2_03_051_V01

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Basic setting of machine

C 2205

02.01 Mi/De - V01 2.003.051

Correct setting:

1. To set product chain in relation to

carton chain

-> The front edge of a cell divider of the No.

001 product chain is located 0,5 mm to

1,0 mm in front of the front edge of the No.

No. 002 finger of the carton chain.

Release No. 003 screws (3x) at pressure sleeve

of drive shaft of product chain.

Advance carton chain using machine handwheel

until located in correct position.

Tighten No. 003 screws (3x) at pressure sleeve.

After slackening of drive elements, release of position indicators and elimination of faults, it is an

absolute necessity to set up the machine again in conformity with the sequence of settings given

below.

When setting or checking the working stations, the sequence of operations given below must be

adhered to.

The correct setting is described in the left-hand column. How to arrive at this setting is described

in the right-hand column.

005_412

003

0,5 mm to 1,0 mm

005_410

005_411

001002

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2.003.052 V01 - 02.01 Mi/De

Mechanical zero setting at degree dial:

Release No. 007 screw at No. 008 degree dial.

Set No. 008 degree dial on zero.

Tighten No. 007 screw.

2. Zero point setting (mechanical zero =electronic zero)

The cartoner is exactly in zero position if the

following two conditions are fulfilled:

-> The support of one of the No. 004 fingers

of the transport chain is flush with the No.

006 zero point marking on the carton chain

(= mechanical zero). The clearance between

the zero point marking and the No. 009

sidepiece of the lateral guide is 110 mm.

-> The degree indicator on the display screenreads '0' (= electronic zero). The No. 008

degree dial on the encoder is also set on '0'.

Mechanical zero setting

0

1 0

2 0

3 0 4 0

5 0 6 0 7 0 8 0

9 0 1 0

2 0

3 0

4 0

5 0

6 0

7 0

8 0

9 0

8 0

7 0

6 0 5 0

4 0 3 0 2 0 10 90

8 0

7 0

6 0

5 0

4 0

3 0

2 0

1 0

001_865008 007

0 - P u n k t

E i n s t e

l l u n g

F i n g e r o f

t r a n s p o r t h a i n

( i n s i d e )

005

004

006

F i n g e r o f

h o l d - u p c h a i n

( o u t s i d e )

003_577

S e t t i n

g

0 - p o i n

t

Setting0-point

110 mm

Mechanical zero setting

005_413

006

009

006

005

009

004004

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02.01 Mi/De - V01 2.003.053

Electronic zero setting on control panel:

Select "Setting up" -> "Programming of

machine" -> "Angles" -> "Init" softkeys ondisplay screen of control panel.

Select "Zero point setting" softkey on display

screen.

Important!

The degree indicator on the display screen

reads "Position: 0".

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Release No. 013 clamping lever at No. 014

handwheel for product loader.

Turn No. 014 handwheel until the loading pusher

is located in correct position.

Lock No. 013 clamping lever.

3. To set product loader and leaflet pre-insertion unit

Important!For the product loader and the leaflet pre-

insertion unit, only one single setting is required.

-> The No. 010 loading pusher is positioned at

equidistance to the cell dividers of the No.

012 transport chain and the No. 011 hold-up

chain of the product chain.

012 011

Travel direction

001_846

Loading tongues(leaflet pre-insertion)

010

014

013

001_848

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C 2205

02.01 Mi/De - V01 2.003.055

4. To set carton feeder

4.1 To set position of vacuum arms

Advance carton feeder via machine handwheel

until the marking of the number "1" and the

marking at the No. 015 housing are exactly lined

up.

-> At the rear side of the machine, the No. 023

marking at the No. 016 control cam and the

No. 024 marking at the No. 019 base plate

are exactly lined up.

If the markings at the rear side of the machine

are not exactly lined up, proceed as follows:

Open cover 1 at rear side of machine.

Important!

Before pulling off the plugs, mark the plug-in

connections in order to ensure that the plugs are

reconnected correctly.

Pull off plugs from all No. 018 proximity

switches.

001_863

View of rear side of machine

Cover 1

1

1

001_496

015

019018016, 017

020022 021

004_839

023 024

017

019

016

004_840

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Release No. 028 screws at No. 029 parallel

coupling.

Release screws at No. 022 front plate.

Remove No. 029 parallel coupling together with

No. 022 front plate and No. 020 drive wheel.

Release No. 027 retaining ring at No. 025 shaft

of No. 021 gear segment.

Remove No. 026 lever and pull off No. 017

control cam.

Release screws at pressure sleeve of No. 016

control cam and rotate No. 016 control cam until

located in correct position.

Tighten screws at pressure sleeve of No. 016control cam using a torque spanner until a

tightening torque of 5 Nm is reached.

026

027

025

021

005_417

Prox.switchsucker 1

Prox.switchsucker 2

Prox.switchsucker 3

1 2 3

12

3

028 029

023 024

017

019

016

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02.01 Mi/De - V01 2.003.057

Re-assemble in reverse order.

If the vacuum arms are not arranged

vertically, proceed as follows:

Release No. 031 screws at No. 032 locator.

Adjust No. 030 vacuum arms until positioned

vertically.

Tighten No. 031 screws.

If the clearance between the cam and theproximity switch 1 is incorrect:

Release screw at No. 034 control plate.

Set No. 033 cam to ensure that the clearance

between it and the proximity switch '1' is 5 mm.

Tighten screw.

Important!

The marking '2' is available three times.

The check described below has to be per-

formed once for each of the vacuum arms 1,2 and 3.


until the marking of the number '2' and the

marking on the housing are exactly lined up.

-> The No. 030 lower vacuum arm is positioned

vertically.

Important!

The following condition applies only to vacuum

arm '1'.

-> The clearance between the No. 033 cam atthe No. 034 control plate and the proximity

switch '1' is 5 mm.

2

1

3

2

001_502

2

1

3

030

Prox.switchvacuum arm 1

033 034 022 5 m m

001_499



001_504

031

032

030

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2.003.058 V01 - 02.01 Mi/De

Important!

The marking '3' is available three times.

The check described below has to be per-

formed once for each of the vacuum arms 1,2 and 3.


until located on the next '3' marking.

-> The No. 035 erector flap below the carton

magazine is located parallel to the No. 030

vacuum arm.

Release No. 036 screws at No. 037 locator forerector flap retainer.

Adjust No. 035 erector flap to ensure that it is

parallel to the No. 030 vacuum arm.


continued next page

036

037

030

035

004_841

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02.01 Mi/De - V01 2.003.059

4.2 To set carton feeder in relation tocarton chain

Advance carton feeder via handwheel untillocated in position '2'.

-> The lower vacuum arm points vertically

downward.

-> The angular position of the machine is

'265°'.

-> The rear edge of the No. 030 vacuum arm

must be 145 mm behind the front edge of

the next No. 002 finger of the transport chain

(carton chain).

If the lower vacuum arm does not point verticallydownward when located in position '2', proceed

as described above under "4.1 To set position of

vacuum arms".

Release No. 038 fixing screws (2x) at housing of

carton feeder at rear side of machine.

Release No. 039 screw at No. 040 belt tightener

for No. 041 drive belt.

Slacken No. 041 drive belt and remove it.

Adjust the whole carton feeder assembly to

ensure that the clearance between the rear edgeof the No. 030 vacuum arm and the front edge

of the next No. 002 finger of the transport chain

is 148 mm.

2

1

3

2

042

040

039

041

038

145 mm

001_507

030

002

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Tighten No. 038 fixing screws at housing.

Instal No. 041 drive belt and tighten drive belt

using the No. 040 belt tightener.

Tighten No. 039 screw at No. 040 belt tightener.

Important!

Check whether vacuum arm is positioned

vertically.

If not, release No. 042 screws.

Position vacuum arm vertically.


042

040

039

041

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02.01 Mi/De - V01 2.003.061

4.3 Vertical setting of carton feeder


until one of the No. 027 vacuum arms pointsvertically downward (position '2').

-> The clearance between the lower edge of the

vacuum arm and the supporting surface of

the transport finger must be 41 mm.

-> The position indicator reads '15'.

Using the No. 043 position indicator, set

clearance between lower edge of vacuum armand supporting surface of transport finger to 41

mm.

Release No. 044 clamping screw at No. 045 ring

of No. 043 position indicator.

Rotate No. 045 ring until 15 is read off on the

position indicator.

Tighten No. 044 clamping screw.

001_869

043

044

045

continued next page

4 1

m m

001_868

Supportingsurface offinger

Lower edge ofvacuum arm

027

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2.003.062 V01 - 02.01 Mi/De

Using the No. 049 'Carton height' positionindicator, move the complete carton magazine

assembly to the left until it is close to the carton

feeder.

Release No. 050 clamping screw at No. 051

ring.

Rotate No. 051 ring until the position indicator

reads '2'.


Set No. 049 'Carton height' position indicator

on 15 using the provided crank handle.

Important!

Set position indicator for 'Height carton feeder'also on 15.

Release all No. 048 fixing screws at carton

magazine rail.

Adjust the complete carton magazine assembly to

ensure that a clearance of 136 mm is set.

Tighten all fixing screws.

continued next page

001_869

049

050

051

136 mm

005_421

047

046

Cartonfeeder

Cartonmagazine

049

048

5. To set carton magazine in relation tocarton feeder

The clearance between the No. 047 right-handedge of the carton feeder and the left-hand edge

of the No. 046 shaft is 136 mm.

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02.01 Mi/De - V01 2.003.063

Adjust No. 030 vacuum arm of carton feeder to

ensure that it is parallel to the No. 052 lower

guide rails of the carton magazine.

Check whether the clearances 43,5 mm, 25 mm

and 2,5 mm as shown on the diagram are

correctly set.

Important!

If the clearances 43,5 mm and 25 mm are not

correctly set, check the settings of all position

indicators provided on the carton magazine.

If the clearance 2,5 mm is not correctly set,

release No. 053 clamping screw. Set clearancecorrectly and tighten clamping screw again.

continued next page

2 5 m m

4 3 , 5 m m

2 , 5 m m

005_415

Uppermagazine rails

030053

052

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2.003.064 V01 - 02.01 Mi/De

6a. Leaflet folder from the stack (GUK)

Locate machine in angular position 'X'. The

angular position 'X' can be seen from thefollowing table.

-> With machine located in angular position 'X',

the No. 055 pick-off sucker of the leaflet

folder must be in its topmost position.

Table for angular position 'X':

300" product chain:

Normal folding table X = 160°

240" product chain:


Horizontal product chain: X = 130°

Locate machine in angular position 'X'.

Release No. 054 clamping screw from the rear

side of the folder.

Turn No. 056 handwheel of leaflet folder in

direction of rotation until the No. 055 pick-off

sucker is in its topmost position.


continued next page

001_866

054

055

056

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02.01 Mi/De - V01 2.003.065


Open cover on leaflet folder at rear side of

machine.

Release screws at No. 057 pressure sleeve of

drive wheel No. 058.

Turn leaflet folder via handwheel until the speed

can be changed.

Tighten screws at No. 057 pressure sleeve until atightening torque of 10 Nm is reached.

The No. 055 pick-off sucker of the leaflet folder

must be located in its topmost position. In case

of discrepancies, set pick-off sucker as describedunder '6a. Leaflet folder from the stack'.

6b. Leaflet folder from the stack withchange-speed gear (GUK)

Locate machine in angular position 'X'. Theangular position 'X' can be seen from the

following table.

-> Speed change-over from 1:1 to 2:1 and vice

versa is performed when the machine is

located in angular position 'X'.


the No. 055 pick-off sucker of the

leaflet folder must be in its topmost

position.


300" product chain:Extended folding table X = 100°

240" product chain:

Extended folding table X = *°

*: value not yet determined.

057 058

2056

continued next page

001_866

055

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Release No. 062 screws at No. 061 belt pulley.

Turn folder using its proper handwheel until the

markings at both No. 059 and No. 060 gear

wheels are positioned exactly opposite each

other.

Tighten No. 062 screws at No. 061 belt pulley.

6c. Leaflet folder from the reel 760 (GUK)


angular position 'X' can be seen from the tablebelow.

-> The leaflet folder from the reel is located in

zero position.

-> The markings at both No. 059 and No. 060

gear wheels (on the left-hand side seen from

operator's side) are positioned exactly

opposite each other.


300" product chain: X = 70°


continued next page

0 0

0

059 060

061062

2055

zahnrad_01

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02.01 Mi/De - V01 2.003.067

Locate machine in angular position 'X';

Place a No. 063 piece of paper (e.g. a leaflet) on

the No. 065 folding table behind the No. 064

cutter block.

Release No. 066 clamping screw at No. 067

clamping piece.

Turn handwheel clockwise until the No. 064

cutter block audibly starts cutting the piece of

paper.


6d. Leaflet folder from the reel 880 (GUK)

Place a No. 063 piece of paper (e.g. a leaflet) on

the folding table.


angular position 'X' can be seen from the table

below.

-> When in angular position 'X', the cutter block

audibly starts cutting the piece of paper.



240" product chain: X = *°

*: value not yet determined.

continued next page

005_416

063

064

065066067

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6e. Leaflet inserter (GUK)



-> When the machine is located in angular

position 'X', the pick-off sucker of the leaflet

inserter is in its topmost position.



240" product chain: X = *°

Horizontal product chain: X = 250°

*: value not yet determined

Locate machine in angular position 'X';

Release No. 068 clamping screw from the rear

side of the leaflet inserter.

Turn handwheel at leaflet inserter in direction of

rotation until the No. 069 pick-off sucker is in

its topmost position.


continued next page

001_866

068

069

004_003

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02.01 Mi/De - V01 2.003.069

6f. Leaflet folder from the stack (LANG)




the No. 095 vacuum roller on the leaflet

folder from the stack must be located in the

upper reversal point (dead centre). The

vacuum nozzles of the No. 095 vacuum

roller are located in upper position.

Table for angular value 'X':

300" product chain:


Important!

For performing this setting, two persons arerequired.

Locate machine in angular position 'X' and open

cover 2.

Important!

Mark the position of the No. 101 belt pulley on

the No. 0100 shaft to ensure that the original

position can be regained after an axial shift.

Loosen No. 097 screws (4x).

Completely unscrew two screws and screw them

into the No. 096 forcing threads. In this way, the

belt drive is disconnected.

Turn No. 098 handwheel on folder in direction

of rotation until the No. 095 vacuum roller is

located in the upper reversal point.

Unscrew No. 097 screws (2x) from forcing

threads.

Screw in the No. 097 screws (2x) at the original

positions and tighten all screws until a tighteningtorque of 10 Nm is reached. The belt drive is

connected again.continued next page

095

005_838

001_863

View from rear side of machine Cover 2

005_839

098

096 097

100101

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2.003.070 V01 - 02.01 Mi/De

6g. Leaflet folder from the stack with speedchange-over gear (LANG)

Locate machine in angular position 'X'. Theangular position 'X' can be seen from the table

below.

-> Speed change-over from 1:1 to 2:1 and vice

versa is performed when the machine is

located in angular position 'X'.


the No. 095 vacuum roller must be located in

the upper reversal point (dead centre). The

vacuum nozzles of the No. 095 vacuumroller are located in upper position.


300" product chain:

Extended folding table X = 0°


Open cover at the rear side of the leafled folder

from the stack.

Loosen screws at No. 057 pressure sleeve of No.

058 drive wheel.

Turn leaflet folder via handwheel until the speed

change-over is permitted to be carried out.

Tighten screws at No. 057 pressure sleeve until atightening torque of 10 Nm is reached.

The No. 095 vacuum roller must be located in

upper dead centre. In case of discrepancies, set

No. 095 vacuum roller as described under '6f.

Leaflet folder from the stack'.

continued next page

057 058

2056

095

005_838

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02.01 Mi/De - V01 2.003.071

7. Closing station

Locate machine in '140°' angular position.

-> The left-hand side and the right-hand side of

the closing station are fully closed.

Important!

Depending on the prevailing situation, both theleft-hand and the right-hand side of the closing

station have to be set.

Right-hand side:

Advance closing station to ensure that the slot on

the eccentric points in travel direction of cartons.

Only when in this position can the clamping of

the eccentric be released.

Release clamping screw for eccentric through the

No. 070 hole.

Advance machine until located in 140° angular

position.

Rotate eccentric until the right-hand side is fully

closed.

Tighten clamping screw.

continued next page

001_455

Closing stationleft-hand side

Closing stationright-hand side

Eccentric,left-handside

Eccentric,right-handside

070

2685

T r a v

e l d i r e

c t i o

n o f

c a r t o

n s

Eccentric Slot

001_510

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C 2205

2.003.072 V01 - 02.01 Mi/De

Left-hand side:

Advance closing station to ensure that the slot on

the eccentric points in travel direction of cartons.Only when in this position can the clamping of

the eccentric be released.

Release clamping screw for eccentric through the

No. 071 hole.

Advance machine until located in 140° angular

position.

Rotate eccentric until the left-hand side is fully

closed.

Tighten clamping screw.

continued next page

001_511

T r a v

e l d i r e

c t i o n

o f c a r t o

n s

Eccentric Slot

071Eccentric

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C 2205

02.01 Mi/De - V01 2.003.073

8. To set blister magazine

Open cover 6.

Advance machine via machine handwheel until

the No. 074 lever is in lower position.

-> The blister magazines are exactly vertical.

-> The LED at the No. 073 proximity switch is

extinguished.

-> The No. 075 cam at the No. 072 belt pulley

is positioned slightly below the centreline of

the No. 073 proximity switch.

Important!

If the lever is in upper position, advance

machine via machine handwheel until the lever

reaches its lower position.

Release No. 076 screws at pressure sleeve.

Adjust No. 075 cam until located in correct

position.

Tighten No. 076 screws at pressure sleeve using

a torque spanner until a tightening torque of 5

Nm is reached.

.

View from rear side of machine

Cover 6

001_863

0537

073072

076

075 074

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9. To set blister counting with slides (not forversions with counting wheels)

The release slide (lower slide) must becompletely extended and just starts to move

backward.

Open cover 6.

-> The No. 078 proximity switch for blister

counting is activated by the No. 077

switching flag.

-> Both LEDs at the No. 078 proximity switch

are illuminated.

Release clamping of No. 080 coupling.

Adjust No. 079 release slide until located in

correct position.

Lock clamping.View of rear side of machine

Cover 6

001_863

b a c k w

a r d

e x t e

n d e d

079

080

002_277

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02.01 Mi/De - V01 2.003.075

004_019

081

004_021

083084085

082

086

102103 004_843

081

10. To set booklet feeder

Locate No. 081 pusher in rearmost position

(against travel direction):

-> The No. 084 cam at the large No. 083 belt

pulley is located approx. 5 mm before the

centreline of the No. 085 proximity switch.

Locate No. 081 pusher in rearmost position

(against travel direction).

Open No. 082 cover.

Release clamping of No. 103 lever at lower end

of No. 086 shaft using the No. 102 screw.

Rotate No. 084 cam until located in correct

position.

Important!

Make sure that the No. 081 pusher remains in

rearmost position.

Tighten No. 102 screw again.

Close No. 082 cover again.

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Hinge up cover 3 at rear side of machine.

Attention!

Do not loosen the No. 090 screw.

Loosen No. 099 screws (3x) and remove No.105 cover.

Locate the two No. 088 upper locators in hori-

zontal position (check position using the No. 087

spirit level).

For performance of setting, remove the upper

vacuum arms. For a correct vertical alignment,

the lower vacuum must remain fitted.

Release No. 100 clamping screws for the No.

089 lower vacuum arm.

Position No. 089 vacuum arm exactly vertical

using the No. 104 spirit level.

Tighten No. 100 clamping screws.

Rotate add card by• 120° and set second vacuum

arm.

Rotate add card again by 120° and set third

vacuum arm.

002_262Cover 3

View of rear side of machine

11. To set the three-arm add card (withservodrive)

De-energize control system as follows:

-> Press STOP button in order to ensure that

the machine stops in a clearly defined

position.

-> Set main switch on '0 - OFF'.

The add card can be rotated manually now.

Check alignment of the three No. 089 vacuum

arms as described below:

-> The two No. 088 upper locators for the

vacuum arms must be located in horizontal

position (remove vacuum arms, check

position using the No. 087 spirit level).

-> The No. 089 lower vacuum arm must be

positioned exactly vertical (check position

using the No. 104 spirit level).

-> This check has to be performed for all three

vacuum arms! To this end, rotate add card

each time by 120°.

006_578

087

105

090

088

089

104

099

006_580

100

089

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C 2205

Checking the setting of the add card in

relation to the supply magazine:

> The distance between the centreline of theNo. 089 vacuum arm and the No. 092

magazine rail is 18 mm.

Checking deposition of the booklet:

-> Switch machine ON.

-> With machine in inching mode (mode

selector on position '1 - Inching'), collect

booklet using the add card. Check the

measure '2 - 3 mm' (clearance between cell

divider and booklet).

Loosen No. 090 screw.

Re-adjust No. 091 housing with the No. 089

vacuum arms until the centreline of the No. 089

vacuum arm (below the supply magazine) is

located at a parallel distance of 18 mm in

relation to the No. 092 upper magazine rail.

Tighten No. 090 screw.

To re-adjust the angular value for the add card:

-> If the booklet is located too far on the left

(measure is too small): set a smaller angular

value.

-> If the booklet is located too far on the right

(measure is too large): set a larger angular

value.

18 mm

006_577

090

092

089

091

006_579

2 - 3 mm 18 mm

089

2_03_051_V01

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