Electric Operating Elements P15-90 - 309F

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ELECTRIC OPERATING
ELEMENTS --
P 15--90/309F
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1.0 MEANING OF TERMS

Touch button:
For switching functions (e.g. blower) on and off, scrolling in the masks, etc.
Field:
Input fields and display fields. Values, data, etc. can be entered in an input field
using the keypad.
Also part of the switch cabinet.
Layer:
A layer consists of several paper sheets collected on top of each other.
Until they are folded in machine section 2 (binding section), the collected paper
sheets are called layers.
Strip:
A strip consists of several folded paper sheets collected on top of each other
which were sewn.
From when they are folded in machine section 2 (binding section), the
collected paper sheets are called strips.
Offset:
When you enter an offset amount, the backlining tape is cut off nearer to the strip
rear edge or nearer to the strip front edge.
>: greater (than).

<: less (than).
⇒: from this, it can be concluded that or this results in.
¶: approximately
Item: Position number
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2.0 OVERVIEW OF ASSEMBLIES
Information!
The order in which the assemblies are installed is shown on the following
general layout diagram and/or the general overviews of assemblies.
The Operating instructions are generally arranged in this order (excluding
the switch cabinet).
Machine section 1 begins at the Unwind unit assembly and ends at the Sewing
right assembly.
Machine section 2 begins at the Transport after sewing assembly and ends at
the Discharge belt assembly.
Machine section 1 is also known as the preceding machine and machine

section 2 is also known as the binding section.
Each machine section can be operated on its own.
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2.1 Machine section 1 (preceding machine)
3 2
Fig. 1 (seen from above)
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. Fig. 1
Pos. Assembly Pos. Assembly

1 Transfer to sewing 3 Reject
2 Sewing right
Information!
The assemblies not listed in machine section 1 are provided by the
customer!
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2.2 Machine section 2 (binding machine)
1 2 3
4
5
6
7
8
10
14
11
12
13
15
16
17
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. Fig. 2
Pos. Assembly Pos. Assembly

1 Sewing thread cutting 11 Transfer after turning
2 Transport after sewing 12 Transfer to backlining
3 Feed and transport section 13 Backlining with gluing de-
vice and cutting unit
4 Turning 180 degrees 14 Transfer after backlining
5 Folding 15 Cutting
6 Sewing thread tip cutting 16 Corner rounding
7 Binding section drive 17 Discharge belt
8 Spine pressing
9 Laminating and gluing and
feeding
10 Feeder
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3.0 SWITCH CABINET AND CONTROL CONSOLE OVERVIEW

3.1 Machine section 1 (preceding machine) and machine section 2 (binding
section)
P9534
P951 P9524
P9511
P9512
P951 P9514
P9511
P9512
T
P6314
P951 1
P21
P9511
P9512 P3718
3
H2
P631
P4222
P190
H34
P4212
P190 2
L341 P210/P211
P2111
P331
P3311
P3312
P371
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. Fig. 3
Pos. Designation and Pos. Designation and

assembly assembly
H2 Switch cabinet for ma- P190 Control console for feed-
chine section 2 and P3718 ers I and II
control console on the in-
side
H34 Switch cabinet for Hot melt P4212 Control console for gluing
gluing assembly and feeding
T Transformer P4222 Control console for gluing
and feeding
1 Main switch on H2 switch P331 Control console in pillar in
cabinet front of backlining
2 Main switch on H34 switch P3311 Control consoles for back-
cabinet P3312 lining
3 Dust extractor L341 Distribution box with con-
trol elements at backlining
P21 Main control console with P371 Control console in pillar in
control panel front of cutting
P951 Control consoles for sew- P2111 Tow cable inching button
P9511 ing I
P9512
P9514 Control console for sewing
thread cutting I
P952 Control consoles for sew-
P9521 ing II
P9522
thread cutting II
P953 Control consoles for sew-
P9531 ing III
P9532
thread cutting III
P631 Control console in column
in front of spine pressing
thread tip cutting and fold-
ing
Tab. 1
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4.0 SAFETY CIRCUITS AND PROTECTIVE DEVICES IN THE

WHOLE MACHINE
4.1 Safety circuits
10
P2111
8 6
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. Fig. 4
Pos. Designation and Pos. Designation and

assembly assembly
6 Safety circuit 9, transfer af- 9 Gluing and feeding, lami-
ter backlining, cutting, cor- nating, feeder I
ner rounding
7 Safety circuit 7, turning, 10 Gluing and feeding, lami-
folding, spine pressing, nating, feeder II
8 Safety circuit 8, transfer to P2111 Tow cable inching button
backlining
8 Safety circuit 8, transfer to
backlining
Tab. 2
The machine can still be moved in inching mode using the corresponding tow
cable inching button despite there being a fault or a protective device being open.
Exception:
EMERGENCY STOP button is pressed, cover above the knife unit is open or
protective device of another safety circuit is open.
D P2111:
Tow cable inching button for safety circuits 6 to 9.
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4.2 Protective devices
The protective devices on the machine prevent persons from being placed at risk
or injured by the machine.
Protective devices -- see Operating instructions/Maintenance instructions for
the individual assemblies.
Further protective devices include the EMERGENCY STOP buttons -- see 9.2.1.
Information!
The plant operator is required to check biannually whether all protective
devices are fitted on the machine and properly functioning.
Never operate the machine without protective devices or with them open!
Exception: Inching mode!
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5.0 RATING PLATES
P15--90/309F
2011
Fig. 5
The electrical rating plate for the machine on the H2 switch cabinet is located in
the vicinity of the main switch.
For electrical ratings, refer to the illustrated rating plate in the wiring diagrams (first
page).
P15--90/309F
2011
Fig. 6
This rating plate is attached to the frame panel of the Folding assembly.
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6.0 SWITCH CABINETS
6.1 H2 switch cabinet for machine section 2 (binding section)
3 4 5
Fig. 7
Pos. Designation Pos. Designation

1 Rating plate 4 Ventilation door control con-
sole
2 Main switch 5 H2 switch cabinet front view
3 Ventilation door
The H2 switch cabinet consists of five fields.
At the binding section it is used for controlling the machine generally and for
controlling the variable--speed drives.
6.1.1 Main switch
The main switch is located at the side on the switch cabinet.

At this main switch, only the power supply from the switch cabinet to the machine
is interrupted.
The power supply to the switch cabinet remains active.
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The entire control system of the machine is de--energized at the main switch: all
electric motors, blowers, fans, pumps, auxiliary units, attachments, in brief the
whole machine and the switch cabinets.
In the OFF position (0 position) the main switch can be secured with a padlock
against unauthorized operation.
The main switch is switched off for longer shutdowns, e.g. end of shift, weekend,
holidays, etc.
When the machine main switch is switched off, the control voltage is automatically
switched off as well, but it should always be switched off first anyway.
! WARNING
Acute danger of death by electrocution from live connections!
DANGER!
Read the Operating instructions before starting up the machine!
Before turning the machine’s main switch on, ensure that the machine is in
a safe operating condition and that no one will be endangered by switching
the machine on.
Turn the main switches off and secure them against unauthorized operation
when carrying out repair or maintenance work.
To shut off all motors, turn the machine main switch OFF and secure against
unauthorized operation by others!
Blowers, fans, pumps, etc. run on for a while after switching off and can
start up on their own when the machine is switched on again!
Never remove connected pipes, hoses, sacks, connectors, etc. when the
blowers, fans, pumps, etc. are running. Increased danger of hair, etc. being
pulled into the machine!
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6.1.2 Ventilation door

The inside of the switch cabinet can be cooled down to below the surrounding
temperature outside.
The switch cabinet doors must be kept closed during operation, otherwise the
ventilation door cannot achieve the required degree of effectiveness and may
be damaged!
For safety information, refer to the Operating instructions for the ventilation
door in the documentation for purchased parts!
Important!
Pay attention to free passage of the condensation water hose.
Empty collecting tank when required.
6.1.3 Ventilation door operator panel

The current internal temperature of the switch cabinet is shown on the control
panel.
For operation, setting, etc. see the Operating instructions of the ventilation
door in the documentation for purchased parts!
6.2 P3718 control console in H2 switch cabinet
Fig. 8
Symbol number: 07868010
White button: Clear fault
D For acknowledging a fault at the clutch of the Turning assembly
D Before acknowledging the clutch fault, ascertain the cause, otherwise the
fast--response excitation card could be destroyed
D This button may only be pressed by service personnel or trained specialists
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6.3 H34 switch cabinet for hot melt gluing
23
21
22
Fig. 9
. Fig. 9

21 Main switch H34 Switch cabinet
22 Time switch
The H34 switch cabinet consists of one field.
This main switch depends on the main switch for machine section 1 or 2, see
also 6.1.1.
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6.3.1 Main switch
The main switch is located at the side on the switch cabinet.

This main switch is only used to interrupt the power supply from the switch cabinet
to the Gluing device assembly and the associated operating elements, etc.
The power supply to the switch cabinet remains active.
In the OFF position (0 position) the main switch can be secured with a padlock
against unauthorized operation.
Because of the timer switch, which controls the heating time for the Gluing
device assembly, this main switch is not normally switched off.
The main switch is only switched off for longer shutdowns, e.g. end of shift,
weekend, holidays, etc.
6.3.2 Timer switch
The timer switch is located on the side of the switch cabinet.

The heating time and the cooling for the Gluing device assembly is set at the timer
switch.
The heating time starts approx. 1/2 hour before the start of production.
For further information see Operating instructions for the Gluing device or
Auxiliary hot melt gluing assembly.
For operation, setting, etc., see the Operating instructions of the timer switch
in the documentation for purchased parts!
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7.0 DISPLAY ELEMENTS

7.1 Speed and fault location indicators, warnings, warning lamps
A main digital display is installed at a highly visible place on each machine section.
A signal column (red/orange/green) is installed on this display.
Acoustic signals are given as a startup warning and if there are other
warnings/faults.
7.1.1 P211 main digital display
999
Fig. 10
While the machine is running, the P211 main digital display and the display of the
control panel in the P21 main control console show the current machine running
speed of machine section 2 in c/min.
If the number flashes when the machine is running, a warning number is shown on
the corresponding main digital display as well as on the display of the control
panel in the corresponding main control console.
The machine, however, continues running.
The meaning of the warning numbers can be read from the display of the control
panel in the corresponding main control console -- see Fault and warning
display main mask.
If there is a fault, the fault number is shown on the corresponding main digital
display as well as on the display of the control panel in the corresponding main
control console.
The machine stops.
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The meaning of the fault numbers can be read from the display of the control panel
on the corresponding main control console -- see Fault and warning display
main mask.
The appropriate fault can be selected by touching the cursor touch button in the
main mask (fault and warning display) on the control panel if there is a
fault/warning.
The complete explanatory text can be read after touching the Enter touch button.
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7.1.2 P210 signal column
Red lamp
Orange lamp
Green lamp
Fig. 11
A signal column (red/orange/green) is installed on every main digital display.
The red lamp in the signal column flashes if inching mode is preselected on the
corresponding tow cable inching button.
If an EMERGENCY STOP button has been activated or unlocked but the fault
number has not yet been acknowledged (using the Machine ON, 001 illuminated
pushbutton), the red lamp does not flash.
The red lamp in the signal column illuminates if a fault is present.
The orange lamp in the signal column illuminates when a warning is present.
The green lamp in the signal column illuminates when the machine is ready for
operation.
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7.1.3 Warning lamps
Fig. 12
A red lamp is installed at every sewing machine.

If the sewing thread is torn or at an end, the red lamp in the sewing machine area
lights up.
At the same time an acoustic signal sounds and a warning number (with explana-
tory text) appears on the corresponding main digital display.
The machine automatically slows down to the value set for automatic decelera-
tion, the corresponding sewing machine disengages, and the corresponding
layers are transported straight on and discharged.
Once the cause of the fault has been rectified, the corresponding electric
operating elements -- see 9.3.2 -- is actuated, the sewing machine engages
again at the exact point in the cycle and the layers are led to the corresponding
sewing machine. The red lamp and the warning number go out and the acoustic
signal ceases.
The sewing thread check is only effective while the machine is running (min.
5 cycles/min).
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7.2 Startup and fault signals
Acoustic signals (e.g. horn, hooter, bell or similar) are mounted on the machine or
switch cabinet to provide a start--up warning signal.
Provided there are no current faults, the start--up warning occurs in the form of a
loud ringing tone every time the Machine ON (001) illuminated pushbutton is
pressed.
DANGER!
Leave the machine’s danger area immediately if the machine’s start--up
warning signal sounds!
The tow cable inching buttons are used for operating the machine in inching
mode -- see 9.1. The machine can still be moved despite a fault having occurred if
the machine has been switched over to inching mode by turning the key switch.
Exception:
EMERGENCY STOP button is pressed or protective device of another safety
circuit is opened.
The start--up warning also occurs when an inching button has been pressed.
If there is a malfunction, an acoustic signal sounds when the inching button is
actuated for as long as the inching button is pressed.
DANGER!
Increased danger of injury from all moving parts in inching mode!
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8.0 SYMBOLS OVERVIEW
Symbol Designation Symbol Designation
Operating mode selection,

Machine ON
078 61 001 T automatic mode
078 68 001 078 61 027
Inching mode, inch forward

Machine OFF
078 61 002 078 61 003 by hand
078 68 002 078 68 003
078 61 026 Machine faster, accelerate Run unit into position

078 68 026 078 61 379
078 61 029 Machine slower, brake

078 68 029
Automatic acceleration,
078 61 261 preselection
078 68 261
Automatic deceleration,
078 61 262 preselection
078 68 262
Clutch engaged / disengaged Lamp OFF/ON

078 68 356 078 68 281
Sewing manual Knife bed up/down

078 68 879 078 68 491
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OFF/ON Intermediate table down

078 68 194 078 68 485
Intermediate table up Raise stack

078 68 484 078 68 040
Glue pump OFF/ON Lock

078 60 333 078 60 015
OFF/ON Home position

078 68 194 078 68 270
Backlining tape fault Clear fault

078 60 297 078 68 010
Backlining tape monitoring (bell

078 61 298 On/Off)
The control buttons on the control console and the machine are marked in part
with symbols.
Refer to the overview of symbols to see the symbols used and the corresponding
symbol numbers.
If a symbol is used in more than one size, each size is assigned its own symbol
number.
The last three digits of a number form the abbreviated symbol number.
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9.0 ELECTRIC OPERATING ELEMENTS

9.1 P2111 tow cable inching button
The machine can still be moved in inching mode using the corresponding tow
cable inching button despite there being a fault or a protective device being open.
Exception:
EMERGENCY STOP button is pressed, cover above the knife unit is open or
protective device of another safety circuit is open.
D P2111:
Tow cable inching button for safety circuits 6 to 9.
Emerg. .003
Stop
Fig. 13
Emergency Stop button -- see 9.2.1.
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White button: Inching mode (incrementally inch machine by
pressing button)
D Turn the key switch (027 on the P21 main control console) to inching mode;
the machine can be moved incrementally by pressing the white button.
T
Information!
If the tow cable inching button, also called “incher”, is used, it is called
“inching”.
DANGER!
The machine can still be moved in inching mode using the tow cable inching
button even if there is a fault or a protective device is open.
Only the operator who activated and pressed the inching button may work
on the machine (e.g. for adjustments, conversions, maintenance, cleaning)
during inching mode.
A second person must not be carrying out any work involving the machine
at this time!
There is an increased danger of injury, e.g. if the inching button is activated
at one end of the machine while a second person is working at the other end
of the machine or on another assembly and does not hear the warning
signal for the machine starting up (or does not notice it for whatever reason)
and consequently gets pulled into the machine!
Serious injuries including loss of limb can result!
If several people are working on the machine at the same time, e.g. for
adjustments, conversion, maintenance, cleaning, etc., the main switch
must be set to OFF and secured against being operated by others or, if this
is not possible, at least all Emergency Stop buttons must be activated!
Operating the inching button:
D Turn the key of the key switch (027 on the P21 main control console) to
inching mode preselection by turning it clockwise
T
D Rectify any apparent fault sources
D Continued on next page
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Press the button once:
D Acoustic start--up warning signal; 3 seconds, then press the button a second
time during the release time of about 4 seconds
Press the button a second time:
D Machine starts when the inching button is pressed
D If a continuous acoustic warning signal sounds, there are still one or more
faults on the machine, a protective device is open or the preceding fault
numbers still have not been acknowledged (deleted) using the Machine ON
illuminated pushbutton
D A fault number can only be acknowledged if the fault has been rectified (e.g.
reconnect overload clutch, close protective device)
D The Machine ON illuminated pushbutton must not illuminate if the fault has
been rectified and the fault number is going to be acknowledged
D The machine is ready for operation if no acoustic signal sounds during

inching
D The machine runs at basic speed when the button is pressed and stops when
pressure on the button is released
D If the button is pressed again within approx. 6 seconds, the machine starts
again
D If the button is not pressed within approx. 6 seconds, see Press the button
once
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9.2 Electric operating elements on the control panel in the P21 main control
console
.001 .026 .029 .002 .027 .261 .262 .379

Emerg.
Stop
Fig. 14

1 Control buttons 2 TP35 control panel
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9.2.1 Emergency Stop button
Emergency Stop button red mushroom pushbutton on a yellow

background
D Use an Emergency Stop button only in an emergency -- never use it for a

normal machine stop
D Press the Emergency Stop button immediately if there is any danger
D The machine is stopped in the shortest possible time
D The button locks in a depressed position
D Unlock the button by turning to restart the machine
D If an Emergency Stop button has been pressed, check without fail why it was
pressed (intentionally or unintentionally)
D If it was pressed intentionally, find out the reason why and, if necessary,
rectify the cause before unlocking the button
D If it was pressed unintentionally, give instructions that this is strictly

forbidden
D Emergency Stop button does not stop the operation of all electric motors,
e.g. external fans
D To shut down all motors, turn the main switch to OFF (0) and secure against
operation by others
D The pneumatically driven machine components always carry out processes

they have commenced.
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9.2.2 Further control buttons, switches and signal lamps on the P21 main
control console
See also the overview of symbols 8.0.

The other control buttons/switches and signal lamps on the control console are
listed from left to right and top to bottom.

White illuminated pushbutton: Machine ON
D This illuminated pushbutton must be pressed two or three times to switch the
machine on
Before starting the machine:
D Turn the key switch (027 on the P21 main control console) to the Automatic
operation position
T
D Rectify all faults
D Close all protective devices
D Clear fault (if this is not possible, there may be another fault, a protective
device may not be closed or an overload protector is not properly connected)
D Start--up warning (acoustic signal sounds for about 3 seconds). After about
3 seconds, the white illuminated pushbutton lights up for approx. 4 seconds.
This is the enable time for starting the machine
Press a third time within the enable period:
D The machine starts up at basic speed and the Machine ON (001) illuminated
pushbutton lights up
Information!
If this was preceded by a normal machine stop, the Machine ON (001) illuminated
pushbutton only has to be pressed twice
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White button: Machine faster
D Pressing this button increases the machine’s running speed, though only up
to the maximum speed set at the factory

White button: Machine slower
D Press this button to reduce the machine’s running speed

Black button: Machine OFF
D The machine is stopped according to the set deceleration curve when this
button is pressed
Empty field

Key switch: Setup mode preselection
T Machine automatic mode/inching mode
D Changeover of operating mode from control console to tow cable inching

button (inching mode)
D Turning the key to the right switches the machine to inching mode (the
machine can be operated using the inching button)
D Afterwards, turn the key to the left again to reset to automatic mode
(machine is operated via the control console)
D The key can be removed in any preselected operating mode to secure the
lock against being operated by others
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White button: Automatic acceleration
D When this button is pressed, the machine accelerates from the current speed
to the speed set in the machine main mask on the TP35 control panel (up to a
maximum of maximum speed)
D The procedure can be interrupted by pressing the Machine slower (029)

button

White button: Automatic deceleration
D When this button is pressed, the machine decelerates from the current speed
to the speed set in the machine main mask on the TP35 control panel

Red signal lamp: Run unit into position (drives not
synchronized)
D If the machine sections were operated separately using the function keys --
see Function keys -- and the machine sections are no longer synchronized
(in phase), the red Run unit into position (drives not synchronized) lamp
lights up
D Press the appropriate function key (LED illuminates) and deselect the
function
D Switch the machine on
D The machine starts up ⇒ the assemblies and machine sections

synchronize (position) themselves automatically ⇒ the red Run unit into
position (drives not synchronized) lamp goes out
Empty field
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9.2.3 Monitor description
Fig. 15

1 Front panel 3 Function keys (not on
all monitors)
2 Touch--sensitive screen behind
contrast filter screen
The monitor is located on an industrial operator panel behind an integrated

contrast filter screen.
The screen is designed as a “touch screen” with touch--sensitive fields and touch
buttons in order to allow entries to be made directly on the screen.
Information!
Please see the attached Operating instructions in the purchased parts
documentation for instructions on operating the control panel and the
meaning/function of the keys.
With foreign language mask texts it is possible that not all special symbols
will be shown on the display.
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9.2.4 Function keys (F keys)
F1 F9 F10
F11 F13
Fig. 16
Information!
The keys shown in the above illustration are function keys. Functions can
be switched on and off using these keys according to their designated
function.
The light--emitting diode (LED) in the function key indicates the switching
status.
F1 function key Control voltage ON/OFF

F1
This function key can only be used to switch the control voltage for machine
section 2 on and off if the control voltage for machine section 1 is switched off.
If the control voltage is switched on at the switch cabinet for machine section 1,
the control voltage for machine section 2 is automatically switched on as well.
The same applies for switching off.
S LED lights up: Control voltage ON (the control volt-

age is switched on by pressing the
function key after the main switch
has been switched on).
The auxiliary aggregates such as blowers, fans, pressure/vacuum pumps, etc.

switched on or preselected in the Auxiliary aggregates main mask or by toggle
switch start immediately when this function key is pressed.
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S LED off: Control voltage OFF (usually only

the auxiliary aggregates such as
fans, blowers, pressure/vacuum
pumps,, etc. are switched off; the
actual status of the counters, timers,
clutches, etc. is generally retained)
The control voltage is automatically switched off as well when the main switch is
switched off. Nevertheless, the control voltage should be switched off first by
pressing the function key.
The control voltage can be switched off for noise reduction during longer
standstills.
F9 function key Display: drive section 2 synchronized

F9 If machine section 2 was operated separately by SOLO mode section 2 and the
assemblies are no longer synchronized (in phase), the red Display: drive
section 2 synchronized LED in the F9 function key lights up. When the SOLO
mode section 2 function has been deselected, the red LED in F9 goes out and the
green LED lights up.
F10 function key SOLO mode section 2

F10 When this function key is pressed, machine section 1 is electrically and
mechanically coupled with or decoupled from machine section 2.
If the machine sections are decoupled, each machine section can be separately
operated.
S LED flashes: Machine sections are synchronizing

themselves
S LED off: Machine section 1 and machine
section 2 are coupled
S LED lights up: Machine section 1 is decoupled
from machine section 2
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F11 function key Size change
F11 The Size change function key (F11) also has to be pressed after the Enter touch
button following a data input or change of feed sheet length (for laminating).
S LED flashes: Data transmission requested

S LED lights up: Data transmission running
S LED off: Data transmission completed -- the

machine can be switched on
Important!
The machine must be switched off before data are entered/transferred.
Inching mode must not have been preselected!
F13 function key Laminating synchronized

F13 Display button.
If the drive of the suction belts in Laminating is no longer synchronized (e.g. after
a change of feed sheet length or a fault) with the drive of machine section 2, the
LED lights up.
S LED lights up: Drive of suction belts in Laminating

not running synchronously with the
drive of machine section 2.
Synchronization is automatic when
the machine is turned on.
Synchronize manually after a size
change or fault -- see 11.5.
S LED off: Drive of suction belts in Laminating
running synchronously with the drive
of machine section 2.
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9.3 Control consoles at the “Sewing I” assembly
9.3.1 P951 control console
.001 .026 .029 .002 .261 .262

Emerg.
Stop
Fig. 17
Emergency Stop button

See 9.2.1.
Additional operating elements:

Symbol number 078 ...
001 Green illuminated pushbutton -- Machine ON
026 White button -- Machine faster
029 White button -- Machine slower
002 Red button -- Machine OFF
261 White button -- Automatic acceleration
262 White button -- Automatic deceleration
See 9.2.2.
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Fig. 18

White button: Sewing -- manual inching mode
D If the sewing machine is disengaged from machine section 1 (preceding

machine), sewing can be performed manually (e.g. for fault
rectification/adjustment work) by pressing the button
WARNING!
The sewing needle moves up and down!
The sewing needle could pierce your fingers!
Never reach under the sewing needle while the machine is running, e.g.
when removing a layer!

White illuminated pushbutton: Engaged / disengaged (sewing
machine 1)
D If sewing machine 1 was disengaged because of a fault in machine section

1, sewing machine 1 is engaged again in machine section 1 at the exact
point in the cycle by pressing the button after the cause of the fault has been
rectified
D Sewing machine 1 can also be disengaged manually by pressing the button
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S Lamp flashes fast Sewing machine engages in ma-

chine section 1 at the exact point in
the cycle
S Lamp illuminates Sewing machine is engaged in ma-
chine section 1
S Lamp flashes Sewing machine disengaging
S Lamp off Sewing machine disengaged
Fig. 19

Toggle switch: Lamp Off/On
D The toggle switch is used to turn the lighting at the Sewing machine 1
assembly on/off
S Position I Lighting switched on
S Position 0 Lighting switched off
9.4 Control consoles at the “Sewing II” and “Sewing III” assemblies
9.4.1 P952, P9521, P9522, P953, P9531, P9532 control consoles
Same as control consoles for Sewing I, see 9.3.
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9.5 Control console at the “Sewing thread cutting I” assembly
Fig. 20

White illuminated pushbutton: Manually raise/lower knife
D When the illuminated pushbutton is pressed, the knife is raised or lowered to

allow manual cutting of the sewing thread, adjustment of the immersion depth
and the cutting gap
S Lamp illuminates Knife is in cutting position

S Lamp off Knife is in home position
Information!
The illuminated pushbutton is used for adjustments of the knife and can
only be used when the machine is switched off!
9.6 Control console at the “Sewing thread cutting II” and “Sewing thread
cutting III” assemblies
9.6.1 P9524 and P9534 control consoles
Same as control console for Sewing thread cutting I, see 9.5.
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9.7 Control console at the “Sewing thread tip cutting” assembly
Fig. 21

White illuminated pushbutton: Manually raise/lower knife
D When the illuminated pushbutton is pressed, the knife is raised or lowered to

allow manual cutting of the sewing thread tip, adjustment of the immersion
depth and the cutting gap
S Lamp illuminates Knife is in cutting position
S Lamp off Knife is in home position
Information!
The illuminated pushbutton is used for adjustments of the knife and can
only be used when the machine is switched off!
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9.8 Control console in the column in front of the “Spine pressing” assembly
.001 .026 .029 .002 .261 .262

Emerg.
Stop
Fig. 22

See 9.2.1.

See 9.2.2.
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9.9 Control console at the “Feeder” assemblies
D Switch on the Feeder assemblies -- see 10.2
.040 .194 .484 .485
Fig. 23

White button: Raise stack
D The stacking table of the feeder moves up when the button is pressed
D The stacking table stops automatically in the top end position
D The movement can be interrupted by releasing the button

Toggle switch: Automatic stacking control ON/OFF
S Position I Automatic stacking control on
S Position 0 Automatic stacking control off
Empty field
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White button: Intermediate table up
D Press the button to raise the intermediate table to the upper position, e.g.
after a stack change
D The intermediate table stops automatically in the top end position

White button: Intermediate table down
D Press the button to lower the intermediate table
Empty field
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9.10 Control consoles at the “Gluing and feeding” assembly
9.10.1 P4212, P4222 control consoles
Fig. 24

Toggle switch: Glue pump Off/On
S Position I Glue wheel on gluing device rotates.

Glue supply can be switched on.
S Position 0 Glue wheel not moving. Switch off
glue supply. Catch dripping glue in a
tray.
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9.11 Control console in the pillar in front of the “Transfer to backlining”
assembly
.001 .026 .029 .002 .261 .262

Emerg.
Stop
Fig. 25

See 9.2.1.

See 9.2.2.
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9.12 Control console in the column in front of the “Backlining” assembly
.001 .026 .029 .002 .261 .262

Emerg.
Stop
Fig. 26

See 9.2.1.

See 9.2.2.
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9.13 Control console at the “Backlining” assembly
9.14 P3311 control console
Fig. 27

Toggle switch: OFF/ON (Backlining)
S Position I For operation with backlining.

If a strip is missing, the drive of the
chain conveyor disengages. Once
the corresponding light scanner is
“engaged” by a strip again, it
switches back on at the exact point
in the cycle.
S Position 0 In operation without backlining, the
drive of the chain conveyor does not
disengage if a strip is missing
(empty cycle); the chain conveyor
instead continues to run.

Toggle switch: Backlining tape monitoring OFF/ON
D An acoustic signal is given if the end of the backlining tape is about to be

reached.
S Position I Acoustic signal switched on
S Position 0 Acoustic signal switched off
After a new backlining tape roll has been mounted, it is essential that the toggle
switch is returned to the Backlining tape monitoring ON position.
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Signal lamp red: Backlining tape roll empty
S Lamp flashes slowly Light scanner at unwind unit “freed”.

Backlining tape nearly finished and
protective device closed. At the
same time, an acoustic signal
sounds at every backlining cycle and
a warning number is shown on the
main digital display.
S Lamp flashes rapidly Light scanner at unwind unit “freed”.
Backlining tape nearly finished but
protective device open. At the same
time, an acoustic signal sounds at
every backlining cycle and a warning
number is shown on the main digital
display.
A full backlining tape roll was
mounted in the unwind unit, but the
Backlining tape monitoring ON/
OFF toggle switch was not returned
to the Backlining tape monitoring
ON position.
S Lamp off Lamp goes out when a new backlin-
ing tape roll has been mounted and
prepared.
Empty field
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Fig. 28

Key switch: home position
D If the key switch is set to ON, the cutting unit on the servomotor releases the
brake and the upper knife holder can, for example, be turned for adjusting the
cutting gap -- see also Operating instructions of the Backlining assembly
D If the key switch home position was set to ON, the upper knife holder rotated,
or the main switch or backlining switched off, the cutting unit has to be
re--referenced -- see 11.4.2
S Position ON (right position) Upper knife holder can be turned on

the toothed belt pulley by hand --
see also Operating instructions of
the Backlining assembly.
S Position OFF (left position) After referencing -- see 11.4.2 -- au-
tomatic operation is possible.
Important!
Damage to the knives!
If the key switch home position was set to ON, the upper knife holder rotated
re--referenced.
During referencing, no strips are permitted to be under the cutting unit!
Remove any strips that are still on the chain conveyor!
If, however, you are so meticulous that before referencing you have turned
the upper knife holder in the direction of rotation until the upper knife is
about 50 mm in front of the proximity switch, the strips can remain in the
chain conveyor!
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Information!
A key switch was selected so that the brake can be released on the
servomotor only deliberately!
Only qualified personnel are allowed to have access to the key.
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9.14.2 L341 distribution box with operating elements
Fig. 29
Temperature regulator:
The temperature for the gluing device is set separately at the temperature
regulator.
Generally speaking, the temperature should rise by about 5 °C to 10 °C from
setting to setting, whereby attention must be paid to the manufacturer’s details
concerning the processing temperature for the hot melt.
Example:
Tank in hot melt unit = 170 °C
Material hose = 175 °C
Gluing device = 185 °C
Experience has shown that a temperature setting at the gluing device of between
175 °C and 195 °C is advantageous. This depends, however, on the hot melt used
and the ambient temperature as well.
The glue manufacturer’s specifications are binding.
Information!
Hot melt loses its adhesive strength if heated for a long time without
cooling!
For further information see Operating instructions for the Gluing device or
Auxiliary hot melt gluing assembly.
DANGER OF HOT
SURFACES
Temperatures over +150 °C!

Danger of severe burns from touching the gluing device or hot melt unit and
material hose!
Allow the parts to cool down and wear leather safety gloves when working
on them!
Please refer to the Operating instructions for the hot melt unit in the
documentation for purchased parts for how to set the temperatures of the hot
melt unit.
For operation, setting, etc. see the Operating instructions of the temperature
regulator in the documentation for purchased parts!
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Toggle switch: Glue supply Off/On
S Position 0 Glue supply switched off.

Catch dripping glue in a tray.
S Position I Glue supply switched on.
The Glue pump Off/On toggle
switch must be in the I position.

Toggle switch: Glue pump Off/On
S Position I Glue wheel on gluing device rotates.

Glue supply can be switched on.
S Position 0 Glue wheel not moving. Switch off
glue supply. Catch dripping glue in a
tray.
Information!
The Glue pump Off/On electric operating element only switches the rotation
of the glue wheel off and on.
The actual glue supply is interrupted or established via a pneumatic
operating element -- see Operating instructions of the Gluing device
assembly.
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9.15 Control console in the column in front of the “Cutting” assembly
.001 .026 .029 .002 .261 .262

Emerg.
Stop
Fig. 30

See 9.2.1.

See 9.2.2.
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9.16 Dust extractor operating elements
D For operating elements and safety information, refer to the Operating

instructions provided by the manufacturer of the dust extractor in the
documentation for purchased parts.
9.17 Temperature regulator operating elements

instructions provided by the manufacturer of the temperature regulator in
the documentation for purchased parts.
9.18 Timer switch operating elements

instructions provided by the manufacturer of the timer switch in the
9.19 Hot melt device operating elements

instructions provided by the manufacturer of the hot melt device in the
9.20 Control elements for compact unit (for central lubrication)
D All important lubrication points on the machine are supplied with lubricant
from the central lubricating unit
D Lubrication takes place according to specific cycles which are entered into
the control panel
D The lubrication cycle set by the manufacturer does not usually have to be
altered
D Lubrication cycle: see circuit diagram
D After exchanging the compact unit the lubrication cycle must be re--adjusted
D Adjusting lubrication cycle: see Oil lubrication submask
D The first lubrication is performed automatically when the main switch/control
voltage is switched on
D See Operating instructions for the Compact unit in the documentation for
purchased parts for topping up, operating elements and safety information
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10.0 MENU STRUCTURE ON THE CONTROL PANEL IN THE P21

MAIN CONTROL CONSOLE (MACHINE SECTION 2)
The software on the control panel in the P21 main control console starts up when
the main switch and the control voltage are switched on. A start screen appears
while the system boots up.
From this it is possible to branch to a setup mask (only for service personnel).
If the setup mask is not called up, the machine main mask appears on the screen
after a while.
10.1 ”Machine” main mask on the control panel in the P21 main control
console
Fig. 31
The screen is designed as a touch screen with touch--sensitive fields in order to

allow entries to be made directly on the screen.
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Branch to the following masks by touching the touch buttons in the Machine main
mask:
D Parameters 1 (data input)
D Auxiliary aggregates
D Production counter
D Backlining
D Collecting
D Cam control
10.1.1 Structure of the screen masks
The mask name is located in the top line

Fields with touch buttons are located on the right--hand side. These touch
buttons can appear on all main masks. They have the following functions:
“Home” symbol:
Straight back to the Machine main mask.
“Help (?)” symbol:
Displays a help text for the selected mask.
“Next submask” symbols:
The next submask is selected here.
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“Previous main mask/submask” symbols:
The previous main mask or submask is selected here.
“Fault” symbol:
The faults/warnings are shown here.

The field flashes red if there is a fault/warning.
More information can be obtained by touching the Help touch button -- see 10.9.
The lowest right field shows the date and time.
“Date and time” symbol:
Fields with touch buttons are located in the bottom line. These touch buttons ap-
pear on all main masks.
The touch buttons branch into other screen masks and are marked with symbols:
“Parameters 1” (data input) symbol:
See 10.2.
“Auxiliary aggregates” symbol:
See 10.3.
“Production counter” symbol:
See 10.4.
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“Backlining” symbol:
See 10.5.
“Collecting” symbol:
See 10.6.
“Cam control” symbol:
See 10.10.
“Fault” symbol:
Any faults (machine stop, warning, etc.) with date, time, fault number and
designation are shown (line illuminates red) above the line with the symbols.
Touch the red line to change to the Fault and warning display main mask -- see
10.9.
More information can be obtained by touching the Help touch button.
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The machine running speed in m/min and c/min is shown in the main field
Touching the main field toggles the display from m/min to c/min.
The other fields in the middle display machine--related data.
The background color corresponds to the following functions:
D Green -- display fields for values
D Blue -- input fields for data
The input values for the production can be entered in the entry screen masks
using a numeric keypad -- see 10.1.5.
10.1.2 Input values
The available input values in the main masks or submasks are shown in the
corresponding help mask, if not listed here.
10.1.3 Help mask (or help masks)
If a main mask or submask is open, an associated help mask can be opened by

touching the ? touch button. A help mask is not stored in every case.
In this help mask a so--called help text is displayed. The help text can describe
work steps or information or tips regarding a function or fault can also be read off.
Touch the Home touch button to change to the previous main mask or submask.
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10.1.4 Machine--related data
Fig. 32
D The machine running speed is shown in c/min in the large field.
“Machine section 2 cam control” symbol:
D The current position of the axes in machine section 2 are shown in degrees
here
“Feed sheet length” symbol:
D The feed sheet length (in laminating) that was entered in the Parameters 1
(data input) main mask is shown here
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“Sewing 1 cam control” symbol:
D The current position of the axes at the Sewing right 1 assembly is shown in
degrees here
degrees here
degrees here
“Collecting” symbol:
D The number of exercise books just collected is indicated in the Collecting

field
“Auto. acceleration”/“auto. deceleration”

symbol:
D The speed to which machine section 2 is to accelerate when the auto.

acceleration button is pressed is entered in the auto. acceleration .... c/min
field.
Touch the blue field ⇒ a numeric keypad is displayed. Enter the numbers of
the new value with this keypad and confirm with √.
The new, altered nominal value is now valid
D The speed to which machine section 2 is to decelerate when the auto.

deceleration button is pressed is entered in the auto. deceleration .... c/min
field.
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Procedure:
D Touch the blue field ⇒ a numeric keypad is displayed
D After this, enter the number sequence for the new value on the keypad and
confirm with √.
D The new, altered nominal value is now valid
Information!
It always limits the assembly which reaches its maximum cycle rate, cutting
rate or meter rate (depending on which) first!
D Touch the Home touch button to change to the Machine main mask
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10.1.5 Value input window
Fig. 33
Use this window to change the current nominal values for the running order.
To do so, touch the appropriate point ⇒ a numeric keypad is shown on the display.
Now enter the figure for the new value using the keyboard and then confirm with √.
Information!
The value is not accepted if this value is exceeded.
The new, altered nominal value is now valid.
Any number of values can be changed as often as required in this mask. They
become valid upon completion by confirming with √.
The numeric keypad can be closed by touching the field with the door.
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10.2 “Parameters 1” (data input) main mask
Fig. 34
“Feed sheet length” symbol:
D The feed sheet length (in laminating) is entered in the blue .... mm field.
D The current length of the feed sheet is shown in mm in the green .... mm field
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“Pressing 1” symbol:
D Touch the Pressing 1 touch button to switch the first pressure plate of the first
laminating unit of the Laminating assembly on and off
S ON: green = 1 First pressure plate of the first lami-

nating unit switched on
S OFF: red = 0 First pressure plate of the first lami-
nating unit switched off
D Touch the Pressing 2 touch button to switch the second pressure plate of the
first laminating unit of the Laminating assembly on and off
S ON: green = 1 Second pressure plate of the first

laminating unit switched on
S OFF: red = 0 Second pressure plate of the first
laminating unit switched off
“Block gluing device 1 swinging away” symbol:
D To ensure that the gluing device is not constantly swung down pneumatically
during adjusting work in inching mode (e.g. when setting the gap between the
glue wheel and the counter cylinder), the pneumatic control can be locked
D The pneumatic control can be locked in inching mode by touching this button
D Inching mode must be preselected
D On switching to automatic mode, the button automatically switches to OFF
S ON: green = 1 Pneumatic control is locked, gluing

unit only swings away following the
cam disk, but is not pneumatically
controlled
S OFF: red = 0 When the machine is stopped, when
there is a fault, or empty cycle, the
gluing device is pneumatically
swung away downwards
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“Laminating and feeder 1” symbol:
D Touch the touch button to switch the pressure plate of the Feeder 1 assembly
on and off.
S ON: green = 1 The Feeder 1 and Laminating 1 as-

sembly and the corresponding pres-
sure/vacuum pump are switched on.
Feeder 1 feeds in sheets on being

triggered by the light scanner
S OFF: red = 0 Feeder 1 and Laminating 1 assem-
bly switched off
“Offset feed sheet feeder 1: .... mm” symbol:
D The offset amount, i.e. how far out the feed sheet is to be transported, is
entered in mm (e.g. -- 10 mm or (+)10 mm) in the blue field.
D The feed sheet is transported out to a greater or lesser extent and deposited
on the strip/layer by entering a + or -- offset
D Input 0: Feed sheet is deposited approximately centrally on the strip/layer
--
+
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Fig. 36
D Touch the Pressing 1 touch button to switch the first pressure plate of the
second laminating unit of the Laminating assembly on and off
S ON: green = 1 First pressure plate of the second

S OFF: red = 0 First pressure plate of the second
D Touch the Pressing 2 touch button to switch the second pressure plate of the
second laminating unit of the Laminating assembly on and off
S ON: green = 1 Second pressure plate of the second

S OFF: red = 0 Second pressure plate of the second
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“Block gluing device 2 swinging away” symbol:
D To ensure that the gluing device is not constantly swung down pneumatically
during adjusting work in inching mode (e.g. when setting the gap between the
glue wheel and the counter cylinder), the pneumatic control can be locked
D The pneumatic control can be locked in inching mode by touching this button
D Inching mode must be preselected
D On switching to automatic mode, the button automatically switches to OFF
S ON: green = 1 Pneumatic control is locked, gluing

unit only swings away following the
cam disk, but is not pneumatically
controlled
S OFF: red = 0 When the machine is stopped, when
there is a fault, or empty cycle, the
gluing device is pneumatically
swung away downwards
“Laminating and feeder 2” symbol:
D Touch the touch button to switch the pressure plate of the Feeder 1 assembly
on and off.
S ON: green = 1 The Feeder 1 and Laminating 1 as-

sembly and the corresponding pres-
sure/vacuum pump are switched on.
Feeder 1 feeds in sheets on being
triggered by the light scanner
S OFF: red = 0 Feeder 1 and Laminating 1 assem-
bly switched off
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“Offset feed sheet feeder 2: .... mm” symbol:
D The offset amount, i.e. how far out the feed sheet is to be transported, is
entered in mm (e.g. -- 10 mm or (+)10 mm) in the blue field.
D The feed sheet is transported out to a greater or lesser extent and deposited
on the strip/layer by entering a + or -- offset
D Input 0: Feed sheet is deposited centrally on the strip/layer
--
D From the Parameters 1 main mask, touch the touch button to access the
Parameters 4 submask
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10.2.1 “Parameters 4 (backlining glue wheel motor)” submask
Fig. 38
“Glue wheel motor” symbol:
D The parameters for the glue wheel motor at the Gluing device (backlining)
assembly are entered below the Glue wheel motor touch button
D The basic speed (initial value) of the glue wheel motor relative to the machine
running speed can be entered in the blue field.
D Input value: 10 -- 100 %
D The green field shows the current speed of the glue wheel motor relative to
the machine running speed as a %
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D In the right blue field by entering a -- or + amount in % you can change the
speed of the glue wheel motor (rotational speed of the glue wheel) relative to
the internally calculated machine running speed.
S -- amount entry, e.g. --10 % Speed of the glue wheel motor (rota-
tional speed of the glue wheel) is
10 % slower than the machine run-
ning speed
S + amount entry, e.g. +10 % Speed of the glue wheel motor (rota-
tional speed of the glue wheel) is
10 % faster than the machine run-
ning speed
Information!
In this case, the machine running speed is the speed at which the backlining
tape passes the glue wheel!
D From the Parameters 4 submask, touch the touch button to access the
Parameters 1 main mask
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10.3 “Auxiliary aggregates” main mask
Fig. 39
“Sewing thread tip cutting 63.N1--M11” symbol:
D Touch the touch button to switch the Sewing thread tip cutting assembly
and the associated sewing thread tip extractor on and off
S ON: green = 1 Sewing thread tip cutting assem-

bly and the associated extractor
switched on
S OFF: red = 0 Sewing thread tip cutting assem-
bly and the associated extractor
switched off
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“Waste extraction 37.N1--M11” symbol:
D By touching the touch button the fan for trim extraction at the Cutting
assembly is switched on and off
S ON: green = 1 Fan switched on, the trimmings pro-

duced at the Cutting assembly are
extracted by the fan.
S OFF: red = 0 Fan switched off.
DANGER!
The fan runs on for a while after being switched off!
“Waste extraction 38.N1--M11” symbol:
D Touch the touch button to switch the fan for cutting waste extraction at the
Corner rounding assembly on and off
S ON: green = 1 Fan switched on, the cutting waste

produced at the Corner rounding
assembly is extracted by the fan.
S OFF: red = 0 Fan switched off.
DANGER!
The fan runs on for a while after being switched off!
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“Sewing manual” symbol:
D Touch the touch button to select whether the layers are also to be sewn in
solo mode (SOLO mode section 2 selected)
S ON: green = 1 The layers are sewn if machine

section 1 and solo mode are in op-
eration.
Remove sewn layers by hand
S OFF: red = 0 The layers are not sewn but instead
discharged if machine section 1
and solo mode are in operation.
D In the main mask, touch the touch button to access the Oil lubrication
submask
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10.3.1 “Oil lubrication” submask
Fig. 40
D The lubrication cycle of the central lubrication system (compact unit) can be
set in the Lubrication every .... cycles field.
D The first lubrication is performed automatically when the main switch/control

voltage is switched on
Information!
This setting does not generally have to be changed!
Lubrication cycle: see circuit diagram.
D The green field shows how many cycles have elapsed since lubrication was
last performed
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10.4 “Production counter” main mask
Fig. 41
D The Total production .... pcs. field displays the current machine output in
pieces
D The Good production ..... pcs. field displays the current good production in
pieces
D Touch the Clear touch button (in the Total production field) twice to reset the
Total production and Good production counters.
D Then confirm with √ and the counter value is reset
D From the Production counter main mask, touch the touch button to get to
the Operating hours counter submask.
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10.4.1 “Operating hours counter” submask
Fig. 42
D The Operation time: ... hours field shows how long the machine has been
running in total (= total operating hours counter)
D The Operation time since last start: ... hours field shows how long the
machine has been running since the last start
D The Stopping time: ... hours field shows how long the machine has not been
running since the last stop
D You can access the Production counter main mask from the Operating
hours counter submask by touching the touch button
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10.5 “Backlining” main mask
Fig. 43
“Backlining: OFF/ON” symbol:
D Here you can touch the touch button to switch the Backlining assembly on
and off
S ON: green = 1 Backlining assembly and associ-

ated pressure/vacuum pump
switched on.
S OFF: red = 0 Backlining assembly switched off.
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“Gap offset” symbol:
D The offset amount is entered in mm (e.g. -- 10 mm or (+)10 mm) in the blue

field.
D When you enter a -- or + offset amount, the backlining tape is cut off nearer to
the strip rear edge or nearer to the strip front edge
D Input 0: Backlining tape is cut off about in the middle between the strips
PRD
PRD
--
PRD
+
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Important!
Malfunction!
The position of light scanner L6 -- see Operating instructions of the
Backlining assembly -- must not be changed!
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10.6 “Collecting” main mask
Fig. 45
“Collecting station” symbol:
D In the Collecting station ... pcs. field the number of exercise books per stack
is entered.
D The number of exercise books just collected is indicated in the green field.
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“Preselect collecting station belt speed” symbol:
D The belt speed can be entered in the Preselect collecting station 2 belt
speed field.
D Input value: 70 % -- 100 %
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10.7 “Password” main mask
Fig. 46
Information!
Not relevant for the machine operator.
Only for service work by trained personnel.
Certain masks or submasks can be opened by entering the corresponding

password.
These masks may be opened only by specially trained personnel for servicing
work, maintenance, setting and adjustment, etc.
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10.8 Fault and warning display for P21
When a fault arises, the corresponding Fault and warning display automatically
appears.
D This mask shows the location of the fault in a graphic display of the
corresponding machine group
D Any faults (machine stop, warning, etc.), along with the date, time, fault
number and designation are shown in a line (flashes red) below the
graphical display
Important!
Touch one of the touch buttons in the bottom line to switch to the respective
main mask
⇒ the graphic display disappears (only the fault line flashes red until the fault has
been rectified and reset).
Information!
After rectifying faults, press the white Machine ON (001) illuminated pushbutton
to reset
D This illuminated pushbutton must be pressed two or three times to switch the
machine on
D Delete fault (if this is not possible, there may be another fault, a protective
device may not be closed or an overload protector is not properly connected)
D Start--up warning (acoustic signal sounds for about 3 seconds). After about
3 seconds, the white illuminated pushbutton illuminates for approx. 4
seconds. This is the enable time for starting the machine
Press a third time within the enable period:
D The machine starts up at basic speed and the Machine ON (001) illuminated
pushbutton lights up
D If this was preceded by a normal machine stop, the Machine ON (001)

illuminated pushbutton only has to be pressed twice
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Information!
If protective devices/safety doors are open, the malfunction mask appears
with the graphic representation of the corresponding assembly and a door
symbol and/or protective device symbol.
Examples:
“Safety door open” symbol:
“Protective device open” symbol:
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10.9 “Fault and warning display” main mask
Fig. 47
This is where fault numbers, warning numbers and the explanatory text are
displayed.
More information can be obtained by pressing the Help touch button.
“Cursor up”, “Cursor down” symbols:
D Touch the touch buttons to scroll by line through the screen pages with the
individual faults.
“Page up”, “Page down” symbols:
D Touch the touch buttons to scroll by page through the screen pages with the
individual faults.
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D Touch the Clear touch button to clear the faults previously selected. Faults
are selected by touching the screen
D Touch the Enter touch button to display the complete fault text for the
individually selected fault
The touch buttons branch into other screen masks and are marked with symbols:
“Serial message system parameters” symbol:
See 10.9.1.
“Terminal parameters” symbol:
See 10.9.2.
“Drives diagnosis” symbol:
See 10.9.3.
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10.9.1 “Parameter serial message system” submask
Fig. 48
In the Serial message system parameters submask, touch the appropriate

fields to enter criteria for how the faults/warnings are to appear in the display (e.g.
with or without time details). This has an effect on how the faults/warnings are
shown in the Fault and warning display main mask.
D Sort criterion: Faults/warnings are shown ordered according to time (new),

time (old) or priority
D Message number: faults/warnings are shown with or without message

number
D Message date: faults/warnings are shown with or without message date
D Message time: faults/warnings are shown with or without message time

Whatever the chosen form of display, the date and time are always recorded
when a fault/warning occurs.
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10.9.2 “Terminal parameters” submask
Fig. 49
Information!
D The Date: .... field displays the date and the date can be set here
⇒ a numeric keypad is displayed. Enter the numbers of the new value with
this keypad and confirm with √.
D The Time: .... field displays the time and the time can be set here
⇒ a numeric keypad is displayed. Enter the numbers of the new value with
this keypad and confirm with √.
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D The field with the flag (top right field) beside the Enter touch button shows
the language. The required language (German in this example) can be
selected by touching the language field.
D Confirm the language selection by pressing the Enter touch button
Information!
The other lines are not relevant for the machine operator.
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10.9.3 “Drive diagnosis” submask with the respective submasks
Fig. 50
Information!
D You can get to the other submasks by touching the corresponding touch
button with the drive symbol.
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10.9.3.1 “Diagnosis ...” submask, e.g. “Diagnosis 2.J1--M1”
Fig. 51
Information!
D From the Diagnosis 2.J1--M1 submask, touch the touch button to access
the further submasks
D From the Diagnosis ... submasks, touch the Fault touch button to access the
Fault and warning display main mask
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10.10 “Cam control” main mask with other associated submasks
Fig. 52
The Cam control masks show the current position of the electronic switch cams
for the corresponding machine functions.
Information!
Only for service work.
Important!
Changes may only be carried out by authorized personnel!
D You can get to the other submasks by touching the corresponding touch
button with the cam control symbol.
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D From the relevant submask, touch the corresponding touch button to access
the Password main mask -- see 10.7
D After the relevant password has been entered, the no. of degrees for
cams ON and cams OFF can be changed.
D To set, bring the machine into the zero position.
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11.0 OPERATING THE MACHINE
Information!
Training on the machine is essential. The following description is intended
merely as a reminder.
! WARNING
Acute danger of death by electrocution from live connections!

Electrical installation work may only be carried out by a qualified
electrician!
The main switch is located on the side of the H2 switch cabinet.
The complete control, all motors, blowers, fans, pumps, auxiliary units,
attachments, in brief the complete machine and the switch cabinets, but not the
feeder cable to the switch cabinet, are switched off using the main switch.
DANGER!
Read the Operating instructions before starting up the machine!
Before turning the main switch on, ensure that the machine is in a safe
operating condition and that no one will be endangered by switching the
machine on.
Before carrying out maintenance/repair work, turn the main switch off and
secure against operation by others!
The main switch can be secured against unauthorized operation by third
parties by locking it in the 0 position (OFF)!
To shut off all motors, turn the main switch OFF and secure against
unauthorized operation by others!
Blowers, fans, pumps, etc. run on for a while after switching off and can
start up on their own when the machine is switched on again!
Never remove connected pipes, hoses, sacks, connectors, etc. when the
blowers, fans, pumps, etc. are running. Increased danger of hair, etc. being
pulled into the machine!
The main switch is switched off for longer shutdowns, e.g. end of shift,
weekend, holidays, etc.
The control voltage is automatically switched off as well when the main
switch is switched off. Nevertheless, the control voltage should be
switched off first.
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11.1 Getting the machine ready for operation and switching it on
The following requirements must be met:
D The machine must be in an operable condition
D Everyone must be outside the danger area
D All protective devices must be in place and closed
D Check the compressed air connection -- the pressure must be > 6 bar
Procedure:
D Turn the main switch on the H1 and H2 switch cabinet on
D Turn on the control voltage(s)
Information!
If the control voltage is switched on at the switch cabinet for machine
section 1, the control voltage for machine section 2 is automatically
switched on as well.
The control voltage for machine section 2 can be switched on and off when
the control voltage for machine section 1 is switched off.
The same applies for switching off.
D If necessary, switch on auxiliary aggregates (e.g. fans, blowers, pumps) and

replenish consumables (e.g. ink, glue)
D Acknowledge fault number(s) by pressing the Machine ON (001) illuminated

pushbutton
D Switch on the machine by pressing the Machine ON (001) illuminated

pushbutton
D Accelerate the machine a little by pressing the Machine faster (026) buttons
and check the operating procedures of the assemblies
D Correct settings with machine at standstill
DANGER!
The machine runs on for a short period (depending on the machine running
speed) if a protective device is opened while the machine is running.
Never reach into the machine during this period!
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11.2 Entering and changing data, values, and operating modes in the masks
D First empty the corresponding machine section or the machine and remove
product
Enter and change data/values in the masks:
D Touch the Home touch button on the respective control panel and then select
the mask for the corresponding data input
D Select the relevant field by touching it
D A numeric keypad appears
D Then enter the required value
D Finish with √ (ENTER)
Change operating modes in masks:
D Touch the Home touch button and select the appropriate mask
D Switch the blowers/fan/assembly, etc. on/off by pressing the appropriate

touch button
D Touch the Home touch button = back to the Machine main mask
Important!
The machine must be switched off before data are entered/transferred.
Inching mode must not have been preselected!
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11.2.1 Example: Changing the automatic acceleration on the control panel in
the P21 main control console
D Touch the Home touch button to select the Machine main mask
D Touch to select the Auto. acceleration: .... m/min field
D Then enter the required maximum speed (the machine accelerates

automatically to the preset value when the Automatic acceleration button is
pressed)
D Finish with √
If required:
D Touch to select the Auto. deceleration: .... m/min field
D Then enter the required minimum speed (the machine decelerates

automatically to the preset value when the Automatic deceleration button is
pressed)
D Finish with √
D Touch the Home touch button to return to the Machine main mask
Important!
The machine must be stopped for entering/transferring data. It must not be
in inching mode.
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11.3 Machine section 1 coupled with machine section 2
D Turn machine off, if necessary
D If necessary, turn the Automatic mode preselection key switch to automatic

mode
D Press SOLO mode section 2 (F10) function key and preselect desired drive
-- see also 9.2.4
D On machine section 2 press a machine ON illuminated pushbutton (001)

twice and switch on machine ⇒ machine section 2 starts up and stops
automatically when in position
D On machine section 1, press a machine ON (001) illuminated pushbutton

twice ⇒ machine section 1 starts up
D If the drives of machine section 1 and machine section 2 are synchronous

to each other, machine section 2 starts up automatically; machine sections
are coupled
WARNING!
The machine sections can start up on their own without any start--up
warning!
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11.4 Cutting unit at the “Backlining” assembly
11.4.1 Release the brake on the servomotor on the cutting unit
After the brake is released, the upper knife holder can be turned manually for
adjusting the cutting gap on the toothed belt pulley -- see also Operating
instructions of the Backlining assembly.
.270
Fig. 53
D Set key switch home position to ON (= turn to right)
Information!
After the key switch has been turned to OFF again, the cutting unit must be
re--referenced!
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11.4.2 Referencing cutting unit
When referencing is necessary:
D Key switch home position was set to ON
D Upper knife holder was turned
D Backlining was switched off
D Main switch was switched off
approx. 50 mm 101 108
N8
PRD
Fig. 54
. Fig. 54
Important!
If the key switch home position was set to ON, the upper knife holder rotated
re--referenced.
During referencing, no strips are permitted to be under the cutting unit!
Remove any strips that are still on the chain conveyor!
If, however, you are so meticulous that before referencing the upper knife
holder 108 you have turned in the direction of rotation so far that the upper
knife 101 is about 50 mm in front of the proximity switch N8, the strips can
remain in the chain conveyor!
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. Fig. 54
D Switch the main switch/control voltage on
D Switching backlining on
D Remove strips from the chain conveyor or turn upper knife holder 108 by
hand in direction of rotation until the upper knife 101 is about 50 mm in front of
the proximity switch N8
D Close the protective device on the cutting unit -- see Operating instructions
for the Backlining assembly
.270
Fig. 55
D Set key switch home position (.270) to OFF ⇒ the upper knife holder 108
begins to turn until the upper knife 101 “engages” proximity switch N8
D Press the Machine ON illuminated pushbutton to acknowledge fault number
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11.4.3 Entering the offset
Important!
Malfunction!
The position of light scanner L6 -- see Operating instructions of the
Backlining assembly -- must not be changed!
When you enter a -- or + offset amount in mm, the backlining tape is cut off nearer
to the strip rear edge or nearer to the strip front edge
D Enter offset amount -- see main mask 10.5
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11.5 Synchronizing the drive of the suction belts in the laminating unit
D If there is a fault, remove strips and in particular glued feed sheets from the
machine, then rectify the cause of the fault
D In machine section 2, press any Machine ON (001) illuminated pushbutton

twice (or three times after a fault) and switch the machine on ⇒ drive of the
suction belts in Laminating starts up and stops automatically when in
position (at the reference point) ⇒ LED in function key F13 goes out
D Press the Machine ON button again ⇒ the machine starts up at basic speed
WARNING!
The machine sections can start up on their own without any start--up
warning!
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11.6 End/Start of shift

11.6.1 End of shift
D Switching the machine off

D Switch off the control voltage
Information!
For shorter shutdowns, e.g. overnight, leave the H2 main switch on because
of the timer switch for the gluing device!
In cases of longer standstills:

D Turn the main switch on the H1 and H2 switch cabinet off
11.6.2 Start of shift
D Turn on the main switch

D Turn on the control voltage
D Switch on web tension if not already switched on
D Move the ruling/squeeze cylinders in, if this is not done automatically
D Check ink level in the ink container, etc.
D Stack the feed sheets
D Check sewing thread
D Check the glue level in containers, etc.
D Check backlining tape rolls
D Switch on backlining as required
Important!
If the main switch or the backlining was switched off, the cutting unit must
be re--referenced!
D Referencing cutting unit
D Press the Machine ON (001) illuminated pushbutton twice (press three times
if a fault has to be deleted)
D The machine can be run at a higher speed when all machine sections have
been synchronized
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12.0 LIST OF FAULT/WARNING MESSAGES
Information!
“800” numbers are warning numbers!
Touch the touch button or the touch button on the control panel in the Faults
and warning display main mask -- see 10.9 -- to scroll line by line (fields 1 and 2)
or page by page (fields 3 and 4) through the screen pages with the individual
faults.
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1.0 MEANING OF TERMS

>: greater (than).

2.0 OVERVIEW OF ASSEMBLIES

Machine section 1 is also known as the preceding machine and machine

2.1 Machine section 1 (preceding machine)

Fig. 1 (seen from above)

Pos. Assembly Pos. Assembly

2.2 Machine section 2 (binding machine)

Fig. 2 (seen from above)

Pos. Assembly Pos. Assembly

3.0 SWITCH CABINET AND CONTROL CONSOLE OVERVIEW

Fig. 3 (seen from above)

Pos. Designation and Pos. Designation and

4.0 SAFETY CIRCUITS AND PROTECTIVE DEVICES IN THE

Fig. 4 (seen from above)

Pos. Designation and Pos. Designation and

4.2 Protective devices

5.0 RATING PLATES

6.0 SWITCH CABINETS

6.1 H2 switch cabinet for machine section 2 (binding section)

Pos. Designation Pos. Designation

The H2 switch cabinet consists of five fields.

6.1.1 Main switch

The main switch is located at the side on the switch cabinet.

Acute danger of death by electrocution from live connections!

6.1.2 Ventilation door

6.1.3 Ventilation door operator panel

6.2 P3718 control console in H2 switch cabinet

Pos. Designation Pos. Designation

The H34 switch cabinet consists of one field.

6.3.1 Main switch

The main switch is located at the side on the switch cabinet.

6.3.2 Timer switch

The timer switch is located on the side of the switch cabinet.

7.0 DISPLAY ELEMENTS

7.1.1 P211 main digital display

A signal column (red/orange/green) is installed on every main digital display.

7.1.3 Warning lamps

A red lamp is installed at every sewing machine.

8.0 SYMBOLS OVERVIEW

Symbol Designation Symbol Designation

Operating mode selection,

Inching mode, inch forward

078 61 026 Machine faster, accelerate Run unit into position

078 61 029 Machine slower, brake

Symbol Designation Symbol Designation

Clutch engaged / disengaged Lamp OFF/ON

Sewing manual Knife bed up/down

Symbol Designation Symbol Designation

OFF/ON Intermediate table down

Intermediate table up Raise stack

Symbol Designation Symbol Designation

Glue pump OFF/ON Lock

OFF/ON Home position

Backlining tape fault Clear fault

Backlining tape monitoring (bell

9.0 ELECTRIC OPERATING ELEMENTS