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THB_engl - prestigeFOLD NET52_V2-1 - Sensible Tech

1. EH AMS7 SKM36 D NS AM 52 Page 44 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 3 6 Paper Thickness Sensor 3 6 1 Basic setting of paper thickness sensor 1 Move the bearing upwards to make sure that roller C does not touch counter roller D To do this loosen screw A and turn screw B counter clockwise Control Base Counter Control Set up 2 Touch the Adjust paper thickness sensor LJ BT N Sae key in the Service Menu S f Password Bi y zu zu om Language English p Total machine counter 10 2 3 Password 4277 necessary CE B Plate reset Activation SES rw 1 e pi E Duae Adiust iesu Ext control Test e on on ww amp configuration switches Adjust Service Servi ie eldest sims inc Fe Speeds ma Foldunti 0 gt m min po Foldunit2 96 m min NN Foldunit3 m min 3 Slightly loosen the screws A 4 Using setting screw B set the uncorrected value to 0 20 mm 0 02mm corresponds to 32xx Bit Re tighten screws A shown in the picture of eo mm it Opio mm Bit Oo 0 20 mm Bit Delete all Oljos0 mm Bit E 4 functions n item 3 m min Fold unit 2 96 m min Fold unit 3 96 m min Mathias Bauerle GmbH Version 2 1 English 10 2005 Pa
2. FALZWERK 52 ANLEGER FSA FOLD UNIT 52 FEEDER FSA 606 00 22 gE m OOoOO0c00Oo000000005 000 AUSRICHTTISCH ALISNMENT TABLE gt AM 52 Auslage De very Ei Schr gollentisch links ROLLER TABLE left Schragollentisch ROLLER TABLE C Ssenkrechtauslage SKM 36 Vertical Stacker SKM 36 FALZWERK 52 0 0 4 FOLD UNIT 52 0 0 4 FALZWERK 52 FOLD UNIT 52 ANLEGER FSA FEEDER FSA Il 1 Se De ALIGNMENT TABLE 000000000000000 AUSRICHTTISCH FALZWERK 92 0 4 FOLD UNT 52 0 4 p NC FALZWERK 52 0 0 4 Schr gollentisch rechts FOLD UNIT 52 0 0 4 ROLLER TABLE right Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 7 1 Options The following options and accessories are available at the moment in connection with the prestigeFOLD NET 52 a Small format vertical stacker SKM 36 with kicker Option b Mobile knife fold unit MS 45 Please note that when using the MS 45 in connection with the shingle delivery AM 52 the delivery rollers cannot be set automatically A fine adjustment by push button is necessary
3. 9 Push the upper grate A forward until there is a gap B of about 0 3 mm to the deflector at the center of the fold plate Tighten the clamp screw A in picture of step 6 10 Push the brackets on the left and right hand side A in direction of the arrow and align them parallel B to the upper grate of the fold plate Tighten the hexhead nuts C Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 37 Service Manual prestigeFOLD NET 52 11 Check the 98 5 degree angle Use setting gauge A 98 5 degrees 2 024 014 12 If not correct readjust the potentiometer Potentiometer value larger Deflector swings further angle increases Potentiometer value smaller Deflector stops earlier angle decreases see step 5 Open the deflector Select buckle plate in the Correction Menu and enter a 260 mm fold plate length Loosen the Allen screw A set the flat of the cam B parallel to the block C 15 Loosen the Allen screw A and set the block C to a gap B of 4 mm Tighten the Allen screw A Page 38 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 3 4 2 Basic setting of fold plate stop potentiometer Tools Setting gauge 2 024 014 Fold plate extension cable 4 008 900 1 In the Service Menu Service Functions Motor Plate x Length Setup run the fold plate stop to the mechanical position NmmTTEEXS vae
4. S NETDCU3C3 Default Device My Documents NETWORK Program Files m Z7 Select directory FFSDISK Delete data files which are to be re installed INDIVIDUALLY EI Windows CE Remote File Viewer Fille View Connection Help B E FFSDISK Mathias Bauerle GmbH Falzarten casnekdb cdb EHES programme Guiexe Ex steuerung mfcce3 n dii BH e olece300 dll Version 2 1 English 10 2005 Page 63 Service Manual prestigeFOLD NET 52 Select Export file EN Windows CE Remote File iewer File View Connection Help FFSDISK EH programme EHI steuerung 3 olece300 dll pg www E My Documents E NETWORK Program Files Temp mg windows Export file to device Select the data file to be exported and click on Open Now the selected data file is transferred to the operator panel Please note If several data files are to be transferred select and transfer them INDIVIDUALLY Export File Suchen in Cy Client V 1 106 amp t E U Exe readme txt o m Li Deskto p in Les Arbeitsplatz Netzwerkumg le Dateiname Gui exe Dateityp A Files Abbrechen Schreibgesch tzt ffnen E Turn off the main switch and turn it on again The new software version must now appear in the menu window Configuration Page 64 Version 2 1 English 10 2005 Mathias B uerle GmbH Service Manual presti
5. C Additional fold unit KF 31 Please note that when using the KF 31 in connection with the shingle delivery AM 52 the delivery rollers cannot be set automatically A fine adjustment by push button is necessary d Anti static devices e Gate fold plate FFT 52 f Slitting scoring and perforating devices trimming center strip cut out g FSA Single blower h Kicker option for AM 52 Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 87 Service Manual prestigeFOLD NET 52 Page 88 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 8 Omron Inverter 8 1 Control Panel Top protection cover d Mounting holes Terminal Two block T SYSDRIVE 303JV INVERTER Digital Operator ALARM display RUN indicator Optional cover mrono t 24 nn nn NE NM eee WARNING cce edit Mees THs tes e Sepi man al telore insiging Sater ieee 23272 t SU FE wml im mM for cagato drszho ge 27er eil c O4Z2 COLA Bet 17 0 SCENON poser Sunes 42e 258 1 Front cover Terminal A2 7 ice 8 u Liezen ig Cermigursatrur y abt wir c block m qursnz nw susp y teulal bor SQV clars _ Front cover mounting screw Bottom protection cover Note 1 The front cover functions as a terminal cover The Digital Operator Unit cannot be removed Note 2 Instead of mounting holes each of the following models has two U shaped cut outs located diagona
6. Keep the fold roller from turning with a 15 mm open end wrench Use a marker pen to number all roller levers at the operator side to make sure that they are re installed in the same position 10 Remove the roller levers at the Operator side and pull out the rollers in this direction INSTALLATION 1 Re install the rollers with the matching roller levers one after the other observe the numbers LE NNI SMamdigdp O HMUMemepHeyonboldds 5 Replace te Mat elisonbomhsdes 6 Cany oattheroleradjusment mI MN Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 83 Service Manual prestigeFOLD NET 52 Page 84 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 7 System Configurations a Parallel folding machine prestigeFOLD NET 52 4 or 6 FSA Auslage Delivery FALZWERK 52 ANLEGER FSA i Ms FOLD UNIT 52 FEEDER FSA a Senkrechtausla
7. shown in the picture of item 2 Totor Password 4277 necessary Fold unit 3 96 m min 2 Mechanical position between round shaft A and paper stop B must be 238 5 mm Use setting gauge A 238 5mm 2 024 014 3 Loosen Allen screw A at gear B and slide it sideways out of mesh 4 In the Service Menu Service Functions select Potentiometer Plate x Length Setup and touch the Off key which then changes to On Turn gear C in picture of step 3 at the IE E potentiometer until the bit value 8 528 appears J Fold unit3 m min Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 39 Service Manual prestigeFOLD NET 52 5 Re engage gear B and re tighten Allen screw A see picture of item 3 3 4 3 Readjusting the fold plate length Tools A3 80 GSM paper Fold plate extension cable 4 008 900 This is done in the Service Menu under Adjust plates from software version x x x 1 Select Adjust plates in the al EOM GN Seres Password valid Language Engish Total machine counter io 2L 3B oo Plate reset Lm bru m BERET an ue info thickness sensor actions functions Speeds Folduniti fo 96 2 m min Foldunit2 96 m min Foldunit3 X 96 m min Service Menu 2 Select the fold unit Base Counter Control Set up Correction Job Configuration Service Set Delete all
8. An emergency stop alarm is input to a multi function input A multi function input 1 2 3 or 4 set to 19 or 21 has operated e The internal circuitry of the Digital Operator has a fault Turn the Digital Operator off and on Replace the Digital Operator if the same fault occurs again e An emergency stop alarm is input to a multi func tion input Remove the cause of the fault eThe sequence is incorrect Check and change the external fault input sequence including the input timing and NO or NC contact e No power supply is provided Check and correct the power supply wire and voltage e Terminal screws are loosened Check and tighten the terminal screws e The Inverter is damaged Replace the Inverter Power supply error e Insufficient power sup ply voltage e Control power supply fault e Hardware fault Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 95 Service Manual prestigeFOLD NET 52 8 2 2 Warning detection minor faults The warning detection is a type of Inverter protective function that does not operate the fault contact output and returns the Inverter to its original status once the cause of the error has been removed The Digital Operator flashes and display the detail of the error If a warning occurs take ap propriate countermeasures according to the table below Note Some warnings or some cases
9. The holes for the mountings screws must line up exactly with the threads Check the correct height adjustment of register table and flat pile feeder Service Manual prestigeFOLD NET 52 Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 9 Service Manual prestigeFOLD NET 52 Do not bend or squeeze hoses cables or sheet metal parts Insert the connecting screws between register table ART and flat pile table FSA 4 and tighten them Insert the plug of the paper thickness measuring device 5 and tighten it Remove the cover 1 of the flat pile feeder Place the round belt 4 of the register table ART on the pulley 5 of the flat pile feeder FSA Re attach the cover 1 Insert the plug register table in the receptacle flat pile feeder Place the compressor on the floor between flat pile feeder and fold unit and make the electrical connection 10 Mount the connecting bars 6 between fold unit and flat pile feeder 24 mm wrench Page 10 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 11 Mount the sliding door at the operator side 12 Hook in the rear cover and lock it in place 1 2 Electrical Installation 1 2 1 Checking the line voltage 1 Check the three phase socket before turning on the machine for the first time When making or breaking any electrial connection always first turn off the main switch or flip the safe
10. eee eee e eene eee eeu 77 5 2 Information about the Control Board cssssssssccccsssssssssssssccccssccsssssssssscscoes 78 5 3 Setting Instructions for the Reflection Light Sensors 00000000000000000000000000000000000 79 Page 4 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 6 Mechanical HardWaEB eie oc iere vo eve eoo a eV Pao e Eee o Yee Pepe aea re Ue epa ee vede aad 1 6 1 Belts for Fold Roller Drive 1 0 2 Replacing th Fold Rollers za 82 7 System C ONMPULAUIONS ovcsacedes icevacetes ciesecessddescuecctesesesveesdsacstareseanacstarsseccsedses 85 MESI E E E E E E E E E E EEE 87 8 Omron IDverteE wcscsicecedcsasesciccscescoaceuesseceaseesdecisesseccesassseasioussecseescasisecssessesees 89 MEGUDUMDNISESTTTT TT TETTE 89 5 2 Faul DISDIOV idee e EAR Eee TREE 91 8 2 1 Kauledetecet10n major DU arena 91 8 2 2 Warning detection minor faults 5 iio RL SR osque toeud Dude 96 8 3 Parameter SellINP e S 99 8 3 1 Description of pParameler setting aus IHE e din Eod a E REEL SUPE EGER Pe EAEE ade 99 9 Cleaning and Maintenance ssusssseesesenssssueeenusesusssnannnsesssssuensuesssessuesnueene 103 9 1 General Information Maintenance Instructions ccccsssccsssscccssscccssssccessscoess 103 9 2 Cleaning the Fold Rollers and Transport Rollers 104 FOS DECAL TOOL s odi ete EE 106 Mathias Bauerle GmbH Version 2 1
11. 1 Select the Service Menu A by touching the reden e erem Service Service tab Job name Job number Counter Total Preselection fio Remainder o C Kicker Control Paper travel control 2 Enter the password in the input window A m Base Counter EE Control Seta Correction Job Configuration Service Valid 1 2 3 4 5 6 8 9 0 Del P Clear seal Y X Enter V 3 After the password has been entered correctly the following message appears next to Valid A Base Counter Control Correction Job Configuration Service Password gO valid Language English PW I for service level 1 PW 2 for service level 2 fio 2 m min 96 m min 96 m min Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 15 Service Manual prestigeFOLD NET 52 4 Now the enabled functions in the service menu can be selected M Please Note To disable access to the service menu the password must be cancelled or a wrong password must be entered OR Turn off the machine by touching End and turn it on again 2 3 Functions in the Service Menu Bezeichnung im Functions without PW PW 2 Display password 4250 4277 Adjust Roller Adjusting the fold rollers DI Adjust Plates Adjusting the fold plates Ext Control Configuration of the DISPLAY Configuration external Stop in
12. EANHEET DISCONNECT AN Delete selected File ADMINISTRATION DELETE COPY ERIT Page 51 Service Manual prestigeFOLD NET 52 8 Press the COPY button 1 to load a new version of the file Another window is opened where the file to be copied can be selected If no files are visible All Files must be selected under Files of type 2 Select the appropriate file 3 and confirm with Open POPPI Dateiname Gui exe y 3 2 4 9 The file transfer starts after the Open button 4 has been pressed i RemoteAdmin E xi CORNENT OF FFSBISE COMMUNICATION PORT adace31 dll 128088 com adacedb3l dl 5722 Bytes ZG NM ETT 3I SEIN NETT canread exe 5632 Bytes canwrlte exe 5532 Bytes casnetdb cdb 180224 Bytes ADMINISTRATION D BA amp dmin exe 115224 Bytes DoppelParallelfalz bmp 1342 Bytes DELETE Fensterfalz bmp 1342 Bytes FensterfaleGeschlassen bmp 1342 Byt N cory French UB lang 50696 Bytes Halbfalz bmp 1342 Bytes N d KeinFalz bmp 1342 Bytes m k r br 1 L I LEE 1 A p LI ib HEEFRHESELFIEEVIE V ERIT Ne adaceoledb31 dl 76331 Byss adoxce31 dl 236633 Bytes cancmd ex e 1126 4 Bytes CANINTF dll 34301 Butes 1 10 Repeat steps 6 to 9 if you want to transfer more files Page 52 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 4 3 Data Transmission via FTP 4 3 1 Preconditions An F
13. English 10 2005 Page 5 Service Manual prestigeFOLD NET 52 Page 6 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 1 Operation 1 1 Mechanical Installation Setting heights during installation During the installation process the following setting heights of the folding stations must be observed 1 1 1 Folder 1 fold unit Type Number of Infeed height FSA Frame height Bridge inclination Outfeed height fold plates see Fig 1 see Fig 2 see Fig 3 see Fig 3 prestigeFOLD NET 50 6 6 fold plates 1060 mm 100 mm 20 mm 920 mm prestigeFODL NET 52 4 4 fold plates 1040 mm 80 mm 40 mm 920 mm Fig 1 Fig 2 Fig 3 1 1 2 Folder 2 fold unit Type Number of Infeed height Frame height Bridge inclination Outfeed height fold plates see Fig 4 see Fig 5 see Fig 3 see Fig 3 prestigeFOLD NET n 52 0 6 6 fold plates 920 mm 130 mm 20 mm 780 mm prestigeFOLD NET 52 0 4 4 fold plates a 130 mm 40 mm 800 mm f no third fold unit is used you can reduce the heights by 30 mm The height difference resulting from this reduction is compensated by the transfer bridge at the first fold unit Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 7 Service Manual prestigeFOLD NET 52 Fig 4 1 1 3 Folder 3 fold unit Type Number of fold Infeed height Frame height Outfeed height plates see Fig 4 see Fig 5 see Fig 3 prestigeFOLD NET 52 0 0 4 4 fold pla
14. and check and repair the wiring eThe cooling fan in not in good condition Check and remove the foreign material or dust on the fan eThe cooling fan is beyond repair Replace the fan Page 98 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 8 3 Parameter Setting 8 3 1 Description of parameter setting Example Changing the value of constant no 02 operation mode selection to 3 ate eg NN NNNM operation data PH Press the Mode Key until the PRGM indicator I Ed 177 minimal Press the Increment Key n02 appears in the data display section Press the Enter Key The value of constant no 02 is displayed Flashinc Change the value to 3 by pressing the Increment Key The data display section flashes indicating that the value is yet to be registered Press the Enter Key The data display section stops flashing After approximately 0 5 second the data display section returns to the constant no display n02 Wie L N dbp M FU u Flashing gU De In 3 53 D rm Am Amt per pmo E After 0 5 second Note 1 If the new data is not to be registered press the Mode Key instead of the Enter Key The new data becomes invalid and the constant no display n02 is re turned Note 2 Holding down the Increment Key or Decrement Key changes data quickly Mathias Bauerle GmbH Version 2 1 English 10 2005 Page
15. mi 1 1111 1 Tis B PEST ET EID LI id TE m ap His 15 Sis oa tes rn Fi gl Oy WT sa yx h te idi m The following information is saved in the Flash Eprom Software for control board Correction values of the fold rollers gt Correction values of the fold plates Please note If a control board including the additional board A is be replaced the following steps must be performed 1 Install software 2 Readjust ALL rollers in this fold unit 3 Readjust ALL fold plates in this fold unit When replacing the control board it is recommended to use the existing additional board A This will make it unnecessary to carry out the above mentioned steps Also see Chapter 4 4 EEprom Management Page 78 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 5 3 Setting Instructions for the Reflection Light Sensors General information The reflection light sensors of the double sheet detection are factory set If malfunctions occur check whether there has been a change in the sensitivity of the light sensors Setting the sensitivity Introduce a dull black paper on both sides between light sensor and reflection plate Adjust the sensitivity at the integrated potentiometer A so that the paper is just barely recognized The red LED B lights up Function check Lighting up of the red light emitting diode B signals recognition For reflection light sen
16. sequence including the input timing and NO or NC contact Digital Operator transmission fault 1 F00 An initial memory fault has been detected Digital Operator transmission fault 2 F01 A ROM fault has been detected e The internal circuitry of the Inverter has a fault Turn the Inverter off and on Replace the Inverter if the same fault occurs again e The internal circuitry of the Inverter has a fault Turn the Inverter off and on Replace the Inverter if the same fault occurs again Page 94 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 Fault display F04 Probable cause and remedy Fault name and meaning Initial memory fault F04 An error in the built in EEPROM of the Inverter has been detected eThe internal circuitry of the Inverter has a fault Initialize the Inverter with n01 set to 8 or 9 and turn the Inverter off and on Replace the Inverter if the same fault occurs again e The internal circuitry of the Inverter has a fault Turn the Inverter off and on Replace the Inverter if the same fault occurs again Analog to digital converter fault F05 An analog to digital converter fault has been detected Digital Operator fault F07 An error in the built in control circuit of the Digital Operator has been detected Emergency stop STP
17. 4 3 3 Connecting A second window is displayed immediately after the start If this window does not appear press the communication button 1 shown in the picture on the previous page The following window should now be displayed 1 Site Manager m e Display amp dy Site Mame buds Disp Display Host IP URL 192 168 78 155 Username anonymous Anonymous Password E Don t zave Fort Timeout Retes 21 EO 2 Er On Options P sv SSH SFTF Use Prox pies ol SES TH AUTH TLE Comments SSL Direct M SSL Transfers OpenSSL windows SSL Mew Category Connect Manager 2 3 a Ifaconnection was established before the connection in question called Display in this case can be used again Select the entry Display 1 in the tree structure and press the Connect button 2 b When establishing the first connection enter the values as shown in the above illustration The Site name is the desired name which will subsequently be taken over in the tree structure in the left section of the illustration and can be re used in later sessions This name is user defined All other entries such as IP Port etc must be adopted as described above There is no need to specify the user name because the user name and its password are set automatically as soon as the Anonymous Checkbox 3 is activated Now press the Connect button 2 to SKMrt the connection If successful the Site n
18. File button All values are now written into the appropriate file and the table is up dated The values of the EEprom and the file should now be identical 4 9 3 Writing EEprom values Press the File gt EEprom button to write values from a backup file into the EEprom When pressing it all values that are not identical are sent to the EEprom and saved there 4 9 4 Memory numbers of the EEprom The memory numbers of the EEprom are defined as follows 00 08 J o O 06 1702 o0 o E o To determine the machine counter use the values 48 and 49 as follows Machine counter 49 65535 48 22 25 4 AD values of the paper thickness for memories 1 4 1 6 Page 74 Version 2 1 English 10 2005 Mathias B uerle GmbH Service Manual prestigeFOLD NET 52 4 10 Software Versions The different software versions for the prestigeFOLD are defined as follows Example Software Software Display Machine V 1 3 01 V 1 3 05 EN Version Level Level Graphic arts Graphic arts 2 Lettershop 2 Lettershop a MTM IE eben Explanations e The first digit indicates whether it is software for graphic arts or lettershop machines or other software The software of the display and that of the machine must show the same digits e The second digit indicates the software level Different software versions between display and machine but with the same level are compatible However malfuctions may occur if the software of the di
19. 99 Service Manual prestigeFOLD NET 52 List of Parameters File name Date 14 07 2004 Time 9 11 AM Series Name 3G3JV Installation type Option A Voltage Class 2 Maximum Motor Capacity 007 opecifications opecial Specifications Software Number 20 Description Stopping Method Selection C n05 Reverse Pt n06 n07 Key sequential Frequency setting Qoo Freq Ref Sel in Local Mode Co 860Hz 86 0 Hz n12 1 5 Hz n17 n18 n19 n20 S shape AccelDecelcharacteristio LT n09 n10 n11 n13 n14 n15 Frequency Reference Lower Limit n33 MotorProtecioncharacteristics T0 O 5 3 n38 Multi Func Input 1 Input terminal S2 C_m Multi Func Input 2 S3 eo n38 Multi Func Input 3 S4 Page 100 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 n39 Multi Func Input 4 S5 21 n40 Multi Func Output MA MB and MC output terminals 0 Analog Freq Ref Filter Time n44 Analog Monitor Output Item Selection Z O T0 O a 50 n45 00 n46 n47 Momentary power interruption compensation n48 Stall Prevention during Deceleration Cd O Overtorque detection function selection UP DOWN Command Freq Memory Cid 2 5 Hz Motor No Load Current n49 n50 n51 n52 n53 n54 n55 n56 n57 n58 n59 n60 n61 n62 n63 n64 n65 n66 Slip Compensation Gain Slip Compensation Time ConSKMnt Time over detection selection i i Bo u NN
20. Loosen the flat head screw SW 3 and swing out the roller motor mounting plate SW3 Password 4277 necessary Machine must be started in the service mode gt see 2 4 Set the steel gear by hand so that there is gap of 0 5 mm between the bottom of the steel gear and the brass block gt use a feeler gauge Now the potentiometer can be removed by loosening the Allen screw SW2 2 mm Allen key and cutting the plug connection Page 34 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 4 Touch the Service Functions key in the Service Menu Select the appropriate potentiometer Roller X Front Rear and Potentiometer set the AD converter to ON Alignment Table Then install a new potentiometer and set the Bit value to 3 279 tighten the set screw SW 2 2 2 mm Allen key ES ame E rr A 5 Return the mounting plate to its original position and re attach it with a flat head screw SW 3 Please note Prior to the basic setting of the rollers step 6 steps 1 to 5 must be carried out also at the opposite side of the roller 6 Now proceed to the mechanical basic setting of the roller For this loosen screw A and set the roller pressure with screw B Check the roller pressure with a paper strip 30g m Re tighten screw A 7 Now proceed to the fine adjustment of the roller pressure as described under 3 3 2 re
21. cable Network cable 4 008 920 For client software operator panel Notebook with configured network interface and Connection via network software CE Remote File Viewer installed Network interface card Network cable 4 008 920 Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 49 Service Manual prestigeFOLD NET 52 4 2 Client Software Operator Panel via Serial Cable 1 Connect the display and the notebook with a serial crossed female female cable At the display use the connector that is located furthest to the right COM2 7 CAN 259 channel Network connection i Li 2 If the display program is running at this time it should be closed with the End button 3 Start the program RemoteAdmin on the notebook directly from the Service CD file RemoteAdmin 4 Select the serial interface where the serial cable of the notebook is connected In most cases COMI is the correct choice ERemoteAdmin CONTENT OF FFSBISE CONNECT WECUNNEET ADMINISTRATION DELETE corr REFRESH FILENE ERIT 5 When everything is connected correctly the content of the display hard disk is shown when pressing the CONNECT button see the following picture Page 50 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 SS RemoteAdmin CONTENT OF FFSBISK adoces1 dll 126088 Bytes adocedb 30 dil 5722 Bytes adocedb31 dll 126554 Bytes adocealed
22. length in display 200 mm Actual fold length measured on paper 198 3 mm Difference 1 7 mm Difference in Bit 1 7 x 32 8 Bit 55 76 Bit Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 41 Service Manual prestigeFOLD NET 52 2 Loosen the Allen screw A at the gear B and push the gear sideways out of mesh 3 In the Service Menu Service Functions select Potentiometer Plate x Length Setup and touch the Off key which then changes to On Light barrier f Alignment in vau of Turn the potentiometer gear C in picture of EP Finish item 2 until the displayed bit value i Fold unit3 m min difference in bit appears bz Example 1 8 528 Bit 4 2 Bit 8 577 Bit Example 2 8 528 Bit 55 76 Bit 8 472 Bit 4 Re tighten the Allen screw A in picture of item 2 on the gear B in the picture of item 2 5 Select Plate reset in the Service Menu after the correction of the potentiometer value 6 Check the fold length Repeat the correction if necessary Page 42 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 3 5 Basic Settings of Shingle Delivery AM 52 3 5 1 Position of the delivery rollers 1 Move the delivery rollers to the stop A at their shortest position by means of the keys at the operator panel AM 52 2 Remove delivery rollers and bracket A at the Non o
23. monito SlveAddess O o 1 1 1 1 0 n72 Parity selection O 0 n74 RTS Control 0 O n75 Low Speed carrier Freq Reduction Selection 0 1 n76 CopyFuncionSeletion O Z O O 0 O n77 Parameter read out selection O O O 0 O n78 Er o 0 0 0 o O 20 n67 n68 n69 n70 n71 Mathias B uerle GmbH Version 2 1 English 10 2005 Page 101 Service Manual prestigeFOLD NET 52 Page 102 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 9 Cleaning and Maintenance 9 1 General Information Maintenance Instructions Cleaning and maitenance Cleaning and maintenance contribute to a long life of the machine and a consistent quality Therefore it is important to clean and service the machine in regular intervals The interval between maintenance jobs depends on the workload Minimum requirements Cleaning Once a week the operator should remove paper or print powder dust from all fixed and movable parts of the machine Do not use any solvents such as Aceton or Toluol 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 rear edge separator Check lifting suckers for wear replace if necessary Check that moving parts move freely Check all
24. pressure as described in chapter 3 3 2 resp save the value of the roller being set in the Service Menu Adjust Rollers Page 30 Version 2 1 English 10 2005 Mathias Bauerle GmbH 3 3 2 Readjusting the rollers 1 Touch the Adjust Rollers key in the Service Menu Password 4277 necessary Machine must be started in the service mode gt see 2 4 2 Select the fold unit 3a Hold a paper strip under the paper thickness sensor or SD 2 55 proceed with 4b 4a Tranfer the thickness of the paper strip by touching the Accept key or 4b Enter the thickness of the paper strip directly in the input window Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 Base Counter Control Setup Correction Job Configuration Service Password O Valid Language English Total machine counter 10 2 F 3 Plate reset Speeds Fold unit 1 fio 2 m min Fold unit 2 m min Fold unit 3 96 m min Fold unit a Paper thickness sensor 074 mm F pt E e E SEES Set value Motor m Hr Right Bit TI mm n Discard Save End E Control Set up x 4 Version 2 1 English 10 2005 Page 31 Service Manual prestigeFOLD NET 52 5 Touch the Set key All currently set roller values are saved and all rollers are DAE Paper thick positioned according to these values Input Set value Left Right 6 Che
25. stop the operation of the Inverter as described in the table 2 Warning Displays and Processing Fault display Probable cause and remedy Fault name and Meaning Uu Main Circuit Undervoltage e Power supply to the Inverter has phase flashing UV loss power input terminal screws are The main circuit DC voltage has loose or the power line is disconnected Kr the undervoltage Check the above and take necessary etection level 200 V DC for countermeasures the 3G3JV A2 and 160 V DC for the 3G3JV ABL e Incorrect power supply voltage Make sure that the power supply voltage is within specifications Ou Main Circuit Overvoltage e The power supply voltage is too high flashing The main circuit DC voltage has Decrease the voltage so it will be reached the overvoltage within specifications detection level 410 V DC oH Radiation fin overheated OH The ambient temperature is too high flashing The temperature of the Ventilate the Inverter or install a radiation fins of the Inverter has cooling unit reached 110 C 10 C oL J Overtorque detection OL3 e The mechanical system is locked or has flashing There has been a current or a failure torque the same as or greater than the setting in n60 for overtorque detection level and that in n61 for overtorque detection time A fault has been detected wi
26. 05 Page 93 Service Manual prestigeFOLD NET 52 Fault Fault name and Probable cause and remedy display meaning oL 3 Overtorque detection eThe mechanical system is locked or has a failure OL3 There has been a current or torque the same as or greater than the setting in n60 for overtorque detection level and that in n61 for overtorque detection time A fault has been detected with n59 for overtorque detection function selection set to 2 or 4 Check the mechanical system and correct the Ground fault GF cause of overtorque e The parameter settings were incorrect The ground fault current at the output of the Adjust the n60 and n61 parameters according Inverter has exceeded to the mechanical system Increase the set values in n60 and n61 the rated output current of the Inverter EFO External fault D EFL An external fault has been input from a multi function input A multi function input 1 2 3 or 4 set to 3 or 4 has operated The EF number indicates the number of the corresponding input S2 to S5 A ground fault has occurred at the Inverter output Check the connections between the Inverter and motor and reset the fault after correcting its cause e An external fault was input from a multi function input Remove the cause of the external fault eThe sequence is incorrect Check and change the external fault input
27. 3 Potentiometer Alignment Table v Value Motor Alignment Table Light barrier Alignment in Fold unit 3 96 m min Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 25 Service Manual prestigeFOLD NET 52 3 With Motor ON and Sense of Rotation up down run the alignment rail to the position shown in the picture Use setting gauge A 150mm 2 024 014 ee Base Counter Control Setup 4 Select Potentiometer Alignment Table reci n T Canfiauratioc Service Register Table and touch the O which then changes to On Dir Up o e Imps switches Light barrier Alignment in Value Off nctions Finish Fold unit 3 96 m min 5 Turn the potentiometer until 11 586 Bit appears in the display 11 586 Bit 358 mm 27 Bit 1 mm 6 Quit the service menu by touching the Correction menu tab Run the alignment rail by entering a random dimension 105 0 mm Fold unit 2 mm Fold unit 3 mm ee Update Fold Read in paper Page 26 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 7 Then enter 358 mm and run the alignment rail to this position 8 The distance to side panel should be 150 mm Use a setting gauge A 2 024 014 to check Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 27 Service Manual prestigeFOLD NE
28. D Mathias B uerle GmbH Gewerbehallestr 7 11 D 78112 St Georgen Mm Tel 07724 882 0 Fax 07724 882 111 Serviceline 49 7724 882 250 E Mail center mbfold de m MATHIAS B UERLE Service Manual PrestigeFOLD NET 32 Version 2 1 English Version 2 1 English 10 2005 Service Manual prestigeFOLD NET 52 Page 2 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 Contents T ODIO 1 MCN Ll Mechanical Installation aaa aa a VE Fue Y TRE ev TENTER ga 7 Setting herehitsduring installation ae Dei a ne En tates 7 1 1 1 Folder tl Stal0n ARS m ME 7 14 2 EOlder 2 SEI O0 er doeet ATO Re ON eR dO ilc iua d E Edd ras us 7 1 1 3 FOldepd 5 95400fl nenne 8 1 1 4 Flat pile teeder ES dos oue Lee pep totes eb ee 8 1 1 5 Folding station with register table ART un a PPS RU Eu E gcn UE PU Ut eda cds 9 1 1 6 Connecino COMPON SING needed ee 9 1 2 Bleetrical Installation auctions are neh 11 1 2 Checking the lire volate us opted dbi tese sale 1 1 2 2 IAC PING 1er der ES Ass tes atomic uno E ee ee 12 1 2 3 CODES SO eon tod een opu tedio e Sotto ano Por adit Suede 13 1 2 4 Checking the setting of the paper thickness SCNSOL ssseeesssseeceeceeeeeeeeeaeaeeeeseseseeceeeeeeeeeeeaaas 14 2 TOOK VIGO NOUN 2er essen L 2 1 Access Codes Password ecran 22 esas wacko seres deve Ioue donet ees devel vez dspetus a duse luus 15 2 2 entering the Password COE onini rr EPI ERES la eu 15 2 5
29. FI gt gui dBlattFormat IGDhBlattFormatTahbelle Dumph llData amp aufgerufen Filename ffsdisk Blatt Format fdb Filesize 336 Bytes Datensaetze 6 Datensatz PK 2 Ei DIN A4 Y 4 4 Page 68 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 When the administration is completed the communication with the display should be terminated by the command exit The following message should appear Verbindung zu Host verloren CM Then the DOS window can be closed Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 69 Service Manual prestigeFOLD NET 52 4 8 Machine Software Control Board Start programm TQLoad of the Service CD TQLoad BootStrapLoader C167 settings 38400 Made C SRAM Flash Terminal Options D DatentEigene Dateien auf DD ateienMASCHINEN prestigeF LD soft pL Path E sit Select the file to be transferred and click on Open ffnen Sucher ir 3 Maschinensteuerung a w1 D05 CMP C166 Enw HEX vi 106 CMP C156 Env HEX v1 107CMP C166 Env HEX Dateiname v1 106 CMP C166 Ens HEX Dateityp Hes BB Files hB5 hex Abbrechen E Page 70 Version 2 1 English 10 2005 Mathias B uerle GimbH Service Manual prestigeFOLD NET 52 Start transfer with Go i TQLoad BootS
30. Fold plate setting Fold plate Adjust Set value mm k Save Delete Current correction mm Measured fold length mm za End Setup Correction Job Configuration Service 3 Select the fold plate to be corrected LC Base Counter Conor and have it set by touching Adjust The selected fold plate is set to 260 mm All other fold plates are P clo sed Fold plate Set value mm R Save Delete Current correction mm Measured fold length mm ee End Page 40 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 4 Start a sheet 80 GSM by touching key A The speed is set automatically to 50 5 Now measure the folded fold length and aaa E ee GA E Correction Job Configuration enter the measured value in the input SIERT ET window Measured fold length Then touch the Save key mm Discard End n Ba mm m Save Delete 6 Now select the next fold plate proceed to item 4 or finish the correction by touching the End key or under 3 4 2 Basic setting of the fold plate stop potentiometer Please note the following two examples 1 mm equals 32 8 Bit Example 1 Nominal fold length in display 200 mm Actual fold length measured on paper 201 5 mm Difference 1 5 mm Difference in Bit 1 5 x 32 8 Bit 49 2 Bit Example 2 Nominal fold
31. Functions m the Service Mer osse ee eek s dade Pea n sehen a Eo vu ea ue eR S RE E EUR 16 3 Potentiometer Settings 2 0 0 3 1 Basic Setting of Flat Pile Feeder FSA e eere eee eee eee eee e eee eee ee eee eee eoe 19 3 1 1 DIIC AAE EEE TI rr ee EESE ree 19 3 1 2 Position of the automatic sheet separator HK Tannet a E 21 3 2 Basic Setting Register Table ART Inclined Roller Table SRT 23 22 Position of the register sidelay ART Folder 1 Station cccccsssssssesesseeeeceeeeeeeeeeeeaas 25 3 2 2 Position of the register sidelay SRT Folder 2 3 Station usessssssnnnnnnnnnsneeeeeeeeennnnn 25 3 3 Basic Setting of Folding Station sscccssscccsssssssssssssccccsccssssccssssccccccssssssscsscocsses 29 3 3 1 Basic toller setina MM HH T m 20 3 3 2 Readj sunsthe FOIE Sue ns een ee er 31 3 3 3 REplacins theroller potentOHelef seo ee 34 3 4 Basic Setting of Buckle Plates ooossssseeccccccsssscccccccsssssccecceocosssssscccocosssssseceesssssssssee 36 3 4 1 Basic setting of deflector potentiometers ans enar a ee 36 3 4 2 Basic setting of buckle plate stop potentiometer uuusssssnssssnnnnnnnnnnsnsnnnnnnnnennennnnnnnnnnnnnnnnnenennnn 39 3 4 3 Read Us hte the buckle plate lene i nee a 40 3 5 Basic Settings of Shingle Delivery AM 52 ecce eere eee eee ee eee ee eee ee eeeeoos 43 3 5 1 Positiomof the delivery Toler
32. SCE TLSTUB OLL And launch CEMGRCE E with the following cmd line YT TCRIPC OLL 0 0E 043139322E 31 36392E 37 382E 31 353300 Cancel Copy this text Mark text right mouse button copy Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 61 Service Manual prestigeFOLD NET 52 Start DOS input window 7 Eingabeaufforderung Microsoft Windows 26680 Wersion 5 44 2195 C gt Copyright 1985 2000 Microsoft Corp GiM ua Enter telnet 192 168 78 155 and press the return button the following message is displayed Pocket CMD V3 0 Please note If the address is unknown it can be tested with ping 192 168 78 xxx Enter cemgrc move the mouse pointer to the DOS input window and press the right mouse button the text copied before is pasted Press the return button Switch to program window Manual Server Action and click on OK Manual Server Action E x Please make sure the following files are on the device Sw I NDS S SEepipo dli WINDOWS SCEMGAC EXE WINDOWS SCE TLS TUB OLL AndNaunch CEMGRLE E with the following cmd line PT TCPIPE DLL D 0E 0431 393226 3136382 aragzE 41 353900 Cancel Page 62 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 Switch to program window Windows CE Remote File Viewer EN Windows CE Remote File Viewer E Bl x File View Connection Help Bal Sa le eE a
33. Sa ie 43 3 5 2 Jumper assisnment n the delivery board su Es 44 Mathias B uerle GmbH Version 2 1 English 10 2005 Page 3 Service Manual prestigeFOLD NET 52 3 6 Paper I h cknesssensora 2 EEK EB ee ev eE eee on EE Due eleva avec a duel ee iav en eR ERREUR 45 3 6 1 Basic setting of paper thickness sensor ccccccccccccsssseseeeeeeeececeeeeeeceeeeeeaaaasaeseeeeeeeeeeeeeeeeaaaasaeesaes 45 3 7 Defined AD Converter Values of the Recognition Potentiometers 47 3 7 1 Igsvarcimirvereuiisrm etc n eed 47 3 7 2 Folding station ID DIP switch recognition eeeeeeeesseseeeseeeeeeeeenenn n nnne nemen nennen nnns 47 3 2719 Recognition of the subsequent module eeesssssssssssssssssesessee nennen eene enne nnne nn nns 47 3 7 4 Buckle Plate TeECOOMILION cns einen 48 92142 Pola roller T6COPTHIUOTL sata a a Mas 48 4 Software o0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 49 4 1 Equipment Needed eee ext eia een e Pe E PEE e SERE E EIER SERES 49 4 2 Client Software Operator Panel via Serial Cable 50 AS Data Transmission via ELP aussi 53 4 3 1 PEC OMGILI een ee nee eure ua 53 4 3 2 PPO cra miss at Yen ED cR MN disc Pd CR Ul Reti 53 4 3 3 OHNE INS einen eines 54 4 3 4 Data CANS ERIT IET Uoc 35 4 3 5 Upload copying f
34. T 52 Page 28 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 3 3 Basic Setting of Fold Unit 3 3 1 Basic roller setting 1 Loosen the flat head screw SW3 3 mm Allen key and swing out the roller motor mounting plate Password 4277 necessary Machine must be started in the service mode gt see 2 4 Set the steel gear by hand until a gap of 0 5 mm is reached between the bottom of the steel gear and the brass block gt use a feeler gauge Touch the Service Functions key in the Service Menu Select the appropriate potentiometer Roller X Front Rear and j on m set the AD converter to ON Alignment Table t Light barrier S Then set the potentiometer to the Bit value of r TE vae 3279 and tighten the set screw SW 2 Finish 2 mm Allen key i Foldunit3 mmn Mathias B uerle GmbH Version 2 1 English 10 2005 Page 29 Service Manual prestigeFOLD NET 52 4 Re position the mounting plate and secure it with the flat head screw SW 323 mm Allen key Please note Prior to the basic setting of the rollers Pos 5 steps 1 to 4 must be repeated at the opposite side of the roller Now proceed to the mechanical basic setting of the roller Loosen screw A and set the roller pressure with screw B using a 30 GSM paper strip Re tighten screw A Now proceed to the fine adjustment of the roller
35. TP client program installed on the notebook is needed to transmit data programs to respectively from the display via a network This program is located on the Service CD and should be installed on the notebook Moreover the notebook must be configured in such a way that it is network capable min 10MBit and should be able to contact the IP address 192 168 78 155 If a network configuration is necessary your EDP department will be pleased to help you A documentation to test the network connection for proper function is contained in chapter 4 7 1 4 3 2 Program start Once the FTP program has been installed successfully on the notebook you can start it immediately During the loading process a small window pops up which provides information about the licence Non registered versions are delayed by a few seconds Then the following program window appears and you can start to connect to the display 1 Lore FIP cE File View Sites Manage Help K e AE Welcome to Core FTP release ver 1 35 build 1416 02 U EI 2003 2005 Wn Sock 2 0 ham 223 326 EB Wit 2 087 024 EB Started on Thursday Aprl 21 2005 at 13 05 Ph t ER 2 23 05 1 r7 DBAdmin exe 02721705 1 Gui exe 02721705 1 E Guid exe O2 23705 1 A GuiH ere 2 23 08 1 readme tet 02 71 05 1 Destination Bytes Size Rae Ma transfers Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 53 Service Manual prestigeFOLD NET 52
36. Total machine counter ibo ob 3 CCC O Plate reset er Adjust Adjust Ext control Test rollers plates Ae configurata switches ide ee thickness sensor actions functions Speeds Folduniti fo m min Foldunit2 m min Foldunit3 m min 3 Select Potentiometer FSA Length and touch the Off key which 2 on t o O n Potentiometer Dir Up ie 3 on Imps Light barrier om in Value Fold unit 3 96 m min Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 21 Service Manual prestigeFOLD NET 52 4 Turn the potentiometer until 2 177 Bit appears in the display 2 177 Bit 210 mm 11 Bit 1 mm 5 Quit the service menu by touching the Correction menu tab Run the H entering a random dimension Alignment rails Fold uniti 105 0 mm Fold unit 2 mm Fold unit 3 mm Delivery rollers rm ibd Em Fold Roller ewm Rote gap sten 6 Then enter 210 mm and run the HKT to this position 7 The distance to the side panel should be 150 mm Use the setting gauge A 2 024 014 to check Page 22 Version 2 1 English 10 2005 Mathias B uerle GmbH Service Manual prestigeFOLD NET 52 3 2 Basic Setting Register Table ART Roller Table SRT 3 2 1 Position of the alignment rail ART Folder 1 fold unit e S er 2 1 Touch the Service Functions key in the popengE EE Le ein z A E E Passw
37. ame is transferred to the tree structure for later sessions Page 54 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 4 3 4 Data transfer The following window is displayed after a connection has been successfully established 1 Core FTP LE 192 168 78 155 21 T E loj x Fie wiew Sites Manage Help NE 265 d Lele BIBE AE A Connect socket 616 to 192 168 778 155 port 1028 125 Data connection already open transfer starting 226 Closing data connection Transferred 3 146 bytes in 0 321 seconds 02 23 05 1 02721705 1 Bi amb ackupF c 04707720 1 04207720 1 04207720 1 04 21 20 T Ma transfers EEpromBackupful 600 bytes 04 07 20 1416 ul NUNT bytes 04 07 20 14 16 2 3 4 Status messages are displayed in the upper section 1 below the toolbar Below you will find the local directory notebook 2 on the left hand side and the directory of the display 3 on the right hand side Below this information there is the transfer display 4 showing all data transfers You can change or adapt the configurations of the display as you wish thus deviating from this description In principle the two sections 2 3 with the directories are mainly needed For additional help tool tips are displayed above each button as soon as you dwell there for an instant with the mouse pointer 4 3 5 Upload copying files from the notebook to the di
38. anager will appear Task Manager Active Tasks Via the button Run the program start window will be activated The desired program name can be entered into the program start window As there is no keyboard the desired program will be activated via selection window In order to activate the selection window the Browse button must be pressed Type the name af the program to start Use the left button to go to the superior directory in the selection window Double click onto the directory FFSDISK in the Root directory supreme directory cemarc exe IB cerdisp exe P FFSDISK er P cercl exe BS crnd exe connmc exe 5 control exe Indcucfg exe P net exe P services exe F unioad exe EIS weeload exe My Documents 3 Windows Network gt Program Files Mame Type Programs Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 57 Service Manual prestigeFOLD NET 52 Browse In the FFSDISK directory two versions of the DBAdmin can be selected either DBAdminDe exe for the German version or DBAdminEng exe for the English version After choosing a version by touching the name the choice will be confirmed via the OK button Once you have pressed the OK button the choice will be accepted and shown in the run window When pressing the OK button the desired application will be started The configuration has been started The user can now r
39. as Bauerle GmbH Version 2 1 English 10 2005 Corre Job name Job number Counter Total fo Remainder F Preselection to Remainder fio O Kicker Control Paper travel control Double sheet detection Sheets h Running time 0 Day s 00 00 00 Time Page 17 Service Manual prestigeFOLD NET 52 Page 18 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 3 Potentiometer Settings 3 1 Basic Setting of Flat Pile Feeder FSA 3 1 1 Side stop e Touch the Service Functions EEG DOW DEW Correction Job Configuration Service al key in the service menu Password valid Language English Total machine counter 1 Jo 2 3j Plate reset ie info thickness sensor actions functions Speeds Folduniti fo 96 2 m min Fold unit 2 96 m min Fold unit 3 96 m min gt gt AE i bN Password 4277 necessary 1 BC gt B IN amp JAJ o UJ i i EJ 2 Select Motor FSA Width am zu E NT I Service Service Functions Fold unit 1 Potentiometer Alignment Table Value Motor Alignment Table Bliss up El Imps o ET Test switches Light barrier Alignment in Value Off inctions Finish Boz i Fold unit3 m min B 3 With Motor ON and Sense of Rotation up down run the side stop to the position shown in the pictur
40. b31 dl 76381 Bytes adoxces 1 dll 236633 Bytes cancmd exe 11264 Bytes LANINTF dI 34901 Bytes canread exe 5632 Bytes canwrite exe 5532 Bytes casnetdb cdb 1890224 Bytes DBAdmin exe 115224 Bytes D appelParallelfalz bmp 1342 Bytes Fensterfalz bmp 1342 Bytes FensterfalzGeschlossen brmp 1342 Byt Frenchz Ub lang 506936 Bites Gul ere 719360 Bytes Halbfalz bmp 1342 Bytes F mnb nla bee 172479 Cooke REFRESH FILEVIEw COMMUNICATION PORT com NETT DISCONNECT ADMINISTRATION DELETE COPY EAIT 6 To update a data file the old version should first be deleted on the display For this select a file in the list using the left mouse button and then delete it by pressing the DELETE button 1 ERemoteAdmin CONTENT OF FFSBISK adace3l di 128088 Bytes adocedb3U dl 5722 Bytes adacedb31 dll 125554 Bytes adocealedb31 dl 76381 Bytes adoxce31 dl 236633 Byte E E canemd exe 11264 Bytes Delete File E CANINTF dil 34301 Bytes canread exe 5632 Bytes canwrlte exe 5632 Bytes casnetdb cdb 180224 Bul DBAdmin exe 116224 But DoppelParalleltalz bmp 1 Abbrechen Fensterfalz bmp 1342 Bul FensterfalzGeschlossen bmp T3327 yh French 06 lang 50696 Bytes Halbfalz bmp 1342 Bytes v F eiL l Brene 7172472 Du REFRESH FILEVIE w 7 Delete the selected file by pressing the OK button Mathias Bauerle GmbH Version 2 1 English 10 2005 X COMMUNICATION PORT com
41. been replaced You can thus avoid a re adjustment of fold plates fold rollers etc 4 9 1 Readout The following window will appear after the start of EEprom Management EEprom management FEprom gt File File gt EEprom Fold unit Now just select the desired fold unit in the Checkbox Fold unit After a short time all values are loaded from the machine EEprom all data received are displayed in the table on the left hand side The following window should be displayed after a successful loading process EEprom management Nr File EEprom 0 n 2 EEprom gt File File gt EEprom Fold unit fi End Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 73 Service Manual prestigeFOLD NET 52 The following columns should be visible in the left section of the table Nr Current memory number of the EEprom Later it is documented in a chart which number contains which value Current value from the EEprom Current value from the backup file The values in the file column are only visible if a backup file for the particular fold unit exists This file is automatically created when you make a backup of the EEprom data and shows the format EEpromBackupFu fold unit number If the values of the EEprom and the file are not identical an underscore precedes the current number 4 9 2 Saving EEprom values To save the EEprom values in a backup file you just have to press the EEprom gt
42. ck the roller pressure with a paper strip by turning the handwheel 7 Select any roller that needs to be corrected by touching ROLLER Fold unit Paper thickness sensor Input Set value 8 Make the correction for front and rear of the poss A 074 mm 010 mm Base Counter Control Set up roller with the Motor keys ps Fold unit Paper thickness sensor Input Set value Page 32 Version 2 1 English 10 2005 prvice a m 010 mm Mathias Bauerle GmbH 9 Save corrections by touching the Save key or cancel them with the Discard key 10 Under Roller select the next roller to be corrected proceed to step 8 11 Touch End when the setting is complete 12 All rollers are reset to the roller settings saved in step 5 Mathias Bauerle GmbH e 2 i Ale 3l Bil KOHL m BEN qi I d 2 mi Version 2 1 English 10 2005 Service Manual prestigeFOLD NET 52 Base Counter Control Set up Set zero points of rollers KR Fold unit 7 Paper thickness sensor 0 74 mm Input 0 10 mm Left Right vice Set zero points of rollers Fold unit A Paper thickness sensor 0 74 mm Input 0 10 mm M Set value Roller setting Roller 1 Left Bit Right Bit Discard Save Page 33 Service Manual prestigeFOLD NET 52 3 3 3 Replacing the roller potentiometer 1
43. e The distance to the side panel should be 150 mm Use a setting gauge A 2 024 014 to check Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 19 Service Manual prestigeFOLD NET 52 4 Open the rear panel of the FSA 5 Select Potentiometer FSA Width and touch the Off key which then changes To 6 Change the potentiomer until 4 680 Bit appears in the display 4 680 Bit 128 mm 36 Bit 1 mm Loosen both hexhead nuts A move the mounting bracket in direction of the arrow change the potentiometer value Quit the service menu by touching the Correction menu tab Run the side stop by entering a random dimension Fold unit 1 mm Fold unit 2 mm Fold unit 3 mm Delivery rollers rm bd Update T Read in paper rom ow s 8 Then enter 128 mm and run the side stop to this position Page 20 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 9 The distance to the side panel should be 150 mm Use the setting gauge A 2 024 014 to check 3 1 2 Position of the rear edge separator HKT Move the automatic sheet separator HKT to the position shown in the picture by pressing the buttons at the HKT The distance to the side panel should be 150 mm Use the setting gauge A 2 024 014 to check Touch the Service Functions key in the PEN cune em Service Menu th Password Oaia Language English H
44. e The Inverter stops ac cording to the method set in n04 bb flashing EF flashing Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 97 Service Manual prestigeFOLD NET 52 Fault Fault name and Meaning Probable cause and remedy display Emergency stop STP eThe parameter setting was incorrect The Digital Operator stops Turn off the forward or reverse operating command once check that the n06 The STOP RESET Key on the parameter setting for STOP RESET Digital Operator is pressed Key function selection and restart the while the Inverter is operating Inverter according to the forward or reverse command through the control circuit terminals Note The Inverter stops ac cording to the method set in n04 The emergency stop alarm signal is input as multi function input A multi function input 1 2 3 or 4 set to 20 or 22 has been used Note The Inverter stops ac cording to the method set in n04 Cooling fan fault FAN The cooling fan has been locked flashing e An emergency stop alarm is input to a multi function input Remove the cause of the fault eThe sequence is incorrect Check and change the external fault input sequence including the input timing and NO or NC contact FRn flashing eThe cooling fan wiring has a fault Turn off the Inverter dismount the fan
45. enerative energy due to overshooting at the time of acceleration Suppress the overshooting as much as possible Main circuit e Power supply to the Inverter has phase loss pow er input terminal screws are loose or the power cable is disconnected Check the above and take necessary countermeasures e Incorrect power supply voltage Make sure that the power supply voltage is within specifications e Momentary power interruption has occurred Use the momentary power interruption compensation Set n47 so that the Inverter restarts after power is restored Improve the power supply e The internal circuitry of the Inverter is damaged Change the Inverter Radiation fin i overheated OH The temperature of the radiation fins of the Inverter has reached 110 G 10 C e The ambient temperature is too high Ventilate the Inverter or install a cooling unit e The load is excessive Reduce the load Decrease the Inverter capacity e The V f setting is incorrect Reduce the V f set voltage e The acceleration deceleration time is too short Increase the acceleration deceleration time e The ventilation is obstructed Change the location of the Inverter to meet the installation conditions e The cooling fan of the Inverter does not work Replace the cooling fan Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 Fault Fault
46. ersion 2 1 English 10 2005 Page 105 Service Manual prestigeFOLD NET 52 10 Special Tools The following special tools are required For loading software 1x 4 008 899 Data cable PC gt Control Serial cable 1 1 Plug Pins Socket 1x 4 008 898 Data cable PC gt Display Operator panel Serial cable cross connected Plug Socket Socket 1x 4 008 920 Network cable lx Tec CD TA 52 Program RemoteAdmin for PC gt Display Operator panel Program TQ Load for PC gt Control Notice Programs run from a CD there is NO need to install them Program Core FTP Lite FTP Server This program MUST be installed For basic settings 1x 4 008 900 Extension cable for fold plates 2x 2 024 014 Setting gauge p 98 5 degrees Page 106 Version 2 1 English 10 2005 Mathias B uerle GmbH Service Manual prestigeFOLD NET 52 11 Revision History 08 01 02 V 1 1 07 04 Gerhard Heisel Compilation of Service Manual N 20 09 2004 Andreas Wollny Revision of the headline structure C and adding the A D converter values N 03 12 11 2004 Gerhard Heisel Mistakes in layout eliminated C Values for basic settings positions alignment rails corrected C New tool setting gauge 2 024 014 N 04 29 11 2004 Gerhard Heisel Various mistakes in layout eliminated C Various values for basic settings corrected C Information about control board compiled N Table with standard folds compiled N po LB C 2 Chan
47. eset all or several data base spreadsheets to the respective software version Version 1 of the DB Admin must go with the display software that has been installed At least the first two figures must be identical XFFSDISKA DB N BY Images Jee DBAdminDe exe Y B DBAdminEng exe Ni exe Mame DBAdminDe exe Type Programs Type the name af the program to start Open FFSDISK DBAdminDe exe Standarctalzarten Auftr ge Extkontrolle Konfiguration The instructions which spreadsheets are reset to the software version are shown in readme txt file of the respective display software version Page 58 Version 2 1 English 10 2005 Mathias B uerle GmbH Service Manual prestigeFOLD NET 52 Those who are not sure can also reset all charts by means of the A button Please bear in mind that in this case all jobs will be deleted 4 5 Operator Panel Files Used The following files are essential for the operation of the display Main Program is SKMrted automatically when turning on the machine power CANINTF DLL CAN Driver Auftrag fdb Data base files that now replace the formerly only data base file Casnetdb cdb The Falzart fdb files contain the following information Auftrag Falzart Falzwerk contain the complete information needed for a fold job BlattFormat contains all standard paper sizes that are shown in the paper size combobox in the Setup Menu StandardFalzart contains t
48. ge 05 27 06 2005 Gerhard Heisel New Software N functions FTP Server N EEprom management N Screen shots inserted A en heights for installation N GE The title copyright and all other proprietary rights in this 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 Version 2 1 English 10 2005 Page 107 Service Manual prestigeFOLD NET 52 12 Feedback Sender Mathias Bauerle GmbH Service Department Name Company Gewerbehallestrasse 7 11 Town Street 78112 St Georgen Germany Did you come across any misprints or typing errors in our Service Manual or do you have any suggestions for improvement Please inform us if this is the case Page 108 Version 2 1 English 10 2005 Mathias Bauerle GmbH
49. ge 45 Service Manual prestigeFOLD NET 52 5 Lower the roller with screw A until the uncorrected value 0 00 mm 0 02 mm appears in the display corresponds to 60xx Bit Re tighten screws A shown in the picture of item 1 6 Select memory space 0 00mm and touch the Save key Password r 0 74 mm Uncorrected value 0 74 mm Memory space Activation qi 00 mm Bit T Delet Opio mm Bit ies Test Switches O 0 20 mm Bit Delete all cec End 0 30 mm Bit functions o m min Fold unit 2 96 m min Fold unit 3 96 m min 7 Slide a 0 10 mm feeler gauge A under the paper thickness sensor Control Base Counter Control Set up 8 Select memory space 0 10mm and touch F gt conection Job Configuration Service zm the Save key x Password rere 7 Valid PW2 Adjustment of paper thickness sensor Sensor 16383 Bit 0 74 mm Uncorrected value 0 74 mm m ET Test switches Service functions N Delete Delete all End Tere o m min Fold unit 2 96 m min Fold unit 3 m min fmi Bi 9 Repeat the process described in items 7 8 for 0 20 mm and 0 30 mm Page 46 Version 2 1 English 10 2005 Mathias B uerle GmbH Service Manual prestigeFOLD NET 52 oO Base Counter a Control Al Set up Correction Job Configuration Ser
50. ge SKM 36 gu Dol O Vertical Stacker SKM 36 u eee 2 lt Zweites Falzweik R 000 Second Fold Unit AUSRICHTTISCH ALIGNMENT TABLE b prestigeFOLD NET 52 4 6 4 6 FSA FALZWERK 52 ANLEGER FSA FOLD UNIT 52 FEEDER FSA nn ee T L III p 22 lt Schr gollentisch ME eee E A A E TET ROLLER TABLE en mE 000 Bo AUSRICHTTISCH m ALIGNMENT TABLE FALZWERK 52 0 4 FOLD UNIT 52 0 4 3 9 D gt Ss a 9 25 B5 i 9 9 3 52 n lt an go Ias 25 o gt i o c prestigeFOLD NET 52 4 6 4 6 MS 45 FSA FALZWERK 52 ANLEGER FSA FOLD UNIT 52 FEEDER FSA lt J Iles tg nt eo Me nes 2 ul Schr gollentisch nn EIE ROLLER TABLE Selene 000 e ed AUSRICHTTISCH _ ALIGNMENT TABLE FALZWERK 52 0 4 FOLD UNT 52 0 4 Auslage Delivery u I mgl l AM 52 E MS 45 senkrechtauslage SKM 36 Vertical Stacker SKM 36 Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 85 Service Manual prestigeFOLD NET 52 d prestigeFOLD NET 52 4 6 4 6 52 0 0 4 FSA Schragollentisch ROLLER TABLE FALZWERK 52 0 4 FOLD UNT 52 0 4 Auslage Delvery AM 92 cH Co Senkrechtauslage SKM 36 Vertical Stacker SKM 36 Page 86 lt lt
51. geFOLD NET 52 4 7 Network Administration Operator Panel The main program Gui exe can also be started with parameters in a console DOS window This permits some additional possibilities which are explained in this chapter 4 7 1 Preparations To be able to use this administration a notebook 1s needed which allows access to an IP address with the number 192 168 78 155 As a rule these notebooks should themselves have an IP address that starts with the numerical sequence 192 168 78 The proper IP address can easily be tested with the DOS command ipconfig Open a DOS window and type in this command The result should then show the following information Please note that the fourth and last figure of the IP address are unimportant Fingabeaufforderung u gt Ipconfig Windows 2660 1 P Konf igurat ion Ethernetadapter LAN Verbindung Verhindungsspezifisches DNS Suffix IP Adresse Subnetzemaske Standardgateway 192 168 738 118 255 255 255 H To test whether a connection to the display can be made the network cable is connected between notebook and display A ping command is testing whether the display can be reached For this the target address must be transferred to the ping command as a parameter i e ping 192 168 78 155 The picture below shows an example for an unsuccessful connection to the display 7 Fingabeaufforderung E G gt ping 192 168 768 155 Ping wi
52. he buckle plate dimensions for all standard folds StandardfalzName contains the names of all standard folds in all languages that are available Konfiguration backs up the current configuration of the machine language set current job activated external channels etc Fehler contains all errors that have occurred ExtKontrolle contains possible channel texts in all languages that are available Mfcce300 dll Microsoft class library for the presentation of the GUI elements Olece300 dll Microsoft class library for the communication of the GUI elements Falzwerk fdb e BlattFormat fdb StandardFalzart fdb StandardfalzName fdb Konfiguration fdb Fehler fdb ExtKontrolle fdb The files used by the main program It is recommended to inSKMII them as well to facilitate the job DoppelParallelfalz bmp Fensterfalz bmp FensterfalzGeschlossen bmp Halbfalz bmp KeinFalz bmp Kreuzbruch12 bmp Kreuzbruch 16 bmp Kreuzbruch24 bmp Kreuzbruch8 bmp Omegafalz bmp WickelfalzT 12 bmp WickelfalzT 1246 bmp WickelfalzT 13 bmp WickelfalzT 135 bmp Zeichnungsfalz bmp Zickzackfalz2 bmp Zickzackfalz3 bmp Zickzackfalz4 bmp Zickzackfalz5 bmp Zickzackfalz6 bmp Optionale Sprachdateien lang Mathias Bauerle GmbH These files represent all standard folds as diagrams They are used when setting up the main program If not all of them are available only a standard diagram with a question mark is displayed It is therefore recommended to install
53. hile this indicator is lit PRGM indicator Note While the Inverter is in operation the pa rameters can be only monitored and only some parameters can be changed Any RUN command input is ignored while this indicator is lit Page 90 Version 2 1 English 10 2005 Mathias B uerle GmbH Service Manual prestigeFOLD NET 52 8 2 Fault Display 8 2 1 Fault detection major faults The Inverter will detect the following faults if the Inverter or motor burns or the internal circuitry of the Inverter malfunctions When the Inverter detects a fault the fault code will be displayed on the Digital Operator the fault con tact output will operate and the Inverter output will be shut off causing the motor to coast to a stop The stopping method can be selected for some faults and the selected stopping method will be used with these faults If a fault has occurred refer to the following table to identify and correct the cause of the fault Use one of the following methods to reset the fault after restarting the Inverter If the operation command is being input however the reset signal will be ignored Therefore be sure to reset the fault with the operation command turned off Turn on the fault reset signal A multi function input n36 to n39 must be set to 5 Fault Reset Press the STOP RESET Key on the Digital Operator Turn the main circuit power supply off and then on again Fault Displays and Process
54. iles from the notebook to the display cccccccccccccecceeesssseeeseeeeeeeeeeeeeeeeeaaas 55 4 3 6 Download copying files from the display to the notebook essseeeeeeeee 56 4 3 7 Further operations ee ates Sepe dM e ese San uA brote i Oo aME 56 4 4 Display CONTIGUT ALON ete 57 4 Operator Panel biles Used iir ERUREFEE OE Pei VERSES AEQ PERIERE 59 4 6 Client Software Operator Panel via Network Cable 61 4 7 Network Administration Operator Panel scccccccccsssssssssssscccccccssssssssssssccosees 65 4 7 1 PEG PARAGON RT x e DE 65 4 7 2 Logon and administration aan dotati a bo tia eco einen Meines 66 4 8 Machine Software Control Board eee eee eere eee eee eee eee eee ee eeeeoos 70 49 EEprom Manasemellt iei ec d vespa ER Eoo bene 73 4 9 iere ninne een 73 4 9 2 Savine LOM valies n ae ebria esc a a Hai ca enun Li da cro ee CAEN lo tr a Muri CR aad 74 4 9 3 MODUS EEPO VAE ser epee CR patet ftd ar ee iore ro cone ela oret ie 74 4 9 4 Memory numbers or the EE pi om oae prio cie o i brenaganinvasnscedsuaswonnh baocagatlavleimabeldnecsemiandlls 74 2510 SOLCW ALE EE ITO UT 75 5 Electronic Ha3r Ware visccseascisccceiesaieccdoniiecsahscchewasssadoncinctoncaiccakoaanciviesseaeeccee d 1 5 1 Setting the Address on the Control Board
55. ing Fault Fault name and oL Overcurrent OC The Inverter output current is as high as or higher than 200 of the rated output current Probable cause and remedy eA short circuit or ground fault has occurred and at the Inverter output Check and correct the motor power cable e The V f setting is incorrect Reduce the V f set voltage e The motor capacity is too large for the Inverter Reduce the motor capacity to the maximum permissible motor capacity e The magnetic contactor on the output side of the Inverter has been opened and closed Rearrange the sequence so that the magnetic contactor will not open or close while the Inverter has current output e The output circuit of the Inverter is damaged Replace the Inverter Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 91 Service Manual prestigeFOLD NET 52 Fault Fault name and Probable cause and remedy d meaning Page 92 undervoltage UV1 The main circuit DC voltage has reached the undervoltage detection level 200 V DC for the 3G3JV A2 and 160 V DC for the 3G3JV ABL Overvoltage OV The main circuit DC voltage has reached the overvoltage detection level 410 V DC eThe deceleration time is too short Increase the deceleration time e The power supply voltage is too high Decrease the voltage so it will be within specifications e There is excessive reg
56. lly 3G3JV A2001 0 1 kW 3G3JV A2002 0 25 kW 3G3JV A2004 0 55 kW and 3G3JV A2007 1 1 kW 3G3JV ABOO1 0 1 kW 3G3JV ABOO2 0 25 kW and 3G3JV AB004 0 55 kW Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 89 Service Manual prestigeFOLD NET 52 Indicators Data display _ Setting Monitor item indicators Keys FREQ adjuster Appearance Name Data display Displays relevant data items such as frequency reference output frequency and parameter set values FREQ adjuster FREF indicator FOUT FOUT indicator Sets the frequency reference within a range between 0 Hz and the maximum frequency The frequency reference can be monitored or set while this indicator is lit The output frequency of the Inverter can be monitored while this indicator is lit f The output current of the Inverter can be monitored while this indicator is lit The direction of rotation can be selected while this indicator is lit when operating the Inverter with the RUN Key The operation of the Inverter through the Digital Operator or according to the set parameters is selectable while this indicator is lit LO RE indicator Note This status of this indicator can be only monitored while the Inverter is in operation Any RUN command input is ignored while this indicator is lit The parameters in n01 through n79 can be set or monitored w
57. m the display to the notebook In principle the download works as the upload First of all the desired files are selected on the right hand side 3 and then transferred by means of the transfer button 2 4 3 7 Further operations Further operations must be executed by means of a pop up menu A file can be renamed by selecting the desired file and pressing the right mouse button A pop up menu will appear In this menu you have to select the item Rename and then rename the file you have selected This works both in the notebook and in the display directory It is also possible to set filters for a more simplified view of the files If for instance only graphics are to be displayed you can enter bmp in the edit field of the filter 5 When doing this only files ending with bmp are displayed after you have confirmed the entry by pressing the Enter button or button 6 two rotating arrows Page 56 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 4 4 Display Configuration To make sure that the display is ready to use you must provide the master program Gui exe which is compatible with the updated data base Therefore there is an administrative program called DBAdmin Sprache exe The language is either De for German or Eng for English This program updates the necessary data base spreadsheets for the respective program version and has to be started as follows Press the display The task m
58. name and Probable cause and remedy display meaning oL Motor overload OL 1 eThe load is excessive The electric thermal relay Reduce the load actuated the motor Decrease the Inverter capacity overload protective ne ipiis cip eThe V f setting is incorrect Reduce the V f set voltage eThe value in n11 for maximum voltage frequency is low Check the motor nameplate and set n11 to the rated frequency eThe acceleration deceleration time is too short Increase the acceleration deceleration time eThe value in n32 for rated motor current is incor rect Check the motor nameplate and set n32 to the rated current eThe Inverter is driving more than one motor Disable the motor overload detection function and install an electronic thermal relay for each of the motors The motor overload detection function is disabled by setting n32 to 0 0 or n33 to 2 e The motor protective time setting in n34 is short Set n34 to 8 the default value Inverter overload OL2 The load is excessive The electronic thermal Reduce the load relay has actuated the The v f setting is incorrect Inverter overload protective function Reduce the V f set voltage e The acceleration deceleration time is too short Increase the acceleration deceleration time e The Inverter capacity is insufficient Use an Inverter model with a higher capacity Mathias Bauerle GmbH Version 2 1 English 10 20
59. nt in Value Off nctions min 2 Bil Finish min poz H Fold unit3 m min 5 Turn the potentiometer at the rear of the register table ART until 12 350 Bit appears in the display 12 350 Bit 146 mm 27 Bit 1 mm Base Counter Control Set up Correction Job Configuration Service 6 Quit the service menu by touching the b Flat pile feeder Correction menu tab Run the alignment rail vee Se FUE by entering a random dimension Length mm L Alignment rails Fold unit 1 7 105 0 mm gt Fold unit 2 mm laf gt Fold unit 3 mm RE Delivery rollers Undo Fee Update Fold m Read in paper 7 Then enter 146 mm and run the alignment rail to this position Page 24 Version 2 1 English 10 2005 Mathias B uerle GmbH 8 The distance to the side panel should be 150 mm Use a setting gauge A 2 024 014 to check 3 2 2 Position of the alignment rail SRT 1 Touch the Service Functions key A in the service menu Password 4277 necessary 2 Select Fold Unit 2 A 2 2 Select Motor Alignment Table Register Table B Service Manual prestigeFOLD NET 52 Folder 2 4 and 3 fold unit Base Counter Control Correction Job Configuration Service Password O Valid Language English Total machine counter 1 o 2 F 3 Plate reset Fold unit 1 fio Fold unit 2 Fold unit
60. nt version number tFalzar dBlattFormat Displays all data sets of the sheet size table rStandardfalzarten Resets the standard type of fold table and the standard folds name table to their original states dKonfiguration Displays all record sets of the configuration table Mathias B uerle GmbH Version 2 1 English 10 2005 Page 67 Service Manual prestigeFOLD NET 52 If for instance the data base must be updated after the installation of a new software version all data bases can be reset with the command gui rAll The picture below shows the display after the successful execution of this command 53 Eingabea lerung I mi x Welcome to the Windows CE Telnet Service on NetDCU3 Pocket CMD v 3 8 I gui u 1 6 15 gt qui rAll Resetting Resetting Auftray Falzart Falzwerk BlattFormat KtandardFalzart KtandardfalzName Konfiguration Fehler ExtKontrolle Please note During a reset of all data base data all the saved jobs as well as the currently saved machine settings are lost irrecoverably Do this only if you really want it At the moment there is no possibility to save and re load jobs but it will become available in a future version With the command gui dBlattFormat it is for instance possible to display all standard sheet sizes that have been saved Eingabeau Forder ung ti B Pi x Welcome to the Windows CE Telnet Service on HetDbCl3
61. ord O Valid Service Menu mo N MEN a Total machine counter m ip o c Password 4277 necessary Plate reset ru Reset Adjust Adjust _ Ext control Test rollers plates cO nfiguration switches Adjust paper Service Service thickness sensor actions functions Speeds Fold unit 1 fio 22 m min Fold unit 2 96 m min Fold unit 3 96 m min m t Il Q i B E ij 1E 2 1 Select Fold Unit 1 2 2 Select Motor Alignment Table Register Table at a atm Base Counter Control Setup arrertinn ah anfiauratian Service e S 2 Fold unit 1 Potentiometer m nment Table Value Motor Alignment Table LIED po l Fold unit3 m min With Motor ON and Sense of Rotation up down run the alignment rail to the position shown in the picture The distance to the side panel should be 150 mm Use a setting gauge A 2 024 014 to check Mathias B uerle GmbH Version 2 1 English 10 2005 Page 23 Service Manual prestigeFOLD NET 52 Control Base Counter Control Setup arrartion oh l anfiairatian Service 4 Select Potentiometer Alignment Table Register Table and touch the Off key whick changes to On Fold unit 1 Potentiometer m nment Table Value Activation Alignment Table 05 Imps Test switches Light barrier Alignme
62. p connected correctly it has a stable value which fluctuates only slightly If no roller is connected the potentiometer is floating and the value rises or drops continuously Please note In a fold unit with 4 fold plates fold rollers 6 and 8 are not available Therefore the bit value of rollers 6 and 8 changes continuously because this input is not wired For the remaining fold rollers 1 2 3 4 5 and 7 a constant value is displayed Page 48 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 4 Software Instructions for the Download of the Software 4 1 Equipment Needed The following equipment is needed for the respective installations For client software operator panel Display with installed FTP Server Notebook with configured network interface Connection via FTP Server nstalled Software Core FTP Lite Network card see chapter 4 3 Network cable 4 008 920 For client software operator panel Notebook with a free serial interface Connection via serial cable Program RemoteAdmin on the Service CD Serial cable crossed Connector Female Female see chapter 4 2 4 008 898 For machine software control Notebook Connection via serial cable Program TQ Load on the Service CD Serial cable 1 1 Connector Male Female see chapter 4 8 4 008 899 For network administration operator panel Notebook with configured network interface Connection via network
63. perator side 3 Remove the cover at the back The screws are located in the areas marked in the picture eo eo 2 cam Conor serp vtec Xb Congraton Sec Password O Valid Language English Total machine counter 10 22 2 a Plate reset i 40 tl 4 Touch the Service Functions key in the Service Menu gt 2 e eo BEIC ll Mee is Y Spee Fold unit 1 fio 96 2 m min Fold unit 2 96 m min Fold unit 3 96 m min io IE mmi 7 Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 43 Service Manual prestigeFOLD NET 52 5 Select Potentiometer Delivery Table and touch the Off key which then changes to On Fold unit 1 Potentiometer m nment Table Value gt 3 S Alignment Table ir ip on B Light barrier Em om in Value ncti Fold unit 3 6 Turn the pontentiometer until a value of 3 345 Bit appears in the display 4 400 Bit 100 mm 11 Bit 1 mm 7 Re attach the cover 3 5 2 Jumper assignment on the delivery board Select the type of delivery by placing the jumper as shown p j J
64. pressor by touching this key Job name Standard job Job number m Counter Total Remander E Preselection 0 2 Remainde O Kicker Control Paper travel control Double sheet detection Sheets h Running time 0 Day s 00 00 00 Time 3 Check the air flow at the hose fittings Single hose fitting Vacuum Double hose fitting Air Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 13 Service Manual prestigeFOLD NET 52 If air and vacuum are reversed the sense of rotation of the compressor motor must be changed 4 Switch off the compressor by touching the appropriate key Turn off the machine by pressing the main switch and pull the power plug 5 Pull off the compressor plug and open the plug housing 6 Switch two wires e g 7 Re connect the compressor plug 8 Insert the power plug and turn on the main switch 9 Check the compressor for correct function as described under items 24 3 1 2 4 Checking the setting of the paper thickness sensor see chapter 3 6 1 Basic setting of paper thickness sensor Page 14 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 2 Service Menu 2 1 Access Codes Password A password must be entered to activate certain functions shown in grey in the service menu Password Service level 1 4250 Password Service level 2 4277 2 2 Entering the Password Code
65. puts Test Switches Testing the switches at AM FSA DISPLAY DISPLAY DISPLAY Machine Info Display of the recognized DISPLAY DISPLAY DISPLAY machine configurations Adjust paper Adjusting the paper DISPLAY DISPLAY thickness thickness sensor Service Function Potentiometer Display of the Bit values of all potentiometers Motor Direct activating deactivating of all positioning motors fold rollers fold plates alignment rails positions Fold unit Selection of the fold unit on which the above mentioned functions are to be carried out Service Action Direct activating deactiving of actuators Page 16 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 2 4 Turning on the Machine in Service Mode When turning on the machine the setting information for the fold plates alignment rails and positions is checked In order to turn on the machine without fold plates e g for fold roller setting this must be done in the service mode Turn off the machine with the main switch 2 Press button A at the shingle delivery AM 52 and hold it while turning on the main switch 3 Now the computer is booting up Functions that CANNOT be selected are shown in red 4 Quit the service mode as follows Turn off the machine by touching End and then turning off the main switch Connect all components Turn on the machine with the main switch Mathi
66. rd ausgef hrt f r 192 168 786 155 mit 32 Bytes Daten Zeit berschreitung der Anforderung AZeit hberschreitung der Anforderung AZeit herzschreitung der Anforderung ZAZeit herzchreitung der Anforderung Ping Statistik f r 1972 168 78 155 Fakete Gesendet 4 Empfangen B Verloren 4 168 Verlust Ca Aeitangaben in Millisek Minimum Bms Maximum Bms Mittelwert CoN Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 65 Service Manual prestigeFOLD NET 52 If the information on the ping command looks like this the connection is working and it is possible to start with the administration Fingabeaulforderung G gt ping 172 166 78 155 Ping wird ausgef hrt f r 1972 168 78 155 mit 32 Bytes Daten von 192 168 78 155 Bytes 32 Zeit lt i ms TIL 128 von 192 168 768 155 Bytes 32 Zeit l1fms TTL 128 Antwort von 192 168 78 155 Bytes 32 Zeit 1PAms TTL 128 Antwort von 192 168 78 155 Bytes 32 Zeit 1PAms TTL 128 Ping Statistik f r 192 169 78 155 Fakete Gesendet 4 Empfangen 4 Verloren A CA Verlust Ga Aeitangaben in Millisek Minimum Bms Maximum Bms Mittelwert FR 4 7 2 Log in and administration To be able to start with the administration it is necessary to log in on the display For this start with the DOS prompt and enter the command telnet 192 168 78 155 ein As a result the following message should appear You are on the displa
67. 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 setting re adjust if necessary Check software version Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 103 Service Manual prestigeFOLD NET 52 9 2 Cleaning the Fold Rollers and Transport Rollers Cleaning the fold rollers At the operator panel set all fold plate stops to 262 mm Turn off the main switch Remove the fold plates Place the fold plates on a table or stand them on their sides never on the deflector Turn on the folder at the main switch and choose the lowest motor speed Dampen the rollers with a special roller cleaning solution Remove dirt from the fold rollers with a soft cloth shaped into a ball Do not use any solvents such as Aceton or Toluol 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 damage and clean them if necessary Grease all moving parts with Molykote grease white Re install the fold plates Page 104 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 Mathias Bauerle GmbH V
68. sors with inverted function the red light emitting diode B goes out when recognizing the dull black paper A B Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 79 Service Manual prestigeFOLD NET 52 Page 80 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 6 Mechanical Hardware 6 1 Belts for Fold Roller Drive Fold unit with 4 fold plates T OO OO OO O O OO OO OO OO O O Operator side Opposite side Fold unit with 6 fold plates o 9 o o OO OO go OO OOO 600 960 oo oe o ee Operator side Opposite side Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 81 Service Manual prestigeFOLD NET 52 6 2 Replacing the Fold Rollers DISASSEMBLY 1 In the CORRECTION Menu Rollers set all fold rollers to 0 10 mm 2 Open the rear panel as follows Loosen the two Allen screws 1 and remove the side panel 3 Remove the hand wheel as follows Pry open the plastic cover Loosen the screw 1 Pull off the hand wheel 4 Open the cover at the operator side as follows Open the lock mechanism 1 Swing open the door to the left 5 Remove the flat belts at the operator and the opposite side Page 82 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 6 Remove the pulleys at the operator side and the opposite side
69. sp save the value of the roller being set in the Service Menu Adjust Rollers Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 35 Service Manual prestigeFOLD NET 52 3 4 Basic Setting of Fold Plates 3 4 1 Basic setting of deflector potentiometer Tools Setting gauge 2 024 014 Fold plate extension cable 4 008 900 1 Move the deflector to the engaged position fold plate closed 2 Insert an M5 screw A in the hole at the location shown in the picture Password 4277 necessary 3 In the Service Menu Service Control Functions select Motor Plate X T NE EM ae Deflector and run the motor until the ps cam B in picture of item 2 touches a i ROME ALGnmMent able the screw A in picture of step 2 gt n rer Select Potentiometer Plate X Deflector and touch the Off key which then changes to On Loosen the Allen screw A and turn the potentiometer until a bit value of 210 appears Remove the M5 screw again A in picture of step 2 Page 36 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 6 Loosen the clamp screw A at the upper grate of the fold plate 7 Loosen the two hexhead nuts A at the left and right hand side of the upper grate of the fold plate 8 Clamp the setting gauge 2 024 014 A 13mm on both sides in the cut out between thrust fork B and fold plate frame C
70. splay Proceed as follows to transfer files from the notebook to the display a Select file s on the left 2 in the notebook directory Select an individual file with a click on the left mouse button If you want to select several files hold the Strg button depressed and add additional files with a click on the left mouse button If you want to select an entire block select at first the first file with a click of the left mouse button hold Shift depressed and select the last file with a click on the left mouse button Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 55 Service Manual prestigeFOLD NET 52 1 2 3 Core FIP LE 192 168 78 155 21 E ml x File View Sidss Manage Help it S Connect socket 616 to 192 168 7155 port 1028 125 Data connection already open trageter starting 226 Closing data connection Transfemed 3 148 bytes in 0 321 seconds 02 23 05 1 BY DoppelPardfls 02721705 1 pease eT S EZ HT BOO 04 07 20 1 BOO 04 07 20 1 eRe 04 07 20 1 foo D4 21 20 T kb D4 21 20 1 NEEDED MUNERE EEprAmBackupFul 600 by 04 07 20 tiA V 4 5 6 b Transfer the files to the display on the right with a click on button 1 All selected files are now automatically pasted in the transfer section 4 and transferred in sequence to the display The transfer display 4 is cleared as soon as all files have been transferred 4 3 6 Download copying files fro
71. splay and that of the machine have different levels e The third digit indicates the software version The versions may be different as long as the software levels are the same see above Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 75 Service Manual prestigeFOLD NET 52 Page 76 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 5 Electronic Hardware 5 1 Setting the Address on the Control Board The address for the fold units shown below must be set on the two DIP switches on the control board Folder 1 fold unit width 52 cm Folder 1 fold unit width 38 cm Folder 2 fold unit Folder 3 fold unit AD Value Bit Switch Position Fold Unit ID 1 Width 52 cm S1 on S2 off Fold Unit ID 1 Width 38 cm Undefined Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 77 Service Manual prestigeFOLD NET 52 5 2 Information about the Control Board The processesor and the Flash Eprom are located on a separate circuit A board A within the control board TI an nt u t E im Te Ear pe T E Th 9 Sg hh LIKE LE Litt prem M TUL a ee ch 2 TTETETTTITES zn nni ae ur 213 T M mnm aJ Ho cee demens LI 111 PEERPP 11 Arm IN nin 1 an HB AT pr id 111 m T P n FE pane PERE Ps VAR 5 4 4 AN FR Pa po rT1 I VLL fii rm r DFPE X 1 TATE we LET
72. t switch of the fold system Non compliance may cause damage to electronic components 2 Turn off the main switch at the first fold unit 3 Insert the power plug into the socket 4 Turn on the main switch Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 11 Service Manual prestigeFOLD NET 52 1 2 2 Flat pile feeder FSA 1 Check the sense of rotation of the drive motor of the flat pile feeder FSA as follows Press button 1 on the operator panel of the FSA The pile table should move down If the pile table does not move check the sense of rotation recognition relay in the flat pile feeder FSA 2 Open the electrical cabinet of the FSA For this you have to remove the safety screw A and pull out the electrical cabinet 3 Check the LED at the sense of rotation recognition relay A LED is on wrong sense of rotation Changing sense of rotation see from chapter item 4 LED is off gt correct sense of rotation 4 Turn off the machine by pressing the main switch and pull the power plug 5 Open the power plug Page 12 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 6 Switch two wires e g L2 L3 7 Insert the power plug and turn on the main switch 8 Function of the pile table as described under item 1 1 2 3 Compressor 1 Check the sense of rotation of the Compressor motor 2 Switch on the com
73. tes in case of 4 fold plates in EE a the second fold unit prestigeFOLD NET 52 0 0 4 4 fold plates in case of 6 fold plates in Un aa the second fold unit 1 1 4 Flat pile feeder FSA 1 Unpack the flat pile feeder FSA When using a knife to cut open the packaging be careful not to damage parts of the machine 2 Adjust the height as follows Loosen the hexhead nuts 24 mm wrench Adjust the height with an 8 mm Allen key Level the feeder using a spirit level Page 8 Version 2 1 English 10 2005 Mathias Bauerle GmbH 1 1 5 Fold unit with register table ART Unpack the fold unit When using a knife to cut open the packaging be careful not to damage parts of the machine 2 Remove the side covers 1 at the rear of the register table ART 2 Remove screws 2 and 3 2 2 Remove the connecting screws 4 between register table and flat pile feeder 2 3 Unscrew the plug of the paper thickness measuring device 5 and pull it off it may otherwise be damaged 3 Raise the fold unit to the same height as the flat pile feeder and level it using a spirit level 1 1 6 Connecting components Move the fold unit up to the flat pile feeder with a jacklift Observe the following The green round belt at the rear of the flat pile feeder FSA 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
74. th n59 for overtorque detection function selection set to 1 or 3 Check the mechanical system and correct the cause of overtorque eThe parameter settings were incorrect Adjust the n60 and n61 parameters according to the mechanical system Increase the set values in n60 and n61 Page 96 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 Fault Fault name and Meaning Probable cause and remedy display Sequence error SER e A sequence error has occurred A sequence change has been Check and adjust the local or remote input while the Inverter is in selection sequence as multi function operation input Local or remote selection is input while the Inverter is in operation Note The Inverter coasts to a stop External base block bb The external base block command has been input Note The Inverter coasts to a stop e The external base block command has been input as multi function input Remove the cause of external base block input e The sequence is incorrect Check and change the external fault input sequence including the input timing and NO or NC contact Forward and reverse rotation A sequence error has occurred input EF Check and adjust the local or remote The forward and reverse selection sequence commands are input to the control circuit terminals simultaneously for 0 5 s or more Not
75. these files if they are not yet present Additional languages can be installed by copying the appropriate language file When starting the machine again the respective language will then be available under the service tab Available languages are shown in the file Display Languages of the Service CD Version 2 1 English 10 2005 Page 59 Service Manual prestigeFOLD NET 52 Administration files DBAdmin exe Auxiliary program to administrate the database files SerialTest exe Tests the output of both serial ports of the display The output can be traced with the notebook by means of the terminal program CANTest exe Tests the communication between the two CAN ports Can only be used with a special adapter All the other files which have not been listed belong to special service programs such as database etc and should therefore not be deleted Page 60 Version 2 1 English 10 2005 Mathias Bauerle GmbH Service Manual prestigeFOLD NET 52 4 6 Client Software Operator Panel via Network Cable Press the END button on the operator panel DO NOT turn off the machine Start program CEFile View Click on Add connection Veri k Wieje DE Dreier EX PETCU AI OOOO ES Select NETDCU3C3 Default Device and click on OK Manual Server Action E E X Please make sure the following files are on the device WIN DOM S Stepipe dll WINDOWS CEMGAC EE WINDOWS
76. trapLoader C157 C SRAM Flash Terminal Options D ADatenEigene Dateien auf D Dateien MASCHINEN prestige OLD soft C SRAM amp Flash Mathias Bauerle GmbH Version 2 1 English 10 2005 Page 71 Service Manual prestigeFOLD NET 52 Transfer is running i TQLoad BootStrapLoader C167 Senngs C SHAM Flash femal Options D Daten Eigene Dateien auf DD ateiensMaSCHINENSprestigeFULD soft i BSL made activated C5 Bootloader 1 successfully installed Nootloader 2 successfully installed Flash Fujitsu 29F S008 Eras Flash please wait Flash Wazed successtully After the successful transfer the message Application now running should appear TQLoad BootStrapLoader C167 Settings C SRAM Flash Terminal D D aten Eigene Dateien auf D Datfen MASCHINEN prestigeF LD soft Turn off the main switch and then on again If necessary terminate the display program by pressing the End button The new software version should now appear in the menu window Configuration Page 72 Version 2 1 English 10 2005 Mathias B uerle GmbH Service Manual prestigeFOLD NET 52 4 9 EEprom Management With the EEprom Manager you can read out and write the EEprom values of every fold unit If for example a chip needs to be replaced it is possible to save the current EEprom values in a file and to re import them from the backup file once the chip has
77. vice Password x M Valid PW2 10 Complete the setting by touching the End A p eo y I AR SEINE or paper tnickne ensor Sensor 16383 Bit 0 74 mm Uncorrected value 0 74 mm ET ren switches Jelete Delete lt 5 Service functions Fold unit 2 i m min Fold unit 3 96 m min 3 7 Defined AD Converter Values of the Recognition Potentiometers The following ranges are defined for the respective potentiometers 3 7 1 Feeder recognition 3 7 3 Folding SKMtion ID DIP switch recognition xm d o defined 0 Also see Chapter 5 1 Setting the address on the control board 3 7 3 Recognition of the subsequent module 10 No plug Mathias B uerle GmbH Version 2 1 English 10 2005 Page 47 Service Manual prestigeFOLD NET 52 3 7 4 Fold plate recognition AD Value Bit Type ID gt 1010 EE NEN Standard fold plate 22500 3 Gatefold fold plate E2500 2 Blind fold plate no fold plate deflector only Not yet defined Fold plate does not exist set automatically in a fold unit with 4 fold plates No fold plate Please note In a fold unit with 4 fold plates fold plates 2 and 5 are not available Therefore a bit value of gt 100 is displayed for these fold plates For the remaining fold plates 1 3 4 and 6 the bit value is gt 1010 3 7 5 Fold roller recognition The fold plates are identified by means of position recognition If a roller is available res
78. y and are able to enter commands for the display to carry out ioli We to the Windows CE Tel Pocket CHD v 3 8 E iol x Page 66 Version 2 1 English 10 2005 Mathias B uerle GmbH Service Manual prestigeFOLD NET 52 The program or the command gui offers a help directory which can be displayed by entering gui h It shows all command line parameters that can be used After entering gui h the following display should appear u uerzion rAll rAuftraege Falzwerk rBlattFormat BlattFormat r5tan dardfalzarten r5tandardFalzart d tandardFalzart r amp tandardfalzName d tandardfalzName rKonf iguration This help Shows actual version number Reset all tables Reset all Auftrag tables Auftrag Falzart Falzwerk BlattFormat Reset Auftrag table Dump all Auftrag data Reset Falzart table Dump all Falzart data Reset Falzwerk table Dump all Falzwerk data Reset BlattFormat table Dump all BlattFormat data Reset StandardfalzName table KtandardFalzart and StandardfalzName Reset StandardFalzart table Dump all StandardFalzart data Reset StandardfalzName table Dump all StandardfalzNMame data Reset Konfiguration table Dump all Konfiguration data Reset Fehler table Dump all Fehler data Reset ExtKontrolle table Dump all ExtKontrolle data The following table describes all available parameters Shows the curre

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