service manual herkules

- 1 -Service / Error Messages at the ONLINE Processor

Are the covers in place and triggering theinterlock switches?

Is interlock switch ok?

Replace coverand switch on

Replace switch

NOTE: There are three interlock switches- processor lid- dryer cover- filter housing cover

no

yes

Is continuity present between interlock switches and pcb GCB?

Has fuse F510 blown?

yes

yes

yes

Replace pcb GCB

no

no

no

Replace wiring

Replace fuse 1.5A (S) 6.3 x 32mm

E00: Check Interlock on OLP


Lift conveyor cover: is there film inside?

Has the film reached the processor input sensor?

Inverstigate location of film in Herkules.

no

no

Has the film reached the input rollers of the sensor?

Are the input sensors seated correctly?

yes

yes

yes

no

yes

no

Are the rollers turning?

E01: Film Jam in Conveyor

Check the position of guides, rollersand grip of rollers.

Are input sensors operating correctly ? I.e... jammed.

Reseat sensors

continued onnext page

no yes

yes

no Replacesensors

no * *


Is input sensor electrical circuit operating correctly?Check by triggering sensors in service mode parameter 32 + 33. Does display status toggle onand off?


Is 5 volts DC present across pcb GCB plug X201 and X202 when plug is removed?

Reconnect plug does voltage return to 0 volts?

Is there 5 volts DC at input sensor?

no

yes

no

no

Change wiring

yes

no

yes

yes

Change pcb GCB

Change sensor

Change pcb GCB

Change pcb GCB



Cut and remove the film

Trigger interlock switch.Do the conveyor rollers rotate?

Check the position of therollers and look for worn belts

Has fuse F301 blown?

Is there 24 volts DC supplied to the conveyor?

Replace fuse 2A (S)

Change conveyor motor

Is there 24 volts across plug X301 on pcb OCM04?

Has the film been released by the Herkules?

Check wiring to conveyor motor

no

no

no

no

no

yes

yes

yes

yes

yes

Change pcb OCM04

no* *


E02: Film Jam in Processor

Is the processor exit sensor too high or dislodgedfrom its mounting and not being triggered by the film?

yes

yes

yes

yes

Is the processor output sensor being held up by a sheet of film?

Is the processor output sensor stuck in the up position?

Is the film stuck in the processor racks or in the bottom of the tanks?

a) ... all racks are located under the drive barb) ... missing worm geer clips causing loss of drive to the racksc) ... damaged geers causing loss of drive in racksd) ... correct location of guides and rollers in racks

no


Reposition sensor

Remove film andempty basket

Release sensor arm and clean or replace sensor

Remove film and check for ...

no

no

no


E02: Film Jam in Processor

yes

yes

yes

no

no

Is the film stuck in the conveyor and triggering the processor input sensor?

Check speedcontrol timing

Remove the processor lid and trigger the interlock switch. Do the processor rollers turn?

Check for nongripping rollers

Is there power to the main drive motor? Change motor

Is there continuity of the wiring between pcb GCB and main drive motor?

Replace wiring

Change pcb GCB

yes

no

no


yesClose coverIs conveyor cover open?

no

no

no

yes

yes

Is interlock switch on conveyor ok? Replace switch

Replace wiringIs there continuity in the wiring through the interlock switch to plug X902 on pcb OCM04?

Replace pcb OCM04

E03: Conveyer Cover open


yesAddress errors

no

no

Replace cable

E04: Level Error Developer

Are errors E07, E10, E13 or E25 also displayed?

no

Is the levellow?

Does the devaccount = 500?

yes

no

yes Is the O-ring seal at the baseof the overflow pipe leaking?

no ja

Is there continuity in the wiring betweenpcb GCB plug X101 and the level sensor?

Replace pcb OCM04

Top up withwater

ReplaceO-ring

With plug X101 removed is there 24V AC at the output from the pcb GCB?

Check fuse F511

yesCheck pcb GCB

yes

no


yesAddress errors

no

no

E05: Level Error Fixer

Are errors E08, E11, E14 or E26 also displayed?

no

Is the levellow?

Does the fixaccount = 500?

yes

no

yes Is the O-ring seal at the baseof the overflow pipe leaking?

no yes


Changepcb OCM04

Top up withwater

ReplaceO-ring


Check fuse F511

noReplace cable

yesCheck pcb GCB

yes


yes Follow flow diagramfor E15

no

no

E06: Level Error Wash (Applies only to Wash Tank 1)

Is E15 showing?

no

Is the level lowin wash tank 1



Check fuse F511

noReplace wiring

yesCheck pcb GCB

yes



yes

E07: Change Developer Replenisher Container

Is E10 alsodisplayed?

no

Follow flow diagramfor E13



yes

E08: Change Fixer Replenisher Container

Is E11 alsodisplayed?

no




yesAre E06 or E15 also displayed?

yes

yes

no

no

no

Remove restriction

E09: Low Flow Mix- with-Fix Pump

Remove fixer replenisher fuse F507, pulse fixer rep button, is wash solution delivered to the fix tank?

Is there a restriction in the hose between the baseof wash tank 1 and the flow sensor?

Check mix- with-fix pumpusing replenisher pumpcheck guide

Follow flow diagramE6 or E15

Check mix- with-fix flow sensor using flow sensor guide


yes

no

yes

yes

yes

no

no

yes

noRemove restriction

E10: Dev Waste Container full

refit

Is the developer waste container full?

Is the dry break connector seated correctly?

Is the developer waste hose restricted?

Is the float sensor short circuit?

Change developer waste container and reset on Herkules panel

Investigate switch failure, possibly:- float stuck in up position- float dropped off spine

no

Is 18V AC supplied to the switch?



E10: Dev Waste Container full

Is the power supply to pcb GCB correct?

no

yes

yes

no

Is fuse F18 blown?

Check transformer output voltage

Replace pcb GCB

Replace fuse 500 mA(F) 250V


E11: Fixer Waste Container full

Use flow diagram for E10 replacing fixer for developer.


E12: Wash Waste Container full

yes

noIs jumper plug X203 pin 1 to 3 in place? Install jumper

Replace pcb GBP01


no

no

yesRefit

E13: Dev Rep Container empty


When arriving in this column clear error code by pulsing dev rep button.If error does not clear continue with process.

Is the developer replenisher container empty?yes

Is the dry break connector seated correctly?no

Change dev repcontainer

Has the rep bag collapsed over its exit?yes

Is the red dev rep hose restricted or is thefilter blocked?

yes

Release obstruction

Remove restriction

no


no

yes

yes

no

Is fuse F508 blown?


Does dev rep reach the tank when the repbutton is pressed?

Check flow sensor using flow sensor guide

Replace fuse 500 mA (F)6.3 x 32 mm

Check rep pump using rep pump guide

WARNING:the replenisher pumps will not work when the processor lid is removed unless the interlockswitch and daylight slot magnet is triggered.


E14: Fixer Replenisher Container empty

Use flow diagram for E13 replacing fixer for developer. Fixer replenisher hose is blue. Fixer fuse number is F507.


E15: Wash Replenisher Container empty

Use flow diagram for E13 replacing wash for developer. Wash replenisher hose is green. Wash fuse number is F18.


E16 / E17: Low / High Processing Speed

Check service parameters (green LED) 46 and 47or static data 10045 and 10046 on herkules panel.Do the values equal -3 and +3 respectively?Is service parameter 51, developer rack length330 mm?

yes

yes

Has OLP been switched off / on during film processing?

yes

no

Set service parameter 35 or static data ID 10034 = processing speed auto-calibrate to 0, and run afew films through the OLP.Observe value of auto-calibrate parameter.Does values stay between -10 and +10?


Set to correct value

no Check adjustmentof film speed onpcb GCB

no Check adjustmentof film speed onpcb GCB


E16 / E17: Low / High Processing Speed

NOTE:The most likely source of this error is the "processing speed autocalibrate"system. This system measures the complete processing time for a film from input sensor to output sensor. For example:If a film is left in the machine at power off, and an additional film is sent through immediately after power on, the film arrives too soon, thus fooling the system. Normally the errors E16 and E17 are a combination of motor control maladjustment and technician / user interference with the system. The OLP calculates a "measured processing speed" based oninput-to-output time and machine length. The value can been seen in casual user parameter 26 (no LED) or measure data 10009 on the herkules interface panel.


E18: Total idle Time exceeded

no

yes

yes

noSet to default value.

noSet to 2.0

Check casual user parameters (no LED) 27 and 28,or measure data ID 10017 + 10018 (time on sincelast job and time off since last job measuredin minutes). Is the sum of these values large?I.e.... > 10000 minutes

Check service parameter (green LED) 52, or static data ID 10051 (alarm for total idle time).Does the value = 14400 min. (= 10 days)?

Check service parameter 66, or static data ID 10065 (idle on time scaling factor). Does the value = 2.0?

Carry out a system check to establish ifthe processor chemicals are exhausted.

yes

Carry out a system check to establish if the processorchemicals are exhausted.


yes

no

E20: Developer Filter blocked

no

yes

Change developer string filter, does error remain?

yes

Is pressure sensor open circuit?

On pcb GBP short circuit plug X104 pin 1 to 3.Does the error clear after 30 seconds?

Replace pcb GBP1

no Reset filter lifetime counter on Herkules panel

Replace pressure sensor

Check continuity of wiring between pressure sensorand pcb GBP plug X104


E21: Fixer Filter blocked

Follow flow diagram for E20 but use plug X105 pin 1 to 3 on pcb GBP.


E22: Wash 1 Filter blocked



E23: Wash 2 Filter blocked



E24: Biocide Container empty

Plumbed system:Follow flow diagram for E13 but use biocide in place of developer(there is no dedicated fuse for this pump). Plumbless system:Check that a jumper is installed on pcb GBP plug X204 pin 1 to 3.



Is E10 also displayed?

no




E26: Fixer Replenisher Container empty

Is E10 also displayed?

no




E27: Replace Fixer Filter

The fixer filter lifetime has elapsed. Replace with a new carbon filterand reset on the Herkules panel.

no

Does the error remainafter changing the filterand resetting on theHerkules panel?

Is fixer filter lifetimecounter serviceparameter 55 (green LED)set to the default value?

yes

System is now operable

noyes

Replacepcb OCM04

Reset todefault


E28: Replace Wash 1 Filter

Follow flow diagram for E27 replacing the carbon filter for a string filterand using service parameter 53.


E29: Replace Wash 2 Filter

Follow flow diagram for E27 and using service parameter 54.


no

no

yes

yes

no

yes

Wait until it comesup to temperature.

E30: Developer Temperature incorrect

Set to 35 °C.

Check recirculationinside dev tank.

Is the developer temperature set to 35°C?Check using casual user parameter 13 (no LED).

Is the developer temperature above 35°C?Check using casual user parameter 23.

Is the developer temperature below 35°C and not increasing?

Is E04 displayed on the processor panel?

no

Is fuse F504 (dev heat) blown?no


yes

yes

Follow flow diagramfor E04.

Replace fuse 5A (F) 250V (6.3 x 32 mm).


no

yes

no

E30: Developer Temperature incorrect

Is 230V AC arriving at dev heater element? Has heater element thermofuse blown?

no ja

Replacethermofuse

Replace heaterelement

Is there 230V at the output from pcb GCB?Measure between plug X508 red wireand plug X507 black wire.

nein

Is the temperature probe resistance(ex. 1200 ohms approx.) in a similarrange to the other temperature probes?

yes

Check continuity of wiring between pcb GCB and heaterelement.

Replace temperature probe

yesReplace pcb GCB


E31: Fixer Temperature incorrect

Follow flow diagram for E30 replacing developer with fixer. Referring to fuse F503 5A (F) 250V 6.3 x 32 mm and measuringpcb GCS output voltage between plug X507 brown wire andplug X507 orange wire.


How to check a Replenisher Pump

NOTE:Replenisher pumps will not operate when:- The processor lid is removed unless the interlock switch and the daylight slot magnet switch is triggered.- When the corresponding replenisher account is equal to 500. Trigger the operation of the replenisher pump by:- Pulsing the rep button for FIX, DEF and MIX-WITH-FIX pump.- Using service parameters 16 (fix) or 17 (dev) on pcb gcb.- Dropping the level in wash tank 1 to operate the wash rep pump.

yesDoes the replenisher pump oscillate?

Is there 180 to 230 V AC supplied to the replenisher pump?Measure on the terminal block under the dryer rack.

no

nocontinued onnext page

yesReplace pump

Check internal popet valveand replace if damaged,if not replace pump.


yes

How to check a Replenisher Pump

Is the supply voltage at the output of the pcb GCB?

no

Check the continuity of thewiring between the pumpand the pcb GCB.

Has the corresponding fuse on the pcb GCB blown?

no

Replace pcb GCB

yesReplace fuse


How to check a Flow Sensor

Observe the replenishment accounts found in extended parameters (yellow LED).

Dev account parameter 12.Fix account parameter 13.Mix with fix account parameter 14.

Does the account change value when squeezing the online rubber gather next to the flow sensor.

no

Remove the plug connection from the flowsensor and connect an alternative plugfrom another flow sensor.Pump replenisher through the flow sensor and monitor the alternative account.Does the account change value?

no

yes


no

NOTE

yes

Check the hose between the pumpand flow sensor, are there anyfloating obstructions?

yes

Carry outprocedure for calibratingflow sensors

Removeobstruction

Replaceflow sensor * *



no

yes

Replace wiringIs there continuity in the wiring between the flow sensor and pcb GBP?

Is there 10V DC between pin 1 and 3 of theflow sensor?

no

yes

Has fuse F19 blown?

no

Is there 18V AC at input to pcb GBP?

no

Check transformer supply

yes

yes

Replace pcb GBP

Replace fuse 500 mA(S) 250V

Replace pcb GBP



NOTE:The MIX-WITH-FIX flow sensor may malfunction due to a build upof black particles on its internal sensor. Removing the particles:- exchange MIX-WITH-FIX flow sensor.- pump fixer through the defective flow sensor. The flow sensor should start to operate after approx. 0.5 to 1 literof fixer has passed through it.

* *

General Remarks - 1 -

PcbsPrinted circuit boards must not be energized when being pulleout.Carry out operations on modules only when they are pulled outand not energized.


Electrostatic Discharge (ESD)Observe ESD (Electrostatic-Sensitive Device) safety regulations! PCBs and semiconductor modules should remain as long as possible in their original packing. When shipped or stored, use either the original or adequate protective packing. Machines, soldering irons, work surfaces and persons should have the same potential as the semiconductor modules. Avoid static charge caused by synthetic floor coverings, synthetic clothing etc. at any cost to prevent destruction or damage of the semiconductor modules. Therefore:- When working on modules, wear a wristlet and establish a ground.- Use a grounded work surface.- Do not disconnect the ground before having finished all operations. For this purpose, use the ESD set (Order No. 02302683).


Soldering OperationsFor soldering operations, only mains isolated low-voltage soldering irons equipped with leakage resistors may be used.E.g. WELLER soldering unit WECP 20 (Order number 02289245,Weller order number 52501199). While soldering, make sure the arising vapor does not get into contact with any optical parts.


MeasurementsPrior to each measurement, make sure that electrical isolation exists, otherwise take respective measures, e.g. use isolating transformer.


Optical PartsAvoid contact of the optical parts with any metal object.Do not leave any small parts on the glass panes.Clean optical parts according to "Cleaning Procedure (order No. 02064634)".


Floppy DiskObserve the manufacturer´s instructions for handling floppy disks and drives.The following items are of special importance:- Always store floppy disks in clean protective covers.- Neither bend nor fold floppy disks.- Do not place heavy articles on floppy disks.- Protect floppy disks from magnetic influences and do not touch magnetic surfaces.

Copyright - 7 -

Copyright by Heidelberger Druckmaschinen Aktiengesellschaft, 24107 Kiel Adobe and Adobe Illustrator are registered trademarks of Adobe Systems Incorporated. Apple, Apple-Logo, AppleTalk, EtherTalk and Macintosh are registered trademarks of Apple Computer, Inc. Ethernet is a trademark of Xerox Corporation. LinoColor, Linotype, Linotronic, Linotype Library, Centennial, Helvetica and Times are registered trademarks of Heidelberger Druckmaschinen Aktiengesellschaft. PostScript is a registered trademark of Adobe Systems, Inc. Taxi is a registered trademark of AMD. We point out that companies, trademarks and product names mentioned in this manual fall within the regulations regarding protection of trademarks and patents.

No. Measure

No. MeasureThis FollowMe documentation corresponds to the hardware version indicated on the modification label with which the machine or the respective component is provided. Modification states are indicated by the number marked on the modification label. If the hardware has a different modification state, please refer to the respective Service Information.

No. Measure

Technical Data - 1 -

DimensionsHeight 930 mmWidth 780 mmDepth 1510 mm

WeightOperating weight ca. 500 kg


Ambient ConditionsOperating temperature +18 ... +28 °CTransport temperature -10 ... +50 °CRelative humidity 45 - 80 % (not condensing)Atmospheric pressure 700 - 1060 mbarHeat dissipation ca. 3200 kJ/h


Power RequirementsMains voltages 1 N PE AC 100 V, 110 V,

120 V, 127 V, 200 V,220 V, 230 V, 240 V

Connecting 115 V to 120 V Mains frequency 47 - 63 Hz Power consumption ca. 0.9 kW with

200 V ... 240 V


FloorThe floor at the installation site must be level.As a rule, the floor (covering) must meet the following quality requirements: Permanently antistatic, i.e.Max. static charge <= 500 V/cmHalf-life period <= 30 sLeakage resistance <= 10 E9 ohmsVolume resistance <= 10 E10 ohms Abrasionproof and easy to clean with a smooth surface Indentation resistance = 80-100 N/mm²


Operating Noise LevelOperating noise level < 55 dB (A)Emission value related to job area

System Configuration - 7 -

RS 232

ETHERNET

OPSVT 100(SERVICE)

TAXI

2x RIP 60

XA20 SpeedwayXA21 Speedway

Herkules -Extension

XB6

XA7 A02

A04

A08/A07

MAC MAC

RS 232

Transport, Packaging, Completeness - 1 -

Herkules must be installed firmly on the transport pallet during transport! Avoidance of condensation:- remove packaging only when the machine has been at the installation site for 24 hours Machine parts:- carefully remove from cardboards- check for transport damages- check for completeness against delivery note

General Notes - 2 -

General Notes

The appliance plug and/or the power outlets of the house installation must be easily accessiblesince the power plug must be pulled to disconnect the machine completely from the power supply, for example, in the case of emergencies. The mains connection is established using the delivered mains cable with the 3-pole plug. The machine may only be operated with the protective conductor connected. The mains connection and the fuses are at the rear of the machine. During installation, it must be ensured that there is sufficient distance between the side panels and the walls or other objects to guarantee an adequate ventilation. The dimensions are to be taken from the installation instructions. During installation, do also observe the notes in the technical data.

Removing the Transport Pallet - 3 -

Wooden screws (1) of the transport safeguard brackets:- remove Bolt (2):- insert into the square tubes Plates (3):- position as shown Screws (4):- screw into the bolts until the machine is raised off the pallet Pallet:- pull out parallel to the axis

Square tube

2

4x

3

4

1 (6x)

5 (4x)

Transportsafeguard bracket


Machine feet:- unscrew slightly Screws (4):- unscrew Machine:- is lowered down and stands on the machine feet NOTE:The transport safeguard brackets must not make contact with the floor. Screws (5):- remove Transport safeguard bracket:- remove Machine feet:- insert

Square tube

2

4x

3

4

1 (6x)

5 (4x)



Machine:- transport to installation site using the transporting rollers Machine feet:- unscrew until the transporting rollers are relieved Machine:- align in longitudinal and lateral direction (use spirit level) Alignment:- performed by rotating the machine feet NOTE:Store transport safeguard bracket and installation accessories.

Square tube

2

4x

3

4

1 (6x)

5 (4x)


- 6 -Installation Instructions (Advantage Option)

Select installation site according to the following criteria: No direct irradiation of the machine through:- sunlight- radiators installed in the room Do not install machine near air-conditioning equipment! Machine must be protected against humidity at the installation site!


ON-LINE Operation

Side view

NOTE: All dimensions in mm

Transport channel

Recorder OnLine-ProcessorTyp 860

Collecting basket

Supplycassette

940

90

1020

1450

1100

115

760 345850475

25


ON-LINE Operation

Top view

NOTE: All dimensions in mm

200 ca. 140

>700

265

1510

>700

1080

>1000

1230

>700

Film run

Power cablelength: 4 m Cable exit: - OnLine-Interface

- RIP-Interface

Recorder

OnLine-ProcessorTyp 860

>700

(establishshield)

Transport Safeguards - 13 -

Transport safeguards:- Remove only at the final location in the mentioned order!

Transport safeguards are marked with red varnish and/or a red adhesive label.Store removed transport safeguards for transport at a later time (Order No. 04587960).

i

1. Guide Panel and Film Exit Unit3. Spindle Motor

2. Trough

4. Carriage

6. Compr. Air Unit 5. Vacuum Pump


Machine cover:- remove Remove cable strap from the axle of the movable holders Foam strips between:- movable holders and guide panelfilm exit unit and cast wall must be removed

Interior, Guide Panel and Film Exit UnitAdhesive foam tape


Remove the following components:- front cover- rear cover- large covers (right and left)- small covers (right and left)- EMC plates

Trough (left-hand side of machine)

Cover

Large cover

Small covers

Right

Left

Cover

EMC plate

Rear

Front


Remove the following components:- lock nuts (1), nuts (2) and washers (3)- screws (4) with strain washers (5)- plates (6)- screw (7) Screws (8) and sealing plates (9):- remove from the bag at the rack Sealing plates (9, 4x):- fasten with four screws (8) each time

4x

76

83

21

945


Fixing screws (1):- loosen Plates (2):- slide radially outside NOTE:Follow adjustment instructions on the adhesivelabel (3). Fixing screws (1):- tighten

Spindle Motor (interior)1 (4x)

2

2

3


Remove:- nut (1) with washer (2) Lock nut (3):- unscrew Remove screw (4) between spindle nut and hinge. Spacer (5):- remove from carriage

Carriage (interior)

X

1

2

Y

View Y

34

5


Carriage:- slide towards the spindle nut Four screws:- remove from the bag at the carriage Spindle nut and hinge:- connect with screws (6)

View X

X

6 (4x)


Remove six screws (1) with strainwashers (2).

Vacuum Pump, Base

1, 2 (6x each time)


Remove screws (1) with strain washers (2). Brackets (3, 4):- remove Screws (5):- unscrew from the base plate NOTE:The screws are secured with Loctite 222.

Compressed Air Unit, Base

X

View X

1, 2(2x each time)

1, 2(2x each time)

3

4

55


Attach covers and EMC plates.

Cover

Large cover

Small covers

Right

Left

Cover

EMC plate

Rear

Front

- 23 -SW Installation / Start-up

Switching on the machines:- Herkules- RIP- MAC(s) Test programs:- start, if necessary NOTE:For start-up and parameter setting, refer to the RIP dcumentation.

Mains Connection - 24 -

Factory settings:- 100, 115, 230 V NOTE:The set voltage is marked on the adhesive label next to the machine's power outlet. If another voltage is set, attach a corresponding label on top of the existing label. CAUTION:If the machine is switched off, the power supply is not interrupted. To separate the machine from the power supply, always pull out the power plug.

General Notes


Power Cables / Connector AdaptationConnection to 230 V: Delivered power cable:- must be used! NOTE:Power cable is designed for 230 V AC. CAUTION:If connections are established using power cables that were not provided by Heidelberg, or if connectors need to be adapted, the national regulations are to be observed. The power cables used in the USA and the Canada must at least be of the SJT type.


RegulationsCountry Connect.voltage

Plug type Cable type

North America125V 15A 110-120V

ANSI C73.11NEMA 5-15-P

IEC 83 Listed, Certified

Type SJT, 14AWG

Connection to 100-127 V AC

Use the following cable:




North America250V 15A 240V

ANSI C73.20NEMA 6-15-PIEC 83UL 198.6

Listed, CertifiedType SJT, 14AWG

Europe250V 10/16A 230V

CEE(7).II.IV.VIIIEC 83IEC 127

<HAR> H05VV-F

United Kingdom240V 6A 220-240V

B.S. 1363IEC 83IEC 127

<HAR> H05VV-F

Australia240V 10A 240-250V A.S. C112

IEC 127 <HAR> H05VV-F


Use one of the following cables in accordance with the national requirements:


The cores in the mains lead are colored in accordance with the following codes:- green and yellow: earth- blue: neutral- brown: live Since the colors of the mains lead may not correspond to the colors identifying the terminals in your plug, proceed as follows:- Connect the green and yellow colored core to the terminal in the plug which is marked with the letter "E", or with the earth symbol, or which is colored green and yellow.- Connect the blue colored core to the terminal in the plug which is marked with the letter "N" or which is colored black.- Connect the brown colored core to the terminal in the plug which is marked with the letter "L" or which is colored red.

Note for Installations in the UK


Check by means of the label next to the machine's power outlet whether the machine is prepared for the local voltage. CAUTION:Only connect the mains cable, if the supplied and the preset voltages are identical.

100 V / 115 V / 230 V


Other VoltagesStrapping plug:- plug onto a corresponding jumper (X28...X35) 100 V -> X28 200 V -> X32110 V -> X29 220 V -> X33120 V -> X30 230 V -> X34127 V -> X31 240 V -> X35 Voltages not listed, e.g. 115 V:- select the connector for the next higher voltage (here 120 V -> X30) Plug jumper:- onto X5 (U <= 127 V)- onto X6 (U > 127 V) "LINK 110 V" jumper at the power supply:- plugged (U <= 127 V)- pulled (U > 127 V)

X5

X6

X32

X33

X34

X35

X31

X30

X29

X28

X7

Pcb AC-CONTROLLER (5.950)

Powersupply module


CAUTION:Machine must only be connected to the power supply if the F1 fuse is equipped correctly. F1 fuse:- in the case of U <= 127 V: T 15 A / 250 V- in the case of U > 127 V: T 6.3 A / 250 V NOTE: Fuses have different bayonet joints. Stick the label indicating the set voltage on top of the old one. Label Order No. 230 V 04137655115 V 04258673all other voltages 04258703

Checking Mains Input FuseF1

Label

Fuse F1 Order No.

T 6.3 A 00138215T 15 A 04188713

Cabling - 33 -

MAC

ETHERNET

Herkules

XA3

XB6

Speedway

RS 232

RS 232

RIP 60

MAC

TAXI

A04

A08

XA7

VT 100(SERVICE)

OPS

A02

CAUTION:To comply with the interferenceregulations, only shielded datacables must be used.

Cabling - 34 -

MAC

ETHERNET

Herkules

XA3

XB6

Speedway

RS 232

RS 232

RIP 60

MAC

TAXI

A04

A08

XA7

VT 100(SERVICE)

OPS

A02

Establish the following connections: XA3 pcb RIP-INTERFACE <--> TAXI RIP:- Speedway - pull off rear panel at the upper edge and lift out of lower guide - loosen clamp screw (below the nest) - unhook upper section of clamp - center dismantled cable 20 mm (Speedway) on lower section of clamp - hook upper section of clamp and set screw

Cabling - 35 -

MAC

ETHERNET

Herkules

XA3

XB6

Speedway

RS 232

RS 232

RIP 60

MAC

TAXI

A04

A08

XA7

VT 100(SERVICE)

OPS

A02

Optional OPS link:- XA7 Pcb MATERIAL-CONTROL <--> on-line processor RIP <--> MAC, ETHERNET:- EtherTalk phase 1 or- EtherTalk phase 2 or- TCP / IP RIP <--> MAC:- RS 232 Mains connection to:- RIP- Herkules- MAC

- 1 -Preventive Maintenance / Maintenance Control

It is possible to set and monitor up to 4 time intervals (dates for maintenance work) using the maintenance control.Parameter setting and checking takes place via the Service terminal.Output when reaching a date additionally takes place via the unit terminal. The maintenance control is available as of the following software versions:Herkules Pro 5.01.001

General


The maintenance control is available via the Service terminal after password entry.

- Basic menu

1. speedway commands menue2. parameter menue3. test menue ... ... ...j. consumptionk. maintenance control

Machine xx ReleaseVersion: xxxDate: xx xx xx

(ON)(ON)

(ON)

General

PID list:PID 900-"Maintenance control" Off (0) / On (1)PID 901-Maintenance interval 1 (in days)PID 902- „-„ 2PID 903- „-„ 3PID 904- „-„ 4PID 905-Next service date 1 (in days)PID 906- „-„ 2PID 907- „-„ 3PID 908- „-„ 4 NOTEA maximum of 4 maintenance controls can be configured.

ATTENTIONPID 900 = 1 must be set in order to edit the "Maintenance control" menu.


Start:- in basic menu Select "Maintenance control". MAINTENANCE CONTROL menu- Display of remaining days until next service- only those intervals are displayed which have been set to greater than 0.

- Basic menu > Maintenance control

1. Service task A is due in 29 days Interval A = 30 days2. Service task B is due in 179 days Interval B = 180 days3. Service task C is due in 359 days Interval C = 360 days4. Service task D is due in 719 days Interval D = 720 days e. set interval valuesq. quit maintenance console

MAINTENANCE CONTROL

to reset a interval counter, select key (1..4)

Start


Output (terminal):- Output to the terminal (MAINTENANCE CONTROL menu) when exceeding a maintenance interval (Interval 1)- Intervals 3 and 4 are set to 0.

1. Since 5 days the service task A is overdue Interval A = 30 days2. Service task B is due in 145 days Interval B = 180 days

e. set interval valuesq. quit maintenance console

MAINTENANCE CONTROL

- Basic menu > Maintenance control

to reset a interval counter, select key (1,2)

Output


Resetting the maintenance counter:- Enter the number of the corresponding maintenance interval in the MAINTENANCE CONTROL menu. NOTEResetting a higher-level maintenance interval also acknowledges the intervals with shorter periods of time. Respond to the alert message with "No" (n):- the maintenance intervals are output without change Respond to the alert message with "Yes" (y):- the maintenance intervals are output in an updated state- the parameters are stored to floppy disk and in the Touchmemory.

Please confirm, that the service task A has been completely executed.

y / n >

MAINTENANCE CONTROL

- Basic menu - maintenance control > e. set interval values

Reset


Parameterizing the maintenance counter:- Press the e key in the MAINTENANCE CONTROL menu (e. set interval values)- Enter the line number to change an interval. Examples:- Set the interval to 90

> Enter line number1

< OutputMaintenace interval 1New Value =

> Enter value and acknowledge90 ENTER

- Set the interval to 720> Enter line number

4 etc...NOTEIntervals are stored in ascending order.0 values are stored after the interval with the highest parameter setting.

- Basic menu - Maintenance control > Reset an interval counter (..)

1. Maintenance interval A = 30 days2. Maintenance interval B = 180 days3. Maintenance interval C = 360 days4. Maintenance interval D = 0 days

q. quit

MAINTENANCE CONTROL

to set a new interval counter, select key(1..4)

Parameterize


The MAINTENANCE CONTROL menu is displayed with the new values after changing. NOTEThe changed intervals are displayed with the current status (time since the last reset). ATTENTIONA slight time delay occurs after entering a new value for an interval, as the new value is stored in the Touchmemory and to diskette.

- Basic menu - Maintenance control

MAINTENANCE CONTROL

to reset a interval counter, select key (1..4)

1. Service time A has to become in 89 days Interval A = 90 days2. Service time B has to become in 179 days Interval B = 180 days3. Service time C has to become in 359 days Interval C = 360 days4. Service time D has to become in 720 days Interval D = 720 days e. set interval valuesq. quit maintenance console

Parameterize

Base - 1 -

Nest

Mains Distributor

Compressed Air Unit

Vacuum Unit

Control Unit

Pcb Configuration

Mains Input

Base / Pcb Configuration - 2 -

1

2

3

4

5

A 07

A 02

A 09

A 08

A 04

A 06

A 01

A 03

A 05

with modification 27 or 28

1 04578503 #VOLTAGE-REG - 5.970

2 04860160 #HERK-IF - 2081.524(for machine with mod. 27)

04859987 #HERK-IF - 2081.523(for machines with mod. 28)

3 04122119 #FEED-CONTROL - 5.941

4 05262569 #TOP_MAINCONTROL - 6.276 cpl.

00049356 #FD drive, FD235HF-7529

05241251 #Adapter, FDD - Data

05130247 #Adapter, FDD - power

Base / Nest - 3 -

1

2

34

5

with modification 40

6

E 1

7 (4x)

1 04577698 #H-MOTHERBOARD - 5.949

2 05318483 #Power supply unit

3 04591402 #TOUCH MEMORY 4KX1

4 04595467 #TOUCH MEMORY + TIME

5 04595874 #Fan, axial

6 05356393 #Encoding connector 10 kOhm(Herkules PRO)

05356407 #Encoding connector 6.81 kOhm(Herkules)

7 02133113 #Flex. loc-element

- 4 -Base / Mains Input

1

3

2

4

5*

6* (2x)

* only for 115V

78*

1 04597575 #Bayonet joint (USA/CND, Japan)

04597583 #Bayonet joint (Europe, UK)

2 00138215 #Fuse T 6.3 A (Europe, UK)

04602080 #Fuse T 15 A (USA/CND, Japan)

3 04597567 #Fuse holder

4 04597591Protective cover

5 04745469Bracket

6 02079836Screw - M3x8 DINEN 7045

Base / Mains Distributor - 5 -

1

2

3

10 (2x)

11

9 (2x)

8 (4x)7 (4x)

5 (4x)

6 (4x)

4

1 04575431AC-CONTROL - 5.950

2 04966708Mains filter

3 04720393 #Toroidal transformer, cpl.

4 04555597Transformer, cpl.

5 00146552Nut - M4 DINEN 24032

6 00219991Serrated washer - DI 4.1

7 02288400Washer - DI 6.4 DIN 6796

8 00166375Nut - M6 DINEN 24032

Base / Mains Distributor - 6 -

1

2

3

10 (2x)

11

9 (2x)

8 (4x)7 (4x)

5 (4x)

6 (4x)

4

9 00219991Serrated washer - DI 4.1

10 00160202Screw - M4x6 DIN 912

11 04551540Housing, cpl.

Base / Control Unit - 7 -

12 (2x)

3 (2x)

4

1 04596692 #Control unit for stepping motor

2 00044946Screw - M4x12 DIN 912

3 02288389Washer - DI 4.3 DIN 6796

4 00028004 #Fan

Base / Compressed Air Unit - 8 -

Frame

Compressor

Heat Sink

10

11

4

59

3

8

7 (without item 6)

6 (2x)


1 2

E 2

12

1 04771982 #Line filter - 0.2 µm

2 04857364 #Vacuum hose130 mm long

3 04717015 #Screw connection

4 04772652 #Prefilter - 25 µm

5 05012546Case


7 05012732 #Filter unit

8 04772660 #Microfilter - 0.1 µm

Base / Compressed Air Unit - 9 -

Frame

Compressor

Heat Sink

10

11

4

59

3

8

7 (without item 6)

6 (2x)


1 2

E 2

12

9 04571347 #Case

10 04307046 #Fan, axial

11 00136603Protective grille

12 04585666 #Compressed air chamber

Base / Compressed Air Unit / Frame - 10 -

1

23

5

6

4

10 (6x)11 (2x)

98

7

12 (4x)

14

13 (4x)


S 11

16 (2x)15

1 04186192 #Compressed air switch

2 00292788 #Gasket

3 04568982Frame, cpl.

4 04718100Collecting tray

5 00292788 #Gasket

6 04771532 #G-quick-fastening attachment


8 04717023 #T-plug-in connector

Base / Compressed Air Unit / Frame - 11 -

1

23

5

6

4

10 (6x)11 (2x)

98

7

12 (4x)

14

13 (4x)


S 11

16 (2x)15


10 01288148Screw - M4x6

11 02455765Setscrew - M6x35 DIN 916

12 00169498Screw - M3x20 DIN 912


14 04718194Plate, cpl.

15 05137497 #Splash guard

16 00127787Cable holder

Base / Compressed Air Unit / Heat Sink - 12 -

1 (2x)2 (2x)

3 (2x)

9

7

56 (4x)

4 (2x)

13

11

15 (2x)

21

16 (2x)

17

14

19

13

18

25 (2x)

2417

10


8

22 20

23 (2x)

12

1 00218979Nut - M4 DIN 917

2 02034077 #Pressure spring

3 00055301Washer - DI 4.3 DIN 9021

4 04219597Insulating bushing

5 04587707Insulating sleeve

6 00033605Screw - M3x8 DINEN 7045

7 04975790 #AIR-CONTROL - 6.165

8 05014085 #Temperature sensor, cpl.


1 (2x)2 (2x)

3 (2x)

9

7

56 (4x)

4 (2x)

13

11

15 (2x)

21

16 (2x)

17

14

19

13

18

25 (2x)

2417

10


8

22 20

23 (2x)

12

9 04766652 #Peltier, cpl.

10 04973755 #Heat sink, cpl.

11 00938297Screw

12 04261976 #Sealing ring

13 04261976 #Sealing ring

14 04218337 #Screw, hollow

15 04219597Insulating bushing

16 00578762Screw - M4x50 DIN 912


1 (2x)2 (2x)

3 (2x)

9

7

56 (4x)

4 (2x)

13

11

15 (2x)

21

16 (2x)

17

14

19

13

18

25 (2x)

2417

10


8

22 20

23 (2x)

12

17 01876910 #Quick-fatening attachment



20 05013658 #Magnetic valve



23 00033605Screw - M3x8 DINEN 7045


1 (2x)2 (2x)

3 (2x)

9

7

56 (4x)

4 (2x)

13

11

15 (2x)

21

16 (2x)

17

14

19

13

18

25 (2x)

2417

10


8

22 20

23 (2x)

12

24 04662857Heat sink

25 01212729Screw - M4x16

Base / Compressed Air Unit / Compressor - 16 -

1

23 (4x)

8 (4x)

7 (4x)

5 (4x)

6 (4x)

4 (4x)

10 (2x)

11

9

12


13 1 04186206 #Compressor

2 04717007 #W- plug in connector

3 00964727 #Tension spring


5 00044938Screw - M4x10 DIN 912

6 02288389Washer - DI 4.3 DIN 6796

7 00164909Screw - M4x20 DIN 912

8 02288389Washer - DI 4.3 DIN 6796

Base / Compressed Air Unit / Compressor - 17 -

1

23 (4x)

8 (4x)

7 (4x)

5 (4x)

6 (4x)

4 (4x)

10 (2x)

11

9

12


13 9 04857364 #Vacuum hose330 mm long

10 04179536Bracket

11 04179528Plate

12 04213343 #Piston

13 04204719 #Filter

Base / Vacuum Unit - 18 -

2

1

34

Vacuum Pump 1 01459678 #Compressed air hose580 mm long

2 01459678 #Compressed air hose210 mm long

3 01459678 #Compressed air hose720 mm long

4 04716795 #Non-return valve

Base / Vacuum Unit / Vacuum Pump - 19 -

13 (2x)

11

12 (2x)

10 (6x)9 (6x)

6 (3x)

7 (3x)8 (3x)

2 (3x)

3 (3x)4 (3x)

5 (3x)

1

14

S 1215

1 04596021 #Vacuum pump

2 00166375Nut - M6 DINEN 24032

3 02288400Washer - DI 6.4 DIN 6796

4 00055557Washer - DI 6.4 DIN 9021

5 04722299Bracket

6 04686098 #Shock absorber

7 00055557Washer - DI 6.4 DIN 9021

8 04899822Setscrew - M6x45 DIN 916

Base / Vacuum Unit / Vacuum Pump - 20 -

13 (2x)

11

12 (2x)

10 (6x)9 (6x)

6 (3x)

7 (3x)8 (3x)

2 (3x)

3 (3x)4 (3x)

5 (3x)

1

14

S 1215

9 00139335Screw - M5x8 DIN 912

10 02288397Washer - DI 5.3 DIN 6796

11 04765826 #Valve, cpl.

12 00207098Screw - M4x40 DIN 912

13 02288389Washer - DI 4.3 DIN 6796

14 04204638 #Piston

15 00281166 #Microswitch

Basic Machine (left) - 1 -

Loading Platform

Optics Head

Rotating Mirror Unit

Drive

ECC Carrier

Bottom Punch

Bottom Punch Adapter

Lateral Punch

Basic Machine (right) - 2 -

Top Punch

Punch Adapter

Film Exit Unit

Cutting Device

Loop Switch

Mains, Safety Switch

Basic Machine / ECC Carrier - 3 -

7

1 2 (5x)

3 (8x)4 (8x)

5

6

8


E 5

1 04743482Cover

2 02936038Screw - M4x10

3 00207047Screw - M3x6 DIN 912

4 02288370Washer - DI 3.2 DIN 6796

5 04896904 #EC-CONTR EXT - 6.125

6 04541707ECC carrier

7 04661478 #Cable guide

8 04743490 #Fan

Basic Machine / Drive - 4 -

1

23 (2x)

45

(2)

6


Polling Unit

Pcb MOD. CONNECT

Opto Switch

Stepping Motor

Spindle

Guide Panels

1 02172550 #Rubber buffer

2 04717058 #Bearing unit (SP set)

3 00045047Screw - M6x20 DIN 912

4 04852222 #Flywheel

5 04721659 #Ring, cpl.

6 04847741 #Ball screw

04852419 #Ball screw (Herkules - M)

Basic Machine / Drive / Spindle - 5 -


6

78 9

1 (4x) 34

5

10

2

14 (4x)15

(8)

11 (4x)

13 (2x)

12

1 00044989Screw - M5x16 DIN 912

2 04847741 #Ball screw

04852419 #Ball screw (Herkules - M)

3 04853156 #Flange

4 04772717 #Sliding bearing

5 04793471 #Hose

6 00079936Screw - M3x12 DIN 912

7 04852834 #Bushing, cpl.

Basic Machine / Drive / Spindle - 6 -


6

78 9

1 (4x) 34

5

10

2

14 (4x)15

(8)

11 (4x)

13 (2x)

12

8 04717058 #Bearing unit (SP set)

9 04551885Ring

10 01507133 #Thrust piece, resilient

11 00166790Screw - M6x30 DIN 912

12 04270355Holder

13 02253356 #Pressing screw - M8x12

14 00207314Screw - M5x35 DIN 912

15 04270452Holder

- 7 -Parts Catalog / Basic Machine / Drive / Stepping Motor

1 (4x)2

3 4 5

6

7 (4x)

89

1110

M 8 1 00044946Screw - M4x12 DIN 912

2 04745418 #Stepping motor

3 04721659 #Ring, cpl.

4 00044938Screw - M4x10 DIN 912

5 00409383Thrust piece

6 04212975 #Stop

7 00146552Nut - M4 DINEN 24032

8 04212975 #Stop

Basic Machine / Drive / Pcb MOD. CONNECT - 8 -

1 (4x)

2 (4x)3

1 00044938Screw - M4x10 DIN 912

2 02288389Washer - DI 4.3 DIN 6796

3 04575423 #MODULE CONNECT - 5.952

Basic Machine / Drive / Opto Switch - 9 -

1

2 (2x)3 (2x)

5 (2x)

64 (2x)

B 2

1 02343533 #Opto switch 1

2 00049158Screw - M4x8 DIN 912

3 02288389Washer - DI 4.3 DIN 6796

4 00045039Screw - M6x16 DIN 912

5 04188039Cable clamp

6 04270347Block

Basic Machine / Drive / Polling Unit (MAT-WIDTH I) - 10 -

1 (2x)2 (2x)

34

6 (2x)

5

7 (2x)8 (2x)

910 (2x)

1 00044938Screw - M4x10 DIN 912

2 02288389Washer - DI 4.3 DIN 6796

3 04662261 #Adapter X82-X87

4 04556054Bracket

5 04662342Bracket

6 02288389Washer - DI 4.3 DIN 6796

7 00049158Screw - M4x8 DIN 912

8 02944863Pressure spring

Basic Machine / Drive / Polling Unit (MAT-WIDTH I) - 11 -

1 (2x)2 (2x)

34

6 (2x)

5

7 (2x)8 (2x)

910 (2x)

9 04576497 #MAT-WIDTH I - 6.004

10 00079936Screw - M3x12 DIN 912

Basic Machine / Drive / Polling Unit (MAT-WIDTH II) - 12 -

1 (2x)

2 (2x)

34

6 (2x)5

7 (2x)

1 01288148Screw - M4x6

2 02288389Washer - DI 4.3 DIN 6796

3 04662261 #Adapter X82-X87

4 04764641Bracket

5 04700805 #MAT-WIDTH II - 6.063

6 02288389Washer - DI 4.3 DIN 6796

7 00049158Screw - M4x8 DIN 912

Basic Machine / Drive / Guide Panels - 13 -

for Machines with Lateral Punch

1

2 (2x)3 (2x)

4 (2x)

5

6 (2x)7 (2x)

8 (2x)

9 (6x)10 (3x)11 (6x)

1 04970527 #Guide panel

2 00207381Screw - M4x25 DIN 912

3 00055301Washer - DI 4.3 DIN 9021


5 04971590 #Cover "Bacher"

04971612 #Cover "Stösser"

04719247Cover "customer-specific systems"



for Machines with Lateral Punch

1

2 (2x)3 (2x)

4 (2x)

5

6 (2x)7 (2x)

8 (2x)

9 (6x)10 (3x)11 (6x)

7 00055301Washer - DI 4.3 DIN 9021

8 00207381Screw - M4x25 DIN 912

9 00049638Nut - M3 DINEN 24032

10 04971620 #Mount

11 00577014Screw - M3x6 DINEN 7046


1 (2x)2 (2x)

3 (2x) 4

65 (2x)

7 (2x)8 (2x)

9 (2x)11 (2x)

10

12

for Machines without Lateral Punch (without modification 25)

1 00207381Screw - M4x25 DIN 912

2 00055301Washer - DI 4.3 DIN 9021


4 04719344 #Guide plate

5 00156566Screw - M4x16 DIN 912

6 04663136Block


8 00055301Washer - DI 4.3 DIN 9021


1 (2x)2 (2x)

3 (2x) 4

65 (2x)

7 (2x)8 (2x)

9 (2x)11 (2x)

10

12

for Machines without Lateral Punch (without modification 25)

9 00207381Screw - M4x25 DIN 912

10 04719344 #Guide plate

11 00156566Screw - M4x16 DIN 912

12 04663136Block

Basic Machine / Loading Platform - 17 -

3

5

2 (2x)

4

1 (4x)

2 (2x)

Guide Panels

Stepping MotorRewind Unit

1 04854209Screw - M4x20 DIN 912

2 04258193 #Elastic buffer

3 04552121 #Loading platform, cpl.(for machines without modification 90)

04766725 #Loading platform, cpl.(for machines with modification 90)

4 00094684 #Elastic buffer

5 04585208 #Polling unit

Basic Machine / Loading Platform - 18 -

3

5

2 (2x)

4

1 (4x)

2 (2x)

Guide Panels

Stepping MotorRewind Unit

Basic Machine / Loading Platform / Guide Panels - 19 -

1 (2x)

2 (2x)

4 (5x)6 (5x)

7 (5x)

5 (5x)

3

8


2 04588657 #Antistatic rail

3 00051209 #Deep-groove ball bearing - DI 6

4 00206903Screw - M3x6 DINEN 7045

5 02288370Washer - DI 3.2 DIN 6796

6 00206903Screw - M3x6 DINEN 7045

7 02288370Washer - DI 3.2 DIN 6796

8 04081226 #Position indicator, cpl.

Basic Machine / Loading Platform / Stepping Motor - 20 -

1

2

3

11 (2x)

5

12 (2x)

10

9

8 (4x)

6 (4x)

7 (4x)4

M 6

1 04270215 #Pin



4 04541014 #Pin

5 04148762 #Spur wheel

6 02080702Screw - M4x12 DIN 965

7 00049921Washer - DI 4.3 DIN 433

8 00146552Nut - M4 DINEN 24032

Basic Machine / Loading Platform / Stepping Motor - 21 -

1

2

3

11 (2x)

5

12 (2x)

10

9

8 (4x)

6 (4x)

7 (4x)4

M 6

9 04538978Bracket

10 00183989Lock washer - DI 6 DIN 6799

11 00213101Setscrew - M4x4 DIN 916

12 00213101Setscrew - M4x4 DIN 916

Basic Machine / Loading Platform / Rewind Unit - 22 -

2 (2x)

1

3

5

6

4

Rewind Motor


2 01487531Screw - M3x10 DINEN 7045

3 04535367Rewind motor

4 04534301Bushing


6 04768302Side panel

Basic Machine / Loading Platform / Rewind Unit / Rewind Motor - 23 -

4

1

2

3 M 5S 4


2 04078926 #Gear wheel

3 04186184 #Microswitch

4 04067282 #Motor w. gear unit

Basic Machine / Optics Head - 24 -

4 (4x)

1

3 (4x)2 (4x)

5 (4x)

67, 8

9 (2x)

10

1 04661397 #Optics head, cpl.

2 05000483Knurled screw - M4x35 DIN 653

3 00055301Washer - DI 4.3 DIN 9021


5 04586190Bushing

6 04718275Bracket

7 00049158Screw - M4x8 DIN 912

8 02288389Washer - DI 4.3 DIN 6796

Basic Machine / Optics Head - 25 -

4 (4x)

1

3 (4x)2 (4x)

5 (4x)

67, 8

9 (2x)

10

9 04222768 #Holder

10 04222571 #Plate

Basic Machine / Rotating Mirror Unit - 26 -

4 (4x)

1

3 (4x)2 (4x)

5 (4x)

7 (2x)

6

8


9

1 05126053 #Rotating mirror unit

2 05000483Knurled screw - M4x35 DIN 653

3 00055301Washer - DI 4.3 DIN 9021


5 04586190Bushing

6 04853091Fishplate

7 00044938Screw - M4x10 DIN 912

8 00164909Screw - M4x20 DIN 912

Basic Machine / Rotating Mirror Unit - 27 -

4 (4x)

1

3 (4x)2 (4x)

5 (4x)

7 (2x)

6

8


9

9 04771834 #W-quick fastening attachment

Basic Machine / Trough - 28 -

1

2

3

without modification 90

Y 2

Y 11

1 04244311 #Solenoid

2 04569962 #Retainer


Basic Machine / Bottom Punch - 29 -

Solenoid, right

Punch Drive

Solenoid, left

Opto Switch

Pressure Rail

Punch Body

Basic Machine / Bottom Punch / Punch Drive - 30 -

1

2 (2x)

3 45

6

8 79 (2x)10 (2x)

11

8

8

M 191 04597443 #Motor with gear unit

2 00044903Screw - M3x10 DIN 912

3 04768493Clamp

4 04768752Eccentric

5 04768566Connecting rod

6 00101028 #Sleeve

7 04768655Pin

8 04883284 #Spare parts set -bottom punch-Customer-specific spare parts set acc. to customer sheet

Basic Machine / Bottom Punch / Punch Drive - 31 -

1

2 (2x)

3 45

6

8 79 (2x)10 (2x)

11

8

8

M 199 00213101Setscrew - M4x4 DIN 916

10 00164909Screw - M4x20 DIN 912

11 04768396Bar

Basic Machine / Bottom Punch / Punch Body - 32 -

1 2

3 4 (6x)

5 (6x)

7 (2x)

6

8 (2x)

13 (4x)

9 (2x)

10

11

12

1 05139597Bracket

2 04772474 #Reflection strip

3 04883284 #Spare parts set -bottom punch-Customer-specific spare parts set acc. to customer sheet

4 00049158Screw - M4x8 DIN 912

5 02288389Washer - DI 4.3 DIN 6796


7 00217662Screw - M3x25 DIN 912

Basic Machine / Bottom Punch / Punch Body - 33 -

1 2

3 4 (6x)

5 (6x)

7 (2x)

6

8 (2x)

13 (4x)

9 (2x)

10

11

12

8 00044946Screw - M4x12 DIN 912

9 02288389Washer - DI 4.3 DIN 6796

10 04767985Collecting try

11 02288389Washer - DI 4.3 DIN 6796

12 00044946Screw - M4x12 DIN 912

13 00207098Screw - M4x40 DIN 912

Basic Machine / Bottom Punch / Pressure Rail - 34 -

1

2

3 (2x)

4 (3x)

5 (3x)6

8 (2x)

7

9

10

11 (2x)

1 04768396Bar

2 04722132Plate

3 00183334Screw - M2x4 DINEN 1207

4 04765737Screw - M3x3x3.5

5 00055255Washer - DI 4.3 DIN 125


7 04765168 #Pressure rail

8 00183334Screw - M2x4 DINEN 1207

Basic Machine / Bottom Punch / Pressure Rail - 35 -

1

2

3 (2x)

4 (3x)

5 (3x)6

8 (2x)

7

9

10

11 (2x)


10 04722132Plate

11 00184241Straight pin - M6x10 DINEN 22338

Basic Machine / Bottom Punch / Opto Switch - 36 -

1 2 (2x)

34 (2x)

5 (2x)

6

B 19

1 04794028Bracket

2 01288121Screw - M3x6 DIN 965

3 02608588 #Opto switch

4 00391611Washer - DI 2.7 DIN 125

5 01212664Screw - M2.5x6

6 04768396Bar

Basic Machine / Bottom Punch / Solenoid, Left - 37 -

1

2

3

4 (2x)

5 (2x)7 (2x) 68 (2x)

Y 2


2 00045330Setscrew - M3x4 DIN 916

3 04979834 #Sleeve

4 02288370Washer - DI 3.2 DIN 6796

5 00207047Screw - M3x6 DIN 912

6 04768485Bracket

7 02288389Washer - DI 4.3 DIN 6796

8 00044946Screw - M4x12 DIN 912

Basic Machine / Bottom Punch / Solenoid, Left - 38 -

1

2

3

4 (2x)

5 (2x)7 (2x) 68 (2x)

Y 2

Basic Machine / Bottom Punch / Solenoid, Right - 39 -

1

2

34

5 (2x)

7 (2x)

6 (2x)

8 (2x)

Y 1

1 00045330Setscrew - M3x4 DIN 916

2 04979834 #Sleeve


4 04768477Bracket

5 02288389Washer - DI 4.3 DIN 6796

6 00044946Screw - M4x12 DIN 912

7 00207047Screw - M3x6 DIN 912

8 02288370Washer - DI 3.2 DIN 6796

Basic Machine / Bottom Punch / Solenoid, Right - 40 -

1

2

34

5 (2x)

7 (2x)

6 (2x)

8 (2x)

Y 1

Basic Machine / Bottom Punch Adapter - 41 -

Solenoid, right

Pressure Rail

Solenoid, left

Basic Machine / Bottom Punch Adapter / Pressure Rail - 42 -

12

3

4 (6x)

5 (6x)6 (2x)

8

7 9

14 (2x)

10 (4x)

11 (4x)

12

13

15 (3x)

16 (3x)18

17

1 04768299Bar

2 05139597Bracket


4 02288389Washer - DI 4.3 DIN 6796

5 00049158Screw - M4x8 DIN 912

6 00183334Screw - M2x4 DINEN 1207


8 04722132Plate


12

3

4 (6x)

5 (6x)6 (2x)

8

7 9

14 (2x)

10 (4x)

11 (4x)

12

13

15 (3x)

16 (3x)18

17


10 02288389Washer - DI 4.3 DIN 6796

11 00156566Screw - M4x16 DIN 912

12 04767969Carrier

13 04722132Plate

14 00183334Screw - M2x4 DINEN 1207

15 04765737Screw - M3x3x3.5

16 00055255Washer - DI 4.3 DIN 125


12

3

4 (6x)

5 (6x)6 (2x)

8

7 9

14 (2x)

10 (4x)

11 (4x)

12

13

15 (3x)

16 (3x)18

17



Basic Machine / Bottom Punch Adapter / Solenoid, Left - 45 -

1

2

3

4 (2x)

5 (2x)7 (2x)6

8 (2x)

Y 2


2 00045330Setscrew - M3x4 DIN 916

3 04979834 #Sleeve

4 02288370Washer - DI 3.2 DIN 6796

5 00207047Screw - M3x6 DIN 912

6 04768485Bracket

7 02288389Washer - DI 4.3 DIN 6796

8 00044946Screw - M4x12 DIN 912

Basic Machine / Bottom Punch Adapter / Solenoid, Left - 46 -

1

2

3

4 (2x)

5 (2x)7 (2x)6

8 (2x)

Y 2

Basic Machine / Bottom Punch Adapter / Solenoid, Right - 47 -

1

2

3

45 (2x)

7 (2x)

6 (2x)

8 (2x)

Y 1

1 00045330Setscrew - M3x4 DIN 916

2 04979834 #Sleeve


4 04768477Bracket

5 02288389Washer - DI 4.3 DIN 6796

6 00044946Screw - M4x12 DIN 912

7 00207047Screw - M3x6 DIN 912

8 02288370Washer - DI 3.2 DIN 6796

Basic Machine / Bottom Punch Adapter / Solenoid, Right - 48 -

1

2

3

45 (2x)

7 (2x)

6 (2x)

8 (2x)

Y 1

Basic Machine / Lateral Punch - 49 -

Punch Replacement Parts

2 (2x)1

1

1

2 (2x)

2 (2x)

3 (3x) 1 04718550Punch body

2 00207098Screw - M4x40 DIN 912

3 04715330Screw - M6x55 DIN 912

Basic Machine / Lateral Punch / Punch Replacement Parts - 50 -

5 (2x)

1

6

4 (2x)

6

6

6

2 (2x)3

1 04766520Holder

2 04715381Screw - M3x30 DIN 7984

3 04719182 #Punch head

4 01487825Screw - M4x8 DINEN 7046

5 00167339Screw - M3x16 DIN 7984

6 04882512 #Spare parts set "Bacher"Customer-specific spare parts set acc. to customer sheet

Lateral Punch "Bacher"

Basic Machine / Lateral Punch / Punch Replacement Parts - 51 -

5 (2x)

1

6

4 (2x)

6

6

6

2 (2x)3

Lateral Punch "Stösser"1 04766520Holder

2 04715381Screw - M3x30 DIN 7984

3 04719182 #Punch head

4 01487825Screw - M4x8 DINEN 7046

5 00167339Screw - M3x16 DIN 7984

6 04881710 #Spare parts set "Stösser"Customer-specific spare parts set acc. to customer sheet

- 52 -Parts Catalog / Basic Machine / Cutting Device

1 (2x)

2 (2x)

3 (2x)

4

Drive

Cutting Wheel

Cutting Rail

1 00055301Washer - DI 4.3 DIN 9021

2 00160202Screw - M4x6 DIN 912

3 00049158Screw - M4x8 DIN 912

4 04552040 #Cutting device

Basic Machine / Cutting Device / Drive - 53 -

1

2

3

15

16

17 (4x)

18 (4x)

1112

14

10

9

8

6

7

4 (2x)

5

19

M 4 13

1 04039203Knob

2 04295544 #Toothed belt

3 04081293 #Toothed belt pulley

4 00045292Setscrew - M4x8 DIN 915

5 04081838 #Ring

6 04081633Housing

7 04081226 #Position indicator, cpl.

8 00146552Nut - M4 DINEN 24032


1

2

3

15

16

17 (4x)

18 (4x)

1112

14

10

9

8

6

7

4 (2x)

5

19

M 4 13

9 02288389Washer - DI 4.3 DIN 6796

10 04212428Axle

11 04086058Retaining disk


13 04086058Retaining disk

14 00055255Washer - DI 4.3 DIN 125

15 00062847Lock washer - DI 3.2 DIN 6799



1

2

3

15

16

17 (4x)

18 (4x)

1112

14

10

9

8

6

7

4 (2x)

5

19

M 4 13

17 02288370Washer - DI 3.2 DIN 6796

18 00044903Screw - M3x10 DIN 912

19 00422142 #Magnet

Basic Machine / Cutting Device / Cutting Rail - 56 -

1

2

3 (3x)

13

15

16

17 (6x)

10

1112 (2x)

9

8 (3x)7 (2x)

5

6 (2x)

14 (2x)

4

1819

1 00106178Adhesive label

2 04552210Cassette mount

3 01424238Screw - ST 2.9x13 DIN 7981

4 04534271Bracket

5 00049158Screw - M4x8 DIN 912

6 01424238Screw - ST 2.9x13 DIN 7981

7 01424238Screw - ST 2.9x13 DIN 7981

8 01424238Screw - ST 2.9x13 DIN 7981


1

2

3 (3x)

13

15

16

17 (6x)

10

1112 (2x)

9

8 (3x)7 (2x)

5

6 (2x)

14 (2x)

4

1819

9 00049158Screw - M4x8 DIN 912

10 04552563Bracket



13 04551788 #Cutting rail

14 00045292Setscrew - M4x8 DIN 915

15 00226017Straight pin - 8x24 DINEN 22338

16 04551974 #Rail


1

2

3 (3x)

13

15

16

17 (6x)

10

1112 (2x)

9

8 (3x)7 (2x)

5

6 (2x)

14 (2x)

4

1819

17 00049158Screw - M4x8 DIN 912

18 00103837Double-stick tape

19 05181259Gasket

Basic Machine / Cutting Device / Cutting Wheel - 59 -- 59 -

1

2

3

4

567

8

1 04082869 #CUT REED 2 - 5.894

2 04082869 #CUT REED 2 - 5.894

3 04209656Holder

4 00158135Cable holder

5 02079658Screw - M4x6 DINEN 7045

6 04144937 #Cutting wheel, cpl.

7 00055255Washer - DI 4.3 DIN 125

8 00164909Screw - M4x20 DIN 912

Basic Machine / Loop Switch - 60 -

4

1 2

3 (2x)

5 (2x)6 (2x)

S 2

1 04078551Plate

2 04661885Holder

3 00044946Screw - M4x12 DIN 912

4 04595890 #Microswitch, Hall

5 00143472Insulating washer - DI 3.2

6 02080095Screw - M2.5x16 DINEN 7045

Basic Machine / Film Exit Unit - 61 -

2 (10x)1

3 (10x)

4


Control Unit

Stepping Motor

Roller Drive

Gear Unit Motor, Solenoid

Diode HolderBlock

1 04542444 #Film exit unit, cpl.

2 00044946Screw - M4x12 DIN 912

3 02288389Washer - DI 4.3 DIN 6796


Basic Machine / Film Exit Unit / Diode Holder - 62 -

1

23

45

7

89

10

1112

13 (2x)

1415 (3x)

16

17

18

19

6B 9

1 04766369Screw - M6x30

2 04661192Block

3 00233102Washer - DI 5.2

4 00409383Thrust piece

5 04588274 #Tapped plate

6 04661702 #Diode holder

7 04721594Guide

8 00441759Spacer


1

23

45

7

89

10

1112

13 (2x)

1415 (3x)

16

17

18

19

6B 9

9 00055352Washer - DI 3.2 DIN 9021

10 01424238Screw - ST 2.9x13 DIN 7981



13 00206849Setscrew - M4x6 DIN 916

14 04081838 #Ring

15 00233102Washer - DI 5.2



1

23

45

7

89

10

1112

13 (2x)

1415 (3x)

16

17

18

19

6B 9

17 01359002Spacer

18 04661966 #Threaded rod

19 04661168 #Flat cable

Basic Machine / Film Exit Unit / Roller Drive - 65 -

1

2

34

7

65

810

11 (2x)

9

12

13

14 (2x)15

16


Stepping Motor

1 04542258 #Front guide panel

2 04662059 #Holder

3 00044938Screw - M4x10 DIN 912

4 00055301Washer - DI 4.3 DIN 9021

5 02288389Washer - DI 4.3 DIN 6796

6 00146552Nut - M4 DINEN 24032



Basic Machine / Film Exit Unit / Roller Drive - 66 -

1

2

34

7

65

810

11 (2x)

9

12

13

14 (2x)15

16


Stepping Motor

9 04551796 #Roller


11 01212729Screw - M4x16

12 01430211Spacer

13 04081838 #Ring

14 00206849Setscrew - M4x6 DIN 916



Basic Machine / Film Exit Unit / Roller Drive / Stepping Motor - 67 -

1 (2x)2 (2x)

3 (2x)4 (2x)

5 (2x)

6 (2x)

9

8 (2x)7

14

1012 (2x) 13

(2x)

11

15

16 (5x)

17

M 3

1 00044938Screw - M4x10 DIN 912

2 02288389Washer - DI 4.3 DIN 6796

3 00100811Spacer

4 00055379Washer - DI 5.3 DIN 9021

5 02288389Washer - DI 4.3 DIN 6796

6 00055891Screw - M4x10 DIN 6912


8 00206849Setscrew - M4x6 DIN 916


1 (2x)2 (2x)

3 (2x)4 (2x)

5 (2x)

6 (2x)

9

8 (2x)7

14

1012 (2x) 13

(2x)

11

15

16 (5x)

17

M 3

9 04081838 #Ring



12 01288148Screw - M4x6

13 02288389Washer - DI 4.3 DIN 6796

14 00593745 #Sliding bearing - DI 8

15 04640829Washer

16 04662148 #Roller


1 (2x)2 (2x)

3 (2x)4 (2x)

5 (2x)

6 (2x)

9

8 (2x)7

14

1012 (2x) 13

(2x)

11

15

16 (5x)

17

M 3

17 04765621 #Vibration damper, cpl.

Basic Machine / Film Exit Unit / Control Unit - 70 -

1 (3x)

2 (6x)

3 (2x)4 (2x)

5

8

7

6

9 (5x)

10

S 16

Control Rollers 1, 2, 4

Rear Guide Panel Control Roller 3 1 04574451 #Magnetic lock

2 02079917Screw - M3x4 DINEN 7045

3 02288389Washer - DI 4.3 DIN 6796

4 01288148Screw - M4x6

5 04542517Block

6 00593745 #Sliding bearing - DI 8

7 04640829Washer

8 00099228 #Safety switch

Basic Machine / Film Exit Unit / Control Unit - 71 -

1 (3x)

2 (6x)

3 (2x)4 (2x)

5

8

7

6

9 (5x)

10

S 16

Control Rollers 1, 2, 4

Rear Guide Panel Control Roller 3 9 04662148 #Roller


Basic Machine / Film Exit Unit / Control Unit / Control Rollers 1, 2, 4 - 72 -

1 (6x)2 (9x)

3 (6x)

4 (6x)5 (3x)

7 (3x)

6 (3x)

9 (3x)

8 (6x)


1 00100064Spacer

2 04587618 #Roller

3 00233064Adjusting washer - DI 5.2


5 04085256Axle

6 04567927 #Holder


8 02080257Screw - M4x8 DIN 965

Basic Machine / Film Exit Unit / Control Unit / Control Rollers 1, 2, 4 - 73 -

1 (6x)2 (9x)

3 (6x)

4 (6x)5 (3x)

7 (3x)

6 (3x)

9 (3x)

8 (6x)


9 04947827 #Block

Basic Machine / Film Exit Unit / Control Unit / Control Roller 3 - 74 -

1 (2x)2 (3x)

3 (2x)

4 (2x)5

87

6

14

1312

11

10

15

9

20

17 (3x)

16

19

18 (3x)


M 14

1 00100064Spacer

2 04587618 #Roller

3 00233064Adjusting washer - DI 5.2


5 04085256Axle

6 04567927 #Holder


8 02080257Screw - M4x8 DIN 965


1 (2x)2 (3x)

3 (2x)

4 (2x)5

87

6

14

1312

11

10

15

9

20

17 (3x)

16

19

18 (3x)


M 14

9 04947827 #Block

10 01338811Screw - M4x16 DINEN 7045


12 00102040Spacer

13 04661893Lever

14 00413216Setscrew - M6x6 DIN 916


16 04567242Bracket


1 (2x)2 (3x)

3 (2x)

4 (2x)5

87

6

14

1312

11

10

15

9

20

17 (3x)

16

19

18 (3x)


M 14

17 00391611Washer - DI 2.7 DIN 125

18 00216534Screw - M2x6 DINEN 1207

19 04566459 #Block

20 00206849Setscrew - M4x6 DIN 916

Basic Machine / Film Exit Unit / Control Unit / Rear Guide Panel - 77 -

1

5 (2x)

6

7

8

9 (3x)

11

10 (3x)

2 3

4

1 00146552Nut - M4 DINEN 24032

2 02288389Washer - DI 4.3 DIN 6796

3 05132819Guide

4 01487477Screw - M3x6 DINEN 7045

5 00975427Screw - ST 2.9x6.5 DIN 7982

6 04662881 #Block



Basic Machine / Film Exit Unit / Stepping Motor - 78 -

12 3 4 (3x)

5 (2x)6

9

8

714 (2x)

10 (2x)

12

13

11 M 2

15 (2x)

1 04661966 #Threaded rod

2 01359002Spacer


4 00233102Washer - DI 5.2

5 00206849Setscrew - M4x6 DIN 916

6 04081838 #Ring



Basic Machine / Film Exit Unit / Stepping Motor - 79 -

12 3 4 (3x)

5 (2x)6

9

8

714 (2x)

10 (2x)

12

13

11 M 2

15 (2x)

9 02034441Spacer

10 00044938Screw - M4x10 DIN 912



13 04081838 #Ring

14 00206849Setscrew - M4x6 DIN 916

15 00055379Washer - DI 5.3 DIN 9021

Basic Machine / Film Exit Unit / Gear Unit Motor, Solenoid - 80 -

1 (2x) 2 (3x)3 (3x)

4

5

6

8 (2x)

7 (2x)


9Y 10

M 1

1 00206849Setscrew - M4x6 DIN 916

2 00216534Screw - M2x6 DINEN 1207

3 00391611Washer - DI 2.7 DIN 125




7 02288370Washer - DI 3.2 DIN 6796

8 00207047Screw - M3x6 DIN 912

Basic Machine / Film Exit Unit / Gear Unit Motor, Solenoid - 81 -

1 (2x) 2 (3x)3 (3x)

4

5

6

8 (2x)

7 (2x)


9Y 10

M 1

9 04662245 #Sleeve

Basic Machine / Film Exit Unit / Block - 82 -

1

2

3 (2x)

1 04662881 #Block

2 04720512Leaf spring

3 00975427Screw - ST 2.9x6.5 DIN 7982

Basic Machine / Top Punch - 83 -


Solenoid

Stepping Motor

Left Rollers

Right Rollers

Basic Machine / Top Punch / Solenoid - 84 -

1 (2x)

2 (4x)3 (4x)

4

8 9 (2x)

11

10 (2x)

12 (3x)

13 (3x)

12

14 (2x)

15 (2x)

Y 6Y 8

13

5 (2x) 7

(2x)

6B 17

Right Connecting Rod


2 00207047Screw - M3x6 DIN 912

3 02288370Washer - DI 3.2 DIN 6796

4 04587251Side panel, cpl.

5 01212664Screw - M2.5x6

6 02608588 #Opto switch

7 00391611Washer - DI 2.7 DIN 125

8 04585305Bracket

Basic Machine / Top Punch / Solenoid - 85 -

1 (2x)

2 (4x)3 (4x)

4

8 9 (2x)

11

10 (2x)

12 (3x)

13 (3x)

12

14 (2x)

15 (2x)

Y 6Y 8

13

5 (2x) 7

(2x)

6B 17

Right Connecting Rod

9 02288389Washer - DI 4.3 DIN 6796

10 00044938Screw - M4x10 DIN 912

11 04721969Spacer hex.

12 02288389Washer - DI 4.3 DIN 6796

13 00044938Screw - M4x10 DIN 912

14 04979834 #Sleeve

15 00045330Setscrew - M3x4 DIN 916

Basic Machine / Top Punch / Solenoid / Right Connecting Rod - 86 -

1

2 34 5

6

8 (2x)7

12

10 (2x)11 (2x)

9

1314

15

1918 (3x)

17 (3x)

16 (3x)

20

22

21

23(13)

24 25

(6)

27

26

M 17

1 00167258Circlip - 8x0.8 DIN 471

2 00232882Washer - DI 8.1

3 02121492 #Sleeve

4 01181041Washer - DI 8.1

5 01763814 #Pin

6 04661257 #Connecting rod

7 04979826Flange

8 00206830Setscrew-M4x10 DIN 916


1

2 34 5

6

8 (2x)7

12

10 (2x)11 (2x)

9

1314

15

1918 (3x)

17 (3x)

16 (3x)

20

22

21

23(13)

24 25

(6)

27

26

M 17


10 00164909Screw - M4x20 DIN 912

11 02288389Washer - DI 4.3 DIN 6796



14 04661354Motor plate


16 00044938Screw - M4x10 DIN 912


1

2 34 5

6

8 (2x)7

12

10 (2x)11 (2x)

9

1314

15

1918 (3x)

17 (3x)

16 (3x)

20

22

21

23(13)

24 25

(6)

27

26

M 17

17 02288389Washer - DI 4.3 DIN 6796

18 04722043Spacer, hex.

19 04661265Bearing block

20 00167258Circlip - 8x0.8 DIN 471

21 00232882Washer - DI 8.1

22 02121492 #Sleeve

23 01181041Washer - DI 8.1

24 04720997 #Pin


1

2 34 5

6

8 (2x)7

12

10 (2x)11 (2x)

9

1314

15

1918 (3x)

17 (3x)

16 (3x)

20

22

21

23(13)

24 25

(6)

27

26

M 17

25 00408557Clamping pin - 2.5x14 DINEN 28752


27 04585348Shaft

Basic Machine / Top Punch / Stepping Motor - 90 -

14 (3x)

131 (2x)

2 (4x)

3 (4x)

4 (2x)

5

6

9 (4x)

1012 11

8 (4x)7 (4x)

15 (3x)

16

A

1 (2x)17 (2x)

A

18 (2x)

Y 9

Y 7

M 7

Left Connecting Rod


2 00207047Screw - M3x6 DIN 912

3 02288370Washer - DI 3.2 DIN 6796

4 00206849Setscrew - M4x6 DIN 916

5 04081838 #Ring


7 00044946Screw - M4x12 DIN 912

8 02288389Washer - DI 4.3 DIN 6796


14 (3x)

131 (2x)

2 (4x)

3 (4x)

4 (2x)

5

6

9 (4x)

1012 11

8 (4x)7 (4x)

15 (3x)

16

A

1 (2x)17 (2x)

A

18 (2x)

Y 9

Y 7

M 7

Left Connecting Rod

9 00146552Nut - M4 DINEN 24032


11 00044938Screw - M4x10 DIN 912

12 02288389Washer - DI 4.3 DIN 6796

13 04721969Spacer hex.

14 02288389Washer - DI 4.3 DIN 6796

15 00044938Screw - M4x10 DIN 912



14 (3x)

131 (2x)

2 (4x)

3 (4x)

4 (2x)

5

6

9 (4x)

1012 11

8 (4x)7 (4x)

15 (3x)

16

A

1 (2x)17 (2x)

A

18 (2x)

Y 9

Y 7

M 7

Left Connecting Rod

17 04979834 #Sleeve

18 00045330Setscrew - M3x4 DIN 916

Basic Machine / Top Punch / Stepping Motor / Left Connecting Rod - 93 -

2122

23

1

2

3 (2x)4 (2x)

5 (2x)

87

6 (2x)

9 (2x)

11 (2x)

12

10 (2x)

13 1415

161718

1920

(18)

1 04585348Shaft

2 00164828Circlip - 10x1 DIN 471

3 00164909Screw - M4x20 DIN 912

4 02288389Washer - DI 4.3 DIN 6796

5 02285908Screw - M4x5 DIN 58450

6 00055301Washer - DI 4.3 DIN 9021

7 04661265Bearing block



2122

23

1

2

3 (2x)4 (2x)

5 (2x)

87

6 (2x)

9 (2x)

11 (2x)

12

10 (2x)

13 1415

161718

1920

(18)

9 00055301Washer - DI 4.3 DIN 9021

10 02285908Screw - M4x5 DIN 58450

11 00206830Setscrew-M4x10 DIN 916

12 04979826Flange

13 01763814 #Pin

14 01181041Washer - DI 8.1

15 02121492 #Sleeve

16 00167258Circlip - 8x0.8 DIN 471


2122

23

1

2

3 (2x)4 (2x)

5 (2x)

87

6 (2x)

9 (2x)

11 (2x)

12

10 (2x)

13 1415

161718

1920

(18)

17 00232882Washer - DI 8.1

18 04661257 #Connecting rod

19 00167258Circlip - 8x0.8 DIN 471

20 00232882Washer - DI 8.1

21 02121492 #Sleeve

22 01181041Washer - DI 8.1

23 04720997 #Pin


2122

23

1

2

3 (2x)4 (2x)

5 (2x)

87

6 (2x)

9 (2x)

11 (2x)

12

10 (2x)

13 1415

161718

1920

(18)

Basic Machine / Top Punch / Right Rollers - 97 -

1 (2x)2 3 (2x)

4 5 (2x)6 (4x)

9 (2x)8 (2x)

7 (2x)



3 04084632 #Roller

4 04586271Plate

5 04533534Washer

6 00206849Setscrew - M4x6 DIN 916



Basic Machine / Top Punch / Right Rollers - 98 -

1 (2x)2 3 (2x)

4 5 (2x)6 (4x)

9 (2x)8 (2x)

7 (2x)

9 04794060 #Roller

Basic Machine / Top Punch / Left Rollers - 99 -

1 (2x)2 (2x)

3 (2x)

4 56

98

7 (2x)

14

10

1213 (2x) 11 (2x)

1516 (2x)

17 (2x)

18 19 (4x)

20 (3x)

21 (3x)

1 04794060 #Roller



4 04588363Tube



7 00206849Setscrew - M4x6 DIN 916

8 04081838 #Ring


1 (2x)2 (2x)

3 (2x)

4 56

98

7 (2x)

14

10

1213 (2x) 11 (2x)

1516 (2x)

17 (2x)

18 19 (4x)

20 (3x)

21 (3x)

9 04533410Washer

10 04586271Plate



13 04084632 #Roller

14 04533534Washer

15 04553268Tube



1 (2x)2 (2x)

3 (2x)

4 56

98

7 (2x)

14

10

1213 (2x) 11 (2x)

1516 (2x)

17 (2x)

18 19 (4x)

20 (3x)

21 (3x)

17 04722132Plate


19 00183334Screw - M2x4 DINEN 1207

20 00055255Washer - DI 4.3 DIN 125

21 04765737Screw - M3x3x3.5

Basic Machine / Top Punch / Punch Replacement Parts - 102 -

1

2

3

4

5

5

55

5

1 00217662Screw - M3x25 DIN 912

2 00217662Screw - M3x25 DIN 912

3 04585054Plate

4 00169498Screw - M3x20 DIN 912

5 Spare parts set (standard)

04851129 # Bacher

04852540 # Stösser

04852370 # LHLTD Customer-specific spare parts set acc. to customer sheet


1

2

3

4

5

5

55

5

Basic Machine / Punch Adapter - 105 -

1

Holder

Drive

1 04719581 #Punch adapter

Basic Machine / Punch Adapter / Drive - 106 -

1 (4x)

2 (4x)

3 (2x)4 (2x)

5 (2x)

876 (2x)

13 (2x)

911

12

10

14 (2x)

1516 (2x)

1718

19

20 (2x)

21 (2x)

22 (4x)

23 (3x)

24 (3x)

25

26 27

28

29 (2x)

30 (2x)

Y 9Y 7

Stepping Motor1 00207047Screw - M3x6 DIN 912

2 02288370Washer - DI 3.2 DIN 6796


4 00045330Setscrew - M3x4 DIN 916

5 04979834 #Sleeve

6 04722280Spacer - 26 mm, size 6

7 04588363Tube



1 (4x)

2 (4x)

3 (2x)4 (2x)

5 (2x)

876 (2x)

13 (2x)

911

12

10

14 (2x)

1516 (2x)

1718

19

20 (2x)

21 (2x)

22 (4x)

23 (3x)

24 (3x)

25

26 27

28

29 (2x)

30 (2x)

Y 9Y 7

Stepping Motor9 04715470 #Toothed belt

10 00206849Setscrew - M4x6 DIN 916

11 04081838 #Ring

12 04533410Washer




16 04084632 #Roller


1 (4x)

2 (4x)

3 (2x)4 (2x)

5 (2x)

876 (2x)

13 (2x)

911

12

10

14 (2x)

1516 (2x)

1718

19

20 (2x)

21 (2x)

22 (4x)

23 (3x)

24 (3x)

25

26 27

28

29 (2x)

30 (2x)

Y 9Y 7

Stepping Motor17 04722124Plate

18 04533534Washer

19 04553268Tube


21 04722132Plate

22 00183334Screw - M2x4 DINEN 1207

23 04765737Screw - M3x3x3.5

24 00055255Washer - DI 4.3 DIN 125


1 (4x)

2 (4x)

3 (2x)4 (2x)

5 (2x)

876 (2x)

13 (2x)

911

12

10

14 (2x)

1516 (2x)

1718

19

20 (2x)

21 (2x)

22 (4x)

23 (3x)

24 (3x)

25

26 27

28

29 (2x)

30 (2x)

Y 9Y 7

Stepping Motor25 04765168 #Pressure rail

26 01487736Screw - M4x8 DINEN 7045

27 02288389Washer - DI 4.3 DIN 6796

28 04721853Bracket

29 00044946Screw - M4x12 DIN 912

30 02288389Washer - DI 4.3 DIN 6796

Basic Machine / Punch Adapter / Drive / Stepping Motor - 110 -

17 (2x)

13 (4x)

1 2 (6x)3 (6x)

45

6 (2x)

9

10

12 (4x)

11

8 (2x)

7 (2x)18 (2x)

14 (4x)

1516 (2x)

M 7

1 04722205Guide plate

2 01487736Screw - M4x8 DINEN 7045

3 02288389Washer - DI 4.3 DIN 6796



6 02288389Washer - DI 4.3 DIN 6796

7 00044938Screw - M4x10 DIN 912

8 00206849Setscrew - M4x6 DIN 916


17 (2x)

13 (4x)

1 2 (6x)3 (6x)

45

6 (2x)

9

10

12 (4x)

11

8 (2x)

7 (2x)18 (2x)

14 (4x)

1516 (2x)

M 7



11 04081838 #Ring

12 00044946Screw - M4x12 DIN 912

13 02288389Washer - DI 4.3 DIN 6796

14 00146552Nut - M4 DINEN 24032




17 (2x)

13 (4x)

1 2 (6x)3 (6x)

45

6 (2x)

9

10

12 (4x)

11

8 (2x)

7 (2x)18 (2x)

14 (4x)

1516 (2x)

M 7


18 04794060 #Roller

Basic Machine / Punch Adapter / Holder - 113 -

1 (2x)2

3 (2x)

4 (2x) 5 (2x)

6 (2x)

1413 (2x)

7 (2x)

8 (2x)9 (2x)10

11 12

Solenoid



3 04084632 #Roller


5 04722035Spacer - 21.5 mm, size 6

6 00206849Setscrew - M4x6 DIN 916


8 00044946Screw - M4x12 DIN 912

Basic Machine / Punch Adapter / Holder - 114 -

1 (2x)2

3 (2x)

4 (2x) 5 (2x)

6 (2x)

1413 (2x)

7 (2x)

8 (2x)9 (2x)10

11 12

Solenoid

9 02288389Washer - DI 4.3 DIN 6796

10 04720881Bracket

11 01487736Screw - M4x8 DINEN 7045

12 02288389Washer - DI 4.3 DIN 6796

13 04533534Washer

14 04722124Plate

Basic Machine / Punch Adapter / Holder / Solenoid - 115 -

1 (2x)

2 (4x)

3 (4x)

4

5

6 (6x)

87 (6x)

9 (2x)

10 (2x)

13 (2x)

14 (2x)

11 (2x)

12 (2x)

Y 8Y 6 1 04244311 #

Solenoid

2 00207047Screw - M3x6 DIN 912

3 02288370Washer - DI 3.2 DIN 6796

4 04720261Side panel


6 01487736Screw - M4x8 DINEN 7045

7 02288389Washer - DI 4.3 DIN 6796


Basic Machine / Punch Adapter / Holder / Solenoid - 116 -

1 (2x)

2 (4x)

3 (4x)

4

5

6 (6x)

87 (6x)

9 (2x)

10 (2x)

13 (2x)

14 (2x)

11 (2x)

12 (2x)

Y 8Y 6 9 04794060 #

Roller


11 02288389Washer - DI 4.3 DIN 6796

12 00044938Screw - M4x10 DIN 912

13 04979834 #Sleeve

14 00045330Setscrew - M3x4 DIN 916

Basic Machine / Power Switch, Safety Switch - 117 -

1

23

4

S 18

S 14 S 1

S 151 02690764 #Safety switch

2 04313623 #Rocker-type switch

3 02690764 #Safety switch

4 01746073 #Key-operated switch

Supply Cassette - 1 -

CAUTION:This module is equipped with a Lithium battery.Observe Technical Remarks on Safety (chapter "General")!

1

Catch

Reel Holder

Rollers

1 04588282 #Supply cassette withoutreel holder and nut segment

Supply Cassette / Reel Holder - 2 -

1

65

7

8

14

1012

13

11 (2x)

15 (2x)

16

17 (2x) 18

19

2

9

3

4

2021

2223

1 04541332 #Reel holder, PRO

05003008 #Reel holder, offset foil (option)

05108667 #Reel holder, NP (option)


3 04541162 #Knurled screw - M5x15

4 04541065 #Cap

5 04686047PT. screw - 3x12

6 04142462 #Nut segment


1

65

7

8

14

1012

13

11 (2x)

15 (2x)

16

17 (2x) 18

19

2

9

3

4

2021

2223


8 04162404Washer - DI 3.2

9 01487396Screw - M3x6 DINEN 7046

10 04586921 #Holder (TOUCH MEMORY)

11 00207985Screw - M4x8 DINEN 1207

12 04142195 #Transmission unit

13 00492302Setscrew-M4x12 DIN 916

14 04148762 #Spur wheel


1

65

7

8

14

1012

13

11 (2x)

15 (2x)

16

17 (2x) 18

19

2

9

3

4

2021

2223

15 00213101Setscrew - M4x4 DIN 916

16 04142616 #Bearing

17 04686039PT. screw - 3x10

18 02533871 #Adhesive foam tape

19 04662474Shaped plate

20 00051195 #Deep-groove ball bearing

21 00234397Circlip - 9,3x4 DIN 6799


Supply Cassette / Rollers - 5 -

1

23

4

56 (2x)

9 (2x)

87

14 (2x)

10

12

13

11

15 (2x)

16 (2x)

17

18

1 05181305 #Gasket

2 04553101Guide

3 04588746 #Roller


5 02894289Plate

6 04242963Screw - M3x5 DINEN 7045

7 04013999 #Bearing



1

23

4

56 (2x)

9 (2x)

87

14 (2x)

10

12

13

11

15 (2x)

16 (2x)

17

18

9 01700758Screw - M3x12 DINEN 7045

10 04663160 #Roller


12 04013999 #Bearing

13 04148762 #Spur wheel

14 00213101Setscrew - M4x4 DIN 916

15 01700758Screw - M3x12 DINEN 7045

16 04242963Screw - M3x5 DINEN 7045


1

23

4

56 (2x)

9 (2x)

87

14 (2x)

10

12

13

11

15 (2x)

16 (2x)

17

18

17 04084845Segment


Supply Cassette / Catch - 8 -

1

2

3 4

1 04270061Catch

2 02288370Washer - DI 3.2 DIN 6796

3 04686039PT. screw - 3x10

4 00055352Washer - DI 3.2 DIN 9021

Supply Cassette (Small) - 9 -


1

Catch

Reel Holder

Rollers

1 04793307 #Supply cassette (small)

Supply Cassette (Small) / Reel Holder - 10 -

1

65

7

8

14

1012

13

11 (2x)

15 (2x)

16

17 (2x) 18

19

2

9

3

4

2021

2223

1 04079442 #Reel holder



4 04541065 #Cap

5 01487736Screw - M4x8 DINEN 7045



8 04162404Washer - DI 3.2


1

65

7

8

14

1012

13

11 (2x)

15 (2x)

16

17 (2x) 18

19

2

9

3

4

2021

2223

9 01487396Screw - M3x6 DINEN 7046


11 00207985Screw - M4x8 DINEN 1207


13 00492302Setscrew-M4x12 DIN 916

14 04148762 #Spur wheel

15 00213101Setscrew - M4x4 DIN 916

16 04142616 #Bearing


1

65

7

8

14

1012

13

11 (2x)

15 (2x)

16

17 (2x) 18

19

2

9

3

4

2021

2223

17 04242963Screw - M3x5 DINEN 7045




21 00234397Circlip - 9,3x4 DIN 6799


23 00234397Circlip - 9,3x4 DIN 6799

Supply Cassette (Small) / Rollers - 13 -

1

23

4

56 (2x)

9 (2x)

87

14 (2x)

10

12

13

11

15 (2x)

16 (2x)

17

18

1 05181305 #Gasket

2 04148215Profil

3 04209540 #Roller


5 02894289Plate

6 04242963Screw - M3x5 DINEN 7045

7 04013999 #Bearing



1

23

4

56 (2x)

9 (2x)

87

14 (2x)

10

12

13

11

15 (2x)

16 (2x)

17

18

9 01700758Screw - M3x12 DINEN 7045

10 04086473 #Roller


12 04013999 #Bearing

13 04148762 #Spur wheel

14 00213101Setscrew - M4x4 DIN 916

15 01700758Screw - M3x12 DINEN 7045

16 04242963Screw - M3x5 DINEN 7045


1

23

4

56 (2x)

9 (2x)

87

14 (2x)

10

12

13

11

15 (2x)

16 (2x)

17

18

17 04084845Segment



1

2

3 4

1 04270061Catch

2 02288370Washer - DI 3.2 DIN 6796

3 00215139Screw - M3x5 DIN 912

4 01733680Washer - DI 4.3

Supply Cassette (Middle) - 17 -


1

Catch

Reel Holder

Rollers

1 04886704 #Supply cassette (middle)

Supply Cassette (Middle) / Reel Holder - 18 -

1

65

7

8

14

1012

13

11 (2x)

15 (2x)

16

17 (2x) 18

19

2

9

3

4

2021

2223

1 04541332 #Reel holder, PRO



4 04541065 #Cap

5 04686047PT. screw - 3x12



8 04162404Washer - DI 3.2


1

65

7

8

14

1012

13

11 (2x)

15 (2x)

16

17 (2x) 18

19

2

9

3

4

2021

2223

9 01487396Screw - M3x6 DINEN 7046


11 00207985Screw - M4x8 DINEN 1207


13 00492302Setscrew-M4x12 DIN 916

14 04148762 #Spur wheel

15 00213101Setscrew - M4x4 DIN 916

16 04142616 #Bearing


1

65

7

8

14

1012

13

11 (2x)

15 (2x)

16

17 (2x) 18

19

2

9

3

4

2021

2223

17 04686039PT. screw - 3x10




21 00234397Circlip - 9,3x4 DIN 6799


23 00234397Circlip - 9,3x4 DIN 6799

Supply Cassette (Middle) / Rollers - 21 -

1

23

4

56 (2x)

9 (2x)

8 7

14 (2x)

10

12

13

11

15 (2x)

16 (2x)

17

18

1 04141490 #Gasket

2 04553101Guide

3 04886631 #Roller


5 02894289Plate

6 04242963Screw - M3x5 DINEN 7045

7 04013999 #Bearing



1

23

4

56 (2x)

9 (2x)

8 7

14 (2x)

10

12

13

11

15 (2x)

16 (2x)

17

18

9 01700758Screw - M3x12 DINEN 7045

10 04663160 #Roller


12 04013999 #Bearing

13 04148762 #Spur wheel

14 00213101Setscrew - M4x4 DIN 916

15 01700758Screw - M3x12 DINEN 7045

16 04242963Screw - M3x5 DINEN 7045


1

23

4

56 (2x)

9 (2x)

8 7

14 (2x)

10

12

13

11

15 (2x)

16 (2x)

17

18

17 04084845Segment



1

2

3 4

1 04270061Catch

2 02288370Washer - DI 3.2 DIN 6796

3 04686039PT. screw - 3x10

Collecting Cassette, Standard - 25 -

1

Cover

Housing

1 04662652 #Collecting cassette

Collecting Cassette / Housing - 26 -

1

2 (4x)

9 (2x)

8 (2x)

7 (2x)5 (2x)

6 (2x)

4 (2x)

13 15

1617

10 (2x)11 (2x)

12 (2x) 14 (2x)

18

19

320

1 04662555 #Reel

2 00213101Setscrew - M4x4 DIN 916

3 04766261 #Foil



6 00611395Setscrew - M2.5x8 DIN 916

7 04640489Lever

8 00089893Washer - DI 6.1


1

2 (4x)

9 (2x)

8 (2x)

7 (2x)5 (2x)

6 (2x)

4 (2x)

13 15

1617

10 (2x)11 (2x)

12 (2x) 14 (2x)

18

19

320

9 04662792 #Handle



12 04553055 #Shaft

13 00415790Sliding bearing w. shoulder - DI 6

14 00213101Setscrew - M4x4 DIN 916

15 04722108 #Gear wheel



1

2 (4x)

9 (2x)

8 (2x)

7 (2x)5 (2x)

6 (2x)

4 (2x)

13 15

1617

10 (2x)11 (2x)

12 (2x) 14 (2x)

18

19

320

17 04586980 #Lock

18 04586891 #Pin

19 04662733Housing

20 05181259Gasket

Collecting Cassette / Cover - 29 -

1 (4x)

2 (4x)

3 (4x)

6 (4x)

4

5 (4x)

1 04640608 #Vibration damper

2 00478091Screw - M4x12 DINEN 7045

3 02288389Washer - DI 4.3 DIN 6796

4 04542304 #Cover

5 04661591 #Roller

6 04640136Block

Collecting Cassette, Middle (NP) - 30 -

1

Cover

Housing

1 05126126 #Collecting cassette, midlle (NP)

Collecting Cassette, Middle (NP) / Housing - 31 -

1

2

3 9

875

6

4

13 15

1617

1011

12 14

18

19

20

1 05126223 #Reel

2 00213101Setscrew - M4x4 DIN 916

3 05126274 #Foil



6 00611395Setscrew - M2.5x8 DIN 916

7 04640489Lever

8 00991015 #Washer - DI 6.1


1

2

3 9

875

6

4

13 15

1617

1011

12 14

18

19

20

9 04662792 #Handle



12 04553055 #Shaft


14 00213101Setscrew - M4x4 DIN 916

15 04722108 #Gear wheel



1

2

3 9

875

6

4

13 15

1617

1011

12 14

18

19

20

17 04586980 #Lock

18 04586891 #Pin

19 05126134Housing

20 04848934 #Gasket

Collecting Cassette, Middle (NP) / Cover - 34 -

1

2

3

6

4

5


2 00478091Screw - M4x12 DINEN 7045

3 02288389Washer - DI 4.3 DIN 6796

4 05006155Cover

5 04661591 #Roller

6 04640136Block

Collecting Cassette, Short - 35 -

1

Cover

Housing

1 04794591 #Collecting cassette, short

Collecting Cassette, Small / Housing - 36 -

1

2 (4x)

39 (2x)

8 (2x)

7 (2x)5

6 (2x)

4

13 15

1617

10 (2x)11 (2x)

12 (2x) 14 (2x)

18

19

20

1 04846915 #Reel

2 00213101Setscrew - M4x4 DIN 916

3 04850416 #Foil



6 00611395Setscrew - M2.5x8 DIN 916

7 04640489Lever

8 00991015 #Washer - DI 6.1


1

2 (4x)

39 (2x)

8 (2x)

7 (2x)5

6 (2x)

4

13 15

1617

10 (2x)11 (2x)

12 (2x) 14 (2x)

18

19

20

9 04662792 #Handle



12 04553055 #Shaft


14 00213101Setscrew - M4x4 DIN 916

15 04722108 #Gear wheel



1

2 (4x)

39 (2x)

8 (2x)

7 (2x)5

6 (2x)

4

13 15

1617

10 (2x)11 (2x)

12 (2x) 14 (2x)

18

19

20

17 04586980 #Lock

18 04586891 #Pin

19 04847253Housing

20 05181259Gasket

Collecting Cassette, Small / Cover - 39 -

1 (3x)

2 (3x)

3 (3x)

6 (3x)

4

5 (3x)


2 00478091Screw - M4x12 DINEN 7045

3 02288389Washer - DI 4.3 DIN 6796

4 04848942 #Cover

5 04661591 #Roller

6 04640136Block

- 1 -Barcode Reader Pen

Supply cassette flap open

1

2

1 04908872 #Barcode reader pen

2 04904605 #Cable, Advantage

Covers - 2 -

12 (2x)

45

3

6

7

8

A

11

109

A

1 04541529 #Cover

2 02339587Hinge

3 04244184 #Operating panel

4 04585917Front cover

5 04556356 #Signal lamp, cpl.

04596773 #Lamp - 28V 40MA

6 04991729 #Flap, cpl.

7 04768361 #Gas spring

Covers - 3 -

12 (2x)

45

3

6

7

8

A

11

109

A

8 05116155 #Cover

9 04574451 #Magnetic lock

10 04662059 #Holder

11 04640039 #Flap

Side Panels - 4 -

1 2 3

98

7

5

6

4

10

11

12

13 (4x)

14 (2x)

Mount

E 3E 4

15 (4x)16 (4x)

1 04775015 #Panel

2 04640330 #Panel

3 04556585 #Panel

4 04557298 #Panel

5 00440191 #Locking pin

6 04640446 #Panel

7 04557476 #Panel

8 04557557 #Panel

Side Panels - 5 -

1 2 3

98

7

5

6

4

10

11

12

13 (4x)

14 (2x)

Mount

E 3E 4

15 (4x)16 (4x)

9 04640330 #Panel

10 01700677 #Lock

11 04555953Front cover

12 04643291 #EMC plate

13 01927965 #Lock

14 04597451 #Fan, axial

15 04138589 #Roller

16 02968754 #Machine foot

Side Panels / Mount - 6 -

2 (5x)

1

4 (8x)3 (5x)

5 (8x)

1 04551532 #Mount

2 02115387Screw - M4x6 DINEN 7046

3 00220345Washer - DI 5

4 02115387Screw - M4x6 DINEN 7046

5 00220345Washer - DI 5

Parts Catalog / Overview - 1 -

Side Panels

Covers

Base

=>marked items are described in the Removal, Installation and Adjustment Instructions.

Basic Machine (right)Basic Machine (left)

Supply Cassette

Barcode Reader Pen

Collecting Cassette

- 2 -Notes on Parts Catalog

Further information on spare parts can be obtained from:

Siemenswall24107 KielGermany

Telephone (0431) 386-0Telefax (0431) 386-1502

Heidelberger DruckmaschinenAktiengesellschaft

Spare parts which are available for delivery are markedwith #.Certain parts not inlcuded in the classification system also appear in these lists, e.g. parts required for mounting, parts belonging to the vicinity of spare parts. If necessary, we also deliver spare parts not included in the spare parts program when to do so- is technically acceptable and- does not adversely affect the quality assurance after reviewing description of fault. For parts not represented the following specifications are required:- machine type / model / system component- locality in machine / in machine component / in module- documentation reference number(s)- further features / special features (e.g. combinations of numbers / letters)

- 3 -Notes on Parts Catalog

Further information on spare parts can be obtained from:

Siemenswall24107 KielGermany

Telephone (0431) 386-0Telefax (0431) 386-1502


Parts manufactured for Heidelberger Druckmaschinen Aktiengesellschaft, if not covered in the documentation provided by Heidelberger Druckmaschinen Aktiengesellschaft, can be found in the manufacturer's documentation. Spare parts must be ordered exclusively from

Heidelberger Druckmaschinen AktiengesellschaftCustomer Support Logistics (CSL)

if not, overall warranty and quality assurance are invalid.

- 1 -Preventive Maintenance / Maintenance Intervals

After every service, check the safety loop for proper funcitoning!

Check List

Maintenance Control

If required (by the customer)- Cleaning trough and loading platform- Cleaning the rubber rollers of the supply cassette; monthly When using photo material with a thickness of 0.18 mm; weekly- Cleaning the dust collecting roller of the supply cassette (option)- Cleaning the rubber rings of the collecting cassette; monthly



Check List

Maintenance Control

Quarterly (by the service department)- Starting the test programs- Checking the compressed air, peltier control, drain valve- Cleaning trough, loading platform and interior- Cleaning the collecting trays for punching waste- Cleaning the rubber rollers of the supply cassette- Cleaning the dust collecting roller of the supply cassette (option)- Cleaning the rubber rings of the collecting cassette- Cleaning the rubber rollers- Checking the voltages- Test exposure



Check List

Maintenance Control

Half-yearly (by the service department)- Starting the test programs- Checking the compressed air, peltier control, drain valve - Cleaning trough, loading platform and interior- Cleaning the collecting trays for punching waste- Cleaning the rubber rollers of the supply cassette- Cleaning the dust collecting roller of the supply cassette (option)- Cleaning the rubber rings of the collecting cassette- Cleaning the rubber rollers- Cleaning the prefilter case- Exchanging the compressor (after approx. 5000 operating hours)- Exchanging the line filter of the compressed air unit - Checking the voltages- Test exposure



Check List

Maintenance Control

Yearly (by the service department)- Starting the test programs- Checking the compressed air, peltier control, drain valve - Checking the elastic buffers (Loading platform)- Checking the pressure rail (Bottom punch adapter)- Cleaning trough, loading platform and interior- Cleaning the collecting trays for punching waste- Cleaning the rubber rollers of the supply cassette- Cleaning the dust collecting roller of the supply cassette (option)- Cleaning the rubber rings of the collecting cassette- Cleaning the rubber rollers- Cleaning the foam and textile rollers- Clean mirror motor and optics (checking the geometry)- Exchanging the compressor (after approx. 5000 operating hours)- Exchange all filters in the compressed air unit - Checking the voltages- Test exposure

- 5 -Preventive Maintenance / Cleaning

Front panel

Flap (left)

Protective plate

Switch off machine, pull out power plug. Open (left) flap. Remove supply cassette. Remove front panel by pulling it out (direction of the arrow). Remove protective plate (loosen bayonet joints by turning through 90 degrees).

Trough, Loading Platform ans Interior


TroughCollecting tray

CAUTION:Only use vacuum cleaner with plastic nozzle, otherwise, surface damages of the trough and/or spindle are possible. Clean trough and loading platform using a vacuum cleaner. Attach protective plate in such a way that the safety switch is actuated. Lock protective plate (lock bayonet joints by turning through 90 degree) in position. Insert front panel in guide and press it against themachine until it engages. Insert supply cassette. Close flap (left).

Trough, Loading Platform ans Interior


Side panel

Protective plate

Stubs

Switch off the machine, pull out the power plug. Pull off right-hand side panel at the upper edge and lift out of the lower guide. Loosen screws of the protective plate (but do not unscrew), slide protective plate upwards a little and remove it. Use a vacuum cleaner to remove the punching waste from the 3 stubs. Hook protective plate into the screws, tighten screws. Insert right-hand side panel in lower guide and press against the machine until it engages.

Top Punch


Front panel

Flap (left)


Switch off machine, pull out power plug. Remove front panel. Loosen bayonet joints of the protective plate by turning through 90 degrees. Remove protective plate. Use vacuum cleaner to remove the punching waste from the collecting tray. CAUTION:Do not damage cable leading to the punch heads Attach protective plate in such a way that the safety switch is actuated. Lock protective plate in position (lock bayonet joint by turning through 90 degrees)

Lateral Punch

Protective plate


Front panel

Flap (left)


Insert front panel in guide and press against the machine until it engages.

Lateral Punch

Protective plate


Side panelProtective plate

Pull off left-hand side panel at the upper edge andlift out of the lower guide. Loosen screws of the protective plate (but do not unscrew). Slide protective plate upwards a little and removeit. Use a vacuum cleaner to remove the punching waste from the stub. Hook protective plate into the screws, tighten screws. Insert left-hand side panel in the lower guide and press against the machine until it engages.

Bottom Punch


1

2

3 (2x)4

3 (2x)5

Take the supply cassette out of themachine and open it. Clean rubber rollers [1] and [2] witha damp cloth (cleaner's naphtha).

Rubber rollers (supply cassette)


1

2

3 (2x)4

3 (2x)5

NOTE:To clean the dust collecting roller, remove it from the cassette! Take the supply cassette out of themachine and open it. Unscrew screws [3]. Mount segment [4] and plate [5]. Remove the dust collecting roller from the supply cassette und cleanit under running water. Allow dust collecting roller to air-dry.

Dust collecting roller (option)


1

2

3 (2x)4

3 (2x)5

CAUTION:Install dust collecting roller only if it is dry! Insert the dust collecting roller intothe supply cassette. Mount segment [4] and plate [5] and fasten with screws [3].

Dust collecting roller (option)


Rubber ring

Reel

Clean the rubber rings on the collecting cassette reel if photo material with a thickness of 0.18 mm is used. Open flap, remove and open collecting cassette. Clean rubber rings with a cloth soaked in methylated spirit. When doing so, turn reel manually. Close collecting cassette and insert it. Close flap.

Rubber Rings (collecting cassette)


Flap (right)

Flap (left)

Switch off machine, pull out power plug. Remove flap (right).

Rubber Rollers


Control rollers (4x)Roller

5 rubber rollers in the film exit unit (4 x short = control rollers, 1 x long = roller) Clean rubber rollers with a cloth soaked in methylated spirit. When doing so, turn rollers manually. Close flap.

Rubber Rollers


Flap (right)

Flap (left)

Supply cassette: Switch off machine, pull out power plug. Open flap (left), remove supply cassette and openit. Clean foam and/or textile rollers using a brush. Close and insert supply cassette. Close flap (left).

Foam and Textile Rollers


Flap (right)

Flap (left)

Trough exit: Open flaps. Remove film exit unit and cutting device. (T1) Clean foam and/or textile rollers using a brush. Install film exit unit and cutting device. (T2) Close flaps.

Foam and Textile Rollers


Remove filter unit. (T1) Unscrew filter case. Clean filter case in the area of the sensors. Screw on filter case. Install the filter unit. (T2)

Prefilter case

Compressed air filter

- 20 -Preventive Maintenance / Checking and Exchanging

The failure rate of the compressor increases afterapprox. 5000 operating hours.There is no indication of a failure in advance and thus results in a machine standstill. If the compressor has more than 5000 h (according to elapsed time meter), it should be exchanged. CAUTION:For quality analyses, the operating time of the exchanged compressor is required.Note the operating time on the return form.

Compressor


Pull the hoses off the line filter. Exchange line filter. CAUTION:Observe installation position! Fit hoses.

Line filtersLine filterPull the hoses off the line filter. Exchange line filter. CAUTION:Observe installation position! Fit hoses.

Line filtersLine filter


EMC plate

Front panel

Switch off machine, pull out power plug. Remove front panel by pulling it out (direction of the arrow). Remove EMC plate. The filter inserts of the following units must be exchanged: - line filter - prefilter (25 µm) - submicrofilter (0.01 µm) - compressor

Replacement of all filter inserts in the compressed air unit


Pull the hoses off the line filter. Exchange line filter. CAUTION:Observe installation position! Fit hoses.

Line filtersLine filter


Remove filter unit. (T1) Unscrew filter case. Disassemble filter element and exchange filter. Assemble filter element and screw in. Clean filter case in the area of the sensors. Screw on filter case. Install the filter unit. (T2)

Prefilter (25 µm)

Prefilter


Unscrew case of the submicrofilter (0.01 µm). Exchange filter element. Clean and screw on case of the submicrofilter.

Submicrofilter (0.01 µm)

Submicrofilter


Screw

Cover

Remove screw and washer. Remove cover. Exchange filter element (in the cover). Insert O-ring into the groove if necessary. CAUTION:Observe that the O-ring is correctly positioned! Mount cover and lock in position with screw.

Compressor


1 (2x)

3

1 (2x)

31 (2x) 1 (2x)

620 mm

2

2 4

4

Check the condition and position of the elastic buffers [1] and [3]. The outer elastic buffers [1] must adhere to the profile [2], flush with the front and outside edges. The inner elastic buffers must be flush with the front and adjacent to the outer buffers. NOTE:If there is only one elastic buffer at each side, these must be removed!Two buffers must then be adhered to each side! The elastic buffer [3] must be flush with the rear edge of the guide plate [4] and 620 mm from the right-hand side.

Elastic buffer


1

2

4 (3x)

3

Check that the fastening screws [4]sit firmly: Remove the bottom punch pdapter.[T1] Tighten the fastening screws [4]. Grease the slots for the pressure rail [1] and the screw shafts [4] with Arconal L78. Remove excess grease. Check the functionality of the pressure rail. Install the bottom punch pdapter. [T2]

Pressure rail, bottom punch adapter


Test Exposure

Following the yearly maintenance, perform a test exposure. See operating manual RIP 50 or RIP 60.


Check the Safety Loop

Switch on the machine and let it run up to operating speed. Move the carriage (material must not be loaded)- Press the following keys at the operating panel: The carriage must stop, when- opening the right-hand flap OR- removing the protective plate. The carriage must continue moving, when- the protective plate is returned AND- the right-hand flap is closed.

or

Front panelProtective plate

Flap (right)

- 1 -Removal, Installation, Adjustment

Input / Side Panels

Output

Exposure Unit

Punches (Option)

Lower Section

Prior to all service work:- switch off machine- pull out power plug NOTE:Before beginning the service work,remove corresponding side panels and EMC plates in accordance withmenu item "Side Panels". SAFETY LOOP:Upon completion of repair work, the safety loop function is to be checked by opening the dust cover!Check the protective covers for completeness while reassembling them and make sure that they show no cracks or other damage.

When performing service work to the upper section:Protect the trough against damage!

- 2 -Removal, Installation, Adjustment / Cable Guide

X78X77

X72, X79, X84, X85, X86

XA4

X58, X59, X69

1

Removal, Cable Guide

ECC carrier (1):- move to the middle of the machine- unscrew and remove cover Disconnect electrical connections:- pull coaxial connectors X77 and X78 off optics head- pull coaxial connectors X72 and X79 off pcb EC-CONTR.- pull flat cables X84, X85 and X86 off pcb EC-CONTR.- unscrew ground cable- pull coaxial connector XA4 off pcb RIP INTERFACE or HERK-IF (slot A08)- pull flat cables X58, X59 and X69 off pcb MODUL-CONNECT


1

4

2

3

XA4

X

View "X"

NOTE:The following work must be carried out in order to dismount the coaxial cable XA4 and the air hose. Coaxial cable:- unscrew nest (2) and pull it out for approx. 5 cm- open cable strap at cable duct (4)- remove bracket of cable duct (4)- pull coaxial cable (3) through cable duct (4) upwards Air hose:- loosen hose at compressed air unit (1)- pull hose through cable duct (4) upwards


1 2 (2x) 3

5

4 (2x)

6

X

View X

View Y

7

Y8 (2x)

Retainer (3):- remove screws (2)- remove retainer Flat cables (1):- tilt to the side CAUTION:During the following work, make sure that the tapped plate (5) does not fall down. Cable guide (7):- open cable strap (8)- remove screws (4, 6)- remove cable guide


1

2 (2x) 3

5

4 (2x)

6

Marking

X

View X

View Y

7

Y8 (2x)

Installation, Cable Guide

Cable guide (7):- insert in machine- screw screws (4) into tapped plate (5) and tighten- screw in and tighten screw (6)- attach cable strap (8) CAUTION:During the following step, align the flat cable in such a way that the marking of the flat cable coincides with the edge of the retainer! Retainer (3):- screw on loosely using screws (2)- align flat cable (1)- tighten retainer


1

4

2

3

XA4

X

View "X"

NOTE:The following work must be carried out in order to install the coaxial cable XA4 and the air hose. Air hose:- pull down hose through cable duct (4)- connect hose to compressed air unit (1) Coaxial cable:- pull down (3) through cable duct (4)- screw on bracket of cable duct (4)- attach cable strap to cable duct (4)- insert and screw on nest (2) CAUTION:After assembly, make sure that the cable duct is light-proof!


X78X77

X72, X79, X84, X85, X86

XA4

X58, X59, X69

1

Establish electrical connections:- plug flat cables X58, X59 and X69 onto pcb MODUL-CONNECT- plug coaxial connector XA4 onto pcb RIP INTERFACE or HERK-IF (slot A08)- screw on ground cable- plug flat cables X84, X85 and X86 onto pcb EC-CONTR.- plug coaxial connectors X72 and X79 onto pcb EC-CONTR.- plug coaxial connectors X77 and X78 onto optics head ECC carrier (1):- screw on cover

- 8 -Removal, Installation, Adjustment / Optics Head

A

B

C

X78X77

X74

2 1

5

6

X83

3

4

Optics Head RemovalCut cable straps A, B and C. Unscrew and remove cover [1] of ECC carrier [2]. Unscrew bracket [6]. Pull connectors X74, X77 and X78 off the optics head [5]. Pull X83 connector off pcb EC-CONTR.


8 (4x)

5

7

9 (4x)

11

10 3

4

The laser diode must never be operated if the optics head is removed!

Loosen screws [4] and pull bracket [3] off the optics head. CAUTION:During the following work, make sure that the optics head [5] cannot fall down. Loosen screws [8] (do not unscrew). Lower the plate [7] until the optics head [5] can be moved. Remove the optics head from the machine.

Optics Head Removal


8 (4x)

5

7

9 (4x)

11

10 3

4

The laser diode must never be operated if the optics head is removed! Optics Head Installation

CAUTION:Prior to installation, note down the value for I (max) which is shown on the optics head! Insert optics head [5] in the holder [10] and slide it up to the stop. CAUTION:The straight pin [11] of the optics head must be positioned in the guide groove of thecarrier! Tighten screws [8] until the optics head is securely positioned in the prism of the carrier. CAUTION:The bushings [9] (4x) must be positioned in the bore holes of the plate [7]. Press the bracket [3] onto the optics head and tighten screws [4].


A

B

C

X78X77

X74

2 1

5

6

X83

3

4

Connect connector X74, X77 and X78 to the optics head. Connect connector X83 to pcb EC-CONTR. Attach cable straps A, B and C and tighten manually. CAUTION:Fasten coaxial cable in such a way that it is squeezed when the exposure unit moves. Screw on plate [6] (do not squeeze cable) Screw cover [1] onto ECC carrier [2]. Perform parameter set-up.

Optics Head Installation

- 12 -Removal, Installation, Adjustment / Rotating Mirror Unit

3

2

1

X71

4

5 (4x)

6

7

9

8

10 (2x)

6

11

Rotating Mirror Unit RemovalPull off connector X71. Pull off air duct [3]. Loosen stop screw [9]. Turn out screws [10] and remove fishplate [8]. CAUTION:During the following work, make sure that the rotating mirror unit [2] cannot fall down. Loosen screws [5] (do not unscrew). Lower plate [4] until the rotating mirror unit [2] can be moved. Remove the rotating mirror unit [2] from the machine. Remove straight pin [7].


3

2

1

X71

4

5 (4x)

6

7

9

8

10 (2x)

6

11

Rotating Mirror Unit InstallationScrew in straight pin [7]. Insert rotating mirror unit [2] in the holder [6] and slide it up to the stop. CAUTION:The straight pin [7] of the rotating mirror unit must be positioned in the guide groove of the carrier [1]! Tighten screws [5] until rotating mirror unit is securely positioned in the prism of the carrier. CAUTION:The bushings [11] (4x) must be positioned in the bore holes of the plate [4]. Fasten fishplate [8] onto the carrier using screws.


3

2

1

X71

4

5 (4x)

6

7

9

8

10 (2x)

6

11

Rotating Mirror Unit InstallationTighten stop screw [9] to a torque of 0.1 Nm. Fit connector X71. Fit air duct [3].

- 15 -Removal, Installation, Adjustment / Stepping Motor

4

8

1

2

3

M 8

Stepping Motor RemovalRemove covers and coverings. (T1) Remove transport safeguard [1] and distance plate [2].


3

4

7

6 (4x)

8

5 6

9 (4x)

11

12

M 8

10

13 (2x)14

View X5

X

CAUTION:Do no loosen stopper [8 and 10] fixing screws [6 and 12]! Pull connector X143 off stepping motor. Loosen screws [13] until the ring [5] no longer jams the spindle end [14]. Pull the stepping motor [3] out of the spindle end [14] and stoppers [8 and 10]. Remove screws [6]. Remove lever [4] from stepping motor [3].

Stepping Motor Removal


3

4

7

6 (4x)

8

5 6

9 (4x)

11

12

M 8

10

13 (2x)14

View X5

X

Y

0.5 mm

View Y

48 or10

Stepping Motor InstallationCAUTION:Do no loosen stopper [8 and 10] fixing screws [6 and 12]!Turn spindle [14] so that the spindle slot is in vertical position! Fasten lever [4] onto stepping motor [3] using screws, but do not tighten screws [6]. Place stepping motor with lever into the spindle end [14] and stoppers [8 and 10]. Tighten screws [6]. Set a distance of 0.5 mm between lever [4] and stopper [8 or 10] (View Y).


3

4

7

6 (4x)

8

5 6

9 (4x)

11

12

M 8

10

13 (2x)14

View X5

X

Turn ring [5] until the ring slot is at an angle of 90° to the spindle slot. Tighten screw [13].

Stepping Motor Installation


4

8

1

2

3

M 8

Mount distance plate [2] and transport safeguards [1]. Fit connector X143 onto stepping motor. Mount covers and coverings.

Stepping Motor Installation

- 20 -Removal, Installation, Adjustment / Flywheel

4

23

1

Flywheel Functions TestUse an adhesive tape to attach a thread to the flywheel [3]. Hook a spring balance into the thread, pull it in the direction of thearrow and measure the tractive force;tractive force 0.45 +0.1 N. If the tractive force is not achieved,exchange the flywheel.


4

23

1

Flywheel RemovalRemove stepping motor [1]. (T1) Pull ring [2] off the spindle. Loosen the setscrew of the flywheel [3]. Pul flywheel off the spindle.


4

23

1

Flywheel InstallationDegrease the spindle end. Slide flywheel [3] onto the spindle.Distance to nut [4]:0.2 mm. Tighten the setscrews of the flywheel. Install the stepping motor [1]. (T1)

- 23 -Removal, Installation, Adjustment / Spindle

A

CAUTION:Before installing the spindle, measure the diameter of the spindle passage A !The removal and installation of the spindle must be performed according to the diameter (46 mm or 49 mm)!


A = 46 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Remove covers and coverings. (T1) Protect the trough (e.g. cover with film). Remove pcb EC-CONTROL with box. (T2) Remove screws [1]. Turn spindle nut [2] out of the flange. Unscrew flange [5] from holder [14].

Spindle Removal


A = 46 mm

21

18

17

15

16

19

20

Remove flywheel [16] and steppingmotor [15]. (T3) Mark position of bearing [21]. Remove bearing.

Spindle Removal


A = 46 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Pull carriage with spindle [3] out ofthe bearing block. Pull ring [11] off the ball bearing [10]. Remove circlip [12]. Pull ball bearing [10] off the spindleand mark installation position. Loosen clamping screw [8]. Pull bushing [9], hose [7] and sliding bearing [6] off the spindle.

Spindle Removal


A = 46 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Move the carriage to the center. Move spindle in the direction of thefloating bearing until the spindle end has no longer contact with the fixed bearing side. Lift spindle end and take the spindle with the flange [5] out of the holder [14].

Spindle Removal


A = 46 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Mount flange [5] onto spindle [3]. Insert the spindle into the holder [14] and move it in the direction of the floating bearing until the spindle end has no longer contact with the fixed bearing side. Move spindle to the fixed bearing side. Move carriage to the fixed bearing side.

Spindle Installation


A = 46 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Mount sliding bearing [6], hose [7] and bushing [9] onto the spindle.Screw in clamping screw [8] but donot tighten it! Insert ball bearing [10] into the ring[11] exerting uniform pressure. CAUTION:Observe installation position! Place ring with ball bearing onto the spindle. Mount circlip [12]. Carefully slide the spindle with the ring [11] and ball bearing [10] into the bearing unit.



A = 46 mm

21

18

17

15

16

19

20

Mount bearing [21]. Observe installation position! Turn nut [17] onto the spindle and tighten to a torque of 9 ±1 Nm.Use an open-end wrench at the other end of the spindle to secure it against turning. Insert the protective plate in the bore hole of the nut [17] and tighten locking screw [18]. The labeling of the spindle and the marking of the spindle nut must face upward.



A = 46 mm

21

18

17

15

16

19

20

Spindle InstallationInstall flywheel [16] and stepping motor [15]. (T1)


A = 46 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

NOTE:The carriage must be at the fixed bearing side. Screw flange [5] onto the holder [14]. Press carriage with flange against the spindle nut. Use your hand to lightly tighten thebox nut of the flange. Fit metal needle (dia. of 2.5 mm) into a bore hole at the outside of the box nut.



A = 46 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Tighten box nut by 35° ±5° (angle distance of bore holes = 30°). This setting corresponds to a torque of 4.6 ±1 Nm. Tighten screw [4] to a torque of 0.4 ±0.05 Nm. Pull the carriage with the flange offthe spindle nut and then press carriage and flange against the spindle nut again.It must be possible to move the spindle nut into the flange and out of the flange smoothly and noiselessly. If necessary, loosen the screws [13] and tighten them again.



A = 46 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Move carriage to the center. Turn in the screws [1] and fasten the spindle nut onto the flange but do not tighten the screws. Move the carriage to the fixed bearing side. Tighten the upper screws of the spindle nut. Move the carriage to the center. Tighten the lower screws of the spindle nut. Loosen the clamping screw [8].



A = 46 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

X

86

A

Set distance Xbetween bushing [9] and ring [11] (see Ill. A): X = 62 - 0.5 mm (Herkules) X = 165 - 0.5 mm (Herkules M) Tighten clamping screws [8]. Move the carriage in both directions for 5 times and remove excess grease. Install pcb EC-CONTROL. (T2) Remove the trough protection. Mount coverings and covers.



A = 49 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Remove covers and coverings (T1). Protect the trough (e.g. cover with film). Remove screws [1]. Turn spindle nut [2] out of the flange.

Spindle Removal


A = 49 mm

21

18

17

15

16

19

20

Remove flywheel [16] and steppingmotor [15]. (T2) Mark position of bearing [21]. Remove bearing.

Spindle Removal


A = 49 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Pull carriage with spindle [3] out ofthe bearing block. Pull ring [11] off the ball bearing [10]. Remove circlip [12]. Pull ball bearing [10] off the spindleand mark installation position. Loosen clamping screw [8]. Pull bushing [9], hose [7] and sliding bearing [6] off the spindle.

Spindle Removal


A = 49 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Move carriage with spindle to the fixed bearing side. Take the spindle out of the machine through the bore hole at the front.

Spindle Removal


A = 49 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Move the carriage to the fixed bearing side. Carefully slide spindle [3] through the front bore hole, the flange [5] and the holder [14]. Mount sliding bearing [6], hose [7] and bushing [9] onto the spindle.Screw in clamping screw [8] but donot tighten it! Insert ball bearing [10] into the ring[11] exerting uniform pressure.



A = 49 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

CAUTION:Observe installation position! Place ring [11] with ball bearing [10] onto the spindle. Mount circlip [12]. Carefully slide the spindle with the ring and ball bearing into the bearing unit.



A = 49 mm

21

18

17

15

16

19

20

Mount bearing [21]. Observe installation position! Turn nut [17] onto the spindle and tighten to a torque of 9 ±1 Nm.Use an open-end wrench at the other end of the spindle to secure it against turning. Insert the protective plate in the bore hole of the nut [17] and tighten locking screw [18]. The labeling of the spindle and the marking of the spindle nut must face upward.



A = 49 mm

21

18

17

15

16

19

20

Spindle InstallationInstall flywheel [16] and stepping motor [15]. (T1)


A = 49 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

Move the carriage to the center. Press carriage with flange against the spindle nut. Turn in screws [1] and fasten the spindle nut onto the flange but do not tighten the screws. Move the carriage to the fixed bearing side. Tighten the upper screws of the spindle nut. Move the carriage to the center. Tighten the lower screws of the spindle nut. Loosen the clamping screw [8].



A = 49 mm

6

7

89

1 (4x)

34

5

10 11

2

12

13 (4x)14

X

86

A

Set distance Xbetween bushing [9] and ring [11] (see Ill. A): X = 62 - 0.5 mm (Herkules) X = 165 - 0.5 mm (Herkules M) Tighten clamping screws [8]. Move the carriage in both directions for 5 times and remove excess grease. Remove the trough protection. Mount coverings and covers.


- 46 -Removal, Installation, Adjustment / Pcb EC-CONTROL

1

2 (8x)

3 (8x)

4

56 (4x)

7

8

10

9 (4x)

RemovalManually move the carriage to the machine center. Remove the screws [4 and 6] from the cover [5]. Carefully lift the cover and pull the fan cable off pcb EC-CONTROL [1]. Remove the cover. Remove all connectors from pcb EC-CONTROL. Remove the screws [2]. Slide pcb EC-CONTROL under the cable and take it out of the machine.


1

2 (8x)

3 (8x)

4

56 (4x)

7

8

10

9 (4x)

RemovalUnscrew the cable guide [7] from the box [10]. Remove the flat cable [8] from the box. Screw out the screws [9] and remove the box.


1

2 (8x)

3 (8x)

4

56 (4x)

7

8

10

9 (4x)

InstallationMount box [10] onto the carriage. Clamp the flat cable [8] onto the box. Fasten the cable guide [7] onto the box using screws. CAUTION:The photo diode of pcb EC-CONTROL [1] must be fit into the centering of the ECC carrier! Position pcb EC-CONTROL in the box and screw on lightly. Plug all connectors onto the pcb.


X73 (SOL)

S2 (HS4)

max. amplitude

40 ... 90 µsecs

S2

X73

K3

PcbInstallationStart the diagnostic software DIAGHERK. Call up test program 49- Input: r49 Abort the test- Input: STOP Connect the oscilloscope to S2 and X73. Move the pcb until the signal to your left appears (max. symmetry amplitude). Tighten the screws of the pcb. Plug the fan cable onto the pcb and mount the cover.

- 50 -Removal, Installation, Adjustment / Pcb MAT-WIDTH I

6 ±0,2

58

910

Mount pressure spring [8] between bracket [5] and pcb MAT-WIDTH I [9]. Insert screw [10] with LOCTITE 222 and set a distance of 6 ±0.2 mm between pcb MAT-WIDTH I[9] and bracket [5]. Fit connector X 87. Perform alignment according to: Pcb MAT-WIDTH I Alignment (T1).

Installation

- 51 -

Order No. 04699629

R5

Pcb MAT-WIDTH I (6.004)

BARCODE

X2

X87

R6

Film material required:- Reference film (20% screen or transparent unexposed infrared film)- Black film (100% black). Remove loading platform (T1). Start test software (T2)Call up test 82 Input: r82[l,m] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>

Alignment

- 52 -

Order No. 04699629

R5


BARCODE

X2

X87

R6

Display:Bit sequence 7654 3210- Bit 4 = 1 > Film is in both opto switches- Bit 4 = 0 > Film is not in opto switches or only in one opto switche. Insert reference film in the trough in front of the two opto switches. CAUTION:Film must have the same position as with normal operation. Cover left-hand opto switch with the black film. So adjust right-hand pot (R6) that bit 4 changes from "0" to "1". Remove black film.

- 53 -

Order No. 04699629

R5


BARCODE

X2

X87

R6

Cover right-hand opto switch with the black film. So adjust left-hand pot (R5) that bit 4 changes from "0" to "1". Perform a test at the end positionsand in the middle of the travel:- without reference film > bit 4 = "0" - with reference film on both opto switches > bit 4 = "1". Install loading platform (T3). Note:If the setting is not possible alter the distance between pcb and carrier.

Starting the Test Software - 54 -

Preparations:- switch off machine Rear panel:- remove from upper edge- lift out of lower guide Mac, PC with terminal emulation or WYSE terminal:- connect using VT 100 connector (SERVICE) Insert floppy disk. Switch on Mac, PC with terminal emulation or WYSE terminal. Switch on Herkules. Input: R0 <ENTER> Check configuration.

- 55 -Removal, Installation, Adjustment / Pcb MAT-WIDTH II

5,5

1 ( 6x)

X87

X2

Mount pcb MAT-WIDTH II. Check that there is a distance of 5.5 mm between pcb and bracket; if necessary, turn screws (1). Fit connectors X2 and X 87. Perform alignment according to: Pcb MAT-WIDTH II Alignment (T1).

Installation

- 56 -

Order No. 04700805

Pcb MAT-WIDTH II (6.063)

R5

X2X87

R6

Film material required:- Reference film (20% screen or transparent unexposed infrared film)- Black film (100% black). Remove loading platform (T1). Displace carriage in such a way that the right-hand opto switch is positioned over the right-hand reflection strip. Start test software (V > 2.00) (T2)Call up test 82 Input: r82[l,m,r] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>

Alignment

- 57 -

Order No. 04700805


R5

X2X87

R6

Display:Bit sequence 7654 3210- Bit 4 = 1 > Film is in opto switch- Bit 4 = 0 > No film is in opto switch. Insert reference film in the trough in front of the right-hand opto switch. Caution:Film must have the same position as with normal operation. So adjust right-hand pot (R4) that bit 4 changes from "0" to "1". Caution:At the ends of the reflection strip, the film must be safely recognized.

- 58 -

Order No. 04700805


R5

X2X87

R6

Stop test 82 Input: stop <Enter> Position left-hand opto switch over the left-hand reflection strip. Call up test 82 Input: r82[l,m,l] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter> So adjust left-hand pot (R5) that bit 4 changes from "0" to "1". Caution:At the ends of the reflection strip, the film must be safely recognized.

- 59 -

Order No. 04700805


R5

X2X87

R6

Install loading platform (T3). Note:If the setting is not possible alter the distance between pcb and carrier.

- 1 -Removal and Installation / Barcode Reader Pen

Supply cassetteflap

Supply cassette

AB

C

750

40

280

75

All dimension in mm

15°Barcode Reader Pen RemovalReader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. Cut cable straps A, B and C.


1

2 33

4 5

6XA7

D

E

Remove the rear panel. Disconnect the connectors [1]. Remove the reader pen from the holder. Lower cable: Unscrew the cable holder [2]. Do not remove thecable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side. Pull off the supply voltage connector [6].

Barcode Reader Pen Removal


1

2 33

4 5

6XA7

D

E

Pull off connector XA7. Pull the cable with the connector through cable passage D into the exposure compartment. Cut cable strap E. Disconnector connectors [1] and take out the cable.



Supply cassetteflap

Supply cassette

AB

C

750

40

280

75

All dimension in mm

15°Barcode Reader Pen InstallationReader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. If necessary, drill holes (3.6 mm) for the reader pen holder and mount the holder. Insert the reader pen into the holder. Attach cable straps A, B and C and tighten them(hand-tight).


1

2 33

4 5

6XA7

D

E

Remove the rear panel. Insert the cable from above into the exposure compartment. Connect connectors [1]: Lower cable: Unscrew the cable holder [2]. Do not take off thecable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side.

Barcode Reader Pen Installation


1

2 33

4 5

6XA7

D

E

Fit connector XA7. Fit the supply voltage connector [6]. Pull the cable with the connector through cable passage D into the exposure compartment. Attach cable strap E and tighten it (hand-tight). Connect connectors [1]. Fasten holding bracket [4] and [5] using screws. Insert the electronics rack and screw tight. Screw on the cable holder [2]. Attach the rear panel.


- 7 -Parameter Set-up of Advantage Option

Parameter PID 815 'Use ABC' Enabling/disabling the 'Advantage' option Parameter PID 837 'Use Barcode' Enabling/disabling the barcode reader pen

NOTE: After the parameter set-up, reset the recorder by switching it off and then on again.

Transferring the parameters to the recorder software via the service terminal.


Parameter PID 527 'Use Online Processor' Switching on/switching off the online processor.Even if the 'Advantage' option is enabled (PID 815 'Use ABC' has value "1"), the online processor can be switched off in the case of an error.




Parameter PID 527 'Use Online Processor'Transfer parameter using the user software.

Return to "Edit Parameter" menu

Save the parameter


- Press the following key at the operating panel:

- General imagesetter parameter set-up: If the parameter record is not "static data":

- Press the following keys to select the parameter:

- Press the following keys in succession to edit the parameter:

- To save the parameter after editing, press the following keys:

- To return to the main menu, press the following key repeatedly:


General imagesetter parameter set-upSelect parameter record To jump to the level below the current one, press the following key: To select the parameter record, press the following key repeatedly: To jump to the next higher level, press the following key:


Input / Side Panels

Output

Exposure Unit

Punches (Option)

Lower Section



- 2 -Removal, Installation, Adjustment / TOUCH MEMORY (Motherboard)

TOUCH MEMORY 4K x 1

TOUCH MEMORY + Timer

RemovalRemove pcb MAINCONTROLLER (slot A04/05) and pcb FEED-CONTROL (slot A06). NOTE:Before replacing any components, check whether the fault occurred due to bad pressure spring contact. Lift the pressure spring a little andremove the TOUCH MEMORY to the side. CAUTION:Do not bend the pressure spring.

- 3 -Removal, Installation, Adjustment / TOUCH MEMORY (Motherboard)

TOUCH MEMORY 4K x 1

TOUCH MEMORY + Timer

InstallationIf necessary, tension the pressure spring before installing it. Insert the TOUCH MEMORY from the side. CAUTION:Do not bend the pressure spring. Insert pcb MAINCONTROLLER (slot A04/05) and pcb FEED-CONTROL (slot A06). Perform parameter set-up.

- 4 -Removal, Installation, Adjustment / Vacuum Hoses

1

2 3

54

RemovalPress the flap [4] against the plug-in connector [1] and hold it. Pull the hose [5] out of the plug-in connector.

- 5 -Removal, Installation, Adjustment / Vacuum Hoses

1

2 3

54

InstallationCAUTION:Cut the hose [5] straight! Insert the hose into the plug-in connector [1] until you can feel the resistance of the collet [3]. Exert pressure to slide the hose through the O-ring [2] (approx. 2-3 mm). Slightly pull back the hose (flap [4] has a distance of approx. 1 mm to the plug-in connector).


Input / Side Panels

Output

Exposure Unit

Punches (Option)

Lower Section



- 2 -Removal, Installation, Adjustment / Side Panels

Front panel

Large side panel

Small side panels

Right

Left

Rear panel

EMC plate

Side panels / rear panel / front panel:- remove by pulling them out NOTE:Remove large side panels before removing the small side panels. EMC plate:- loosen bayonet joint- remove EMC plate

General Notes

- 3 -Removal, Installation, Adjustment / Loading Platform

Loading Platform

Stepping Motor M6

Rewind Motor M5

Guide Panels, Antistatic Rails

Cassette Polling Unit

Caution:Remove the loading platform before exchanging individual components!

Removal, Installation, Adjustment / Loading Platform - 4 -

1 2

3

4

6, 7

5

Switch off the machine, pull out thepower plug. Remove supply cassette. Remove side panels [3, 4 and 5]. Remove rear panel [6] and EMC plate [7]. Open the dust cover [2]. Loosen the screw used to attach the gas spring [1] to the inner side of the dust cover. Swing dust cover to the rear.

Loading Platform Removal


9 10

8

11 (7x)

12 (7x)

PcbMODULE-CONNECT

Remove lateral screw [9] with washer [10]. Remove screws [11] with washers [12]. Lift the cassette mount [8] out of the machine. Pull connector X52 off pcb MODULE-CONNECT.



14 (4x)

13

CAUTION:Do not loosen the guide disks screws (the screws are secured with gray varnish)! Loosen the screws [14]. Lightly lift laoding platform, pull it to the rear and lift it out of the machine.Lift loading platform out of the machine.



14 (4x)

13

CAUTION:Do not loosen the guide disks screws (the screws are secured with gray varnish)! Insert the loading platform [13] in the machine.The guide disks must be positioned in the bore holes of the loading platform. Tighten screws [14].

Loading Platform Installation


9 10

8

11 (7x)

12 (7x)

PcbMODULE-CONNECT

Connect connector X52 to pcb MODULE-CONNECT. Insert cassette mount [8] in the machine. Turn in screws [9] and [11] with washers [10 and 12].



1 2

3

4

6, 7

5

Mount the gas spring [1] onto the inner side of the dust cover. Close dust cover [2]. Mount coverings [3...7]. Insert the supply cassette.


- 10 -Removal, Installation, Adjustment / Loading Platform / Guide Panels

View X

X

2

4

1 (5x)3 (5x)

RemovalNOTE:Antistatic rails [4] are found under the guide panels [2]. Guide panels [2]:- remove 5 fixing screws with washers [1] each time- remove Antistatic rails [4]:- remove 5 fixing screws with washers [3] each time- remove

- 11 -Removal, Installation, Adjustment / Loading Platform / Guide Panels

View X

X

2

4

1 (5x)3 (5x)

InstallationAntistatic rails [4]:- insert- screw in 5 fixing screws with washers [3] each time Guide panels [2]:- insert- screw in 5 fixing screws with washers [1] each time CAUTION:The brushes of the antistatic rails [4] must not become caught under the beading of the guide panels [2]!

- 12 -Removal, Installation, Adjustment / Loading Platform / Cassette Polling Unit

Cable, red

Cable, gray

Setscrew (2x)

RemovalCoverings:- remove Guide:-remove Cable (red, gray):- pull off Two setscrews:- loosen Polling unit:- slide in direction of the arrow- remove

- 13 -Removal, Installation, Adjustment / Loading Platform / Cassette Polling Unit

Cable, red

Cable, gray

Setscrew (2x)

318

InstallationPolling unit:- insert into the guide- slide in direction of the arrow CAUTION:Observe installation measure 318 mm (sensor center)! Two setscrews:- tighten manually Cable (red, gray):- plug on Guide:- insert Coverings:- mount

- 14 -Removal, Installation, Adjustment / Loading Platform / Stepping Motor M6

4x

8 (4x)

76

5

4

3

1

2

10

9

RemovalLoading platform:- remove Cable strap:- remove between X93 and stepping motor Connector X93:- pull off CAUTION:During the following work, make sure that the stepping motor [1] cannot fall down! Circlip [2]:- remove Spring [3]:- unhook on both sides


4x

8 (4x)

76

5

4

3

1

2

10

9

Stepping motor [1]:- pull with bracket [4] off pin [5] Nuts [6] with washers [7]:- remove Stepping motor [1]:- remove from bracket [4] Two setscrews [10]:- loosen Pin [9]:- pull off motor shaft with installed spur wheel [11] For the replacement of pin [9]:- dismount spur wheel [11] where necessary

Removal


6.5

PinStepping motor

Ill. A

M 6

InstallationSpur wheel [11]:- fasten to pin [9] where necessary Pin [9] with spur wheel [11]:- slide on the motor shaft Two setscrews [10]:- tighten NOTE:Observe installation measurement (Ill. A)! Stepping motor [1]:- fasten to bracket [4] with screws [8], washers [7] and nuts [6] CAUTION:Observe installation position of themotor!


6.5

PinStepping motor

Ill. A

M 6

Pin [5]:- grease slightly with Arcanol L78 Stepping motor [1] with bracket [4]:- slide on the pin [5] Circlip [2]:- slide on Spring [3]:- hook in on both sides Connector X93:- plug Cable strap:- fasten between X93 and stepping motor Loading platform:- install

Installation

- 18 -Removal, Installation, Adjustment / Loading Platform / Rewind Motor M5

1

1

4

2

4

3

RemovalSupply cassette:- remove where necessary Loading platform:- remove Two cables (gray, red):- unsolder from machine Cable strap:- remove Circlip [1]:- remove Spring [2]- unhook on both sides Rewind motor [3]:- pull out of bushing [4] in the direction of the arrow


1

2

3

4

Exchange defective parts:- spur wheel [1]- gear wheel [2]- microswitch [3]- DC motor with gear unit [4]

Removal


1

1

4

2

4

3

InstallationRewind motor [3]:- insert in bushing [4] contrary to the direction of the arrow Spring [2]:- hook in on both sides Circlip [1]:- mount


Capacitor

red gray+

When connecting, observe correct polarity!

Solder two cables onto the machine:- red, left side -> plus (see Ill.)- gray, right side -> minus Cable:- fasten with cable strap Loading platform:- install

Installation

- 22 -Removal, Installation, Adjustment / Bottom Punch

Bottom Punch Adapter

Solenoid, Left

Solenoid, Right

- 23 -Removal, Installation, Adjustment / Bottom Punch Adapter

1 (4x)

RemovalRemove the loading platform. (T1) Disconnect the connector X91. Remove the fixing screws [1]. Remove the bottom punch adapter from the machine.

- 24 -Removal, Installation, Adjustment / Bottom Punch Adapter

1 (4x)

InstallationInsert the bottom punch adapter in the machine. Use the screws [1] to fasten the bottom punch adapter onto the trough. Connect the connector X91. Install the loading platform. (T1)

- 25 -Removal, Installation, Adjustment / Bottom Punch Adapter / Solenoid, Left

1

2

3

4 (2x)

5 (2x)7 (2x) 68 (2x)

Y 2

RemovalPull the flat connector off the solenoid [1]. Turn out the screws [5] and remove the solenoid. Loosen the setscrew [2] and pull the sleeve [3] off the magnet armature.


1

2

3

4 (2x)

5 (2x)7 (2x) 68 (2x)

Y 2

InstallationSlide the sleeve [3] onto the magnearmature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 ±0.2 mm. Tighten the setscrew [2]. Fasten the solenoid onto the bracket [6] using screws. Connect the flat connector, observepolarity.

Install the bottom punch adapter and adjust the solenoid.

X

GY OG


B

AdjustmentLoosen the solenoid fixing screws. With the armature pushed back, slide the solenoid against the pressure rail [1] until the pressure rail can no longer be moved (Ill. A). Tighten the solenoid fixing screws. Release the armature: The pressure rail must push back the armature smoothly. Push back the aramture completely: There must be a gap between the armature and the pressure rail (Ill. B).

A

Gap

Armature pushed back

Armature pulled out

1

1

- 28 -Removal, Installation, Adjustment / Bottom Punch Adapter / Solenoid, Right

1

2

34

5 (2x)

7 (2x)

6 (2x)

8 (2x)

Y 1



1

2

34

5 (2x)

7 (2x)

6 (2x)

8 (2x)

Y 1

InstallationFit the sleeve [2] onto the magnet armature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 ±0.2 mm. Tighten the setscrew [1]. Fasten the solenoid onto the bracket [4] using screws. Connect the flat connector, observepolarity.

Install the bottom punch adapter and adjust the solenoid.

X

GYOG


B


A

Gap


Armature pulled out

1

1


Supply cassetteflap

Supply cassette

AB

C

750

40

280

75

All dimension in mm

15°Barcode Reader Pen RemovalReader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. Cut cable straps A, B and C.


1

2 33

4 5

6XA7

D

E

Remove the rear panel. Disconnect the connectors [1]. Remove the reader pen from the holder. Lower cable: Unscrew the cable holder [2]. Do not remove thecable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side. Pull off the supply voltage connector [6].



1

2 33

4 5

6XA7

D

E

Pull off connector XA7. Pull the cable with the connector through cable passage D into the exposure compartment. Cut cable strap E. Disconnector connectors [1] and take out the cable.



Supply cassetteflap

Supply cassette

AB

C

750

40

280

75

All dimension in mm

15°Barcode Reader Pen InstallationReader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. If necessary, drill holes (3.6 mm) for the reader pen holder and mount the holder. Insert the reader pen into the holder. Attach cable straps A, B and C and tighten them(hand-tight).


1

2 33

4 5

6XA7

D

E

Remove the rear panel. Insert the cable from above into the exposure compartment. Connect connectors [1]: Lower cable: Unscrew the cable holder [2]. Do not take off thecable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side.



1

2 33

4 5

6XA7

D

E

Fit connector XA7. Fit the supply voltage connector [6]. Pull the cable with the connector through cable passage D into the exposure compartment. Attach cable strap E and tighten it (hand-tight). Connect connectors [1]. Fasten holding bracket [4] and [5] using screws. Insert the electronics rack and screw tight. Screw on the cable holder [2]. Attach the rear panel.



Input / Side Panels

Output

Exposure Unit

Punches (Option)

Lower Section



- 2 -Removal, Installation, Adjustment / Film Exit Unit

Prior to removing components or parts, remove the complete film exit unit!

Film Exit Unit, cpl.

Stepping Motor M3

Roller

Front Guide Panel

Holder Assembly

Rear Guide Panel

Control Rollers

Motor M14

Stepping Motor M2

Threaded Rod

Motor M1

Diode Holder

Solenoid


2 (10x)1

3 (10x)

RemovalOpen flap. Remove collecting cassette where appropriate. Disconnect electrical connection X54. Remove 10 fixing screws [2]. Tilt film exit unit [1] slightly forward and pull it out carefully.


2 (10x)1

3 (10x)

InstallationCarefully insert film exit unit [1]. NOTE:Screw in marked screw (x) first! Loosely screw in fixing screws [2]. Tighten fixing screws [2]. If necessary, insert collecting cassette and close flap. Establish electrical connection X54.

x

- 5 -Removal, Installation, Adjustment / Film Exit Unit / Diode Holder

1

23

45

6 7

8

9B 9

RemovalCut the cable strap at the diode holder [6]. Pull off flat cable [9]. Loosen screw [1] (approx. 1 revolution). Move block [2] to the left across the assembly opening in the shaped strip [7]. CAUTION:Do not lose the washer [3]! Manually turn the threaded rod [8] until the diode holder [6] no longer touches the threaded rod.


1

23

45

6 7

8

9B 9

Remove the diode holder through the assembly opening. Remove screw [4]. Remove tapped plate [5] from the diode holder.

Removal


1

23

45

6 7

8

9B 9

InstallationInsert tapped plate [5] int diode holder [6] and secure in position using screw [4]. Insert the diode holder through theassembly opening of the shaped strip [7] and push it against the threaded rod [8]. Turn threaded rod into the tapped plate [5]. Place washer [3] onto the threaded rod shoulder. Push bearing block [2] against the threaded rod and tighten screw [1] (approx. 1 revolution).


1

23

45

6 7

8

9B 9

Lightly grease threaded rod using LOSOID 1160B. Fit flat cable [9]. Fasten cable using cable straps. Perform parameter set-up.

Installation

- 9 -Removal, Installation, Adjustment / Film Exit Unit / Threaded Rod

1

23

45 6

7

89 10

1112

13 (2x)

14

15 (3x)

16

17

18

RemovalRemove the toothed belt [12] from the toothed belt pulley [11]. Cut the cable strap at the diode holder [6]. Disconnect the electrical connection. Loosen the screw [1] (approx. 1 revolution). Move the block [2] to the left acrossthe assembly opening in the shaped strip [7]. CAUTION:Do not lose the washer [3]! Manually turn the threaded rod [18] until the diode holder [6] no longer touches the threaded rod.


1

23

45 6

7

89 10

1112

13 (2x)

14

15 (3x)

16

17

18

Remove the screw [10] with the washer [9] and spacer [8]. Pull the threaded rod out of the film exit unit. Loosen the setscrew [13] by one revolution. Pull the toothed belt pulley [11] andthe ring [14] off the threaded rod. Pull the washers [15], ball bearing [16] and bushing [17] off the threaded rod.

Removal


1

23

45 6

7

89 10

1112

13 (2x)

14

15 (3x)

16

17

18

InstallationSlide the bushing [17], the ball bearing [16] and the washers [15] onto threaded rod [18]. Slide the ring [14] and the toothed belt pulley [11] and lock in positionusing setscrews [13]. Insert the threaded rod in the film exit unit. Insert the ball bearing [16] in the bore hole of the housing. Place the washer [9] and spacer [8]onto the screw [10]. Turn in the screw [10] using Loctite222 and tighten it slightly.


1

23

45 6

7

89 10

1112

13 (2x)

14

15 (3x)

16

17

18

Insert the diode holder [6] through the assembly opening of the shaped strip [7] and slide it up to the threaded rod [18]. Turn the threaded rod into the tapped plate [5]. Mount the washer [3] onto the sholder of the threaded rod. Slide the bearing block [2] against the threaded rod and tighten the screw [1] (approx. 1 revolution). Lightly grease the threaded rod using LOSOID 1160B. Establish the electrical connection.

Installation


1

23

45 6

7

89 10

1112

13 (2x)

14

15 (3x)

16

17

18

Fasten the cable using cable straps. Check axial backlash:- diode holder -> no backlash- threaded rod -> max. backlash 0.2mm Position the toothed belt [2] onto toothed belt pulley [11]. NOTE:It must be possible to easily press the toothed belt by approx. 9 mm centrally between the gear wheels on one side. Perform the paramter set-up.

Installation

- 14 -Removal, Installation, Adjustment / Film Exit Unit / Motor M1

View X

+

3

grayred

2

41

X

Side panel


5M 1

RemovalRemove cable strap. Unsolder red (+) and gray ( - ) cables. Spur wheel [1]:- loosen two setscrews [2]- pull spur wheel off the motor shaft CAUTION:Observe installation position of thestepping motor and, if necessary, mark it! Motor [3]:- remove three fixing screws [4] with washers [5]- remove motor


View X

+

3

grayred

2

41

X

Side panel


5M 1

InstallationMotor [3]:- insert in correct installation position- fasten with three fixing screws [4] and washers [5] Fixing screws [4]:- secure with Loctite 242 Spur wheel [1]:- slide onto the motor shaft- fasten with two setscrews [2] Solder on red (+) and gray ( - ) cables (see view X). Attach cable strap.

- 16 -Removal, Installation, Adjustment / Film Exit Unit / Stepping Motor M2

1

X92

2

3

4

5

1

6

7toX92

8

RemovalRemove cable strap. Remove screw [1]. Stepping motor [2]:- rotate in direction of the arrow NOTE:The toothed belt [3] is now released. Toothed belt [3]:- remove from toothed belt pulley [4] Stepping motor [2]:- remove fixing screw [5]- remove stepping motor [2]


1

X92

2

3

4

5

1

6

7toX92

8

InstallationToothed belt pulley [4] withring [6]:- slide on the motor shaft- tighten with two setscrews [7] Stepping motor [2]:- hold onto spacers [8]- tighten with fixing screw [5] Toothed belt [3]:- position onto toothed belt pulley [4] Stepping motor [2]:- rotate contrary to the direction of the arrow- fasten with screw [1]


1

X92

2

3

4

5

1

6

7toX92

8

NOTE:It must be possible to easily press the toothed belt [3] by approx. 9 mm centrally between the gear wheels on one side! If necessary, tension or release toothed belt [3]. Check whether the toothed belt runs straight. Attach cable strap.

Installation


RemovalRemove cable strap. Disconnect electrical connection X89. CAUTION:Observe installation position of thestepping motor and, if necessary, mark it! Remove screws [1] with washers [2]. Remove toothed belt [10] from toothed belt pulley [11]. Remove stepping motor [7]. Loosen setscrews [8] by one revolution.

>


InstallationSlide ring [9] with toothed belt pulley [11] on the shaft. Fasten setscrews [8]. Position toothed belt [10] on toothed belt pulley [11]. Position Stepping motor [7] onto spacer [3] in correct installation position. Fasten screws [1] with washers [2]. NOTE:It must be possible to easily press the toothed belt by approx. 9 mm centrally between the gear wheels on one side!

>


1

Axle

2

3

45

76

8

11

10 9

RemovalPreconditions:- front guide panel is dismounted. Remove two nuts [1] with washers [2]. Tilt motor [3]. Unsolder red (+) and gray ( - ) cables. NOTE:Observe polarity, if necessary, notedown! Loosen setscrew [4]. Remove block [5].


1

Axle

2

3

45

76

8

11

10 9

NOTE:Observe installation position, note down if necessary! Remove three screws [6] with washers [7]. Remove motor from bracket [8]. NOTE:Observe installation position of themotor, note down if necessary!

Removal


1

Axle

2

3

45

76

8

11

10 9

InstallationMotor M14 [3]:- use three screws [6] and washers [7] to fasten to bracket [8] in correct installation position Block [5]:- use setscrew [4] to fasten onto the motor shaft in correct installation position Solder on red (+) and gray ( - ) cables. CAUTION:The cables may not touch the strut [11]!


1

Axle

2

3

45

76

8

11

10 9

Motor [3]:- tilt and position in installation position- fasten with two nuts [1] and washers [2] CAUTION:When tilting the block [5], the ball bearing [9] always has to be remain in the grasp of the lever [10]! - mount front guide panel.

Installation

- 25 -Removal, Installation, Adjustment / Film Exit Unit / Holder Assembly

3 (2x)2 (2x)

5

1

4

6

RemovalNOTE:Observe installation position of block [1]! Block [1]:- loosen setscrew- pull off the axle Remove from both sides:- 2 screws [2]- washers [3] Holder assembly [4]:- pull out of milling [5]


3 (2x)2 (2x)

5

1

4

6

InstallationHolder assembly [4]:- insert into milling [5] On both sides:- fasten washer [6] with washers [3] and 2 screws [2] Block [1]:- slide onto axle in correct installation position- set in position with setscrew Perform holder adjustment.


58 ±1

1 +0.6

Guide panel

Holder

12

4

35

Pivot pointAdjustmentThe holders must reach the following measurements:- as far as the screw [1]: 58 ±1 mm- as far as the bracket [2]: 1 +0.6 mm Adjustment: Block [3]:- loosen setscrew [4] Holder:- use your hand to set to 58 ±1 mm Block [3]:- lightly press against screw [1] until it has contact- tighten setscrew [4]


58 ±1

1 +0.6

Guide panel

Holder

12

4

35

Pivot point Bracket [2]:- loosen fixing screw [5] by one revolution Holder:- set to 1 +0.6 mm using feeler gauge Bracket [2]:- lightly press against block [3] until it has contact- tighten fixing screws [5]

Adjustment

- 29 -Removal, Installation, Adjustment / Film Exit Unit / Solenoid

1

4 (2x)3 (2x)

2

RemovalRemove film exit unit. (T1) Remove front guide panel. (T2) Remove screws [4]. Remove solenoid [1] from the film exit unit.


1

4 (2x)3 (2x)

2

InstallationDegrease solenoid armature [1] in the adhering area. Note:Hold solenoid vertically and plug the sleeve [2] onto the armature from below! Adhere the sleeve with Loctite 638 to the armature. Screw the solenoid to the film exit unit. Grease the tip of the sleeve with Losoid 1160B. Check the holder adjustment. (T1)


1

4 (2x)3 (2x)

2

InstallationInstall the front guide panel. (T2) Install film exit unit. (T3)

- 32 -Removal, Installation, Adjustment / Film Exit Unit / Roller

Right:

Left:

11

10

9

8

5

2

1Side panel

Side panel

1067

M3

3

Left

11

4

RemovalRemove a fixing screw of the stepping motor M3. Swing stepping motor M3, remove toothed belt. Toothed belt pulley [1] with ring [3]:- loosen two setscrews [2] by one revolution- pull off roller shaft Spacer [4]:- pull off roller shaft Clamp [5]:- remove screw [6] with washer [7]- remove clamp [5]


Right:

Left:

11

10

9

8

5

2

1Side panel

Side panel

1067

M3

3

Left

11

4

Screw [8] and washer [9]:- remove Roller [10]:- remove Ball bearing [11]:- remove from both sides

Removal


Right:

Left:

11

10

9

8

5

2

1Side panel

Side panel

1067

M3

3

Left

11

4

InstallationBall bearing [11]:- slide on the roller axle on both sides Roller [10]:- insert Screw [8]:- attach with washer [9] Clamp [5]:- mount- fasten with screw [6] and washer [7] Spacer [4]:- slide on the roller shaft


Right:

Left:

11

10

9

8

5

2

1Side panel

Side panel

1067

M3

3

Left

11

4

Toothed belt pulley [1] with ring [3]:- slide onto the roller shaft as far as the stop- lock in position on the roller shaft using two setscrews [2] Toothed belt:- position on toothed belt pulley [1] and toothed belt pulley of the stepping motor M3 Stepping motor M3:- move into installation position- lock in position with fixing screw NOTE:It must be possible to press the toothed belt by approx. 9 mm centrally between the gear wheels on one side!

Installation

- 36 -Removal, Installation, Adjustment / Film Exit Unit / Front Guide Panel

1

2

RemovalPull the front guide panel [1] up from the screws.

- 37 -Removal, Installation, Adjustment / Film Exit Unit / Front Guide Panel

1

2

InstallationPlace the front guide panel [1] fromthe top onto the screws [2].

- 38 -Removal, Installation, Adjustment / Film Exit Unit / Rear Guide Panel

2

3

4 (3x)

1

5 (3x)

RemovalRemove front guide panel. (T1) Remove roller. (T2) Remove screws [5] with distance sleeve [4]. Remove rear panel [1] with guide panel [3].


2

3

4 (3x)

1

5 (3x)

InstallationScrew the rear guide panel [1] with the screws [5] and distance sleeves [4] loosely to the back panel of the film exit unit. CAUTION:Observe the installation position ofthe guide panel [3], upper rim mustpoint in the direction of the exit unit! Insert guide panel [3] and press on the middle screw, align horizontally and sidewards. Tighten screws [5].


2

3

4 (3x)

1

5 (3x)

InstallationWhen exchanging the guide panel [1] adhere strips [2] as follows:Edge "a" even with outer edgeEdge "b" 0.1 +0.15 mm lapping over the metal edge Mount front guide panel. (T1) Mount roller. (T2)

a

b

- 41 -Removal, Installation, Adjustment / Film Exit Unit / Control Rollers

Drive M14

Strut

Cable harness

1 2 3 4

M

GeneralOnly control roller 3 is moved with motor M14 (see Ill.). The other rollers are moved synchronously over struts around their pivot point. The force transmission from the motor to the control roller 3 is performed via lever impact. Prior to removing a control roller, remove the cable harness mountedonto it.

- 42 -Removal, Installation, Adjustment / Film Exit Unit / Control Rollers 1, 2, 4

1 (4x)2

3

RemovalRemove front guide panel. (T1) CAUTION:Do not loosen screws (3x) secured with Loctite from the strut [2] ! Remove circlip [1]. Remove strut [2] from the fork pins.


5 (2x)6 (3x)

7 (2x)

89

10

12

11

13

4 (2x)

RemovalRemove fixing screws [4] on the back side. Remove entire unit. Pull the fork [11] out of the holder [13] and remove pressure spring [12]. Remove lock washer [8]. Carefully pull axle [9] out of the fork and rollers [6].


5 (2x)6 (3x)

7 (2x)

89

10

12

11

13

4 (2x)

InstallationPack the rollers [6], distance sleeves [5] and washers [7] in the fork [11] together to one set. Thread the axle [9] into the fork and the roller set. Mount lock washer [8]. Mount pressure spring [12] onto the shaft of the fork. Grease shaft with Losoid 1160B. Insert fork into the holder [13].


1 (4x)2

3

InstallationInstall the entire unit into the film exit unit. Check foam rubber stopper [3] andexchange, if required. CAUTION:Do not loosen screws (3x) secured with Loctite from the strut [2]! Set the complete strut [2] with boreholes onto the pins of the fork. Set circlip [1] onto the pins. Adjust control rollers. (T1)

- 46 -Removal, Installation, Adjustment / Film Exit Unit / Control Roller 3

1 (4x)2

3

RemovalRemove front guide panel. (T1) CAUTION:Do not loosen screws (3x) secured with Loctite from the strut [2] ! Remove circlip [1]. Remove strut [2] from the fork pins.


5 (2x)6 (3x)

7 (2x)

89

10

4 (2x)12

11

15

14

13

RemovalLoosen setscrew [15]. Remove level [14].

Remove fixing screws [4] on the back side. Remove entire unit. Pull the fork [11] out of the holder [13] and remove pressure spring [12]. Remove lock washer [8]. Carefully pull axle [9] out of the fork and rollers [6].


5 (2x)6 (3x)

7 (2x)

89

10

4 (2x)12

11

15

14

13

InstallationPack the rollers [6], distance sleeves [5] and washers [7] in the fork [11] together to one set. Thread the axle [9] into the fork and the roller set. Mount lock washer [8]. Mount pressure spring [12] onto the shaft of the fork. Grease shaft with Losoid 1160B. Insert fork into the holder [13].

Mount lever [14] centered to the fork.


1 (4x)2

3

InstallationInstall the entire unit into the film exit unit. Check foam rubber stopper [3] andexchange, if required. CAUTION:Do not loosen screws (3x) secured with Loctite from the strut [2]! Set the complete strut [2] with boreholes onto the pins of the fork. Set circlip [1] onto the pins. Adjust control rollers. (T1)


Drive M14

Strut

Cable harness

1 2 3 4

M

Auxiliary tools

AdjustmentPrerequisites:1. Struts have to be fastened to thecontrol rollers!2. Struts are secured with the locking rings! Position tools with a flat surface onthe front of the control rollers. NOTE:Control rollers are aligned straight,if they have contact with the flat surface over the entire length of the auxiliary tools.


Motor M14

Lever

Strut

Setscrew

Axle

Rollers CAUTION:The lever has to be adjusted in such a way that the rollers can be moved uniformly when starting at the zero position. The greatest allowable tolerance between the two rollers may be ±1°. Adjustment:- loosen setscrew- turn lever on axle- tighten setscrew Check adjustment. If necessary, repeat the adjustment. Install front guide panel. (T1)

Adjustment

- 52 -Removal, Installation, Adjustment / Cutting Device

Gear Unit Motor M4

Cutting Device

Before removing the cutting device, the film exit unit must be removed! Before removing individual components, remove the complete cutting device!

Cutting Wheel

Cutting Rail


3 (2x)

2 (2x)

1 (2x)

RemovalRemove the film exit unit. (T1) Pull off connector X55. Loosen screw [1] by one revolution. Remove the screw [2]. Remove the washer [3]. Remove the cutting device.


3 (2x)

2 (2x)

1 (2x)

InstallationInsert the cutting device into the machine. Tighten screw [1]. Tighten screw [2] with washer [3]. NOTE:The washer [3] must be positioned onto the shaped strip of the cuttingdevice. Fit connector X55. Install the film exit unit. (T1)

- 55 -Removal, Installation, Adjustment / Cutting Device / Gear Unit Motor M4

X

M4

+grayred

View X

1

2

3

45

6

789

Motor shaft

Setscrew

Flat surface

Ill. A

RemovalKnob [1]:- pull off motor shaft Cable strap [2]:- cut and remove Pull connector [3] off motor. NOTE:Observe installation position of motor [6], mark if necessary. Remove four fixing screws [4] with washers [5]. Motor [6]:- tilt- remove toothed belt from toothed belt pulley [7]


X

M4

+grayred

View X

1

2

3

45

6

789

Motor shaft

Setscrew

Flat surface

Ill. A

Two setscrews [8]:- loosen by one revolution at the ring [9] Toothed belt pulley [7] with ring [9]:- pull off motor shaft Remove gear unit motor [6].

Removal


X

M4

+grayred

View X

1

2

3

45

6

789

Motor shaft

Setscrew

Flat surface

Ill. A

InstallationGear unit motor [6]:- insert motor shaft through the bore hole Toothed belt pulley [7] with ring [9]:- slide on the motor shaft Screw in setscrew [8] so that it reaches the flat surface (Ill. A). Slide up toothed belt pulley [7] withring [9] until the setscrew [8] touches the end of the flat surface (Ill. A). In this position (Ill. A):- tighten both setscrews [8]


X

M4

+grayred

View X

1

2

3

45

6

789

Motor shaft

Setscrew

Flat surface

Ill. A

Motor [6]:- tilt- position toothed belt on toothed belt pulley [7] Gear unit motor [6]:- fasten with four fixing screws [4] and washers [5] Fit connector [3]. CAUTION:Observe polarity: red to +, gray to - ! Attach cable strap [2]. Knob [1]:- position on the motor shaft

Installation

- 59 -Removal, Installation, Adjustment / Cutting Device / Cutting Wheel

Assembly opening

1

2

Danger of being cut while removing orinstalling the cutting wheel!

3

4

RemovalPrecondition:Cutting device is removed. CAUTION:During the following procedure, press back the cutting wheel be means of an appropriate tool before reaching the assembly opening so that it does not slip off the cutting rail [2]! Cutting wheel [1]:- use the handwheel to move in the direction of the assembly opening as far as the stop- press axially- remove carefully

- 60 -Removal, Installation, Adjustment / Cutting Device / Cutting Wheel

Assembly opening

1

2

Danger of being cut while removing orinstalling the cutting wheel!

3

4

InstallationUse methylated spirit to clean the cutting wheel [1] and, if necessary, remove protruding burr with a grindstone. CAUTION:Cutting wheel [1] blade must not touch the cutting rail [2]! Cutting wheel [1]:- press axially- insert in assembly opening- press back; while the cutting wheel is pressed back, use the handwheel to move it in the direction of the arrow

- 61 -Removal, Installation, Adjustment / Cutting Device / Cutting Rail

1

3 (6x)

2 (2x)

RemovalRemove cutting wheel [1]. (T1) Turn out setscrews [2]. Loosen screws [3].


1

3 (6x)

2 (2x)

RemovalRemove cutting wheel [1]. (T1) Turn out setscrews [2]. Loosen screws [3].


4

5

2(2x)

3 (6x)

4A

A

InstallationUse methylated spirit to clean the cutting rail [4] and, if necessary, remove protruding burr with a grindstone. CAUTION:Observe the installation position ofthe cutting rail (bore holes for setscrews [2], s. Ill. A)! Slide cutting rail into the cutting device and screw tight.


1

3 (6x)

2 (2x) C

4 2

5

B

B

6

7 5

CLoosen setscrew [6] and remove tensioner [7]. Insert toothed belt [5], the setscrews [2] must engage in the first two gaps (s. Ill. C). Turn in setscrew against slight resistance. Mount tensioner [7]. Slightly tighten the toothed belt using the setscrew [6]. Insert cutting wheel [1] and install cutting device. (T1)

Installation

- 65 -

Punch Adapter

Stepping Motor M7

Solenoids

Solenoids

Removal, Installation, Adjustment / Punch Adapter

Removal, Installation, Adjustment / Punch Adapter - 66 -

112

RemovalHolder [1] and safety switch [2]:- loosen fixing screws- swing out of position Remove film exit unit and cutting device. Disconnect electrical connection X61:- punch adapter <->pcb MODULE CONNECT


Three fixing screws:-loosen at the marked positions NOTE:Screws remain at the punch adapter. - Lift out punch adapter

Removal


Installation- Insert punch adapter from above Punch adapter:- position in correct installation position at the trough (screws reach into the milling at the trough)- use three fixing screws to fasten at the marked positions


112

Establish electrical connection X61:- punch adapter <->pcb MODULE CONNECT Install film exit unit and cutting device. Holder [1] and safety switch [2]:- swing into installation position- fasten with fixing screws

Installation

- 70 -

Film exit side

Y 8

Y 9

Trough sideY 6

Y 7

Removal, Installation, Adjustment / Punch Adapter / Solenoids

Installation, SolenoidsSolenoids:- fastened on each side with two screws and washers Set a corresponding distance X for each solenoid: X for the trough side: 2.5 mm X for the film exit side: 5.0 mm Sleeve [1]:- slide onto the solenoid- lightly press against the armature- set sleeve [1] into position with setscrew [2]

X

1 2

X

1 2

- 71 -Removal, Installation, Adjustment / Punch Adapter / Solenoids

Installation of the solenoids:- loosely fasten slenoids- position solenoids to measure 1 mm- tighten fixing screws

Installation, Solenoids

1 mm

1 mm

- 72 -Removal, Installation, Adjustment / Punch Adapter / Stepping Motor M7

Motor holder1

2

45

6

3

1.5 mm

RemovalRemove cable strap. Disconnect electrical connection X61. CAUTION:Observe installation position of thestepping motor, mark if necessary. Remove four nuts [1] with screws [2] and washers [3]. Remove toothed belt from toothed belt pulley [4]. Remove stepping motor.

- 73 -Removal, Installation, Adjustment / Punch Adapter / Stepping Motor M7

Motor holder1

2

45

6

3

1.5 mm

InstallationRing [5] with toothed belt pulley [4]:- slide onto the shaft- use two setscrews [6] to fasten onto motor shaft Position toothed belt on toothed belt pulley [4]. Stepping motor:- position in correct installation position at the motor holder- fasten with four nuts [1], screws [2] and washers [3] NOTE:It must be possible to easily press in the toothed belt by approx. 9 mmcentrally between the toothed belt pulleys on one side.

Observe the distance of 1.5 mm for the toothed belt pulley (4)!

- 74 -Removal, Installation, Adjustment / Collecting Cassette

1

X

2 (2x)View "X"

4

3

CAUTION:Prior to installing the collecting cassette [1], the following functions must be checked! Functions check of handles [2]:- it must be possible to press the handles easily and without resistance into the cassette [1]- when releasing the handles, they must be automatically pressed out of the cassette by means of the elastic force of their pressure springs

Adjustment

>


Input / Side Panels

Output

Exposure Unit

Punches (Option)

Lower Section



- 2 -

The top punch is an option. If no top punch is installed, the punch adapter must be installed. The top punch may only be actuated if it is installed! After removal of the entire unit, remove and install individual parts.

Top Punch

Gear Unit Motor M17

Stepping Motor M7

Solenoids Solenoids

Removal, Installation, Adjustment / Top Punch


Removal, Installation, Adjustment / Top Punch - 3 -

112

RemovalHolder [1] and safety switch [2]:- loosen fixing screws- swing out of position Remove film exit unit and cutting device. Disconnect electrical connection X61:- top punch <-> pcb MODULE CONNECT


3

Fasten two long cable straps or a suitable tape at both sides as handles. CAUTION:Ensure, that pressure strip [3] is not twisted or damaged due to the handles! Loosen the three fixing screws at the marked positions. NOTE:Screws remain in the top punch! Hold top punch at the handles and lift out.

Removal


3

InstallationFasten two long cable straps or a suitable tape at both sides as handles. CAUTION:Make sure that pressure strip [3] is not twisted or damaged due to the handles! Hold top punch at the handles and insert from above. Top punch:- position in correct installation position at the trough (screws reach into the milling at the trough)- use three fixing screws to fasten at the marked positions


112

Establish electrical connection X61:- top punch <-> pcb MODULE CONNECT Manually move the pressure rail back and forth to check for easy movements. Install film exit unit and cutting device. Holder [1] and safety switch [2]:- swing into installation position- fasten with fixing screws Check and, if necessary, perform the parameter set-up.

Installation

- 7 -Removal, Installation, Adjustment / Top Punch / Gear Unit Motor M17

RemovalToothed belt pulley [1]:- loosen two setscrews [6] by one revolution- pull off motor shaft together with toothed belt [2] Unsolder two cables (red, gray). CAUTION:Observe installation position of thegear unit motor, mark if necessary. Remove nut [3]. Gear unit motor [5]:- take out of holder [4]

- 8 -Removal, Installation, Adjustment / Top Punch / Gear Unit Motor M17

RemovalToothed belt pulley [1]:- loosen two setscrews [6] by one revolution- pull off motor shaft together with toothed belt [2] Unsolder two cables (red, gray). CAUTION:Observe installation position of thegear unit motor, mark if necessary. Remove nut [3]. Gear unit motor [5]:- take out of holder [4]

- 9 -

Film exit side

Y 8

Y 9

Trough sideY 6

Y 7

Parts Catalog

Removal, Installation, Adjustment / Top Punch / Solenoids

Installation, SolenoidsSolenoids:- fastened on each side with two screws and washers Set a corresponding distance X for each solenoid: X for the trough side: 2.5 mm X for the film exit side: 5.0 mm Sleeve [1]:- slide onto the solenoid- lightly press against the armature- set sleeve [1] into position with setscrew [2]

Xa

1 2

Xm

1 2

- 10 -

Parts Catalog

Removal, Installation, Adjustment / Top Punch / Solenoids

Installation of the solenoids:- loosely fasten slenoids- position solenoids to measure 1 mm- tighten fixing screws

Installation, Solenoids

1 mm

1 mm

Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts

Exchange the punch replacement parts in the specified order!

- 11 -

12

6

5

43

5

Cutting Plate RemovalNOTE:As a rule, punch needle, cutting plate and guide panel should be exchanged. Remove coverings. Cover the trough. Remove the film exit unit. (T1) Remove the cutting device. (T2) Remove the top punch. (T3) Cut the cable strap. Pull the connector off the punch motor.



- 12 -

12

6

5

43

5

Unhook the springs [6] (2x). Unscrew the screws [4] from the brackets [3]. Remove the screws [1] (6x) from the holding brackets [2] and [5]. Remove the holding brackets with the rollers from the top punch.

Cutting Plate Removal



- 13 -

6

78

1110

9

12

13 (3x)

14

15

Remove the screws [8] (5x). Remove the collecting tray [7]. Perform the following steps on both sides:- Remove the circlips [10] (2 at eachside) and washers [11] (2 at each side).- Remove the connecting rods [9] (2 x).- Remove the washers [12] (2 at each side). Remove screws [13] (3 x). Remove the pressure rail [14]. CAUTION:Do not unscrew the lever [15].




- 14 -

17

16

16

18

Remove the screws [17] (3 x) and remove holding brackets [18]. Unscrew bearing blocks [16] (2 x) and take off the motor unit.




- 15 -

19

20

2122

Remove the screws [19] (4 x). Remove the holder [22]. NOTE:Remove the securing varnish from the hexagon socket of the fixing screws [20] using a pointed device. Remove the fixing screws [20] and take the cutting plate [21] off the carrier.


Install the cutting plate



- 16 -

19

20

2122

Cutting Plate InstallationCAUTION:Punch needle, cutting plate and guide panel fit together precisely.Components of different spare parts sets must not be mixed! Take the components included in the spare parts set out of the bag and degrease them. Mark installation positions and replacement parts accordingly. Distinctive feature of cutting plate or guide panel:Cutting plate = 4.8 mm thickGuide panel = 3.8 mm thick



- 17 -

19

20

2122

Insert cutting plate [21] and tightenscrews [20] slightly. Position the cutting plate:- lateral distance: 1 mm- distance to lower contact surface: 0.2 mm Tighten screws [20]. CAUTION:The screw ends must no protrude beyond the cutting plate. The position of the guide panels may be checked by mounting a register pin row.

A

A

1 mm1 mm

0.2 mm

Cutting Plate Installation

Remove punch needle and guide panel



- 18 -

2324

252627

28

3129

30

Punch Needle and Guide Panel RemovalRemove the screws [28] from the plate [24]. Swing bar [23] away. Remove the plate [24]. Pull the pin [26] out of the punch needle [25] and remove the punch needle from the guide panel [29]. NOTE:Remove the securing varnish from the hexagon socket of the fixing screws [30] using a pointed device.



- 19 -

2324

252627

28

3129

30

Punch Needle and Guide Panel RemovalUnscrew guide panel from holder [31].

Install punch needle and guide panel



- 20 -

2324

252627

28

3129

30

Punch Needle and Guide Panel InstallationCAUTION:Make sure, the punch needle, cutting plate and guide panel belong to the same set! Insert punch needle [25] in the guide. Insert pin [26]. Insert guide panel [29] and screw on loosely.It must still possible to move the guide panel. Push the punch needle into the guide panel.



- 21 -

19

20

2122

Carefully position the bar onto the carrier. CAUTION:The punch needle must not slip outof the guide panel. Insert the screws [19] (4x) into the carrier from below and tighten them slightly. The lateral surfaces of the holder [22] and of the carrier musut be flush with each other. Tighten the screws and check the position of the holder to the carrier.

Punch Needle and Guide Panel Installation



- 22 -

2324

252627

28

3129

30

Insert punch needle [25] through the guide panel [29] into the cuttingplate. Swing up bar. Install the punch in the machine. Press guide panel upward slightly, carefully press punch needle into the cutting plate and pull it out again. Tighten screws [30] of guide panel alternately and uniformly. Check the punch needle for smooth and easy movement (manually).




- 23 -

2324

252627

28

3129

30

NOTE:If smooth and easy movement of the punch needle is not achieved by moving the guide panel, then check the position of the holder in relation to the carrier. Adjust all guide panels and screw tight. Remove the punch again. Insert new balls [27]. Lift punch needle and position plate [24] between holder and pin.




- 24 -

2324

252627

28

3129

30

Position pin [26] centrally in the punch needle and press punch needle downward as far as the stop. Swing bar onto the holder. Insert screws [28], position plate [24] carefully and tighten screws.




- 25 -

6

78

1110

9

12

13 (3x)

14

15

Observe installation position of pressure rails [14]! Mount pressure rail and tighten screws [13] (3x). Check pressure rail for smooth andeasy movement. CAUTION:The bar must touch the carrier!The punch needle must not slip outof the guide panel!




- 26 -

17

16

16

18

Mount motor unit with blocks [16]. Mount holding bracket [18].




- 27 -

6

78

1110

9

12

13 (3x)

14

15

Punch Needle and Guide Panel InstallationPerform the following steps on both sides:- Mount washers [12] (2 at each side). - Mount connecting rod [9] (2x). - Mount washers [11] (2 at each side). - Mount circlip [10] (2 at each side)



- 28 -

12

6

5

43

5

32

3334

35

35

GYOG+ -

Mount holding brackets with rollers.Check that the ball bearings (4x) in the guides are sitting correctly. NOTE:The slotted disk [34] must run centrally through the opto switch [32]. Hook in springs [6] (2x). Mount collecting tray. Plug connector onto the motor [33](observe polarity). Fasten cables onto the holder [35] using cable straps.




- 29 -

12

6

5

43

5

32

3334

35

35

GYOG+ -

Install the top punch and check theparameters. (T1) Install the cutting device. (T2) Install the film exit unit. (T3)


- 30 -Removal, Installation, Adjustment / Top Punch / Stepping Motor M7


>

- 31 -Removal, Installation, Adjustment / Top Punch / Stepping Motor M7


>

- 32 -Removal, Installation, Adjustment / Lateral Punch

Punch Body

Lateral punch:- produced according to customer specifications- can be equipped with different numbers of punch bodies- is delivered as a pre-assembled module

Millings forfurther punch bodies(customer-specific)


- 33 -Removal, Installation, Adjustment / Lateral Punch / Punch Body

2 (2x)1

1

1

2 (2x)

2 (2x)

RemovalRemove the front covering and the front cover. Disconnect electrical connections. Remove screws [2]. Remove punch body [1] from the machine.

- 34 -Removal, Installation, Adjustment / Lateral Punch / Punch Body

2 (2x)1

1

1

2 (2x)

2 (2x)

InstallationUse screws to fasten the punch body [1] onto the trough, but do not tighten screws [2]. Position the available (punched) film into the trough. Insert the punch needles of the punch bodies in the available punch holes. Tighten screws [2]. Establish electrical connections. Perform a functions test of the lateral punch and check the punch parameters.

- 35 -Removal, Installation, Adjustment / Lateral Punch / Punch Replacement Parts

2 (2x)

5 (2x)

1

6

3

7

8

94 (2x)

RemovalNOTE:As a rule, all punch needles, cutting plate and guide panel should be exchanged. Remove the punch body. (T1) Turn out the screws [4] and take the holder [1] out of the punch body. Remove the pin [6] from the punch needle [7]. Remove the punch needle from theholder. Remove the cutting plate [8] and the guide panel [9].


2 (2x)

5 (2x)

1

6

3

7

8

94 (2x)

0.2 ±0.01 mm

1

8

9

InstallationCAUTION:The punch needle, cutting plate andguide panel fit together precisely.Parts from different spare parts sets must not be mixed! Take the components out of the spare parts set and degrease them. Insert the cutting plate [8] in the holder [1] and lightly tighten the screws [5]. Position the cutting plate:- make sure the sides of the cutting plate are flush with the holder sides- distance to the front edge 0.2 ±0.01 mm


2 (2x)

5 (2x)

1

6

3

7

8

94 (2x)

0.2 ±0.01 mm

1

8

9

InstallationTighten the screws [5] and check the position of the cutting plate. Screw the guide panel [9] onto the holder, but do not tighten the screws [2]. Insert the punch needle [7] in the cutting plate and guide panel and insert the pin [6]. NOTES:While locking the guide panel in position, move the punch needle back and forth. Tighten the screws [2] alternately insteps of 1/2 revolution.


2 (2x)

5 (2x)

1

6

3

7

8

94 (2x)

0.2 ±0.01 mm

1

8

9

InstallationCheck the punch needle for smoothand easy movement. Insert the holder in the punch body [3]. Install the punch body and check the parameter set-up. (T1)

- 39 -

The bottom punch is an option. If no bottom punch is installed, the bottom punch adapter must be installed. The bottom punch may only be actuated if it is installed! After removal of the entire unit, remove and install individual parts.

Bottom Punch

Gear Unit Motor

Removal, Installation, Adjustment / Bottom Punch

Solenoid, Left

Solenoid, RightPunch Replacement Parts


1 (4x)

RemovalRemove the loading platform. (T1) Pull off connectors X66 and X91. Screw out the fixing screws [1]. Remove the bottom punch from the machine.


1 (4x)

InstallationInsert the bottom punch in the machine. Fasten the bottom punch onto the trough using screws [1]. Check the bottom punch for properfunctioning by turning the motor axle. Fit connectors X66 and X91. Install the loading platform. (T1) Perform the parameter set-up.

- 42 -Removal, Installation, Adjustment / Bottom Punch / Gear Unit Motor

1 2 (2x)3

4 (2x)

5 6

7 (2x)9

A

A

ORGY

+

-

8

10

M 19RemovalRemove the screws [2]. Remove the bracket [1] with the opto switch and carefully put it to the side. Pull the flat connector off the motor[3]. Remove setscrew [7]from the eccentric [6]. Pull the pin [9] out of the eccentric. Turn out the screws [4], remove theclamp [5]. Remove the motor with the connecting rod [8] and punch needle from the bottom punch.


1 2 (2x)3

4 (2x)

5 6

7 (2x)9

A

A

ORGY

+

-

8

10

M 19RemovalPull the connecting rod off the eccentric. Loosen the setscrew position at the motor [7] and pull the eccentricoff the motor axle.


1 2 (2x)3

4 (2x)

5 6

7 (2x)9

A

A

ORGY

+

-

8

10

M 19InstallationPlace the eccentric [6] onto the motor axle and turn it until the setscrew [7] positioned at the motor exerts pressure onto the milled area of the motor axle. Tighten the setscrew. Position the connecting rod [8] onto the eccentric. Insert the punch needle [10] in the guide panel, move motor [3] into installation position and fasten the clamp [5] using screws. Insert the pin [9] in the eccentric. Screw in the setscrew [7] but do not tighten it.


1 2 (2x)3

4 (2x)

5 6

7 (2x)9

A

A

ORGY

+

-

8

10

M 19InstallationCAUTION:The switch lug of the pin [9] must run through the center of the opto switch. Mount the bracket [1] with the optoswitch. Turn the motor axle until the punchneedle is at its upmost position (setscrew [7] is at the top). Turn the pin [9] until the slot of the switching lug is in the opto switch. Tighten the setscrew. Fit the flat connector onto the motor, observe polarity.

- 46 -Removal, Installation, Adjustment / Bottom Punch / Solenoid, Left

1

2

3

4 (2x)

5 (2x)7 (2x) 68 (2x)

Y 2



1

2

3

4 (2x)

5 (2x)7 (2x) 68 (2x)

Y 2

InstallationSlide the sleeve [3] onto the magnetarmature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 ±0.2 mm. Tighten the setscrew [2]. Fasten the solenoid onto the bracket [6] using screws. Connect the flat connector, observepolarity.

Install the bottom punch and adjustthe solenoid.

X

GY OG


B


A

Gap


Armature pulled out

1

1

- 49 -Removal, Installation, Adjustment / Bottom Punch / Solenoid, Right

1

2

34

5 (2x)

7 (2x)

6 (2x)

8 (2x)

Y 1



1

2

34

5 (2x)

7 (2x)

6 (2x)

8 (2x)

Y 1

InstallationFit the sleeve [2] onto the magnet armature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 ±0.2 mm. Tighten the setscrew [1]. Fasten the solenoid onto the bracket [4] using screws. Connect the flat connector, observe polarity.

Install the bottom punch and adjustthe solenoid.

X

GYOG


B


A

Gap


Armature pulled out

1

1

Removal, Installation, Adjustment / Bottom Punch / Punch Replacement Parts - 52 -


12

5

4 (3x)

3 (3x)

RemovalNOTE:As a rule, punch needle, cutting plate and guide panel should be exchanged. Remove coverings. Cover the trough. Remove the bottom punch. (T1) Unhook the springs [1] and [5]. Remove the pressure rail [2].



6

7

11 10

9

8

Remove the collecting tray [11]. Remove bracket [8] with opto switch. Cut the cable strap at the gear unit motor, pull off the flat connector. Unscrew the cover plates [7] and [9]. Unscrew holding bracket with solenoids [6] and [10] and remove it from the punch. Remove the gear unit motor. (T2)

Removal



17

16

19 (4x)

18

12 13 (2x)

14 15

2021 (2x)

Press pin [14] out of the connecting rod [15] and remove the punch needle [16]. Unscrew the carrier [20] from the bar [12]. Turn out the screws [21] and take the cutting plate [18] off the carrier. Turn out the screws [13] and remove the guide panel [17].

Removal



17

16

19 (4x)

18

12 13 (2x)

14 15

2021 (2x)

CAUTION:The punch needle, cutting plate and guide panel fit together precisely.Components of different spare parts sets must not be mixed! Take the components included in the spare parts set out of the bag and degrease them. Insert cutting plate [18] and tightenscrews [21] lightly. Position the cutting plate:- distance parallel to the lower contact surface: 0.4 ±0.015 mm Tighten screws [21].

Installation

0.4 ±0.015 mm

1820



17

16

19 (4x)

18

12 13 (2x)

14 15

2021 (2x)

CAUTION:The screw ends must not protrude beyond the cutting plate. Insert guide panel [17] and screw on loosely.It must be possible to move the guide panel. Carefully position the carrier [20] onto the straight pins of the bar [12]. Tighten the screws [19] (4x). Insert pin [14] in punch needle [16]. Carefully insert the punch needle through the guide panel [17] in the cutting plate [18].

Installation



17

16

19 (4x)

18

12 13 (2x)

14 15

2021 (2x)

Install the punch in the machine. NOTE:The guide panel is locked in position step by step. Between the individual steps, the punch needle must be moved in both directions. Tighten the screws [13] of the guide panel alternately by 1/2 revolution. Check the punch needle for smoothmovement. Remove the punch. Remove the pin [14] from the punch needle. Insert the punch needle in the connecting rod [15].

Installation



6

7

11 10

9

8

Insert the pin and secure it in position by tapping lightly on both sides using a center punch. Mount the holding bracket with solenoids [6] and [10]. Install the gear unit motor. (T1) Fasten the cable onto the motor using cable straps. Fasten the cover plates [7] and [9] using screws. Mount the collecting tray [11].

Installation



12

5

4 (3x)

3 (3x)

InstallationObserve the installation position ofthe pressure rail [2]! Mount the pressure rail and tightenthe screws [3]. Check the pressure rail for smooth movement. Attach the springs [1] and [5]. Install the bottom punch and checkthe parameters. (T2) Adjust the solenoids.

- 1 -Adapter List, Exposure Unit

MODULE-CONNECT 5.952

X50 => B01 H-MOTHERBOARD 5.949Adapter 2081.1080200.0 04640047

X51 => C01 H-MOTHERBOARD 5.949

Adapter 2081.1080200.0 04640047 X59 => X85 EC-CONTR. 5.951

Flat cable 2081.1080000.0 04537335 X60 => X8 AC-CONTROLLER 5.950

Adapter 2081.1080300.0 04640144 X63 => X113 lateral punch A (option)

Adapter 2081.1081400.0 04556747 # X64 => X114 lateral punch B (option)

Adapter 2081.1081400.0 04556747 # X65 => X115 lateral punch C (option)

Adapter 2081.1081400.0 04556747 #


MODULE-CONNECT 5.952

X66 => X116 lateral punch D (option)Adapter 2081.1081400.0 04556747 #

X68 => Safety switches S14, S15, S18

Wiring 2081.2060012.0 04661214 X98 => X90 loop monitoring

Cable 2081.1081500.0 04556488


EC-CONTR. 5.951

X70 => X71 rotating mirrorAdapter 2081.1081001.0 04743598

X72/ => XA4 RIP-INTERFACE 5.976X79 X77/X78 optics head

Adapter 2081.1080100.0 04587162 X80 => X74 optics head

Flat cable 2083.1081500.0 04156951 X82 => X87 MAT.WIDTH I 6.004 or

MAT.WIDTH II 6.063Flat cable 2083.1081500.0 04156951

X84 => X69 MODULE-CONNECT 5.952

Flat cable 2081.1080000.0 04537335 X85 => X59 MODULE-CONNECT 5.952

Flat cable 2081.1080000.0 04537335 X86 => X58 MODULE-CONNECT 5.952

Flat cable 2081.1080000.0 04537335


Optics head

X74 => X80 EC-CONTR. 5.951Flat cable 2083.1081500.0 04156951

X77/ => XA4 RIP-INTERFACE 5.976X78 X72/X79 EC-CONTR. 5.951

Adapter 2081.1080100.0 04587162

- 5 -Adapter List, Base

H-MOTHERBOARD 5.949

B01 => X50 MODULE-CONNECT 5.952Adapter 2081.1080200.0 04640047

C01 => X51 MODULE-CONNECT 5.952

Adapter 2081.1080200.0 04640047 X39 => Valve controller

Adapter 2081.2056218.0 04671511 X44 => X140 Berger controller

Adapter 2081.1080600.0 04641027 X47 => X147 operating panel

Adapter 2081.1080900.0 04640756 X48 => X13 AC-CONTROLLER 5.950

Adapter 2081.1080500.0 04640586 X49 => Fan E2

Adapter 2081.2056014.0 04569237


AC-CONTROLLER 5.950

X8 => X60 MODULE-CONNECT 5.952Adapter 2081.1080300.0 04640144

X13 => X48 H-MOTHERBOARD 5.949

Adapter 2081.1080500.0 04640586 X15 => Vacuum pump

Power cable 2081.2056216.0 04671422 X16 => Compressed air pump

Power cable 2081.2056012.0 04569156 X17 => S1, H1 mains, illuminated display

Adapter 2081.1080400.0 04640837 X20 => X142 Berger controller

Adapter 2081.1080800.0 04640667


XA4 => X72/X79 EC-CONTR. 5.951 X77/X78 optics headAdapter 2081.1080100.0 04587162

RIP-INTERFACE 5.976

XA4 => X72/X79 EC-CONTR. 5.951 X77/X78 optics headAdapter 2081.1080100.0 04587162


Berger controller

X140 => X44 H-MOTHERBOARD 5.949Adapter 2081.1080600.0 04641027

X141 => X143 stepping motor M8

Adapter 2081.1080701.0 04557182 X142 => X20 AC-CONTROLLER 5.950

Adapter 2081.1080800.0 04640667

Cleaning and Lubricating Agents, Adhesives, Varnish - 9 -

Cleaner's NaphthaCleaning Agents

Precision oil Clock 859 02098318 #Oil Tonna T 68 00593850Universal grease Arcanol L78 00129631 #Special-purpose grease LOSOID 1160B 02463253 #

Lubricating Agents

Varnish retouching pen light gray 04321928 #Varnish retouching pen gray 04321936 #

Varnish

Thermolube, e.g. Electrolube HTC 02722070Securing varnish, f. screws, gray 00129003Adhesive, Loctite 222 01169939 #Adhesive, Loctite 242 01169920 #Adhesive, cyanoacrylate (Sicomet 99) 02225360 #Adhesive, Loctite 572 04138856Adhesive, Loctite 638 02427052 Film material 150x30 mm

Sundries

Tools - 10 -

Screwdriver 00187119Hex. size 2 angled

Screwdriver, ball head 00349712Hex. size 3 T-handle


Screwdriver 02203359Hex. size 3 T-handle


Screwdriver, ball head 01276786Hex. size 4 angled

Screwdriver, ball head 01276778Hex. size 5 angled

Screwdriver 01167057Size 1 Pozidriv

Screwdriver 01234188Size 2 Pozidriv

Screwdrivers

Tools - 11 -

Open-end wrench set Combi. wrench set 02454769

Square ¼"Torque wrench 01760491

0.2-4 Nm ¼"

Wrenches

Tools - 12 -

Dial gauge 00576212Div. 0.01 meas. range 5 mm

Meas. tip f. dial gauge 02486725Meas. disk dia. 10 mm

Magnetic stand 02863286with prism guide

Contactor 00996521500 - 2000 g

Spring balance 04001745Div. 0.05 meas. range 0 - 5 N

Measuring Tools, Mechanical

Tools - 13 -

Oscilloscope 019125932 channels 100 MHz

Digital multimeter 013278524 1/2 digits

Adapter 1:1 f. Service PC 045365769-pin SUB-D max.10 m

Conv. adapter f. Service PC 042350459/25-pin

Adapter SMC/BNC 01959891 #1.5 m

Measuring Tools, Electrical

Tools - 14 -

Spring hook 00494534Rd 1.5 155 mm

Wrench for filter container 05914469 #

Sundries

Error Messages - 2 -

Error messages are displayed on the operating panel display. Press the "?" key, the stored errors are displayed. Leaf through the messages using key.

- 3 -

EC-CONTR. (6.500)MODULE-CONNECT (5.952)

Pcb ConfigurrationNest

H-MOTHERBOARD (5.949)

AC-CONTROLLER (5.950)

MAT-WIDTH IMAT-WIDTH II

Overview

[only Herkules extension]

- 4 -

EC-CONTR. (5.951)MODULE-CONNECT (5.952)

Pcb ConfigurrationNest

H-MOTHERBOARD (5.949)

AC-CONTROLLER (5.950)

MAT-WIDTH IMAT-WIDTH II

Overview

Pcb MODULE CONNECT (5.952) - 5 -

X64 X63 X62

X57

X51

X52

X61 X98

X50

X54X55X53

X56

Order No. 04575423

X65X66

X69X58 X59

X60

X68

BARCODE

Pcb EC-CONTROL (5.951) - 6 -

X82

K3

X80 X83

S2

S3

S1

Order No. 04577736

X85X86X84

X3

X4 TP15

X72

X73

X70

X1

X38X79

TP15: Light Measurement, Test Program 41- Between 0 and 2.5V (10 mV are approx. 1 digit light value) Example: 200 LV = 2 V.


X82

K3

X80 X83

S2

S3

S1

Order No. 04577736

X85X86X84

X3

X4 TP15

X72

X73

X70

X1

X38X79

Connector X3- Window signal for the SOL photo diode


X82

K3

X80 X83

S2

S3

S1

Order No. 04577736

X85X86X84

X3

X4 TP15

X72

X73

X70

X1

X38X79

Connector X4

- 5 V for test purposes


X82

K3

X80 X83

S2

S3

S1

Order No. 04577736

X85X86X84

X3

X4 TP15

X72

X73

X70

X1

X38X79

Connector X73

- SOL (analog) signal - Check of the direction of rotation, of the rotating mirror - In the case of incorrect direction of rotation actuate switch S1

Correct signal run

Wrong signal run


X82

K3

X80 X83

S2

S3

S1

Order No. 04577736

X85X86X84

X3

X4 TP15

X72

X73

X70

X1

X38X79

Switch S2

- SOL window generation 60 µs per motor rotation

Pcb EC-CONTROL (6.500) [only Herkules Extension] - 11 -

X82

K3

X80 X83

S2

S3

S1

Order No. 04896904

X85X86X84

X3

X4 TP15

X72

X73

X70

X1

X38X79

TP15: Light Measurement, Test Program 41- Between 0 and 2.5V (10 mV are approx. 1 digit light value) Example: 200 LV = 2 V.


X82

K3

X80 X83

S2

S3

S1

Order No. 04896904

X85X86X84

X3

X4 TP15

X72

X73

X70

X1

X38X79

Connector X3- Window signal for the SOL photo diode


X82

K3

X80 X83

S2

S3

S1

Order No. 04896904

X85X86X84

X3

X4 TP15

X72

X73

X70

X1

X38X79

Connector X4

- 5 V for test purposes


X82

K3

X80 X83

S2

S3

S1

Order No. 04896904

X85X86X84

X3

X4 TP15

X72

X73

X70

X1

X38X79

Connector X73

- SOL (analog) signal - Check of the direction of rotation, of the rotating mirror - In the case of incorrect direction of rotation actuate switch S1

Correct signal run

Wrong signal run


X82

K3

X80 X83

S2

S3

S1

Order No. 04896904

X85X86X84

X3

X4 TP15

X72

X73

X70

X1

X38X79

Switch S2

- SOL window generation 60 µs per motor rotation

- 16 -

Order No. 04699629

R5


BARCODE

X2

X87

R6

Film material required:- Reference film (20% screen or transparent unexposed infrared film)- Black film (100% black). Remove loading platform (T1). Start test software (T2)Call up test 82 Input: r82[l,m] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>

Alignment

- 17 -

Order No. 04699629

R5


BARCODE

X2

X87

R6

Display:Bit sequence 7654 3210- Bit 4 = 1 > Film is in both opto switches- Bit 4 = 0 > Film is not in opto switches or only in one opto switche. Insert reference film in the trough in front of the two opto switches. CAUTION:Film must have the same position as with normal operation. Cover left-hand opto switch with the black film. So adjust right-hand pot (R6) that bit 4 changes from "0" to "1". Remove black film.

- 18 -

Order No. 04699629

R5


BARCODE

X2

X87

R6

Cover right-hand opto switch with the black film. So adjust left-hand pot (R5) that bit 4 changes from "0" to "1". Perform a test at the end positionsand in the middle of the travel:- without reference film > bit 4 = "0" - with reference film on both opto switches > bit 4 = "1". Install loading platform (T3). Note:If the setting is not possible alter the distance between pcb and carrier.

- 19 -

Order No. 04700805


R5

X2X87

R6

Film material required:- Reference film (20% screen or transparent unexposed infrared film)- Black film (100% black). Remove loading platform (T1). Displace carriage in such a way that the right-hand opto switch is positioned over the right-hand reflection strip. Start test software (V > 2.00) (T2)Call up test 82 Input: r82[l,m,r] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>

Alignment

- 20 -

Order No. 04700805


R5

X2X87

R6

Display:Bit sequence 7654 3210- Bit 4 = 1 > Film is in opto switch- Bit 4 = 0 > No film is in opto switch. Insert reference film in the trough in front of the right-hand opto switch. Caution:Film must have the same position as with normal operation. So adjust right-hand pot (R4) that bit 4 changes from "0" to "1". Caution:At the ends of the reflection strip, the film must be safely recognized.

- 21 -

Order No. 04700805


R5

X2X87

R6

Stop test 82 Input: stop <Enter> Position left-hand opto switch over the left-hand reflection strip. Call up test 82 Input: r82[l,m,l] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter> So adjust left-hand pot (R5) that bit 4 changes from "0" to "1". Caution:At the ends of the reflection strip, the film must be safely recognized.

- 22 -

Order No. 04700805


R5

X2X87

R6

Install loading platform (T3). Note:If the setting is not possible alter the distance between pcb and carrier.

Pcb AC-CONTROLLER (5.950) - 23 -

K3

L1

K5K1

K7

F7

K4K2

X2

X19

X18

F5

F6F4

Order No. 04575431

F2F3

X13X17

X3X20

X12X8

X15X16

X4

7X... 306

31

28

5

3533

3432 29X...

Pcb H-MOTHERBOARD (5.949) - 24 -

Order No. 04577698

X48

X47

X42

X46

X43X49 X39

X44

X500

X45

C01 B01


- 25 -

A 07

ERIAL-CONTROL (5.948)NCONTROLLER (5.933)ED-CONTROL (5.941)IF (2081.523 or 2081.524)VOLTAGE REG (5.970)

A 02

A 09

A 08

A 04

A 06

unoccupied A 01

unoccupied A 03

unoccupied A 05

Pcb Configuration, Nest

- 26 -

A 07

ERIAL-CONTROL (5.948)NCONTROLLER (5.933)ED-CONTROL (5.941)P INTERFACE(5.976)VOLTAGE REG (5.970)

A 02

A 09

A 08

A 04

A 06

unoccupied A 01

unoccupied A 03

unoccupied A 05

unoccupied

Pcb Configuration, Nest

- 27 -

Meas.Points,

DiagnosticConnector

KK1 XA3X1

BARCODE XB3

Pcb VOLTAGE REG (5.970) Slot 09

Order No. 04578503

- 28 -

Pin 010203040506070809101112131415161718

Diagnostic connector XA 3 on pcb VOLTAGE-REG (slot 09): measuring points

Signal MGND+ 5 V- 2 V B- 15 VREF P1 - P4REF TIGHT MOTSENSE FANREF GUI MOTPWR FANREF LOOP MOTMOT REG SPG CTRLREF B MOT+ 15 V+ 7.5 VMOT REG SPGEXT 2EXT 4+ 24 V

Meaning Supply logic unitfor RIP IF ECL logic unitSupply analog systemReference voltage, punches 1-4Reference voltage for M7Electronics frame fanReference voltage for M2+24 V electronics frameReference voltage for M3Mirror motorReference voltage for M5Supply, analog systemSOP supplyMirror motorn.c.n.c.Motors / solenoids supply

Block Diagrams, Overviews

- 29 -

Pin 19202122232425262728293031323334353637


Meaning GND of the 24 Vn.c.n.c.Reference voltage for M6ECL & Peltier element supplyfor ECL RIP IF logic unit+10 V of the DAC for stepping motorReference voltage for punches 5-6Supply, RS 232 (MAINCONTROLLER)S11 compressed air monitoring unitSupply, RS 232 (MAINCONTROLLER)Supply cassette motorCollecting cassette motorMirror motorReference voltage for M1Reference voltage for M15n.c.Opto switch B9 reference voltageSupply, mirror motor

Signal 0 VEXT 3EXT 6Ref SUP CAS- 5.2 V- 2 V ARef 10Ref P5-P6+ 12 VA SWI*- 12 VB MOT 1TA MOT 10 V MOT REG SPG CRTLRef TA MOTRef VVExt 5Ext 1+ 28 V


Pcb HERK - IF (2081.523 or 2081.524) slot 07 / 08 - 30 -

X1

Order No. 04859987 (machines with mod. status 27)Order No. 04860160 (machines with mod. status 28)

X2 X1

XA4 X21 X20

Pcb RIP INTERFACE (5.976) Slot 08 - 31 -

XA4

X2

BARCODE

X1

XA3

XA7

Order No. 04576330

Pcb FEED-CONTROL (5.941) Slot 06 - 32 -

Order No. 04122119

X1X2

BARCODE

S1S2

XA3

Pcb MAINCONTROLLER (2081.526) Slot 04 - 33 -

X2

BARCODE

X1

V1V2S1

XA4

XC4

XB5

XA6 XB6

XA5

Order No. 05266521

FD drive

FD drive- FD235HF-7529

Pcb MATERIAL-CONTROL (5.948) Slot 02 - 34 -

XA7

X5 X2

BARCODE

X1

S1

Order No. 04576497

- 35 -

F1

Label

Fuse F1 Order No.

T 6.3 A 00138215T 15 A 04188713

Mains Connection

CAUTION:Machine must only be connected to the power supply if the F1 fuse is equipped correctly. F1 fuse:- in the case of U <= 127 V: T 15 A / 250 V- in the case of U > 127 V: T 6.3 A / 250 V NOTE: Fuses have different bayonet joints. Stick the label indicating the set voltage on top of the old one. Label Order No. 230 V 04137655115 V 04258673all other voltages 04258703

Checking Mains Input Fuse

- 36 -

K3

L1

K5K1

K7

F7

K4K2

X2

X19

X18

F5

F6F4

Order No. 04575431

F2F3

X13X17

X3X20

X12X8

X15X16

X4

7X... 306

31

28

5

3533

3432 29X...

Pcb AC-CONTROLLER (5.950)

F2 T 0.3 A 00138452F3 T 0.125 A 01468367

F4 MT 10 A 00240699F5 T 4 A 00442836F6 T 1.5 A 00138525F7 T 8 A 04188691

Fuse Order No.

Block Diagram - 37 -

XA3A08

X44A06

XB6 service

2081.526

XA7

5.948

XB3 C01

XA6

XA3A01

5.970

MATERIAL-CONTROL

MAIN-CONTROLLER

FEED-CONTROL

RIPINTERFACE

A04, 05

5.976 5.941

STEPPINGMOTOR

M8X143

X141X140

SOL, CLOCK, BIAS, VIDEO

A CPU Bus X100

B Priv.Wir X200

C Priv.Wir X500

VT 10019200 bauds8 bitsNo parity1 stop bitNo handshake

RIP 60REC-IF

Motherboard B01

C01

SENSORIKACTUATORS

SPEEDWAY

PcbMODULE

CONNECT

PcbEC-CONTR. /

OPTICS HEAD

AMPLIFIER

VOLTAGE-REG+7.5V SOP-2V A ECL-2V B ECL+28V MIRROR MOTOR

XA4

FDD


SOL, CLOCK, BIAS, VIDEO

X85

5.951 X72 X79 X80

X70

X84X82

X86

OPTICS HEADX78X74 X77

X87

X71

MAT-WIDTH

ROT. MIRRORUNIT

6.004

EC-CONTR.

MODULE CONNECT

RIP INTERFACE


X51

5.952

MODULE-CONNECT

SENSORSACTUATORS

X59X69 X58

X63X64X65X66

X50 X52

X54X55

X53

X61

X98

X68

X60

X57

X56

LOADING PLATFORM

EXPOSURE UNIT

FILM EXIT UNIT

CUTTING DEVICEX90 LOOP MONITORING UNIT

TOP PUNCH (OPTION)

SAFETY SWITCHESS14, S15, S18

(OPTIONS)

AC-CONTROLLER X8 (5.950)

DIAG SENSORS

DIAG ACTUATORSX113 LATERAL PUNCH A (1)X114 LATERAL PUNCH B (2)X115 LATERAL PUNCH C (3)X116 LATERAL PUNCH D (4)

EC-CONTR.

MOTHERBOARD

- 40 -

Pin 010203040506070809101112131415161718


Signal MGND+ 5 V- 2 V B- 15 VREF P1 - P4REF TIGHT MOTSENSE FANREF GUI MOTPWR FANREF LOOP MOTMOT REG SPG CTRLREF B MOT+ 15 V+ 7.5 VMOT REG SPGEXT 2EXT 4+ 24 V

Meaning Supply logic unitfor RIP IF ECL logic unitSupply analog systemReference voltage, punches 1-4Reference voltage for M7Electronics frame fanReference voltage for M2+24 V electronics frameReference voltage for M3Mirror motorReference voltage for M5Supply, analog systemSOP supplyMirror motorn.c.n.c.Motors / solenoids supply


- 41 -

Pin 19202122232425262728293031323334353637


Meaning GND of the 24 Vn.c.n.c.Reference voltage for M6ECL & Peltier element supplyfor ECL RIP IF logic unit+10 V of the DAC for stepping motorReference voltage for punches 5-6Supply, RS 232 (MAINCONTROLLER)S11 compressed air monitoring unitSupply, RS 232 (MAINCONTROLLER)Supply cassette motorCollecting cassette motorMirror motorReference voltage for M1Reference voltage for M15n.c.Opto switch B9 reference voltageSupply, mirror motor

Signal 0 VEXT 3EXT 6Ref SUP CAS- 5.2 V- 2 V ARef 10Ref P5-P6+ 12 VA SWI*- 12 VB MOT 1TA MOT 10 V MOT REG SPG CRTLRef TA MOTRef VVExt 5Ext 1+ 28 V


Block Diagram, Overviews - 42 -

Abbreviations M 1M 2M 3M 4M 5M 6M 7M 8M 9M10M11M12M13M14M15M16M17M18M19

Motors

Allocation Film Exit UnitFilm Exit UnitFilm Exit UnitCutting DeviceLoading PlatformLoading PlatformExposure UnitExposure UnitOptics HeadOptics HeadOptics HeadCompressed Air UnitVacuum UnitFilm Exit UnitVacuum UnitExposure UnitTop PunchLateral PunchBottom Punch

Component Collecting Cassette DriveStepping Motor, Lateral GuideStepping Motor, LoopCutter MotorRewind Motor, Supply CassetteStepping Motor, FeedStepping Motor, Loading UnitStepping Motor, Feed (Spindle)Stepping Motor, FocusStepping Motor, Filter WheelStepping Motor, ShutterCompressed Air PumpVacuum PumpFilm Guide DriveValve ControllerRotating Mirror DriveGear Unit Motor, Top PunchGear Unit Motor, Lateral PunchGear Unit Motor, Bottom Punch

Block Diagram, Overviews - 43 -

Abbreviations S 1S 2S 4S11S12S14S15S16S18

Switches

Allocation Control PanelFilm Exit UnitLoading PlatformCompressed Air UnitVacuum UnitBaseUpper SectionFilm Exit UnitBase

Component On/Off SwitchPolling Unit, LoopFilm End, RemainderPressure SwitchValve ControllerSafety SwitchSafety SwitchCollecting Cassette Polling UnitKey-operated Switch

Interface Recorder <--> Transport Channel / Processor - 44 -

RECORDER - READY

RECORDER - CUT

PROCESSOR - CONNECT

PROCESSOR - ON

PROCESSOR - WAIT

FRAME - GND (shield)

RECORDER Transportchannel / processor

...please refer to the next pages

For explanation on signal names

Interface Timing


RECORDER - READYThe recorder is switched on and ready for operation.Now the CUT signal can be evaluated.READY = between pins 1 and 9 24 volts are applied that are evaluated by an opto coupler.

Explanation on Signal NamesX69

READY

CUT

CONNECT

ON

WAIT

SHIELD

Opto coupler

Opto coupler

SUB - D 15-pinSUB - D 15-pin

+24V

+24V

+24V

+24V

Transportchannel

Interfacecable

Recorderinterface

XA7

+24V / max. 150mA

01

09

02

10

03

11

0412

05

13

09

0210

03

11

0412

0513

01

Sign.

Sign.

Sign.


RECORDER - CUTThe signal appears-> for the time the film is being cut in the recorder or-> at film end, the supply cassette as simulated signal between galley proof and the rest of the film which is not cut. During this time, the film may not be transported. CUT = between pins 2 and 10, 24 volts are not applied that can be evaluated by an opto coupler.


READY

CUT

CONNECT

ON

WAIT

SHIELD

Opto coupler

Opto coupler


+24V

+24V

+24V

+24V

Transportchannel

Interfacecable

Recorderinterface

XA7

+24V / max. 150mA

01

09

02

10

03

11

0412

05

13

09

0210

03

11

0412

0513

01

Sign.

Sign.

Sign.


PROCESSOR - CONNECTInstead of the cassette, the transport channel is coupled with the recorder and connected via the interface cable.This coupling is ensured bysignal CONNECT.Dependent on this, the film unloading sequence is switched from cassette operation to on-line operation. Via pins 3 and 11, a ground cable is looped throughthe transport channel and polled in the recorder via 5 volts.CONNECT = ground loop closed. The cassette switch must not be actuated if the transport channel is coupled.


READY

CUT

CONNECT

ON

WAIT

SHIELD

Opto coupler

Opto coupler


+24V

+24V

+24V

+24V

Transportchannel

Interfacecable

Recorderinterface

XA7

+24V / max. 150mA

01

09

02

10

03

11

0412

05

13

09

0210

03

11

0412

0513

01

Sign.

Sign.

Sign.


PROCESSOR - ONThe on-line processor and the transport channel are connected to the mains and switched on.ON = at pins 4 and 12, 24 volts areapplied which are evaluated in therecorder via opto couplers.


READY

CUT

CONNECT

ON

WAIT

SHIELD

Opto coupler

Opto coupler


+24V

+24V

+24V

+24V

Transportchannel

Interfacecable

Recorderinterface

XA7

+24V / max. 150mA

01

09

02

10

03

11

0412

05

13

09

0210

03

11

0412

0513

01

Sign.

Sign.

Sign.


PROCESSOR - WAITFor the following reasons, the processorcan receive no galley proofs: -> The level regulations of the baths indicate an incorrect liquid level. -> The temperature sensors of the baths indicate an incorrect temperature (e.g. during the warm-up time after swiching on). -> There is still a galley proof in the transport channel or-> a malfunction in the processor makes it impossible to receive galley proofs.


READY

CUT

CONNECT

ON

WAIT

SHIELD

Opto coupler

Opto coupler


+24V

+24V

+24V

+24V

Transportchannel

Interfacecable

Recorderinterface

XA7

+24V / max. 150mA

01

09

02

10

03

11

0412

05

13

09

0210

03

11

0412

0513

01

Sign.

Sign.

Sign.


WAIT = at pins 5 and 13, 24 volts are not applied that can be evaluated in the recorder via opto couplers.In the case of a contact error or line break, the error state or an uncritical state should always be entered.


READY

CUT

CONNECT

ON

WAIT

SHIELD

Opto coupler

Opto coupler


+24V

+24V

+24V

+24V

Transportchannel

Interfacecable

Recorderinterface

XA7

+24V / max. 150mA

01

09

02

10

03

11

0412

05

13

09

0210

03

11

0412

0513

01

Sign.

Sign.

Sign.


PROCESSORCONNECT-L

RECORDERREADY

PROCESSORON

PROCESSORWAIT

RECORDERCUT

FILMLAUF

<---------->--------------->

5V

----------------->

CUT

0V

24V

24V

24V

24V

0V

0V

0V

0V

WAIT WAIT

Pin Interface connector

03

11

09

01

12

04

13

05

10

02

<-------------><-------><----------------->

Interface - Timing

Switch-on process of recorder and processor completed


PROCESSORCONNECT-L

RECORDERREADY

PROCESSORON

PROCESSORWAIT

RECORDERCUT

FILMLAUF

<---------->--------------->

5V

----------------->

CUT

0V

24V

24V

24V

24V

0V

0V

0V

0V

WAIT WAIT


03

11

09

01

12

04

13

05

10

02

<-------------><-------><----------------->

Interface - Timing

The recorder did not transport the galley proof continuously through the transport channel due to loop controlling.


PROCESSORCONNECT-L

RECORDERREADY

PROCESSORON

PROCESSORWAIT

RECORDERCUT

FILMLAUF

<---------->--------------->

5V

----------------->

CUT

0V

24V

24V

24V

24V

0V

0V

0V

0V

WAIT WAIT


03

11

09

01

12

04

13

05

10

02

<-------------><-------><----------------->

Interface - Timing

Galley proof is being cut, film transport not permissible


PROCESSORCONNECT-L

RECORDERREADY

PROCESSORON

PROCESSORWAIT

RECORDERCUT

FILMLAUF

<---------->--------------->

5V

----------------->

CUT

0V

24V

24V

24V

24V

0V

0V

0V

0V

WAIT WAIT


03

11

09

01

12

04

13

05

10

02

<-------------><-------><----------------->

Interface - Timing

Galley proof is continuously transported at a speed of approx.140 mm / sec


PROCESSORCONNECT-L

RECORDERREADY

PROCESSORON

PROCESSORWAIT

RECORDERCUT

FILMLAUF

<---------->--------------->

5V

----------------->

CUT

0V

24V

24V

24V

24V

0V

0V

0V

0V

WAIT WAIT


03

11

09

01

12

04

13

05

10

02

<-------------><-------><----------------->

Interface - Timing

The recorder is ready for exposure, galley proof is slowly transported into the processor


PROCESSORCONNECT-L

RECORDERREADY

PROCESSORON

PROCESSORWAIT

RECORDERCUT

FILMLAUF

<---------->--------------->

5V

----------------->

CUT

0V

24V

24V

24V

24V

0V

0V

0V

0V

WAIT WAIT


03

11

09

01

12

04

13

05

10

02

<-------------><-------><----------------->

Interface - Timing

WAIT extinguishes only if the transport channel is empty and a new galley proof can be transported out of the recorder

Explanations on the Test Page - 57 -

BAR 2BAR 3

BAR 4

BAR 5BAR 6

BAR 9

BAR 7

BAR 1

BAR 8

BAR 10

BAR 11

BAR 12

Note


Introduction The setup of a technical test page (TTP 2083) is described.The data stock of this TTP 2083 is available as a Postscript file and it can be copied to Postscript imagesetter systems using a floppy disk.The file is protected by Heidelberger Druckmaschinen Aktiengesellschaft copyright. Application TTP 2083 can be used in all cases where the output quality of Postscript imagesetter systemsis checked and the output is evaluated.By means of this file, a test pattern in the form of a test page is exposed on photo material in the output format of the imagesetter.This test page is analyzed visually, by means of a microscope or by means of an automatic measuring device.REMARK:This test page is used exclusively for evaluating the exposure quality. Notes on possible error sources can only contribute coarsely to the error identification.

General


Structure of test page The test page consists of different test patterns, BAR 1 - BAR 12. Base fog Base fog:- can be measured on every unexposed position of the test page,- depends to a high degree on the photo material and on the set threshold value of the imagesetter. If the imagesetter is correctly adjusted, the following values are valid:0.3 - 0.5 density, orthochromatic0.5 - 0.8 density, ultraviolet Measuring instruments: Densitometer with a corresponding measuring range Possible error sourcesIf the base fog is too high, check the photo material, the developing processes,the storage and the handling of photo material.

General


Is there a pre-exposure?The imagesetter is adjusted by means of a light test including a threshold value adjustment.In the case of an incorrect adjustment of the threshold value, it may happen that the photo material is pre-exposed.

General


BAR 1, BAR 12 as well as the grid patterns between corner points A and K as well as C and Mare line images consisting of lines of identical width and spacing.With these grid patterns, the geometrical reproduction accuracy can be checked.This applies to page width, page height, diagonal, linearity, straightness, line width in FastScan and SlowScan directions.Evaluation should be performed with an automatic measuring instrument. A coarse, fast evaluation can be performed visually. REMARK:During evaluation of the absolute precision, it must be observed that an error-free calculationof the geometry data was performed by Postscript.Otherwise, only the determination of the repetition accuracy is possible. An enlargement or reduction of the test page is always performed symmetrically to the X- or Y-axis. The 50% and the 90% screen areas in the four corners are used to measure of screen homogeneity in comparison with the screen areas in BAR 7, 9 and 10. In addition, BAR 1 comprises:- the test page designation TTP 2083 and its version number- 3 register marks which are used to accurately position the test page in a punch

BAR 1 and BAR 12: Explanation


Geometry can be checked or measured using BAR 1 and BAR 12. Page lengthsAll four lengths (AC, KM, AK, CM) are compared with the lengths pre-set by the front-end system.Check the absolute deviation and the delta of the opposite side. Perpendicularityis the difference value between the diagonals (AM and CK). Linearityis the repetition accuracy of the partial distances of the lengths AC, KM, AK, CM. Length(actual) * partial length(set)Partial length(actual) = ---------------------------------------------------------- Length(set) Linearity error = Partial length(set) - partial length(actual) StraightnessThe lines AC, KM, AK, CM must be straight.

BAR 1 and BAR 12: Evaluation


Line widthThe lines AC, KM, AK, CM as well as all short horizontal lines must have the same width. The imagesetters offer a highly precise geometrical recording function.However, this is very strongly influenced by the photo materials. The photo materials in particular change under temperature, humidity and mechanical influences.Depending on the used photo material, different results are to be expected.



A ruler (glass ruler) is suitable for coarse measurements.For precise measurements, an automatic measuring instrument is required. For a further simple and coarse evaluation, the test page is cut into halves at that X or Y axis.The two halves of the test page are put on top of each other with the emulsion sides facing each other and brought to coincidence at the corner points.Thus, page length, linearity, straightness and perpendicularity can be evaluated using a microscope (40- to 50-fold enlargement).

BAR 1 and BAR 12: Measuring instruments


Sharply focused exposure, but geometrical distortion-> Observe photo material handling, such as transport, temperature, humidity, development. Unsharpness and distortion-> Possible reason(s): photo material not fitting during exposure. Linearity error and page length error in FastScan direction-> Possible reason(s): drive failure of the rotating mirror. Linearity error and page length error in SlowScan direction-> Possible reason(s): drive failure of the exposure carriage. Straightness error: deflection of lines in FastScan direction-> Possible reason(s): deadjustment of the beam position. Straightness error: deflection of lines in SlowScan direction-> Possible reason(s): failures in the travel distance of the exposure carriage.

BAR 1 and BAR 12: Possible error sources


BAR 2 is a solid area density bar (100%).It is used to measure the solid area density during exposure in landscape and portrait format. The inserted recesses (bright rectangles) change the black and white information in such a way that possible density changes in large areas between different video dynamics can be detected. This only applies to FastScan direction. When changing the test page format, the bar height of 10 mm remains constant, the bar width changes symmetrically to the center axis.

BAR 2: Explanation


If the test page is exposed in landscape and portrait format, the solid area density lets and itshomogeneity can be measured at any point using a densitometer. The solid area density depends on the photo material and imagesetter specifications. At the bar recesses, the solid area density can be measured from transparency to black in FastScan direction, and vice versa.

BAR 2: Evaluation


Densitometer with measuring range in accordance with the selected solid area density.Microscope with 40- to 50-fold enlargement.

BAR 2: Measuring instruments


Continuous decline of density in FastScan direction and exceeding of the density tolerance-> Possible reason(s): excessive dirt accumulation of the rotating mirror. Continuous decline of density in FastScan and SlowScan directions-> Possible reason(s): interruption of the developing process, pre-exposure of photo material. Check material packing, cassette shutter, machine cover.

BAR 2: Possible error sources


In BAR 3, all page-specific parameters can be read off. The image parameters- width:... mm- height: ... mm- rotation: ... degand the screen system- DotShape: ...- Screensystem: ...- HFactor: ...- resolution: ... pixel / cm [dots / inch]- Screenangle: ... deg- Screenruling: ... screen lines / cm [lines / inch]are selected for exposure via operation. Specifications- Version: ...- Revision: ...- Serial No.: ...are system parameters and are output on every test page exposure.

BAR 3: Explanation


In addition to the company name and the copyright note, the following fields are available for entries:MATERIAL:DATE:TIME:SIGN.:TESTNO.: CAUTION:Prior to each evaluation of the test page, the parameters set for exposure must be checked inorder to avoid misinterpretations.

BAR 3: Explanation


The round test symbol is used for visual determination of the focus and the focus homogeneity. The size and the shape of the dark area in the center of the test symbol is a criterion for the focus evaluation. When changing the test page format, the size of the test symbol remains unchanged, their number, however, changes. The concentric rings are an aid for comparing the test symbols of an exposure.

BAR 4: Explanation


The smaller the black area in the center - assumung that the work density is constant - the sharper is the adjustment of the imagesetter.In the case of an error-free exposure of the test symbol, the centers of all symbols must be identical. This is applies to FastScan and SlowScan directions. The size of the black area is a coarse indication for the resolution selected for the exposure.Coarse resolution --> large black areaFine resolution --> small black area NOTE:When using photographic paper, the dark area is larger.

BAR 4: Evaluation


Evaluation is performed purely visually.



A large black area in all symbols indicates poor focusing or excessive density if photo material was exposed, e.g., in the saturation area.Uneven black area sizes in the test symbols indicate that the photo material did not fit during exposure. This is applies to FastScan and SlowScan directions.



Various resolution symbols (micro character = M ) can be found in BAR 5 across the entire test page width.Their distances are 10 mm. The resolution symbol is can be found on further positions in the test page so that it is possible to compare the results. The resolution symbol is used to evaluate the resolution and further criteria using a microscope.The structure of the symbol allows the evaluation in FastScan and SlowScan directions.

BAR 5: Explanation


Resolution symbol (enlarged representation) in BAR 5


The essential evaluation criteria are:- repetition of lines- repetition of line spacings- geometry of the lines and line spacings- transitions between the lines or between spacings- fringing between transparency and solid density- density structure in the case of different line combinations- fine structure of the lines The repetition of the lines and the line spacings is especially important.This repetition (width and black density range) is strongly influenced by:- focus setting of the imagesetter- the selected resolution of the imagesetter- the used photo material

BAR 5: Evaluation


The evaluation of the criteria is performed using a microscope with 40- to 50-fold enlargement.A microdensitometer is required for more precise and objective evaluations.



The focus setting of the imagesetter is important. Different resolution symbols in the exposure positions-> Possible reason(s): photo material not fitting during exposure.



This is a text bar with font sizes 1, 1.5 and 3 mm of all letters of the alphabet.It can be used to evaluate the repetition of the fonts, in particular the fine structure in the case of complex fonts.

BAR 6: Explanation


The large-area screen field in the 90% tone value is used to evaluate the area quality.

BAR 7: Explanation


The screen field must be a uniform 90% tone value area. It must be free of screen interferences, tone value changes and other patterns which can be detected by eyesight. This applies to exposure in landscape and portrait format.

BAR 7: Evaluation


Densitometer and visual evaluation.



Interferences (structures at periodic distances)-> Possible reason(s): defect in the feed system of the exposure carriage. Continuous tone value decline in FastScan direction-> Possible reason(s): excessive dirt accumulation of the rotating mirror, photo material not fitting during exposure. See also screen field with 90% tone value in BAR 1 and BAR 12.



The vertical middle of the test page is between BAR 7 and BAR 8. If the page is cut horizontally in this position, the halves can be placed on top of each other for a visual check of the exposure geometry.

Note


These screen bars represent a total of a screen shading from 2% to 98%. BAR 8 includes graduations 60, 70, 80, 90, 92, 94, 96, 98%, that is, the shadow and middle ranges. BAR 11 includes graduations 2, 4, 6, 8, 10, 20, 30, 40%, that is, the highlights and middle ranges. BAR 10 represents the 50% tone value. By means of these screen bars, the following criteria are checked:- repetition of the screen tone value in %; all levels from 2% to 98% in the case of basic adjustment and with screen tone value correction performed (linearization)- recognition of interferences in shadow ranges >90%- determination of the screen homogeneity per screen bar- using the microscope, the increase and decline of the screen dot area

BAR 8, 10, 11: Explanation


The screen bars must be a uniform area according to the tone value. They must be free of screen interferences, tone value changes and other structures which are visible by eyesight. This applies to exposure in landscape and portrait format. In the case of a correct solid area density (depending on the film type), the exposed screen tone values only deviate slightly from the calculated ones (set input). However, depending on the selected resolution, differences are to be expected in the tone value repetitions.

BAR 8, 10, 11: Evaluation


Microscope with 40- to 50-fold enlargement.Densitometer and visual evaluation.

BAR 8, 10, 11: Measuring instruments


Interferences (structures at periodic distance)-> Possible reason(s): defect in the feed system of the exposure carriage. Continuous tone value decrease in FastScan direction-> Possible reason(s): excessive dirt accumulation at the rotating mirror, photo material not fitting during exposure. Linearizations which might have been set with regard to used photo material and developing processes must be observed.

BAR 8, 10, 11: Possible error sources


This sample consists of a screen area and bars. It is used to determine possible tone value changes in the 90% screen during video changes differing in time. For this purpose, the bar must run in FastScan direction.

BAR 9: Explanation


In the 90% screen field, no trailing strips in the rhythm of the"black -> screen" and "white -> screen" transitions may occur.

BAR 9: Evaluation


Evaluation is performed purely visually.



BAR 1, BAR 12 as well as the grid patterns between corner points A and K as well as C and Mare line images consisting of lines of identical width and spacing.With these grid patterns, the geometrical reproduction accuracy can be checked.This applies to page width, page height, diagonal, linearity, straightness, line width in FastScan and SlowScan directions.Evaluation should be performed with an automatic measuring instrument. A coarse, fast evaluation can be performed visually. REMARK:During evaluation of the absolute precision, it must be observed that an error-free calculationof the geometry data was performed by Postscript.Otherwise, only the determination of the repetition accuracy is possible. An enlargement or reduction of the test page is always performed symmetrically to the X- or Y-axis. The 50% and the 90% screen areas in the four corners are used to measure of screen homogeneity in comparison with the screen areas in BAR 7, 9 and 10. In addition, BAR 1 comprises:- the test page designation TTP 2083 and its version number- 3 register marks which are used to accurately position the test page in a punch

BAR 1 and BAR 12: Explanation


Geometry can be checked or measured using BAR 1 and BAR 12. Page lengthsAll four lengths (AC, KM, AK, CM) are compared with the lengths pre-set by the front-end system.Check the absolute deviation and the delta of the opposite side. Perpendicularityis the difference value between the diagonals (AM and CK). Linearityis the repetition accuracy of the partial distances of the lengths AC, KM, AK, CM. Length(actual) * partial length(set)Partial length(actual) = ---------------------------------------------------------- Length(set) Linearity error = Partial length(set) - partial length(actual) StraightnessThe lines AC, KM, AK, CM must be straight.



Line widthThe lines AC, KM, AK, CM as well as all short horizontal lines must have the same width. The imagesetters offer a highly precise geometrical recording function.However, this is very strongly influenced by the photo materials. The photo materials in particular change under temperature, humidity and mechanical influences.Depending on the used photo material, different results are to be expected.



A ruler (glass ruler) is suitable for coarse measurements.For precise measurements, an automatic measuring instrument is required. For a further simple and coarse evaluation, the test page is cut into halves at that X or Y axis.The two halves of the test page are put on top of each other with the emulsion sides facing each other and brought to coincidence at the corner points.Thus, page length, linearity, straightness and perpendicularity can be evaluated using a microscope (40- to 50-fold enlargement).

BAR 1 and BAR 12: Measuring instruments


Sharply focused exposure, but geometrical distortion-> Observe photo material handling, such as transport, temperature, humidity, development. Unsharpness and distortion-> Possible reason(s): photo material not fitting during exposure. Linearity error and page length error in FastScan direction-> Possible reason(s): drive failure of the rotating mirror. Linearity error and page length error in SlowScan direction-> Possible reason(s): drive failure of the exposure carriage. Straightness error: deflection of lines in FastScan direction-> Possible reason(s): deadjustment of the beam position. Straightness error: deflection of lines in SlowScan direction-> Possible reason(s): failures in the travel distance of the exposure carriage.

BAR 1 and BAR 12: Possible error sources

- 1 -Setting the Parameters

... of the Punches

... of the Optics Head

... of the TOUCH MEMORY (Motherboard)

... the Guide Opto Switch

Parameter Set-up ...

Modifying a Parameter (Example with Menu Description)

Modifying a Parameter (BriefDescription)

... of the TOUCH MEMORY (Supply Cassette)

... the Advantage Option

- 2 -Modifying a Parameter (Brief Description)

Starting with the basic menu: Enter the password, for this purpose- press key f Search a parameter, for this purpose- press key 2 Select the data record "static data", for this purpose- press key 1 Change to default, for this purpose- press key d Enter the PID or the parameter name, for this purpose- press key 1 Enter new value Save the value (on floppy disk), for this purpose- press key s

- 3 -Modifying a Parameter (Example with Menu Description)

1. speedway commands menu2. parameter menu3. test menu8. adjust tests9. external testsa. recorder informationb. recorder measurementc. quick set of geometry paramd. quick set of other parame. toggle recorder status linef. password

HERKULES Test Releaseversion: 2.01.xxxdate: xx xx xx

(ON)(ON)

(PF1)(PF2)(PF3)(PF4)(OFF)

Basic menu:After entering the password (for this purpose, press key f), parameters can be modified. To modify a parameter (here: Punch Configuration) press key 2.


PARAMETER MENU - WORK DATAq. Quit1. static data2. application data3. action data4. material data5. measure data6. save machine configuration7. restore machine configuration8.

This menu contains only data records,as well as commands for saving andrestoring recorder-specific data.After selecting a data record(here: static data) you are ...


WORK STATIC DATA - FIND & EDIT1. Find parameter2. Normal sorted list3. Pid sorted list4. Name sorted list

q. Quitd. Switch to Default

DEFAULT STATIC DATA - FIND & EDIT1. Find parameter2. Normal sorted list3. Pid sorted list4. Name sorted list

q. Quitw. Switch to Workr. Read parameterss. Save parameters

... immediately in the new parameter editor.Press key d to go to the default data record.If, e.g., key 1 is pressed, you can either ...

Description of the KEYSKEY 1Extended parameter search function.You can either search for PID or parameter names. It does not matter how the name is written. If no corresponding parameter is found, the search function suggests a similar parameter. KEY 2The parameters are listed according to their function (the most important parametersare shown in the first positions, the order corresponds to the one shown on the recorder display). KEY 3This list is sorted according to the PID numbers. KEY 4This list is sorted according to the parameter names.


WORK STATIC DATA - FIND & EDIT1. Find parameter2. Normal sorted list3. Pid sorted list4. Name sorted list

q. Quitd. Switch to Default


q. Quitw. Switch to Workr. Read parameterss. Save parameters

... immediately in the new parameter editor.Press key d to go to the default data record.If, e.g., key 1 is pressed, you can either ...

KEY qQuits the parameter editor. KEY wChanges to work mode. Only temporary changescan be performed in the recorder. KEY dChanges to default mode. All changes are permanently effective (as soon as this data record is saved with "s"). KEY rThe data record is read from the recorder floppy disk (only possible in default mode). KEY sThe data record is written onto the floppy disk (only possible in default mode).

Description of the KEYS


DEFAULT STATIC DATA Search PanchKonfugirDo you mean 'punch configur' like'Punch Configuration' ?(y)es, find this(n)o, continue with next proposal(q)uit


q. Quitd. Switch to Defaultr. Read parameterss. Save parameters

Continue with any key ...Enter an PID or Parameter name:PanchKonfugir

... enter the name or the PID. If the name is written incorrectly, a name as similar as possibleis suggested. It is also possible to enter a partial string (e.g. 'punch'). After pressing key y...

Description of the KEYSKEY yThe suggested parameter is correct.A list of all parameters containingthe specified names is drawn up. KEY nLooks for more common criteria. KEY qQuits the search function and return to the previous menu.


DEFAULT STATIC DATA Search punch0. | Punch Shape P31. | Punch Shape P4..........9. | Punch Advance P0a. | Punch Advance P1.....e. .....

| PID= 83| PID= 84..........| PID= 110| PID= 111..........

| free| free..........| mm| mm..........

| 0| 0..........| 0| 0..........

(q)uit (p)rev (n)ext

... a list of all parameters containing thispartial string is displayed (here: 'punch' ).If the key for 'Punch Configuration' is pressed, ...

Description of the KEYSKEY qQuits the list. KEY pPrevious page of the list (key is only active if there is more than one page to be selected). KEY nNext page of the list (key is only active ifif there is more than one pageto be selected). KEYS 0 - eSelects the parameter to be edited.


PARAMETER EDITParameter ClassParameter SetDescriptionIdent (PID)UnitTypeAccessMinimum ValueMaximum ValueCurrent Value

New value (?) help:

: DEFAULT PARAMETER: STATIC DATA: Punch Configuration: 766: free: UINT: User Read, Service Write: 0: 32: 16

... the PARAMETER EDIT menu is displayed (noalphabetical character string can be assignedto a numerical parameter). If default parametershave been modified, then they must be ...

Description of the KEYSKEY ?Call up parameter-sensitive ONLINE help.



q. Quitd. Switch to Workr. Read parameterss. Save parameters

Continue with any key ...

Default parameter changed. Save (y / n) ?

... saved in the parameter editor with key s. If you exit the editor without saving the modifed values an appropriate message is displayed.


DEFAULT STATIC DATA PID sorted parameter

(q)uit, (p)rev, (n)ext, (f)irst of list, (l)ast of list, (g)o to

Key | Name | PID | UNIT | VALUE

0. | SS2UZP1. | FS2UZP..........9. | SS2P2a. | Punch Link P2.....e. | FS2P4

| 3| 4..........| 17| 18.....| 22

| µm| µm..........| µm| free.....| µm

| 0| 0..........| 0| 0.....| 0

Example for a list sorted according to PID.

Description of the KEYSKEY qQuits the list KEY pPrevious page of the list KEY nNext page of the list KEY fFirst page of the list KEY lLast page of the list KEY gGo to a specific parameter (input options: PIDor name) and show the list from this positiononwards KEY 0 - eSelects the parameter to be edited

- 12 -Parameter Set-up of the Punches

NOTE:The parameter setting should be performed on a backup diskette. Precondition:- Switch off the punch on the RIP- Set the RIP to collect mode. At the service terminal:Input Explanation f PasswordInput check 2 Parameter menu d Set default data flag 1 Static parameter 3 Geometry 1 Recorder geometry b Changing SS SOP -34500 New value

Return to geometry

Lateral punches

Bottompunch

Arrangement of Punches

Top punches

Punch Type Punch Geometry Key Punch LinkLateral...

Bottom...Top...

1

12

5

56

PL0 = 1PL1 = 2PL2 = 4PL3 = 8PL4 = 8PL5 - 9= 16 each

Activating the Punches


At the service terminal:Input Explanation

Punch configuration (PID 766) X Adding the punch links according to

the available lateral punches:1+2+4+8 = X (variable value)

16 Constant value of top punches Y = X (value of lateral punches) + 16 (const. value of top punches) Z = X (value of lateral punches)

+ 8 (const. value of bottom punches) + 16 (const. value of top punches)

Example of punch configuration:Z = 31 = (1+2+4) + (8) + (16)

lateral bottom top

Lateral punches

Bottompunch


Top punches



Bottom...Top...

1

12

5

56



Lateral punches

Bottompunch


Top punches

At the service terminal:Input Explanation Change punch links according to the list

For non-available punch linksenter value 0.

q return q return w save



Bottom...Top...

1

12

5

56



Exposing the Test Film

At the RIP terminal:- perform job ‘Punch-li.ps’. At the service terminal:Input Explanation 8 Adjust tests p Punching At the RIP terminal:- perform job ‘Punch-Help.ps’ (measuring template).


Measuring the Test Film

At the service terminal:Input Explanation a Recorder information Values ‘Exposing window’:- note down 'FS to begin' and 'SS to begin' on the exposed test film. NOTE:The parameter determination for the lateral punches described in the following is meant as example.The parameters for the other punches are determined accordingly.For the arrangement and allocation of the respective punches, refer to the test film:- Lateral punch = Punch 0 to punch 3- Bottom punch = Punch 4- Top punch = Punch 5 to punch 9

Lateral punches

Bottompunch


Top punches


Take measurements on the film using the exposed measuring template(do not interchange scales for Stoesser or Bacher punches). Determine lateral punch - 'Punch 0 FS':- Position the template on top of punch 0- The line reaching from the center of the punch hole to the two scales below the hole indicates the value 'b0' in mm- Calculate und enter 'Punch 0 FS'.

Template for 'b0'Punch hole 0Punch

Value 'b0'

Punch 0 FS = 'FS to begin' + 'b0' (all values in µm)



Determine the lateral punch - ‘Punch 0 SS’:- Position the template on top of punch 0- Measure the line from the center of the punch hole to the ‘20mm measuring edge’ = value ‘a0’- Calculate und enter ‘Punch 0 SS’. Take the respective measurement and make the entries for all punches.

Template for 'b0'

Punch 0 SS = ‘a0’ + ‘SS to begin’ (all values in µm)

Punch hole 0Punch

20mm measuring edge



Determine the lateral punch - ‘Punchend SS’:- Measure the black bar positioned opposit to punch hole 0 starting at ‘20mm measuring edge’ = value ‘y’- Value 'c' = 20000 - 'y'- Calculate und enter punchend SS.

Punchend SS = ‘c’ + ‘SS to begin’ (all values in µm)

Punch hole 0Punch

20mm measuring edge

yc



Entering Punch Parameters

At the service terminal:Input Explanation 2 Parameter menu d Set default data flag 1 Static parameter 3 Geometry 5 / 6 Punch geometry 1 / 2

Enter the measured or calculated parameters and save them Space w

Enter and save value 'Punchend SS'. Reset the Herkules and wait for the message ‘Recorder ready’. At the RIP terminal:

Activate the punch Expose the job

Check the punch geometry and, if necessary, correct it.

- 21 -Parameter Set-up of the Optics Head

Start the diagnostic software Determine I(max) of the laser head:- Input: r 42 (The program asks for the approximate value of I(max))- Input: the noted down value for the optics head (After approx. 1.5 min., the determined value is displayed. Note down this value) Entries in the parameter list for the diagnostics:- Input: r 0 [c] > I(max) value of the laser diode: determined value Save value in the TOUCH MEMORY:- Input: r 0 [w] (determined value) Terminate the diagnostic software:- Input: ex Remove the floppy disk containing the diagnostic software. Insert the floppy disk containing the recorder software.

- 22 -Parameter Set-up of the Optics Head

Perform a RESET on slot A04. Transfer the determined parameter value ('Max Laser current') onto the recorder software. Transfer the parameters by means of the user software.- Press the following keys at the operating panel: Perform filter, light, focus tests and calibration. NOTES:- The data stocks in the TOUCH MEMORY and in the recorder software must be identical.- Update the backup floppy disks.- Enter the modified values in the machine manual.

'Max Laser current' (PID 563)

- 23 -Parameter Set-up of the TOUCH MEMORY (Motherboard)

Start the diagnostic software Format the TOUCH MEMORY:- Input: r 9 [w] (both TOUCH MEMORIES are created) Test the TOUCH MEMORY:- Input: r 9 (duration: approx. 2 minutes) Initialize the timer:- Input: r 9 [t, i] (The time, operating hours, number of switch-on processes are set to 0) Read the timer:- Input: r 9 [t, r] Enter the serial number (from the type label):- Input: r 0 [s, w] (for Herkules)- Input: r 0 [s, w, m] (for Herkules M)- Input: r 0 [s, w, n] (for Herkules NP)


Read the serial number:- Input: r 0 [s, r] Entries in the parameter list for diagnosis:- Input: r 0 [c] > Peltier temperature: 135 > Hall-Selekt fore mirror motors: 4 > I(max) value of the laser diode: machine-specific parameter (TEST 42) > Light sensor type: 1 > Work. current of guide opto switch:machine-specific parameter (TEST 82) > Max. feed position (mm): 750 (for Herkules) or

550 (for Herkules M) Save values in the TOUCH MEMORY:- Input: r 0 [w] Terminate the diagnostic software:- Input: ex Remove the floppy disk containing the diagnostic software. Insert the floppy disk containing the recorder software.


Perform a RESET on slot A04. Transfer the parameters by means of the user software.- Press the following keys at the operating panel: Check whether the floppy disk is being accessed. NOTES:- The data stocks in the TOUCH MEMORY and in the recorder software must be identical. - Update the backup floppy disks.- Enter the modified values in the machine manual.

- 26 -Parameter Set-up of the TOUCH MEMORY (Supply Cassette)

Prior to removing the TOUCH MEMORY ask for the values and note them down (material mustnot be loaded)- Press the following keys at the operating panel: Install new TOUCH MEMORY. Initialize TOUCH MEMORY:- Press the following keys at the operating panel: Enter the material-specific values:- For this purpose, see operating manual RIP 50, RIP 60 or operating manual delta technology online documentation NT-Utility NOTES:If the values of the old TOUCH MEMORY are unknown (TOUCH MEMORY defective),then test jobs must be run.For this purpose, see operating manual RIP 50, RIP 60 or operating manual delta technology onlinedocumentation NT-Utility

or

- 27 -Parameter Set-up of the Guide Opto Switch

Starting the Diagnostic Software Position the opto switch over the reflection foil:- Input: r 86 [g,d,75,300] Start the current measurement:- Input: r82 [r,l,0]- Output: current value XY in mA Entries in the parameter list for diagnosis:- Input: r 0 [c) > working current of guide opto switch : XY + 7 Save the current value in the TOUCH MEMORY:- Input: r 0 [w] Terminate the diagnostic software:- Input: ex Remove the floppy disk containing the diagnostic software. Insert the floppy disk containing the recorder software.

- 28 -Parameter Set-up of the Guide Opto Switch

Perform a RESET on slot A04. Transfer the parameter value XY + 7 ('Guide LB current') onto the recorder software. Transfer the parameters by means of the user software.- Press the following keys at the operating panel: NOTES:- The data stocks in the TOUCH MEMORY and in the recorder software must be identical. - Update the backup floppy disks.- Enter the modified values in the machine manual.

'Guide LB current' (PID 549)


Parameter PID 815 'Use ABC' Enabling/disabling the 'Advantage' option Parameter PID 837 'Use Barcode' Enabling/disabling the barcode reader pen




Parameter PID 527 'Use Online Processor' Switching on/switching off the online processor.Even if the 'Advantage' option is enabled (PID 815 'Use ABC' has value "1"), the online processor can be switched off in the case of an error.




Parameter PID 527 'Use Online Processor'Transfer parameter using the user software.

Return to "Edit Parameter" menu

Save the parameter


- Press the following key at the operating panel:

- General imagesetter parameter set-up: If the parameter record is not "static data":

- Press the following keys to select the parameter:

- Press the following keys in succession to edit the parameter:

- To save the parameter after editing, press the following keys:

- To return to the main menu, press the following key repeatedly:


General imagesetter parameter set-upSelect parameter record To jump to the level below the current one, press the following key: To select the parameter record, press the following key repeatedly: To jump to the next higher level, press the following key:

- 1 -Service / Settings at the Power Supply Module

110 VLINKLNGND

25 AMPS 6A TOTAL12 AMPS 4 AMPS 7 AMPS

B EC DRP D

+S -S+5.2V 0V +36V 0V +24V 0V 0V0V+5.1V 0V

+15V +15V+S -S+S -S+S -S

Potentiometer

1 23 4

OV ADJ*)

V. ADJ

*)By newer power supply modules this potentiometer is no longeravailable for the over-voltage protection. The over-voltage protection will beguaranteed during the alignment of the output voltage. **)Jumper at:- 90 - 132 V AC to be screwed in - 180 - 264 V AC to be removed

Module

Settings at the module

**)

- 2 -Service / Settings at the Power Supply Module

Settings at DRP moduleProgrammable connectorPin 1: NCPin 2: NCPin 3: Prog inPin 4: 0 V

1: Power output2: 0 volt3: + ve sense4: - ve sense

1 2

3 4

1 2

3 4

DRP module

Table

| Resistance 0 ... 10 kOhms (see| table) between pins 3 and 4.

012345678910

12,014,416,819,221,624,026,428,831,233,636,0

R prog(kOhm)

U out(V)

Depending upon the desired output voltage, connect a resistor (see table) between pins 3 and 4.

Base / Nest - 3 -

1

2

34

5


6

E 1

7 (4x)

1 04577698 #H-MOTHERBOARD - 5.949

2 05318483 #Power supply unit

3 04591402 #TOUCH MEMORY 4KX1

4 04595467 #TOUCH MEMORY + TIME

5 04595874 #Fan, axial

6 05356393 #Encoding connector 10 kOhm(Herkules PRO)

05356407 #Encoding connector 6.81 kOhm(Herkules)


- 1 -Technical Remarks on Safety

Proper UseThe Herkules is a laser image setter for photo material and must only be used for this purpose in accordance with the operating instructions. Do not use the machine as a depository for any articles or fluids.Do not cover the ventilation slots.


GeneralNon-observance of the safety regulations may result in the loss of accident insurance coverage. The mains plugs and the local supply sockets must be easily accessible because it may be necessary to disconnect the machine from the mains - for example, in an emergency - by unplugging the mains plug from the socket. The machine is connected to the mains using the supplied mains cable with a three-pole plug. The machine must not be used if the protective ground wire has been disconnected.The mains connector and the fuses are located at the rear of the machine. In order to provide proper ventilation, ensure that there is sufficient distance between the machine and the wall or between the machine sides and other equipment when the equipment is installed. Please refer to the chapters Installation and Technical Data when installing the machine.The machine must:- not be installed in the vicinity of air conditioning systems- be protected from direct sunlight or electric spotlights in the room- be protected from humidity


CAUTION: Lithium BatteryVORSICHT:EXPLOSIONSGEFAHR BEI UNSACHGEMÄßEM AUSTAUSCH DER BATTERIE. ERSATZ NUR DURCH DENSELBEN ODER EINEN VOM HERSTELLER EMPFOHLENEN GLEICHWERTIGEN TYP.ENTSORGUNG GEBRAUCHTER BATTERIEN NACH ANGABEN DES HERSTELLERS. CAUTION: DANGER OF EXPLOSION IF BATTERIE IS INCORRECTLY REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER.DISCARD USED BATTERIES ACCORDING TO THE MANUFACTURER`S INSTRUCTIONS. ATTENTION: IL Y DANGER D´EXPLOSION S´IL Y A REPLACEMENT INCORRECT DE LA BATTERIE.REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU MŹME TYPE OU DŁN TYPE RECOMMANDÉPAR LE CONSTRUCTEUR. METTRE AU RÉBUT LES BATTERIES USAGÉES CONFORMÉMENT AUX INSTRUCTIONS DU FABRICANT.


Mechanical HazardsCAUTION:If, in case of servicing, the dust cover is open and the key-operated switch has been actuated (safety switch is disabled), there is a danger of being squeezed in the carriage travel range!


Laser SafetyDefinitions - Laser equipment: Equipment which includes a laser unit.- Laser unit: Laser with laser power pack General The laser imagesetter Herkules is a laser equipment of laser class 1. This means that the laser radiation generated in the machine is screened using protective covers. The laser unit installed in the Herkules corresponds to class 3B (5 ... 500 mW). Companies which have servicing performed in Germany must appoint a representative for laser safety in accordance with the Regulation for the Prevention of Accidents VBG 93 of the trade unions.

Servicing must only be performed by persons which have been instructed correspondingly by the appropriate representative for laser safety.


Laser SafetyLaser Standards and Regulations The laser imagesetter Herkules complies with the valid safety regulations. It is manufactured in accordance with the Regulation for the Prevention of Accidents VBG 93 and the EN 60825, IEC 825 ("Radiation safety of laser equipment"), and 21 CFR 1040 (USA) standards. Service and Maintenance No laser adjustment should be performed at the Herkules since the modules have been adjusted atthe factory and are to be used without any additional adjustments. CAUTION:If, in case of servicing, the Herkules is operated in an open state, with the key-operated switch actuated, there is a danger of class 3B laser radiation if the laser beam is lead outside by reflectingmaterial. If necessary, a temporary laser area must be set up. The Regulation for the Prevention of Accidents VBG 93 ("Laser Radiation") as well as the implementation instructions for the VBG 93 must be met. In addition, the national safety regulations must be observed.


Laser SafetyAfter repair work has been completed, correct functioning of the safety loop must be checked by opening the cover. During reassembly, the protective covers must be checked for completeness. It must be ensured that these covers do not show any cracks or other damages. CAUTION:If operating or a adjustment devices other than the ones mentioned are used, or if other procedures are applied, this may lead to dangerous exposure to radiation.


Laser SafetyAdjusting goggles:- protective goggles with closed frame for wearers of glasses, order No. 02440628- protective goggles with standard frame, order No. 04161793

Laser LabelsSee the illustration of the labels


Norms and StandardsThe machine meets the safety regulations of the standards listed below.

General - GSG - 73/23/EEC

(law regarding machine safety, Germany)(law regarding technical equipment)(low-voltage directive, Europe)

Mechanical Safety - EN 292 (Europe)- Accident prevention regulations for trade associations (Germany)


Norms and StandardsElectrical Safety - EN 60950- IEC 950- UL 1950- CSA C22.2 No.950- EN 60204-1- IEC 204-1

(Europe)(international)(USA)(Canada)(Europe)(international)

Electromagnetic Compatibility (EMC) - EMVG- 89/336/EEC

Law regarding electromagnetic compatibility of devices (Germany) EMC directive of the European Council (Europe)


Norms and StandardsInterference Emission (interference radiation and interference voltage) - EN 50081-1- EN 55022, limit B- CISPR 22 mod., limit B- FCC, Part 15, Subpart B, Class A- DOC, Radio Act SOR/88-475, Class A

(Europe)(Europe)(international)(USA)(Canada)

Interference Immunity - EN 50082-2- EN 60801-2- IEC 801-2/-3/-4

(Europe)(Europe)(international)


Certifications and MarkingsGS certifiedUL E156891 (NWGQ)cUL E156891 (NWGQ 7)CE declaration of conformityCDRH applied

For labels see section "Schilder-Uebersicht" (label overview).

(Germany)(USA)(Canada)(Europe)(USA)


PollutantsWhen using cleaning and lubricating agents, observe the manufacturer's instructions.If necessary, consider the safety data sheets, and for Germany the List of Threshold Values quotingthe maximum permissible concentrations (List of Threshold Values issued by the Federal Ministry of Labor and Social Affairs) as well as the appropriate local regulations.


CleaningAlways disconnect the machine by pulling out the mains plug if liquid cleaning agents are used. The machine surface can be cleaned using a dry cloth. In the case of stubborn dirt, a dry cloth soaked in water with a cleaning agent and then wrung out may be used. Prevent water from reaching the machine interior and protect the connectors at the machine rear from the humidity. Do not use any abrasive detergents or solvents.


in accordance with Council Directives 73/23/EEC relating to Electrical Equipment designed foruse within certain voltage limits, and 89/336/EEC relating to electromagnetic compatibility

Name des Herstellers / supplier`s name:Adresse / address:

Heidelberger Druckmaschinen AGSiemenswallD- 24107 Kiel, Germany

declares, that the product

Produktname / product name:Geräteart / product class:Typenbezeichnung / type designation:

conforms with the above mentioned Directives

CE-Declaration of Conformity


HerkulesLaser Recorder2081


Applicable Standards:

- EN 60950

- EN 50081-1- EN 55022, Klasse B- EN 50082-2

Safety of Information Technology Equipmentincluding electrical business equipmentEMC Generic Emission Standard

EMC Generic Immunity Standard


Kiel,.......................................................................................................................................................Ort / place Datum / date gezeichnet / signed Stempel / stamp

20. October 1997


Siemenswall - D-24107 KielW. Boppel

Senior Vice President

service manual herkules

Documents

heidelberger

overflow pipe

handle screwdriver

excessive

automatic

toothed belt

og gy fit

line images