Central lubrication Basic concept
Central lubrication
Basic concept
Distinction
Two lubrication systems supply the press with lubri-
cant:
– grease lubrication system (for the delivery),
– oil lubrication system (for the printing units,
feeder and bearings on the D.S. and O.S. of
the delivery chain sprocket shaft).
The grease lubrication system is divided into:
– lubrication circuit 1 (chain lubrication),
– lubrication circuit 2 (bearing lubrication).
The oil lubrication system is divided into:
– the circular lubrication system (drive side),
– the distributing lubrication system (operator
side and some lubricating points on the drive
side).
231
Central lubrication Service display
Service display
Buttons to be actuated
Oil lubrication
Pressure monitoring 1bar, 1F33 (flashes if the
pressure switch was not actuated).
Pressure monitoring 12bars, 1F34 (flashes if the
pressure switch was not actuated).
Oil pump M44 (flashes if motor overload switch
15Q44 has responded).
Number of cylinder revolutions since the last
distributing lubrication. After completion of
lubrication the counter is automatically zeroed.
Distributing lubrication initiated manually (only
when press is on ”Run”).
Service display ”Oil lubrication”
Number of cylinder revolutions at which
automatic oil lubrication is initiated.
232
Central lubrication Service display
Grease lubrication
7 Sensor ”Lubrication monitoring 2” – 12 B77
(bearing lubrication); (flashes if sensor is not
actuated).
8 Sensor ”Lubrication monitoring 1” – 12 B47
(chain lubrication); (flashes if sensor is not
actuated).
9 Motor for grease lubrication 12M47.
ß Number of cylinder revolutions since the last
chain lubrication. After completion of lubrication
the counter is automatically zeroed.
Service display ”Grease lubrication”
q Number of cylinder revolutions since the last
bearing lubrication. After completion of
lubrication the counter is automatically zeroed.
w Chain lubrication initiated manually (lubrication
circuit 1); (only when press is on ”Run”).
e Bearing lubrication initiated manually (lubrica-
tion circuit 2); (only when press is on ”Run”).
r Number of cylinder revolutions at which
bearing lubrication is initiated automatically.
t Number of cylinder revolutions at which chain
lubrication is initiated automatically.
233
Central lubrication Fault messages
Fault messages
Display ”Entire press”/”Warning”
Buttons to be actuated
Dependent on the press model, the fault display
”Entire press” /”Warning” shows the fault symbols of
the grease lubrication or oil lubrication system:
Oil lubrication not possible Oil lubrication has not occurred.
– After main switch ”On” and changeover
between circular and distributing lubrication,
the oil pressure has not been built up within
3 minutes.
– Pressure switch 1F33 (1 bar) or pressure
switch 1F34 (12 bars) not actuated.
– Filter unit clogged.
Grease lubrication not possible Chain or bearing lubrication has not occurred.
– The sensor ”Lubrication monitoring 1” –
12 B47 or the sensor ”Lubrication monitoring
2” – 12 B77 has not responded within
10 minutes.
– Solenoid valve 12 Y78 defective. Changeover
between chain and bearing lubrication is not
possible.
– Motor for grease lubrication 12 M 47 defective.
Motor overload switch Q 44
has tripped The motor overload switch has tripped. Oil pump
M 44 not ready to run.
The audible signal devices 11H55 While lubrication is in progress, a warning signal
and 12H55 give out a warning sounds if the printing speed is 3 000 i.p.h.
234
Central lubrication Grease lubrication
Grease lubrication
Block diagram
15 Q 66
15 Q 47
12B47
15 K47 M 12M47 12Y78
12B77
11H55
12H55
Electronic control system
Control line
Power supply
Grease line
Block diagram of grease lubrication
Pressure relief valve (38 bars) 12M47 Motor grease lubrication
Metering elements 12Y78 Changeover grease lubrication
15Q66 Main switch 12B47 Lubrication monitoring 1 (chain)
15Q47 Motor overload switch 12B77 Lubrication monitoring 2 (bearings)
15K47M Contactor 11H55 Audible signal device (warning feeder)
12H55 Audible signal device (warning delivery)
235
Central lubrication Grease lubrication
Place of installation
The motor for grease lubrication is located on
the D.S. of the last printing unit. The sensors
monitoring lubrication are fitted at the first
progressive distributor behind the motor.
Layout
Motor grease lubrication 12 M 47
Grease reservoir
Pressure relief valve
Lubrication monitoring 2 – 12 B77
(bearing lubrication)
Lubrication monitoring 1 – 12 B47
(chain lubrication)
Progressive distributor
Changeover grease lubrication 12 Y78
(between bearing and chain lubrication)
Components of the grease lubrication system
Function
When the press is switched on, the grease lubrica-
tion is ready for operation. The motor for grease
lubrication 12M47 delivers the lubricant to the
progressive distributors via solenoid valve 12 Y78.
Depending on the position of the solenoid valve,
either the chains in the delivery (lubrication cir-
cuit 1) or the bearings (lubrication circuit 2) are
supplied with lubricant.
The progressive distributors pass the lubricant to
the lubricating points via pistons. The progressive
distributors are sequentially force-controlled and
thus all pistons move uniformly. For this reason,
only the movement of one piston is monitored per
lubrication circuit.
236
Central lubrication Grease lubrication
Monitoring the lubrication system
Inductive sensors monitor the two lubrication
circuits. Each is equipped with an LED and can
LED assume two circuit states.
– Pin of progressive distributor extended, sensor
damped: LED is lit.
– Pin of progressive distributor retracted, sensor
not damped: LED is not lit.
On presses with standard delivery, the sensor
12 B47 (chain lubrication) is actuated twice while
lubrication is in progress and three times on pres-
ses with extended delivery.
The sensor 12 B77 (bearing lubrication) is actuated
Sensor with LED monitoring the lubrication circuit
once while lubrication is in progress.
If the sensors do not switch within 10 minutes after
a lubrication process was triggered, the electronic
control system shuts down the motor for grease
lubrication. A warning appears: ”Grease lubrication
not possible”.
237
Central lubrication Grease lubrication
Triggering a lubrication process
When the press is switched on, the grease
lubrication is ready for operation. Lubrication is
triggered either automatically:
chain lubrication every 2 500 to 30 000 cylinder
revolutions; (after a basic initialization, the
cycle is preset to 20 000 cylinder revolutions).
bearing lubrication every 200 000 cylinder
revolutions.
or manually by actuating the function button
”Manual chain or bearing lubrication”.
Central lubrication selected, press on ”Run”
Setting the lubrication cycle for lubrication circuit 1 (chain lubrication)
Buttons to be actuated
Number of cylinder revolutions for automatic
chain lubrication (lubrication circuit 1). The
cylinder revolutions can be set in the range
from 2 500 to 30 000 in steps of 2 500.
Note:
To set the lubrication cycle an additional button must
be fitted on the EAM (input/output module). Before
fitting or removing this button, turn off the main
switch 15 Q 66 on the central control cabinet ZSG!
Number of cylinder revolutions set to 20000
238
Central lubrication Grease lubrication
Attention: Even if the main switch is turned off, the press
is not voltage-free and there are current-con-
ducting components in the central control
cabinet!
The input/output module EAM is on the underside
EAM
of the central control console. Plug the additional
button into slot 7 of the EAM - X12.
Turn off the main switch 15Q66.
Fit the button.
EAM-X12
Group
Turn on the main switch 15Q66.
Now press the button you just fitted plus group
button 2 on the central control console.
Set the cylinder revolutions with the left-hand + / –
buttons.
– 2 500
Lubrication cycle for delivery – 5 000
30000 – L
– 25 000
– 30 000
Remove the button from slot 7 of the EAM - X12.
Then check the cylinder revolutions for chain
lubrication (lubrication circuit 1) in the service
display ”Central lubrication” on the central control
console.
Changing the lubrication cycle
Note:
The value for bearing lubrication (lubrication circuit
2) is set to 200 000 cylinder revolutions and is
non-adjustable.
Pressure relief valve of the motor
The motor for grease lubrication is protected by a
pressure relief valve. In the case of malfunctions,
this valve prevents the building up of impermissible
high pressures in the lubrication system and opens
at a pressure of 150 bars.
239
Central lubrication Oil lubrication
Oil lubrication
Block diagram
15 Q 66
15 Q 44
1F33
15X3 M44 Y67
1F34
11H55
12H55
Electronic control system
Control line
Power supply
Oil line
Block diagram of oil lubrication
Pressure relief valve (18 bars) Y67 Changeover oil lubrication
Metering elements 1F33 Pressure monitoring (1 bar)
15Q66 Main switch 1F34 Pressure monitoring (12 bars)
15Q44 Circuit-breaker 11H55 Audible signal device (warning feeder)
15X3 Plug 12H55 Audible signal device (warning delivery)
M44 Oil pump
240
Central lubrication Oil lubrication
Place of installation
The oil reservoir with oil pump M44, filter unit,
solenoid valve Y67 and pressure relief valve is
located on the D.S. under the footboard (on
presses with up to 5 units at the last unit, with 6
or more units in the middle).
On presses with coating unit the guard serves
as oil reservoir and contains the oil pump, filter
unit and valves.
The two pressure switches, 1 F 33 and 1 F 34,
are fitted at the first printing unit under the
feeder.
Layout
Oil pump M 44
Filter unit
Oil lubrication press – Y 67 (changeover
between circular lubrication and distributing
lubrication)
Pressure relief valve (18 bars)
Pressure switch 1F34 (12 bars)
Pressure switch 1 F 33 (1 bar)
Oil reservoir
Components of the oil lubrication system
241
Central lubrication Oil lubrication
Function
Switching on the press activates oil lubrication, i. e.
the circular lubrication system is active and
continuously lubricates the gears on the D.S.
For the changeover to distributing lubrication the
solenoid valve Y67 must be actuated. This is
effected either automatically or with the function
button ”Manual distributing lubrication”. Thus the
bearings on the D.S. and O.S. are supplied with oil.
After every changeover between distributing and
circular lubrication, the oil pressure must build up
within 3 minutes; otherwise the electronic control
system outputs a fault message.
Circular lubrication
The oil is continuously fed to the lubricating points
via the oil riser and drip pan. The circular lubrication
system works at an oil pressure y 1 bar. The oil
pressure is monitored by pressure switch 1 F 33
(1 bar).
The oil flowing back down the side frames on the
D.S. is returned to the lubrication circuit. Through a
return line the oil flows either into the oil reservoir or
into the coating unit guard. The return line is fitted
above the cable duct on the D.S.
Distributing lubrication
The distributing lubrication system supplies the
lubricating points through piston distributors. The oil
pressure in the system is y 12 bars and monitored
by pressure switch 1 F 34 (12 bars).
On SM102-presses the residual oil is collected in
the bases and can be drained off through a drain
cock on the O.S.
On CD-presses the residual oil is collected in a
reservoir on the D.S. which can be emptied.
242
Central lubrication Oil lubrication
Triggering a lubrication process
Distributing lubrication is triggered:
automatically every 45 000 cylinder revolutions
or
by actuating the function button ”Manual
distributing lubrication”.
For activation the printing press must be on ”Run”
(3 000 i.p.h.).
Central lubrication selected, press on ”Run”
Filter unit
Optical differential pressure indicator
Filter housing with cartridge
The filter unit is fitted between the pump and the
solenoid valve. The optical differential pressure
indicator shows the degree of soiling of the filter
cartridge:
– Green: filter cartridge okay
– Red: change filter cartridge
If the filter cartridge is soiled, the oil pressure
between the oil pump and filter unit rises. The relief
Filter unit valve in the filter unit opens the bypass and the oil
flows to the lubricating points without having been
filtered. Change the filter at least every 6 months.
243
Central lubrication Oil lubrication
Changing the filter
Changing the filter
Optical differential pressure indicator
The tightening torque of the filter housing must be
120 Nm +/– 15 Nm.
Pressure relief valve of the oil pump
A pressure relief valve is installed to protect the oil
pump. In the case of malfunctions, this valve
prevents the building up of impermissible high
pressures in the lubrication system. It opens at a
pressure of 18 bars and the oil flows back into the
coating unit guard or the oil reservoir.
244
Central lubrication M44 Oil pump
M44 Oil pump
Place of installation
On presses with coating unit, the oil pump is
located on the D.S. of the coating unit, below the
footboard.
Oil pump for presses with coating unit, D.S.
On presses without coating unit, the oil pump is
installed at the oil reservoir. The reservoir is located
under the footboard on the D.S. (on presses with
up to 5 printing units at the last printing unit).
Oil pump for presses with up to 5 PUs
245
Central lubrication M44 Oil pump
On presses with 6 or more units, the oil reservoir is
bigger and located in the middle of the press, under
the footboard on the D.S.
Oil pump for presses with 6 or more PUs
Pin assignment
Pin Function
A2 AC 400 / 480 V phase U
A B C
1
B3 AC 400 / 480 V phase V
2
3 C2 AC 400 / 480 V phase W
4
PE conductor
5
Plug M44-X1
246
Central lubrication 12M47 Motor for grease lubrication
12M47 Motor for grease lubrication
Place of installation
The motor for grease lubrication 12M47 is located
on the D.S. of the delivery.
Motor for grease lubrication with grease reservoir
Pin assignment
Plug 12M47-X1
Pin Function
3
1 DC 24 V
1
2 Grease lubrication delivery chains
2
3 –
PE
PE –
Plug 12M47-X1
247
Central lubrication 1F33 Pressure monitoring
oil lubrication 1bar
1F33 Pressure monitoring oil lubrication 1bar
Place of installation
The switch ”Pressure monitoring oil lubrication
1F33” 1 bar is located on the drive side of the first
printing unit, under the sheet alignment system. It
is accessible through the door between the
feeder and first printing unit on the O.S.
Place of installation ”Pressure monitoring oil
lubrication 1F33”, 1bar
248
Central lubrication 1F34 Pressure monitoring
oil lubrication 12bars
1F34 Pressure monitoring oil lubrication 12bars
Place of installation
The switch ”Pressure monitoring oil lubrication
1F34” 12 bars is located on the O.S. of the first
printing unit, under the feeder. It is accessible
through the door between the feeder and first
printing unit on the O.S.
Place of installation ”Pressure monitoring oil
lubrication 1F34“, 12bars
249
Central lubrication 12B47 Lubrication monitoring 1
12B77 Lubrication monitoring 2
12B47 Lubrication monitoring 1 and
12B77 lubrication monitoring 2
Layout
The sensor 12 B47 monitoring chain lubrication and
the sensor 12 B77 monitoring bearing lubrication
are of identical design.
LED
Sensor
Locking nut
Receptacle
Plug
Stop pin
Sleeve
12B47 Lubrication monitoring 1 and
12B77 lubrication monitoring 2
Connection
Input 47 or 77 at EAK 12:
0 ¢ sensor not damped (LED off)
1 ¢ sensor damped (LED lit)
250
Central lubrication 12B47 Lubrication monitoring 1
12B77 Lubrication monitoring 2
Pin assignment
Marking Colour Function
47 or 77 black signal
+1 brown DC 24 V
–1 blue ă
Sensor for lubrication monitoring
Removal and installation
To fit the sensor screw the receptacle into the
sleeve using a copper disk and tighten it up. In
doing so, align the receptacle in such a way that
the sensor can be screwed in parallel to the
distributor.
Screw in the sensor manually until it contacts the
stop pin and secure it with the locking nut. Then
close the threaded hole of the receptacle from the
bottom using the plug.
251
