Control Counter Stacker 3631.60.

Table of Contents

Designation Page

Control- and Operating Unit . . . . . . . . . . . . . . . . . . . . . . . . 9

Keyboard F1-F16

Special Characters and Declarations . . . . . . . . . . . . . 12

Help Function with Keyboard

Programming Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Switching from Menu to Menu

Switching from Submenu to Submenu
Moving the Cursor in the Submenu
Changing the Variables
Cursor Characteristics
Language Selection

Display Overview of all Menus . . . . . . . . . . . . . . 14

Menu 1 - 5 . . . . . . . . . . . . . . . . . . . 15

Function Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Standard-Stack
Over-Stack
Separation
Loose Leaf Production
Key Bundle
External Control
Small Size Production
Small Size Configuration

Machine Power On . . . . . . . . . . . . . . . . . 21

Display On
Hardware Ready
Machine Initialization
Empty Machine Bin
Machine Start, Stop
External Control
Standard-Signals
External Stacker Control
External Turning and Ejection
External Layer

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Table of Contents

Function. . . . . . . . . . . . . . . . . . . . 24

Jam Limit
Shredder Inhibit
Stack Size

Turning 24

Layer Size
Compensated Layer Size
Turning Function
Final Turn
Pusher Functions / Remains Up

Ejector 25

Without / With Ejector Plate

Machine with one or two deliveries
Ejector Switch
Lower Shuttle Overstack Limit
Bin 240/300mm

Key Bundle Formation 26

Key Bundle Control

Key Bundle Size
Compensating Stacks

Operating Mode 27

Key Bundle Control

Key Bundle Configuration
Key Bundle Configuration Travel Monitor / Time Monitor
Key Bundle Configuration Travel Monitor
Key Bundle Configuration Signal Sequence
Key Bundle Error
Double Key

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Table of Contents

System . . . . . . . . . . . . . . . . . . . . 34

Automatic Stand By
Calculation of Total Run
Standard Stack Total Production
Total Production Key Bundle
Eject Cycle
Stack Consisting of One Layer
Stack Consisting of Several Layers
Stack Consisting of One Layer and must have a Final Turn
Stack Consisting of Several Layers and must have a Final Turn

Menu 1- Menu 5 . . . . . . . . . . . . . . . . . . 36

Language Change . . . . . . . . . . . . . . . . . 45

Alarm and Alarm-History . . . . . . . . . . . . . . . . 46

Fault Indication . . . . . . . . . . . . . . . . . . 47

Help Functions with Keyboard . . . . . . . . . . . . . . 48

Fault Indication
Diagnostic F7
Ejector
Turntable
Pusher
Copy Gap by Time
Copy Gap by Distance
Speed
Clearing Machine
Test Run

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Table of Contents

Help Function with SHIFT and Keyboard . . . . . . . . . . . . 51

Change Menu Customer Configuration (F12) & F2 (View &F3)

Setting
Customer Configuration
Detect Key Bundle

Version (F12) &F6 . . . . . . . . . . . . . . . . . 53

Time (F12) & F7

Change Factory Configuration (F12) & F10 (View & F11) . . . . . . . . 55

Shuttle Configuration
Superfast Configuration
Store Factory Configuration
Factory Configuration is Stored

Layout . . . . . . . . . . . . . . . . . . . . 56

List of In- and Outputs

Definition . . . . . . . . . . . . . . . . . . . 58

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Control- and Operating Unit

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1 A B C D E

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Control- and Operating Unit

1A Main Switch
1B Start-Key - Acknowledge fault
- Start counter stacker
1C Stop-Key - Timed machine stop
1D Display - Display with 2x40 characters
1 E Keyboard F1 - F16 - Only keys with a lit LED are activated.
- A blinking LED shows a certain status.

Keyboard F1-F16
Key Label 1. Function 2. Function (SHIFT F12)

F1 Globus Language Change (D,E,F,I,E,P,H,D,N,S,F)

F2 < Cursor to left Change customer configuration (F12 a.

F2)

F3 > Cursor to right View customer configuration (F12 a. F3)

F4 Ù PageUp in menu

F5 ! Alarm Alarm History (F12 a. F5)

F6 123 Counter reset Version (F12 a. F6)

F7 Time Diagnostic Time setting (F12 a. F7)

F8 Ú PageDown in menu

F9 Empty

F10 clearing Empty machine Change factory configuration (F12 a. F10)

F11 Test run Machine runs without products View factory configuration (F12 a. F11)

F12 Home (SHIFT) Menu and Cursor go to Home Position

F13 - Minus, decrement value at cursor, decrement menu when cursor is top left

F14 + Plus, increment value at cursor, increment menu when cursor is top left

F15 x10 Move number at cursor one position to left and add a zero

F16 Clear Deletes number at cursor and shows 0 (zero)

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Special Characters and Declarations

1. Line > The cursor marks the active value in the display and blinks constantly.
? After an incomplete entry of a variable the blinking > is replaced by a blinking ?
2. Line # The reason for the alarm no longer exists (i.e. door was opened)
! The reason for the alarm still exists (i.e. door is open)
The following display description should be understood as follows:
The first line in the screen overview corresponds to the top line in the display. The second to n-th line in the
screen overview is the explanation on the number value at the actual cursor > position.
The cursor can be controlled in each screen with > < ÚÙ. The value at the cursor can be changed with + - x10.
The cursor can only change the variable field if the variable value is within the mechanical limits. If you still try to
change the value jumps to the limit value that was exceeded. At the same time the 2nd line shows the following
screen for 3 seconds:

1 VALUE TOO BIG

2 VALUE TOO SMALL

After this time the old line 1 and 2 are shown again. The value that was outside the limits is automatically set to
the limit. You can exit the field now with a second cursor command.
You can only exit menu fields if all variables in the field are within the logical limits.

Help Function with Keyboard

You exit all functions with the same key combination or with 2min Time-Out.
Improperly closed entries are ignored.
All SHIFT functions can only be selected from the default position "Speed" except for the alarm displays.

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Programming Unit (see Display Overview)

Switching from Menu to Menu

- This switch is only possible if a screen from submenu A is in the display.
- At the same time the cursor in the display must be in the top writing line on the first written position.
- The various menu numbers are selected with +/-.

Switching from Submenu to Submenu

- With arrows ÚÙ

Moving the Cursor in the Submenu

- Use arrows </> to jump from variable position to variable position

Changing the Variables

- The value is changed with +/- and x10 at the actual cursor position (you can delete the value with F16).

Cursor Characteristics:
- The cursor is a blinking > character.
- If a variable can be changed at the actual cursor position, it blinks rapidly.
- If the variable is changed and is outside the limits, the cursor is replaced by a rapidly blinking ?. As long as the
? is blinking, the cursor cannot be moved.
The panel is mounted against the product direction of travel. The terms left and right in the display are also
mirror-reversed to the direction of ejection in relation to the machine.

Language Selection
Every machine display is loaded with 11 languages. These are German, English, French, Italian,
Spanish, Portugese, Dutch, Danish, Swedish, Norwegian, Finnish.
If your press the keys SHIFT and ON together, you can switch temporarily to German. If the network is on or
after pressing again the selected foreign language comes up again.

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Display Overview of all Menus

Menu 1 Menu 2 Menu 3 Menu 4 Menu 5

MONITOR ENTER LOAD JOB STORE JOB STORE
PROGRAM PROGRAM
Submenu A Speed Stack No. Entry Stack No. Entry

Submenu B Stack Layer Load PG Comp.Layer Store PG

Submenu C Split Key *** Key ***

Submenu D Infeed Turning Turning

Submenu E Data Line Distribute Distribute

Submenu F Store Job No. Entry

Submenu G Store PG

Speed

Default Position (Standard Display)

An entry is only accepted if you exit the menu by going down and all values are within the
limits.
*** Key-Menu only comes up when the customer configuration key configuration is selected.

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Menu 1: Monitor

Mechanical Speed T = Total run in c/h

C = Copy counter

S = Stack counter

M = Key bundle counter

Stack Stack in bin

I = Number in infeed belt

U = Number in upper shuttle

L = Number in lower shuttle

S = Number in stack

Distribute Prod. to left and right

A = Delivery to left

B = Delivery to right

C = Left final turn

D = Right final turn

Infeed -Book * Key #Off $Turn = Layer

Data line >>

<<

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Menu 2: Enter Program

Stack Stack program overview

T = Book thickness

U = Number upper shuttle

B = Number bottom shuttle

S = Number in stack

K = 0 without small size kit

K = 1 with small size kit

Layer Layer free programmable comp.layers

A = 1. Comp. layer (bottom layer)

B = 2. Comp. layer

C = 3. Comp. layer

D = 4. Comp. layer

E = 5. Comp. layer

Key *** Key bundle production

S = 0 without key bundle

S = 1 with key bundle

M Max. size key bundle

U = 0 without ejection change

U = 1 with ejection change

C = 0 without compensating stack

C = 1 with compensating stack

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Menu 2: Enter Program

Turning Turning for Comp. Layers

K = 0 without comp. layer

K = 1 with comp. layer
K = 2 Pusher up w/o comp. layer
K = 3 Plate mounted w/o comp. layer

A = 0 Left without final turn

A =1 Left with final turn
A = 2 Alternating left final turn

L = c Final turn left alternating

A = 0 Right without final turn

A = 1 Right with final turn
A = 2 Alternating right final turn

R = Final turn right alternating

Distribute Distribute left

L = Eject 0-9 Stacks

R = Eject 0-9 Stacks

Job Program is accepted

Stack program overview

2sec

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Menu 3: Load Job

Read job from storage N = Job number

Job is read 2sec 3 Read job from storage

The machine can store 50 jobs. Each job is filed under a number in the library. With this number the job can be
copied from the library into the working memory of the stacker. The next started stack is made according to the
new job.

Menu 4: Store Job

Like menu 2 Like menu 2

Store job N = job number

Job is stored 2sec Store job

A library slot can be filled with a new job description during the production. The library slot is defined with the job
number. The programming remains the same as the direct programming. At the end the job number has to be
entered.

Menu 5: Store Program

Store machine job N = Job number

Job is stored 2sec Store machine job

The library slot can be overwritten with the actual data from the working memory during production. At the end
the job number must be entered.

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Function Sequence

Standard-Stack (Max. mechanical speed 18 000 C/hr)

A layer is formed on the upper shuttle. When it is complete, the upper shuttle opens and it drops on the lower
shuttle. The upper shuttle remains open. The following products now drop directly on the lower shuttle. After the
last product required for the layer has passed the upper shuttle, it closes. Now the lower shuttle opens and the
layer drops into the bin. The first following product is then slowed down again on the upper shuttle.

Overstack (Max. mechanical speed 14 400 C/hr)

Certain compensated stacks are higher than the clearance of the lower shuttle. These require the additional
clearance of the upper shuttle. In this case the upper shuttle can only close during the sequence when the lower
shuttle is open. This function is automatically activated by the control when the stack measurements require it.

Separation (Max. mechanical speed 9 000 C/hr)

The product cannot tolerate a direct drop from the infeed on the lower shuttle.
This production mode is activated if you enter "zero" on the upper shuttle.
Always one product is stopped for a short time on the upper shuttle and immediately dropped on the lower
shuttle.
Only there they are stacked into a layer. This setting makes sense for small, thick sizes.

Loose Leaf Production (Max. mechanical speed 7 200 C/hr)

This production mode stacks loose signatures and pages. It is activated on the upper and lower shuttle by
entering the same number of products.
This production mode is selected for those products that would hang through too much on the lower shuttle. In
this mode they do not remain on the lower shuttle, but drop practically undelayed on the turntable.

Key Bundle (Max. mechanical speed 18 000 C/hr)

This production mode stacks addressed products and ejects them reliably at the end of the route (key bundle).
If all products on the inclined run still fit on the stack, it is ejected as a key bundle when the product at the end of
the route is in the bin.
If not all the products on the inclined run fit on the stack, it is formed as a normal one and ejected.
The remaining products are then formed into a small key bundle. It is ejected when the product of the route end
is in the bin.
In this production mode the processing capacity is determined by dividing the ejection cycle time by the
difference between a key bundle minus a normal bundle.

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Function Sequence

External Control (Max. mechanical speed 18 000 C/hr)

With this production the stack formation is controlled by external units. They generate the necessary control
signals such as layer formation, turning and ejection. In this operating mode only the book thickness must be
entered into the stacker. All other stacker settings are not considered by it. For the first total run calculation it
uses a default value of the maximum load in the bin. Afterwards it functions with the stack value of the respective
last stack.

Small Size Production (Max. mechanical speed 6 000 C/hr)

The upper and lower shuttle work with different timing. (Install small size kit).

Small Size Configuration

The small size configuration consists of guide plates that are installed into the stack bin. The guide plates
decrease the position width of the products on the shuttle. This changes the response time of the products. This
is also compensated by other shuttle-holding times.
The run time of the shuttle is changed by the use of bin guide plates.

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Machine Power On

If not mentioned specifically one production must always be completed before the next one begins.

Display On
If the machine is connected to the network the display is initialized immediately. Then the version display
comes up.

Hardware Ready
If mushroom emergency stop buttons, door end switches and hardware are in order, you can start with the start
button. As soon as the display is totally initialized, the Start-up begins or an indication on the missing signal
comes up in the display.

Machine Initialization
Parallel to the pneumatic system activation the display automatically shows the respective movement from the
diagnostic menu and continues. In case of a fault the wrong action with passing time will remain standing in the
display.

Step Action Response Normal Fault

Waiting
+ continue switching
Time
1 Turn on compressed air- main valve Pressure switch on 10sec

2 Turntable moves into end position due to 2/4 way valve. Limit switch covered 10sec

3 Open gate Continue after 1sec

4 Search ejector end position by changing direction of 5/2 way Limit switch covered 10sec
valve every 4 seconds
5 Bring ejector into resting position Limit switch covered 10sec

6 Close gate Continue after 1sec

7 Machine initialized

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Machine Power On

Empty Machine Bin

This sequence runs in operation with the actual times, layer sizes and interactions.

Step Action Response at standstill

and continued
switching
1 Open upper shuttle 1sec

2 Open lower shuttle 1sec

3 Lift pusher * Limit switch up

4 Close upper shuttle 1sec

5 Open gate 1sec

6 Close lower shuttle 1sec

7 Ejector operating stroke Limit switch operating

stroke
8 Lower pusher * Limit switch down

9 Ejector resting stroke Limit switch resting

stroke
10 Close gate 1sec

11 Machine initialized

* If permitted mechanically

Machine Start, Stop

If at least 1 downstream machine is ready, and initializing and clearing have run correctly, the machine can be
started. The PLC turns on the two motors.
When the inclined belt is empty, the ’Ready’ signal goes to the upstream machine.
The motors remain on continuously and the pneumatic system functions after the incoming products. If there is
an internal machine fault or when the downstream machine stops, motors and pneumatic system are stopped by
the PLC immediately.
The main pneumatic valve closes only at an emergency stop and when the door is opened. After internal faults
the machine must be started again, after the upstream machine returns ’Ready’, it starts up by itself.

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Machine Power On

External Control
Two seconds after the belts run the machine generates a Ready-Signal. This signal gives the upstream machine
the release to supply in the direction of the stacker.

Standard-Signals
The machine can be controlled externally via the following contacts:
- Left pick-up ready
- Right/central pick-up ready
- Key bundle detection
These three signals are described elsewhere.

External Stacker-Control
For external control you must select the stack variables O=0/U=0/S=0 in the stack menu.
The stacker then functions based on the number preselection in the upper shuttle. The lower shuttle functions,
turning and ejection, are taken over uncontrolled by the external control.
The signal is applied to the product under the infeed photocell at the rising edge or to the last detected product.
Its travel is tracked and in the bin it generates the respective control commands for shuttle and ejector.

External Turning and Ejecting

This signal controls both shuttles and generates a new layer in the bin. Afterwards the bin is turned or a stack is
ejected.
External ejection is triggered by a signal at least 10 msec long.
External turning is triggered by two signals within 50 msec of at least 10 msec impulse/pause.

External Layer
This signal controls both shuttles and generates a new layer in the bin.
External layer is triggered by a signal at least 10 msec long.

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Function

Jam Limit
If a count photocell is covered longer than one book length, the machine stops with a fault indication.
The factory setting is 400mm

Shredder Inhibit
Photocell signals less than a certain travel distance are not counted as a copy.
The factory setting is 50mm

Stack Size
This size refers to the number of copies in the completed stack.

Turning
Layer Size
Products not in a layer. The layer is formed on the upper shuttle. The max. for this number can be equal to the
compensated stack size.

Compensated Stack Size

The compensated stack size is given by the number on the lower shuttle. The control distributes the stack count
independently to the individual compensated layers. If the distribution cannot be made completely, each layer is
increased by 1 beginning on the bottom. The automatic distribution generates maximum 5 compensated layers.
In the menu compensated layer the layers can be adjusted individually. This is to compensate for large spine
inclines.

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Function

Turning Function
This function can be turned on if more than 1 compensated layer is formed. It turns the turntable around once
after each new compensated layer.

Final Turn
At the end the stack is turned once more. This way the spine of the products in the downstream machine points
in the other direction.
This function increases the ejection time. This function can be selected alternating.

Pusher Functions / Remains Up

This function can only be selected if turning is not selected. The pusher remains up continuously.

Ejector
Without/With Ejector Plate
The ejector plate is attached stationary on the pusher. The pusher cannot come down anymore and the table
cannot turn. For this mode the pusher must be set to raised continuously. This function only works if valve Y31 is
installed. During this function the pusher cannot come down anymore.

Machine with One or Two Deliveries

Machines are manufactured with one or two deliveries. One delivery is called left- or right or center delivery. Two
deliveries are called left- and right delivery. Left and right always refers to the direction of transport. With two
deliveries the machine can distribute and run emergency delivery mode.
The waiting position of the ejector is always in the end position of the cylinder oppsite the next bundle ejection.
For a machine with one delivery it is always at the same place.
For machines with two deliveries the direction of ejection is determined for the next stack when the ejector
begins delivering for the running stack. This direction can still be changed until the last product of the running
stack in the infeed is detected.
For machines with one delivery the operating stroke is always 'Retract Cylinder' and resting stroke is always
’Extend Cylinder’.
For machines with two deliveries the operating stroke is always 'Retract Cylinder' right and working stroke
'Extend Cylinder' left.

Ejector Switch
This function only runs on machines with two deliveries.
- the machine can eject key bundles in opposite direction. This function is required when these stacks are
ejected in opposite direction of the standard stacks.
- In normal mode the machine can change the direction of ejection automatically if a downstream machine has
stopped (emergency delivery).

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Function

Lower Shuttle Overstack Limit

The overstack limit can be set individually.

Bin 240/300mm
Machines are manufactured with 240mm and 300mm bin height.
- Stack height on lower shuttle 120/150mm.
- With both bin heights the stack height on the upper shuttle is 60mm.

Key Bundle Formation

Key Bundle Control
This function requires a reader. The machine can cancel running stacks with that signal. This function is only
necessary for route production.

Key Bundle Size

Products that can be in the key bundle.
This number can be selected from the number in the stack to bin height divided by the book thickness. During
the preselection 0 the function -key bundle- is turned off.
Key bundle size is stack size.

Compensating Stacks
Uneven stacks are created if during production ’Route End’ or ’Clearing Machine’ is run. Such stacks are a
problem during palletizing. To reduce this problem we increase or decrease the following stack by the fault
number of the preceding one when running compensating stacks.
For increases no stack larger than the bin can be created, in that case the next following stack is increased, too.
For decreases no stack with incomplete bottom layer can be created (speed reduction). In this the products are to be
applied to the next standard stack.

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Function

Operating Mode
Depending on the configuration the machine can operate with print marks, with OCR or with barcode key
detection. The position of the infeed photocell, the change detection and the time operation of the reader require
varying operating modes.

Key Bundle Control

Rear Edge Control / Front Edge Control
The reader of the key bundle configuration is activated by the infeed photocell. Depending on the sequence of
reader and photocell the front- or rear edge of the product are used.
Depending on the installation position of the infeed photocell and the timing of the reader these signals come at
different times. This time difference must be compensated by the control. This compensation functions with the
edge detection. Depending on label and production mode one route switch is made at the last product of the
running stack (print mark detection) or with the first product of the new stack (zip code detection).
With front edge detection the reading signal occurs between front edge of the triggering product and front edge
of the next following product.
With rear edge detection the reading signal occurs between the rear edge of the triggering product and the rear
edge of the next following product.
See next page for application of signals.

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Detection of Key Signals

„External“ Signal Application
for Reader Installation with Use of Vendor Products

product flow photocell time axis

1 n n-1 n-2
B11

K=0
detect B12
rear edge

K=1
detect B12
front edge

K=2
rear edge B12
next book

K=3
front edge B12
next book

K = customer configuration
n = last book
= book
= reading time
B11 = infeed photocell
B12 = external input
no book permitted between B11 and B12

The signal in the hatched area is applied to the n’th book. If the n’th book is the last book on the belt and is
already applied to an external signal, an incoming signal is ignored. If no book is on the belt, the signal is
executed directly, provided the channel is not empty, and K=0 / K=1 is. At K=2 / K=3 you wait for the next book.

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Key Bundle Configuration Travel Monitor / Time Monitor

A key bundle signal must be delivered inside the label window to the stacker control. The label window always
begins with the selected edge detection. The distance from edge and label window is compensated by the
distance from photocell and reader.
There are two different window techniques:

Travel Window
Travel Window A travel window covers an area on the product. Within this range must be the label. Within a
certain product travel distance the reader must transmit the signal to the control. Signals
outside the travel window are not considered. (Print marks).

Travel Window, First Book Detection

product flow photocell time axis

2 1 n n-1
B 11

travel window

K=0
detect B 12
rear edge

K=1
detect B 12
front edge

K = Customer configuration
1 = first book with detection
n = last book of preceding stack
B11 = infeed photocell
B12 = external input

The n’th book is ejected.

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Travel Window, Last Book Detection

product flow photocell time axis

2 1 n n-1
B 11

travel window

K=0
detect B 12
rear edge

K=1
detect B 12
front edge

K = customer configuration
n = last book with detection
B11 = infeed photocell
B12 = external input

The n’th book is ejected.

The n’th book is detected by a mark (i.e. period, alu mark, etc.) on the top book of the stack.

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Time Window
Time Window A time window always suffices from the selected edge of a product to the same edge of the
next product. The reader must transmit the signal to the control within this time span. (OCR
or barcode).

Time Window, First Book Detection (E=0)

product flow photocell time axis

2 1 n n-1
B 11

K=0
detect B 12
rear edge

K=1
detect B 12
front edge

K=2
rear edge B 12
next book

K=3
front edge B 12
next book

K = customer configuration
1= first book with detection
n = last book of preceding stack
B11 = infeed photocell
B12 = external input

The n’th book triggers the release.

If the n’th book is no longer on the infeed belt the signal is passed on to the hopper and ejected immediately.
i.e. zip code detection

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Time Window, Last Book Detection (E=1)

photocell
product flow time axis
2 1 n n-1
B 11

K=0
detect B 12
rear edge

K=1
detect B 12
front edge

K=2
rear edge B 12
next book

K=3
front edge B 12
next book

K = customer configuration
n = last book with detection
B11 = infeed photocell
B12 = external input

The n’th book triggers the release. If the infeed belt is empty, ejection is immediate.

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Function

Key Bundle Configuration Travel Monitor

The stacker must know the travel window length of the key label. The travel monitor can be edited in 6mm
increments.

Key Bundle Configuration Signal Sequence

Depending on the machine configuration the sequence of key signal and book signal varies. This must be
adjusted individually at the customer’s plant to the upstream machine.

Key Bundle Error

Errors in the key bundle production are signalled by the key fault horn for 5 seconds. If during this time another
error occurs the horn goes off for 2 seconds and then sounds another 5 seconds. If this error occurs the forming
bundle may be faulty. The machine operator must check it.

Double Key
As long as the last key has not exited the machine, the reader cannot indicate a new key. Should this happen
anyway, the second key is stacked on the first one. During this time all bin monitors and count functions are
turned off.

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System

Automatic Stand By
On this input the stacker can be operated with Start/Stop Automatic. When this input has a signal longer than 1.5
mm, the stacker stops. When the signal disappears it starts immediately again. A photocell on the transport belt
makes this operation possible.

Calculation of Total Run

Total run refers to the number of products that can be processed by the machine with the selected stacking
mode. The net run is the actually processed quantity. The total run is calculated from the reverse value of the
signature gap time. (A large total run requires a low signature gap time).

The machine monitors the signature gap time. It stops when it is not reached as follows:
- If a layer separation was to occur between two products, the minimum time distance must correspond to the
signature gap time.
- The average signature gap time in a layer must be longer than the calculated signature gap time.

Standard Stack Total Production

The signature gap time is calculated in two ways.
Machine operates without turning: Basic ejection time divided by the bottom compensated layer
Machine operates with turning: Lower turning time divided by each compensated layer
Basic eject time by the bottom compensated layer
(The longest time found is the signature gap time)

Total Production Key Bundle

For the key bundle the same signature gap time applies as for the normal stack. The following additional
conditions apply:

- If the difference between maximum stack and standard stack is less than the bottom layer, the difference is
used for the calculation instead of the bottom layer. (For large runs the maximum stacks should be rather
large)
- If the travel time of the products between the infeed- and the bin photocell is less than the basic eject time, the
basic eject time is increased by the ratio of the two times. (For large runs the travel time should be long, i.e. low
belt speed).

3.99 e
Control Counter Stacker 3631.60.35

System

Eject Cycle
The eject cycle has a decisive effect on the processing capacity of a stacker. The processing speed is calculated
by the reverse value x 3600 of the signature gap time.

Stack Consisting of One Layer

The cycle run is as follows:
- Last product runs through the bin photocell
> Pusher goes up
- Last product is in the bin and pusher left bottom end layer
- Ejector reaches operating stroke limit switch
> Ejector makes operating stroke
> Lower pusher
- Pusher left upper end layer
> Ejector return stroke
- Ejector ends return stroke
> Ejector ready for next stack
The signature gap time is calculated from the following times and sizes:
(Raise pusher + ejector operating stroke + lower pusher + ejector resting stroke) / stack

Stack Consisting of Several Layers

The cycle as above:
The signature gap time is calculated from the following times and sizes:
(Raise pusher + ejector operating stroke) / bottom compensating layer

3.99 e
3631.60.36

System

Stack Consists of one Layer and must be Turned at the End

The cycle runs as follows:
- Last product passes the bin photocell
- Last product is in the bin
> Turntable operates
- Turntable has reached other end layer
> Pusher goes up
- Pusher has left bottom end layer
> Ejector makes operating stroke
- Ejector reaches operating stroke limit switch
> Lower pusher
- Pusher has left upper end layer
> Ejector resting stroke
- Ejector ends resting stroke
> Ejector ready for next stack
The signature gap time is calculated from the following times and sizes:
(Raise pusher + ejector operating stroke + lower pusher + ejector resting stroke + turntable operating stroke) /
stack

Stack Consisting of Several Layers and must be Turned at the End

The cycle as above:
The signature gap time is calculated from the following times and sizes:
(Raise pusher + ejector operating stroke + turntable operating stroke) / bottom compensating layer.

3.99 e
Control Counter Stacker 3631.60.37

Menu 1: Monitor

Speed
1 >1 >B=aa* >E=bb >S=ccc >M=dd*

2.1 1 MACHINE MECHANICAL SPEED

2.2 >T = TOTAL RUN IN C/H (*LIMITED)

2.3 >C = COPY COUNTER

2.4 >S = STACK COUNTER

2.5 >M = KEY BUNDLE COUNTER (*KEY)

* Key travels in the machine

Limited means that the total run of the machine is limited by the stack set-up.
A key bundle is the same as a remaining stack.

Stack
1 >STACK >E=aa >O=bb >U=cc* >S=dd

2.1 STACK IN BIN

2.2 >I = NUMBER IN INFEED BELT

2.3 >U = NUMBER IN UPPER SHUTTLE

2.4 >L = NUMBER IN LOWER SHUTTLE (*OVER)

2.5 >S = NUMBER IN STACK

(* OVERSTACKED means that the total run is limited)

Eject Delivery
1 >PRODUCTION >A=aa >B=bb >C=cc >D=dd

PROD. TO LEFT AND RIGHT

2.2 >A = DEL. TO LEFT

2.3 >B = DEL. TO RIGHT

2.4 >C = LEFT FINAL TURN

2.5 >D = RIGHT FINAL TURN

Final turn means that the orientation of the stack is changed. I.e. what is rear in a normal stack, is in the front in
a stack with final turn.

3.99 e
3631.60.38

Menu 1: Monitor

Infeed Book Monitor

1 >INFEED..................... * -

2 -BOOK *KEY #E-OFF $E-TURN +E-LAYER

A book is between infeed photocell and bin. The lines travel at the transport speed across the 1st line.
* is a key bundle, will be on top of the stack
# Externally controlled ejection
+ Externally controlled layer
$ Externally controlled turning

Display of Data Line with Management System

1 >> . . . . . . . . . . . . . . . . .

2 << . . . . . . . . . . . . . . . . .

>> Receive
<< Send
On the dotted lines the communication between the participants is displayed. It is overwritten with Time-Out of 5"
with. . . . . or with the new indication.

3.99 e
Control Counter Stacker 3631.60.39

Menu 2: Enter Program

An * in the stack programming means that the respective menu line is only possible as an entry with the
respective factory- or customer configuration. Otherwise the variable is blocked on the 1. possible value.

Stack
1 >2 >B=aa >O=bb >U=cc* >S=dd >K=0

2.1 2 STACK PROGRAM OVERVIEW

2.2 >T = BOOK THICKNESS

2.3 >U = NUMBER UPPER SHUTTLE

2.4 >B = NUMBER BOTTOM SHUTTLE (*OVER)

2.5 >S = NUMBER IN STACK

2.6* >K=0 WITHOUT SMALL SIZE KIT

>K=1 WITH SMALL SIZE KIT

O=0 Upper shuttle operates as separation shuttle

S=0 Layer formation and count is controlled externally
K=1 Small size configuration must be entered into the customer configuration.

Limits max. Geometry Max. Number Min. Number

Book thickness 70 mm 1mm

Number upper shuttle 60 divided by the book 60 1

thickness + 1
Number lower shuttle 120(150) divided by the 99 Number upper shuttle or 1/5 of stack
book thickness
Overstack 180 (210) divided by book 99 Number upper shuttle
thickness
Number bin 240 (300) divided by book 5x lower Number bottom shuttle
thickness shuttle

3.99 e
3631.60.40

Menu 2: Enter Program

Compensating Layer
1 >LAYER >A=aa >B=bb >C=cc >D=dd >E=ee

2.1 LAYER FREE PROGRAMMABLE COMP. LAYERS

2.2 >A 1.COMP. LAYER (BOTTOM LAYER)

2.3 >B 2.COMP. LAYER

2.4 >C 3.COMP. LAYER

2.5 >D 4.COMP. LAYER

2.6 >E 5.COMP. LAYER

The program determines the optimum layer compilation from the stack program. It can be changed by the user.
The program divides by whole numbers (S= number in stack divided by L = number on lower shuttle). This gives
a maximum of 5 equal compensated layers. The remainder of the division is distributed equally to the
compensated layers. A lower positioned compensated layer must never be smaller than a higher positioned one.
The total run is calculated from the smallest compensated layer.

Key
* The key menu only comes up if key configuration was selected in the customer configuration
1 >KEY >S=aa >M=bb >U=c >K=d

2.1 KEY BUNDLE PRODUCTION

2.2 >S=0 WITHOUT KEY BUNDLE

>S=1 WITH KEY BUNDLE
2.3 >M MAX. SIZE KEY BUNDLE

2.4 >U=0 WITHOUT EJECTION CHANGE

>U=1 WITH EJECTION CHANGE
2.5 >K=0 WITHOUT COMPENSATING STACK
>K=1 WITH COMPENSATING STACK

Limits max. Geometry Max. Number Min. Number

S Key bundle 240 (300) divided by the

book thickness Stack

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Control Counter Stacker 3631.60.41

Menu 2: Enter Program

Turning
1 >TURNING >K=a >A=b >L=c >A=d >R=e

2.1 TURNING FOR COMP. LAYERS

2.2 >K=0 WITHOUT COMP. LAYER

>K=1 WITH COMP. LAYER
>K=2 PUSHER UP W/O COMP. LAYER
>K=3 PLATE MOUNTED W/O COMP. LAYER
2.3 >A=0 LEFT WITHOUT FINAL TURN
>A=1 LEFT WITH FINAL TURN
>A=2 ALTERNATING LEFT FINAL TURN
2.4 >L=c FINAL TURN LEFT ALTERNATING

2.5 >A=0 RIGHT WITHOUT FINAL TURN

>A=1 RIGHT WITH FINAL TURN
>A=2 ALTERNATING RIGHT FINAL TURN
2.6 >R=e FINAL TURN RIGHT ALTERNATING

Distribution
1 >DISTRIBUTE >L=0-9 >R=0-9

2.1 DISTRIBUTE LEFT AND RIGHT

2.2 >L = EJECT STACK TO LEFT

2.3 >R = EJECT STACK TO RIGHT

Store Job
1 > PROGRAM IS ACCEPTED

3.99 e
3631.60.42

Menu 3: Load Job

1 >3 >N=aa

2.1 3 READ JOB FROM STORAGE

2.2 >N = JOB NUMBER

Job is Read
1 > JOB IS READ

When you exit the screen properly the job is read and transferred to the machine. HOME exits the menu and the
job will not be read.
The machine can store 50 jobs. Each job is filed under a number in the library. With this number the job can be
copied from the library into the working memory of the stacker. The next started stack is made according to the
new job

3.99 e
Control Counter Stacker 3631.60.43

Menu 4: Store Job

Enter all steps the same as program stack. After distribution comes another screen for the job number input.

1 >JOB >N=aa

2.1 4 STORE JOB

2.2 >N = JOB NUMBER

Job Is Stored
1 JOB IS STORED

When you exit the screen properly the job is stored. HOME exits the menu and the job is not stored.
A library slot can be filled with a new job description during the production. The library slot is defined with the job
number. The programming remains the same as the direct programming. At the end the job number has to be
entered

3.99 e
3631.60.44

Menu 5: Store Program

Store Machine Program as Job

1 >5 >N=aa

2.1 5 STORE MACHINE JOB

2.2 >N = JOB NUMBER

Machine Program is Stored as Job

1 > MACHINE JOB IS STORED

When you exit the screen properly the job is stored. HOME exits the menu and the job is not stored.

The library slot can be overwritten with the actual data from the working memory during production. At the end
the job number must be entered.

3.99 e
Control Counter Stacker 3631.60.45

Language Change F1

1 >LANGUAGE >S=1

2.1 >ENTER LANGUAGE

2.2 >S=1 DEUTSCH

2.3 >S=2 ENGLISH (metric)

2.4 >S=3 FRANCAISE

2.5 >S=4 ITALIANO

2.6 >S=5 ESPANOL

2.7 >S=6 PORTUGESE

2.8 >S=7 NEDERLANDS

2.9 >S=8 DANSK

2.10 >S=9 NORSK

2.11 >S=10 SVENSKA

2.12 >S=11 SUOMI (FINNISCH)

2.13 >S=12 JAPAN (ENGLISH)

2.14 >S=13 ENGLISH (inches)

2.15 >S=14 DEUTSCH

3.99 e
3631.60.46

Alarm And Alarm-History F5, (F12) & F5

An alarm is a fault indication. Warnings are alarms during which the machine continues running, faults are
alarms during which the machine stops.
Every alarm is entered in the current alarm register. It remains there until it is acknowledged. Then it is in the
Alarm-History Register. Both registers can be scrolled in steps.
Alarms triggered by the operating personnel are not displayed. They come up as an indication when you try to
start the standing machine.
Every standing alarm turns on the lamp in the stop sensor. The lamp is on until all alarms are in the history.
When the menu is in the HOME position, the indications are displayed immediately. Otherwise you can look at
them with F1 or SHIFT F1. Indications are acknowledged individually with F15. They are all acknowledged
simultaneously with Start.
If no alarm is activated and you press F5 this indication appears
1.1 hh.mm NO INDICATION

2 # ÚÙ

Warnings
1.1 hh.mm COMP. AIR SUPPLY TOO LOW

2 # ÚÙ

1.2 hh.mm TOTALIZER EXCEEDED

1.3 hh.mm STAND-BY

hh.mm is the actual time when the warning occurs.

3.99 e
Control Counter Stacker 3631.60.47

Fault Indications

Alarm Text
- Cause
Þ Remedy
hh.mm EMERGENCY STOP
-> Release emergency stop
hh.mm GUARD
-> Close all doors
hh.mm OVERCURRENT

hh.mm COMP. AIR SUPPLY TOO LOW

-> Line has no pressure
-> Main valve does not switch
-> Pressure switch does not switch
-> Short pressure loss during operation
hh.mm JAM IN INFEED
- Several products without gap in front of photocell
- Defective photocell
hh.mm JAM IN BIN
- Several products without gap in front of photocell
- Defective photocell
hh.mm INFEED MOTOR FAULT

hh.mm INFEED TOO FAST

- Two products have a smaller distance than permitted after the maximum speed (subsequent fault)
hh.mm EJECTOR FAULT
hh.mm PUSHER FAULT
hh.mm TURNTABLE FAULT
- One of the time limits was exceeded and is displayed.
-> Defective limit switch
-> Defective valve
-> Mechanical defect
hh.mm INTERFACE FAULT

hh.mm RIGHT DOWNSTREAM MACHINE STANDS

- Downstream machine has or had a short interruption
hh.mm LEFT DOWNSTREAM MACHINE STANDS
- Downstream machine has or had a short interruption
hh.mm DOWNSTREAM MACHINE STANDS

hh.mm KEY SIGNAL ACTIVATED

3.99 e
3631.60.48

Help Functions with Keyboard

Exit all functions with the same key combination or with 2 min Time-Out.
Improperly completed entries are ignored.

Fault Indication
Function:
The control continuously sets activators. Every activator effects a change on the machine. This change is
monitored by sensors. If no change occurs within the warning waiting time, an indication comes up in the display.
After some more time passes the machine turns off. The machine can only be started again after
acknowledgment and/or correction of the fault.
In case of several faults, only one is displayed, after it is corrected the next one is displayed!

1.1 hh.mm GUARD

2 # ÚÙ

hh.mm is the actual time when the fault occurs, ! it means the reason for it still exists.

3.99 e
Control Counter Stacker 3631.60.49

Help Functions with Keyboard

Diagnostic F7
Diagnostic is a monitor/control of machine settings and function

Ejector
1 >DIAGNOSTIC >A=a.aasec >B=b.bbsec

2.1 EJECTOR CYLINDER RUN TIME

2.2 >A = EXTEND CYLINDER

2.3 >B = RETRACT CYLINDER

Turntable
1 >DIAGNOSTIC >A=a.aasec >B=b.bbsec

2.1 TURNTABLE CYLINDER RUN TIME

2.2 >A = EXTEND CYLINDER

2.3 >B = RETRACT CYLINDER

Pusher
1 >DIAGNOSTIC >A=a.aasec >B=b.bbsec

2.1 PUSHER CYLINDER RUN TIME

2.2 >A = EXTEND CYLINDER

2.3 >B = RETRACT CYLINDER

Signature Gap Time

1 >DIAGNOSTIC >A=aa.aasec >B=bb.bbsec

2.1 SIGNATURE GAP TIME

2.2 >A = INFEED

2.3 >B = BIN

3.99 e
3631.60.50

Help Functions with Keyboard

Diagnostic F7
Signature Gap by Travel
1 >DIAGNOSTIC >A=aaa >B=bbb

2.1 SIGNATURE GAP INFEED PHOTOCELL

2.2 >A = SIGNATURE LENGTH mm

2.3 >B = GAP LENGTH mm

Speed
1 >DIAGNOSTIC> A=aaa >B=bbb

2.1 SPEED

2.2 >A = INFEED BELT SPEED m/min

2.3 >B = BOOK MONITOR SPEED m/min

Clearing Machine F10

The machine runs a sequence 'Clearing Machine' at a random point.

Test Run F 11
The machine runs the pneumatic movements of its cylinders independent of the belts. It is achieved by a simulated
count signal on the bin photocell calculated from the total run.

3.99 e
Control Counter Stacker 3631.60.51

Help Function with SHIFT and Keyboard

Change Menu Customer Configuration (F12)& F2 (View &F3)

1 >PASSWORD >P=****

2 ENTER PASSWORD CUST.CONFIG.

This menu is subject to a Time-Out of 10 sec. and after the first time the button is pressed for 4 sec.
The password is F3, F7, F9, F1
After successful entry the menu switches automatically after change customer configuration.
View customer configuration comes up without password.

Setting
1 >SETTING >U=aaa >S=bbb >Ü=ccc

2.1 CHANGE CUSTOMER CONFIGURATION / (VIEW)

2.2 >I = INHIBIT SHREDDER mm

2.3 >J = JAM DETECTOR mm

2.4 >O = OVERSTACK LIMIT mm

2.5 >D = FEEDER DELAY

Customer Configuration
1 >CONFIGURATION >S=a >K=b >A=c >L=d

2.1 CHANGE CUSTOMER CONFIGURATION /(VIEW)

2.2 >S=0 WITHOUT EXTERNAL CONTROL

>S=1 KEY BUNDLE CONTROL ACTIVATED
>S=2 EXTERNAL CONTROL ACTIVATED
2.3 >K=0 WITHOUT SMALL SIZE KIT
>K=1 WITH SMALL SIZE KIT
2.4 >L=0 CLEAR IMMEDIATELY
>L=1 CLEAR WITH NEXT PRODUCT
>L=2 CLEAR WHEN BELT IS EMPTY
2.5 >A= GATE DELAY TIME sec

10.2000 e
3631.60.52

Help Functions With SHIFT and Keyboard

Detect Key
Configuration Key Signal (comes only if key configuration menu S =1 )
1 >EXTERNAL >K=a >E=b >F=c >W=ddd

2.1 CHANGE CUSTOMER CONFIGURATION / (VIEW)

2.2 >E=0 REAR EDGE DETECTED

>E=1 FRONT EDGE DETECTED
>E=2 REAR EDGE NEXT BOOK DETECTED
>E=3 FRONT EDGE NEXT BOOK DETECTED
2.3 >D=0 FIRST DETECTION
>D=1 LAST DETECTION
2.4 >W=0 TRAVEL WINDOW
>W=1 TIME WINDOW
2.5 >W = TRAVEL WINDOW LENGTH mm

Customer Configuration is Stored

1 > CUSTOMER CONFIGURATION IS STORED

When you exit the screen properly the customer configuration is saved. HOME exits the menu without
burning the menu.

3.99 e
Control Counter Stacker 3631.60.53

Help Function with SHIFT and Keyboard

Version (F12) &F6

This display comes up automatically for 5 sec during Network On

1 PANEL 3631....... aaaa.a

2 CONTROL 3631....... bbbb.b

Time (F12)& F7

Time Setting (24h Day)

1 >TIME >h=hh >m=mm >s=ss

2.1 TIME SETTING

2.2 >h HOURS

2.3 >m MINUTES

2.4 >s SECONDS

3.99 e
3631.60.54

Help Function with SHIFT and Keyboard

Change Factory Configuration (F12)& F10 (View &F11)

1 >PASSWORD >P=****

2 > ENTER PASSWORD FACT. CONFIG.

This menu is subject to a Time-Out of 10" and 4sec after you press the key the first time. The password is F1, F9,
F7, F3. If entry is successful the menu switches automatically after factory configuration.
Viewing the factory configuration comes up without password.

1 >MACHINE >V=a >M=b >A=c

2.1 CHANGE FACTORY CONFIGURATION / (VIEW)

2.2 >V=0 LEFT AND RIGHT MACHINE

>V=1 RIGHT MACHINE
>V=2 LEFT MACHINE
>V=3 CENTER MACHINE
2.3 >M=0 MAGAZINE 300mm
>M=1 MAGAZINE 240mm
2.4 >A=0 STANDARD EJECTOR
>A=1 TOP EJECTOR
2.5 >S=0 WITHOUT VALVE Y31
>S=1 WITH VALVE Y31

Shuttle Configuration
1 >HOLDING TIME >O=aaa >U=bbb >A=ccc

2.1 CHANGE FACTORY CONFIGURATION / (VIEW)

2.2 >U UPPER SHUTTLE HOLDING MSEC

2.3 >L LOWER SHUTTLE HOLDING MSEC

2.4 >E EJECTOR HOLDING MSEC

Superfast Configuration
1 >MEASUREMENT >O=a >U=b

2.1 CHANGE FACTORY CONFIGURATION / (VIEW)

2.2 >U=0 WITHOUT DROP TIME UPPER SHUTTLE

>L=1 WITH DROP TIME UPPER SHUTTLE
2.3 >L=0 WITHOUT DROP TIME LOWER SHUTTLE
>L=1 WITH DROP TIME LOWER SHUTTLE

10.2000 e
Control Counter Stacker 3631.60.55

Help Function with SHIFT and Keyboard

Store Factory Configuration

After all entries are completed the following comes up when factory configuration is started
1 > STORE FACTORY CONFIGURATION S = 1

>S = 0 CANCEL
>S = 1 STORE

Factory Configuration is Stored

1 > FACTORY CONFIGURATION IS STORED

If you exit the screen properly, the factory configuration is stored. HOME exits the menu without burning
the configuration.

3.99 e
3631.60.56

Layout

List of In- and Outputs

DM476 Fast Inputs DM476 Outputs

Addr. Name Schematic Addr. Name Schematic

1 3.1 Bin photocell B10 3.1 Stop Lamp H1

2 3.2 Infeed photocell B11 3.2 Start Lamp H2

3 3.3 Key Signal B12 3.3 Ready K8

4 3.4 Infeed encoder B13 3.4 Motor On K11

5 3.5 Ejector extended S22 3.5 Main valve Y40

6 3.6 Ejector retracted S23 3.6 Flap Y41

7 3.7 Pusher extended S30 3.7 Key signal H11

8 3.8 Pusher retracted S31 3.8 Key fault H10

9 3.9 Drop above B60 3.9 Extend turntable Y20

10 3.10 Drop below B61 3.10 Retract turntable Y21

11 3.11 Encoder prerun B62 3.11 Extend ejector Y22

12 3.12 External clearing Ext 3.12 Retract ejector Y23

13 3.13 External turning Ext 3.13 Extend pusher Y30

14 3.14 External ejection Ext 3.14 Retract pusher Y31

and turning
15 3.15 Free 152 3.15 Upper shuttle Y32

16 3.16 Free 153 3.16 Lower shuttle Y33

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Control Counter Stacker 3631.60.57

Layout

List of In- and Outputs

DM476 Slow Inputs DM476 Outputs

Addr. Name Schematic Addr. Name Schematic

1 4.1 Emergency stop K21 4.1 Free

2 4.2 Door limit switch K22 4.2 Free

3 4.3 Overload infeed Q2 4.3 Free

4 4.4 Operation K26 4.4 Free

5 4.5 Turntable extended B20 4.5 Free

6 4.6 Turntable retracted B21 4.6 Free

7 4.7 Downstream right runs Ext 4.7 Free

8 4.8 Downstream left runs Ext 4.8 Free

9 4.9 Overload delivery Q3 4.9 Free

10 4.10 Start K25 4.10 Free

11 4.11 Free 151 4.11 Free

12 4.12 Free 152 4.12 Free

13 4.13 Free 153 4.13 Free

14 4.14 Free 4.14 Free

15 4.15 Stand By B63 4.15 Free

16 4.16 Pressure switch S73 4.16 Free

3.99 e
3631.60.58

Definition

Activator Unit receiving a signal from a control and activating a status on a machine.
Final turn A stack is final turned when it is turned after completed stacking. I.e. what is the rear when the
product comes in, is in front when the stack is delivered.
BCD switch Preselector switch with 16 positions. The positions run from 0-9. The positions 10-15 are
normally written with A-F.
Total run The number of products a machine can process. This value is calculated from the machine
setting and the stack summary. The total run normally refers to one hour. Short-term
exceeding this value generates a warning, longer exceeding it stops the machine and
generates a fault indication.
Data interface This is a connection possibility for units that deliver/read ASCII characters. Operation of a
data interface always requires a driver software and an evaluation software. Data interfaces
are between reader and PLC and between PLC and process management system.
True time Time during which an identification must be made. Practically the time the label is under the
reader.
Error-redundant The route production functions corredtly although products (especially the control product)
are missing.
Window Area of product in which there must be a label.
Speed Speed of label passing by the reader.
Compliment stack A key bundle is not the same size as a standard stack. It may be a problem during
palletizing. A key bundle and the next following compliment stack are the same size as two
standard stacks.
Limited A value is limited by an occurrence not immediately apparent.
Label A machine-readable change on a product useable for product identification.
Reader Unit detects a change necessary especially for product identification. A reader always is a
sensor, too.
Zip code Alpha-numeric characters on a product. These may be zip codes, route numbers,
customer numbers or similar.
Maximum stack The maximum stack is the largest possible key bundle. It is limited by the machine
geometry.
Medium Label material.

3.99 e
Control Counter Stacker 3631.60.59

Definition

Minimum stack The minimum stack is also called key bundle. It is the number of products in a
remaining stack that the machine can process without speed reduction. For automatic
production the logistic system must make stacks smaller than the minimum stack
impossible or they must be rejected by the stacker. If remaining stacks smaller than the
minimum stack still occur, they are shifted into the running stack. This fault is signalled by
the stacker.
Net run The number of products a machine effectively processes. This value normally refers to one
hour.
OCR-Monitor Optic Recognition : Detection of written or printed alpha-numeric characters. (Zip code,
writing).
Product offset Layer error of a label or transport play of a product.
Process Mgt. SystemMaster computer system in reference to controls. In this instance it maintains the
position of individual customer-assigned products in the delivery system.
Remaining stack See route production.
Route production The products are stacked as to be distributed. ’As to be distributed’ means that per delivery
position only complete stacks are unloaded. Unavoidable incomplete stacks are produced
as remaining stacks in the production already.
Resting zone Every label has a circumferential zone. This zone is used to limit the print on the label.
Sensor Unit that monitors a status on the machine and transmits a respective signal to the control.
Shift register Machine movement which is simulated in the control. (I.e. position and number of products on
the belt between infeed and bin).
Key production See route production
Key product See control product
Standard stack A normal stack with handable size.
Stack adjustment A master system optimizes the standard stack size independently of route. In such a system
the remaining stack can be run with narrower limitations.
Control copy Last product in a route production. It is the last product of a route and is on top of the
remaining stack after a counter stacker.
Travel window Area of a product where the label must be.

3.99 e