BB3002 EVA & PUR Wiring Diagrams PDF

SERVICE
MANUAL
For EVA system
and PUR system
Initial issue: 02/04

Latest revision: 11/08
9.133.925
Content of this documentation has a confidential nature and remains the
exclusive property of C.P. Bourg SA. It is only put at the user (including without
limitation: Renter or Purchaser or their employees) disposal within the
exclusive scope of using and servicing the product. Without C.P. Bourg SA
prior agreement in writing, disclosure to third party and/or reproductions as well
as changes are prohibited.
Changes Initial
Initial issue:
issue: 02/04
02/04
Page 0 - ii Latest
Latest revision:
revision: 12/04
12/04
Section 7:
WIRING DIAGRAMS
Wiring Diagrams Initial issue: 04/04

Page 7 - 0 Latest revision: 11/08
This page is intentionally left blank.

Page 7 - ii Latest revision: 08/04
TABLE OF CONTENTS
1. Wiring diagrams ..........................................................................................................................................1

1.1 Diagram block .................................................................................................................................................................1
1.2 Interlock connections (part 1 of 2)...................................................................................................................................2
1.3 Interlock connections (part 2 of 2)...................................................................................................................................3
1.4 Power parts single-LINE representation (part 1 of 4) .....................................................................................................4
1.8 Main supply .....................................................................................................................................................................8
1.9 Interlock board.................................................................................................................................................................9
1.10 Interlock by pass .........................................................................................................................................................10
1.11 Interlock power supply 36V .........................................................................................................................................11
1.12 Interlock power supply 24V (part 1 of 5) .....................................................................................................................12
1.17 Carriage clamp (part 1 of 2) ........................................................................................................................................17
1.18 Carriage clamp (part 2 of 2) ........................................................................................................................................18
1.19 Translation (part 1 of 3)...............................................................................................................................................19
1.22 Jogger .........................................................................................................................................................................22
1.23 Milling (part 1 of 2) ......................................................................................................................................................23
1.24 Milling (part 2 of 2) ......................................................................................................................................................24
1.25 Glue system (part 1 of 8) ............................................................................................................................................25

1.33 Book clamp (part 1 of 2)..............................................................................................................................................33
1.34 Book clamp (part 2 of 2)..............................................................................................................................................34
1.35 Prefeed (part 1 of 2) ....................................................................................................................................................35
1.36 Prefeed (part 2 of 2) ....................................................................................................................................................36
1.37 Cover clamp ................................................................................................................................................................37
1.38 Creasing ......................................................................................................................................................................38
1.39 Can ..............................................................................................................................................................................39
1.40 Conveyor .....................................................................................................................................................................40
1.41 Signalling lighting ........................................................................................................................................................41
1.42 BBR Power supply and interlock (part 1 of 4).............................................................................................................42
1.43 BBR Head motor (part 2 of 4) .....................................................................................................................................43
1.44 BBR Inputs sensor (part 3 of 4) ..................................................................................................................................44
1.45 BBR Fork motor (part 4 of 4) ......................................................................................................................................45
1.46 External dust extractor and option ..............................................................................................................................46
1.47 Cover detection ...........................................................................................................................................................47
1.48 BB3002 PUR - VersaPail connection..........................................................................................................................48
2. Graphical symbols for diagrams .............................................................................................................49
3. Component list ..........................................................................................................................................54
4. Description of electrical components.....................................................................................................58
4.1 Numbering of BB3002 binder modules .........................................................................................................................58
4.2 Covers ...........................................................................................................................................................................58
4.3 Carriage.........................................................................................................................................................................60
4.4 Jogger module...............................................................................................................................................................61
4.5 Milling module ...............................................................................................................................................................62
4.6 Glue tank and EP48 Gun System .................................................................................................................................63
4.7 Carriage movement .......................................................................................................................................................66
4.8 Cover clamp module .....................................................................................................................................................67
4.9 Cover picking.................................................................................................................................................................68
4.10 Creasing ......................................................................................................................................................................69
4.11 Cover transport............................................................................................................................................................70
4.12 Output and conveyor ...................................................................................................................................................71

4.13 BBR .............................................................................................................................................................................72
5. General Description of the electronics rack ..........................................................................................73
5.1 General schematic for the electronics rack ...................................................................................................................73
5.2 Relays and fuse holders................................................................................................................................................76
5.3 B&R Modules ................................................................................................................................................................77
5.3.1 CPU 474 : ..........................................................................................................................................................77
Exchanging the battery of the CPU.............................................................................................................78
5.3.2 Module DO 135 : ...............................................................................................................................................79
5.3.3 Module DI 140 : .................................................................................................................................................80
5.3.4 Module MM432 : ................................................................................................................................................81
5.3.5 Module CM 211 : ...............................................................................................................................................83
5.3.6 Module DI 439 : .................................................................................................................................................87
5.3.7 Module MM424 : ................................................................................................................................................89
5.3.8 Module DO 435 : ...............................................................................................................................................90
5.4 Electronics cards ...........................................................................................................................................................91
5.4.1 DRIVER Card - A1 : .........................................................................................................................................93
5.4.2 DRIVER Card - A2 :...........................................................................................................................................94
5.4.3 INTERLOCK Card - A3 : ..................................................................................................................................95
5.4.4 DISPATCH Card - A4 : ......................................................................................................................................97
5.4.5 GLUE TANK Card - A5 :....................................................................................................................................99
5.4.6 ISOLATION Card - A30 : .................................................................................................................................100
5.4.7 POWER Card - A20 :.......................................................................................................................................101
5.4.8 BBR Card - A7 : ...............................................................................................................................................103
6. Interlock Circuit .......................................................................................................................................104
6.1 General presentation ...................................................................................................................................................104
6.2 Interlock circuit ............................................................................................................................................................105
6.3 Timer ...........................................................................................................................................................................106
6.4 Technical box ..............................................................................................................................................................107
6.5 Thermal protection of the milling motor.......................................................................................................................108
6.6 Interlock Diagram ........................................................................................................................................................109
7. Thermal control of glue heating ............................................................................................................110
7.1 Technical description...................................................................................................................................................110

7.2 “Heating tank” electrical diagram ................................................................................................................................111
7.3 Diagram of tank heating ..............................................................................................................................................112
7.4 Making the system safe in the event thattemperature is exceeded ...........................................................................113
7.5 Temperature at bottom of tank....................................................................................................................................114
8. ABB frequency variator ..........................................................................................................................115
8.1 Connection ..................................................................................................................................................................115
8.2 List of parameters .......................................................................................................................................................116
8.2.1 GROUP 2: Motor data and limit values : .........................................................................................................116
8.2.2 GROUP 3 : Command characteristics :...........................................................................................................117
8.2.3 GROUP 4 : Inputs and outputs :......................................................................................................................118
8.2.4 GROUP 5 : Supervision and faults : ................................................................................................................119
8.3 Programming ...............................................................................................................................................................121
8.3.1 Menu structure : ...............................................................................................................................................121
8.3.2 Procedure to be followed : ...............................................................................................................................121
8.3.3 Manual control of motors : ...............................................................................................................................122
8.4 Parameterisation of frequency variators- Version 01.00.01 ........................................................................................123
8.5 Error messages ...........................................................................................................................................................124
9. TELEMECANIQUE Frequency driver.....................................................................................................125
9.1 Connections ................................................................................................................................................................125
9.1.1 Power Terminals : ............................................................................................................................................125
9.1.2 Control Terminals : ..........................................................................................................................................125
9.1.3 Wiring diagrams : .............................................................................................................................................126
9.2 General description of the menu .................................................................................................................................127
9.3 Parameters of the frequency driver.............................................................................................................................128
9.3.1 First level adjustment parameters : .................................................................................................................128
9.3.2 Motor Control Menu : drC ................................................................................................................................129
9.3.3 Application functions menu : Fun ....................................................................................................................130
9.3.4 Monitoring Menu : SUP ...................................................................................................................................132
9.4 Faults - Causes - Remedies .......................................................................................................................................133
9.5 Programmation of the frequency driver.......................................................................................................................134

1. WIRING DIAGRAMS
1.1 Diagram block
To 2 To
electrovalves VersaPail
To
VersaPail
* Only for BB3002 EVA

9133813D/9134119-

1.2 Interlock connections (part 1 of 2)
9133813G/9134119-

1.3 Interlock connections (part 2 of 2)
Only for
BB3002 EVA
9133813D/9134119-

1.4 Power parts single-LINE representation (part 1 of 4)
* Only for BB3002 EVA 9133813D/9134119-

* Only for BB3002 EVA 9133813F/9134119-



1.8 Main supply

1.9 Interlock board

1.10 Interlock by pass

1.11 Interlock power supply 36V

1.12 Interlock power supply 24V (part 1 of 5)





1.17 Carriage clamp (part 1 of 2)

1.18 Carriage clamp (part 2 of 2)

1.19 Translation (part 1 of 3)



1.22 Jogger

1.23 Milling (part 1 of 2)

1.24 Milling (part 2 of 2)

1.25 Glue system (part 1 of 8)
[CABLE1/BKWH]
[CABLE1/GN]
0-10V_VFD[48]
GND_VFD[48]
9133813G/9134119-

Glue tank
9133813G/9134119A


Only for BB3002 PUR * Only for BB3002 EVA
Control module
206080
Retrosuction module
204994
[CABLE2/RD]
[CABLE2/BK]
5XY2-COMD[48]
5XY2-GND[48]
9133813D/9134119-


NC
NC
NC
NC
NC
NC
NC
NC
X51
[CABLE1/BU] :6
[CABLE1/OG] :5
[CABLE1/BK]
[CABLE1/RD]
X51
650mA
:1
EMPTY-ERR [48]
EMPTY-WARN [48]
:2
24V [48]
GND [48]
9133813D/9134119-


NC NC
NC NC
NC
NC
NC
NC NC
X51
[CABLE1/WH] :3
[CABLE1/BN] :7
NC
NC
READY [48]
WAKE-UP [48]
NC
NC
NC
[CABLE1/GN] X51 :4
* Only for BB3002 EVA Only for BB3002 PUR

FAULTED [48]
9133813E/9134119-

* Only for BB3002 EVA * Only for BB3002 EVA
9133813E/9134119-

1.33 Book clamp (part 1 of 2)

1.34 Book clamp (part 2 of 2)

1.35 Prefeed (part 1 of 2)

1.36 Prefeed (part 2 of 2)

1.37 Cover clamp

1.38 Creasing

1.39 Can

1.40 Conveyor

1.41 Signalling lighting

1.42 BBR Power supply and interlock (part 1 of 4)

1.43 BBR Head motor (part 2 of 4)

1.44 BBR Inputs sensor (part 3 of 4)

1.45 BBR Fork motor (part 4 of 4)

1.46 External dust extractor and option

1.47 Cover detection

1.48 BB3002 PUR - VersaPail connection

Page 7 - 48 Latest revision: -
2. GRAPHICAL SYMBOLS FOR DIAGRAMS

08/04
08/04
08/04
08/04
3. COMPONENT LIST

08/04
08/04
08/04
08/04
4. DESCRIPTION OF ELECTRICAL COMPONENTS
4.1 Numbering of BB3002 binder modules 4.2 Covers
66 Covers.
33 Carriage.
36 Carriage movement.
39 Jogger module.
42 Milling module.
45 Waste suction.
48 Glue tank.
54 Cover clamp.
57 Cover picking.
60 Cover transport clamp.
63 Creasing.
69 Binder Output.
79 Output conveyor.
72 BBR.
Number Description PLC Connection Page
85 UI extension arm.
66-B01p Security barrier for loading area Module CM 211 – X131 : 11 15
66-H1 Red signal (*) Module DO 435 – X171 : 8 41
66-H2 Green Signal +Upper cover lighting (*) Module DO 435 – X171 : 7 41
66-H4 Book clamp lighting Connected on Power board A20 41
66-S01p Green Button Module CM 211 – X121 : 10 41
66-S02p Black button Module CM 211 – X121 : 11 41
66-S03p Carriage clamp nipping pedal Module MM432 – X112 : 13 10
66-S04s Main primary switch Module MM432 – X112 : 14 2-4-8
66-S05s Emergency stop switch Module CM211 – X131 : 12 10
66-S06s Cover interlock switch Module CM211 – X131 : 12 10
66-S08s Door interlock switch Module CM211 – X131 : 12 10

08/04
Notes : - 66S05p -> 66S08p: Interlock reporting.
Interlock key at:
- Emergency shut-down button.
- Top panel.
- Front door.
- Binder CPC connector to output conveyor.
- CPC Connector from output conveyor to BBR.
- CPC Connector to ON line module (3502) in the
electronics rack.
- Interlock Card.
- Safety barrier disturbance.

08/04
4.3 Carriage
Inventory of inputs :
33-B01p Carriage emitter Dispatch card - 5V 18
33-B02p Paper detection Module DI439 – X141 : 3 18
33-B04p Carriage clamp thickness gauge Module MM432 – X112 : 5 & 5 17
33-B05p Fixed clamp jaw detection (On line) Module DI439 – X141 : 4 18
33-B06p Moving clamp jaw detection (On line) Module DI439 – X141 : 4 18
33-R1 Limiting current resistor 17
Inventory of drives :

33-M01p Carriage clamping Motor Module MM432 – X11 : 3 & 4 17

08/04
4.4 Jogger module
39-B01p Jogger home position Module DI439 – X141 : 8 22

39-M01p Jogger positioning stepper Clock : Module DO135 – X101 : 2 22
Direction : Module CM211 – X132 : 5 22
39-Y02p Jogger coil Clock : Module DO135 – X102 : 7 22

08/04
4.5 Milling module Various :
42k02p
42k03p
42-S01s Milling exhaust blocked detection Module CM211 – X121 : 7 24
42-B04i Phases Reporting + notching tools Module MM432 – X112 : 10 24
42-B05i Phases order Reporting Module MM432 – X112 : 11 24
45-S01s Dust collector full detection Module MM432 – X112 : 17 24
45-S02s Dust collector in place detection Module CM211 – X121 : 12 24
42-M01p Milling motor Module CM211 – X121 : 9 23
42-M02i Notching tools indexing Module MM424 – X161 : 7 16
45-M01p Dust collector motor Module CM211 – X121 : 9 23

42-M01p-Brake Milling motor Brake No Reporting PLC 23
42-M01p-Protection Milling motor Protection No Reporting PLC 23
42-K02p Milling motor process relay Module CM211 – X121 : 9 23
42-K03p Over Temperature dust collector relay Module CM211 – X122 : 10 23
45-M01p-Protection Intern dust collector motor Protection No reporting PLC 23

08/04
4.6 Glue tank and EP48 Gun System
A. Glue tank for BB3002 EVA :
48-B01s Min glue level Module CM211 – X131 : 5 29
48-B02s Max glue level Module CM211 – X131 : 6 29
48-B03p Cylinder 1 Temperature Module CM211 – X121 : 14 30
48-B04p Cylinder 2 Temperature Module CM211 – X121 : 17 30
48-B05p Glue tank Low temp thermostatic control Module CM211 – X131 : 7 31
48-B08i Clixon glue tank over heating control Module CM211 – X131 : 10 31
48-B09i Side glueing home position Module DI439 – X141 : 10 29
48-B10i Spinner home position Module DI439 – X141 : 11 29
48-B11p Glue tank High temp thermostatic control Module CM211 – X131 : 7 31

08/04
Inventory of outputs :

48-E01p Glue tank resistor 1Kw Regulation with clixon 48B05p or 48B11p 32
48-E02p Cylinder 1 resistor 0.3Kw Module CM211 – X122 : 11 30
48-E03p Cylinder 2 resistor 0.3Kw Module CM211 – X122 : 12 30
48-E04p Spinner resistor 24V/50w No command 32
48-E05p Glue tank resistor 0.3Kw Regulation with clixon 48B05p or 48B11p 32
48-M01p Glue tank cylinders motor Glue tank variable frequency driver 26
48-M02b Side glueing positioning stepper Clock : Module DO135 – X101 : 4
Direction : Module CM 211 – X132 : 6 27
48-M03i Spinner positioning stepper Clock : Module DO135 – X101 : 7
48-U01p Glue tank variable frequency driver Start fwd : Module CM211 – X122 : 8
Consigne 0-10V : Module CM211 – X122 : 17 26
48-Y01p Cylinder 1 scraper coil Module DO135 – X102 : 9 28
48-Y02p Cylinder 2 scraper coil Module DO135 – X103 : 2 28
48-Y03p Side glueing scrapper coil Module DO135 – X102 : 4 28

08/04
B. EP48 Gub System for BB3002 PUR :

48-M03i Spinner positioning stepper Clock : Module DO135 – X101 : 7
48-M02b Side glueing positioning stepper Clock : Module DO135 – X101 : 4
48-B09i Gun opening home position DI439 - X141 :10 29
48-B10i Gun height home position DI439 - X141 :11 29

4.7 Carriage movement

36-B03p Carriage translation encoder Signal A : Module DI140 – X104 : 4 19
Signal B : Module DI140 – X104 : 3 19
36-B04p Book edges detection Module DI140 : X104 : 1 19
36-S01p Translation end switch left Module MM432 – X112 : 15 19

36-M01p Carriage translation motor Translation variable frequency driver 21
36-U1p Translation variable frequency driver Start FWD : Module CM211 – X122 : 5 21
Start REV : Module CM 211 – X122 : 7 21
Speed 5Hz : Module DO 135 – X103 : 7 21
Speed : Module CM211 – X122 : 14 21

4.8 Cover clamp module

54-B01p Book clamp home position Module DI439 – X141 : 12 33
54-B03p Book clamp fully close Module DI439 – X141 : 14 33
54-B04p Book clamp up / down home position Module DI439 – X141 : 15 33
54-B05p Book clamp / exit backstop positions Module DI140 – X104 : 2 33
54-B06p Book clamp pre opening Module DI439 – X141 : 16 34

54-M01p Book clamp up/down motor Module MM424 : X161 : 3 & 4 34
54-M02p Book clamping motor Module MM432 : X111 : 7 & 8 34
54-M03p Book clamp positioning stepper Clock : Module DO135 – X101 : 9

4.9 Cover picking
57-B01p Pre-feed home position Module DI439 : X141 : 17 35
57-B02p Cover pre-feed detection Module DI439 : X141 : 18 36
57-B03p Double cover detection Not yet determined /
57-S02p Creasing unit motor safety switch / 38
57-S01p Creasing unit motor safety switch / 38
57-M01p Prefeed positioning stepper Clock : Module DO135 – X101 : 9
57-M02p Prefeed blower suction Module CM211 – X132 : 14 & 15 36
57-Y01p Blower manifold up coil Module DO435 – X171 : 3 35
57-Y02p Prefeed suction valve Module DO435 – X171 : 4 35

4.10 Creasing

63-B01p Creasing home position Module DI439 - X141 : 5 38
63-B02p Creasing cell 2 Module DI439 - X141 : 6 38
63-B03p Creasing cell 3 Module DI439 - X141 : 7 38

63-M01p Creasing motor Module MM424 – X161 : 5 & 6 38
63-Y01p Creasing up / down selection coil Module DO435 – X171 : 6 38

4.11 Cover transport
60-B01p Cover detection in cover clamp Module MM432 – X112 : 18 37
60-B02p Cover clamp home position Module DI140 – X104 : 5 37
60-B03p Cover clamp safe area detection Module DI140 – X104 : 6 37
60-M01p Cover clamp positioning stepper Clock : Module DO135 – X102 : 4
60-Y01p Cover clamp nipping coil Module DO435 - X171 : 5 37

4.12 Output and conveyor

69-B01p Book out of binder detection Module DI439 – X141 : 13 33
79-B01p Book out of conveyor detection Module DI439 – X141 : 9 40

79-M01p Reception conveyor Module MM424 – X161 : 8 40

4.13 BBR
Software
revision of
the BBR
72-B01p 9107064 Book incoming detection sensor
72-B02i 9107063 Head home position sensor
72-B03p 9107063 Head positioning sensor
72-B06i 9107063 Fork up position sensor
72-B08p 9107063 BBR full sensor
72-S01s 9146354+9146339_1NC+COUT_DE_POING Emergency BBR switch
72-S02s 9150079 Security switch fork down sensor
72-S03s 9150073 Security switch book press sensor
79-B01p 9107064 Book out of conveyor detection
72-M01p 9151136_MOTOR_24VDC_90T Head motor
72-M02p 9151136_MOTOR_24VDC_90T Fork motor
79-M01p 9151136_MOTOR_24VDC_90T Reception conveyor

5. GENERAL DESCRIPTION OF THE
ELECTRONICS RACK
5.1 General schematic for the electronics rack
This section describes the location of the various components
found in the BB3002 electronics rack. To the front of the electronics rack.
The principal items are the programmable B & R automatic control • Programmable Logic Controller PLC - B&R.
system and some 7 electronic cards. • Electronics cards.
Electronic boards
DO 435
PLC B&R MM 424
DI 439
CM 211-2
CM 211-1
MM 432
CPU 474

Connector locations.
CPU 474 MM 432 CM 211-1 CM 211-2 DI 439 MM 424 DO 435
X143
X161
X173
X122
X132
X142
X172
X112
DO135-X101
DO135-X102
DO135-X103
DI140-X104
X141
X171
X121
X131
X111

To the rear of the electronics rack.
16
11 1. Current limiting resistor for the carriage clamp
15
closure motor (inside the rack).
2. Connector 4X3 to the internal turbine supply.
3. Connector 4X5 to the milling motor supply.
4. Spare connector.
1
5. CPC Connector to the ON line module (3502).
6. Command relay for the milling blade and waste
extraction suction (internal or
10
external) -> 42K02p
7. Over-temperature relay for the internal turbine
12 -> 42K03p.
13 8. Connector for command of external waste
14 2 suction.
3
4 9. Fuses F1, F2, F3 (12A) for three-phase supply to
5 the binder.
10. Transformer.
11. Three-phase input filter.
12. Frequency variator for the movement motor.
13. Frequency variator for the glue tank motor.
14. “POWER - A 20” card.
15. Card for isolation of command signals for
frequency variators - A6.
6 16. 1000W, 24V - 36V supply.
7

5.2 Relays and fuse holders
At the rear of the rack there are : Notes: In the event of the milling motor overheating, a
thermal fuse operates and cuts off supply to the
1. Command relays for the milling blade and waste extraction motor. To re-set the motor, press the red button on
suction (internal or external) relay 42K02p.
-> 42K02p.
2. Internal turbine over-temperature relays
-> 42K03p.
3. Connector for command of external waste suction.
4. Fuses F1, F2, F3 (12A) for three-phase supply to the
binder.
Note : Only replaced by a fuse of same type and rating.
5. Re-activation of the 42K02p relay (command for the milling
blade and waste extraction suction).
5
1
2
3
4

5.3 B&R Modules
5.3.1 CPU 474 :

The CPUs CP474/CP774 have four slots for screw-in
The CPU is operated on the far left hand side of the module rack. module.
There are status LEDs and the connection sockets for an RS232 The screw-in modules are plugged into the CP interface as
and a CAN interface on the module. required, and are attached using the fastening screws.
The interface modules can be installed in slots 1, 2 and 3.
2 4 6 2 4 6
0 8 0 8
E C A E C A
Alimentation 24V (++ --) + ground
Serial port to UI
CAN port to BBR
DO 135
DO 135 Conn X103 DO 140
Conn X101 Conn X104
DO 135
Conn X102

EXCHANGING THE BATTERY OF THE CPU
1) Remove voltage to power supply.
ATTENTION: Data is lost when the battery is
exchanged ! The battery removal strip
must be routed behind the
2) Discharge electrostatic energy by touching the mounting rail or battery (sticking out in
the ground connection (not the power supply !). front of battery).
3) Open the battery compartment cover with the help of a
screwdriver.
4) Remove the battery from the battery compartment using the
removal ribbon (don’t touch the battery with uninsulated tools ->
short circuit). 6) Place the free end oof the battery removal strip under the
Pick up the battery by the flat sides (don’t pick up the battery by battery so that it doesn’t hang out of the battery compartment.
the edges). An isolated tool can also be used to remove the 7) Replace the battery compartment cover. Make sure that the slot
battery. for the screwdriver is facing upwards.
The left side of the battery compartment cover is placed in the
Right: Wrong: battery compartment and the right side is pressed into place.
8) Return voltage to power supply.
ATTENTION: Lithium batteries are considered

hazardous waste !
Please dispose of batteries according to the
guidelines in your area.
Battery: CR2477N
Hazardous Components
5) Insert the battery with the proper polarity. Place battery over the Battery Fluid: Propylenecarbonate (69%)
removal strip with the “+” side facing the back. Ethyleneglycoldimethylether (25%)
The battery removal strip must be routed behind the battery Lithiulperchlorate (6%)
(sticking out in front of the battery) in order to be able to Metallic Lithium
removed it again.

5.3.2 Module DO 135 :
Connector X102 (slot 2).
The DO135 is a 4 channel
Pin assignment
output module. 1 Shield
The type of operation can be 2 Output 1
57M01b_clock : Prefeed positionning
stepper
1
set for each output
1
3 GND
2
3
DO 135
separately. It is used for TPU Output 2 60M01p_clock : Cover clamp
4
4
5
Conn X103 positionning stepper
Shield
6
operation (for example for the
5
7
8
DO 135 6 Shield
9 10 11 12
clock of the steppers motors). DO 135 Conn X102
12
7 Output 3 39Y02p : PWM signal for jogger coil
Conn X101 8 GND
TB712
9 Output 4 48Y01p : Cylinder 1 scraper coil/
Connections 10 Shield PUR INJECTION
11 +12bis +24 VDC Alim 24V logic

GND
Connector X101 (Slot 1).
12 GND
1
Pin assignment Connector X103 (slot 3).
1
1 Shield
2
3
39M01b_clock : Jogger positionning

Output 1
4
2
stepper
5
GND
6
3
7
8
4 Output 2 48M02b_clock : Side glueing positionning

9 10 11 12
stepper/PUR WIDTH Pin assignment

5 Shield
12 1 Shield
6 Shield 48Y02p : Cylinder 2 scraper coil/
2 Output 1 PUR HIGH PRESSURE
TB712 7 Output 3 48M03i_clock : Spinner positionning 1
1
stepper/PUR HEIGTH 3 GND
2
GND
3
8
Output 2 48Y03p : Side glueing scraper coil/
4
4
Output 4
5
9 54M03b_clock : Book clamp PUR SNUFFBACK
Shield
6
5
Shield positionning stepper
7
10
8
6 Shield
9 10 11 12
7 Output 3 36M01p_break : Carriage translation break
12 GND GND
12
8 GND
TB712
9 Output 4 Virtual : Virtual variable for glue cutting
10 Shield
12 GND GND

5.3.3 Module DI 140 :
The DI140 digital input module is a screw-in

module for the B&R SYSTEM 2003 and for
the B&R Power Panel. It has 10 inputs for 24
VDC, four of which are equipped with
counter functions. The counter inputs can be
configured either as encoder or event
counter inputs. The DI140 supports TPU DO 140
functionality. The module is also equipped Conn X104
with supply voltage monitoring.
Connector X104 (Slot 4).
Pin assignment
1 Input 1 (TPU) B36B04p : Book edges detection (voltage)

2 Input 2 (TPU) B54B05p : Book clamp/exit backstop positions
1
1
3 Input 3 (TPU) B36B03p : Carriage translation encoder_B

2
3
Input 4 (TPU) B36B03p : Carriage translation

4
4
5
Input 5 Encoder Channel A / Event counter 1 B60B02p : Cover clamp home position
6
5
7
8
6 Input 6 Encoder Channel B / Event counter 2 B60B03p : Cover clamp safe area
9 10 11 12
12
7 Input 7 / Reference Pulse
8 Input 8 / Reference Enable
TB712
9 Input 9
10 Input 10
11 + 24 VDC supply for inputs Alim 24V logic
12 GND GND
DI140 - pin assignment

5.3.4 Module MM432 :
The motor bridge module MM432 is used to control two DC Connections
motors with a nominal voltage of 10 - 24 VDC at a nominal
current up to 4 A. The module is also equipped with two ABR
channels as well as six normal digital inputs for creating
positioning tasks which are not too complex.
Each motor is controlled with a full-bridge (H-bridge). Therefore

the motors can be moved in both directions.
Each bridge branch has its own supply voltage.
The advantage of this is that two different motors with different
voltages can be used. Each channel has current measurement,
supply voltage measurement, and short circuit recognition to
ground and to the positive supply voltage. Motor control takes status LEDS
place using a 16 kHz PWM signal and is therefore mostly noise-
free.
Connector X111 (Slot 1 of module MM432).
A local processor provides the required intelligence and is used
for communication with the higher level CPU.
It handles the preparation of the ABR inputs and normal digital Power Element X1
1 2 3 4 5 6 7 8 9 10
input, the control of both motors (each with a PWM signal) and Pin assignment TB710
the Analog measurements.
1 + DC supply for motor 1 Alim. 24V Logique
2 - DC supply for motor 1 GND
3 + motor output motor 1 33M01p : Carriage clamping motor (+)
4 - motor output motor 1 33M01p : Carriage clamping motor (GND)
5 + DC supply for motor 2 Alim. 24V puissance
6 - DC supply for motor 2 GND
7 + motor output motor 2 54M02p : Book clamping motor (+)
8 - motor output motor 2 54M02p : Book clamping motor (+)
X111 9 Not assigned

10 Not assigned
X112

Connector X112 (Slot 2 of module MM432).
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X2
Digital inputs
TB718
Pin Assignment
1 + 24VDC supply for inputs and incremental Alim. 24V Logique

2 GND GND
3 ABR encoder 1 : +24 VDC Supply 33B04p : Carriage clamp thickness (A)
4 ABR encoder 1 : GND 33B04p : Carriage clamp thickness (A)
5 ABR encoder 1 : A-Signal

6 ABR encoder 1 : B-Signal
7 ABR encoder 1 : R-Signal
8 ABR encoder 2 : +24 VDC Supply
9 ABR encoder 2 : GND
Phases order reporting + notching
10 ABR encoder 2 : A-Signal 42B04i : tools index
11 ABR encoder 2 : B-Signal 42B05i : Phases order reporting
12 ABR encoder 2 : R-Signal
13 Digital input 1 (reference enable 1[sre1]) 66S03p : Carriage clamp nipping pedal
14 Digital input 2 (limit switch 1 left [sel1]) 66S04s : Timer mode activation
15 Digital input 3 (limit switch 1 right [ser1]) 36S01p : Translation end switch left
16 Digital input 4 (reference enable 2[sre2]) 57B03p : Double cover detection
17 Digital input 5 (limit switch 2 left [sel2]) 45S01p : Dust collector full detection
18 Digital input 6 (limit switch 2 right [ser2]) 60B01p : Cover detection in cover clamp

5.3.5 Module CM 211 :
CM 211 - 1.
The CM 211 module is a Combination Module :
• 8 inputs, 24 VDC, 4 ms, sink, 3 one channel or 2 two
Connector X 121.
channel counters or 2 incremental encoders, 20 kHz,
• 8 transistor outputs, 24 VDC, 0.5 A, comparator function,
1 18
short-circuit protection, 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
• 2 inputs, ±10 V / 0-20 mA, 12 bit, X2
• 2 outputs, ±10 V, 12 bit.

Terminal Block X1
1 + 24VDC Alim. 24V Logique

2 + 24VDC
3 + 24VDC
4 n.c.
X121
5 Digital Input DI1 36M01p_error : Carriage translation drive error
6 Digital Input DI2 48M01p_error : Glue tank cylinders driver error
X122
7 Digital Input DI3 42S01p : Milling exhaust blocked detection
8 Digital Input DI4 57B04p : Miss cover detection
9 Digital Input DI5 42E01p : Milling motor overcurrent + themostat
Repoting
10 Digital Input DI6 66S01p : Carriage clamp nipping button
11 Digital Input DI7 66S02p : Carriage clamp opening button
12 Digital Input DI8 45S02p : Dust collector in place detection
13 Shield
14 Analog Input AI1+ 48B03p : Cylinder 1 temperature (+)
15 Analog Input 1 GND (AGND) 48B03p : Cylinder 1 temperature (GND)
16 Shield
17 Analog Input AI2+ 48B04p : Cylinder 2 temperateur (+)
18 Analog Input 2 GND (AGND) 48B04p : Cylinder 2 temperateur (GND)
status LEDS BB3002 EVA ONLY

Connector X 122.
1 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X2
Terminal Block X2
1 GND GND
2 GND
3 GND
4 n.c.
36M01p_start_fwd : Carriage translation start
5 Digital Output DO1 (to right)
6 Digital Output DO2
7 Digital Output DO3 36M01p_start_rev : Carriage translation start
(to left)
8 Digital Output DO4 48M01p_start : Glue tank cylinder start/
BB3002 EVA ONLY
9 Digital Output DO5
10 Digital Output DO6 42M01p : Milling dust collector command
11 Digital Output DO7 48E02p : Cylinder 1 resistor command/PUR : START PUMP

12 Digital Output DO8 48E03p : Cylinder 2 resistor command/PUR START HEATING
13 Shield Carriage translation speed setting shield
14 Analog Output AO1+ 36M01p_speed : Carriage translation speed
setting (+)
15 Analog Output 1 GND (OGND) 36M01p_speed : Carriage translation speed
Shield setting (GND)
16 Glue tank cylinders speed setting shield
17 Analog Output AO2+ 48M01p_speed : Glue tank cylinder speed
setting (+)
18 Analog Output 2 GND (OGND) 48M01p_speed : Glue tank cylinder speed
/PUR PUMP SPEED
setting (+)

CM 211 - 2.
Connector X 131.
1 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Terminal Block X1 X131

X132
1 + 24VDC Alim. 24V Logique
2 + 24VDC
3 + 24VDC
4 n.c.
5 Digital Input DI1 48B01s : Min glue level/PUR : GLUE LEVEL LOW
6 Digital Input DI2 48B02s : Max glue level/PUR : GLUE NOT EMPTY
7 Digital Input DI3 48E07s : Glue tank thermostat reporting/PUR : READY

8 Digital Input DI4
9 Digital Input DI5
10 Digital Input DI6 48E06s : Glue tank temperature error/PUR : NOT FAULTED
11 Digital Input DI7 66B01p : Safety light curtain reporting
12 Digital Input DI8 66S : Interlock reporting
13 Shield
14 Analog Input AI1+
15 Analog Input 1 GND (AGND)
16 Shield
17 Analog Input AI2+
18 Analog Input 2 GND (AGND)

Connector X 132.
1 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Terminal Block X2
1 GND GDN
2 GND
3 GND
4 n.c.
5 Digital Out put D01 39M01b_direction jogger stepper direction/PUR : WIDTH DIRECTION
6 Digital Out put D02 48M02b_direction Side glueing stepper direction/PUR : HEIGHT DIRECTION
7 Digital Out put D03 48M02b_direction Spinner stepper direction
8 Digital Out put D04 54M03b_direction Book clamp stepper direction
9 Digital Out put D05 57 M01b_direction Prefeed stepper direction
10 Digital Out put D06 60M01b_direction Cover clamp stepper direction
11 Digital Out put D07 30E01s Book binding counter
12 Digital Out put D08 48V01p Glue tank heating enable with timer/PUR : STANDBY
13 Shield
14 Analog Output A01+ 57M02p_level Prefeed blower succion level (+)
15 Analog Output 1 GND (OGND) 57M02_level Prefeed blower succion level (GND)
16 Shield
17 Analog Putput A02+
18 Analog Output 2 GND (OGND)

5.3.6 Module DI 439 :
Source connection.
Digital input modules are used to convert binary signals for a process Inputs are wired as source connections :
to the internal signal level required for the PCC. When an input is active the signal is earthed.
The states of the digital inputs are shown using Status LEDs.
Characteristics relevant for input modules :

- Number of Inputs : 16.
- Input Voltage : 24 VDC.
- Input delay : 1 ms.
X141
X142
X143
status LEDS

Module DI 439 : Connector X141.
1 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Terminal Block X1
1
2
3 Digital Input DI1 33B02p Carriage clamp paper detection
4 Digital Input DI2 33B05s - 33B06s Fixed & &moving clamp jam detection
5 Digital Input DI3 63B02p Creasing home position
6 Digital Input DI4 63B02p Creasing cell 2
7 Digital Input DI5 63B03p Creasing cell 3
8 Digital Input DI6 39B01p Jogger home position
9 Digital Input DI7 79B01p Book out of conveyor detection
10 Digital Input DI8 48B09i Side glueing home position/PUR : WIDTH HOME
11 Digital Input DI9 48B10i Spinner home detection/PUR : HEIGHT HOME
12 Digital Input DI10 54B01p Book clamp home position
13 Digital Input DI11 69B01p Book out of binder detection
14 Digital Input DI12 54B03p Book clamp fully closed
15 Digital Input DI13 54B04p Book clamp up/down home position
16 Digital Input DI14 54B06p Book clamp pre opening
17 Digital Input DI15 57B01p Prefeed home position
18 Digital Input DI16 57B02p Cover prefeed detection

5.3.7 Module MM424 :
The motor module MM424 is used for digital control of up to 4 DC

motors with a nominal voltage of 24 VDC at a nominal current of max.
2 A.
Unlike the motor bridge module MM432, the motor module MM424
can only digitally switch the 24 VDC supply voltage to the respective
motor.
X161
Connector X 161.
Pin assignment
1 GND GND
2 +24 VDC supply for inputs for motors Alim. 24V Logique interlock
3 Motor 1 (-), Movement in Left Direction 54M01p_R : Book clamp down motor
4 Motor 1 (+), Movement in Right Direction 54M01p_L : Book clamp down motor
status LEDS 5 Motor 2 (-), Movement in Left Direction 63M01p_R : Creasing motor
6 Motor 2 (+), Movement in Right Direction 63M01p_L : Creasing motor
7 Motor 3 (-), Movement in Left Direction 42M02i : Notching tools indexing
8 Motor 3 (+), Movement in Right Direction 79M01p : Reception convoyor
9 Motor 4 (-), Movement in Left Direction
10 Motor 4 (+), Movement in Right Direction
1 2 3 4 5 6 7 8 9 10
X1
TB710

5.3.8 Module DO 435 : Connector X171.
Digital output modules are used to control external loads (relays,

motors, solenoids). The states of the digital outputs are indicated with
status LEDs.
Terminal Block X1
1
X171
2
X172
X173 3 Digital Ouput DO1 57Y01i Blower manifold up coil
4 Digital Ouput DO2 57Y02p Prefeed suction valve
5 Digital Ouput DO3 60Y01p Cover clamp nipping coil
6 Digital Ouput DO4 63Y01p Creasing up/down selection coil
7 Digital Ouput DO5 66H01s_green Green light
8 Digital Ouput DO6 66H01s_red Red light
9 Digital Ouput DO7
10 Digital Ouput DO8
1 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X1
TB710
status LEDS

5.4 Electronics cards
To the front of the electronics rack. 4. Dispatch card - A4 : This card is used to provide a 5V supply to
5 optoelectronic cells and to send 24V signals from
4 the cells to the automatic control system.
3
5. Glue Tank Card - A5 : This card is controls the heating of the glue
2
tank:
1
- Management of min and max glue levels in the tank,
- Regulation of the temperature of cylinders 1 and 2,
- Protection against over-heating etc.
Note : For the BB3002 PUR Board A5 is just on

interface board.
1. Driver Card - A1 : This is the power driver for supplies to

stepper motors.
It has three outputs per card to supply three
motors.
For each motor the B & R PLC provides the
clock and direction to the driver.
2. Driver Card - A2 : Idem driver card 1.
3. Interlock Card - A3 : This card is used to control the machine’s safety

loop.
In the event of an emergency shut-down the
interlock card opens the safety loop and cuts off
the power supply to all motors.

To the rear of the electronics rack.
Isolation board for

frequency converter Power Supply 24V-36V
Translation
frequency converter
Glue Tank
frequency converter
Power board
Relays and fuse holde
Isolation Card - A6 : This card is used to provide galvanic isolation Power card - A 30 : On this card are mounted the various relays
for frequency variator command signals. supplying the movement motor, glue tank
heating elements, transistors for activation of
glue-cut-off solenoids etc.

5.4.1 DRIVER Card - A1 :
Only for BB3002 EVA :
Front view Front face
Power (36V)
Direction
Clock
Motor 54M03
Motor 57M01
Motor 39M01
24V - 5V not used
Connector A1 - X14
A1 - X14
Connector A1 - X11
A1 - X11
Connector A1 - X12
Handle

5.4.2 DRIVER Card - A2 :
Power (36V)
Direction
Clock
Green lights
Motor 60M01
Motor 48M03
Motor 48M02
24V - 5V not used
Connector A2 - X24
A2 - X24
Connector A2 - X21
A2 - X21
Connector A2 - X22
Handle

5.4.3 INTERLOCK Card - A3 :
Top part.
Barrier Cells OK
Power indicator
Reporting interlock
36V
24V
A3 - X38: Connector A3 - X38: Connector

Bottom part.
A3 - K3: Interlock relay A3 - X32: Connector
A3 - X36:
Connector
A3 - K7: Carriage in loading

area position relay Connector A3 - X36
A3 - K4: Interlock relay to A3 - K1 & K2: Loading area lights

entry module curtains relay
A3 - K8 & K9: Bookclamp lights curtains

relay (not used)
A3 - K11: Technical box relay
A3 - X31: Connector

5.4.4 DISPATCH Card - A4 :
Top part.
Set counter 888 888

Set counter
Hour counter Hour counter 888 888
Connector A4 - X46
Connector A4 - X46
1 hour
1/10 hour

Bottom part.
24V Logic
24V Sensor OFF when
A4-F2 released
5V Sensor OFF when
A4-F1 released
Connector A4 - X41
Connector A4 - X43
A4 - F1 (500mA) A4 - F2 (1A)
Protection 24V converter 24 VDC - 5 VDC Protection 24V sensor

5.4.5 GLUE TANK Card - A5 :
Connector A5 - X52
Green Led: Interlock OK

Yellow Led: Glue High Level
Yellow Led: Glue Low Level
Red Led: Error Cylinder 1
Test point Red Led: Error Cylinder 2
R102 Glue level
potentiometer
High temp. Test point High temp.
Low temp. Low temp.
For board Glue tank temperature

9423348C switch: Min - Max
and up
A5 - K1: Interlock
over temperature
A5 - R102: Glue level potentiometer
Located on the front face for board 9423348C and up
Handle A5 - F1: Thermal breaker in case
of over temperature
Notes: When an error occurs K1 opens and sends a large current to breaker A5 - F1.
This in turn opens after a certain time in order to record the appearance of a fault (problem with temperature regulation,
fault at klixon etc.).
The “Glue High Level” and “Glue Low Level” level LED’s are lit if the probes are immersed in the glue, and vice versa.

5.4.6 ISOLATION Card - A30 :
Connector X301: Command signals

from the B&R PLC.
Connector X304:
Board power supply
220VAC.
Connector X302: Command signals to Connector X303: Command signals to

the frequency variator for the translation motor. the frequency variator for the glue tank motor.

5.4.7 POWER Card - A20 :
A20 - X219: connector for A20 - F3 & F4: fuse 6.25A A20 - X12: Connector for A20 - X207: board 24V
220V power supply protection Glue tank resistor protection rack ventilation power supply
Glue tank frequency converter
A20 - F7 & F8: 6.25A
A20 - X218: A20 - X214: conn for 220V for A20 - F1 & F2: fuse 6.25A A20 - X213: lighting
200V power supply protection Power supply 24 - 36V Glue drum resistor
Translation frequency converter Protection Power supply protection
A20 - F11 & F12: 6.25A A20 -X206: 24V to BBR
A20 - R1: Polyswitch 3.75A
Jogger power supply 24V
Red Led: Jogger error
A20 - X204: A20 - X203: glue tank
connector for solenoid + jogger command
220V power supply
Power board A20 - X211
A20 - 36K5: interlock relay
carriage clamp
A20 - F5 & F6: Translation brake
220V power supply
protection A20 - 42K7:
Prefeed blower suction interlock relay - 2
Milling motor
A20 - X215: A20 - X201: process and
connector for interlock command
fumes extractor
power supply 220V
A20 - X205:
connector for prefeed
blower suction prefeed A20 - 42K6:
power supply 220V interlock relay - 1
Milling motor
A20 - X223:
connector for isolation
board power supply 24V A20 - X210: milling motor
power supply 380V
glue drum rotation motor A20 - K1: interlock relay
A20 - X217: glue tank Glue drums resistor
carriage clamp translation motor A20 - X222: glue tank resistance resistor connection
power supply 1KW A20 - U2: static relay
A20 - X221: glue tank resistance Glue drum 2 resistor
power supply 0.3 KW A20 - U1: static relay
A20 - U3: static relay Glue drum 1 resistor
Glue tank resistor
A20 - U2: interlock relay
Glue tank resistor

List of components: Power card
Fuses : Relays :
A20 - F1 : 6.25A fuse - Protects tank cylinder elements. A20 – U1 : Static relay for cylinder 1 heating element.
A20 - F2 : 6.25A fuse - Protects tank cylinder elements. A20 - U2 : Static relay for cylinder 2 heating element.
A20 - F3 : 6.25A fuse - Protects elements at bottom of tank. A20 - U3 : Static relay for heating element at bottom of tank.
A20 - F4 : 6.25A fuse - Protects elements at bottom of tank.
A20 - F5 : 4 A fuse - Protects cover suction - feed. A20 – K1 : Cylinder heating element relay interlock.
A20 - F6 : 4 A fuse - Protects cover suction - feed. A20 – K2 : Bottom of tank heating element relay interlock.
A20 - F7 : 6.25A fuse - Protects glue tank frequency variator. A20 – 36K4 : Carriage movement motor relay interlock.
A20 - F8 : 6.25A fuse - Protects glue tank frequency variator. A20 – 36K5 : Movement brake relay interlock.
A20 - F9 : 6.25A fuse - Protects movement frequency variator. A20 – 42K6 : Milling motor relay interlock.
A20 - F10 : 6.25A fuse - Protects movement frequency variator. A20 – 42K7 : Second milling motor relay interlock.
A20 - F11 : 6.25A fuse - Protects 24-36V power supply. A20 – 48K6 : Cylinder rotation motor relay interlock.
A20 - F12 : 6.25A fuse - Protects 24-36V power supply.

5.4.8 BBR Card - A7 :
A7-F3 Fuse 500 mA Relay A7-K1
Relay A7-K1
Connector A7-X7
For communication
CAN with PLC BB3002
Green led A7-B1

Blinking in RUN mode
Switch A7-S2
RUN mode / Download mode
Connector A7-X2
Serial connector for
microprocessor download
Connector A7-X1 Connector A7-X1
A7 - K2 : Safety relay.
List of components: BBR Card Safety relay that only allows the BBR head to pass when
the book separator harrow is lowered.
Fuses :
A7 - F3 : Protects BBR 24V supply. Safety :
If fuse A7 - F3 is open there is no longer 24V to the card and A7 - S2 : Selector: “run” mode/“download” mode.
Led A7-B2 turns off.
- Selector down: “RUN” mode:
Relays : normal use of BBR.
A7 - K1 : BBR card interlock relay.
Relay open if BBR emergency shut-down or BB3002 Interlock. - Selector up: “DOWNLOAD” mode:
for the Microcontroller.

6. INTERLOCK CIRCUIT
6.1 General presentation

The interlock circuit will be composed of 4 levels :
• The first level corresponds to the cover and will stop all
dangerous power features.
• The second level is used to stop all movement except the

rotation of the glue tank when a over Temperature has
occurred.
• The third level is activated during the loading of paper in off

line mode.
• The fourth level is used for the creasing. It’s enabled by a

switch when the prefeed is located in a right position.

6.2 Interlock circuit
Différent cases : - During loading :
• First level interlock. Carriage clamp current is reduced.
The first level interlock corresponds to the cover and will All movements of carriage are disabled. -> Safety OK
stop all dangerous elements like translation motor, milling The milling and the glue tank are
motor, clamping, creasing and the glue tank (see electric protected by mechanical parts.
diagrams p.2).
- During carriage movement :
• Second level interlock. Intrusion of anything between barrier cell,
If the glue Temperature increase dangerously, a security the carriage, milling and the glue tank
switch activate a security relay and disabled all the
main motor are stopped. -> Safety OK.
motorizations except the rotation of the glue tank to
homogenate the glue Temperature
(see electric diagrams p.3).
• Fourth level and Creasing.
The pre-feed ramp must be located in a right place to allow
• Third level and Current limiting by RESISTOR.
During the paper loading, a resistor connected in series the creasing process. In this position, a double security
with the motor limits the clamping motor current. switch activates a security relays and the creasing motor is
This resistor activated by the barrier cell and the resulting powered.
force corresponding to the limited current is about 80N In all other position, the motor is disabled. Some
with a permanent 24V power supply mechanical parts are design to prevent finger introduction.
(See electric diagrams p.17 and 18). The fourth interlock level must stop this motor.
The milling and the glue tank main motor are not Different cases : - During the movement of pre feed :
interlocked by the secondary level in loading paper The creasing motor is not powered
position, in other position, all intrusion in the barrier cells and the movement of -> Safety OK
stop the milling motor and the glue tank. For this one pre feed is not dangerous.
switch is located on the translation and correspond to the
loading zone, we need a double direction contact to switch - In the position to allow creasing :
between the two states (loading zone, translation). The The creasing motor can rotate,
contact switch NC must be only used like a security contact but it’s not possible to introduce
and than the switching must be realised by a security relay fingers. ->Safety OK
supply through the NC switch-loading zone (see electric (See electric diagrams p.38).
diagrams p.2 and 3).

6.3 Timer
To be able to use a GUI software timer based, we have a 3 positions
rotary main switch to energize the main glue tank resistor.
The 3 position are :

• OFF.
• ON 1 : the main use of this machine.
• ON 2 or timer mode : The main interlock loop is open and
the resistors are energized through a static relay
placed on the glue tank control board.
At this time the static relay is drive by the GUI
timer.

6.4 Technical box
CPB part number 9432545, for field engineers use only.
• The switch is used to by pass the covers interlock and allows

engineer to see what append in a running machine.
• The push button is use to energise the 2 brakes used in the

machine and allows engineers to manually move translation and
milling motors.
9432545

6.5 Thermal protection of the milling motor
If the current in the milling motor increase dangerously, a thermal
protection is activated and disable all the motorizations.
After a few minutes, the technician can restart the machine by pushing
on the red button on the relay support (see p.23 and 74).

6.6 Interlock Diagram
See page 7 - 2

7. THERMAL CONTROL OF GLUE HEATING
7.1 Technical description

Cylinder heating :
Two separate circuits regulate the tank and cylinder heating :
The cylinders are heated when the icon is activated (at the
Tank heating : bottom of the UI screen).
Two elements at the bottom of the tank are used to heat the glue
in the tank. Two sensors (Pt 1000) measure the temperature of the glue at the
cylinders. These are connected to two inputs of the automatic
These elements are supplied : control system.
- Continuously when the binder is powered up (main
switch position ON1). The automatic control system regulates the glue temperature.
- When the binder is in “TIMER” mode (main switch
position ON2).
• Heating of the tank and cylinders is protected by a thermal sensor
when the glue temperature exceeds 170°C.
Notes : There is still power supplied to the elements at
the bottom of the tank even during an emergency
• A heating element is also installed in the spinner.
shut-down.
The spinner temperature is not regulated.
The elements at the bottom of the tank may be set to two

different temperatures. A switch located on the “Glue tank” card is
used to select the required temperature. For National Coolbind,
select a tank bottom temperature of 115°C.
The temperatures are regulated using a thermal sensor (klixon)

fixed to the tank.

7.2 “Heating tank” electrical diagram
• Diagram Legend :
1. Cylinder 1 heating device : 300 W; 230 VAC; with regulation.

2. Cylinder 2 heating device : 300 W; 230 VAC; with regulation.
PLC + Glue tank board 3. Cylinder 3 heating device : 50 W; 24 V DC; without regulation.
4. Cylinder 1 temperature managing device : 2 x PT1000 (a and b).
9
24 VDC 5. Cylinder 2 temperature managing device : 2 x PT1000 (c and d).
Outputs Inputs
6. Glue tank heating device : 1000 W; 230 VAC; with regulation.
300 W; 230 V AC; with regulation.
Error bit 7. Glue tank thermostat.
Temperature
8. Glue tank safety thermostat (can be reset manually).
Digital setting
9. Regulation and safety device :
Digital 4 analog. inputs Error if : - difference between a and b temperatures too
important,
- difference between c and d temperatures too
important,
- over temperature.
State relay
230 VAC
State relay
4 5 24 VDC
1 2 7
24 VDC
8
Timer
6
State relay 230 VAC

7.3 Diagram of tank heating
Additional heating
T (c°) Heating time out: 55 min. Drums
delay setted
heating Binder waiting start
on the UI
Glue T° setted on the UI

CYLINDERS T°
Glue Tank T° : High - Low GLUE TANK T°
Glue T° setted on the UI - 40°C
CYLINDERS ROTATION
ON 1 Switch opening Check glue level : if OK => continue

if KO => Stop cylinders + stop heating + return a
(Hardware) Error
1. Power on (main switch at ON 1) -> Tank bottom heaters start automatically when power is applied.
The glue temperature is regulated at temperature corresponding to switch position.
-> A 55 minute time delay is activated.
2. If the operator presses the green button -> All setup manoeuvres are carried out except for those that require the glue to be hot.
3. If the operator presses icon -> Cylinder heating is activated.
-> The temperature of the glue on the cylinders is regulated at 40°C below the gluing temperature.
4. When the 55 minute time delay has expired and if the icon has been activated : -> Cylinder rotation.
-> Rise in cylinder temperature until gluing
temperature is reached.
5. When the temperature of the glue reaches gluing temperature, the glue tank set-up alone will be automatically carried out.
From that time on the glue levels will be (continually) controlled.
6. A further heating delay period, set using the UI, may be added in order to make sure that the glue temperature is uniform throughout
the tank (optional).
7. The green signal light on the loading zone comes on to indicate that the machine is ready to start -> “Binder waiting start”.

7.4 Making the system safe in the event that
temperature is exceeded
In order to meet international standards, the glue temperature is
maintained at a temperature that is 20°C below the flash-point
temperature of the glue.
A thermal fuse (which can be reset manually) operates in the event of
this temperature being exceeded.
In the event that the glue temperature exceeds 190°C:
• The thermal fuse A5 - F1 operates.

• Tank and cylinder heating is stopped immediately through 3
safety relays.
• The machine shuts down completely except for the cylinders,
which continue to turn in order to maintain the glue at a uniform
temperature.
• An error message appears on the screen: “Glue temperature too
high”
The machine will remain shut down as long as fuse A1 - F1 has not
been reinstated.
In order to re-start the machine, it is necessary to wait until the glue

temperature falls below 130°C before re-setting the fuse. Technicians
must therefore wait approximately 15 minutes before they can
re-initialise the machine.

7.5 Temperature at bottom of tank
The elements at the bottom of the tank may be set to two different
temperatures.
A switch located on the “Glue tank” card is used to change from one
temperature setting to the other.
Connector A5 - X52
Green Led: Interlock OK

Yellow Led: Glue High Level
Yellow Led: Glue Low Level
Red Led: Error Cylinder 1
Test point Red Led: Error Cylinder 2
R102 Glue level
potentiometer
High temp. Test point High temp.
Low temp. Low temp.
For board Glue tank temperature

9423348C switch: Min - Max
and up
A5 - K1: Interlock
over temperature
A5 - R102: Glue level potentiometer
Located on the front face for board 9423348C and up
Handle A5 - F1: Thermal breaker in case
of over temperature

8. ABB FREQUENCY VARIATOR COMMAND connection terminal block :
8.1 Connection
Power connection terminal block :
Note : Only three power-ups in five

minutes are allowed.

8.2 List of parameters
8.2.1 GROUP 2: Motor data and limit values : Note : Ensure fmin < fmax.
• 201 Unom : Nominal motor voltage as shown on identification
plate. • 208 Verrou sens : Backward rotation can be locked.
U nom is the maximum voltage applied to the motor by 1 = AV/ ARR
the ACS 100. 2 = AV only
F nom is the frequency at which the output voltage is • 209 Bruit moteur: Control of motor noise level
equal to Unom. 0= standard (switching frequency 4 kHz)
The ACS 100 can supply a voltage that is greater than the 1= reduced noise (switching frequency 8 kHz)
mains supply voltage to the motor. 2 = silent (switching frequency 16 kHz)
See Figure 3.
• 202 fnom : Nominal motor frequency as shown on identification Note : When the “reduced noise” (8 KHz) setting is
plate (field attenuation value). used, the maximum load capacity of the ACS 100 is
See Figure 3. I2 at an ambient temperature of 30°C or 0.9 x I2 at
• 203 Inom : Nominal motor current as shown on identification 40°C. When the “Silent” (16 kHz) setting is used, the
plate. maximum load capacity is 0.75 * I2 at an ambient
temperature of 30°C.
Note : This parameter is only used when the motor
thermal protection function is in service.
See parameter 502 (f lim). See Figure 5. Figure 1 : F min and F max parameters to limit the output
frequency.
• 204 Vitesse nom : Nominal motor speed as shown on
identification plate.
• 205 Imax : Maximum current supplied to the motor by the
ACS 100.
• 206 fmax : Maximum frequency applied to the motor by the
ACS 100.
Figure 1: Parameterisation of fmin and fmax to limit
output frequency.
• 207 fmin: Minimum frequency applied to the motor by the
ACS 100.

8.2.2 GROUP 3 : Command characteristics :
• 301 Arrêt Shut down mode : 1 = free wheel clutch. Note : RI compensation must be as low as possible.
2 = on ramp.
See also parameter 307 (Temps inj. cc).
• 307 Temps inj cc Time of c.c. injection after modulation
• 302 Rampe Shape of ramp : 0 = Linear stops. If freewheel shut down occurs, the
1 = Rapid S-shaped ramp ACS 100 uses braking by injection of c.c. If
2 = Medium S-shaped ramp ramped shut down occurs, the ACS 100 uses
3 = Slow S-shaped ramp braking by maintenance of the c.c. after the
ramp.
Figure 2 : Output frequency.
• 308 Ucmax Control of over-voltage regulator.
Select 0, if braking choppers are connected.
0 = no over-voltage regulation of the

intermediate circuit.
1 = over-voltage regulation in service
Figure 3 :Output voltage.
• 303 Acc Time to accelerate from frequency of zero to max.

frequency (0 - fmax).
• 304 Déc Time to decelerate from max. frequency to
frequency of zero (fmax - 0).
• 305 Loi U/f U/f at attenuation point:
1 = Linear (curves A and C)
2 = Quadratic (curves B and D)
Linear is preferable for constant torque applications

and for pumping application (centrifugal fans).
• 306 Comp RI compensation value (application of an
additional voltage between 0 Hz and fnom).

8.2.3 GROUP 4 : Inputs and outputs :
• 401 EA mini Scaling of analogue input.
Note : After changing switch power off and then on
0 % = 0 mA (or 0 V) and 100 % = 20 mA
again to confirm the change.
(or 10 V) on input.
• 402 EA maxi Scaling of analogue input. • 406 Vitesse const. Constant speed. May be called through
0 % = 0 mA (or 0 V) and 100 % = 20 mA a logic input.
(or 10 V) on input.
Note : EA mini < EA maxi.
• 403 Réf mini Reference value corresponding to minimum

AI.
• 404 Réf maxi Reference value corresponding to maximum

AI.
Figure 4 :
• 405 Config EL Configuration of logical inputs:

Note : In alternate operation the variator will shut off if
1 = standard ABB config.
EL1 and EL2 are activated at the same time.
2 = 3-wire control.
3 = alternate operation.
8.2.4 GROUP 5 : Supervision and faults :
• 501 EA Fault Supervision of analogue input • 503 Verrou param Locking out of access to parameters.
0 = no supervision. 0 = START/STOP keys and DIRECTION
1 = if the analogue input value is OF ROTATION keys locked, no
less than the parameter value. parameters may be changed. Only
display of parameters is possible.
401 (EA mini), display of a fault code and free-wheel
shut-down of the ACS 100. 1 = Access to parameters not locked.
• 502 flim Threshold frequency for motor thermal protection. 2 = Modified values not stored in permanent
memory.
Flim and Inom (param. 203) define the safe operating range
of the motor in continuous operation. • 504 Blocage démarrage Start-up function locked. A locked
start-up means that a start-up order has
0 Hz = motor thermal protection deactivated. not been executed:
• in the event of a fault being re-set or
during a change of command mode
Figure 5 : (local -> remote).
0 = No -> Start-up lock function

deactivated.
The variator will start-up after re-set of a
fault or a change of command mode
when a start-up command is received.

1 = Yes -> Start-up un-lock function There is a constant number of re-set attempts (5) and the time
activated. period is constant (30 secs).
The variator will not start up after re-set of At time “A” there are three faults, with the following fault being
a fault or a change of command mode. the fourth. The variator is re-set because the number of attempt
In order to re-activate the variator, a new is less than 5.
start-up command must be given.
• 505 Automatic re-set This function can be used to re-set the

variator automatically after an over-voltage
fault.
It defines the number of automatic re-sets that
are allowed (5) in a given period of time (30
secs).
0 secs = function deactivated
If a value greater than 0 s is selected, the over-voltage fault is

automatically re-set after the set delay.
If 0 is selected, the fault is not automatically re-set.
Figure 6 : Operation of the automatic re-set function.

8.3 Programming
• Press on the menu to enter the parameter groups.
8.3.1 Menu structure :
• Using the up and down arrows, select “02” and press
“ENTER” to access the group 2 parameters.
Parameter 201 is then selected.
• When “ENTER” is pressed rapidly, the variator will display
the selected parameter for 1 second.
• By pressing on “ENTER” for longer, the selected parameter
value can be altered using the up and down arrows.
Press “enter” once more to confirm the value.
Example : parameter P304.
8.3.2 Procedure to be followed :

• Apply voltage to the variator.
• Place the keyboard on the variator.
• Go to “LOCAL” mode (press “enter + menu” at the same
time to change from “REMOTE” mode to “LOCAL” mode and
vice versa). • The values in the table on page 1 must be entered into
parameters 201 to 205 in this way.
• Press “menu” to gain access to the various groups of
parameters. • Once these parameters have been input, press twice on
“menu“ to leave any application.
• Using the up and down arrows to select “DL” and press
“ENTER” for 3 seconds to download the parameters from • Terminate programming by pressing “enter+menu”.
the keyboard to the variator. The variator is then in “REMOTE“ mode.
The automatic control system and not the keyboard will
therefore be in control of the variator.

8.3.3 Manual control of motors :
Manual control of motors is possible through the keyboard.
In “LOCAL” mode, pressing “start / stop” will cause the motor to run.
Pressing on it once more will stop the motor.
The rotation speed of the motor may be altered. Press “enter” and
increase the frequency using the up and down arrows.
Confirm the frequency by pressing “enter”.
Pressing the up and down arrows will display the current

frequency or the electrical current passing through the motor.
Terminate the test by pressing “start / stop” to stop the motor.

8.4 Parameterisation of frequency variators-
Version 01.00.01 “Glue Tank” parameters
DI 1 DI 2 DI 3 ACTION P201 = 230 P202 = 50 P203 = 1.5 P204 = 2830 P205 = 2.1 P206 = 60
0 0 0 Stop P207 = 0 P208 = 1 P209 = 0 P301 = 2 P302 = 0 P303 = 0.1

P304 = 0.4 P305 = 1 P306 = 20 P307 = 0 P308 = 1 P401 = 0
1 0 0 Start FWD
P402 = 100 P403 = 0 P404 = 60 P405 = 3 P406 = 5 P501 = 0
0 1 0 Start REV
P502 = 60 P503 = 1 P504 = 0 P505 = 1 P506 = 0
1 1 0 Stop
1 0 1 FWD at 5 Hz Notes : After changing parameter P405, the variator must be shut
down and re-started to confirm the change.
0 1 1 REV at 5 Hz
If P306 increases, braking will be more violent and vice
0 0 1 Stop versa.
1 1 1 Stop Remote Mode : Automatic control system in control.
DI 1 : Start Fwd.
Local Mode : Keyboard control - motor can be
DI 2 : Start Rev. controlled manually using the keyboard.
DI 3 : Set frequency = 5 Hz.
Press “Enter+Menu” at the same time to change from one
DC Com connected to GND. Terminal 7 linked to terminal 9. mode to the other.
AGND connected to 0V of the automatic control system.
Download : Save everything from the keyboard onto the
variator.
0-10V analogue input on the AI terminal (2). Upload: Save everything from the variator onto the
0V at terminal (3) AGND. keyboard.
Be in local mode to carry out this operation.
“Movement” parameters : With download or upload, data is transferred except for
P201 = 230 P202 = 50 P203 = 1.8 P204 = 2780 P205 = 4.5 P206 = 60 parameters 201 to 205 (motor parameters).
P207 = 0 P208 = 1 P209 = 0 P301 = 2 P302 = 0 P303 = 0.1 The keyboard screen will display the variator parameters
P304 = 0.4 P305 = 1 P306 = 20 P307 = 0 P308 = 1 P401 = 0 (never the keyboard parameters).
P402 = 100 P403 = 0 P404 = 60 P405 = 3 P406 = 5 P501 = 0
Alternative ABB Config. Parameter 405 at 3.
P502 = 80 P503 = 1 P504 = 0 P505 = 1 P506 = 0

8.5 Error messages
Errors :
Alarms : Code Description
FL 1 Excess current:
Code Description - Possible mechanical problem.
CF 0 – CF 9 Position of selector S1 - Acceleration / deceleration times may be too short.
Some parameters can only be modified if S1 = 0. FL 2 Over-voltage c.c.
- Circuit voltage too high.
AL1 Loading (read/write) has failed. - Deceleration time may be too short.
AL 2 Action forbidden with variator functioning. FL 3 ACS 100 overheating.
- Ambient temperature too high.
AL 3 Action not allowed in remote mode (REM) or local
- Serious overload.
mode (LOC). FL 4 * Fault current: output earth fault or short circuit.
AL 4 Rotation direction key locked. Locking activated FL 5 Output overload.
(parameter 208). FL 6 Under-voltage cc.
FL 7 Analogue input fault (see parameter 501)
AL 5 RUN key on micro-console locked. FL 8 Motor overheating (see parameter 502)
Logical input configured for 3-wire commands and FL 9 Micro-console disconnected in LOCAL mode.
EL 2 not connected. Note: If FL 9 is displayed when power switched off, the ACS 100 will
start in remote command mode (REM) when power is switched
AL 6 Action not allowed. Locking activated (parameter on.
503). FL10 Inconsistency between parameters.
AL 10 * Excess current regulator activated. Check that EA mini (Fmin) is not greater than EA maxi (Fmax).
FL11 * cc bus ripple too high.
AL 11 * Over-voltage regulator activated. Check supply circuit.
AL 12 * Under-voltage regulator activated. FL 12 Reserved. Contact your supplier.
FL 13 - FL 14 * Equipment fault. Contact your supplier.
AL 13 Reserved. Contact your supplier. FL 15 * Analogue input outside value range.
AL 14 Attempt to go to remote mode (REM) when locking Check AI level.
is activated (parameter 208). FL 16 - FL 19 * Equipment fault. Contact your supplier.
Any display Series connection fault.
AL 15 – AL 16 Reserved. Contact your supplier. flashing . Connection fault between micro-console and ACS 100.
Note : Alarm codes (*) will be displayed only if Note : Faults (*) where the red diode flashes are re-set
parameter 506 is set to 1 (Yes). by switching power off and then switching it back
on. Other faults are re-set by pressing on the
START/STOP button.

9. TELEMECANIQUE FREQUENCY DRIVER
Frequency driver used : 9.1.2 Control Terminals :
TELEMECANIQUE ATV11 PU12M2E (9132017)

- Output nominal current = 3A.
- Output maximum current = 4.5A.
- Maximum power = 550 W.
9.1 Connections
RC – RA : Fault relay contact : Open if there is a fault or the drive
9.1.1 Power Terminals :
is off.
9.1.1.1 Power Terminals : OV : I/O common OV
Ai 1 : Voltage analog input Analog input : 0-5V or 0-10V
+5V : Power supply Reference potentiometer : 2.2 to
10kΩ (Max current available : 10 mA).
DO : Output which can be configured as
analog or logic input.
Li 1 – Li 2 - Li 3 – Li 4 : Programmable logic inputs. Power supply +15 V (max 30V)
State 0 if < 5V - State 1 if > 11V.
+15V : Logic input power supply
Translation Glue Tank Translation Glue Tank

RC -> 703 Grey 713 L1 -> 012 Grey 004 (Power supply)
RA -> 704 Orange 714 L2 -> 013 Grey 005 (Power supply)
0V -> 707 Black 717
AI1 -> 706 Grey 716 T1 -> 059 Grey 049 (To motor)
LI1 -> 701 Grey 711 T2 -> 058 Grey 048 (To motor)
LI2 -> 702 Grey 710 T3 -> 057 Grey 047 (To motor)
LI3 -> 700 Grey 712
Please don’t forget connecting ground Yellow/Green on left terminal of L1 and L2.
Black wire 705 (translation)/715 (glue tank) must be disconnected and isolated
(see wiring diagrams 1-20: Translation).

9.1.3 Wiring diagrams :
• Power Supply :
• Inputs and Outputs :

To the PLC
To the PLC

OR
M OT OR
MOT
TI ON
rdy LA NK
S TA
AN UE
TR GL
ENT
ACC Value 0.1 0.1
Page 7 - 127
ENT
dEC Value 0.2 0.2
ENT
Wiring Diagrams
LSP Value 0 0
ENT
HSP Value 60 60
ENT
ItH Value 1.8 1.3
ENT
SP2 Value 5 10
xxx
xxx
SP3
xxx ESC ESC
9.2 General description of the menu
xxx xxx xxx xxx

SP4
ENT ENT
Ait ACt Value 10U 10U
ENT ENT
drC UnS Value 230 230
ENT
FrS Value 50 50
ENT
StA Value 12 12
ENT
FLG Value 25 25
Initial issue: 04/04

ENT
UFr Value 50 50
Latest revision: 06/07

ENT
nCr Value 2.3 1.2
ENT
CLI Value 4.5 3
ENT
nSL Value 3.6 2.8
ENT
SLP Value 100 100
ENT
COS Value 0.77 0.76
ENT ENT ENT

Fun tCC ACt Value 2C 2C
ENT
SUP tCt Value trn trn
ENT
rrS Value Li 2 Li 2
ENT ENT
PS2 LIA Value Li 3 Li 3
ENT
HSP LIB Value Li 4 Li 4
TLS
Note : The others parameters are
adjusted with factory settings.
9.3 Parameters of the frequency driver
9.3.1 First level adjustment parameters :
Code Description Adjustment range Factory setting

bFr Motor frequency 50 Hz 50 (E range)
or or
60 Hz 60 (U range)
This parameter is only visible the first time the drive is switched on.
It can be modified at any time in the FUn menu.
Displays the drive status XXX A C C Acceleration ramp time 0.1 s to 99.9 s 3
Range: 0 Hz to motor nominal frequency FrS (parameter in drC menu).
ESC
1st level dEC Deceleration ramp time 0.1 s to 99.9 s 3
bFr adjustment Range: motor nominal frequency FrS (parameter in drC menu) to 0 Hz.
parameters
LSP Low speed 0 Hz to HSP 0
Motor frequency to 0.
ESC HSP High speed LSP to 200 Hz = bFr
Menu: Motor control Motor frequency to max. reference.
drC Check that this setting is appropriate for the motor and the application.
ItH Motor thermal current 0 to 1.5 In (1) According to drive
ESC
Menus rating
Menu: Application functions Fun Current used for motor thermal protection. Set ItH to the nominal current marked on the motor rating
plate.
The memory of the motor thermal state returns to zero when the drive is switched off.
ESC
Menu: Monitoring SUP SP2 2nd preset speed (2) 0.0 to 200 Hz 10
SP3 3rd preset speed (2) 0.0 to 200 Hz 25
SP4 4th preset speed (2) 0.0 to 200 Hz 50
Ait Configuration of the analog input 5U, 10U, 0A, 4A 5U
- 5 V : voltage 0 - 5 volts (internal power supply)
- 1 0 V : voltage 0 - 10 volts (external power supply)
- 0 A : current 0 - 20 mA
- 4 A : current 4 - 20 mA
(1) In = nominal drive current
(2) The preset speeds only appear if the corresponding function has remained at the factory setting or has been
reconfigured in the FUn menu.

9.3.2 Motor Control Menu : drC
The parameters in clear boxes can only be modified when the drive is stopped and locked
Parameters in shaded boxes can be modified with the drive operating or stopped.
Value Nominal motor voltage

Drive performance can be optimised by entering the values marked on the motor rating plate
Code Description Adjustment range Factory setting
U n S Nominal motor voltage marked on the rating plate. 100 to 500 V Acc. to rating
FrS Nominal motor frequency marked on the rating plate. 40 to 200 Hz 50 / 60Hz dep. on
bFr
StA Frequency loop stability 0 to 100% when 20
stopped
1 to 100% when
Value Motor nominal cosine ϕ operating
Value too high: lengthening of response time
Value too low: overspeed, possible instability.
F L G Frequency loop gain 0 to 100% when 20
stopped
1 to 100% when
operating
Value too high: overspeed, instability.
Value too low: lengthening of response time
UFr IR compensation 0 to 200% 50
Used to optimise the torque at very low speed, or to
adapt to special cases (example: for motors connected
in parallel, lower UFr).
nCr Nominal motor current marked on the rating plate 0.25 to 1.5 In (1) Acc. to rating
CLI Limiting current 0.5 to 1.5 In (1) 1.5 In
nSL Nominal motor slip 0 to 10.0 Hz Acc. to rating
Calculate using the formula: nSL = parameter FrS x (1 - Nn/Ns)
Nn = nominal motor speed marked on the rating plate
Ns = motor synchronous speed
SLP Slip compensation 0 to 150% (of nSL) 100
Used to adjust the slip compensation around the value set by the nominal motor slip nSL, or to adapt
to special cases (example: for motors connected in parallel, lower SLP).
C O S Nominal motor cosine j marked on the rating plate 0.50 to 1.00 Acc. to rating
(1) In = nominal drive current

9.3.3 Application functions menu : Fun
The parameters in clear boxes can only be modified when the drive is stopped and locked.
Parameters in shaded boxes can be modified with the drive operating or stopped.
Code Description Factory setting

tCC Type of control
A C t 2 C = 2-wire control 2C
3 C = 3-wire control
2-wire control: The open or closed state of the input controls the running
or stopping.
+15 V LI1 LIx
Example of wiring:
ENT ESC LI1: forward
Type of control LIx: reverse
FUn tCC 3-wire control (pulse control): a "forward" or "reverse" pulse is sufficient to
ESC ENT
command starting, a "stop" pulse is sufficient to command stopping.
Example of wiring: +15 V LI1 LI2 LIx
ESC ESC LI1: stop
FCS Reminder of the configuration LI2: forward [ [ [
ENT
LIx: reverse
To change the assignment of tCC press the "ENT" key for 2 s. This
causes the following functions to return to factory setting: rrS, tCt,
Atr, PS2 (LIA, LIb).
t C t Type of 2-wire control trn
(parameter can only be accessed if tCC = 2C):
L E L : state 0 or 1 is taken into account for running or stopping.
t r n : a change of state (transition or edge) is necessary to initiate operation,
in order to prevent accidental restarts after a power supply interruption.
P F O: same as LEL, but the "forward" input always takes priority over the
"reverse" input.
rrS Reverse if tCC = 2C: LI2
n O : function inactive if tCC = 3C: LI3
LII to L I 4 : choice of the input assigned to the reverse command
PS2 Preset speeds
If LIA and LIb = 0: speed = reference on AI1
If LIA = 1 and LIb = 0: speed = SP2
Assignment of input LIA if tCC = 2C: LI3
- n O : function inactive if tCC = 3C: LI4
- L I I to L I 4 : choice of the input assigned to LIA
Assignment of input LIb if tCC = 2C: LI4
- n O : function inactive if tCC = 3C: nO
- L I I to L I 4 : choice of the input assigned to LIb
SP2 is only accessible if LIA is assigned, SP3 and SP4 if LIA and LIb are
assigned.
S P 2 2nd preset speed, adjustable from 0.0 to 200 Hz (1) 10
S P 3 3rd preset speed, adjustable from 0.0 to 200 Hz (1) 25
S P 4 4th preset speed, adjustable from 0.0 to 200 Hz (1) 50
(1) The preset speeds can also be accessed in the 1st level adjustment parameters.

Code Description Factory setting
Code Description Factory setting Catch on the fly nO
FLr
rSF Fault reset nO Enables a smooth restart if the run command is maintained after the
- n O : function inactive following events:
- L I I to L I 4 : choice of the input assigned to this function - loss of line supply or disconnection
- fault reset or automatic restart
The reset takes place at a transition on the input (rising edge: 0 to 1). It is - freewheel stop.
only authorised if the fault has disappeared. The motor resumes from the estimated speed at the time of the restart
rP2 Second ramp then follows the ramp to the reference speed.
LI Assignment of the 2nd ramp control input nO This function requires 2-wire control (tCC = 2C) with tCt = LEL or PFO.
n O : function inactive
- n O : function inactive Y E S : function active
- L I I to L I 4 : choice of assigned input The function intervenes at each run command, resulting in a slight delay
AC2 and dE2 are only accessible if LI is assigned. (1 second max.).
If continuous automatic injection braking has been configured (Ct) this
A C 2 2nd acceleration ramp time, adjustable from 0.1 to 99.9 s 5.0
function cannot be activated.
d E 2 2nd deceleration ramp time, adjustable from 0.1 to 99.9 s 5.0
dO Analog/logic output DO
StP Controlled stop on loss of line supply nO A C t Assignment rFr
- n O : locking of the drive and freewheel stopping of the motor - n O : not assigned
- F r P : stop according the valid ramp (dEC or dE2) - O C r : analog output = current in the motor. The full signal corresponds
- Y E S : fast stop, the stopping time depends on the inertia and the braking to 200% of the nominal drive current.
ability of the drive. - r F r : analog output = motor frequency. The full signal corresponds to
100% HSP.
brA Deceleration ramp adaptation YES - F t A : logic output = frequency threshold reached, closed (state 1) if the
- n O : function inactive motor frequency exceeds the adjustable threshold Ftd.
- Y E S : This function automatically increases the deceleration time, if this - S r A : logic output = reference reached, closed (state 1) if the motor
has been set at too low a value for the inertia of the load, thus avoiding the frequency is equal to the reference.
overvoltage fault. - C t A : logic output = current threshold reached, closed (state 1) if the
motor current exceeds the adjustable threshold Ctd.
AdC Automatic DC injection Ftd is only accessible if ACt = FtA, Ctd is only accessible if ACt = CtA.
A C t Operating mode YES F t d frequency threshold, adjustable from 0 to 200 Hz = bFr
- n O : function inactive C t d current threshold, adjustable from 0 to 1.5 In (In = nominal drive current) In
- Y E S : DC injection on stopping, duration adjustable via tdC, when Atr Automatic restart nO
operation is no longer controlled and the motor speed is zero. The value - n O : function inactive
of this current can be adjusted via SdC. - Y E S : Automatic restart, after locking on a fault, if the fault has disappeared
- C t : Continuous DC injection on stopping, when operation is no longer and the other operating conditions permit the restart. The restart is performed
controlled and the motor speed is zero. The value of this current can be by a series of automatic attempts separated by increasingly long waiting
adjusted via SdC. periods: 1 s, 5 s, 10 s, then 1 min for the following periods. If the restart has
not taken place after 6 min, the procedure is aborted and the drive remains
In 3-wire control the injection is only active when LI1 is at 1.
locked until it is disconnected and then reconnected.
tdC is only accessible if ACt = YES, SdC if ACt = YES or Ct. The following faults permit this function: OHF, OLF, ObF, OSF, PHF.
t d C Injection time on stopping, adjustable from 0.1 to 30.0 s 0.5 The drive fault relay remains activated if this function is active. The speed
S d C Injection current, adjustable from 0 to 1.2 In (In = nominal drive current) 0.7 In reference and the operating direction must be maintained.
This function is only accessible in 2-wire control (tCC = 2C) with tCt = LEL
SFt Switching frequency or PFO.
A C t Frequency range LF Check that an accidental start does not present any danger to
- L F r : random frequency around 2 or 4 kHz according to SFr personnel or equipment.
- L F : fixed frequency of 2 or 4 kHz according to SFr bFr Motor frequency 50 (E range)
- H F : fixed frequency of 8, 12 or 16 kHz according to SFr (Same as bFr 1st level adjustment parameter) or
Set to 50 Hz or 60 Hz, taken from the motor rating plate. 60 (U range)
S F r Switching frequency: 4
- 2 : 2 kHz (if ACt = LF or LFr) (if ACt = LF or LFr) IPL Line phase loss fault configuration YES
- 4 : 4 kHz (if ACt = LF or LFr) 12 This parameter is only accessible on 3-phase drives.
- n O : inhibition of the line phase loss fault
- 8 : 8 kHz (if ACt = HF) (if ACt = HF) - Y E S : monitoring of the line phase loss fault
- 12 : 12 kHz (if ACt = HF)
SCS Configuration backup nO
- 16 : 16 kHz (if ACt = HF)
- n O : function inactive
When SFr = 2 kHz, the frequency automatically changes to 4 kHz at high - Y E S : saves the current configuration to the EEPROM memory. SCS
speed. automatically switches to nO as soon as the save has been performed.
When SFt = HF, the selected frequency automatically changes to the This function is used to keep another configuration in reserve, in addition
lower frequency if the thermal state of the drive is too high. It automatically to the current configuration. When drives leave the factory the current
returns to the SFr frequency as soon as the thermal state permits. configuration and the backup configuration are both initialised to the
factory configuration.

9.3.4 Monitoring Menu : SUP
Code Description Factory setting ENT ESC
SUP FrH Value Frequency reference

FCS Reminder of the configuration nO ESC ENT
- n O : function inactive
- r E C : the current configuration becomes identical to the backup
configuration previously saved by SCS. rEC is only visible if the backup ESC ESC
Drive thermal state
has been carried out. FCS automatically switches to nO as soon as this tHd Value
ENT
action has been performed.
- l n l : the current configuration becomes identical to the factory setting.
FCS automatically switches to nO as soon as this action has been When the drive is running, the value displayed is that of one of the monitoring parameters. The default value
performed. which is displayed is the motor reference (parameter FrH).
For rEC and InI to be taken into account the ENT key must be
held down for 2 s. While the value of the required new monitoring parameter is being displayed, the "ENT" key must be pressed
a second time to confirm the change of monitoring parameter and to store it. From then on the value of this
parameter will be displayed during operation (even after the drive has been switched off).
If the new choice is not confirmed by pressing the "ENT" key for a second time, the drive will return to the
previous parameter after it has been switched off.
The following parameters can be accessed, with the drive stopped or running.
Code Parameter Unit
FrH Display of the frequency reference (factory configuration) Hz
rFr Display of the output frequency applied to the motor Hz
LCr Display of the motor current A
ULn Display of the line voltage V
tHr Display of the motor thermal state: 100% corresponds to the nominal thermal state. %
Above 118%, the drive trips on an OLF fault (motor overload). It can be reset below 100%.
tHd Display of the drive thermal state: 100% corresponds to the nominal thermal state. %
Above 118%, the drive trips on an OHF fault (drive overheating). It can be reset below 80%.

9.4 Faults - Causes - Remedies
Starter does not start, no fault displayed
• Check that the run command input(s) have been actuated in accordance with the chosen control mode.
• When the drive is switched on, at a manual fault reset, or after a stop command, the motor can only be
powered once the "forward" and "reverse" commands have been reset. If they have not been reset, the drive
will display "rdY" or ìnStî but will not start.
Faults displayed
The cause of the fault must be removed before resetting.
Faults SOF, OHF, OLF, OSF, ObF, and PHF can be reset via a logic input if this function has been configured.
Faults OHF, OLF, OSF, ObF, and PHF can be reset via the automatic restart function, if this function has been
configured. All faults can be reset by switching the drive off then on again.
Fault Remedy
OCF • Ramp too short, check the settings.
overcurrent • Inertia or load too high, check the size of the motor/drive/load.
• Mechanical locking, check the state of the mechanism.
SCF • Check the cables connecting the drive to the motor, and the insulation of the motor.
motor short-circuit,
insulation fault
InF • Check the environment (electromagnetic compatibility).
internal fault • Replace the drive.
CFF • Return to factory settings or call up the backup configuration, if it is valid. See
configuration fault parameter FCS in the FUn menu.
SOF • Instability, check the motor, gain and stability parameters.
overspeed • Driving load too high, add a braking module and resistor and check the size of the
motor / drive / load.
OHF • Check the motor load, the drive ventilation and the environment. Wait for the drive to
drive overload cool before restarting.
OLF • Check the setting of the motor thermal protection, check the motor load. Wait for the
motor overload drive to cool before restarting.
OSF • Check the line voltage.
overvoltage
ObF • Braking too harsh or driving load. Increase the deceleration time, add a braking
overvoltage resistor if necessary and activate the brA function if it is compatible with the
during deceleration application.
PHF This protection only operates with the drive on load.
line phase failure • Check the power connection and the fuses.
• Reset.
• Check the line supply / drive compatibility.
• If there is an unbalanced load, inhibit the fault via IPL = nO (FUn menu).
USF • Check the voltage and the voltage parameter.
undervoltage
CrF • Replace the drive.
charging circuit

9.5 Programmation of the frequency driver
LI 1 - Fwd LI 2 - Rev LI 3 - X1 ACTION

0 0 0 Stop
1 0 0 Start FWD
0 1 0 Start REV
1 1 0
1 0 1 FWD à 5 Hz
0 1 1 REV à 5 Hz
0 0 1 Stop
1 1 1
LI 1 : Start Fwd
LI 2 : Start Rev
LI 3: Constant frequency = 5 Hz.
Attention : The frequency inverter does not stop if LI 1

and LI 2 = 1.

NOTES
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BB3002 EVA & PUR Wiring Diagrams PDF

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BB3002 EVA & PUR Wiring Diagrams PDF

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SERVICE

Initial issue: 02/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

1. Wiring diagrams ..........................................................................................................................................1

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

1.1 Diagram block

* Only for BB3002 EVA

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

* Only for BB3002 EVA 9133813D/9134119-

Wiring Diagrams Initial issue: 04/04

* Only for BB3002 EVA 9133813F/9134119-

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

* Only for BB3002 EVA

Wiring Diagrams Initial issue: 04/04

* Only for BB3002 EVA

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

* Only for BB3002 EVA

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

* Only for BB3002 EVA Only for BB3002 PUR

Wiring Diagrams Initial issue: 04/04

* Only for BB3002 EVA * Only for BB3002 EVA

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04

Wiring Diagrams Initial issue: 04/04