The
Challenge Machinery Company provides owner's
manuals on its products solely as a courtesy to its customers.
See the informati on belo w b efore usi ng this ma nu al.
These manuals are for reference only. These manuals include products which are noncurrent, unsupported or no longer produced by The Challenge Machinery Co mpany, and are
provided solely as an accomodation to our customers. By providing these manuals, The
Challenge Machinery Company makes no representation or warranty as to the products,
their current condition, or their suitability or fitness for use in any particular application, which
are the sole and indepe ndent responsibility of the product owner and user.
Older products may not comply with current safety procedures, guidelines or regulations,
and it is the product owner's and user's responsibility to evaluate the suitability and fitness of
the products in their current use and application. The Challenge Machinery Company makes
no representation, warranty or recommendation regarding any modifications which may be
required on non-current or unsupported products. The Challenge Machinery Company
assumes no liability for any modification or alteration to any Challenge product, and any such
modification or alteration to any Challenge product is not authorized by The Challenge
Machinery Company. The availability of these manuals is solely for the purpose of providing
reference information for the products.
This
products should be used only by qualified and properly trained personnel, following proper
safety procedures. All products should be regularly inspected and maintained, and their condition,
application and use should be periodically evaluated by qualified personnel. Only qualified and
properly trained technicians should perform maintenance,
procedures. Attempting these procedures without proper training
damage or
Products
unavailability
available
the pro duct does n ot have a U L label it is not a list ed produc t), and m ay not com ply with
applicable installation or other regulations or requirements if
Many
to them. Often the cost of updating an older product to comply with current safety regulations is
greater than the value of the product.
manual
municipalities require a product
may not be
operator
may be
of parts from their
to repair or
injury!
unsupported by The Challenge Machinery Company
maintain unsupported
complete
original manufacturer.
in all aspects of
products.
to be UL
listed
product
No parts or
Older
before
maintenance
products
an
repair
may
product support
may not be UL
relocated
electrician
and
repair.
and replacement
cause
due to age or the
to a new
will
connect
All
machine
will be
listed (if
facility.
power
THE CHALLENGE MACHINERY COMPANY
CMT 330
Three-Knife Trimmer
Installation and
Operator's Manual
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441 USA
ChallengeMachinery.com
SERIAL No.: _____________
F.033B / JUL 2011
07/11
CMT 330 Three Knife Trimmer ii Contents
NOTICE
Service documentation is supplied to Challenge external customers for informational
purposes only. Service documentation is
intended for use by certified, producttrained personnel only. Challenge does not
warrant or represent that such documentation is complete, nor does Challenge represent or warrant that it will notify or provide
to such customer any future changes to this
documentation. Customer performed service of equipment may affect the warranty
offered by Challenge with respect to such
equipment. If the customer services this
equipment, modules, components or parts
thereof, the customer releases Challenge
from any and all liability for the customer
actions, and the customer agrees to indemnify, defend and hold Challenge harmless from any third party claims which arise
directly or indirectly from such service.
Prepared by:
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441 USA
Phone: 231.799.8484 Fax: 231.798.1275
ChallengeMachinery.com
©2002-2011 by The Challenge Machinery
Company. All rights reserved.
Challenge® is a registered trademark of
The Challenge Machinery Company.
07/11
CMT 330 Three Knife Trimmer iii Contents
Contents
Description Page
1 Introduction 1-1
1.1 Warranty Information ................................1-2
1.2 Warning Label Definitions.........................1-3
1.3 Note Definitions.........................................1-3
1.4 Safety........................................................1-3
1.5 Power Lockout Procedure.........................1-4
1.6 Packing List...............................................1-5
1.7 Specifications............................................1-8
1.8 General Locations.................................. 1-10
2 Installation Guide 2-1
2.1 Shipping Claims........................................2-2
2.2 Unpacking.................................................2-2
2.3 Moving.......................................................2-2
2.4 Option Setup.............................................2-2
2.5 Power Hookup...........................................2-8
2.6 Air Hookup ............................................. 2-10
2.7 Cleaning................................................. 2-10
3 Operator's Guide 3-1
3.1 Programming.............................................3-2
3.2 User Interface Map ...................................3-5
3.3 Power up...................................................3-6
3.4 Improper Wiring.........................................3-6
3.5 Run Mode..................................................3-6
3.6 Job Mode ..................................................3-7
3.7 Status Messages ................................... 3-10
3.8 Example Job .......................................... 3-13
3.9 Serial Communication............................ 3-15
4 Routine Tasks 4-1
4.1 Under Book Air Blast.................................4-2
4.2 Waste Bins................................................4-2
4.3 Cut Stick / Cut Plates................................4-3
4.4 Knives .......................................................4-4
4.5 Check Pressure Switch.............................4-9
4.6 Safety Systems Check..............................4-9
5 Book Quality 5-1
5.1 Burr Marks.................................................5-2
5.2 Jagged Bottom Cover...............................5-2
5.3 Burr Marks/Jagged Cover.........................5-2
5.4 Rectangular Crease Lines ........................5-3
5.5 Linear Crease Lines................................. 5-3
5.6 Draw......................................................... 5-3
5.7 All Sheets Not Cut.................................... 5-4
5.8 Book Not Square...................................... 5-4
07/11
CMT 330 Three Knife Trimmer iv Contents
Notes:
07/11
CMT 330 Three Knife Trimmer 1-1 Introduction
Section Contents
TITLE PAGE
1.1 Warranty Information ................................1-2
1.2 Warning Label Definitions.........................1-3
1.3 Note Definitions.........................................1-3
1.4 Safety........................................................1-3
1.5 Power Lockout Procedure.........................1-4
1.6 Packing List...............................................1-5
1.6.1 Basic Machine/Options....................... 1-5
1.6.2 Standard Accessories ........................ 1-6
1.6.3 Optional Items .................................... 1-7
1.6.4 Consumables...................................... 1-7
1.7 Specifications............................................1-8
1.7.1 Book Size Chart ................................. 1-9
1.8 General Locations.................................. 1-10
1.8.1 Front Views....................................... 1-10
1.8.2 Back View......................................... 1-11
1.8.3 Exit Conveyor................................... 1-12
1.8.4 Tilt In-feed Conveyor........................ 1-13
1.8.5 Elevator ............................................ 1-14
1.8.6 Site Specifications............................ 1-15
Introduction
The introduction section of this manual is intended to provide installers and operators with
basic information. Safety recommendations are
made, and machine options and specifications
are listed.
1 Introduction
07/11
CMT 330 Three Knife Trimmer 1-2 Warranty Information
1.1 Warranty Information
READ THIS MANUAL BEFORE OPERATING!
Follow all precautions and instructions. For
parts and service contact the Authorized Challenge Dealer from whom the machine was purchased. Always give the SERIAL NUMBER
and MODEL of your machine to ensure the correct parts are sent.
* WARRANTY INFORMATION *
PLEASE REVIEW THE ENCLOSED
WARRANTY INFORMATION SHEET
It is very important that you read and understand the conditions outlined in the Warranty
Information Sheet attached to the outside of the
shipping container of your machine. The War-
ranty Information Sheet must be filled out completely and returned to THE CHALLENGE
MACHINERY COMPANY in order for the warranty to be issued for this machine.
NOTICE: Failure to use dry, non-lubricated
compressed air that meets or exceeds the requirements given in Section 2.6 may cause
damage to the machine and will result in THE
WARRANTY BEING VOIDED.
RECORD YOUR MACHINE SERIAL NUMBER
in the space provided on the front cover of this
manual. Fill in the warranty card accompanying
this manual and return it DIRECTLY TO CHAL-
LENGE.
The letters in the following diagram correspond
to the accuracy adjustment values listed in the
Installation Information table on the affixed label.
A________
B________
C________
If you bought a used machine, it is important to
have the following information on record at
Challenge. Copy this page, fill in the information and send it care of The Challenge Service
Department, 6125 Norton Center Drive • Norton
Shores • MI 49441.
* INSTALLATION INFORMATION *
Model: CMT 330B
Serial No.:
Company Name:
Address:
City:
State/Province:
ZIP Code
Phone No.:
Date Installed:
Dealer Name:
Dealer City:
07/11
CMT 330 Three Knife Trimmer 1-3 Warning Label Definitions
1.2 Warning Label Definitions
Warning labels are posted throughout the machine to indicate areas where physical injury
may occur.
Read the instruction manual.
The instruction manual should be
read and understood before operating this machine.
Do not operate with more than
one person!
One person only should operate
this machine at a time.
Cut / Crush Hazard!
Do not operate with covers removed.
Do not disable safety devices.
Crush Hazard!
Do not operate with covers removed.
Do not disable safety devices.
Crush / Entanglement Hazard!
Do not operate with covers or
guards removed.
Electrical Shock Hazard!
Disconnect power before removing
cover.
Electrical Shock Hazard!
Disconnect power before removing
cover.
1.3 Note Definitions
The formats of three specific types of notes
found throughout this manual indicate the level
of danger or importance associated with the
task presented. The format of warning notes,
caution notes, and regular notes imply a certain
level of danger. The following examples give a
description. Associate the text format with its
level of danger or importance.
Warning Definition:
WARNING
A warning indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in injury or loss of life.
Caution Definition:
CAUTION
A Caution indicates an operating or maintenance procedure,
practice, or condition that, if not strictly observed could result in damage to, or destruction of, equipment.
Note Definition:
Note: A regular note indicates an operating or maintenance
procedure, practice, or condition that is necessary to accomplish a task efficiently.
1.4 Safety
Before installing or operating any equipment, it
is important to take precautions. Read and
thoroughly understand the safety precautions
outlined below.
• This machine is designed for oneperson operation. Never operate the
machine with more than one person.
• Safe use of this machine is the responsibility of the operator. Use good judgment and common sense when working
with and around the machine and its
accessories.
• Read and understand all instructions
thoroughly before using the machine. If
questions remain, contact your Authorized Challenge Dealer. Failure to understand the operating instructions may
result in personal injury.
• Only trained and authorized individuals
should operate this machine.
• Only trained and authorized service
technicians should service this machine.
• Do not alter safety guards or devices.
They are there for your protection. Severe laceration or dismemberment may
result if safety devices are altered.
• Disconnect power and lock out before
performing any maintenance. See Section 1.5 , Power Lockout Procedure.
• Observe all caution and instruction labels on this machine.
• Be extremely careful when handling
and changing knives. Severe lacerations or dismemberment could result
from careless handling procedures.
• Perform the Safety Systems Check
given on page 4-9 before each shift begins.
07/11
CMT 330 Three Knife Trimmer 1-4 Power Lockout Procedure
• Keep all conveyors and elevator accessories clear of foreign objects. Do not
manually place foreign objects within
the machine. Cutting anything other
than qualifying perfect bound books
could result in serious damage to the
machine and create safety hazards. A
qualifying perfect bound book will fall
into the size range described in the
specifications on page 1-8.
• Make sure all applicable accessories
are securely bolted to the main machine. Tip hazards may result from unsecured accessories.
• If the machine operates abnormally,
consult a Challenge authorized service
agent.
1.5 Power Lockout Procedure
For maximum safety while making ADJUSTMENTS or REPAIRS to your machine, lock out
the main power disconnect switch. The switch
should be moved to the OFF position and a
padlock securely fastened through the loop.
The person adjusting or servicing the machine
should hold the key.
Figure 1-1. Main Power Disconnect
07/11
CMT 330 Three Knife Trimmer 1-5 Packing List
1.6 Packing List
Compare the contents of the crate against the
following lists and the packing slip to be sure all
items are included with your shipment.
1.6.1 Basic Machine/Options
This parts list includes the basic machine and
any accessories that may have been ordered
with the machine.
Part Number Description Qty.
CMC-330B CMT 330 Basic Machine 1
Accessory Options
In-Line Option In-Line with Tilt In-Feed Conveyor
56600 Tilt In-Feed Conveyor 1
56421 Cooling Elevator 1
Stand-Alone Option Stand Alone
56413 Hand Feed Conveyor 1
Exit Option Fixed (shown above)
56420 Exit Conveyor 1
07/11
CMT 330 Three Knife Trimmer 1-6 Packing List
1.6.2 Standard Accessories
The following list contains pre-installed, standard accessories for the CMT 330.
Item Part Number Description Qty.
1 5064 Cut Stick Puller 1
2 56028 Knife Lifter 1
3 56143 Waste Bin 3
4 56246 HSS Knife Set (scabbard not shown) 2
5 56303 Cut Stick 1
6 56305 Cut Plate 2
7 H-6910-605 Knife Bolt- 3/8-16 x 5/8 BHCS 18
8 W-180 7/32" T-Handle Hex Wrench 1
07/11
CMT 330 Three Knife Trimmer 1-7 Packing List
Part Description Qty. Frequency
E-967-1 Lamp 6 10,000 hrs
47264-2101 UHMW Tape (Elevator) 4 1 yr.
56523-1000 UHMW Tape (Joggers) 2 1 yr.
SU-30-103 Grease (Ext. Pressure) BULK 1 wk.
SU-30-104 Grease (Rycotac EP) BULK each knife change
56228 Face Clamp Pad 1 6 mo.
56181 Left Clamp Pad 1 6 mo.
56181-1 Right Clamp Pad 1 6 mo.
56178 Center Pad 1 6 mo.
56246 HSS Knives (set of 3) 1 5000 books
56303 Cut Stick 1 rot. 1000, change 8000 books
56305 Cut Plate 2 rot. 1000, change 4000 books
The following consumables are found in Oil Change Kit, K-56040.
Part Description Qty. Frequency
56041 Filter Element (air) 1 1 yr.
H-227-1 Filter Element (oil) 1 1 yr.
S-1991-3 Grade 46 Hydraulic Fluid 1 1 yr.
1.6.3 Optional Items
The following items are optional.
56246-1 Tungsten Carbide Knives (3)
56246-2 DMD 5X Knives (3)
41058 Waste Wagon
K-56030 Spare Parts Kit
K-56040 Oil Change Kit
K-56031 Oil Change Tool Kit
S-1991-3 Hydraulic Fluid (5 Gal.)
1.6.4 Consumables
The CMT 330 uses the following consumable
items.
07/11
CMT 330 Three Knife Trimmer 1-8 Specifications
1.7 Specifications
WARNING
The CMT 330 was designed specifically for use with the
Challenge in-feed and exit accessories listed in this
table. If any other accessories are used, it is the purchaser's responsibility to comply with ANSI B65.4
Safety Standard for Three-knife Trimmers. Failure to
comply with this standard could result in personal injury or death.
CAUTION
The CMT 330 was specifically designed to trim perfect
bound books only. It should not be used for trimming other
materials. Trimming other materials with the CMT 330 may
result in safety hazards or damage to the machine.
For trimmable book sizes, see section 1.7.1 .
See manuals F.501 and F.502, for specifica-
tions for the Book Pile Feeder and the Vertical
Stacker.
Multiple Book Mode: Note that up to 3 books
may be stacked in multiple book mode. The
total thickness is not to exceed 1-1/4 in. (32
mm). Larger pile thicknesses may be cut, but
the trim may be less accurate and more out-ofsquare. Always test before running books outside the published specifications.
NOTE: Challenge reserves the right to make changes to
any product or specification without notice and without incurring responsibility to existing units.
Description US Units Metric Units
Perfect bound books only
Max. start book 13 (spine) x 9.5 in. 330 (spine) x 241 mm
Min. start book (bottom cover)
7 (spine) x 6.75 in. 177.8 (spine) x 171.4 mm
Min. start book (w/feeder)
7 (spine) x 6.75 in. (single book mode)
7 x 7 in. (multi-book mode)
177.8 (spine) x 171.4 mm
177.8 x 177.8 mm
Min. finish book 5.82 (spine) x 4 in.
147.8 (spine) x 101.6 mm
Max. face trim (fore-edge) 5.5 in. 140mm
Book thickness range 0.048-2.000 in. 1.22-50.8 mm
Min. Trim 0.125 in. 3.2 mm
CMT 330 Basic Machine
Width 34.5 in. 876 mm
Depth 84 in. 2134 mm
Height 61 in 1549 mm
Net Weight 2540 lb. 1140 kg
Shipping Weight 2850 lb. 1300 kg
Floor Loading 60 PSI 4.2 kg/cm
2
Waste Bin Capacity 3 @ 14.75 gal. per bin 3 @ 55.8 L per bin
Oil Capacity 5 gal. 19 L
Air Consumption 5 CFM @ 80 PSI 142 LPM @ 5.5 Bar
Knife Re-grind 1/4 in. 6.4 mm
60 Hz Requirements 208/230 V, 20 A, 3 phase
50 Hz Requirements 380/415 V, 10 kW, 3 phase, 12 A
Memory 99 jobs
Time to change book size 15 sec.
Throughput up to 400 books/hr.
56420 Exit Conveyor (85 lb/39 kg net) (210 lb/95 kg ship) (6.76 PSI/.48 kg/cm
2
load)
Depth 12.14 in. 308.4 mm
Width 47 in. 1194 mm
Height 39.5 in. 1003 mm
56421 Cooling Elevator (335 lb/152 kg net) (470 lb/214 kg ship) (11.86 PSI/.83 kg/cm
2
load)
Depth 21.5 in. 546 mm
Width 37.03 in. 941 mm
Height 45.5 in. 1156 mm
56600 Tilt In-feed Conveyor (150 lb/68 kg net) (230 lb/105 kg ship) (5.62 PSI/.40 kg/cm
2
load)
Depth 28.62 in. 727 mm
Width 39.38 in. 1000 mm
Height 26 in. 660 mm
Mates w/ binder @ exit
heights
17.5-25.5 in. 445-648 mm
07/11
CMT 330 Three Knife Trimmer 1-9 Specifications
1.7.1 Book Size Chart
The physical parts of a book are defined as follows and will be referenced as such throughout
this manual. Book dimensions are referenced
as (spine length) X (top or bottom edge length).
Spine: The edge of a book where the pages
are bound together.
Top edge: Also know as the head, the top
edge is the edge of the book that is facing away
from the reader.
Bottom edge: Also known as the foot, the bottom edge is the edge of the book that is facing
toward the reader.
Face: The face or fore-edge is the edge of the
book from which it is opened.
Book block: A book block is the printed and
collated form of a book that does not include the
cover. It contains all front and end matter as
well as the text block.
Untrimmed book: An untrimmed book is a
book block that has been bound with a cover
but has not yet been trimmed to finish size.
Trimmed book: A trimmed book has been
bound and trimmed to a finish size.
Figure 1-2 can be used to determine if a specific
book layout can be trimmed using the CMT 330.
From Error! Reference source not found.,
see that (x) is the bottom trim and (h) is the
height of the book. The book size must fall
within the shaded region of the chart but never
exactly on the sloped line.
The CMT 330 software will not allow a book to
be cut outside this range. The operator should
be aware of these size constraints before books
are printed. The CMT 330 will not allow only
one top or bottom edge to be trimmed.
Figure 1-2. Trimmable Book Sizes
Figure 1-3 CMT 330B Throughput Chart
07/11
CMT 330 Three Knife Trimmer 1-10 General Locations
1.8 General Locations
Become familiar with general machine locations. This manual frequently refers to these
locations. In order to understand the instructions presented, it is necessary to have a working knowledge of machine locations.
Note: The word "rear" refers to the general direction closer
to the back end of the machine. "Back" refers only to the
backside of the machine.
1.8.1 Front Views
The front views shown in Figure 1-4 and Figure
1-5 locate the front, back, right, and left sides of
the machine. Remember these references
while reading instructions in this manual. Refer
back to these figures as necessary.
Figure 1-4. Right Front View
Figure 1-5. Left Front View
07/11
CMT 330 Three Knife Trimmer 1-11 General Locations
1.8.2 Back View
Important locations at the back of the machine
are shown in Figure 1-6.
Figure 1-6. Back View
07/11
CMT 330 Three Knife Trimmer 1-12 General Locations
1.8.3 Exit Conveyor
Part Number: 56420
Important locations are shown in Figure 1-7.
Figure 1-7. Exit Conveyor Locations
07/11
CMT 330 Three Knife Trimmer 1-13 General Locations
1.8.4 Tilt In-feed Conveyor
Part No.: 56600
Important locations are shown in Figure 1-8.
Figure 1-8. Tilt In-feed Conveyor
07/11
CMT 330 Three Knife Trimmer 1-14 General Locations
1.8.5 Elevator
Part Number: 56421
Important locations are shown in Figure 1-9.
Figure 1-9. Elevator Locations
07/11
CMT 330 Three Knife Trimmer 1-15 General Locations
1.8.6 Site Specifications
The installation site must have adequate space
and utilities to support the trimmer with its setup
options. It requires a supply of compressed air
and electricity. Refer to section 1.7
Specifications on page 1-8 to verify that the site
can accommodate these requirements. Use the
following figures to determine floor space requirements for the option to be installed.
1.8.6.1 In-Line Option
This In-Line option is used when automated
transport of books from a binder to the trimmer
is required and book size changes are frequent.
It includes the CMT 330 basic machine, two
conveyors, and an elevator. See Figure 1-10
for space requirements.
Note the locations of the air and power hook-up
locations. Air and power lines should be
dropped from the ceiling in order to have clear
access to the waste bins using a rolling cart.
Figure 1-10. In-Line Option 2
07/11
CMT 330 Three Knife Trimmer 1-16 General Locations
1.8.6.2 Stand-Alone Option
The Stand-Alone option is used when books are
fed to the trimmer by hand. It includes the CMT
330 basic machine and two conveyors. See
Figure 1-11 for space requirements.
Note the locations of the air and power hook-up
locations. Air and power lines should be
dropped from the ceiling in order to have clear
access to the waste bins with a rolling cart.
Figure 1-11. Stand Alone Option
07/11
CMT 330 Three Knife Trimmer 2-1 Installation Guide
Section Contents
TITLE PAGE
2.1 Shipping Claims........................................2-2
2.2 Unpacking.................................................2-2
2.3 Moving.......................................................2-2
2.4 Option Setup.............................................2-2
2.4.1 In-Line Option..................................... 2-3
2.4.2 Stand-Alone Option............................ 2-7
2.5 Power Hookup...........................................2-8
2.5.1 Power Hookup Procedure..................2-8
2.6 Air Hookup ............................................. 2-10
2.7 Cleaning................................................. 2-10
Introduction
The installation guide provides information and
instructions essential to the proper setup of
each of the CMT 330 and its accessory options.
These applications include one option for InLine operation and one option for Stand-Alone
operation.
2 Installation Guide
07/11
CMT 330 Three Knife Trimmer 2-2 Shipping Claims
2.1 Shipping Claims
The CMT 330 has been packed to prevent
damage during shipment. Claims for damage
or loss are the responsibility of the recipient.
Inspect all shipments as soon as they are received. If there is any noticeable damage, note
it on the freight bill. Visual and/or hidden damage must be reported to the claims department
of the carrier within 15 days. Contact your
dealer if you need any assistance. Check the
contents of the crate against both the packing
list on page 1-5 and the freight bill. Make sure
there are no missing items.
2.2 Unpacking
Remove the packing materials and four lag
bolts. One lag bolt is located in the frame, behind each of the lower side doors as shown in
Figure 2-1.
Figure 2-1. Lag Bolt Locations
Remove Lag Bolts
1. Remove four screws from each of the
two front side doors using a 1/8" hex
wrench.
2. Using a 9/16" open-ended wrench, remove the lag bolts from the two front locations shown in Figure 2-1.
3. Pull open the two lower rear doors and
remove the waste bins.
4. Remove the two lag bolts from the two
rear locations shown in Figure 2-1.
5. Reinstall the waste bins and close the
rear doors.
6. Reinstall the two front side doors.
Use a forklift to remove the machine from the
skid and place it as close as possible to its installation location. The machine has accessory
power cables and air hoses wrapped-up and
placed inside the machine. Be careful not to
pinch or entangle these in the forks while lifting.
Figure 2-2. Fork Location for Lifting
2.3 Moving
Once the machine is near its final location, it
can be rolled into place.
WARNING
Do not roll on a graded surface. Roll only on a flat surface. Personal injury could result.
It may be necessary to raise the six leveling
pads in order to roll the machine. A pad is located under each corner of the machine. Each
of the remaining two pads is located under the
middle of each side of the machine. Using either a 3/4" open-ended wrench or an adjustable
wrench, turn the leveling pad counterclockwise
to raise it.
Figure 2-3. Leveling Pads
Push the CMT 330 into position. Do not lower
the leveling pads at this time. Its final position
may require slight adjustment depending upon
the setup.
2.4 Option Setup
The CMT 330 can be used either In-Line with a
perfect binder or as a Stand-Alone three knife
trimmer. The following table lists the accessories required for each application.
In-Line option: 56600 Tilt In-feed Conveyor
56421 Cooling Elevator
56420 Exit Conveyor
Stand-Alone option:
56413 Hand-feed Conveyor
56420 Exit Conveyor
07/11
CMT 330 Three Knife Trimmer 2-3 Option Setup
2.4.1 In-Line Option
Use the following procedure to setup the In-Line
option.
2.4.1.1 Tilt In-feed Conveyor
1. The ledge on the right end cover should
be set to about 13.5" (343 mm) from the
floor. Adjust the leveling pads as necessary.
Figure 2-4. Height Adjustment
2. The Tilt In-feed Conveyor is set in front
of the binder such that adjustable portion of the conveyor is centered on the
exit chute of the binder.
3. The adjustable portion should be set to
the height of the bottom of the binder's
exit chute. After adjusting the legs, lock
into place with jam nuts.
Figure 2-5. Adjustment Range
4. Move the entire conveyor close to the
binder to minimize the distance between the adjustable conveyor and the
binder's exit chute.
Figure 2-6. Book Slide Placement
07/11
CMT 330 Three Knife Trimmer 2-4 Option Setup
2.4.1.2 Elevator
1. The top shelf should be 36" (914 mm)
from the floor as shown in Figure 2-9.
Adjust the leveling pads as necessary.
2. Align the elevator with the in-feed conveyor by sliding the opening of the clear
plastic cover over the in-feed conveyor's plastic cover.
Figure 2-7. Elevator Placement
2.4.1.3 Trimmer
1. Install the scanner bracket onto the left
front door of the trimmer. Make sure
the top of the bracket is flush with the
trimmer's in-feed conveyor belt.
2. Remove the lower front door of the
trimmer and locate the loose photoelectric sensor. Remove the nuts from the
sensor and push the sensor through the
split cap bushing in the left side of the
trimmer's base. Attach the sensor as
shown in Figure 2-8. Attach the optional bar code scanner and sensor if
applicable.
Figure 2-8. Scanner Bracket Installation
3. Remove the two sets of screws and
washers from the holes in the right side
of the top cover of the elevator (Figure
2-9). Save them for later use.
4. Move the trimmer next to the elevator
such that the two holes in the right side
of the top cover of the elevator (Figure
2-9) line up with the two slots on the left
side of the trimmer's sheet metal enclosure.
5. Adjust the trimmer's leveling pads such
that the top of the table is 36" (914mm)
off the floor. Raise the two pads at the
center of the machine.
Figure 2-9. Elevator Mounting
6. Open the trimmer's front door and use a
level on the table inside the machine.
Level the front end of the machine by
adjusting the leveling pads. Keep the
final table height at 36".
7. Open the rear doors and repeat step 4
on the rear end of the machine.
8. Check the front end of the machine with
the level to make sure the front is still
level. Adjust as necessary.
9. After leveling the machine, lower the
two pads at the center of the machine.
10. Lock all (6) leveling pads in place by
tightening the jam nuts against the inside of the machine's base as in Figure
2-10. The nuts are accessed from inside the machine.
07/11
CMT 330 Three Knife Trimmer 2-5 Option Setup
Figure 2-10. Tighten Jam Nuts
11. Align the two long slots in the trimmer's
enclosure with the two mounting holes
in the top cover of the elevator.
12. Using the hardware removed in step 1,
reach through the trimmer's front door
and fasten the trimmer to the elevator.
13. Connect shop air to the port at the rear
of the trimmer. Refer to 2.6
07/11
CMT 330 Three Knife Trimmer 2-6 Option Setup
Air Hookup on page 2-10.
At this point, the setup should look like
Figure 2-11.
Figure 2-11. Current Progress
2.4.1.4 Exit Conveyor
Before proceeding, go to Section 2.5 Power
Hookup on page 2-8. Main power must be connected to the machine before proceeding.
1. Remove (4) sets of screws and washers from the power panel door of the
Trimmer. Save them for later use.
2. Make sure the exit conveyor's leveling
pads are set to 33-7/8" as shown in
Figure 2-12. Adjust as necessary.
Figure 2-12. Exit Conveyor Leveling Pads
3. Move the exit conveyor to the righthand side of the trimmer such that the
slots in the conveyor mounting brackets
line up with the holes in the power
panel door as shown in Figure 2-13.
4. Fasten the conveyor to the trimmer using the hardware from step 1.
Figure 2-13. Exit Conveyor Placement
The completed setup should look like Figure
2-14. The accessory cables and hoses can
now be connected to the trimmer.
Figure 2-14. Completed Setup
2.4.1.5 Hookup Accessory Cables
Power cables must now be connected to each
conveyor. Two air hoses and one power cable
must also be connected to the elevator.
Access the cables and hoses stored inside the
machine through the front door.
07/11
CMT 330 Three Knife Trimmer 2-7 Option Setup
In-feed Conveyor
1. Unwrap the two cables labeled In-feed
Conveyor.
2. Route the cable behind the hydraulic
power unit and under the left-hand side
of the machine base.
3. Connect the cables to the sockets on
the backside of the in-feed conveyor.
Lock into place by threading the connector collar onto the socket.
4. Connect the yellow cable from the Cooling Elevator to the in-feed conveyor.
5. If the Tilt In-feed Conveyor is being
used, connect the air hose with the red
cap to the port on the conveyor. Also,
Cooling Elevator
1. Unwrap the cable labeled Cooling Elevator.
2. Route the cable behind the hydraulic
power unit and under the left-hand side
of the machine base.
3. Connect the cable to the socket on the
backside of the elevator. Lock into
place by threading the connector collar
onto the socket.
4. Unwrap the two coiled hoses with quick
disconnect fittings that have yellow and
black caps. Route them with the cable
from step 3.
5. Push the hose connector with the black
cap into the fitting on the elevator with
black label above it.
6. Push the hose connector with the yellow cap into the fitting on the elevator
with yellow label above it.
Exit Conveyor
1. Unwrap the cable labeled Exit Conveyor.
2. Route the cable under the power panel
enclosure and out the right-hand side of
the trimmer base.
3. Connect the cable to the socket on the
backside of exit conveyor. Lock into
place by threading the connector collar
onto the socket.
2.4.2 Stand-Alone Option
This option uses the hand-feed conveyor and
exit conveyor options to make the CMT 330 a
Stand-Alone trimmer.
The gate opening in the hand-feed conveyor is
set slightly larger than the thickness of books to
be cut. Books are stacked onto the conveyor.
The conveyor feeds them into the trimmer
where they are cut. Finally, the books are delivered to exit conveyor where they are shingled
out as necessary.
Follow these steps to setup the Stand-Alone
option.
2.4.2.1 Trimmer
1. Make sure there is adequate floor
space for this setup. Figure 2-15 illustrates how much space this setup will
require.
2. Move the trimmer to the appropriate location.
3. Complete steps 5-10, and 13 in section2.4.1.3 on page 2-4.
4. Complete section 2.5 Power Hookup on
page 2-8.
Figure 2-15. Stand Alone Space Claim
2.4.2.2 Exit Conveyor
Complete section 2.4.1.4 Exit Conveyor on
page 2-6.
2.4.2.3 Hand Feed Conveyor
1. Remove (4) sets of screws and washers fastened to the center of the door
on the left-hand side of the trimmer as
shown in Figure 2-17. Save them for
later use.
2. Make sure the hand-feed conveyor's
leveling pads are set at 1-1/2" as shown
in Figure 2-16.
Figure 2-16. Hand-feed Leveling Pads
07/11
CMT 330 Three Knife Trimmer 2-8 Power Hookup
3. Move the hand-feed conveyor to the
left-hand side of the trimmer such that
the slots in the conveyor mounting
brackets line up with the holes in the
Trimmer's left-hand door as shown in
Figure 2-17 and Figure 2-18.
Figure 2-17. Hand Feed Mounting
Figure 2-18. Stand Alone Application
4. Fasten the conveyor to the trimmer using the hardware from step 1.
2.4.2.4 Hookup Accessory Cables
Power cables must now be connected to each
conveyor.
Remove the lower front door from the trimmer to
access the cables and hoses stored inside the
machine.
Hand Feed Conveyor
1. Unwrap the cable labeled In-feed Conveyor.
2. Route the cable behind the hydraulic
power unit and under the left-hand side
of the machine base.
3. Connect the cable to the socket on the
backside of Hand-feed Conveyor. Lock
into place by threading the connector
collar onto the socket.
Exit Conveyor
To setup the exit conveyor, follow the instructions in section 2.4.2.4 Hookup Accessory Cables / Exit Conveyor on page 2-7.
2.5 Power Hookup
This section describes how to hookup main
power to the CMT 330. An adequate power
supply must be provided to the machine. See
section 1.7 Specifications on page 1-8 for
power requirements. It should be on its own
circuit with a lockable, disconnect switch. Too
many machines on the same circuit will reduce
power to each machine. Insufficient voltage
may cause overheating, loss of cutting/clamping
force, and in extreme cases, failure to operate.
Test the line voltage when the shop is at actual
working levels.
The following table lists recommended wire
sizes for different voltage options. If a wire is
run over 75 feet (23 meters), the next size wire
should be used.
Recommended Wire Sizes
for Main Power Hookup
V
Circuit Size A Wire Size
# AWG
Metric Wire
mm
2
380/415 15 12 2.5
230 30 10 4
208 30 10 4
2.5.1 Power Hookup Procedure
The following procedure describes how to
hookup main power to the CMT 330. After
power is hooked up, running the machine will
verify if wires are correctly connected to the
terminal block on the power panel.
WARNING
Shock Hazard! Always disconnect power at main disconnect switch before working on the trimmer. Lock it
out to prevent accidental power up. See Power Lockout
Procedure on page 1-4.
1. Locate the power panel door at the
front, right-hand side of the machine.
Figure 2-19. General Locations
2. Remove the four screws that mount the
door to the machine and set the door
aside. The terminal block is located at
the lower, left-hand corner of the power
07/11
CMT 330 Three Knife Trimmer 2-9 Power Hookup
panel. The ground screw is located beneath the terminal block as shown in
Figure 2-20.
3. Remove the four screws that mount the
lower front door to the machine and set
the door aside.
4. Route the power cable under the righthand side of the machine and behind
the power panel enclosure.
5. Locate the cable hole in the back of the
power panel enclosure. Mount a strain
relief in this hole. Access this hole
through the front door of the machine.
6. Route the cable through the strain relief
and through the access hole in the
power panel.
7. Fasten the ground lead to the ground
terminal lug, labeled GND in Figure
2-20.
Figure 2-20. Power Panel
8. Fasten the three power leads to the
three terminals L1, L2, and L3 (Figure
2-20) on the main power terminal block.
9. Replace all panel doors. Make sure the
shop air hose in connected to the machine and shop air is switched on.
Open the lower, rear door and switch
the main, air disconnect valve to the on
(
I) position and close the door.
10. Unlock and switch on (
I) the main
power disconnect.
11. Switch on (
I) the machine's power.
12. Press the green start button key on the
console, shown in Figure 2-21. The
hydraulic motor should turn on. The
machine was shipped with all three
knives in the down position. If power is
hooked up correctly, the knives will
automatically raise to the up position. If
power is incorrectly connected, the
knives will remain in the down position.
Continue at step 13 if the knives do not
move to the up position. If the knives
move, skip to step 17.
Figure 2-21. CMT 330 Console
13. Switch off (
O) the machine's main
power switch.
14. Switch off (
O) the main power discon-
nect switch and lock it out.
15. Remove the power panel door at the
right-hand side of the machine.
16. Exchange any two of the main power
leads at the terminals L1, L2, or L3.
17. Repeat steps 9-12.
07/11
CMT 330 Three Knife Trimmer 2-10 Air Hookup
2.6 Air Hookup
The CMT 330 requires 80-90 PSI regulated,
dry, non-lubricated compressed air at a minimum of 5 cubic feet per minute (at 80-90 PSI).
The recommended minimum air quality rating is
ISO 8573.1 Class 2.4.2 (see chart on next
page).
Air Quality Classifications ISO 8573.1 2001
SOLIDS
ISO QUALITY
CLASS
Particle size in microns
1 0.1
2 1
3 5
4 15
5 40
6 -
WATER
@ 100 psig Pressure Dew Point
ISO QUALITY
CLASS
°C
°F
1 -70 -94
2 -40 -40
3 -20 -4
4 +3 +38
5 +7 +45
6 +10 +50
OIL
Including Liquid and Vapor
ISO QUALITY
CLASS
Mg/m
3
ppm
1 0.01 0.008
2 0.1 0.08
3 1 0.8
4 5 4
5 25 21
6 - -
NOTICE: Failure to use dry, non-lubricated
compressed air that meets or exceeds the
above requirements may cause damage to the
machine and will result in THE WARRANTY
BEING VOIDED.
The main air connector shown in Figure 2-22 is
a female 3/8 NPT port. A facilities maintenance
technician should connect shop air using a male
3/8 NPT fitting using either Teflon thread tape or
a liquid, pipe sealing compound.
Figure 2-22. Main Air Connector
Using a flexible hose to connect the machine to
shop air is preferred in case the location of the
machine needs adjustment later. A line
dropped from the ceiling is also preferred. Having the line off the floor enables the operator to
wheel a cart to the lower left rear door for waste
bin removal
2.7 Cleaning
It may be necessary to clean the machines after
installation. They may be cleaned with a solution of dish soap and water. Do not use petroleum or acid based solvents to clean the machine. Damage may result.
07/11
CMT 330 Three Knife Trimmer 2-11 Cleaning
NOTES:
07/11
CMT 330 Three Knife Trimmer 3-1 Operator's Guide
Section Contents
TITLE PAGE
3.1 Programming.............................................3-2
3.1.1 Console Descriptions ......................... 3-2
3.1.2 Key Descriptions ................................ 3-3
3.1.3 Using the Keypad............................... 3-4
3.2 User Interface Map ...................................3-5
3.3 Power up...................................................3-6
3.4 Improper Wiring.........................................3-6
3.5 Run Mode..................................................3-6
3.6 Job Mode ..................................................3-7
3.6.1 Creating a Job.................................... 3-7
3.6.2 Editing a Job Name............................ 3-7
3.6.3 Lock/Unlock a Job.............................. 3-7
3.6.4 Erasing a Job...................................... 3-7
3.6.5 Editing a New Job .............................. 3-7
3.6.6 Editing an Existing Job....................... 3-7
3.6.7 Job Options ........................................ 3-8
3.6.8 Running a Job .................................... 3-9
3.6.9 Closing a Job...................................... 3-9
3.7 Status Messages ................................... 3-10
3.8 Example Job .......................................... 3-13
3.9 Serial Communication............................ 3-15
Introduction
The operator's guide provides instructions essential to operating the CMT 330 with each accessory option. These instructions include programming instructions and book size changeover, tasks.
3 Operator's Guide
07/11
CMT 330 Three Knife Trimmer 3-2 Programming
3.1 Programming
The programming section gives detailed descriptions of how to efficiently program and
store jobs within the CMT 330 computer.
3.1.1 Console Descriptions
The console is found on the front, right-hand
side of the machine. General areas of the console are shown in Figure 3-1. The specific function of each key on the console is given in this
section.
Figure 3-1. CMT 330 Console
07/11
CMT 330 Three Knife Trimmer 3-3 Programming
Safety Warnings
Multi-language safety instructions with symbols
are listed in this area of the console. Each operator should read and understand the instructions listed. If the operator does not understand
these instructions, he should ask his supervisor
for clarification.
IN/mm Scale
The IN/mm scale can be used for measuring the
size of the start book while programming a job.
The scale can also be used to verify the size of
a trimmed book.
Start Button
The green start button is used to switch on the
hydraulic pump and begin to trim books. A remote start button is located at the back of the
machine.
Stop Button
The red stop button is used to switch off the
hydraulic pump and stop trimming books. A
remote stop button is located at the back of the
machine.
LCD Screen
The LCD screen is used to program and view
jobs. It also lists any errors or messages. A
message is displayed on the screen when the
status light on top of the machine blinks.
Keypad
The keypad is used to enter values into a program, scroll through programs, and navigate
through maintenance screens.
3.1.2 Key Descriptions
Number Keys
Number keys are used to write number values
on the display.
Decimal Point
This decimal key is used to write a decimal
point on the display.
Priority Add Key
The priority add key is used to input fractional
numbers when combined with a whole number.
An underscore (_) is displayed on the screen
after the key is pressed. 1_1/2 is an example of
a number entered using the priority add key.
This is equivalent to 1.500.
Addition Key
The plus key is used to add numbers in the display.
Subtraction Key
The minus is used to subtract numbers in the
display.
Multiplication Key
The multiply key is used to multiply numbers in
the display.
Division Key
The forward slash key is used to divide numbers in the display.
Send Key
The send key is used to instruct the computer to
change the machine setup to match newly entered book dimensions.
Clear Key
The clear key is used to clear an entry value or
clear an status message.
07/11
CMT 330 Three Knife Trimmer 3-4 Programming
Enter Key
The enter key selects items in menu screens
and processes data that has been entered in
the other modes.
IN/mm Key
The units key is used to toggle between decimal
inch, fractional inches, and mm units of length.
Soft Keys
The soft keys, or letter keys, are used to select
screen menu options listed at the bottom of the
display screen. The keys include the letters A,
B, C, and D.
Up Arrow Key
The up arrow key is used to move the screen
cursor up. It is also used to scroll forwards
through the alphabet while naming a job.
Down Arrow Key
The down arrow key is used to move the screen
cursor down. It is also used to scroll backwards
through the alphabet while naming a job.
Right Arrow Key
The right arrow key is used to move the screen
cursor right. It is also used to move the cursor
to the right while naming a job.
Left Arrow Key
The left arrow key is used to move the screen
cursor left. It is also used to move the cursor to
the left while naming a job.
3.1.3 Using the Keypad
The following information briefly describes efficient ways to use the functions of the keypad.
Entering Fractions
Fractions are entered using the priority add key.
The underscore symbol, _, is displayed when
the key is pressed. This instructs the computer
to add the fractional portion of the entry before
performing the remaining math. This eliminates
the need for parentheses.
Example: 3X2_3/4=8.250. If you use a plus instead of
the priority add, the result would be 3X2+3/4=6.750.
Entering Math
Rather than using a separate calculator, the
CMT 330's computer can calculate lengths as
you enter values. However, you should be familiar with the order of numerical operations if
you intend to use this feature. Multiplication
and division operations are always performed
before addition and subtraction.
Example: You wish to enter a dimension, which is 8
inches, minus (2 times 1 and 5/32 inches), plus 1/2
inch. This sentence can be entered as: 82X1_5/32+1/2. The result is 6.188.
07/11
CMT 330 Three Knife Trimmer 3-5 User Interface Map
3.2 User Interface Map
The following chart illustrates the organization
of user interface screens encountered in the
CMT 330 software.
Figure 3-2. CMT 330 User Interface Map
07/11
CMT 330 Three Knife Trimmer 3-6 Power up
3.3 Power up
When the CMT 330 is switched on, the power
up screen will appear.
>
Book Transport
Gripper must move to
Preset. Please press
the START button
Revision X.X
C)Light
B)Job
Figure 3-3. Start up Screen
Press and hold the green start button until the
hydraulic motor starts. The following message
will be displayed.
PLEASE WAIT
The book transport
gripper is moving to
the home location
Figure 3-4. Start Prompt
The gripper will not move for approximately 3
seconds. The gripper will then move to approximately 1 inch in front of home position,
back past home, then to home.
3.4 Improper Wiring
If the knives do not move to the up position after
power up, then the three phase power is
hooked up incorrectly. The following message
is displayed.
Waiting for knives
to lift. If this
message is displayed
for more than 10sec
verify the Hydraulic
motor rotation. (See
user manual -POWER
HOOKUP- section)"
Figure 3-5. Power Hook Up Warning
See section 2.5.1 Power Hookup Procedure or
page 2-8 to correct the wiring.
3.5 Run Mode
After the gripper reaches the home location, the
Run screen will appear if there are no jobs
stored in memory. Otherwise, the machine will
initialize at the last job that was run. The conveyors will then start. The CMT 330 will sense
incoming books and trim until the last book of
that size is done.
S-Cut ON Run
J-Extend
Stack = 1
9.000
0.500
0.250
6.000
11.000
A)Maint. C)Light
B)Job D)Exit
Figure 3-6. Run Screen
07/11
CMT 330 Three Knife Trimmer 3-7 Job Mode
3.6 Job Mode
The CMT 330 can be programmed for up to 99
different jobs. A job is a particular book size
including trim dimensions and options. Enter
the Job screen by pressing the soft-key B. In
the Job screen, all previously programmed job
numbers will be displayed with their name and
lock status. Locked jobs are indicated by a padlock symbol after their name. A plus sign at the
bottom of the job list indicates there are more
programmed jobs that are not displayed. Pressing the down arrow key will step through all jobs
one at a time. Pressing the left arrow key and
the down arrow key simultaneously will move
the cursor down the list nine at a time.
>
1 Name1
2 Name2
5 Name5
11
12
18 Name18
25
33 Name33
+
Select Job & Enter
A)Lock C)Erase
D)Exit
Figure 3-7. Job Screen
3.6.1 Creating a Job
To create a job, enter an unused job number
between 1 and 99 inclusive. The job number is
created with a blank name.
3.6.2 Editing a Job Name
The job name is edited in the job mode screen.
To edit the name, use the up/down arrow keys
to move the cursor to the appropriate job number. Then press the right arrow key to move the
cursor to the desired character position and edit
the character by pressing the up or down arrow
keys to toggle between characters of the alphabet. Numbers can be entered directly by using
the number keys. Pressing the clear key clears
the current character. When finished, you may
edit the current job by pressing the enter key,
go to a different job, or exit job mode.
3.6.3 Lock/Unlock a Job
Locking a job prevents it from being edited. In
the Job screen, the soft-key “A” will display
Lock or Unlock depending on the status of the
job. If a job is locked, the padlock symbol will
be displayed at the right of the job name. To
change the lock status of a job, move the cursor
to the appropriate job using the up/down arrow
keys, and press the soft-key “A” (Lock/Unlock).
The locking function may also be accessed
through the Job Options menu (section 3.6.7 )
in the Job Run screen as shown in Figure 3-8.
3.6.4 Erasing a Job
Erasing a job will permanently remove it from
memory. Use the arrow keys to select a job to
be erased. Press the soft-key ”C” (Erase).
Clear channel # is displayed, followed by
Yes and No. Use the up/down arrow key to
select either yes or no, then press enter. Note
that locked jobs cannot be erased.
3.6.5 Editing a New Job
To edit a new job, type in a number that is not
already assigned to a job and press enter (en-
tering a job number greater that 99 will create
#99). The cursor will move to the line corresponding to the number you entered, prompting
your for a job name. If a job name is not desired, pressing enter again bring up the job edit
screen.
S-Cut ON NAME1
J-Extend #1
Stack = 1
--.---
--.---
--.---
--.---
--.---
A)Maint. C)Options
B)Job D)Exit
Figure 3-8. Job Run Screen
Use the arrow keys to move the cursor to the
dimension to be edited. Type the dimension
value, then press enter.
All dimensions must be supplied, or the job will
not run. If the book size is outside the machine
specifications, the message, BOOK SIZE
CANNOT BE TRIMMED, is displayed. Refer to
section 1.7.1 for sizes that can be cut.
3.6.6 Editing an Existing Job
If the job is not locked, it may be edited from
either the Run screen or the Job Run screen.
Using the arrow keys, move the cursor to the
dimension to be changed. Enter a new value.
07/11
CMT 330 Three Knife Trimmer 3-8 Job Mode
If the job is locked, it must be unlocked before
editing. See section Lock/Unlock a Job.
3.6.7 Job Options
Each job has three options that are listed in the
upper left corner of the display. These are Side
Cut (ON/OFF), Jogger (Extend/Retract), and
Stack number (1-3). To edit these options
press the C key from the Job Run screen shown
in Figure 3-8.
Options
-----------------------Side Cut
Jogger
Stack Num
Select & Press Enter
A)Lock
D)Exit
Figure 3-9. Job Options Screen
Use the up/down arrow keys to select the option
and press enter to set the option.
3.6.7.1 Side Cut
When Side Cut is set to On, both the sides (top
and bottom) and the face of the book are cut.
When the Side Cut option is set to Off, only the
face is cut. The side cut menu screen is shown
below.
Side Cut
-----------------------ON
OFF
Select & Press Enter
A)Maint.
B)Job D)Exit
Figure 3-10. Side Cut Option Screen
3.6.7.2 Jogger
This parameter sets the jogger to remain extended as a book leaves the jogging station or
retract immediately. In the jogger screen, use
the up/down arrow keys to toggle the required
jogger action and press enter.
Jogger
-----------------------Extend
Retract
Select & Press Enter
A)Maint.
B)Job D)Exit
Figure 3-11. Jogger Option Screen
When cutting very thin books with overhanging
covers, the jogger option should be set to Extend. Otherwise, it should be set to Retract.
07/11
CMT 330 Three Knife Trimmer 3-9 Job Mode
3.6.7.3 Stack Number
This parameter sets the number of books to be
stacked on top of each other at the exit conveyor before it is incremented. It can range between 1 and 200.
>
Enter number of
books to be stacked
before incrementing
the output conveyor
Select & Press Enter
A)Maint.
B)Job D)Exit
Figure 3-12. Stack Number Option Screen
This option is used to increase the capacity of
the exit conveyor when cutting thin books. Be
careful not to set the Stack Number too high. If
the books stack too high before incrementing
the exit conveyor, later books will jam inside the
machine.
3.6.8 Running a Job
The job must first be opened from the Job
screen by using one of two methods:
1. Move the cursor to the desired job with
the arrow keys and press enter.
2. Enter the job number with the keypad
and press enter.
Once a job has been opened, the current job
name and number will be displayed in the upper
right corner. Press the green start button on the
console to start the hydraulics and conveyors.
Press the send key to set the side knives and
the registration assembly to the proper position.
Once the motors start, books can be fed into the
machine.
3.6.9 Closing a Job
To close an open job, press the soft-key B (Job)
to return to Job mode, or press the soft-key D
(Exit) to exit to the Run screen.
07/11
CMT 330 Three Knife Trimmer 3-10 Status Messages
3.7 Status Messages
Message Description
^ WASTE BIN FULL
The face knife waste bin sensor is covered.
< WASTE BIN FULL
The right side waste bin sensor is covered.
> WASTE BIN FULL
The left side waste bin sensor is covered.
Book jam between CMT-330 and
elevator
Book was covering upper elevator sensor when the book was trying to lift.
Book elevator FAILED to lift
to the proper level
The shelf level proximity sensor did not activate properly or in time. This con be caused
by either a misadjusted or a faulty proximity sensor.
Center clamp error Down when
it should be up
The proximity sensor on the center clamp did not turn on. This fault can be caused by
either the air cylinder not returning or a faulty proximity sensor.
Center clamp error Up when
it should be down
The proximity sensor on the center clamp did not turn off. This fault can be caused by
either the air cylinder not coming down or a faulty proximity sensor.
Clamp/knife down
The side knife was down while the side knives or registration assembly was mo ving.
DATA IS OUT OF RANGE
This error message displays when the operator tries to send either the knives or the registration assembly to a position that is out of range.
Elevator book jam.
Check book in elevator sensor.
Book did not clear the sensor in time.
F-knife latch error OFF when
it should be ON
The face knife latch proximity did not activate. This can be caused by a misadjusted or
faulty sensor, or the the air cylinder did not pull in.
F-knife latch error ON when
it should be OFF
The face knife latch proximity sensor did not de-activate. This can be caused by a misadjusted or faulty proximity sensor, or the air cylinder did not extend.
F-Knife at down limit failed
to move
This message displays when the face knife fails to leave the down proximity sensor. It
may be caused by either the cut valve not de-energizing or a faulty down limit proximity
sensor.
F-Knife at up limit, Failed
to move
This message displays when the face knife fails to leave the up proximity sensor. There
are four possible reasons for this failure: The dump valve did not energize, the hydraulic
cushion valve did not energize, the knife down valve did not energize, or the side knife up
proximity is faulty.
F-Knife down FAILURE timed
out before reaching down
limit
This message displays when the face knife leaves the up limit but does not reach the
down limit in time. If the knife went down, the proximity sensor is either faulty or misadjusted. If the knives only moved down slightly, either the dump valve or the proportional
valve may not have energized.
F-Knife up FAILURE timed out
before reaching up limit
This message displays when the face knife does not reach the up limit in time. The proximity sensor is either misadjusted or faulty.
F-Slow down Failure
The slow down proximity sensor did not respond before the down proximity sensor. The
face knife slow down proximity sensor is either misadjusted or faulty.
07/11
CMT 330 Three Knife Trimmer 3-11 Status Messages
Status Messages Continued.
Message Description
Input jam. Book was lost
between binder & elevator
A book was detected on the in-feed conveyor but did not reach the elevator.
Input JAM Conveyor and Lift
sensors are active
Both the proximity sensors on the elevator and on the input conveyor were on for more
than three seconds.
Input door open
A door on either the Tilt In-feed conveyor or the Elevator is open, or the interlock circuit is
open.
Jogger error! OUT when it
should be IN
Jogger cylinder was out when it should have been in. Output 18 is off but input 12 shows
jogger extended.
Jogger error! IN when it
should be OUT
Jogger cylinder was in when it should have been out. Output 18 is on but input 12 shows
jogger retracted.
Lost book in machine
The book proximity sensor deactivated during a cycle. The book may not have been
gripped properly due to bad feeding. Stray pieces of scrap may also cause this error.
Lower door is Open
One of the three waste bin doors is open.
Lubricate Machine
The number of machine cycles has exceeded that which is recommended for lubrication.
It is time to lubricate the machine.
Memory failed
One of the four EEPROM chips on the CMT controller board is faulty.
Motor starter error! ON when
it should be off
Motor starter was on when it should have been off. Output 11 off with output 24 on.
Motor starter error! OFF
when it should be off
Motor starter was off when it should have been on. Output 11 on with output 24 off.
NO Air Pressure
This error message displays when the air pressure falls below 20 PSI (1.4 Bar).
Number outside limit
The value entered is not valid.
OUTPUT CONVEYOR FULL
The output conveyor proximity sensor is covered.
Positioning error
This message displays after three failed attempts are made to position either the side
knives or the registration assembly. It may be caused by a faulty drive motor, faulty encoder, or a loose connection between the motor and the lead screw.
Result is negative
This warning displays when a calculated result is a negative value.
Send canceled!
This message is displayed when a key is pressed while the side knives or registration
assembly is moving.
Servo Disabled
This message is given when the hydraulic motor is off and the gripper is issued a move
command. It is typically caused by pressing the stop button in the middle of a book cycle.
Sharpen Knife
The number of machine cycles has exceeded that which is recommended for a knife
change. It is time to change knives.
Shorted Key error
A key on the keypad has been actuated for more than 90 seconds.
Side knife latch failed to
disengage
The side knife latch proximity sensor did not activate. This can be caused by a faulty or
misadjusted proximity sensor. The air cylinder may have failed to pull in.
S-knife latch error OFF when it
should be ON
The side knife latch proximity did not activate. This can be caused by a faulty or misadjusted proximity sensor. The air cylinder may have failed to pull in.
07/11
CMT 330 Three Knife Trimmer 3-12 Status Messages
Status Messages Continued.
Message Description
S-knife latch error ON when it
should be OFF
The side knife latch proximity sensor did not de-activate. This can be caused be a faulty
sensor. The air cylinder may have failed to extend.
S-Knife at down limit Failed to
move
This error message displays when the side knives do not leave the down proximity
switch. Either the cut valve did not de-energize, or the down limit proximity sensor may
be faulty.
Serial Communication Port Failed
The external control port is not working properly.
Serial error no response from the
servomotor
The servo control port is not working properly.
Servo Port Failed
RS-232 port controlling the servo drive failed.
Servo Relay Error! ON when
it should be off
Output 11 is off and input 23 is on.
Servo Relay Error! OFF when
it should be on
Output 11 is on and input 23 is off.
S-Knife at up limit, Failed
to move
This message is displayed when the side knives do not leave the up proximity sensor.
There are at least four reasons for this failure: the dump valve did not energize, the proportional valve did not energize, the knife down valve did not energize, or the side knife
up proximity sensor is faulty.
S-Knife down FAILURE timed
out before reaching down
limit
This message is displayed when the side knives leave the up limit but do not reach the
down limit in time. If the knives did come down, the proximity sensor may be faulty or
misadjusted. If the knives only moved down slightly, either the unload valve or the proportional valve may not have energized.
Start Button Held in at power up
Either the start button or remote cut button is being held in. Either button may be faulty.
S-Knife up FAILURE timed out
before reaching up limit
This message displayed when the side knives do not reach the up limit in time. Either a
faulty or misadjusted up proximity sensor may cause this error.
S-Slow down Failure
The slow down proximity did not respond before the down proximity sensor. Either a
faulty or misadjust side knife slow down proximity sensor may cause this error.
Stop button pressed
Either a stop button is pressed or one is faulty.
Upper door is Open
One of the upper doors is open.
07/11
CMT 330 Three Knife Trimmer 3-13 Example Job
3.8 Example Job
This example will step through a typical In-Line
job. An In-Line job uses the in-feed conveyor to
accept books from a perfect binder. The in-feed
conveyor transfers books into the elevator. The
elevator feeds books into the trimmer. The
trimmer then drops books onto the exit conveyor.
This example will trim a 1" thick, 9" x 12" book
to 8.5" x 11". The right side trim will be 1/4" as
shown below.
Figure 3-13. Example Book Dimensions
Preparation
Before books are printed, the document layout
should be checked against the Book Size Chart
on page 1-9.
Draw a vertical line, up from x=0.25 as shown in
Figure 3-14. Draw a horizontal line, right from
h=8.5. The lines intersect within the shaded
region; therefore, the layout is acceptable.
Figure 3-14. Book Chart
Program the Job
Switch on the trimmer. Allow a few seconds for
the gripper to find home position. The screen
will look similar to Figure 3-15.
S-Cut ON Run
J-Extend
Stack = 1
11.000
0.500
0.250
6.000
12.000
A)Maint. C)Light
B)Job D)Exit
Figure 3-15. Example Start Screen
Press soft-key B to enter the Job screen. The
display will look similar to Figure 3-16.
>
1 Factory Test Job
Select Job & Enter
A)Lock C)Erase
D)Exit
Figure 3-16. Job Screen
Create a new job number by typing a number
from 2 to 99, then press the enter key. The
screen will then look like Figure 3-17.
07/11
CMT 330 Three Knife Trimmer 3-14 Example Job
>
1 Factory Test Job
2>
Select Job & Enter
A)Lock C)Erase
D)Exit
Figure 3-17. Job Number
Name the job. Use the right arrow key to move
the cursor at least one space to the right. Use
the up/down arrow keys to cycle through the
alphabet. After arriving at the desired letter,
symbol, or number, press the right arrow key to
move to the next character field. Continue until
the name is complete. The screen looks similar
to Figure 3-18.
>
1 Factory Test Job
2>Example Job_
Select Job & Enter
A)Lock C)Erase
D)Exit
Figure 3-18. Job Name
After the job has been named, press the enter
key to enter the book dimensions into the job.
The screen looks similar to Figure 3-19.
S-Cut ON Example Job
J-Extend #2
Stack = 1
11.000
0.250
1.000
8.500
12.000
A)Maint. C)Options
B)Job D)Exit
Figure 3-19. Job Run Screen
After all values have been entered, press the
send key. The side knives will move into position followed by the registration assembly.
The job can now run. Before running books
through the binder, press and hold the green
start button on the console. Release the button
when the hydraulics and conveyors start. Begin
running books.
07/11
CMT 330 Three Knife Trimmer 3-15 Serial Communication
3.9 Serial Communication
Note: Approximate time per book with size
change 26 seconds
Approximate time per book no size
change 13 seconds
1. Physical connection
1.1 Standard PC Comm port to CMT330. --DB9 male/Female Null Mode Cable
9600 baud
1 stop bit
8 data bits
no Parity
no Flow control
2. Message Format
2.1 All messages start with ASCII -1010FF
2.2 All messages end with a Longitudinal
Redundancy Check (LRC) Value. This
value is calculated from the first byte of
the Start sequence to the last byte if the
data after the messages has been converted from ASCII to hex. Example
1010FF
(0x31,0x30,0x31,0x30,0x46,0x46) becomes (0x10,0x10,0xFF).
2.3 All message are formatted as follows
Text Start------------------------------------
1010FF
Sequence number-------------------------00-FF
Message type------------------------------see following information
Data length---------------------------------00-FF
Message type sub code 1-----------------see following information
Sub code 1 data length
(Optional) Message type sub code 2
Sub code 2 data length
(Optional) Message type sub code (n)
Sub code n data length
(LRC)---------------------------------------XOR of the first byte to the last
(ASCII Carriage Return)-----------------0x0d
(ASCII Line Feed)------------------------0x0a
3. Error Detection
3.1 All messages are responded to with an
positive or Negative acknowledgment
1) Positive Acknowledgement (ACK)—
10100600(CR)(LF)
2) Negative Acknowledgement(NAK)--
-10101500(CR)(LF)
3.2 The receiver shall send a (NAK) response if the calculated LRC does not
match the incoming value.
3.3 The receiver shall send a NAK response if the header is not 1010FF.
3.4 If a NAK is received the sender shall
wait 150ms before retransmitting the
message.
3.5 After 3 NAK’s in a row an unrecoverable error should be declared.
3.6 An ACK shall be sent in 50ms after a
good message is received. After
250ms NAK is assumed.
4. Command Codes and Sub Codes
4.1 Host command - Wake Up (00)
4.1.1 Sub Code (10) request Ma-
chine information and reset
message sequence number.
Example --1010FF02000110EC(CR)(LF)
4.2 CMT330 - Response to Wake Up (60)
4.2.1 Sub Code (10) Description of
product “trimmer “
4.2.2 Sub Code (11) Software level
“3.3”
4.2.3 Sub Code (12) Brand
“Challenge”
Example1010FF02601910087472696D6D65722
01102030312094368616C6C656E6765
8F(CR)(LF)
4.3 CMT330 - Serial Initialize (55)
4.3.1 Sub Code (01) Ready to Communicate Sent at power
On
Example-1010FF01550101AB
4.4 Host command - (66)
4.4.1 Sub code (
10) Start
Enable Process
Example-1010FF026601108A(CR)(LF)
4.4.2 Sub code (11) Temp Stop
Hold Process
Example-1010FF026601118B(CR)(LF)
4.5 Host Command- (04)
4.5.1 Sub Code (21) Job number (1-
99)
4.5.2 Sub Code (22) Bottom Trim
(0.1inch – max) (X 1000 no
decimal point) 0.100in=0064
4.5.3 Sub Code (23) Trimmed Book
Height (5.875-12.000in)
(16F3-2EE0)
4.5.4 Sub Code (24) Trimmed Book
Width (4.000-9.000in) (0FA0251C)
4.5.5 Sub Code (25) Book Thickness
(0.100-
2.000)(0064-07D0)
4.5.6 Sub Code (26) PreTrimmed
Book Height (7.000-
12.500)(1B58-30D4)
Example1010FF0204172101032202006423022AF8
24022328250201F4260230D445(CR)(LF)
07/11
CMT 330 Three Knife Trimmer 3-16 Serial Communication
4.5.7 Sub Code (30) Current Job
Data Request will respond
with code (64) data
Example-1010FF02040130C8(CR)(LF)
4.6 Host command- (03)
4.6.1 Sub Code (13) Initiate/Eject
Book
Example-1010FF01030113EF(CR)(LF)
07/11
CMT 330 Three Knife Trimmer 4-1 Routine Tasks
Section Contents
TITLE PAGE
4.1 Under Book Air Blast.................................4-2
4.2 Waste Bins................................................4-2
4.3 Cut Stick / Cut Plates................................4-3
4.3.1 Changing the Cut Stick....................... 4-3
4.3.2 Changing the Cut Plates .................... 4-4
4.4 Knives .......................................................4-4
4.4.1 Knife Change...................................... 4-4
4.4.2 Knife Adjustment ................................ 4-7
4.4.3 Knife Sharpening Rules...................... 4-8
4.5 Check Pressure Switch.............................4-9
4.6 Safety Systems Check..............................4-9
4.6.1 Safety Check-off Sheet .................... 4-11
Introduction
Certain tasks will be performed on a regular
basis but not necessarily on a set schedule.
The safety systems check, however, should be
done before each shift. The waste bins must be
emptied when full. The knives should be replaced when cut quality becomes unacceptable.
Performing as many of these tasks before a
shift begins prevents down time while a job is in
progress and ensures safe operation of the machine.
4 Routine Tasks
07/11
CMT 330 Three Knife Trimmer 4-2 Under Book Air Blast
4.1 Under Book Air Blast
The under cover air blast may require adjustment depending on the thickness of books being trimmed. The blast reduces scratching of
the bottom cover as the books moves through
the machine.
The valve is located on the left-hand side of the
machine.
Figure 4-1. Underside Air Blast
For thicker books, adjust the valve counterclockwise. Adjust the valve clockwise for thinner books.
4.2 Waste Bins
The three waste bins may actually require emptying in the middle of a shift, but it is a good idea
to do it before a shift begins. When the waste
bins are near capacity during a job run, the
CMT 330 continues cutting. The status indicator light on top of the machine blinks slowly, and
the screen displays a message stating that the
waste bins are full.
Use the following procedure to change waste
bins.
If running, stop the machine's cutting mode by
pressing the red stop button on the console
shown in
1. Figure 4-2. To preserve the status of
each book in the job, press the stop
button after the gripper transport releases a trimmed book, but before it
clamps the next untrimmed book. If the
untrimmed book is clamped by the gripper transport and not trimmed, it will be
ejected onto the Exit Conveyor when
the machine is restarted. The book can
be manually placed onto the In-feed
conveyor to be trimmed later.
Figure 4-2. Stop Button Location
2. Wheel a cart to any of the three waste
bin locations. One is located at both
the rear, right-hand and left hand sides
of the machine. The remaining waste
bin is located at the back of the machine. Figure 4-3 and Figure 4-4 show
the waste bin locations.
Figure 4-3. Waste Bin Locations
07/11
CMT 330 Three Knife Trimmer 4-3 Cut Stick / Cut Plates
Figure 4-4. Waste Bin Location
3. Open a door. Tilt and lift the waste bin
from the base of the machine.
4. Place the waste bins on the cart and
repeat for the remaining bins.
5. After emptying and placing the bins
back into the trimmer, close the doors
securely. The machine will not operate
if a door is ajar.
Hint! Static can accumulate on the plastic waste bins. This
can occasionally cause trimmings to cling to the handles of
the bin. The Bin Full sensor is at this location, so trimmings
blocking the sensor will cause the Waste Bin Full status
even if the bin is not full. To prevent this from happening,
lightly spray the inside of each bin with an anti-static spray.
This need only be done on occasion.
Using additional waste bins may reduce down
time. To order additional waste bins, use Challenge part number, 56143.
4.3 Cut Stick / Cut Plates
The cut stick and cut plates should either be
changed or rotated with every knife change.
They may also require changing at other times if
deep grooves or jagged edges can be seen
along the score marks. Cut stick/plate wear
effects cut quality.
4.3.1 Changing the Cut Stick
The cut stick can be rotated 8 times before disposal. It is located under the face knife, accessed through set of double doors at the back
of the machine. The cut stick puller provided
with the machine is used to remove the cut
stick. The cut stick and other tools are located
on the inside of the left rear door that is shown
in Figure 4-3. The cut stick puller has a finger
hold and hook as shown in Figure 4-5.
Figure 4-5. Cut Stick Puller
1. Switch off
(O) main power at the front
of the machine and lock out the main
power disconnect switch as described
in section 1.5 Power Lockout Procedure
on page 1-4.
2. Open the set of double doors at the
back of the machine.
3. Remove the black plastic waste chute
from the table by lifting and tilting toward the outside of the machine.
4. Hook the Cut Stick Puller over one of
the ends of the cut stick with a finger in
the loop of the puller. Keep the Cut
Stick Puller In-Line with the cut stick.
5. Pull the Cut Stick Puller at a slight angle
over the cut stick until the end of the cut
stick comes out of the table.
Figure 4-6. Pull at slight angle
6. Remove the remaining cut stick from
the table by hand.
7. Inspect the cut stick for wear. It may be
used 8 times (twice on each surface)
before disposal. To use a surface
twice, reinstall the cut stick by turning it
such that end that came out of the right
end of the slot goes into the left end of
the slot. If a surface has been used
twice, rotate the stick to an unused surface before reinstalling. If all (4) surfaces have been used twice, replace
the stick with a new one.
Figure 4-7. Cut Stick Rotation
8. Reinstall the waste chute.
9. Securely close the set of double doors
at the back of the machine.
07/11
CMT 330 Three Knife Trimmer 4-4 Knives
10. Unlock the main power disconnect and
resume operation.
Refer to section 1.6.2 Standard Accessories to
obtain the part number for replacement cut
sticks.
4.3.2 Changing the Cut Plates
The cut plates can be rotated once before disposal. One is located underneath each side
knife. They are accessed by opening the sliding
doors on each side of the machine. A flat
screwdriver is helpful but not necessary when
removing cut plates.
1. Send the book height cutting dimension
to 6 inches so the side knives move to
the center of the machine.
2. Switch off
(O) main power at the front
of the machine and lock out the main
power disconnect switch as described
in section 1.5 Power Lockout Procedure
on page 1-4.
3. Open a sliding door on either the left or
right side of the machine.
4. Remove the black plastic waste chute
from the table by lifting and tilting toward the outside of the machine.
5. Lift and wiggle the edge of the cut plate
until it slides off the four pins in the table. Alternatively, slide the end of a
screwdriver between the slot in the table and the cut plate. Rock the screwdriver. Alternate between each of the
two slots until the cut plate is free.
Figure 4-8 shows the location of the
slots.
Figure 4-8. Slots Under Cut Plates
6. Inspect the cut plate for wear. It may
be used two times (once on each surface) before disposal. If only one side
of the plate is used, turn the plate over
and reinstall it with the smooth side up.
Replace the cut plate with a new one if
both sides are used.
7. Reinstall the waste chute.
8. Securely close the double doors at the
back of the machine.
9. Repeat steps 3 through 8 with the remaining cut plate.
10. Unlock the main power disconnect and
resume operation.
Refer to section 1.6.2 Standard Accessories to
obtain the part number for replacement cut
plates.
Hint! Depending on what locations on the cut plates are
most worn, they may be able to be rotated 180
o
before they
are turned over. By using this method of rotation, each cut
plate may be used four times.
Hint! Save your old cut plates to use when trimming out of
the ordinary sizes.
4.4 Knives
The knives should be changed when cut quality
becomes unacceptable. By default, the com-
puter will issue a Sharpen Knife alarm after
2500 cuts. This is a good general-purpose
value, but the most appropriate number will vary
depending on the type of paper stock being cut.
Refer to the Operator's Guide for instructions on
changing the value for the Sharpen Knife alarm.
CAUTION
The knives must be adjusted after every knife change.
Improper knife adjustment may cause damage to the machine.
4.4.1 Knife Change
A stable rolling cart, approximately 36" tall, the
knife lifter, the T-handle hex wrench, an empty
scabbard, and a set of sharp knives are required to perform a knife change.
CAUTION
All three knives are a set. They must be sharpened as a
set. Damage or poor performance may result if knives are
not from the same set.
WARNING
Changing knives can be very dangerous unless safety
precautions are observed and extreme care is taken
when handling knives. Keep handling of unprotected
knives to an absolute minimum. Have the scabbard
nearby and insert knife immediately. Warn people of
any unprotected knife.
WARNING
Knife changing is a ONE PERSON OPERATION! More
than one person changing a knife creates safety hazards.
WARNING
Even used knives are extremely sharp! Use extreme
care when handling new/re-ground knives and used
knives.
07/11
CMT 330 Three Knife Trimmer 4-5 Knives
The following procedure should be used to
change knives.
1. Switch off
(O) main power at the front
of the machine and lock out the main
power disconnect switch as described
in section 1.5 Power Lockout Procedure
on page 1-4.
2. Place three empty scabbards on the
rolling cart. The knives may be removed or installed in any order.
3. The knives are located behind the plastic doors shown in Figure 4-9 and
Figure 4-10.
Figure 4-9. Knife Locations
Figure 4-10. Left Side Knife Location
4. Open the door and remove the waste
chute to access the knife.
5. Using the T-handle hex wrench, remove
the two knife bolts that are in open slots
in the knife bar. They are the second
and fifth bolts from either end of the
knife. Set the bolts aside and save for
knife installation.
Figure 4-11. Knife Bolt Locations
6. Place the knife lifter on top of the knife
bar and align each lifter handle with the
holes from which the two knife bolts
were removed in the previous step.
Turn the handles clockwise until the
lifter is securely fastened to the knife
bar as in Figure 4-12.
Figure 4-12. Knife Removal
7. Use the T-handle wrench to remove the
remaining (4) knife bolts. Save the
bolts with the two previously removed.
WARNING
Make certain to have a scabbard on the cart, prepared
to receive a knife. The screws should be removed from
the scabbard. The protecting edge of the scabbard
should be facing the person changing the knife when
he is placing the knife in it. Make sure the cart is
nearby. Do not carry the knife across obstructed or
slippery floors. Warn people nearby that a knife is being removed.
8. Slowly turn the knife lifter handles counterclockwise only until the knife is released from the machine. DO NOT turn
the handles any more than what is required to free the knife.
9. When the knife is free, move it down
and clear of the knife bar.
10. Hold the knife lifter with knife at a safe
distance from the body. Other people
07/11
CMT 330 Three Knife Trimmer 4-6 Knives
should not be nearby. Carry the lifter to
the cart containing the prepared scabbard.
11. Place the knife lifter with knife into the
scabbard such that the edge of the
knife is in the scabbard slot.
12. Carefully turn the knife lifter handles
counterclockwise and disconnect the
lifter from the knife while the knife-edge
remains in the scabbard slot.
13. Align the two knife-bolt holes with the
holes in the scabbard such that no portion of the knife-edge remains exposed.
14. Place a scabbard screw into each hole
and turn them clockwise to tighten.
15. Use a wrench to secure the knife to its
scabbard.
16. Set the knife aside.
17. Repeat steps 4 through 16 with the remainder of the knives.
With all knives removed, the replacement
knives may be installed.
CAUTION
All three knives are a set. They must be sharpened as a
set. Damage or poor performance may result if knives are
not from the same set.
WARNING
Changing knives can be very dangerous unless safety
precautions are observed and extreme care is taken
when handling knives. Keep handling of unprotected
knives to an absolute minimum. Have the scabbard
nearby and insert knife immediately. Warn people of
any unprotected knife.
WARNING
Knife changing is a ONE PERSON OPERATION! More
than one person changing a knife creates safety hazards.
WARNING
Even used knives are extremely sharp! Use extreme
care when handling new/re-ground knives and used
knives.
18. Make sure main power is still turned off
(O) at the front of the machine and is
locked out at the main power disconnect switch as described in section 1.5
Power Lockout Procedure on page 1-4.
Make sure all the waste chutes are still
removed from the machine.
19. Turn both knife depth adjustment
handles clockwise until they stop.
They are accessed through the rear, left
sliding door and back double doors.
Figure 4-13. Knife Adjustment Knobs
20. Place a scabbard containing a replacement knife on the cart. Move the
cart as close as possible to where the
knife is to be installed. The knives may
be installed in any order.
21. After the cart is located, make sure the
scabbard containing the replacement
knife has its protected edge facing the
installer. Have the knife lifter nearby.
22. Carefully remove the two screws that
fasten the knife to its scabbard.
23. Place the knife lifter on the knife and
align the left handle with the second
hole from the left end of the knife.
24. Align the right handle with the second
hole from the right end of the knife.
25. Turn the lifter handles clockwise until
the ends of the handles touch the scabbard under the knife.
26. Turn the handles counterclockwise 1/2
turn so the ends of the handles will not
interfere with the clamp inside the machine.
27. Hold the knife lifter with knife at a safe
distance from the body. Other people
should not be nearby. Carry the lifter to
the installation location.
28. Place the knife behind the knife bar
while aligning the lifter handles to the
open bolt slots in the knife bar as
shown in Figure 4-14.
07/11
CMT 330 Three Knife Trimmer 4-7 Knives
Figure 4-14. Knife Installation
29. Lift the knife into the knife bar such that
the lifter handles are at the extreme top
of the slot.
CAUTION
The knife lifter handles must be at the extreme top of the
slot. If they are not, it will be difficult to adjust the cutting
depth of the knives. Damage to the cut plates may result.
30. Turn the lifter handles clockwise and
securely fasten the lifter and knife to the
knife bar. Make certain the knife does
not move down as the handles are
tightened.
31. Place 4 knife bolts into the 4 available
holes in the knife and use the T-handle
wrench to secure them as shown in
Figure 4-14.
32. Turn the lifter handles counterclockwise
and remove the lifter from the machine.
33. Place 2 knife bolts into the holes from
which the knife lifter handles were removed. Use the T-handle wrench to
secure them. Viewed through the inspection holes, the blade should be inserted against the stops.
34. Repeat steps 18 through 33 to install
the remaining two knives.
Once the knives have been installed, they must
be adjusted.
4.4.2 Knife Adjustment
The knives require adjustment after every knife
change. The face knife is adjusted independently from the side knives. The side knives are
adjusted simultaneously. To properly adjust the
side knives, the side knives must be properly
installed. They should have been installed to
the top of the slots of the knife bar. If one side
knife cuts through and the other does not, the
knives were not properly installed.
Use the following procedure to adjust the depth
at which the knives cut. ½” thick scrap or extra
books are recommended for use when adjusting
the knives. No tools are needed.
WARNING
Knife adjustment is a ONE PERSON OPERATION! More
than one person adjusting the knives creates safety
hazards.
Face Knife Adjustment
1. At the console, enter maintenance
mode and choose Knife Adjust.
2. Open the set of double doors at the
back of the machine.
3. Remove the waste chute by lifting it and
pulling it toward the outside of the machine.
4. Find the face knife adjustment knob in
the upper right-hand corner of the opening as shown in Figure 4-15.
Figure 4-15. Knife Adjustment Knobs
5. If the knives were just replaced, the
face knife adjustment knob should be
turned to the full down position. If it is
not, do so by turning the knob clockwise
until it stops.
6. Turn the face knife adjustment knob
back out about three full revolutions
counterclockwise.
7. Place the face side of a scrap book underneath the knife with the binding facing the inside of the machine.
8. Securely close the set of double doors.
9. Press and hold the green button on the
right-hand side of the double doors.
The hydraulic motor turns on, and in
about 1 second, the machine cuts the
book.
INSPECT.
HOLES
07/11
CMT 330 Three Knife Trimmer 4-8 Knives
10. Open the set of double doors and check
the book. If the bottom cover of the
book is not fully cut. Turn the face knife
adjustment knob 1/4 revolution counterclockwise. Repeat steps 7 through 10
until the bottom cover is cut fully. All
doors must be closed for the machine
to cut.
11. Now complete the Side Knife Adjustment procedure.
Side Knife Adjustment
1. The computer should still be in Knife
Adjust mode.
2. If the knives were just replaced, the
side knives adjustment knob should be
turned to the full down position. If it is
not, do so by turning the knob clockwise
until it stops.
3. Turn the side knives adjustment knob
about three full revolutions counterclockwise.
4. Securely close the doors.
5. Open the sliding door at the left-hand
rear of the machine. Place a scrap
book underneath the knife with the
binding facing the front of the machine.
6. Securely close the sliding door.
7. Press and hold the green button until
the machine cuts the book. If the bottom cover and binding of the book are
not fully cut, turn the side knives adjustment knob 1/4 revolution counterclockwise and repeat steps 5 through 7.
All doors must be closed for the machine to cut. Continue with the next
step if the book is fully cut.
8. Open the sliding door at the right rearhand side of the machine.
9. Place a book under the knife with the
binding facing the front of the machine.
10. Securely close the sliding door.
11. Press and hold the green button on the
right-hand side of the double doors at
the back of the machine until the book
is cut. If the bottom cover and binding
are not fully cut, turn the side knives adjustment knob 1/4 revolution counterclockwise and repeat steps 8 through
11. All doors must be closed for the
machine to cut. If the book is fully cut,
the knife adjustment procedure is complete.
12. Reinstall all waste chutes.
13. Securely close all doors and resume
normal operation at the console.
4.4.3 Knife Sharpening Rules
The CMT 330's knives must be sharpened as a
matching set. A total of 1/4" (6.4mm) of material may be removed due to grinding. Beyond
this, the machine will not fully cut through a
book.
Figure 4-16. Knife Height Range
The knives must not be sharpened to less than
2.50 in. (63.5 mm) of knife height as shown in
Figure 4-16.
07/11
CMT 330 Three Knife Trimmer 4-9 Check Pressure Switch
4.5 Check Pressure Switch
The main air pressure switch should be
checked for proper operation each month. The
main air pressure switch is used to verify that
main air is connected and switched on. If this
switch fails, damage to the machine could result.
1. Switch on power, open lower back door.
2. Switch off main air valve.
3. Close the door.
4. Go to the console and read the LCD
display. The message, "No air pressure," should be displayed.
5. Open lower back door.
6. Switch on main air valve.
7. Close the door.
8. Go to the console and read the LCD
display. The message, "No air pressure," should not be displayed.
4.6 Safety Systems Check
Test Frequency: Daily
CAUTION
Only one person should perform this test at a time.
Use the following procedures to test the safety
devices throughout the machine. If the machine
fails any safety system test, DO NOT USE the
machine. Have the machine serviced by an
authorized service technician.
Console Stop Button:
1. Switch on the main power.
2. Press the green start button at the console to start the hydraulic motor.
3. Press the clear button, and wait for the
machine to reset itself.
4. Press the red stop button at the console. The hydraulic motor should shut
off.
Knife Change Operator Stop Button:
1. Press the green start button at the console to start the hydraulic motor.
2. Press the red stop button at the back of
the machine. The hydraulic motor
should shut off.
Front Sliding Door Interlock:
1. Press the green start button at the console to start the hydraulic motor.
2. Open the front sliding door. The hydraulic motor should shut off.
3. Close the door.
Right rear Sliding Door Interlock:
1. Press the green start button at the console to start the hydraulic motor.
2. Open the right rear sliding door. The
hydraulic motor should shut off.
3. Close the door.
Left rear Sliding Door Interlock:
1. Press the green start button at the console to start the hydraulic motor.
2. Open the left rear sliding door. The hydraulic motor should shut off.
3. Close the door.
Back Double Door Interlocks:
1. Press the green start button at the console to start the hydraulic motor.
2. Open the left-hand door in the set of
double doors at the back of the machine. The hydraulic motor should shut
off.
3. Close the door.
4. Press the green start button at the console to start the hydraulic motor.
5. Open the right-hand door in the set of
double doors at the back of the machine. The hydraulic motor should shut
off.
Right rear Door Interlock:
1. Press the green start button at the console to start the hydraulic motor.
2. Open the right rear door. The hydraulic
motor should shut off.
3. Close the door.
07/11
CMT 330 Three Knife Trimmer 4-10 Safety Systems Check
Left rear Door Interlock:
1. Press the green start button at the console to start the hydraulic motor.
2. Open the left rear door. The hydraulic
motor should shut off.
3. Close the door.
Lower Back Door Interlock:
1. Press the green start button at the console to start the hydraulic motor.
2. Open the lower back door. The hydraulic motor should shut off.
3. Close the door.
Use the table on the following page to record
the initials of the person performing the tests
and the date the tests are performed. Make
photocopies of the check-off sheet as necessary.
07/11
CMT 330 Three Knife Trimmer 4-11 Safety Systems Check
4.6.1 Safety Check-off Sheet
Use this sheet to sign tester's initials and test
dates for performing the Safety Systems Check
on page 4-9 of the Installation and Operator's
Manual.
Machine Model: CMT 330
Serial Number: _________________________
TESTER DATE TESTER DATE TESTER DATE
07/11
CMT 330 Three Knife Trimmer 5-1 Book Quality
Section Contents
TITLE PAGE
5.1 Burr Marks.................................................5-2
5.2 Jagged Bottom Cover...............................5-2
5.3 Burr Marks/Jagged Cover.........................5-2
5.4 Rectangular Crease Lines ........................5-3
5.5 Linear Crease Lines..................................5-3
5.6 Draw..........................................................5-3
5.7 All Sheets Not Cut.....................................5-4
5.8 Book Not Square.......................................5-4
Introduction
Operators may occasionally need to troubleshoot book quality issues. These quality issues
are addressed by either changing machine settings or replacing knives. Machine settings may
require adjustment to be compatible with the
type of paper and cover being used. Knives
and cut sticks/cut plates may require replacement because they are consumable items.
Other quality issues such as accuracy and
square should be referred to an authorized
technician because they involve service repairs
or adjustments, which are outside the scope of
an operator's training.
5 Book Quality
07/11
CMT 330 Three Knife Trimmer 5-2 Burr Marks
5.1 Burr Marks
Description
Burr marks are found on books cut with a knife
whose cutting edge has been burred. Figure
5-1 illustrates the appearance of burr marks.
Figure 5-1. Burr Marks
Possible Causes
1. Burrs on knives can occur from improper knife handling.
2. Burrs may also occur from cutting hard,
irregular materials.
Solutions
• If the any knife is burred, replace all
three knives and maintain as a set.
CAUTION
All three knives must be sharpened as a set. Damage to
the cut plates may result from using knives sharpened separately.
5.2 Jagged Bottom Cover
Description
Books can appear as though the bottom few
sheets and cover were torn apart rather than
sharply cut. Tearing of the bottom sheets and
cover occur when deep score marks develop in
the cut stick or cut plates. The cover is pushed
into the score mark, folded over and torn.
Figure 5-2. Jagged Cover
Possible Causes
1. The knife may be dull.
2. The cut stick/cut plates may be worn.
Solutions
• If the problem is on the face of the
book, the cut stick may need rotation or
replacement. The knives may also require replacement.
• If the problem is on the top or bottom
faces of the book, the cut plates may
need rotation or replacement. The
knives may also require replacement.
5.3 Burr Marks/Jagged Cover
Description
A jagged bottom cover may also accompany
burr marks. A burred knife may not fully cut into
the cut stick or cut plate. As a result, it will
leave a jaggedly cut bottom cover.
Figure 5-3. Burr Marks/Jagged Cover
Possible Causes
• The knife is burred, and the cut stick/cut
plates are worn.
Solutions
• If the problem is on the face of the
book, replace the knives. Rotate or replace the cut stick.
• If the problem is on the top or bottom
faces of the book, replace the knives.
Rotate or replace the cut plates.
07/11
CMT 330 Three Knife Trimmer 5-3 Rectangular Crease Lines
5.4 Rectangular Crease Lines
Description
Indentations or crease lines may appear in a
rectangular pattern in the center of the book.
Figure 5-4. Crease Lines on Cover
Possible Causes
• The gripper has too much clamp pressure for the stock being cut.
Solutions
• Reduce the gripper clamp pressure by
turning the control dial counterclockwise. Reduce the pressure until crease
lines disappear on test books. The
gripper adjustment gauge only reads
gripper pressure while the gripper is
holding the book.
5.5 Linear Crease Lines
Description
Indentations or crease lines may appear in a
rectangular pattern in the near the edges of the
book.
Figure 5-5. Linear Crease Lines
Possible Causes
• The clamps have too much clamp pressure for the stock being cut.
Solutions
• Reduce the clamp pressure by turning
the control dial counterclockwise. Reduce the pressure until crease lines
disappear on test books.
• Worn cut plates may create these lines
on the bottom cover. Turn or change
the cut plates.
Note: Reducing the clamp pressure too much will cause
other quality problems such as draw. Only reduce clamp
pressure by necessary amounts.
5.6 Draw
Description
The cut face appears to have a slope because
all of the sheets are cut at different lengths.
Figure 5-6. Draw
Possible Causes
• Clamp pressure may be too low.
• The knife may be dull.
Solutions
• Check clamp pressure. Clamp pressure should be 80-90 PSI. Turn control
dial clockwise to increase clamp pressure. Make sure shop air is 80-90 PSI.
• If the problem is on the face of the
book, replace all three knives. Rotate
or replace the cut stick.
• If the problem is on the top or bottom
faces of the book, replace the knives.
Rotate or replace the cut plates.
07/11
CMT 330 Three Knife Trimmer 5-4 All Sheets Not Cut
5.7 All Sheets Not Cut
Description
Bottom sheets are not being cut.
Figure 5-7. Not Cutting Through
Possible Causes
• The knife is not adjusted to cut deep
enough.
• The cut stick or cut plates may be worn
out.
Solutions
• If not cutting deep enough on the face
of the book, adjust the face knife according to instructions in section 4.4.2
Knife Adjustment on page 4-7.
• If not cutting deep enough on the top or
bottom faces of the book, adjust the
side knives according to section 4.4.2
Knife Adjustment on page 4-7.
• Replace the cut stick or cut plates.
5.8 Book Not Square
Description
The book appears as though it was not cut
square.
Possible Causes
• The book was allowed to cool with a
twisted binding as shown in Figure 5-8.
When the book is straightened after
trimming, it looks similar to the book
shown in Figure 5-9. This is the most
common cause of out of square, especially in a Stand-Alone trimming application where the binding has had significant time to harden.
• Cover overhangs the book. The overhang reduces the reliability of the
squaring process within the trimmer.
• Glue was applied past the binding, leaving a knob-like protrusion. The protrusion interfered with the trimmer's squaring process.
• Normal wear has forced the cutting or
transport mechanisms out of square.
Solutions
• Carefully handle books with soft bindings. Keep twist out of the binding
when storing. Allow bindings to harden
before stacking.
• Cut cover to fall within the size of the
untrimmed book.
• Adjust binder such that glue will not be
applied past the end of the binding.
• If normal wear has forced the cutting or
transport mechanisms out of square, refer the problem to an authorized service
agent.
Figure 5-8. Twisted Binding
Figure 5-9. Straightened Binding
07/11
CMT 330 Three Knife Trimmer 5-5 Book Not Square
in. fractional in. mm
0.016 1/64 0.40
0.031 1/32 0.79
0.047 3/64 1.19
0.063 1/16 1.59
0.078 5/64 1.98
0.094 3/32 2.38
0.109 7/64 2.78
0.125 1/8 3.18
0.141 9/64 3.57
0.156 5/32 3.97
0.172 11/64 4.37
0.188 3/16 4.76
0.203 13/64 5.16
0.219 7/32 5.56
0.234 15/64 5.95
0.250 1/4 6.35
0.266 17/64 6.75
0.281 9/32 7.14
0.297 19/64 7.54
0.313 5/16 7.94
0.328 21/64 8.33
Inch / Metric Conversion Chart
in. Fractional in. mm
0.344 11/32 8.73
0.359 23/64 9.13
0.375 3/8 9.53
0.391 25/64 9.92
0.406 13/32 10.32
0.422 27/64 10.72
0.438 7/16 11.11
0.453 29/64 11.51
0.469 15/32 11.91
0.484 31/64 12.30
0.500 1/2 12.70
0.516 33/64 13.10
0.531 17/32 13.49
0.547 35/64 13.89
0.563 9/16 14.29
0.578 37/64 14.68
0.594 19/32 15.08
0.609 39/64 15.48
0.625 5/8 15.88
0.641 41/64 16.27
0.656 21/32 16.67
in. fractional in. mm
0.672 43/64 17.07
0.688 11/16 17.46
0.703 45/64 17.86
0.719 23/32 18.26
0.734 47/64 18.65
0.750 3/4 19.05
0.766 49/64 19.45
0.781 25/32 19.84
0.797 51/64 20.24
0.813 13/16 20.64
0.828 53/64 21.03
0.844 27/32 21.43
0.859 55/64 21.83
0.875 7/8 22.23
0.891 57/64 22.62
0.906 29/32 23.02
0.922 59/64 23.42
0.938 15/16 23.81
0.953 61/64 24.21
0.969 31/32 24.61
0.984 63/64 25.00
1.000 64/64 25.40
© 2002-2011 by The Challenge Machinery Company. All rights reserved. Printed in the USA F.033 / CMT 330B / JUL 2011
Loading...