MultiStrip 9480

Automatic Cut & Strip Machine

Reference Manual
Edition 2.0 (07-2015)

| |MultiStrip 9480
1 | 192
Address / distributors

Schleuniger AG Schleuniger, Inc.

Bierigutstrasse 9 87 Colin Drive
3608 Thun Manchester, NH 03103
Switzerland USA
P +41 (0)33 334 03 33 P +1 (603) 668 81 17
F +41 (0)33 334 03 34 F +1 (603) 668 81 19
info@schleuniger.ch sales@schleuniger.com
www.schleuniger.com www.schleuniger-na.com

Schleuniger AG Schleuniger Japan Co., Ltd.

Business Unit Solutions 4-5-8, Tokai, Ota-ku
Gewerbestrasse 14 Tokyo 143-0001
6314 Unteraegeri Japan
Switzerland P +81 (0)3 57 55 80 41
P +41 (0)41 754 53 53 F +81 (0)3 57 55 80 45
F +41 (0)41 754 53 50 sales@schleuniger.co.jp
solutions@schleuniger.ch www.schleuniger.co.jp
www.schleuniger.ch

Schleuniger GmbH Schleuniger Trading (Shanghai) Co., Ltd.

Raiffeisenstrasse 14 108, BH Center
42477 Radevormwald 7755 Zhongchun Rd
Germany Shanghai, 201101
P +49 (0)21 959 29-0 China
F +49 (0)21 959 29-105 P +86 (21) 62 52 66 77
info@schleuniger.de F +86 (21) 62 40 86 55
www.schleuniger.com sales@schleuniger.com.cn
www.schleuniger.cn

© 2015 Schleuniger
EN | ID-0000000184-004
Part #:
Order #:

2 | 192 Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480

Topic list

TOPIC LIST
ADDRESSES ▸ www.schleuniger.com
Web site for our products, manufacturer address and distributors, email ▸ info@schleuniger.ch
addresses. ▸ Page 2

GENERAL ▸ Page 9
General information and hints to this documentation general symbols and
notations.

SAFETY ▸ Page 15
General information about this manual, warranty statements and policies,
sources of danger, safety marking (symbols), safety equipment.

PRODUCT OVERVIEW ▸ Page 33

An overview of the models and options. Machine overview and description on ▸ Page 37
the processing- and function modules.

INSTALLATION / FIRST COMMISSIONING ▸ Page 71

Step by step instruction for the installation and commissioning of the product.
Production of a test wire. Safety instructions during the installation.

PROGRAMMING EXAMPLES ▸ Page 88

Simple programming- and application examples for the beginner.

MAINTENANCE ▸ Page 93
The maintenance work on the product includes: Cleaning, maintenance, set- ▸ Page 94
tings, calibration and repair.

MODIFICATION ▸ Page 141

Describes the retrofit work for the product and its options.

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Topic list

4 | 192 Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480

Table of contents

TABLE OF CONTENTS
1 GENERAL 9
1.1 MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 PRODUCT TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 INFORMATION ABOUT THE OPERATOR'S HANDBOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.2 Safekeeping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 LEGEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7 LIMITATION OF LIABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.8 WARRANTY STATEMENTS AND POLICIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.9 COPYRIGHT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.9.1 Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.10 SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 SAFETY 15
2.1 TARGET AUDIENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 WARNING NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 CAUTION PROPERTY DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 GENERAL SAFETY NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 RESIDUAL RISKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6 SAFETY SYMBOLS IN MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 SAFETY SYMBOLS ON PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8 SAFETY INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.9 RETROFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.10 PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3 TRANSPORTATION 21
3.1 PACKAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 PACKAGING SIGNS (STICKERS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3 TRANSPORT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4 PRODUCT SPECIFICATIONS 23
4.1 APPLICATION PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.1 Intended usage of product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.2 Reasonably foreseeable misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 DIMENSIONS AND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3 PLANNING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3.1 Installation location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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4.3.2 Layout model S, M, RX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.3.3 Layout model MR, RS, RSX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4 RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.6 POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.7 INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.8 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5 MODELS 33
5.1 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.3 APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6 PRODUCT DESCRIPTION 37
6.1 OVERVIEW COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.1.1 Model S and M. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.2 MR model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.3 RS model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.1.4 Model RSX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.1.5 Model RX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.2 MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3 DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3.1 Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4 REAR OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.5 CONNECTIONS / INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.5.1 SIS (Schleuniger interface slot). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.6 SAFETY ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.6.1 Safety appliances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.7 DANGER ZONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.7.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.7.2 Danger labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.8 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.9 SCOPE OF DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.10 OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

7 COMMISSIONING 71
7.1 INTERNAL TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.2 UNPACKING / POSITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.3 CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.4 SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.4.1 Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.4.2 Mounting the blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.4.3 Turning machine on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.4.4 Basic settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.4.5 Turning machine off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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7.5 PRODUCING A TEST WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

7.5.1 Program a test wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.5.2 Produce a test wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

8 PROGRAMMING EXAMPLES 88

9 FAULT LOCALIZATION 89
9.1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.2 BEHAVIOR IN CASE OF AN ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.3 DISPLAY OF ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
9.4 MACHINE FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
9.5 DRAWINGS / CIRCUIT DIAGRAMS / FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
9.6 ACTIONS AFTER SOLVING ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

10 MAINTENANCE 93
10.1 CUSTOMER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.2 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
10.3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
10.3.1 Replacing blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.3.2 Opening the housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10.4 SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10.5 REPAIR WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.5.1 Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

11 MODIFICATIONS 141

12 SPARE PARTS / EXPLODED VIEW DRAWINGS 156

13 DECOMMISSIONING / DISPOSAL 157

14 APPENDIX 161
14.1 ELECTRIC INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
14.1.1 SMI interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
14.1.2 HS/PF interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
14.1.3 Pre-/postfeed interface (PPI, option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
14.1.4 RS232 interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
14.1.5 ESC interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
14.2 BLOCK DIAGRAM ELECTRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
14.2.1 Power supply and control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
14.2.2 Power amplifiers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
14.2.3 Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
14.3 BLOCK DIAGRAM PNEUMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
14.4 OPERATOR MANUAL BANNER DF-G1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

INDEX 187

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Table of contents

8 | 192 Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480

1. General

GENERAL
Thank you for your trust in the Schleuniger technique! You have acquired a high performance Schleuniger
product, designed and manufactured in our factory to your needs. Read through this manual with due
care and attention. It contains important tips and safety instructions, which allow precise and reliable pro-
duction.

1.1 MANUFACTURER
In this Manual, Schleuniger AG Thun, Switzerland is referred to as manufacturer and abbreviated with
„Schleuniger“.

Schleuniger AG Phone: +41 (0)33 334 03 33

Bierigutstrasse 9 Fax: +41 (0)33 334 03 34
3608 Thun Email: info@schleuniger.ch
Switzerland Web: www.schleuniger.com

1.2 PRODUCT TYPE

This manual is valid for the following products/models:
■ MultiStrip 9480 S
■ MultiStrip 9480 M
■ MultiStrip 9480 MR
■ MultiStrip 9480 RS
■ MultiStrip 9480 RSX
■ MultiStrip 9480 RX

The applicable product type and the manufacture year can be found on the rating plate or the EG decla-
ration of conformity. See “EU-Declaration of Conformity (Register 2)“ of the ring binder.

1.3 INFORMATION ABOUT THE OPERATOR'S HANDBOOK

We have taken every possible measures to ensure the accuracy and completeness of this documentation.
Since errors can be avoided despite the diligence never fully, we are always grateful for any advice and
suggestions.
■ This manual is stated as "Operating instructions according to the machinery directive 2006/42/EU"
and is part of the product. It contains all the relevant information necessary to operate the product
efficiently and safely as intended.
■ The following phases of the product life cycle are described:
● Shipping
● Commissioning
● Operation
● Maintenance
● Disposal
■ Observe the safety regulations and instructions. The local accident preventions and safety regulations
must be followed.
■ If the product changes hands, the manual must be supplied to the new owner.
■ Published modifications and corrections from the manufacturer must be complemented. Ask your
local Schleuniger distributor.

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1. General

1.3.1 Contents
General
Each person using the product must be properly trained and have read and understood the operator
manual. This is also imperative, even when the respective person has operated such a product or similar
previously and where they have been trained by the manufacturer.
The operator manual is no longer valid, if any of its contents (except a Quick Start Card, where available)
are removed or is changed on the data storage medium.
As operator manual we declare:
■ In printed form the entire content of the folder according to the contents table.
■ In electronic form, this „Reference Manual“, and the document „Parts Catalog“.

Construction
The operating instructions consist of the following parts:

Reference Manual MultiStrip 9480

The Reference manual contains all information to the product. It serves as a learning- and general refer-
ence work for the personnel.

■ Safety
■ Description of the product
■ Shipping
■ Commissioning
Contents
■ Operation
■ Troubleshooting
■ Maintenance
■ Disposal
■ Operator
Target audiences ■ Qualified personnel
■ Technical specialists

Reference manual S.ON

The Reference manual contains all information for operating the S.ON software. It serves as a learning-
and general reference work for the personnel.

■ Safety
■ Description of the product
■ Schleuniger wire processing concept
■ Installation
Contents ■ Operation
■ Programming
■ Configuration
■ Diagnostics
■ Data management
■ Operator
Target audiences ■ Qualified personnel
■ Technical specialists

Parts catalog
The parts catalog contains the following.

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1. General

■ Options
■ Parts subject to wear and tear
Contents
■ Spare parts
■ Exploded view drawings and parts lists of modules
Target audiences ■ Technical specialists

1.3.2 Safekeeping
■ Keep the operator manual nearby of the product and safe against immissions.
■ The manual must be available for the operating personnel at all times.
■ The contents must remain clearly legible beyond the expected lifespan of the product.

1.4 SYMBOLS
The symbols are placed in the marginal notes column and refer to the adjacent text. They have the follow-
ing meaning:

Symbol Meaning Description

Info Information which helps to operate the product efficiently and error-
free.
Overview Detailed description or introductional chapter.

Recycle Recycle parts. Do not dispose off to regular waste.

Tip Recommendations and tips which improve the intended utilization of

the product.

Topic Important link.

1.5 LEGEND
In the text, mark-up is used in the following manner.

Mark-up Meaning Description

[SWITCH] Switch / button Commands and buttons on screen representations are
in the text shown in squared brackets, capital letters and
orange colored.
„Configuration“ Screen title / menu Screen titles and menus are represented in the text in
"quotation marks".
Schleuniger Product names and Product- and company names are represented italic.
company
"1.5 Legend (Page 11)" Cross referencing Cross referencing are represented in blue and italic.
1.▹ Activity direction Activity directions are a summary of activity steps.
➥ Consequence of an Results or released actions in activity directions are rep-
activity direction resented with a leading arrow.

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1. General

The following abbreviations are used.

Abbreviation Meaning Description

Fig. Figure Figures are captioned as "Fig."
mm Millimeter All Measures in the manual are given in millimeters.
CW Clockwise Direction of rotation for a component or an operating
element viewed from rotation axis.
CCW Counter clockwise Direction of rotation for a component or an operating
element viewed from rotation axis.

1.6 DECLARATION OF CONFORMITY

See document “EG-Declaration of Conformity (Register 2)“ of the ring binder.

1.7 LIMITATION OF LIABILITY

The content of these operating instructions was put together taking into consideration the current stand-
ards and guidelines according to the state of the technology and our many years of experience.
The manufacturer disclaims any liability for damages and accidents as a result of:
■ Disregard of the instructions
■ Disregard of safety regulations
■ Non-intended usage

1.8 WARRANTY STATEMENTS AND POLICIES

See Schleuniger document „General Conditions of Sale and Delivery”.

1.9 COPYRIGHT PROTECTION

Keep this operator manual confidentially. It is intended for the exclusive use of persons operating the
product. Without written agreement, this manual shall not be made available to third parties.
The content of the operator manual in the form of text, illustrations, drawings, circuit diagrams or other
presentation, is protected by copyright law of the manufacturer.

1.9.1 Trademarks
Cayman™, the Cayman-logo, Iguana™ and the Iguana-logo are trademarks of Schleuniger.
Windows® (XP, Vista, 7, 8 or CE) are registered brands of Microsoft Corporation in USA and other coun-
tries.
The rights for other brands and product names are deposited by their owners and must be accepted
herewith. Mentioning products not manufactured by Schleuniger is intended exclusively for information
purposes. It does not constitute advertising. Schleuniger is not responsible in terms of selection, perform-
ance or usability of this products. Registered trademarks are not specially marked in these instructions.
However, this does not mean that they can be used freely.

1.10 SPARE PARTS

Always order original spare parts from your local Schleuniger distributor.
Any modifications in design or function of the spare parts, in terms of ongoing product improvement, are
subject to change without prior notification.

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1. General

CAUTION
Use of unverified spare parts!
Unverified- or defective spare parts can lead to personnel injury or property damage.
To avoid any damage, exclusive use of original Schleuniger spare parts is imperative.

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1. General

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2. Safety

SAFETY

2.1 TARGET AUDIENCES

This operating instruction is intended for individual target audience. Certain chapters therefore are with-
hold for a particular target audience and mentioned accordingly in the introductional section. Only this
group is authorized to carry out the appropriate tasks. The other contents generally is intended for all
audience and is not stated specially.

Operating company
■ Higher level juristic person
Qualification ■ Authority to give directives
■ Define competences
■ Teaching
Authority / activity ■ Deploy authorized personnel
■ Use product according to the intended usage

Technical specialists
■ Mechanical and electrical basic education
Technical specialist / service techni-
■ Product-specific training
cian
■ Know-how in wire processing technics
■ Unpacking
■ Installation
■ Commissioning, start-up
Authority / activity ■ Operating
■ Programming
■ Maintenance and repair
■ Disposal

Qualified personnel
■ Technical skill
Qualification ■ Product-specific training
■ Know-how in wire processing technics
■ Operating
■ Programming
Authority / activity
■ Instructor
■ Maintenance

Operating personnel
■ Product-specific training
Qualification ■ Accident prevention
■ First aid assistance

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2. Safety

■ Operating
Authority / activity
■ Clean

Third party
Externally called in personnel of the operating company, service technicians and staff from Schleuniger.

■ Mechanical and electrical education

Qualification
■ Specialist in wire processing technics
■ Commissioning, start-up
■ Maintenance and repair
Authority / activity
■ Repair
■ Modifications

2.2 WARNING NOTICES

The warning notices in the entire operator manual are marked with the warning banner and the appropri-
ate danger symbol. The following three endangering levels are primarily distinct by the signal word.
Compulsory comply the warning notices to avoid accidents and personnel injury.

DANGER
Warning notice „Danger”
This panel indicates a hazardous situation, which if not avoided, will result in
death or serious injury.

WARNING
Warning notice „Warning”
This panel indicates a hazardous situation, which if not avoided, could result in
death or serious injury.

CAUTION
Warning notice „Caution
This panel indicates a potential hazardous situation, which if not avoided, may
result in minor or moderate injury.

2.3 CAUTION PROPERTY DAMAGE

NOTICE
"Property damage"
This panel indicates a hazardous situation, which if not avoided, can result in
damage to property.

2.4 GENERAL SAFETY NOTES

■ The product must only be operated when in good working order and condition. It must be checked
for intactness prior to the start of operation.
■ Never operate the product in an explosive or flammable environment.

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2. Safety

■ Only operate the product in a dry, dust-free environment.

■ Processing carbon fiber or similar wire material disperses electrically conducting parts. This cause
short circuit in the electronics. Thus electronic components may be damaged. Use appropriate suc-
tion appliances.
■ Before carrying out any maintenance or repair work, unplug the machine from the mains and/or from
the compressed air supply.
■ After completing maintenance work on the wiring or the electronic components, always perform the
safety check.
■ Only operate the product with connected earth conductor in the power cord.
■ Only use original Schleuniger equipment, especially interface connection cables (electromagnetic
compatibility).
■ Compulsory operate the product connected to the Schleuniger emergency stop circuit, if it is operat-
ed together with peripheral devices in a production line. Only then can a safe interruption of the
complete production line be guaranteed during an emergency.
■ Only use supplied lubricating grease according to the instructions given in this manual.

2.5 RESIDUAL RISKS

With the use of technical products are dangers associated. Dangers that could not be eliminated by
design measures and also not by protection devices are residual risks. The safety instructions in this oper-
ator manual refer to the known residual risks. Should be shown additional operational risks, the operator
is obliged to inform Schleuniger immediately.
However, the following risks remain:
■ Danger due to catching body parts and clothing in the wire axis between peripheral devices and the
wire processing machine.
● Always close off these areas
■ Danger due to stab wound or concussion injury or to death on the outlet. Wires/cables are ejected at
high speed.
● Always close off this area!
■ Danger due to blocked wire/cable on the inlet. Tensile forces can move to overturn machine, periph-
eral or bobbin and injure the operator personnel.
● Fixate machines and devices
● Ensure a continuing wire/cable supply
■ A free standing panel may fall due to vibration and injure the operator.
■ Tripping, falling, slipping due to connection cables, wire residue and air hoses lying around.
● Lay out connecting cables and hoses accordingly
● Collect wire residue
■ Risk due to increased noise level while working in an environment with multiple machines.
● Take up noise control measures!
■ Some wires/cables contain Talc. This contaminates the working environment during production.
● Install the suction unit
● Wear a dust protecting mask

2.6 SAFETY SYMBOLS IN MANUAL

In this manual, the warning hints are supplemented with the following symbols. They refer to potential
danger.

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2. Safety

Symbol Meaning Description

General danger! Notes and instructions with this safety symbol should be fol-
lowed strictly. Disregarding may lead to injury and damage to
the machine.

Electric current! There is a danger of electric shock by contact with parts inside
the machine and on the mains socket. Therefore before open-
ing, always switch off the main switch and unplug it from the
mains. Touching electric components can cause injury to the
operator personnel.
Electrostatic sensi- Electronic parts react sensitive to static charge. Specially
tive components! marked components and packaging must only be handled by
trained personnel after a potential equalization and with spe-
cial equipment.

2.7 SAFETY SYMBOLS ON PRODUCT

There are warning symbols on the product. They advise the user about potential danger. An overview of
the stickers can be found in chapter "6.7 Danger zones (Page 63)".

2.8 SAFETY INSTALLATIONS

The built in safety interlocks on the product (safety, protection, monitoring) must not be removed, by-
passed or changed. Check the safety appliances in certain intervals. Defective safety equipment's must be
fixed immediately.
■ Never operate the product with open covers.
■ Never operate the product if the safety cover is open.
■ The emergency stop buttons must always be accessible.
■ Do not remove any safety barriers.
■ Do not break in the emergency stop link between the processing machine and the peripheral devices
in a production line.

2.9 RETROFITTING
Without written permission of Schleuniger, do not make changes or any retrofit work on the product. The
performance and the safety is affected thereby.
Standard options and accessories supplied by Schleuniger are excluded therefrom.

2.10 PERSONAL PROTECTIVE EQUIPMENT

While working on the product, the personnel must be protected from injury or disease.
■ Observe the local regulations and instructions of the operating company
■ The following protective equipment is recommended

Symbol Meaning Description

Workwear Wear tight-fitting workwear with high tensile strength. Avoid
loose or protruding items. They may be catched from movable
machine parts.

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2. Safety

Symbol Meaning Description

Safety shoes Wear safety shoes. They protect the feet from heavy parts and
bobbins.

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2. Safety

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3. Transportation

TRANSPORTATION
Personnel qualification
The instructions in this chapter must be carried out by technical specialists!

3.1 PACKAGING
The packaging provides enough protection during transport with common means of transportation. It
consists of:
■ Cardboard box
■ Wooden base

Store the packaging for later use on a weatherproof location.

Recycle the unneeded packaging.

NOTICE
Inadvertently transportation of the product can lead to property damage.
■ Handle the packaging with care
■ Observe the packaging signs
■ Wherever applicable remove the packaging not before placing on site of operation
■ Move the packaging with a forklift or pallet truck to the site of operation

3.2 PACKAGING SIGNS (STICKERS)

On the packaging, the following packaging stickers are attached:

Symbol Meaning Description

Fragile Handle the packaging carefully. Avoid intense shock and pres-
sure.

This side up The arrows point to the top side of the packaging. Store and
transport the packaging upright. Do not tilt.

Avoid moistness Store and transport the packaging protected against moist-
ness.

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3. Transportation

3.3 TRANSPORT INSPECTION

Check the goods immediately after receiving for completeness and loss during shipment.
On recognizable loss during shipment proceed as follows:
■ Do not accept the delivery or only with retentions
■ Declare loss of shipment
■ Immediately report damages on the product to the shipping company or the vendor

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4. Product specifications

PRODUCT SPECIFICATIONS

4.1 APPLICATION PURPOSE

4.1.1 Intended usage of product

The product MultiStrip 9480 is exclusively determined for processing of following materials:
■ Wire
■ Solid
■ Tube
■ Rope/cord

The materials must be treated in the following way:

■ Cut through
■ Incision
■ Stripping
■ Slit
■ Separate

See also chapter "5.3 Applications (Page 35)".

As limits the areas in the technical data apply. Any other use of this product is regarded as non-intended
use. For damages arising therefrom, Schleuniger is not liable.

4.1.2 Reasonably foreseeable misuse

The product MultiStrip 9480 is not intended for the processing of materials with the following characteris-
tic:
■ Explosive
■ Flammable
■ Toxic

4.2 DIMENSIONS AND WEIGHT

A B

Fig. 1: Dimensions MultiStrip 9480

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4. Product specifications

Description Model Value Unit

Weight - S 80 kg
M 86 kg
MR 89 kg
RS 95 kg
RSX 95 kg
RX 80 kg
Measures Width (A) S, M, RX 734 mm
MR, RS, 922 mm
RSX
Depth (B) 700 mm
Height (C) 333 mm
Height (C) with monitor 553 mm

4.3 PLANNING DATA

4.3.1 Installation location

Place the machine on a solid, level work bench. This must have adequate payload. Secure the machine
from slipping off during operation.
The optional Schleuniger system rack fits ideally to the MultiStrip 9480. The system rack is robust and the
machine can be positioned on it safely. The serviceable appliance facilitates the daily work on the
machine. See document „Parts Catalog“.

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 238.5

4. Product specifications

4.3.2 Layout model S, M, RX

Housing width 600 mm
0
Front 5.8

675
168

16.8
0
590
575 88
560
530

(Schneid-
Achse)
108.5

330.5

552.5
4.5

478.5
0

661
(734)

238.5
Page
1:5

264.8

147
333
0
5.8
(Kabelachse)
170

45.2

0
(23)

168
16.8

238.5

530

575
0

675
88 (701.8)

0 - MS 9480 M - - - -

Stk. Materialtext Pos.Werkstoff-Nr.

Werkstoff-Bez.
Material-Nr.
-0.4 Index Datum Visum
Allgemeintoleranzen: -0.2 +0.4
ISO 2768-mK zerspante Metallteile Massstab A 30.09.14 MaL
ISO 13920-BE Schweisskonstruktionen
ISO 2768-cL zerspante Kunststoff- und Blechteile Blechteile gratfrei 3:10
Format
MS 9480 A2
Blatt gez. 22.05.14 MaL
MS 9480 M 1/1 freig. 30.09.14 MaL

Für dieses Dokument behalten wir uns alle Rechte

MS9480M_MANUAL
vor. Ohne unsere schriftliche Zustimmung darf es
weder dritten Personen mitgeteilt, noch miss-
bräuchlich kopiert oder anderweitig benutzt werden.

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4. Product specifications

Bottom
675

590
575
560
530
30

238.5

0
5.8

168
16.8
0

88

0
(Schneid-
Achse)
108.5

330.5

552.5
4.5

478.5
0

661
(734)

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4. Product specifications
238.5

4.3.3 Layout model MR, RS, RSX

Housing width 800 mm

Front S 0
5.8

675

590
575 168
560

16.8
0
530
88

(Schneid-
Achse)
108.5
4.5

424.5

666.5

740.5
0

849
(922)

238.5

Page
1:5

264.8

0
147

333
5.8
(Kabelachse)
170

45.2

0
(23)
168
16.8

238.5

530

575
0

88 675
(701.8)

0 - MS9480 MR - - - -

Stk. Materialtext Pos.Werkstoff-Nr.

Werkstoff-Bez.
Material-Nr.
-0.4 Index Datum Visum
Allgemeintoleranzen: -0.2 +0.4
ISO 2768-mK zerspante Metallteile Massstab A 30.09.14 MaL
ISO 13920-BE Schweisskonstruktionen
ISO 2768-cL zerspante Kunststoff- und Blechteile Blechteile gratfrei 3:10
Format
MS 9480 A2
Blatt gez. 03.06.14 MaL
MS9480 MR 1/1 freig. 30.09.14 MaL

Für dieses Dokument behalten wir uns alle Rechte

MS9480MR_MANUAL
vor. Ohne unsere schriftliche Zustimmung darf es
weder dritten Personen mitgeteilt, noch miss-
bräuchlich kopiert oder anderweitig benutzt werden.

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4. Product specifications

Bottom
675

590
575
560
530
30

238.5

0
5.8

4.4 RATING PLATE

The rating plate is situated on the rear cover besides the power plug. It contains the following details:
168

16.8
0
Schleuniger AG 88
Bierigutstrasse 9 CH-3608 Thun / Switzerland

Product: 1 MultiStrip 9480

Serial No: 2 XXXX 0

Year: 3 20XX
(Schneid-

2× T8AH 8
Achse)
108.5

Power rating: 4 100–240 VAC Fuses:

4.5

424.5

666.5

740.5
0

5 50/60 Hz 1000 VA 7
Weight: Type: S / M 80-90kg 849
6 (922)
Type: MR / RS 90-100 kg
Made in Switzerland

1 Product 5 Mains frequency

2 Serial number 6 Weight
3 Manufacturing date 7 Power consumption
4 Permissible mains voltage 8 Internal fuse protection

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4. Product specifications

4.5 TECHNICAL SPECIFICATIONS

The technical data correspond to the theoretical values and are achievable under normal conditions.
Any modifications in design or function, in terms of ongoing product improvement, are subject to change
without prior notification.

Description Model Value Unit

Environment Temperature range +5 to +40 °C
Storage temperature -25 to +55 °C
Relative humidity, at 20 °C 90 %
Relative humidity at 40 °C 50 %
Limit values wire pro- Wire outer diameter S, M, MR, Ø 12.5 mm
cessing RS
RX, RSX Ø 6.5 mm
Cross section S, M, MR, 20 mm2
RS (4 AWG)
RX, RSX 6 mm2
(10 AWG)
Wire length standard 62.5-1‘000‘000 mm
Wire length standard (short mode kit) 29-1‘000‘000 mm
Wire length short mode 0.1-62.4 mm
Wire length short mode (short mode kit) 0.1-28.9 mm
Stripping length 0.1-1‘000‘000 mm
Pull-off length left 95 mm
Pull-off length left RX 17.25 mm
Pull-off length right S, M, MR 195 mm
Pull-off length right RS, RSX 135.5 mm
Pull-off length right RX 40.25 mm
Number of blades S 1× 16 mm
(with cartridge) 2× 16 mm
3× 10.6
Feeding system Belts 4 Pcs.
Double rollers (option) S, M, MR 8 Pcs.
Transport speed 2.0 m/s
Noise emission Emission sound pressure level <70 dB(A)
Article storage capaci- Memory for programming 1 GB
ty
Memory usage for approx. 1000 articles 3 MB
(average value for mixed applications)
Operation Color touch screen with LED background light 5.7 Inch
(Option) 10.4 Inch
Resolution 5,7“ 640×480 Pixel
10,4“ 1024×768 Pixel

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4. Product specifications

4.6 POWER SUPPLY

Description Model Value Unit
Power supply Mains 100-240 VAC
Line frequency 50/60 Hz
Fusing 2× T8 AH
Power consumption max. 1000 VA
Compressed air con- Pressure 7.0 bar
nection 0.7 MPa
Consumption 10 l/min

4.7 INTERFACES
Description Quantity Application Type
USB 3 (1 on USB memory stick, Cayman-dongle, external key- V 1.1/2.0
monitor) board, mouse compatible
Monitor 1 Reserved for monitor M12
HS/PF (SIS 1) 1 Predefined devices like prefeeder or hot stamp unit D-Sub 15pol,
f
PPI (SIS 2) 1 Synchronized pre- or post processing devices D-Sub 15pol,
f
RS232 (SIS 3+4) 2 Inkjet printer (option) D-Sub 9pol,
m
SMI (SIS 5–6) 2 Universal interface for pre- or post processing devices D-Sub 15pol,
and pedal (option) f
ESC (SIS 7) 1 Emergency stop circuit (option) D-Sub 25pol,
m
Ethernet 1 For PC with Cayman software RJ-45
generally for local network
1 Schleuniger internal RJ-45

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4. Product specifications

4.8 ACCESSORIES
Description Model Quantity Unit
Case with the following contents: 1 Pcs.
Tools Hex wrench set 1.5–5 mm 1 Pcs.
Screwdriver # 2 1 Pcs.
Brush 1 Pcs.
USB memory stick 1 Pcs.
Lubricating grease Microlube GBU-Y 131 1 Pcs.
Expendable materials Filter pad 115×115 mm 2 Pcs.
Power cord - 1 Pcs.

Blades and guides, ordered individually.

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4. Product specifications

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5. Models

MODELS
The MultiStrip 9480 is a flexible automatic cut and strip machine for a wide range of applications. It can be
used as stand alone machine or within a product line in conjunction with peripheral devices.
The modular architecture demands two different housings. Therein an individual number of components
can be built in. All models can subsequently be extended or retrofitted. Therefore a wide variety of
options are available.
The chart represents an overview of the base models with its configurations and options.

5.1 EQUIPMENT
MultiStrip 9480
Model S M MR RS RSX RX
Housing width 600 mm × × ×
Housing width 800 mm × × ×
Cutting unit single blade ×
Cutting unit multi blade × × × ×
Cutting unit RX ×
Rotary incising unit CX × ×
Rotary incising unit RX × ×
Swivel guide × × ×
Linear guide, Y-Axis × × × × ×
Linear guide, Z-Axis × ×
Immovable guide RX ×
Feeding unit belts, 2 m/s × × × × ×
Feeding unit belts RX ×
Revolver guide × ×
Wire end monitoring × × × × × ×
Monitor FPD 5,7“ × × × × × ×
Blades (grid dimension mm) 1× 16 2× 16 2× 16 2× 16 2× 16 2× 16
3× 10.6 3× 10.6 3× 10.6 3× 10.6 3× 10.6
Air jet unit × × ×

× = Component or function included in the basic equipment.

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5. Models

5.2 OPTIONS
MultiStrip 9480
Model S M MR RS RSX RX
Lengths monitoring × × × × ×
Feeding unit rollers, 2 m/s × × ×
Retrofit kit rollers to belts × × ×
Retrofit kit short mode × × × × ×
Guides short mode × × × × ×
Magnetic guides × × × × × ×
Cartridge (SmartBlade) × × × ×
Cartridge RX ×
Cutting unit booster × × ×
Air jet unit × × ×
Jam detector × × × × × ×
LED, illumination × × × × × ×
Suction unit × × × × ×
Suction unit RX ×
Combing unit × × × ×
Slitting unit × × × ×
Interface RS232 × × × × × ×
Interface SMI × × × × × ×
Interface ESC × × × × × ×
SIS extension × × × × × ×

x = Component or feature available.

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5. Models

5.3 APPLICATIONS
The MultiStrip 9480 can process a wide range of commercial wires. The processing capabilities are many
and of various types.

Application Wire sample Model

S M MR RS RSX RX
Cut to length × × × × × ×

Full- or partial strip left and × × × × × ×

right
Multi-step stripping × × × × × ×

Multi step stripping (×) × × × × ×

Jacket stripping of multi- × × × × ×

cord wires
Jacket stripping of extremely × × × × ×
thin insulations
Jacket- and inner wire strip- × × × (×)
ping

Trim, separate and stripping × × × (×)

of individual wires

Multi-step stripping with slit- × × × (×)

ting and window

Wire marking Schleuniger

× × × × × ×
Schleuniger

Coaxial cable
Multi step stripping without × × × ×
shield processing

Multi step stripping includ- × × × ×

ing shield processing

Stripping with slitting and × × × ×

window

× = Application possible
(×) = restricted

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5. Models

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6. Product description

PRODUCT DESCRIPTION
The product description explains operating elements and modules of the machine. For a better under-
standing, the models are represented in an appropriate view. The composition of the models vary. Devi-
ant layout is described as option.

6.1 OVERVIEW COMPONENTS

All models of the MultiStrip 9480 are equipped the following components. Therefore they are not presen-
ted repeatedly. The safety appliances are described in a separate chapter, "6.6 Safety elements (Page 60)".

10
1

9
8
3 7
6
4 5

Fig. 2: Machine front side general components

1 Monitor 6 Wire end monitoring

2 Fan 7 Illumination
3 Extensible carry handles, both side 8 Processing front (dependent on the model)
4 Peripheral adapter entry 9 Exit
5 Entry 10 Safety cover

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6. Product description

6.1.1 Model S and M

The representation shows the basic equipment of both models S and M. They have a housing width of
600 mm. Non-standard equipment is described in the options.

1 2 3 4 5 6 7

Fig. 3: Machine front side model S and M

1 Wire end monitoring 5 Cutting unit, single blade (S model)

2 Revolver guide 5 Cutting unit
Multiple blades (SmartBlade, model M)
3 Feeding unit 6 Linear guide
4 Swivel guide 7 Feeding unit

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6. Product description

6.1.2 MR model
The representation shows the basic equipment of the model MR. It has a housing width of 800 mm. Non-
standard equipment is described in the options.

1 2 3 4 5 6 7

Fig. 4: Machine front MR model

1 Wire end monitoring 5 Cutting unit, multiple blades (SmartBlade)

2 Rotary incising unit CX 6 Linear guide
3 Feeding unit 7 Feeding unit
4 Swivel guide

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6. Product description

6.1.3 RS model
The representation shows the basic equipment of the model RS. It has a housing width of 800 mm. Non-
standard equipment is described in the options.

1 2 3 4 5 6 7

Fig. 5: Machine front RS model

1 Wire end monitoring 5 Cutting unit, multiple blades (SmartBlade)

2 Rotary incising unit CX 6 Linear guide Y-axis
3 Feeding unit 7 Feeding unit
4 Linear guide, Z-axis

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6. Product description

6.1.4 Model RSX

The representation shows the basic layout of the model RSX. It has a housing size of 800 mm. Deviant
layout is described in the options.

1 2 3 4 5 6 7

Fig. 6: Machine front RSX model

1 Wire end monitoring 5 Cutting unit, multiple blades (SmartBlade)

2 Rotary incising unit RX 6 Linear guide Y-axis
3 Feeding unit 7 Feeding unit
4 Linear guide, Z-axis

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6. Product description

6.1.5 Model RX
The representation shows the basic layout of the model RX. It has a housing size of 600 mm. Deviant lay-
out is described in the options.

1 2 3 4 5 6 7

Fig. 7: Machine front RX model

1 Wire end monitoring 5 Cutting unit, multiple blade

2 Rotary incising unit RX 6 Immoveable guide
3 Feeding unit 7 Feeding unit
4 Immoveable guide

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6. Product description

6.2 MONITOR

Fig. 8: Overview monitor

1 Display 3 Swivel base

2 Cables to the machine 4 USB interface

6.3 DESCRIPTION OF COMPONENTS

The features of the individual components are explained in the following. The charts have the following
information content.
■ Model: The component is available/compatible for the marked model
■ Function: Functional description

Peripheral adapter
Model all
Function The peripheral adapter is a perforated plate
besides the inlet and outlet. Pre- or post-pro-
cessing appliances or devices can be moun-
ted at it.

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6. Product description

Carry handles
Model all
Function On the left and right in the housing, carry han-
dles are integrated. On this the machine can
be lift up.

Entry
Model all
Function On the inlet the wire is fed into the machine
for production.
The sleeve is a wearing part. It must be
replaced if wear off

Wire end monitoring

Model all
Function The wire end monitoring monitors the ade-
quate supply of the raw material.
If the very end of the raw material is fed
beyond the wire end monitoring, the lever
falls down. The current production stops.
If there is no raw material available, the pro-
duction can not be started.

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6. Product description

Revolver guide
Model S; M
Function The revolver guide feeds the raw material to
the feeding units.
Select the hole diameter appropriate to the
raw material.
There is a recess between the Ø 2 and Ø 14
mm. A customer specific guiding inset can be
mounted there.

Rotary incising unit CX

Model MR; RS
Function The rotary incising unit allows the precise
radial incision into jacket and shield. For one
wire any number and varying deep incisions
can be processed. In the unit, a pair of blades,
a rotary cutting guidance and a precise cen-
tering mechanism is integrated.
The replaceable guide feeds the raw material
through the unit up to the blades.
The centering centers and clamps the raw
material during processing.
The rotary incising unit is capable for process-
ing coaxial cables with outer diameters from
2.0 - 12.5 mm.

Rotary incising unit RX

Model RSX, RX
Function The function is identical with the rotary incis-
ing unit CX.
The rotary incising unit is capable for process-
ing wires up to 6.5 mm.

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6. Product description

Feed unit with belts

Model S, M, MR, RS, RSX
Function The belts of the feeding unit close centrically
and move the raw material back and forth.
The feeding unit comprises of a driven and a
revolving pulley as well as a support pulley
Used up feeding belts can be replaced easily.
Option
■ Retrofit kit for short mode

Feeding unit with rollers (option)

Model S, M, MR
Function Both rollers are driven and close centrically.
They move the Raw Material back and forth.
Option
■ Retrofit kit for short mode
■ Retrofit kit for feeding belts

Feeding unit RXD with belts

Model RX
Function The architecture of the feeding unit RX is
dimensioned for the processing of very fine
and short wires. The small feeding belts and
the small-sized diverting rollers position the
wire closely at the blades.
Exchangeable guides are integrated into the
feeding units.
Used up feeding belts can be replaced easily.

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6. Product description

Swivel guide
Model S; M; MR
Function The swivel guide transports the raw material
directly to the cutting unit. After the cut the
guide is lift up. Therewith there is clearance
for processing the left wire end.
If the swivel guide is up the wire deflector
rejects the wire down. This way we prevent
the wire from colliding with the feeding unit
during the back transport.

Linear guide, Z-axis

Model RS, RSX
Function The linear guide is positioned before the cut-
ting unit. Together they form an assembly.
The linear guide transports the raw material
directly to the cutting unit. After the cut the
raw material is retracted up to the feeding
unit. Only then is the guide lift up. Therewith
there is clearance for processing the left wire
end.

Cutting unit, single blade

Model S
Function This cutting unit can only hold one pair of
blades. The cutting unit can not re-position
the blades.
The cut procedure is carried out in the Z axis.
The blades thereby cut through the raw mate-
rial, incise the jacket or clamp it during pull-
off.

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6. Product description

Cutting unit, multiple blade

Model M; MR; RS, RSX
Function This cutting unit can hold a cartridge (Smart-
Blade) with a maximum of three pairs of
blades or additionally tooling. The cutting
unit is able to position the blades in Y axis.
During production it is possible to use differ-
ent blades.
The use of tooling allows additionally to slit
the wire or to position single wires.
The cut procedure is carried out in the Z axis.
The blades thereby cut through the raw mate-
rial, incise the jacket or clamp it during pull-
off.

Cutting unit, multi blades RX

Model RX
Function The function is identical with the cutting unit
multi blades.

Air jet unit

Model RS, RSX, RX
Function The air jet unit blows off wire residue from the
blades and the cutting unit. Therewith the risk
of a wire jam is reduced. Moment and dura-
tion of the air jet is freely configurable.
With the two flexible nozzles, the direction of
the air jet can be set.
NOTICE
Do not direct the air jet into the machine inte-
rior. Blow away the residue from the machine.

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6. Product description

Linear guide Y-axis

Model S, M, MR, RS, RSX
Function The linear guide is built into the cutting unit.
The linear guide transports the raw material
directly to the feeding unit. For the processing
of the right wire end, the guide is moved in (Y
axis). Thereby the waste can fall down unhin-
dered.

Exit
Model all
Function On the outlet, the wire is ejected from the
machine or it is delivered to a post processing
device.
The sleeve is a wearing part. It must be
replaced if wear off

Fan
Model all
Application Fans guaranty a permanent air flow inside the
machine. Thereby the waste heat of the
motors and the electronics is blown off
through the fan exhaust.
The fans are equipped with air filters. They
prevent that dust and other particles can get
into the machine.
Clean the dust pads regularly.

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6. Product description

Monitor

NOTICE
Sensitive operator panel surface
Do not touch the screen with sharp finger nails, solid objects or tools. The surface
may be damaged.
Only touch the screen with your fingertip or a suitable touch screen pen.

Model all
Function The monitor comprises the touchscreen, swiv-
el socket and connecting cable. The machine
is operated and programmed directly by just
touching the screen.

6.3.1 Options

Monitoring
Model S, M, MR, RS, RSX
2 3
Function The length monitoring is a combination of 4
recoil brake (1), the revolver guide (3) and the
length monitoring (4). 1

The recoil brake prevents the wire to move in

the opposite direction of the processing. This
is useful if pre-feeding devices are used or
with heavy cables.
The length monitoring serves for the exact
determination of the raw material length. On
any abnormality a warning message is shown.
This function is activated after assembling the
option.
Operation recoil 1.▹ Feed the wire up and in-between the
brake feeding belts.
2.▹ Activate [RECOIL BRAKE] (2).
➥The key lights up
➥Both rollers close and hold the wire.
3.▹ Wire [LOAD]
➥The wire is feed forwards and cut.
➥The rollers of the recoil brake open up.

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6. Product description

Air jet unit

Model S, M, MR
Function The air jet unit blows off wire residue from the
blades and the cutting unit. Therewith the risk
of a wire jam is reduced. Moment and dura-
tion of the air jet is freely configurable.
With the two flexible nozzles, the direction of
the air jet can be set.
NOTICE
Do not direct the air jet into the machine inte-
rior. Blow away the residue from the machine.

Suction unit
Model S, M, MR, RS, RSX (not in combination with
cutting unit booster)
Function The suction unit removes wire residue in the
area of the cutting unit. Therewith the risk of a
wire jam is reduced. Additionally it prevents
harmful particles penetrating into the
machine and the environment.
The vacuum cleaner must be operated man-
ually and is not part of the suction unit kit.

Suction unit RX
Model RX
Function The type of construction for the cutting unit
RX requires an adapted suction unit. The func-
tion is identical with the suction unit of other
models.

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6. Product description

Cutting unit booster

Model S, M, MR (not in combination with suction
unit)
Function The cutting unit booster gives the cutting unit
additional cutting strength. Both cylinders
thereby press onto the blade holders.
The booster is suitable for the processing of
large cross sections or tough raw material.

Short mode
Model S, M, MR
Function The short mode unit is mounted on the right
feeding unit. Therewith the distance between
cutting unit and feeding unit is eased. This
allows the processing of very short wires.

Jam detector
Model all
Function The jam detector monitors the wire exit sec-
tion of the machine during production. If
within a certain time no wire is sensed, the
machine generates the warning message
"Wire jam". The production stops.
This component is independently configura-
ble in the software.
Operating the jam detector is described
detailed in "14.4 Operator Manual Banner DF-
G1 (Page 172)".

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6. Product description

LED, illumination
Model all
Function The LED illumination brings light into the pro-
cessing area. On difficult light conditions, the
processing may be monitored in a better way.

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6. Product description

6.4 REAR OF MACHINE

The MultiStrip 9480 is equipped the following components.

12

11

10
9
1 8

7
2
6
3 5
4

Fig. 9: Machine view rear

1 Maintenance unit (depending on model) 7 SIS 1–7, Interface slot

2 Ethernet interface 8 Rating plate
3 USB interface 9 Power connection
4 Compressed air connection (depending 10 Mains fuses
on model)
5 Fan 11 Main power switch
6 Earth connector 12 Monitor connector

6.5 CONNECTIONS / INTERFACES

NOTICE
Property damage during production!
Connecting or disconnecting components on the interfaces during operation,
may damage the electronics.
Plug or unplug components to the interfaces only when the machine is switched
off.
Exception: USB, Ethernet

The behavior of the individual interfaces are described in the following. The charts have the following
information content.
■ Model: The interface is available/compatible for the listed models
■ Application: The application purpose of the interface is described

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6. Product description

■ Valuation/type: When required, the type of the connector or the limit values are declared

Power connection
Model all
Application On the power plug the power cord is connec-
ted. The machine therewith is connected to
the mains power supply.
The following voltages are allowed.
Values Single phase with protective earth
■ 100-240 VAC
■ 50/60 Hz
■ 1000 VA

Mains fuses
Model all
Application In the fuse holders, two fuses are contained.
On serious faults, the fuses blow-off and pro-
tect thereby the machine from damage. This
can be caused by errors from the mains sup-
ply or by malfunction of components on the
machine
Always replace both fuses.
Values 2× T8

Main power switch

Model all
Application With the main switch, the power supply is
turned on. Thereby the control unit starts
automatically.
Do not switch off the main switch directly on
the operable machine. Data loss may occur.
The machine can only be switched off
through the command on the touch screen. It
is not operable then any more but still under
power.
To restart the machine, switch off the main
switch and then on again.

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6. Product description

Rating plate
Model all
Application The rating plate is situated besides the power
plug. It contains the following details:
■ Manufacturers address
■ Model
■ Serial number and manufacturer year
■ Electric ratings
■ Weight

ETHERNET interface
Model all
Application Via the Ethernet interface, the machine is
linked to the local computer network (LAN).
This allows to operate the machine from an
external PC or the integration into an order
management system. For this the optional
wire processing software "Cayman" is
assumed.
Type RJ-45
2× to main controller

USB interface
Model all
Application The USB interface, can hold a memory stick or
the copy protection dongle of „Cayman“.
For the operation of the machine also a PC
keyboard and a mouse can be connected.
Type USB 1.1/2.0; max 500mA
2× to main controller

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6. Product description

Monitor
Model all
Application On this interface the monitor is connected. Via
this connection the data transfer and the
power supply of the monitor is provided.
Do not disconnect the monitor cable if the
machine is operating!
Type M12

Local air pressure supply

Model RS, RSX, RX (other models depending on
option) 1
Application The maintenance unit (1) controls and cleans
the compressed air before entering into the
machine. The manometer (2) shows the set up
pressure.
The residual moisture of the compressed air is 2
isolated to the water separator (3).
The maintenance unit is connected to the 4
3
compressed air connector (4) on the machine.
For machines without connector, the opening
is covered with a dummy plate.
Values max. 7.0 bar (0.7 MPa)
Dry, clean, oil free compressed air.

6.5.1 SIS (Schleuniger interface slot)

The machine is prepared for connecting to many peripheral devices. Additional interfaces can be built in
on the 1–7 slots. The machine is equipped with the following interfaces ex factory.
■ HS/PF (SIS 1)
■ PPI (SIS 2)

When this available slots are not enough, an optional SIS extension can be connected.

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6. Product description

HS/PF (HotStamp/PreFeeder)
Model all
Application The "HS/PF" interface is for the connection of
pre-processing devices.
Hotstamp
■ HotStamp 4140
■ HotStamp 4500
■ TTP 4000

PreFeeder
■ PreFeeder 1000
■ PreFeeder 1000 MX
■ PreFeeder 1100
■ PreFeeder 2200
■ PreFeeder 2500
■ PreFeeder 3300
■ PreFeeder 4300
■ PreFeeder 4650
Type D-Sub 15pol, f

PPI (pre-/postfeed interface)

Model all
Application The PPI interface is designed for the connec-
tion of synchronized pre- or post processing
devices of Schleuniger or custom devices.
PreFeeder
■ Custom device

Cable coiler
■ CableCoiler 500
■ CableCoiler 1300
■ CableCoiler 1400
■ CableCoiler 4000

Wire stacker
■ WireStacker 1500
■ WireStacker 3150
Type D-Sub 15pol, f

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RS232
Model All (option)
Application The RS232 interface is made for connecting to
an Inkjet printer device.
Type D-Sub 9pol, m

SMI (Schleuniger machine interface)

Model All (option)
Application The SMI interface is for all-purpose use.
■ Pre-processing devices
■ Post processing devices
■ Pedal
Type D-Sub 15pol, f

ESC (emergency stop circuit)

Model All (option)
Application The ESC interface is made for connecting the
machine with the external emergency stop
circuit ESC 1000. In case of emergency, linked
devices of a production line can be stopped
immediately and simultaneously.
Type D-Sub 25pol, m

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6. Product description

6.6 SAFETY ELEMENTS

6.6.1 Safety appliances

The MultiStrip 9480 is equipped the following safety appliances. For an overview the position on the prod-
uct is shown and the function is described.
Operating the machine is only allowed if the safety elements operate correctly.

2
3
4 5

Fig. 10: Overview safety elements

1 Safety switch 4 Lower safety cover

2 Emergency stop button 5 Access protector
3 Cover rotary incising unit (MR, RS, RSX, RX) 6 Safety cover

Safety cover
Model all
Function The safety cover protects the processing area.
Hence to prevent the user to touch moving
components during production.
The safety switch is open when the cover is
open. The production is not possible.

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Safety switch
Model all
Function The safety switch is coupled with the safety
cover. If this is open or removed, the switch
interrupts the power to the motors immedi-
ately.
The production is not possible without- or
with opened cover.

Emergency stop button

Model all
Function The emergency stop button stops immediate-
ly the to the motors. The power supply for the
control unit remains switched on. Not saved
settings stay in memory.
The emergency stop button does not inter-
rupt the compressed air supply.
NOTICE
After touching the emergency stop button,
do not switch on again the machine immedi-
ately. Malfunction may result. Wait at least 3
sec. before switching on again.
Operation 1.▹ Push the emergency stop button
➥The emergency stop button snaps in
➥The motors loose the power

1.▹ Turn the emergency stop button to the

left or right
➥The emergency stop button is disen-
gaged
➥The power supply is switched on
➥The machine initializes automatically

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6. Product description

Lower safety cover

Model all
Function The lower cover protects from grasping into
the processing area from the underside.
Hence to prevent the user to touch moving
components during production.
Through the lower cover, the raw material res-
idue is led down to a waste container
The lower cover can be swiveled down for
maintenance work. The safety switch is open
when the lower cover is open. The production
is not possible.

Access protector
Model all
Function The access protection prevents the access via
the outlet into the processing area. Hence, to
prevent the user to touch moving compo-
nents.

Cover rotary incising unit

Model RS, RSX, RX
Function The cover protects the rotary incising unit.
Hence to prevent the user to touch moving
components during production.
The cover must always be mounted during
production.
CAUTION: When the safety cover is closed,
the production is also possible without cover!

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6. Product description

6.7 DANGER ZONES

The dangerous zones on the product are marked with the following warning symbols. In this area special
care must be taken. The user must compulsory follow the safety regulations.
The user must additionally inform him selves in chapter "2 Safety (Page 15)" about residual risks.

6.7.1 Overview

5
1 4

2 2
3

Fig. 11: Overview danger areas

1 Rotating parts 4 Pacemaker prohibited

2 General danger zone 5 Strong magnetic field!
3 Escaping processed wire 6 Unplug the machine from the mains- and the air
pressure supply

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6. Product description

6.7.2 Danger labels

The danger areas on the product are marked with danger labels (stickers). This advert to possible danger
situations and must be strictly observed. The safety labels must not be removed. Worn out or defective
labels must promptly be replaced.

Rotating parts! There is a danger from rotating parts.

When touching, the user can be caught on hands, hair or clothing
and be injured.
Open the safety cover not before the rotary incising unit stand still
and the machine is disconnected from the mains.
General danger There is a general risk of injury from rotating parts in the process-
zone! ing area.
When reaching into the feeding area during production, the user
can infringe on the fingers.
Safety- and the lower covers must always be closed during produc-
tion.
Escaping pro- On the wire exit wires are fed out at high speed of the machine.
cessed wires! Escaping wires can injure eyes, face and other parts of the body. Do
not stay in this area if the machine is running.

Strong magnetic Magnets generate a broad, strong magnetic field. They can dam-
field! age including electronic devices and data storage medium. The fin-
gers can be trapped while attaching magnetic components.

No pacemakers in Magnets can affect the function of pacemakers and implanted

this area! defibrillator's. A pacemaker can be switched to test mode and
cause discomfort. A defibrillator can stop functioning. Warn per-
sonnel caring such devices before approaching magnets.

Unplug the machine from the mains- and the air pressure sup-
ply!
There is a danger of electric shock by contact with parts inside the
machine and on the mains socket. Touching electric components
can cause injury or death to the operator personnel.
Unintentional operation of pressurized components, or uninten-
tionally escaping compressed air can cause injury.
Therefore always before opening the machine:
■ Switch off the main switch and unplug the power cord.
■ Unplug the machine from the air pressure supply.

6.8 TOOLS
On the MultiStrip 9480 individual blades can be attached. For the processing of standard wires, V-Blades
are adequate in general cases. Special wires however need blades adapted to the wire type. For special
applications besides there are optional tooling available.
The blades in the rotary incising unit are mounted and calibrated ex factory.
The overview shows the individual tooling's: The charts have the following information content.
■ Model: The tooling's are available/compatible for the marked models
■ Characteristic: Describes the characteristic of the tooling's and their importance to the applications

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6. Product description

■ Applications: Names the typical application

■ Variants: Names the potential variants of tooling's

Ordering information to the compatible tooling's can be found in the "Parts Catalog".

V-Blades
Model all
Property The standard V-Blades have a V-shaped blade
edge. They do not surround the conductor
fully. The insulation is not incised throughout
during stripping.
Processing speed is fast with V-Blades. The
blade position must not be changed between
cutting and stripping. Both operations can be
performed with the V-Blade.
Application Universally applicable for elementary require-
ments. For the cutting-through and stripping
of strands and solid wires up to middling
cross section.
Variants ■ Double V-Blade
■ Multi conductor V-Blades

V-Radius blades
Model all
Property The V-Radius blades have a V-shaped blade
edge with a rounded center part. They sur-
round the conductor more precise then V-
Blades. Thus the insulation is incised more
precise.
The processing with V-Radius blades is fast.
The blade position must not be changed
between cutting and stripping. Both opera-
tions can be performed with the V-Radius
blades.
Application Universally applicable for elementary require-
ments. For cutting-through and stripping of
strands and solid wires up a cross section of
4 mm2.
Variants ■ Double V-Radius blades
■ Multi conductor V-Radius blades

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6. Product description

Radius blades
Model all
Property The radius blades have a precise radius in the
center of the blade edge. During processing
these blades center the wire and exactly sur-
round the conductor. Thus the insulation is
incised all around.
The radius must fit exactly to the shape of the
conductor.
The processing with Radius blades is fast. The
blade position must not be changed between
cutting and stripping. Both operations can be
performed with the Radius blade.
Application Applicable for wires with tough, thick, thin or
extremely elastic insulation. For cutting-
through and stripping of strands and solid
wires up a cross section of 4 mm2.
Variants ■ Individual sized radius
■ Double Radius blades
■ Multi conductor Radius blades

Radius blade with centering

Model M; MR; RS, RSX, RX
Property The radius blades with centering are shaped
widely identical as the Radius blades. They dif-
fer only by the additional centering system. It
prevents the blade edge to incise too much.
This way the strands are not deformed and
squeezed.
This blades can only be used for stripping. The
processing steps require an additional blade
for cutting-through.
Application Applicable for wires with loose shaped wires.
Variants ■ Various radius

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Die blades
Model M; MR; RS, RSX, RX
Property Die blades are manufactured exactly accord-
ing to the outer shape and the diameter of
the conductor. The precise fit incises the insu-
lation exactly. The conductor thereby is not
harmed.
This blades can only be used for stripping. The
processing steps require an additional blade
for cutting-through.
Application Suitable for stripping demanding material like
Teflon, Kynar, Wirerap and with strict safety
specifications.
Variants ■ Die blades with centering
■ Special manufacturing according to wire
type

Special blades
Model M; MR; RS, RSX
Property Special blades involve varying blade shapes
for special applications.
This blades can only be used according their
specific function. The completely processing
of the wires requires additional blades for
stripping and cutting.

Fig. 12: Slit blades

Application Applicable for wires with special characteris-
tic.

Fig. 13: Separating blade

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6. Product description

Variants ■ Slit blades

■ Separating blade
■ Flat blades

Fig. 14: Flat blades

Blades rotary incising unit

Model MR, RS, RSX, RX
Property This blades are applicable exclusively for the
rotary incising unit CX and RX.
The special cutting geometry allows precise
rotary incision.
Application Universally applicable for many varying wire
types and diameters.

Variants none

Cartridge system
Model M; MR; RS, RSX, RX
Property The cartridge facilitates the efficient replace-
ment of a complete blade set. The cartridges
may be mounted on the blade holder with
few hand grips. During the production, the
cartridges may be prepared for the subse-
quent job.
Application The cartridges may be equipped as follows.
Two blades same size:
■ 2 pcs. 16 mm
■ 3 pcs. 10.6 mm

With optional tooling:

■ Slitting unit
■ Combing unit

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6. Product description

Slitting unit
Model M; MR; RS, RSX
Property The slitting unit improves the flexibility of the
MultiStrip 9480. Compared to wire specific
slitting blades it has the following advantag-
es:
■ Short changeover time
■ On slitting blade only for all wire outer
diameters

The slitting unit slits the jacket in length. It

may be used for "Stripping" as well for "Win-
dows". The design allows the processing of
most wire diameters. For special wires also a
slitting blade adapted to the wire diameter
can be ordered.
The incision depth of the slitting unit must be
adjusted on the micrometer screw before the
production.
Application The slitting unit can not be used in parallel
with the combing unit.

Combing unit
Model M; MR; RS, RSX
Property With the combing device, multi-conductor
cables can be processed in one operation
step. The separated conductors are posi-
tioned and clamped between the jaws. The
spring mechanism allows the incision of the
blades without squeezing the conductor.
The conductors are stripped with a multi con-
ductor Radius blade.
Application The combing unit can not be used in parallel
with the slitting unit.

6.9 SCOPE OF DELIVERY

In the scope of delivery for the machine there are parts and accessories according to the material packag-
ing list, see „Material packaging list (Register 1)“.

6.10 OPERATING MODES

Standard operation
The MultiStrip 9480 features only the standard operation. No other operations can be selected. In this
operation mode, all functions for programming and production of wires can be utilized.

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6. Product description

Remote controlled operation

The wire production with the MultiStrip 9480 can be controlled via a Cayman-PC. For this the machine
must be connected via a local computer network or directly to the computer.
This operating mode can only be activated from the Cayman-PC. The control of the machine is blocked in
this mode.
Cayman is the PC software of Schleuniger for the programming and management of wire data.

CAUTION
Remote control!
With the wire processing software Cayman, the MultiStrip 9480 may be controlled
from a remote PC. Thereby there is a risk of injury for the personnel on the
machine.
It is strictly forbidden to operate the MultiStrip 9480 from a Cayman-PC out of the
range of site.

Protected mode
The protected mode (safe operation) is pending in the following circumstances.
■ Diagnostics of components
■ Initialization aborted
■ Machine overheated
■ Malfunction of a component

Fig. 15: Message in protected mode

The production cannot be started in protected mode. The operating elements in the touch screen are
grayed-out and the motor movement is blocked. The axes can only be moved in reduced speed and only
for diagnostic purposes.
Restart the machine to get out of protected mode. The initialization procedure must successfully be con-
firmed thereby.
If the mode occurs only temporarily, it can be terminated without restarting the machine.

1.▹ [SHUTDOWN]
2.▹ [TOGGLE PROTECTED MODE]
➥The machine is initializing.

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COMMISSIONING
This chapter describes the procedure for the installation of the MultiStrip 9480.
■ Internal transportation
■ Unpacking / positioning
■ Connections
■ Setup
■ Producing a test wire

In advance defining the installation site. The machine needs a solid, level workbench with sufficient pay-
load.

Personnel qualification
The instructions in this chapter must be carried out by technical specialists!

7.1 INTERNAL TRANSPORTATION

NOTICE
Inadvertently transportation of the product can lead to property damage.
■ Handle the packaging with care
■ Observe the packaging signs
■ Wherever applicable remove the packaging not before placing on site of operation
■ Move the packaging with a forklift or pallet truck to the site of operation

7.2 UNPACKING / POSITIONING

1.▹ Open the fastener tapes.
2.▹ Carefully lift up the packaging box.
3.▹ Remove the foam.
4.▹ Take out the accessories box and the operator
manual.

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7. Commissioning

5.▹ Push out the carrying handles (1) through the

opening on the down side of each side cover.
6.▹ Push out the carrying handles up to the stop.

Lifting up with crane

For lifting wherever applicable use a mechanical
appliance.

1.▹ Hang in the hoisting sling on the lifting device

and on the carrying handles.

Lifting up by hand
CAUTION
The weight of the machine exceeds the allowable
load for one adult. There is a risk of physical over-
load during lift up the machine.
For lifting up the machine for persons are needed.

1.▹ While lifting up by hand grasp the carrying

handles.
2.▹ Carefully lift up the machine from the pallet
and position on the work bench.

Store the packaging for later use on a weatherproof location.

NOTICE
Over temperature!
With improper cooling the machine can overheat and may be damaged.
■ Do not block or cover the ventilator exhaust on the back and the side.
■ The air exhaust on the back and downside must always be kept free.
■ A distance of at least 30 cm to the next object should be maintained.

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Positioning machine on workbench

1.▹ Position the work bench with sufficient dis-
tance to surrounding objects.
➥The ventilator exhaust on the machine must
always be kept free.
2.▹ Place the machine on the work bench.
➥Machine feet and table edge must flush.
➥Wire residue will then fall freely into the
waste container.

3.▹ Push in the carrying handles on the machine

up to the stop.

4.▹ Place the waste container bellow the machine.

Placing on system rack (option)

1.▹ Assemble the system rack according to the sep-
arate mounting instruction.
2.▹ Position the system rack with sufficient dis-
tance to surrounding objects.
➥The ventilator exhaust on the machine must
always be kept free.

3.▹ Mount both attachments (1) in the frontage

grove of the table top.

Dimensioning:
Model S, M, RX: (2) 108,5 mm (3) 444 mm
1
Model MR, RS, RSX: (2) 108,5 mm (3) 632 mm

3 2

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7. Commissioning

4.▹ Place the machine on the system rack.

➥Place the machine feet in the attachments.

5.▹ Push in the carrying handles on the machine

up to the stop.

6.▹ Place the waste container bellow the machine.

7.3 CONNECTIONS
NOTICE
Property damage during production!
Connecting or disconnecting components on the interfaces during operation,
may damage the electronics.
Plug or unplug components to the interfaces only when the machine is switched
off.
Exception: USB, Ethernet

Connection of monitor
1.▹ Place the monitor on top of the
MultiStrip 9480.
2.▹ Plug-in the cable from the monitor to the con- 1
nector „Monitor“ (1) on the machine.
➥Via this cable the data transfer and the pow-
er supply takes place.

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Connecting USB device (option)

The USB interface is provided for the connection of a PC mouse and a keyboard.

1.▹ Connect the USB cable to the appropriate USB

interface (1).
1

Connecting to Cayman (option)

Cayman is a PC software for the programming and management of wire data. The MultiStrip 9480 can be
operated from a Cayman-PC. For this the Cayman-PC must be connected via a local computer network or
directly to the machine.
Installation and operation of the software can be found in the reference manual of Cayman.

1.▹ Connect the RJ-45 cable from the Cayman-PC

or the network to the "LAN" interface (1).
1

CAUTION
Remote control!
With the wire processing software Cayman, the MultiStrip 9480 may be controlled
from a remote PC. Thereby there is a risk of injury for the personnel on the
machine.
It is strictly forbidden to operate the MultiStrip 9480 from a Cayman-PC out of the
range of site.

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Connecting peripheral devices

On the MultiStrip 9480 optional pre- and post processing devices
can be connected. For this the interfaces „HS/PF“ and „PPI“ built
in ex factory. As required, additional interfaces can be built in on
the „SIS 3–7“ plug-in modules.
Procedure

1.▹ Connect the device to the corresponding interface.

2.▹ Screw the connector in place.

Device Interface Option Comments

PreFeeder HS/PF - -
PPI - Synchronized Schleuniger devices
HotStamp HS/PF - -
Cable coiler PPI - Synchronized Schleuniger devices
Wire stacker PPI - Synchronized Schleuniger devices
Pedal SMI × (SIS 3)
Printer RS232 × (SIS 4)
Miscellaneous devices SMI × (SIS 3–6) Schleuniger devices with uni-
versal SMI interface
ESC 1000 ESC × (SIS 7) Emergency Stop Circuit

For details of the installation and commissioning, see the operating instructions for the relevant peripher-
al device.

Connect the mains power supply

DANGER
Hazardous mains voltage!
With mains connection, there is a hazardous mains voltage present in the fuses
and inside the machine. Contact with current-carrying parts can result in serious
injuries or death.
Before carrying out servicing tasks, always switch off the machine and disconnect
the mains plug.

Permitted line voltage

Single phase with protective earth
■ 100-240 VAC
■ 50/60 Hz
1
■ 1000 VA

1.▹ Connect the power cord to the power plug (1)

on the machine.
2.▹ Connect the power cord to the mains outlet.

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Connecting compressed air (option)

The compressed air connector is only available when components are built in which need compressed air.

NOTICE
High operating pressure!
Very high pressure damages the compressed air system in the machine.
The supplied compressed air pressure must not exceed the stated value in the
technical specifications.

Permitted pressure
■ Standard 6.0 bar (0.6 MPa)
■ max. 7.0 bar (0.7 MPa)

1.▹ Hook up the air pressure hose (1) on the main-

tenance unit. 1
2.▹ Hook-up the output (2) to the compressed air
connector.
3.▹ Pull up the setting knob (3).
3
4.▹ Set the compressed air supply to 6.0 bar.
2
CW = Increase pressure
CCW = Reduce pressure
➥The set-up pressure is shown on the man- 4
ometer (4).
5.▹ Push the setting knob (3) down.

7.4 SETUP
■ Before the daily operation a visible check on the machine must be carried out.
■ Guides, feeding units and the blade area must be clean.

7.4.1 Guides
Set the diameter of the guides 1-3 mm larger than the outer diameter of the wire. The wire must slide
through the wire guides without resistance.

1.▹ Open the safety cover.

Revolver guide

2.▹ Pull out the lock (1).

3.▹ Turn the revolver guide (2). Thereby select the
matching diameter.
4.▹ Release the lock.
➥The lock must engage. 2

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Swivel guide

5.▹ Hold the guide (X1) and pull off the holder. X1

6.▹ Slide in the matching guide (1) into the holder.

➥The guide engages. The magnets holds the
guide in position.

Rotary incising guide (model MR, RS, RSX)

7.▹ Remove the cover, see "10.3.2 Open the rotary

incising unit (Page 113)".
8.▹ Remove the guide (4) from the unit.
9.▹ Slide in the matching guide (4) into the unit.
10.▹ Mount the cover, see "10.3.2 Open the rotary 4
incising unit (Page 113)".

The illustration shows the model MR. The procedure

hence is the same for all rotary incising units.

Linear guide

11.▹ Hold the guide (X1) and pull off the holder.
12.▹ Slide in the matching guide (1) into the holder.
X1
➥The guide engages. The magnets holds the
guide in position.

7.4.2 Mounting the blades

On a new machine, the blades must be mounted, see "Replacing blades (Page 97)".
In the rotary incising unit CX or RX, the blades are mounted and calibrated already.

7.4.3 Turning machine on

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1.▹ Close the safety cover (1).

1
1.▹ Turn the emergency stop button (2) to the left
or right
➥The emergency stop button is disengaged

2.▹ Switch on the main switch (3) on the back of

the machine.
➥The control software is booting and the mon-
itor is switched on.
➥The control software automatically initializes
the axis. 3

After a new machine has left the factory, „User lev-

els“ is deactivated. The user has access to most com-
mands and functions of the MultiStrip 9480.

7.4.4 Basic settings

Before any use the basic settings on the control software have to be carried out.

1.▹ Confirm the message with [OK] (1).

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2.▹ [NAVIGATION] (2)

2
3.▹ [EXTENDED VIEW] (3)
3

4.▹ [USER] (4)

5.▹ [USER INTERFACE] (5)
4

6.▹ Select the [LANGUAGE] (6) of the user inter-

face.
7.▹ Set the country specific [MEASURING UNIT] (7) 6 7
to „mm“ or „Inch“.
8.▹ Set the country specific [TIME FORMAT] (8) and 8
the [DATE FORMAT] (9).
9
9.▹ Confirm the setting with [OK].
➥Leave the screen.

Activate the access right. This helps to avoid unau-

thorized personnel to operate the machine.
See „Register“ Reference manual S.ON.

7.4.5 Turning machine off

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1.▹ Close the safety cover. 1

2.▹ [PRODUCTION COMMANDS] (1).
3.▹ [UNLOADING] (2). 2

4.▹ Remove the raw material from the machine.

5.▹ Confirm [SHUTDOWN] (3) on the touch screen. 3

6.▹ Confirm [SHUTDOWN] (4) in the drop down
list.
4
7.▹ Confirm the message with [OK].
➥The data are saved.
➥A switch off icon is shown on the touch
screen.

8.▹ Switch off the main switch (5) on the back of

the machine.
9.▹ Unplug the machine from the mains outlet
and the machine.

NOTICE
Do not switch off the main switch directly on the 5
operable machine. Data loss may occur. Shut down
the machine properly.

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7. Commissioning

7.5 PRODUCING A TEST WIRE

To verify the correct functioning of the MultiStrip 9480 after the delivery, a step by step instruction follows
which illustrates the production of a basic wire sample. Before this, the operator must carry out some set-
up work like mounting guide tubes and blades and the blades must be declared and activated in the
"Configuration".
Before continuing with the test wire, the operator must be familiar with chapter „General Operation/
Handling“.
See „Register“ Reference manual S.ON.
Sample specification for the test wire:

Step Quantity Parts Wire length Stripping length Pull-off length

Cut to length 10 Strand 2.5 mm2 200 mm
Stripping left 10 mm 5 mm
Stripping right 10 mm 5 mm

*) Due to the selected pull-off length < stripping length, the wire will only be partially stripped. The strip-
ped piece remains on the conductor.
200 mm

5 mm 5 mm

10 mm 10 mm

Fig. 16: The sample wire

7.5.1 Program a test wire

1.▹ [NAVIGATION] (1) 1
2.▹ [BASIC VIEW] (2)
3 2
3.▹ [ARTICLE LIBRARY] (3)
4.▹ [CREATE NEW FILE] (4)

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5.▹ [SINGLE ARTICLE] (5)

6.▹ [SIMPLE MODE] (6)
7.▹ [OK] (7)

5 6

8.▹ Touch the empty text field (8).

➥The alpha numeric touch-keyboard pops up.

9.▹ Enter the name of the test wire

„Test_wire_2.5mm2“ (9).
10.▹ [OK] (10).
11.▹ [OK] 9

➥The new file created is opened in the "Article

editor".

10

12.▹ Touch the spin button "Wire size" (11).

13.▹ Enter the conductor cross section "2.5".
14.▹ [OK] (12).

11

12

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15.▹ [DEFAULT] (13)

➥The values for the processing are adapted
automatically to the wire size.

13

16.▹ Touch the spin button "Wire length" (14).

17.▹ Enter the wire length = "200" mm
18.▹ [OK]
19.▹ [APPLICATION TYPE RIGHT] (15)
➥From the drop-down menu, select the appli-
cation type "Partial strip" (16).
20.▹ [APPLICATION TYPE LEFT] (17) 14
➥From the drop-down menu, select the appli- 17 15
16
cation type "Partial strip".

21.▹ [EDITOR APPLICATION RIGHT] (18)

➥The screen "Application" shows up.

18

22.▹ Touch the spin button "Stripping length" (19).

23.▹ Enter the stripping length "10".
24.▹ Touch the spin button "Pull-off length" (20).
25.▹ Enter the pull-off length "5".
19

20

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26.▹ Tab [APPLICATION LEFT] (21).

27.▹ Touch the spin button "Stripping length" (22).
28.▹ Enter the stripping length "10".
21
29.▹ Touch the spin button "Pull-off length" (23).
30.▹ Enter the pull-off length "5". 22
31.▹ [OK] (24).

23

24

32.▹ Tab [PRODUCTION DATA] (25).

33.▹ Touch the spin button "Quantity" (26).
34.▹ Enter the quantity "10". 27 25
35.▹ Tab [BASIC WIRE DATA] (27).
26

7.5.2 Produce a test wire

1.▹ Open the safety cover.
2.▹ Insert a stranded wire 2.5 mm2 up in-between
the left feeding belts.
3.▹ Close the safety cover.

4.▹ [PRODUCTION COMMANDS] (1). 1

5.▹ [LOAD] (2).
➥The wire is clamped, fed and cut-through. 2
The slug is ejected.

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7. Commissioning

6.▹ [SINGLE WIRE] (3).

➥The screen "Production" shows up.
3

7.▹ [CONTINUE] (4).

➥The slug is ejected.
➥A single test wire will be produced.

8.▹ Inspect the produced wire and if required cor- 5

rect it again:
6
■ Wire length (5)
■ Stripping length (6) 7
■ Pull-off length
■ Quality of the stripping (Incision quality, no
strands damaged, no nicking (7)?, is the
wire not squeezed (8)?)

To improve the wire quality, the following chapters

in the Reference manual "S.On" may be helpful.
See „Register“ Reference manual S.ON.
■ To localize typing errors, see Programming
examples.
■ For a detailed description on Processing set-
tings (diameter, retraction, contact pressure,
feeding speed etc.), see Simple programming
mode.
■ For errors or improper configuration settings on
the machine, see Diagnostics.

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9.▹ [RUN] (9).

➥The desired quantity of wires is produced.
9

10.▹ Wait for the production to be finished.

➥The screen "Production" informs about pro-
gress and status of the production.

11.▹ [OK] (10).

➥Confirm the information "Production com-
plete" and leave the screen.

10

12.▹ [OK] (11).

➥The warning appears.
13.▹ [OK]
➥Confirm the warning.
➥The file is saved and the screen is left.

11

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8. Programming examples

PROGRAMMING EXAMPLES
For examples to our Schleuniger MultiStrip 9480, we refer to the add-on document „Programming exam-
ples for wire processing“. There you will find different examples from the field, which can be work through,
and give the user an in-depth understanding in handling the control software S.On.
See Table of contents.

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FAULT LOCALIZATION
Errors and others can occur if excessive pollution affects the components. If the Fan filters are dirty, it is
recognized specially with height ambient temperature.
Regular inspection and maintenance reduces the risk of unexpected faults and increases the reliability
and life cycle of the machine. Maintenance work must be accomplished according to the instructions and
the time intervals listed. See chapter "10 Maintenance (Page 93)".
The machine is equipped with a comfortable diagnostics software, which is used to monitor the state of
the machine and the connected peripheral devices. Here the user can check the parts of the machine and
the peripheral devices in case of an error condition.

9.1 SAFETY INSTRUCTIONS

9.1.1 General
Safety appliances must not be deactivated or removed inadvertently.
If a fault condition occurs always check first if the line power is switched on and then perform a diagnostic
check.

Personnel qualification
The instructions in this chapter must be carried out by qualified personnel!

9.2 BEHAVIOR IN CASE OF AN ERROR

In case of an unrecoverable fault contact your local Schleuniger distributor, see "Page 2".
Thereby, always report the software version number. Additionally inform about the selected stripping
type and if the wire/cable was stripped in normal- or "Short mode".
If an error shows up on the touch screen which tends to be unrecoverable, the user has the option via the
button displayed, to save an error log to an USB memory stick inserted on the operator panel. This log can
then be handed over to the local Schleuniger distributor for analysis.

9.3 DISPLAY OF ERRORS

Most errors are recognized by the software or the internal electronics. These are shown on the touch
screen.

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9. Fault localization

9.4 MACHINE FAULTS

Diagnostics Cause of fault Actions to be taken
The machine does not ■ Blown fuse ■ Exchanging mains fuses
respond. ■ Not connected to the mains ■ Plug in power cord
■ Emergency stop button engag- ■ Disengage the emergency stop
ed button
■ Safety cover is open ■ Close the safety cover
■ Main switch off ■ Turn on the main switch
Production cannot be star- ■ Entering of values not comple- ■ Touch [OK] or [CANCEL]
ted ted ■ Switch on peripheral devices or
■ Peripheral devices not switched brake connection to the
on machine
■ Emergency stop button engag- ■ Disengage the emergency stop
ed button
■ Safety cover is open ■ Close the safety cover
Feeding mechanism not ■ Tension force on wire straight- ■ Reduce tension force to the
working ener too high wire straightener
■ Wire feeding improperly ■ Check for constant and smooth
■ Transport speed too high wire guiding
■ Reduce feed speed and velocity
No feeding even if transport ■ Contact pressure too low ■ Increase contact pressure
belts are moving ■ Outworn or slippery transport ■ Replace feeding belts
belts ■ Reduce tension force to the
■ Tension force on Wire straight- wire straightener
ener too high
Cable length not correct ■ Wrong setting ■ Correct setting
■ Transport speed too high ■ Alter feed speed
■ Slippage ■ Increase contact pressure
■ Calibrated length in the "Feed ■ Repeat calibration
resolution" is not correct
Bad incision quality ■ Outworn blades ■ Replacing blades
■ Improper fine tuning ■ Correct fine tuning
■ Elastically insulation ■ Increase incision pause
■ Wrong blade type ■ Use suitable blades
Insulation is not stripped ■ Pull-off speed too high ■ Adjust pull-off speed
anymore ■ Contact pressure too low ■ Increase contact pressure
■ Outworn or slippery feeding ■ Exchanging feed belts
belts ■ Alter incision diameter
■ Incision diameter not set deep ■ Mount other blade type
enough ■ Replacing blades
■ Wrong blade type ■ Increase pull-off length
■ Outworn blades
■ Pull-off length too short
Cable is flat or damaged ■ Contact pressure too high ■ Correct contact pressure
Slug is stuck in-between the ■ Wire warped ■ Eject slug with [CUT]
feeding belts ■ Wire too short

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Diagnostics Cause of fault Actions to be taken

Error Inkjet printer ■ The Inkjet printer is not ready or ■ Switch on device
switched off ■ Check power connection
■ Confirm error on the display of
the Inkjet printer
Error CableCoiler ■ The CableCoiler is not ready or ■ Switch on device
switched off ■ Check power connection
Safe mode was activated ■ Ambient temperature too high ■ Wait until the machine has
during production ■ Machine is overheated with cooled-down and then restart
high transport speed/ramp ■ Reduce the speed/ramp, use a
stabilization transformer if the
mains voltage is too low,
(<100 V)
The LED in the power on/off ■ A serious hardware fault exists ■ Perform a general diagnostic,
switch is blinking constantly see above
(no display on the operator ■ Contact the service department
panel) of your Schleuniger distributor
The LED in the power on/off ■ The software upgrade has ■ Check the logging file on the
switch is blinking after a soft- failed PC and forward the data to the
ware upgrade service department of your
local Schleuniger distributor
During or after the software ■ The software upgrade has ■ Forward the error number to
upgrade, a general error failed the service department of your
message is shown on the Schleuniger distributor
operator panel

9.5 DRAWINGS / CIRCUIT DIAGRAMS / FLOW DIAGRAMS

Drawings, circuit diagrams and diagrams can be useful during troubleshooting.
Refer to the file "Operating Manual"

9.6 ACTIONS AFTER SOLVING ERRORS

To check the correct functioning of the machine before the series production, a functional check has to
be performed.

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10. Maintenance

MAINTENANCE
The machine must regularly be inspected and maintained. This way unexpected faults can mostly be
avoided.
The following chapters support the personnel in maintaining again the machine within a reasonable time.
■ Maintenance
■ Settings
■ Repair work

Only the maintenance work stated in this operating instruction must be carried out. The personnel must
have the required skill. For all other work consult your local Schleuniger distributor.
The stated intervals refer to one-shift-operation (9h). For work in multiple shift operation, the interval
times are shorten accordingly.

Parts subject to wear and tear

This wear parts are subject to particularly high wear. The service life depends on the operational time and
the material to be processed. Wear parts are to be replaced with moderate effort. Thus only short down-
time results.
■ Feed belts
■ Blade
■ Blades rotary incising unit

Drawings, spare parts, exploded views

■ Available spare parts are listed in the "Parts Catalog".
■ Additional information to the maintenance work can be found in the component drawings and the
diagrams of the electric parts. See "14.2 Block diagram electric (Page 166)".

CAUTION
Use of unverified spare parts!
Unverified- or defective spare parts can lead to personnel injury or property damage.
To avoid any damage, exclusive use of original Schleuniger spare parts is imperative.

10.1 CUSTOMER SERVICE

On serious faults or damage, the help of a specialist may be necessary. For that, the Schleuniger distributor
or the service specialists can help. These need a detailed description of the problem.
■ Exact product description
■ Serial number of the product
■ Software version (incl. language packages)
■ Exact description of the fault (error no. shown on touch screen, if available)
■ Under what circumstances has the error shown up
■ What peripheral devices where connected to the machine when the error occurred
■ Wire type to be produced at the time the error occurred

Some of this information is available in the diagnostics of the operating software.

For technical support, see „www.schleuniger.com“.

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10. Maintenance

10.2 MAINTENANCE SCHEDULE

The maintenance schedule summarizes the work.

Maintenance task Page Duration Interval Personnel qualification

Cleaning (95) 5 Min. Daily Operator
Exchanging fan filters (96) 5 Min. Check monthly. Replace Operator
every half year.
Exchanging single blade (97) 5 Min. Check daily. Replace as Operator
needed
Exchanging multi blades (98) 10 Min. Check daily. Replace as Operator
needed
Mounting the slitting unit (101) 5 Min. As needed Operator
Mounting combing unit (104) 5 Min. As needed Operator
Exchanging feed belts (107) 10 Min. Check daily. Replace as Technical specialists
needed
Lubricating drives (114) 10 Min. every 6 months Technical specialists
Lubricating linear grease (115) 10 Min. every 6 months Technical specialists
Calibration of feeding belts (117) 5 Min. - Technical specialists
Calibrating V-Blades (120) 5 Min. - Operator
Calibrating the Die-Blades (122) 5 Min. - Operator
Calibration of user defined blades (123) 5 Min. - Operator
Adjusting jam detector (option) (124) 5 Min. As needed Technical specialists
Adjusting slitting depth (126) 1 Min. As needed Operator
Adjusting centering force RSX, RX (128) - As needed Qualified personnel
Replacing blades rotary incising unit (129) 5 Min. Check daily. Replace as Technical specialists
MR, RS needed
Replacing blades rotary incising unit (130) 5 Min. Check daily. Replace as Technical specialists
RSX, RX needed
Mains fuses replace (133) 2 Min. - Technical specialists
Safety check electronics (135) 5 Min. - Technical specialists

10.3 MAINTENANCE
The maintenance involves regular cleaning work and the replacement of wearing parts.

NOTICE
Cleaning!
■ For cleaning do not use aggressive solvents
Painting and plastic parts may be damaged.
■ Do not use compressed air for cleaning.
Dust and conduction parts may lead to malfunction of the machine.

Clean the exterior casing and the plastic parts with a soft cloth and a usual com-
mercial cleaning agent.

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10. Maintenance

Cleaning

Goal Clean processing area. Avoid faults and malfunction.

Duration 5 Min.
Interval Daily
Personnel qualification Operator
Support tools ■ Brush
■ Cleaning cloth
■ Vacuum cleaner
■ Commercial cleaning agent
Prerequisite Unloading raw material

DANGER
Hazardous mains voltage!
With mains connection, there is a hazardous mains voltage present in the fuses
and inside the machine. Contact with current-carrying parts can result in serious
injuries or death.
Before carrying out servicing tasks, always switch off the machine and disconnect
the mains plug.

1.▹ Open the safety cover.

2.▹ Remove residue and dirt from the processing 1
area with a brush and a vacuum cleaner.
3.▹ Clean the cutting unit (1) and the feeding unit
(2) properly with a brush.
4.▹ Clean heavily polluted feeding belts.

5.▹ Clean the casing with a soft cloth.

6.▹ Clean the dust filters on the fans (3) with a vac-
uum cleaner.
7.▹ Clean heavily polluted parts with a commercial
cleaning agent.
8.▹ Close the safety cover.
9.▹ Empty the waste container bellow the
machine.

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10. Maintenance

Dirt and debris affect the sensors on the exit. This

leads to maloperation and faults on the jam detec- 4
tor.

10.▹ Remove residue and dirt from the exit area

with a brush and a vacuum cleaner.
11.▹ Clean the sensors (4) of the jam detector left
and right on the exit with a brush. (For a
detailed view, the access protection is
removed.)

Exchanging fan filters

Goal Avoid overheating and damage to the machine

Duration 5 Min.
Interval Check monthly. Replace every half year.
Personnel qualification Operator
Parts 2 pcs. filter pad 115×115 mm
Prerequisite Machine switched off and power cord disconnected

NOTICE
Property damage caused by pollution
Without filter dust and dirt deposits inside the machine. It may cause leakage cur-
rents an short circuit in the electronics.
If the filters are heavily polluted the machine overheats.
■ Never operate the machine without filters.
■ Only use original filters from Schleuniger.

The diagnostics of the control software informs about the inside temperature of the machine. Detailed
information for this, can be found in the Reference manual S.ON.
See „Register“ Reference manual S.ON.

1.▹ Remove the cover (1).

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2.▹ Replace dirty filters (2).

3.▹ Put on the cover (1) onto the fan and press on
to each side.

10.3.1 Replacing blades

Not all blades are mounted the same way for the different models. The procedure differs in cutting unit,
single- or multi blades (cartridge).

Exchanging single blade

Goal Replace defective or worn out blades.

Duration 5 Min.
Interval Check daily. Replace as needed
Personnel qualification Operator
Support tools Allen key 4,0 mm, 3,0 mm
Parts Pair of blades
Prerequisite Machine operational

1.▹ [NAVIGATION] (1)

1
2.▹ [BASIC VIEW] (2)
3.▹ [SET UP] (3) 3 2

4.▹ [BLADE] (4)

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10. Maintenance

5.▹ On position „1.“ select the type [V] (5).

➥On the 1. blade position a V-blade is config-
ured.
6.▹ [CHANGE BLADES] (6) 5
➥The blade holders are positioned.
7.▹ Open the safety cover.

After a new machine has left the factory, no blades

are mounted. Continue with step 11.
CAUTION: The cutting edge of the blades are very
sharp. This leads to stab wound and concussion 8
injury on fingers. Do not touch the blades on the
cutting edge.

8.▹ Loosen the screws (7)

9.▹ Remove the blades (8).
10.▹ Clean the blade holders‘ contact surface. 7
11.▹ Attach the blades (8) and mount with the screw
(7).
12.▹ Close the safety cover.
13.▹ Confirm the message with [OK].
➥The blades are configured.
14.▹ Confirm the setting with [OK].
➥Leave the screen.

Exchanging multi blades

Goal Replace defective or worn out blades

Duration 10 Min.
Interval Check daily. Replace as needed
Personnel qualification Operator
Support tools Allen key 4,0 mm, 3,0 mm
Parts ■ Cartridge
■ Pair of blades
Prerequisite Machine operational

The procedure describes the common usage of V- and radius blades. Other blade types are mounted the
same way. Only the values in the blade configuration are different.

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1.▹ [NAVIGATION] (1)

1
2.▹ [BASIC VIEW] (2)
3.▹ [SET UP] (3) 3 2

4.▹ [BLADE] (4)

5.▹ Select „Blade width“ [2× 16 MM] (5).

6.▹ On position „1.“ select the type [V] (6).
➥On the 1. blade position a V-blade is config- 5
ured.
7.▹ On position „2.“ select the type [RADIUS] (7). 6
➥On the 2. position, a radius blade is config-
7
ured.
8.▹ [CHANGE BLADES] (8)
➥The blade holders are positioned.
8
9.▹ Open the safety cover.

10.▹ Remove the swivel- or movable guide of the Z-

Axis.
11.▹ Remove the screws (10).
12.▹ Loosen the screws (11).
10

11

13.▹ Pull out the cartridge (12) from the pins.

12

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10. Maintenance

14.▹ Pull out the lower cartridge (13) up and out of

the guides.
15.▹ Clean the surface contact area on the blade
holders and the cartridges.

13

CAUTION: The cutting edge of the blades are very

sharp. This leads to stab wound and concussion 14
injury on fingers. Do not touch the blades on the
cutting edge.

16.▹ Loosen screws (14) and remove one or several

blade pairs.
17.▹ Clean the surface (15) on the cartridge.

15

18.▹ Attach both V-bladed (16) on position 1 and

screw on.
16
19.▹ Attach both radius blades (17) on position 2
and screw on.

The blades must lie evenly on the support surface.

Otherwise the blades may brake off.

17

20.▹ Slide the cartridge (12) onto the pins.

10
21.▹ Tighten the screws (10) with a tool.

12

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22.▹ Slide in the lower cartridge (13) from top into

the guides.
➥Carefully observe that the cartridge remains
13
full on the guides. Blade bars and cartridge
must flush on the underside.
23.▹ Tighten the screws (11) with a tool.
24.▹ Close the safety cover.

11

25.▹ Confirm the message with [OK].

➥The blades are configured.
26.▹ Confirm the setting with [OK].
➥Leave the screen.

Mounting the slitting unit

Goal Mount the slitting unit on the cartridge

Duration 5 Min.
Interval As needed
Personnel qualification Operator
Support tools Allen key 4,0 mm, 3,0 mm
Parts ■ Radius blades
■ Slitting unit
Prerequisite Machine operational

On position "1" mount a blade for stripping and for cutting through.
The slitting unit can only be mounted on position "2" on the cartridge

1.▹ [NAVIGATION] (1)

1
2.▹ [BASIC VIEW] (2)
3.▹ [SET UP] (3) 3 2

4.▹ [BLADE] (4)

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5.▹ Select „Blade no.“ [2× 16 MM] (5).

6.▹ On position „1.“ select the type [RADIUS] (6).
➥On the 1. blade position, a Radius blade is 5
configured.
7.▹ On position „2.“ select the type [SLITTING 6
UNIT] (7).
7
➥On the 2. position the slitting unit is config-
ured.
8.▹ [CHANGE BLADES] (8)
➥The blade holders are positioned. 8

9.▹ Open the safety cover.

10.▹ Remove the swivel- or movable guide of the Z-

Axis.
11.▹ Remove the screws (10).
12.▹ Loosen the screws (11).
10

11

13.▹ Pull out the cartridge (12) from the pins.

12

14.▹ Pull out the lower cartridge (13) up and out of

the guides.
15.▹ Clean the surface contact area on the blade
holders and the cartridges.

13

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CAUTION: The cutting edge of the blades are very

sharp. This leads to stab wound and concussion 14
injury on fingers. Do not touch the blades on the
cutting edge.

16.▹ Loosen screws (14) and remove one or several

blade pairs.
17.▹ Clean the surface (15) on the cartridge.

15

18.▹ Attach both radius blades (16) on position 1

and screw on.
16
19.▹ Attach the slitting unit (17) to position "2" on
the lower cartridge and mount with the screw.
20.▹ Attach the prism (18) to position "2" on the
upper cartridge and mount with the screw.

The blades must lie evenly on the support surface. 18

Otherwise the blades may brake off.
17

21.▹ Slide the cartridge (12) onto the pins.

10
22.▹ Tighten the screws (10) with a tool.

12

23.▹ Slide in the lower cartridge (13) from top into

the guides.
➥Carefully observe that the cartridge remains 13
full on the guides. Blade bars and cartridge
must flush on the underside.
24.▹ Tighten the screws (11) with a tool.
25.▹ Close the safety cover.

11

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10. Maintenance

26.▹ Confirm the message with [OK].

➥The blades are configured.
27.▹ Confirm the setting with [OK].
➥Leave the screen.

28.▹ Adjust the slitting depth.

See settings .

Mounting combing unit

Goal Mount the combing unit on the cartridge

Duration 5 Min.
Interval As needed
Personnel qualification Operator
Support tools Allen key 4,0 mm, 3,0 mm
Parts ■ V-Blades or Radius blades
■ Multi conductor radius blades
■ Combing unit
Prerequisite Machine operational

Using the combing unit in combination with a pair of Radius blades and multi conductor Radius blades.
This combination allows optimal stripping results.
The combing unit functions autonomous. There are no adjustment in the control unit.

1.▹ [NAVIGATION] (1)

1
2.▹ [BASIC VIEW] (2)
3.▹ [SET UP] (3) 3 2

4.▹ [BLADE] (4)

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5.▹ Select „Blade no.“ [2× 16 MM] (5).

6.▹ On position „1.“ select the type [RADIUS] (6).
➥On the 1. blade position, a Radius blade is 5
configured.
7.▹ On position „2.“ select the type [RADIUS] (7). 6
➥On the 2. position, a multi conductor Radius
7
blade is configured.
8.▹ [CHANGE BLADES] (8)
➥The blade holders are positioned.
8
9.▹ Open the safety cover.

10.▹ Remove the swivel- or movable guide of the Z-

Axis.
11.▹ Remove the screws (10).
12.▹ Loosen the screws (11).
10

11

13.▹ Pull out the cartridge (12) from the pins.

12

14.▹ Pull out the lower cartridge (13) up and out of

the guides.
15.▹ Clean the surface contact area on the blade
holders and the cartridges.

13

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10. Maintenance

CAUTION: The cutting edge of the blades are very

sharp. This leads to stab wound and concussion 14
injury on fingers. Do not touch the blades on the
cutting edge.

16.▹ Loosen screws (14) and remove one or several

blade pairs.
17.▹ Clean the surface (15) on the cartridge.

15

18.▹ Attach both radius blades (16) on position 1

16
and screw on.
19.▹ Attach both multi conductor Radius blades (17)
on position 2 and screw on.
20.▹ Attach the combing unit with the screws to the
upper and lower mounting thread (18) .
17
The blades must lie evenly on the support surface.
Otherwise the blades may brake off.

18

21.▹ Slide the cartridge (12) onto the pins.

10
22.▹ Tighten the screws (10) with a tool.

12

23.▹ Slide in the lower cartridge (13) from top into

the guides.
➥Carefully observe that the cartridge remains
full on the guides. Blade bars and cartridge 13
must flush on the underside.
24.▹ Tighten the screws (11) with a tool.
25.▹ Close the safety cover.

11

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26.▹ Confirm the message with [OK].

➥The blades are configured.
27.▹ Confirm the setting with [OK].
➥Leave the screen.

Exchanging feed belts

Goal Check or replace defective or worn out feed belts

Duration 10 Min.
Interval Check daily. Replace as needed
Personnel qualification Technical specialists
Support tools Allen key 4,0 mm
Parts Feed belts
Prerequisite Machine operational

This procedure is identical for the left and right feeding units. Both are identical
Always replace the feed belts in pairs

1.▹ [NAVIGATION] (1) 1

2.▹ [EXTENDED VIEW] (2)
2
3.▹ [CONFIGURATION] (3) 3
4.▹ [MACHINE] (4)

5.▹ [FEEDING UNITS] (5)

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10. Maintenance

6.▹ [CHANGE FEEDING BELTS] (6)

7.▹ Remove the raw material.

8.▹ Confirm the message with [OK].
➥The machine is ready.

9.▹ Open the safety cover.

➥The machine changes over to the protected
mode.

10.▹ Loosen screw (X1) for two turns, do not remove

completely. X1

11.▹ Turn tension pulley (X2) until the feeding belt is

released.
Tension pulley upper = UZS X2
Tension pulley lower = GUZS
12.▹ Remove the tension pulley (X2).

13.▹ Pull off the feed belt from the pulley (9) and
remove it. 9

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14.▹ Attach the feed belt to the pulley (10) and

bring into position. 10

15.▹ Attach the tension pulley (X2).

X1
➥The toothing of the feeding belt must match
in the pulleys. X2

16.▹ Turn tension pulley (X2) until the feeding belt

touches the support pulley (X3).
Tension pulley upper = GUZS
Tension pulley lower = UZS

NOTICE Heavily tensioned feed belts may lead to X3

damage the feeding unit.
■ Do not overwind the tension pulley.
■ Tension the tension pulley without using any
tool.

17.▹ Tighten the screw (X1).

18.▹ Close the safety cover.
19.▹ Confirm the message with [OK].
20.▹ Confirm the settings with 2× [OK].
➥Leave the "Feeding unit" screen.

For the feeding unit calibration, see .

10.3.2 Opening the housing

For any repair of defective parts and components, the housing of the machine must be partially or com-
pletely removed.

DANGER
Hazardous mains voltage!
With mains connection, there is a hazardous mains voltage present in the fuses
and inside the machine. Contact with current-carrying parts can result in serious
injuries or death.
Before carrying out servicing tasks, always switch off the machine and disconnect
the mains plug.

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10. Maintenance

Removing the upper cover

Goal Access to the mechanical components

Duration 2 Min.
Interval -
Personnel qualification Technical specialists
Support tools -
Prerequisite Machine switched off and power cord disconnected.

1.▹ Loosen both screws (1).

1

2.▹ On both sides slide the screws with the locks

(2) outwards. 2

3.▹ Push the upper cover (3) against the front.

3

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4.▹ Lift up the upper cover.

Mounting the upper cover

5.▹ Place the upper cover on top of the machine.

➥The cover must stand back on the rear.
➥Observe that the cover is leveled flat.
6.▹ Push the upper cover against the rear.
➥The six flaps must lock in the machine chas-
sis.
7.▹ On both sides slide the locks (2) inwards.
8.▹ Tighten the two screws (1).

Open the rear cover

Goal Access to the electronic components

Duration 2 Min.
Interval -
Personnel qualification Technical specialists
Support tools Hex screwdriver 4,0 mm
Prerequisite Machine switched off and power cord disconnected.

1.▹ Loosen both screws (X1) on the rear cover.

X1
1

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10. Maintenance

2.▹ Swivel down the rear cover.

➥The cord limits the opening range.

Mounting the rear cover

3.▹ Mount the rear cover in opposite direction.

➥Tighten the two screws (X1) only with the
hex screwdriver. The cover may be deformed if
tightening to much.

Remove the front

Goal Access to the mechanical components on the outside

Duration 2 Min.
Interval -
Personnel qualification Technical specialists
Support tools Allen key 4.0 mm
Prerequisite Machine switched off and power cord disconnected.

1.▹ Loosen both screws (1).

1
2.▹ Remove the safety cover (2).

3.▹ Turn the lock (3) ¼ in the direction of the

machine.
4.▹ Swivel down the flap (4).

3 4

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Mounting the front

5.▹ Swivel up the lower cover and lock it.

6.▹ Mount the safety cover.
➥Screw on both screws (1) squared to not
damage the thread.

Open the rotary incising unit

Goal Access to the rotary incision unit.

Duration 2 Min.
Interval -
Personnel qualification Technical specialists
Support tools Allen key 3.0 mm
Parts
Prerequisite ■ Machine switched off and power cord disconnected.
■ Front opened, see "10.3.2 Remove the front (Page 112)".

The illustration shows the model MR. The procedure hence is the same for all rotary incising units.

1.▹ Pull out the lock (1).

2.▹ Swivel the cover (2) away from the machine
and slide off the bolts.
1

3.▹ Loosen the screw (3).

4.▹ Swivel out the unit (4).

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10. Maintenance

Mounting the cover

3
5.▹ Swivel in the unit (4).
6.▹ Tighten the screw (3).
4

7.▹ Slide the cover onto the bolts (5).

8.▹ Swivel the cover in direction of the machine.
➥The lock (1) must engage.
1

Lubricating drives

Goal Lubricate the gearing of the feeding unit

Duration 10 Min.
Interval every 6 months
Personnel qualification Technical specialists
Support tools Allen key 4.0 mm
Parts ■ Microlube GBU-Y 131
■ Brush
Prerequisite Machine switched off and power cord removed

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1.▹ Lift up the upper cover, "Removing the upper

cover (Page 110)".
1 1
2.▹ Remove the safety cover, "Remove the front
(Page 112)".

3.▹ With the brush apply some lubricating grease

to the toothing of the spur gear of both feed-
ing units.
4.▹ Move around the feeding belts manually.
➥The grease is distributing in the drives.
5.▹ Possibly put on some more grease while mov-
ing around the feeding belts.
➥An equal thin film of grease shall be formed
on the toothing of the spur gear.

Notice waste grease is thrown from the drives to

adjacent components. Electronic components and
plastic parts may be damaged due to the chemical
reaction of the grease.
Only apply little grease. Clean adjacent components
from grease.
6.▹ Swivel up the lover cover and attach it.
7.▹ Mount the safety cover.

8.▹ Mount the upper cover.

Lubricating linear grease

Goal Lubricate the drives of the linear guide, the Z-axis

Duration 10 Min.
Interval every 6 months
Personnel qualification Technical specialists
Support tools Allen key 4.0 mm
Parts ■ Microlube GBU-Y 131
■ Brush
Prerequisite Machine switched off and power cord removed

1.▹ Lift up the upper cover, "Removing the upper

cover (Page 110)". 1

2.▹ Remove the safety cover, "Remove the front

(Page 112)".

3.▹ With the brush apply some lubricating grease

to the pinion.
4.▹ Move the linear guide forth and back manually.
➥The grease is distributing.
5.▹ Possibly put on some more grease while mov-
ing around the linear guide.
➥An equal thin film of grease shall be formed
on the toothing.

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10. Maintenance

6.▹ Swivel up the lover cover and attach it.

7.▹ Mount the safety cover.

8.▹ Mount the upper cover.

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10.4 SETTINGS
If the machine leaves the factory it is calibrated exactly.
A calibration is necessary in the following cases:
■ Replacement of blades.
New blades normally must not be calibrated. Anyway if misalignment occurs a calibration has to be
performed.
■ Replacement of mechanical components
■ Replacement of electronic components
■ Use of peripheral devices
■ Improper production results

Calibration of feeding belts

Goal Checking/correcting the feeding and the gap of the feed belts
Duration 5 Min.
Interval -
Perform after ■ Length deviation of wires
■ Changing belts
■ Retrofit from rollers to belts
■ Retrofit from belts to rollers
■ Retrofit to short mode
Personnel qualification Technical specialists
Support tools Sliding caliper
Parts Stranded wire 10 mm2 or AWG 8.
Prerequisite ■ Machine operational
■ Unloading a wire
■ Follow the calibration order

1.▹ [NAVIGATION] (1) 1

2.▹ [EXTENDED VIEW] (2)
2
3.▹ [CONFIGURATION] (3) 3
4.▹ [MACHINE] (4)

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10. Maintenance

5.▹ [FEEDING UNITS] (5)

Left feeding unit

6.▹ [CALIBRATION LEFT GAP AXIS] (6)

7.▹ Open the safety cover.

8.▹ Measure the gap in-between the feed belts 7
with a sliding caliper (7).
9.▹ Close the safety cover.

10.▹ Enter the measured value in the "Distance" (8)

field.
11.▹ Confirm the settings with [OK] (9).
➥Leave the screen.

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10. Maintenance

Right feeding unit

12.▹ Repeat the calibration procedure (10) on the

right feeding unit.

10

Feeding axes

13.▹ [CALIBRATE FEEDING AXES RESOLUTION] (11)

14.▹ Open the safety cover.

11

15.▹ Insert a stranded wire 10 mm2 or AWG 8 up in-

between the left feeding belts.
16.▹ Close the safety cover.

17.▹ [LOAD] (12)

➥The wire is clamped, fed and cut-through.

12

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10. Maintenance

18.▹ [SINGLE] (13)

➥One wire will be produced.
➥If necessary produce additional wires.
19.▹ [CONTINUE] (14)

13

14

20.▹ Exactly measure the length of the wire.

21.▹ Enter the measured value in the "Length" (15)
field.
22.▹ Confirm the settings with [OK] (16).
➥The feeding axes resolution is recalculated
from the measured value.
23.▹ 2 x [OK]
15
➥Leave the screen.

16

Calibrating V-Blades

Goal Checking/correcting the gap of the V-Blades

Duration 5 Min.
Interval -
Perform after ■ Improper incision
■ Repair of cutting unit
Personnel qualification Operator
Support tools ■ Flash light
■ V-Blades
Prerequisite ■ V-Blades mounted
■ Machine operational

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1.▹ [NAVIGATION] (1)

1
2.▹ [BASIC VIEW] (2)
3.▹ [SET UP] (3) 3 2

4.▹ [BLADE] (4)

5.▹ Select [V] V-Blade( 5).

6.▹ [CALIBRATE] V-Blade (6).
➥The wizard starts.

5 6

7.▹ If required, mount V-Blades.

8.▹ [CONTINUE] (7)

9.▹ Point a flashlight beam from the left of the cut-

ting unit to the direction of the blades.
10.▹ Observe the blades from the right side of the
machine.

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10. Maintenance

11.▹ Close the blades step by step, until the light in

the center of the blade edges disappears.
Large steps = 0.1mm) (8)
Small steps = 0.01 mm) (9)
12.▹ Open the V-Blades step by step, until the light
in the center of the blade edges just appears.
Large steps = 0.1mm) (11)
Small steps = 0.01 mm) (10) 8 9 10 11 12

With [RESTORE] (12), the blades travel back to the

starting position. The procedure may be repeated.
13
13.▹ [OK] (13).
➥The settings are taken over and the wizard
terminates.

With "Cancel", the wizard is terminated without

changing any previous settings.

14.▹ [OK]
➥Leave the "Blade" screen. The settings are
saved.

Calibrating the Die-Blades

Goal The gap of the Die blades must always be calibrated

Duration 5 Min.
Interval -
Perform after Mounting Die blades on cartridge
Personnel qualification Operator
Support tools Die blades
Prerequisite ■ Die blades mounted
■ Machine operational

1.▹ [NAVIGATION] (1)

1
2.▹ [BASIC VIEW] (2)
3.▹ [SET UP] (3) 3 2

4.▹ [BLADE] (4)

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5.▹ Select [DIE] Die Blade( 5).

6.▹ [CALIBRATE] Die Blade (6).
➥The wizard starts.

5 6

7.▹ When required, mount Die blades.

8.▹ [CONTINUE] (7)
➥The calibration is starting.

The Die blades are closing down until the drive

mechanism blocks. This value is saved and taken
over as Z-null position for the Die blades.
The position of the closed Die blades must be in the
valid range. If the values are out of the given limits,
the Die blades should be checked for proper
mounting and if needed be corrected.

9.▹ [OK] (13).

➥The settings are taken over and the wizard
terminates. 13

10.▹ [OK]
➥Leave the "Blade" screen. The settings are
saved.

Calibration of user defined blades

Goal User defined blades (user defined) have individual dimensions. The gap must
be entered manually.
Duration 5 Min.
Interval -
Personnel qualification Operator
Support tools ■ Special blades
■ Default value "Z-zero" (delivered with blade)
Prerequisite ■ User defined blade mounted
■ Machine operational

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10. Maintenance

1.▹ [NAVIGATION] (1)

1
2.▹ [BASIC VIEW] (2)
3.▹ [SET UP] (3) 3 2

4.▹ [BLADE] (4)

5.▹ Select [USER DEFINED] User defined blade (5).

6.▹ [Z-ZERO] entry field (6).
➥The touch-keyboard shows up

5
6

7.▹ Enter default value.

8.▹ [OK] (7).
➥Confirm entry. The default value is taken over
into the value field.

9.▹ [OK]
➥Leave the "Blade" screen. The settings are
saved.

Adjusting jam detector (option)

Goal Adjust sensitivity of jam detector

Duration 5 Min.
Interval As needed
Personnel qualification Technical specialists
Support tools ■ Wire approx. Ø 2.0 mm
■ Hex key 2.5 mm
Prerequisite Machine operational

Operating the jam detector is described detailed in "14.4 Operator Manual Banner DF-G1 (Page 172)".

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10. Maintenance

1.▹ Open the safety cover.

2.▹ Loosen both screws (1) and remove the access
protection.

3.▹ Loosen the screws (2) and remove the right

side cover (3).

4.▹ Close the safety cover.

5.▹ Connect the machine to the mains.
6.▹ Switch on the machine.
➥Wait for the boot process to be finished.
7.▹ Open the cover of the sensor and set the switch
(4) to „DO“. 4 5
8.▹ Set switch (5) to „ADJ“.
9.▹ Touch switch „SET“ (6).
➥The light level without a wire is saved.

8 9 6

10.▹ Hold a fine wire (approx. Ø 2 mm) (7) in-

between the light barrier and touch „SET“ (6)
again.
➥The light level with wire is saved.
11.▹ Remove the wire.
12.▹ Set switch (5) to „RUN“.
➥The difference from light level „red“ (8) to the
threshold „green“ (9) is approx.:
■ 100 ±30 for wires Ø ≤2 mm
■ 150 ±30 for wires Ø ≤4 mm 7

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10. Maintenance

Possibly correct the threshold.

5
13.▹ Set switch (5) to „ADJ“.
14.▹ Change the threshold (9) with the switch (6),
increase „+“ or decrease „–“.
15.▹ Set switch (5) to „RUN“.

Dirt and debris affect the sensors on the exit. This

leads to maloperation and faults on the jam detec- 9 6
tor.
The difference value should not exceed 70.

16.▹ Open the safety cover.

17.▹ Mount the right cover (3) with the screws (2).

18.▹ Mount the access protection with both screws

(1).
19.▹ Close the safety cover.
20.▹ Switch off the machine.

Adjusting slitting depth

Goal Adjust the slitting depth into jacket on the slitting unit.
Duration 1 Min.
Interval As needed
Personnel qualification Operator
Support tools Wire sample
Prerequisite ■ Slitting unit mounted
■ Machine operational

Calculation formula
L1 = Set value of setting screw
L1 = L2 + L3 L2 = Distance blade to wire
L3 = Jacket thickness

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Ø mm L2 mm
3 0.62 Ø

4 0.83
5 1.04 L3

6 1.24
L2
7 1.45
8 1.66
9 1.86
10 2.07
11 2.28
12 2.49
L1

1.▹ Measure the outer diameter of the wire (Ø).

2.▹ Read the corresponding value (L2) from chart.
3.▹ Measure the jacket thickness (L3).
4.▹ Add both values (L2) and (L3).

5.▹ Open the safety cover.

6.▹ Loosen the set screw (1).
7.▹ Adjust the calculated setting "L1" on the micro-
meter (2).
8.▹ Tighten the set screw (1).
9.▹ Close the safety cover. 1

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10. Maintenance

Adjusting centering force RSX, RX

Goal Reduce or increase the force for centering the wire in the rotary incising unit.
Duration -
Interval As needed
Personnel qualification Qualified personnel
Support tools Hex key 1.5 mm
Prerequisite Machine switched off

10.▹ Swivel out the rotary incising unit, "10.3.2

Open the rotary incising unit (Page 113)". 1

1.▹ Loosen the set screw (1).

2.▹ Turn the nut (2).
➥Plus (+) = increase centering force
➥Minus (–) = decrease centering force +
– 2
3.▹ Tighten the set screw (1).
4.▹ Swivel back the rotary incising unit and attach
the cover, see "10.3.2 Open the rotary incising
unit (Page 113)".

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10. Maintenance

10.5 REPAIR WORK

Repair work describes the replacement of units and components. Only qualified personnel must carry out
repair work. The sequence of the procedure steps must be followed.

Replacing blades rotary incising unit MR, RS

Goal Replace defective or worn out blades.

Duration 5 Min.
Interval Check daily. Replace as needed
Personnel qualification Technical specialists
Support tools Screwdriver # 1
Parts Pair of blades
Prerequisite Machine operational

1.▹ [NAVIGATION] (1) 1

2.▹ [EXTENDED VIEW] (2)
2
3.▹ [CONFIGURATION] (3) 3
4.▹ [MACHINE] (4)

5.▹ [ROTARY INCISING UNIT] (5)

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10. Maintenance

6.▹ [CHANGE BLADES] (6)

7.▹ Swivel out the rotary incising unit, "10.3.2 Open

the rotary incising unit (Page 113)".

CAUTION: The cutting edge of the blades are very

sharp. This leads to stab wound and concussion 7
injury on fingers. Do not touch the blades on the
cutting edge.
8
8.▹ Loosen the screws (7).
9.▹ Remove the blades (8).
10.▹ Clean the blade holders‘ contact surface.
11.▹ Position the new blades on the blade support.
12.▹ Mount the blades with the screws (7).
13.▹ Swivel back the rotary incising unit and attach
the cover, see "10.3.2 Open the rotary incising
unit (Page 113)".
14.▹ Confirm the message with [OK].
➥The blades are configured.
15.▹ Confirm the setting with [OK].
➥Leave the screen.

Normally the blades must not be calibrated. When

inaccuracy occurs during wire processing, the blade
calibration has to be performed.

Replacing blades rotary incising unit RSX, RX

Goal Replace defective or worn out blades.

Duration 5 Min.
Interval Check daily. Replace as needed
Personnel qualification Technical specialists
Support tools ■ Allen key 2 mm
■ Screwdriver # 1
Parts Pair of blades
Prerequisite Machine operational

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1.▹ [NAVIGATION] (1) 1

2.▹ [EXTENDED VIEW] (2)
2
3.▹ [CONFIGURATION] (3) 3
4.▹ [MACHINE] (4)

5.▹ [ROTARY INCISING UNIT] (5)

6.▹ [CHANGE BLADES] (6)

7.▹ Swivel out the rotary incising unit, "10.3.2 Open

the rotary incising unit (Page 113)".

8.▹ Loosen the screws (7). 7

9.▹ Remove the cover (8).

7
8

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10. Maintenance

10.▹ Rotate the spindle (9) manually in CW direction.

➥The blade levers (10) must protrude by
approx. 2 mm.
9
11.▹ Rotate the rotary head (11) manually.
➥Adjust the blade position "1" to 12 a clock.

10

11

12.▹ Swivel the blade holder (12) off the slot and
then pull it off the blade lever (10).
13.▹ Rotate the rotary head (11) manually. 10
➥Adjust the blade position "2" to 12 a clock.
14.▹ Remove the blade holder "2" the same way.

12

11

Notice Observe, that the slide block (13) does not

get lost. 13
14
CAUTION: The cutting edge of the blades are very
sharp. This leads to stab wound and concussion
15
injury on fingers. Do not touch the blades on the
cutting edge.

15.▹ Loosen the screw (14).

16.▹ Remove the blades (15).
17.▹ Clean the contact surface of the blade holders.
18.▹ Position the new blade on the blade holder. 16

➥The blade must fit on both pins (16).

19.▹ Mount the blade with the screw (14).

Always replace both blades.

When inserting the blade holders into the blade lev-

ers, the marks (17) on the slide blocks (13) must be 13
visible.

17

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20.▹ Slide in the blade holder (12) with slide block

(13) into the blade lever (10).
21.▹ Swivel in the blade holder to the slot of the 10
rotary head (11).
22.▹ Rotate the rotary head manually.
➥Adjust the blade position "1" to 12 a clock.
23.▹ Mount the blade holder "1" the same way. 12

11

24.▹ Attach the cover (8).

➥The marks (18) on cover and rotary head 18
must coincide.
25.▹ Mount all screws (7). 7

26.▹ Swivel back the rotary incising unit and attach

the cover, see "Open the rotary incising unit
(Page 113)".

27.▹ Confirm the message with [OK].

➥The blades are configured.
28.▹ Confirm the setting with [OK].
➥Leave the screen.

Normally the blades must not be calibrated. When

inaccuracy occurs during wire processing, the blade
calibration has to be performed.

Mains fuses replace

Goal Replace defective mains fuses

Duration 2 Min.
Interval -
Personnel qualification Technical specialists
Support tools -
Parts 2 fuses 250V T8AH
Prerequisite Machine switched off and power cord disconnected.

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10. Maintenance

DANGER
Hazardous mains voltage!
With mains connection, there is a hazardous mains voltage present in the fuses
and inside the machine. Contact with current-carrying parts can result in serious
injuries or death.
Before carrying out servicing tasks, always switch off the machine and disconnect
the mains plug.

1.▹ Press the two clips together.

2.▹ Remove the fuse holder (1) from the mains fil-
1
ter.

3.▹ Remove both fuses (2).

4.▹ Insert the new fuses with identical rating.
5.▹ Attach the fuse holder to the mains filter.
➥The two clips must lock.
6.▹ Turn the machine on, see "Page 78".

If the fuses burn out again, a malfunction in the

power supply may be the cause. In such cases con-
tact your local Schleuniger distributor.
2

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10.5.1 Tests

Safety check electronics

Goal Ensure the correct function of the safety appliances

Duration 5 Min.
Interval -
Perform after Always after repair or other work on the wiring and electronics
Personnel qualification Technical specialists
Support tools ■ Hex key 4 mm
■ Test protocol
Prerequisite Machine connected to the mains and operational

Connectors may due to the design be plugged-in on the electronic components to wrong positions. In
order to avoid wrong connections, the labeling of of the connector and the socket must be identical.
Wrong wiring may cause malfunction in the safety circuits.

CAUTION
Wrong connections!
After completing maintenance work on the wiring or the electronic components, always perform the
safety check. This assures that safety appliances on the machine operate correctly. The safety appliances
protect the personnel from dangers.

Test procedure

DANGER
Dangerous line voltage!
Dangerous line voltage is present inside the machine and around the area of the
mains socket, which can lead to serious injury or death if touched.
Do not touch electric components.

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10. Maintenance

A10 A13 A3
A8

A6

A1

A4

Fig. 17: Overview electronic parts

A3

A6 A13 A8 A10

J2 LED power J2 LED power

J28

J27

J26

LED interlock A + B LED E-stop A + B

Fig. 18: Overview LED's and connections of power supply

Test phase 1

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1.▹ Loosen both screws (X1) on the rear cover.

X1
2.▹ Swivel down the rear cover.
➥The cord limits the opening range.

3.▹ Switch on the machine

4.▹ Close the safety cover (1).
5.▹ Disengage the emergency stop button (2).

6.▹ Check the state of the LED's on the electronic

components. See following chart.

1
2

Component Description LED color LED state Machine model

A3 Interlock A Orange On all
A3 Interlock B Orange On all
A3 E-Stop A Orange On all
A3 E-Stop B Orange On all
A6, A8, A10 Power Green On S, M, MR, RS, RSX
A8, A10 Power Green On RX
A13 Power Green On MR, RS, RSX, RX

7.▹ If the individual LED's light-up, the test phase

was successful.
➥Continue with test phase 2
8.▹ If one or more LED's do not light-up, the test
phase failed.
➥Take the following actions

Task:

Component A3
1.▹ Turn the machine off
2.▹ Check the connections J26, J27, J28. The label-
ing on connector and socket must match.
3.▹ Repeat the test phase

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10. Maintenance

Components A6, A8, A10 or A13:

1.▹ Turn the machine off
2.▹ Check the connections J2. The labeling on
connector and socket must match.
3.▹ Repeat the test phase

If the actions do not lead to to a positive result,

additional steps have to be performed.

1.▹ Check the other wiring from and to the com-

ponent A3.
2.▹ Check the wiring of the components among
themselves

Test phase 2
1.▹ Engage the emergency stop button (2).
2.▹ Check the state of the LED's on the electronic
components. See following chart.

Component Description LED color LED state Machine model

A3 Interlock A Orange off all
A3 Interlock B Orange off all
A3 E-Stop A Orange off all
A3 E-Stop B Orange off all
A6, A8, A10 Power Green off S, M, MR, RS, RSX
A8, A10 Power Green off RX
A13 Power Green off MR, RS, RSX, RX

3.▹ If the individual LED's do not light-up, the test

phase was successful.
➥Continue with test phase 3
4.▹ If one or more LED's light-up, the test phase
failed.
➥Adopt the actions from test phase 1

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Test phase 3
1.▹ Open the safety cover (1).
2.▹ Disengage the emergency stop button (2). 1

3.▹ Check the state of the LED's on the electronic

components. See following chart.

Component Description LED color LED state Machine model

A3 Interlock A Orange off all
A3 Interlock B Orange off all
A6, A10 Power Green off S, M, MR, RS, RSX
A10 Power Green off RX
A13 Power Green off MR, RS, RSX, RX

4.▹ If the individual LED's do not light-up, the test

phase was successful.
➥Terminate the test
5.▹ If one or more LED's light-up, the test phase
failed.
➥Adopt the actions from test phase 1

Terminate the test

1.▹ Turn the machine off
2.▹ Close the safety cover
3.▹ Close the rear cover
4.▹ The safety check has to be logged by the
responsible personnel.
Therefore use the log in this manual.

See Table of contents.

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10. Maintenance

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11. Modifications

MODIFICATIONS
DANGER
Hazardous mains voltage!
With mains connection, there is a hazardous mains voltage present in the fuses
and inside the machine. Contact with current-carrying parts can result in serious
injuries or death.
Before carrying out servicing tasks, always switch off the machine and disconnect
the mains plug.

NOTICE
Property damage caused by modification!
Unauthorized modification with components from third party vendors may lead to property damage.
■ Only carry out modifications with parts and units from Schleuniger.
■ Only mount components designed for this machine type.

Mounting the LED illumination

Goal Mounting and wiring the optional LED illumination

Duration 5 Min.
Interval -
Personnel qualification Technical specialists
Support tools ■ Allen key 4.0 mm
■ Screwdriver size 2
Parts 1 pcs. LED illumination
Prerequisite Machine switched off and power cord disconnected

The procedure applies for the housing size 600 and 800

1.▹ Lift up the upper cover, "Removing the upper

cover (Page 110)".

2.▹ Remove the safety cover, "Remove the front 1

(Page 112)".

3.▹ Slide the LED illumination (1) from the top obli-
2
quely into the profile (2) and turn away.
4.▹ Align the LED illumination centered.

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11. Modifications

5.▹ Plug the connector (3) into the socket on the

side and screw -on.

6.▹ Swivel up the lover cover and attach it. 3

7.▹ Mount the safety cover.

8.▹ Mount the upper cover.

9.▹ Connect the machine to the mains.

10.▹ Turn on the main switch
➥The LED illumination is switched on automat-
ically.

When the machine is switched on, the LED illumina-

tion is on permanently. It can not be configured via
the control software.

Short mode

Goal Modification of right feeding unit for the processing of very short wires
Duration 15 Min.
Interval -
Personnel qualification Technical specialists
Support tools Allen key 4.0 mm, 2.5 mm
Parts ■ 2 pcs. feed belts
■ 1 pcs. pulley with plate, upper
■ 1 pcs. pulley with plate, lower
■ 1 pcs. guide
■ 3 pcs. screws
Prerequisite ■ Machine operational
■ Raw material removed

1.▹ [NAVIGATION] (1)

1
2.▹ [BASIC VIEW] (2)
3.▹ [SET UP] (3) 3 2

4.▹ [SHORT MODE] (4)

5.▹ [SHORT MODE UNIT] (5)
➥Observe the messages. 4

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6.▹ 2× [OK] (6).

➥Leave screen.
7.▹ Switch off the machine.
8.▹ Open the safety cover.

9.▹ Loosen screw (X1) for two turns, do not remove

completely. X1

10.▹ Turn tension pulley (X2) until the feeding belt is

released.
Tension pulley upper = UZS X2
Tension pulley lower = GUZS
11.▹ Remove the tension pulley (X2).

12.▹ Pull off the feed belt from the pulley (9) and
remove it. 9

13.▹ Remove the guide (10).

10

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11. Modifications

14.▹ Slide in the short mode guide (11).

15.▹ Mount the short mode unit (12) with the 12
screws (13) to the drives. 13

11

16.▹ Attach the long feeding belt to the pulley (14)

and then onto the deflection pulley (15). 15 14

17.▹ Attach the tension pulley (X2).

X1 X2
➥The toothing of the feeding belt must match
in the pulleys.

18.▹ Turn tension pulley (X2) until the feeding belt

touches the support pulley (X3).
Tension pulley upper = GUZS
Tension pulley lower = UZS

NOTICE Heavily tensioned feed belts may lead to

X3
damage the feeding unit.
■ Do not overwind the tension pulley.
■ Tension the tension pulley without using any
tool.

19.▹ Tighten the screw (X1).

20.▹ Repeat the procedure on the lower drive.

21.▹ Push the insert (16) from the right out of the
guide (11).
22.▹ Press a different insert from the left into the
guide (11).

23.▹ Close the safety cover.

For the feeding unit calibration, see .

11

16

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11. Modifications

Retrofit of feed rollers to feed belts

Goal Retrofit the feeding units from feed rollers to feed belts
Duration 40 Min.
Interval -
Personnel qualification Technical specialists
Support tools ■ Allen key 3,0 mm, 2,5 mm, 2,0 mm
■ Torque wrench
Parts ■ 4 pcs. feed belts
■ 4 pcs. pulley with washer disk
■ 4 pcs. pulley with mounting set
■ 4 pcs. support pulley
■ 4 pcs. tension pulley
■ 4 pcs. screws M4×10
■ 20 pcs. serrated washer
Prerequisite Machine operational

This procedure is identical for the left and right feeding units. Both are identical.

1.▹ [NAVIGATION] (1) 1

2.▹ [EXTENDED VIEW] (2)
2
3.▹ [CONFIGURATION] (3) 3
4.▹ [MACHINE] (4)

5.▹ [FEEDING UNITS] (5)

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11. Modifications

6.▹ [CHANGE FEEDING BELTS] (6)

7.▹ Remove the raw material.

8.▹ Confirm the message with [OK].
➥The machine is ready.

9.▹ Remove the safety cover, "Remove the front

(Page 112)".

First disassemble the upper drives on both side.

7
Then the lower ones.

10.▹ Remove the tab (7).

11.▹ Loosen screws (8) and remove the guide (9).

9
8

12.▹ Loosen the set screw (10).

13.▹ Remove the rollers (11). 10

11
10

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11. Modifications

First mount the lower drives on both side. Then the

upper ones.
12
14.▹ Insert the support pulley (12) up to the stop
into the bore hole.
15.▹ Fasten with pre-mounted set screw (13).

13

16.▹ Slide the pulley with washer disk (14) onto the
14
shaft up to the stop.
17.▹ Mount with the set screw (15).
15
Notice To avoid any damage to the shaft, the pulley
with washer disk must exclusively be mounted onto
the right shaft.

18.▹ Attach the feed belt (16) onto the pulley.

17 16
19.▹ Slide the pulley (17) onto the shaft all the way
up to the stop.

14

20.▹ Insert the tension set (18) into the pulley.

➥Do not tighten! 18

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11. Modifications

21.▹ Attach the tension pulley (X2).

➥The toothing of the feeding belt must match X2
in the pulleys.

22.▹ Attach five serrated washers to the screw (X1). X1

Observe the sequence of the procedure.

23.▹ Turn tension pulley (X2) until the feeding belt

touches the support pulley (X3).
Tension pulley upper = GUZS
Tension pulley lower = UZS
X3
NOTICE Heavily tensioned feed belts may lead to
damage the feeding unit.
■ Do not overwind the tension pulley.
■ Tension the tension pulley without using any
tool.

24.▹ Tighten the screw (X1).

25.▹ Tighten the screws in the tension set (18)
equally, crosswise with 1.2 Nm. 18

26.▹ Swivel up the lover cover and attach it.

27.▹ Mount the safety cover.

For the feeding unit calibration, see .

Retrofit of feeding belts to feeding rollers

Goal Retrofitting feeding units from feeding belts to feeding rollers

Duration 40 Min.
Interval -
Personnel qualification Technical specialists
Support tools Allen key 3,0 mm, 2,5 mm, 2,0 mm
Parts ■ 8 pcs. rollers
■ 4 pcs. guides
■ 4 pcs. tab
■ 8 pcs. screws M4×25
Prerequisite Machine operational

The procedure applies to the left and right feeding unit. Both are identical.
The feeding unit must be designed for the roller drive.

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11. Modifications

1.▹ [NAVIGATION] (1) 1

2.▹ [EXTENDED VIEW] (2)
2
3.▹ [CONFIGURATION] (3) 3
4.▹ [MACHINE] (4)

5.▹ [FEEDING UNITS] (5)

6.▹ [CHANGE FEEDING BELTS] (6)

7.▹ Remove the raw material.

8.▹ Confirm the message with [OK].
➥The machine is ready.

9.▹ Remove the safety cover, "Remove the front

(Page 112)".

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11. Modifications

First disassemble the upper drives on both side.

Then the lower ones. X1

10.▹ Loosen screw (X1) for two turns, do not remove X2

completely.
11.▹ Turn tension pulley (X2) until the feeding belt is
released.
Tension pulley upper = UZS
Tension pulley lower = GUZS
12.▹ Remove the tension pulley (X2).

13.▹ Loosen the four screws in the tension unit (9).

10
14.▹ Screw one of the screws into the thread (10)
9
until the tension unit gets loose.
15.▹ Remove the pulley together with the feeding
belt.

16.▹ Loosen the set screw (11).

12
17.▹ Remove the pulley (12).
11

18.▹ Loosen the set screw (13), do not remove.

19.▹ Remove the support pulley (14).
14

13

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11. Modifications

First mount the lower drives on both side. Then the

upper ones. 16
20.▹ Slide the rollers (15) up to the stop onto the
shaft.
21.▹ Mount with the set screw (16).
15
16

22.▹ Fasten the guide (18) with the screws (17).

19
23.▹ Insert the tab (19).

18
17

24.▹ Swivel up the lover cover and attach it.

25.▹ Mount the safety cover.

For the feeding unit calibration, see .

Mounting suction unit

Goal Mounting the optional suction unit

Duration 10 Min.
Interval -
Personnel qual- Technical specialists
ification
Support tools ■ Allen key 4.0 mm, 2.5 mm
■ Screwdriver size 2
Parts ■ 1 pcs. holder
■ 1 pcs. support
■ 1 pcs. suction tube adapter
■ 1 pcs. inlay sheet housing size 600 or 800
■ 1 pcs. finger protection sheet housing size 600 or 800
■ 1 pcs. finger protection sheet right
■ 2 pcs. hex screws M5x6

The vacuum cleaner is not part of the delivery. Schleuniger recommends a boosted
industrial vacuum cleaner from FESTO.
Prerequisite Machine switched off and power cord disconnected
Suction unit and cutting unit booster can not be mounted in parallel

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11. Modifications

The procedure for the housing size 600 and 800 is basically the same. Only the inlay sheet and the finger
protection sheet left have different dimensions.
The suction unit can not be configured in the control software. It is switched on or off manually with the
vacuum cleaner.

26.▹ Remove the safety cover, "Remove the front

(Page 112)".

1.▹ Loosen screws (1) and remove the finger safety

sheet (2).
2

2.▹ Loosen screws (3) and remove the inlet sheet

(4).

3.▹ Attach the holder (5) with both screws (6) to

the front.

4.▹ Put the support (7) from the front onto the
holder (5).

5.▹ Remove the screw (8).

6.▹ Loosen the screw (9).
7

9
8

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11. Modifications

7.▹ Mount the finger protection sheet left (10) with

the screws (1) to the front.
10

8.▹ Mount the finger protection sheet right (11)

with the screws (1) to the front.

11

9.▹ Mount the inlet sheet (4) with the screws (3) to
the lower cover.
10.▹ Swivel up the lover cover (12) and lock.

3
12

11.▹ Insert the suction tube adapter (13) from the

underside into the holder and tighten with the
screw (14).
12.▹ Close the safety cover.
13.▹ Put the tube from the vacuum cleaner into the
suction tube adapter.
14

13

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11. Modifications

Mounting SIS slot

Goal Add additional interfaces for the connection of peripheral devices

Duration 5 Min.
Interval -
Personnel qualification Technical specialists
Support tools ■ Allen key 4.0 mm, 2.0 mm
■ Test protocol
Parts Interface with back plate and cable
Prerequisite Machine switched off and power cord disconnected

The procedure is shown on mounting position "SIS 3". It is identical for the individual interfaces. The
mounting position and the connection to the electronics is shown in the following chart.

Mounting position Interface connect to

HS/PF PPI RS232 SMI ESC Print Connection
SIS 1 × Installed ex factory
SIS 2 × Installed ex factory
SIS 3 × × × A1 J42*
SIS 4 × × A1 J43*
SIS 5 × A1 J44*
SIS 6 × A4 J45*
SIS 7 × A3 J27**

*If the connections are occupied, also A4, J46–J50 can be used on the PCB.
**Remove the termination connector.

CAUTION
Wrong connections!
After completing maintenance work on the wiring or the electronic components, always perform the
safety check. This assures that safety appliances on the machine operate correctly. The safety appliances
protect the personnel from dangers.

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11. Modifications

A10 A13 A3
A8

A6

A1

A4

Fig. 19: Overview electronic parts

1.▹ Loosen screws (1) and remove the cover (2).

2

1.▹ Insert the interface (3) and fasten with the two
screws (1). 3

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12. Spare parts / exploded view drawings

1.▹ Loosen both screws (X1) on the rear cover.

X1
2.▹ Swivel down the rear cover.
➥The cord limits the opening range.

3.▹ Connect the cable of the interface (3) to the

PCB (connection, see previous chart).
4.▹ Position the wire in the cable duct (4).

J27 3

5.▹ Close the rear cover and screw together.

6.▹ Connect the machine to the mains.
7.▹ Turn on the main switch
➥Start the machine.
8.▹ Carry out a safety check, see "Tests (Page 135)".

SPARE PARTS / EXPLODED VIEW DRAWINGS

For original Schleuniger spare parts see „Parts Catalog“.

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13. Decommissioning / disposal

DECOMMISSIONING / DISPOSAL
Decommissioning

Goal Prepare the machine for the transport or the disposal

Duration 5 Min.
Interval -
Perform after ■ When the machine is not in use for longer period
■ Before shipping
■ Before disposal
Personnel qualification Technical specialists
Support tools Screwdriver
Prerequisite Machine operational

1.▹ Close the safety cover. 1

2.▹ [PRODUCTION COMMANDS] (1).
3.▹ [UNLOADING] (2). 2

4.▹ Remove the raw material from the machine.

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13. Decommissioning / disposal

5.▹ Confirm [SHUTDOWN] (3) on the touch screen. 3

6.▹ Confirm [SHUTDOWN] (4) in the drop down
list.
4
7.▹ Confirm the message with [OK].
➥The data are saved.
➥A switch off icon is shown on the touch
screen.

8.▹ Switch off the main switch (5) on the back of

the machine.
9.▹ Unplug the machine from the mains outlet
and the machine.

NOTICE
Do not switch off the main switch directly on the 5
operable machine. Data loss may occur. Shut down
the machine properly.

10.▹ Pull up the setting knob (6).

7
11.▹ Set pressure to zero
CW = Increase pressure
CCW = Reduce pressure
➥The set-up value is shown on the manome- 6
ter.
12.▹ Push the setting knob down.
9
13.▹ Remove the air pressure hose (7) on the main- 8
tenance unit.
14.▹ Unplug the Ethernet- (8) and USB-connections
(9).

15.▹ Loosen the screws on the plugs.

16.▹ Remove all cables connected to peripheral
devices.

Storage
If the product is not in use for a longer period, the following should be taken into consideration:
■ Do not store outdoor
■ Repack or guard with an enclosure

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13. Decommissioning / disposal

■ Observe temperature and climatic conditions, see "4.5 Technical specifications (Page 29)".

Disposal

Goal Separate parts. Dispose off the product according to regulations.

Duration -
Interval -
Personnel qualification Technical specialists
Support tools Others
Prerequisite Product out of operation

NOTICE
Recycle the materials!
Bring the materials to the recycle station. Thereby observe the local regulations.

Product
Schleuniger machines mainly consist of the following materials:

Parts Disposal
Aluminum Scrap metal
Steel Scrap metal
Other metal Scrap metal
Electric parts Electronic waste
Plastics Recycling

The product contains no harmful batteries.

1.▹ Disassemble the product properly.

2.▹ Bring the materials to the recycle station.

Packaging
The packaging mainly consist of the following materials:

Parts Disposal
Carton Recycling
Wood Recycling
Foam Recycling

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13. Decommissioning / disposal

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14. Appendix

APPENDIX

14.1 ELECTRIC INTERFACES

14.1.1 SMI interface

The SMI Interface (Schleuniger machine interface) is based on a D-sub 15pin socket. It is used for the con-
nection of Schleuniger devices, equipped with SMI. The entire interface is a galvanically separated design.
Therewith damage due to maloperation by the user can widely be avoided.
■ No serial communication with external devices.
■ The internal 24 V supply is provided.

Pin Description Function Signal type

1 OutEncA Impulse output to feeding synchronization Output Push/Pull
2 OutEncB Impulse output to feeding synchronization Output Push/Pull
3 Out0 Multifunction output Output PNP
4 Out1 Multifunction output Output PNP
5 Out2 Multifunction output Output PNP
6 Out3 Multifunction output Output PNP
7 +24V Internal 1A Supply -
8 GND Internal use Ground -
9 InEncA Impulse input Input PNP
10 InEncB Impulse input Input PNP
11 In2 Multifunction input Input PNP
12 In3 Multifunction input Input PNP
13 Present Presence device Input PNP
14 +24V Extern Supply -
15 GND Extern Ground -

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14. Appendix

14.1.2 HS/PF interface

For use with a PreFeeder

With Schleuniger PreFeeders the appropriate connection cable is delivered with the Prefeeder. As per the
following diagram, the D-sub-connector can be self-wired by a qualified technician.

PreFeeder HS/PF interface

PFOUT
+24 VDC

S1 PFPRESENT

PFREADY
GND

D-Sub 15-pin (F)

Fig. 20: Connecting a PreFeeder

Input „PFREADY“, Pin 10 & 11:

If the D-sub connector is plugged in and the control contact S1 closed, the machine can be started nor-
mally. When the control contact S1 is opened, the automatic processing is interrupted and the "Prefeeder
blocked" error message is shown the display. After closing the control contact S1 again, the program can
be continued with [RUN].

Output „PFOUT“, pin 14 & 15

This output is set to open collector (ground potential) during processing. This means the output is held
active. It is dimensioned for inductive loads up to 0.2 A at 24 VDC (relays, valves) and is protected against
stress peaks.

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14. Appendix

For use with a HotStamp

The Schleuniger HotStamp devices are shipped with their appropriate connection cable. As per the follow-
ing diagram, the D-sub-connector can be self-wired.
HS/PF interface
HotStamp

HSINPUT
+24 VDC

HSOUT
+24 VDC

D-Sub 15-pin (F)

Fig. 21: Connecting a PreFeeder

Input „HSINPUT“, Pin 4 & 5:

When operating a wire marker through this input, the wire feeding on the MultiStrip 9480 is stopped until
the marking process is terminated.

Output „HSOUT“, Pin 1 & 2

The wire marker is operated through this output. It is dimensioned for inductive loads up to 0.2 A at
24 VDC (relays, valves) and is protected against stress peaks.

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14. Appendix

14.1.3 Pre-/postfeed interface (PPI, option)

The PPI interface is designed for the connection of synchronized pre- or post processing devices of
Schleuniger or custom devices.

Pin Description Function Signal type

1 +24 V - Supply -
2 /WSELECT Output control to wire stacker Output PNP
3 /LDETECT Wire sensing Input NPN
4 /RDETECT Wire sensing Input NPN
5 IN0 Multifunction input Input PNP
6 IN1 Multifunction input Input PNP
7 IN2 Multifunction input Input PNP
8 IN3 Multifunction input Input PNP
9 +24V - Supply -
10 - not assigned -
11 - not assigned - -
12 xENCB Impulse output to feeding synchronization Output +3.3V diff.
13 xENCA Impulse output to feeding synchronization Output +3.3V diff.
14 - not assigned - -
15 - not assigned - -
16 GND - Ground -
17 GND - Ground -
18 OUT0 Multifunction output Output PNP
19 OUT1 Multifunction output Output PNP
20 OUT2 Multifunction output Output PNP
21 OUT3 Multifunction output Output PNP
22 - not assigned - -
23 GND - Ground -
24 /xENCB Impulse output to feeding synchronization Output +3.3V diff.
25 /xENCA Impulse output to feeding synchronization Output +3.3V diff.

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14. Appendix

14.1.4 RS232 interface

The RS232 interface is made for connecting to an Inkjet printer device.

Pin Description Function Signal type

1 DCD Receive ready data Input -
2 RxD Receive data Input -
3 TxD Data transmit Output -
4 DTR Transmit ready for operation Output -
5 GND - Ground -
6 DSR Receive ready for operation Input -
7 RTS Transmit ready data Output -
8 CTS Transmit release data Input -
9 RI Request establish connection Input -

14.1.5 ESC interface

The ESC interface is made for connecting the machine with the external emergency stop circuit ESC 1000.
In case of emergency, linked devices of a production line can be stopped immediately and simultaneous-
ly.
Detailed specifications can be found in the instruction manual of the ESC 1000.

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165 | 192
 COT2
T2

COW7
W7 PIT20L

L
14.2
Cable Supply Drv Nonstop Power2 COW6
W6
PIW70OUT1 PIW70IN1 PIA30J8
J8 Cable Supply Power1
PIW60OUT2 PIT20V00

V0+
964006 PIA30J9 PIA30J4 PIW60IN1 PIT20E

E
J9 J4
500mm PIW60OUT1 PIT20V00

V0-
439161 PIA30J10
J10 Power In 964002

Nonstop
Power Out
400mm
14. Appendix

PIA30J11 PIA30J5 PIT20N

N
J11 J5 439158

166 | 192
Driver (all variants) COW5
W5
POA3 (bSLiPowerSafety)
(BSLIPOWERSAFETY) Power Supply 60VDC,10A,600W; SMC600PS60
A3 -0 J12
J12(bSLiPowerSafety) PIA30J12 J12 Cable Supply Power2
PIW50OUT2 SMC600PS60
W10, A8 (Power Slot 2, Gap/Blade)
PIA30J13 PIA30J3 PIW50IN1 401369
J13 Logic Power J3

Power Out
PIW50OUT1
COT1
T1

Emergency Stop
964003
Driver Variant S / M / MR / RS / RSX 600mm
POA3
A3 -0 J19 (bSLiPowerSafety)
(BSLIPOWERSAFETY)
J19(bSLiPowerSafety) PIA30J19 J19 439159

L
W9, A6 (Power Slot 1, Guides) PIT10L
PIA30J20
COA3
A3 COW4
J20 W4
Variant MR / RS 962010
Cable Supply Logic
POA3 (bSLiPowerSafety)
(BSLIPOWERSAFETY) bSLiPowerSafety PIW40OUT2 PIT10V00

Interlock
V0+
A3 -0 J21
J21(bSLiPowerSafety) PIA30J21 J21

Power Out
438297 PIW40IN1 PIT10E

E
COA22 COA21 W50, A13 (Power Slot 4, Rotation)
A22 A21 PIA30J22 PIW40OUT1 PIT10V00

V0-
J22
962005 962006 Driver (all variants) 964001
bIntPPI bIntHSnPF POA3 (bSLiPowerSafety)
(BSLIPOWERSAFETY)
A3 -0 J22
J22(bSLiPowerSafety) 600mm
448058 448059 PIT10N

N
PIA2 0J3 PIA210J3 W11, A10 (Power Slot 3, Feed/Cut) 439157
PIA30J34 J34 Interlock J28 PIA30J28

J3
J3
Brake
PIA30J33

Resistors
PPI HS/PF J33
E-Stop Circuit (Options) Power Supply 24VDC,13A,312W; SP-320-24
PIA30J27 POA3 (bSLiPowerSafety)
(BSLIPOWERSAFETY) SP-320-24
E-Stop Circuit J27 A3 -0J27
J27(bSLiPowerSafety)
408584
S-Link S-Link W13 / W81, A27 (w/o E-Stop Circuit)
PIA30J16
J16

SIS Slot 2
SIS Slot 1

J2
J2
PIA30J17 J17 Emergency Stop J26 PIA30J26
PIA2 0J2 PIA210J2

STO
COW19
W19 PIA30J41
J41
Driver (all variants) Cable Feedback Termination
POA3 (bSLiPowerSafety)
(BSLIPOWERSAFETY) PIW190IN1

Emergency Stop
PIW170IN1 PIW160IN1 A3 -0 J23
J23(bSLiPowerSafety) PIA30J18 J18

Feed-
back
COW17 COW16 W21, A8 (STO Slot 2, Gap/Blade)
W17 W16 964017
Cable S-Link Cable S-Link Option Booster 439170 PIW20IN1 PIW20IN2 PIW20IN3
COW2
POA10J42(BbMaIiNnCoTtRrLlEe) 964021 964021 POA3
A3 -0 J24 (BSLIPOWERSAFETY)
(bSLiPowerSafety)
J24(bSLiPowerSafety) PIA30J23 J23 W2

A1 - J42..44 (bMainController)
800mm 800mm 964047
W72, E7/E8 (Safety Valves)

Optional S-Link Devices

Option RS-232, SMI, SmartDetect, ...
PIW170OUT1 444536 PIW160OUT1 444536 PIA30J24 J24
300mm
PIW30OUT3 PIW30OUT2 PIW30OUT1

STO
439721
COW20
W20 PIA30J42
COW3
W3 PIW20OUT1 PIW20OUT2 PIW20OUT3
J42

Interlock
Cable STO/Feedback Termination 964038
PIW200IN1 PIA30J25
400mm
J25

Feed-
back
439156

J35 Operating Mode Switch

J2 S-Link
Cable Main Supply Extension

964018 PIW30IN3 PIW30IN2 PIW30IN1

Cable Main Supply

Option Length Monitoring 439718 PIA30J35 PIA30J2
POA4 0 J58
A4 - J58 (BDRVIO)
(bDrvIO)
(bDrvIO) COW15
W15
W76, B21 (Length Monitoring)
Cable S-Link
PIW150IN1 PIW150OUT1
14PIK1014 11
PIK1011
964021

ohne bDrvIO
mit bDrvIO
400mm 24PIK1024 21
PIK1021

NL0xD10 6 NL0xD10 5 NL0xD10 4 NL0xD10 3 NL0xD10 2 NL0xD10 NL0x1 0 1 452339

0x0D010006
0x0D010005
0x0D010004
0x0D010003
0x0D010002
0x0D010001
0x01010001
PIA10J4 PIA10J43 PIA10J42 PIA10J41 PIA10J40 PIA10J39 PIA10J2 Option Booster
NL0x03010005
0x03010005
J24 POA4 0 J24
A4 - J24 (BDRVIO)
(bDrvIO)
(bDrvIO)

J2
NL0x03010006
0x03010006

J44
J43
J42
J41
J40
J39
COA1

J58
A1 J25 W69, E6 (Booster)
962001 COW26
W26 A2
PIK10A2 A1
PIK10A1
PIA10J10 S-Link COK1A
COK1B
COK1C
K1A
J10 LAN 2 bMainController Option Air Jet Unit Cable Output Faston 6.3x0.8
Relay Finder 24VDC 2NO 250V/30A; 6.3x0.8
PIW260OUT2
BLOCK DIAGRAM ELECTRIC

432241 POA4 0 J25

A4 - J25 (BDRVIO)
(bDrvIO)
(bDrvIO)

POWER
PIA10J14 J11 PIW260IN1 66.82-x300
LAN 1 W74, E9 (Air Jet Unit)
PIW260OUT1 439746
14.2.1 Power supply and control unit

964004
POA40J2(BbDRrVvI) 600mm

A4 - J2 (bDrvIO)
PIA10J14 J14A 439160
COA2

(Supply bDrvIO)
A2 T30 Option bDrvIO
USB
PCB Colibri T30 1GB
J14B
451253 (Slave 1) Option Length Monitoring
A4 NL0x03010012
0x03010012 POA4 0 J42 (bDrvIO)
(BDRVIO)
J42 A4 - J42 (bDrvIO)
NL0x03010013
0x03010013
J43 W75, E10 (Length Monitoring)
NL0x03010014
0x03010014
J44 COA14
Option Length Monitoring A14
PIA10J45 Inputs Outputs POA4 0 J43 (bDrvIO)
(BDRVIO) Power Entry Module DD12; Filter 6A 2pole
J45 A4 - J43 (bDrvIO)
DD12.6121.111
W79, S3 (Recoil Brake)
439726

J30
J28
J38
J36
J34
J32

Monitor
L

1-Wire
Bus
Option Length Monitoring
L

PIA10J30 PIA10J28 PIA10J38 PIA10J36 PIA10J34 PIA10J32 POA4 0 J44

A4 - J44 (bDrvIO)
(BDRVIO)
(bDrvIO) PIA140L PIA1401

J15 USB Intern

J18
J3
J26 EtherCAT
J29
J27
J37
J35
J33
J31
J20
J21
J22
J23
W77, E11 (Recoil Brake)
COW1
W1
Cy

PIA10J15 PIA10J18 PIA10J3 PIA10J26 PIA10J29 PIA10J27 PIA10J37 PIA10J35 PIA10J3 PIA10J31 Cable Entry Main Supply
PIW10IN3 PIW10OUT3
E

NL0x310 4 NL0x310 3NL0x310 2 NL0x310 NL0x710 8 NL0x710 5 NL0x710 4 NL0x710 3NL0x710 2 NL0x710 NL0x710 5 NL0x710 6 NL0x710 7 NL0x710 8 PIW10IN2 PIW10OUT2 PIA140E PIA1402
PIW830IN1 PIW10IN1 PIW10OUT1

0x03010004
0x03010003
0x03010002
0x03010001
0x07010008
0x07010005
0x07010004
0x07010003
0x07010002
0x07010001
0x07010015
0x07010016
0x07010017
0x07010018
Cx

COW83
W83
964037
Cable Monitor FPD Internal
Cy

650mm
964034
L

439155
N

800mm Option Length Monitoring PIA140N PIA1403

446998 PIW830OUT1 POA4 0 J23
A4 - J23 (bDrvIO)
(BDRVIO)
(bDrvIO)
Monitor FPD
W79, S3 (Recoil Brake)

COA16
A16 Option Length Monitoring
Display 5.7" VGA pCap; ETMV570G2BDHU POA4 0 J22
A4 - J22 (bDrvIO)
(BDRVIO)
(bDrvIO)
COW12
W12
Fuse 8/AT SPT 5x20
640*480 W78, B22 (Recoil Brake) COF1
F1 0001.2513
PIW840IN1 Cover Switch AZ17-02ZK; 1400mm COS2
S2
436988 COW84 627.0015
W84 PIW120OUT1 PIW120IN1 PIS20IN
Safety Switch Schmersal; AZ17-02ZK
COA15
A15 Option Booster
964033 AZ17
PIA160IN1 962003
2000mm
POA4 0 J21
A4 - J21 (bDrvIO)
(BDRVIO)
(bDrvIO)
964040 622.0083
Fuse 8/AT SPT 5x20
bIntUI W71, B18 (Booster) COF2
F2 0001.2513
446997 1200mm
431794 627.0015
PIW840OUT1 Option Booster 439174
COW85
W85 POA4 0 J20
A4 - J20 (bDrvIO)
(BDRVIO)
(bDrvIO) COW14
W14
PIW850IN1 PIW850OUT1 PIA150J11
J6 PIA150J6 W70, B17 (Booster) COS1

Cable Monitor FPD External

J11 E-Stop PTF00; 1400mm S1

LCD
LVDS
PIW140IN1 PIW140OUT1 PIS10IN
Emergengy Stop Button Schlegel; RXJUV
Rippon cable FFC 40P 50mm
Variant RS RXJUV
50mm
964039 411351
447001 POA1
A10- J35 (bMainController)
(BMAINCONTROLLER)
J35 (bMainController)
1200mm
W64, E5 (Linear Cutting Guide)
COW27
W27 439171
Cable Output D-Sub
Option Lighting

J5 USB
PIW270IN1 PIW270OUT1 POW27 (Wire
W27(WIRE Supply
(WireSUPPLY Lighting)
SupplyLIGHTING)
Lighting)
PIA150J5 964046
W80, E12 (Lighting Processing Area)
1600mm
439720
Option Wire End Monitoring
POA1
A10- J37 (bMainController)
(BMAINCONTROLLER)
J37 (bMainController)
Driver (all variants) W67, M12 (Wire End Monitoring)
CO0
POA1
A1 0- J26 (bMainController)
(BMAINCONTROLLER)
J26(bMainController)
W23, A5/A7 (EtherCAT Master - Slot x) 1 Stk 410575 Sicherungsschublade zu Gerätestecker
COE1
E1
COW30
W30
Option Wire End Monitoring Fan 24VDC 7W 105x105; 1200mm Zubehör
POA1A10- J30 (bMainController)
J30 (BMAINCONTROLLER)
(bMainController) PIW300OUT1 PIW300IN1 PIE10IN
W68, B16 (Wire End Monitoring)
964030
Variant RS 1200mm
439182 Fan 24VDC 7W; 105x105
POA1
A10- J29 (bMainController)
J29 (BMAINCONTROLLER)
(bMainController)

Machine Wall
4710KL05WB50
W66, B24 (Linear Cutting Guide) E-Box <-> Deckel
639.0009
Option Jam Detector COW33
W33
POA1A10- J28 (bMainController)
J28 (BMAINCONTROLLER)
(bMainController)
COE3
E3 Cable Earth Faston
W73, B19 (Jam Detector)
COW29
W29
PIW330IN1 PIW330OUT1
Fan 24VDC 7W 105x105; 310mm Drawn by Checked by
Variant RS 224003 Version Date Signature Date Signature
POA1A10- J27 (bMainController)
J27 (BMAINCONTROLLER)
(bMainController) PIW290OUT1 PIW290IN1 PIE30IN
160mm 01.00.00 25.03.14 GR * *
W65, B23 (Linear Cutting Guide) 01.00.01 10.04.14 GR 18.04.14 WMA

E-Box
614010 701.5109
310mm 01.01.00 21.05.14 GR 22.05.14 WMA
402249 Fan 24VDC 7W; 105x105 01.02.00 02.07.14 GR * *
4710KL05WB50 V02.00 04.12.14 GR * *
Project MS 9480 Component Blockschema
639.0009 V02.01 09.02.15 GR 09.02.15 GR
V02.02 20.02.15 GR 20.02.15 GR
Title 992000 Power&Control.SchDoc
* * * * *
* * * * *
Size Document Number Article Nr. Version
* * * * *
A2 V02.02
992000 * * * * * *
Date : 20.02.2015 Time : 11:33:43 Sheet 2 of 6 * * * * *

Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480

 Driver Variant S / M / MR / RS / RSX COW9
W9
Rotary Incising Unit CX or None Cable Supply Drv Interlock Power2
COW36
W36 COB1
B1
POA3
A3 0
- J19 (bSLiPowerSafety)
(BSLIPOWERSAFETY)
J19(bSLiPowerSafety) PIW90IN1 PIW90OUT1
Light Barrier SX913; 1000mm
(Power Slot 1, Guides) NLLinear Innen
964010 PIW360OUT1 PIW360IN1 Linear Guide
GuideHome
Home Innen PIB10IN
14. Appendix

800mm
444535 COW37
W37 964025 COB2
B2
PIA50J2 PIA60J3 PIA60J2 Light Barrier SX913; 1000mm 1000mm Light Barrier 24VDC PNP; SX913
PIW370OUT1 PIW370IN1
439178 NLLinear
Linear Guide
GuideHome
HomeAussen
AussenPIB20IN EE-SX913P-R

J3
J2
436345
Motor1 J9 PIA60J9
964025
PIA50J10 PIA60J18 1000mm COW34
W34 Light Barrier 24VDC PNP; SX913
J10 EtherCAT2 Limit1 J18
439178 Stepper Motor 0.7Nm 2End; 1000mm EE-SX913P-R

POWER J2
POWER
PIW340OUT1 PIW340IN1 PIM10IN1 436345
Linear Feeding Guide Right -
PIA60J11
964031
Motor2 J11 COW35 Lineare Vorschubführung Rechts
COA5 COA6 W35 1000mm COM1

M1
439189

17HDB002N
COW23 A5 A6 NL0x03020002
W23 PIA60J19
0x03020002 Encoder 500 5mm; 1200mm 439680 COB3
962002 962022 Limit2 J19 B3
Cable Ethernet PIW350OUT1 PIW350IN1 PIB30IN6 J1
bSlaveController bDrvDC2Stepper2 Encoder 500 5mm
POA1
A1 -0 J26 (bMainController)
(BMAINCONTROLLER)
J26(bMainController) PIW230IN1 PIW230OUT1 428039 427232 PS30B-500-5A-L
1200mm
(EtherCAT Master - Slot 1) NL0x06020003
300mm 0x06020003
PIA60J12 439194
Motor3 J12
439444
NL0x03020003

Stepper Motor Moons 0.7Nm 2End

PIA50J9A J9A EtherCAT0 0x03020003
Limit3 J20 PIA60J20
PIA50J9B J9B EtherCAT1
NL0x06020004
Variant S / M / MR
PIA60J13
0x06020004 POA6 (bDrvDC2Stepper2)
(BDRVDC2STEPPER2)

Hall1
Hall2
Encoder1
Encoder2
Encoder3
Encoder4
Motor4 J13 A6 0
- J13
J13(bDrvDC2Stepper2)
NL0x03020004
W61, M8 (Swivel Guide)
Driver Slot 1 0x03020004
PIA60J21
Limit4 J21

J8
J10
J14
J15
J16
J17
(Slave 2)
PIA60J8 PIA60J10 PIA60J14 PIA60J15 PIA60J16 PIA60J17 Variant S / M / MR
POA6
A6 0
- J21 (bDrvDC2Stepper2)
(BDRVDC2STEPPER2)
J21(bDrvDC2Stepper2) Swivel Guide
W63, B10 (Swivel Guide)
NL0x01020003
0x01020003
Variant S / M / MR

(EtherCAT Slot 1 - Slot 2)

NL0x01020004
0x01020004 POA6 (bDrvDC2Stepper2)
(BDRVDC2STEPPER2)
14.2.2 Power amplifiers

PIW240OUT1 A6 0
- J17
J17(bDrvDC2Stepper2)
W62, B11 (Swivel Guide)
COW24
W24
300mm
439444

Cable Ethernet
PIW240IN1
COW10
W10
Cable Supply Drv E-Stop Power1 COW39
W39 COB4
B4
PIW100IN1 PIW100OUT1
Light Barrier SX911; 1000mm
POA3
A3 0
- J12 (bSLiPowerSafety)
(BSLIPOWERSAFETY)
J12(bSLiPowerSafety) NLGap
Gap Right Home
RightHome
(Power Slot 2, Gap/Blade) PIW390OUT1 PIW390IN1 PIB40IN
964007

Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480

COW21
W21 800mm 964023
Cable STO/Feedback Type B 439162 1000mm COW38
W38 Light Barrier 24VDC PNP; SX911
POA3 (bSLiPowerSafety)
(BSLIPOWERSAFETY) PIW210IN1 PIW210OUT1 439176 Stepper Motor 2.3Nm; 1000mm EE-SX911P-R
A3 0
- J23
J23(bSLiPowerSafety)
PIW380OUT1 PIW380IN1 PIM20IN1
436342
(STO Slot 2, Gap/Blade) Feeding Unit Right -
964013
500mm 964031
439168 1000mm COM2 Vorschubeinheit Rechts

M2
Stepper Motor Moons 2.3Nm
ML23HSAL4500
439191
PIA70J2 PIA80J4 PIA80J2 PIA80J3 439682

J4
J2
J3
Gap
PIA70J10
NL0x06030001
0x06030001
PIA80J14
COW42
W42 COB6
B6

STO
J10 EtherCAT2 Motor1 J15
Light Barrier SX911; 1000mm

POWER J2
NL0x03030001 NLGap Home

POWER
0x03030001
PIA80J11 PIW420OUT1 PIW420IN1 Gap Left
LeftHome PIB60IN
Limit1 J11
964023
1000mm COW41
W41 Light Barrier 24VDC PNP; SX911
COA7
A7 COA8
A8
439176 Stepper Motor 2.3Nm; 1000mm EE-SX911P-R
962002 962021
NL0x06030002
0x06030002
PIA80J15 PIW410OUT1 PIW410IN1 PIM30IN1
436342
bSlaveController bDrvStepperL Motor2 J16
428039 432841 NL0x03030002
0x03030002 964031
Feeding Unit Left -
Limit2 J12 PIA80J12
COW43
W43 1000mm COM3 COB7
B7

M3
Stepper Motor Moons 2.3Nm
ML23HSAL4500
439191
Light Barrier SX911; 1000mm 439682
Vorschubeinheit Links
PIA70J9A PIW430OUT1 PIW430IN1 Gap Left Pressure PIB70IN
J9A EtherCAT0

PIA70J9B
NL0x06030003
0x06030003
PIA80J16
964023 Gap
J9B EtherCAT1 Motor3 J17
1000mm Light Barrier 24VDC PNP; SX911
NL0x03030003
0x03030003
PIA80J13 439176 EE-SX911P-R

Encoder1
Encoder2
Encoder3
Limit3 J13
436342
Driver Slot 2

J8
J9
J10
(Slave 3) Variant M / MR / RS
PIA80J8 PIA80J9 PIA80J10 POA8 J17
A8 -0J17 (bDrvStepperL)
(BDRVSTEPPERL)
(bDrvStepperL)
W59, M7 (Blade Change)
Blade Changing Axis
Variant M / MR / RS
POA8 J13
A8 -0J13 (bDrvStepperL)
(BDRVSTEPPERL)
(bDrvStepperL)
COW11 W60, B9 (Blade Change)
W11
Cable Supply Drv Interlock Power1

(EtherCAT Slot 2 - Slot 3)

POA3
A3 0
- J22 (bSLiPowerSafety)
(BSLIPOWERSAFETY)
J22(bSLiPowerSafety) PIW110IN1 PIW110OUT1
PIW250OUT1 (Power Slot 3, Feed/Cut)
964009
COW25
W25
300mm
COW22
W22 500mm
Cable STO/Feedback Termination 439165
439444
PIW220IN1
COW44

Cable Ethernet
PIW250IN1 W44
964018 Stepper Motor 5.5Nm 2End; 1000mm
439718 PIW440OUT1 PIW440IN1 PIM40IN1
Feeding Unit Right -
PIA90J2 PIA10 J4 PIA10 J2 PIA10 J3
964031 Vorschubeinheit Rechts

J4
J2
J3
1000mm COM4
M4
Stepper Motor Moons 5.5Nm 2End
34HD1404-07
439190

439681
PIA90J10
NL0x06040001
0x06040001
PIA100J14

STO
J10 EtherCAT2 Motor1 J15 Feeding Axis

POWER J2
POWER
Limit1 J11 PIA100J11

Stepper Motor Moons 5.5Nm 2End

COW45
W45
COA9
A9 COA10
A10
Stepper Motor 5.5Nm 2End; 1000mm
962002 962021 Feeding Unit Left -
NL0x06040002
0x06040002
PIA100J15 PIW450OUT1 PIW450IN1 PIM50IN1
bSlaveController bDrvStepperL Motor2 J16
428039 432841 NL0x03040002 NLGap Pressure Vorschubeinheit Links
0x03040002
PIA100J12
Gap Left
Left Pressure 964031
Limit2 J12
1000mm COM5
M5
34HD1404-07
439190

439681
PIA90J9A J9A EtherCAT0
Variant MR / RS / RSX Feeding Axis
PIA90J9B
NL0x06040003
0x06040003
PIA100J16
Rotary Incising Unit CX / RX POA9
A9 - J9B
0 (Slot (Slot 3)
J9B3) (SLOT J9B EtherCAT1 Motor3 J17
W51, A12 (EtherCAT Slot 3 - Slot 4)
NL0x03040003
0x03040003
PIA100J13

Encoder1
Encoder2
Encoder3
Limit3 J13 COW48 COB25
W48 B25
Driver Slot 3 Light Barrier SX911; 1000mm

J8
J9
J10
(Slave 4) PIW480OUT1 PIW480IN1 PIB250IN

PIA10 J8 PIA10 J9 PIA10 J10 964023

1000mm COW46
W46 Light Barrier 24VDC PNP; SX911
439176 Stepper Motor 5.5Nm 2End; 1000mm EE-SX911P-R
NL0x140 3 PIW460OUT1 PIW460IN1 PIM60IN1
436342 Cutting Unit -

0x01040003
964031 Schneideinheit
COW47
W47 1000mm COM6
M6
Stepper Motor Moons 5.5Nm 2End
34HD1404-07
439190

Encoder 500 8mm; 1200mm 439681

COB8
B8
PIW470OUT1 PIW470IN1 J1
PIB80IN6 Encoder 500 8mm
PS30B-500-8A-L
1200mm Cutting Axis
439196
Drawn by Checked by
Version Date Signature Date Signature
01.00.00 25.03.14 GR * *
01.00.01 10.04.14 GR 18.04.14 WMA
01.01.00 21.05.14 GR 22.05.14 WMA
01.02.00 02.07.14 GR * *
V02.00 04.12.14 GR * *
Project MS 9480 Component Blockschema
V02.01 09.02.15 GR 09.02.15 GR
V02.02 20.02.15 GR 20.02.15 GR
Title 992000 Driver CX.SchDoc
* * * * *
* * * * *
Size Document Number Article Nr. Version
* * * * *
A2 V02.02
992000 * * * * * *
Date : 20.02.2015 Time : 11:33:43 Sheet 3 of 6 * * * * *

167 | 192
 Driver Variant RX
Rotary Incising Unit RX
14. Appendix

168 | 192
COW10
W10
Cable Supply Drv E-Stop Power1 COW39
W39 COB4
B4
POA3 (bSLiPowerSafety)
(BSLIPOWERSAFETY) PIW100IN1 PIW100OUT1 Light Barrier SX911; 1000mm
A3 0
- J12
J12(bSLiPowerSafety) NLGap Home
PIW390OUT1 PIW390IN1
Gap Right
RightHome PIB40IN
(Power Slot 2, Gap/Blade)
964007
COW21
W21 800mm 964023
Cable STO/Feedback Type B 439162 1000mm COW38
W38 Light Barrier 24VDC PNP; SX911
POA3 (bSLiPowerSafety)
(BSLIPOWERSAFETY) PIW210IN1 PIW210OUT1 439176 Stepper Motor 2.3Nm; 1000mm EE-SX911P-R
A3 0
- J23
J23(bSLiPowerSafety)
PIW380OUT1 PIW380IN1 PIM20IN1 436342
(STO Slot 2, Gap/Blade) Feeding Unit Right -
964013
500mm 964031
439168 1000mm COM2 Vorschubeinheit Rechts

M2
Stepper Motor Moons 2.3Nm
ML23HSAL4500
439191
PIA70J2 PIA80J4 PIA80J2 PIA80J3 439682

J4
J2
J3
Gap
PIA70J10
NL0x06020001
0x06020001
PIA80J14
COW42
W42 COB6
B6

STO
J10 EtherCAT2 Motor1 J15
Light Barrier SX911; 1000mm

POWER J2
NL0x03020001 NLGap Home

POWER
0x03020001 PIW420OUT1 PIW420IN1 Gap Left
LeftHome PIB60IN
Limit1 J11 PIA80J11
964023
COA7 COA8 1000mm COW41
W41 Light Barrier 24VDC PNP; SX911
COW23 A7 A8
W23 439176 Stepper Motor 2.3Nm; 1000mm EE-SX911P-R
962002 962021 NL0x06020002
Cable Ethernet 0x06020002
PIA80J15 PIW410OUT1 PIW410IN1 PIM30IN1 436342
bSlaveController bDrvStepperL Motor2 J16 Feeding Unit Left -
POA1
A1 -0 J26 (bMainController)
(BMAINCONTROLLER)
J26(bMainController) PIW230IN1 PIW230OUT1 428039 432841 NL0x03020002
0x03020002 964031
(EtherCAT Master - Slot 2) Limit2 J12 PIA80J12 COW43 COB7 Vorschubeinheit Links
300mm W43 1000mm COM3 B7

M3
Stepper Motor Moons 2.3Nm
ML23HSAL4500
439191
439444 Light Barrier SX911; 1000mm 439682
PIA70J9A PIW430OUT1 PIW430IN1
Gap Left Pressure PIB70IN
J9A EtherCAT0
PIA70J9B
NL0x06020003
0x06020003
PIA80J16 964023 Gap
J9B EtherCAT1 Motor3 J17
1000mm Light Barrier 24VDC PNP; SX911
NL0x03020003
0x03020003 439176 EE-SX911P-R

Encoder1
Encoder2
Encoder3
Limit3 J13 PIA80J13
436342
Driver Slot 2
COW60
W60 COB9
B9

J8
J9
J10
(Slave 2) Light Barrier SX911; 1000mm
PIA80J8 PIA80J9 PIA80J10 PIW600OUT1 PIW600IN1 PIB90IN

964023
1000mm COW59
W59 Light Barrier 24VDC PNP; SX911
439176 Stepper Motor 2.3Nm; 1000mm EE-SX911P-R
Cutting
Unit -

(EtherCAT Slot 2 - Slot 3)

PIW590OUT1 PIW590IN1 PIM70IN1
436342

964031 Schneideinheit
COW11
W11 1000mm COM7

M7
Stepper Motor Moons 2.3Nm
ML23HSAL4500
439191
Cable Supply Drv Interlock Power1 439682
POA3
A3 0
- J22 (bSLiPowerSafety)
(BSLIPOWERSAFETY)
J22(bSLiPowerSafety) PIW110IN1 PIW110OUT1
PIW250OUT1 (Power Slot 3, Feed/Cut)
Blade Changing Axis
964009
COW25
W25 COW22
W22 500mm
300mm
Cable STO/Feedback Termination 439165
439444
PIW220IN1
Stepper Motor Moons 2.3Nm
PIW250IN1 COW44

Cable Ethernet
W44
964018 Stepper Motor 2.3Nm; 1000mm Feeding Unit Right -
439718 PIW440OUT1 PIW440IN1 PIM40IN1
PIA90J2 PIA10 J4 PIA10 J2 PIA10 J3 Vorschubeinheit Rechts
964031

J4
J2
J3
1000mm COM4

M4
ML23HSAL4500
439191
439682
PIA90J10
NL0x06030001
0x06030001
PIA100J14

STO
J10 EtherCAT2 Motor1 J15 Feeding Axis

POWER J2
POWER
Limit1 J11 PIA100J11

Stepper Motor Moons 2.3Nm

(STO Slot 2, Gap/Blade) COW45
W45
COA9
A9 COA10
A10 Feeding Unit Left -
Stepper Motor 2.3Nm; 1000mm
962002 962021
NL0x06030002
0x06030002
PIA100J15 PIW450OUT1 PIW450IN1 PIM50IN1
bSlaveController bDrvStepperL Motor2 J16 Vorschubeinheit Links
428039 432841 NLGap Pressure
NL0x03030002
0x03030002
PIA100J12
Gap Left
Left Pressure 964031
Limit2 J12
1000mm COM5
M5
ML23HSAL4500
439191

439682
PIA90J9A J9A EtherCAT0
Variant RX Feeding Axis
PIA90J9B
NL0x06030003
0x06030003
PIA100J16
Rotary Incising Unit RX POA9
A9 -0J9B (Driver
(DRIVER
J9B(Driver Slot 3)
Slot 3)SLOT J9B EtherCAT1 Motor3 J17
W51, A12 (EtherCAT Slot 3 - Slot 4) COW48 COB25
NL0x03030003
0x03030003
PIA100J13
W48 B25

Encoder1
Encoder2
Encoder3
Limit3 J13
Light Barrier SX911; 1000mm
Driver Slot 3 PIW480OUT1 PIW480IN1 PIB250IN

J8
J9
J10
(Slave 3) 964023
PIA10 J8 PIA10 J9 PIA10 J10 1000mm COW46
W46 Light Barrier 24VDC PNP; SX911
439176 Stepper Motor 2.3Nm; 1000mm EE-SX911P-R
PIW460OUT1 PIW460IN1 PIM60IN1
436342 Cutting
Unit -
NL0x130

0x01030003
964031 Schneideinheit
COW47
W47 1000mm COM6
M6
Stepper Motor Moons 2.3Nm
ML23HSAL4500
439191

Encoder 500 8mm; 1200mm 439682

COB8
B8
PIW470OUT1 PIW470IN1 PIB80IN6 J1
Encoder 500 8mm
PS30B-500-8A-L
1200mm Cutting Axis
439196

Drawn by Checked by
Version Date Signature Date Signature
01.00.00 25.03.14 GR * *
01.00.01 10.04.14 GR 18.04.14 WMA
01.01.00 21.05.14 GR 22.05.14 WMA
01.02.00 02.07.14 GR * *
V02.00 04.12.14 GR * *
Project MS 9480 Component Blockschema
V02.01 09.02.15 GR 09.02.15 GR
V02.02 20.02.15 GR 20.02.15 GR
Title 992000 Driver RX.SchDoc
* * * * *
* * * * *
Size Document Number Article Nr. Version
* * * * *
A2 V02.02
992000 * * * * * *
Date : 20.02.2015 Time : 11:33:43 Sheet 4 of 6 * * * * *

Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480

 Variant M / MR / RS Variant MR / RS
Blade Changing Axis Rotary Incising Unit CX
BLDC Motor Fulling 80W 2End
14. Appendix

COW52
W52
COW60 COB9 BLDC Motor 80W; 1200mm
W60 B9 PIW520OUT1 PIW520IN1 PIM90IN
Light Barrier SX911; 1000mm COW50
W50
POA8 J13 (bDrvStepperL)
(BDRVSTEPPERL) PIW600OUT1 PIW600IN1 PIB90IN Cable Supply Drv Interlock Power2 PIW520OUT1 PIW520IN2 PIM90IN1
A8 -0J13 (bDrvStepperL)
POA3 (bSLiPowerSafety) PIW500IN1 PIW500OUT1
(Blade Change) A3 -0J21
J21(bSLiPowerSafety) 964032
964023 COW53
COW59 (Power Slot 4, Rotation) W53 1200/1400mm COM9

M9
42BL81
439193
1000mm W59 Light Barrier 24VDC PNP; SX911 964010
Encoder 500 5mm; 1200mm 439683 COB12
439176 Stepper Motor 2.3Nm; 1000mm EE-SX911P-R 600mm B12
PIW530OUT1 PIW530IN1 PIB120IN6 J1
POA8 J17 (bDrvStepperL)
(BDRVSTEPPERL) PIW590OUT1 PIW590IN1 PIM70IN1 436342 439166 Encoder 500 5mm
A8 -0J17 (bDrvStepperL) PIA120J2 PIA130J3 PIA130J2 PS30B-500-5A-L
(Blade Change) 1200mm Rotation
964031

Cutting Unit -
439194

J3
J2
NL0x04050001

Schneideinheit
1000mm COM7 PIA130J9
0x04050001

M7
Stepper Motor Moons 2.3Nm
ML23HSAL4500
439191
Motor1 J9
439682
PIA120J10 J10 EtherCAT2 Limit1 J18 PIA130J18 BLDC Motor Fulling 80W 2End
Blade Changing Axis

POWER J2
POWER
COW54
W54
BLDC Motor 80W; 1200mm
NL0x04050002
0x04050002 PIW540OUT1 PIW540IN1 PIM100IN
Motor2 J11 PIA130J11
COA12
A12 COA13
A13
962002 962022 Limit2 J19 PIA130J19 PIW540OUT1 PIW540IN2 PIM100IN1

bSlaveController bDrvDC2Stepper2 964032

428039 427232 1200/1400mm COM10

M10
42BL81
439193

COW55
W55 439683
COW51
W51 NL0x06050003
0x06050003
PIA130J12
COB13
B13
Variant S / M / MR Motor3 J12 PIW550OUT1 PIW550IN1 PIB130IN6 J1
Cable Ethernet Encoder 500 5mm
Swivel Guide PIW510IN1 PIW510OUT1 PIA120J9A
NL0x03050003
0x03050003
PIA130J20 PS30B-500-5A-L
POA9
A9 - J9B
0 (Slot
J9B3) (Slot 3) J9A EtherCAT0 Limit3 J20 Encoder 500 5mm; 1200mm Centering Axis
(EtherCAT Slot 3 - Slot 4) 1200mm
300mm PIA120J9B J9B EtherCAT1 439194
439444 COW58 COB15
W58 B15
PIA130J13

Hall1
Hall2
Encoder1
Encoder2
Encoder3
Encoder4
Rotary Incising Unit -

COW63 COB10 Motor4 J13 Light Barrier SX912; 1400mm

W63 B10
Rotative Schneideinheit

Light Barrier SX912; 1000mm Driver Slot 4 PIW580OUT1 PIW580IN1 PIB150IN

Limit4 J21 PIA130J21
POA6 (bDrvDC2Stepper2)
(BDRVDC2STEPPER2) PIW630OUT1 PIW630IN1 PIB100IN

J8
J10
J14
J15
J16
J17
A6 -0 J21
J21(bDrvDC2Stepper2) (Slave 5) 964024
(Swivel Guide) PIA130J8 PIA130J10 PIA130J14 PIA130J15 PIA130J16 PIA130J17 COW56
W56 1400mm Light Barrier 24VDC PNP; SX912
964024 Stepper Motor Moons 2.3Nm 2End
COW61 Stepper Motor 2.3Nm 2End; 1200mm 444563 EE-SX912P-R
1000mm W61 Light Barrier 24VDC PNP; SX912 ML23HSAL4500-02
PIW560OUT1 PIW560IN1 PIM110IN1 436343
439177 Stepper Motor 0.7Nm 2End; 1000mm EE-SX912P-R NL0x150 1 NL0x150 2 NL0x150 3

0x01050001
0x01050002
0x01050003
POA6 (bDrvDC2Stepper2)
(BDRVDC2STEPPER2) PIW610OUT1 PIW610IN1 PIM80IN1
436343
A6 -0 J13
J13(bDrvDC2Stepper2) 964032
(Swivel Guide) 1200mm COM11
M11
439192

964031 COW57
COW62 439771 W57 COB14
W62 1000mm COM8 B14

M8
Stepper Motor Moons 0.7Nm 2End
17HDB002N
439189
PIW570OUT1 PIW570IN1 PIB140IN6 J1

Swivel Guide -
Encoder 500 5mm; 1200mm 439680 Encoder 500 6.3mm
COB11
B11

Schwenkführung
POA6 (bDrvDC2Stepper2)
(BDRVDC2STEPPER2) PIW620OUT1 PIW620IN1 J1 PS30B-500-6.35A-L
A6 -0 J17
J17(bDrvDC2Stepper2) PIB110IN6 Encoder 500 5mm Encoder 500 6.35mm; 1200mm Rotary Incising
(Swivel Guide) PS30B-500-5A-L 1200mm

Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480

1200mm Axis
439195
439194

Variant RS Variant RX / RSX

Linear Guide Z-Axis Rotary Incising Unit RX
COW65
W65
COB23 BLDC Motor Fulling 80W 2End
Sensor D-A93-L; 1400mm B23
POA1
A1 -0J27 (BMAINCONTROLLER)
(bMainController)
J27(bMainController) PIW650OUT1 PIW650IN1 PIB230IN W52
(Linear Cutting Guide) BLDC Motor 80W; 1200mm

Zylinder
964027 Reed Contact; D-A93-L PIW520IN1 PIM90IN

eingefahren
1400mm D-A93-L W50
439180 400528 Cable Supply Drv Interlock Power2 PIW520OUT1 PIW520IN2 PIM90IN1
POA3
A3 -0J21 (BSLIPOWERSAFETY)
J21(bSLiPowerSafety) PIW500IN1 PIW500OUT1 964032
COW64
W64 COE5
E5
(Power Slot 4, Rotation) 1200/1400mm
M9
42BL81
439193

Cable Valve Small 964010

439683 W53
POA1 (bMainController)
(BMAINCONTROLLER) PIW640IN1 PIW640OUT1 PIE50IN 600mm B12
A1 -0 J35
J35(bMainController) PIW530OUT1 PIW530IN1 PIB120IN6 J1
439166 Encoder 500 5mm
(Linear Cutting Guide) PIA120J2 PIA130J3 PIA130J2
964028 Air Valve 5/2; SY3220-5LOU-C4-Q PS30B-500-5A-L
Encoder 500 5mm; 1200mm Rotation
1200mm SY3120
1200mm

J3
J2
439181 256.0157 NL0x04040001
0x04040001
PIA130J9
Motor1 J9 439194
COW66
W66
Sensor D-A93-L; 1400mm COB24
B24 PIA120J10 J10 EtherCAT2 Limit1 J18 PIA130J18
Stepper Motor Sonceboz 0.925Nm

POWER J2
POA1 (bMainController)
(BMAINCONTROLLER) PIW660OUT1 PIW660IN1 PIB240IN

Linear Guide Z-Axis -

POWER
A1 -0J29
J29(bMainController)

Lineare Führung Z-Axis

(Linear Cutting Guide) W54

Zylinder
964027 Reed Contact; D-A93-L

ausgefahren
Stepper Motor 0.925Nm; 1200mm
1400mm D-A93-L Motor2 J11 PIA130J11
439180 400528 A12 A13 PIW540OUT1 PIW540IN1 PIM100IN1

962002 962022 Limit2 J19 PIA130J19

964036
bSlaveController bDrvDC2Stepper2
1200mm
M10
6600-20-2-0.37
637.0053

428039 427232
445914
W51 NL0x06040003
0x06040003
PIA130J12
Motor3 J12
Cable Ethernet Centering Axis
POA9
A9 - J9B
0 (Slot
J9B3) (SLOT 3) PIW510IN1 PIW510OUT1 PIA120J9A J9A EtherCAT0 Limit3 J20 PIA130J20

(EtherCAT Slot 3 - Slot 4)

300mm PIA120J9B
W58 B15
J9B EtherCAT1
439444 Light Barrier SX912; 1400mm
NL0x06040004
0x06040004
PIA130J13 PIW580OUT1 PIW580IN1 PIB150IN
Hall1
Hall2
Encoder1
Encoder2
Encoder3
Encoder4
Rotary Incising Unit -

Motor4 J13
Rotative Schneideinheit

Driver Slot 4 Limit4 NL0x03040004

0x03040004
J21 PIA130J21
964024
W56 1400mm Light Barrier 24VDC PNP; SX912
J8
J10
J14
J15
J16
J17

(Slave 4) Stepper Motor Sonceboz 0.925Nm 2End

Stepper Motor 0.925Nm 2End; 1200mm 444563 EE-SX912P-R
PIA130J8 PIA130J10 PIA130J14 PIA130J15 PIA130J16 PIA130J17 PIW560OUT1 PIW560IN1 PIM110IN1
436343

NL0x140 964036
0x01040004

NL0x140 1 1200mm
0x01040001
M11
6600R506
411420

445916 W57
B14
PIW570OUT1 PIW570IN1 PIB140IN6 J1
Encoder 500 6.3mm
PS30B-500-6.35A-L
Encoder 500 6.35mm; 1200mm Rotary Incising
1200mm Axis
439195

Drawn by Checked by
Version Date Signature Date Signature
01.00.00 25.03.14 GR * *
01.00.01 10.04.14 GR 18.04.14 WMA
01.01.00 21.05.14 GR 22.05.14 WMA
01.02.00 02.07.14 GR * *
V02.00 04.12.14 GR * *
Project MS 9480 Component Blockschema
V02.01 09.02.15 GR 09.02.15 GR
V02.02 20.02.15 GR 20.02.15 GR
Title 992000 Variants.SchDoc
* * * * *
* * * * *
Size Document Number Article Nr. Version
* * * * *
A2 V02.02
992000 * * * * * *
Date : 20.02.2015 Time : 11:33:44 Sheet 5 of 6 * * * * *

169 | 192
 Option bDrvIO Option RS-232 Option Wire End Monitoring
Benötigt für Optionen Length Monitoring / Booster / Air Jet Unit RS-232 * Kabelendüberwachung Standard
A* COW67
W67 COM12
M12
962063 Magnet 24VDC Reset Spring; 1400mm
14. Appendix

Option Length Monitoring bSLiRS232 POA1 (bMainController)

(BMAINCONTROLLER) PIW670OUT1 PIW670IN1 PIM120IN
A1 -0J37
J37(bMainController)
POA4 0 J58 (BDRVIO) 440542

170 | 192
A4 - J58 (bDrvIO) (Wire End Monitoring)
964041 Magnet 24VDC; Reset Spring
W76, B21 (Length Monitoring) COW0
Optional S-Link Devices W* SIS Slot 3..6 1400mm TDS-06UB
POA4 0 A4 (bDrvIO)
(BDRVIO)
J2- J2 Cable S-Link 439183 401419
(bDrvIO) A1 - J42..44 (bMainController)
Optional S-Link Devices PIW00OUT1 PIW00IN1 PIA00J2 PIA00J4
W7, A3 (Supply bDrvIO) J2 J4

S-Link
POA1 (bMainController) POA4 0 J450050

RS-232
COW8 A10- J420044
J42..44 (bMainController) A4 - J45..50 (bDrvIO)(bDrvIO) COW68 COB16
W8 964021 W68 B16
NL0x0D010007 000 0x0D01000C Option RS-232, SMI, SmartDetect, ...
Cable Supply Drv Extension Strand NL0x1 0 1 0x0D010007 ... 0x0D01000C 800mm Light Barrier SX912; 1400mm
PIW80IN1 PIW80OUT1 444536 POA1 (bMainController)
(BMAINCONTROLLER) PIW680OUT1 PIW680IN1 PIB160IN

0x01010001
PIA40J3 PIA40J2 PIA40J53 PIA40J58 PIA40J46 PIA40J48 PIA40J50 A1 -0J30
J30(bMainController)
964016 NL0x03010005
0x03010005
Option Booster (Wire End Monitoring)
964024
J24 PIA40J24 POA4 0 J24
A4 - J24 (bDrvIO)
(bDrvIO)

J3
J2
100mm NL0x03010006
0x03010006 1400mm Light Barrier 24VDC PNP; SX912

J58
J46
J48
J50
439719
PIA40J45 PIA40J47 PIA40J49 J25 PIA40J25 W69, E6 (Booster)
444563 EE-SX912P-R
J26 PIA40J26
Option Air Jet Unit 436343
J27 PIA40J27

J45
J47
J49
J28 PIA40J28 POA4 0 J25
A4 - J25 (BDRVIO)
(bDrvIO)
14.2.3 Options

POWER
Encoder
S-Link J29 PIA40J29 W74, E9 (Air Jet Unit) Option SMI

1-Wire Bus J53

J30 PIA40J30 SMI
COA4
A4
J31 PIA40J31 *
J37 PIA40J37 COA0
962040 A*

A1 - J2 (bMainController)
J38 PIA40J38 Option Jam Detector
bDrvIO 962061
J39 PIA40J39

Outputs
431825 bSLiSMI Staudetektor
Inputs J40 PIA40J40
Option Length Monitoring 437125
J41 PIA40J41 NL0x03010012 COW73 COB20
0x03010012 W73 B20

J8
J9
J10
J11
J42 PIA40J42 POA4 0 J42
A4 - J42 (BDRVIO)
(bDrvIO)
NL0x03010013
0x03010013
Optional S-Link Devices W* SIS Slot 3..6 Cable Optical Sensor DF-G1 COB19
B19
PIA40J8 PIA40J9 PIA40J10 PIA40J1 J43 PIA40J43 NL0x03010014 W75, E10 (Length Monitoring)
0x03010014 Cable S-Link POA1 (bMainController)
(BMAINCONTROLLER) PIW730IN1 PIW730OUT1 PIB190IN
J44 PIA40J44 A1 - J42..44 (bMainController) A1 -0J28
J28(bMainController)
PIW00IN1 PIW00OUT1 PIA00J2 PIA00J3

J12
J13
J14
J15
Option Length Monitoring J2 J3 (Jam Detector)

SMI
964042 A399641

S-Link
J54 PIA40J54 POA4 0 J43
A4 - J43 (BDRVIO)
(bDrvIO) A4 - J45..50 (bDrvIO)
PIA40J12 PIA40J13 PIA40J14 PIA40J15 J55 PIA40J55
W79, S3 (Recoil Brake)
964021 1400mm Optical Sensor; DF-G1-PS-Q7
800mm 439184 434274 A301916

J16
J17
J18
J19
J56 PIA40J56
Analog PIA40J57 Option Length Monitoring 444536 440338
PIA40J16 PIA40J17 PIA40J18 PIA40J19 J57
POA4 0 J44 (BDRVIO) Optical Fiber PIRS1X166UMPM.75
A4 - J44 (bDrvIO)

J20
J21
J22
J23
J51
J52
J36
W77, E11 (Recoil Brake)
PIA40J20 PIA40J21 PIA40J2 PIA40J23 PIA40J51 PIA40J52 PIA40J36
Option Length Monitoring
NL0x710 5 NL0x710 6 NL0x710 7 NL0x710 8 POA4 0 J23
A4 - J23 (BDRVIO)
(bDrvIO)

0x07010015
0x07010016
0x07010017
0x07010018
W79, S3 (Recoil Brake) Option Smart Detect Option Lighting Processing Area (600mm)
Option Length Monitoring Erkennung Einschnitt Beleuchtung Bearbeitungsraum
POA4 0 J22
A4 - J22 (BDRVIO)
(bDrvIO) COW80
W80
W78, B22 (Recoil Brake) COA30 COE12
A30 Lighting 500mm; 300mm E12
Option Booster 962064 POW27 Lighting) PIW800OUT1 PIW800IN1 PIE1200
W27 (Wire
(WireSupply
SupplyLighting)
POA4 0 J21 (bDrvIO) bSLiSmartDetect
A4 - J21 (bDrvIO) (Lighting Processing Area)
445523 964044
W71, B18 (Booster)
300mm LED Lighting
Option Booster PIA300J4A
439186
COW82 J4A
W82
POA4 0 J20
A4 - J20 (bDrvIO)
(bDrvIO) Optional S-Link Devices Cable S-Link M8 4p
W70, B17 (Booster) POA1
A10- J420044 (BMAINCONTROLLER)
J42..44 (bMainController) J4B PIA300J4B
PIW820IN1 PIW820OUT1 PIA300J2 J2
POA4 J450050 (BDRVIO) PIA300J5A

S-Link
Blades
A4 - 0
J45..50 (bDrvIO) J5A
964022
500mm PIA300J5B
J5B Option Lighting Processing Area (800mm)
451380
Option Length Monitoring Option Booster Beleuchtung Bearbeitungsraum
Längenüberwachung Verstärker W80
Lighting 660mm; 300mm E12
COW75
W75 COW70
W70 POW27
W27 (Wire
(WIRESupply LIGHTING)
SUPPLYLighting) PIW800OUT1 PIW800IN1 PIE1200
Cable Valve Small COE10
E10 Sensor D-A93-L; 1400mm COB17
B17
(Lighting Processing Area)
POA4 (bDrvIO) PIW750IN1 PIW750OUT1 PIE100IN POA4 J20 (BDRVIO) PIW700OUT1 PIW700IN1 PIB170IN
964044
A4 -0J42
J42(bDrvIO) A4 -0J20 (bDrvIO) Without Option E-Stop Circuit 300mm LED Lighting

Zylinder
(Length Monitoring) (Booster)

eingefahren
964028 964027 Reed Contact; D-A93-L Keine Nothaltverknüpfung Standard 442715
1200mm Air Valve 5/2; SY3220-5LOU-C4-Q 1400mm D-A93-L
439181 SY3120 439180 400528
256.0157 COW13
W13
COW69
W69 COE6
E6 Cable ESC Termination
Cable Valve Small POA3 (BSLIPOWERSAFETY) PIW130IN1
A3 0- J27
J27(bSLiPowerSafety)
COW76
W76 PIW690IN1 PIW690OUT1 PIE60IN
Encoder 1000 8mm; 1200mm
POA4
A4 -0J24J24 (BDRVIO)
(bDrvIO) (without E-Stop Circuit)
964020
COB21
B21 (Booster)
POA4 (bDrvIO) PIW760OUT1 PIW760IN1 PIB210IN6 J1 964028 Air Valve 5/2; SY3220-5LOU-C4-Q 439173
A4 -0J58
J58(bDrvIO) Encoder 1000 8mm
1200mm SY3120
(Length Monitoring) PS30B-1000-8A-L
1200mm 439181 256.0157
439748
COW71
W71
Sensor D-A93-L; 1400mm COB18
B18
COW78
W78 POA4
A4 -0J21J21 (BDRVIO)
(bDrvIO) PIW710OUT1 PIW710IN1 PIB180IN Option E-Stop Circuit
Sensor D-A93-L; 1400mm COB22
B22

Zylinder
(Booster)

ausgefahren
POA4 (bDrvIO) PIW780OUT1 PIW780IN1 PIB220IN
964027 Reed Contact; D-A93-L Anbindung Nothaltverknüpfung ESC 1000
A4 -0J22
J22(bDrvIO)
1400mm D-A93-L
(Recoil Brake) COA27
964027 Reed Contact; D-A93-L 439180 400528 A27

Zylinder
1400mm D-A93-L 962007

eingefahren
439180 400528 bIntEStopCircuit
443085
COW77
W77 COE7
E7
Cable Valve Small COE11
E11 Air Valve 5/2; SY3220-5LOU-C4-Q COW81
W81 SIS Slot 7
PIW770IN1 PIW770OUT1 PIE110IN
Cable ESC
POA4
A4 -0J44 (bDrvIO)
J44(bDrvIO)
(Recoil Brake) PIE70IN POA3
A3 0- J27 (bSLiPowerSafety)
J27(bSLiPowerSafety) PIW810IN1 PIW810OUT1 PIA270J2 J2 J1 PIA270J1
COW72

ESC
964028 W72

Valve V?
(with E-Stop Circuit)
1200mm Air Valve 5/2; SY3220-5LOU-C4-Q Cable STO Safety Valves SY3120 964019
439181 SY3120 PIW720OUT2 256.0157 500mm

(Sicherheitsventil A)
256.0157 POA3
A30- J24 (bSLiPowerSafety)
(BSLIPOWERSAFETY)
J24 (bSLiPowerSafety) PIW720IN1 439172
(Safety Valves) PIW720OUT1
COW79
W79 COE8
E8
COS3 964045
Button Lighted 1NO Type CTL; 1400mm S3
POA4 (bDrvIO) PIW790OUT1 600mm
A4 -0J23
J23(bDrvIO) PIE80IN
PIW790IN1 PIS30IN
439448
(Recoil Brake)

Valve V?
POA4
A4 -0J43 (bDrvIO)
J43(bDrvIO) PIW790OUT2 Air Valve 5/2; SY3220-5LOU-C4-Q
(Recoil Brake) 964043 COSymbol2
SY3120
Button Lighted 1NC/1NO; Type CTL
1400mm 256.0157
CTL In den SIS-Slots 3..6 können

(Sicherheitsventil B)
439185 *
415115 beliebige Kombinationen von
Erweiterungen verbaut werden.
Die Reihenfolge soll aber immer
sein:
1. RS-232
Option Air Jet Unit 2. SMI
Luftstrahleinheit 3. ...

COW74
W74 COE9
E9
Cable Valve Small
POA4 0 J25
A4 - J25 (bDrvIO)
(bDrvIO) PIW740IN1 PIW740OUT1 PIE90IN

(Air Jet Unit)

964028 Air Valve 5/2; SY3220-5LOU-C4-Q
1200mm SY3120
439181 256.0157

Drawn by Checked by
Version Date Signature Date Signature
01.00.00 25.03.14 GR * *
01.00.01 10.04.14 GR 18.04.14 WMA
01.01.00 21.05.14 GR 22.05.14 WMA
01.02.00 02.07.14 GR * *
V02.00 04.12.14 GR * *
Project MS 9480 Component Blockschema
V02.01 09.02.15 GR 09.02.15 GR
V02.02 20.02.15 GR 20.02.15 GR
Title 992000 Options.SchDoc
* * * * *
* * * * *
Size Document Number Article Nr. Version
* * * * *
A2 V02.02
992000 * * * * * *
Date : 20.02.2015 Time : 11:33:44 Sheet 6 of 6 * * * * *

Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480

14. Appendix

14.3 BLOCK DIAGRAM PNEUMATIC

3608 Thun/Switzerland
Bierigutstrasse 9
Schleuniger AG

Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480

171 | 192
14. Appendix

14.4 OPERATOR MANUAL BANNER DF-G1

DF-G1 - Expert Fiber Amplifier Install Sheet

Advanced sensor with dual digital displays for use with plastic and glass fiber optic assemblies
For complete technical information about this product, including dimensions, accessories, and specifications, see www.bannerengineering.com and search 161999.

Overview

1 Output LED

2 LO/DO Switch

3 RUN/PRG/ADJ Mode Switch

4 Lever Action Fiber Clamp

5 Red Signal Level

6 Green Threshold

7 +/SET/- Rocker Button

Figure 1. DF-G1 Model Features

WARNING: Not To Be Used for Personnel Protection

Never use this device as a sensing device for personnel protection. Doing so could lead to serious injury or death. This device
does not include the self-checking redundant circuitry necessary to allow its use in personnel safety applications. A sensor failure or
malfunction can cause either an energized or de-energized sensor output condition.

Models
Model Outputs Connector1

DF-G1-NS-2M Single NPN

DF-G1-PS-2M Single PNP

2 m (6.5 ft) cable, 4-wire
DF-G1-KS-2M Dual outputs, 1 push-pull IO-Link and 1 PNP (comple-
mentary outputs)

DF-G1-NS-Q5 Single NPN

DF-G1-PS-Q5 Single PNP

150 mm (6 in) PVC pigtail, M12 Euro QD connector, 4-pin
DF-G1-KS-Q5 Dual outputs, 1 push-pull IO-Link and 1 PNP (comple-
mentary outputs)

DF-G1-NS-Q7 Single NPN

DF-G1-PS-Q7 Single PNP

Integral M8 Pico QD connector, 4-pin
Dual outputs, 1 push-pull IO-Link and 1 PNP (comple-
DF-G1-KS-Q7
mentary outputs)

1 Connector options:

• A model with a QD connector requires a mating cordset .

• For 9 m cable, change the suffix 2M to 9M in the 2 m model number (example, DF-G1-NS-9M).
• For 150 mm (6 in) PVC pigtail, M8 Pico QD connector, 4-pin change the suffix 2M to Q3 in the 2 m model number (example, DF-G1-NS-Q3).
P/N 161275 Rev. B 9/4/2013

0 161275 2
172 | 192 Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480
14. Appendix

DF-G1 - Expert Fiber Amplifier Install Sheet

Hookups
NPN Models PNP Models Key
1 = Brown
2 = White
3 = Blue
4 = Black
Euro

2
1
3
4

Pico
IO-Link Models
4 2
3 1
PUSH-PULL

(C/Q) For cable options, see http://

www.bannerengineering.com

(Q)

Mounting Instructions

Mount on a DIN Rail

1. Hook the DIN rail clip on the bottom of the DF-G1 over the edge of the DIN
rail (1).
2. Push the DF-G1 up on the DIN rail (1).
3. Pivot the DF-G1 onto the DIN rail, pressing until it snaps into place (2).

Mount to the Accessory Bracket

1. Position the DF-G1 in the SA-DIN-BRACKET.

2. Insert the supplied M3 screws.
3. Tighten the screws.

2 www.bannerengineering.com - tel: 763-544-3164 P/N 161275 Rev. B

Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480

173 | 192
14. Appendix

DF-G1 - Expert Fiber Amplifier Install Sheet

Remove from a DIN rail

1. Push the DF-G1 up on the DIN rail (1).

2. Pivot the DF-G1 away from the DIN rail and remove it (2).

Installing the Fibers

Follow these steps to install glass or plastic fibers.
1. Open the dust cover. Move forward
2. Move the fiber clamp forward to unlock it. to release the
fibers
3. Insert the fibers into the fiber ports until they stop.
Fiber Receiver
4. Move the fiber clamp backward to lock the fibers. Port
5. Close the dust cover. Fiber Emitter
Port

Top Panel Interface

Opening the dust cover provides access to the top panel interface. The top panel interface consists of the RUN/PRG/ADJ mode switch, LO/DO switch, +/SET/- rocker
button, dual red/green digital displays, and output LED.

RUN/PRG/ADJ Mode Switch

The RUN/PRG/ADJ mode switch puts the sensor in RUN, PRG (Program), or ADJ (Adjust) mode. RUN mode allows the sensor to operate normally
and prevents unintentional programming changes via the +/SET/- button. PRG mode allows the sensor to be programmed through the display driven
programming menu (see Program Mode below). ADJ mode allows the user to perform Expert TEACH/SET methods and Manual Adjust (see Adjust
Mode below).

LO/DO Switch
The LO/DO switch is used to select Light Operate or Dark Operate mode. In Light Operate mode, the output is ON when the sensing condition is above
the threshold (for Window SET, the output is ON when the sensing condition is inside the window). In Dark Operate mode, the output is ON when the
sensing condition is below the threshold (for Window SET, the output is ON when the sensing condition is outside the window).

+/SET/- Rocker Button

The +/SET/- rocker button is a 3-way button. The +/- positions are engaged by rocking the button left/right. The SET position is engaged by clicking
down the button while the rocker is in the middle position. All three button positions are used during PRG mode to navigate the display driven program-
ming menu. During ADJ mode, SET is used to perform TEACH/SET methods and +/- are used to manually adjust the threshold(s). The rocker button is
disabled during RUN mode, except when using Window SET, see Window SET on page 7 .

Red/Green Digital Displays

During RUN and ADJ mode, the Red display shows the signal level and the Green display shows the threshold. During PRG mode, both displays are
used to navigate the display driven programming menu.

Output LED
The output LED provides a visible indication when the output is activated.

Remote Input/IO-Link
For more information about how to perform TEACH/SET methods, to program the sensor remotely, or to interface with the sensor via IO-Link, see the DF-G1 Manual (P/N
161999).

Run Mode
Run mode allows the sensor to operate normally and prevents unintentional programming changes. The +/SET/- rocker button is disabled during RUN mode, except when
using Window SET, see Window SET on page 7 .

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Program Mode
Program (PRG) mode allows the following set-
tings to be programmed in the DF-G1 :

Factory Default Settings:

Setting Factory Default

Threshold 2026

TEACH Selection Two-Point TEACH

Response Speed Standard - 500 µs

Offset Percent 10%

Auto Thresholds OFF

OFF Delay 0 (Disabled)

OFF One-Shot 0 (Disabled)

ON Delay 0 (Disabled)

ON One-Shot 0 (Disabled)

Display Readout Numeric, ECO disa-

bled, Normal Orien-
tation

Gain Selection Auto Gain

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Adjust Mode
Sliding the RUN/PRG/ADJ mode switch to the ADJ position allows the user to perform Expert TEACH/SET methods and Manual Adjustment of the threshold(s).
Two-Point TEACH
• Establishes a single switching threshold
• Threshold can be adjusted using “+” and “-” rocker button (Manual Adjust)
Two-Point TEACH is used when two conditions can be presented statically to the sensor. The sensor locates a single sensing threshold (the switchpoint) midway between
the two taught conditions, with the Output ON condition on one side, and the Output OFF condition on the other (see Figure below). The Output ON and OFF conditions can
be reversed by using the LO/DO (Light Operate/ Dark Operate) switch (see LO/DO Switch in Top Panel Interface on page 3).

Darkest Taught Lightest Taught Two-Point TEACH and Manual Adjust Moves switching threshold value up or down to
Condition Condition make adjustments
Sensor positions • Slide Mode switch to ADJ to enter Adjust mode
threshold midway • Press “+” to increase; press “-” to decrease
between taught conditions
◦ GREEN display shows the switching threshold value
◦ 2 seconds after adjustment, the GREEN display will flash 3 times to con-
Output OFF Output ON firm
• Slide Mode switch to RUN to complete operation
Darkest Position Most Light
(no signal) adjusted by (saturated
Manual Adjust signal) Remember: Manual adjustments are disabled
Figure 2. Two-Point TEACH (Light Operate shown) when Auto Thresholds are ON

SET Button Remote Input Result

0.04 seconds < "Click" < 0.8 seconds 0.04 seconds < T < 0.8 seconds

Note: TEACH Selection must be programmed to 2Pt tcH (see Program Mode on page 4 )

Set Mode switch to ADJ No action required; sensor is ready for Display: Red - Signal Level; Green -
Enter Adjust Two-Point TEACH method Threshold
Mode

• Present 1st condition • Present 1st condition Display: Flashes "2Pt tch" then holds
• Click the SET rocker button • Single-pulse remote input on "1234 2nd"
TEACH 1st
Condition T

• Present 2nd condition • Present 2nd condition TEACH Accepted

• Click the SET rocker button • Single-pulse remote input Displays alternate "PASS" and % Mini-
mum Difference*; Sensor returns to Ad-
TEACH 2nd T
just mode
Condition TEACH Unacceptable
Displays alternate "FAIL" and % Mini-
mum Difference*; Sensor returns to Ad-
just mode

Move Mode switch to RUN No action required; sensor returns to Display: Red - Signal Level; Green -
Return to RUN RUN mode automatically Threshold
Mode

*See Troubleshooting on page 11 for more explanation of the % Minimum Difference displayed after the Two-Point TEACH method.

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Dynamic TEACH
• Teaches on-the-fly
• Establishes a single switching threshold
• Threshold can be adjusted using “+” and “-” rocker button (Manual Adjust)
Dynamic TEACH is best used when a machine or process may not be stopped for teaching. The sensor learns during actual sensing conditions, taking multiple samples of
the light and dark conditions and automatically setting the threshold at the optimum level (see Figure below).
The output ON and OFF conditions can be reversed using the LO/DO switch (see LO/DO Switch in Top Panel Interface on page 3).

Dynamic TEACH and Manual Adjust Darkest Taught Lightest Taught

Moves switching threshold value up or down to make adjustments Condition Condition

• Slide Mode switch to ADJ to enter Adjust mode Sensor positions

threshold midway
• Press “+” to increase; press “-” to decrease
between taught conditions
◦ GREEN display shows the switching threshold value
◦ 2 seconds after adjustment, GREEN display will flash 3 times to confirm
• Slide Mode switch to RUN to complete operation Output OFF Output ON

Darkest Position Most Light

(no signal) adjusted by (saturated
Remember: Manual adjustments are disabled Manual Adjust signal)
when Auto Thresholds are ON
Figure 3. Dynamic TEACH (Light Operate shown)

SET Button Remote Input Result

0.04 seconds < "Click" < 0.8 seconds 0.04 seconds < T < 0.8 seconds

Note: TEACH Selection must be programmed to dYn tcH (see Program Mode on page 4 )

• Set Mode switch to ADJ No action required; sensor is ready for Display: Red - Signal Level; Green -
Enter Adjust Dynamic TEACH method Threshold
Mode

• Click the SET rocker button • Single-pulse remote input Display: Flashes "dYn tch" then
holds on "1234 dYn"
Enter Dynamic
TEACH T

Present ON • Present ON and OFF conditions • Present ON and OFF conditions Display: Red - Signal Level; Green -
and OFF Con- Threshold
ditions

• Click the SET rocker button • Single-pulse remote input TEACH Accepted
Displays alternate "PASS" with % Min-
T imum Difference*, Sensor returns to
Exit Dynamic Adjust mode
TEACH TEACH Unacceptable
Displays alternate "FAIL" with % Mini-
mum Difference*, Sensor returns to
Adjust mode

• Move Mode switch to RUN No action required; sensor returns to Display: Red - Signal Level; Green -
Return to RUN RUN mode automatically Threshold
Mode

*See Troubleshooting on page 11 for more explanation of the % Minimum Difference displayed after the Dynamic TEACH method.

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Window SET
• Sets window thresholds that extend a programmable % offset above and below the presented condition
• All other conditions (lighter or darker) cause the output to change state
• Sensing window center can be adjusted using “+” and “-” rocker button (Manual Adjust)
• Recommended for applications where a product may not always appear in the same place, or when other signals may appear
• See Program Mode in the user's manual for programming the Offset Percent setting (to increase/decrease the window size)
A single sensing condition is presented, and the sensor positions window thresholds a programmable % offset above and below the presented condition. In LO mode,
Window SET designates a sensing window with the Output ON condition inside the window, and the Output OFF conditions outside the window (see Figure below).
Output ON and OFF conditions can be reversed using the LO/DO switch (see LO/DO Switch in Top Panel Interface on page 3).

Sensing window Window SET and Manual Adjust

center adjusted by
Manual Adjust Moves sensing window center value up or down to make adjustments
Sensor positions
window thresholds • Slide Mode switch to ADJ to enter Adjust mode
a programmable % • Press “+” to increase; press “-” to decrease
offset from the
presented condition ◦ GREEN display shows the sensing window center value
◦ 2 seconds after adjustment, the GREEN display will flash 3 times to confirm
Output OFF Output ON Output OFF
• Slide Mode switch to RUN to complete operation

Darkest Condition Most Light

(no signal) Presented (saturated
signal) Remember: Manual adjustments are disabled
Figure 4. Window SET (Light Operate shown) when Auto Thresholds are ON

SET Button Remote Input Result

0.04 seconds < "Click" < 0.8 seconds 0.04 seconds < T < 0.8 seconds

Note: TEACH Selection must be programmed to wind SEt (see Program Mode on page 4 )

• Set Mode switch to ADJ No action required; sensor is ready for Display: Red - Signal Level; Green -
Enter Adjust Window SET method Threshold
Mode

• Present sensing condition • Present sensing condition Threshold Condition Accepted

• Click the SET rocker button • Single-pulse the remote input Displays read "wInd SEt" then alternate
"PASS" with % Offset*; Sensor returns
T
to Adjust mode
SET Sensing
Condition Threshold Condition Unacceptable
Displays read "wInd SEt" then alternate
"FAIL" with minimum % Offset* for
sensing condition; Sensor returns to Ad-
just mode

Return to RUN • Move Mode switch to RUN No action required; sensor returns to Display: Red - Signal Level; Green -
Mode RUN mode automatically Window Center (see Figure below for in-
structions on how to display upper and
lower thresholds)

* See Troubleshooting on page 11 for more explanation of the % Offset displayed after the Window SET method

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Light SET
• Sets a threshold a programmable % offset below the presented condition
• Changes output state on any condition darker than the threshold condition
• Threshold can be adjusted using “+” and “-” rocker button (Manual Adjust)
• Recommended for applications where only one condition is known, for example a stable light background with varying darker targets
• See Program Mode on page 4 for programming the Offset Percent setting
A single sensing condition is presented, and the sensor positions a threshold a programmable % offset below the presented condition. When a condition darker than the
threshold is sensed, the output either turns ON or OFF, depending on the LO/DO switch setting (see LO/DO Switch in Top Panel Interface on page 3).

Light SET and Manual Adjust Threshold position

Moves switching threshold value up or down to make adjustments adjusted by
Manual Adjust
• Slide Mode switch to ADJ to enter Adjust mode
Sensor positions
• Press “+” to increase; press “-” to decrease
threshold a programmable
◦ GREEN display shows the switching threshold value % offset below the
presented condition
◦ 2 seconds after adjustment, the GREEN display will flash 3 times to con-
firm
Output OFF Output ON
• Slide Mode switch to RUN to complete operation

Darkest Condition Most Light

(no signal) Presented (saturated
Remember: Manual adjustments are disabled signal)
when Auto Thresholds are ON
Figure 5. Light SET (Light Operate shown)

SET Button Remote Input Result

0.04 seconds < "Click" < 0.8 seconds 0.04 seconds < T < 0.8 seconds

Note: TEACH Selection must be programmed to Lt SEt (see Program Mode on page 4 )

• Set Mode switch to ADJ No action is required; sensor is ready Display: Red - Signal Level; Green -
for Light SET method Threshold
Enter Adjust
Mode

• Present sensing condition • Present sensing condition Threshold Condition Accepted

• Click the SET rocker button • Single-pulse the remote input Displays read "Lt SEt" then alternate
"PASS" with % Offset*; Sensor returns
T
to Adjust mode
SET Sensing
Condition Threshold Condition Unacceptable
Displays read "Lt SEt" then alternate
FAIL with minimum % Offset* for sens-
ing condition; Sensor returns to Adjust
mode

• Move Mode switch to RUN No action required; sensor returns to Display: Red - Signal Level; Green -
RUN mode automatically Threshold
Return to RUN
Mode

* See Troubleshooting on page 11 for more explanation of the % Offset displayed after the Light SET method

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Dark SET
• Sets a threshold a programmable % offset above the presented condition
• Any condition lighter than the threshold condition causes the output to change state
• Threshold can be adjusted using “+” and “-” rocker button (Manual Adjust)
• Recommended for applications where only one condition is known, for example a stable dark background with varying lighter targets
• See Program Mode on page 4 for programming the Offset Percent setting

NOTE: Offset Percent MUST be programmed to Minimum Offset to accept conditions of no signal (0 counts).

A single sensing condition is presented, and the sensor positions a threshold a programmable % offset above the presented condition. When a condition lighter than the
threshold is sensed, the output either turns ON or OFF, depending on the LO/DO switch setting (see LO/DO Switch in Top Panel Interface on page 3).

Threshold position Dark SET and Manual Adjust

adjusted by Moves switching threshold value up or down to make adjustments
Manual Adjust
• Slide Mode switch to ADJ to enter Adjust mode
Sensor positions
• Press “+” to increase; press “-” to decrease
threshold a programmable ◦ GREEN display shows the switching threshold value
% offset above the ◦ 2 seconds after adjustment, the GREEN display will flash 3 times to con-
presented condition
firm
Output OFF Output ON • Slide Mode switch to RUN to complete operation

Darkest Condition Most Light

(no signal) Presented (saturated Remember: Manual adjustments are disabled
signal) when Auto Thresholds are ON

Figure 6. Dark SET (Light Operate shown)

SET Button Remote Input Result

0.04 seconds < "Click" < 0.8 seconds 0.04 seconds < T < 0.8 seconds

Note: TEACH Selection must be programmed to dr SEt (see Program Mode on page 4 )

• Set Mode switch to ADJ No action required; sensor is ready for Display: Red - Signal Level; Green -
Dark SET method Threshold
Enter Adjust
Mode

• Present sensing condition • Present sensing condition Threshold Condition Accepted

• Click the SET rocker button • Single-pulse the remote input Displays read "dr SEt" then alternate
"PASS" with % Offset*; Sensor returns
T
to Adjust mode
SET Sensing
Condition Threshold Condition Unacceptable
Displays read "dr SEt" then alternate
"FAIL" with minimum % Offset* for sens-
ing condition; Sensor returns to Adjust
mode

• Move Mode switch to RUN No action required; sensor returns to Display: Red - Signal Level; Green -
RUN mode automatically Threshold
Return to RUN
Mode

* See Troubleshooting on page 11 for more explanation of the % Offset displayed after the Dark SET method

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Calibration SET
• Sets a threshold exactly at the presented condition
• Threshold can be adjusted using “+” and “-” rocker button (Manual Adjust)
A single sensing condition is presented, and the sensor positions a threshold exactly at the presented condition. When a condition lighter than the threshold is sensed, the
output either turns ON or OFF, depending on the LO/DO switch setting (see LO/DO Switch in Top Panel Interface on page 3).

Calibration SET and Manual Adjust Threshold position

Moves switching threshold value up or down to make adjustments adjusted by
Manual Adjust
• Slide Mode switch to ADJ to enter Adjust mode
• Press “+” to increase; press “-” to decrease
Sensor positions
◦ GREEN display shows the switching threshold value threshold exactly at
◦ 2 seconds after adjustment, the GREEN display will flash 3 times to con- the presented condition
firm
Output OFF Output ON
• Slide Mode switch to RUN to complete operation

Darkest Condition Most Light

(no signal) Presented (saturated
Remember: Auto Thresholding is automatically signal)
disabled in Calibration SET
Figure 7. Calibration SET (Light Operate shown)

SET Button Remote Input

Result
0.04 seconds < "Click" < 0.8 seconds 0.04 seconds < T < 0.8 seconds

Note: TEACH Selection must be programmed to CAL SEt (see Program Mode on page 4 )

• Set Mode switch to ADJ No action required; sensor is ready for Display: Red - Signal Level; Green -
Calibration SET method Threshold
Enter Adjust
Mode

• Present sensing condition • Present sensing condition Threshold Condition Accepted

• Click the SET rocker button • Single-pulse the remote input Displays read "cAL SEt" then flashes
"PASS"; Sensor returns to Adjust
SET Sensing T
mode
Condition
Threshold Condition Unacceptable
Displays read "cAL SEt" then flashes
"FAIL"; Sensor returns to Adjust mode

• Move Mode switch to RUN No action required; sensor returns to Display: Red - Signal Level; Green -
RUN mode automatically Threshold
Return to RUN
Mode

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Troubleshooting
Manual Adjustments Disabled
Manual adjustments are disabled when Auto Thresholds are ON. If a manual adjustment is attempted while Auto Thresholds are ON, the Green display will flash
.
% Minimum Difference after TEACH
The Two-Point and Dynamic TEACH methods will flash a % minimum difference on the displays after a PASS or FAIL.

Value PASS/FAIL Description

0-99% FAIL The difference of the taught conditions does not meet the required minimum

100-300% PASS The difference of the taught conditions just meets/exceeds the required minimum, minor sensing variables may affect
sensing reliability

300-600% PASS The difference of the taught conditions sufficiently exceeds the required minimum, minor sensing variables will not affect
sensing reliability

600% + PASS The difference of the taught conditions greatly exceeds the required minimum, very stable operation

% Offset after SET

The Window, Dark, and Light SET methods will flash a % offset on the displays after a PASS or FAIL.

SET Result % Offset Meaning

PASS (with % Offset) Displays the % offset used for the SET method

FAIL (with % Offset) Displays the minimum required % offset necessary to PASS the SET method

FAIL (without % Offset) Presented condition cannot be used for the SET method

Threshold Alert or Threshold Error

Severe contamination/changes in the taught condition can prevent the Auto Thresholds algorithm from optimizing the threshold(s).

State Display Description Corrective Action

Threshold Alert Alternates The threshold(s) cannot be optimized, but the Cleaning/correcting the sensing environment and/or a
sensor's output will still continue to function re-teach of the sensor is highly recommended
and

Threshold Error The threshold(s) cannot be optimized, and the Cleaning/correcting the sensing environment and/or a
sensor's output will stop functioning re-teach of the sensor is required

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Specifications
Sensing Beam Output Protection
660 nm visible red Protected against output short-circuit, continuous overload, transient
over-voltages, and false pulse on power up
Supply Voltage
NPN/PNP models: 10 to 30V dc Class 2 (10% max ripple) Output Response Time
IO-Link models: 18 to 30V dc (10% max ripple) High Speed: 200 µs; Standard: 500 µs; Long Range: 2 ms; Extra Long
Range: 5 ms
Power and Current Consumption (exclusive of load)
Standard display mode: 960 mW, Current consumption < 40 mA at Repeatability
24V dc High Speed: 66 µs, Standard/Long Range/Extra Long Range: 100 µs
ECO display mode: 720 mW, Current consumption < 30 mA at 24V dc Construction
Supply Protection Circuitry Black ABS/polycarbonate alloy (UL94 V-0 rated) housing, clear polycar-
Protected against reverse polarity, overvoltage, and transient voltages bonate cover
Delay at Power Up Environmental Rating
500 milliseconds max.; outputs do not conduct during this time IEC IP50, NEMA 1
Output Configuration Operating Conditions
NPN/PNP models: 1 current sinking (NPN) or 1 current sourcing (PNP) Temperature: −10 °C to +55 °C (+14 °F to +131 °F)
output, depending on model Storage Temperature: −20 °C to +85 °C (−4 °F to +185 °F)
IO-Link models: 1 push-pull and 1 PNP (complementary outputs) Humidity: 90% at +60 °C maximum relative humidity (non-condensing)
Output Rating IO-Link Interface
100 mA max. load (derate 1 mA per °C above 30 °C) Supports Smart Sensor Profile: Yes
OFF-state leakage current: NPN/PNP models: < 5 μA at 30V dc; IO- Baud Rate: 38,400 bps (COM2)
Link models: < 50 μA at 30V dc Process Data Width: 16 bits
ON-state saturation voltage: NPN: < 1.5V; PNP /IO-Link: < 2V IODD files: Provide all programming options of top panel interface, plus
additional functionality, see the DF-G1 Manual (P/N 161999)
Certifications

Ind. Cont. Eq.

3TJJ

Banner Engineering Corp Limited Warranty

Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year following the date of shipment. Banner Engineering Corp.
will repair or replace, free of charge, any product of its manufacture which, at the time it is returned to the factory, is found to have been defective during the warranty
period. This warranty does not cover damage or liability for misuse, abuse, or the improper application or installation of the Banner product.
THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED (INCLUDING, WITHOUT LIMITATION,
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), AND WHETHER ARISING UNDER COURSE OF PERFORMANCE,
COURSE OF DEALING OR TRADE USAGE.
This Warranty is exclusive and limited to repair or, at the discretion of Banner Engineering Corp., replacement. IN NO EVENT SHALL BANNER ENGINEERING CORP. BE
LIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR ANY EXTRA COSTS, EXPENSES, LOSSES, LOSS OF PROFITS, OR ANY INCIDENTAL, CONSE-
QUENTIAL OR SPECIAL DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE PRODUCT, WHETHER ARIS-
ING IN CONTRACT OR WARRANTY, STATUTE, TORT, STRICT LIABILITY, NEGLIGENCE, OR OTHERWISE.
Banner Engineering Corp. reserves the right to change, modify or improve the design of the product without assuming any obligations or liabilities relating to any product
previously manufactured by Banner Engineering Corp.

www.bannerengineering.com - tel: 763-544-3164

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Index

INDEX

A connector 54
Connector
Abbreviations 12
- HotStamp 163
Access protection 62
- Prefeeder 162
Accident preventions 9
Consumption, compressed air 30
Activity direction 11
Contact pressure 90
Adjust centering force 128
Contents operating instructions 10
Air jet unit 48, 51
Control contact 162
Applications 35
Cover rotary incising unit 62
Article storage capacity 29
Cross reference 11
Customer service 93
B Cutting unit - multi blade 48
Bad incision quality 90 Cutting unit - single blade 47
Basic settings 79 Cutting unit booster 52
Basic wire sample 82 Cutting unit multi blades 48
Blade 64
Blade rotary incising unit 68 D
Blocked wire/cable 17
Daily maintenance 94
Brands 12
Danger areas 63
Danger banner 17
C Danger labeling 64
Cable length incorrect 90 Dangerous zones 63
CableCoiler 91 Date format 80
Calibrate feeding axes resolution 119 Decommissioning 157
Calibrating the Die-Blades 122 Diagnostic 89
Calibrating V-Blades 120 Diagnostic software 89
Calibration of feeding belts 117 Die blades 67
Calibration of user defined blades 124 Dimensions 23
Calibration Disposal 11, 159
- Jam detector 125 D-sub connector 162
Carbon fiber 17
Carry handles 44 E
Carrying handles 72
Earth conductor 17
Cartridge 68, 100, 103, 106
Electric current 18
Caution
Emergency stop button 18, 61, 90
- Rotating parts 64
Emergency stop circuit 17
- Compressed air 64
Emergency stop link 18
- Electric shock 64
Emission sound pressure level 29
- General danger area 64
Environment
Cleaning 95
- Relative humidity 29
Clockwise 12
- Storage temperature 29
Combing unit 69
- Temperature range 29
Combing unit mount 104
Error 89
Commands 11
Error Inkjet printer 91
Compressed air connection 30
ESC 30
Configuration 33
Ethernet 30
Connecting 74
Exchange multi blades 98
Connection cable 162
Exchanging fan filters 96
Connection power cord 76
Exchanging single blade 97
Connection value
- Fusing 30
- Line frequency 30 F
- Mains 30 Fan 49
- Power consumption 30 Fan filter 89

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Index

Fault localization 89 Loss during shipment 22

Feeding belt 90 Lower cover 62
Feeding unit 46 Lubricating feeding unit transmition 114
Feeding unit calibration 118 Lubricating grease 17
Figure 12 Lubricating linear guide drive 115
Foreseeable misuse 23
Fuse holders 55 M
Machine switching off 81, 157
G Machine switching on 79
General Danger 18 Main switch 55
Ground potential 162 Mains fuses replace 133
Guidelines 12 Maintenance 93
Maintenance unit connection 77
H Maintenance schedule 94
Maintenance unit 57
Harmful material 159
Malfunction 135
Hotline 93
Manual 9
HS/PF 30
Manufacture year 9
Mark-up 11
I Measures 12, 24
Illumination 53 Model M 38
Incision diameter 90 Model MR 39
Inductive load 163 Model RS 40, 41
Info 11 Model RX 42
Information to manual 9 Model S 38
Inlet 44 Models 33
Installation 71 Modifications 141
Installation location system rack 73 Module 37
Installation location work bench 73 Monitor 30, 43, 50
Intended usage 23 Monitor connection 74
Interface 54, 57 Mount slitting unit 101
Interface connection cable 17 Mounting guides 77
Interface Mounting short mode 142
- ESC 59, 165 Mounting SIS slot 154
- Ethernet 56
- HS/PF 58 N
- Monitor 57
Noise emission 29
- PPI 58, 164
Noise level 17
- RS232 59, 165
- SMI 59
- USB 56 O
Opening the front 112
J Opening the housing 109
Operating company 15
Jam detector 52, 124
Operating element 37
Operator personnel 15
L Option 33
Language user interface 80 Original spare parts 12
LED illumination mounting 141 Outlet 17, 49
Legend 11 Over temperature 72
Length monitoring 50 Overview 11
Length unit 80
Liability for damage 12 P
Lifting device 72
Packaging 21, 71, 72
Linear guide Y axis 49
Packaging signs 21
Linear guide Z axis 47

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Index

Pedal 59 Scope of delivery 69

Peripheral adapter 43 Screen titles 11
Peripheral device 90 Serious faults 93
Power connection 55 Service technician 16
Power supply 30 Set up 77
PPI 30 Settings 117
PreFeeder 162 Short mode 89
Processing setting 86 Short Modus 52
Product name 11 Site of operation 24
Product type 9 Slitting blade 69
Property damage 16 Slitting depth adjust 127
Protected mode 70 Slitting unit 69
Protective equipment 18 SMI 30, 161
Pull-off speed 90 Spare parts 13, 93
Special blade 67
Q Standard operation 69
Standards 12
Qualified personnel 15
Storage 158
Quality of stripping 86
Suction unit 51
Suction unit mounting 152
R Suction unit RX 51
Radius blade 66 Swivel guide 47
Radius blade with centering 66 Symbols 11
Rating plate 28, 56 System rack 24
Rear cover 112, 137, 156
Recoil brake 50 T
Recycle 11
Talk 17
Registered trademarks 12
Target audience 15
Regular inspection 89
Technical data 29
Remote controlled operation 70
Technical specialist 15
Repair work 129
Third parties 12
Replace blades rotary incision unit 129, 131
Time format 80
Replace feed belt 107
Tip 11
Residual risks 17
Tools 64
Result 11
Topic 11
Retrofit 18
Trademark 12
Retrofit feeding belts to rollers 148
Transport speed 90
Retrofit rollers to belts 145
Revolver guide 45
Rotary incising unit 45 U
Rotary incising unit cover remove 113 Unpacking 71
RS232 30 Upper cover 110
USB 30
S User level 79
Safekeeping operating instructions 11
Safety appliances 60 V
Safety barrier 18 V-Blade 65
Safety check 135, 154 Version number 89
Safety check electronics 135 Visible check 77
Safety circuit 135 V-Radius blade 65
Safety cover 18, 60, 90 wire marker 163
Safety interlock 18
Safety regulations 9 W
Safety shoes 19
Warn symbol
Safety switch 61
- On product 63
Schleuniger distributor 93

Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480

189 | 192
Index

Warn symbols 17 Wire end monitoring 44

Warning notice 16 Wire feeding 90, 163
Warning symbol 18 Wire quality 86
Wearing parts 93 Wire straightener 90
Weight 24 Workwear 18

190 | 192 Reference Manual |Edition 2.0 (07-2015) |MultiStrip 9480