Perfecta 76 UC Operating instructions

1/01 E Service Instructions 1
The Service Instructions manual
belongs to the hands of the
repair and maintenance personnel !
PERFECTA 76 / 92 / 115 / 132 / 168
UC /TV
SERVICE
INSTRUCTIONS
(Servo)

1/01 E Service Instructions 2
Table of Contents Page
General Instructions ...................................................................................................................... 4
Safety Inspection........................................................................................................................... 4
Knife Drive..................................................................................................................................... 6
Setting the Automatic Stopping Device ............................................................................... 6
Knife Drive Clutch and Brake Assembly ............................................................................. 6
Clutch/Brake Assembly Maintenance ................................................................................. 8
Malfunctions in the Knife Drive............................................................................................ 8
Clamping System .......................................................................................................................... 9
Gap Between the Knife Back and the Clamp Edge............................................................. 9
Play in the Clamp Guideways ............................................................................................. 10
Clamp Parallelism with the Cutting Table............................................................................ 11
Cutting System.............................................................................................................................. 13
Play in the Knife Beam Guideways ..................................................................................... 13
ReadjustingtheKnifeCut-ThroughPosition ........................................................................ 15
Non-RepeatDevice.............................................................................................................. 15
CuttingSystem Maintenance .............................................................................................. 18
CuttingTable ................................................................................................................................. 18
Backgauge DriveSystem .............................................................................................................. 18
BackgaugeGuidance........................................................................................................... 19
ThreadBacklashCompensation .......................................................................................... 20
MeasuringSystem......................................................................................................................... 21
CalibratingtheMeasuringSystem ....................................................................................... 21
Setting the Proximity Switches............................................................................................ 21
HydraulicClampingSystem .......................................................................................................... 22
Pre-Clamping ....................................................................................................................... 24
CutTriggering ...................................................................................................................... 25
MainClamping..................................................................................................................... 26
Decompression.................................................................................................................... 27
ClampReturn....................................................................................................................... 28
Start-Up ............................................................................................................................... 29
Adjusting the Hydraulic Clamping System ........................................................................... 29
CheckingtheAdjustment..................................................................................................... 30
Main Clamping Pressure Setting Instructions ...................................................................... 30
HydraulicClampingSystemMaintenance ........................................................................... 30
Malfunctions in the Hydraulic Clamping System............................................................................ 31

1/01 E Service Instructions 3
ComputerControl........................................................................................................................... 33
Control Processor ...............................................................................................................33
SafetyModule...................................................................................................................... 34
PC Design ........................................................................................................................... 35
Software ........................................................................................................................................ 35
UC Software Change .......................................................................................................... 35
TV Software Change........................................................................................................... 36
Settings/OperatingData................................................................................................................. 37
ServiceNenu ................................................................................................................................. 39
I/O Test Menu ............................................................................................................................... 41
KeyboardCode .............................................................................................................................. 45
SensorTest Menu ......................................................................................................................... 46
Activating the Differential Display .................................................................................................. 47
SpeedMenu .................................................................................................................................. 49
CharacterSetMenu ....................................................................................................................... 50
Texts Menu ................................................................................................................................... 50
KnifeControl(ControlSwitches) .................................................................................................... 51
PSG16 Light Guard....................................................................................................................... 62
ErrorMessages .............................................................................................................................63

1/01 E Service Instructions 4
General Instructions
This Service Instructions manual
isprovidedasasupplementtothe
OperatingInstructionsmanualfor
the repair and maintenance
personnel and, therefore, is
referredto the OperatingInstruc-
tions manual in several cases.
As a great deal of setting and
repairinstructionsaffectthesafety
oftheoperatorandofthemachine,
such work should be performed
bytrainedorinstructedpersonnel.
In this place, a few fundamental
instructions be given which, as
practice shows, are often disre-
garded:
• Whenever you remove sepa-
ratingguardingssuchashoods,
panelings etc. for repair and
maintenance purposes, always
remember that, in most cases,
machine elements with hazard-
ousmovementsarebehind. For
this reason, guardings must, by
all means, be refitted after com-
pletion of work.
• Open switch cabinets and
switching rooms do not only col-
lectdustthatleadstofailures,but
also involve danger to life and
limb.
You are encouraged to take
theopportunityPERFECTAof-
fers you to have your techni-
cians trained at our Training
Centre.
Safety Inspection
Duetotheirwayofoperationcon-
sisting of hazardous movements
such as clamping and cutting,
guillotinesmustmeetanumberof
safety regulations. Such regula-
tionsaremetby"SafetyDevices"
described under the same cap-
tion in the Operating Instructions
manual.
According to the Accident Pre-
ventionProceduresforthePrint-
ing and Paper Processing In-
dustry, VBG 7i, § 40, the user
must ensure that the safety
devices-particularlythecontrol
system-shouldbeinspectedby
aspecialisteveryfiveyears.The
result of the inspection should
be recorded and filed.
Fig.2showsanacceptancecheck
list as used by PERFECTA.
Machines accepted without any
objections are provided with a
plaquette (Fig. 1) which shows
the next inspection date.
Fig. 1

1/01 E Service Instructions 5
Fig. 2

1/01 E Service Instructions 6
Knife Drive
The timing of the S52, S53, S54
control switches on the crank-
shaft is explained by a chart in
the "Knife Control" section (con-
trol switches).
Theproperfunctioningofthecon-
trolswitchescanbecheckedfrom
the service menu (I/O Test).
S53
- Knife-down travel.
-Clamp locking whilethe knife is
coming down.
S54
- Checking the UDC.
- Emergency shut-off in case of
S52 failure.
The gap shown in the timing
chart (switching distance) be-
tween S54 and S53 should be
1/3to1/2ofaflywheelturn.For
thispurpose,energizetheclutch
(referto"ManualCranking"inthe
Operating Instructions manual)
andchecktheswitchingdistance.
Whentheknifedriveisautomati-
callystopped,theknifeedgemust
protrude at least 6 mm over the
right-hand clamp bottom edge.
Setting the
Automatic Stopping
Device
Fig. 3
8
9
7
54
6
1
2
3
14
11
12 13 10
The cam of S52 should be set
sothatthemachinewouldstop
at the upper dead centre and
thecamfollowerofS54comes
to stop within the first third of
its cam length.
When the knife beam runs over
the UDC (S54 no longer oper-
atedatstopposition),anysubse-
quent cut triggering is disabled.
The display reads Error 28:
Safety Module Detecting Error.
Bypressingthe"C"key,concrete
Error 7 appears: Knife Overrun.
After turning off and on the ma-
chine,thesubsequentcutcanbe
restarted by the knife pushbut-
tons.
If there is another overrun at the
UDC,slightpre-stoppingcorrec-
tioncan beperformed byturning
forward the entire cam package
within the permissible range.
If such correction by the above-
mentioned cam shifting is not
successful, i. e. if there is still
overrun, checking the clutch/
brakeassemblyoftheknifedrive
should,underanycircumstances,
be checked.
The control switches have the
followingfunction:
S52
-Takingoverknifeup-movement
fromthelowerdeadcentre(LDC).
- Deactivating the light guard ef-
fect.
- Stopping the knive travel to-
wards the upper dead centre
(UDC).
Knife Drive Clutch
and Brake Assembly
System Design (Fig. 3)
Armature disk 3 provided with
brake lining 1 or clutch lining 2,
respectively, is axially movable
on a spline bushing. It is forced
againstbrakering6bysprings5.
Thisreliablybrakesthemachine.
When the clutch is energized,
armature disk 3 is attracted by
the magnetic field of coil body 7
and pressed against friction ring
8. The machine is engaged.

1/01 E Service Instructions 7
Checking and Setting the Air
Gap
Under normal operating condi-
tions, the air gap should be
checked once per year.
For air gap A, refer to the Table
(Fig. 5).
• Engaged state (clutch "ON"):
If air gap A min is smaller than
specified in the Table, Fig. 5,
shims 10 of uniform thickness
should be inserted
between coil body 7 and friction
ring 8 (Fig. 4) for
machine sizes 76 and 92, or
between friction ring 8 and
spacing segment 9 (Fig. 3) for
machine sizes 115 and 132.
Forthispurpose,slackenscrews
11aroundthecircumferenceand
then re-tighten them uniformly.
The shims are available in vari-
ous thicknesses. Refer to the
Spare Parts Catalogue in the
Operating Instructions manual.
After the successful installation
of the shims, make sure that air
gapAmaxspecifiedintheTable
is not exceeded (use thinner
shims) and air gap A min in the
brakedstate(clutch"OFF")isnot
undercut.
Checking the Bearing Play
Formachinesizes115and132
only.
De-energize the clutch.
No perceptible play in the bear-
ing must appear when the fly-
wheelrimtopispulledandpushed
by hand.
In case of evident play, replace
the antifriction bearings.
Caution!
Bringtheknifebeamtoitslow-
ermost position prior to dis-
mantling the clutch/brake as-
sembly,asthebrake becomes
ineffectivewhenthecompres-
sion springs are relieved.
Fig. 4
8
7
2 1 6
3 4 5
Fig. 5
Knife Drive Clutch/Brake Assembly Air Gaps ( mm )
Braked state (clutch "OFF")
If air gap A max is wider than
specified in the Table, shims 12
of the same thickness should be
inserted between brake ring 6
and gearbox cover 14. For this
purpose, energize the clutch as
described in the Operating In-
structionsmanualunder"Manual
Cranking", slacken screws 13
around the circumference, and
then re-tighten them uniformly.
1411
10
13
12
Machine Size 76 92 115 132 168
Clutch "ON" A min 0,2 0,2 0,2 0,2 0,2
A max 0,4 0,5 0,5 0,5 0,6
Clutch "OFF" A min 0,6 0.7 0,7 0,7 0,7
A max 0,8 11,2 1,2 1,4

1/01 E Service Instructions 8
Clutch/Brake
Assembly
Maintenance
Check the air gap annually as
describedaboveandcorrectwith
shims, if required.
Keep the slip rings clean and
grease-free.Cleanwithfine-grain
abrasive cloth, if necessary. En-
sure proper contacting between
the carbon brushes and the slip
ring to avoid brush sparking.
Removecarbondustwithabrush
(without metal ring).
If the brake or clutch linings are
badly worn out or contaminated
with oil, the armature disk must
be replaced. Before installing a
newarmaturedisk,cleanthefric-
tion surfaces of the clutch and
brake rings with white spirit.
After installation, check the air
gapsinconformitywiththeTable
(Fig. 5).
Protecttheasbestos-freefriction
liningsfromoilandgrease.Even
when doing installation and set-
tingwork,makesureyourmeas-
uring tools and also your hands
are grease-free.
Caution!
Bringtheknifebeamtoitslow-
ermost position prior to dis-
mantling the clutch/brake as-
sembly,asthebrake becomes
ineffectivewhenthecompres-
sion springs are relieved.
Malfunctions in the
Knife Drive
The following malfunctions may
occur in the knife drive and are
not indicated by the computer
control system as error codes:
• The main motor cannot be
started.
Remedy:
- Switch S56 for "Manual Crank-
ing" (refer to the Operating In-
structions manual) under the fly-
wheel guard is locked. Unlock
the switch.
-The flywheel guard is not prop-
erly closed. Turn in the screw
until the safety switch is closed.
-Defectivefuses.Replacethecor-
responding fuses.
•Theknifeorclampdrivecannot
be started.
Remedy:
-Main motor switched off.
-Defective two-hand control
pushbutton.Replacepushbutton.
-No contact between the carbon
brushesand theslip rings.Refer
to"Clutch/BrakeAssemblyMain-
tenance".
-Refer to "Malfunctions in the
HydraulicClampingSystem"(flow
indicator).
-Pedallocked(S69).
-Y62doesnotmakecontactoris
defective.
• Heavy jerk when the knife re-
verses at its lowermost position.
Remedy:
- The overload protection device
hasbecomeloose.Re-tightenthe
overloadprotectionscrew.Refer
to "Knife Drive Assembly Over-
load Protection Device" in the
OperatingInstructionsmanual.
- Very dull knives are often the
cause for the responding of the
overloadprotectionring.

1/01 E Service Instructions 9
Clamping
System
Fig. 7
7
1
4
6
5
8
3
9
2
Fig. 6
Keeping specified gaps, it is im-
portanttobringtheclampingpres-
sure as close as possible to the
cutting line.
Gaps shown in Fig. 6 should be
0.2 + 0.1 mm.
Clamp 1 can be readjusted with
respect to cutting line 2 as fol-
lows:
In addition to gap s between the
knife back and the clamp edge,
the play of the clamp in its
guidewaysisdecisivetoobtaina
high-quality and high-accuracy
cut.
Gap Between the
Knife Back and the
Clamp Edge
Machine Size 76 (Fig. 7)
• Slacken screws 3 to release
clamp guideway 4 at the clamp
left and right rear sides.
•Adjustrequiredgapsbymeans
ofshims5tobeinsertedbetween
clamp 1 and clamp guideway 4.
Inserting shims reduces the gap
by the shim thickness, while re-
moving shims widens the gap.
The shims are 0.05 and 0.2 mm
thick. Refer to the Spare Parts
Catalogue in the Operating In-
structions manual.
• Tighten the clamp guideway
and check the gap across the
entire cutting width with a feeler
gauge.

1/01 E Service Instructions 10
Machine Size 92 (Fig. 8)
Fig. 8 shows shims3 under pre-
tensioned roller guideway 4 by
means of which the position of
clamp 1 with respect to cutting
line 2 was set in the factory.
Inserting shim 3 between clamp
1and roller guideway 4 mini-
mizes gap s by the shim thick-
ness, while removing shim 3 in-
creases the gap.
For the proper procedure, refer
to"PlayintheClampGuideway".
Machine Sizes 115/132 (Fig. 9)
• Slacken lower nuts 3 at the
clamp left and right sides.
•Slightly turningeccentric pins4
(bothsidesuniformly)movesthe
clamp away from or towads the
cutting line.
Check gap s across the entire
cuttingwidthwithafeelergauge.
•Whenjammingthenuts,ensure
thatthepositionsoftheeccentric
pins are locked.
Fig. 8
Fig. 9
Play in the Clamp
Guideways
Machine Size 76 (Fig. 7)
• Slacken screws 6of adjusting
strip 7.
• Move adjusting strip 7 against
clamp guideway4with eccentric
pin 8 until play a between both
parts is < 0.05 mm.
When performing this setting,
ensure that clamp guideway 4
restsonguidestrip9oftheoppo-
siteside.Forthispurpose,press
the clamp towards the knife.
5
8
7
6
1
2
34
184
9
3
7
8
5 6
1
9
65
12
11
10
10
4