1/01 E Service Instructions 1
The Service Instructions manual
belongs to the hands of the
repair and maintenance personnel !
PERFECTA 76 / 92 / 115 / 132 / 168
UC / TV
SERVICE
INSTRUCTIONS
(Servo)
1/01 E Service Instructions 2
Table of Contents
Page
General Instructions ...................................................................................................................... 4
Safety Inspection........................................................................................................................... 4
Knife Drive..................................................................................................................................... 6
Setting the Automatic Stopping Device ............................................................................... 6
Knife Drive Clutch and Brake Assembly ............................................................................. 6
Clutch/Brake Assembly Maintenance ................................................................................. 8
Malfunctions in the Knife Drive............................................................................................ 8
Clamping System .......................................................................................................................... 9
Gap Between the Knife Back and the Clamp Edge............................................................. 9
Play in the Clamp Guideways ............................................................................................. 10
Clamp Parallelism with the Cutting Table............................................................................ 11
Cutting System..............................................................................................................................13
Play in the Knife Beam Guideways ..................................................................................... 13
Readjusting the Knife Cut-Through Position ........................................................................ 15
Non-Repeat Device.............................................................................................................. 15
Cutting System Maintenance .............................................................................................. 1 8
Cutting Table .................................................................................................................................18
Backgauge Drive System .............................................................................................................. 1 8
Backgauge Guidance...........................................................................................................19
Thread Backlash Compensation ..........................................................................................20
Measuring System......................................................................................................................... 21
Calibrating the Measuring System ....................................................................................... 2 1
Setting the Proximity Switches............................................................................................21
Hydraulic Clamping System .......................................................................................................... 22
Pre-Clamping .......................................................................................................................24
Cut Triggering ...................................................................................................................... 25
Main Clamping..................................................................................................................... 2 6
Decompression.................................................................................................................... 2 7
Clamp Return.......................................................................................................................28
Start-Up ............................................................................................................................... 29
Adjusting the Hydraulic Clamping System ...........................................................................29
Checking the Adjustment..................................................................................................... 3 0
Main Clamping Pressure Setting Instructions...................................................................... 30
Hydraulic Clamping System Maintenance ........................................................................... 3 0
Malfunctions in the Hydraulic Clamping System............................................................................ 3 1
1/01 E Service Instructions 3
Computer Control........................................................................................................................... 33
Control Processor ...............................................................................................................33
Safety Module......................................................................................................................34
PC Design...........................................................................................................................35
Software ........................................................................................................................................ 35
UC Software Change .......................................................................................................... 35
TV Software Change........................................................................................................... 36
Settings/Operating Data................................................................................................................. 37
Service Nenu ................................................................................................................................. 3 9
I/O Test Menu ............................................................................................................................... 41
Keyboard Code .............................................................................................................................. 45
Sensor Test Menu .........................................................................................................................46
Activating the Differential Display .................................................................................................. 47
Speed Menu ..................................................................................................................................49
Character Set Menu.......................................................................................................................50
Texts Menu ................................................................................................................................... 5 0
Knife Control (Control Switches) ....................................................................................................51
PSG 16 Light Guard....................................................................................................................... 6 2
Error Messages .............................................................................................................................63
1/01 E Service Instructions 4
General Instructions
This Service Instructions manual
is provided as a supplement to the
Operating Instructions manual for
the repair and maintenance
personnel and, therefore, is
referred to the Operating Instructions manual in several cases.
As a great deal of setting and
repair instructions affect the safety
of the operator and of the machine,
such work should be performed
by trained or instructed personnel.
In this place, a few fundamental
instructions be given which, as
practice shows, are often disregarded:
• Whenever you remove separating guardings such as hoods,
panelings etc. for repair and
maintenance purposes, always
remember that, in most cases,
machine elements with hazardous movements are behind. For
this reason, guardings must, by
all means, be refitted after completion of work.
• Open switch cabinets and
switching rooms do not only collect dust that leads to failures, but
also involve danger to life and
limb.
You are encouraged to take
the opportunity PERFECTA offers you to have your technicians trained at our Training
Centre.
Safety Inspection
Due to their way of operation consisting of hazardous movements
such as clamping and cutting,
guillotines must meet a number of
safety regulations. Such regulations are met by "Safety Devices"
described under the same caption in the Operating Instructions
manual.
According to the Accident Prevention Procedures for the Printing and Paper Processing Industry, VBG 7i, § 40, the user
must ensure that the safety
devices - particularly the control
system - should be inspected by
a specialist every five years.The
result of the inspection should
be recorded and filed.
Fig.2 shows an acceptance check
list as used by PERFECTA.
Machines accepted without any
objections are provided with a
plaquette (Fig. 1) which shows
the next inspection date.
Fig. 1
1/01 E Service Instructions 5
Fig. 2
1/01 E Service Instructions 6
Knife Drive
The timing of the S52, S53, S54
control switches on the crankshaft is explained by a chart in
the "Knife Control" section (control switches).
The proper functioning of the control switches can be checked from
the service menu (I/O Test).
S53
- Knife-down travel.
- Clamp locking while the knife is
coming down.
S54
- Checking the UDC.
- Emergency shut-off in case of
S52 failure.
The gap shown in the timing
chart (switching distance) between S54 and S53 should be
1/3 to 1/2 of a flywheel turn. For
this purpose, energize the clutch
(refer to "Manual Cranking" in the
Operating Instructions manual)
and check the switching distance.
When the knife drive is automatically stopped, the knife edge must
protrude at least 6 mm over the
right-hand clamp bottom edge.
Setting the
Automatic Stopping
Device
Fig. 3
8
9
7
54
6
1
2
3
14
11
12 13 10
The cam of S52 should be set
so that the machine would stop
at the upper dead centre and
the cam follower of S54 comes
to stop within the first third of
its cam length.
When the knife beam runs over
the UDC (S54 no longer operated at stop position), any subsequent cut triggering is disabled.
The display reads Error 28:
Safety Module Detecting Error.
By pressing the "C" key, concrete
Error 7 appears: Knife Overrun.
After turning off and on the machine, the subsequent cut can be
restarted by the knife pushbuttons.
If there is another overrun at the
UDC, slight pre-stopping correction can be performed by turning
forward the entire cam package
within the permissible range.
If such correction by the abovementioned cam shifting is not
successful, i. e. if there is still
overrun, checking the clutch/
brake assembly of the knife drive
should, under any circumstances,
be checked.
The control switches have the
following function:
S52
- Taking over knife up-movement
from the lower dead centre (LDC).
- Deactivating the light guard effect.
- Stopping the knive travel towards the upper dead centre
(UDC).
Knife Drive Clutch
and Brake Assembly
System Design (Fig. 3)
Armature disk 3 provided with
brake lining 1 or clutch lining 2,
respectively, is axially movable
on a spline bushing. It is forced
against brake ring 6 by springs 5.
This reliably brakes the machine.
When the clutch is energized,
armature disk 3 is attracted by
the magnetic field of coil body 7
and pressed against friction ring
8. The machine is engaged.
1/01 E Service Instructions 7
Checking and Setting the Air
Gap
Under normal operating conditions, the air gap should be
checked once per year.
For air gap A, refer to the Table
(Fig. 5).
• Engaged state (clutch "ON"):
If air gap A min is smaller than
specified in the Table, Fig. 5,
shims 10 of uniform thickness
should be inserted
between coil body 7 and friction
ring 8 (Fig. 4) for
machine sizes 76 and 92, or
between friction ring 8 and
spacing segment 9 (Fig. 3) for
machine sizes 115 and 132.
For this purpose, slacken screws
11 around the circumference and
then re-tighten them uniformly.
The shims are available in various thicknesses. Refer to the
Spare Parts Catalogue in the
Operating Instructions manual.
After the successful installation
of the shims, make sure that air
gap A max specified in the Table
is not exceeded (use thinner
shims) and air gap A min in the
braked state (clutch "OFF") is not
undercut.
Checking the Bearing Play
For machine sizes 115 and 132
only.
De-energize the clutch.
No perceptible play in the bearing must appear when the flywheel rim top is pulled and pushed
by hand.
In case of evident play, replace
the antifriction bearings.
Caution!
Bring the knife beam to its lowermost position prior to dismantling the clutch/brake assembly, as the brake becomes
ineffective when the compression springs are relieved.
Fig. 4
8
7
2 1 6
3 4 5
Fig. 5
Knife Drive Clutch/Brake Assembly Air Gaps ( mm )
Braked state (clutch "OFF")
If air gap A max is wider than
specified in the Table, shims 12
of the same thickness should be
inserted between brake ring 6
and gearbox cover 14. For this
purpose, energize the clutch as
described in the Operating Instructions manual under "Manual
Cranking", slacken screws 13
around the circumference, and
then re-tighten them uniformly.
1411
10
13
12
Machine Size
76 92 115 132 168
Clutch "ON"
A min 0,2 0,2 0,2 0,2 0,2
A max 0,4 0,5 0,5 0,5 0,6
Clutch "OFF"
A min 0,6 0.7 0,7 0,7 0,7
A max 0,8 1 1,2 1,2 1,4
1/01 E Service Instructions 8
Clutch/Brake
Assembly
Maintenance
Check the air gap annually as
described above and correct with
shims, if required.
Keep the slip rings clean and
grease-free. Clean with fine-grain
abrasive cloth, if necessary. Ensure proper contacting between
the carbon brushes and the slip
ring to avoid brush sparking.
Remove carbon dust with a brush
(without metal ring).
If the brake or clutch linings are
badly worn out or contaminated
with oil, the armature disk must
be replaced. Before installing a
new armature disk, clean the friction surfaces of the clutch and
brake rings with white spirit.
After installation, check the air
gaps in conformity with the Table
(Fig. 5).
Protect the asbestos-free friction
linings from oil and grease. Even
when doing installation and setting work, make sure your measuring tools and also your hands
are grease-free.
Caution!
Bring the knife beam to its lowermost position prior to dismantling the clutch/brake assembly, as the brake becomes
ineffective when the compression springs are relieved.
Malfunctions in the
Knife Drive
The following malfunctions may
occur in the knife drive and are
not indicated by the computer
control system as error codes:
• The main motor cannot be
started.
Remedy:
- Switch S56 for "Manual Cranking" (refer to the Operating Instructions manual) under the flywheel guard is locked. Unlock
the switch.
-The flywheel guard is not properly closed. Turn in the screw
until the safety switch is closed.
-Defective fuses. Replace the corresponding fuses.
• The knife or clamp drive cannot
be started.
Remedy:
-Main motor switched off.
-Defective two-hand control
pushbutton. Replace pushbutton.
-No contact between the carbon
brushes and the slip rings. Refer
to "Clutch/Brake Assembly Maintenance".
-Refer to "Malfunctions in the
Hydraulic Clamping System" (flow
indicator).
-Pedal locked (S69).
-Y62 does not make contact or is
defective.
• Heavy jerk when the knife reverses at its lowermost position.
Remedy:
- The overload protection device
has become loose. Re-tighten the
overload protection screw. Refer
to "Knife Drive Assembly Overload Protection Device" in the
Operating Instructions manual.
- Very dull knives are often the
cause for the responding of the
overload protection ring.
1/01 E Service Instructions 9
Clamping
System
Fig. 7
7
1
4
6
5
8
3
9
2
Fig. 6
Keeping specified gap s, it is important to bring the clamping pressure as close as possible to the
cutting line.
Gap s shown in Fig. 6 should be
0.2 + 0.1 mm.
Clamp 1 can be readjusted with
respect to cutting line 2 as follows:
In addition to gap s between the
knife back and the clamp edge,
the play of the clamp in its
guideways is decisive to obtain a
high-quality and high-accuracy
cut.
Gap Between the
Knife Back and the
Clamp Edge
Machine Size 76 (Fig. 7)
• Slacken screws 3 to release
clamp guideway 4 at the clamp
left and right rear sides.
• Adjust required gap s by means
of shims 5 to be inserted between
clamp 1 and clamp guideway 4.
Inserting shims reduces the gap
by the shim thickness, while removing shims widens the gap.
The shims are 0.05 and 0.2 mm
thick. Refer to the Spare Parts
Catalogue in the Operating Instructions manual.
• Tighten the clamp guideway
and check the gap across the
entire cutting width with a feeler
gauge.
1/01 E Service Instructions 10
Machine Size 92 (Fig. 8)
Fig. 8 shows shims 3 under pre-
tensioned roller guideway 4 by
means of which the position of
clamp 1 with respect to cutting
line 2 was set in the factory.
Inserting shim 3 between clamp
1 and roller guideway 4 mini-
mizes gap s by the shim thickness, while removing shim 3 increases the gap.
For the proper procedure, refer
to "Play in the Clamp Guideway".
Machine Sizes 115/132 (Fig. 9)
• Slacken lower nuts 3 at the
clamp left and right sides.
• Slightly turning eccentric pins 4
(both sides uniformly) moves the
clamp away from or towads the
cutting line.
Check gap s across the entire
cutting width with a feeler gauge.
• When jamming the nuts, ensure
that the positions of the eccentric
pins are locked.
Fig. 8
Fig. 9
Play in the Clamp
Guideways
Machine Size 76 (Fig. 7)
• Slacken screws 6 of adjusting
strip 7.
• Move adjusting strip 7 against
clamp guideway 4 with eccentric
pin 8 until play a between both
parts is < 0.05 mm.
When performing this setting,
ensure that clamp guideway 4
rests on guide strip 9 of the oppo-
site side. For this purpose, press
the clamp towards the knife.
5
8
7
6
1
2
34
184
9
3
7
8
5 6
1
9
65
12
11
10
10
4
1/01 E Service Instructions 11
Machine Size 92 (Fig. 8)
The clamp is guided by pre-
tensioned roller guideways, i. e. it
is play-free. Therefore, readjusting is not necessary.
If any wear is found due to long
and hard use of the machine, the
roller guides should be replaced.
For this purpose, proceed as follows:
• Support clamp 1 by wooden
wedges, for example.
• Pull out pins 5 and slacken
screws 6 of knife beam guide strip
7.
• Remove roller guideway 4 by
slackening screws 8. Observe
the assignment of shims 3.
• Slightly tighten the new roller
guideways with their associated
shims 3 by means of screws 8.
• Re-pin knife beam guide strip 7
and tighten with screws 6.
• Check air gap a on the roller
guideway. Gap a should be
0.5 mm when the roller guideway
is properly pre-tensioned.
• If necessary, re-tension the outer
roller guide strip by means of
screws to be introduced into the
tapped holes in knife beam guide
strip 7 until gap a is obtained.
Then, tighten the roller guideway
with screws 8.
Remove the wooden wedges and
check the clamp for free movement by pressing the pedal.
Machine Sizes 115/132 (Fig. 9)
• Slacken lock nuts 5 on adjusting
screws 6.
• Slightly slacken screws 7 on
adjusting strip 8.
• Reset adjusting strip 8 against
guide blocks 9 by adjusting
screws 6 until play a between the
adjusting strip and the guide block
is < 0.05 mm.
When performing this adjustment,
ensure that guide blocks 9 rest
on the opposite side of guide strip
10. For this purpose, press the
clamp towards the knife.
• After completing the adjustment,
tighten the screws and nuts and
check the play over the entire
clamp stroke with a feeler gauge.
The lateral play (face play) should
be b = 0.1 + 0.05 mm.
For this purpose, adjust supporting screws 11 with screws 12
slightly slackened until play b is
obtained between guide strip 10
and guide block 9. Tighten screws
12.
Clamp Parallelism
with the Cutting
Table
In the factory, the clamp is aligned
in parallel with the cutting table
surface.
This can be checked by preclamping with paper strips put
under the left and right sides of
the clamp.
If correction should be necessary, proceed as follows:
Machine Sizes 76/92
Fig. 10 shows the clamping principle for machine sizes 76 and
92.
Machine Size 76 (Fig. 11):
• Remove the hydraulic system
front paneling under the cutting
table.
• Slacken clamping screws 1 in
pusher rod eyes 2 and 3.
• Turn pusher rod 4 as follows:
- Increasing the distance between
the pusher rod eyes moves down
the clamp on the right.
Fig. 10
Fig. 11
5 2 4 3
3 4 1 2
1/01 E Service Instructions 12
- Reducing the distance between
the pusher rod eyes moves up
the clamp on the right.
• Tighten clamping screws 1,
check for parallelism as described
above, and re-fit the paneling.
Machine Size 92 (Fig. 12):
Adjusting the clamp right-hand
side is analogue to that for machine size 76.
The clamp left-hand side must be
adjusted on clamp lever bearing
5 in Fig. 10. For this purpose,
proceed as follows:
• Slacken clamping screw 1 on
the front of the cross beam.
• Turn clamping lever pivot pin 2
from the machine back using key
surface 3.
• After checking for parallelism
with paper strips, tighten clamping screw 1.
Machine Sizes 115/132 (Fig. 14)
The clamping principle is shown
in Fig. 13.
• Remove the clamping system
front and rear paneling under the
cutting table.
• Slacken screw 1 on the front
lower cross beam.
• Gently turn clamping lever pivot
pin 2 or 3 by the key surface from
the back of the machine until the
paper strip, see above, is seized
by the clamp.
Only readjust that clamping lever
pivot pin where the deviation exists.
• Tighten screw 1 and re-fit the
paneling.
Fig. 12
Fig. 13
Fig. 14
31 2
2 3
132
1/01 E Service Instructions 13
Cutting System
All PERFECTA guillotines work
on the basis of what is called the
slant rocking cut, i. e. the knife as
the cutting tool moves along a
curved path from left to right.
All findings and experience
related to the cutting system
regarding the questions of cutting
stock, knives, clamping, cutting
inaccu-racies and their
rectification are summarized in
our "Cutting Compendium" that
you can ob-tain from PERFECTA.
Play in the Knife
Beam Guideways
In addition to many other factors,
a smooth guidance of the knife
beam is a prerequisite to a highquality and high-accuracy cut.
Over the years, and depending
upon the working conditions, the
guideways are subject to wear,
although the latter is minimal.
Therefore, the play in the knife
beam guideways should, from
time to time, also be measured
and readjusted, if required.
Machine Sizes 76/92 (Fig. 16)
Knife beam 1 moves between
slide surfaces 2 on the machine
frame and guide strips 3.The guide
strips have been adjusted with
respect to the knife beam with
shims 4 so that gap s required for
establishing the necessary
lubrication film is
< 0.05 mm.
Checking the play:
• Push the knife beam (without
knife) against the frame from the
rear at the top and bottom positions. Check the play between
the knife beam and the guide
strip on the left and right sides
using a feeler gauge.
• Removing shims reduces air
gap s. Under any circumstances
should it be ensured that the gap
is not too small, as, otherwise,
lubrication is not guaranteed, with
the knife beam tending to get
jammed.
This would result in seizure of the
sliding surfaces.
Whenever the positions of the
guide strips are changed, the air
gap between the knife back and
the clamp edge must always be
checked as described under
"Clamping System" and readjusted, if necessary.
12
34
Fig. 16
Machine Size 168 (Fig. 15 )
Slacken upper lock nut 3 on ten-
sion spindle 2 located in clamp 1.
Turn nuts 4 to adjust the clamp
in parallel with the cutting table.
Thighten lock nut 3.
Only adjust the side which shows
the deviation.
3
1
2
4
Abb.15
1/01 E Service Instructions 14
Machine Size 168 (Fig.18)
Knife beam 1 moves between the
slide surfaces on machine frame
2 and guide strips 3. On top, the
guide strips rest on two stud bolts
4 each and are fixed to the machine frame by two nuts 5.
Below, the guide strips are supported on the machine frame by
four threaded bushes 6 and are
fastened to the frame by screws
7.
Gap s should be < 0.05 mm.
Checking the play:
• Push the knife beam (without
knife) against the frame from the
rear at the top and bottom positions. Use a feeler gauge to check
the play between the knife beam
and the guide strip on the left and
right sides.
If required, readjust gap s as
follows:
• Remove the light guards and the
upper lateral paneling.
• Set the knife beam to medium
feed height and push it against
the frame.
• Slacken nuts 5 and screws 7.
• Use nuts 5 and threaded bushes
6 to adjust the play.
• Lock nuts 5 and tighten screws
7 and check the play once again
at the topmost and lowermost
positions of the knife beam on the
left and right of the guide strip.
Correct, if required.
• Re-fit the paneling and the light
guards.
Important: Check the light
guards for proper functioning.
Checking the play:
• Push the knife beam (without
knife) against the frame from the
rear at the top and bottom positions. Check the play between
the knife beam and the guide
strip on the left and right sides
using a feeler gauge.
If required, readjust gap s as fol-
lows:
• Set the knife beam to medium
feed height and push it against
the frame.
• Remove the front paneling.
• Slacken clamping screws 8 on
the left and right of the cutting
table (8 screws in total).
• Remove plastic cover 7 and
adjust guide strip 3 against the
knife beam with adjusting screws
6 until the required play is obtained.
• Re-tighten clamping screws 8
and check the play at the knife
beam top and bottom positions
once again.
• Re-fit the front paneling.
Machine Sizes 115/132 (Fig. 17)
Knife beam 1 moves between
slide surfaces 2 on the machine
frame and guide strips 3. The
guide strips are supported in
machine front part 5 by guide pins
4. By means of adjusting screws
6 located under plastic covers 7
on the machine front parts, the
guide strips can be moved towards
the knife beam. On the cutting
table side, guide pins 4 and
adjusting screws 6 are secured
against moving or turning by
clamping screws 8.
Gap s should be < 0,05 mm .
Fig. 17
5
3
8
2
1
6
7
4
Fig. 18
5
3
2
6
7
4
1
1/01 E Service Instructions 15
Readjusting the
Knife Cut-Through
Position
The cut-through position is described under "Adjusting the CutThrough Position" in the Operating
Instructions manual.
Machine Size 76/92 (Fig.19)
For a.m. cutting sizes the Knife Cut-
through position is readjusted at the
right hand side of the machine as
following:
Right side:
Remove cap from opening 3.
Loosen screw 5 by two turns.
Insert knife changing tool 1 into
centre of bolt 6.
Anticlockwise turning: Lift knife.
Clockwise turning: Drop knife.
Tighten screw 5. The position
of screw 5 indicates the position
of the knife. Screw up means knife up.
Remove the tool after setting!
5
6
3
3
1
Fig. 19
Non-Repeat Device
The upper dead centre of the knife
beam is stopped and controlled
by control switches S52 and S54
and is monitored by the safety
processor control system which
immediately stops the knife travel
in case of any irregularities. Refer
to "Setting the Automatic Stopping Device".
In addition, all PERFECTA
guillotines are provided with a
mechanical non-repeat device
(catch/locking pin), a third safety
means for the upper dead center,
which locks the knife beam to the
machine frame.
If this non-repeat device responds
due to excessive overrun, the
knife beam must be manually
returned to its upper dead centre.
Refer to "Manual Cranking".
In case the overload protection
device responds, refer to "Knife
Drive Assembly Overload Protection Device".
1/01 E Service Instructions 16
Setting Instructions
Machine Size 76 (Fig. 20)
The length of chain 1 between
solenoid Y80 and catch 2 is set
by a screw 3 so that the catch
forms a gap s = 0.6 - 1.0 mm with
re-spect to the bearing surface on
the frame.
Align switch plate 4 with screws 5
so that switch S81 is operated by
stop 6 when the solenoid is dead,
and switch S82 is operated by
stop 6 when the solenoid is ener-
gized (by activating the manual
clutch - refer to "Manual Cranking").
Set the spring-contact switch so
that the cam follower still travels
ap-prox. 1.5 mm beyond the
switching point.
Machine Size 92 (Fig. 21)
Catch 2 connected with solenoid
Y80 through chain 1 forms gap
s = 0.6 - 1.0 mm with the stop
located on the machine frame
when the solenoid is dead. At this
position, S81 is operated. In the
energized state (by activating the
manual clutch - refer to "Manual
Cranking" in the Operating Instructions manual), S82 is operated by stop 3.For this purpose,
switches S81 and S82 can be
aligned on switch plate 6 within
the range of their oblong holes by
screws 5.
1
3
6
S82
Y80
5
2
S81
Fig. 21
1
2 6 3
S81
5
S82
6
4
Y80
Fig. 20
1/01 E Service Instructions 17
Machine Sizes 115 and 132
(Fig. 22)
Screw in chain 1 which connects
solenoid Y80 with catch 2 with
the aid of threaded pin 3 to be
turned in deep enough and lock it
so that between catch 2 and catch
stop 4 is a gap of s = 0.6 - 1.0 mm
when the solenoid is dead. At this
position, S81 must be in actuated
state.
Switch S82 should be aligned so
that it is operated by the catch
when the solenoid is energized
(by activating the manual clutch refer to "Manual Cranking" in the
Operating Instructions manual).
Machine Sizes 168
(Fig. 23)
S81
Y80
Fig. 22
S82
1
4
2
3
Important!
When the catch rests on the knife
beam contour with Y80 being
dead, S82 must not yet be oper-
ated (except machine size 168).
Locking pin 1 is guided by bush 2
supported by machine frame 3.
Solenoid Y80 withdraws this pin
against pull-back spring 4 so that
a gap of s = 2 - 3 mm is obtained
between knife beam slide surface
5 on the frame and the face of the
locking pin.
Adjust stop 6 in the solenoid axis
so that S81 is actuated when the
solenoid is in its de-energised
state.
Adjust switch S82 so that it is
actuated by the stop when the
solenoid is in its
energised state (by activating the
manual clutch - refer to "Manual
Cranking" in the Operating
Instructions manual).
53124
S82 S81 Y80
6
Fig. 23
1/01 E Service Instructions 18
Cutting System
Maintenance
It should be ensured that the knife
beam guideways are lubricated at the
top and bottom positions of the
knife beam. Refer to "Lubrication" in
the Operating Instructions manual.
A lubrication chart is provided on
the back of the machine.
Never use knives other than those
assigned to the respective ma-chine
models and sizes.
For PERFECTA guillotines of the
same models and sizes, the knives
are interchangeable.
When changing the knife, ensure,
under any circumstances, that the
tapped holes in the knife are clean
and the knife bolts are undamaged.
Cutting Table
All PERFECTA guillotines are
supplied with standard cutting tables and the associated side tables with ground surfaces and of
special-quality cast iron. In the
factory, the tables are provided
with temporary corrosion protective before being shipped. When
the machine is installed at the
user's, this corrosion preventive
must be removed with white spirit.
Never use any caustic agents.
The clean table is susceptible to
corrosion, particularly in the handling area.
PERFECTA offers corrosion-protective wax which inhibits corrosion and improves the sliding properties.
Due to the abrasion caused by the
cutting stock, the treatment must
be repeated from time to time.
If small deposits of rust should
have built up as a result of insufficient care or negligence, remove
them immediately. Never use
abrasive cloth or sand paper. Titanium fleece or a conventional
household fibre scouring pad has
proven useful for this purpose.
When treating the table always
work in the grinding direction.
PERFECTA offers optional cutting and side tables with upgraded,
i. e. corrosion-resistant surfaces.
Backgauge
Drive System
All PERFECTA guillotines have a
controlled backgauge drive system.The advantage of this drive
system is a gentle approaching to
and a soft, precise positioning of
the cut measurement. The optimum backgauge speed is automatically determined from the distance between the cut marks.
For most of the applications, the
guillotines are factory-set to optimum. Via the "Speed" (TV)/"Settings" (UC) menu, the backgauge
speeds as well as the start and
stop ramps can be adapted to the
stock to be processed and to
other requirements.
For manual positioning, cutting or
programming according to the
print, PERFECTA guillotines have
a so-called "electronic handwheel" with nine different forward
and reverse speeds each. Refer
to "Backgauge" in the Operating
Instructions manual.
1/01 E Service Instructions 19
Backgauge Guidance
Machine Sizes 115 and 132
The backgauges of the 115 and
132 size machines have a round
guidance (slide guidance) located
above the cutting table.
If any play on the backgauge
should be noted, check the setscrews between the backgauge
and the guideway for firm seating
and proper locking and re-tighten
them, if necessary. Refer to "Adjusting Square Cutting" in the
Operating Instructions manual.
If excessive play in the backgauge
guidance may occur after a longer
time of operation, readjust the
play with draw-in screws 1 and
adjusting screws 2 (Fig. 24).
Check the play on the rear hub of
guide block 3. For this purpose,
bring the hub to rest on guide
column 4 by manually pushing the
backgauge on the left and right
and read the absolute play off the
dial gauge in no-load condition.
The play should be within the
limits of 0.03 - 0.04 mm. by
Depending upon the operating
conditions, the guide column
should be cleaned with white spirit
once per year. The lubrication cycle specified under "Lubrication"
in the Operatring Instructions
manual or in the lubrication chart
on the back of the machine should
be kept.
Machine Sizes 76 and 92
The backgauges of the 76 and 92
size guillotines are guided by pretensioned linear guideways (roller
guideways), i. e. the guideways
work in a play-free manner. Therefore, resetting is not necessary.
If any play on the backgauge
should be noted, check the setscrews between the backgauge
and the guideway for firm seating
and proper locking and re-tighten
them, if necessary. Refer to "Adjusting Square Cutting" in the
Operating Instructions manual.
Depending upon the operating
conditions, the linear guideways
should be cleaned (with white
spirit) and lubricated at least once
per year. Refer to "Lubrication" in
the Operating Instructions manual.
2 1
4
3
Fig. 24
1/01 E Service Instructions 20
Then check the rollers for smooth
running over the entire length of
the guideway.
Depending upon your operating
conditions, use white spirit to clean
the rollers and the guideways. Do
not grease the rollers and the
guideways.
4
2
3
1
Thread Backlash
Compensation
Machine Sizes 76, 92, 115, 132,
168 (Fig. 26)
For these machine sizes, the
backgauge is moved by an acme
thread leadscrew 1. The cutting
positions are always approached
in forward direction. The existing
backlash in the thread is compensated by a compression spring 2
which permanently and firmly
presses nut 3 fixed to the back-
gauge against the driving flank of
the leadscrew via nut 4 axially
movable but locked against twisting. This flank contact, particularly at the positioning or braking
phase, is not discontinued.
Depending upon the operating
conditions, the acme thread
leadscrew should, as applicable
to the backgauge guide assembly, be cleand with white spirit
and be greased according to the
specified lubrication cycle once
per year.
Refer to "Lubrication" in the Operating Instructions manu-al, or to
the lubrication chart on the back
of the machine.
Fig. 26
Machine Sizes 168 (Fig. 25)
Backgauge 1 is guided by a car-
riage 2 which, run on rollers, moves
along a profile guideway beam 3
fitted over the cutting table.
If you find any play on the backgauge check setting screws 4 on
the side of the backgauge for
tightness and proper locking. Retighten, if required. Refer to
"Adjusting Square Cutting"in the
Operating Instructions manual.
Around the horizontal axis, the
carriage is supported by three
fixed rollers 5 and one eccentric-
ally adjustable roller above the
guideway beam and by four eccentrically adjustable rollers 6
beneath.
Around the vertical axis, the
carriage is secured against distortion by two fixed rollers 5 on the
right and two eccentrically
adjustable rollers 6 on the left.
If some play should occur after a
longer period of operation, you
can use the eccentric rollers to
eliminate it.
For this purpose, slacken outer
nut 7 and gently rotate eccentric
pin 8 until the roller gets into
contact with the guideway. Retighten the nut.
3
4
1 2 6
5
7
6
8
Fig. 25
1/01 E Service Instructions 21
Measuring
System
On PERFECTA guillotines, the
actual and desired measurements
are displayed on the control panel.
You can choose from four different units. Refer to "Measurement Display" in the Operating
Instructions manual.
The machines are factory-set.
During operation, i. e. while the
backgauge is running, the measurement is automatically monitored.
After 70 travels since the last
check, the control system makes
sure before each backgauge travel
event whether a zero pulse is
expected within the range of 0.5
mm in front of the destination
measurement.
If this is the case, the brake ramp
will be started earlier to be able to
evaluate the zero pulse.
If the zero pulse appears at the
expected position, the travel
counter will be reset and will begin
to count up again.
If no zero pulse is found at the
expected position, the "calibrate
machine first" message will be
displayed.
If 100 travel events have been
done already with no opportunity
to check the measurements, the
next travel which is in excess of 5
mm will be used to begin braking
5 mm in front of the destination
already. Thus, the last 4 mm will
be done at slow speed. Within
these 4 mm, a zero pulse will
appear under any circumstances
(4 mm = one motor turn, one zero
pulse per turn) and can be used
for evaluation.
If the zero pulse appears at the
expected position, the travel
counter will be reset and will begin
to count up again.
If no zero pulse is found at the
expected position, the "calibrate
machine first" message will be
displayed.
Calibrating the
Measuring System
Select the "Calibration" (TV)/
"Factory Calibration" (UC) option
from the service menu.
Type in through the keyboard the
actual measurement between the
knife back and the backgauge
and press the enter key to accept
it. This will change the machineinternal measuring system to the
value entered. From the actual
position known from the entry, a
forward travel will take place until
a zero pulse is recognised. This
detects and stores the distance
between the last millimeter
measurement divisible by four
(theoretical zero position) and the
first actual zero pulse. Then the
length will be measured to
recognise the machine model/the
cutting width.
Caution: Entering a wrong
actual measurement may lead
to collision as the machine
would expect its end positions
in the wrong places.
You can use a steel rule for measuring to make a rough check and
compare absolutely and relatively
positioned and cut material strips
for a fine check.
Calibrating from the "Settings"
menu will only convert the abovedetermined offset between the
theoretical and the practical zero
position to the first zero pulse
after calibration range sensor B39
has been reached. For reasons of
time, no length measuring will be
done.
Important:
Calibrating from the "Settings"
menu will, therefore, only make
sense after previous calibration
from the service menu.
Adjust front proximity switch B39
so that it is activated at 200 ± 50
pulses (= 2 ± 0.5 mm) below the
measurement of 200 mm (= a
reading of 20000 pulses) while the
backgauge is running forward, i.
e. proximity switch B39 must
become active in the range of
20174 ± 50 at a count of 19974,
for example, for the first zero
pulse below the 20000 mark. Refer
to the "Sensor Test" menu.
Set rear proximity switch B27 so
that it is activated at the dimension of rear table length + 2 mm.
Adjust both proximity switches
so that distance a between the
proximity switch and the vane is 3
mm (Fig. 27).
Setting the Proximity
Switches
Fig. 27
1/01 E Service Instructions 22
Hydraulic
Clamping System
PERFECTA guillotines have a
continuously adjustable doublepiston hydraulic system with a
very wide clamping force range.
For the ordering designations of
the hydraulic equipment, refer to
the Operating Instructions
manual.
The basic arrangement of the
equipments and pipelines is
shown in Fig. 28.
Explanation of the abbreviations
used:
P =Gear pump
Z = Clamping cylinder (plunger
cylinder with fast-speed piston)
Y1, Y2, Y62
=
Solenoid-operated multiway
valves with reset spring
VD1, VD1.1
= Pre-clamping pressure-re-
lief valves
M1
= Test point for "free circu-
lation" and pre-clamping
M2
= Clamping pressure test
point
Z1, T2
= Return line to oil tank
In the hydraulic circuit diagram:
___ = Pressurized oil line
____ = Passive oil line
The spatial assignment of the
equipment on the control assembly is shown in Fig. 28.
VD2
= Fast-speed pressure-relief
valve
VD3
= Clamping pressure-relief
valve (clamping pressure
valve)
VDR
=Pre-clamping multi-way
valve
RV1
= Non-return valve
SRV
= Suction valve
STV
= Stop valve
S = Flow indicator
F = Filter
Markings on the control
assembly:
PZ
= Line to clamping cylinder
(main pressure chamber)
PE
= Line to clamping cylinder
(fast-speed piston)
PV
= Clamping pressure valve
pressure line
Fig. 28
VD1
VD1.1
VD2
VDR
Y2/VW2
Y1/VW1
Y62/STV
1/01 E Service Instructions 23
The individual working stages of
the hydraulic clamping system
are:
Machine at Basic Position
(free circulation)
(Fig. 29)
The main motor is on. The pump
runs. The knife beam and the
clamp are at their topmost positions.
Multi-way valves VW1 and VW2
are at rest (Y1, Y2 not operated).
The oil flow returns to the tank via
RV1, VW1, VW2, VDR and F with
almost no pressure.
Fig. 29
1/01 E Service Instructions 24
Pre-Clamping
(Fig. 30)
From the basic position, the VDR
valve is operated by the pedal.
The former inlet of VW1/VW2 is
closed. Pressure builds up from
pump P, via RV1, VW1/VW2 as
well as VD1 and VD1.1 which determine the value of the pressure.
The oil flow is applied to the fastspeed piston. The plunger of cylinder Z comes out and moves the
clamp down. Via SRV, the big
cylinder chamber fills up with oil.
When the clamp touches down,
the oil returns to the tank through
VD1 and VD1.1.
Fig. 30
1/01 E Service Instructions 25
Cut Triggering
Clamp Fast Speed (Fig.31)
Operating the two-hand knife con-
trol pushbuttons activates Y1/
VW1 and Y2/VW2. This blocks
the oil circulation and applies the
entire oil flow to the fast-speed
piston of cylinder Z. The plunger
comes out with fast speed and
moves the clamp down. Via SRV,
the big cylinder chamber fills up
with oil. When the clamp touches
down, VD2 responds due to an
increase in pressure.
Fig. 31
1/01 E Service Instructions 26
Main Clamping
(Fig. 32)
Due to the overflowing of VD2,
the main pressure preset by
clamping pressure valve builds
up in the fast-speed and main
cylinder chambers.
Fig. 32
1/01 E Service Instructions 27
Decompression
(Fig. 33)
After the knife has cut through,
the computer control system turns
off Y1/VW1 which then goes open.
The pressure existing in the cylinder chamber can thus relax. The
oil flow from the pump returns to
the tank via VW1, VDR and F.
Fig. 33
1/01 E Service Instructions 28
Clamp Return
(Fig.34)
Due to the decompression, VD3
is no longer overflown, the flow
indicator does not detect any
volume flow and opens Y2/VW2,
whereby the flow cross section
for the oil displaced from the
cylinder chambers is increased.
The clamp moves up.
Machine Sizes 115/132 Only:
The pressure decrease in the pump
line opens the SRV suction valve,
and further cross section is made
available for the oil to be displaced from the cylinder chambers.
For the 76 and 92 machines, the
clamp is brought to its topmost
position by a compression spring,
and by tension springs on the 115
and 132 size machines. This
forces the oil out of the cylinder
chambers into the tank.
The last section of the stroke is
damped without any jerks before
the end position in the cylinder is
reached.
The basic position as shown in
Fig. 29 is restored.
Fig. 34
Stroke Limit Function
You can preselect the stroke limit
from the machine's setting menu
(refer to the Operating Instructions
manual).
After a short stroke (the clamp
has lifted off the pile), the oil to be
displaced from the plunger
chamber is blocked through Y62/
STV with the clamp being held at
this position.
1/01 E Service Instructions 29
Start-Up
For reasons of fire precautions,
the machine is supplied with an
empty oil tank.
When filling in fresh hydraulic oil,
follow the instructions given under "Hydraulic Oil Change" in the
Operating Instructions manual.
For oil grades to be used, refer to
"Lubricants" in the Operating Instructions manual.
When starting up the system, first
check whether the clamp comes
down by pressing the pedal and
using the "pre-clamping" function. If the movement is not
smooth, or if the clamp does not
touch down on the cutting table,
the hydraulic system must be
ventilated. This is done automatically by triggering several cuts
with the knife pushbuttons and
the clamping pressure (VD3) set
to minimum.
Check again by using the "preclamping" function. Otherwise,
proceed as described above.
VD2
With the aid of the VD2 acting as
acceleration or fast-speed valve,
the clamp fast speed is regulated. The clamp should move
down freely. For pre-clamping, it
must be possible to stop and start
it at any position and should, however, smoothly touch down onto
the cutting table. Too high a clamp
speed may cause damage to the
machine.
Adjust as follows:
• Slacken the lock nut.
• Gently readjust the setting
spindle
clockwise = to speed up;
anticlockwise = to slow down.
• Tighten the lock nut.
VD3
The clamping pressure valve is
set to the maximum clamping
pressure required for the respective machine sizes. Changing the
setting is not necessary and may
cause damage to the machine.
Fig. 35
Hydraulic Clamping System
Settings (MPa)
Important!
Insufficient alignment of the
machine at its place of installation
as well as canting of the clamp
draw rods may adversely affect
free traveling of the clamp. The
clamp is moved up by compression or tension springs.
Adjusting the
Hydraulic Clamping
System
If some readjustment of the pressure-relief valves should be necessary, perform the adjustment
in a gentle way and observe the
fol-lowing:
VD1, VD1.1
For safety reasons, these valves
must not be readjusted, as they
are set to the pre-clamping force
specified in prEN 1010. Increasing the pressure bears the hazard of injuries to the fingers or
hands of the operator during preclamping.
Machine Size 76 92 115 132 168
Free Circulation Test Point M1 0,25-0,35 0,25-0,35 0,25-0,35 0,25-0,35 0,25-0,35
VD1, VD1.1 Test Point M1 1,5 2,5 1,5-1,8 1,5-1,8 2,5
Max. pre-clampimg force (N) acc. to
prEN 1010
300 300 300 300 500
VD2 Test Point M1 1,8 2,8 2 2 2,8
VD3
min. 0,18 0,29 0,2 0,2 0,3
max. 13 15,5 12 12 16
Clamping Force (kN)
min. 2 2 3 3 3,5
max. 25 30 45 45 60
1/01 E Service Instructions 30
Flow Indicator S
Adjusting should be performed
with no oil flowing through the
flow indicator (machine at basic
position).
The white arrow in Fig. 36 indicates the flow direction of the
hydraulic oil.
1st Switching Point (Fig. 36)
Pull the switching unit (reed contact) from the cable connection
side into the direction of the arrow until the signal in the I/O test
menu display becomes 3E - 32.
Mark this position on the switching unit with respect to the enclosure of the flow indicator with a
pencil.
Checking the
Adjustment
All pressure stages can be
checked at test point M1 or M2 by
means of a test pressure gauge
(option).
For setting values, refer to Fig.
35.
Main Clamping
Pressure Setting
Instructions
A few basic rules for selecting the
clamping pressure are given in
the"Clamping" section of the
"Cutting Compendium" you can
obtain from PERFECTA .
Stock-dependent empirical values can be obtained from the
tables in the "Cutting Compen-
dium" (Figs. 6 to 10).
They represent reference values
for about 2/3 of the maximum
feed height and cutting width.
The Operating Instructions
manual shows the diagrams of
the clamping pressure curves for
the individual machine sizes as a
function of scaling. The ranges of
"low", "medium" and "high" assigned to the various types of
stock in the Tables of the "Cut-
ting Compendium" are explained there, and their assignment in the clamping pressure
scale is marked.
Hydraulic Clamping
System Maintenance
Refer to "Hydraulic Oil Change",
"Checking the Filter" and "Lubricants" in the Operating Instructions manual.
Fig. 36
Fig. 37
Fig. 38
2nd Switching Point (Fig.37)
Beginning opposite to the cable
connection side (reed contact
end), pull into the direction of the
arrow until the signal in the I/O
test menu display becomes 3E -
32. Mark as described above.
Adjustment (Fig.38)
Set the switching unit to 1/4 of the
switching range from the upper
switching point and adjust it.
1/01 E Service Instructions 31
Malfunctions in the
Hydraulic Clamping
System
If malfunctions occur in the hydraulic clamping system, always
check the following first:
- Oil filling level in the tank. Replenish, if necessary.
- Pump drive. Re-tension belt, if
necessary.
Possible malfunctions and their
rectification:
•When a cut is triggered by the
knife pushbuttons, the clamp
touches down on the stock, however, no cut follows. Releasing
the knife pushbuttons makes the
clamp return to its topmost position.
Remedy:
- The flow indicator is not operated.
To adjust the flow indicator, refer
to "Adjusting the Hydraulic
Clamping System".
- Defective reed contact of the
flow indicator.
Replace contact.
• When a cut is completed,
- the clamp stays on the stock
(machine sizes 76 and 92);
-slowly returns to its topmost position (machine sizes 115 and
132).
When another cut is triggered,
the display reads error 28: Safety
Module Detecting Error.
When the "C" key is pressed concrete error 23: Valve Monitoring,
appears.
. .
Remedy:
- The flow indicator remains operated.
- Reed contact welding. Replacement of the contact is necessary.
• No "pre-clamping" when the
pedal is pressed, i. e. the clamp
would not come down.
Remedy:
- Check the pump pressure at M1
with a test pressure gauge when
the oil is freely circulating, and
when pre-clamping. For the values, refer to the Table (Fig. 34)
When no pressure is available:
- Defective pump. Replace the
pump.
- VD1, VD1.1 or VD2 is overflown.
Repair may, for safety reasons,
only be performed by trained personnel.
When the required pressure is
available:
- Check the machine for proper
alignment and, in conjunction
therewith, for free movement of
the clamp. Check for possible
canting of the clamp draw rods.
Readjust the clamp guideways, if
necessary.
•The clamp moves up slowly after pre-clamping.
Remedy:
- Check the clogging indicator on
the filter according to "Checking
the Filter" in the Operating Instructions manual.
- Check the machine for proper
alignment and, in conjunction
therewith, for free movement of
the clamp. Check for possible
canting of the clamp draw rods.
Readjust the clamp guideways, if
necessary.
- Fatigue of the clamp balancing
spring.
For machine sizes 76 and 92:
Replace spring assembly.
For machine sizes 115 and 132:
Tension the tension spring assembly in the machine upper
cross beam. Accessible under
the upper right paneling.
• No clamp fast-speed movement
before clamping pressure buildup.
Remedy:
- VD2 not properly set. Refer to
"Adjusting the Hydraulic Clamping System".
Check the pressure at M1 with a
pressure gauge according to the
Table (Fig. 34).
- VD2 overflow (e. g. spring breakage). Insufficient pressure buildup. Replace valve.
- Multi-way valve Y1 or Y2 does
not operate.
Y1 does not operate: Insufficient
pressure build-up through VD1,
VD1.1.
Y2 does not operate: Free flow
through VDR and F into the tank.
Replace multi-way valve.
- Air in the hydraulic system. Ventilate system according to Section "Start-Up".
1/01 E Service Instructions 32
• No clamping pressure build-up,
or clamping pressure is built up
too slowly.
Remedy:
- See above: "No clamp fastspeed movement before clamping pressure build-up".
- Lock the clamp after cutting by
means of the clamp switch on the
front panel.
Refer to "Clamping" in the Operating Instructions manual.
Readjust VD3 over the entire
range and check the pressure at
M2 with a pressure gauge according to the Table (Fig. 35).
Replace VD3, if necessary.
- Check the pressure of the gear
pump at M1 with the aid of a test
pressure gauge when the clamp
is locked and VD3 is set to maximum. If the gear pump does not
deliver the maximum pressure,
replace the pump.
•The clamp moves up slowly after
the cut.
Remedy:
- See above: "The clamp moves
up slowly after pre-clamping“.
- Y2 does not operate (spring
reset). Replace multi-way valve.
- For machine sizes115 and 132:
Suction valve SRV does not go
open. Check the return spring.
• The clamp bounces when touching down on the stock to be cut.
Remedy:
- Check non-return valve RV1:
Foreign bodies in the ball seat.
Jammed spring.
• The clamp hits hard against its
upper end position.
Remedy:
- Check the end position damping
in the clamping cylinder.
• The hydraulic oil forms much
foam.
Remedy:
- The suction line of the pump is
not immersed deep enough into
the oil tank. Push the hose more
deeply into the oil tank.
- The connection between the
suction line and the pump is not
tight. Re-tighten the connection.
- Defective pump. Replace the
pump.
• The clamp comes down slowly
and with heavy noise only/the
clamp does not release the pile
any more.
Remedy:
- Rapid speed is blocked by the
STV stop valve. Check the stop
valve.
• Preclamping with the pedal does
not work.
Remedy:
- The rapid speed line is blocked
by stop valve STV. Check the
stop valve.
- Check the setting of switch
S69.1.
• The stroke limit function does
not work.
Remedy:
- Activate the stroke limit function
from the settings menu.
- Check connector X801 on the
control processor for proper
seating.
- Check the setting of switch
S69.1.
- Check stop valve STV.
Adjusting the S69.1 Stroke
Limit Pedal Switch
When the stroke limit function is
active, adjust switch S69.1 on the
pedal so that it deactivates this
function before VDR comes into
effect (clamp upward movement)
when you are slowly pressing down
the pedal. VDR will only respond
when you press the pedal further
down, the ascending movement
changing into a descending
movement. This guarantees that
no pressure will be applied to
clamping cylinder Z through the
main cylinder chamber, even though
STV is closed.
There are two possible malfunctions:
• The stroke limit function is not
deactivated.
Remedy:
-S69.1 is not sufficiently released
to change over when the pedal is
fully pressed down.
-Move away the switch some
more.
• No stroke limit function takes
place.
Remedy:
-S69.1 is not sufficiently pressed
to change over when the pedal is
not pressed.
-Bring the switch nearer.
Make a sensitive switch correc-
tion in both cases.
Loading...