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Instruction Manual

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CHALLENGE

CMT 130

BOOK TRIMMER

Summary of Contents for CMT 130

Page 1: ...Instruction Manual Provided By http www MyBinding com http www MyBindingBlog com CHALLENGE CMT 130 BOOK TRIMMER ...

Page 2: ...CHINERY COMPANY CMT 130 Book Trimmer Installation and Operator s Manual The Challenge Machinery Company 6125 Norton Center Drive Norton Shores MI 49441 USA ChallengeMachinery com SERIAL No _____________ F 013 NOV 2009 ...

Page 3: ...ffect the warranty offered by Challenge with respect to such equipment If the customer services this equipment modules components or parts thereof the customer releases Challenge from any and all liability for the customer actions and the customer agrees to in demnify defend and hold Challenge harm less from any third party claims which arise directly or indirectly from such service Prepared by Th...

Page 4: ... 2 7 2 6 Air Hookup 2 9 2 7 Cleaning 2 9 3 Operator s Guide 3 1 3 1 Programming 3 2 3 2 User Interface Map 3 5 3 3 Power Up 3 6 3 4 Improper Wiring 3 6 3 5 Run Mode 3 6 3 6 Job Mode 3 7 3 7 Status Messages 3 10 3 8 Example Job 3 13 3 9 Serial Communication 3 15 4 Routine Tasks 4 1 4 1 Under Book Air Blast 4 2 4 2 Waste Bin 4 2 4 3 Cut Stick 4 2 4 4 Knife 4 3 4 5 Check Pressure Switch 4 6 4 6 Safet...

Page 5: ...11 09 CMT 130 Book Trimmer iv Notes ...

Page 6: ...d Accessories 1 6 1 6 3 Optional Items 1 7 1 6 4 Consumables 1 7 1 7 Specifications 1 8 1 7 1 Book Size Chart 1 9 1 8 General Locations 1 10 1 9 Exit Conveyor 1 11 1 9 1 Advanced In Feed Conveyor 1 12 1 9 2 Elevator 1 13 1 9 3 Site Specifications 1 14 Introduction The introduction section of this manual is in tended to provide installers and operators with basic information Safety recommendations ...

Page 7: ... MACHINERY COMPANY in order for the war ranty to be issued for this machine RECORD YOUR MACHINE SERIAL NUMBER in the space provided on the front cover of this manual Fill in the warranty card accompanying this manual and return it DIRECTLY TO CHAL LENGE The letters in the following diagram correspond to the accuracy adjustment values listed in the Installation Information table at the right A_____...

Page 8: ...nance procedure practice or condition that if not strictly observed could re sult in damage to or destruction of equipment Note Definition Note A regular note indicates an operating or maintenance procedure practice or condition that is necessary to ac complish a task efficiently 1 4 Safety Before installing or operating any equipment it is important to take precautions Read and thoroughly underst...

Page 9: ...in the specifications on page 1 8 Make sure all applicable accessories are securely bolted to the main ma chine Tip hazards may result from un secured accessories If the machine operates abnormally consult a Challenge authorized service agent 1 5 Power Lockout Procedure For maximum safety while making ADJUST MENTS or REPAIRS to your machine lock out the main power disconnect switch The switch shou...

Page 10: ... that may have been ordered with it Part Number Description Qty CMC 130 CMT 130 Base Machine 1 Accessory Options Stand Alone Options 58500 Book Pile Feeder shown above 1 58000 Vertical Stacker shown above 1 59200 CMT 130 Manual In feed small not shown 1 56413 Hand Feed Conveyor large not shown 1 56420 Exit Conveyor not shown 1 In line Option not shown 56600 Tilt In feed Conveyor 1 56421 Cooling El...

Page 11: ...contains pre installed stan dard accessories for the CMT 130 Item Part Number Description Qty 1 5064 Cut Stick Puller 1 2 41058 Waste Bin 1 3 59050 Cut Stick 3 4 59051 2 DMD 5X Knife 2 5 59070 Knife Lifter Assembly 1 6 H 6910 606 Knife Screw 3 8 16 X BHC 7 7 W 180 7 32 T Handle Hex Wrench 1 ...

Page 12: ...ife 1 30 000 40 000 cuts 59050 Cut Stick 1 rot 1000 change 8000 cuts The following consumables are found in Oil Change Kit K 56040 Part Description Qty Frequency 56041 Filter Element Air 1 1 yr H 227 1 Filter Element Oil 1 1 yr S 1991 3 Grade 46 Hydraulic Fluid 1 1 yr 1 6 3 Optional Items The following items are optional or maintenance kits 59051 High Speed Steel Knife 59051 1 Tungsten Carbide Kni...

Page 13: ...tart book 13 spine x 9 5 in 330 spine x 241 mm Min start book bottom cover 7 spine x 6 75 in 177 8 spine x 171 4 mm Min start book w feeder 7 spine x 6 75 in single book mode 7 x 7 in multi book mode 177 8 spine x 171 4 mm 177 8 x 177 8mm Min finish book 5 82 spine x 4 in 147 8 spine x 101 6 mm Max trim Top 6 in 152 mm Max trim Bottom 3 5 in 89 mm Max trim Face 5 5 in 140 mm Minimum trim all sides...

Page 14: ...d form of a book that does not include the cover It contains all front and end matter as well as the text block Untrimmed book An untrimmed book is a book block that has been bound with a cover but has not yet been trimmed to finish size Trimmed book A trimmed book has been bound and trimmed to a finish size Figure 1 2 Book Size Charts can be used to determine if a specific book layout can be trim...

Page 15: ...ns Become familiar with general machine loca tions This manual frequently refers to these locations In order to understand the instruc tions presented it is necessary to have a work ing knowledge of machine locations Figure 1 3 Left Rear View Figure 1 4 Right Front View ...

Page 16: ...11 09 CMT 130 Book Trimmer 1 11 Exit Conveyor 1 9 Exit Conveyor Part Number 56420 Important locations are shown in Figure 1 5 Figure 1 5 Exit Conveyor Locations ...

Page 17: ...11 09 CMT 130 Book Trimmer 1 12 Exit Conveyor 1 9 1 Advanced In Feed Conveyor Part No 56600 Important locations are shown in Figure 1 6 Figure 1 6 Advanced In Feed Conveyor ...

Page 18: ...11 09 CMT 130 Book Trimmer 1 13 Exit Conveyor 1 9 2 Elevator Part Number 56421 Important locations are shown in Figure 1 7 Figure 1 7 Elevator Locations ...

Page 19: ...n automated transport of books from a binder to the trimmer is required and book size changes are frequent It includes the CMT 130 base machine the Ad vanced Infeed Conveyor the Elevator and the Vertical Stacker See Figure 1 8 for space re quirements If the basic Exit Conveyor is used in place of the Book Stacker use 47 120 cm in place of the 18 shown in the diagram If the standard hand feeder is ...

Page 20: ...equirements If the basic Exit Conveyor is used in place of the Book Stacker use 47 120 cm in place of the 18 shown in the diagram If the standard hand feeder is used in place of the Pile Feeder use 16 41cm in place of the 22 shown in the diagram Note the locations of the air and power hook up locations Air and power lines should be dropped from the ceiling in order to have clear access to the wast...

Page 21: ...11 09 CMT 130 Book Trimmer 1 16 Exit Conveyor Notes ...

Page 22: ... Feed Exit Options 2 3 2 4 1 In Line Options 2 3 2 4 2 Stand Alone Options 2 6 2 5 Power Hookup 2 7 2 5 1 Power Hookup Procedure 2 7 2 6 Air Hookup 2 9 2 7 Cleaning 2 9 Introduction The installation guide provides information and instructions essential to the proper setup of each of the CMT 130 and its accessory options 2 Installation Guide ...

Page 23: ...move the lag screws from the two front locations shown in Figure 2 1 3 Open the rear door 4 Remove the two lag screws from the two rear locations shown in Figure 2 1 5 Close the rear door Use a forklift to remove the machine from the skid and place it as close as possible to its in stallation location The machine has accessory power cables and air hoses wrapped up and placed inside the machine Be ...

Page 24: ...he floor Adjust the leveling pads as nec essary Figure 2 4 Height Adjustment 2 The Advanced In Feed Conveyor is set in front of the binder such that adjust able portion of the conveyor is centered on the exit chute of the binder 3 The adjustable portion should be set to the height of the bottom of the binder s exit chute After adjusting the legs lock into place with jam nuts Figure 2 5 Adjustment ...

Page 25: ...chine by adjusting the leveling pads Keep the final table height at 36 6 Open the rear doors and repeat step 4 on the rear end of the machine 7 Check the front end of the machine with the level to make sure the front is still level Adjust as necessary 8 Lock all 4 leveling pads in place by tightening the jam nuts against the in side of the machine s base as in Figure 2 9 The nuts are accessed from...

Page 26: ...amp 59093 2 4 1 5 Exit Conveyor Optional Accessory Before proceeding go to Section 2 5 Power Hookup on page 2 7 Main power must be con nected to the machine before proceeding 1 Make sure the exit conveyor s leveling pads are set to 33 7 8 as shown in Figure 2 12 Adjust as necessary Figure 2 12 Exit Conveyor Leveling 2 Move the exit conveyor to the right hand side of the as shown in Figure 2 13 Fig...

Page 27: ...abel adjacent to it Exit Conveyor 1 Unwrap the cable labeled Exit Con veyor 2 Route the cable under the power panel enclosure and out the right hand side of the trimmer base 3 Connect the cable to the socket on the backside of exit conveyor Lock into place by threading the connector collar onto the socket 2 4 2 Stand Alone Options This option uses the hand feed conveyor and exit conveyor options t...

Page 28: ... socket Exit Conveyor To install the exit conveyor follow the instruc tions in section 2 4 2 5 Hookup Accessory Ca bles Exit Conveyor on page 2 6 2 5 Power Hookup This section describes how to hookup main power to the CMT 130 An adequate power supply must be provided to the machine See section 1 7 Specifications on page 1 8 for power requirements It should be on its own circuit with a lockable dis...

Page 29: ...e 2 21 on the main power terminal block 8 Replace all covers Make sure the shop air hose in connected to the ma chine and shop air is switched on Switch the main air disconnect valve to the on I position at the left rear corner of the machine See Section 2 6 as necessary 9 Unlock and switch on I the main power disconnect 10 Switch on I the machine s power 11 Press the green start button key on the...

Page 30: ...n thread tape or a liquid pipe seal ing compound Figure 2 23 Main Air Connector Using a flexible hose to connect the machine to shop air is preferred in case the location of the machine needs adjustment later A line dropped from the ceiling is also preferred Hav ing the line off the floor keeps it clear of the waste bin 2 7 Cleaning It may be necessary to clean the machines after installation They...

Page 31: ...11 09 CMT 130 Book Trimmer 2 10 Cleaning NOTES ...

Page 32: ...ck Unlock a Job 3 7 3 6 4 Erasing a Job 3 7 3 6 5 Editing a New Job 3 7 3 6 6 Editing an Existing Job 3 7 3 6 7 Job Options 3 8 3 6 8 Running a Job 3 9 3 6 9 Closing a Job 3 9 3 6 10 Service Code 2 001 3 9 3 6 11 Resetting to Factory Defaults 3 9 3 7 Status Messages 3 10 3 8 Example Job 3 13 3 9 Serial Communication 3 15 Introduction The operator s guide provides instructions es sential to operati...

Page 33: ...onsole Descriptions The console is found on the front right hand side of the machine General areas of the con sole are shown in Figure 3 1 The specific func tion of each key on the console is given in this section NOTE Advanced operators may benefit from accessing the Service menu To access the Service menu select Service from the menu and enter 2 001 when prompted Figure 3 1 CMT 130 Console ...

Page 34: ...rograms and navigate through maintenance screens 3 1 2 Key Descriptions Number Keys Number keys are used to write number values on the display Decimal Point This decimal key is used to write a decimal point on the display Priority Add Key The priority add key is used to input fractional numbers when combined with a whole number An underscore _ is displayed on the screen after the key is pressed 1_...

Page 35: ...ey is used to move the screen cursor left It is also used to move the cursor to the left while naming a job 3 1 3 Using the Keypad The following information briefly describes effi cient ways to use the functions of the keypad Entering Fractions Fractions are entered using the priority add key The underscore symbol _ is displayed when the key is pressed This instructs the computer to add the fracti...

Page 36: ...130 Book Trimmer 3 5 User Interface Map 3 2 User Interface Map The following chart illustrates the organization of user interface screens encountered in the CMT 130 software Figure 3 2 CMT 130 User Interface Map ...

Page 37: ... If the knives do not move to the up position after power up then the three phase power is con nected incorrectly The following message is displayed Waiting for knives to lift If this message is displayed for more than 10 sec verify the Hydraulic motor rotation See user manual POWER HOOKUP section Figure 3 5 Power Hook Up Warning See section 2 5 1 Power Hookup Procedure or page 2 7 to correct the ...

Page 38: ...vents it from being edited In the Job screen the soft key A will display Lock or Unlock depending on the status of the job If a job is locked the padlock symbol will be displayed at the right of the job name To change the lock status of a job move the cursor to the appropriate job using the up down arrow keys and press the soft key A Lock Unlock The locking function may also be accessed through th...

Page 39: ...on 3 6 7 1 Side Cut When Side Cut is set to On both the sides top and bottom and the face of the book are cut When the Side Cut option is set to Off only the face is cut The side cut menu screen is shown below Side Cut ON OFF Select Press Enter A Maint B Job D Exit Figure 3 10 Side Cut Option Screen 3 6 7 2 Jogger This parameter sets the jogger to remain ex tended as a book leaves the jogging stat...

Page 40: ...d key to set the side knives and the registration assembly to the proper position Once the motors start books can be fed into the machine 3 6 9 Closing a Job To close an open job press the soft key B Job to return to Job mode or press the soft key D Exit to exit to the Run screen 3 6 10 Service Code 2 001 Advanced operators may benefit from access ing the Service menu To access the Service menu se...

Page 41: ...imity sensor or the air cylinder did not extend Knife at down limit failed to move This message displays when the knife fails to leave the down proximity sensor It may be caused by either the cut valve not de energizing or a faulty down limit proximity sensor Knife at up limit Failed to move This message displays when the knife fails to leave the up proximity sensor There are four possible reasons...

Page 42: ...tor starter was on when it should have been off Output 11 off with input 24 on Motor starter error OFF when it should be on Motor starter was off when it should have been on Output 11 on with input 24 off NO Air Pressure This error message displays when the air pressure falls below 20 PSI 1 4 Bar Number outside limit The value entered is not valid OUTPUT CONVEYOR FULL The output conveyor proximity...

Page 43: ...ly Servo Port Failed RS 232 port controlling the servo drive failed Servo Relay Error ON when it should be off Output 11 is off and input 23 is on Servo Relay Error OFF when it should be on Output 11 is on and input 23 is off Start Button Held in at power up Either the start button or remote cut button is being held in Either button may be faulty Stop button pressed Either a stop button is pressed...

Page 44: ... Draw a vertical line up from x 0 25 as shown in Figure 3 14 Draw a horizontal line right from h 8 5 The lines intersect within the shaded region therefore the layout is acceptable Figure 3 14 Book Chart Program the Job Switch on the trimmer and press the green start button Allow a few seconds for the gripper to find home position The screen will look similar to Figure 3 15 S Cut ON Run J Extend S...

Page 45: ... Test Job 2 Example Job_ Select Job Enter A Lock C Erase D Exit Figure 3 18 Job Name After the job has been named press the enter key to enter the book dimensions into the job The screen looks similar to Figure 3 19 S Cut ON Example Job J Extend 2 Stack 1 11 000 0 250 1 000 8 500 9 000 12 000 A Maint C Light B Job D Exit Figure 3 19 Job Run Screen After all values have been entered press the send ...

Page 46: ...ed to with an positive or Negative acknowledgment 1 Positive Acknowledgement ACK 10100600 CR LF 2 Negative Acknowledgement NAK 10101500 CR LF 3 2 The receiver shall send a NAK re sponse if the calculated LRC does not match the incoming value 3 3 The receiver shall send a NAK re sponse if the header is not 1010FF 3 4 If a NAK is received the sender shall wait 150ms before retransmitting the message...

Page 47: ...t 7 000 12 500 1B58 30D4 Example 1010FF0204172101032202006423022AF8 24022328250201F4260230D445 CR LF 4 5 7 Sub Code 30 Current Job Data Request will respond with code 64 data Example 1010FF02040130C8 CR LF 4 6 Host command 03 4 6 1 Sub Code 13 Initiate Eject Book Example 1010FF01030113EF CR LF ...

Page 48: ... 6 4 6 Safety Systems Check 4 7 4 6 1 Safety Check Off Sheet 4 8 Introduction Certain tasks will be performed on a regular basis but not necessarily on a set schedule The safety systems check however should be done before each shift The waste bin must be emptied when full The knives should be re placed when cut quality becomes unacceptable Performing as many of these tasks before a shift begins pr...

Page 49: ...tton Location 2 Remove the waste bin and replace with an empty one 3 After replacing the bin press the green start button to continue Using additional waste bins will reduce down time To order additional waste bins use Chal lenge part number 41058 4 3 Cut Stick The cut stick should either be changed or ro tated with every knife change They may also require changing at other times if deep grooves o...

Page 50: ...after every knife change Improper knife adjustment may cause damage to the ma chine 4 4 1 Knife Change A stable rolling cart approximately 36 tall the knife lifter the T handle hex wrench an empty scabbard and a sharp knife are required to per form a knife change WARNING Changing knives can be very dangerous unless safety precautions are observed and extreme care is taken when handling knives Keep...

Page 51: ...lace a scabbard screw into each hole and turn them clockwise to tighten 15 Use a wrench to secure the knife to its scabbard 16 Set the knife aside With the knife removed the replacement knife may be installed WARNING Changing knives can be very dangerous unless safety precautions are observed and extreme care is taken when handling knives Keep handling of unprotected knives to an absolute minimum ...

Page 52: ...ing depth must be adjusted 4 4 2 Knife Depth Adjustment The knife requires adjustment after every knife change To properly adjust the knife it must be properly installed It should have been installed to the top of the slots of the knife bar If one side knife cuts through and the other does not the knife was not properly installed Use the following procedure to adjust the depth at which the knives ...

Page 53: ...ght as shown in Figure 4 10 4 5 Check Pressure Switch The main air pressure switch should be checked for proper operation each month The main air pressure switch is used to verify that main air is connected and switched on If this switch fails damage to the machine could re sult 1 Switch on power open lower back door 2 Switch off main air valve 3 Close the door 4 Go to the console and read the LCD...

Page 54: ...ess the green start button at the con sole to start the hydraulic motor 2 Press the red stop button at the back of the machine The hydraulic motor should shut off Front Door Interlock 1 Press the green start button at the con sole to start the hydraulic motor 2 Open the front door The hydraulic mo tor should shut off 3 Close the door Right Side Door Interlock 1 Press the green start button at the ...

Page 55: ... 6 1 Safety Check Off Sheet Use this sheet to sign tester s initials and test dates for performing the on page 4 7 of the In stallation and Operator s Manual Machine Model CMT 130 Serial Number _________________________ TESTER DATE TESTER DATE TESTER DATE ...

Page 56: ...lacement be cause they are consumable items The majority of quality issues are resolved by changing the knife and cut stick The trimmer is supplied with mid grade knives To increase the number of cycles before a knife change is required use tungsten carbide knives Carbide is more brittle and prone to damage due to accidentally cutting staples or other very hard materials Use extra care when trimmi...

Page 57: ...n sharply cut Tearing of the bottom sheets and cover occur when deep score marks develop in the cut stick The cover is pushed into the score mark folded over and torn Figure 5 2 Jagged Cover Possible Causes 1 The knife may be dull 2 The cut stick may be worn Solutions Rotate or replace the cut stick The knife may also require replacement 5 3 Burr Marks Jagged Cover Description A jagged bottom cove...

Page 58: ...ar pattern in the near the edges of the book Figure 5 5 Linear Crease Lines Possible Causes The clamps have too much clamp pres sure for the stock being cut Solutions Reduce the clamp pressure by turning the control dial counterclockwise Re duce the pressure until crease lines dis appear on test books Worn cut plates may create these lines on the bottom cover Turn or change the cut plates Note Red...

Page 59: ...ed after trimming it looks similar to the book shown in Figure 5 9 This is the most common cause of out of square espe cially in a stand alone trimming applica tion where the binding has had signifi cant time to harden Cover overhangs the book The over hang reduces the reliability of the squaring process within the trimmer Glue was applied past the binding leav ing a knob like protrusion The protr...

Page 60: ...ut Stick Puller 41058 Waste Bin 59032 Clamp Pad 59050 Cut Stick 59051 High Speed Steel Knife 59051 1 Tungsten Carbide Knife 59051 2 DMD 5X Knife 59070 Knife Lifter Assembly E 967 1 Lamp H 6910 606 Knife Screw W 180 7 32 T Handle Hex Wrench K 56030 Spare Parts Kit K 56031 Oil Change Tool Kit K 56040 Oil Change Kit S 1991 3 Hydraulic Fluid 5 gal SU 30 103 EP2 Grease black SU 30 104 EP Grease red in ...

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