Manual

Autobind 500 HS
(semi-automatic binding machine)

Chr. RENZ GmbH

Rechbergstr. 44
73540 Heubach
Deutschland

Phone: + 49 (0) 7173/186-0

Fax: + 49 (0) 7173/3720
mail@renz-germany.de

www.renz.com
www.renz-germany.de
 AB500HS Table of contents page 1

1 Table of contents
1 Table of contents ................................................................................................................. 1
2 EG conformity declaration .................................................................................................. 3
3 AB500HS specific machine datas ...................................................................................... 4
4 General Information............................................................................................................. 5
4.1 Intended Use..................................................................................................................................................5
4.2 Operating description .....................................................................................................................................5
4.3 Sequence of operation ...................................................................................................................................5
5 General Safety Instructions ................................................................................................ 6
5.1 User´s Duty of Care .......................................................................................................................................6
5.2 Safety Instructions..........................................................................................................................................6
5.3 Description of symbols ...................................................................................................................................6
5.4 Safety Requirements for Normal Operation...................................................................................................7
5.5 Safety Requirements for Maintenance and Servicing....................................................................................7
5.6 Working on Electrical Equipment ...................................................................................................................8
5.7 Working on Pneumatic Equipment.................................................................................................................8
5.8 Environment Protection Regulations..............................................................................................................8
6 Transport and Installation................................................................................................... 9
6.1 Safety Instructions for Transport....................................................................................................................9
6.2 Unpack the AB500HS ....................................................................................................................................9
6.3 Support points for transportation..................................................................................................................10
6.4 Space requirement with simple output tray..................................................................................................10
6.5 Space requirement with conveyor (shingle) belt..........................................................................................11
6.6 Electrical connection ....................................................................................................................................11
6.7 Installation ....................................................................................................................................................12
6.8 Installation of the de-spooling device...........................................................................................................12
7 RENZ Autobind 500 - Technical data ............................................................................... 13
7.1 Binding format ..............................................................................................................................................13
7.2 Electrical connection ....................................................................................................................................13
7.3 Dimensions ..................................................................................................................................................13
7.4 Environmental conditions .............................................................................................................................13
7.5 Pneumatic requirement ................................................................................................................................13
7.6 Weights ........................................................................................................................................................13
8 RENZ RING WIRE® Chart................................................................................................... 14
9 Touch-screen display and switches................................................................................. 15
10 Adjustable machine elements ....................................................................................... 16
10.1 Paper side stops.......................................................................................................................................16
10.2 Clamping rail.............................................................................................................................................16
10.3 Table height adjustment ...........................................................................................................................16
10.4 Table front stop position ...........................................................................................................................16
10.5 Closing limiter ...........................................................................................................................................17
10.6 Opening limiter .........................................................................................................................................17
10.7 Simple output tray (optional) ....................................................................................................................17
10.8 Conveyor (shingle) belt.............................................................................................................................18
10.9 Maintenance unit for compressed air .......................................................................................................18
11 Handling of the touch-screen-display........................................................................... 19
11.1 Appearing screens....................................................................................................................................19
11.1.1 Starting screen......................................................................................................................................19
11.1.2 Set up screen........................................................................................................................................19
11.1.3 Operation mode (main menue).............................................................................................................19
11.1.4 Automatic ..............................................................................................................................................20
11.1.5 Manual Operation .................................................................................................................................20
11.1.6 Step by step ..........................................................................................................................................20
11.1.7 Inlet check.............................................................................................................................................21
11.1.8 Display messages.................................................................................................................................21
11.1.9 Input box ...............................................................................................................................................23
11.2 Example 1 for 3:1 pitch (Standard A4 book) ............................................................................................23
11.3 Example 2 for 3:1 pitch (with calendar hanger)........................................................................................25
 AB500HS Table of contents page 2
11.4 Example 3 for 3:1 pitch (skip binding) ......................................................................................................27
11.5 Programming for 2:1 pitch ........................................................................................................................28
12 Changing of the RING WIRE spool................................................................................ 28
13 Adjustment of the binding unit ...................................................................................... 29
13.1 Changing of inlet channel and feeding wheel ..........................................................................................29
13.1.1 Changing of the inlet channel ...............................................................................................................29
13.1.2 Changing of the feeding wheel and height adjustment of the knife......................................................30
13.1.3 Changing of the closing bar ..................................................................................................................31
13.1.4 Adjusting the opening limitation ............................................................................................................32
13.1.5 Adjusting the closing limitation..............................................................................................................32
13.2 Binding table adjustments ........................................................................................................................33
13.2.1 Paper clamping rail ...............................................................................................................................33
13.2.1.1 Adjustment of the left side .............................................................................................................33
13.2.1.2 Adjustment of the right side ...........................................................................................................33
13.2.2 Side stops .............................................................................................................................................34
13.2.2.1 Adjustment of the paper side stops ...............................................................................................34
13.2.2.2 Installation and adjustment of the loop side stop ..........................................................................34
13.2.3 Table height ..........................................................................................................................................35
13.2.4 Front stop position of the table .............................................................................................................35
13.2.5 Adjustments in the automatic mode display .........................................................................................36
13.2.6 Ajust the output section.........................................................................................................................37
13.2.6.1 Adjust the conveyor (shingle) belt (CB120HS)..............................................................................37
13.2.6.2 Adjustment of the simple output tray (optional) .............................................................................38
14 Trouble shooting AB500HS............................................................................................ 38
15 Calendar hanger tool (KAS)/optional ............................................................................ 42
15.1 Technical data KAS ..................................................................................................................................42
15.2 Product information KAS unit ...................................................................................................................42
15.3 Sequence of operation .............................................................................................................................42
15.4 Closing bar protection cover.....................................................................................................................42
15.5 Connect the KAS at the AB 500HS ..........................................................................................................43
15.6 Set the KAS to different shaft lengths ......................................................................................................44
15.7 Adjustment of the KAS unit according to your product.............................................................................45
15.8 Adjustment of the slider inclination...........................................................................................................45
15.9 Supply the KAS unit with compressed air ................................................................................................46
15.10 Trouble shooting KAS unit........................................................................................................................47
16 Maintenance .................................................................................................................... 48
16.1 Regular maintenance work.......................................................................................................................48
17 For your notes................................................................................................................. 49
 AB500HS EG conformity declaration page 3

2 EG conformity declaration

according to the EG guidelines

- EG guidelines for machines 2006/42/EG

- electromagnetic consistency 2004/108/EG
- low tension 2006/95/EG

The construction of the machine/system

Model SEMI-AUTOMATIC BINDING MACHINE

Type AUTOBIND 500 HS
Machine no. 7541
Year of construction 02/2010

was developed, constructed and produced in accordance with the EG guidelines 89/392/EWG and with the sole
responsibility of

Company: Chr. Renz GmbH, Rechbergstraße 44, D-73540 Heubach

The following harmonized specifications were applied:

EN ISO 12100, security of machines, units and systems

EN 60 204-1, electrical equipment for industrial machines
..............................................................................................................................................................................
..............................................................................................................................................................................
..............................................................................................................................................................................
..............................................................................................................................................................................

The following national norms, guidelines and specifications were applied:

..............................................................................................................................................................................
..............................................................................................................................................................................
..............................................................................................................................................................................
..............................................................................................................................................................................

A complete technical documentation as well as the relevant manual is available.

The operating manual for the machine is available

; in the original version

; in the European languages German, English, Spanish,

Heubach, 02/2010
(place, date) signature General Manager
 AB500HS AB500HS specific machine datas page 4

3 AB500HS specific machine datas

Machine number : 405002200.7591

Year of construction : 02/2011

Pitch : 2:1 3:1 4:1

Voltage : 230V

Frequency : 50Hz

SPS / PLC program : AB_HS_V60_FX3U

Display program : AB_HS_V61_FX3U

Closing tools delivered together with the Autobind:

∅ No. yes no ∅ No. yes no ∅ No. yes no

3/16" R 1/4" 3980 R 5/16" 3984 R
3/8" R 7/16" R 1/2" 3977 R
9/16" R 5/8" 3943 R 3/4" 3942 R
7/8" R 1" 3684 R 1 1/8" R

Calendar hanger unit:: KAS300 s/n 43300000561.4318 without KAS

Conveyor belt: CB120HS s/n 4350022135. without CB120HS
output tray: yes no

Special equipment :
additional closing bar 1/4" s/n 3981R

Heubach, Wednesday, February 08, 2012

signature
 AB500HS General Information page 5

4 General Information

Please read this manual very carefully before installing or starting the
Autobind 500HS
Caution
4.1 Intended Use
The RENZ® AutoBind 500 (subsequent named AB500HS) is a binding machine for Ring Wire
elements. Optional you can cut Ring Wire elements.
• Any other use is not allowed. Each operator has to be familiar with all safety regulations and the
intended purpose of the machine.
• The machine is not intended for types of use other than those listed here. Any infringement of this is
considered improper use!
We would like to draw particular attention to the fact that it is forbidden:
• to do other jobs like binding (and optional Ring Wire cutting) with the AB500HS
• If the AB500HS is not used in accordance with this requirement, safe use of the
machine cannot be guaranteed.
• The user, and not the manufacturer, of the machine is liable for all personal and
material damage arising from improper use.
Caution
4.2 Operating description
The RENZ® AB 500 is a semi automatic binding machine to close double loop wire from 100mm –
500mm working width and a diameter range from 3/16” – 1 1/8”. Additional equipment (KAS-unit)
enables you to bind calendar with hangers. Skip binding up to 10 elements are possible in standard
configuration.

4.3 Sequence of operation

• The product has to be placed at the front and side stops at the table.
• By pressing the foot pedal the clamping device and the front stop angle of the binding table moves
down.
• If a KAS is installed the delivery slider moves forward and the table follows with the product.
• Now the lower closing bar moves upwards and pushes the narrow loops through the perforation and
therefore closes the Ring Wire.
• The lower closing bar moves down and synchronous the holding rail of the upper closing bar lifts up
to provide enough space for the product to come out of the closing bars.
• The table moves back, the clamping is opened, the front stop angle comes up and the holding bar of
the upper closing bar comes down.
• If you have activated the function "belt on" the product will be removed sidewards from the table by
the belts.
• Parallel a new section of loops will be feed into the closing bars. The machine is ready for the next
cycle.
 AB500HS General Safety Instructions page 6

5 General Safety Instructions

5.1 User´s Duty of Care
• The RENZ® AB500HS binding machine has been designed and built after
careful selection of the harmonised standards to be complied with and of
other technical specifications. It is state-of-the-art technology and enables a
very high degree of safety during operation.
• Machine safety can however only be converted into operational practice if all
the action required for this has been taken. The planning of this action and
the control of its implementation fall under the duty of care of the user of the
machine.
The user must especially ensure that
• the machine is only used as intended.
• the machine is only operated in perfect working order and the safety
equipment in particular is regularly inspected as regards its fitness for
operation.
• necessary personal protective equipment for operating, maintenance and
repair personnel is available and is worn.
• the operating manual is always in a legible condition and is fully available at
the site the machine is used.
• only qualified and authorised personnel operate, maintain and repair the
machine.
• this personnel is regularly trained in all relevant matters of Health and Safety
and Environmental Protection, as well as knowing the operating manual and
in particular the safety instructions contained in it.
• all safety instructions and warnings applied to the machine itself are not
removed and are legible.

5.2 Safety Instructions

In this operating manual concrete safety instructions are given to indicate the residual risks that cannot
be avoided when operating the machine. These residual risks include risks to
• People, in particular the operating personnel
• Product and machine
• Environment

5.3 Description of symbols

Symbols indicated below are used in the appropriate place in the operating manual to indicate notably
the named residual risks!

This symbol indicates that there are, above all, hazards to people!
(Danger to life, risk of injury)
Danger

This symbol indicates that there are, above all, hazards to machine, material and
environment! (Damage, collision, loss of data)
Caution

This symbol indicates that there are, above all, hazards to people by electricity.
(see also information chapter 5.7) (Danger to life, risk of injury and risk of fire)
 AB500HS General Safety Instructions page 7

The most important objective of the safety instructions is to prevent people from being injured.
• If there is a warning triangle in front of a safety instruction with the caption “Danger”, hazards to
machinery, material and environment are not excluded.
• If there is a warning triangle in front of a safety instruction that contains a jagged arrow, hazards to
machinery, material and environment are not excluded.
• If there is a warning triangle in front of a safety instruction with the caption “Caution”, hazards to
people are however not anticipated.
The respective symbol used may not replace the text of the safety instruction. For this reason
the text must always be read in its entirety!

This symbol identifies points, which are of particular importance for the operator and / or
serves as information for a better understanding of the operating sequences of the
machine!
Information

5.4 Safety Requirements for Normal Operation

The machine may only be operated by trained and authorised personnel who
are familiar with the operating manual and are capable of working in
accordance with the manual! Before turning the machine on, check and ensure
that Only authorised personnel are in the working area of the machine!
No one may be injured when the machine starts! Every time you start
production, inspect the machine for visible damage and ensure that it is
operated only in perfect working order! The supervisor must be informed of any
faults that have been noticed! Every time you start production, clear any
material and objects that are not required for production from the working area
of the machine! Every time you start production, check and ensure that all
safety equipment is working perfectly!

5.5 Safety Requirements for Maintenance and Servicing

• Adhere to the inspection and maintenance intervals specified in the operating manual!
• Comply with the maintenance and repair instructions for the individual components in this operating
manual!

Before carrying out maintenance or repair work, block access to the working area of
the machine by unauthorised personnel! Attach or put up a sign that draws attention to
the maintenance or repair work!

Before carrying out maintenance and repair work turn off the main isolator switch for
the power supply and lock it with a padlock! The key to this lock must be in the hands
of the person carrying out the maintenance or repair work!

When replacing heavy machine components, use only appropriate and perfectly
operating lifting equipment and accessories! Before carrying out maintenance and
repair work ensure that all parts of the machine that may be touched have cooled down
to ambient temperature!

Properly dispose of lubricants, coolants or cleaning materials that may harm the
environment!
 AB500HS General Safety Instructions page 8

5.6 Working on Electrical Equipment

Repair work on electrical equipment of the machine may only be carried out by a trained
and skilled electrical personnel!
• Regularly inspect electrical equipment!
• Retighten loose connections!
• Immediately replace damaged leads/cables!
• Always keep the electrical cabinet closed! Access is only permitted to authorised
personnel with key/tool!
• Never clean electrical cabinets and other electrical equipment casings by spraying
them down with a water hose!

5.7 Working on Pneumatic Equipment

¾ Only allow maintenance and repair work on pneumatic equipment to be carried out
by specially trained personnel!
¾ Before carrying out maintenance and repair work remove the pressure from the
pneumatic equipment of the machine!
¾ Regularly replace pipelines through preventive maintenance even when no damage
is visible!
Before starting the machine after maintenance or repair work:
• check that loosened screw connections are securely fitted.
• ensure that container covers, screening equipment or filters that have been
removed are re-installed.
• remove all materials, tools and other equipment necessary for maintenance or
repair work from the working area of the machine.
• check all machine safety equipment for perfect operation!
5.8 Environment Protection Regulations
In the case of all work on and with the machine, statutory obligations for waste
avoidance and proper recycling/disposal are to be complied with!
In particular in installation, repair and maintenance work, substances hazardous to
water such as
• Lubricant greases and oils
• Hydraulic oils
• Coolants
• Cleaning fluids containing solvent
may not pollute the ground or may not enter the sewerage system!
These substances must be stored, transported, collected and disposed of in
suitable containers!
 AB500HS Transport and Installation page 9

6 Transport and Installation

6.1 Safety Instructions for Transport
In order to exclude damage to the machine and highly dangerous injuries during
transport the following are to be observed:
• Lifting equipment and accessories must meet the requirements of the
regulations for the prevention accidents!
• The weight of the AB500HS (about 290 kg) should be taken into consideration
when choosing the lifting equipment and accessories!
• Transport routes should be blocked off and marked so that no unauthorised
party may enter the danger area!
• Transport work may only be carried out by qualified and authorised personnel!
• Individual machine components may only be transported with a forklift or
Danger pallet truck with an adequate load bearing capacity!
• Only use lifting equipment with forks long enough to extend through the whole
machine frame to ensure safe conditions during transport!
• Take note of the support points for lifting the machine shown in the sketch
below!
• Use only lifting apparatus to transport the machine over ramps!!

• Movement is only allowed with fork lifts or pallet trucks with an adequate load
bearing capacity.
• The AB500HS can tilt if you move on uneven or slanting surfaces.
Danger
6.2 Unpack the AB500HS

If the machine was delivered in a wooden crate please proceed as follows (to unpack the machine):
• Release the screws for the top cover and remove the top cover.
• Release the screws for the side frames and remove them.
• Remove the rear and the side sheet metal cover of the machine.
• Remove the clamping devices for machine fixing.
• Lift the AB500HS off the pallet with a suitable fork lift or a crane.

• The covers of the wooden crate are very heavy. Please remove them with a
minimum of two people.
Danger

• Do not damage any cable and wiring during the transportation and lifting.

Caution
 AB500HS Transport and Installation page

6.3 Support points for transportation

Set the forks of the pallet truck/forklift truck as

wide as possible and lift the machine in the
centre! Do not use manual pallet jacks without a
brake if you want to move the machine on
declinations.

6.4 Space requirement with simple output tray

~2,05mtr.

• Please ensure that for the safe

operation of the machine the working
~1,96mtr.

area of the operating personnel is of

an adequate size.
• Set the machine up on a level
surface.

The full weight of the AB500HS (approx. 240kg without closing tools or KAS unit) will
be put on the four adjusting feet. Please make sure that your floor has enough load
capacity.
Caution
 AB500HS Transport and Installation page

6.5 Space requirement with conveyor (shingle) belt

~2,11mtr.

• Please ensure that for the

safe operation of the
machine the working area

~1,97mtr.
of the operating personnel
is of an adequate size.
• Set the machine up on a
level surface.

6.6 Electrical connection

• The standard voltage is 230V (1 ph.) 50Hz [115V (1ph.) 60Hz on request]
• The socket must have a protective wire (PE)
• The socket must be secured with 16 Amps.
If you are not sure that your socket is fulfilling the specifications please consult an
electrician before you install the AB500HS.
 AB500HS Transport and Installation page

6.7 Installation
To avoid the risk of tripping up:
• Lay the connecting cable in such a way as to avoid creating any tripping points (Use
of cable conduits, bridges etc.)!
To ensure fault-free operation:
• Prepare the installation site so that the machine is level on an even floor!
Danger • Lay the connecting cable so that that there is no tensile strain on the connectors!
• Avoid chafing points on the connecting cable!
Before starting the AB500HS for the first time check:
• Have all transport securing devices and desiccant bags been removed?
• Is the electrical connection correct?
Information • Are all safety devices operational?
Before starting the AB500HS for the first time, without fail carry out the following
procedures:
• Clean all painted and metal surfaces in the working area with a mild cleaning agent
Information to remove residues of rust proofing materials applied for transport!!

6.8 Installation of the de-spooling device

• Remove the two screwse of the de-

spooling devicec.
• Put the de-spooling device into the
square piped at the left side of the
machine frame.
• Fix the de-spooling device with the two
screwse.
• Plug in the plug for the de-spooling
device into the socketf.
• Hold the sheet metal guiding deviceg
at the upper areai with your hand.
Release the two small clamping
handlesh.
• Adjust the slope of the sheet metal
guiding device according to the sketch
beside.
• Tighten the two clamping handles.
 AB500HS RENZ Autobind 500 - Technical data page

7 RENZ Autobind 500 - Technical data

7.1 Binding format
Bound product min. 60 mm - max. 500 mm

Unbound edge with/without autom. ejection min. 100 mm

Book thickness max. 23 mm

1/8
RENZ RING WIRE 3/16“ – 1 "
Pitch standard: 3:1 and 2:1(4:1 optional)

Mechanical capacity 2000 bindings per hour

7.2 Electrical connection

Voltage see page 4

average power requirement 340 VA

max. power requirement 600 VA

system of protection IP42

7.3 Dimensions
length approx. 1,65m

depth approx. 1,56m

height approx. 1,70m

7.4 Environmental conditions

Environmental temperature (operation): min. 15°C - max. 35°C

Environmental temperature (storage): min. 5°C - max. 50°C

Max. humidity: max. 85% rel. humidity (not condensing)

7.5 Pneumatic requirement

air pressure requirement 300-340 Lit./minc at 7-7,5 bar (101-108psi)

max. source pressure 10 bar (145psi)

c depends on using KAS-unit or not
7.6 Weights
AB500HS binding unit 240kg (approx. net without closing tools or KAS unit)

with shipping crate 390kg (approx. net without closing tools or KAS unit)

load capacity of floor 500kg/m2

 AB500HS RENZ RING WIRE® Chart page

8 RENZ RING WIRE® Chart

∅ max. book
thickness
max. book
thickness
min.
binding
max.
bindin
minimum size of perforation
in mm
pitch
without with hanger width g width square hole round hole
inch mm hanger

3/16“ 4,8 3:1 3,0 60 500 4,0 x 4,0 Ø 4,0

1/4“ 6,9 3:1 4,5 3,5 60 500 4,0 x 4,0 Ø 4,5

5/16“ 8,0 3:1 6,0 5,0 60 500 4,0 x 4,0 Ø 4,5

3/8“ 9,5 3:1 7,5 6,5 60 500 4,0 x 4,0 Ø 4,5

7/16“ 11,0 3:1 9,0 8,0 60 500 4,0 x 4,0 Ø 4,5

1/2“ 12,7 3:1 10,0 60 500 4,0 x 4,0 Ø 5,0

9/16“ 14,3 3:1 11,0 60 500 4,5 x 4,5 Ø 5,0

5/8“ 16,0 2:1 13,5 100 420 6,0 x 6,0 Ø 6,0

3/4“ 19,0 2:1 15,0 100 420 6,0 x 6,0 Ø 6,5

7/8“ 22,0 2:1 18,0 100 420 6,5 x 6,5 Ø 6,5

c 25,4 2:1 20,0 100 420 6,5 x 6,5 Ø 7,0
1“
d 28,5 2:1 23,0 100 420 6,5 x 6,5 Ø7,0
11/8 “

• Calendars can only be bound in the sizes 1/4" to 7/16". When you bind 7/16“ the
calendar hanger can slide out of the binding.
• Please adhere to the numbers in the above chart.
• Increasing of the book thickness or decreasing of the perforation size may lead
Information
to difficulty with production.

c
Operating the AB500HS with 1" may cause some unexpected problems. We recommend to de-activate the belt
function while working with 1".
d 1/8
Operating the AB500HS with 1 " the automatic belt function must be de-activated at all. The belt function is
not processable with this diameter.
 AB500HS Touch-screen display and switches page

9 Touch-screen display and switches

c Touch Screen display

The touch screen display is not only for data
display but also for entry of the machine and
production data. Any data can be changed or
deleted at the respective position by touching the
display.
d Switch on button
Push the green button to start the machine
(power on switch)
e Rheostat for spool motor
This switch controls the speed of the spool de-
winding.
0 = OFF
10 = ON, max. de-winding speed
f Emergency-off switch
This switch interrupts the entire power supply and
the machine stops immediately.
g Main switch
The main switch is at the switch box on the back
of the machine.

Even if the main switch is off, there is still voltage in the control box.
Repair and maintenance work should only be carried out by qualified
personnel. The key of the switching cabinet must be stored secured. In
DANGER! no case it may lie unattended openly.
 AB500HS Adjustable machine elements page

10 Adjustable machine elements

10.1 Paper side stops

• At the left side of the machine table, there are the two side stopsc
which can be adjusted to align the holes in the paper with the RING
WIRE® elements in the closing bar.

10.2 Clamping rail

• The clamping railc is mounted transversely over the front

area of the machine table. It helps to secure the product
to be bound during the transport into the closing bar. The
opening height of the clamping rail can be adjusted
according to the diameter of the RENZ RING WIRE®
element selected.

10.3 Table height adjustment

• According to the used diameter you have to adjust the front stop
position of the table. The screwc enables you to adjust the front
stop position. The screw is located at the lower front side of the
binding table.

10.4 Table front stop position

• According to the used diameter you have to adjust the front stop
position of the table. The screwc enables you to adjust the front
stop position. The screw is located at the lower front side of the
binding table.
 AB500HS Adjustable machine elements page

10.5 Closing limiter

• With the closing limiter knobc you can adjust on how far you want to
close your RENZ RING WIRE® element.

10.6 Opening limiter

• The distance between the lower and the upper closing bars must be
adjusted according to the used diameter. The adjusting wheelc
enables you to adjust the distance.

10.7 Simple output tray (optional)

The output tray could be placed beside the

AB500HS instead of the conveyor belt.
• You can adjust the height by releasing the
clamping lever and lifting the upper section up or
down.
• The slope is adjustable as well. Release the
according clamping lever and adjust the slope of
the upper part.
• For different sizes there is a guiding sheet metal
in the output tray. You can move it to any place in
the tray and it is been held by a magnetic tape.
 AB500HS Adjustable machine elements page

10.8 Conveyor (shingle) belt

Usually the AB500HS is equipped with a

conveyor or shingle belt device.
• You can adjust the conveyor by releasing
the clamping levers.
• The area for the paper output is variable to
be able to adjust different products.

Please adjust the height of the conveyor only with a minimum of two persons. If you
release the clamping levers the upper part of the conveyor immediately starts
falling down and possibly hurts you.
Danger
10.9 Maintenance unit for compressed air

• At the right side of the machine, the maintenance unit

becomes accessible after the sheet metal cover has been
opened. This maintenance unit prepares the compressed
air for the machine. The air is dried and kept at a constant
pressure. The water trap functions automatically when the
water in the water container reaches a certain height, a
float valve opens and the water is drained off.
• The standard operation pressure is set at about 7-7,5 bar
(101- 109psi). when the machine is delivered. This
pressure can be changed by turning the pressure setting.
Attention!! do not set more than 8,0 bar (116psi)
• (A higher pressure may be required for larger diameters).
If the pressure will fall below 5,5 bar (80psi), an error
message is shown on the display.
• The air supply for the calendar hanger tool (KAS) is
turned off and on by pushing and turning the manual KAS
supply valve.

Never set the pressure higher than 8,0 (116psi) bar. By higher mechanical load you
will damage possibly some components at your AB500HS.
Caution
 AB500HS Handling of the touch-screen-display page

11 Handling of the touch-screen-display

Never ever use hard, sharp or pointed items to operate the Touch screen display.
You might destroy the surface of the Display and as for this the display and the
AB500HS is not operatable any longer.
Caution
11.1 Appearing screens
11.1.1 Starting screen

• After you switched on the AB700 the display carry out a

system check. This takes a few seconds. After this check
the starting screen appears. It contains the program
version and the manufacturers address.
• By touching the arrows at the left and right of the
language box you can change the display language.
• By touching the “Kontrast” button you can change the
Kontrast of your display.
• By touching the area of the word „Next“ the screen
changes to the menu „set up“.

11.1.2 Set up screen

• The “set up” menu directly appears after the starting

screen. You also can open it in the “operation mode”
menu.
• The „set up“ menu is for setting the data like pitch, no. of
loops, calendar hanger on/off and the feeding speed.
• By touching the „Next“ button the initial run starts. After
finishing the reference run the display changes to the
„Operation mode“ menu.

11.1.3 Operation mode (main menue)

automatic ¾ production mode
manual operation ¾ you can operate each single function
manually
step by step ¾ operate a complete binding cycle
step by step
wire feeding check ¾ slow loop feeding and cutting for
testing and adjusting the main drive.
<== ¾ Moves the wire at the feeding wheel
to the left
==> ¾ Moves the wire from the feeding
wheel to the knife
Set up ¾ for input of no. of loops, pitch, cal.
hanger on/off etc.
exit ¾ back to the starting screen.
 AB500HS Handling of the touch-screen-display page

11.1.4 Automatic

• The automatic mode is for working (production mode).

• All values could be changed during the automatic mode.
• The piece counter increases the value by 1 after each
completed binding cycle.
• With the button „Back“ the display changes to the main
menu.

11.1.5 Manual Operation

By touching the virtual switches you can execute the following functions.
Clamp ¾ Move the paper clamping at the table up
and down.
front stop ¾ Move the front stop angle at the table up
and down.
table ¾ Move the binding table forward or
backward.
close ¾ Move the lower closing bar up or down.
holding bar ¾ Move the rail of the upper closing bar up
and down.
cutting ¾ Move the cutting knife up or down.
bend hanger ¾ Move the calendar hanger unit forming
cylinder forward/backward.
feed hanger ¾ Move the delivery cylinder of the
calendar hanger unit forward/backward.
feed new loops ¾ Feeding in of new loops according to the
input of the set up.
pushing belt ¾ Removes your product from the table via
the belts.
exit ¾ Return to the main menu.

Returning to the main menu is only possible if all the switches are switched off (vertical
position).
Information
11.1.6 Step by step

• By touching the arrow key the AB500HS will execute step

by step a complete binding cycle.
• After the binding cycle is done the screen will change to
the operation mode.

The steps that will be done by touching the

arrow key are shown in the text beside the
Information arrow key.
 AB500HS Handling of the touch-screen-display page

11.1.7 Inlet check

• If you touch the „Start“ button the AB700 feeds in a few loops
with a very slow speed. Now the drive is fixed and you can
adjust the feeding wheel and the transport chain according to
the cutting position. The wire will not be cut off.
• If you touch the “cutting” button the knife cuts the loop at the
momentary position.
• By touching the “eject wire” button the wire will be moved out
of the closing bar.
• If you touch the "<= chain" button the position of the
transport chain will be corrected by one step clock-wise.
• If you touch the "chain =>" button the position of the
transport chain will be corrected by one step anti-clock-wise.
• If you touch the “exit” button the screen will change to the
main menu.

11.1.8 Display messages

• If you leave the „Set up“ menu by pushing the „exit“ button
this screen appears. It appears as long as the initial run is
active.

• This screen only appears in manual operation. If want to

move the table forward the front stop angle and the
clamping rail must be moved downward. This screen
reminds you to do that first.
• By pushing the „exit” button you will come back to the
previous screen.

• If your air pressure drops below 5,5 (approx. 80psi) bar

this message appears.
• By pushing the „exit” button you will come back to the
previous screen.
 AB500HS Handling of the touch-screen-display page

• This screen appears if the magazine of the calendar

hanger unit is empty.
• By pushing the „exit” button you will come back to the
previous screen.

• This screen appears if the proximity switch for the table

front stop position query is defective or disadjusted.
• By pushing the „exit” button you will come back to the
previous screen.

• This screen appears if the proximity switch for the

pressure bar query is defective or disadjusted.
• By pushing the „exit” button you will come back to the
previous screen.

• This screen appears if the proximity switch for the table

rear (home) stop position query is defective or wrong
adjusted.
• By pushing the „exit” button you will come back to the
previous screen.
 AB500HS Handling of the touch-screen-display page

11.1.9 Input box

If you want to enter numeric values an input box opens. This box enables you to enter
numeric data.
Information

cThis small display shows your input

d This button is not in use because we do not need minus values.
e This button confirms your input and closes the input box.
f This button deletes wrong inputs.
g. Numerical buttons 0-9 for entering numerical data

11.2 Example 1 for 3:1 pitch (Standard A4 book)

Now we want to bind a book in A4 size with a thickness of about 6,5mm. In this case you can use a 3:1
pitch RENZ Ring Wire with a diameter of 5/16”. Normally for A4 size you need 34 loops. As for this we
want to program 34 loops with 3:1 pitch.

The numeric fields are fulfilling the following functions.

c Distance from the knife to the first loop.
d No. of loops for the first loop section
e Distance between the 1st and the 2nd loop section (for
calendar hangers).
f No. of loops for the second loop section
g Distance between the and the 3rd loop section (skip
binding).
h No. of loops for the 3rd loop section.
i Distance between the 3rd and the section (skip-binding).
j No. of loops for the loop section.
k Distance between the 4th and the 5th loop section (skip-
binding).
l No. of loops for the 5th loop section (and so on)

The 2nd row of numerical fields is for additional skip elements. In sum you can set a
maximum of 10 skip elements.
Information
 AB500HS Handling of the touch-screen-display page

1. Switch on the AB500HS

2. After the starting screen appears please push the „Next“
button. Now you are in the set up screen.
3. Push the first numberc at the left side. The input box appears.
4. Type in 3. The value appears in the small input box screeng.
This is the distance from the knife to the first loop section.
Confirm the value by pushing the Enterf button. The input
box closes and the value appears in the first fieldc.
5. Push the second numberd. Again the input box appears.
6. Type in 34 for the first number of loops. Confirm the value by
pushing the Enterf button. The input box closes and the
value appears in the second fieldd.

• In regular cases the distance from the knife to the first loop section is 3 for 3:1 pitch. For
2:1 the value is 2. These values could be increased but not decreased.
Information

• With the button e you can delete wrong inputs.

• If you type in 0 for the first value (distance from the knife to the first loop section) the
AB500HS will not feed in loops.
Information

7. Push the pitch buttonh and set the value 3 (for 3:1 pitch).
Confirm the value by pushing the “ENT” button. The input box
closes and the value appears in the field for the pitch.

8. Push one of the key buttonsi for switching off/on the KAS
unit (optional equipment). The display shows “1 long”, “1
short” and “Off”. We change the value to “Off”, because we do
not need a KAS unit.
 AB500HS Handling of the touch-screen-display page

9. By pushing the feeding speed valuej the input box opens

and you can set the feeding speed. Out of our experience
the most reliable speed is 100%. You can increase the
speed to a maximum of 130% (if you have no problems).
The minimum speed is 10% (you can decrease the speed it
if you have feeding problems). Please set your value in the
input box and confirm with the “ENT” key.
10. The programming for example 1 is now finished. Your
screen must show the same inputs like the sketch at the
right side.
11. Push the „Next“ button. The reference run starts. The
main menu appears after the reference run has finished.

• The button „Clamping“ usually is in pos. “Clamped”. If you set this button to „Open“ the
clamping opens during the binding. Out of our experience in 99% of all the cases it does
not affect the binding result positively.
Information

• If you set prohibited values the display shows an error message (for example if you want
to set the feeding speed to 180% or the pitch to 6:1).
Information

11.3 Example 2 for 3:1 pitch (with calendar hanger)

Now we want to bind a calendar in A4 size with a thickness of about 3,0mm. In this case you can use a
3:1 pitch RENZ Ring Wire with a diameter of 1/4”. For this case we have to program 15 loops at the left
side, 3 loops free for the calendar hanger and 15 loops at the right side.

1. Switch on the AB500HS

2. After the starting screen appears please push the „next“
button. Now you are in the set up screen.
3. Push the 1st numberc at the left side. The input box
appears.
4. Type in 3. This is the distance from the knife to the first loop
section. Confirm the value by pushing the Enterh button.
The input box closes and the value appears in the 1st
fieldc.
 AB500HS Handling of the touch-screen-display page

5. Push the 2nd numberd and type in 15 for the first number of loops. Confirm the value by pushing the
Enterh button. The input box closes and the value appears in the 2nd fieldd.
6. Push the 3rd numbere and type in 3 for (it is the distance for the calendar hanger) the space between
the loop sections. Confirm the value by pushing the Enterh button. The input box closes and the value
appears in the 3rd fielde.
7. Push the 4th numberf and type in 15 for the second loop sections. Confirm the value by pushing the
Enterh button. The input box closes and the value appears in the 4th fieldf.

• With the button i you can delete wrong inputs.

• If you type in 0 for the 1st value (distance from the knife to the first loop section) the
AB500HS does not work.
Information

8. Push the pitch buttonh and type in 3. Confirm the value by

pushing the “ENT” button. The input box closes and the
value appears in the pitch field.

The change of the pitch is only necessary if it is

not set to your desired value.
Information

9. Push one of the key buttonsj . The valuei will be shown

at the screen. Changing from “1 short” to “1 long” and then
to “Off” by each touch.
10. Switch on the KAS unit by setting the value to “1 short” or
"1 long" (Please find the differences in the KAS modes
directly in the information below).
11. The programming for example 2 is now finished. The
screen must show the same as the sketch at the right side.
12. Push the „next“ button. The reference run starts. The main
menu appears after the reference run has finished.

• “1 short” is for short calendar hangers up to 250mm. This value covers about 98% of all
calendars.
• “1 long” is for calendar hangers with a length of more than 250mm and/or with critical kind
Information of paper.

The clamping must be set to „Closed“ when you work with a calendar hanger unit. If
you work in “Open” condition the slider of the KAS unit will be damaged.
Caution
 AB500HS Handling of the touch-screen-display page

11.4 Example 3 for 3:1 pitch (skip binding)

• The AB500HS permits to bind skip bindings. By means you can bind your book with
several short Ring Wire elements. The maximum of skip elements is 10.
• The distance between the elements could be also 0 by means there is no space between
the elements. A value of 0 for the first numeric field (distance from the knife to the first
Information loop section) is not possible.

Now we want to bind a book in A4 size with a thickness of about 8,5mm. In this case you can use a 3:1
pitch RENZ Ring Wire with a diameter of 7/16”. We want to divide the book into 5 binding elements by
means we need 5 elements with 4 loops and 4 times space with value 3. Because of the longer distance
of the loops to the paper edge we need a value of 4 for the distance to the knife.

1. Switch on the AB500HS

2. After the starting screen appears please push the „next“
button. Now you are in the set up screen.
3. Push the 1st numberc at the left side. The input box
appears. Type in 4. This is the distance from the knife to
the 1st loop section. Confirm the value by pushing the
“ENT” button. The input box closes and the value appears
in the 1st fieldc.
4. Push the 2nd numberd and type in 4 for the 1st number of
loops. Confirm the value by pushing the “ENT” button. The
input box closes and the value appears in the 2nd fieldd.

• 3:1 elements with less than 4 loops do not work.

• 2:1 elements with less than 3 loops do not work.
• A value of "0" for the first numeric field (distance from the knife to the first loop section) is
Information not possible.

5. Push the 3rd numbere and type in 3 for the 1st space. Confirm the value by pushing the “ENT” button.
The input box closes and the value appears in the 3rd field.
6. The display should show the same information as the sketch beside.
7. Push the 4th numberf and type in 4 for the 2nd number of loops. Confirm the value by pushing the
“ENT” button. The input box closes and the value appears in the 4th fieldf
8. Please enter all data up to the 10th numeric field (g-l).

• The change of the pitch is only necessary if it is not set to the desired value (the
procedure how to change is described in the programming example 1).
• The change of the hanger setting is only necessary if it is not set to the desired value (the
Information procedure how to change is described in the programming example 1).
 AB500HS Changing of the RING WIRE spool page

9. The programming for example 3 is now finished. The

display should show the same information as the sketch
at the right side.
10. Push the „Next“ button. The reference run starts. The
main menu appears after the reference run has finished.

11.5 Programming for 2:1 pitch

The programming for the 2:1 pitch is similar to the programming of the 3:1 pitch.
Please proceed the same way as described in the examples before.
Information

12 Changing of the RING WIRE spool

• Remove the spool clamping devicee and the springd by opening the
orange clamping leverc.
• Pull off the empty spoolf and slide a new one onto the shaft.
• Slide the pressure spring onto the shaft. Then slide the spool clamp
onto the shaft until it applies pressure on the spring. Tighten the spool
clamp.

The spring is under pressure. If you open the clamping lever the spring and the
clamping device possibly jumps off the shaft. It could hurt you or your colleagues.
Please take care when you release clamping lever.
Danger

The change of the Paper winding spool (lower spool) is similar to the change of the
upper spool. Take care of your safety (see warning above)
Information

• Attach the separation paper stripc onto the paper winding spoold as
shown in sketch 11. Take care for the correct paper guiding to have a
disturbance free running.

Glue the paper strip with a tape onto the lower spools card
board core or onto the paper strip end of the previous
spool.
Information
 AB500HS Adjustment of the binding unit page

13 Adjustment of the binding unit

To adjust the AB500HS you must have all information about the product that you want to
bind:
• Book thickness and the according Ring Wire diameter.
• Binding length (to calculate the no. of loops).
• Pitch (2:1 or 3:1)
Informatio • Ring Wire configuration (no. of loops? skip- binding?)
n • Calendar hanger yes/no.
• Sample of you product for adjusting the AB500HS.

Select the required RING WIRE diameter according to the chart on chapter 8.

13.1 Changing of inlet channel and feeding wheel

13.1.1 Changing of the inlet channel

• Fold the table back like shown on sketch 12 to get

better access to the inlet area.

To be able to change the inlet channel or the feeding wheel you first must remove the
knife device.
Information

• Remove the two fixing screwsc of the knife deviced.

Pull out the knife and lean the device onto the table
frame.
 AB500HS Adjustment of the binding unit page

• Remove the two screwsf, that fixes the inlet channelg.

• If the feeding wheel has not to be changed (in case of
using the same pitch) you can remove the inlet channel
by pulling it downwards out.
• If you have to change the pitch the feeding wheel must
be changed first (see chap. 13.1.2).
• Put in the new inlet channel
• The correct height of the inlet channel is pre-set at the
factory. In any case if you have to correct the height
open the nuts of the two height adjustment screwsh.
Open the two channel fixing screwsf. Turn the two
adjustment screws parallel as long as you reach the
correct height.
• Take care before you tighten the channel fixing
screwsf that both heads of the hexagon height
adjusting screwsh are touching the lower surfacei.

The height of the inlet channel should be in one line with the height of the lower closing
bar to enables the wire an easy access to the closing bar without resistance.
Information

13.1.2 Changing of the feeding wheel and height adjustment of the knife

To change the feeding wheel please proceed as follows:

• Release the clamping screwd of the feeding wheelc.
• Pull the feeding wheel off the shaft.
• Put the new feeding wheel onto the shaft.
• Do not tighten the clamping screw because you must
adjust the feeding wheel later on.
• Assemble the knife device but do not tighten the two fixing
screws.
• Feed in a piece of the according Ring Wire that it will pass
the knife.
• Now adjust the height of the knife as long as you will have
a distance of about 0, 2-0,4mm between the wire and the
matrixe.
• Tighten the two screws for the knife device.

Make sure that the knife is always set to a correct height. A knife that is set to deep will
deform the wire. The in-feed of the wire will be very choppy if the knife is set to high.
Informatio
n
 AB500HS Adjustment of the binding unit page

13.1.3 Changing of the closing bar

To change the closing bars proceed as following:

• Fold the table back like shown on sketch 12 to get better access to the inlet area.
• Remove the two screwsc at the upper closing bar and remove the closing bar.
• Remove the three screwsd of the lower closing bar.
• Remove the two screwse at the left bushf and the right eccentric bushg.
• Remove the lower closing bar together with the two bushes.

The left bush and the right eccentric bush are in use for all closing bars. You only have one
set delivered with the machine. Take care that you will not lose one ore damage one of
these bushes.
Information

• Put the left bush into the lower closing bar. Put the closing bar with the bush onto the pressure bar of
the AB500HS.
• Lift the closing bar at the left and put the eccentric bush into the according hole. Turn the eccentric
bush into the highest position.
• Screw in the two screwse for the bushes and the three fixing screwsd but do not tighten them.
• Now turn the eccentric bush as long as the stop angleh touches the pressure bar.
• Now you can tighten all the screws (5x).

To fix the left bush and the right eccentric bush only use screws with a dimension of
M6x25. If you use shorter screws you will damage the thread. If you use longer
screws you will press against the slide bearings and as for this you may destroy
them.
Caution

• Now you can put in the upper closing bar and tighten the two screwsc.
 AB500HS Adjustment of the binding unit page

13.1.4 Adjusting the opening limitation

• The opening limitation enables you to set the distance between the lower and the upper
closing bar. The goal is to adjust the distance like there is not too much or to less space.
Therefore you can adjust the stopping position of the lower closing bar with the hand
Information wheel for the opening limitation.
The distance of the closing bars must be adjusted in dependence
to the used Ring Wire diameter. In normal operation the closing
cylinder presses against the adjusting spindle by means you can
not turn it by hand. Please proceed as following:
• Change into “Manual operation” (touch screen) and activate
the “Closing” button. The closing bar moves up and the spindle
is free of pressure.
• Now you can open the clamping nutd and turn the wheelc to
get a proper distance between the closing bars (for easier
opening of the nut you can put a rod or something else into the
holese at the circumference).
• Turning clockwise = less distance
• Turning counter clockwise = more distance
• Set the distance to a measure that the Ring Wire does not
clamp during the feeding in, but as close as possible (if it is set
to far the Wire will tilt).

13.1.5 Adjusting the closing limitation

• The closing limitation limits the way of the lower closing bar. The upper position of the
pressure bar decides on how far the wire will be closed. The adjustment is infinitely
variable.
Information

• Feed a new wire element into the closing bar (Manual

operation „New loops“ (see chapter 11.1.5).
• Close the loops in manual operation
• Check the binding.
• To adjust the closing limitation, please release the clamping
screwc and turn the knobd.
• turning counterclockwise = less closing
• turning anticlockwise = more closing

• Your closing result is ok if it is like shown at picturec

• If your result is like shown at pictured the loops are not closed
enough. Please adjust like above mentioned.
• If your result is like shown at picturee the loops are closed to
much. Please adjust like above mentioned.

The adjustment of the closing limitation without paper

is only an approx. adjustment. If you close with paper
normally you must correct the adjustment.
Information
 AB500HS Adjustment of the binding unit page

13.2 Binding table adjustments

With the various table adjustments you set your product according to the loops in the
closing bar.
Information

13.2.1 Paper clamping rail

• According to the wire diameter you must adjust the height of the paper clamping rail to
provide enough space for moving the product below the clamping rail.
• The height must be set on left as well as on the right side.
Information

13.2.1.1 Adjustment of the left side

• Folder the table upwards.
• Release the clamping screwd of the grooved nute and
turn it out by 5 rotations.
• Move the complete device (grooved nut, cylinder etc.)
upwards/downwards as long as you reach the correct
height of the clamping railc according to your product.
• Clamp the grooved nute by tightening the screwd.
• The distance of the table surface and the lower side of the
clamping rail according to the grooved nut position is
approx.:
1st groovef (top view) approx. 14mm
2nd grooveg approx. 20mm
3rd grooveh approx. 26mm
4th groovei approx. 32mm
13.2.1.2 Adjustment of the right side

• Release the two screwsc for the cylinder mounting angle.

• Move the cylinderd up-/downwards as long as you has
reached the correct height. If the long holes are not long
enough, please remove the screws and use the other
threads of the mounting angle to get the correct height of
the clamping raile.
• Tighten the screws.

• When you tighten the clamping screw please take care that the peak of the
screw is in the groove. Otherwise you will destroy the outer diameter of the
grooved nut and it will not be moveable any more.
• If you work with calendar hanger unit (KAS) the grooved nut must be set into the
lowest position. If not the clamping rail will hit the KAS unit within each closing
cycle and possibly damages it.
Caution • Set both grooved nuts always to the same height. The clamping rail should be
parallel to the table surface. If the grooved nuts are set to a different height you
may destroy the pneumatic cylinders and your product is not clamped properly.
 AB500HS Adjustment of the binding unit page

13.2.2 Side stops

13.2.2.1 Adjustment of the paper side stops

The side stops are fixing the product at the binding table according to the provided loops in
the closing bar.
Information

• If you work with products that has a long binding length and a short unbound length it is
enough to use the front side stop.
• If you work with a short binding length but a long unbound length we recommend to use
Information both side stops for quick and precise handling.

• Put your producte onto the front stop anglef and move
it to the left against the side stopsc.
• Go to „manual operation“ and use step by step the
following functions.
1. „Clamping“ on
2. „Front stop“ on
3. „Table “ on
• Check if the loops are in the center of the perforation or
not. If not please correct the position by adjusting the
side stops. Open the clamping screwsd and move the
side stopsc as long as your loops are in the center of the
perforation.

13.2.2.2 Installation and adjustment of the loop side stop

If you have problems with a varying pitch (if the pitch is sometimes too long) please use
the loop side stop. Wire that is too short in pitch, could not be used with the
Autobind500HS
Information

To avoid damages at the closing bars or the loop side stop, we recommend to use
the loop side stop not with diameter smaller than 7/16".
Caution

• Feed the sheet metal of the loop stope

between the closing bars.
• Snap the guiding of the loop stop to the
tool holding railc.
• Move the loop stop against the end of the
loop section as long as the pitch
corresponds to your perforation. Then
close the knurled clamping screwd.
• Now the loops will be fixed in a defined
position.
 AB500HS Adjustment of the binding unit page

13.2.3 Table height

Dependent to the wire diameter that is used the height of the table must be adjusted to get
the paper between the closing bars.
Information

• Put your product onto the table and move it to the front stop
and the side stop.
• Activate (in “Manual operation) the following functions:
1. „Clamping“ on
2. „Front stop“ on
3. „Table“ on
• Release the clamping nutd of the height adjustment.
• Turn the hand wheelc as long as the lower surface of your
product is closed to the lower holding railf (distance approx.
0,2-0,5mm).
• Tighten the clamping nut after the adjustment.

For an easy release of the clamping nutd you can

put a rod in one of the holese around the
circumference of the nut.
Information

13.2.4 Front stop position of the table

Dependent to the wire diameter that is used you have to adjust the front stop position of the
table. This position enables the wire to slide through the perforation of the product without
resistance.
Information
• Put your product onto the table and move it to the front stop
and the side stop.
• Activate (in “Manual operation) the following functions:
1. „Clamping“ on
2. „Front stop“ on
• 3. „Table“ on
• The perforation is now above the wire.
• To set the correct front stop position please release the
clamping nutd.
• Turn the screwc clockwise or counter-clockwise to move
the table to the correct position.
• turning clockwise => table pos. moves forward
• turning counter-clockwise => table pos. moves backward
• Adjust the table as long as the peaks of the wire are in the
center of the perforation.
 AB500HS Adjustment of the binding unit page

• Sketchc shows a correct adjusted front stop position.

• Sketchd shows a front stop position that is to far to
the rear. Turn the screw counterclockwise as long as
you reach a result as shown in sketchc.
• Sketche shows a front stop position that is to far to
the front. Turn the screw anticlockwise as long as you
reach a result as shown in sketchc.

13.2.5 Adjustments in the automatic mode display

feeding speed ¾ This value is for adusting the speed of the
wire feeding. The settable range is from 10-
130%. The bigger the diameter the lower
the speed.
clamping ¾ Usually the clamping is closed. If the
clamping is set to "open" it will release the
product during the closing procedure. You
can try the "open" position if you have thick
products and your binding quality is not ok.
counter ¾ If you press the counter button the value will
be set automatically to "0".
pushing belt on ¾ If you want to deactivate the belts on the
table please push the button and the belts
will be switched off.
delivery belt ¾ Drücken Sie auf das Feld für das
Förderband (optional) um die Zeitspanne für
die Bewegung des Bandes pro Bindezyklus
ein zu stellen.
 AB500HS Adjustment of the binding unit page

13.2.6 Ajust the output section

13.2.6.1 Adjust the conveyor (shingle) belt (CB120HS)

Please adjust the height of the conveyor only with a minimum of two persons. If you
release the clamping levers the upper part of the conveyor immediately starts falling
down and possibly hurts you.
Danger

To adjust the conveyor belt please proceed as following:

• Place the belt beside the AB500HS. The Table edgec and the guiding raild should be in one line.
The distance between the conveyor belt and the AB500HS table should be approx. 0,5 - 1cm.
• Now set the height of the CB120HS. Release the clamping leversj and move the belt down or lift it
up as long as the guiding rail is about 0,5 - 1cm below the tablek surface. Set the rear of the
CB120HS by the same way.
• Place your producti onto the CB120HS. Move the rear stop angleh to the product with a distance of
approx. 1- 2cm. The position of the angle is fixed by a magnet and is simply adjustable.
• Set the left edge of the left angle in one line to the left edge of the CB120HS. The position of this
angle will be held by magnet as well.
• Adjust the right side stopsf+g ein. Release the two clamping screws and move the side stops as
long as there is a space of about 1-2cm between the product and the side stops.
• Check your adjustments and correct if necessary.
 AB500HS Trouble shooting AB500HS page

13.2.6.2 Adjustment of the simple output tray (optional)

• Place the output tray beside the AB500HS. The right

sidef of the tray should be in one line with the front
stop angle of the AB500HS table.
• Release the lower clamping leverc and move the tray
down- or upwards.
• Release the upper clamping leverd to adjust the
desired gradient of the tray.
• Move the side stop angle e to a position according to
your product. The position of the angle is held by a
magnet.
• Check your adjustments and correct if necessary.

Be careful when you adjust the height of the tray. If you release the clamping lever
for the height or the gradient the tray immediately starts falling down or tilting and
possibly hurts you. First hold the tray tight before you open one of the clamping
levers.
Danger

After all adjustments have been done can start your production.

Information

14 Trouble shooting AB500HS

Error Reason Remedy
display shows: 1. Pressure setting at the air 1. Increase pressure adjustment
“air pressure too low” maintenance unit is too
low.
2. Compressed air not 2. Connect air supply.
connected.
3. Supplying hose too long or 3. Check length and thickness of the supplying
too thin which leads to a hose and change if necessary.
decrease of pressure.
display shows: 1. Shaft magazine is empty. 1. Fill up shaft magazine.
“empty shaft magazine“ 2. Connector at the KAS 300 2. Plug in connector.
is not plugged in.
3. KAS is activated at the 3. Deactivate the KAS function at your display.
touch screen but not in use.
RING WIRE element is not Closing limit is not correctly Turn the manual wheel for the closing limit
entirely closed. adjusted. counter-clockwise.
RING WIRE element is closed Closing limit is not correctly Turn the manual wheel for the closing limit
too much. adjusted. clockwise.
RING WIRE is not evenly Closing bars are not adjusted Loosen the clamp screws on the lower closing
closed. parallel. bar and adjust the closing bar eccentric.
RING WIRE are twisted after 1. Closing bars are adjusted 1. Turn the adjusting wheel for the closing limits
the binding. too close. counter-clockwise.
2. Side stop of the table is
not correctly adjusted. 2. Readjust the side stop.
3. Stop for loops with a large 3. Correct the loop stop.
diameter is not adjusted
correctly.
 AB500HS Trouble shooting AB500HS page
Binding is not round. 1. Table does not move far 1. Adjust the table stop (see chapter 13.2.4)
enough to the front. 2. Check the book thickness according to the
Problem 1 2. Book thickness too thick. chart at chapter 0.
Points of the elements stick 3. Perforation is too small. 3. Use perforation according to the chart.
out. 4. The points of the RING 4. Install shim washers behind the upper
WIRE elements are bent closing bar 0.1 mm, 0.2 mm or 0.5 mm
to the outside of the (included in the tool box).
holding rail during
binding.
Binding is not round. 1. Table moves too far 1. Adjust the table stop (see chapter 13.2.4)
forward.
Problem 2 2. Loops are closed too much 2. Turn the manual wheel for the closing limits
Points of the elements are and are pressed to the clockwise.
back. front.
3. Too many washers behind 3. Remove some of the shim washers.
the upper closing bar.
4. Not enough washers 4. Put some washers behind the lower closing
behind the lower closing bar.
bar.
Different shape of the binding 1. Side stops are not 1. Adjust the side stops so that the paper lines
left and right. adjusted at a right-angle up against the angle stop as well as at the
to the angle stop. side stops.
2. The perforation is not 2. Check perforation.
parallel to the paper edge.
3. With smaller formats, the 3. Run an additional book "blind" at the right
upper holding rail is lifted side of the machine.
only at the left side.
Belt on the table does not 1. Belt function is 1. Activate the belt function
move after the binding deactivated
2. Belt speed set to "0" 2. Set the speed of the belt to a higher value
 AB500HS Trouble shooting AB500HS page

Machine starts binding cycle, 1. Sensor for the table front 1. Check the sensor by touching the switch area
the table moves forward but position is defective. with a metallic object. LED X3 at the SPS/PLC
stops suddenly. 2. Sensor for the table front must light. If not, change sensor.
position is disadjusted 2. Correct the sensor position.

Machine starts binding cycle 1. Sensor for the pressure bar 1. Check the sensor by touching the switch area
but stops immediately after is defective. with a metallic object. LED X5 at the SPS/PLC
binding (pressure bar up). 2. Sensor for the pressure bar must light. If not, change sensor.
is disadjusted. 2. Correct the sensor position.
Machine completes a full 1. Sensor for the table rear 1. Check the sensor by touching the switch area
binding cycle but does not position is defective. with a metallic object. LED X4 at the SPS/PLC
release the clamping. 2. Sensor for the table rear must light. If not, change sensor.
position is disadjusted 2. Correct the sensor position.

RING WIRE element is not cut Knife is not centered on the Change to the operation mode "run-in test" and
in the center. wire element. check the position of the knife. Readjust, if
necessary

RING WIRE elements are cut 1. Adjustment of the transport 1. Please check the setting of the transport
with different numbers of wheel is not correct. wheel in the menu "run-in test".
loops. 2. Adjustment of the transport 2. The basic setting of the transport chain is not
chain is not correct. correct. Adjust the transport chain as
RING WIRE elements are following: Change into the "wire feeding
pressed or torn during the run- check" screen. Feed in a few loops and touch
in. 2-3 times the "Start" button. Check the
position of the loops according to the knife
and the feeding wheel by touching the "<=
Chain" or "Chain =>" button. The adjusted
chain position will be saved in the PLC.
3. Height of knife is not 3. Check the height of the knife and correct (see
correct. chapter 13.1.2)
4. Height of inlet channel is 4. Check height of inlet channel and correct (see
not correct. chapter 13.1.1)
The display shows "shaft 1. Connector of the sensor is 1. Plug in the connector at the KAS.
magazine empty" even though not plugged.
there are enough shafts in the 2. Sensor is defective 2. Check the sensor by touching the switch area
magazine. with a metallic object. LED X1 at the SPS/PLC
must light.
3. Position of the sensor or of 3. The shafts must be in the middle behind the
the separation wheel is not sensor with a distance of approx. 0.3 - 0.5
correct. mm. If necessary, tighten the wood brake at
the shaft of the separation wheel.
 AB500HS Trouble shooting AB500HS page

Calendar hangers (CH)are 1. Hanger transported to far 1. Move the CH unit (KAS) backward to get
bended after closing. into the closing bars and more distance to the pins of the transport
hits the pins of the chain.
transport chain. 2. Take a PVC piece with a width of about 10-
2. Sometimes if you are 12mm and prepare it like shown in the sketch
working with 5/16“ the CH below. Glue the PVC-part onto the closing
skips to a vertical position rail (with an adhesive tape). Fix the PVC-part
and will be bended by the centrically to the delivery slider of the KAS-
closing bars. unit. The PVC-part avoids the coming up of
the calendar hanger.

CH is outside of the binding or CH is not moving deep Move the KAS-unit forward to set the CH deeper
the RENZ RING WIRE® enough into the closing bars. into the closing bars.
elements are damaged in the
area of the CH.
CH is outside of the binding at 1. KAS-unit is not fixed 1. Check the position of the KAS-unit and adjust
one side parallel parallel if necessary.
2. Support rails at the 2. Check the two support rails of the delivery
delivery section are section. They must movable easily.
clamping.
Malfunction at the separation Wrong distance between the Adjust the side frames according to the used
wheel. The shafts are not two side frames. The shafts shaft length. (see chapter 15.6)
falling down into the forming are clamping between the
area. side frames.
Malfunction during the hanger 1. CH is not clamped 1. Check the pressure spring of the delivery
delivery into the closing bars correctly in the delivery finger and correct if necessary.
finger.
2. delivery finger moves to 2. Adjust the compressed air throttle to increase
fast or slow or decrease the moving speed of the delivery
cylinder.

If you have problems that are not mentioned above please call your local RENZ Service
(see cover page of this manual)
Information
 AB500HS Calendar hanger tool (KAS)/optional page

15 Calendar hanger tool (KAS)/optional

The KAS unit enables you to bind with calendar hangers. The calendar hangers will be
formed and delivered automatically by the KAS unit.
Information
15.1 Technical data KAS

The max. workable calendar hanger length depends on what KAS unit you ordered. The
min. length, the shape and the wire∅ is the same for each KAS unit (please check the
type plate of your KAS unit for the operatable max. length).
Information
Maximum length of straight wire shaft (KAS300) 308mm = 300mm hanger
Maximum length of straight wire shaft (KAS200) 208mm = 200mm hanger
Minimum length of straight wire shaft (for all KAS units) 88mm = 80mm hanger
Diameter of straight wire shaft 2mm
Shape of calendar hanger AUTOBIND Standard

15.2 Product information KAS unit

c
The RENZ KAS unit is for forming calendar hangers from max. 308 mm down to 88mm
out of straight shafts. After the hangers are formed the KAS unit automatically feeds the
hangers into the closing bars.
Information c max. length depends on KAS unit that you have ordered (see above mentioned table)

15.3 Sequence of operation

• The straight shafts are put into a reservoir of the KAS (up to 1000 pcs.)
• The separation wheel separates the shafts and delivers them to the forming station.
• A sensor is watching for missing shafts.
• The calendar hanger is formed and drops down to the feeding station.
• Now the delivery mechanism feeds the calendar hanger between the closing bars.
• If the binding is finished a new formed calendar hanger is available at the feeding station ready for a
new binding cycle.

15.4 Closing bar protection cover

• Before you assemble the KAS unit please

remove the protection coverc. from the tool
holding raile.
• Release and remove the two hexagon
socket screwsd and take out the protection
cover.

It is not permitted to work

without the protection cover if
the KAS unit is not installed.
Danger
 AB500HS Calendar hanger tool (KAS)/optional page

15.5 Connect the KAS at the AB 500HS

• Put the KAS onto the tool holding railc of the AB500HS. Pull the KAS in directioni as shown
beside. The two „noses“e should fit at the tool holding rail.
• Do not tighten the screws of the clamping anglesd because the side position of the KAS must be
adjusted later on.
• Plug in the pneumatic pipes into the cylinder connectorsf+g. The connectors of the cylinders and
the pipes are marked with a colored tape.
• Plug in the plugh for the recount function for missing shafts.

• Plug in the plug for the recount function always directly after you put the KAS
unit onto the tool holding rail.
• The plug must be connected before you activate the KAS function in the
display. This avoids wrong recognition of missing shafts.
Caution

Be careful when you put the KAS unit onto the AB500HS. The KAS unit has a
weight of about 30-35kg. Please do this work always with two people.
Danger
 AB500HS Calendar hanger tool (KAS)/optional page

15.6 Set the KAS to different shaft lengths

You can set the KAS unit to different shaft lengths from 88mm up to the maximum
(depending onto KAS you ordered). After the shaft is formed to a calendar hanger the
length is about 8mm shorter.
Information
• Open the four clamping screwsd of the side
framesg.
• Move both side frames to a value
(according to the scaleh) half of the desired
shaft length plus 1mm (example: shaft 158;
set to each side frame to 80). Refer to the
inside edge of the side frames according to
the scale.
• Open the clamping screwsi of the support
wheelsc and move them as close as
possible to the side framesg.
• Tighten the two screws slightly.
• The additional support railse are only
necessary of you work with shafts longer
than 158mm. You can „store“ the rails at the
very left and right side on the shafts.
Therefore open the clamping screwsj and
pull them backwards out of the shafts.
• If you work with shafts longer than 158mm
move the support rails to a centered
position between the separation wheelf
and the support wheelsc.
• Now put a shaft into the reservoir. The shaft
must have a space to the side frame of
about 1-2mm. Correct if necessary.

The width of the side frames must be always adjusted 1-2mm bigger than the shaft
length. If you set the side frames to close to the wire it is possible that the shaft
clamps on its way down to the forming station. If this happens possibly the forming
station will be damaged.
Caution

Always switch off the pneumatic valve if you adjust the shaft length (see chapter
15.9). Never ever put your hands, fingers or anything else into the forming area of
the KAS unit. If the cylinder moves forwards or backwards it will cause heavy
injury.
Danger
 AB500HS Calendar hanger tool (KAS)/optional page

15.7 Adjustment of the KAS unit according to your product

Before you adjust the KAS unit to your product the AB700 must be adjusted. Make sure
that the AB700 closes in good quality without KAS unit.
Information

The KAS unit now must be adjusted to a centered position according to the thumb cut of
your product.
Information
• Switch off the air supply for the KAS unit (chapter 0)
• Change into the “Manual operation” menu.
• Put your product onto the table.
• Activate “clamping” and “front stop” function.
• Activate the “table” function.
• Push the slider of the KAS unit forward (by pushing
to the two railsc) until it reaches his end position
(empty slider without calendar hanger).
• Now you can look forward to the closing bar. Move
the whole KAS unit sideward as long as the slider
finger is exactly in the center of the thumb cut of your
product.
• If you have reached the perfect position tighten the
screwse of the clamping anglesd at both sides.
15.8 Adjustment of the slider inclination

Depending on the diameter you use the inclination of the slider must be corrected.

Information

• The upper surface of the sliderc should have a distance of about

0,2-0,4mm to the slope of the upper raile.
• If you lift up the upper rail with the slider, it is set to high. Open
the two clamping screws (No.f at sketch 30) on each side and
lift the complete slider mechanism down. Tighten the clamping
screws.
• The straight part of the calendar hanger should be closed to the
paper edge. If the calendar hanger is too deep or not deep
enough in between the closing bars you must move the whole
KAS unit forward or backwards. If you readjust the depth of the
calendar hanger position you have to check again the slider
height according to the upper rail (like above mentioned).

It is essential to set the slider into a correct height. If the slider is not adjusted
properly you will possibly damage the slider mechanism and the upper rail of the
closing bar.
Caution

The slider speed could be adjusted with the two compressed air throttles directly at the
connectors of the cylinder (see sketch 28 no.f). Use a screwdriver to adjust the throttles.
Turning counterclockwise increases the speed, turning anticlockwise decreases the speed.
Information
 AB500HS Calendar hanger tool (KAS)/optional page

15.9 Supply the KAS unit with compressed air

You can switch off the KAS from the compressed air supply by a turning valve.

Information

• Open the sheet metal cover at the right side of your

machine.
• Push the blue turning knobc down (to unlock) and
turn it.
• Now the KAS unit is supplied with compressed air.

• turning clockwise = Valve is open

• turning counter clockwise = Valve is closed

Never ever put your hands, fingers or anything else into the forming area of
the KAS unit. If the cylinder moves forwards or backwards it will cause
heavy injury.
Danger

Make sure that your pneumatic pipes are fixed properly in the connector. If
you supply the pipes with compressed and they are not plugged in
properly you can hurt you and your colleagues.
Danger
 AB500HS Calendar hanger tool (KAS)/optional page

15.10 Trouble shooting KAS unit

Error: Reason: Remedy:
KAS does not work 1. manual valve not activated. 1. Switch on air pressure for KAS with
2. Calendar function is not set manual valve (see chapter 0).
at the display. 2. Set the calendar function in the “set up”
menue.

Calendar hangers are not bent 1. Air pressure is too low. 3. Check if the capacity of the compressor is
evenly. 2. Compression springs are sufficient. Control pressure setting and
broken. correct, if necessary.
4. check the bending area of the KAS unit
for broken compression springs. Change
if necessary (for more information contact
your local dealer).

Calendar hanger is not in the slider unit not centered to the adjust the KAS unit to a correct position
closing at both sides thumb cut

Slide of the KAS hits the paper table height is too high correct the table height (see chapter 13.2.3
clamping rail

closing result without KAS unit 1. slider unit is not centered to 1. adjust the KAS unit to a correct position
better than with the thumb cut. (see chapter 0).
2. table is set to high 2. adjust the table as deep as the lowest
3. delivery slider is to high it paper sheet is very close to the moveable
hits the moveable rail of the rail of the lower closing bar (see chapter
upper closing bar 13.2.3).
4. front stop position of the 3. correct the inclination of the delivery slider
table is not correct (too far (see chapter 15.8).
to the front) 4. correct the table as long as your closing
result is o.k. (see chapter 13.2.4).

All adjustments are correct but the Delivery cylinder is bent. Change the cylinder for the delivery of the
slider does not move forwards calendar hanger.

If you have problems that are not above mentioned please call your local RENZ Service
(see cover page of this manual)
Information
 AB500HS Maintenance page

16 Maintenance

The Autobind needs only little maintenance. Please find the maintenance work listed below.

Hinweis

16.1 Regular maintenance work

• Clean the transport chain (for the loop feeding) every 6 months and put teflon- or oil-free PTFE chain
care on it.
• Check the chain for tension monthly within the first half year. Later on it is enough to check it every 6
months. If necessary tension the chain.
• Grease the gears of the main drive once a month if you work in one shift. If you operate the machine
in two shifts please grease it every two weeks.
• Clean the table and the visible surfaces of the machine every day from dust.
• Remove the wire waste every day, for example calendar hangers underneath the table..
• Disassemble the closing bars and clean them from paper dust and or small markings once a month.
• Clean the transport belts at the table daily. Remove paper and wire waste directly.
• Clean the water separator of the pneumatic maintenance unit every 2 months. Use warm, clean
water free of cleaning agents.

• Too much tension to the chain will cause trouble with the stepping motor.
• Never oil or grease any part of the closing bars. The oil will absorb the dust and
effects like a glue. The reliability of the closing results will decrease
dramatically.
Caution

Repair and maintenance work on at the machine may only be carried out by a
trained and skilled personnel! Failure to observe this instruction could endanger
your health or damage the machine.
Caution/
Danger
 AB500HS For your notes page

17 For your notes

AB500HS For your notes page
AB500HS For your notes page