Service Manual multimaster CAS 52 multimaster CAS 38
Contents
1. e Re attach the plug and turn on the main switch e Select the desired fold plate on the operator panel enter 262 and set the fold plate stop e Make a test fold with 80 GSM offset paper and check the measurement of 262 mm Repeat the setting process if deviations of more than 1 mm occur Using a digital voltmeter the equivalent electrical tension can be measured at the connections of the potentiometer for the purpose of checking the position of the fold plate stops in basic position Fold plates 1 and3 Measure between the green and yellow cable Fold plates 2 and 4 Measure between the grey and yellow cable In both cases the voltmeter must read 5 24 VDC 0 01 VDC in the basic position Moving the fold plate stop by 1 mm corresponds to a change of 0 02 VDC SI l 27 Service Manual multimaster CAS 52 38 Service Instructions Checking the Fold Plates 28 Clean the fold plate Check the deflector for damage and the lever mechanism for easy movement Oll all bearings with a light machine oil Apply a light grease Molykote white to all sliding surfaces and gears Check the gap 1 between upper and lower lip re adjust 1f necessary For setting loosen the mounting screws 2 of the lower lip Place a feeler gage with a thickness corresponding to the desired gap between lower lip and deflector Gap for fold plate 1 2 0 mm 0 1 m2. Q NS NN y N lt S NON 4 SN gt WIS i 6 DOs San VILLAT Mathias B uerle GmbH 15 Service Manual multimaster CAS 52 38 Operation Setting of the Zero Point Check 16 e Loosen screws 8 and 9 with a2 mm Allen key so bracket 10 may be moved by means of the setting screw 11 using a 2 5 mm Allen key e Press key F12 on the operator panel Select the setting PAPER SENSOR by pressing key F6 The display shows BASIC SETTING ZERO POINT PAPER SENSOR e Set the value shown in the display to 0 00 by turning the setting screw 11 with a 2 5 mm key e Secure the bracket by tightening Allen screws 8 and 9 When tightening the Allen screws the value set may shift to or gt The deviation from zero has to be taken into account when repeating the setting e Switch on the fold roller drive to check the correct function e Introduce a paper strip between the measuring rollers while observing the number in the display e Remove the paper strip double it and introduce it again between the measuring rollers The value shown in the display must also double After removing the paper strip the numbers must
3. 20 Via the operator panel set all fold plate stops to 262 mm Turn off the main switch Pull the plugs of the fold plates and remove the fold plates AN Place the fold plates on a table or stand them on their sides NEVER on the deflector Turn on the folder choosing the lowest motor speed Dampen the rollers with a special roller cleaning solution Do not use solvents such as Aceton Toluol etc gt Remove dirt from the fold rollers with a soft cloth shaped into a ball Exercise caution when the machine is running Serious injury may result Repeat the cleaning process several times if necessary if there is a thick layer of deposits on the fold rollers Turn off the main switch Check the fold plates for damages and clean them if necessary Grease all moving parts with Molykote grease white Re install the fold plates Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Instructions Proper roller setting 1s essential for precise folding and while the pressure itself plays Basic Setti ng of an important role parallelism between the adjoining rollers make the difference when Fold Rollers it comes to accuracy The basic setting of the fold rollers should be checked in the course of each service inspection resp after each replacement of the rollers Proceed as follows Turn off power e Set all setting knobs 1 left and right to basic position 0 position e Pull the safety
4. Loosen the securing knob 4 of the handwheel by turning it counter clockwise Loosen both Allen screws 2 5 mm Allen key on the sprocket 5 2 NUUT N KKK A O 7 Hold the spindle 6 Turn the handwheel 7 somewhat to the left or right thus changing the basic setting of the alignment rail Turning clockwise The alignment rail moves in direction of the operator side Turning counter clockwise The alignment rail moves in direction of the opposite side Check parallelism by introducing a sample sheet as described above Repeat the adjusting process if necessary Tighten both Allen screws on the sprocket 5 Secure the handwheel by turning the securing knob 4 clockwise Re attach the side covers of the register table using a 4 mm Allen key Service Manual multimaster CAS 52 38 Mounting Instructions Transfer Bridge When using a second fold unit a transfer bridge must be attached at the exit side of the first fold unit This bridge ensures a secure transfer of the sheet onto the roller table EM IS e Connect the transfer bridge 1 to the gt JA F 5 delivery section of the first fold unit TE El and secure it with two hexhead screws wa 7 i i N I using a 13 mm wrench SCS A Bike dan AS A 4 Place two drive belts 2 on the pulleys Second
5. Mathias B uerle GmbH GewerbehallestraBe 7 11 D 78112 St Georgen Telefon 07724 882 0 Telefax 07724 882 111 T U MATHIAS B UERLE Internet http www mbfold de E mail center mbfold de multimaster CAS 52 multimaster CAS 38 multimaster 38 Ka Kal Service Manual Service Manual multimaster CAS 52 38 CONTENTS 1 MOUNTING INSTRUCTIONS 3 Flat Pile Feeder 5 Fold Unit with Register Table 5 Connecting Components 5 Air Feeder PBA 7 Fold Unit with Register Table 7 Connecting Components I Adjusting the Register Table 9 Transfer Bridge 10 Second Fold Unit 10 Fanned Delivery AM 52 11 Electrical Installation 12 2 OPERATION 13 Checking the Line Voltage 13 Flat Pile Feeder 13 Compressor 14 Pumps 14 Setting Instructions for Paper Thickness Sensor 15 Setting Instructions of Reflection Type Photodetector 17 Speed Controller 18 3 SERVICE INSTRUCTIONS 19 Cleaning and Maintenance 19 Cleaning the Fold Rollers 20 Basic Setting of Fold Rollers 21 Replacing the Fold Rollers 22 Basic Setting of Roller Potentiometers 24 Automatic Fold Plates 25 Gate Fold Plate 30 Basic Setting of Segment Fold Plates 34 Squareness of the Register Table 34 Replacing the Flat Belt 31 Exchanging the One Way Drive Roller 38 Delivery 39 Pump Manufacturer Rietschle 40 Pump Manufacturer Becker 42 4 SERVICE PROGRAM 43 Graphic Arts Applications 43 Systems Configuration 49 The title copyright and all other proprietary rights in th
6. e Attach the bearing flange 1 to the housing s tA i SAN JAR e Remove the roller drive belt from the belt tensioner e Zahnriemenrad 3 mit dem Lagerbolzen in die untere Bohrung einsetzen und mit der Mutter verschrauben e Slide the enclosed spacer and the timing belt pulley 4 on the shaft 2 Attach the timing belt pulley 4 with the set screw to the shaft by means of a 3 mm key Make sure that the set screw is positioned on the flat of the shaft and that there is a side play of about 0 2 mm e Place the timing belt 5 on the timing belt pulleys Introduce the tension roller 4 with the bearing stud into the upper hole elongated hole and lightly tighten the nut Tighten the timing belt by exerting a slight pressure on the tension roller while completely tightening the nut at the same time e Position the roller drive belt Mathias B uerle GmbH 45 Service Manual multimaster CAS 52 38 Service Instructions Renlacin h Fold rollers are subject to more or less wear depending on their material and type eplacing the or the paper that is folded They should be replaced if damages occur that affect their Fold Rollers proper function or if the degree of wear makes a replacement inevitable The determination of the degree of wear is done in the basic setting of the fold rollers all setting knobs in zero position As explained in chapter Basic Setting of Fold Rollers the even pres
7. Now check the following basic setting en i The dimensions between the fold plate ree F frame and the lower lip must be 3 mm Ae A Upper lip Check this with a scale looking into E li SC the fold plate from the front on each Ed side next to the timing belt idler op Lower lip pulley Deflector a 8 If OK g0 to 6 renee 77 ae If not go to 5 ul Fold plate l frame CS The lower lip setting must be 7 2 correct before doing step 5 Sa Pi A 3 mm 1 8 5 Setting the lower lip If the 3 mm setting is not correct turn the fold plate over so its underside faces up Loosen two flat head screws 4 4 on each side fh f You can now move the entire VA dl lower grate with the lower lip attached to it until the 3 mm gap is obtained Retighten the 4 screws 4 4 i A A 3 Ei U Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Mathias B uerle GmbH 6 7 Service Instructions Setting the Stop Deflector Segments With the fold plate still upside down use the handwheel to move the stop deflector segments forward until they are in the position shown in the drawing The distance from the front a KA edge of the lower lip should Fold er be 3 5 mm rollers Upper lip ATTS Check all across the fold plate Pas KA pE If it is not parallel recheck the setting of the lower lip I Sto
8. 38 Service Instructions Installing the Drive The additional fold unit KF 31 is driven by the same mechanical link as the transfer bridge normally used on a fold unit The KF 31 is equipped with a friction drive with KF 31 a flat belt serving as a drive element The drive unit has an exchangeable pulley that depending on its use is either a round pulley for the transfer bridge or a flat pulley for the KF 31 There 1s a choise of two different drive units The short version K is meant for the multimaster 38 A and multimaster CAS 38 A folder lines whereas the longer version L is intended for the multimaster CAS 52 A fold systems N N N LLP LL ARTI IN 777 RW A AN 07227 TT 7 L O ASS TLL WY 7S N N NI NI L N N Zeile GEHN IN Cr u In all types of folders assembly takes place on the right side of the fold roller drive as seen in direction of paper transport e Remove the right side cover by loosening the 5 Allen screws with a4 mm key 2 Me J 7 JE Pa VAT N Af f Z 4 AA SE W For better centering of the bearing flanges first install 2 the shaft 2 with the pulley incl the two ball bearing li l Sn Om flanges then tighten the Allen screws a n m
9. Check the three phase socket before switching on the machine for the first time Line Voltage 230V 230V When making or breaking any electrical connection always first turn off the main switch or the safety switch on the folder Non compliance may cause damage to electronic components Turn off the main switch at the first fold unit Insert the power plug into the socket e Turn on the main switch Flat Pile Feeder e Check the sense of rotation of the drive motor of the flat pile 4 feeder as follows OF Ov On Push button 1 on the operator panel of the flat pile feeder The pile table should move down If the pile table moves upwards after pushing the AN down button 1 turn off the machine immediately by pressing the main switch The limit switches are inactive and considerable damage may occur To change direction of the motor proceed as follows Turn off the machine by pressing the main switch and pull the power plug Open the control box of the fold unit Switch two of the three black wires of the power cable of the flat pile feeder at the terminal block By doing this the sense of rotation of the drive motor is reversed Close the control box insert the power plug Turn on main switch Check the drive motor of the flat pile feeder for correct function Mathias B uerle GmbH 13 Service Manual multimaster CAS 52 38 Ope
10. Manual multimaster CAS 52 38 Service Instructions Basic Setting of the Roller Potentiometers R10 to R21 Each setting knob from no 1 to no 5 is associated with a certain pair of fold rollers whereas setting knob no 6 is associated with the slitter delivery shafts The gap between the fold rollers or delivery shafts with respect to each other are trans formed into an electrical voltage value by the potentiometers These voltage values are recognized by the microcomputer system and shown as the actual value on the display In the basic setting of the fold rollers and delivery shafts with all the scales of the setting knobs pointing to 0 the actual value of the roller gaps on the display must show 0 00 Adjustment ofthe basic setting for a roller potentiometer 1s needed when a the actual value on the display shows a plus or minus value instead of 0 00 with the setting knobs pointing to 0 b a defective potentiometer was replaced by a new one Proceed as follows for setting the basic position of a roller potentiometer The associated fold rollers or delivery shafts must be in their basic positions The scale of the setting knobs must be in the 0 position To a Loosen the Allen screw 1 at the upper collar on A the threaded rod of the adjustment plate by means of a 2 mm key At the same time push the potentio meter 2 slightly upwards and hold it there Turn the second knurled collar 3 at the potentio meter shaft
11. before installing resp removing the fold plates Pulling or inserting the plugs at the fold plates with the main switch turned on may cause damage to electronic components The mechanical basic setting is identical for all 4 fold plates Proceed as follows e Select the fold plate on the operator panel enter 262 and set the stop by pressing the respective button e Turn off the main switch e Remove the plug from the fold plate e Remove the cover plate 1 from the fold plate by means of a 7 mm key 2 e Reconnect the plug and turn on the main switch SI AN NZ d eo N W amp NNY7ZRS TEZ FE 4 3 8 a x ul L Loosen two Allen screws 3 on the gear 7 of the drive shaft next to the fold adjust motor By pressing the plus resp minus key the second screw of the gear can be reached Insert the measuring bracke
12. cover 2 from the handwheel unscrew the Allen screw 5 mm key and remove the handwheel e Remove the covers 3 on both sides of the fold unit Temporarily replace the handwheel again e Remove the plug from each fold plate Loosen the locking knobs and remove all fold plates e Use a strip of 30 GSM paper 4 to check the pressure of the top roller pair 5 While turning the handwheel run the test strip across the entire width of the rollers The strip should not break If it does or if the rollers are out of parallel adjust by loosening the lock screw 6 with a 5 mm key on the appropriate roller mounting arm Turn the hexhead adjusting screw 7 until the test strip shows even pressure across the entire width of the rollers without breaking Test this setting by opening the setting knob 1 to 0 05 mm 5 divisions After the setting is done tighten the lock screw 6 on each roller mounting arm Set the remaining rollers the same way Also test nn N JI and adjust if necessary the ejector roller e Replace the fold plates in their proper positions 2 and 4 on the bottom 1 and 3 on top Reconnect the plugs e Remove the handwheel and replace the covers 3 Attach the handwheel 2 Mathias B uerle GmbH 21 Service Manual multimaster CAS 52 38 Service Instructions Replacing the Fold Rollers Removal 22 Fold rollers are subject to wear the degree of which is determ
13. covers must be removed 4 Allen screws 4 mm key Loosen the nuts and screws on both sides of the fold unit hexhead nut 17 mm key and the feeder Allen screws 5 mm key with hexhead nut 10 mm key Remove the drive belts from the fold unit to the register table and from the register table to the feeder Remove the control cable to the feeder the cable of the paper thickness sensor and in case ofthe CAS 524 the mounting bracket with the photodetector Unhook the tension spring 1 of the belt tensioner Remove the fixed tension roller 2 Allen screw 5 mm key Loosen the spacer rod 3 Lift the flat belt 4 from the drive roller 5 and remove it over the register table towards the operator side i Place the new flat belt round the drive roller 5 and the tension roller 6 Attach the fixed tension roller 2 and the tension spring 1 Connect the register table with the fold unit and the feeder Re attach all components which were removed Make a test run The transport belt can be aligned accurately by shifting the front tension roller 7 37 Service Manual multimaster CAS 52 38 Service Instructions Exchanging the To exchange the drive roller proceed
14. enter 4 length of the unfolded sheet Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Instructions Sample Folds and Correction of Mal functions Mathias B uerle GmbH Ne I i Start the machine by pushing keys li E Make some sample folds The following malfunctions may occur The upper folded panel first fold is opened The lower folded panel second fold is folded again The lower folded panel second fold is folded back over itself Cause The deflector bracket is engaged too late and therefore does not exert pressure on the folded upper panel Remedy Turn the potentiometer of the gate fold plate somewhat TP counter clockwise This reduces the time between recognition of the paper by the photodetector and the engagement of the deflector Repeat this in small steps until the folded sheet remains closed The upper folded panel first fold has an additional fold Cause The deflector is engaged too early Remedy Turn the potentiometer of the gate fold plate somewhat clockwise This increases the time between recognition of the paper by the photodetector and the engagement of the deflector Repeat this in small steps until the folded sheet remains closed The sheet does not hit the fold plate stop Cause Timing of the deflector incorrect Remedy Readjust the timing of the deflector by means of the potentiometer The sheet remains in the fold unit Cause In
15. refers especially to the photo detector in the infeed section of fold unit 1 This makes sense for some applications with certain cutters e g in connection with an extended register table 55 Service Manual multimaster CAS 52 38 Service Program Test F5 Optional Equipment F7 56 In mode SERVICE TEST the first display 1s as described above By pressing key F5 SELECT all inputs from fold unit 1 are depicted as rectangles and may thus be monitored In addition to the photodetectors the following inputs may be checked Input from emergency button kicker on off external control encoder actual freguency can t be shown optical mark detection of a code reader as in cutter key DRIVE ON OFF key FEED ON OFF on the additional control panel an input for an external double sheet detection Optical mark detection is active only when the optional equipment ACCUMUL has been selected see below For fold unit 2 pressing the key F5 SELECT will display the belt speed plus the inputs KICKER ON OFF external control encoder and keys DRIVE and FEED on the additional control panel This will show whether the option ACCUMULATOR s available or not Moreover SELECTIVE FOLDING can be switched on or off in the current software version V 7 5 5 2 not yet included The settings must be repeated after replacement of the RAM memory see above Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Ser
16. unit The photodetector in the delivery section of fold unit I is at the same time the infeed section photodetector for the second fold unit 1 e it is also connected there In this operating mode the sensor for measuring the paper thickness can be set to its basic zero setting The value set can for example be influenced by the ambient temperature This change has however no influence on the measurement of the paper thickness It is imperative however to keep the zero point within the range of 0 09 mm to 0 50 mm If these limits are exceeded the control indicates the following error message during the LEARN DOUBLE SHEET step ZERO POINT PAPER SENSOR OUT OF RANGE The zero point must then be reset in this operating mode 53 Service Manual multimaster CAS 52 38 Service Program Optional Equipment F7 CODE READING OFF CODE READING ON Options can be chosen resp switched on or off This possibility exists starting with software version V 7 4 7 CODE READING ON for instance means that the input EXTERNAL CONTROL at fold unit I is inverted If an external CODE READING facility is connected it is not possible to switch on the system without being enabled by the code reading facility The setting procedure has to be repeated when the RAM has been replaced see above With Crossfold Unit The operating mode SERVICE TEST FOLD UNIT 2 is different The photodetectors of the crossfold unit are also depi
17. until 0 1s shown as actual value on the display Secure the zero position of the roller potentiometer by tightening the Allen screw 1 Turn the associated setting knob several times to the L LY O position and check whether the zero reading at 3 _ the knob agrees with the 0 00 reading on the display If not repeat the procedure To b Turn off the machine at the main switch Use a soldering iron to separate the electrical wires 2 of the defective potentiometer from the connections Before doing this mark the connections n order to prevent errors Loosen the Allen screw 1 on the upper collar by means of a 2 mm key and remove the defective kusi potentiometer Solder the electrical wires to the new potentiometer with the help of the markings resp the wiring diagram Turn on the machine again at the main switch Install the potentiometer in the threaded rod of the adjustment plate push it slightly upwards and hold it there Turn the second knurled collar 3 at the potentiometer shaft until 0 is shown as actual value on the display Secure the zero position of the roller potentiometer by tightening the Allen screw 1 Turn the associated setting knob several times to the 0 position and check whether the zero reading at the knob agrees with the 0 00 reading on the display If not repeat the procedure i 24 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Servi
18. 6 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Mounting Instructions Air Feeder PBA e Unpack the air feeder PBA and remove both covers of the stand 1 Adjust the height as follows Loosen the two locknuts 2 on the feet 3 by wee 7 means of a24 mm key 1 AN Setall4 feetto a height of 9 cm using a 8 mm PC Allen key en Level the feeder with a spirit level E Readjust the position of the feet if necessary 2 Secure all feet by tightening the locknuts Remove setting knobs 4 and 5 with a 3 mm key Remove both side covers 6 by loosening Allen screws 7 with a 4 mm key Fold Unit with e Unpack the fold unit Register Table When using a knife to cut open the packaging be careful not to damage parts of the machine Remove the Allen screws 8 left and right 10 Then remove both side covers 9 of the register table To Remove the connecting screws 10 0 8 between air feeder PBA and register lt table e Set the fold unit to the same height as the air feeder and level it using a spirit level Connecting e Move the fold unit up to the air feeder with a jacklift Components e Slide the fold unit with register table over the connecting bracket of the air feeder N Do not bend or squeeze hoses cables or sheet metal parts The fold unit with register table is in its correct position when the h
19. B uerle GmbH 49 Service Manual multimaster CAS 52 38 Service Program CLEAR DATA F1 With this function the RAM can be re initialized or information can be cleared selectively First of all a code number must be entered to prevent unintentional clearing This number 4277 should be known to the service technician only SERVICE COUNTERS e ALL Fl For initialising a complete RAM When touching this key the relevant question appears in die display Then the question must be confirmed After initializing a RAM test is automatically made to detect defective memories e COUNTERS F3 All counts total batch interval also the sum are cleared after confirmation JOBS F5 All jobs that are saved in the memory are cleared after confirmation 50 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Program SYSTEM CONFIG The configuration or the version of the fold system can be determined or changed here F3 if it does not correspond to the standard version The configuration must be made after replacement of the operator panel the so called Masterboard PC board in the operator panel with controller 8032 EPROM and battery buffered RAM M48Z18 or after replacement of the RAM only because the information 1s stored in this memory First enter a code number 4250 which may also be known to the operator Depending of the number of fold units the following message comes on in the display One fold un
20. Check connections according to wiring diagram Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Instructions 3 SERVICE INSTRUCTIONS Cleaning and Cleaning and maintenance are vital for keeping a machine in perfect operating condition for a long period of time Maintenance For this reason cleaning and maintenance work should be carried out at regular intervals The maintenance intervals depend on the workload Minimum e Cleaning Requirements The operators should clean all fixed and moving parts from paper or powder dust once a week For cleaning purposes MB offers a special cleaning fluid AN Solvents such as Aceton Toluol must not be used e Maintenance A service technician should conduct a maintenance service twice per year This maintenance should comprise the following jobs Check the proper function of air and vacuum controls Clean the separating head Check suction cups for wear replace if necessary Check that moving parts move freely Check all safety switches for proper function Check whether chains are damaged Check drive elements for premature wear Check movable parts of the fold plates incl deflector for free movement Clean air filter of the compressor Clean fold rollers Check roller adjustment re adjust if necessary Check software version Mathias B uerle GmbH 19 Service Manual multimaster CAS 52 38 Service Instructions Cleaning the Fold Rollers
21. Fold Unit Unpack the second fold unit with roller table When using a knife to cut open the packaging be careful not to damage parts of the machine e Set the second fold unit to the same height as the roller table and level it using a spirit level Place the second fold unit with the roller table next to the first fold unit Set the adjusting plates 3 on both sides of the transfer bridge n such a way that the belts do not touch the roller table e Plug the connecting cable of the second fold unit into the socket 4 of the first fold unit 10 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Mounting Instructions Fanned Delive ry e Unpack the fanned delivery AM 52 When using a knife to cut open the packaging be careful not to damage parts of the machine Place the fanned delivery next to the first or second fold unit Proceed as follows to set the transfer height Loosen the securing knob 1 by turning it counter clockwise Lift or lower the delivery table Secure the knob 1 by turning it clockwise Plug the connecting cable of the delivery into the socket 2 of the first or second fold unit Mathias B uerle GmbH 11 Service Manual multimaster CAS 52 38 Electrical Installation multimaste
22. The speed controller retains voltage for up to 3 minutes after the machine has been switched off The plug in type terminals may only be inserted or removed with power off When the machine is in operation the operating condition of the speed controller is indicated by means of two LEDs 1 at the front panel of the lt speed controller Displays LED green LED red Operating condition on off Speed controller enabled on on Power supply off flashing off Speed controller off off flashing 1 0 sec pulse Error off flashing 0 4 sec pulse Low voltage off Error Display LED Display off Cause Programming status Remedy Green LED flashing Controller blocked via terminal 28 Check connections and switch relay according to wiring diagram Red LED flashing 0 4 sec pulse Input voltage below 190V Check input voltage Red LED flashing 1 sec pulse Ground or neutral con ductor defective Speed controller defective Re establish connection or replace speed control ler part no 1 030 430 LED s are dark Programming mode still on or no line voltage applied Turn off programming mode
23. again be identical with the original value If this is not the case repeat the complete setting process Also check whether the mechanical components of the paper thickness sensor are tight Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Operation Setting Instructions of Reflection Type Photodetector General The reflection type photodetectors which monitor the paper travel n the fold units are set at the factory If malfunctions occur always check first whether the input sensitivity of the photodetector is still the same Adju sti ng the Introduce a dull black both sides sheet of paper between the photodetector and the S itivit reflector At the potentiometer located on the face of the photodetector adjust the ENnsitivity input sensitivity in such a way that the black paper is just recognized Functional control A red LED signals recognition of the paper For photodetectors with inverted function the LED goes out when recognizing the black paper Dimensions 286 p 37 24 5 e e JPC Mathias B uerle GmbH 17 Service Manual multimaster CAS 52 38 Speed Controller General Operating Conditions 18 Operation The information refers to the speed controller of the type EVF 8202 E manufactured by Lenze GmbH amp CoKG Defective fuses may only be replaced with the recommended type of fuse There are no other fuses installed in the machine
24. as follows One Way Drive Roller 38 Remove both s de covers 1 and 2 4 Allen screws 4 mm key Remove the round belt 3 from the pulley 4 Loosen the hexhead nut M8 13 mm key and remove the pulley key and spacer roller from the drive shaft 5 When loosing the hexhead nut hold the drive roller with a T fork key 13 ov oe ll ENL AA Unhook the tension spring 6 of the belt tensioner and remove the fixed roller 7 Allen key 5 mm Loosen the screw on the left side of the guide rail for the sound cover hexhead screw 7 mm key i 7 and tilt the rail downwards to gether with the sound cover until A i the lower Allen screw 4 mm key m of the bearing mount becomes accessible Loosen bearing mount 2 Allen screws 4 mm key and pull the drive shaft with the bearing from the drive roller Remove the drive roller from the mounting bracket and insert a new roller Make sure that the one way bearing is installed correctly with respect to the paper feed direction Make sure that the flat belt is guided properly round the rollers Guide the drive shaft through the drive roller then install the bearing and the bearing mount and screw them to the side panel Attach the fixed roller of the belt tensioner 7 to the bearing bracket Attach the tensioner spring 6 Install the guide rail for th
25. ce Instructions Automatic Fold Plates Checking the Basic Make sure to turn off the main switch before installing resp removing gt the fold plates Pulling or inserting the plugs at the fold plates with the mig of Fold Plate main switch turned on may cause damage to electronic components Ops Turn off the main switch Open the upper and lower noise absorbing covers e Remove the plugs of fold plates 1 and 2 Loosen the locking knobs and remove fold plate 1 and 2 e Turn on the main switch e Select fold plate 4 on the operator panel enter 262 and set the stop by pressing the respective button After the stop has settled the physical distance between the stop and the cross bar holding the upper rods should be 207 5 mm Check with the measuring bracket 1 If the difference is more than 1 mm do the basic setting see next page lt 207 5 gt a RS e Repeat above check for fold plate 3 e Turn offthe main switch Insert fold plate 1 and 2 and connect the plugs Turn on the main switch e Repeat above check for fold plates 1 and 2 Mathias B uerle GmbH 25 Service Manual multimaster CAS 52 38 Service Instructions Basic Setting of Fold Plate Stops 26 Make sure to turn off the main switch
26. cted as rectangular squares in the same arrangement as they are located n the fold unit from right to left seen in direction of paper transport first the photodetector in the delivery section of fold unit 1 the trigger photodetector of knife 1 the photodetector indicating the position of knife 1 as well as two photodetectors of knife 2 and the photodetector in the delivery section of the crossfold unit The delay shows the value of the two potentiometers at the crossfold unit for control purposes With these potentiometers the delay time of the two knives can be modified to allow more or less time for the sheet to reach the stop Safety cover push buttons The condition of the switch for the cover and the 4 push buttons in the crossfold unit can also be displayed 54 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Program Systems Configuration Mathias B uerle GmbH There are some differences in systems configuration as compared to the graphic arts version CONFIGURATION FEED EXTERNAL EXT SELECT PSF There is a choice between the pneumatic sheet feeder and external paper feed by a cutter printer etc By pushing F5 SELECT again the following message comes on in the display MONITORING TRANSPORT WITH LEADING EDGE LEAD TRAIL SELECT Here you can determine whether the paper transport control should work with the leading edge or the trailing edge of the sheet This
27. d for triggering this mechanism 1s generated by a photodetector 5 mounted on the paper stop of fold plate no 3 It can be set by means of a potentiometer 7 Make the setting in such a way that the deflector moves forward at the right moment before the third fold s made thus preventing the upper folded in panel from being opened The deflector remains in this position until the folded in panels are gripped by the fold rollers and the third fold s made 2 Sheet leaving the gate fold plate OO Sheet entering the gate fold plate Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Setting the Fold Lengths Setting the Gap between the Fold Rollers Mathias B uerle GmbH Turn off the main switch e Remove fold plate 4 standard fold plate Turn on the main switch e Press key and enter the fold lengths Fold plate 1 Fold plate 2 Fold plate 3 Fold plate 4 4 length of unfolded sheet 0 fold plate is closed by deflector 2 length of unfolded sheet is not set because this position will later be occupied by the gate fold plate Service Instructions To get a sharp fold and to avoid box folds accurate setting of the fold roller gap is very important Example 80 GSM offset paper Roller 1 Roller 2 Roller 3 Roller 4 Roller 5 Roller 6 O position l 0 position 2 1 fold paper thickness 3 1 5 fold paper thickness 4 4 to 10 fold paper thickness 5 min 10 fo
28. ding which allows the segments to be moved in and out with the fine adjustment without actually changing the 0 reading 35 Service Manual multimaster CAS 52 38 Service Instructions Register Table Sg uareness of the a the ce table must be ings whenever a fold system is a installed resp in the course of a service inspection Register Table Proceed as follows e Set the indicator 1 of the alignment rail to the center of the scale by turning the knurled screw 2 e Run a sheet of paper A2 80 GSM along the alignment rail by turning the handwheel 3 e Drive the sheet close to the upper infeed plate of the fold rollers and check whether the leading edge of the sheet is parallel to the infeed plate e Ifthe deviation is more than 1 mm align the register table by moving the entire feeder Move the supports 4 by gripping the lower part of the feeder Other sections of the machine or the upper parts of the feeder are not suitable for this purpose because damage may occur 36 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Instructions Replacing the Flat Belt Mathias B uerle GmbH General The purpose of the flat belt 1s to transport paper During this transport the sheets are aligned against the reference edge of the sheet rail To exchange the flat belt proceed as follows Separate the register table from the fold unit and feeder For this the side
29. displayed by pressing this key Program Version If there are discrepancies the number on the EPROM label is valid F4 SERVICE SOFTWARE VERSION V 7 4 2 3 E The letter E stands for the third language Spanish besides German and English 52 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Program Test F5 Basic Setting Paper Sensor F6 Mathias B uerle GmbH In this operating mode the functions of the different inputs can be checked SHINGLING Potentiometer position for the delivery sheet gap SPEED Potentiometer position for the speed ofthe transport belt Display also in m min GAP Potentiometer position for the sheet gap in the infeed section SHEET TIME Time measured in milliseconds during which the photodetector in the infeed section is covered by a sheet COMMAND _ Ifno value is shown under COMMAND the function is correct If there is a value a data transfer malfunction has occurred sometime since the main switch was turned on PHOTODETECTORS The two rectangles are symbols for the photodetectors of a fold unit and indicate the switch condition white stands for free black for covered The arrangement corresponds to the location of the photodetectors in the fold unit Fast switches cannot be made visible FOLD UNIT Itis possible to switch to the display of the belt speed in the second fold unit and to the photodetectors which are connected to the second fold
30. e sound cover and the pulley 4 Place the round belt on the pulley Make a test run to check for proper function Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Instructions Delivery Checking the Clutch Play Cleaning the Clutch Mathias B uerle GmbH A spacer disk 3 part no 2 011 619 must be installed between the rotor 1 and the clutch disk 2 to guarantee proper functioning of the solenoid clutch The clutch play 5 is set by means of a collar 4 which can be shifted on the shaft If a suitable spacer gage is not available it is also possible to adjust the clutch play with a 80 GSM paper strip that is folded three times to achieve the required gap Bole AY N 0 2 0 4 mm Very dirty clutch disks in connection with high air humidity or insufficient maintenance may cause the clutch to stick In such a case the clutch must be completely disassembled and cleaned with roller cleaning solution A function test of the delivery incl proper shingling of the folded sheets should be made after each adjustment or cleaning of the solenoid clutch 39 Service Manual multimaster CAS 52 38 Service Instructions Pump Manufacturer Rietschle Lubrication Air Filter Replacing the Filter 40 When pe
31. he vanes if this width is smaller Before that clean the rotor with dry compressed air Each millimeter over than the minimum width means approx 1000 hours more useful life Observe correct orientation Sense of rotation of motor 42 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Instructions Cleaning the Rear Edge Separating Head Mathias B uerle GmbH Regular cleaning of the rear edge separating head practically avoids malfunctions in paper transport The intervals between cleaning cycles depend on the ambient conditions e g percentage of print powder dust etc For cleaning proceed as follows e Remove the two rear edge stop rods 1 e Loosen both Allen screws 2 with a 4 mm key ia v 2 and remove the sucker assembly Make sure not to lose the O ring in the sucker assembly Loosen both oval head screws 3 at the suction assembly by means of a 2 5 mm key and dis engage the bracket with the suction sleeves from the plunger by pulling 1t downwards e Clean all parts that you have removed as well as the plunger with MB roller cleaning solution e Before re assembling the parts in reverse order slightly grease the plungers 4 and the rear edge stop rods 1 The sliding surfaces 5 at the support can be cleaned without the need for disassembly Lubricate with sil
32. icon grease Service Manual multimaster CAS 52 38 Service Instructions Installing the Kicker 44 It is possible to install the kicker unit 1 in a vertical stacker SKM 36 at a later date For this purpose there are two holes 2 3 in the left and right side plates of the vertial stacker 4 22 0 E 8 g E 0 Route the connecting cable of the kicker with its plug 4 through the hole 2 in the right side plate of the vertical stacker Then insert the plug into the proper socket at the bottom ofthe vertical stacker When making or breaking any electrical connection always first turn off the main switch or the safety switch on the folder Non compliance may cause damage to electronic components Disengage the knurled nut 6 and the bushing 7 before mounting the shaft 5 Introduce the shaft from the inside into the hole 3 in the left side plate against the spring pressure Screw the knurled nut 6 on the threaded part of the shaft Slide the bushing 7 from the outside through the hole 2 on the right side plate onto the round part of the shaft and secure it with a cl p 8 Place the kicker 1 and the guide plate 9 on the shaft in a position suitable for the folding job Place the kicker approx 4 5 mm from the edge of the passing sheet Fine adjustment of the kicker position is possible by turning the knurled screw 6 Mathias B uerle GmbH Service Manual multimaster CAS 52
33. ined by the material and the type of paper that is folded They should be replaced when they show damage that impairs their proper function resp when high wear makes a replacement inevitable The degree of wear is determined in the course of the basic setting of the fold rollers O position of all setting knobs The even pressure of the fold rollers 1s checked by means of a paper strip see Basic Setting of fold Rollers The handwheel as well as the left and right side plates of the fold unit are removed and all the setting knobs are in their basic position 0 position Sr Always remove the fold rollers from the operator side of the fold unit gt SI Proceed as follows l 6 e Mark the routing of the roller drive belts 1 e On both sides number all levers 2 in a O continuous sequence and mark the position of the gear 3 with respect to the setting plate 4 This mark makes it easier to find the 0 position lee of the gear and the setting knob during re assembly e Loosen the hexhead nuts 5 on both sides with a 13 mm open end wrench and remove them together with the washers from the fold rollers e On both sides unhook the plates with the springs for the belt tension Remove the roller drive belts 1 round belt resp V belt 6 from the
34. ion The paper thickness sensor is listed as a complete unit together with the photo sensor for sheet recognition under part no 4 006 478 It is attached to the register table with an Allen screw 1 M5x30 using a 4 mm key The basic adjustment must be made after each installation or whenever the value without paper shown in the display varies considerably from the zero point Measuring paper thicknesses above 0 25 mm should be avoided as it may lead to erroneous interpretations in the program for calculating the roller gap Basic Setting of the Loosen Allen screws 2 and 3 by means of a 3 mm key so that the setting plate 4 E with setting screw 5 can be moved Turn the setting screw 5 by means ofa3 mm Measuri ng Roller key to separate the upper measuring roller 6 from the lower one 7 Switch on the fold roller drive Adjust the upper measuring roller 6 until the upper roller touches the lower roller 7 and the upper roller starts to turn Introduce a strip of paper between the upper and the lower roller There should be a slight drag on the paper Secure the setting plate 4 by means of screws 2 and 3 using a 3 mm Allen key DEIN NEE N a NEA Ar Va LL SE K
35. is document are vested in Mathias B uerle GmbH and no part of it may be reproduced in any form without the written permission of Mathias B uerle GmbH Mathias B uerle GmbH Service Manual multimaster CAS 52 38 4 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Mounting Instructions 1 MOUNTING INSTRUCTIONS Flat Pile Feeder e Unpack the flat pile feeder Adjust the height as follows Loosen the hexhead nuts 24 mm wrench Set the height to 9 cm by means of an 8 mm Allen key Level the feeder using a spirit level 9cm Fold Unit with e Unpack the fold unit Register Table When using a knife to cut open the packaging be careful not to damage parts of the machine Remove both side covers of the 1 6 register table 1 A Remove screws 2 and 3 Remove the connecting screws between register table and flat pile feeder 4 0 NL No Ww a ie Unscrew the plug of the paper thickness Ht measuring device 5 and pull it off may otherwise be damaged Pull out the studs at the register table 6 e Set the fold unit to the same height as the flat pile feeder and level it using a spirit level Con necting e Move the fold unit up to the flat pile feeder with a jacklift C omponen ts Observe the following The green round belt at the rear of
36. it CONFIGURATION FEEDER Feeder being used at the moment FLAT PILE FEEDER FPF flat pile feeder PSF pneumatic sheet feeder SELECT PSF By operating the function keys F1 resp F2 another type of feeder is selected Two fold units CONFIGURATION NUMBER OF FOLD PLATES IN FOLD UNIT 2 4 SELECT Selection of fold unit By operating the function keys Fl resp F2 the number of fold plates for the second fold unit is selected Mathias B uerle GmbH 51 Service Manual multimaster CAS 52 38 Service Program For emergencies the following information is hidden under CONFIGURATION By pushing function key F7 not indicated the following message comes on in the display FOLD UNIT ROLLER GAP ACT VALUE YES NO SELECT Early folders were not equipped with potentiometers for fold roller setting In this menu the machine configuration may be changed to allow use of the latest software with those machines In order to achieve this the display of the actual roller gap setting must be turned off by selecting NO Conversely on a newer machine which does not show the actual roller gap setting this function may be turned on again by selecting YES If this parameter has changed without input from the menu a defective RAM could be the cause for this error After pressing the key F3 SELECT the procedure can be repeated for fold unit 2 The software version being used will be
37. ld paper thickness 6 0 00 mm 0 00 mm 0 10 mm 0 25 mm 0 55 mm 1 00 mm 31 Service Manual multimaster CAS 52 38 Service Instructions Checking the Fold Lengths in Fold Plates 1 and 3 Inserting and Connecting the Gate Fold Plate Setting the Fold Length for the Gate Fold Plate 32 To check the fold lengths in fold plates 1 and 3 make the first folds without fold plate 4 and without the gate fold plate The sheets drop out of the folder in position 4 A Always turn off the main switch before removing the fold plates Set folding speed GB to 3 4 Start the machine by pressing keys e r 1 t r e e Make some trial folds CS If a box fold occurs when making the first fold fold roller 5 is set too tight Relieve the pressure and try again e Do not insert the gate fold plate until the fold lengths are correct Turn off main switch Insert the gate fold plate in position 4 e Insert the plug in the right socket 1 of the gate fold plate e Attach the photodetector 2 to the stop of fold plate 3 To be able to do this pull out the plug on fold plate 1 and pull back fold plate 1 somewhat e Insert the plug of the photodetector cable into the center socket 3 of the gate fold plate e Move fold plate 1 back to its original 15 position and insert the plug lt Sa Turn on the main switch e Press key 5 and
38. m Gap for fold plate 2 4 3 0 mm 0 1 mm Y y KoT Tr 2 VASO Z x Applying a light pressure press the lower lip against the deflector and tighten the mounting screws 2 at the same time Remove the feeler gage and re check whether there 1s a uniform gap across the entire width of the lower lip Make a function test of the machine after completing the setting procedure Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Instructions Replacing the Deflector Mathias B uerle GmbH Broken mounting bolts of the deflector or bent deflectors sometimes make it necessary to replace the deflector at the customer site Before doing this check whether the complete lever mechanism is damaged or considerably bent Replacing the complete lever mechanism at the customer site is not recommended In such a case the whole fold plate should be repaired and re adjusted at the factory e On the side without activating lever first remove all 4 C clips as well as the spacer and the washer Older fold plates are equipped with a needle bearing n place of the ID SI spacer e First remove the U shaped lever with the return spring then pry the second lever from the remaining lever mechanism of the fold plate e On the opposite side remove both C clips from the mounting pi
39. ns of the deflector e Remove the needle bearing and the washer from the long mounting pin of the deflector The deflector can now be pulled from the bearing holes of the levers e The new deflector is installed in reverse order Make sure that the imprinted side of the ball bearing points towards the inside e After installation of the complete lever mechanism check the fold plate for easy movement If necessary grease all sliding surfaces with a light grease Molykote white 29 Service Manual multimaster CAS 52 38 Service Instructions Gate Fold Plate FFT General Functional Description 30 A parallel fold system with 3 standard fold plates and one a gate fold plate is needed for making a gate fold with 3 folds The gate fold is always made in fold plates 1 3 and 4 while the gate fold plate is in position 4 Always turn off the main switch before installing resp removing fold plates Inserting or pulling the plugs at the fold plates with the main switch on may damage electronic components The photodetector must be screwed to the paper stop of fold plate 3 If there 1s not yet a hole in the paper stop an M4 tapped hole must be added M4 tapped hole Contrary to the standard fold plates the gate fold plate 4 is equipped with movable deflectors 6 across the whole width of the fold plate This is to prevent that folds made in fold plates 1 and 3 are opened again The impulse neede
40. oles of the connecting brackets of the air feeder are lined up with the holes of the register table e Connect the register table to the air feeder with 11 attaching screws 11 using a 6 mm key e Place the V belt 6x450 12 on the pulleys of register table and air feeder Mathias B uerle GmbH 7 Service Manual multimaster CAS 52 38 Mounting Instructions e Connect the plug type connector for the reflection type photodetector and the control valve with the matching counterparts at the register table e Re attach all side covers of register table and air feeder 1 e Mount the setting knobs for the adjustment of the vacuum plenum 2 and for the air 3 e Re attach the covers 4 8 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Mounting Instructions Adjusting the Register Table Mathias B uerle GmbH OF Set the infeed angle to the zero position 1 by turning the knurled screw 2 Slide an A2 sheet that is known to be exactly square between the ball cage and the align ment belt up to the alignment rail Br BE i Transport the sheet along the whole length of N SA the register table by turning the handwheel at 2 A the fold unit Stop when the leading edge of the sheet reaches the infeed guide 3 of the fold unit Check the gap between sheet and infeed guide for parallelism If there is a discrepancy adjust parallelism as follows
41. ople are in danger of getting injured by moving or live parts when carrying out certain maintenance jobs disconnect the compressor from the mains and reliably prevent unintentional restarting by pulling the power plug or operating the main switch Do not perform any maintenance while the compressor is still hot you may get injured The bearings of the compressors are lubricated for life It is therefore not necessary to grease them CS Inadequate maintenance of the air filters reduces the performance of the compressors Clean the filter cartr dges for vacuum 1 air 2 and air charge 3 by blowing through them from the inside out We recommend to replace the filters after six months eee ji Remove the exhaust grid 4 Loosen the covers 5 and the knurled knobs 6 Loosen the knurled nut and remove the filter cover 7 Remove the filter cartridges 1 2 3 and clean resp replace them Reassemble in reverse order Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Instructions Inspecting the Vanes Replacing the Vanes Mathias B uerle GmbH Vanes are subject to wear during operation of the compressor The first check should therefore take place after approx 5 000 operating hours then every 1 000 operating hours To inspect the vanes unscrew the exhaust grid 1 Remove the cover 2 from the housing Take out the vanes 3 for in
42. p IK L 1 Deflector en After you read 3 5 mm across segment a A i the width of the fold plate Se Fold plate retighten the two set screws frame on the gear next to the servo A motor a M 7 gt e 3 5 mm Put the fold plate back into the machine and reconnect the plug Turn on power On the control panel select the fold plate you are working on Use a small screwdriver and insert it into the slot on the potentiometer shaft Turn the shaft until the display reads 10 mm Retighten the set screw Select 0 deflector position on the control panel The fold plate stop will move forward about 3 mm If you took the fold plate out again to check the position of the segments you would see that the distance from the front edge of the segments to the lower lip is now 6 5 mm 7 N In this position the segments KA are about 3 mm away from the a a l 7 r fold roller j PPer ap This can be verified by looking A KA with the side overs off into Pi AN E the side of the machine Nee i Stop ns L 1 Deflector one N segment mern u A Fold plate frame 3 mm E N L F p 3 mm CS The reason why we set for a gna cin SI 3 5 mm dimension with a 10 mm 6 5 mm with segments in deflector position 3 5 mm with segments set to 10 mm on the display reading on the display 1s that this gives a closer setting than the 0 rea
43. pulleys e Pull off the pulleys on both sides Watch for the woodruff keys 7 on the fold rollers e Remove the setting knobs with hexhead shafts 8 from the frame by pulling them upwards Before doing this pry off the white position indicator with a screwdriver e Use a cable tie loop to unhook all extension l springs 9 at the levers and remove the C clips from the locating studs Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Instructions e Remove the lever for the upper roller For this loosen the Allen screw 1 with a 5 mm key Watch for the washers on the dowel pin and the Allen screw e Pull all levers from the fold rollers e Remove all fold rollers starting from the top Make sure that the woodruff keys do not fall into the fold unit Replacement Install the new fold rollers gt When using rubber steel combination rollers make sure that the PE rings S of one roller are directly opposite the knurled steel surface of the other roller e Before replacing the parts in reverse order slightly 2 grease the mounting pins 2 of the levers The surface of all pulleys and deflector rollers as well as the drive belts must be free of grease Clean them if necessary or install new parts Before replacing the belts check the roller assembly for easy movement Make the basic setting of the fold rollers m Mathias B uerle GmbH 23 Service
44. r CAS 52 and CAS 38 multimaster 38 12 Mounting Instructions Always pull the power plug before making or breaking any electrical AN installation Plug the connecting cable of the operator panel into the socket 1 in the rear panel of the control box Route the power cord of the compressor 2 approx 30 cm through the strain relief and tighten it Route the power cord of the flat pile feeder 3 through the strain relief and tighten it Loosen the safety screw 4 against unauthorized opening of the control box 5 so that you can pull the control box towards the front Connect the power cord of the flat pile feeder and the compressor according to the wiring diagram wiring diagram 1s located inside the control box 5 i Route the power cord of the pump for vacuum 6 approx 30 cm through the strain relief and tighten it Route the power cord of the pump for air 7 approx 30 cm through the strain relief and tighten it Loosen the safety screw 4 against unauthorized opening of the control box 5 so that you can pull the control box towards the front a ggg Connect the power cord of the pump according to the wiring diagram wiring diagram s located inside the control box Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Operation 2 OPERATION Checki ng the
45. ration Compressor i Check the sense of rotation of the compressor motor Switch on the compressor by pressing button 1 Check the air flow at the hose fittings Single hose fitting vacuum Double hose fitting air Che B Ou Ch Oil s CH Bil vacuum air If air and vacuum are reversed the sense of rotation of the compressor motor must be changed Turn off the compressor by pressing button 1 Turn off the machine by pressing the main switch and pull the power plug Open the control box of the fold unit Switch two of the three black wires of the power cable of the compressor at the terminal block By doing this the sense of rotation of the compressor is reversed Close the control box plug in the power plug Turn on the main switch Check the compressor for correct function Slide the vacuum and air hoses over the hose fittings of the compressor and secure them with hose clamps Pumps The pumps are connected single phase to the corresponding terminals in the control box of the fold unit Checking the sense of rotation is therefore not necessary If necessary the intensity of vacuum and air can be adjusted at the pump by sliding the bypass ring 2 up and down over the bleeder hole 14 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Operation Setting Instructions for Paper Thickness Sensor CAS 52 and CAS 38 only Installat
46. spection The height of the vanes must be at least 35 mm 4 Vanes must always be replaced as a complete set The vane set must be replaced if the height of the vanes has reached the recommended minimum or less Place new vanes into the rotor slots taking care that the angled side 5 of the vanes points outwards and that this oblique side coincides with the shape of the housing in the sense of rotation 6 Reattach the cover 2 and the exhaust grid 1 Before operation check the blades for free movement by turning the fan For this the suction grid must be removed 41 Service Manual multimaster CAS 52 38 Service Instructions Pump Before carrying out any maintenance disconnect the pump from the mains and reliably prevent unintentional restarting Manufacturer Becker en Clean the cover of the fan and the surface of the er gt compressor to prevent overheating VA KLE lt a SS Ar i lt OI A Filter cartridge 1 So U Blow through the filter cartridges from the NE inside out 2 If grease or oil are found in the cartridge it should always be replaced e Cooling ducts 2 Clean the cooling ducts with compressed air when they are clogged Clogged ducts can cause overheating and the breakdown of the pump e Width of vanes 3 After 5000 hours inspect the width of vanes The minimum width is 28 mm Replace t
47. sufficient pressure of the fold rollers Remedy Reduce gap of roller 4 e g from 0 25 to 0 15 Potentiometer of gate fold plate in upper or lower end position Cause Folding speed too high Remedy Reduce folding speed set potentiometer to 3 E As soon asthe folding speed 1s changed the trigger moment for the deflector at the potentiometer of the gate fold plate must also be changed Further information about automatic setting via the operator panel 1s contained in the Operator s Manual 33 Service Manual multimaster CAS 52 38 Service Instructions Basic Setting of Segment Fold Plates 34 1 2 Check whether the fold plate to be set is in Zero position 0 Gy If not loosen one cap screw on each side and slide the fold plate to Zero position Retighten the screws Pull the connector 1 and remove the rear cover 2 hexhead screws Check whether the two set screws on gear 2 and one set screw on gear 3 are accessible If not replace the connector 1 and use the fine adjustment on your control panel to turn the gear motor until all set screws are in view Loosen the set screws and turn power off Pull the connector 1 3 Remove the fold plate from the machine and place it on a flat surface AN Never stand a fold plate on its mouth 4
48. sure of the rollers is checked by means of a paper strip Disassembly e Remove the fold plates or deflector e Remove both side covers e Mark roller drive belts right hand side left hand side The additional fold unit KF 31 is equipped with two drive belts that are gt different in length and are routed differently e Path of the belt on the right hand side seen in direction of paper transport Drive belt 1 with an inner length of the belt of 1144 mm e Path of the belt on the left hand side seen in direction of paper transport Drive belt 2 with an inner length of the belt of 1080 mm 46 Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Instructions e Remove both roller drive belts Turn the roller setting knobs 1 clock wise all the way to the stop basic pos e Loosen all hexhead nuts 2 on both sides and remove them from the fold rollers togehter with the washers e Pull off all pulleys on both sides Make sure that the woodruff keys are not lost e Auf der gleichen Seite die beweglichen Walzenlager ausbauen Dazu die Lagerbolzen 4 herausschrauben Bei diesem Arbeitsgang muss die innenliegende Befestigungsschraube mit einem Inbusschlussel gegen Verdrehen gesichert werden Unbedingt darauf achten dass die Zwischenscheiben zwischen den beweg gt lichen Walzenlagern und zwischen Lager und Seitenwand nicht verloren gehen Einbau der Falzwalzen e Neue Falzwal
49. t as described on the preceeding page Set the fold plate stop to 207 5 mm by means of the handwheel 4 This basic setting corresponds to a real fold length of 262 mm e Retighten one of the two Allen screws 3 e Loosen the Allen screw 5 with a 2 5 mm key With a small screwdriver turn the potentiometer at the shaft 6 in such a way that 262 is shown on the display of the operator panel Retighten the Allen screw 5 after the setting has been completed By pressing the plus resp the minus key on the operator panel move the gear 7 to a position where the second Allen screw 3 can be reached Retighten the second Allen screw 3 e Enter 0 on the operator panel and set the stop e Turn off the main switch Mathias B uerle GmbH Service Manual multimaster CAS 52 38 Service Instructions Basic Adjustment of Potentiometer Mathias B uerle GmbH e Unscrew the plug of the fold plate Position the cover 1 and fix it with the attaching screws 2 INZA
50. the flat pile feeder must be guided through the elongated hole in the register table Slide the register table exactly in the mating part of the flat pile feeder The holes for the mounting screws must line up exactly with the threads Check the correct height adjustment of register table and flat pile feeder Check for parallelism i e the gap between register table and flat pile feeder must be the same on the operator side and on the opposite side AN Do not bend or squeeze hoses cables or sheet metal parts Insert the connecting screws between register table and flat pile table 4 and tighten them Re insert the stud at the register table 6 Insert the plug of the paper thickness measuring device 5 and tighten it Mathias B uerle GmbH 5 Service Manual multimaster CAS 52 38 Mounting Instructions Remove the cover 1 of the flat pile feeder Pull off the round belt 2 from the pulley 3 Place the round belt 4 on pulleys 5 and 3 inside Place the round belt 2 again on pulley 3 out side N oe Re attach the cover 1 e Insert the plug register table in the receptacle flat pile feeder e Place the compressor on the floor between flat pile feeder and fold unit Mount the connecting bars 6 between the fold unit and the flat pile feeder using a JI 24 mm wrench 7 6 L
51. vice Program Special software version V 7 5 0 4 for systems This is used in connection with certain cutters or printers e g Stralfors and an extended register table There is an additional operating mode key F6 SETTINGS DELAY S S seconds MAIN DRIVE OFF 95 To make sure that the last sheet still reaches the register table after an ERROR PAPER FEED it is possible to switch off the drive with a certain delay A range of 0 9 seconds is possible Please note however that in this special software version it 1s not possible to choose between front edge or rear edge paper travel control In this mode the infeed section of fold unit 1 paper is always monitored by the trailing edge of the sheet 1 X00 12 99 Mathias B uerle GmbH 57
52. zen einsetzen Vor dem Einbau der Teile sind die Lagerbolzen an den Anlauffl chen leicht einzu len Darauf achten dass alle Umlenkrollen und Riemenscheiben frei von Schmier mittelr ckst nden sind Grundstellung der Falzwalzen pr fen ggf nachjustieren Die Grundeinstellung ist mit einem Testpapierstreifen auf die gleiche Weise zu pr fen wie dies im Kapitel Grundeinstellung Falzwalzen beschrieben ist e Die Nachjustage der Falzwalzen erfolgt beidseitig an der Walzenstellmechanik 5 durch Verdrehen der Stellschraube 6 bei gel ster Kontermutter Nach erfolgter Einstellung Kontermuttern festziehen und mit Sicherungslack sichern e Beide Seitenverkleidungen anschrauben e Zusatzfalzwerk in das Falzwerk einh ngen und Funktionstest durchf hren Mathias B uerle GmbH 47 Service Manual multimaster CAS 52 38 Service Program 4 Service Program All service functions can be called up by pressing key F12 Graphic Arts Parallel fold units Applications SERVICE 0000001111 OPTIONAL EQUIPMENT gt BASIC SETTING PAPER SENSOR gt SYSTEM PROG CONFIG VERS TEST The first item shown is the so called SUM This is a total counter counting all the sheets that have been folded on this machine It cannot be reset except by re initializing the battery buffered RAM or by clearing all counts If initializing becomes necessary for whatever reason the count should be written down prior to this operation Mathias
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