SHB - HD 153.P - ENG - AB PDF

Basic setting
HD 153 P 0-1
HD 153 P Table of contents
05/2008
Table of contents
1 Home position of the machine ........................................................ 0-2
2 Infeed ............................................................................................. 0-2
3 Lateral knives ................................................................................. 0-2
4 Front knives.................................................................................... 0-3
5 Cutting table ................................................................................... 0-3
6 Pressing block ................................................................................ 0-3
7 Spine support knives ...................................................................... 0-3
8 Delivery .......................................................................................... 0-4
9 Calibrating the axes........................................................................ 0-4
10 Siemens control system.................................................................. 0-4
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Basic setting
HD 153 P 0-2
05/2008
1 Home position of the machine

1.1 Home position ................................................................................................. 1-2
2 Home position with index holes ....................................................................... 1-3
3 Absolute shaft encoder .................................................................................... 1-4
3.1 Setting at 353°.................................................................................................. 1-4
4 Zero setting of the infeed unit .......................................................................... 1-5
3.2 Correction of the infeed setting ......................................................................... 1-6
2 Infeed
1 Infeed ............................................................................................................... 2-2

2 Infeed clamp .................................................................................................... 2-3
2.1 Infeed clamp stroke length ............................................................................... 2-3
2.2 Return stroke, bottom clamp ............................................................................ 2-4
2.3 Top clamp ........................................................................................................ 2-5
3 Clamp transport ............................................................................................... 2-6
3.1 Setting the clamp transport path ...................................................................... 2-6
4 Step-by-step system ........................................................................................ 2-7
4.1 Setting the step-by-step system ....................................................................... 2-7
4.2 Setting the stack fingers ................................................................................... 2-8
3 Lateral knives
1 Lateral knives .................................................................................................. 3-2
2 Setting the lateral knives .................................................................................. 3-3
2.1 Information on setting the lateral knives ........................................................... 3-3
3 Aligning lateral knives ...................................................................................... 3-4
3.1 Prerequisites for aligning the lateral knives ...................................................... 3-4
4 Removing the tooth play between the gearwheels............................................ 3-5
4.1 Setting for setting the gearwheels..................................................................... 3-5
5 Setting the knife movement ............................................................................. 3-6
5.1 Setting the LH side using a measuring gauge .................................................. 3-6
5.2 Setting procedure ............................................................................................ 3-7
5.3 Ring clamping elements on the LH side ........................................................... 3-8
6 Setting the measuring device............................................................................ 3-9
6.1 Setting the RH side using a measuring gauge .................................................. 3-9
6.2 Setting dimensions between flange and pin...................................................... 3-9
6.3 Setting the RH side using a measuring gauge ................................................ 3-10
6.4 Setting the measuring gauge.......................................................................... 3-11
Page 2 of 4
Basic setting
HD 153 P 0-3
05/2008
7 Setting the eccentric pin ................................................................................. 3-12

7.1 Converting the measuring gauge and measuring............................................ 3-12
8 Setting the eccentric pin ................................................................................. 3-13
9 Information concerning assembly ................................................................... 3-14
4 Front knives
1 Front knives...................................................................................................... 4-2
2 Setting the running roller in relation to the cam disc ......................................... 4-3
3 Setting the gap at the front knife beam ............................................................ 4-4
4 Setting the knife holder in relation to the cutting table....................................... 4-5
5 Setting the stop damper.................................................................................... 4-6
5 Cutting table
1 Cutting table and lateral knife holder ................................................................ 5-2
2 Table top ......................................................................................................... 5-3
2.1 Setting the table top ......................................................................................... 5-3
3 Head / foot setting of the knives in relation to the table..................................... 5-4
4 Table clamping ................................................................................................. 5-6
6 Pressing block
1 Pressing block .................................................................................................. 6-2
2 Pressure build-up ............................................................................................ 6-3
2.1 Setting the guide rollers on the pressure spring ............................................... 6-3
3 Replacing the pressure spring ......................................................................... 6-4
4 Pressing block cam including arm .................................................................... 6-5
4.1 Setting: Running roller with arm in relation to the cam ..................................... 6-6
5 Pressing block guide ........................................................................................ 6-6
6 Setting the pressing block in relation to the lateral knives ................................. 6-7
7 Setting the pressing block play ........................................................................ 6-8
5 Motorised height adjustment of the pressing block ........................................... 6-9
7 Spine support knives

1 Spine support knives ....................................................................................... 7-2
2 Setting the spine support knives ...................................................................... 7-3
2.1 Setting the spine support knives parallel to the lateral knife ............................. 7-3
2,2 Set the LH and RH knives in the same manner. ............................................... 7-3
2.3 Setting the spine support knives at an angle to the cutting table....................... 7-4
2.4 Readjusting the spine support knives following regrinding ................................ 7-4
Page 3 of 4
Basic setting
HD 153 P 0-4
05/2008
8 Delivery
1.1 Delivery ............................................................................................................ 8-2
2 Delivery clamp.................................................................................................. 8-3
9 Calibrating the axes

1 Calibrating the axes ......................................................................................... 9-2
2 Correcting the basic setting ............................................................................. 9-3
3 Example: Change calibration value of axis 1 .................................................... 9-5
3.1 Changing the calibration value entry................................................................. 9-7
3.2 Calibrating axis 11 ............................................................................................ 9-9
3.3 Overview of the individual axes ...................................................................... 9-10
3.4 Inching the axes ............................................................................................. 9-11
3.5 Parameter list ................................................................................................. 9-12
3.6 Value entry mask............................................................................................ 9-13
4 Setting the shaft encoder zero impulse in relation to the calibration initiator ... 9-14
5 Switching status calibration/max initiator......................................................... 9-15
10 Siemens control system

1 Control system concept HD 153.P including transport path ............................ 10-2
2 Switch cabinet ................................................................................................ 10-3
3 Simotion drive train......................................................................................... 10-4
3.1 ALM 36 kW and ALM 16 kW........................................................................... 10-4
3.2 Drive Cliq........................................................................................................ 10-5
3.3 ET 200 with DP nodes.................................................................................... 10-5
4 Replace module ET 200 ................................................................................. 10-6
5 Replacement of the CF card........................................................................... 10-7
6 Commissioning/start-up and diagnosis through LED ..................................... 10-8
7 Running rail during the start of the Copilot (HD 453.P) ................................... 10-9
8 Electric mains (RS485) – bus connection plug.............................................. 10-11
9 Diagnosis via LED ........................................................................................ 10-11
9.1 Diagnosis through LED ET 200 .................................................................... 10-12
9.2 Active Line Module ....................................................................................... 10-13
9.3 Simotion D4 X 5............................................................................................ 10-14
9.4 LEDs during the start-up of CU 320.............................................................. 10-17
9.5 LEDs after the start-up of CU 320................................................................. 10-18
9.6 Motor modules.............................................................................................. 10-19
Page 4 of 4
Basic setting
HD 153 P Home position 1-1

05/2008
Table of contents
1 Home position ................................................................................ 1-2
2 Home position with index holes ...................................................... 1-3
3 Absolute shaft encoder................................................................... 1-4
3.1 Setting at 353°.................................... ............................................ 1-4
4 Zero setting of the infeed................................................................ 1-5
5 Correction of the infeed setting....................................................... 1-6
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\\Fscla1\et_info\Service-Handbuecher\Word-Dokumente\HD_153 P\HD_153_P_gb\1_Home_position_HD_153_P .doc
Basic setting

05/2008
1 Home position
This basic setting has been created as an aid for qualified personnel.
Basic knowledge of operating and function sequences for machine HD 153 P is an absolute pre-
requisite for the qualified personnel.
The qualified personnel is held responsible for their actions.
The following description is valid from ma- No. to except

chine for /
and
Check
These instructions were prepared by the Technical Development Department:
Responsible: Name TE 2007

Revised: Name TE 2007
Checked by Name TE 2007
Page 2 of 6
Basic setting

05/2008
2 Home position with index holes
(Fig.1)
5
4
− Inch the machine forward until bolt (1) (Fig.1) can be pushed through bearing (2) (Fig.1) into
index hole (3) of cam disk (5) (Fig.1)
− Attention: Immediately remove the bolt again
− In this position, ensure that graduated disk (4) (Fig.1) is at 353° and then set shaft encoder (1)
(Fig.2) to 353°
Page 3 of 6
Basic setting

05/2008
3 Absolute shaft encoder
3.1 Setting at 353°

(Fig.1) (Fig.2)
353
1
− Loosen clamping ring (2) (Fig.1) by means of screw (3) (Fig.1) and turn until display (1) (Fig.2)
indicates 353°, then firmly retighten the clamping ring.
− The current value (1) (Fig.3) of absolute shaft encoder (1) (Fig.2) can be viewed on screen
mask (1) (Fig.3)
Page 4 of 6
Basic setting

05/2008
4 Zero setting of the infeed

(Fig.1) (Fig.2)
4
3
2
1
− Continue inching the machine until degree scale (1) (Fig.1) indicates 0°
− In position 0°, ensure that bolt (1) (Fig.2) fits through cam disc (2) (Fig.2) into hole (3) (Fig.2) of
lateral section (4) (Fig.2)
− Bolt (1) (Fig.2) is included in the machine accessories
Page 5 of 6
Basic setting

05/2008
5 Correction of the infeed setting
(Fig.1) Fig.2
2
2
− Attention: Ensure machine is at 0°

• Loosen hexagon screws (2) (Fig.1) on chain wheel (1) (Fig.1)
• Subsequently, turn cam disk (1) (Fig.2) in such a way that bolt (3) (Fig.2) fits into hole (2)
(Fig.2) of the frame
• Then retighten hexagon screws (2) (Fig.1) on chain wheel (1) (Fig.1)
− Attention: Remove the bolt again
Page 6 of 6
Basic setting
HD 153 P Infeed 2-1

05/2008
Table of contents
1 Infeed ............................................................................................. 2-2
2 Infeed clamp................................................................................... 2-3
2.1 Infeed clamp stroke length.............................................................. 2-3
2.2 Return stroke, bottom clamp........................................................... 2-4
2.3 Top clamp ...................................................................................... 2-5
3 Clamp transport.............................................................................. 2-6
3.1 Setting the clamp transport path..................................................... 2-6
4 Step-by-step system....................................................................... 2-7
4.1 Setting the step-by-step system...................................................... 2-7
4.2 Setting the stack fingers ................................................................. 2-8
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Basic setting
HD 153 P Infeed 2-2

05/2008
1 Infeed

chine for /
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Page 2 of 8
Basic setting
HD 153 P Infeed 2-3

05/2008
2 Infeed clamp
2.1 Infeed clamp stroke length
Fig.1 Fig.2
• Set the machine to any desired format

− Set bottom infeed clamp (1) (Fig.1) in horizontal position
− Perform the setting using hexagon screws (2) (Fig.2)
Fig.3 Fig.4
0.5 mm
• Set the machine to any desired format

• Inch the machine forward until the clamp in its return stroke is located at the front most position
of the cutting table (2) (Fig.4)
• In this position, ensure a 0.5 mm spacing between the clamp and the cutting table, see (2) Fig.
4).
− Perform the setting with the aid of front coupling rod (1) (Fig.3)
Page 3 of 8
Basic setting
HD 153 P Infeed 2-4

05/2008
2.2 Return stroke, bottom clamp
Fig.1
• Continue inching the machine forward until the bottom clamp leaves the table.
− Ensure that the clamp is positioned beneath the guide plate during the return stroke (1) (Fig.1).
− If the clamp is too high, a collision will occur in the magazine
Page 4 of 8
Basic setting
HD 153 P Infeed 2-5

05/2008
2.3 Top clamp

Fig.1
− Inch the machine to 38° - 55°

− Ensure that rubber buffers (2) (Fig.2) close simultaneously with the galvanized clamp (in direc-
tion of the cutting table) and are parallel in relation to bottom clamp (5) (Fig.2) when the top
clamp is completely pulled out
− The parallelism of the top clamp is adjustable via screws (1) (Fig.1).
• Once the setting is correct, set the scale at height adjustment device (3) (Fig.3) to the set di-
mension with a pretension of 3 - 4 mm (4) (Fig.3)
Fig.2 Fig.3
5 2
Page 5 of 8
Basic setting
HD 153 P Infeed 2-6

05/2008
3 Clamp transport
3.1 Setting the clamp transport path
(Fig.1)
Kolbus
HD 153 P
• Place a block into the magazine and inch the machine forward until magazine pusher (1)
(Fig.1) has pushed block (2) (Fig.1) against stops (3) (Fig.1) .
• Mark the position (4) (Fig.1) using a felt pen.
• Inch the machine forward until the clamp has deposited the block in the front most position
(Fig.2).
− Ensure a spacing of precisely 400 - 400.5 mm from the front edge of the block to the mark
(Fig.2).
− Perform the setting with the aid of eccentric bolt (5) (Fig.3) .
− In the front position, ensure that the block does not come in contact with the stop brackets (6)
(Fig.2) .
(Fig.2) (Fig.3)
Kolbus
5
HD 153 P
400 - 400.5 mm
Page 6 of 8
Basic setting
HD 153 P Infeed 2-7

05/2008
4 Step-by-step system
4.1 Setting the step-by-step system

Fig.1 Fig.2
5 4
3
1
− Invoke the setting mask (Fig.1)

• Switch off the step-by-step system (2) (Fig.3) manually or using function key (1) (Fig.1) on
the setting mask (Fig.).
• Loosen Seeger circlip (3) (Fig.2) and push forward until coupling sleeve (4) (Fig.2) can be
disengaged.
Page 7 of 8
Basic setting
HD 153 P Infeed 2-8

05/2008
Fig.3 Fig.4
4 3
2
2
4.2 Setting the stack fingers

• Push coupling sleeve (4) (Fig.3) to the left and back to the right offset by a respective num-
ber of teeth.
• Using function key (5) (Fig. 1) on the setting mask, start the coupling several times and
subsequently check whether or not stacking finger (6) (Fig.5) is in horizontal position.
• Once stacking finger (6) (Fig.5) is in horizontal position, push Seeger circlip (3) (Fig.6) back
into groove (7) (Fig.6).
Fig.5 Fig.6
7
3
Page 8 of 8
Basic setting
HD 153 P Lateral knives 3-1

05/2008
Table of contents
1 Lateral knives .......................................................................................... 3-2
2 Setting the lateral knives.......................................................................... 3-3
2.1 Information on setting the lateral knives................................................... 3-3
3 Aligning lateral knives.............................................................................. 3-4
3.1 Prerequisites for aligning the lateral knives.............................................. 3-4
4 Removing the tooth play between the gearwheels................................... 3-5
4.1 Presetting for setting the gearwheels....................................................... 3-5
5 Setting the knife movement ..................................................................... 3-6
5.1 Setting the LH side using a measuring gauge.......................................... 3-6
5.2 Setting procedure .................................................................................... 3-7
5.3 Ring clamping elements on the LH side................................................... 3-8
6 Setting the measuring gauge................................................................... 3-9
6.1 Setting the RH side using a measuring gauge ......................................... 3-9
6.2 Setting dimensions between flange and pin............................................. 3-9
6.3 Setting the RH side using a measuring gauge ....................................... 3-10
6.4 Setting the measuring gauge................................................................. 3-11
7 Setting the eccentric pin ........................................................................ 3-12
7.1 Converting the measuring gauge and measuring................................... 3-12
8 Setting the eccentric pin ........................................................................ 3-13
9 Information concerning assembly .......................................................... 3-14
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Basic setting

05/2008
1 Lateral knives

chine for /
and
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Page 2 of 15
Basic setting

05/2008
2 Setting the lateral knives
2.1 Information on setting the lateral knives
Important!
− Prior to setting the lateral knives, precisely check and observe the following points!
− Safety measures!
− Prior to working on the machine, define the responsibilities and thoroughly read the safety in-
structions in chapter 1.
− Always remove the knives prior to working on the machine.
− Checking the setscrews in the machine foot.

− Ensure that all setting screws have uniform contact with the shims.
− Ensure that the locknuts are firmly tightened.
− Check the horizontal position of the machine using a spirit level.

− Ensure that the precision of the spirit level is 0.1 mm/m.
− Align the machine in horizontal direction with the aid of the 4 setting screws.
− Ensure that the admissible deviation of 0.1 mm/m is not exceeded.
− Check the home position of the machine.

− Index hole = 353°
− Once these points have been checked, the lateral knives may be set.
Page 3 of 15
Basic setting

05/2008
3 Aligning lateral knives
3.1 Prerequisites for aligning the lateral knives

(Fig.1) (Fig.2)
1 2 1
3 3
4 4
− In inching mode, set the knife holder to its lowest position, between 269°- 270°.
− Removing the knife shaft
• Loosen the screws in the clamping elements (1) (Fig.1) and remove the complete knife shaft
(2) (Fig.1).
− Do not interchange the clamping elements!
− Removing the lateral bearings (4) (Fig.1).
• Pull the lateral bearings (4) (Fig.1) from the ball bearings.
• Pull the ball bearings from the cam shafts (6) (Fig.2). (Use the pulling off device.)
• Remove the protective covers (7) (Fig.1)
• Pull the ball bearings from the cam shafts. (Use the pulling off device.)
• Check the setting using the setting gauge.
− Now you can see the gearwheels (5) (Fig.2) with the cam (6) (Fig.2) in the lateral sections, the
front cam is positioned vertically downward.
Page 4 of 15
Basic setting

05/2008
4 Removing the tooth play between the gear-

wheels
4.1 Presetting for setting the gearwheels
(Fig.1) (Fig.2)
• Undo ring clamping elements (1) (Fig.1) and remove clips (2) (Fig.1) at all 4 gearwheels (LH
and RH side).
− The 4 journals responsible for the knife movement are now released and can be turned
− Ensure that no play exists between the gearwheels (4, 5 and 6) (Fig.2).
− Perform the setting using the eccentric bolt (7) (Fig.2).
− Each gearwheel (4) (Fig.2), LH and RH side, is equipped with two bolts (7) (Fig.2), only use
one bolt for setting purposes!
− The gearwheels have two parts an can be adjusted in relation to each other!
− For setting purposes, loosen screws (3) (Fig.2) (6 times) and then set the gearwheel without
play using eccentric bolt (7) (Fig.2)
Page 5 of 15
Basic setting

05/2008
5 Setting the knife movement

5.1 Setting the LH side using a measuring gauge
(Fig.1) (Fig.2)
− Ensure that the machine is positioned between 269 and 270°

− Start on the drive side (main drive motor).
• First, loosen the eccentric bolts (1) (Fig.1) in the cams
• Insert measuring gauge (2) (Fig.2).
Page 6 of 15
Basic setting

05/2008
5.2 Setting procedure
(Fig.1)
• Loosen screws (4) (Fig.1) and turn eccentric bolts (1 and 3) (Fig.1) away from measuring gau-
ge (2) (Fig.1+2) .
(Fig.1)
− Swing the cams with the large flange, Ø 72 mm, (5 and 6) (Fig. 1+2) against bolts (7) (Fig.1) of
the measuring gauge.
Attention!
− Do not apply pressure on bolts (7) (Fig.1)
Page 7 of 15
Basic setting

05/2008
5.3 Ring clamping elements on the LH side

(Fig.1)
− Lock the gearwheels in place using clips (7) (Fig.1)

− Now firmly tighten ring clamping elements (6) (Fig.1) uniformly on the LH side by applying 41
Nm using the accessible screws.
− Attention: Remove clip (7) (Fig.1) and firmly tighten all seven screws on the ring clamping
element by applying 41 Nm
− When tightening, also check the RH side
(Fig.2)
• Now swing eccentric bolts (1 and 3) (Fig.1) against surface (2) (Fig.2) of the device.
• Check the setting and firmly tighten screws (4) (Fig.2) .
− Important! Ensure that the eccentric bolts do not apply pressure on the device.
− The drive side is now set
Page 8 of 15
Basic setting

05/2008
6 Setting the measuring gauge

6.1 Setting the RH side using a measuring gauge
(Fig.1)
− Use measuring gauge (1) (Fig.) to take measurement (A) (approx.272 mm) (Fig.1) at the LH
side and transfer it to the opposite RH side.
Important! The admissible tolerance for all measurements is +/- 0.05 mm
6.2 Setting dimensions between flange and pin

(Fig.2)
− Pin (2) (Fig.2) is located in the hole of the shaft.
Page 9 of 15
Basic setting

05/2008
6.3 Setting the RH side using a measuring gauge

(Fig.1)
• Use measuring gauge (1) (Fig.1) opposite the LH side and set cam (2) (Fig.1) to the meas-
urement to be transferred.
− Important! Strictly observe the admissible tolerance of +/- 0.05 mm between the RH and LH
side.
− Lock the gearwheels in place using the clips
• Tighten the ring clamping element of cam (2, on the RH side) (Fig.2) , to ensure that the set-
ting cannot change.
− Change back to the LH side with the measuring gauge.
(Fig.2)
View of RH side in running direction
Page 10 of 15
Basic setting

05/2008
6.4 Setting the measuring gauge
(Fig.1) (Fig.2)
View of LH side in running direction
• On the drive side, measure distance (B) (approx. 279 mm) (Fig.1) and transfer it to the oppo-
site side.
− Important! The admissible tolerance is +/- 0.05 mm between the drive side and the RH side.
(Fig.1) (Fig.2)
View of RH side in running direction
− Once the setting has been completed, lock the gearwheels in place using the clips, subse-
quently tighten the ring clamping element on the back of the cam (3) (Fig.1+2), to prevent the
setting from changing.
− Important! After the ring clamping elements have been tightened, it is of utmost importance
to check the dimensions again.
Page 11 of 15
Basic setting

05/2008
7 Setting the eccentric pin

7.1 Converting the measuring gauge and measuring
(Fig.1)
− Convert the measuring gauge by dismantling the spacer piece (1) (Fig.1).
(Fig.2)
Left-hand
• On the drive side, measure spacing (C) (approx. 297 mm) in relation to small eccentric bolt (2)
(Fig.1).
− Transfer the dimension to the opposite side.
− The admissible tolerance between the two measuring points is +/- 0.05 mm.
(Fig.3)
Page 12 of 15
Basic setting

05/2008
8 Setting the eccentric pin
(Fig.1)
Left-hand
− On the drive side, measure distance (D) (approx. 309 mm) (Fig.1) in relation to small cam (1)
(Fig.1) and transfer the value to the opposite side.
− The admissible tolerance between the two measuring points is +/- 0.05 mm.
− Precisely check all settings again prior to reinstalling the knife holders.
(Fig.2)
Page 13 of 15
Basic setting

05/2008
9 Information concerning assembly

(Fig.1) (Fig.2)
− Prior to assembling the knife holders, clean and grease crown gears (1) (Fig.1) in the deflec-
tion devices.
• Tighten all screws appropriately using a torque wrench.
− Information concerning the installation of the lateral bearings and the knife holder
• Now refit lateral bearings (2) (Fig.2) and install knife shaft (3) (Fig.2) including the knife hold-
ers.
• Cleaning and greasing
• Fit lateral bearings, observe supporting rake
• Fit knife shaft
• Loosely install the bearing shell
• Fixed point 269.5°
• Holder parallel in relation to the table
• Tighten bearing shell with 210 Nm
• Check parallelism
• Check for distorsion and eliminate, if necessary
• Check lateral play and correct by using shims
Page 14 of 15
Basic setting

05/2008
(Fig.1) (Fig.2)
− Ensure that the machine with the knife holders is at the lowest position (approx. 269.5°).
• Now refit the lateral bearings (1) (Fig.1) and install the knife holders.
• Place a suitable measuring piece (2) (Fig.2) on the cutting table and set the knife holders par-
allel. (Fig.2)
− Measure the head/foot tolerance on both sides, LH and RH side of the cutting table
• Firmly tighten the fastening screws in bearing (1) (Fig.1) in a cross pattern with a torque of
210 Nm.
Page 15 of 15
Basic setting
HD 153 P Front knives 4-1

05/2008
Table of contents
1 Front knives.................................................................................... 4-2
2 Setting the running roller in relation to the cam disc........................ 4-3
3 Setting the gap at the front knife beam ........................................... 4-4
4 Setting the knife holder in relation to the cutting table..................... 4-5
5 Setting the stop damper ................................................................. 4-6
Page 1 of 6
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Basic setting

05/2008
1 Front knives

chine for /
and
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Page 2 of 6
Basic setting

05/2008
2 Setting the running roller in relation to the

cam disc
(Fig.1)
− Ensure that running roller (1) (Fig.1) applies light pressure on the running surface of the cam
(2) (Fig.1) .
• To set the pressure, loosen screws (3) (Fig.1) .
• Loosen nuts (4 and 5) (Fig.1) on threaded spindle (6).
• Now the cam roller can be easily turned by hand.
• Lightly tighten screws (3) (Fig.1) on the opposite side.
• Use nuts (4) (Fig.1) turn both arms together in such a way, that cam roller (1) (Fig.1) can still
be turned lightly by hand.
• Subsequently, check the running roller at several points of the cam to ensure uniform pressure
against the running surfaces.
• Important: Ensure that the running roller is set without play in the cutting area
− Firmly retighten all screws and nuts upon completion.
Page 3 of 6
Basic setting

05/2008
3 Setting the gap at the front knife beam
(Fig.1) Fig.2
0.1 mm gap in 0.05 mm gap in

the top posi- the bottom po-
tion sition
1
Fig.3 Fig.4
− Setting the gap

− Ensure that a gap of 0.05 mm is set between the knife beam and the slide rails (3) (Fig.3) in
the lowest position.
− Ensure that a gap of 0.1 mm exist in the top position (4) (Fig.4)
− Use a feeler gauge to check the gap on the entire support surface (1) (Fig.3)
− Perform the setting with the aid of grooved nuts (1). (Fig.2)
− Tighten nuts (2) (Fig.2) applying a torque of 210 Nm!
− In the bottom position, the gap must be 0.05 mm and only in the top position up to 0.1 mm.
Page 4 of 6
Basic setting

05/2008
4 Setting the knife holder in relation to the cut-

ting table
(Fig.1)
Fig.2 Fig.3
− Setting the knife holder in relation to the cutting table

− The knife beam is in its bottom position.
− In this position, ensure that a spacing of 32 mm exists between front knife cassette (4) (Fig.1)
and top edge of table (5) (Fig.1) .
− For setting purposes, turn pulling rod (2) (Fig.2) (remove clamping pin) by loosening nuts (1)
(Fig.2) at the ends of the pulling rod.
− A slight displacement of bearing (3) (Fig.3) in its holes aids in the precise alignment of the kni-
fe beam.
Page 5 of 6
Basic setting

05/2008
5 Setting the stop damper
(Fig.1)
− The stop dampers prevent the front knife beam from overrunning its end position.
− When front knife beam (1) (Fig.1) is in its bottom position, stop dampers (2) (Fig.1) must make
contact with the bottom side of the front knife beam.
− Setting:
• Inch the machine forward until the front knife beam is in its bottom position.
• Use a feeler gauge to check if a 0.05 mm gap exists betwen front knife beam (1) (Fig.1) and
stop dampers (2) (Fig.1) .
− For setting purposes, loosen the screws in the clamping element (4) (Fig.1) , then set stop
damper (2) (Fig.1) with the aid of eccentric screw (3) (Fig.1) to a spacing of 0.05 mm.
− Important! No knocking sounds may occur during operation, i.e. the front knife beam must not
hit the stop dampers.
Page 6 of 6
Basic setting
HD 153 P Cutting table 5-1

05/2008
Table of contents
1 Cutting table and lateral knife holder........................................................ 5-2
2 Table top ................................................................................................. 5-3
2.1 Setting the table top................................................................................. 5-3
3 Head / foot setting of the knives in relation to the table............................ 5-4
4 Table clamping ........................................................................................ 5-6
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Basic setting

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1 Cutting table and lateral knife holder

chine for /
and
Check

Page 2 of 6
Basic setting

05/2008
2 Table top
2.1 Setting the table top
Fig.1 Fig.2
Screw Cam
2
Pin Spindle
Screw
− Continue inching the machine until the graduated disk indicates 38°- 55°.
• Remove the table.
− Ensure that the lateral table tops (1) (Fig.1+3) have the same spacing to the table console (2)
(Fig.1+3) .
− The admissible tolerance is 0.1 mm.
• For setting purposes, remove the pins in sleeve (4) (Fig.3).
− With the aid of spindles (3) (Fig.3) align the lateral guides.
− If necessary, pin the spindles in place again.
Fig.3
Page 3 of 6
Basic setting

05/2008
3 Head / foot setting of the knives in relation to

the table
(Fig.1) Fig.2
Screw 5 Cam 3
1
Pin Spindle
Screw 5
− Ensure that lateral knife holders (1) (Fig.1) are centred in relation to table (2) (Fig.3) .
• and the spacings at measuring points (4) (Fig.2).
− Set the parallelism with the aid of eccentric screw (3) (Fig.1+2) .
• For this purpose, loosen fastening screws (5) (Fig.1+2).
− Install table (1) (Fig.1) and then use a square (2) (Fig.1) to check the parallelism. The knife
holders are in a slightly conical position.
− If necessary, find the mean dimension of the two sides.
− Ensure that the table contact has no play.
Page 4 of 6
Basic setting

05/2008
(Fig.2) (Fig.3)
3 3 3
4
− Set uniform spacing for the lateral knife holders:

• Loosen clamping device (4) (Fig.3) and turn brass sleeves (3) (Fig.2), until both sides are uni-
formly spaced in relation to the table. (Fig.3)
(Fig.1) (Fig.3)
2
1
centred
− Install table (1) (Fig.1) and then use a square (2) (Fig.1) to check the parallelism. The knife
holders are centred in relation to the table
− If necessary, find the mean dimension of the two sides.
− Ensure that the table contact has no play.
Page 5 of 6
Basic setting

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4 Table clamping
(Fig.1) (Fig.2)
• To set, remove a plate (1) (Fig.1) from a table insert and fit it into table clamping device (2)
(Fig.1+2) .
− Allow the plate to be clamped.
− In this position, set cylinder switch (3) (Fig.4) .
− Determine the illumination range of LED (3) (Fig.3).and lock the cylinder switch in the centre
(3) (Fig.3).
− Ensure that the LED on the cylinder switch only lights up when the table is clamped.
• Remove the plate and check the 4 mm extra lift (see sketch) (Fig.1).
− Perform the setting with the aid of piston rod (4) (Fig.4) of the cylinder.
(Fig.3) (Fig.4)
Page 6 of 6
Basic setting
HD 153 P Pressing block 6-1

03/2009
Table of contents
1 Pressure build-up..................................................................................... 6-3
1.1 Setting the guide rollers on the pressure spring ....................................... 6-3
2 Replacing the pressure spring ................................................................. 6-4
3 Pressing block - Cam with arm ................................................................ 6-5
3.1 Setting: Running roller with arm to the cam.............................................. 6-5
4 Pressing block guide................................................................................ 6-6
4.1 Setting the vertical pressing block guide running rollers........................... 6-6
5 Setting the pressing block in relation to the lateral knives ........................ 6-7
6 Motorised height adjustment of the pressing block................................... 6-8
Page 1 of 8
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Basic setting

03/2009
1 Pressing block

chine for /
and
Check

Page 2 of 8
Basic setting

03/2009
2 Pressure build-up
2.1 Setting the guide rollers on the pressure spring
(Fig.1)
− The pressure build-up system consists of a pressure spring kit (3) (Fig.1) and protects the
pressing block against damage, e.g. in the event of an incorrect setting.
− Ensure that guide rollers (1) (Fig.1) make contact without play.
Setting:
• Loosen the nuts of cam screw (2) (Fig.1) and turn it until running roller (1) (Fig.1) makes con-
tact without play.
− Attention: Also ensure that the bottom running rollers make contact
Page 3 of 8
Basic setting

03/2009
3 Replacing the pressure spring
(Fig.1) (Fig.2)
4
5.4
3
5.3
1
5.1 2
5.2 1
5.1 2
5.2
• Diagonally replace screws (1) (Fig.1+2) (4 screws) with screws 2 (Fig.1+2) (4 screws)
Attention!
Risk of injury! Never loosen/remove the screws (1) (Fig.1+2) at the same time!
• Turn in screws (2) (Fig.1+2) approx. 20 mm and lock in place by means of nut (3) (Fig.1+2)
− Ensure that screws (2) (Fig.1) are size M12 x 150 (not included in the machine accessories)
• After replacing the screws, uniformly loosen nuts (3) (Fig.1)
− Spring (4) (Fig.1) is relaxed and can be replaced
− Tension the spring in reverse order
Page 4 of 8
Basic setting

03/2009
4 Pressing block - Cam with arm
4.1 Setting: Running roller with arm to the cam

(Fig.1) (Fig.2)
− Ensure that running rollers (1) (Fig.1) make contact with cam (2) (Fig.1) , and can only be tur-
ned by hand with difficulty.
Setting:
• Loosen screws (6) (Fig.2), 6 screws.
• Loosen the nuts on threaded spindle (5) (Fig.2).
• Use the nuts of threaded spindle (5) (Fig.2) to pull arms (3 + 4) (Fig.2) against the cam, until
running roller (1) (Fig.1) can only be turned by hand with difficulty.
− Check the running roller at several points of the cam when tightening.
− Firmly retighten all screws.
Page 5 of 8
Basic setting

03/2009
5 Pressing block guide

5.1 Setting the vertical pressing block guide running rollers
(Fig.1)
− For precise guidance of the pressing block, ensure that no play exists between running rollers
(2) (Fig.1) and guide (1) (Fig.1).
Setting:
− Set one side first.
− Loosen the locknuts behind running roller (2) (Fig.1).
− Use the eccentric bolt (the highest point is marked in red) (3) (Fig.1) to position the running rol-
ler such, that it applies light pressure against the guide.
− Then set the opposite side.
− Ensure that the points marked in red on eccentric bolts (3) (Fig.1) point up in a uniform man-
ner.
Page 6 of 8
Basic setting

03/2009
6 Setting the pressing block in relation to the lateral

knives
Fig.1 Fig.2
Holder No. 4
6
• Perform the setting with the aid of setscrews (4) (Abb.2) at the block mounting.
• Fit pressing block No. 6 (Fig.1) in holder (2) (Fig.1).
• Inch the machine forward until lateral knife holders (1) (Fig.1) are positioned at the same
height as pressing block No. 6 (Fig.1).
− In this position, pressing block holder No. 6 (Fig.1) must be parallel in relation to the knife hol-
ders.
• Check the lateral play (measuring point M1and M2) of the pressing block (Fig.1).
− The admissible deviation is 0.2 mm on both sides of the knife holder (M1+M2) (Fig.1).
• Use eccentric screws (3) (Fig.3) to adjust the play of the pressing block holder.
• Measure the play at measuring points M1 and M2.
Fig.3
Page 7 of 8
Basic setting

03/2009
7 Motorised height adjustment of the pressing

block
(Fig.1)
− Calibration initiator (2) (Fig.1) absolute value encoder (1) (Fig.1).
− Calibrate the axis towards min. in the negative range.

− Enter the cardboard thickness at the Copilot.
− Move the machine to its home position.
− Now the spacing between cardboard (3) (Fig.2) and cutting table (4) (Fig.2) must be 52 mm.
Fig.2
52 mm
Page 8 of 8
Basic setting
HD 153 P Spine support knives 7-1

05/2008
Table of contents
1 Spine support knives ............................................................................... 7-2
2 Setting the spine support knives .............................................................. 7-3
2.1 Setting the spine support knives parallel to the lateral knife..................... 7-3
2.2 Set the LH and RH knives in the same manner. ...................................... 7-3
2.3 Setting the spine support knives at an angle to the cutting table.............. 7-4
2.4 Readjusting the spine support knives following regrinding ....................... 7-4
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1 Spine support knives

chine for /
and
Check

Page 2 of 4
Basic setting

05/2008
2 Setting the spine support knives

2.1 Setting the spine support knives parallel to the lateral kni-
fe
Fig.1 Fig.2
0.1 – 0.2 mm
1
2
3
4
1
• Move axis 8 and axis 11 to max. and insert the largest table
• Loosen clamping screws (1) (Fig.1) and (2) (Fig.1)
• Push arms (3) (Fig.1) and (4) (Fig.1) together in such a way that an angle (1) (Fig.2) can be
positioned against spine support knives (2) (Fig.2) ()
• Important Retighten clamping screws (1) (Fig.1) and (2) (Fig.1)
2.2 Set the LH and RH knives in the same manner.
Fig.3
0.1 – 0.2 mm
1
3 4
• Move the spine support onto the table

• Loosen clamping screw (1) (Fig.3) and position angle (3) (Fig.3) against spine support knife (4)
(Fig.3)
• Turn eccentric setting aid (2) (Fig.3) by means of an Allen wrench (width across flats 6) to set
spine support knife (4) (Fig.3)
− Ensure a gap of 0.1 - 0.1 mm in the top area (Fig.2)
− Ensure a gap of approx. 0.5 mm in relation to the table (Fig.2)
Page 3 of 4
Basic setting

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• Important Retighten clamping screw (1) (Fig.3)

2.3 Setting the spine support knives at an angle to the cutting
table
Fig.1 Fig.2
1 3
2 3
− Inch the machine until the spine supports are on the table
− Loosen clamping screw (1) (Fig.1)
− Turn the eccentric setting aid using an Allen wrench (width across flat 6) (Fig.1) to set the incli-
nation of the holder including spine support knife (3) (Fig.1) at an angle of 90° in relation to the
cutting table, and then check by means of an angle (4) (Fig.1)
− Retighen clamping screw (1) (Fig.1)
− To correct the book block width (book block parallelism), you can decouple and readjust the
right-hand spine support (head side) from the central adjustment system.
− Slide coupling ring (1) (Fig.2) to the left and use it to make the correction. Sign (3) (Fig.2) ser-
ves an an orientation
2.4 Readjusting the spine support knives following regrinding

Fig.3
2
1
• Loosen screws (1) (Fig.1)

• Adjust spine support knife (2) (Fig.3) in relation to base frame (1) (Fig.3)
− Ensure that spine support knife (2) (Fig.3) protrudes 0.3 to 0.5 mm over the front edge of the
base frame
• Retighten screws (1) (Fig.3)
Page 4 of 4
Basic setting
HD 153 P Delivery 8-1

05/2008
Table of contents
1 Delivery .......................................................................................... 8-2
2 Delivery clamp................................................................................ 8-3
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Basic setting

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1 Delivery

chine for /
and
Check

Page 2 of 3
Basic setting

05/2008
2 Delivery clamp
Fig.1
3
2
Setting:
− Use eccentric bolt (5) (Fig.3) to set delivery clamp (2) (Fig.1) in the centre(Fig.1) of cutting ta-
ble (3) (Fig.1) without play.
• Loosen locknut (4) (Fig.3) and turn eccentric screws (5) (Fig.3), until rollers (1) (Fig.2) are posi-
tioned against the side wall without play, and delivery clamp (2) (Fig.1) is centred to cutting ta-
ble (3) (Fig.1) .
• Subsequently, retighten the locknuts and check the setting.
Fig.2 Fig.3
5
1
4
Page 3 of 3
Basic setting
HD 153 P Calibration 9-1

05/2008
Table of contents
1 Calibrating the axes.......................................................................................... 9-2
2 Correcting the basic setting .............................................................................. 9-3
3 Example: Change calibration value of axis 1 .................................................... 9-5
3.1 Changing the calibration value entry................................................................. 9-7
3.2 Calibrating axis 11 ............................................................................................ 9-9
3.3 Overview of the individual axes ...................................................................... 9-10
3.4 Inching the axes ............................................................................................. 9-11
3.5 Parameter list ................................................................................................. 9-12
3.6 Value entry mask............................................................................................ 9-13
4 Setting the shaft encoder zero impulse in relation to the calibration initiator ... 9-14
5 Switching status calibration/max initiator......................................................... 9-15
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Basic setting

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1 Calibrating the axes

chine for /
and
Check

Page 2 of 15
Basic setting

05/2008
2 Correcting the basic setting

Fig.1
Attention!
Prior to calibrating an axis, inch the machine to its home position.
• Graduated disk (1) (Fig.1) indicates approx. 38° - 55° (Fig.1)
The home position symbol (Fig.2) appears in the status line

Fig.2
2
4
• Use Plus/Minus key (3) (Fig.2) to select the axis in the main mask
− The axis is displayed with a circle and axis number (4) (Fig.2)
• Press button (2) (Fig.2) in the main mask
Page 3 of 15
Basic setting

05/2008
• The mask ”Individual axis” including adjustment (1) (Fig.1) (LH spine alignment) appears on
the screen
Fig.1
Spindle pitch (overall trans-

Calibration value mission ratio of the spindle
drive)
Set point value Inching time
Control value for calibration

Actual value
initiator
Min. value Loop value
Max. value
Page 4 of 15
Basic setting

05/2008
3 Example: Change calibration value of axis 1
Attention!
− The machine collision protection only applies to automatic mode. Therefore, carefully
monitor all processes performed on the basic setting mask.
Fig.1
1 2
4 3
− Press button (3) (Fig.1)

− Axis 1 moves to calibration value (1) (Fig.1) (302.5 mm)
− Press button (4) (Fig.1)

− Axis 1 returns to preset set point value (2) (Fig.1) (158.5 mm),
− 158.5 mm - actual value
− Determine the real actual value
Page 5 of 15
Basic setting

05/2008
Example:
− Set point value 158.5 mm corresponds to an actually measured actual value of 161.5 mm
− Change the calibration value by the difference between the displayed and the measured actual
values.
− to reduce an adjustment, increase the calibration value
− to increase an adjustment, reduce the calibration value
− displayed actual value = 158.5 mm (2) (Fig.1)

− measured actual value = 161.5 mm
− Difference = + 3.0 mm (adjustment has to be reduced)
− resulting in: Calibration value 302.5 mm + 3.0 mm = Calibration value (1) (Fig.1) new = 305.5
mm
Page 6 of 15
Basic setting

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3.1 Changing the calibration value entry

Fig.1
161,5
• Press the field used to enter the calibration value (1) (Fig.1)
− The field appears in yellow
Fig.2
161,5
• Use the numerical keys (2) (Fig.2) of the input keyboard to enter code number 4993
• Press the ENTER key
− The input of the calibration value is authorised (this authorisation is only valid once and must
be re-invoked each time)
Page 7 of 15
Basic setting

05/2008
Fig.1
2 1
• enter the corrected calibration value using numerical keys (1) (Fig.1) (Abb. 7)
− In this example 305.5 (2) (Fig.1)
• Press Enter key (3) (Fig.1)
− The corrected calibration value will be applied (1) (Fig.2)
Fig.2
Press the button

− The adjustment axis is automatically calibrated and moves to the set point value
− measured value (158.5 mm) and actual value (158.5 mm) coincide (1) (Fig.1)
Page 8 of 15
Basic setting

05/2008
3.2 Calibrating axis 11

Attention!
− Remove table when calibrating axis 11.
Page 9 of 15
Basic setting

05/2008
3.3 Overview of the individual axes
Alignment Alignment
LH spine RH spine
LH
RH alignment (half of
alignment (half of block
block height)
height)
Pressing block Delivery clamp
Spine support, cut book

Head/foot knives
block width
Infeed conveyor, ma-

Infeed conveyor, spine
gazine (half of block
(block width)
height)
Acceleration roller –
Cutting table block thickness adjust-
ment
When calibrating
axis 11, remove the (only +/- adjustment
table possible)
Page 10 of 15
Basic setting

05/2008
3.4 Inching the axes

Fig.1 Fig.2
1 1
Attention!
− The machine collision protection only applies to automatic mode. Therefore, carefully
monitor all processes performed on the basic setting mask.
Use buttons (1) (Fig.1) to select an axis

− Once the axis is selected, it can be inched by pressing luminous push buttons (1) (Fig.2)
Note!
− If you keep keys (1) (Fig.2) pressed for longer than two seconds, the rapid motion of the
selected axis is activated.
Press the button

− The axis moves back to the set setpoint
Page 11 of 15
Basic setting

05/2008
3.5 Parameter list
Axis
Calibration min. value max. value Spindle Loop value Inching
value pitch time, cons-
tant
10
11
Attention!
− When changing the calibration values, always enter the new values in the table or perform a
data backup!
Page 12 of 15
Basic setting

05/2008
3.6 Value entry mask

Value entry mask
6
5
If the value entry mask is not readily available, it will open after pressing on a number input but-
ton.
Pos. Explanation
1 Highest possible input value (if a top entry limit is defined)
2 Smallest possible input value (if a bottom entry limit is defined)
3 Number keys 0 to 9
4 Decimal point (if a decimal value is permitted)
5 Clear the input field
6 Take over the entered value from the input field
− The entered values are written into the input field and not adopted until the Enter button has
been pressed.
− Min. and max. limit the interval in which the entered value is allowed to be.
− You can enter a number using the number keys 0 to 9. For this purpose, use the decimal
point button to segregate integer digits from the fractions of a number.
− Press button 6, if you wish to adopt your entries.
− Press button 4, if you wish to clear the input field without adopting your entry.
Page 13 of 15
Basic setting

05/2008
4 Setting the shaft encoder zero impulse in rela-

tion to the calibration initiator
− For machines with Copilot, always set the zero track of the rotary shaft encoder in connection
with the calibration initiator.
− This setting is valid for the HD 153 P.
− The HD 153 P is only equipped with a combined calibration/Max initiator.
− During the calibration process, the adjustment moves to -MAX- and changes the rotational di-
rection.
− After leaving the calibration/Max initiator, the calibration value is assigned to the axis as an ac-
tual value with the occurrence of the first zero impulse.
− If the zero impulse appears immediately after leaving the initiator, it may occur that sometimes
the zero impulse and sometimes the calibration initiator switches first due to mechanical play in
the adjustment.
− This results in an incorrect axis setting, equalling exactly the dimension of one spindle pitch.
− Now use the – key to inch the axis in increments until the -Max- symbol on the Copilot disap-
pears.
− Optimally, the actual value of the axis should now exceed the calibration value by 50% of the
spindle pitch
− This will ensure that the switching points are spaced far enough apart
− If the deviation from the ideal value is too great, turn the encoder on its shaft until 50% is
achieved
− This will ensure that the switching points are spaced far enough apart.
Page 14 of 15
Basic setting

05/2008
5 Switching status calibration/max initiator
Calibration value
Calibration symbol
Axis 5 (Setting the shaft encoder zero impulse in relation to the calibration initia-
tor)
− For machines with the new Copilot version, always set the zero track of the rotary shaft en-
coder in connection with the calibration initiator.
− These setting instructions are valid for axis 5.
− The calibration value is assigned to the axis as an actual value, when the first zero impulse is
detected once the calibration initiator is reached.
− If this takes place almost simultaneously, it may occur that sometimes the zero impulse and
sometimes the calibration initiator switches first due to mechanical play in the adjustment.
− This results in an incorrect axis setting, equalling exactly the dimension of one spindle pitch.
− For setting purposes, change to the individual axis mask, and prior to checking ensure that the
adjustment is set larger than the calibration initiator.
− Then move the axis in calibration value direction using the Minus key. Ideally, the centre switch
(colour corresponds to the switching status of the calibration initiator) should change colour at
an actual value of ½ spindle factor (½ x 2) 1 mm + calibration value 197.5 mm = 198.5.
− This will ensure that the switching points are spaced far enough apart.
− If repair work was performed on the axis beforehand, it is important to manually calibrate the
adjustment, first (following a power failure, the calibration process is automatically initiated the
first time the format is set).
− In the event of an excessive deviation, either the calibration initiator must be displaced me-
chanically or the encoder must be turned on its shaft.
− It is important to perform the check while moving from Plus to Minus, and the switching status
changes from free to covered.
− Attention: Axis 5 is calibrated to the negative
− Correct / Incorrect
− Signal of calibration initiator covered / free
− Zero impulse
Switching status calibration/max initiator
Calibration value
Calibration symbol
Spindle factor
Page 15 of 15
Basic setting
HD 153 P Siemens Control system 10-1
05/2008
Table of contents
1 Control concept HD 153.P with transport path ................................... 2
2 Switch cabinet ................................................................................... 3
3 Simotion drive train............................................................................ 4
3.1 ALM 36 kW and ALM 16 kW.............................................................. 4
3.2 Drive Cliq........................................................................................... 5
3.3 ET 200 with DP nodes....................................................................... 5
4 Replace module ET 200 .................................................................... 6
5 Replacement of the CF card.............................................................. 7
6 Commissioning/start-up and diagnosis through LED ......................... 8
7 Running rail during the start of the Copilot (HD 453.P) ..................... 9
8 Electric mains (RS485) – bus connection plug................................. 10
9 Diagnosis via LED ........................................................................... 11
9.1 Diagnosis through LED ET 200 ....................................................... 12
9.2 Active Line Modules ........................................................................ 13
9.3 Simotion D4 X 5 .............................................................................. 14
9.4 LEDs during the start-up of CU 320................................................. 17
9.5 LEDs after the start-up of CU 320.................................................... 18
9.6 Motor modules................................................................................. 19
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Basic setting
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1 Control concept HD 153.P with transport path

TOUCH-
Screen
VGA RS 232
COPILOT
Phoenix positioning modules

Switch
11 adjustment axes with DC drives
Ethernet
Siemens ET200S
TS Digital I/O
Profibus DP 1
Siemens ET200S
Profibus DP 2 HD Digital I/O
Profibus DP 1
Drive - Cliq
Encoder
400 V
FI delivery conv.
Servo inf. push.
FI accel. Roller
FI infeed conv.
FI main drive
TS CU 320
Mains filter
Simotion
Simotion
Simotion
Simotion
TS group 3
TS group 5
TS group 6
TS group 2
TS group 1
TS group 4
Simotion
Simotion
Simotion
Feed-in
Simotion
Simotion
Simotion
Simotion
D 435
M M M M M M M
M M M M
Page 2 of 19
Basic setting
05/2008
2 Switch cabinet
Simotion
drive train
DP nodes
ET 200
Phönix adjustment
module (positioning
module)
Page 3 of 19
Basic setting
05/2008
3 Simotion drive train

Simotion drive train
Drive
Simotion Cliq
D4x5
Cu ALM 36 kW Motor modules

320
3.1 ALM 36 kW and ALM 16 kW

Simotion with belt control system Simotion without belt control
system
AML ALM
36 kW 16 kW
Page 4 of 19
Basic setting
05/2008
3.2 Drive Cliq
Drive Cliq
Plug-in connections
3.3 ET 200 with DP nodes
ET 200 with DP nodes
DP nodes ET 200
Page 5 of 19
Basic setting
05/2008
4 Replace module ET 200

Replace DP nodes
1. Hook the module in the profile rail.
2. Swing the module towards the back until the slide valve audibly engages
Removing the module

The module is wired and terminal modules are located on the RH side
1. Switch off the supply voltage at the interface module
2. Disconnect the wiring and the bus connection plug at the interface module.
3. Use a screwdriver to push the slide valve on the module down to the stop and then
displace the module to the left
Note: The slide valve is located beneath the module.
4. Keep the slide valve pressed and swing the interface module out of the profile rail.
Replace the module of the ET 200
The modules of the ET 200 are engaged on the terminal module

and can be replaced by pressing on the locking device
Page 6 of 19
Basic setting
05/2008
5 Replacement of the CF card

Simotion drive train Cu320 D 4X5
How to proceed
− Turn off the main switch
− Replace the CF card
− Turn on the main switch again
− If error message 694 or 698 appears on the Copilot, turn the main switch on and off
again.
Page 7 of 19
Basic setting
05/2008
6 Commissioning/start-up and diagnosis

through LED
LED status, machine ready
Simotion drive train
Drive
Simotion Cliq
D4x5
Cu ALM 36 kW Motor modules

320
ALM Motor module

RDY green RDY green
DC link yellow DC link yellow
Simotion D4x5 7 segments 6
RDY green
RUN green
STOP off
SU/PF off
SF off CU320 (option) with belt control system
DP1 green RDY green
DP2 green DP1 green
OPT off OPT off
MOD off
DP nodes ET200S
SF off
BF off
ON green
Page 8 of 19
Basic setting
05/2008
7 Running rail during the start of the Copilot

(HD 453.P)
0- Start of log book server

Log in OPC group CopiStart
Start Diag server
Log in OPC group life cycle
Start timer loop
10 - Send axes with (send parameter)

configuration R0010 — R0014 to the PLC (infeed, etc.)
20 - Correction, infeed belt – send factor

Set mask identification to 0
Set axis number to 0
30 - Synchronise time
Axis collision - check
40 - Set lubricating cycles
60 - Set PC parameters
Set belt parameters
Set product mass
65- Set IP address for Xl30
66 - Send cam data
70 - Send correction values (for HD)
75 - If necessary, reset counter of quantity produced during service life
80 - Set or synchronise the counter of quantity produced during service life
90 - Handshake PC - - PLC
100 - ALL OK
Page 9 of 19
Basic setting
05/2008
8 Electric mains (RS485) – bus connection plug

CA 01 Electric mains (RS485) – bus connection plug RS 485
Function
The bus connection plug is snapped directly onto the PROFIBUS interface (9 pole Sub-D port) of the PROFIBUS
participant or a PROFIBUS network components.
The incoming and outgoing bus line for PROFIBUS is connected in the plug via 4 terminals
The line connection, integrated in the bus connection plug, can be activated via an externally accessible switch (not for
6ES7 972-0BA30-0XA0). During this process, incoming and outgoing bus lines are disconnected in the plug
(disconnection function).
This is necessary on both ends of a PROFIBUS segment.
Technical data
Bus connection plug 6ES7 972-0BA12-0XA0 6ES7 972-0BA41-0XA0 6ES7 972-0BA30-0XA0
6ES7 972-0BB12-0XA0 6ES7 972-0BB41-0XA0
Cable outlet 90° cable outlet 35° cable outlet 30° cable outlet
Transmission rate 9.6 kbit/s ….12 Mbit/s 9.6 kbit/s …12 Mbit/s 9.6 kbit/s...1500 Mbit/s
Terminating resistance Resistance combination Resistance combination No connection resistance,
st
integrated and can be switched integrated and can be switched cannot be used for 1 and
on via sliding switch on via sliding switch last device in the bus
Disconnecting function When Disconnecting function When segment.
the resistance is switched on the resistance is switched on
the outgoing bus is the outgoing bus is
disconnected disconnected
Interfaces
PROFIBUS participants 9 pole Sub-D port 9 pole Sub-D port 9 pole Sub-D port
PROFIBUS bus line 4 series terminals for wires up 4 series terminals for wires up 4 ID terminals for wires
to 1.5 mm² to 1.5 mm² 0.644 +- 0.040 mm²
FasrConnect IDC method of No No Yes
termination
Supply voltage must be DC 4.75 to 5.25 V DC 4.75 to 5.25 V -
provided by end unit
Current consumption Max. 5 mA Max. 5 mA -
Admiss. ambient conditions
Operating temperature 0°C to +60°C 0°C to +60°C 0°C to +60°C
Transport /storage -25°C to +80°C -25°C to +80°C -25°C to +80°C
temperature
Page 10 of 19
Basic setting
05/2008
9 Diagnosis via LED
Commissioning/start-up and diagnosis

6.2 Commissioning/start-up and diagnosis on PROFIBUS DP
6.2.4 Diagnosis through LED display

6.2.4.1 LED displays on the interface module
Interface module
LED display on the interface module:
DIP switch for nodes – address
1. Composite error(red)
2. Bus error (red)
3. Supply voltage(green)
− The line connection, integrated in the bus connection plug, can be activated via an externally
accessible switch (not for 6ES7 972-0BA30-0XA0).
− During this process, incoming and outgoing bus lines are disconnected in the plug
(disconnection function)
Page 11 of 19
Basic setting
05/2008
9.1 Diagnosis through LED ET 200

Commissioning/start-up and diagnosis
6.2 Commissioning/start-up and diagnosis on PROFIBUS DP
Status and error displays through LEDs at IM151-1 BASIC / IM151-1 STANDARD/ IM151-1 FO STANDARD / IM151-1
HIGH FEATURE
The table shows the status and error displays of the IM151-1 BASIC / IM151-1 STANDARD/ IM151-1 FO STANDARD /
IM151-1 HIGH FEATURE
Table 6-3: Status and error displays of the IM151-1 BASIC / IM151-1 STANDARD/ IM151-1 FO STANDARD / IM151-1
HIGH FEATURE
Event (LEDs) Cause Measure:
SF BF ON
off off off No voltage at the interface module or Switch on the supply voltage DC 24 V at the
hardware defect of the interface module interface module.
on Voltage at the interface module. -
flashi on Incorrect or no projecting of the interface - Check the interface module.
ng module – no data exchange between the - Check the configuration and parameterisation.
DP master and the interface module - Check the PROFIBUS address.
Cause:
- Incorrect PROFIBUS address
- Configuration error
- Parameterisation error
on on Baud rate search, inadmissible PROFIBUS Set a valid PROFIBUS address at the interface
address or bottom DIL switch (PROFIBUS moduel (1 to 125) or check the bus configuration.
address) not in OFF position - Check to ensure that the bus connection plug is
Cause: correctly inserted.
- The response monitoring time has - Check if the bus cable to the DP master is
elapsed interrupted.
- The bus communication via PROFIBUS - Switch the supply voltage DC 24V on the
DP to the interface module is interrupted inferface module off and on again.
on on Projected configuration of the ET 200S Check the configuration of the ET 200S whether a
does not coincide with the actual module is missing or defective or whether a non-
configuration of the ET200S. projected module is plugged in.
Check the design (e.g. with COM PROFIBUS or
STEP7) and rectify the parameterisation error.
Error in a peripheral module or defective Replace the interface module or notify your
interface module Siemens contact partner
off off on A data exchange is taking place between
the DP master and the ET 200S.
Set point and actual configuration of the ET
200S coincide.
Page 12 of 19
Basic setting
05/2008
9.2 Active Line Modules

Diagnosis
Diagnosis via LEDs
8.1.4 Active Line Modules
Table 8-4 Active Line Modules – Description of the LEDs

Status Description, Cause Remedy
Ready (H200) DC Link (H201)
Off Off Electronic power supply is missing or outside of the
admissible tolerance range.
Green: Off Component is operational and cyclic DRIVE-CliQ
communication takes place.
Orange Component is operational and cyclic DRIVE-CliQ
communication takes place. The intermediate circuit
voltage is applied.
Red Component is operational and cyclic DRIVE-CliQ Check mains
communication takes place. The intermediate circuit voltage
voltage is too high.
Orange Orange The DRIVE-CliQ communication is established.
Red At least one malfunction from this component is Rectify and
pending. acknowledge
Note: The LED is activated independent of reprojecting malfunction
the respective messages.
Green/Red Firmware Download is executed.
Green/Orange Detection of the components via LED is activated
or Red/Orange (p0124).
Note: The two possibilities depend on the status of the
LED during activation via p0124=1.
Warning
Dangerous intermediate circuit voltage can always be applied regardless of the LED status “DC-Link”.
Observe the warning information on the component!
Page 13 of 19
Basic setting
05/2008
9.3 Simotion D4 X 5
9.1 Diagnosis via LED displays
Legends of the LED statuses
The various operating conditions or occurring errors can be viewed on the LED displays of the SIMOTION D4x5. For this
purpose, they are illuminated, flash or flicker in different colours.
All possible combinations of the LED displays are summarized in the following table.
The meanings in the table read as follows:
- 1 = LED on
- 0 = LED off
- 0.5/1 = LED flashes (0.5 Hz)
- 2/1 = LED flashes (2 Hz)
- = LED flickers
- x = LED can be illuminated
LED displays
Each LED can illuminate in yellow, red or green. In the following table, the respective colour is indicated in addition to the
illumination status
Table 9-1 LED displays

Meaning LED display
RDY RUN STOP STOPU SF DP1 DP2 OPT
Start-up 1 (Yellow 1 1 1 (Yellow) 1 1 (Yellow) 1 1 (Yellow)
) (Yellow) (Yellow) (Yellow) (Yellow)
Compact Flash not 1 1 1 1 (Yellow) 1 1 (Yellow) 1 1 (Yellow)
plugged in or no (Yellow (Yellow) (Yellow) (Yellow) (Yellow)
SIMOTION CF )
Booting of CF 0.5 / 000000
started but error 1(Red)
occurred (faulty
FW)
D4x5 operational: 1 x x x x x x x
SIMOTION task (Green)
system is running,
SINAMICS
Integrated
operational
SINAMICS Xxxx00
Integrated not 1 x
Page 14 of 19
Basic setting
05/2008
Alarm, error/fault and system messages

Meaning LED display

Started-up (FW SINAMICS (Red)
not available/faulty) or
malfunctioning
Access to SIMOTION CF, ^ (Yellow) x x x x x x x
reading or writing
RUN x 1 (Green) 00xxxx
Transition from RUN – X1 (Green) 0 2/1 (Yellow) x x x x
STOPU
Transition from STOPU – X 2/1 (Green) 01 (Yellow) x x x x
RUN
STOPU x 0 0 1 (Yellow) x x x x
Operating status Service x (Green) 0 2/1 (Yellow) x x x x
2/1
Transition from STOPU – X 02/1 (Yellow) 1 (Yellow) x x x x
STOP
STOP X01 (Yellow) (Yellow)
Transition from STOP – X01 (Yellow) 2/1 x x x x
STOPU
(Yellow)
Request complete deletion X 0 0.5/1 (Yellow) 0xxxx
through the D4x5 itself or
via operating mode switch
Complete deletion running 1 1
0000000
(Yellow)
Complete deletion (Green) 01 0xxxx 0xxxx
concluded 1
Acknowledgeable event 1 xxx1 (Red) x x x
(Alarm, message, note ) is (Green)
pending
Malfunction to which no …. …. …. …. …. …. …. ….
reaction is possible from the (Red) (Red) (Red) (Red) (Red) (Red) (Red) (Red)
user program (SIMOTION).
The following may be
necessary to rectify the
error:
Switching OFF/ON
Check CF
Restart
Replacing the D4x5
Sub-licencing 1 (Green) Xxx0.5/1 (Red) x x x
Technological/ optional
objects
PROFIBUS DP
Interfaces as master
No parameterisation 1 Xxxx00x
(Green)
At least 1 slave is missing 1 Xx11x
xx
Page 15 of 19
Basic setting
05/2008
Alarm, error/fault and system messages

Meaning LED display

(Green/ (Red)
Red)
Bus status "Clear" 1 (Green) Xxxx0.5/ (Green) 0.5/1 x
1 (Green)
Bus status (Green) Xxxx1 (Green) 1 (Green) x
"Operate" 1
PROFIBUS DP
interfaces as i-Slave
No parameterisation 1 Xxxx00x (Red) 1 (Red)
(Green)
No parameterisation 1 Xxxx1 (Green) 0.5/1 x
master (Green) (Green)
Bus status "Clear" 1 (Green) Xxxx0.5/ (Green) 1 (Green x
1
Bus status (Green) Xxxx1 x
"Operate" 1
STOP status X 0.5/1 (Green) 1 (Yellow) 1 (Yellow) x x x x
Once the program
runs on a break
point, the
SIMOTION
assumes the STOP
status When the
break point is
exited, STOP is also
exited.
Fan not plugged-in 2/1
or insufficient fan (Red/yell
speed ow)
Incompatibel 1 (Red) x x x x x x
hardware; (Yellow)
SIMOTION kernel 1 (Red)
does not run at full
function on the
hardware used
No CBE30 plugged
in 0
CBE30 runs 1 Green
malfunction free
Bus error (CBE30): 2/1 Red
- Failure of a
connected IO
device
- At least one of the
allocated IO devices
is not accessible
- Incorrect
projecting or no
projecting
Firmware Download 2/1 Green
in progress
Faulty Firmware 05/1 Red
Download
Page 16 of 19
Basic setting
05/2008
9.4 LEDs during the start-up of CU 320

Diagnosis
Diagnosis via LEDs
8.1 Diagnosis via LEDs

8.1.1 LEDs during start-up of the control unit
The individual conditions during start-up are displayed via the LEDs on the control unit (CU 310, CU 310).
- The durations of the individual conditions differ in length

- In case of an error the start-up is terminated and the cause respectively displayed via the LEDs
- At the end of a malfunction free start-up all LEDs are briefly switched off.
- After the start-up, the LEDs are activated via the loaded software.
The description of the LEDs following start-up applies (see chapter EMPTY FLAG)
Table 8-1 Control unit 320 – Description der LEDs during start-up
LED Loading Loading software 2 Firmware

software 1
Reset Error loaded running Error Error FW initializing running
file crc loaded
RDY Red Red Off Off Off Off Off Off See
2 Hz table 8-2
DP1/COM Red Red Red Orange Red Red Off Off
2 Hz 0.5
Hz
OPT/OUT>5V Red Red Red Red Red Red Red Off
MOD Off Off Off Off Off Off Off Off
Possible causes:
- CompactFlash Card not available.
- Loading software 2 on CompactFlash Card not available or faulty.
- Software on CompactFlash Card incomplete or faulty.

- CRC faulty
Remedy:
Plug-in the CompactFlash Card appropriate for the machine line, including the correct software and parameterisation.
Page 17 of 19
Basic setting
05/2008
9.5 LEDs after the start-up of CU 320

Diagnosis
Diagnosis via LEDs
8.1.2 LEDs after start-up of the control unit CU320
Table 8-2 Control unit 320 – Description of the LEDs after start-up
LED Colour Status Description, Cause Remedy
RDY - Off Electric power supply is missing or -
(READY) outside of the admissible tolerance
range.
Green Steady light Module is operational and cyclic -
DRIVE-CliQ communication takes
place.
Flashing light 2 Hz Writing on CompactFlash Card -
Red Steady light At least one malfunction from this Rectify and acknowledge
module is pending. malfunction
Flashing light 0.5 Hz Boot failure Check to ensure that the
CompactFlash Card is plugged
in correctly
Replace CompactFlash Card
Replace control unit
Switch POWER ON
Green/Red Flashing light 0.5 Hz Control unit 320 is operational. Purchase licences
However, software licences are
missing.
Orange Steady light The DRIVE-CliQ communication is -
established.
Flashing light 0.5 Hz Firmware cannot bel loaded into the Check to ensure that the
RAM. CompactFlash Card is plugged
in correctly
Switch POWER ON
Flashing light 2 Hz Firmware Check sum error (CRC Check to ensure that the
error) CompactFlash Card is plugged
in correctly
Switch POWER ON
Page 18 of 19
Basic setting
05/2008
9.6 Motor modules

Diagnosis
Diagnosis via LEDs
8.1.8 Single Motor Module / Double Motor Module / Power Module
Table 8-8 Motor Module / Power Module – Description of the LEDs

Status Description, Cause Remedy
Ready (H200) DC Link (H201)
Off Off Electronic power supply is missing or -
outside of the admissible tolerance
range
Green Off Component is operational and cyclic -
DRIVE-CLiQ communication takes
place.
Orange Component is operational and cyclic -
DRIVE-CliQ communication takes place.
The intermediate circuit voltage is
applied.
Red Component is operational and cyclic Check mains voltage
DRIVE-CliQ communication takes place.
The intermediate circuit voltage is too
high.
Orange Orange The DRIVE-CliQ communication is -
established.
Red - At least one malfunction from this Rectify and acknowledge
component is pending. malfunction
Note: The LED is activated independent
of reprojecting the respective messages.
Green/Red - Firmware Download is executed. -
Green/Orange or - Detection of the components via LED is -
Red/Orange activated (p0124).
Note: The two possibilities depend on
the status of the LED during activation
via p0124=1.
Warning
Dangerous intermediate circuit voltage can always be applied regardless of the LED status “DC-Link”. Observe the
warning information on the component!
Page 19 of 19

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Basic setting

1 Home position of the machine ........................................................ 0-2

2 Infeed ............................................................................................. 0-2

3 Lateral knives ................................................................................. 0-2

4 Front knives.................................................................................... 0-3

5 Cutting table ................................................................................... 0-3

6 Pressing block ................................................................................ 0-3

7 Spine support knives ...................................................................... 0-3

8 Delivery .......................................................................................... 0-4

9 Calibrating the axes........................................................................ 0-4

10 Siemens control system.................................................................. 0-4

1 Home position of the machine

1 Infeed ............................................................................................................... 2-2

7 Setting the eccentric pin ................................................................................. 3-12

7 Spine support knives

9 Calibrating the axes

10 Siemens control system

HD 153 P Home position 1-1

1 Home position ................................................................................ 1-2

2 Home position with index holes ...................................................... 1-3

3 Absolute shaft encoder................................................................... 1-4

3.1 Setting at 353°.................................... ............................................ 1-4

4 Zero setting of the infeed................................................................ 1-5

5 Correction of the infeed setting....................................................... 1-6

HD 153 P Home position 1-2

The following description is valid from ma- No. to except

Responsible: Name TE 2007

HD 153 P Home position 1-3

2 Home position with index holes

HD 153 P Home position 1-4

3 Absolute shaft encoder

3.1 Setting at 353°

HD 153 P Home position 1-5

4 Zero setting of the infeed

HD 153 P Home position 1-6

5 Correction of the infeed setting

− Attention: Ensure machine is at 0°

HD 153 P Infeed 2-1

1 Infeed ............................................................................................. 2-2

2 Infeed clamp................................................................................... 2-3

2.1 Infeed clamp stroke length.............................................................. 2-3

2.2 Return stroke, bottom clamp........................................................... 2-4

2.3 Top clamp ...................................................................................... 2-5

3 Clamp transport.............................................................................. 2-6

3.1 Setting the clamp transport path..................................................... 2-6

4 Step-by-step system....................................................................... 2-7

4.1 Setting the step-by-step system...................................................... 2-7

4.2 Setting the stack fingers ................................................................. 2-8

HD 153 P Infeed 2-2

The following description is valid from ma- No. to except

Responsible: Name TE 2007

HD 153 P Infeed 2-3

• Set the machine to any desired format

• Set the machine to any desired format

HD 153 P Infeed 2-4

2.2 Return stroke, bottom clamp

HD 153 P Infeed 2-5

2.3 Top clamp

− Inch the machine to 38° - 55°

HD 153 P Infeed 2-6

HD 153 P Infeed 2-7

4.1 Setting the step-by-step system

− Invoke the setting mask (Fig.1)