Basic setting of machine C 2205 After slackening of drive elements, release of position indicators and elimination of faults, it is an absolute

necessity to set up the machine again in conformity with the sequence of settings given below. When setting or checking the working stations, the sequence of operations given below must be adhered to. The correct setting is described in the left-hand column. How to arrive at this setting is described in the right-hand column.

Correct setting:
1. To set product chain in relation to carton chain Release No. 003 screws (3x) at pressure sleeve of drive shaft of product chain. Advance carton chain using machine handwheel until located in correct position. Tighten No. 003 screws (3x) at pressure sleeve.
002 001

-> The front edge of a cell divider of the No. 001 product chain is located 0,5 mm to 1,0 mm in front of the front edge of the No. No. 002 finger of the carton chain.
0,5 mm to 1,0 mm

003

005_410

005_412

005_411

02.01 Mi/De - V01

2.003.051

Basic setting of machine C 2205 2. Zero point setting (mechanical zero = electronic zero)

Mechanical zero setting

004 004 005

The cartoner is exactly in zero position if the following two conditions are fulfilled: -> The support of one of the No. 004 fingers of the transport chain is flush with the No. 006 zero point marking on the carton chain (= mechanical zero). The clearance between the zero point marking and the No. 009 sidepiece of the lateral guide is 110 mm.

110 mm

Setting 0-point

-> The degree indicator on the display screen reads '0' (= electronic zero). The No. 008 degree dial on the encoder is also set on '0'.

006 009

005

hol Fing (ou d-up er of tsid cha e) in

004

g ttin Se oint 0-p

tra Fing n e (inssport r of ide hai n )

kt g un n 0-P tellu s n Ei

006

009

006
003_577 005_413

Mechanical zero setting Mechanical zero setting at degree dial:

90

30 10 20 40 50

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

0 80 90 80 70 60

60 7

80

10 20

30

Set No. 008 degree dial on zero. Tighten No. 007 screw.

40

50
4 0

0 10 0

30 2

008

2.003.052

10

90

60 80 70 50 40

007

001_865

V01 - 02.01 Mi/De

Basic setting of machine C 2205 Electronic zero setting on control panel: Select "Setting up" -> "Programming of machine" -> "Angles" -> "Init" softkeys on display screen of control panel. Select "Zero point setting" softkey on display screen. Important! The degree indicator on the display screen reads "Position: 0".

02.01 Mi/De - V01

2.003.053

Basic setting of machine C 2205 3. To set product loader and leaflet preinsertion unit Important! For the product loader and the leaflet preinsertion unit, only one single setting is required. -> The No. 010 loading pusher is positioned at equidistance to the cell dividers of the No. 012 transport chain and the No. 011 hold-up chain of the product chain.

Release No. 013 clamping lever at No. 014 handwheel for product loader. Turn No. 014 handwheel until the loading pusher is located in correct position. Lock No. 013 clamping lever.

010 Loading tongues (leaflet pre-insertion)

Travel direction

012

011

001_848

013

014
001_846

2.003.054

V01 - 02.01 Mi/De

Basic setting of machine C 2205 4. To set carton feeder 4.1 To set position of vacuum arms Advance carton feeder via machine handwheel until the marking of the number "1" and the marking at the No. 015 housing are exactly lined up. If the markings at the rear side of the machine are not exactly lined up, proceed as follows:

Open cover 1 at rear side of machine.

1

View of rear side of machine

Cover 1

015
1

001_863

001_496

Important! Before pulling off the plugs, mark the plug-in connections in order to ensure that the plugs are reconnected correctly. Pull off plugs from all No. 018 proximity switches.

-> At the rear side of the machine, the No. 023 marking at the No. 016 control cam and the No. 024 marking at the No. 019 base plate are exactly lined up.
023 024 019

016, 017

018

019

016

017

004_840

022

021

020
004_839

02.01 Mi/De - V01

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Basic setting of machine C 2205

Prox.switch sucker 1 028 029

Prox.switch sucker 2 Prox.switch sucker 3

2 3

Release No. 028 screws at No. 029 parallel coupling. Release screws at No. 022 front plate. Remove No. 029 parallel coupling together with No. 022 front plate and No. 020 drive wheel.

3
005_417

025

026

027

021

Release No. 027 retaining ring at No. 025 shaft of No. 021 gear segment. Remove No. 026 lever and pull off No. 017 control cam.
023 024 019

016

017

Release screws at pressure sleeve of No. 016 control cam and rotate No. 016 control cam until located in correct position. Tighten screws at pressure sleeve of No. 016 control cam using a torque spanner until a tightening torque of 5 Nm is reached.

2.003.056

V01 - 02.01 Mi/De

Basic setting of machine C 2205 Important! The marking '2' is available three times. The check described below has to be performed once for each of the vacuum arms 1, 2 and 3. Advance carton feeder via machine handwheel until the marking of the number '2' and the marking on the housing are exactly lined up. -> The No. 030 lower vacuum arm is positioned vertically.
2
1
3
001_502

Re-assemble in reverse order.

If the vacuum arms are not arranged vertically, proceed as follows: Release No. 031 screws at No. 032 locator. Adjust No. 030 vacuum arms until positioned vertically.
2

Tighten No. 031 screws.

3 2 1
030 031 032

030

Important! The following condition applies only to vacuum arm '1'. -> The clearance between the No. 033 cam at the No. 034 control plate and the proximity switch '1' is 5 mm.
m 5m

001_504

If the clearance between the cam and the proximity switch 1 is incorrect: Release screw at No. 034 control plate.

033

034

022

Set No. 033 cam to ensure that the clearance between it and the proximity switch '1' is 5 mm. Tighten screw.

Prox.switch vacuum arm 1

Prox.switch vacuum arm 2

Prox.switch vacuum arm 3

001_499

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Basic setting of machine C 2205 Important! The marking '3' is available three times. The check described below has to be performed once for each of the vacuum arms 1, 2 and 3. Advance carton feeder via machine handwheel until located on the next '3' marking. -> The No. 035 erector flap below the carton magazine is located parallel to the No. 030 vacuum arm.
036 035

Release No. 036 screws at No. 037 locator for erector flap retainer.
037

Adjust No. 035 erector flap to ensure that it is parallel to the No. 030 vacuum arm. Tighten No. 036 screws.

030

004_841

continued next page 2.003.058 V01 - 02.01 Mi/De

Basic setting of machine C 2205 4.2 To set carton feeder in relation to carton chain If the lower vacuum arm does not point vertically downward when located in position '2', proceed as described above under "4.1 To set position of vacuum arms". Release No. 038 fixing screws (2x) at housing of carton feeder at rear side of machine.

Advance carton feeder via handwheel until located in position '2'. -> The lower vacuum arm points vertically downward. -> The angular position of the machine is '265'.
2
1
3

038
2

-> The rear edge of the No. 030 vacuum arm must be 145 mm behind the front edge of the next No. 002 finger of the transport chain (carton chain).
030

145 mm

Release No. 039 screw at No. 040 belt tightener for No. 041 drive belt. Slacken No. 041 drive belt and remove it.

002

041 039

040
001_507

042

Adjust the whole carton feeder assembly to ensure that the clearance between the rear edge of the No. 030 vacuum arm and the front edge of the next No. 002 finger of the transport chain is 148 mm. 02.01 Mi/De - V01 2.003.059

Basic setting of machine C 2205 Tighten No. 038 fixing screws at housing.
041 039

Instal No. 041 drive belt and tighten drive belt using the No. 040 belt tightener. Tighten No. 039 screw at No. 040 belt tightener.
040

Important! Check whether vacuum arm is positioned vertically.

042

If not, release No. 042 screws. Position vacuum arm vertically. Tighten No. 042 screws.

2.003.060

V01 - 02.01 Mi/De

Basic setting of machine C 2205 4.3 Vertical setting of carton feeder Advance carton feeder via machine handwheel until one of the No. 027 vacuum arms points vertically downward (position '2'). -> The clearance between the lower edge of the vacuum arm and the supporting surface of the transport finger must be 41 mm. -> The position indicator reads '15'.
41 mm
027

Using the No. 043 position indicator, set clearance between lower edge of vacuum arm and supporting surface of transport finger to 41 mm. Release No. 044 clamping screw at No. 045 ring of No. 043 position indicator. Rotate No. 045 ring until 15 is read off on the position indicator. Tighten No. 044 clamping screw.

Lower edge of vacuum arm

043

Supporting surface of finger

044

001_869

045

001_868

continued next page 02.01 Mi/De - V01 2.003.061

Basic setting of machine C 2205 5. To set carton magazine in relation to carton feeder The clearance between the No. 047 right-hand edge of the carton feeder and the left-hand edge of the No. 046 shaft is 136 mm.
Carton feeder Carton magazine

Using the No. 049 'Carton height' position indicator, move the complete carton magazine assembly to the left until it is close to the carton feeder.
049

048

136 mm
050

046

047

001_869

051

Release No. 050 clamping screw at No. 051 ring.

049

Rotate No. 051 ring until the position indicator reads '2'. Tighten No. 050 clamping screw.
005_421

Set No. 049 'Carton height' position indicator on 15 using the provided crank handle. Important! Set position indicator for 'Height carton feeder' also on 15. Release all No. 048 fixing screws at carton magazine rail. Adjust the complete carton magazine assembly to ensure that a clearance of 136 mm is set. Tighten all fixing screws.

continued next page 2.003.062 V01 - 02.01 Mi/De

Basic setting of machine C 2205 Adjust No. 030 vacuum arm of carton feeder to ensure that it is parallel to the No. 052 lower guide rails of the carton magazine. Check whether the clearances 43,5 mm, 25 mm and 2,5 mm as shown on the diagram are correctly set. Important! If the clearances 43,5 mm and 25 mm are not correctly set, check the settings of all position indicators provided on the carton magazine. If the clearance 2,5 mm is not correctly set, release No. 053 clamping screw. Set clearance correctly and tighten clamping screw again.

Upper magazine rails

25

m m

052

,5 43 m m 2, 5 m m

030

053

005_415

continued next page 02.01 Mi/De - V01 2.003.063

Basic setting of machine C 2205 6a. Leaflet folder from the stack (GUK) Locate machine in angular position 'X'. The angular position 'X' can be seen from the following table. -> With machine located in angular position 'X', the No. 055 pick-off sucker of the leaflet folder must be in its topmost position. Table for angular position 'X': Tighten No. 054 clamping screw. 300" product chain: Normal folding table 240" product chain: Normal folding table Horizontal product chain: X = 160
055 054

Locate machine in angular position 'X'. Release No. 054 clamping screw from the rear side of the folder. Turn No. 056 handwheel of leaflet folder in direction of rotation until the No. 055 pick-off sucker is in its topmost position.

X = 30 X = 130

056

001_866

continued next page 2.003.064 V01 - 02.01 Mi/De

Basic setting of machine C 2205 6b. Leaflet folder from the stack with change-speed gear (GUK) Locate machine in angular position 'X'. Open cover on leaflet folder at rear side of machine. Release screws at No. 057 pressure sleeve of drive wheel No. 058. Turn leaflet folder via handwheel until the speed can be changed. Tighten screws at No. 057 pressure sleeve until a tightening torque of 10 Nm is reached.
057 058

Locate machine in angular position 'X'. The angular position 'X' can be seen from the following table. -> Speed change-over from 1:1 to 2:1 and vice versa is performed when the machine is located in angular position 'X'. -> With machine located in angular position 'X', the No. 055 pick-off sucker of the leaflet folder must be in its topmost position.
055

001_866

2056

Table for angular position 'X': 300" product chain: Extended folding table 240" product chain: Extended folding table *: value not yet determined.

X = 100

The No. 055 pick-off sucker of the leaflet folder must be located in its topmost position. In case of discrepancies, set pick-off sucker as described under '6a. Leaflet folder from the stack'.

X = *

continued next page 02.01 Mi/De - V01 2.003.065

Basic setting of machine C 2205 6c. Leaflet folder from the reel 760 (GUK) Locate machine in angular position 'X'. The angular position 'X' can be seen from the table below. -> The leaflet folder from the reel is located in zero position. -> The markings at both No. 059 and No. 060 gear wheels (on the left-hand side seen from operator's side) are positioned exactly opposite each other. Table for angular position 'X': 300" product chain: 240" product chain: X = 70 X = 340 Locate machine in angular position 'X'. Release No. 062 screws at No. 061 belt pulley. Turn folder using its proper handwheel until the markings at both No. 059 and No. 060 gear wheels are positioned exactly opposite each other. Tighten No. 062 screws at No. 061 belt pulley.

059

060

0 0

zahnrad_01

062

061
2055

continued next page 2.003.066 V01 - 02.01 Mi/De

Basic setting of machine C 2205 6d. Leaflet folder from the reel 880 (GUK) Locate machine in angular position 'X'; Place a No. 063 piece of paper (e.g. a leaflet) on the No. 065 folding table behind the No. 064 cutter block. Release No. 066 clamping screw at No. 067 clamping piece.
064

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

Turn handwheel clockwise until the No. 064 cutter block audibly starts cutting the piece of paper. Tighten No. 066 clamping screw.

067

066

065
005_416

Locate machine in angular position 'X'. The angular position 'X' can be seen from the table below. -> When in angular position 'X', the cutter block audibly starts cutting the piece of paper. Table for angular position 'X': 300" product chain: 240" product chain: *: value not yet determined. X = 50 X = *

continued next page 02.01 Mi/De - V01 2.003.067

Basic setting of machine C 2205 6e. Leaflet inserter (GUK) Locate machine in angular position 'X'. The angular position 'X' can be seen from the table below. -> When the machine is located in angular position 'X', the pick-off sucker of the leaflet inserter is in its topmost position. Locate machine in angular position 'X'; Release No. 068 clamping screw from the rear side of the leaflet inserter. Turn handwheel at leaflet inserter in direction of rotation until the No. 069 pick-off sucker is in its topmost position. Tighten No. 068 clamping screw.
068

069

001_866

004_003

Table for angular position 'X': 300" product chain: 240" product chain: Horizontal product chain: *: value not yet determined X = 250 X = * X = 250

continued next page 2.003.068 V01 - 02.01 Mi/De

Basic setting of machine C 2205 6f. Leaflet folder from the stack (LANG) Locate machine in angular position 'X'. The angular position 'X' can be seen from the table below. -> With machine located in angular position 'X', the No. 095 vacuum roller on the leaflet folder from the stack must be located in the upper reversal point (dead centre). The vacuum nozzles of the No. 095 vacuum roller are located in upper position.
095

Important! For performing this setting, two persons are required. Locate machine in angular position 'X' and open cover 2.
View from rear side of machine Cover 2

001_863

Important! Mark the position of the No. 101 belt pulley on the No. 0100 shaft to ensure that the original position can be regained after an axial shift. Loosen No. 097 screws (4x). Completely unscrew two screws and screw them into the No. 096 forcing threads. In this way, the belt drive is disconnected.
005_838

Table for angular value 'X': 300" product chain: Normal folding table

Turn No. 098 handwheel on folder in direction of rotation until the No. 095 vacuum roller is located in the upper reversal point.
096 097

X = 0

101

100

098
005_839

Unscrew No. 097 screws (2x) from forcing threads.

Screw in the No. 097 screws (2x) at the original positions and tighten all screws until a tightening torque of 10 Nm is reached. The belt drive is connected again. continued next page 02.01 Mi/De - V01 2.003.069

Basic setting of machine C 2205 6g. Leaflet folder from the stack with speed change-over gear (LANG) Locate machine in angular position 'X'. The angular position 'X' can be seen from the table below. -> Speed change-over from 1:1 to 2:1 and vice versa is performed when the machine is located in angular position 'X'. -> With machine located in angular position 'X', the No. 095 vacuum roller must be located in the upper reversal point (dead centre). The vacuum nozzles of the No. 095 vacuum roller are located in upper position.
095 057 058

Locate machine in angular position 'X'. Open cover at the rear side of the leafled folder from the stack. Loosen screws at No. 057 pressure sleeve of No. 058 drive wheel. Turn leaflet folder via handwheel until the speed change-over is permitted to be carried out. Tighten screws at No. 057 pressure sleeve until a tightening torque of 10 Nm is reached.

005_838 2056

Table for angular position 'X': 300" product chain: Extended folding table

X = 0

The No. 095 vacuum roller must be located in upper dead centre. In case of discrepancies, set No. 095 vacuum roller as described under '6f. Leaflet folder from the stack'.

continued next page 2.003.070 V01 - 02.01 Mi/De

Basic setting of machine C 2205 7. Closing station Locate machine in '140' angular position. -> The left-hand side and the right-hand side of the closing station are fully closed. Important! Depending on the prevailing situation, both the left-hand and the right-hand side of the closing station have to be set. Right-hand side: Advance closing station to ensure that the slot on the eccentric points in travel direction of cartons. Only when in this position can the clamping of the eccentric be released.

Closing station left-hand side

Closing station right-hand side

Tra
Eccentric, left-hand side Eccentric, right-hand side
001_455

ca of n o cti ire d l ve

rto

ns

001_510

Eccentric

Slot

Release clamping screw for eccentric through the No. 070 hole.

070

Advance machine until located in 140 angular position.

2685

Rotate eccentric until the right-hand side is fully closed. Tighten clamping screw. continued next page 02.01 Mi/De - V01 2.003.071

Basic setting of machine C 2205 Left-hand side: Advance closing station to ensure that the slot on the eccentric points in travel direction of cartons. Only when in this position can the clamping of the eccentric be released.
Eccentric Slot

e rav

ir ld

o cti

f no

rt ca

on

001_511

Release clamping screw for eccentric through the No. 071 hole.
Eccentric 071

Advance machine until located in 140 angular position. Rotate eccentric until the left-hand side is fully closed. Tighten clamping screw.

continued next page 2.003.072 V01 - 02.01 Mi/De

Basic setting of machine C 2205 8. To set blister magazine Open cover 6. View from rear side of machine
Cover 6

Release No. 076 screws at pressure sleeve. Adjust No. 075 cam until located in correct position. Tighten No. 076 screws at pressure sleeve using a torque spanner until a tightening torque of 5 Nm is reached.
072 073

001_863

Advance machine via machine handwheel until the No. 074 lever is in lower position. -> The blister magazines are exactly vertical. -> The LED at the No. 073 proximity switch is extinguished. . -> The No. 075 cam at the No. 072 belt pulley is positioned slightly below the centreline of the No. 073 proximity switch.

076

075

074
0537

Important! If the lever is in upper position, advance machine via machine handwheel until the lever reaches its lower position.

02.01 Mi/De - V01

2.003.073

Basic setting of machine C 2205 9. To set blister counting with slides (not for versions with counting wheels) The release slide (lower slide) must be completely extended and just starts to move backward. Open cover 6. View of rear side of machine
Cover 6

Release clamping of No. 080 coupling. Adjust No. 079 release slide until located in correct position. Lock clamping.

001_863

-> The No. 078 proximity switch for blister counting is activated by the No. 077 switching flag. -> Both LEDs at the No. 078 proximity switch are illuminated.

080

ba

ck

wa

rd

079

ex

te

nd

ed
002_277

2.003.074

V01 - 02.01 Mi/De

Basic setting of machine C 2205 10. To set booklet feeder Locate No. 081 pusher in rearmost position (against travel direction): -> The No. 084 cam at the large No. 083 belt pulley is located approx. 5 mm before the centreline of the No. 085 proximity switch.

Locate No. 081 pusher in rearmost position (against travel direction). Open No. 082 cover. Release clamping of No. 103 lever at lower end of No. 086 shaft using the No. 102 screw. Rotate No. 084 cam until located in correct position. Important! Make sure that the No. 081 pusher remains in rearmost position. Tighten No. 102 screw again. Close No. 082 cover again.
082

081
004_019

085 081

084

083

086
004_021

103

102

004_843

02.01 Mi/De - V01

2.003.075

Basic setting of machine C 2205 11. To set the three-arm add card (with servodrive) De-energize control system as follows: -> Press STOP button in order to ensure that the machine stops in a clearly defined position. -> Set main switch on '0 - OFF'.
Cover 3
002_262

Hinge up cover 3 at rear side of machine.

View of rear side of machine

The add card can be rotated manually now.

Check alignment of the three No. 089 vacuum arms as described below: -> The two No. 088 upper locators for the vacuum arms must be located in horizontal position (remove vacuum arms, check position using the No. 087 spirit level). -> The No. 089 lower vacuum arm must be positioned exactly vertical (check position using the No. 104 spirit level). -> This check has to be performed for all three vacuum arms! To this end, rotate add card each time by 120.
087

Attention! Do not loosen the No. 090 screw. Loosen No. 099 screws (3x) and remove No. 105 cover. Locate the two No. 088 upper locators in horizontal position (check position using the No. 087 spirit level). For performance of setting, remove the upper vacuum arms. For a correct vertical alignment, the lower vacuum must remain fitted. Release No. 100 clamping screws for the No. 089 lower vacuum arm.

100 099

089 088 104

006_580

090 105

Position No. 089 vacuum arm exactly vertical using the No. 104 spirit level. Tighten No. 100 clamping screws.

089
006_578

Rotate add card by 120 and set second vacuum arm. Rotate add card again by 120 and set third vacuum arm.

2.003.076

V01 - 02.01 Mi/De

Basic setting of machine C 2205 Checking the setting of the add card in relation to the supply magazine: > The distance between the centreline of the No. 089 vacuum arm and the No. 092 magazine rail is 18 mm. Loosen No. 090 screw. Re-adjust No. 091 housing with the No. 089 vacuum arms until the centreline of the No. 089 vacuum arm (below the supply magazine) is located at a parallel distance of 18 mm in relation to the No. 092 upper magazine rail. Tighten No. 090 screw.
090

18 mm

092 089

091
006_577

Checking deposition of the booklet: -> Switch machine ON. -> With machine in inching mode (mode selector on position '1 - Inching'), collect booklet using the add card. Check the measure '2 - 3 mm' (clearance between cell divider and booklet).

To re-adjust the angular value for the add card: -> If the booklet is located too far on the left (measure is too small): set a smaller angular value. -> If the booklet is located too far on the right (measure is too large): set a larger angular value.

089

2 - 3 mm

18 mm

006_579

02.01 Mi/De - V01

2.003.077