Hohner ORION 4 User manual

Operating-Instructions
Spare parts list
ORION 4
05/2008
Pad and Folder Wire Stitching Machine
Hohner Maschinenbau GmbH
Gänsäcker 19, 78532 Tuttlingen, Telephone 07462 / 9468-0, Fax 07462 / 9468-20

Hohner Maschinenbau GmbH – ORION 4

Hohner Maschinenbau GmbH – ORION 4
Contents
1. Safety notices....................................................................................................................4
2. Technical Data ..................................................................................................................5
3. Measures plan of the ORION 4 ........................................................................................6
4. Installation of the stitching table.........................................................................................7
5. Installation of the narrow stitching heads 70/20 ................................................................8
6. Installation of the chlincher box .........................................................................................9
7. Basic adjustment of clinchers ..........................................................................................10
8. Pressure adjustment for clincher back pressure..............................................................11
9. Adjustment of the stitching thickness...............................................................................12
10. Adjustment by hand of the ORION 4 .............................................................................13
11. Accessories .....................................................................................................................14
12. Flow diagrams .................................................................................................................15

Hohner Maschinenbau GmbH – ORION 4 - 4 -
1. Safety notices
A T T E N T I O N
1. Only trained and instructed specialised staff may operate, maintain and repair the
machine.
2. Before working on the machine, please read the Hohner operating instructions and
heed all warnings on the machine.
3. Do not operate the machine until all safety devices, locking mechanisms and other
safety precautions are functioning and fitted to the machine.
4. Electrical work on the machine may only be carried out by a qualified electrician.
5. For safety reasons, before performing maintenance or repairs, always shut off the
current supply and set the main switch to “0”.
6. Before sample stitching and production, remove all tools from the stitching head and
from the machine
7. Residual risks: if there is no stitching material beneath the stitching head, there is a
risk that your hand or fingers may slip beneath the finger guard.
The user is responsible for the safe function of the machine at any time as well as for
the observance of all prescriptions of these instructions for use by the operating
person. For all questions regarding the safe operation of this machine, please, contact
your senior officer or Hohner sales representative or directly to:
Hohner Maschinenbau GmbH
Street: Gänsäcker 19
Town: D-78532 Tuttlingen
Telephone: 07462 / 94 68 - 0
Fax: 07462 / 94 68 - 20
Email: [email protected]
Internet: www.hohner-postpress.com
Spare Parts / Customer Service
Fax: 07462 / 9468-20
- modifications reserved -

Hohner Maschinenbau GmbH – ORION 4 - 5 -
2. Technical Data
Stroke length - driver: 66 mm
Stroke length - bender: 55 mm
Stroke length - clincher: 5,5 mm
Size of stitching table: 1000 x 330 mm
Max. depth from staple, towards the back up to stand: 230 mm
Staple distance min. 70 mm
max. 550 mm
Max. stitching thickness standard stitching: 20 mm
Max. stitching thicknessloop stitching: 4 mm
Crown width of the staple: 14 mm
Stitching capacity per minute and stitching head: 192
Max. number of usable stitching heads: 4
Stitching wire, round: No. 20 - 28 (0,90 - 0,40 mm ∅*)
Stitching wire, flat: No I - VI (0,70 - 0,35 mm *)
up to
(0,96 - 0,78 mm *)
Machine net weight: around 512,0 kg
Net weight per narrow stitching head UNIVERSAL 70/20 around 8,5 kg
This version of the wire stitching machine ORION 4 affords room for four (4) narrow
stitching heads UNIVERSAL 70/20.
The stitching table is placed in a horizontal position for block stitching and in a saddle
position for brochure stitching. Positioning occurs via stops. The machine has a three-
phase-motor (1,10 kW) 230/400 volt, 50 Hz - 3 phases with clutch-brake combination.
Tripping occurs via a pedal switch.
Wire dimensions according to German standards!
IMPORTANT!
Danger due to electric current!
Electrical works on the machine may only be performed by a trained electrical engineer.
When installing the machine, please observe the local connection instructions. The
machine power supply cable must be secured accordingly.
According to the latest regulations for electrical installations (VDE regulations), the
safety conductor is coded yellow-green.
Should the engine protective switch have been tripped, first switch off the machine at
the main switch. Then determine and eliminate the cause. Once the cause has been
eliminated, the engine protective switch can be set to pos.1 by turning (see figure).
While doing so, ensure that all protective systems are installed on the machine and
all tools have been removed from the machine. Switch on machine at the main switch.

Hohner Maschinenbau GmbH – ORION 4 - 6 -
3. Measures plan of the ORION 4

Hohner Maschinenbau GmbH – ORION 4 - 7 -
4. Installation of the stitching table
Installation of stitching table: flat stitching
With the lever 1 lift all stitching heads to the highest position. Slide the stitching table
2 with the small side into the machine. Move it with both handles 3 right and left over
the centering discs 4 . Put down the stitching table until it will be supported. Push the
triangle-handles 5 upwards and tighten them.
Installation of the stitching table: for brochure stitching
With the lever 1 lift all stitching heads to the highest position. Slide the stitching table
2 with the small side into the machine. Tilt the stitching table downwards to 45
degrees. Move the stitching table with both fixed angle-supports over the centering
discs 4 . Put down the stitching table until it will be supported. Push the triangle
handles 5 upwards and tighten them.
Important!
The „stick-on-level“ 8 on the front panel 7 shows, how to fix the
safety guard 6 in the two way position of the stitching table.

Hohner Maschinenbau GmbH – ORION 4 - 8 -
5. Installation of the narrow stitching heads 70/20
Insert key blocks 1 into the traverses 2 . Milled part must point downwards.
Install the stitching head with the boring over the peg of the key blocks 1 , at the
same time also align the driving block 3 , the pusher 4 and adjusting block 5 with
the corresponding rails. Clamp the stitching head to the machine by turning down the
hex sockets 6 of the eccentric until it is tight.

Hohner Maschinenbau GmbH – ORION 4 - 9 -
6. Installation of the chlincher box
Slide both clincher box mounting studs 1 in the T-slot of the clincher box receiver 2 .
Install the clincher box 3 on with the mounting studs 1 and make certain that the
adjustment screw 4 is aligned with the driving slot as shown. Tighten both clamp nuts
6. Be sure the clincher box is correctly aligned with the stitching head.

Hohner Maschinenbau GmbH – ORION 4 - 10 -
7. Basic adjustment of clinchers
In case of replacement or retrofit of the stitching heads UNIVERSAL 70/20 and the
clincher boxes a basic adjustment will be necessary.
The pressure of the clincher spine pressure must be adjusted at minimal pressure
(correspond to 2-sheet-stitching). See page 8.
Adjustement:
Loosen the allen set screw 1 . Cycle the machine by hand (see page 10) until the
clincher points reach their highest position. Adjust the clincher pusher screw 2 until
the center of the clincher points are approx. 1 mm above the clincher box surface.
Tighten the allen set screw 1 .

Hohner Maschinenbau GmbH – ORION 4 - 11 -
8. Pressure adjustment for clincher back pressure
The clincher back pressure can be adjusted, it depends on the stitching thickness and
the kind of paper. First loosen clamp levers 1 on the right and left side of the
machine, then loosen the clamp lever 2 and adjust the clincher back pressure with the
adjusting lever 3.
After the pressure adjustment tighten again clamp lever 2 and both clamp levers 1 .
If an individual pressure adjustment is required, please revert to page 7.

Hohner Maschinenbau GmbH – ORION 4 - 12 -
9. Adjustment of the stitching thickness
Turn the stitching head wire transport (orange knob) to the off position. Cycle the
machine once to remove the stitching currently loaded in the former. These wire
pieces can also be removed by hand. Loosen the hexagon head screws 1 on both
sides of the machine. Measure the book thickness in milimeters. Move adjusting lever
2 to the proper thickness indicated on the scale 3 . Tighten the hexagon head screws
1 . (Be sure they are extremely tight. If they are not tightened securely, your machine
could go out of adjustment during operation.) Turn the stitching head wire transport
knob back to the engaged position. Cycle the machine once, this will load the stitching
heads with the new proper stitch length. You may begin production. Be sure all safety
quards are in place!

Hohner Maschinenbau GmbH – ORION 4 - 13 -
10. Adjustment by hand of the ORION 4
For any adjustment or installation work at the wire stitching machine ORION 4 ,
the drive unit can be moved by hand. For this step use the pipe spanner 19 mm 2
Attention!
Before all repairs, disconnect the power supply and set safety switch (main switch)
to „0“.
First remove the plug 1 . Put the double offset ring wrench 2 on the hexagon 3 of
the motor shaft and turn the pipe spanner 2 in direction of arrow 4 .
Important!
Before resumption of work the pipe spanner 2 has to be removed from the hexagon
of the motor shaft.

Hohner Maschinenbau GmbH – ORION 4 - 14 -
11. Accessories
Every ORION 4 WIRE STITCHING MACHINE is supplied with:
Art.-No. 31 44 030 setting gauge
Art.-No. 46 00 003 1 screw driver SB 4,5
Art.-No. 46 00 004 1 screw driver SB 7,0
Art.-No. 46 00 008 1 hexagon socket screw key SW 3
Art.-No. 46 00 014 1 diagonal cutting nipper
Art.-No. 46 00 019 1 hexagon socket screw key SW 5
Art.-No. 46 00 038 1 double offset ring wrench
Art.-No. 46 00 044 1 Torx angle screwdriver T10
Art.-No. 46 00 045 1 Torx angle screwdreiver T20
Art.-No. 94 36 340 1 setting gauge for clincher box
Art.-No. 99 67 700 2 centering device, cpl.

Hohner Maschinenbau GmbH – ORION 4 - 15 -
12. Flow diagrams
Orion 4 Nr. 43 44 360 P. 1-3
400 V 3 Phase AC / Y 50/60 Hz
Orion 4 Nr. 43 44 362 P. 1-3
230 V 3 Phase AC / ∆50/60 Hz

1
C Hohner Maschinenbau GmbH
Änderung Name
Seite Sheet Page
Schaltplan / flow diagrams / schéma des circuits 400V 3 Phase AC / Y 50 / 60 Hz
Bennenung / Title / Dénomination
43 44 360
Orion IV
Maschine / Machine / Machine Zeichnungs-Nr. / Drawing-Nr. / Dessin-No.
1 2 3 4 5 6 7 8 9
29.03.05 VEK
L1
-Q1
L1 T1
L2 T2
L3 T3
-X1
1
-Q2
1 2
3 4
5 6
-X1
5
-M1
U V W
PE
L2
2 6
L3
3 7
N
N
4
PE
PE
PE
-X1
11
-S3
11 12
10
14
-S1
23 24
15
1 2 .5 3 4 .8
21 22 .9
-K1
A1 A2
-K1
.4
1 2
-X1
17
-S2
21 22
16
8
-M2
12
-Y1
~
9
-G1
~
13
+
18
K
-K1
.4
3 4
19
K
A1 A2
-Z1
B
-K1
.4
21 22
20
B
A1 A2
-Z2

2
C Hohner Maschinenbau GmbH
Änderung Name
Seite Sheet Page
Klemmleiste
Bennenung / Title / Dénomination
43 44 360
Orion IV
21.05.08 VEK
Maschine / Machine / Machine Zeichnungs-Nr. / Drawing-Nr. / Dessin-No. Index
1 2 3 4 5 6 7 8 9
Klemmleiste / connector block / borne plate
Kabelbezeichnung
cable marker
repére
Kabelbezeichnung
cable marker
repére
Anschluß supply reccordement Zielpunkt destination destination Brücken bridge pont Klemmennummer binder number numero borne Anschluß supply reccordement Zielpunkt destination destination
Bezeichnung
description
désignation
Bezeichnung
description
désignation
Seite/Pfad
page/path
bord/sentier
=ORION4+400V-X1
T1
/1.1 -Q1 1 1 -Q2
T2
/1.2 -Q1 2 3 -Q2
T3
/1.2 -Q1 3 5 -Q2
/1.2 -N 4 A2 -K1
2
/1.1 -Q2 5 U -M1
4
/1.2 -Q2 6 V -M1
6
/1.2 -Q2 7 W -M1
/1.6 8 -M2
A2
/1.7 -K1 9 -G1
/1.3 10 12 -S3
/1.3 11 11 -S3
1
/1.6 -K1 12 -M2
/1.7 13 -G1
/1.4 14 23 -S1
A1
/1.4 -K1 15 24 -S1
A1
/1.5 -K1 16 22 -S2
2
/1.5 -K1 17 21 -S2
3
/1.8 -K1 18 -G1
4
/1.8 -K1 19 A1 -K
22
/1.9 -K1 20 A1 -B
/1.2 -PE PE PE -M1

3
C Hohner Maschinenbau GmbH
Änderung Name
Seite
Sheet
Page
Ersatzteileliste / spare parts list / liste des piéces de rechange Bennenung / Title / Dénomination
43 44 360
Orion IV
19.05.08 VEK
Maschine / Machine / Machine Zeichnungs-Nr. / Drawing-Nr. / Dessin-No. Index
1 2 3 4 5 6 7 8 9
Bez. Art.Nr Bezeichnung Description Description
-K1
-M1
-M2
-Q1
-Q2
-S1
-S2
-S3
-Y1
-Z1
-Z2
4300076
4200142
4200165
4300007
4300223
4300068
4300003
4300004
4300237
4300237
Schütz
Motor
Lüfter-Motor
Hauptschalter
Motorschutzschalter
Fußschalter
Endschalter
Sicherheitsschalter
Kupplungs-Brems-Kombination
Funkenlöschglied
Funkenlöschglied
contactor
motor
ventilator-motor
main switch
protective motor switch
pedal switch
stop switch
safety switch
clutch brake-combination
spark absorber
spark absorber
contacteur
moteur
ventilateur-moteur
interrupteur principal
coffret de protect. disjoncteur-protecteur
commande par pédale
déclenchem. fin du course
interrupteur fin de course
combinaison, frein d'embrayage
absorbeur d'ondes
absorbeur d'ondes

1
C Hohner Maschinenbau GmbH
Änderung Name
Seite Sheet Page
Schaltplan / flow diagrams / schéma des circuits 230V 3 Phase AC / 50 / 60 Hz
Bennenung / Title / Dénomination
43 44 362
Orion IV
21.05.08 VEK
Maschine / Machine / Machine Zeichnungs-Nr. / Drawing-Nr. / Dessin-No. Index
1 2 3 4 5 6 7 8 9
L1
-Q1
L1 T1
L2 T2
L3 T3
-X1
1
-Q2
1 2
3 4
5 6
-X1
5
-M1
U V W
PE
L2
2 6
L3
3 7
N
4
PE
PE
PE
-X1
11
-S3
11 12
10
14
-S1
23 24
15
-K1
A1 A2
-K1
1 2
-X1
17
-S2
21 22
16
8
-M2
12
-Y1
~
9
-G1
~
13
+
18
K
-K1
3 4
19
K
A1 A2
-Z1
B
-K1
21 22
20
B
A1 A2
-Z2

2
C Hohner Maschinenbau GmbH
Änderung Name
Seite Sheet Page
Klemmleiste
Bennenung / Title / Dénomination
43 44 362
Orion IV
19.05.08 VEK
Maschine / Machine / Machine Zeichnungs-Nr. / Drawing-Nr. / Dessin-No. Index
1 2 3 4 5 6 7 8 9
Klemmleiste / connector block / borne plate
Kabelbezeichnung
cable marker
repére
Kabelbezeichnung
cable marker
repére
Anschluß supply reccordement Zielpunkt destination destination Brücken bridge pont Klemmennummer binder number numero borne Anschluß supply reccordement Zielpunkt destination destination
Bezeichnung
description
désignation
Bezeichnung
description
désignation
Seite/Pfad
page/path
bord/sentier
=ORION4+230V-W1
=ORION4+230V-X1
ÖLFLEX CLASSIC 110CY-G
T1
+230V/1.1 -Q1 1 1 -Q2
T2
+230V/1.2 -Q1 2 3 -Q2
T3
+230V/1.2 -Q1 3 5 -Q2
+230V/1.2 -N 4
2
+230V/1.1 -Q2 5 U -M1
4
+230V/1.2 -Q2 6 V -M1
6
+230V/1.2 -Q2 7 W -M1
+230V/1.6 8 -M2
A2
+230V/1.7 -K1 9 -G1
12
+230V/1.3 -S3 10
1
+230V/1.3 11 11 -S3
1
+230V/1.6 -K1 12 -M2
+230V/1.7 13 -G1
+230V/1.4 14 23 -S1
A1
+230V/1.4 -K1 15 24 -S1
A1
+230V/1.5 -K1 16 22 -S2
2
+230V/1.5 -K1 17 21 -S2
3
+230V/1.8 -K1 18 -G1
4
+230V/1.8 -K1 19 A1 -K
22
+230V/1.9 -K1 20 A1 -B
+230V/1.2 -PE PE PE -M1