Electrical Diagrams Komax Alpha 433

Bitte legen Sie dieses Schema in Ihrer
Betriebsanleitung ab.
Please file these diagrams in your

operating instructions.
Elektroschemasatz
Electrical diagrams
Crimpvollautomat
Fully automatic crimping machine
Alpha 433
Gültig ab Maschinen Nummer:

Valid from machine number:
647
Elektroschemasatz/Electrical diagrams Alpha 433 - Version 6 1

Art. Nr. 0025280 - Version 6
Herausgeber
Komax AG
Industriestrasse 6
CH-6036 Dierikon - Luzern
Telefon +41 41 455 0 455

Telefax +41 41 450 4 266
Email info.din@komaxgroup.ch
Internet www.komaxgroup.ch
Stand Juni 2006, Änderungen vorbehalten
Der Nachdruck dieser Liste, auch auszugsweise, gleichgültig in welcher Form, ist ohne aus-
drückliche, schriftliche Genehmigung des Herausgebers verboten.
Gegenüber Darstellungen und Angaben in dieser Liste sind technische Änderungen, die zur
Verbesserung der Maschine notwendig werden, vorbehalten.
Publisher
Komax AG
Industriestrasse 6
CH-6036 Dierikon - Luzern
Phone +41 41 455 0 455

Fax +41 41 450 4 266
Email info.din@komaxgroup.ch
Internet www.komaxgroup.ch
As of June 2006, subject to change
Reproduction of this list or parts hereof, in any form whatsoever, is prohibited without the
express written permission of the publisher.
The representations and information in this list are subject to technical changes required to
improve the machine.
© 2006 by Komax AG, Wire Processing Systems lua
2 Elektroschemasatz/Electrical diagrams Alpha 433 - Version 6

Inhaltsverzeichnis / Table of contents
Bezeichnung Description Blatt Nr. /Sheet No.
Elektroschemasatz ............................................... Electrical schematics ................................................... 1

Haupteinspeisung, Transformator ......................... Main power, transformer ........................................... 100
Peripherie, 3-Phasen Landesspannung ................ Periphery, 3-phase national voltage .......................... 101
Speisung Motorregler N1 - N6 .............................. Power supply motor regulators N1 - N6 .................... 102
Kontrollkreis Motorregler N1 - N6 ......................... Control circuit motor regulators N1 - N6 .................... 103
Motorregler N1 - N6; Netzwerk RS485 .................. Motor regulators N1 - N6; network RS485 ................. 104
Motor 1 + 2; Schwenk-/Abzugseinheit Seite 1 ...... Motor 1 + 2; swivel/pull-off unit side 1 ...................... 105
Motor 3 + 4; Schwenk-/Abzugseinheit Seite 2 ...... Motor 3 + 4; swivel/pull-off unit side 2 ...................... 106
Motor 5; Schneidkopf ........................................... Motor 5; knife unit ..................................................... 107
Motor 6; Bandantrieb A, Encoder von N6 ............. Motor 6; belt drive A, encoder of N6 ......................... 108
Speisung Wärmetauscher 24VDC ........................ Power supply heat exchanger 24VDC ....................... 112
Speisung Computer 220VAC ................................ Power supply computer 220VAC ............................... 113
Peripherie 1-Phase 230VAC, 24VDC ..................... Periphery 1-phase 230VAC, 24VDC ........................... 114
Not-Aus-Kreis, Lastspannung, Emergency stop circuit, on-load voltage,
Sicherheitsrelais K5, Hauptventil ......................... safety relay K5, main valve ....................................... 115
Signallampe Power on/off .................................... Indicator lamp power on/off ...................................... 116
RCS Haube, Rückmeldung RSA extern ................ RCS cover, feedback signal RSA external ................. 117
RCS Haube, Zustimmtaste .................................. RCS cover, confirm button ........................................ 118
BIO, Speisung BIO, Eingang 0-2 .......................... BIO, power supply BIO, input 0-2 ............................. 119
BIO, Eingang 3-7 .................................................. BIO, input 3-7 ........................................................... 120
BIO, Eingang 8-12 ................................................ BIO, input 8-12 ......................................................... 121
BIO, Eingang 13-17 .............................................. BIO, input 13-17 ....................................................... 122
BIO, Eingang 18-22, Fast input 18/19 ................... BIO, input 18-22, fast input 18/19 ............................. 123
BIO, Fast input 38/39, Analog input, Spleiss ........ BIO, fast input 38/39, analog input, splice ................ 127
BIO, Ausgang 0-15, Ventilbatterie ........................ BIO, output 0-15, valve group ................................... 128
BIO, Ausgang 0- 3, Ventilbatterie ......................... BIO, output 0-3, valve group ..................................... 129
BIO, Ausgang 4-7, Ventilbatterie .......................... BIO, output 4-7, valve group ..................................... 130
BIO, Ausgang 8-11, Ventilbatterie ........................ BIO, output 8-11, valve group ................................... 131
BIO, Ausgang 12-14, Ventilbatterie ....................... BIO, output 12-14, valve group ................................. 132
BIO, Ausgang 16-18 ............................................. BIO, output 16-18 ..................................................... 133
BIO, Ausgang 19-23 ............................................. BIO, output19-23 ...................................................... 134

Bezeichnung Description Blatt Nr. /Sheet No.

BIO/RCS, Speisung RCS, BIO/RCS, power supply RCS,
Flachkabel BIO/RCS ............................................ flat cable BIO/RCS .................................................... 139
MRS CH0-CH4 (RS422) ........................................ MRS CH0-CH4 (RS422) ............................................. 140
MRS CH5-CH9 (RS422) ........................................ MRS CH5-CH9 (RS422) ............................................. 141
MRS CH10-CH14 (RS422) .................................... MRS CH10-CH14 (RS422) ......................................... 142
MRS, Speisung MRS, Verbindung zu PCC ........... MRS, power supply MRS, connection with PCC ....... 143
PC Systemeinheit................................................. PC system unit ......................................................... 144
Übersicht Regler N1-N6 ....................................... Overview regulators N1-N6 ....................................... 145
Übersicht BIO, RCS, MRS ................................... Overview BIO, RCS, MRS ......................................... 147
Option 3-Phase Landesspannung für Option 3-phase national voltage for
Nicht mci-Pressen ............................................... non-mci presses ....................................................... 148
Verdrahtung Stationen .......................................... Equipment wiring ............................................... 149/150

Umfang des Elektroschemasatzes
Einführung 6 Seiten, durchgehend numeriert von Seite 1 bis 6
Schemas 48 Seiten, durchgehend numeriert von Seite 100 bis 150
Weitere Blätter - Modifizierungen bei einem Spannungswechsel 2 Seiten
- Relais Ausgänge / I/O-Beschaltung 3 Seiten
- Haubenschalter und ihre Zustände 3 Seiten
Bemerkungen
Litzenfarben Funktion
grün-gelb Schutzleiter
hellblau Neutralleiter
grau Hauptstromkreise Wechsel-/Gleichstrom
rot Steuerstromkreise mit Wechselstrom
rosa Steuerstromkreise mit Gleichstrom
orange Verriegelungsstromkreise mit externer Stromquelle
Volume of these diagrams

Introduction 6 pages, numbered consecutively from page 1 to 6
Diagrams 48 pages, numbered consecutively from page 100 to 150
Further sheets - Modifications when changing the voltage 2 pages
- Relay outputs / I/O control 3 pages
- Cover switches and their status 3 pages
Remarks
Strand color Function
green-yellow Protective conductor
light-blue Neutral conductor
grey Main circuits AC/DC
red Control circuits AC
pink Control circuits DC
orange Locking circuits with external supply

1 .0 1 .1 1 .2 1 .3 1 .4 1 .5 1 .6 1 .7 1 .8 1 .9
A A
ELEKTROSCHEMASATZ
B B
Electrical schematics
C C
Fuer dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte vor. Vervielfaeltigung, Bekanntgabe an Dritte oder Verwendung
seines Inhaltes sind ohne ausdrueckliche Zustimmung verboten. Komax AG SCHWEIZ
D
ALPHA 433 D
Litzenfarbe Funktion
GRUENGELB Schutzleiter
E HELLBLAU Neutralleiter E
GRAU Hauptstromkreise Wechsel/Gleichstrom
ROT Steuerstromkreise mit Wechselstrom
ROSA Steuerstromkreise mit Gleichstrom
ORANGE Verriegelungsstromkreise mit externer Stromquelle
We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without express authority
is strictly forbidden. Komax AG SWITZERLAND
F F
Created: 12.12.05 File Name: SCHD00035193

Machine type: A433 Sheet Description: Diagram Description:
Changed:
Index: 005 Status: Serie Released: ik Total Sheet: 48 SheetNr: Next Sheet:
Serial Nr.: 647 xxx Doc.Nr: D00035193 1 100
Used in ArtNr: 0025280 Language: Deutsch
1 .0 1 .1 1 .2 1 .3 1 .4 1 .5 1 .6 1 .7 1 .8 1 .9
100 .0 100 .1 100 .2 100 .3 100 .4 100 .5 100 .6 100 .7 100 .8 100 .9
L1_Q2
/101.0
X97:102
L2_Q2
/101.0
X97:104
A L3_Q2 A
/101.0
X97:106
.5 /101.8
N_Q1
/101.8 /102.0
X620:106 /102.2
X97 401 403 405
PE /112.6
/112.9
/113.5
/113.7
X200 102 X97 101 X97 103 X97 105 /115.8
1 3 5
Q2
022960
Leitungsschutzschalter LP3D32T X200 104 X200 105 X200 106 X200 108 X200 103
Line safety switch 230/400VAC When changing
32A 2 4 6 Connection Bridge between...
B input voltage B
from main power +20V 0V 20V
PE PE PE PE Refer to manual!
230 VAC 250 VAC 230 VAC 210 VAC
Beim Wechsel
PE1 PE2 PE3 PE4 400 VAC 420 VAC 400 VAC 380 VAC der Eingangspannung
2 4 6 8 Handbuch kontaktieren
460 VAC 480 VAC 460 VAC 440 VAC
Montage Boden Tuer Maschine
Platte
Q1
024450 X200 101
Hauptschalter H240
Main switch 40A Mounting Base Door machine
1 3 5 7 plate plate PE 460 400 230 460 400 230 460 400 230
+20V
0V
20V
+20V
0V
20V
+20V
0V
20V
L1
L2
L3
N
PE
C L1 L2 L3 C
T1
024785
Trafo 3Ph
1*120VAC
5,65kVA
Transformer
Z1
024366 3*230VAC L1 L2 L3 3*400VAC L1 L2 L3
Netzfilter B84131M1G135 0V 2,7kVA 230 230 230 2,7kVA 400 400 400 120 0V PE
250440VAC
35A
Net filter
D D
X100 404
F104
10AT
000545
Schmelzsicherung /Fuse
Sicherungklemme ASK1
L1
L2
L3
002149
PE
X100 104
X96 401 402 403 404 405 16A 2 4 6
230/400VAC
Leitungsschutzschalter LP3D16T
Line safety switch 022962
Q4
1 3 5 X102 101 X103 102
E E
X96 101 102 103 104 105
MAIN POWER
L1_Q4
L2_Q4
L3_Q4
230V_L1
230V_L2
230V_L3
120V_T1
N_T1
K2:1
K2:3
K2:5
MAIN POWER HAUPTEINSPEISUNG
X100:401
X100:402
X100:403
/102.0
/102.0
/102.0
/112.0
/113.0
/114.0
/113.3
/112.0
6mm^2 6,0kVA
(with two MCI 711
and two MCI 761)
F F

Machine type: A433 Sheet Description: Main power Diagram Description:
Changed:
Transformer
100 .0 100 .1 100 .2 100 .3 100 .4 100 .5 100 .6 100 .7 100 .8 100 .9
101 .0 101 .1 101 .2 101 .3 101 .4 101 .5 101 .6 101 .7 101 .8 101 .9
L3_Q2
/100.9
L2_Q2
A /100.9 A
PE
L1_Q2 /100.9
/100.9
X200 107
X97 102 104 106 N_Q1
/100.9
Q1:8
16A 2 4 6
230/400VAC
Leitungsschutzschalter LP3C16T
Line safety switch 022961
Q3
/115.9 1 3 5
B K1 1 3 5 B
2 4 6
/115.8
53 63 73
wiring mci711
K2h 54 64 74 Refer to manual
.6
/115.9 /115.9 /115.9
X600 2 4 6 8
C X600 1 3 5 7 C
2 4 6
/134.1
K6 1 3 5
/134.2
D D
X620 105 205 305 X600 101 201 301 X600 102 202 302 X600 103 203 303 X600 104 204 304 X620 106 107
1 3 5
.4 .5 .8
Q5
024548 X620 X600 X600 X600 X600
Motorschutzschalter
Motor protecting switch
E X620 1L1 1L2 1L3 5PE X600 1L1 1L2 1L3 PE X600 2L1 2L2 2L3 1PE X600 3L1 3L2 3L3 3PE X600 4L1 4L2 4L3 4PE X620 N 6PE E
2 4 6
L1_RCS
L2_RCS
L3_RCS
Earth
Option
Foerderband
Neutral
Foerderband Module 3Phase Module 3Phase Module 3Phase

K_BIO:2 Option
K_BIO:4 Option
K_BIO:6 Option
Grundmodul Verlaengerung
/148.1
/148.1
/148.1
N_RCS
F Conveyer belt Conveyer belt F
X599:105
main extension Module

/148.8

Machine type: A433 Sheet Description: Periphery Diagram Description:
Changed:
3xPhase national voltage
101 .0 101 .1 101 .2 101 .3 101 .4 101 .5 101 .6 101 .7 101 .8 101 .9
102 .0 102 .1 102 .2 102 .3 102 .4 102 .5 102 .6 102 .7 102 .8 102 .9
L3_Q4 PE
/100.5 /100.9
A Q4:5 L2_Q4 A
/100.5
Q4:3 L1_Q4 /115.9
/100.5
Q4:1
K2 1 3 5
/115.8
2 4 6
2 4 6
K3 1 3 5
X107 101 103 105

PE
B /100.9 B
.1
X200 115 X107 401 405 X107 402 406 X200 116 X107 302 306 X200 117 X107 201 205 X200 118
403 404 304 203
C C
2 4 6 8 10 2 4 6 8 10 2 4 6 8 10 2 4 6 8 10
X2N1 1 3 5 7 9 X2N3 1 3 5 7 9 X2N5 1 3 5 7 9 X2N6 1 3 5 7 9
1
1
1
1
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
10
10
10
10
/145.2 SwivelUnit /145.4 SwivelUnit /145.7 Knife_Unit /145.8 Wire_Drive

1 2 A
N1 N3 N5 N6
D D
2 4 6 8 10 2 4 6 8 10
X2N2 1 3 5 7 9 X2N4 1 3 5 7 9
E E
1
1
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
10
10
/145.3 Pull_off /145.6 Pull_off
1 2
N2 N4
F F

Machine type: A433 Sheet Description: Power supply Diagram Description:
Changed:
Motor regulator N1N6
102 .0 102 .1 102 .2 102 .3 102 .4 102 .5 102 .6 102 .7 102 .8 102 .9
103 .0 103 .1 103 .2 103 .3 103 .4 103 .5 103 .6 103 .7 103 .8 103 .9
Reg_0VDC
/112.9
X105:203
A Reg_24VDC A
/112.7
X104:203
NOT_REG
/135.1
/135
X106:113
X106 213
Setup_aktiv
/103.5
X5N6:8
X5N1 1 3 5 7 9 11 13 X5N2 1 3 5 7 9 11 13 X5N3 1 3 5 7 9 11 13 X5N4 1 3 5 7 9 11 13

B B
2 4 6 8 10 12 14 2 4 6 8 10 12 14 2 4 6 8 10 12 14 2 4 6 8 10 12 14
1
1
1
1
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
11
11
11
11
10
12
13
14
10
12
13
14
10
12
13
14
10
12
13
14
/145.2 SwivelUnit /145.3 Pull_off /145 SwivelUnit /145 Pull_off

1 1 2 2
N1 N2 N3 N4
C C
D D
Setup_aktiv
/103.1
X5N1:5
Reg_ok
/115.4
K5:33
X5N5 1 3 5 7 9 11 13 X5N6 1 3 5 7 9 11 13
E E
2 4 6 8 10 12 14 2 4 6 8 10 12 14
1
1
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
11
11
10
12
13
14
10
12
13
14
/145.7 Knife_Unit /145.8 Wire_Drive

A
N5 N6
F F

Machine type: A433 Sheet Description: Control circuit Diagram Description:
Changed:
Motor regulator N1N6
103 .0 103 .1 103 .2 103 .3 103 .4 103 .5 103 .6 103 .7 103 .8 103 .9
F
E
D
C
B
A
We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without express authority Fuer dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte vor. Vervielfaeltigung, Bekanntgabe an Dritte oder Verwendung
is strictly forbidden. Komax AG SWITZERLAND seines Inhaltes sind ohne ausdrueckliche Zustimmung verboten. Komax AG SCHWEIZ
104 .0
104 .0
N1
X3
/145.2
/145.2
Serial Nr.:
X4
N1
Machine type:
104 .1
104 .1
A433
647 xxx
N2
X4
104 .2
104 .2
/145.3
/145.3
X3
N2
NETWORK RS458
104 .3
104 .3
Sheet Description: Motor regulators N1N6
N3
X3
/145
/145
Doc.Nr:
X4
N3
104 .4
104 .4
Diagram Description:
D00035193
Used in ArtNr:
Index: 005
104 .5
104 .5
N4
X4
/145.6
/145.6
X3
N4
Status: Serie
0025280
104 .6
104 .6
Created:
Changed:
Released:
ik
N5
X3
/145
12.12.05
/145
104 .7
X4
104 .7
N5
File Name:
Total Sheet: 48
104 .8
104 .8
Language: Deutsch
N6
SCHD00035193
X4
/145.8
/145.8
X3
N6
SheetNr:
104
104 .9
104 .9
105
Next Sheet:
F
E
D
C
B
A
105 .0 105 .1 105 .2 105 .3 105 .4 105 .5 105 .6 105 .7 105 .8 105 .9
A N1 N2 A
Power Encoder Power Encoder
/145.2 /145.3
U2 V2 W2 PE /145 U2 V2 W2 PE /145.3
11
1
3
13
2
12
14
4
5
6
7
8
9
10
15
11
1
3
13
2
12
14
4
5
6
7
8
9
10
15
N1 N2
X1N1 2 3 4 1 X1N2 2 3 4 1
X6N1 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15 X6N2 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15
B B
C C
X6M1 11 3 2 14 5 7 9 15 X6M2 11 3 2 14 5 7 9 15
1 13 12 4 6 8 10 1 13 12 4 6 8 10
U V W PE 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15 U V W PE 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15
A+
A
B+
B
NP+
NP
+5V
GND
Schirm
U+
U
V+
V
W+
W
A+
A
B+
B
NP+
NP
+5V
GND
Schirm
U+
U
V+
V
W+
W
D D
PE PE
MS RX MS RX
3~ .3 3~ .8
M1 M2
024844 024845
AC3Ph Servomotor .1 AC3Ph Servomotor .6
2000U/min 2500U/min
5,8Nm 1,8Nm
E M1 M2 E
024844 024845
AC3Ph Servomotor AC3Ph Servomotor
Schwenker 1 Abzug 1
Swivel unit 1 Pull off 1
F F

Machine type: A433 Sheet Description: Motor 1 + 2 Diagram Description:
Changed:
Swivel unit 1
Serial Nr.: 647 xxx Pull off 1 Doc.Nr: D00035193 105 106
105 .0 105 .1 105 .2 105 .3 105 .4 105 .5 105 .6 105 .7 105 .8 105 .9
106 .0 106 .1 106 .2 106 .3 106 .4 106 .5 106 .6 106 .7 106 .8 106 .9
A N3 N4 A
Power Encoder Power Encoder
/145.4 /145
U2 V2 W2 PE /145.4 U2 V2 W2 PE /145.6
11
1
3
13
2
12
14
4
5
6
7
8
9
10
15
11
1
3
13
2
12
14
4
5
6
7
8
9
10
15
N3 N4
X1N3 2 3 4 1 X1N4 2 3 4 1
X6N3 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15 X6N4 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15
B B
C C
X6M3 11 3 2 14 5 7 9 15 X6M4 11 3 2 14 5 7 9 15
1 13 12 4 6 8 10 1 13 12 4 6 8 10
U V W PE 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15 U V W PE 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15
A+
A
B+
B
NP+
NP
+5V
GND
Schirm
U+
U
V+
V
W+
W
A+
A
B+
B
NP+
NP
+5V
GND
Schirm
U+
U
V+
V
W+
W
D D
PE PE
MS RX MS RX
3~ .3 3~ .8
M3 M4
024844 024845
AC3Ph Servomotor .1 AC3Ph Servomotor .6
2000U/min 2500U/min
5,8Nm 1,8Nm
E M3 M4 E
024844 024845
AC3Ph Servomotor AC3Ph Servomotor
Schwenker 2 Abzug 2
Swivel unit 2 Pull off 2
F F

Machine type: A433 Sheet Description: Motor 3 + 4 Diagram Description:
Changed:
Swivel unit 2
Serial Nr.: 647 xxx Pull off 2 Doc.Nr: D00035193 106 107
106 .0 106 .1 106 .2 106 .3 106 .4 106 .5 106 .6 106 .7 106 .8 106 .9
107 .0 107 .1 107 .2 107 .3 107 .4 107 .5 107 .6 107 .7 107 .8 107 .9
A N5 A
Power Encoder
/145.7
U2 V2 W2 PE /145.7
N5
X1N5 2 3 4 1
X6N5 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15
B B
C C
X6M5 11 3 2 14 5 7 9 15
1 13 12 4 6 8 10
U V W PE 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15
A+
A
B+
B
NP+
NP
+5V
GND
Schirm
U+
U
V+
V
W+
W
D D
PE
MS RX
3~ .3
M5
024845
AC3Ph Servomotor .1
2500U/min
1,8Nm
E M5 E
024845
AC3Ph Servomotor
Messer
Knife unit
F F

Machine type: A433 Sheet Description: Motor 5 Diagram Description:
Changed:
Knife unit
107 .0 107 .1 107 .2 107 .3 107 .4 107 .5 107 .6 107 .7 107 .8 107 .9
108 .0 108 .1 108 .2 108 .3 108 .4 108 .5 108 .6 108 .7 108 .8 108 .9
A N6 A
Power Encoder Wire
/145.8 Encoder
U2 V2 W2 PE /145.8 /145.8
11
1
3
13
2
12
14
4
5
6
7
8
9
10
15
34
1
31
3
33
4
N6 N6
X1N6 2 3 4 1
X6N6 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15 X11 34 1 31 3 33 4
B B
C C
X6M6 11 3 2 14 5 7 9 15
1 13 12 4 6 8 10
U V W PE 11 1 3 13 2 12 14 4 5 6 7 8 9 10 15
+UB A A B B GND
A+
A
B+
B
NP+
NP
+5V
GND
Schirm
U+
U
V+
V
W+
W
D D
PE B2N6
MS 024881 TX
RX Encoder 1000Inc.
3~ .3
M6
024843
AC3Ph Servomotor .1
3000U/min
5,8Nm
E M6 E
024843
AC3Ph Servomotor
Kabelantrieb A
Wire drive A
F F

Machine type: A433 Sheet Description: Motor 6 Diagram Description:
Changed:
Wire drive A
Serial Nr.: 647 xxx Wire encoder of N6 Doc.Nr: D00035193 108 112
108 .0 108 .1 108 .2 108 .3 108 .4 108 .5 108 .6 108 .7 108 .8 108 .9
112 .0 112 .1 112 .2 112 .3 112 .4 112 .5 112 .6 112 .7 112 .8 112 .9
A A
N_T1 N_T1
/100.9 /113.0
X103:102
230V_L1
/100.7
T1:400
/100.9
/100.9
/100.9
PE
PE
.1 X103 302 X103 202

B B
X102 302 X102 202
X200 112 X200 114
X100 401
P N PE
E1
E1
E1
115/200240V PE
F101 AC
1,50 mm2 schwarz
1,50 mm2 blau
1,50 mm2 gelbgrün
C G1 C
10AT 007533
000545 Stromversorgung AC/DC
24 VDC= Power supply
Schmelzsicherung
Sicherungklemme ASK1 Fuse DC
002149 24V
X100 101 P N PE
.9 +
X100 405 X200 09

E1
024336 Fan 1 Fan 2
X102 102 Waermetauscher 36,0 W/K
Heat exchanger
P P .5
F105
D N N .5 12,5AT D
PE .6 PE 006225
P N PE Schmelzsicherung
002149
X100 105
X102:402
/114.1 L1
E1
E1
E1
1,50 mm2 schwarz
1,50 mm2 blau
1,50 mm2 gelbgrün
X104 101 X105 101 X105 402

X200 113
/116.3
E X103 402 E
/136.9 /114
/100.9
X104 203 X105 203
Reg_24VDC
+24V_DC
0V_DC
Reg_0VDC
X5N1:11
X5N1:12
/103.1
/103.1
/115.0
/114.8
F F

Changed:
Heat exchanger
Serial Nr.: 647 xxx 24VDC = Power supply Doc.Nr: D00035193 112 113
112 .0 112 .1 112 .2 112 .3 112 .4 112 .5 112 .6 112 .7 112 .8 112 .9
113 .0 113 .1 113 .2 113 .3 113 .4 113 .5 113 .6 113 .7 113 .8 113 .9
N_T1 N_T1
/112.9 /114.0
230V_L2
/100.7
A T1:400 A
120V_T1 120V_T1
/100.8 /115.2
X102:101
/114.6
/100.9
/100.9
X103 403
PE
PE
X102 401 .1
/100.8 X102 403
X100 402 X200 119

B X200 111 X102 104/114.3 B
F102
X103 204
10AT
000545
X102 405
Schmelzsicherung
Sicherungklemme ASK1 Fuse
002149
Version 120V
X100 102
C C
X102 103
X102:203
/114.1 L2
D D
X20 L N PE X21 L N PE
A6 P N PE A7 P N PE
/144.2
E E
L2_PC
N_PC
PE_PC
L2_VGA
N_VGA
PE_VGA
A6:P
A6:N
A6:PE
X_VGA:L
X_VGA:N
X_VGA:PE
/144.0
/144.0
/144.0
/144.7
/144.7
/144.7
F Steckdose (Computer) Steckdose (Monitor) F
Computer socket Screen socket

Changed:
Computer 220VAC (Option 120VAC)
113 .0 113 .1 113 .2 113 .3 113 .4 113 .5 113 .6 113 .7 113 .8 113 .9
114 .0 114 .1 114 .2 114 .3 114 .4 114 .5 114 .6 114 .7 114 .8 114 .9
A N_T1 N_T1 A
/113.9 /115.7
230V_L3
/100.7
T1:400
X103 104 X103 103 X103 101
X100 403
F103
B 10AT 0V_DC 0V_DC B
000545 /112.9 /115.0
Schmelzsicherung
Sicherungklemme ASK1 Fuse
002149
X100 103 /113.1
L2
L1 /112.0
/113
X102 203 402
53 63 73
/115.7
C C
K1h 54 64 74
24V_K5
53 63 73
K3h 54 64 74 /115.8
/121.1
X106 407 X105 103

D D
X610 101 201 X610 102 202 X610 103 203 X610 104 204 X610 105 205 X610 106 206 X610 107 207 X610 108 208 X610 109 209 X610 110 210 X630 101 103
.2 .3 .6 .7
E X610 X610 X610 X610 X610 X610 X610 X610 X610 X610 E
X610 1L3 1N 1PE X610 2L3 2N 2PE X610 3L3 3N 3PE X610 4L3 4N 4PE X610 5L3 5N 5PE X610 6L2 6N 6PE X610 7L2 7N 7PE X610 8L2 8N 8PE X610 9L1 9N 9PE X610 10L1 10N 10PE X630 401 301 402 302 403 303 404 304
Module 1xPhase Auxiliary +24V DC 0V DC
F F

Machine type: A433 Sheet Description: Periphery Diagram Description:
Changed:
1xPhase 230VAC
Serial Nr.: 647 xxx 24VDC = (switched of K5) Doc.Nr: D00035193 114 115
114 .0 114 .1 114 .2 114 .3 114 .4 114 .5 114 .6 114 .7 114 .8 114 .9
115 .0 115 .1 115 .2 115 .3 115 .4 115 .5 115 .6 115 .7 115 .8 115 .9
+24V_DC +24V_DC
/112.8 /119.0
0V_DC 0V_DC
/114.9 /112.9
/116.1
A /112.8 A
X105 401
X104 401 402 X104 102

120V_T1 120V_T1
/113.4 /148.6
X102:301
X100 406
/116.1
/116.1
/100.8
S4:X1
X102 201
1AT
H4_K5
F106
24V_K5
Safety relay K5
K5
024629
NotAusRelais DUELCO NST3
24VDC
000553
Schmelzsicherung
Fuse
002149
X100 106
B 24V_K5 B
/114.8
41
42
X106:407
11 21
33
34
413
Reg_ok Reg_ready
/103.5 /120.5
X5N6:9 X106:313
S1
23
1
2
2
24
NotStoppPilz EAO
BX1 1
/112
Bedienpanel
X106 307
X106 207
X105 201
12 22
/121.1
/121.1
Emergency stop button
13
PE
14
Operator panel
BX1 PE
X106 102 101

B1
/147.5
043579
X200 110
Main valve
K1
Hauptventil
K2
K1.2
K2.2
X106 402 401
K1
.8
Contactor
110VAC
50/60H
C C
A1
A2
Wartungseinheit FRL3000
11 21
PE
K1.1
K2.1
S2
RC_K1
024653
NotStoppPilz EAO
A2
110VAC
280VAC
Kabelantrieb rechts
/100.9
12 22
RC snubber
Wire drive right side
RCGlied FSC280
A1
X106 302 301
K1
110VAC K1h
.7 54 53 /114.0
K2
.8
Contactor
110VAC
21 22 .3
64 63 /114.0
A1
A2
D X106 202 201 5 6 /101.2 D

74 73 /114.1
X2
3 4 /101.1
1 2 /101.1 84 83
X1
025437 025436
Schuetz 100C16KD01110V Hilfskontakt 100FA40
BV_B
X106 104 103
RC_K2
024653
110VAC
280VAC
K1 21
A1:39O
X106 106
RC snubber
K2 K2h
RCGlied FSC280
110VAC
/138.3
X106 404 403 .7 54 53 /101.1
22 21 22 .3 64 63 /101.1
5 6 /102.1
X106 406 74 73 /101.2
11 21 3 4 /102.1
22
84 83
K3
.8
Contactor
110VAC
1 2 /102.1
025436
A1
A2
S8 025437
Hilfskontakt 100FA40
Schuetz 100C16KD01110V
E K2 21 E
NotStoppPilz EAO 13
Kabelantrieb links
/116.5
12 22
Wire drive left side
Service conditions
S3 K3 K3h
Leuchttaster .7 54 53 /114.0
024653
110VAC
280VAC
RC_K2*1
X106:205 X106 304 303 Illuminated button 21 22 .3 64 63 /114.0

/122.3 14
RC snubber
NotStop POWER ON 5 6 /102.1
/138.3
RCGlied FSC280
74 73 /114.1
.9 3 4 /102.1
A1:O39
X106 204 203 1 2 /102.1 84 83
X103 201 025436

025437
BV_A
K3 21 X106 405 Hilfskontakt 100FA40
11 Schuetz 100C16KD01110V
/116.3
/114
F S4 22 F
Leuchttaster
Illuminated button X106 105 N_T1 N_T1
POWER OFF /114.9 /148.6
12 X103:203
Emergency stop circuit Created: 12.12.05 File Name: SCHD00035193

Onload voltage Changed:
Safety relay K5 Index: 005 Status: Serie Released: ik Total Sheet: 48 SheetNr: Next Sheet:
Serial Nr.: 647 xxx Main valve Doc.Nr: D00035193 115 116
115 .0 115 .1 115 .2 115 .3 115 .4 115 .5 115 .6 115 .7 115 .8 115 .9
116 .0 116 .1 116 .2 116 .3 116 .4 116 .5 116 .6 116 .7 116 .8 116 .9
24V_K5 24V_K5
A /115.7 /121.1 A
X106:107
H4_K5
/115.6
K5:42
X106 208
B B
/115.1 /115.3
C C
X1 X1
H4 H3
008357 008357
Signallampe 24V/50mA Signallampe 24V/50mA
POWER OFF POWER ON
X2 X2
0V_DC_Bed
/133.2
H23:X2
D D
X105 102
E E
0V_DC 0V_DC
/115.9 /119.0
X105:201
F F

Machine type: A433 Sheet Description: Indicator lamp Diagram Description:
Changed:
POWER OFF / ON
116 .0 116 .1 116 .2 116 .3 116 .4 116 .5 116 .6 116 .7 116 .8 116 .9
117 .0 117 .1 117 .2 117 .3 117 .4 117 .5 117 .6 117 .7 117 .8 117 .9
A A
/147.6 /147.6 /147
A3 A3 A3
INPUT INPUT INPUT
RCS RCS Setup
Haube_0 Cover_5 Rueckmeldung
B RSA_extern B
Cover_0 Cover_5 Feedback_signal
RSA_external
I I+ I I I+ I I I+ I
I0 I0+ I0 I5 I5+ I5 I6 I6+ I6
C C
D D
E E
RM_BIO
K_BIO:13 only Option wiring
/148.3
F F

Machine type: A433 Sheet Description: RCS Diagram Description:
Changed:
Cover RCS
Serial Nr.: 647 xxx Setup feedback signal external (RSA) Doc.Nr: D00035193 117 118
117 .0 117 .1 117 .2 117 .3 117 .4 117 .5 117 .6 117 .7 117 .8 117 .9
118 .0 118 .1 118 .2 118 .3 118 .4 118 .5 118 .6 118 .7 118 .8 118 .9
/147.6 /147.6 /147.6 /147.6 /147.6

A A
A3 A3 A3 A3 A3
INPUT INPUT INPUT INPUT INPUT
Haube_1 Haube_2 Haube_3 Haube_4 Zustimm
Maschine_rechts Maschine_links Kabelantrieb_A Kabelantrieb_B Taste
Cover_1 Cover_2 Cover_3 Cover_4 Confirm

Maschine_right Machine_left Wire_drive_A Wire_drive_B button
I I+ I I I+ I I I+ I I I+ I I I+ I
I1 I1+ I1 I2 I2+ I2 I3 I3+ I3 I4 I4+ I4 I7 I7+ I7
B B
X660 1 2 X660 3 4 X660 5 6 X660 7 8
C C
X660 1 2 X660 3 4 X660 5 6 X660 7 8
X106 109 110
W301
W301
0,75 mm2 braun
0,75 mm2 blau
W_03
W_03
0,75 mm2 schwarz1
0,75 mm2 schwarz2
21 13 S303 2 4 .9 .9 .9
024655
S301 MikroSchalter X106 209 X106 409 X106 309
D 025208 D
Haubenschalter T1R23611z180 22 14 1
13 13 13
3S37 1S37 2S37

Schaltelement 1S Schaltelement 1S Schaltelement 1S
Zustimmtaste 14 Zustimmtaste 14 Zustimmtaste 14
E Kabelantrieb links Bedienpanel Kabelantrieb rechts E
Confirm button Confirm button Confirm button
Wire drive left Operator panel Wire drive right
X106 210 X106 410 X106 310
.9 .9 .9
F F

Machine type: A433 Sheet Description: RCS Diagram Description:
Changed:
Cover RCS
Serial Nr.: 647 xxx Confirm button RCS Doc.Nr: D00035193 118 119
118 .0 118 .1 118 .2 118 .3 118 .4 118 .5 118 .6 118 .7 118 .8 118 .9
119 .0 119 .1 119 .2 119 .3 119 .4 119 .5 119 .6 119 .7 119 .8 119 .9
A A
/147.2 /147.3 /147.3 /147.3
A1 A1 A1 A1
POWER BIO INPUT INPUT INPUT
B Haube_1 Haube_2 B
24VDC GND Reserved Maschine_rechts Maschine_links
Cover Cover
Machine_right Machine_left
24V GND I I+ I I I+ I I I+ I
0 0+ I0 1 1+ I1 2 2+ I2
C C
X660 30 31 X660 32 33
D X104 201 D
/112.8 X105 302 X660 30 31 X660 32 33
/116.3
W101
W101
0,75 mm2 braun
0,75 mm2 blau
E 21 13 E
S101
025208
+24V_DC +24V_DC 22 14
/115.9 /120.5 Haubenschalter T1R23611z180
104:104
0V_DC 0V_DC
/116.9 /134.0
F F

Machine type: A433 Sheet Description: BIO Diagram Description:
Changed:
Power supply BIO
Serial Nr.: 647 xxx INPUT 02 Doc.Nr: D00035193 119 120
119 .0 119 .1 119 .2 119 .3 119 .4 119 .5 119 .6 119 .7 119 .8 119 .9
120 .0 120 .1 120 .2 120 .3 120 .4 120 .5 120 .6 120 .7 120 .8 120 .9
A A
/147.3 /147.3 /147.3 /147.3 /147.3
A1 A1 A1 A1 A1
Haube_3 Haube_4 Regler Start Stop
Kabelantrieb_A Kabelantrieb_B bereit Taste Taste
Cover Cover Motor_regulators Start Stop

B Wire_drive_A Wire_drive_B ready button button B
3 3+ I3 4 4+ I4 5 5+ I5 6 6+ I6 7 7+ I7
C C
X660 34 35 X660 36 37 X106 313
/135.1
X660 34 35 X660 36 37
D D
Reg_ready
X106:413
W_03
W_03
0,75 mm2 schwarz3
0,75 mm2 gelbgrün
/115.7
14 14
Leuchttaster EAO Leuchttaster EAO
H23 H117
Illuminated button Illuminated button
S103 2 4
13 13
/133.3
/133.5
024655
MikroSchalter
E 1 +24V E
/121.6
S111:13
/115.4
X104 302
+24V_DC +24V_DC
/119.1 /136.6
X104:101 X104:104
F F

Changed:
INPUT 37
120 .0 120 .1 120 .2 120 .3 120 .4 120 .5 120 .6 120 .7 120 .8 120 .9
121 .0 121 .1 121 .2 121 .3 121 .4 121 .5 121 .6 121 .7 121 .8 121 .9
/147.3 /147 /147.3 /147.3 /147.3
A1 A1 A1 A1 A1
A INPUT INPUT INPUT INPUT INPUT A
Last 0Position 0Position Haube_Auf Haube_Zu
spannung_Ein Schwenker_1 Schwenker_2 Taster Taster
Onload_voltage 0Position 0Position Cover_open Cover_close

ON Swivel_unit_1 Swivel_unit_2 button button
8 8+ I8 9 9+ I9 10 10+ I10 11 11+ I11 12 12+ I12
B B
C C
W109
W109
W109
W110
W110
W110
0,25 mm2 blau
0,25 mm2 braun
0,25 mm2 schwarz
0,25 mm2 blau
0,25 mm2 braun
0,25 mm2 schwarz
14 14
Schaltelement 1S Schaltelement 1S
S111 S112
X106 107 Illuminated button Illuminated button
13 13
D +24V D
/120.9
H117:13
W109 3 1 2 W110 3 1 2
24V_K5
E B109 B110 E
022406 022406
/116.9
Sensor PNP Sensor PNP
W109 W110
007634 007633
Sensorkabel ES9.5P 180G. Sensorkabel ES8.5P 90G.
.3 .3 .2 .5 .4
F br sw bl br sw bl F
.3

Changed:
INPUT 812
121 .0 121 .1 121 .2 121 .3 121 .4 121 .5 121 .6 121 .7 121 .8 121 .9
122 .0 122 .1 122 .2 122 .3 122 .4 122 .5 122 .6 122 .7 122 .8 122 .9
/147.3 /147 /147.3 /147.3 /147.3
A1 A1 A1 A1 A1
A A
Kabelwanne NotStop OPTION OPTION OPTION
eingefahren Kreis_in_Ordnung Reserved Reserved Rueckmeldung_RSB
for for Fremdpressen
Wire_tray Emergency_stop SCH_K_H SCH_K_H Feedback_signal_RSB
retracted circuit_ok external
13 13+ I13 14 14+ I14 15 15+ I15 16 16+ I16 17 17+ I17
B B
148.3 only Option wiring
C C
XRM_RCS
If option Non mcipress
remove the connection
W113
W113
W113
between Input 17 and Output 25
0,25 mm2 blau
0,25 mm2 braun
0,25 mm2 schwarz
X106 205
/115.4
D D
W113 3 1 2
NotStop
Bruecke
E E
A1:O25
B113
022406
/115.0
/135.3
Sensor PNP
W113
007633
Sensorkabel ES8.5P 90G.
.1 .0
br sw bl
F F

Changed:
INPUT 1317
122 .0 122 .1 122 .2 122 .3 122 .4 122 .5 122 .6 122 .7 122 .8 122 .9
123 .0 123 .1 123 .2 123 .3 123 .4 123 .5 123 .6 123 .7 123 .8 123 .9
A /147.3 /147 /147.3 /147.3 /147.3 A
A1 A1 A1 A1 A1
OPTION OPTION
FAST_INPUT FAST_INPUT Reserved for for
F_R_W F_R_W
I I+ I I I+ I I I+ I
I I+ I I I+ I
18 18+ I18 19 19+ I19 20 20+ I20 21 21+ I21 22 22+ I22
B B
C C
D D
E E
F F

Changed:
INPUT 1822
Serial Nr.: 647 xxx FASTINPUT 18/19 Doc.Nr: D00035193 123 124
123 .0 123 .1 123 .2 123 .3 123 .4 123 .5 123 .6 123 .7 123 .8 123 .9
124 .0 124 .1 124 .2 124 .3 124 .4 124 .5 124 .6 124 .7 124 .8 124 .9
/147.3 /147.3 /147.3 /147.3 /147.3
A A1 A1 A1 A1 A1 A
Hauben Dynamic Dynamic Dynamic
umkehr Input Input Input Fuehrungsgreifer
Cover guide_gripper
reverse S1_A
23 23+ I23 24 24+ I24 25 25+ I25 26 26+ I26 27 27+ I27
B B
C C
W123
W123
W127
W127
W127
0,75 mm2 braun
0,75 mm2 weiss
0,25 mm2 blau
0,25 mm2 braun
0,25 mm2 schwarz
D D
Splice
W127 3 1 2
B38:1 Option
/127.8
1 3
E
P E
B123 B127
047006 022406
Druckwaechter Sensor PNP
Pressure controller
W127
007634
Sensorkabel ES9.5P 180G.
.8
br sw bl
F .8 F

Changed:
INPUT 2327
124 .0 124 .1 124 .2 124 .3 124 .4 124 .5 124 .6 124 .7 124 .8 124 .9
125 .0 125 .1 125 .2 125 .3 125 .4 125 .5 125 .6 125 .7 125 .8 125 .9
/147.3 /147 /147.3 /147.3 /147.3
A1 A1 A1 A1 A1
A INPUT INPUT INPUT INPUT INPUT A
Hochalter Absenker Absenker Greifer Greifer
oben unten unten geschlossen offen
Holdup_device Lowering_unit Lowering_unit Gripper_closed Gripper_opened

S2_A S1_A S2_A S1_A S2_A
28 28+ I28 29 29+ I29 30 30+ I30 31 31+ I31 32 32+ I32
B B
C C
W131
W131
W131
W128
W128
W128
W129
W129
W129
W130
W130
W130
W132
W132
W132
0,25 mm2 blau
0,25 mm2 braun
0,25 mm2 schwarz
0,25 mm2 blau
0,25 mm2 braun
0,25 mm2 schwarz
0,25 mm2 blau
0,25 mm2 braun
0,25 mm2 schwarz
0,25 mm2 blau
0,25 mm2 braun
0,25 mm2 schwarz
0,25 mm2 blau
0,25 mm2 braun
0,25 mm2 schwarz
D D
W128 3 1 2 W129 3 1 2 W130 3 1 2 W131 3 1 2 W132 3 1 2
E B128 B129 B130 B131 B132 E

022406 022406 022406 022406 022406
Sensor PNP Sensor PNP Sensor PNP Sensor PNP Sensor PNP
W128 W129 W130 W131 W132

007633 007633 007633 007633 007633
Sensorkabel ES8.5P 90G. Sensorkabel ES8.5P 90G. Sensorkabel ES8.5P 90G. Sensorkabel ES8.5P 90G. Sensorkabel ES8.5P 90G.
.1 .0 .3 .2 .5 .4 .7 .6 .9 .8
br sw bl br sw bl br sw bl br sw bl br sw bl
F F

Changed:
INPUT 2832
125 .0 125 .1 125 .2 125 .3 125 .4 125 .5 125 .6 125 .7 125 .8 125 .9
126 .0 126 .1 126 .2 126 .3 126 .4 126 .5 126 .6 126 .7 126 .8 126 .9
A A
/147.3 /147 /147.3 /147.3 /147.3
A1 A1 A1 A1 A1
Taster Einfaedeln
Kabelantrieb_A Kabelantrieb_A Druckwaechter Reserved Reserved
Button Draw_in_wire Pressure_controller

Wire_drive_A Wire_drive_A
B B
33 33+ I33 34 34+ I34 35 35+ I35 36 36+ I36 37 37+ I37
C C
W134
W134
W135
W135
0,75 mm2 braun
0,75 mm2 weiss
0,75 mm2 braun
0,75 mm2 weiss
WS133
WS133
0,75 mm2 weiss
0,75 mm2 braun
D D
13 14
Leuchttaster
S133 S134
Schaltelement 1S
E E
/134
14 13
1 3
P
B135
043579
Wartungseinheit FRL3000 /147
Pressure controller
F F

Changed:
INPUT 3337
126 .0 126 .1 126 .2 126 .3 126 .4 126 .5 126 .6 126 .7 126 .8 126 .9
127 .0 127 .1 127 .2 127 .3 127 .4 127 .5 127 .6 127 .7 127 .8 127 .9
A A
/147.3 /147.3 /147.3 /147.3 /147.3
A1 A1 A1 A1 A1
INPUT INPUT INPUT INPUT
Attention!
Attention!
OPTION
FAST_INPUT FAST_INPUT SPLICE_2 Input_39
Splice_2 Analog_Input Analog_Input
B not_active B
X38
not_active
X76 X77
J43
GND +24V In GND +24V In J43
1 2 3 1 2 3
I I+ I
X38 4 3
I I+ I
38 38+ I38

39 39+ I39
X38 4 3
C C
Splice
/124.5
A1:I25
D D
Option 1 2 3
upper wheel
E E
NC2
NO4
S125 S38
C1
lower wheel
Splice dedection
B38
046523
Spliceueberwachung
F F
BIO Created: 12.12.05 File Name: SCHD00035193

FAST INPUT 38 / 39 Changed:
ANALOG INPUT X76 AND X77 Index: 005 Status: Serie Released: ik Total Sheet: 48 SheetNr: Next Sheet:
Serial Nr.: 647 xxx SPLICE 2 INPUT Doc.Nr: D00035193 127 128
127 .0 127 .1 127 .2 127 .3 127 .4 127 .5 127 .6 127 .7 127 .8 127 .9
128 .0 128 .1 128 .2 128 .3 128 .4 128 .5 128 .6 128 .7 128 .8 128 .9
Ventile
BIO
A /147.2 A
Valve_1
Valve_3
Valve_5
Valve_7
Valve_9
Valve_11
Valve_13
Valve_15
COM
Valve_2
Valve_4
Valve_6
Valve_8
Valve_10
Valve_12
Valve_14
COM
A1
X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Y_GND
B /128.2 B
XY 12 XY 24
YB YB
043580 043580
Ventilbatterie COM GND Ventilbatterie COM GND
Y_GND
S_14
/132.1
XY:20
C C
/128.4
S_12
/131.0
XY:19
S_10
/131.0
XY:18
S_8
/130.0
XY:17
S_6
/130.0
XY:16
S_4
/129.0
XY:15
S_2
/129.0
XY:14
D D
S_15
/132.1
XY:8
S_13
/132.1
XY:7
S_11
/131.0
XY:6
S_9
/131.0
XY:5
S_7
/130.0
XY:4
S_5
/130.0
XY:3
E E
S_3
/129.0
XY:2
S_1
/129.0
XY:1
F F

Changed:
OUTPUT 015
Serial Nr.: 647 xxx Valve group DSub 25P. Doc.Nr: D00035193 128 129
128 .0 128 .1 128 .2 128 .3 128 .4 128 .5 128 .6 128 .7 128 .8 128 .9
129 .0 129 .1 129 .2 129 .3 129 .4 129 .5 129 .6 129 .7 129 .8 129 .9
A A
S_4
/128.8
W1_Y:11 W1_Y :11
S_3
/128.8
W1_Y:2 W1_Y :2
S_2
/128.8
W1_Y:10 W1_Y :10
B B
S_1
/128.8
W1_Y:1 W1_Y :1
C C
XY 14 XY 2 XY 15
XY 1
Y100 Y101 Y102 Y103
YB YB YB YB
043580 043580 043580 043580
Ventilbatterie Ventilbatterie Ventilbatterie Ventilbatterie
D D
Reserve Reserve Fuehrungsgreifer S1_A Zerhacker
Reserved Reserved guide gripper S1_A Terminal strip cutter
E E
F F

Changed:
OUTPUT 03
129 .0 129 .1 129 .2 129 .3 129 .4 129 .5 129 .6 129 .7 129 .8 129 .9
130 .0 130 .1 130 .2 130 .3 130 .4 130 .5 130 .6 130 .7 130 .8 130 .9
A A
S_8
/128.8
W1_Y:13 W1_Y :13
S_7
/128.8
W1_Y:4 W1_Y :4
B S_6 B
/128.8
W1_Y:12 W1_Y :12
S_5
/128.8
W1_Y:3 W1_Y :3
C C
XY 3 XY 16 XY 4 XY 17
Y104 Y105 Y106 Y107
YB YB YB YB
043580 043580 043580 043580
D D
Hochhalter S2_A Kabelbolzen Greifer S1_A Greifer S2_A
Wire lifter S2_A wire guide Gripper S1_A Gripper S2_A
E E
F F

Changed:
OUTPUT 47
130 .0 130 .1 130 .2 130 .3 130 .4 130 .5 130 .6 130 .7 130 .8 130 .9
131 .0 131 .1 131 .2 131 .3 131 .4 131 .5 131 .6 131 .7 131 .8 131 .9
A A
S_12
/128.8
W1_Y:15 W1_Y :15
S_11
/128.8
W1_Y:6 W1_Y :6
S_10
/128.8
W1_Y:14 W1_Y :14
B B
S_9
/128.8
W1_Y:5 W1_Y :5
C C
XY 5 XY 18 XY 6 XY 19
Y108 Y109 Y110 Y111
YB YB YB YB
043580 043580 043580 043580
D D
Kabelwanne ausfahren Wire drive A Kabelkippwanne Ausblasluft

Auf / Zu Auf / Ab
Wire tray extended Wire drive A Wire Drop Tray Air blowoff

E open / close E
F F

Changed:
OUTPUT 811
131 .0 131 .1 131 .2 131 .3 131 .4 131 .5 131 .6 131 .7 131 .8 131 .9
132 .0 132 .1 132 .2 132 .3 132 .4 132 .5 132 .6 132 .7 132 .8 132 .9
A A
S_15
/128.8
W1_Y:8 W1_Y :8
S_14
/128.8
W1_Y:16 W1_Y :16
S_13
/128.8
W1_Y:7 W1_Y :7
B B
C C
XY 7 XY 20 XY 8
Y112 Y113 Y114
YB YB YB
043580 043580 043580
Ventilbatterie Ventilbatterie Ventilbatterie
D D
Abdeckhaube Abdeckhaube RESERVE

Auf Zu
Machine cover Machine cover Reserved

open close
E E
F F

Changed:
OUTPUT 1214
132 .0 132 .1 132 .2 132 .3 132 .4 132 .5 132 .6 132 .7 132 .8 132 .9
133 .0 133 .1 133 .2 133 .3 133 .4 133 .5 133 .6 133 .7 133 .8 133 .9
A A
/147.2 /147.2 /147.2
A1 A1 A1
OUTPUT OUTPUT OUTPUT
Start Stop
B Lampe Lampe Stueckzaehler B
Start_lamp Stop_lamp Piececounter
green red
GND O GND O GND O
GND O16 GND O17 GND O18
C C
D D
/120.7 /120.9
X1 X1
1 Stueckzaehler
H116 H117 000136
008357 008357 P118
E E
Signallampe 24V/50mA Signallampe 24V/50mA 2
X2 X2
0V_DC_Bed
/116.6
S3:X2
F F

Changed:
OUTPUT 1618
133 .0 133 .1 133 .2 133 .3 133 .4 133 .5 133 .6 133 .7 133 .8 133 .9
134 .0 134 .1 134 .2 134 .3 134 .4 134 .5 134 .6 134 .7 134 .8 134 .9
/147.2 /147.2 /147.2 /147.2 /147.2

A A
A1 A1 A1 A1 A1
OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT
Lampe
Foerderband Einfaedeltaste OPTION OPTION OPTION
Thread_in_button for for for
Conveyor_belt lamp SCH_K_H SCH_K_H SCH_K_H
active Wire_drive_A
GND O GND O GND O GND O GND O
GND 019 GND O20 GND O21 GND O22 GND O23
B B
W120
W120
0,75 mm2 braun
0,75 mm2 blau
C C
D D
/126
K6 X1
24VDC
A1
K6 13 14
5 6 /101 H120
3 4 /101.1 008357
24VDC A2 1 2 /101.1 Signallampe 24V/50mA
024628 X2
Schuetz CA49CD10
Contactor
X105 301
E E
/112.9
0V_DC 0V_DC
/119.1 /143.0
X105:104
F F

Changed:
OUTPUT 1923
134 .0 134 .1 134 .2 134 .3 134 .4 134 .5 134 .6 134 .7 134 .8 134 .9
135 .0 135 .1 135 .2 135 .3 135 .4 135 .5 135 .6 135 .7 135 .8 135 .9
A A
/147.2 /147.2 /147.2 /147.2 /147.2
A1 A1 A1 A1 A1
B B
OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT
NotStop
Kreis_Regler Sicherheitskanal_ASA Reserved Reserved Reserved
Fremdpressen
Emergency_stop Safety_chanel_A
circuit_regulators external
GND O GND O GND O GND O GND O
GND O24 GND O25 GND O26 GND O27 GND O28
C C
BIO_OUT
only Option wiring /148.4
BIO:A1
D If option Non mcipress D
remove the connection
between Input 17 and Output 25
X106 113
E E
NOT_REG
Bruecke
A1:I17
X106:213
/103.1
/122.9
F F

Changed:
OUTPUT 2428
135 .0 135 .1 135 .2 135 .3 135 .4 135 .5 135 .6 135 .7 135 .8 135 .9
136 .0 136 .1 136 .2 136 .3 136 .4 136 .5 136 .6 136 .7 136 .8 136 .9
/147.2 /147.2 /147.2 /147.2 /147.2
A A1 A1 A1 A1 A1 A
OUTPUT OUTPUT OUTPUT RELAY RELAY
RCS_OK
DYNAMISCHER_OUTPUT DYNAMISCHER_OUTPUT DYNAMISCHER_OUTPUT Reserved Sicherheits
verteiler
Dynamic Dynamic Dynamic RCS RCS
Output Output Output Safety_contact
GND O GND O GND O
GND O29 GND O30 GND O31 NC COM NO NC COM NO
32C O32 32O 33C O33 33O
B B
X106 414
/148.4
C C
X104 103
RCS
/148.4
D X106:114 D
+24V_DC +24V_DC /137.1

/120.7 /143.0
X104:104
E E
F F

Changed:
OUTPUT 2933
136 .0 136 .1 136 .2 136 .3 136 .4 136 .5 136 .6 136 .7 136 .8 136 .9
137 .0 137 .1 137 .2 137 .3 137 .4 137 .5 137 .6 137 .7 137 .8 137 .9
A A
/147 /147.2 /147.2 /147.2
A1 A1 A1 A1
RELAY RELAY RELAY RELAY
Dynamic Dynamic Dynamic Dynamic
Output Output Output Output
RCS RCS
B B
NC COM NO NC COM NO NC COM NO NC COM NO
34C O34 34O 35C O35 35O 36C O36 36O 37C O37 37O
C C
/148.1
K_BIOh 54
D D
53
X104 104
E E
+24V_DC
Airfeed_Side1
Airfeed_Side2
/136.9
X598:102
X598:103
/148.8
/148.8
F F

Changed:
OUTPUT 3437
137 .0 137 .1 137 .2 137 .3 137 .4 137 .5 137 .6 137 .7 137 .8 137 .9
138 .0 138 .1 138 .2 138 .3 138 .4 138 .5 138 .6 138 .7 138 .8 138 .9
A A
/147.2 /147.2 /147.2 /147.2
A1 A1 A1 A1
RELAY RELAY ANALOG ANALOG
Dynamic Betriebs OUTPUT OUTPUT
Output voraussetzung Proportionalregler
Greifer
Service_conditions pressure_regulator
Gripper
B B
X36 1 2 3 4 X37 1 2 3 4
NC COM NO NC COM NO
38C O38 38O 39C O39 39O

X36 1 2 3
C C
W36
W36
W36
0,25 mm2 braun
0,25 mm2 weiss
0,25 mm2 grün
BV_A
/115.2
S4:12
D K5:A1 D
/115.2 BV_B
BX36 COM 1 2
COM 24VDC 010V

E E
Proportional
Druckregler
pressure_regulator
Gripper
B36
F F

Changed:
OUTPUT 3839
138 .0 138 .1 138 .2 138 .3 138 .4 138 .5 138 .6 138 .7 138 .8 138 .9
139 .0 139 .1 139 .2 139 .3 139 .4 139 .5 139 .6 139 .7 139 .8 139 .9
/147.6
A A3 A
RCS A3 RCS
POWER
/147.6 FLACHBAND
24VDC GND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
2 1
X1A3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
B B
C C
X1A1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
24V GND
D 1 D
2
3
4
5
6
7
8
9
11
21
10
12
13
14
15
16
17
18
19
20
22
23
24
25
26
24VDC GND /147.2 FLACHBAND

POWER
BIO A1 BIO
A1
/147
E E
F F

Machine type: A433 Sheet Description: BIO / RCS Diagram Description:
Changed:
Power supply RCS
Serial Nr.: 647 xxx Flat cable BIO / RCS Doc.Nr: D00035193 139 140
139 .0 139 .1 139 .2 139 .3 139 .4 139 .5 139 .6 139 .7 139 .8 139 .9
140 .0 140 .1 140 .2 140 .3 140 .4 140 .5 140 .6 140 .7 140 .8 140 .9
A CH0 CH1 CH2 CH3 CH4 A

Gateway_1 Gateway_2
/147.8 /147.8 /147.8 /147.8 /147
A4 A4 A4 A4 A4
Reserved
024710
W12
1
2
3
4
5
6
7
8
B B
1 W12
2
3
4
5
6
7
8
C C
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
W12
024710
D D
N6
/145.8
N6
RJ45
REGLER RS422
E E
Regulators RS422
F F

Machine type: A433 Sheet Description: MRS (Interface RS422) Diagram Description:
Changed:
CH0CH4
140 .0 140 .1 140 .2 140 .3 140 .4 140 .5 140 .6 140 .7 140 .8 140 .9
141 .0 141 .1 141 .2 141 .3 141 .4 141 .5 141 .6 141 .7 141 .8 141 .9
CH5 CH6 CH7 CH8 CH9
/147.8 /147.8 /147.8 /147.8 /147

A A
A4 A4 A4 A4 A4
B B
C C
D D
E E
F F

Changed:
CH5CH9
141 .0 141 .1 141 .2 141 .3 141 .4 141 .5 141 .6 141 .7 141 .8 141 .9
142 .0 142 .1 142 .2 142 .3 142 .4 142 .5 142 .6 142 .7 142 .8 142 .9
CH10 CH11 CH12 CH13 CH14

BIO_1 BIO_2
/147.8 /147.8 /147.8 /147.8 /147
A A
A4 A4 A4 A4 A4
Reserved Reserved
Kabel RS422 mit RCS
024710
W13
1
2
3
4
5
6
7
8
B B
1 W13
2
3
4
5
6
7
8
1
2
3
4
5
6
7
C 8 C
1
2
3
4
5
6
7
8
W13
024710
Kabel RS422 mit RCS
A1
/147.2
D BIO D
RJ45
BIO RS422
BIO RS422
E E
F F

Changed:
CH10CH14
142 .0 142 .1 142 .2 142 .3 142 .4 142 .5 142 .6 142 .7 142 .8 142 .9
143 .0 143 .1 143 .2 143 .3 143 .4 143 .5 143 .6 143 .7 143 .8 143 .9
A PCC PCC A
PCC_A PCC_B
/144.3 /144.3
A5 A5
B X1A5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 X2A5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 B
+24V_DC +24V_DC
/136.9 /148.3
X104:301
0V_DC 0V_DC
/134.1 /148.3
X105:101
C C
/136.9
X104 403
/114.9
X105 403
D D
X1A4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 X2A4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
E E
A4 A4
24VDC GND /147.8 /147.8

PCC_A PCC_B
POWER
A4
MRS MRS MRS
F F

Changed:
Power supply MRS (24VDC)
Serial Nr.: 647 xxx Connection with PCCBoard Doc.Nr: D00035193 143 144
143 .0 143 .1 143 .2 143 .3 143 .4 143 .5 143 .6 143 .7 143 .8 143 .9
144 .0 144 .1 144 .2 144 .3 144 .4 144 .5 144 .6 144 .7 144 .8 144 .9
A6
025599
A A6 PC TOP WIN Systemeinheit A
N
N_PC 025599
/113.5
A6:N PC TOP WIN Systemeinheit
.2
PE
PE_PC Mouse
/113.5
Mouse
A6:PE
L2_PC
/113.5
.2
Power
A6 P
A6:P
A8
022975
PC Tastatur
Keyboard
B B
A6 A7
025599 025417
PC TOP WIN Systemeinheit VGA Bildschirm
230VAC Screen
Video
50Hz
A8
022975
PC Tastatur
C C
A5
D 023415 D
PCC Rechnerprint
EPROM 4/4
EPROM 3/4
EPROM 2/4
EPROM 1/4
PCC A : /143.2
PCC A : /143.6
Video
A7
025417
VGA Bildschirm
L
L2_VGA
/113.6
E X3:1 E
PE
PE_VGA
/113.6
X3:3
N_VGA
/113.6
X3:2
X_VGA N
F F

Machine type: A433 Sheet Description: PCSystem unit Diagram Description:
Changed:
144 .0 144 .1 144 .2 144 .3 144 .4 144 .5 144 .6 144 .7 144 .8 144 .9
145 .0 145 .1 145 .2 145 .3 145 .4 145 .5 145 .6 145 .7 145 .8 145 .9
A A
N1 N2 N3 N4 N5 N6
B 024517 024516 024517 024516 024516 024846 B
Motorregler DELTADRIVE DAC08 Motorregler DELTADRIVE DAC05 Motorregler DELTADRIVE DAC08 Motorregler DELTADRIVE DAC05 Motorregler DELTADRIVE DAC05 Motorregler DELTADRIVE DAC08 (FBK100)
3x80..230VAC 3x80..230VAC 3x80..230VAC 3x80..230VAC 3x80..230VAC 3x80..230VAC

115W 80W 115W 80W 80W 115W
3x0..200VDC 3x0..200VDC 3x0..200VDC 3x0..200VDC 3x0..200VDC 3x0..200VDC
8A 5A 8A 5A 5A 8A
gn gn ye rd gn gn ye rd gn gn ye rd gn gn ye rd gn gn ye rd gn gn ye rd
gn gn ye rd gn gn ye rd gn gn ye rd gn gn ye rd gn gn ye rd gn gn ye rd
C C
Standard jumper setting Standard jumper setting Standard jumper setting Standard jumper setting Standard jumper setting Standard jumper setting
JP101 JP101 JP101 JP101 JP101 JP101
JP103 JP103 JP103 JP103 JP103 JP103
JP104 JP104 JP104 JP104 JP104 JP104
JP105 JP105 JP105 JP105 JP105 JP105
JP302 JP302 JP302 JP302 JP302 JP302
I I I I I I
I I I I I I
I I I I I I
I I I I I I
I I I I I I
I I I I I I
JP303 JP303 JP303 JP303 JP303 JP303

JP701 JP701 JP701 JP701 JP701 JP701
JP702 JP702 JP702 JP702 JP702 JP702
I
I
I
I
I
I
JP801 JP801 JP801 JP801 JP801 JP801

D D
Power Motor /105.1 Power Motor /105.6 Power Motor /106.1 Power Motor /106 Power Motor /107.1 Power Motor /108.1
Power Supply /102.0 Power Supply /102.0 Power Supply /102.2 Power Supply /102.2 Power Supply /102.4 Power Supply /102.6
Port1 RS485 /104.1 Port1 RS485 /104.2 Port1 RS485 /104 Port1 RS485 /104.5 Port1 RS485 /104 Port1 RS485 /104.9
Port2 RS485 /104.1 Port2 RS485 /104.2 Port2 RS485 /104 Port2 RS485 /104.5 Port2 RS485 /104 Port2 RS485 /104.9
In/Out/24VDC /103.0 In/Out/24VDC /103.2 In/Out/24VDC /103 In/Out/24VDC /103 In/Out/24VDC /103.0 In/Out/24VDC /103.2
Encoder Interface /105 Encoder Interface /105.7 Encoder Interface /106.2 Encoder Interface /106.7 Encoder Interface /107.2 Encoder Interface /108.2
Multiplug1 Multiplug1 Multiplug1 Multiplug1 Multiplug1 Multiplug1
Port RS232 /140.0
Network RS /108.4
E Schenker 1 Abzug 1 Schenker 2 Abzug 2 Messer Kabelantrieb A E
Swivel unit 1 Pull off 1 Swivel unit 2 Pull off 2 Knife unit Wire drive A
F F

Machine type: A433 Sheet Description: Overview Diagram Description:
Changed:
Regulator N1N6
145 .0 145 .1 145 .2 145 .3 145 .4 145 .5 145 .6 145 .7 145 .8 145 .9
147 .0 147 .1 147 .2 147 .3 147 .4 147 .5 147 .6 147 .7 147 .8 147 .9
A A
Print/PCB Print/PCB Print/PCB

BIO Karte 40/40 RCSPrint mit Software ALPHA MRSPrint
A1 024863 A3 024653 A4
Power Inputs Power Interfaces

X25 Power 24VDC/GND /119.1 X1A Input 0 /119.4 X4 Power 24VDC/GND /139.2 X_CH0 RS422 CH0 /140.0
X26 Power 24VDC/GND /139 X2A Input 1 /119.6 Inputs X_CH1 RS422 CH1 /140.2
X27 Power 24VDC/GND X3A Input 2 /119.8 X5A Input0 /117.3 X_CH2 RS422 CH2 /140.4
X4A Input 3 /120.0 X5B Input1 /118.1 X_CH3 RS422 CH3 /140.6
B X5A Input 4 /120.2 X6A Input2 /118.3 X_CH4 RS422 CH4 /140 B
X6A Input 5 /120.4 X6B Input3 /118.5 X_CH5 RS422 CH5 /141.0
X7A Input 6 /120.6 X7A Input4 /118.7 X_CH6 RS422 CH6 /141.2
Outputs X8A Input 7 /120.8 X7B Input5 /117.5 X_CH7 RS422 CH7 /141.4
X50 VentilOut 015 /128.1 X9A Input 8 /121.1 X8A Input6 /117 X_CH8 RS422 CH8 /141.6
X28A Output 16 /133.3 X10A Input 9 /121 X8B Input7 /118.9 X_CH9 RS422 CH9 /141
X29A Output 17 /133.5 X11A Input 10 /121.5 Interfaces X_CH10 RS422 CH10 /142.0
X30A Output 18 /133.7 X12A Input 11 /121.7 X1 Interface RCS/BIO X_CH11 RS422 CH11 /142.2
X31A Output 19 /134.1 X13A Input 12 /121.8 X3 Interface BIO /139.5 X_CH12 RS422 CH12 /142.4
X32A Output 20 /134.3 X14A Input 13 /122.1 X_CH13 RS422 CH13 /142.6
X33A Output 21 /134.5 X15A Input 14 /122 X_CH14 RS422 CH14 /142
X34A Output 22 /134.7 X16A Input 15 /122.5 X_DebA RS422 DebA
C X35A Output 23 /134.9 X17A Input 16 /122.7 X_DebB RS422 DebB C
X28B Output 24 /135.1 X18A Input 17 /122.9 X_PCC_A PCCA /143.2
X29B Output 25 /135.3 X19A Input 18 FAST INPUT /123.1 X_PCC_B PCCB /143.6
X30B Output 26 /135.5 X20A Input 19 FAST INPUT /123 X_RS232_LR RS232 LR /143.1
X31B Output 27 /135.7 X1B Input 20 /123.5
X21A RelOut 32 /136.7 X6B Input 25 /124.4
X22A RelOut 33 /136.9 X7B Input 26 /124.6 /115.7
X23A RelOut 34 /137 X8B Input 27 /124.8
D X24A RelOut 35 /137.4 X9B Input 28 /125.1 D
X21B RelOut 36 /137.6 X10B Input 29 /125
X22B RelOut 37 /137.8 X11B Input 30 /125.5
Main valve

X36 Analog Out AO0 /138.5 X14B Input 33 /126.1 /126
X37 Analog Out AO1 /138.7 X15B Input 34 /126
X16B Input 35 /126.5
X17B Input 36 /126.7
Interfaces X18B Input 37 /126.9
X70 Interface BIO Extended X19B Input 38 FAST INPUT /127.0
Pressure
controller
X75 Interface RCS /139.5 X20B Input 39 FAST INPUT /127.2 B135

043579
E X40 Interface RS422 OMI /142.6 X77 AnalogIn 0 /127.5 Wartungseinheit FRL3000 E
X41 Interface RS422 MCI X76 AnalogIn 1 /127.7
X39 Input Splice 1 /127.8
F F
Overview Created: 12.12.05 File Name: SCHD00035193

BIO (BASIC INPUT OUTPUT) Changed:
RCS (REDUNDANT CONTROL SYSTEM) Index: 005 Status: Serie Released: ik Total Sheet: 48 SheetNr: Next Sheet:
MRS (MULTI RS) Used in ArtNr: 0025280 Language: Deutsch
147 .0 147 .1 147 .2 147 .3 147 .4 147 .5 147 .6 147 .7 147 .8 147 .9
148 .0 148 .1 148 .2 148 .3 148 .4 148 .5 148 .6 148 .7 148 .8 148 .9
L3_RCS RM_BIO BIO_OUT 120V_T1 N_RCS

/101.4 /117.6 /135.4 /115.3 /101.9
X600:1L3 A3:I6 X620:N
A A
/100.8 Airfeed_Side2
L2_RCS /137.4
/101.4 A1:35O
X600:1L2 X102 301
Airfeed_Side1
/137.2
L1_RCS RCS A1:34O
/101.4 /136.9
X600:1L1 X106:414
X106 114
13
B 13 B
K_BIO K_BIO 13
110VAC RCS 14
.7 BIO 14
13 14 .3 2 4 6
5 6 .2 14 .5
.6
3 4 .2
1 2
K_BIO 1 3 5
025438
A2 A1 A2 A1 A1 A1
K_BIOh 14 K_RCS RC1 K_BIO RC2
C 54 53 /137.2 024653 024653 C
.0 .0
64 63 RCGlied RCGlied FSC280
/112.8 110VAC 110VAC
74 73 K_RCS 1 3 5 110VAC A2 110VAC A2
K_RCS 13 ~ .4 ~ 280VAC 280VAC
60Hz 60Hz
84 83 X104 301
025436 .1 RCS BIO
Hilfskontakt 100FA40 2 4 6 008206 008206
+24V_DC Relais RS30 Relais RS30
/143.1 24VDC 24VDC
K_RCS X105 303 RCS BIO X103 203

110VAC
24VDC 24VDC
.6
.5 .6
13 14 .3
/114.9 14 13 .6 14 13 .7 /114.6
5 6 .2
D 008206 008206
D
3 4 .2
Relais RS30 Relais RS30
1 2 RM_RCS N_T1
122.9 /115.8
025438
0V_DC
/143.1
X105 104
X599 105 205 106 206

X599 101 201 301 X599 102 202 302 X599 103 X599 203 X599 303
.5
E X598 101 102 103 E
.1 .3 .5
X599 X599 X599

.5
X599 1L1 1L2 1L3 1PE X599 2L1 2L2 2L3 2PE X599 3L1 X599 3L2 X599 3L3 3PE X598 401 301 402 403 X599 51N 52N 61N 62N
Station S1.1 Station S2.1 Reserved Airfeed Neutral

Side_1
F NON MCIPress NON MCIPress F
Side_2

Machine type: A433 Sheet Description: OPTION Diagram Description:
Changed:
3xPhase national voltage
Serial Nr.: 647 xxx for NON MCIPress Doc.Nr: D00035193 148 149
148 .0 148 .1 148 .2 148 .3 148 .4 148 .5 148 .6 148 .7 148 .8 148 .9
149 .0 149 .1 149 .2 149 .3 149 .4 149 .5 149 .6 149 .7 149 .8 149 .9
A A
K24 Art.Nr.025490
Pawomat S1 Art.Nr.051567
ALPHA K24
Dynamic input 26+ braun/brown pin 1 ALPHA / BIO HMG 99
weiss/white
weiss/white Dynamic input I18 pin 1
Feedback Dynamic input I26 pin 5
braun/brown
gruen/green Dynamic input I18+ pin 3
Activation Dynamic output O38 pin 3
(Output 3638) gruen/green
gelb/yellow Dynamic output O36 pin 6
Dynamic output O38O pin 6
B gelb/yellow B
Dynamic output O360 pin 5
ab K1062/3 Art.Nr.025493
ALPHA / BIO K106 signal ALPHA HMG99 power

Stop wire feeding Dynamic input I18 weiss/white pin 3 Phase X610.L braun/brown L
Speed code 0 Dynamic input I24 gelb/yellow pin 6 Neutral X610.N blau/blue N
Speed code 1 Dynamic input I26 gruen/green pin 7 Earth X610.PE gruengelb PE

greenyellow
C Dynamic input 26+ braun/brown pin 4 C
pin 5
ALPHA K106 power Pawomat S2 Art.Nr.051567

Phase X610.L braun/brown L
ALPHA / BIO HMG 99
blau/blue weiss/white
Neutral X610.N N Dynamic input I38 pin 1
gruengelb braun/brown
Earth X610.PE PE Dynamic input I38+ pin 3
greenyellow
D gruen/green D
Dynamic output O37 pin 6
gelb/yellow
SRSA SEALER Art.Nr.025511 Dynamic output O370 pin 5
ALPHA Input SRSA SEALER

+24 VDC X630.401 braun/brown pin 1
ALPHA HMG99 power
0 VDC X630.403 weiss/white pin 5
Phase X610.L braun/brown L
Ready / Done Dynamic input I26 gruen/green pin 12

Neutral X610.N blau/blue N
Output
E X610.PE gruengelb PE E
Start Sequence Dynamic output O36 braun/brown pin 8 Earth
(Output 3638) greenyellow
Dynamic output O36O weiss/white pin 10
F F

Machine type: A433 Sheet Description: equipment wiring Diagram Description:
Changed:
149 .0 149 .1 149 .2 149 .3 149 .4 149 .5 149 .6 149 .7 149 .8 149 .9
150 .0 150 .1 150 .2 150 .3 150 .4 150 .5 150 .6 150 .7 150 .8 150 .9
Press P104 Side_1 Art.Nr.059298+Art.Nr.045757
A ALPHA P104 A
braun/brown
Phase1 X599.L1 L1
schwarz/black
Phase2 X599.L2 L2
schwarz/black
Phase3 X599.L3 L3 Power
blau/blue
Neutral X599.N N
gruengelb
Earth X599.PE PE
greenyellow
B ALPHA / BIO P104 B
braun/brown
Dynamic output O36
blau/blue
Dynamic output O360
ALPHA Airfeed valve
rot/red
Dynamic output O340 X598.402
Art.Nr.026428
schwarz/black
C Gnd X598.401 C
Press P104 Side_2 Art.Nr.059298+Art.Nr.045757
ALPHA P104
braun/brown
Phase1 X599.L1 L1
schwarz/black
D Phase2 X599.L2 L2 D
schwarz/black
Phase3 X599.L3 L3 Power
blau/blue
Neutral X599.N N
gruengelb
Earth X599.PE PE
greenyellow
ALPHA / BIO P104
braun/brown
Dynamic output O38
start Press
E blau/blue E
Dynamic output O380
ALPHA Airfeed valve
rot/red
Dynamic output O350 X598.403
Art.Nr.026428
schwarz/black
Gnd X598.301
F F

Machine type: A433 Sheet Description: equipment wiring Diagram Description: Electrical Diagram xxx Changed:
Serial Nr.: 647 xxx Doc.Nr: D00035193 150
150 .0 150 .1 150 .2 150 .3 150 .4 150 .5 150 .6 150 .7 150 .8 150 .9
Modifizierungen bei einem Spannungswechsel Alpha 433/477/488
Bestehend Neu
1 Spannung
Spannung
210V bis 250V 2 210V bis 250V
Spannung 3 Spannung
380V bis 420V 4 380V bis 420V
Spannung 5 Spannung
440V bis 480V 6 440V bis 480V
Modifikation n (380V-420V to 210V-250V) Modifikation q (440V-480V to 380V-420V)

Pos. Bez. Anweisung Bemerkung Pos. Bez. Anweisung Bemerkung
1 T1 Brücke wechseln siehe D1 1 T1 Brücke wechseln siehe D1
2 T1 Trafo-Anschluss 230 V, siehe D1 2 T1 Trafo-Anschluss 400 V, siehe D1
wechseln wechseln
3 Förderbandmotor auf Auch 3 Neue Spannung auf dem
Dreieck umschalten Verlängerungen Kleber eintragen
4 Q5 Motorschutz-Schalter Art.-Nr.0024548
Förderb. auswechseln Bereich: 2,7A
5 Motorschutz-Schalter Art.-Nr.0024588
Verläng. auswechseln Bereich: 2,7A
6 Pressen umverdrahten siehe D2
7 Neue Spannung auf dem
Kleber eintragen
Modifikation o (440V-480V to 210V-250V) Modifikation r (210V-250V to 440V-480V)

wechseln wechseln
3 Förderbandmotor auf Auch 3 Förderbandmotor auf Auch
Dreick umschalten Verlängerungen Stern umschalten Verlängerungen
4 Q5 Motorschutz-Schalter Art.-Nr.0024548 4 Q5 Motorschutz-Schalter Art.-Nr.0024547
Förderb. auswechseln Bereich: 2,7A Förderb. auswechseln Bereich: 2,7A
5 Motorschutz-Schalter Art.-Nr.0024588 5 Motorschutz-Schalter Art.-Nr.0008914
Verläng. auswechseln Bereich: 2,7A Verläng. auswechseln Bereich: 2,7A
6 Pressen umverdrahten siehe D2 6 Q2 Leitungsschutzschalter Option mit 2 LS:
7 Neue Spannung auf dem Q3 austauschen Art.-Nr. 0022963
Kleber eintragen 7 Pressen umverdrahten siehe D3
Kleber eintragen
Modifikation p (210V-250V to 380V-420V) Modifikation s (380V-420V to 440V-480V)

wechseln wechseln
3 Förderbandmotor auf Auch 3 Q2 Leitungsschutzschalter Option mit 2 LS:
Stern umschalten Verlängerungen Q3 austauschen Art.-Nr. 0022963
4 Q5 Motorschutz-Schalter Art.-Nr.0024547 4 Neue Spannung auf dem
Förderb. auswechseln Bereich: 2,7A Kleber eintragen
5 Motorschutz-Schalter Art.-Nr.0008914
Verläng. auswechseln Bereich: 2,7A
6 Pressen umverdrahten siehe D3
Kleber eintragen
ES Alpha 433, 477, 488 23.06.06 Seite 1/2

Modifizierungen bei einem Spannungswechsel Alpha 433/477/488
D3 D2
Steuerschrank Alpha Steuerschrank Alpha
PE L1 L2 L3 1 2 PE L1 L2 L3 1 2
gegn sw1 sw2 sw3 sw4

PE L1 L2 L3 M PE L1 L2 L3 M
Crimpmodul mci 711 Crimpmodul mci 711
D1
Transformator
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
210V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
230V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
250V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
380V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
400V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
420V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
440V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
460V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
480V
PE L1 L2 L3
ES Alpha 433, 477, 488 23.06.06 Seite 2/2

Modifications when changing the voltage Alpha 433/477/488
Existing New
1 Voltage
Voltage
210V bis 250V 2 210V bis 250V
Voltage 3 Voltage
380V bis 420V 4 380V bis 420V
Voltage 5 Voltage
440V bis 480V 6 440V bis 480V
Modification n (380V-420V to 210V-250V) Modification q (440V-480V to 380V-420V)

Pos. Desc. What to do Remark Pos. Desc. What to do Remark
1 T1 Change bridge refer to D1 1 T1 Change bridge refer to D1
2 T1 Change transformer 230 V, refer to D1 2 T1 Change transformer 400 V, refer to D1
connection connection
3 Switch conveyor Extensions too 3 Note new voltage on
motor to triangle sticker
4 Q5 Change motor protection Art.-No.0024548
switch of conveyor Setting: 2,7A
5 Change motor protection Art.-No.0024588
switch of conv. extension Setting: 2,7A
6 Change wiring of presses refer to D2
7 Note new voltage on
sticker
Modification o (440V-480V to 210V-250V) Modification r (210V-250V to 440V-480V)

3 Switch conveyor Extensions too 3 Switch conveyor Extensions too
motor to triangle motor to star
4 Q5 Change motor protection Art.-No.0024548 4 Q5 Change motor protection Art.-No.0024547
switch of conveyor Setting: 2,7A switch of conveyor Setting: 2,7A
5 Change motor protection Art.-No.0024588 5 Change motor protection Art.-No.0008914
switch of conv. extension Setting: 2,7A switch of conv. extension Setting: 2,7A
6 Change wiring of presses refer to D2 6 Q2 Replace circuit breakers Option with 2 break.:
7 Note new voltage on Q3 Art.-No. 0022963
sticker 7 Change wiring of presses refer to D3
sticker
Modification p (210V-250V to 380V-420V) Modification s (380V-420V to 440V-480V)

3 Switch conveyor Extensions too 3 Q2 Replace circuit breakers Option with 2 break.:
motor to star Q3 Art.-No. 0022963
4 Q5 Change motor protection Art.-No.0024547 4 Note new voltage on
switch of conveyor Setting: 2,7A sticker
5 Change motor protection Art.-No.0008914
switch of conv. extension Setting: 2,7A
6 Change wiring of presses refer to D3
sticker
ES Alpha 433, 477, 488 23.06.06 Page 1/2

Modifications when changing the voltage Alpha 433/477/488
D3 D2
C ontrol cab inet A lpha C ontrol cabinet A lp ha
PE L1 L2 L3 1 2 PE L1 L2 L3 1 2

PE L1 L2 L3 M PE L1 L2 L3 M
C rim p m odule m ci 711 C rim p m odule m ci 711
D1
Transformer
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
210V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
230V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
250V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
380V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
400V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
420V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
440V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
460V
PE L1 L2 L3
+ 20+ 20+ 20 0 0 0 -20 -20 -20 230 230 230 400 400 400 460 460 460
480V
PE L1 L2 L3
ES Alpha 433, 477, 488 23.06.06 Page 2/2

1.1.1 Relay Outputs
Die BIO verfügt über 8 potentialfreie Outputs.

The BIO has 8 potential free outputs.
Wichtig / Important:
Nicht alle Relays sind gleich geschalten, Output 32 - 35 sind sogenannte Sicherheits-
Outputs.
Diese können nur mit Zustimmung der RCS (ASB Signal) aktiv werden.
Output 32 - 35 are safety outputs, they can only be activated with the confirm of the RCS
(ASB signal).
Schalter_Relay_433.doc komax AG / I.Kadrijan 23.06.06

Elektro Manual ALPHA 433 / 477 Page 2 of 6
1.1.2 Neue BIO Output-Beschaltung / New BIO - output control (pull up)
Die BIO hat eine neue Ausgangsschaltung, die gegenüber der DZIO und ZEIO abweicht!
Die Outputs der BIO „bringen„ +24VDC wenn sie aktiv sind.
The BIO has a new output control that is different from the known DZIO and ZEIO handling!
The BIO outputs are switched with +24VDC.
Bei der DZIO und ZEIO wurde der Ground geschalten, um einen Output zu aktivieren!
Bei der BIO werden +24VDC geschalten, um den Output zu schalten!
The DZIO and the ZEIO were switching ground to activate the output!
The BIO is switching +24VDC to activate the output!
Wichtig / Important:
Um einen Output zu schalten z.B. für Testzwecke, darf keine Brücke mehr zwischen
Outputklemme und Ground gemacht werden; führt zu Kurzschluss!
For test reasons you cannot use a wire bridge to check the output. A bridge between output
and ground = short circuit.!
__________________________________________________________________________
Schalter_Relay_433.doc komax AG / S. Christen 23.06.2006
1.1.3 Proportional Ventil / Proportional valve

Electro-pneumatic regulator
Der Greiferdruck Seite 1 und 2 wird über das Proportional-Ventil B36 gesteuert.
The gripper pressure on side 1&2 is controlled with an proportional valve B36.
Der Soll-Druck wird von der Software an die BIO weitergeleitet. Die BIO wandelt die
Druckvorgabe in ein Signal im Bereich 0 - 10VDC um und gibt es über den Analog-Output 0
Stecker X36 an das Proportional-Ventil B36 weiter. Dieses reguliert den gewünschten
Druck (0 - 8,8 bar)
The desired pressure is transfered from the software to the BIO. The BIO converts the signal to 0 -
10VDC and with the analog output 0 (connector X36) the valve B36 regulates the desired pressure.
__________________________________________________________________________
1.1.4 Maschinen Haube / Machine cover
1.1.5 Wire Drive Haube alpha 433 / Wire drive cover alpha 433
X660s
1 weiss
6 Input 3
S303 4
Channel B (RCS) 8 Input 4 (RCS)
2 braun
5 24V
1 grün
S103 S303
34 24V
4 Channel A (BIO) gelb
S103 35 Input 3 (BIO)
2
37 Input 4
Cover
open closed
Input 3 low high
BIO
Input 4 low high
Input 3 low high
RCS
Input 4 low high
__________________________________________________________________________
1.1.6 Wire Drive Haube alpha 477 / Wire drive cover alpha 477
X660s
1 weiss
6 Input 3
4
S303 Input 4
Channel B (RCS) 8 (RCS)
2 braun
5 24V
S303 S103 1 grün

34 24V
4 Channel A (BIO) gelb
S103 35 Input 3 (BIO)
2 Cover
37 Input 4
open closed
Input 3 low high
BIO
Input 4 low high
Input 3 low high
RCS
Input 4 low high
1.2 Zusammenfassung / Summary
BIO board (A1) RCS board (A3)

Haube Geschlossen Input HIGH Input HIGH
Cover closed
Haube OFFEN Input LOW Input LOW
Cover open
1.3 Betriebsart / Operating mode
Automatik / automatic mode:

Alle Hauben müssen geschlossen, und alle Haubeneingänge auf HIGH sein
All covers must be closed, and all cover-inputs must be on HIGH.
Einrichten / setup:
Mindenstens eine Haube offen, und ein Haubeneingang auf LOW
Minimum one cover open and one cover-inputs LOW.
__________________________________________________________________________
1.4 Wie wird der Kanal B (RCS) aktiv?

How to activate the channel B (RCS)?
__________________________________________________________________________

Electrical Diagrams Komax Alpha 433

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Electrical Diagrams Komax Alpha 433

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Bitte legen Sie dieses Schema in Ihrer

Please file these diagrams in your

Gültig ab Maschinen Nummer:

Elektroschemasatz/Electrical diagrams Alpha 433 - Version 6 1

Telefon +41 41 455 0 455

Stand Juni 2006, Änderungen vorbehalten

Phone +41 41 455 0 455

As of June 2006, subject to change

© 2006 by Komax AG, Wire Processing Systems lua

2 Elektroschemasatz/Electrical diagrams Alpha 433 - Version 6

Elektroschemasatz ............................................... Electrical schematics ................................................... 1

Elektroschemasatz/Electrical diagrams Alpha 433 - Version 6 3

BIO, Ausgang 38-39 ............................................. BIO, output 38-39 ..................................................... 138

4 Elektroschemasatz/Electrical diagrams Alpha 433 - Version 6

Volume of these diagrams

Elektroschemasatz/Electrical diagrams Alpha 433 - Version 6 5

Created: 12.12.05 File Name: SCHD00035193

Created: 12.12.05 File Name: SCHD00035193

Foerderband Module 3Phase Module 3Phase Module 3Phase

main extension Module

Created: 12.12.05 File Name: SCHD00035193

X107 101 103 105

403 404 304 203

/145.2 SwivelUnit /145.4 SwivelUnit /145.7 Knife_Unit /145.8 Wire_Drive

Created: 12.12.05 File Name: SCHD00035193

X5N1 1 3 5 7 9 11 13 X5N2 1 3 5 7 9 11 13 X5N3 1 3 5 7 9 11 13 X5N4 1 3 5 7 9 11 13

/145.2 SwivelUnit /145.3 Pull_off /145 SwivelUnit /145 Pull_off

/145.7 Knife_Unit /145.8 Wire_Drive

Created: 12.12.05 File Name: SCHD00035193

Created: 12.12.05 File Name: SCHD00035193

Created: 12.12.05 File Name: SCHD00035193

Created: 12.12.05 File Name: SCHD00035193

Created: 12.12.05 File Name: SCHD00035193

.1 X103 302 X103 202

X200 112 X200 114

X100 405 X200 09

X104 101 X105 101 X105 402

Created: 12.12.05 File Name: SCHD00035193

/100.8 X102 403

X100 402 X200 119

Created: 12.12.05 File Name: SCHD00035193

X103 104 X103 103 X103 101

X102 203 402

X106 407 X105 103

Module 1xPhase Auxiliary +24V DC 0V DC

Created: 12.12.05 File Name: SCHD00035193

X104 401 402 X104 102

X106 102 101

D X106 202 201 5 6 /101.2 D

X106:205 X106 304 303 Illuminated button 21 22 .3 64 63 /114.0

Not­Stop POWER ON 5 6 /102.1

X103 201 025436

Emergency stop circuit Created: 12.12.05 File Name: SCHD00035193

Created: 12.12.05 File Name: SCHD00035193

/147.6 /147.6 /147

I0­ I0+ I0 I5­ I5+ I5 I6­ I6+ I6

Created: 12.12.05 File Name: SCHD00035193

/147.6 /147.6 /147.6 /147.6 /147.6

Cover_1 Cover_2 Cover_3 Cover_4 Confirm

X660 1 2 X660 3 4 X660 5 6 X660 7 8

3S37 1S37 2S37

X106 210 X106 410 X106 310

Created: 12.12.05 File Name: SCHD00035193

/147.2 /147.3 /147.3 /147.3

/112.8 X105 302 X660 30 31 X660 32 33

Created: 12.12.05 File Name: SCHD00035193

/147.3 /147.3 /147.3 /147.3 /147.3

NotStop POWER ON 5 6 /102.1

I0 I0+ I0 I5 I5+ I5 I6 I6+ I6

Onload_voltage 0Position 0Position Cover_open Cover_close

8 8+ I8 9 9+ I9 10 10+ I10 11 11+ I11 12 12+ I12

Holdup_device Lowering_unit Lowering_unit Gripper_closed Gripper_opened

38 38+ I38

Wire tray extended Wire drive A Wire Drop Tray Air blowoff

COM 24VDC 010V