Ink trough
Spray tube for washup solution, washup brush
Washup brush

Function
When the command has been enabled and the
washup speed reached (5 000 i.p.h.), the drive of
the washup brush is engaged by the solenoid valve
nY56. The washup brush then turns at washup
speed. The wiper roller and washup brush are
driven.
When the washup brush has been engaged and
the 1st spray procedure has occurred, the washup
device is brought in the position for washup (nY53),
i.e. thrown on the blanket cylinder.
First spraying with washup solution occurs. The
solution is sprayed onto the blanket cylinder in two
different ways: via the drop tube (nY52), rider roller
and rubber roller and via the washup solution spray
tube for the washup brush and the washup brush
(nY55).
282
After the spray procedures with washup solution

spraying with water occurs (nY54).
The blade is in permanent contact with the wiper
roller. The ink removed by the blade is collected in
the ink trough and passed to a reservoir from there.
Such a reservoir is provided on the drive side of
each printing unit.
After washing of the blanket, the press stays in
operation (3000 i.p.h.).
283
Setting the number of cylinder revolutions and spray procedures for water and
washup solution
Button sequence
The first actuation of the function button allocates

the corresponding device to the right-hand and
left-hand +/– buttons.
After the allocation, the parameters can be changed
with the +/– buttons.
Pressing the function button again inactivates the
device again.
Blanket washup device selected
Changeover between settings for water (top) and

for washup solution (bottom) with the 1st function
button (above the left-hand +/– buttons).
Enter the number of cylinder revolutions with the

left-hand + / – buttons.
– water from 0 to 50
– washup solution from 0 to 150.
Enter the number of spray procedures with the

right-hand +/– buttons.
The setting range for the spray procedures goes
from 10% to 100%.
– 10% = 1 spray procedure.
– 100% = 10 spray procedures.
284
Example
Setting for water:
10 ¢ 10 cylinder revolutions
30% ¢ 3 spray procedures
Setting for washup solution:

30% ¢ 3 spray procedures
Flow chart:
”Washing with washup solution and water”
1.2 s
Water (nY54)
0.7 s (0.3 s if vegetableĆbased)
Washup solution (nY52)

0.3 s
Blanket
washup brush (nY55)
Blanket
driving clutch (nY6)
Blanket
washup blade (nY53)
Revolutions 0 4 40 99 104
102
Flow chart: ”Washing with washup solution and water”
285
Washup devices Inking roller washup device (FWW)
Inking roller washup device (FWW)
Block diagram
1...nY44 1...nY50 1...nY9 1...nY10 1...nY11 1...nY51
E4
E9
EAK
Parallel data line
Serial data line
Washup solution or
water conduit
DNK2
Pneumatic line
ZID
Block diagram ”Washing the inking rollers”
E4 Pneumatic system compressor Y44 Inking rollers, water

E9 Washup solution container Y50 Inking rollers, washup solution
Y9 Inking form rollers Y51 Ink blade
Y10 Ink ductor
Y11 Dampening rollers
286
Layout
Ink fountain roller
Ink ductor
Drop tubes for water and washup solution
Dampening roller
Plate cylinder
Inking form roller
Distributor cylinder
Ink blade with rubber strip and ink fountain
ÂÂÂ
ÂÂÂ

Function
washup speed reached (5 000 i.p.h.), washup
solution is sprayed onto the inking rollers. For this
purpose, the valve nY50 ”Inking rollers washup
solution” is actuated.
Then the ink ductor is thrown on (nY10).
After 40 cylinder revolutions and two spray
procedures, the ink blade is thrown on ( nY51).
The preselected spray procedures / cylinder
revolutions are carried out.
After the last spray procedure, the ink ductor is
thrown off. Simultaneously, the inking form rollers
(nY9) are brought into contact with the plate
cylinder.
When the inking form rollers are thrown off again,
the plate cylinder is predampened during 20
revolutions, nY11 actuated.
The press stops when washing is completed.
287
Setting the number of cylinder revolutions and spray procedures for water
and washup solution
Button sequence

After the allocation the parameters can be changed
device again.


Enter the number of cylinder revolutions with the

left-hand + / – buttons.
Water: 0 ... 500
Washup solution: 150 ... 1000; if the ink fountain
roller is washed in addition: 225 ... 1500.
Enter the number of spray procedures with the

right-hand + / – buttons.
Setting possible from 0% ... 100%.
Setting 1 spray procedure every ...
100% 16
90% 20
80% 24 revolutions
70% 28
60% 32
50% 36
L L
0% 56
The first spray procedure lasts 0.8 s, the others 0.4 s.
288
Additional washing of printing plate and ink fountain roller

Additional washing of Condition:
printing plate Before selecting the function ”Additional washing of
ink fountain roller”, remove the ink from the ink
Additional washing of ink fountain and carry out an ink shut-off at CPC 1-04.
fountain roller The printing plate and ink fountain roller can be
washed in addition via the inking roller washup
device. The inputs are valid for the selected printing
units.
Example
Setting for water:
70% ¢ one spray procedure every
28 revolutions

70% ¢ one spray procedure every
28 revolutions
289
Flow chart:
”Washing with mineral oil-based washup solution without water”
If printing plate is
washed as well
Dampening rollers
(n Y11)
Inking form
80% of preselected cylinder
rollers (n Y9) revolutions if printing plate is
washed as well
Ink ductor (n Y10)
Ink blade 66% of preselected cylinder revolutions if

printing plate is washed as well
(n Y51)
Water (nY44)
Washup solution 0.4 s 0.2 s 0.2 s

(n Y50)
Revolutions 20 20 x x x 40 30 20
Preset spray procedures washup solution
Preselected cylinder revolutions washup solution
Flow chart: ”Washing with mineral oil-based washup solution without water”
Flow chart:
”Washing with mineral oil-based washup solution and water”
Dampening rollers
(n Y11)
Inking form
rollers (n Y9) as 1st section
above (with-
Ink ductor (n Y10) out water)
Ink blade
(n Y51)
Water (nY44) 0.4 s 0.4 s
Washup solution 0.2 s

(n Y50)
Revolutions x1 x2 x2 40 30 20
Preset spray proce- Preset spray procedures water
dures washup solution
Preselected cylinder revolutions Preselected cylinder revolutions

washup solution water
Flow chart: ”Washing with mineral oil-based washup solution and water”
290
Flow chart:
”Washing with vegetable oil-based washup solution and water”
If printing plate is
washed as well
Dampening rollers
(nāYā11)
Inking form
rollers (nāYā9) 80% of preselected cylinder
revolutions if printing plate is
washed as well
Ink ductor (nāYā10)
Ink blade 66% of preselected cylinder revolutions if

printing plate is washed as well
(nāYā51)
Water (nY44) 8
0.4 s 0.4 s
Washup solution 0.4 s 0.2 s 0.2 s
(nāYā50)
Revolutions 80 30 20
x1 x1 x1 x1 x2 x2
Preset spray procedures Preset spray procedures
Preselected
cylinder revolutions
Preselected cylinder revolutions washup solution water
Flow chart: ”Washing with vegetable oil-based washup solution and water”
291
Washup devices Impression cylinder washup device (DZW)
Impression cylinder washup device (DZW)
Block diagram
1...nY43 1...nY42 1...nY41 M M50 ... M56, M43
E4
E9
EAK
Parallel data line
Serial data line

Washup solution or
water conduit
DNK2 Pneumatic line
ZID
Block diagram ”Washing the impression cylinder”
E4 Pneumatic system compressor 1...nY41 Impression cylinder, washup brush

E9 Washup solution container 1...nY42 Impression cylinder, washup solution
M50 ... M56, M43 Washup brush motors 1...nY43 Impression cylinder, water
292
Layout
Impression cylinder
Spray tube for water
Washup brush motor
Washing trough
Spray tube for washup solution
Blade
Washup brush
Impression cylinder washup device
Function
Each printing unit has a washup brush which is
connected with the washup brush motor via gears.
The motor is located in the middle of the printing
unit, under the impression cylinder.
washup speed of 5000 i.p.h. has been reached, the
following functions are initiated:
– starting up the washup brush motors
M50 ... M56, M43
– throwing on the washup brushes (1...nY41)
– opening the spray tubes for washup solution
(1...nY42)
– opening the spray tubes for water (1...nY43).
The washup solution and water for the impression

cylinder washup device come from the washup
solution container E9 which also supplies the
blanket washup device.
After washing, the press stays in operation
(3000 i.p.h.).
293
Setting the number of cylinder revolutions and the spray duration for water
and washup solution
Button sequence

After the allocation the parameters can be changed
device again.
Impression cylinder washup device selected

Enter the number of cylinder revolutions for water

and washup solution with the left-hand +/– buttons:
– Water: 0 and 30
– Washup solution: 0, 50 and 100
Enter the spray duration for water and washup

solution with the right-hand +/– buttons:
Setting range from 0 to 100%. Dependent on the
setting, the basic pulse duration for washup solution
and water is shortened or lengthened.
Setting Change in basic pulse duration
0% – 0.5 s
10% – 0.4 s
L L
50% 0
L L
90% + 0.4 s
100% + 0.5 s
294
Example
Setting for water:
50% ¢ basic spray duration +/– 0 s

50% ¢ spray duration 0 s
Flow chart:
”Washing with washup solution and water”
Washup brush motor

(M43, M50...M56)
Impression cylinder
washup brush
2.0 s+/–x
(n Y41) 3.0 s+/–x 1.0 s+/–x
Spray duration
Water (nY43)
2.0 s+/–x 0.7s+/–x 0.7 s+/–x 0.5 s+/–x 1,0 s
Washup solution 0.5 s
(n Y42)
25 25 25 25 15 15 30
Revolutions Preselected
Preselected cylinder revolutions cylinder revolutions
Flow chart: ”Washing with washup solution and water”
295
Washup devices M43, M50...M56 Washup brush motors
M43, M50 ... M56 Washup brush motors
The washup brush motors are located in the middle
of each printing unit, below the impression cylinder.
They are accessible through the lower opening in
the side frame on the O.S.
These washup brush motors are only available

for CD102.
Washup brush motor in printing unit
Pin assignment
Pin Function
A2 AC 400 / 480 V phase U
A B C B3 AC 400 / 480 V phase V

1
C2 AC 400 / 480 V phase W
2
PE conductor
3
4
5
Plugs M43-X1, M50-X1 ... M56-X1
296
Washup devices E9 Washup solution container
E9 Washup solution container
Block diagram
Pressure reducer with check valve
15K4M
Safety valve
15K4M Contactor, pneumatic system compressor
M4 Pneumatic system compressor
B1 Sensor ”Monitoring water”.
M4
B54 Sensor ”Monitoring washup solution,
blanket washup device”
B55 Sensor ”Monitoring washup solution,
inking roller washup device”
E9 Washup solution container
E9
F70 F70 Pressure switch
B1 B54 B55
EAK
ESK
REK
Pneumatic line
Control line
Parallel data line
Block diagram: washup solution container E9
297
Warnings
Symbols appear in the following displays if there are
malfunctions in connection with the washup solution
container:
– production run display,
– display which appears after initiating the
command ”Washup”,
– fault display ”Entire press/warning”.
Not enough washup solution Not enough washup solution in the washup solution
container E9.
Sensor B54 ”Monitoring washup solution, blanket
washup device”.
Sensor B55 ”Monitoring washup solution, inking roller
washup device”.
Not enough water Not enough water in the washup solution

container E9.
Sensor B1 ”Monitoring water”.
Insufficient pressure in the At an air pressure x 0.48 bars, pressure switch F 70

container responds.
In the control console display ZID both symbols
appear: ”Not enough washup solution” and ”Not
enough water”.
298
Place of installation of washup solution container E9
Washup solution container E9
The washup solution container is located under

the footboard on the O.S. (on presses with up to
5 units at the 2nd unit, with 6 units at the 3rd unit;
with 7 or more units one container at the 2nd unit
and one at the 6th unit).
Layout
Attention: Only refill the washup solution container

with the press switched off or the air supply
shut off (stop-cock closed).
Refill opening with cover and sieve

Pressure regulator with manometer
Three-way stop-cock
Solenoid valve
Check valve
Pressure switch F70
Safety valve
Sensor B55 ”Monitoring washup solution,
Sensor B1 ”Monitoring water”
Sensor B54 ”Monitoring washup solution,

Terminal box with terminal strip E9-X1
Washup solution container E9
299
Task
The washup solution container E9 supplies:
– the blanket washup device with water and
washup solution,
– the inking roller washup device with water
and washup solution.
In order to deliver water and washup solution, the
pressure in the container must be between
0.48 bars and 1.0 bar.
The pressure reducer reduces the air pressure
from the pneumatic system compressor M4 to
0.5 bars. If the pressure drops below 0.48 bars,
the pressure switch F70 responds. A warning
appears in the control console display ZID. If the
air pressure rises above 1.0 bar, the safety valve
opens.
The sensors B1, B54 and B55 monitor the liquid
levels.
If the levels drop below the min. permissible
values, a warning appears in the control console
display ZID. The initiated washup procedure is
completed, but a new washup procedure cannot
be started anymore.
Pin assignment E9-X1
Pin Function
3 4 1 DC 24 V
2 24 V
5 3 ”Monitoring water”
2 1 4 ”Monitoring washup solution,
5 ”Monitoring washup solution,
Plug E9-X1
300
Washup devices B1, B54, B55 Sensors at the washup
solution container
B1, B54, B55 Sensors at the washup solution container
B1 Monitoring water
B54 Monitoring washup solution,
blanket washup device
B55 Monitoring washup solution,
inking roller washup device
Sensors at washup solution container
Connection
Input at EAK :
0 ¢ level too low
1 ¢ level OK
Pin assignment
Marking Colour Function
X1 white signal
+1 brown DC +24 V
301
Washup devices B1, B54, B55 Sensors at the washup
solution container

Float
Sensor
Width across flats 27 with marking
All three sensors are of identical design. For

removal loosen the thread and unscrew the sensor.
For installation introduce the sensor into the
threaded hole, position the thread carefully and
screw it in. The sensor is sealed up by the tapered
thread and the Teflon sealing tape around it.
Tighten the sensor with 5 Nm.
Sensor at the washup solution container
Adjustment
The mounting position of the sensor determines its
switching function. Pay attention to the arrow on the
flat face of the screw.
Direction of arrow Function Symbol
upward ° NC contact
downward ± NO contact
Mounting position of sensor
302
Washup devices 1...nB43 Monitoring the ink blade
1...nB43 Monitoring the ink blade
The inductive sensor is located on the inside of
the side frame on the O.S. It is fitted in each
printing unit at the paper outlet.
Sensor ”Monitoring the ink blade”
Layout
Sensor
Nut and locking nut
Connecting cable
Sensor ”Monitoring the ink blade” with nut and

locking nut
303
Washup devices 1...nB43 Monitoring the ink blade
Task
The inductive sensor ”Monitoring the ink blade
1...nB43 monitors the correct installation of the ink
blade. When the ink blade is not fitted, automatic
washing of the inking rollers is not possible.
Connection
Core Function
brown DC 24 V
blue ă 24 V
black signal
Pin assignment
Input 43 of EAKn:
(n = corresponding printing unit)
0¢ ink blade not fitted

1¢ ink blade fitted

Blade
Sensor
4.0 mm Nut/locking nut

Side frame
When fitting the sensor, screw it so far in the

holder that the distance between ink blade and
sensor is 4.0 mm. Tighten the nut and locking nut.
Installation of sensor Monitoring the ink blade”
304
Inking unit Servo-drive ink fountain roller
Inking unit
Servo-drive ink fountain roller
The servo-drives for the ink fountain rollers are

located on the operator side of the printing units.
D.S.
O.S.
Place of installation of servo-drive for ink fountain

roller O.S.
Layout and task

The servo-drive for the ink fountain roller is a
dc motor with brushes and potentiometer for
position feedback.
It is used for adjustment of the ink fountain

roller stroke. Thus the ink stripe width can be
influenced.
Servo-drive ink fountain roller
305
Technical data
Motor data
U = DC 12 V
Potentiometer data
U = DC 10 V
R = 10 k
Terminal assignment
Terminal Function
black 6 6 black 6 6 black
1
yellow
5 5 yellow
5 5 blue DC 12 V (motor)
beige beige red 2
4 4 4 4
yellow/green
3 3 yellow/green
3 3 4 DC 10 V (potentiometer)
brown brown black
blue
2 2
blue
2 2 5 potentiometer
1 1 1 1 red
6 Potentiometer tap
Terminal strip of servo-drive for ink fountain

roller
306
Attention: Small parts can fall into the press during

disassembly!
Nut on servomotor
O.S. Gear wheel
Locking screw
Anti-rotation element
Retaining nut
1 Zero position of ink fountain roller

Turn the threaded rod against the left stop
with the nut .
2 Disconnect the potentiometer from the
terminal strip.
3 Loosen the locking screw and take out the
potentiometer.
4 Attach the anti-rotation element to the new
potentiometer.
5 Connect the new potentiometer and turn until
Ink fountain roller O.S. the display on the central control console
indicates 0,00.
6 Install in reverse sequence.
7 If you want to make a precision correction,
loosen the retaining nut .
Correct the value by slightly turning the
potentiometer.
8 Check the value displayed on the central
control console.
307
Inking unit Servo-drive diagonal register 1...nM6
Servo-drive diagonal register 1...nM6
The servo-drives for the diagonal register are

D.S.
O.S.
Place of installation of servo-drive for diagonal

register O.S.
Layout and task

The servo-drive for the diagonal register is a dc
motor with brushes and potentiometer for position
Speedmaster SM 102
feedback.
It is used for cocking the plate cylinder.
Speedmaster CD 102
Servo-drive diagonal register on SM 102 and CD 102
308
Technical data
Motor data
U = DC 24 V
Potentiometer data
U = DC 10 V
R= 10 k
Pin assignment
Pin Function
1
1
2 DC 24 V (motor)
3 4 2
5
3 3 DC 10 V (potentiometer)
2 1 4 Potentiometer tap
4 5 potentiometer
5
Plug of servo-drive of diagonal register
309

disassembly!
Plug 1...nM6-X1
Fixing bolts
Hexagon nut
Block
Upper stop of eccentric sleeve
Eccentric bolt
Servo-drive
1 Withdraw the plug from the servo-drive .

2 Remove the servo-drive by loosening the four
fixing bolts .
3 Positioning the diagonal register to zero:
Turn the hexagon below the block until
the distance between the upper stop of the
eccentric sleeve O.S. and the eccentric bolt
is 5 mm.
4 Setting the central position for the new
servo-drive:
Connect the plug to the servo-drive . Set
the diagonal register display to 0,00 on the
central control console.
Alternatively, it is possible to set the variable
Eccentric sleeve voltage of the potentiometer to 5V at the
behind block servo-drive conversion module SSM in the
distribution box of the printing unit.
5 Installing the servo-drive:
When installing the servo-drive, the backlash
(flank clearance) is of no importance and can
be neglected. When tightening the fixing bolts,
5mm pull the servo-drive outwards (away from the
PU). Thus the backlash of the two pinions is
adjusted.
Note:
Do not loosen the eccentric bolt .
After loosening the eccentric bolt, the plate cylinder
Servo-drive diagonal register, e.g. SM 102 and the dampening distributor must be adjusted
parallel to each other again.
310
Inking unit Servo-drive lateral register
Servo-drive lateral register
The servo-drives for the lateral register are
D.S.
O.S.
Place of installation of servo-drive for lateral

register O.S.
Layout and task

The servo-drive for the lateral register is a dc
motor with brushes and potentiometer for position
feedback.
It is used for adjustment of the plate cylinder in

lateral direction.
Servo-drive lateral register
311
Technical data
Motor data
U = DC 12 V
Potentiometer data
U = DC 10 V
R = 10 k
Terminal assignment
Terminal Function
1
black black DC 12 V (motor)
yellow
6 6 red
2
beige
5 5 blue
4 DC 10 V (potentiometer)
4 4 5 potentiometer
yellow/green 6
brown
3 3 brown
Potentiometer tap
blue
2 2 blue
1 1
Terminal strip of servo-drive for lateral register
312

disassembly!
Nut
Gear wheel
Nut
2.2...2.27 mm
Nut
Sleeve
2.2...2.27 mm
1 Positioning the lateral register to zero:
Turn the gear wheel with the help of the nut
until the distance of 2.2...2.27 mm is
obtained.
Note:
Lateral register O.S. Use a feeler gauge!
2 Unscrew the nut .

3 Loosen the nut .
4 Take out the potentiometer and disconnect the
cable from the terminal strip.
potentiometer.
6 Connect and install the new potentiometer and
turn until the display on the central control
console indicates 0,00.
loosen the nut . To correct the value insert a
screw driver in the sleeve and turn the
potentiometer axis slightly. Check the value
displayed on the central control console.
313
Inking unit Servo-drive circumferential register
Servo-drive circumferential register
The servo-drives for the circumferential register

are located on the drive side of the printing units.
O.S.
D.S.
Place of installation of servo-drive for circumferen-

tial register D.S.
Layout and task

The servo-drive for the circumferential register is a
dc motor with brushes and potentiometer for
position feedback.
It is used for adjustment of the plate cylinder in

circumferential direction.
Servo-drive for circumferential register D.S.
314
Technical data
Motor data
U = DC 12 V
Potentiometer data
U = DC 10 V
R = 10 k
Terminal assignment
Terminal Function
1
black black DC 12 V (motor)
yellow
6 6 red
2
beige
5 5 blue
4 DC 10 V (potentiometer)
4 4 5 potentiometer
yellow/green 6
brown
3 3 brown
Potentiometer tap
blue
2 2 blue
1 1
Terminal strip of servo-drive for circumferential

register
315

disassembly!
Nut
6.2...6.3 mm
6.2...6.3 mm Gear wheel
Locking screw
Nut
1 Positioning the circumferential register to zero:

Turn the gear wheel with the help of the nut
until the distance of 6.2...6.3 mm is obtained.
Note:
Use a feeler gauge!
2 Disconnect the potentiometer from the terminal

Circumferential register D.S. strip.
3 Loosen the locking screw and take out the
potentiometer.
potentiometer.
5 Connect and install the new potentiometer and
turn until the display on the central control
console indicates 0,00.
loosen the nut . Correct the value by slightly
turning the potentiometer. Check the value
displayed on the central control console.
316
Inking unit Inking unit temperature control
Inking unit temperature control
Activation and inactivation
The inking unit temperature control can be

activated and inactivated at the central control
console.
Power supply is effected via plug E39-X1.
On 7- and 8-colour presses, the required
second inking unit temperature control is
switched on and off via plug E39a-X1.
Actual valueā/āfine display of

control console display (ZID)

on/off
317
Inking unit E39 Inking unit temperature control
E39 Inking unit temperature control
Connection
Different models are available which differ in
power. 7- and 8-colour presses require two inking
unit temperature controls (E39 and E39a). The
power supply for the unit(s) comes from the
printing press.
The illustration opposite is an example. The units
differ in cabinet height and width.

Connection of inking unit temperature control E39
Pin assignment E39-X1 (only model 3/8)
Pin Function
3 Phase U
7 Phase V
1 6
9 Phase W
2 7
PE conductor
3 8
4 9 Remain- –
ing pins
5 10

318

(models 6/12; 6/16; 9/20 and 9/25)
Pin Function
1 Phase U

2 Phase V

3 Phase W

PE conductor

Remain- –
ing pins
4Ćpole
cable

319
320
Dampening 1...nM1 Pan roller motors
Dampening
1...nM1 Pan roller motors
Place of installation / plug connections

Connector 1...nM1-X3
( power supply )
1...nM1-X3
1M1 2M1 3M1
Pan roller motors 1...nM1 at PU/CU on D.S.
Pin assignment
6 Pin Function
7 5
8 4 1 X motor line
1
3 2 Y motor line
9
3 Z motor line
10 14 4 Hall-effect sensor, signal C
5 Hall-effect sensor, tacho signal
11 13
12 6 Hall-effect sensor, signal B
2
7 DC 15 V
Connector 1...nM1-X3, pins in plug insert 8 Hall-effect sensor, signal A
9 Ground of DC 15 V
10 –
11 Motor code
12 –
13 –
14 –
PE
321
Dampening 1...nM45 Blower motor for dampening system
1...nM45 Blower motor for dampening system
Place of installation and task

The blower combination with the motor 1...nM45 is
located under the guard of the inking and dampen-
nM45 ing rollers.
The motor is a dc motor with brushes.
It is integrated in the middle of the blower bar and
drives a cross-flow fan.
Place of installation of blower motor for dampening

system
Pin assignment
Pin Function
1 Enable message
2 Ground 24 V
3 DC 24 V
1
2
3
Plug of blower motor for dampening system
322
Dampening 1...nB32 Sensor ”Dampening solution control”
1...nB32 Sensor ”Dampening solution control”
The capacitive sensor is located on the paper
infeed side, D.S., in the dampening solution
fountain.
nB32
Place of installation of sensor ”Dampening solution

control”
Layout/connection
Core Function
brown DC 24 V
blue ground 24 V
black message
Sensor ”Dampening solution control”
323
Dampening 1...nB32 Sensor ”Dampening solution control”
Task/function
The capacitive sensor 1...nB32 monitors the level
of the dampening solution in the fountain.
The sensor works correctly when its sensing area
is immersed in the dampening solution.
With its sensing area immersed, the sensor is
actuated. If the level of the dampening solution
drops, the sensor will only change its circuit state
if its sensing area is no longer in contact with the
water film.
The sensor is supplied with a stabilized direct
voltage of DC 24 V.
324
Dampening E40 Central dampening solution supply/
E40 Central dampening solution supply/cooling and circulating unit
Layout of central dampening solution supply

The central dampening solution supply is in a
separate cabinet. Generally, this cabinet is in the
proximity of the central control cabinet. It is
connected to the CP Tronic control system via a
serial interface. The power supply and circuit-
ÁÁÁÁ
breakers are in the control cabinet of the printing
press. For details please refer to the manufacturer’s
ÁÁÁÁ manual.
ÁÁÁÁ
ÁÁÁÁ
E40-X1: power supply
ÁÁÁÁ
E40-X2: serial interface
X1 X2
Central dampening solution supply Technotrans
Á
Á
X2
Á
Á
X1
Central dampening solution supply Baldwin, rear view
325
Pin assignment X1, central dampening solution supply
Pin Function
3 Phase U
1 6
7
9
Phase V
Phase W
*)
2 7 PE conductor
3 8
Remain- –
4 9 ing pins
5 10
380...415 V " 15V

* ) AC
AC 460...500 V " 15V
at 50Hz
at 60Hz
Connector E40-X1, coming from the press
326
Layout of cooling and circulating unit

The cooling and circulating units have no serial
interfaces. The power supply and circuit-breakers
are in the control cabinet of the printing press. A
manufacturer’s manual is available.
E40-X1
Cooling and circulating unit
Pin assignment X1, cooling and circulating unit

Pin Function
2 AC 230 V
4 Zero 230 V
1 6
2 7 PE conductor
3 8
Remain- –
4 9 ing pins
5 10
327
Dampening E41 Dampening solution mixing unit
E41 Dampening solution mixing unit

The dampening solution mixing unit is an additional
unit for cooling and circulating devices without
integral additive-mixing units. It admixes additives to
the dampening solution. Power supply comes
directly from the mains and not from the press.
For details please refer to the manufacturer’s
documentation.
Dampening solution mixing unit
328
Central lubrication Basic concept
Central lubrication
Basic concept
Distinction
Two lubrication systems supply the press with
lubricant:
– grease lubrication system (for the delivery),

– oil lubrication system (for the printing units,
feeder and bearings on the D.S. and O.S. of
the delivery chain sprocket shaft).
The grease lubrication system is divided into:

– lubrication circuit 1 (chain lubrication),
– lubrication circuit 2 (bearing lubrication).
The oil lubrication system is divided into:

– the circular lubrication system (drive side),
– the distributing lubrication system (operator
side and some lubricating points on the drive
side).
329
Central lubrication Service display
Service display
Button sequence
Oil lubrication
Pressure monitoring 1bar, 1F33 (flashes if the
pressure switch was not actuated).
Pressure monitoring 12bars, 1F34 (flashes if the
pressure switch was not actuated).
Oil pump M44 (flashes if motor circuit-breaker
15Q44 has responded).
Number of cylinder revolutions since the last
distributing lubrication. After completion of
lubrication the counter is automatically zeroed.
Distributing lubrication initiated manually (only
when press is on ”Run”).
Service display ”Oil lubrication”
Number of cylinder revolutions at which
automatic oil lubrication is initiated.
330
Central lubrication Service display
Grease lubrication
7 Sensor ”Lubrication monitoring 2” – 12 B77
(bearing lubrication) (flashes if sensor is not
actuated).
8 Sensor ”Lubrication monitoring 1” – 12 B47
(chain lubrication) (flashes if sensor is not
actuated).
9 Motor grease lubrication 12M47.
ß Number of cylinder revolutions since the last
chain lubrication. After completion of lubrication
the counter is automatically zeroed.
Service display ”Grease lubrication”

q Number of cylinder revolutions since the last
bearing lubrication. After completion of
lubrication the counter is automatically zeroed.
w Chain lubrication initiated manually (lubrication
circuit 1); (only when press is on ”Run”).
e Bearing lubrication initiated manually (lubrica-
tion circuit 2); (only when press is on ”Run”).
r Number of cylinder revolutions at which
bearing lubrication is initiated automatically.
t Number of cylinder revolutions at which chain
lubrication is initiated automatically.
331
Central lubrication Fault messages
Fault messages
Display ”Entire press/warning”

Button sequence
Dependent on the press model, the fault display

”Entire press” / ”Warning” shows the fault symbols of
the grease lubrication or oil lubrication system:
Oil lubrication not possible Oil lubrication has not occurred.

– After main switch ”On” and changeover
between circular and distributing lubrication,
the oil pressure has not been built up within
3 minutes.
– Pressure switch 1F33 (1 bar) or pressure
switch 1F34 (12 bars) not actuated.
– Filter unit clogged.
Grease lubrication not possible Chain or bearing lubrication has not occurred.
– The sensor ”Lubrication monitoring 1” –
12 B47 or the sensor ”Lubrication monitoring
2” – 12 B77 has not responded within
10 minutes.
– Solenoid valve 12 Y78 defective. Changeover
between chain and bearing lubrication is not
possible.
– Motor for grease lubrication 12 M 47 defective.
The motor circuit-breaker has tripped. Oil pump

Motor circuit-breaker Q 44
M 44 not ready to run.
has tripped
The audible signal devices 11H55 While lubrication is in progress, a warning signal
and 12H55 give out a warning sounds if the printing speed is u 3 000 i.p.h.
332
Central lubrication Grease lubrication
Grease lubrication
Block diagram
15 Q 66
15 Q 47
12B47
15 K47 M 12M47 12Y78
12B77
11H55
12H55

Control line
Power supply
Grease line
Block diagram of grease lubrication
Pressure limiting valve (38 bars) 12M47 Motor ”Grease lubrication”

Metering elements 12Y78 Changeover grease lubrication
15Q66 Main switch 12B47 Lubrication monitoring 1 (chains)
15Q47 Motor circuit-breaker 12B77 Lubrication monitoring 2 (bearings)
15K47M Contactor 11H55 Audible signal device (audio alert feeder)
12H55 Audible signal device (audio alert delivery)
333
The motor for grease lubrication is located on
the D.S. of the last printing unit. The sensors
”Lubrication monitoring” are fitted at the first
progressive distributor behind the motor.
Layout
Motor ”Grease lubrication” 12 M 47
Grease reservoir
Pressure relief valve
Lubrication monitoring 2–12 B77 (bearing
lubrication)
Lubrication monitoring 1–12 B47 (chain
lubrication)
Progressive distributor
Changeover grease lubrication 12 Y78
(between bearing and chain lubrication)
Components of the grease lubrication system
Function
When the press is switched on, the grease lubrica-
tion system is ready for operation. The motor for
grease lubrication 12M47 delivers the lubricant to
the progressive distributors via solenoid valve
12 Y78. Depending on the position of the solenoid
valve, either the chains in the delivery (lubrication
circuit 1) or the bearings (lubrication circuit 2) are
supplied with lubricant.
The progressive distributors pass the lubricant to
the lubricating points via pistons. The progressive
distributors are sequence-controlled and thus all
pistons move uniformly. For this reason, only the
movement of one piston is monitored per lubrica-
tion circuit.
334
Monitoring the lubrication system

Inductive sensors monitor the two lubrication
circuits. Each is equipped with an LED and can
LED assume two circuit states.
– Pin of progressive distributor extended, sensor
damped:
LED is lit.
– Pin of progressive distributor retracted, sensor
not damped:
LED is not lit.
On presses with standard delivery, the sensor

12 B47 (chain lubrication) is actuated twice while
lubrication is in progress and three times on pres-
Sensor with LED monitoring the lubrication circuit ses with extended delivery.
The sensor 12 B77 (bearing lubrication) is actuated
once while lubrication is in progress.
If the sensors do not switch within 10 minutes after
a lubrication process was triggered, the electronic
control system shuts the motor for grease lubrica-
tion down. The warning ”Grease lubrication not
possible” appears.
335
Triggering a lubrication process

When the press is switched on, the grease
lubrication system is ready for operation. Lubrication
is triggered either automatically:
chain lubrication every 2 500 to 30 000 cylinder

revolutions; (after a basic initialization, the
cycle is preset to 20 000 cylinder revolutions),
bearing lubrication every 200 000 cylinder
revolutions,
or manually by actuating the function button
”Manual chain or bearing lubrication”.
Central lubrication selected, press on ”Run”
Setting the lubrication cycle for lubrication circuit 1 (chain lubrication)

Button sequence
Number of cylinder revolutions for automatic

chain lubrication (lubrication circuit 1). The
cylinder revolutions can be set in the range
from 2 500 to 30 000 in steps of 2 500.
Note:
To set the lubrication cycle an additional button must
be fitted on the EAM (input/output module). Before
fitting or removing this button, turn off the main
switch 15 Q 66 on the central control cabinet ZSG!
Number of cylinder revolutions set to 20000
336
Attention: Even if the main switch is turned off, the press

is not voltage-free and there are current-
conducting components in the central control
cabinet!
The input/output module EAM is on the underside

EAM
of the central control console. Plug the additional
button into slot 7 of the EAM - X12.
Turn off the main switch 15Q66.

Fit the button.
EAM-X12
Group
Turn on the main switch 15Q66.
Now press the button you just fitted plus group
button 2 on the central control console.
Set the cylinder revolutions with the left-hand + / –

buttons.
– 2 500
Lubrication cycle for delivery – 5 000
30000 – L
– 25 000
– 30 000
Remove the button from slot 7 of the EAM - X12.

Then check the cylinder revolutions for chain
lubrication (lubrication circuit 1) in the service
display ”Central lubrication” on the central control
console.
Changing the lubrication cycle
Note:
The value for bearing lubrication (lubrication circuit
2) is set to 200 000 cylinder revolutions and is
non-adjustable.
Pressure relief valve of the motor

The motor for grease lubrication is protected by a
pressure relief valve. In the case of malfunctions,
this valve prevents the building up of impermissible
high pressures in the lubrication system and opens
at a pressure of 150 bars.
337
Central lubrication Oil lubrication
Oil lubrication
Block diagram
15 Q 66
15 Q 44
1F33
15X3 M44 Y67
1F34
11H55
12H55

Control line
Power supply
Oil line
Block diagram of oil lubrication
Pressure relief valve (18 bars) Y67 Changeover oil lubrication

Metering elements 1F33 Pressure monitoring (1 bar)
15Q66 Main switch 1F34 Pressure monitoring (12 bars)
15Q44 Motor circuit-breaker 11H55 Audible signal device (audio alert feeder)
15X3 Plug 12H55 Audible signal device (audio alert delivery)
M44 Oil pump
338
The oil reservoir with oil pump M44, filter unit,
solenoid valve Y67 and pressure relief valve is
located on the D.S. under the footboard (on
presses with up to 5 units at the last unit, with 6 or
more units in the middle).
On presses with coating unit the guard serves as
oil reservoir and contains the oil pump, filter unit
and valves.
The two pressure switches, 1 F 33 and 1 F 34, are
fitted at the first printing unit under the feeder.
Layout
Oil pump M 44
Filter unit
Oil lubrication press – Y 67 (changeover
between circular lubrication and distributing
lubrication)
Pressure relief valve (18 bars)
Pressure switch 1F34 (12 bars)
Pressure switch 1 F 33 (1 bar)
Oil reservoir
Components of the oil lubrication system
339
Function
Switching on the press activates oil lubrication, i.e.
the circular lubrication system is active and
continuously lubricates the gears on the D.S.
For the changeover to distributing lubrication the
solenoid valve Y67 must be actuated. This is
effected either automatically or with the function
button ”Manual distributing lubrication”. The
distributing lubrication system supplies the bearings
on the D.S. and O.S. with oil.
After every changeover between distributing and
circular lubrication, the oil pressure must build up
within 3 minutes; otherwise the electronic control
system outputs a fault message.
Circular lubrication
The oil is continuously fed to the lubricating points
via the oil riser and drip pan. The circular lubrication
system works at an oil pressure y 1 bar. The oil
pressure is monitored by pressure switch 1 F 33
(1 bar).
The oil flowing back down the side frames on the
D.S. is returned to the lubrication circuit. Through a
return line the oil flows either into the oil reservoir or
into the coating unit guard. The return line is fitted
above the cable duct on the D.S.
Distributing lubrication
The distributing lubrication system supplies the
lubricating points through piston distributors. The oil
pressure in the system is y 12 bars and monitored
by pressure switch 1 F 34 (12 bars).
On SM102-presses the residual oil is collected in
the bases and can be drained off through a drain
cock on the O.S.
On CD102-presses the residual oil is collected in a
reservoir on the D.S. which can be emptied.
340
Triggering a lubrication process

Distributing lubrication is triggered:
automatically every 45 000 cylinder revolutions

or
by actuating the function button ”Manual
distributing lubrication”.
For activation the printing press must be on ”Run”

(3 000 i.p.h.).
Central lubrication selected, press on ”Run”
Filter unit
Optical differential pressure indicator
Filter housing with cartridge
The filter unit is fitted between the pump and the

solenoid valve. The optical differential pressure
indicator shows the degree of soiling of the filter
cartridge:
– Green: filter cartridge okay
– Red: change filter cartridge
If the filter cartridge is soiled, the oil pressure

between the oil pump and filter unit rises. The relief
Filter unit valve in the filter unit opens the bypass and the oil
flows to the lubricating points without having been
filtered. Change the filter at least every 6 months.
341
Changing the filter
Changing the filter
Optical differential pressure indicator
The tightening torque for the filter housing must be

120 Nm +/– 15 Nm.
Pressure relief valve of the oil pump

A pressure relief valve is installed to protect the oil
pump. In the case of malfunctions, this valve
prevents the building up of impermissible high
pressures in the lubrication system. It opens at a
pressure of 18 bars and the oil flows back into the
coating unit guard or the oil reservoir.
342
Central lubrication M44 Oil pump
M44 Oil pump
On presses with coating unit, the oil pump is
located on the D.S. of the coating unit, below the
footboard.
Location of oil pump on presses with coating unit, D.S.
On presses without coating unit, the oil pump is

installed at the oil reservoir. The oil reservoir is
located on the D.S. under the footboard (on
presses with up to 5 printing units at the last
printing unit).
Location of oil pump on presses with up to 5 PUs
343
Central lubrication M44 Oil pump
On presses with 6 or more units, the oil reservoir is

bigger and located in the middle of the press, under
the footboard on the D.S.
Location of oil pump on presses with 6 or more PUs
Pin assignment
Pin Function

A B C
1
B3 AC 400 / 480 V phase V
2
3 C2 AC 400 / 480 V phase W
4
PE conductor
5
Plug M44-X1
344
Central lubrication 12M47 Motor for grease lubrication
12M47 Motor for grease lubrication
The motor for grease lubrication 12M47 is located
on the D.S. of the delivery.
Motor for grease lubrication with grease reservoir
Pin assignment
Plug 12M47-X1
Pin Function
3
1 DC 24 V
1
2 Grease lubrication delivery chains
2
3 –
PE
PE –
Plug 12M47-X1
345
Central lubrication 1F33 Pressure monitoring
oil lubrication 1bar
1F33 Pressure monitoring oil lubrication 1bar
The pressure switch ”Pressure monitoring oil
lubrication 1 bar” 1F33 is located on the drive
side of the first printing unit, under the sheet
alignment system. It is accessible through the
door between the feeder and first printing unit on
the O.S.
Place of installation ”Pressure monitoring

oil lubrication 1 bar”, 1F33
346
Central lubrication 1F34 Pressure monitoring
oil lubrication 12bars
1F34 Pressure monitoring oil lubrication 12bars
The pressure switch ”Pressure monitoring oil
lubrication 12 bars” 1F34 is located on the O.S.
of the first printing unit, under the feeder. It is
accessible through the door between the feeder
and first printing unit on the O.S.
Place of installation ”Pressure monitoring

oil lubrication 12 bars”, 1F34
347
Central lubrication 12B47 Lubrication monitoring 1
12B47 Lubrication monitoring 1 and

Layout
The sensor 12 B47 for chain lubrication monitoring
and the sensor 12 B77 for bearing lubrication moni-
toring are of identical design.
LED
Sensor
Locking nut
Receptacle
Plug
Stop pin
Sleeve
Distributor
12B47 Lubrication monitoring 1 and

12B77 lubrication monitoring 2
Connection
Input 47 or 77 at EAK 12:
0 ¢ sensor not damped (LED off)
1 ¢ sensor damped (LED lit)
348
Pin assignment
Marking Colour Function
47 or 77 black signal
+1 brown DC 24 V
–1 blue
Sensor ”Lubrication monitoring”

To fit the sensor screw the receptacle into the
sleeve using a copper disk and tighten it up. In
doing so, align the receptacle in such a way that
the sensor can be screwed in parallel to the
longitudinal axis of the distributor.
Screw the sensor manually into the receptacle until

it contacts the stop pin and secure it with the
locking nut. Then close the threaded hole of the
receptacle from the bottom using the plug.
349
350
Pneumatic system 15Y11 Admission of pressure, pneumatic system
Pneumatic system
15Y11 Admission of pressure, pneumatic system
The solenoid valve ”Admission of pressure,
pneumatic system” 15Y11 is fastened to the side
frame on the O.S. of the feeder and accessible
through the protecting door.
15Y11
Admission of pressure, pneumatic system 15Y11

with plug
Task
When the pressure has been built up ( u5 bars ),
the solenoid valve switches the pneumatic energy
through the piping.
351
Pneumatic system 15Y11 Admission of pressure, pneumatic system
Pin assignment
Plug 15Y11-X1
Pin Function
1 DC 24 V
1 2 Signal 4 mA ... 20 mA
3 3 –
PE –
PE
2
Plug 15Y11-X1
352
Pneumatic system 15B14 Pressure sensor ”Pneumatic system”
15B14 Pressure sensor ”Pneumatic system”
The pressure sensor ”Pneumatic system” 15B14

is located at the side frame on the O.S. of the
feeder where it measures the air pressure in the
pneumatic piping.
15B14
Place of installation of pressure sensor ”Pneumatic

system” 15B14
353
Pneumatic system 15B14 Pressure sensor ”Pneumatic system”
Pin assignment
Plug 15B14-X1
Pin Function
3
1 1 DC 24 V
2 2 Sensor signal 4 mA ... 20 mA
PE 3 –
PE –
Pressure sensor and connector
354
Pneumatic system E4 Pneumatic system compressor
E4 Pneumatic system compressor
Technical data
Technical data, see operating instructions 71.102.9100
Pin assignment
Pin Function

A B C B3 AC 400 / 480 V phase V
1
2
C2 AC 400 / 480 V phase W
3 C4 DC 24 V
4 A5 Pressure switch F45
5 B5 Blow-off valve Y68
PE conductor
Plug E4-X1
355
Pneumatic system E4 Pneumatic system compressor
356
Suction and blast air 1M9 Blast air regulation at the feeder
Suction and blast air
1M9 Blast air regulation at the feeder
Block diagram
The blast air regulation at the feeder adapts the
Displays blast air pressure at the suction head to the press
speed and ensures that the printing material is
MID11 ZID
fanned.
MID12 DNK The blast air pressure is regulated by servo-drive
1M9 which controls a relief valve.
DSK The blast air pressure depends on two factors:
IDS – the thickness of the stock (e.g. paper
calliper);
– the production speed (preset speed).
In the operator program of CPTronic the blast air
EAK ESK SVM regulation can be switched on and off.
”Automatic blast air regulation switched on”
means:
characteristic-curve-dependent blast air regulation.
SSK SAK REK2 The blast air pressure is automatically adapted by
the CPTronic operator program on the basis of the
entered paper thickness and the preset press
1SSM1 speed.
By pressing the right-hand +/– buttons on the
1M9 control console the characteristic curve stored in
the CPTronic control system can be modified
manually.
M
”Automatic blast air regulation switched off”
Blast air regulation means:
manual blast air setting.
Legend: Data lines
The blast air pressure is set independently of the
Control lines paper thickness and preset speed.
It can be modified with the right-hand +/– buttons
Block diagram: blast air regulation at the feeder on the control console.
The blast air regulation at the feeder does not
intervene in the press control.
357
Characteristic-curve-dependent blast air regulation
Selection of the characteristic-curve-dependent

blast air regulation
Function button ”Blast air regulation at the feeder

on / off”
If the background of the symbol is light, the

characteristicĆcurveĆdependent blast air regulation
is switched on.
The characteristic curves are stored in the
CPTronic operator program. The operator program
automatically selects a suitable characteristic curve
dependent on the thickness of the stock and the
press speed.

358
Selection: manual change of characteristic-curve-

dependent blast air regulation
Function button ”Changing the slope”

When you switch over to the actual value display
and the background of the symbol is light, you can
set the slope of the characteristic curves manually
(and thus deviate from the CPTronic-values).
The setting is made at the control console with the
Manual change of the characteristicĆcurveĆdepenĆ

dent blast air regulation
For a 0.05 mm thick paper the setting range for the

p [bar] slope is as follows for SM 102 and CD 102:
1.0 Minimum: 0% (corresponds to the
0%-characteristic curve)
Maximum:100% (corresponds to the
0.9
100%-characteristic curve)
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0 3000 6000 9000 12000 15000
n [sheets / h]
Field of characteristic curves for a printing paper

with a thickness of 0.05 mm (corresponds to a
paper weight of approx. 50 g/m2)
359
Manual blast air setting
Selection: changing the manual blast air setting
Function button ”Manual setting of blast air at

feeder” actuated (ON)
The manual blast air setting is activated automati-

cally when the characteristic-curve-dependent blast
air regulation is switched off. It does not depend on
the paper thickness or preset speed.
In this mode you can enter a percent value which
is displayed on the control console display ZID.
The setting is made at the control console with the

The setting range for SM 102 and CD 102 is as

p [bar] follows:
Minimum: 20% (corresponds to 0.2 bar above
1.0 atmospheric pressure)
Maximum:100% (corresponds to 1.0 bar above
atmospheric pressure)
0.8
0.6
0.4
0.2
20 40 60 80 100
ZID display [%]

360
The blast air regulation is located on the bottom
crossbar of the feeder in direction of the drive side
(D.S.).
O.S.
D.S.
Blast air regulation at the feeder
361
Layout and task

Dependent on the thickness of the printing
material and the production speed, the blast
air regulation at the feeder adapts the blast
air pressure at the suction head and thus
ensures that the printing material is fanned.
The blast air regulation at the feeder consists
of the following components:
Servo-drive 1M9 with dc motor with
brushes, flange-mounted gear unit and
potentiometer for position feedback.
Motor bracket with protecting cover and
threaded spindle inside
Adjustable relief valve
Manometer measuring the pressure
above atmospheric (at feeder frame)
The servo-drive and relief valve are con-
nected with each other by means of a
mechanical coupling.
Servo-drive with adjustable relief valve
Manometers at feeder frame for pressure above

atmospheric and low pressure
362
Technical data
Motor data
U = DC 24 V
P=5W
Potentiometer data
U = DC 10 V
R = 10 k
Pin assignment
Contact Assignment
+ 1 Motor, + (DC 24 V)
1
M –
2
2
3
Motor, – (DC 24 V)
Potentiometer, + (DC 10 V)
+
3
3 4 Potentiometer wiper
4
5 Potentiometer, – (DC 10 V)
4
2
1 5
–
5
Pin assignment: blast air regulation at the feeder
363

disassembly!
1 Inch the press until all blast air ducts at the

rotary valve in the suction head are closed.
2 Turn off the main switch.
3 Loosen the four fixing bolts and remove
the protecting cover .
(4×)
4 Unscrew the connector 1M9–X1 and

(4×) withdraw it from the servo-drive . Loosen
the four fixing bolts and remove the
servo-drive together with the sleeve .
5 Turn on the main switch (blast air is present).
364
6 Turn the threaded spindle manually

until the manometer measuring the
pressure above atmospheric at the feeder
indicates 0.6 bar. Check whether all
blast air ducts at the rotary valve in the
suction head are closed.
7 Turn off the main switch.
8 Connect the connector with the new
servo-drive and tighten up the bolts.
9 Turn on the main switch.
ß Switch off the automatic blast air regulation

(this activates the manual blast air setting).
Note:
Also refer to the section ”Manual blast air
setting”.
q Operate the servo-drive with the

right-hand +/– buttons at no-load until the
value 60% is indicated on the control
console display ZID.
Note:
While doing this, do not place the servo-
drive on the threaded spindle .
365
w Push the servo-drive onto the threaded

spindle so that the pin engages with
two slots of the sleeve .
Note:
Take care that the pin of the threaded spindle is
not turned more than "90° while doing this.
(4×)
e Fasten the servo-drive with the four
fixing bolts .
r Let the servo-drive run over the entire

operating range with the right-hand +/–
buttons (i.e. from 20% to 100%).
Note:
See also the next section ”Checking the
operating range”.
t Put the protecting cover back in place

and fasten it with the four fixing bolts .
(4×)
366
Selecting the service display
Incremental values for the servo-drive

”1M9 Blast air regulation at the feeder”
Operating range for SM 102 and CD 102:
Incremental value ZID display Air pressure
[n] [%] [bar]
768 (min.) 20 0.2
2048 60 0.6
3328 (max.) 100 1.0
Note:
The incremental values may differ from the

displayed percent values / air pressure by up to
"4 increments.
When you have finished checking, switch on the

characteristic-curve-dependent blast air
regulation.
367
368
Other components E4a Varnish supply unit
Other components
E4a Varnish supply unit
Connections
The varnish supply unit receives 3AC 380 V and
AC 230 V from the printing press. Both voltages
pass through plug E4a-X1.
The varnish sensor is located at the coating pan on
the O.S. of the coating unit. It is connected to the
distribution box at the coating unit. From there a
E4a-X21 cable leads to the varnish supply unit, plug
E4a-X21.
The varnish supply unit is remotely controlled with
E4a-X22 a cable. This cable is connected to plug E4a-X22.
E4a-X1 The varnish supply unit is located under the

footboard on the D.S. of the coating unit.
A manufacturer’s manual is available.
Varnish supply unit
Pin assignment
E4a-X1
Pin Function
A1 –
A B C
A2 Phase L1
1
A3 –
2 A4 AC 230 V
3 A5 –
B1 –
4 B2 –
5 B3 Phase L2
B4 –
B5 –
C1 –
C2 Phase L3
C3 –
Plug E4a-X1, coming from the control cabinet C4 –
C5 Zero 230 V
PE conductor
369
Other components E4a Varnish supply unit
E4a-X21
Pin Function
2 3 1 DC 24 V (+1) for fault message

4 2 Fault message
6
1 5 3 Analog sensor signal:
0 ... 5 V
4 Conductive level sensor
Plug E4a-X21, control lines 5 DC 24 V

voltage for
6 Ground sensor
Fault messages
If the sensor ”Level in coating pan” B32 detects
that the level is too low and if the operating
mode ”Varnish circulation” has been selected
for the coating unit, a fault message is
transmitted to the CPTronic control system and
the audible signal devices 11H55 and 12H55
output a warning. It is possible that the fault
message is caused by the height adjustment of
the level controller ( coating pan insert ).
Sensor ”Level in coating pan” and level controller
370
Other components L-B32 Level in coating pan
L-B32 Level in coating pan
The sensor ”Level in coating pan” is located at the
coating pan on the O.S. of the coating unit.
Sensor ”Level in coating pan”
Connection, pin assignment

Plug E4a-X2:
3 Pin Colour Function

2 4
E4a-X2 1 brown DC 24 V (+1) for fault mes-
6 sage
1 5
2 grey Fault message
3 yellow Analog sensor signal:
183 170 171 L-LVT1-X2 0 ...5 V
4 – Conductive level sensor
blk br bl 5 green DC 24 V
voltage for
6 white Ground sensor
L-B32 Sensor
Connection of sensor ”Level in coating pan”
371
Other components L-B32 Level in coating pan
Layout, adjustment
Coating pan
Pan roller
Sensor
Sensor holder
Level controller
Adjusting screws
108 mm
Adjust the sensor so that the distance between
the upper edge of the sensor and the upper edge
of the sensor holder is 108 mm.
The height of the level controller can be regulated
by means of the adjusting screws. This influences
the level in the coating pan. The immersion depth
approx. 10 mm
of the pan roller in the varnish should be approx.
10 mm.
Mounting dimensions of sensor ”Level in coating pan”
372
Other components 12E2 Powder spray unit
12E2 Powder spray unit
Place of installation, layout

Powder spray device
Powder tube
Blower motor with suction filter
The powder spray device is located on the O.S. of

the delivery. The motor is fitted on the O.S. of the
delivery, on the inside of the press. Different types
of powder spray devices can be connected to the
printing press. We distinguish between:
– powder spray devices without serial interface,

– powder spray devices with serial interface.
In the case of powder spray devices with serial

Powder spray device, powder tube and motor at interface, the motor is connected directly to the
delivery control box of the powder spray device.
Powder spray device with serial interface

Pin assignment 12E2-X1
Pin Function
A2 L2
B3 L1
C2 L3

A4 AC 230 V

C5 Zero 230 V

PE

Plug 12E2-X1, coming from the press
373
Powder spray device without serial interface

Pin assignment 12E2-X2
The plug 12E2-X2 is at the distribution box of

the delivery.
Instead of the mechanical switch 12S68 a
proximity switch can be fitted in the feeder (e.g.
Betatronic powder sprayers). This switch is then
connected directly to the powder spray device

and is not led via the distribution box or plug
12E2-X2.

Pin Function

A1 Switch ”Powder on” 12S68,
switch contact 2 (not with
proximity switch)
A2 DC 24 V for test button
A3 AC 230 V
Plug 12E2X2, coming from the press, distribution
A4 Switch ”Powder on” 12S68,
box at delivery
switch contact 1 (not with
proximity switch)
A5 Impression on ( AC 230 V)
B1 Test ( DC 24 V)
B2 Zero 230 V
B3 PE conductor
B4 Press turns ( AC 230 V)
B5 –
C1 – C5 –
PE
Pin assignment of proximity switch 12S68
Pin Function
3 1 Ground
4 2 2 DC 24 V
3 Signal
5 1 4 Ground
5 –
Plug of proximity switch
374
Correcting the beginning of powdering

Settings
The following settings are only required for

powder spray devices with serial interface.
Control panel at last printing unit / coating unit
Selector switch ”Safe” 1 Set the selector switch ”Safe” to ”Safe”.
Pushbutton ”Forward”/ 2 Inch the press until the front edge of the
”Backward” sheet is below the spray nozzles of the
powder tube.
Sheet of
paper
Required position of
front edge of sheet
Positioning the sheet of paper
Control panel at delivery
Press display MID
3 Read off the degree value indicated on the

press display MID.
Display of degree value
Indication on the MID while press is in inching mode
375
Service display ”Delivery”
Variable degree
can be changed by entering another
degree value.
Standard degree
– cannot be changed
– depends on the press model.
Service display ”Delivery”
Entering the degree value 5 With the right-hand " buttons the degree
value read off at the press display MID under
3 can be entered. When the function button is
pressed, the variable degree jumps back to
the standard degree value .

SM102 + extended + coating unit + coating unit

( CD102) High-pile delivery high-pile delivery + high-pile delivery + extended high-pile delivery
2 PUs 132° 101 ) 225° 102 83° 176 84° 177

4 PUs 166° 250 259° 251 118° 326 119° 326
5 PUs 3° 325 97° 326 315° 39 316° 40
6 PUs 201° 39 294° 40 152° 114 153° 115
7 PUs 38° 114 131° 115 349° 189 350° 189
8 PUs 235° 189 328° 189 188° 263 188° 264 )
+ 74.6° 74.6 + 74.6° 74.6

for every further for every further
coating unit coating unit
Degree values for the beginning of powdering SM102 (CD102)
376
Other components 12M35 Blower motor for powder spray device
12M35 Blower motor for powder spray device
Place of installation, filter change

The motor is located at the delivery. It is mounted
on the baseplate on the inside of the side frame, on
the O.S.
To change the suction filter, open the hinged cover
above the footboard.
12E2-X1
Blower motor for powder spray device at delivery
Layout
Suction filter
Air hose leading to powder spray device
Plug connection M35-X1
Baseplate
Casing cover with rotor vanes underneath
Compressed-air cooler
Hood for motor fan
Pressure relief valve
Compressor motor M35
377
Other components 12M35 Blower motor for powder spray device
Changing the rotor vanes

Remove the casing cover of the compressor motor
M35.
Note:
When you loosen the lower fixing bolts of the
casing cover, the compressed-air cooler becomes
loose as well. Hold it tight.
The rotor vanes are accessible. If they are shorter

than 27 mm (min. permissible length), they must
be replaced.
27mm
min.
Rotor vanes in motor 12M35
378
Other components 12S68 Switch ”Powdering cycle”
12S68 Switch ”Powdering cycle”
The switch ”Powdering cycle” 12S68 is located
on the D.S. of the delivery. In the case of
Betatronic from Grafix, Weko T 77Cs and Weko
Ionomat Cs, the switch is connected directly to
the powder spray device. With all other powder
spray devices the switch is connected to the
distribution box at the delivery.
Place of installation of switch ”Powdering cycle”,

12S68
379
Other components 12S9, -a, -b, -c Monitoring
the IR slide-in dryer
12S9, -a, -b, -c Monitoring the IR slide-in dryer
Each IR slide-in dryer is equipped with a safety
switch with NC and NO contacts. When the IR dryer
is inserted, the switching element provided on the
slide-in dryer actuates the safety switch on the drive
side.
Printing presses with several IR slide-in dryers
(extended delivery) have 4 switches (12S9, 12S9a,
12S9b, 12S9c). The NC contacts of the safety
switches are connected in series and the NO
contacts in parallel.
ÂÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂÂ
Place of installation of safety switch ”Monitoring
the IR slide-in dryer”
Layout and connection
Sensor
Openings for switching element
Switching element (fitted on slide-in dryer)
Marking Function
21-22 NC contact
13-14 NO contact
NC contact ( s ) at input 9 of EAK12:

0¢ IR dryer(s) inserted
1¢ IR dryer(s) removed
NO contact ( s ) at input 9 of SEK:

Sensor ”Monitoring the IR slide-in dryer” 1¢ IR dryer(s) inserted
0¢ IR dryer(s) removed
380
Other components E8 Air supply cabinet
E8 Air supply cabinet
Connections
The air supply cabinet receives 2 AC 380 V and the
control signal ”Compressor on” from the printing
press.
A thermostat in the control cabinet signals
excessive temperatures to the CP Tronic control
system.
All cables are connected directly to terminal strips
and are not led via plugs. For the exact terminal
connections please refer to the circuit diagram and
technical instructions of the manufacturer.
Cable entries
Air supply cabinet, rear view
381
Other components E39 Inking unit temperature control
E39 Inking unit temperature control
Layout
The supply voltage for the inking unit temperature
control comes from the control cabinet and is
connected via plug E39-X1. A manufacturer’s
manual is available.
Pin Function
3 AC 230 V, phase U
6 1
7 AC 230 V, phase V
7 2
8 3 9 AC 230 V, phase W
9 4 PE
10 5
382
Other components 12E3 Static electricity eliminator
12E3 Static electricity eliminator
Attention:

Cut off the power supply before working on the
device!
Place of installation of static electricity eliminator
Power supply for static electricity eliminator

(D.S.)
Neutralizer bar
Ion blowers
Air-supported neutralizer bar
The static electricity eliminator consists of a power

supply unit with high-voltage transformer, a
neutralizer bar at the feeder and an air-supported
neutralizer bar at the delivery. Two ion blowers can
be additionally attached to the suction head
(optional).
Note:
The static electricity eliminator is optional and
therefore not fitted on all presses.
For subsequent installation, threads are provided in
the side frame as standard.
383
Layout
Mains switch
Pilot lamp
Power supply unit
Power cable AC 230 V
Ion blowers at feeder
Neutralizer bar at delivery
Note:
2 different versions are available. Differences in
the housing design do not affect the functions.
Static electricity eliminator 12E3 (ELTEX)
Static electricity eliminator, version 2 (SIMCO)
384
Task
The unit consisting of the power supply with
high-voltage transformer plus connected
neutralizer bars and ion blowers eliminates static
charges on the sheets of paper.
385
Other components WSA Intercom
WSA Intercom
Layout
Loudspeaker
Microphone
Volume controller
Illuminated pushbutton
The WSA consists of one intercom at the control

panel at the feeder and one at the control panel at
the delivery. Each intercom has a microphone,
loudspeaker, illuminated pushbutton, volume
controller and two electronic boards (main and
secondary boards). The electronic boards are
directly in the intercom.
Intercom at feeder
Intercom at delivery
386
Other components WSA Intercom
Function
Secondary board with terminal strip
11WSA-X2/ 12WSA-X2
Main board
Connection for volume controller
Connection for microphone
Connection for secondary board 11WSA-
X1/ 12WSA-X1
Connection for illuminated pushbutton
Changeover switch main/secondary intercom
The intercom is set in such a way that the main

intercom (H) is at the delivery and the secondary
intercom (N) at the feeder.
When the illuminated pushbutton is pressed at the
delivery, speaking at the feeder is interrupted.
The priority between the two intercoms can be
reversed any time by means of the changeover
switch on the main board. The setting of the switch
must then be changed at both intercoms.
Electronic boards of intercom
387
Other components IDS Encoder
IDS Encoder
Encoder IDS
Place of installation of encoder in 1st PU
Task
The encoder is the basis for all speed- and
degree-dependent functions.
Examples of speed- and degree-dependent
functions:
– motor regulation,
– interrogation points of sensors,
– positioning for plate change.
388
Function
The encoder generates three pulse signals:
5V
Track A – track A,
0V
– track B,
5V – track 0.
Track B
0V Track B is staggered by 90° in relation to track A.
5V Per revolution track 0 generates one zero pulse.
Track 0 The inverted signals are also available from all 3
0V tracks.
Pulse signals from the encoder Tracks A and B each generate 1024 pulses per
revolution.
Pin assignment
Pin Function
M, G, H DC+5V
G E
F
A, L, D 5V
H
M
D C Track A/
J B Track A
L
C F Track B/
A
K
B E Track B
K Track 0/
J Track 0
Encoder plug
389
Installation variants
For presses with more than five printing units and
sheet turning device a second encoder IDS is
used. This IDS is used for closed-loop control of
the main drive. The mechanical installation and
removal of both IDS is identical (steps 1, 2, 3
and 6, 7, 8).
For the installation of the 2nd IDS (main drive
regulation) the zero point adjustment is not
required.
CD 102 Straight-printing presses

On CD102 presses the IDS is always fitted in
the 1st printing unit.
SM102 Straight-printing presses SM102 Perfector presses

IDS 1 IDS 2 IDS 1 IDS 2
SM102–2 Printing unit 1 – SM102–2 Printing unit 1 –
SM102–2+L Printing unit 1 – SM102–2+L Printing unit 1 –
SM102–3+L Printing unit 1 – SM102–3+L Printing unit 1 –
SM102–4+L Printing unit 1 – SM102–5 Printing unit 1 –
SM102–5 Printing unit 1 – SM102–5+L Printing unit 1 Printing unit 4/5
SM102–5+L Printing unit 4 – SM102–6 Printing unit 1 Printing unit 4/5
SM102–6+L Printing unit 4 – SM102–7 Printing unit 1 Printing unit 4/5
SM102–7+L Printing unit 4 – SM102–8 Printing unit 1 Printing unit 4/5/6
SM102–8 Printing unit 4 – SM102–8 P5 Printing unit 4 –
SM102–8+L Printing unit 4 – SM102–8+L Printing unit 1 Printing unit 4/5
SM102–8+L P5 Printing unit 4 –
SM102–8+L Printing unit 5 –

1 Remove the plug.
2
2 Loosen the stud.
3 Remove the encoder.
ÁÁÁÁ 3
ÁÁÁÁ
ÁÁ 1
Encoder IDS
ÁÁ
390
4 Insert the gauge in printing unit 1.
Inserting the gauge
5 Line mark ”D”
Positioning to zero
5 Use the crank handle to turn the impression

cylinder to the zero position (line mark ”D”).
6 Fit the new encoder.

8 0 1 7 Connect the encoder.
8 Turn on the main switch 15Q66.
6
15Q66
ÁÁ
ÁÁ 7
ÁÁ
Fitting the new encoder IDS
ÁÁ
391
ß 9 Turn the shaft of the encoder until 000.0 is

displayed in the MID.
ß Tighten the stud.
Note:
If the value 000.0 is not displayed in the MID,
continue with step q.
Á If the setting is correct, continue with r.
Á 9
Adjustment of the encoder IDS
q Loosen the locking nut.
ÁÁÁÁÁÁÁÁ w
ÁÁÁÁÁÁÁÁ
Turn the adjusting screw until 000.0 is
ÁÁÁÁÁÁÁÁ
displayed in the MID.
ÁÁÁÁÁÁÁÁ e Tighten the locking nut.
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
Á e
w
Á q
Precision adjustment of the encoder IDS
r Remove the gauge from PU 1.
Removing the gauge
392
Location diagrams ZSG Central control cabinet
Location diagrams
ZSG Central control cabinet
Location and layout
Equipment zone E
”Swing frame”
Equipment zone A Equipment zone D

”Power supply” ”Flat cable mounting plate”
Equipment zone B Equipment zone C

”Partition wall” ”Mounting rack / control devices”
Layout of central control cabinet
393
Equipment zone A ”Power supply”

This equipment zone contains the components
necessary for connection to the power supply. The
chapter ”Control systems” describes how the press
is connected to the power mains.
15M1 Fan ”Power components”

15L1 Power choke - power converter
15R120 Load resistor
(only for presses with Preset)
15R48 Load resistor
(only for presses with auxiliary pile
at the delivery)
15F2 Semiconductor fuses
”Armature circuit M1”
15Q66 Main switch
15Z2 EMC filter
15F1 Semiconductor fuses ”Mains”
15X1 Terminal strip
PE PE conductor

15Z1 EMC filter
15T1 Control transformer
Equipment zone ”Power supply”
394
Equipment zone B ”Partition wall”

SLT Converter power part
GRM5 Rectifier module
GRM120-2 Rectifier module
SLT
15Q61 Flat switch
”Transformer protection, secondary”
15Q62 Flat switch
”Transformer protection, secondary”
15Q37 Circuit-breaker
”Feeder / delivery main pile”
(not for Preset version)
15Q38 Circuit-breaker
GRM5 GRM24 GRM48 GRM120-2
”Feeder auxiliary pile”
15K37M Contactor ”Pile control”
STK1 (without Preset) /
LSR (with Preset)”
15K38M Contactor
”Pile control”
STK1 (with Preset) /
STK2 (without Preset)”
15K48A Contactor ”Power supply
15Q61 15Q37 15K37M 15K48A 15Q65
connecting part of power converter”
15Q2 Motor circuit-breaker
”Air supply cabinet E 8”
15Q65 Motor circuit-breaker
15Q62 15Q38 15K38M 15Q2
”Transformer protection, primary”
Equipment zone ”Partition wall”
SLT Converter power part

The converter power part SLT contains the power
electronics for driving the main drive. The chapter
”Control systems”, subchapter ”Direct-current main
drive” lists the components of the converter power
part.
SLT
Converter power part
395
GRM Rectifier modules

The equipment zone B ”Partition wall” contains four
rectifier modules.

F6
F8 F3
GRM120-2 Rectifier module
F5 F4
F7
The rectifier modules GRM24 and GRM48 are of
identical design and interchangeable.
Fuses:
Rectifier modules GRM F6, F7, F8 (GRM5) – 15 A, quick-acting,
6.3 x 32 mm
F5, F4 (GRM24 / GRM48) – 20 A, quick-acting,
6.3 x 32 mm
ca. AC 24 V 3 x ca. AC 35 V F3 (GRM120) – 32 A, slow-blowing
3 x ca. AC 26 V 3 x ca. AC 100 V
ca. DC 36 V ca. DC 120 V
ca. DC 33 V ca. DC 50 V
Voltages at the rectifier modules GRM
396
Equipment zone C ”Mounting rack / control devices”
Q.... Motor circuit-breakers

Q2a Q4 Q4a Q22 Q24 Q28 Q33 Q33a Q35 Q39
K....M Main contactors

22M K22M K33M K33aM K35M K39M
Earth-leakage monitor
Q39 Q39a Q40 Q44 Q22a Q80
IWM module
K39M K40M K22aM
K39M K39aM K46A K61A K50M K51M K52M K53M K54M K55M K56M K43M
Terminal amplifier module
Flat-cable output module
64 outputs
Flat-cable input module
KVM FAM 64 FEM 64
64 inputs
BAM BKM SPM VSM SVM SVM ESM FEM10 AUM
Optocoupler 15U2
15X4
Terminal strips
15X3
Analog conversion module
Flat-cable input module 10 inputs
Interference suppressor module
Interface distributor module
Amplifier module
Memory analog board module
Brake coupling module
Brake control module
Equipment zone ”Mounting rack / control devices”
397
Equipment zone D ”Flat cable mounting plate”

The rectifier reduces the voltage from the
15V1 power supply board NTK 24 (in the REE) to
the supply voltage (22 V) for the signal lamps.
Leading to the swing frame:

backplane of input/output plug-in unit EAR /
I/O 1 input/output auxiliary drive plug-in unit EHR
I/O 2 From each press unit, input and output cables

lead to the swing frame. The input/output
cables are fastened on the flat cable mounting
I/O 3
plate. Cable routing as shown in the sketch
opposite.
I/O 4
Fixing clips
13,15 5, 6 3, 4 1, 2 11,12
Flat cables from the press units
Equipment zone ”Flat cable mounting plate”
398
Equipment zone E Swing frame”

Equipment of swing frame for presses with:
ÍÍÍÍ – 2 - 5 PUs, without Preset
ÍÍÍÍ
REE2 REE2 Computer plug-in unit 2
ÍÍÍÍ EHE2 Input/output
ÍÍÍÍ
EHE2 auxiliary drive plug-in unit 2
ÍÍÍÍ LTE Power part plug-in unit
ÍÍÍÍ SSE2 Servo-drive plug-in unit 2
ÍÍÍÍ
ÍÍÍÍ
LTE – 2 - 5 PUs, with Preset
ÍÍÍÍ
REE2 Computer plug-in unit 2
ÍÍÍÍ
EHE2 Input/output
auxiliary drive plug-in unit 2
LTE Power part plug-in unit
Swing frame for presses with 2- 5 PUs SSE2/LSE Servo-drive plug-in
unit 2/ power part plug-in unit for
brushless pile motors
Note:
The electronic boards must be in their respective
board slots. They must be correctly connected to
the connectors of the backplane. In front of each
plug-in unit the safety crossbar must be fitted.
399
ÍÍÍÍ – 6 - 7 PUs, without Preset
ÍÍÍÍ
ÍÍÍÍ
REE2 REE2 Computer plug-in unit 2
ÍÍÍÍ
EAE Input/output plug-in unit
EAE
ÍÍÍÍ
HAE2 Auxiliary drive plug-in unit 2
ÍÍÍÍHAE2 LTE Power part plug-in unit
ÍÍÍÍ SSE2 Servo-drive plug-in unit 2
ÍÍÍÍ
LTE
– 6 - 7 PUs, with Preset,
ÍÍÍÍ – 8 PUs, with Preset, without non-stop
ÍÍÍÍ
delivery
ÍÍÍÍ REE2
EAE
Computer plug-in unit 2
Input/output plug-in unit
Swing frame for presses with 6- 8 PUs HAE2 Auxiliary drive plug-in unit 2
SSE2/LSE Servo-drive plug-in
unit 2 / power part plug-in unit for
brushless pile motors
– 8 PUs, with Preset, with auxiliary pile at
the delivery
HAE2 Auxiliary drive plug-in unit 2
SSE2/LSE2 Servo-drive plug-in
brushless pile motors 2
Note:
400
ÍÍÍÍ – 9 PUs, with Preset, without non-stop
ÍÍÍÍ delivery
ÍÍÍÍ
REE2
ÍÍÍÍEAE
ÍÍÍÍ
ÍÍÍÍ
EHE2 Input/output
EHE2 auxiliary drive plug-in unit 2
ÍÍÍÍ
ÍÍÍÍ
LTE

ÍÍÍÍ
SSE2/LSE Servo-drive plug-in unit 2/
ÍÍÍÍ
power part plug-in unit for brushless
pile motors
ÍÍÍÍ – 9 PUs, with Preset, with auxiliary pile at

the delivery
Swing frame for presses with ≥ 9 PUs REE2 Computer plug-in unit 2
EHE2 Input/output
auxiliary drive plug-in unit 2
unit 2/ power part plug-in unit for
Note:
401
Computer plug-in unit REE 2
NTK24 Power supply board

REK386 Processor board 386
ESK_2 Input/ output control board
SAK2 Memory analog board
REK1 Processor board
Computer plug-in unit REE
SRK Power converter board
Note:
All electronic boards of the same type in the swing
frame are identical in design (e.g. power supply
boards NTK , input / output control boards ESK 2).
Boards of the same type are interchangeable.

The input/ output control board ESK_2 is required
for presses with ≥ 9 printing units.
REK386 Processor board 386

EPROM Computer The processor board 386 REK 386 consists of the
module motherboard computer motherboard RGP 3, the EPROM module
EPM and the RGPĆcomputer module RRM.
RGPĆcomputer
module
Layout of computer unit RGP3+RRM
REK1 Processor board

EPROM The processor board REK 1 consists of the computer
module motherboard RGP 2 and the EPROM module EPM.
Computer
motherboard
Layout of processor board REK1
402
Input/output auxiliary drive plug-in unit EHE 2
The input/output auxiliary drive plug-in unit EHE 2

is required for presses with:
– 2 - 5 printing units,
– ≥ 9 printing units.

HAK2 Auxiliary drive board
Input/output auxiliary drive plug-in unit for EAK2 Input/output board
presses with 2- 5 printing units from right to left for:
– feeder,
– delivery,
– central control cabinet,
– printing units 1 to 5.
EAK2 Input/output board for printing unit 9
Note:
boards NTK , auxiliary drive boards HAK 2,
Input/output auxiliary drive plug-in unit for input/ output boards EAK 2). Boards of the same
presses with ≥ 9 printing units type are interchangeable.
Input/output plug-in unit EAE
The input/output plug-in unit EAE is required for

presses with:
– ≥ 6 printing units.

.
EAK2 Input/output board
from right to left for:
– feeder,
Input/output plug-in unit for
– delivery,
presses with ≥ 6 printing units
– central control cabinet,
– printing units 1 to 8.
Note:
boards NTK , input / output boards EAK 2). Boards
of the same type are interchangeable.
403
Auxiliary drive plug-in unit HAE 2
The auxiliary drive plug-in unit HAE 2 is required for

presses with:
– 6 - 8 printing units.

HAK2 Auxiliary drive board
Note:
Auxiliary drive plug-in unit for presses with 6- 8 frame are identical in design (e.g. power supply
printing units boards NTK , auxiliary drive boards HAK 2). Boards
404
Power part plug-in unit LTE
The power part plug-in unit LTE is required for all
ÍÍ Í ÍÍ Í presses.
ÍÍ
ÅÅ ÍÅ ÍÍ
Å ÍÅ LTK500 Power part board
ÅÅ Å Å Å
LTK50 Power part board
STK_2 Pile control board
Power part plug-in unit for presses with ≤ 7 printing
units, without Preset, with auxiliary pile at feeder Note:
and delivery All electronic boards of the same type in the swing
frame are identical in design (e.g. power part
boards LTK50, power part boards LTK500). Boards
ÍÍ Í ÍÍ Í ÍÍ
ÍÍ
Å ÍÅ ÍÍ
Å ÍÅ ÍÍ
Å
Å Å Å Å Å
The power part board LTK50 is only used for
presses with:
– 2 - 7 printing units, with Preset, with auxiliary
pile at the delivery,
– ≤ 7 printing units, without Preset, with auxiliary
Power part plug-in unit for presses with 8- 9 print-
pile at the delivery
ing units, with Preset, with auxiliary pile at the
feeder
ÍÍ Í ÍÍ Í ÍÍ The pile control board STK_1 is used for all
ÍÍ
Å ÍÅ ÍÍ
Å ÍÅ ÍÍ
Å
presses except for those with:
– 8 - 9 printing units, with Preset, without
Å Å Å Å Å
auxiliary pile at the feeder.

The pile control board STK_2 is only used for
Power part plug-in unit for presses with 8- 9 print- presses:
ing units, with Preset, without auxiliary pile at the – without Preset, with auxiliary pile at the feeder.
feeder
405
Servo-drive plug-in unit SSE2
The servo-drive plug-in unit SSE2 is required for

presses with:
– 2 - 4 PUs, without Preset (only one SSK 2),
– 2 PUs, without Preset, without CPC,
– 5 - 7 PUs, without Preset,
Servo-drive plug-in unit for a press with 2- 7 PUs, NTK24 Power supply board
without Preset SSK2 Servo-drive control board
Note:
boards NTK , servo-drive control boards SSK 2).
Servo-drive plug-in unit 2 /

power part plug-in unit for brushless pile
motors SSE 2/ LSE
Í
The servo-drive plug-in unit / power part plug-in unit
Í
for brushless pile motors SSE 2/ LSE is required for
presses with:
Å
Å
– 2 - 5 PUs, with Preset (only one NTK 24 and
two SSK 2s),
– 2 PUs, with Preset, without CPC,
– 6 - 7 PUs, with Preset,
Servo-drive plug-in unit/power part plug-in unit for – 8 - 9 PUs, with Preset, without non-stop
brushless pile motors for presses with 6- 7 PUs, delivery
with Preset

SSK2 Servo-drive control board
Note:
406
Servo-drive plug-in unit 2 /

power part plug-in unit for brushless pile
motors SSE 2/ LSE
Í The servo-drive plug-in unit / power part plug-in unit
Í
for brushless pile motors SSE 2 / LSE2 is required
Å
for presses with:
Å
– 8 - 9 PUs, with Preset, with auxiliary pile at the
delivery

Servo-drive plug-in unit/power part plug-in unit for SSK2 Servo-drive control board
brushless pile motors 2 for presses with 8 - 9 PUs,
with Preset, with auxiliary pile at the delivery LTK50 Power part board
Note:
407
Location diagrams ZSP Central control console
ZSP Central control console
Layout
Fixing bolts for console plate
Console plate
Display control board DSK
Input / output module EAM
Display unit consisting of:

– display power supply board DNK
– display support plate
– control console display ZID
Support plate for:
A – transformer 13T1
B – connector 13X1
C – terminal strip 13X2
Hinged cover with opening for cables
Casing of central control console
Door
Overall view
408
Location diagrams Position switches
Position switches
2S29 1S29
2S28 1S28 11S37 11S34 11S31

11S65
11S56
2S25 2S26 1S25 1S26 11S40
2S25a 1S25a 11S32
2S25b 1S25b 11S38
2S24 1S24 11S38a
1S40a 11S4
2S20 2S37 11S38b
1S40
11S36
2S31
11S39
Preset feeder, printing units 1 and 2
12S55 12S55a
12S40 3...9S28
12S44
12S38 12S56 12S39 12S37 3...9S29
12S33
12S35 12S36 3...9S24
12S422) 12S130a 12S34 12S9
12S421) 12S130 12S65a
3...9S20
12S41 3...9S37
12S117
12B129a
12B129 12S34b 12S43
12S34a
1 Version with rake

2 Version with board
Delivery with coating unit
Legend:
Equipment O.S.
Equipment D.S.
Equipment which can be allocated neither to
the D.S. nor to the O.S.
409
Location diagrams Position switches
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12S55 12S55a
12S44 12S40 3...9S28
12S68 12S37
12S56 3...9S29
12S35 12S36
12S34 12S37a 3...9S24
12S42 12S39 12S9
12S65a 3...9S20
12S411)
12S65 12S34b 3...9S37
12S412) 12S34a 12S43
12S9c 12S9b 12S9a
1 Version with rake
2 Version with board
Extended delivery with coating unit
Legend:
Equipment O.S.
Equipment D.S.
410
Location diagrams Solenoid valves
Solenoid valves
2Y56 1Y56
11Y74 11Y66
1Y45
15Y11 11Y16
1Y15
11Y15
2Y12 1Y12
1Y16
2Y48 1Y48
back
2Y2 1Y2 1Y50
2Y63 1Y44
2Y9 1Y9 1Y63 1Y52
2Y62 1Y54
2Y10 1Y10 1Y62 1Y55
2Y11 2Y61 1Y11 1Y61 1Y43
1Y42
2Y13 2Y7 1Y13 1Y7 front
2Y53 2Y51 1Y53 1Y51
2Y39/2Y40 1Y47 1Y39/1Y40 or
back
1Y52
1Y55
1Y42
1Y54
1Y43
front
Legend:
Equipment O.S.
Equipment D.S.
411
Location diagrams Solenoid valves
12Y14/
12Y15
12Y11
12Y60/ 12Y49
12Y61
12Y13
12Y4
3...9Y12
12Y78 4...9Y67
3...9Y48
12Y62
12Y14/
12Y15
12Y11
12Y60/
12Y49
12Y61
12Y13
3...9Y12
12Y4
4...9Y67
3...9Y48
12Y78
12Y62
Legend:
Equipment O.S.
Equipment D.S.
412
Location diagrams Motors
Motors
2MD 1MD
11M11
11M12
2M45 1M45 11M2 11M1
Lateral register Lateral register
11M6
2M1 1M1
2M6 1M6 1M4 11M7
1M8 11M5
2M5 1M5
Circumferen- Circumferen-
1M7
tial register tial register
11M3
M52 M51 1M2
1M4 1M3
11M9
11M8
1M9
12M2
12M5 12M1 3...9M2
12M7 12M6
12M3
12M47 M44
Legend:
Equipment O.S.
Equipment D.S.
413
Location diagrams Motors
12M2
3...9M2
12M5 12M1
12M7 12M6
12M3
12M47 M44
Legend:
Equipment O.S.
Equipment D.S.
414
Location diagrams Sensors
Sensors
2B43 2B32 1B43 1B32
15B14 11B10
11B35
1B11 11B55
1B13 1B9
2B48 1B48
2B48a 1B48a 1B10 11B33
HWI
1B49 11B11
3...9B32
12B129
12B69
12B129a 12B65
12B77 12B47
Legend:
Equipment O.S.
Equipment D.S.
415
Location diagrams Sensors
3...9B32
12B129
12B69
12B129a 12B65
12B77 12B47
Legend:
Equipment O.S.
Equipment D.S.
416
Location diagrams Control panels
Control panels
F F
C C
D D
A B
H
C F
G
417
H
C
F
G
418
Feeder
A Press control
B Pile control
Preset feeder
419
Printing unit/coating unit
C Printing unit control O.S. D Printing unit/

coating unit control D.S.
F Dampening system control G Coating unit control D.S.
Printing unit/coating unit
420
Delivery
H Press control
H Pile control
H Press display MID
Preset version
421
H Dampening system control
H Fan and dryer control
Preset version
422
Location diagrams Operator’s controls
Operator’s controls
Description Feeder Printing/coating Delivery Remark

unit
Pushbutton ”Run” 11S2 12S2
Pushbutton ”Stop” 11S30 12S8
Pushbutton ”Production run” 11S19 12S60
”Emergency stop” button 11S1 1...nS1 (O.S.) 12S1

1...nS2 (D.S.)
Illuminated pushbutton 11S3 11S58

”Compressor on/off” 11H3 11H58

”Feeder on/off” 11H7 12H59

”Paper run on/off” 11H5 12H57
Pushbutton ”Fast” 11S20 12S6
Pushbutton ”Slow” 11S21 12S7
Pushbutton ”Forward” 11S17 1...nS3 (O.S.) 12S3

1...nS6 (D.S.)
Selector switch ”Safe” 11S18 1...nS4 (O.S.) 12S4

1...nS7 (D.S.)
Pushbutton ”Backward” 1...nS5 (O.S.) 12S5

1...nS8 (D.S.)
Signal lamp 11H51 12H9

”Malfunction press”
Signal lamp 11H1 1...nH1 12H1

”Malfunction feeder”
”Malfunction delivery”
”Malfunction printing/coating unit”
”Malfunction dryer”
423

unit
Illuminated pushbutton 12S63

”Job counter on/off” 12H63
Pushbutton 1...nS23
”Crawl speed”
Pushbutton ”Position” 1...nS17
Illuminated pushbutton 1...nS59

”Plate mounting” 1...nH59
Pushbutton ”Auxiliary pile down” 11S29 12S54
Pushbutton ”Auxiliary pile up” 11S28 12S53
Toggle switch 11S27

”Auxiliary pile on/off”
Pushbutton ”Main pile down” 11S25 12S46
Pushbutton ”Main pile up” 11S24 12S45
Pushbutton ”Pile stop” 11S26 12S124
Pushbutton 12S10
”Pile board on/off” 12H10
Pushbutton ”Removal of 12S11

inspection sheet” 12S11a
Press display MID

”Inking form rollers on/off” 1...nS57
424

unit

”Ink ductor on/off” 1...nH58
Pushbutton 1...nS22 12S17...

”+ dampening” 12S24
„Washing dampening/varnishing
rollers”
Illuminated pushbutton 12S25...
”– dampening” 12S32
Selector switch 1...nS21

”Adjusting dampening rollers”
Pushbuttons 11S117
”Blast air regulation” 11S118
Pushbuttons 11S44
”Suction head height” 11S44a
11S45
11S45a
Pushbuttons 11S46
”Suction head format” 11S47
Pushbuttons 11S58
”Main pile centering” 11S58a
11S59
11S59a
Pushbuttons 11S59
”Auxiliary pile centering” 11S60
Pushbutton 11S63
”Pile stops – larger format”
Pushbutton 11S62
”Pile stops – smaller format”
Pushbutton ”Pile stops D.S.” 11S9
Pushbutton ”Pile stops O.S.” 11S10
Pushbuttons 11S48
”Format wheels” 11S57
Pushbuttons 12S68
”Sheet slowdown format” 12S69
425

unit
Pushbuttons 12S61
”Sheet slowdown speed” 12S62
Pushbuttons 12S73
”Sheet jogger D.S.” 12S74
Pushbuttons 12S75
”Sheet jogger O.S.” 12S76
Potentiometer to DSM5
regulate the displayed fans
Pushbutton ”Dryer on/off”
Selector switch for dryer
Potentiometer to
regulate dryer output
Volume controller
Illuminated pushbutton
”Intercom”
Pushbutton 11S8
”Lifting the sheet stop fingers”
426

unit
Illuminated pushbutton 11S6

”Dampening rollers” 11H6
Pushbutton ”Suction air for suction 11S41

tape +”
Pushbutton ”Suction air for suction 11S42

tape –”
Illuminated pushbutton ”Turning 1...nS45

the ink fountain roller”
Varnish circulation
Varnish pump ON/OFF
Turning the pan roller
Draining the coating pan
Varnish flow rate to varnish pump
Spraying
Rinsing
Stopping the pan roller 2...nS57

2...nH57
Potentiometer ”Blast air at front 11R1

lays”
427
428
Location diagrams ZSP Control panel of control console
ZSP Control panel of control console
7 8 9
4 5 6
1 2 3
0
CPC
Control panel of central control console ZSP
Selector buttons ”Unit” (from left to right): ”Emergency stop” button

–
–
Entire press
Delivery
Button ”Stop”
– Printing unit Command buttons (from left to right):
– Feeder – Presetting
– Job change
Preselection display
– Progressives (colour separations)
Actual value display – Washup
Fine display of preselection/actual value
Command control buttons
display
Signal lamps (from left to right):
Fault display: – Malfunction press (red)
– Press not ready to run – Malfunction control console (blue)
– Warning – Malfunction production run (yellow)
Service display: Button ”Page up/down” in the display
–
–
Central lubrication
Service 1
Control console display
– Service 2 Numeric keypad
Colour buttons CPC keys
(for presses without CPC equipment)
Function buttons
Adjustment buttons
429
Location diagrams ZSP Control panel of control console
430
Abbreviations
Abbreviations
Abbreviation Description Abbreviation Description
AEM Drive extension module EAE Input/output plug-in unit

ANZ Display board EAK Input/output board
ATV Display and key distribution EAM Input/output module
board
EAR Backplane of input/output
ASE Job memory card unit plug-in unit
AUM Analog signal distribution EE Electronic plug-in unit
module
EEM Single-fault fail-safe
AVM Control and distributor module extension module
EGK External equipment board
BAK Brake control board EHE Auxiliary drive input/output

plug-in unit
BAM Brake control module
EHR Backplane of auxiliary drive
BEK Control unit board input/output plug-in unit
BFM Filter module of brushless ELK Mains discharge board
power part
ELR Backplane of electronic plug-in
BKM Brake/ clutch module unit
BLT Brushless power part EPM EPROM module
BSM Control unit interface module ESG Extension control cabinet
BVM Control unit distributor module ESK Input/output control board
ESM Interference suppressor
module
CSM CPC3 interface module
EVG Electronic ballast
CVK CPC3 distributor board
EVK Front-corner alignment control
EVM Input/output distributor module
DAM Double-sheet indication
EWK Extension board
module
DAK Digital output board EWM Extension module
DAS Speed ratio display system EXK External equipment supply

board
DBE Double-sheet detector
DGP Display motherboard
FAM Flat-cable output module
DLW Diskette drive
FCA Adaptor between telediagnosis
DNK Display power supply board board and CPC2S
DSK Display control board FCK Flash memory controller board
DSM Speed control module ”Fans” FDK Telediagnosis board
431
Abbreviations
FEM Flat-cable input module LDM Air pressure sensor module

FKK Ink fountain board LG Light pen
FKV Ink fountain distributor LLM Power logic module
FÜK Sensor for overshooting-sheet LPM Varnish pump control module
control
LRM Power part control module
FVM Flat-cable connection module
LS Light barrier
FZA Ink zone display board
LSE Power part plug-in unit for
FZT Distribution board for ink zone brushless pile motors
keys
LSM Lamp control module
LSR Backplane of power part plug-
GKM Compact rectifier module in unit for brushless pile motors
GRM Rectifier module LTE Power part plug-in unit
GSM Rectifier module with fuses LTK Power part board

LTM Power part module
LTR Backplane of power part plug-
HAE Auxiliary drive plug-in unit
in unit
HAK Auxiliary drive board LUM Interconnection module
HAR Backplane of auxiliary drive LVM Air distributor module
plug-in unit
LVT Distribution box
HLM Auxiliary drive logic module
HSK Main drive control board
HSQ Sheeter MAE Motor drive plug-in unit
HTM Auxiliary drive driver module MAR Motor drive backplane
HVK Main current distributor board MCM Microcontroller module
HWI Encoder MEE Motor drive/electronic plug-in

unit
MID Press display
IDS Encoder MK Measuring head
ITF Terminal interface MOT Motor drive board
ITM IGBT driver module MRK Motor regulation board
IWM Earth-leakage monitor module MRM Measuring bar computer
module
KID Compact information display MSK Motor control board
KKM Heat sink module MSM Measuring bar sensor module
KLM Compact power module MWE Measured-value acquisition

board
KNT Compact power supply unit
MZK State indication board
KOK Communication board
KVM Terminal amplifier module
KVT Heat sink unit
432
Abbreviations
NAM Mains connection module SBM Power bridge module
NEK Electronics supply board SDM Servo-drive pushbutton module
NSM Supplementary module of SEK Safety input board

power supply unit SEM Interface input module
NTE Power supply plug-in unit SIK Actual current measuring
NTK Power supply board board
NTM Power supply module SLA Suction air control
NTR Power supply backplane SLM Pile power module
NVK Mains supply board SLT Converter power part
NVM NV-RAM module SM Stepper motor
NVTE Power distributor of SMM Current measuring module

electronic plug-in unit SMR Stepper motor control board
SNT Chopper-type power supply
unit
PBK Back-up battery board
SPM Memory analog board module
PD Printer
SPR Voltage regulator
PEK Extension board for plate
image reader SPW Voltage selector switch
PRZ Processor board SRK Power converter board
PRM Plate position detection module SSA Serial interface adapter
PSL Positioning lamps SSE Servo-drive plug-in unit
PSM Profibus interface module SSK Servo-drive control board
PU Printing unit SSM Servo-drive distributor module
SSR Backplane of servo-drive plug-
in unit
REE Computer plug-in unit
STA Interface adapter
REK Processor board
STK Pile control board
REM Register module
STL Pile power part
RER Backplane of computer plug-in
unit STM Pile control module
RGP Computer motherboard STS Vacuum cleaner
RRM RGP computer module STT Supporting element of power
converter
RSK Plug-on control board
SUM Signal conversion module
RSM Plug-on control module
SVK Control voltage distributor
RWK Backplane board
SVM Interface distributor module
SAK Memory analog board SVT Connecting part of power
converter
SAM Interface output module
SW Voltage fluctuation relay
SAS Busbar system
SWM Setpoint module
433
Abbreviations
TAM Button and display module ZRM ZSK computer module
TEM Tacho input module ZSG Central control cabinet
TLK Transistor power board ZSK Central control board
TML Terminal ZSP Central control console
TMP Buttons for manual positioning ZT Zenith terminal

of measuring head ZTK Central control board
TRK Transistor control board
TRM Transistor control module
TSK Driver/interface board
TSM Dryer control module
TTK Transistor driver board
TUM Keyboard coding module
TVK Key distributor board
TVM Encoder distribution module
TVS Tacho signal distribution
system
UFK Filter board

USM Interconnection module
UVM Converter and distributor
module
VEN Fan
VMM Distributor for measuring
module
VP Distributor board
VSM Amplifier module
VTL Distributor board for diskette
drives
VTR Distributor board
VVK Ballast supply board
WDM Resistance decade module
ZID Control console display

ZMM Double current-measuring
module
434
Equipment identification
To be able to clearly identify the electrical equip-

ment, the following equipment identification is used:
Press model
Identification letter or
Position code Number
abbreviation
Where on the press ... ? Which equipment ... ? Distinguishes equip-

ment of the same type
Example 1: 1LVT1
1 LVT 1
PU1 Distribution box 1st distribution box

(main distributor)
Example 2: 1S3
1 S 3
Printing unit 1 Switch Consecutive number of

here: pushbutton ”Forward” switch on PU 1
Example 3: E4
Blank E 4
Cannot be allocated Other equipment: Consecutive number

to any unit motor / pneumatic system compressor
Note:
– If a field of the equipment identification is not
required or not defined, it is left blank.
– In most cases the consecutive number
corresponds to the inputs or outputs of the
associated EAK.
435
436
Position codes
Position codes
Overview of position codes
The position code indicates on which unit of the

press the equipment in question is located.
The position codes 1 to 10 are reserved for

the printing units or the coating unit.
1 Printing unit 1
2 Printing unit 2 or coating unit
5 ... 10
11 Feeder
12 Delivery
13 Central control console
14 Sheeter HSQ
15 Central control cabinet ZSG
16 Extension control cabinet ESG
20 Dryer
101 Control unit CPC1
Example:
Position codes on a Speedmaster
15
4 3 2 1
12
101 13 11
Speedmaster SM102
437
Position codes
438
Index
Automatic sheet arrival control 11M3

Index – Activation and inactivation, 239
– Block diagram, 238
– Graphical representation, 240
– Preset version, 247
A – Checking the operating range, 250
– Interconnection diagram, 248
Abbreviation, 435 – Place of installation, 247
Abbreviations, 431 – Removal and installation, 249
Adjustment of format wheels 11M4, 47 – Technical data, 247
– Checking the operating range, 52 – Sheet alignment, 238
– Fault message, 47 – Sheet arrival control, 239
– Interconnection diagram, 49 – Standard version, 241
– Place of installation, 48 – Checking the operating range, 246
– Removal and installation, 50 – Interconnection diagram, 242
– Technical data, 48 – Place of installation, 241
Adjustment of pile support plate 11M8, 31, 33 – Removal and installation, 243
– Checking the operating range, 37 – Technical data, 241
– Interconnection diagram, 34 Autoplate, 267
– Place of installation, 33 – Block diagram, 269
– Removal and installation, 35 – Fault display, 268
– Technical data, 33 – Method of functioning, 267
Adjustment of printing pressure 1...nM5, 85 – Sequence of functions, 270
– Checking the operating range, 95 auxiliary pile detection 11B11
– Interconnection diagram for CU, 89 – checking the circuit state, 151
– Interconnection diagram for PU, 88 – connection, 150
– Place of installation, 87 – layout, 149
– Removal and installation of motor, 90 – place of installation, 149
– Removal and installation of potentiometer, 92 – removal- and installation, 150
– Technical data, 87 – setting, 151
Adjustment of pull lays 1M7/1M8, 96 – task and function, 150
– Automatic positioning, 96 auxiliary pile motor 11M2
– Checking the operating range, 103 – layout, 146
– Interconnection diagram 1M7, 99 – pin assignment, 148
– Interconnection diagram 1M8, 100 – place of installation, 146
– Place of installation, 98 – task and function, 147
– Precision adjustment of pull lay, 97 – Technical specifications, 147
– Removal and installation, 101 auxiliary pile motor 12M2
– Technical data, 98 – layout, 192
Admission of pressure, pneumatic system 15Y11 – pin assignment, 194
– Pin assignment, 352 – place of installation, 192
– Place of installation, 351 – Task and function, 193
– Task, 351 – Technical specifications, 193
Air supply cabinet E8, 381
Automatic misalignment control 11M7
– Activation and inactivation, 252
– Block diagram, 251 B
– Checking the operating range, 257 Blanket washup device GTW, 281
– Graphical representation, 253 Blast air regulation at feeder 1M9, – Manual blast air
– Interconnection diagram, 255 setting, 360
– Place of installation, 254 Blast air regulation at the feeder 1M9
– Removal and installation, 256 – Block diagram, 357
– Sheet alignment, 251 – Characteristic–curve–dependent blast air regulation,
– Technical data, 254 358
automatic pile transport 11B35 – Checking the operating range, 367
– checking the circuit state, 157 – Layout and task, 362
– connection, 156 – Pin assignment, 363
– Layout, 155 – Place of installation, 361
– place of installation, 155 – Removal and installation, 364
– -removal and installation, 156 – Technical data, 363
– task and function, 156 Block diagram, – Sheet alignment, 207
Blower bar, – see blower motor for dampening system,
322
1
Index
Blower motor for dampening system M45, 322 Place of installation, 271
Blower motor for powder spray device 12M35, 377 Removal and installation, 272
bottom main pile limitation 11S34 Coarse register monitoring 1...nB48, – Task/function,
– checking the circuit state, 159 272
– place of installation, 158 Coating unit, – Position code, 437
– setting, 159 Control console
– task and function, 158 – Layout, 408
bottom main pile limitation 12S34 – Location diagrams, 408
– checking the circuit state, 206 Control panel ZSP, – Location diagrams, 429
– place of installation, 204 Control panels
– setting, 205 – Delivery, 421
– task and function, 204 – Feeder, 419
Brushless main motor from 37KW, 12 – Location diagrams, 417
– Printing unit/coating unit, 420
Cooling and circulating unit E40, 325
C Cover guide height adjustment 1M4, 67
– Checking the operating range, 76
Central control cabinet ZSG, 393 – Interconnection diagram, 70
– Equipment zone A ”Power supply”, 394 – Place of installation, 69
– Equipment zone B ”Partition wall”, 395 – Positioning, 67
– Equipment zone C ”Mounting rack / control devices”, – Removal and installation of motor, 71
397 – Removal and installation of potentiometer, 73
– Equipment zone D ”Flat cable mounting plate”, 398 – Technical data, 69
– Equipment zone E ”Swing frame”, 399
– GRM Rectifier module, 396
– Location and layout, 393
Central dampening solution supply E40, 325 D
Central lubrication, 329 Dampening, 321
– Basic concept, 329 Dampening solution mixing unit E41, 328
– Fault messages, 332 Dampening system
– Grease lubrication – Blower motor, 322
– Block diagram, 333 – Dampening solution sensor, 323
– Function, 334 Delivery, – Position code, 437
– Layout, 334 delivery pile control
– Monitoring the lubrication system, 335 – automatic pile height control, 170
– Motor for grease lubrication 12M47, 345 – auxiliary drive control, 165
– Place of installation, 334 – block diagram (Preset), 161
– Pressure relief valve of the motor , 337 – block diagram (standard), 162
– Settings, 336 – non–stop operation, 177
– Triggering a lubrication process, 336 – overview (Layout), 163
– Oil lubrication – overview of components (drive side), 167
– Block diagram, 338 – overview of components (operator side), 166
– Changing the filter, 342 – overview of motors, 168
– Distributing lubrication, 340 – overview of solenoid–operated valves, 169
– Filter unit, 341 – overview of switches and sensors, 168
– Function, 340 – paper blockage, 185
– Layout, 339 – press control, 164
– Place of installation, 339 – removal of sample sheet, 184
– Pressure relief valve of oil pump, 342 – safety circuit, 164
– Triggering a lubrication process, 341 – Transport of auxiliary pile, 175
– Service display, 330 – transport of main pile (Preset), 171
changeover fast/slow 12B65 – transport of main pile (standard), 173
– checking the circuit state, 197 delivery upper edge of pile 12B129
– connection, 196 – checking the circuit state, 203
– layout, 195 – connection, 202
– place of installation, 195 – layout, 201
– -Removal and installation, 196 – place of installation, 201
– task and function, 196 – -removal and installation, 203
Circumferential register SM/CD 102, 314 – task and function, 202
Coarse register monitoring, 271 Diagonal register SM/CD 102, 308
Adjustment, 273 Double–sheet detector 1B11
Connection, 271 – Adjustment, 237
Layout, 271 – Block diagram, 231
2
Index
– Connection, 235 I
– Fault messages, 232
– Layout, 234 Identification letter, 435
– Pin assignment, 235 Impression cylinder washup device DZW, 292
– Removal and installation, 236 Inactivating pile centering 11B55, 28
– Sheet alignment, 231 Ink blade, – Sensor monitoring the ink blade 1...nB43,
303
Ink fountain roller motor SM/CD 102, 305
Inking roller washup device FWW, 286
E Inking unit temperature control, 382
Encoder, – Place of installation, 388 – SM/CD 102, 317
Encoder IDS, 388 Inking unit temperature control E39, E39a, – SM/CD
– Installation variants, 390 102, 318
– Pin assignment, 389 Intercom WSA
– Removal and installation, 390 – Function, 387
Equipment identification, 435 – Layout, 386
Extension control cabinet ESG, 437 IR slide–in dryer, – Switches monitoring the IR slide–in
dryer 12S9, –a, –b, –c, 380
F
Feeder, – Position code, 437
L
Feeder pile control Lateral register SM/CD 102, 311
– block diagram (Preset), 119 Level in coating pan L–B32, 371
– block diagram (Standard), 120 Location diagrams, 393
– Overview of components (Standard), 125 – Control panel ZSP, 429
feeder pile control – Control panels, 417
– automatic pile height control of auxiliary pile , 129 – Delivery, 421
– automatic pile height control of main pile (standard), – Feeder, 419
128 – Printing unit/coating unit, 420
– auxiliary drive control, 123 – Motors, 413
– non–stop operation (Preset), 134 – Operator’s controls, 423
– non–stop operation (standard), 137 – Position switches, 409
– overview (layout), 121 – Sensors, 415
– Overview of components (Preset), 124 – Solenoid valves, 411
– overview of motors, 126 – ZSP Central control console, 408
– overview of switches and sensors, 126 Location diagrams , – Central control cabinet ZSG, 393
– pile height control of main pile (Preset), 127 Lubrication monitoring 1 – 12B47, 348
– press control, 122 Lubrication monitoring 2 – 12B77, 348
– safety circuit, 122
– transport of auxiliary pile, 132
– Transport of main pile, 130 M
Format adjustment
– Adjustment of format wheels 11M4, 47 M1 Direct–current main motor, 7
– Adjustment of printing pressure 1...nM5, 85 Main drive
– Cover guide height adjustment 1M4, 67 – Brushless main motor from 37KW, 12
– Pile stops 11M11/11M12, 59 – Direct–current main motor, 7
– Sheet joggers 12M6/12M7, 110 – Motor terminal board, 15
– Sheet slowdown/format adjustment 12M5, 104 – Replacing the brake, 9
– Suction head/format adjustment 11M6, 53 – Replacing the carbon brushes, 10
– Rotor position encoder, 13
main pile motor (Preset) 11M1
– layout, 140
G – pin assignment, 142
Grease lubrication, 333 – place of installation, 140
– Lubrication monitoring 1 – 12B47, 348 – task and function, 141
– Lubrication monitoring 2 – 12B77, 348 – technical specifications, 141
GRM Rectifier module, – Central control cabinet ZSG, main pile motor (standard) 11M1
396 – Layout, 143
– pin assignment, 145
– place of installation, 143
– task and function, 144
– Technical specifications, 144
3
Index
main pile motor 12M1 (Preset) – Sensor 11B10, 20

– layout, 186 – Sensor 11B55, 29
– pin assignment, 188 – Servo–drive ”Pile centering” 11M9, 21
– place of installation, 186 Pile centering 11M9, 23
– Task and function, 187 – Checking the operating range, 27
– Technical specifications, 187 – Interconnection diagram, 24
main pile motor 12M1 (standard) – Place of installation, 23
– layout, 189 – Removal and installation, 25
– pin assignment, 191 – Technical data, 23
– place of installation, 189 pile height control 12B69
– Task and function, 190 – checking the circuit state, 200
– technical specifications, 190 – connection, 199
Malfunctions in printing unit, 268 – Layout, 198
Misalignment control 11M7, – Misalignment control, 252 – place of installation, 198
Monitoring the ink blade, sensor 1...nB43, 303 – -removal and installation, 199
– Connection, 304 – setting, 200
– Layout, 303 – Task and function, 199
– Pin assignment, 304 Pile merging, 31
– Place of installation, 303 – Adjustment of pile support plate 11M8, 31
– Removal and installation, 304 Pile stops 11M11/11M12, 59
– Task, 304 – Checking the operating range, 66
Monitoring the IR slide–in dryer, – Switches 12S9, –a, – Fault message, 60
–b, –c, 380 – Interconnection diagram 11M11, 62
Motor for grease lubrication – Interconnection diagram 11M12, 63
– Pin assignment, 345 – Place of installation, 61
– Place of installation, 345 – Prepiling, 60
Motor terminal board, 15 – Removal and installation, 64
Motors – Technical data, 61
– Blower motor for powder spray device 12M35, 377 Pin assignment
– Location diagrams, 413 – Servo–drive circumferential register SM/CD 102, 315
– Washup brush motors M43, M50 ... M56, 296 – Servo–drive diagonal register M4 SM/CD 102, 309
Motors / functional units, – Servo–drive diagonal register – Servo–drive ink fountain roller SM/CD 102, 306
SM/CD 102, 308 – Servo–drive lateral register SM/CD 102, 312
Motors / motor–driven units Coarse register monitoring, 271
– Servo–drive circumferential register SM/CD 102, 314 Plate clamping device
– Servo–drive ink fountain roller SM/CD 102, 305 – Autoplate, 267
– Servo–drive lateral register SM/CD 102, 311 1...nB53 Coarse register monitoring, 271
Pneumatic system, – Admission of pressure, pneumatic
system 15Y11, 351
N Pneumatic system compressor E4
– Pin assignment, 355
Number, 435 – Technical data, 355
Position code, 435
Position codes, 437
O Position switches, – Location diagrams, 409
Oil lubrication, 338 Potentiometer, 308
– Pressure monitoring oil lubrication 1F33 (1 bar), 346 Powder spray unit 12E2, 373
– Pressure monitoring oil lubrication 1F34 (12 bars), Powdering cycle switch 12S68, 379
347 Pressure monitoring oil lubrication 1F33 (1 bar), – Place
Oil pump M44, 343 of installation, 346
– Pin assignment, 344 Pressure monitoring oil lubrication 1F34 (12 bars), –
– Place of installation, 343 Place of installation, 347
Operator’s controls, – Location diagrams, 423 Pressure sensor pneumatic system 15B14
– Place of installation, 353
Print–free margin 1M2/1M3
P – Checking the operating range, 84
Pan roller motors 1...nM1, 321 – Interconnection diagram, 79
Pile centering, 17 – Place of installation, 78
– Activation and inactivation, 18 – Removal and installation of motor, 80
– Block diagram, 17 – Removal and installation of potentiometer, 81
– Sensor ”Inactivating pile centering” 11B55, 28 – Technical data, 78
– Sensor ”Pile centering” 11B10, 19 Print–free margin D.S./O.S. 1M2/1M3, 77
4
Index
Printing unit, – Position code, 437 – Pile stops 11M11/11M12, 59

Pull lay control 1B9/1B10 – Sheet joggers 12M6/12M7, 110
– Block diagram, 223 – Sheet slowdown/format adjustment 12M5, 104
– Checking the sensing distance, 230 – Suction head height adjustment 11M5, 40
– Place of installation, 226 – Suction head/format adjustment 11M6, 53
– Sheet alignment, 223 Servo–drive circumferential register SM/CD 102, 314
– Sheet infeed error/pull error, 224 Servo–drive diagonal register SM/CD 102, 308
Preset version, – Adjustment, 227 Servo–drive ink fountain roller SM/CD 102, 305
Standard version, – Adjustment, 229 Servo–drive lateral register SM/CD 102, 311
Sheet alignment, 207
– Automatic misalignment control 11M7, 251
R – Automatic sheet arrival control 11M3, 238
Rotor position encoder, 13 – Degree values, 209
– Layout, 13 – Double–sheet detector 1B11, 231
– Pin assignment, 13 – Pull lay control 1B9/1B10, 223
– Sheet alignment control, 210
Sheet alignment control
S – Adjustment, 219
Sensor ”Inactivating pile centering” 11B55 – Block diagram, 210
– Adjustment, 29 – Misaligned–sheet display (trend display), 214
– Check, 29 – Sheet alignment, 210
– Place of installation, 29 – Sheet alignment error
Sensor ”Pile centering” 11B10, 20 – ANK sensors, 212
– Check, 20 – FÜK sensors, 213
– Place of installation, 20 Sheet alignment control 1B13/1B49, 215
– Removal and installation, 20 – Checking the circuit state, 222
Sensor for dampening solution control B32, 323 – Layout and task, 215
Sensors – Pin assignment, 215
– Admission of pressure, pneumatic system 15Y11, – Place of installation, 215
351 – Removal and installation, 216
– at the washup solution container B1, B54, B55, 301 Sheet joggers 12M6/12M7, 110
– Adjustment, 302 – Checking the operating range, 117
– Connection, 301 – Fault message, 111
– Pin assignment, 301 – Interconnection diagram 12M6, 113
– Place of installation, 301 – Interconnection diagram 12M7, 114
– Removal and installation, 302 – Place of installation, 112
– Level in coating pan L–B32, 371 – Removal and installation, 115
– Location diagrams, 415 – Technical data, 112
– Monitoring the ink blade 1...nB43, 303 Sheet monitoring, 259
Sensors/switches, 1...nB53 Coarse register monitoring, – Sheet travel monitor 1...nB48/1...nB48a, 259
271 Sheet slowdown / format adjustment 12M5
Service display – Checking the operating range, 109
– Grease lubrication, 331 – Interconnection diagram, 107
– Oil lubrication, 330 – Place of installation, 106
Service display Washup, 278 – Removal and installation, 108
– Functions of the blanket washup device, 278 – Technical data, 106
– Functions of the impression cylinder washup device, Sheet slowdown/format adjustment 12M5, 104
278 – Fault message, 105
– Functions of the inking roller washup device, 279 Sheet travel monitor 1...9B48/1...9B48a, 259
Servo–drive – Adjustment, 263
– Adjustment of format wheels 11M4, 47 – Components, 263
– Adjustment of pile support plate 11M8, 33 – Place of installation, 262
– Adjustment of printing pressure 1...nM5, 85 – Service display, 261
– Adjustment of pull lays 1M7/1M8, 96 Size adjustment, 45
– Automatic misalignment control 11M7, 251 – Block diagram, 45
– Automatic sheet arrival control 11M3 – Command ”Presetting”, 46
– Preset version, 247 – Print–free margin D.S./O.S. 1M2/1M3, 77
– Standard version, 241 Solenoid valves, – Location diagrams, 411
– Blast air regulation at the feeder 1M9, 357 Static electricity eliminator 11E3, – Task, 385
– Cover guide height adjustment 1M4, 67 Static electricity eliminator 12E3
– Pile centering 11M9, 21, 23 – Layout, 384
5
Index
– Place of installation, 383 – Settings, 294

Suction head height adjustment 11M5, 39, 40 – Inking roller washup device FWW
– Checking the operating range, 43 – Additional washing of printing plate and ink foun-
– Interconnection diagram, 41 tain roller, 289
– Removal and installation, 42 – Example, 289
– Technical data, 40 – Flow chart, 290
Suction head height control, 39 – Function, 287
– Suction head height adjustment 11M5, 39 – Layout, 287
Suction head/format adjustment 11M6, 53 – Settings, 288
– Checking the operating range, 58 – Messages, 276
– Fault message, 54 – Selection of functions, 275
– Interconnection diagram, 56 – Service display, 278
– Place of installation, 55 – Washup solution container, – Warnings, 298
– Removal and installation, 57 Washup solution container E9
– Technical data, 55 – Block diagram, 297
Switches – Layout, 299
– Monitoring the IR slide–in dryer 12S9, –a, –b, –c, – Pin assignment, 300
380 – Place of installation, 299
– Powdering cycle 12S68, 379 – Sensors B1, B54, B55, 301
– Task, 300
– Warnings, 298
T
Temperature control, – SM/CD 102. Siehe
Farbwerk–Temperierung Z
Zentralschmierung, – Oil lubrication, – Circular
lubrication, 340
U Zero position
– Servo–drive circumferential register SM/CD 102, 316
upper main pile limitation 11B33 – Servo–drive diagonal register SM/CD 102, 310
– checking the circuit state, 154 – Servo–drive ink fountain roller SM/CD 102, 307
– connection, 153 – Servo–drive lateral register SM/CD 102, 313
– Layout, 152
– place of installation, 152
– removal and installation-, 153
– setting, 154
– task and function, 153
V
Varnish supply unit E4a, 369
W
Washup brush motors M43, M50 ... M56, 296
– Place of installation, 296
Washup devices
– Blanket washup device GTW
– Example, 285
– Flow chart, 285
– Function, 282
– Layout, 282
– Settings, 284
– Control by command, 275
– Impression cylinder washup device DZW, 292
– Example, 295
– Flow chart, 295
– Function, 293
– Layout, 293

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Important safety instructions

Observe the general and press-specific safety

At first start-up or after the exchange of

Control cabinet and machine housing have to be

Make sure that the main power switch is turned

If it is necessary to repair the press while it is

Never exchange components and units while the

Safety equipment must not be modified. Do not

If extra accessories not corresponding to

Handling and replacing electronic boards

Storage: ALWAYS NEVER NEVER

Protective measures for ESDs

DISCHARGE UNPACK REPLACE PACK

2. Speedmaster CD 102 1 – 438

39 Suction head height control

119 Feeder pile control

161 Delivery pile control

207 Sheet alignment

259 Sheet monitoring

267 Plate clamping device

275 Washup devices

305 Inking unit

329 Central lubrication

351 Pneumatic system

357 Suction and blast air

369 Other components

393 Location diagrams

435 Equipment identification

437 Position codes

M1 Direct-current main motor

Representation of a dc main motor M1

Installation area of fan impeller

Attention: Make sure the motor is disconnected from

Terminal box of ”SIEMENS” main motor

Terminal box of a ”SIEMENS” main motor

Terminal box of ”BAUMÜLLER” main motor

Terminal box of a ”BAUMÜLLER” main motor

Removal and installation of brake

Removal of defective brake

Brake at main motor

Connecting cable of brake

Installation of the new brake

Main motor with brake removed

Removal/installation of carbon brushes

Removal of carbon brushes

Carbon brush connections

Installation of new carbon brushes

Insert the new carbon brushes and

M1 Brushless main motor

Construction with terminal board (from 37kW)

Main motor M1 with terminal box

Rotor position encoder

Attention: Do not loosen the safety screws of the adjusting

ÁÁÁÁ Adjusting ring

Front view of rotor position encoder

Rotor position encoder of main motor M1

Motor casing / brake

Terminal box of main motor BAUMÜLLER 37KW

Pin and socket bases, 6-pole 6 Brake –

If the pile support plate reaches the sensor ”Inactivat-

Automatic control is resumed as soon as

Legend: Data line

Block diagram for pile centering

Activating and inactivating pile centering

To avoid damage to the press, make sure nothing is