10259130-EN-20150615 Operating Manual

Operating instructions
Inliner with MLT 40
Read the instructions prior to performing any task!

Translation of the original operating manual (German), as of: 15/06/2015 English
Baumer hhs GmbH
Adolf-Dembach-Straße 19
47829 Krefeld
Germany
Telephone: +49 (0)2151 4402 -200
Fax: +49 (0)2151 4402 -111
email: service.de@baumerhhs.com
Internet: www.baumerhhs.com
Translation of the original operating instructions
IL mit MLT 40, 3, en_US
© Baumer hhs GmbH 2015
2 Inliner with MLT 40 19.06.2015

Supplemental instructions
Information on the operating This manual is an integral part of the Inliner systems with MLT 40
manual and must be kept within close proximity of the system for personnel
to access at all times. This manual enables the system to be used
safely and efficiently and must be passed to the new owner if sold
on.
Personnel must have carefully read through and understood this
manual before starting any work. Following all safety guidelines
and instructions in this manual is the basic prerequisite for safe
work. Furthermore, the local health and safety regulations and gen-
eral safety regulations for the field of application of the Inliner sys-
tems with MLT 40 also apply.
The diagrams in this manual are examples. There may be differ-
ences at the discretion of Baumer hhs.
Baumer hhs will continually update this operating manual. Should
you notice that information is missing or that there is an error,
please notify Baumer hhs.
Contact Baumer hhs if you have any questions concerning this
manual.
Help us Help us make Baumer hhs products even safer!

We, Baumer hhs GmbH, constantly strive to improve our products.
You can help us in this process of continuous optimisation by
reporting any hazardous situations involving Baumer hhs products
n that are directly caused by the product,
n that arise when using the product, or
n that are caused by materials that are processed by the Baumer
hhs products.
Contact Please report any hazardous situations to the following email

address: Hazardous@baumerhhs.com. Please include the fol-
lowing information, if known.
n Affected product
n Description of the hazardous situation
n Sketches, photos
n Name and contact information in case of any queries.
The report will be passed internally to the departments responsible.
Note on electrical parts Due to the sometimes very short innovation cycles for electrical
parts, it is possible for the original manufacturer to withdraw prod-
ucts from the market early on (parts discontinuation).
This can mean that the availability of replacement parts being
limited, and that the original assembly cannot be repaired. There-
fore, in the event of repairs, Baumer hhs GmbH reserves the right
to replace the entire assembly concerned with another assembly
with an identical or extended functionality.
19.06.2015 Inliner with MLT 40 3

Supplemental instructions
Other applicable documents In addition to this document, the operating manual and the safety
advice contained therein for the components of the Inliner systems
with MLT 40 and the super-ordinate production equipment also
apply.
Copyright protection Baumer hhs GmbH operating manuals and handbooks are pro-
tected by copyright. The copying, reproduction and translation, etc.
of them is prohibited. Additional copies of this operating manual
and copies in other languages can be obtained directly from the
manufacturer for a fee.
is a registered trademark of Baumer hhs GmbH (international
registration 915310).
The right to make changes at any time and without providing
advance notice is reserved.
Customer service Baumer hhs GmbH

Adolf-Dembach-Str. 19
47829 Krefeld
Germany
Tel.: +49 2151 4402-200
Email: service.de@baumerhhs.com
Website: www.baumerhhs.com
A current list of local contact persons can be found on our website
under "Contact".
Reporting hazards Email: Hazardous@baumerhhs.com
Documentation Email: dokumentation@baumerhhs.com

Table of contents
Table of contents
1 General............................................................................... 13
1.1 System at a glance .................................................... 13
1.2 Components at a glance............................................. 13
1.2.1 Control cabinet overview......................................... 13
1.2.2 CPU module............................................................ 14
1.2.3 Application head module......................................... 14
1.2.4 Terminal interface module....................................... 14
1.2.5 MLD module............................................................ 15
1.2.6 Stopp-Link front plate............................................... 15
1.2.7 Linux terminal.......................................................... 15
1.2.8 Glue delivery unit (KFE)........................................... 16
1.2.9 Fill level sensor........................................................ 17
1.2.10 3-way blank guide.................................................. 17
1.2.11 3-way multi-application head................................. 18
1.2.12 MLT sensor............................................................ 19
1.2.13 (optional) UV lighting for MLT-40........................... 19
1.2.14 MLT colour filter installation kit.............................. 20
1.2.15 (optional) Skew...................................................... 20
1.2.16 Inliner light sensor installation kit........................... 21
1.2.17 FHDK light sensor.................................................. 21
1.2.18 (optional) Marking system...................................... 21
1.2.19 Pressure vessel..................................................... 22
1.2.20 Marking valve......................................................... 22
1.2.21 (optional) Sprayed air shut-off .............................. 22
1.2.22 IE-65-508 Encoder................................................. 23
1.2.23 Alert set.................................................................. 23
2 Safety................................................................................. 25
2.1 Symbols in this manual............................................... 25
2.2 Intended use............................................................... 27
2.2.1 Reasonably foreseeable misuse.............................. 28
2.3 Safety devices............................................................ 28
2.4 Work areas and danger zones.................................... 29
2.5 Safety marking............................................................ 29
2.6 Preventing an unintentional restart............................. 29
2.7 Residual risks............................................................. 30
2.7.1 Fundamental workplace hazards............................. 30
2.7.2 Risks due to electrical current.................................. 31
2.7.3 Dangers due to connection lines and connection
cables...................................................................... 32
2.7.4 Danger due to machine movements........................ 32
2.7.5 Danger due to pressurised components and mate-
rials.......................................................................... 34
2.7.6 Danger due to pneumatics....................................... 34

Table of contents
2.7.7 Danger due to adhesive........................................... 35

2.7.8 Risk due to batteries................................................ 37
2.7.9 Risk of material damage.......................................... 38
2.8 Responsibility of the owner......................................... 38
2.9 Personnel requirements.............................................. 40
2.10 Personal protective equipment................................. 42
2.11 Safety information for replacement parts.................. 42
2.12 Component-specific safety guidelines...................... 43
2.12.1 Control cabinet safety ........................................... 43
2.12.2 Linux terminal........................................................ 44
2.12.3 Glue delivery unit (KFE)......................................... 45
2.12.4 3-way blank guide.................................................. 45
2.12.5 Multi-application head............................................ 47
2.12.7 Pressure vessel..................................................... 49
2.12.8 Encoder IE-65-508................................................. 51
2.12.9 Alert set.................................................................. 52
3 Layout and functional description.................................. 53
3.1 Corrugated board blank - definition of terms.............. 53
3.2 Functional description................................................. 55
3.3 Function of the components....................................... 56
3.3.1 Control cabinet description ..................................... 56
3.3.2 CPU module............................................................ 58
3.3.3 Application head module......................................... 60
3.3.4 Terminal interface module....................................... 60
3.3.5 MLD module description.......................................... 61
3.3.6 Stopp-Link front plate............................................... 62
3.3.7 Linux terminal.......................................................... 62
3.3.8 Glue delivery unit (KFE)........................................... 63
3.3.9 Display and operating elements on the glue
delivery unit ............................................................. 71
3.3.10 Optional components for the glue delivery unit...... 73
3.3.11 Fill level sensor...................................................... 75
3.3.12 3-way blank guide.................................................. 77
3.3.14 MLT sensor............................................................ 82
3.3.15 (optional) UV lighting for MLT-40........................... 84
3.3.17 (optional) Skew...................................................... 87
3.3.18 Inliner light sensor installation kit........................... 88
3.3.20 Marking system...................................................... 89
3.3.21 Pressure vessel..................................................... 90
3.3.22 Marking valve......................................................... 91
3.3.23 (optional) Sprayed air shut-off............................... 93

Table of contents
3.3.24 IE-65-508 Encoder................................................. 94

3.3.25 Alert set.................................................................. 95
4 Transport and storage...................................................... 97
4.1 Safety guidelines for transport and storage................ 97
4.2 Delivery....................................................................... 97
4.3 Transport inspection................................................... 97
4.4 Storage of packages................................................... 98
4.5 Disposing of packaging materials............................... 98
4.6 Component-specific transport information.................. 99
5 Assembly and installation.............................................. 101
5.1 Safety guidelines for assembly and connection........ 101
5.2 Assembling the components..................................... 103
5.2.1 Assembling the control cabinet.............................. 103
5.2.2 Assemble modules................................................ 104
5.2.3 Mounting the Linux terminal onto the terminal
holder..................................................................... 105
5.2.4 Glue delivery unit................................................... 106
5.2.5 Glue delivery unit with separate material pressure
regulator ................................................................ 108
5.2.6 Media supply to the glue delivery unit.................... 111
5.2.7 3-way blank guide.................................................. 114
5.2.9 MLT sensor............................................................ 121
5.2.10 (optional) UV lighting for MLT-40......................... 122
5.2.11 MLT colour filter installation kit............................ 123
5.2.12 (optional) Skew.................................................... 125
5.2.13 FHDK light sensor................................................ 125
5.2.14 Marking system.................................................... 126
5.2.15 Pressure vessel................................................... 127
5.2.16 Connecting the pressure vessel material supply. 128
5.2.17 Assemble the spray application head.................. 129
5.2.18 Connecting the material supply to the spray appli-
cation head.......................................................... 130
5.2.19 (optional) Sprayed air shut-off ............................ 130
5.2.20 IE-65-508 Encoder............................................... 131
5.2.21 Alert set................................................................ 136
5.3 Electrical connection of the components.................. 137
5.3.1 Connecting the control cabinet electrically............ 137
5.3.2 Connecting the modules electrically...................... 138
5.3.3 Linux terminal........................................................ 138
5.3.5 (optional) fill level display....................................... 140
5.3.6 (optional) fill level sensor....................................... 141
5.3.7 3-way blank guide.................................................. 141
5.3.8 Multi-application head............................................ 142

Table of contents
5.3.9 MLT sensor............................................................ 144

5.3.10 Additional lighting for MLT-40.............................. 145
5.3.11 Additional lighting for MLT-40.............................. 147
5.3.13 (optional) Marking system.................................... 149
5.3.14 Spray application head........................................ 149
5.3.15 Connect the (optional) sprayed air shut-off electri-
cally...................................................................... 149
5.3.16 IE-65-508 Encoder............................................... 150
5.3.17 Status indicator.................................................... 151
5.4 Pneumatic connection of the components................ 151
5.4.2 3-way blank guide.................................................. 152
5.4.3 Marking system...................................................... 154
5.4.4 Connecting the pressure vessel pneumatically..... 155
5.4.5 Connecting the spray application head pneumati-
cally........................................................................ 156
5.4.6 (optional) Sprayed air shut-off............................... 157
6 Commissioning............................................................... 159
6.1 Safety guidelines for commissioning........................ 159
6.2 Preparing test material for commissioning................ 162
6.2.1 Preparing products................................................ 162
6.2.2 Preparing adhesive................................................ 162
6.3 Commissioning the components............................... 163
6.3.1 Commissioning the Linux terminal......................... 163
6.3.3 3-way blank guide.................................................. 182
6.3.5 MLT sensor............................................................ 193
6.3.7 (optional) Skew...................................................... 194
6.3.9 (optional) Marking system...................................... 197
6.3.10 Pressure vessel................................................... 204
6.3.11 Commissioning the marking valve....................... 205
6.3.12 (optional) Sprayed air shut-off I .......................... 206
6.3.13 IE-65-508 Encoder............................................... 206
6.4 Commissioning the controller................................... 207
6.4.1 System settings for the Inliner systems with MLT
40........................................................................... 208
6.4.2 Set language, date and time.................................. 214
6.4.3 Defining basic settings........................................... 218
6.4.4 Configuring application heads I............................. 225
6.4.5 Adjusting the pressure curve................................. 234
6.4.6 Defining IO signals................................................. 244

Table of contents
6.4.7 Defining interfaces and machine connections....... 254

6.4.8 Defining the MLT offset and light barrier................ 256
6.4.9 Entering the parameters for the adhesive sensor.. 259
6.4.10 Configuring user levels........................................ 263
7 Operation......................................................................... 269
7.1 Controller operation.................................................. 269
7.1.1 Production mode.................................................... 269
7.1.2 Changing user level............................................... 278
7.1.3 Enter model data................................................... 279
7.1.4 Editing the model list.............................................. 292
7.1.5 Monitoring the adhesive line.................................. 297
7.1.6 Fault messages..................................................... 305
7.1.7 Locating the source of a fault ................................ 307
7.1.8 Statistics................................................................ 314
7.1.9 Saving statistics..................................................... 317
7.2 Operation of the components................................... 322
7.2.1 Operating the Linux terminal.................................. 322
7.2.3 3-way blank guide.................................................. 324
7.2.5 MLT sensor............................................................ 326
7.2.6 Pressure vessel..................................................... 327
7.2.7 Operating the marking valve.................................. 331
8 Maintenance.................................................................... 337
8.1 Safety guidelines for maintenance............................ 337
8.2 Maintenance table.................................................... 338
8.3 Maintenance of the components............................... 344
8.3.1 Linux terminal........................................................ 344
8.3.3 F1-2 Fill level sensor maintenance........................ 407
8.3.4 3-way blank guide.................................................. 408
8.3.6 MLT sensor............................................................ 432
8.3.7 Pressure vessel..................................................... 433
8.3.8 Status indicator...................................................... 435
9 Fault elimination............................................................. 437
9.1 Safety guidelines for fault elimination....................... 437
9.2 Fault table................................................................. 438
9.3 Component-specific fault elimination........................ 451
9.3.1 Fault messages on the CPU module..................... 451
9.3.2 Rectifying faults on the CPU module..................... 451
9.3.3 Fault messages on the Linux terminal................... 453
9.3.4 Fault messages on the KPE9 piston pump............ 453
9.3.5 Fault messages on the fill level display................. 460

Table of contents
9.3.6 Fault messages on the terminal............................. 460

9.3.7 Eliminating faults in the glue delivery unit.............. 460
9.3.8 3-way blank guide.................................................. 462
9.3.9 3-way multi-application head ................................ 464
9.3.10 Replacing the MLT sensor................................... 474
9.3.11 Fault messages on the MLT sensor.................... 475
9.3.13 MLT colour filter installation kit............................ 477
9.3.15 Troubleshooting faults on the pressure vessel.... 480
9.3.16 Spray application head trouble-shooting............. 481
9.3.17 Fault messages on the alert set........................... 504
10 Disassembly and disposal............................................. 505
10.1 Inliner system with MLT 40 disposal....................... 505
11 Technical data................................................................. 507
11.1 Technical data for the components......................... 507
11.1.1 Control cabinet .................................................... 507
11.1.2 CPU module (CPU circuit board 50MHz) ........... 508
11.1.3 Application head module (PME8 Power
module) ............................................................... 508
11.1.4 Terminal interface module (front plate MFRW-
X2ALUTHERM single) ........................................ 509
11.1.5 Xtend² BG15-ALU-Linux terminal (Linux
terminal) .............................................................. 509
11.1.6 Glue delivery unit KFE-KPE9-PMDRE6.............. 511
11.1.7 Fill level sensor F1-2............................................ 515
11.1.8 FFG-BG-3P-7,5-L/R-W 3-way blank guide.......... 516
11.1.9 Multi-application head PL5-316-7.5 R/L.............. 517
11.1.10 SMLT-40 Multi-line sensor................................. 518
11.1.11 UV lighting installation kit for MLT-40 multi-line
sensor................................................................ 519
11.1.12 MLT colour filter installation kit Colour filter and
additional lighting............................................... 520
11.1.13 Inliner light sensor installation kit ...................... 521
11.1.14 FHDK light sensor ............................................. 522
11.1.15 Marking system Heavy duty version.................. 522
11.1.16 DB-2-S VA Pressure vessel .............................. 523
11.1.17 Marking valve DSR-403..................................... 525
11.1.18 Sprayed air shut-off installation kit .................... 527
11.1.19 Encoder IE-65-508............................................. 528
11.1.20 Status display + horn for Inliner (alert set) ........ 530
12 Replacement parts.......................................................... 531
12.1 Replacement parts.................................................. 534
12.1.1 Linux terminal replacement parts list................... 534
12.1.2 Glue delivery unit................................................. 535

Table of contents
12.1.3 Optional accessories........................................... 550

12.1.4 Fill level sensor.................................................... 557
12.1.5 3-way blank guide (FFG-BG-3P-7,5-R/L-W)........ 558
12.1.6 Inliner pneumatic accessories............................. 561
12.1.7 3-way multi-application head (PL5-316-7,5 R/L). 562
12.1.8 MLT sensor.......................................................... 564
12.1.10 MLT colour filter installation kit.......................... 565
12.1.11 (optional) Skew.................................................. 567
12.1.12 Inliner light sensor installation kit....................... 567
12.1.13 FHDK light sensor.............................................. 567
12.1.14 (optional) Marking system.................................. 569
12.1.15 Pressure vessel................................................. 571
12.1.16 Marking valve..................................................... 572
12.1.17 (optional) Sprayed air shut-off........................... 573
12.1.18 IE-65-508 Encoder............................................. 574
12.1.19 Status display + horn for Inliner (alert set)......... 575
13 Index................................................................................. 577
Appendix.......................................................................... 589
A IE-65-508 Encoder...................................................... 590
A.A Encoder attachment kit 50 replacement parts......... 591
A.B Encoder attachment kit 51 replacement parts......... 592
A.C Encoder attachment kit 52 replacement parts......... 593
A.D Encoder attachment kit 53 replacement parts......... 594
A.E Encoder attachment kit 54 replacement parts......... 595
A.F Encoder attachment kit 60 replacement parts.......... 596
A.G Encoder attachment kit 90 replacement parts......... 598
A.H Encoder attachment kit 91 replacement parts......... 599
A.I Encoder attachment kit 92 replacement parts........... 600
A.J Encoder attachment kit 93 replacement parts.......... 601
A.K Encoder attachment kit 94....................................... 602
A.L Encoder attachment kit 95........................................ 603
A.M Encoder attachment kit 96 replacement parts......... 604
A.N Encoder attachment kit 97 replacement parts......... 605
A.O Encoder attachment kit 99 replacement parts......... 607
B Declaration of conformity............................................. 609
C Circuit diagrams.......................................................... 610

Table of contents

General
Components at a glance > Control cabinet overview
1 General
1.1 System at a glance
The Baumer hhs Inliner system with MLT 40 is intended for instal-
lation in an Inliner. Inliners are used for further processing of corru-
gated or heavy board sheets. Flat sheets are passed through the
Inliner machine, where they are printed, slotted, grooved, stamped,
folded and glued as needed in a single process. The result is gen-
erally a folding box that is ready for use.
The adhesive application system consists of a glue delivery unit,
application heads, electronic controller and accessory components
such as sensors and encoders. An MLT sensor is used for moni-
toring. Products that must be ejected are marked using a separate
marking unit. The components of the Inliner systems with MLT 40
are described below.
1.2 Components at a glance

1.2.1 Control cabinet overview
Description
Control cabinet
Fig. 1: Example: Control cabinet

General
Components at a glance > Terminal interface module
1.2.2 CPU module
Item number Description

74490015 CPU module
(CPU circuit board 50MHz)
Fig. 2: 74490015
1.2.3 Application head module

74490030 Application head module
(PME8 Power module)
Fig. 3: 74490030
1.2.4 Terminal interface module

75909450 Terminal interface module
Fig. 4: 75909450 (Front plate MFRW-X2ALU-
THERM single)

General
Components at a glance > Linux terminal
1.2.5 MLD module

75915120 MLD module
Fig. 5: 75915120
1.2.6 Stopp-Link front plate

75918030 Stopp-Link front plate
Fig. 6: 75918030
1.2.7 Linux terminal

75010350 Linux terminal
Fig. 7: 75010350

General
Components at a glance > Glue delivery unit (KFE)
1.2.8 Glue delivery unit (KFE)
Fig. 8: 16940000, 16940005
For glue delivery unit with:
Item number
16940000 16940005

General
Components at a glance > 3-way blank guide
1.2.9 Fill level sensor

For fill level sensor with:
Item number
15990021
Fig. 9: 15990021
1.2.10 3-way blank guide

27893000 3-way blank guide
(FFG-BG-3P-7,5-L/R-W)
Fig. 10: 27893000

General
Components at a glance > 3-way multi-application head
(optional) Guide plate extension
Item number Device

10259300 Guide plate extension
Fig. 11: 10259300
1.2.11 3-way multi-application head

28590330 Multi-application head
PL5-316-7,5-R/L
Fig. 12: 28590330

General
Components at a glance > (optional) UV lighting for MLT...
1.2.12 MLT sensor

79020100 SMLT-40 Multi-line sensor
Fig. 13: 79020100
1.2.13 (optional) UV lighting for MLT-40

10259120 UV lighting installation kit for MLT-40
multi-line sensor
Fig. 14: 10259120

General
Components at a glance > (optional) Skew
1.2.14 MLT colour filter installation kit
10259160

10259160 MLT colour filter installation kit
consists of:
79029110 Holder with yellow MLT colour filter
79029365 MLT 40 deep blue additional lighting
Fig. 15: 79029110 (mounted on the

MLT sensor)
Fig. 16: 79029365
1.2.15 (optional) Skew

10259205 Item Description
number
10259205 Skew (skew control)
Consists of:
2x 27894200 Inliner light sensor assembly kit

General
Components at a glance > (optional) Marking system
1.2.16 Inliner light sensor installation kit

27894200 Inliner light sensor assembly kit
Contains: 96310151 light sensor
Fig. 17: 27894200
1.2.17 FHDK light sensor

For light sensor with:
Item number
96310102 96310103 96310105
96310109 96310112 96310113
96310115 96310151
Fig. 18: 963101xx
1.2.18 (optional) Marking system

10259295 Marking system
1 12020300 DB-2-S Pressure vessel
2 27480300 DSR-403 Spray application head
3 10259291 Sprayed air shut-off (optional)
Fig. 19: 10259295

General
Components at a glance > (optional) Sprayed air shut-of...
1.2.19 Pressure vessel

For pressure vessel with:
Item number
12020300
Fig. 20: 12020300
1.2.20 Marking valve

Item number Ø Nozzle Description
27480300 0.3 mm DSR-403-6V Spray application
head
Fig. 21: 27480300
1.2.21 (optional) Sprayed air shut-off

10259291 Sprayed air shut-off
Fig. 22: 10259291

General
Components at a glance > Alert set
1.2.22 IE-65-508 Encoder

For encoders and encoder installation kits with:
Item number
96313103 96313150 96313151
96313152 96313153 96313154
96313160 96313190 96313191
Fig. 23: 96313103
96313192 96313193 96313194
96313195 96313196 96313197
96313199
1.2.23 Alert set

10259250 Status display + horn for Inliner
(Alert set)
Fig. 24: 10259250

General
Components at a glance > Alert set

Safety
Symbols in this manual
2 Safety
This section provides an overview of all important safety aspects
for the protection of people and for safe and failure-free operation.
Other task-related safety guidelines are included in the sections on
individual life phases.
2.1 Symbols in this manual

Safety guidelines Safety guidelines in this manual are identified by symbols. The
safety guidelines are introduced by signal words, which convey the
extent of the hazard.
DANGER!
This combination of symbols and signal words indi-
cates an immediate dangerous situation that causes
death or serious injuries if not avoided.
WARNING!
cates a potentially dangerous situation that can result
in death or serious injuries if not avoided.
CAUTION!
in minor or slight injuries if not avoided.
NOTICE!
in material damage if not avoided.
ENVIRONMENT!
in environmental damage if not avoided.
Safety guidelines in the instruc- Safety guidelines may relate to particular, individual instructions.
tions Such safety guidelines are embedded within the instructions so
that they do not interrupt the reading flow when performing opera-
tions. The signal words described above are used.

Safety
Symbols in this manual
Example:
1. Loosen the screw.
2.
CAUTION!
Risk of getting caught in the lid!
Close the lid carefully.

3. Tighten the screw.
Special safety instructions The following symbols are used in the safety instructions in order
to draw attention to specific hazards:
Warning signs Type of danger

Warning – high-voltage.
Warning – danger of entangle-

ment.
Warning – explosive sub-

stances.
Warning – danger zone.
Tips and recommendations

This symbol highlights useful tips and recommenda-
tions, as well as information for efficient and fault-free
operation.
Other labels The following labels are used to highlight instructions, results, lists,
references and other elements in this manual:
Marking Explanation
Step-by-step instructions
ð Results of steps
References to sections of this manual and
other applicable documents

Safety
Intended use
Marking Explanation
Lists without a specified order
[Button] Operating elements (e.g. button, switch),
display elements (e.g. signal lights)
“Display” Screen elements (e.g. keys, layout of func-
tion keys)
2.2 Intended use

The Inliner system with MLT 40 is used exclusively for portioned
application of solvent-free, liquid, water-based adhesives and for
monitoring the adhesive application.
WARNING!
Danger due to misuse!
Misuse of the Inliner systems with MLT 40 and con-
nected components can result in unforeseeable,
uncontrollable and life-threatening situations for oper-
ating personnel and/or serious material damage!
– Modifications to the Inliner system with MLT 40 or
devices produced by third parties must be
expressly approved in writing by Baumer hhs.
– Always use solvent-free glues.
– Never operate the Inliner system with MLT 40 in a
potentially explosive atmosphere.
– Never store volatile, flammable and/or explosive
materials, liquids or gases near the device.
– Never modify the supplied software or replace it
with third-party software.
– Never operate the control cabinet of the Inliner
systems with MLT 40 when open.
– Never set incorrect control parameters for the
application heads in use.
– Never make changes to the end switches, on pro-
tective equipment, for example.
– Never simulate the presence of protective equip-
ment or safety devices.

Safety
Safety devices
2.2.1 Reasonably foreseeable misuse

The following is considered improper use:
n the use of unsuitable glues
n the use of solvent-based glues
– Adhesives that contain solvents can cause explosions
n the use of the Inliner systems with MLT 40 and/or the applica-
tion head in an explosive environment.
– The devices are not designed for use in explosive environ-
ments.
The Inliner system with MLT 40 must not be used:
n if no protective equipment and clothing are available.
n if protective equipment and clothing are not correctly fitted.
n if protective equipment and clothing are damaged.
n if part of the delivery equipment, such as pumps, pressure
vessel, lines, distributors, couplings, is defective.
n if components are used that are not designed and intended for
the maximum pressure of the system.
Significant changes to the Inliner system with MLT 40, such as
extensions and upgrades, are only deemed proper use if they have
been expressly approved in writing by Baumer hhs GmbH.
The device software may not be modified or replaced with third-
party software. This also applies to the electrical power supply of
the device.
DANGER!
DANGER! Any improper use can result in unforesee-
able, uncontrollable and life-threatening risks for oper-
ators and third-parties. Baumer hhs GmbH accepts no
liability in this case.
2.3 Safety devices
WARNING!
Danger of death due to malfunctioning safety
devices!
Malfunctioning or overridden safety devices could lead
to serious injuries or death.
– Before starting work, check whether all safety
devices are functional and correctly installed.
– Never override or bypass safety devices.
– Make sure that all safety devices are accessible at
all times.

Safety
Preventing an unintentional rest...
The individual safety equipment for the components can be found

in the “Component-specific safety information and residual risks of
the hhs system” chapter.
2.4 Work areas and danger zones

The work areas and danger zones depend on the layout of the
components of the Inliner systems with MLT 40 in the super-ordi-
nate production equipment and the prevailing circumstances at the
installation site. For this reason, they must be determined by the
owner.
2.5 Safety marking

The following symbols and information signs can be found in the
work area. They refer to the immediate surroundings in which they
are mounted.
WARNING!
Danger due to illegible signage!
Over time, labels and signs may become dirty or
unrecognisable for some other reason, meaning that
the dangers are not recognised, and necessary oper-
ating instructions cannot be followed. This can lead to
injury.
– All safety instructions, warnings and operating
instructions must be easily legible at all times.
– Damaged signs or labels must be replaced imme-
diately.
DANGER!
Danger if the safety markings are missing or are
not understandable.
Observe the component-specific safety information.
2.6 Preventing an unintentional restart

The Inliner system with MLT 40 is prevented from restarting unin-
tentionally at the control cabinet. Observe the safety information for
the components. Ä Chapter 2.12.1 “Control cabinet safety ”
on page 43

Safety
Residual risks > Fundamental workplace hazards
2.7 Residual risks

The Inliner system with MLT 40 has been designed in accordance
with the latest state of technology and current safety requirements.
However, there may still be residual risks that necessitate careful
handling. The residual risks and the corresponding behaviour and
measures required are listed below.
2.7.1 Fundamental workplace hazards

Risk of fire
WARNING!
Risk of death due to fire!
There is a risk of death in the event of a fire.
– Do not store flammable materials near the equip-
ment
– Do not bring sources of ignition close to the equip-
ment. Fire, naked flames and smoking in this area
are forbidden.
– Ensure extinguishers are available.

Safety
Residual risks > Risks due to electrical current
2.7.2 Risks due to electrical current

Electrical current
DANGER!
Danger of death due to electrical current!
Touching live parts poses the risk of immediate death
by electric shock. Damage to the insulation or indi-
vidual parts can be life-threatening.
– Only have work on the electrical system carried out
by electricians.
– In the event of damage to the power cable, imme-
diately switch off the power supply and replace the
cable.
– Only connect the power cable to sockets with a
protective earth conductor (safety socket).
– Keep heat sources away from power cables.
– Protect the safety socket according to the current
local requirements.
– Make sure the safety socket is kept easily acces-
sible.
– Before beginning work on active components of
electrical systems and equipment, ensure that their
power supply has been disconnected and that it
remains so for the duration of the work. Observe
the 5 safety rules:
– Switch off.
– Ensure that it cannot be switched back on.
– Confirm that no voltage is present.
– Earth and short circuit.
– Cover neighbouring live parts or make them
inaccessible.
– Never override or bypass fuses. Maintain the cor-
rect current when changing fuses.
– Keep live parts free of moisture. This can cause a
short circuit.

Safety
Residual risks > Danger due to machine movements
2.7.3 Dangers due to connection lines and connection cables

Risk of tripping
CAUTION!
Danger of tripping due to improperly laid connec-
tion lines and cables!
There is a risk of injuries due to falling over improperly
laid connection lines and cables.
– Move carefully in the danger zone of the produc-
tion unit.
– Lay connection lines and cables so that no trip
hazards arise.
– Use cable and line bridges, if necessary.
– Mark unavoidable risk hazards with yellow and
black marking tape.
2.7.4 Danger due to machine movements

Moving components
CAUTION!
Danger of injury due to moving components!
The super-ordinate machine contains moving compo-
nents. There is a risk of injury when standing or
walking within the equipment due to the movement of
components.
– Do not enter the danger zones designated by the
owner.
– Only start the equipment when the protective cov-
ering and safety equipment are intact.
– When working on components of the Inliner sys-
tems with MLT 40, switch off the super-ordinate
production system and ensure it cannot be
switched back on accidentally.

Safety
Residual risks > Danger due to machine movements
Transport devices
WARNING!
Entanglement hazard on the system's transport
devices!
The super-ordinate machine includes a transport
device. Items can be pulled into this and become
entangled.
– Do not touch the transport device during operation.
– Wear close-fitting protective clothing when working
on the transport device.
– During setup work on the Inliner system with MLT
40, ensure that there is nobody within the danger
zone and that the transport device is only operated
manually.
DANGER!
Risk of injury when entering the operating space of
the super-ordinate machine and its moving parts
It may become necessary to enter the operating space
of the super-ordinate machine for maintenance work or
fault elimination. Moving parts in the super-ordinate
machine and products passing through can cause
serious, even fatal injuries.
– Ensure that the super-ordinate machine is com-
pletely and securely disconnected from the power
supply whenever possible. Read and ensure you
understand the process of “ Switching off securely”
in the operating manual for the super-ordinate
machine.
– If the power supply is required for maintenance
work or to eliminate a fault, the super-ordinate
machine must be secured so that it is unable to
run. Read and ensure you understand the process
of “Ensuring the machine cannot run” in the oper-
ating manual for the super-ordinate machine.
– Inform all machine operators and people in the sur-
rounding area that work is taking place in the oper-
ating area of the super-ordinate machine.
– Hang an informative sign that explains that work is
taking place in the operating area of the super-
ordinate machine.
– Never manipulate or substitute the safety equip-
ment of the super-ordinate machine.

Safety
Residual risks > Danger due to pneumatics
2.7.5 Danger due to pressurised components and materials

Pressurised components
WARNING!
Risk of death due to pressurised components!
There is a risk of death if pressurised components
move uncontrollably.
– Only have work on the equipment carried out by
trained, authorised personnel who are familiar with
the contents of this operating manual.
– Ensure that the system is depressurised before
beginning any work. Also ensure that any residual
energy is discharged.
Pressurised materials
WARNING!
Risk of injury due to pressurised materials!
There is a risk of injury should pressurised materials
leak uncontrollably.
Pressurised materials include:
– Air
– Adhesive
– Only have work on the equipment carried out by
trained, authorised personnel who are familiar with
the contents of this operating manual.
– Ensure that the system is depressurised before
beginning any work. Also ensure that any residual
energy is discharged.
2.7.6 Danger due to pneumatics

Pneumatics
WARNING!
Risk of injury due to movements caused by stored
pneumatic energy!
Pneumatically driven components can move unexpect-
edly due to stored residual energy, and can therefore
cause serious injuries.
– Only have work on the pneumatic equipment car-
ried out by trained, authorised personnel who are
familiar with the contents of this operating manual.
– Before beginning work on the pneumatic equip-
ment, ensure that it has been completely depres-
surised. Completely release the pressure accumu-
lator.

Safety
Residual risks > Danger due to adhesive
2.7.7 Danger due to adhesive

Improper use
WARNING!
Danger due to improper use of adhesive!
Improper use of adhesive and not observing the asso-
ciated safety data sheet can lead to dangerous situa-
tions.
– Ensure that the manufacturer's current safety data
sheet for each glue being used is always available.
– Always follow the safety instructions on the data
sheet.
– When working with glue, always wear the protec-
tive equipment stated in the operating manual.
Risk of slipping, tripping or falling

CAUTION!
Risk of slipping, tripping or falling in the area of
the master machinery!
There is an increased risk of slipping, tripping or falling
in the area of the machinery resulting from adhesive
residues sprayed on to the floor.
– Immediately remove any sprayed adhesive and
dispose of in an environmentally correct manner.
– Move carefully in the area of master machinery.
– Wear protective equipment in the area of master
machinery. Safety boots.

Safety
Residual risks > Danger due to adhesive
Unusable cold glue

NOTICE!
Risk of material damage due to defective cold
glue!
Using cold glue that has expired or is contaminated
can damage the system.
– When filling the container, ensure that the adhe-
sive
– contains no dirt particles,
– contains no mould particles,
– does not have a thick skin on the surface,
– is stirred before filling,
– is poured into the container through a fine filter
mesh
– Always fill the container completely.
– During the operating life of the adhesive, ensure
that
– the storage period for the adhesive is not
exceeded,
– the adhesive is not exposed to freezing tem-
peratures and
– the adhesive container is sealed tightly.

Safety
Residual risks > Risk due to batteries
2.7.8 Risk due to batteries

Batteries
WARNING!
Risk of injury if batteries are handled incorrectly!
If rechargeable batteries (e. g. in a UPS) are handled
incorrectly, there is a risk that the batteries may
explode or that hazardous liquid may leak out from the
batteries. The liquid can cause a chemical burn if it
comes into contact with the skin, may cause severe
poisoning if swallowed, and can cause blindness if it
comes into contact with the eyes.
– Only charge and operate the batteries with the
UPS.
Only connect the batteries with the correct poles
(+/-).
– Never short circuit the contacts (plus and minus
poles) on the battery.
– Never expose the battery to liquids or moisture
(rain, salt water, other liquids). Damp or wet bat-
teries must never be used or charged.
– Never attempt to solder, repair, change the shape,
modify or disassemble batteries.
– To reduce the risk of fire, overheating, explosions
or liquids leaking out of the battery, never expose it
to strong vibrations, heavy weights or other dam-
aging forces. Leaked battery acid may ignite.
– Should battery acid come into contact with the eye,
rinse the eye under the eyelid with clean water for
at least 15 minutes. Direct a gentle stream of water
directly into the eye and do not rub. Seek medical
assistance immediately.
– Avoid skin contact with leaked battery acid. Should
it come into contact with the skin accidentally,
wash the affected area of the skin with plenty of
water.

Safety
Responsibility of the owner
2.7.9 Risk of material damage

Connection lines and connection
cables NOTICE!
Danger of material damage due to improperly laid
connection lines and cables!
Moving parts of the production unit can cause material
damage by catching on improperly laid connection
cables and lines.
– Lay connection lines and cables so that they
cannot become caught on moving parts of the
higher-level production unit.
– Protect the Inliner systems with MLT 40 connection
cable from being pulled out by screwing it into the
control cabinet.
– Always make sure that the pins of the connectors
and sockets are correctly aligned.
2.8 Responsibility of the owner

Owner The owner is the person who operates or owns the Inliner system
with MLT 40, or who has assumed the decisive economic authority
over the technical operation of the equipment. Normally, the owner
is not Baumer hhs, but rather the purchaser of the system.
Owner duties The Inliner system with MLT 40 is used in the commercial sector.
The system owner is therefore subject to the legal obligations con-
cerning occupational safety.
In addition to the safety instructions in this manual, the safety,
occupational health and safety and environmental protection regu-
lations applicable to the field of application of the system must also
be complied with.
The following, in particular, applies:
n The owner must be familiar with the applicable health and
safety regulations and must identify additional hazards that
arise due to the specific working conditions at the Inliner sys-
tems with MLT 40 installation site in a risk assessment. The
owner must implement this in the form of operating instructions
for using the Inliner systems with MLT 40.
n The owner must define work areas and danger zones.
Ä “Determining the location for installation” on page 102
n The owner must define a procedure for preventing the super-
ordinate production equipment from being turned on uninten-
tionally. The procedure in this manual refers to the Inliner
system with MLT 40 only.

Safety
Responsibility of the owner
n The owner must request and regularly evaluate and update the
safety data sheets for the operations and process equipment
used. He must produce operating instructions for handling the
operations and process equipment safely.
n Throughout the entire operating life of the Inliner systems with
MLT 40, the operator must check whether the operating
instructions he created correspond with the latest regulations
and must adjust them as necessary.
n The owner must clearly regulate and specify in writing the
responsibilities for installation, operation, troubleshooting,
maintenance and cleaning.
n The owner must ensure that all persons handling the Inliner
system with MLT 40 have read and understood this manual.
Furthermore, he must also train the personnel and inform them
about the dangers at regular intervals. This training must be
documented.
n The owner must provide personnel with the necessary protec-
tive equipment and instruct them of their obligation to wear the
necessary protective equipment.
Furthermore, the owner is responsible for permanently maintaining
the Inliner system with MLT 40 and other components of the pro-
duction system in a perfect technical condition. The following there-
fore applies:
n The owner must ensure that the service intervals described in
this manual are adhered to.
n The owner must carry out checks at regular intervals, or at
least following any maintenance work, to ensure that the safety
devices of all components of the production system are func-
tional.
n In the event of faults or irregular system behaviour, the owner
must ensure that operation is stopped immediately, the cause
is identified, and that the fault is resolved before operation is
resumed.
n The owner must ensure that the Inliner system with MLT 40 is
disconnected from the power and pressurised air system
during maintenance and repair works.

Safety
Personnel requirements
2.9 Personnel requirements
WARNING!
Risk of injury if personnel are insufficiently quali-
fied!
If unqualified personnel carry out work on the device or
are present in the system danger zone, hazards arise
that can result in serious injuries and considerable
material damage.
– Have all activities carried out by qualified per-
sonnel only.
– Keep unqualified personnel away from danger
zones.
Only persons 18 years of age or above, who can therefore be

expected to carry out their work dependably, are permitted as per-
sonnel. Personnel must have carefully read through and under-
stood this manual before starting any work. Following all safety
guidelines and instructions in this manual is the basic prerequisite
for safe work.
Persons whose reactions are affected, e.g. by drugs, alcohol or
other medication, are not permitted.
Observe the age and occupation-specific regulations applicable to
the installation site when selecting personnel.
Baumer hhs distinguishes between the personnel qualifications
listed below for the different fields of activity:
Manufacturer
Certain work operations may only be carried out by specialist staff
of Baumer hhs GmbH. Other staff are not authorised to carry out
these work operations. Contact our customer service department
about carrying out the work in question.
Operator
In training by the owner, the operator has been informed of the
tasks assigned to him and the possible hazards in the event of
improper conduct. Tasks beyond operation in the regular operating
mode may only be carried out by the operator if this is indicated in
this manual and the owner has explicitly entrusted the operator
with the task.
Owner
The owner is the person who operates or owns the Inliner system
with MLT 40, or who has assumed the decisive economic authority
over the technical operation of the equipment. Normally, the owner
is not Baumer hhs, but rather the purchaser of the system.
Professional pneumatic engineers

The professional pneumatic engineers are specially trained for the
sphere of work in which they are operating and are familiar with the
relevant standards and provisions.

Safety
Personnel requirements
Based on their professional training and experience, the profes-

sional pneumatic engineers are able to carry out work on pneu-
matic systems and identify and avoid possible risks independently.
Qualified electrician
Due to his technical training, knowledge and experience, as well as
his understanding of the relevant standards and regulations, a
qualified electrician is able to carry out work on electrical systems,
and identify and avoid possible hazards independently.
A qualified electrician has been specially trained in the working
environment in which he operates and knows the relevant stand-
ards and regulations.
Qualified mechanic
Due to his technical training, knowledge and experience, as well as
his understanding of the relevant standards and regulations, a
qualified mechanic is able to carry out work on mechanical sys-
tems, and identify and avoid possible hazards independently.
A qualified mechanic has been specially trained in the working
environment in which he operates and knows the relevant stand-
ards and regulations. A qualified mechanic is also familiar with the
super-ordinate system.
Unauthorised persons
WARNING!
Risk of death for unauthorised persons due to haz-
ards in the danger zones and work areas!
Unauthorised persons who do not fulfil the require-
ments described here are not familiar with the hazards
in the work area. For this reason, there is a risk of
serious injuries or death for unauthorised persons.
– Keep unauthorised persons away from the danger
zone and work area.
– If in doubt, address people and direct them out of
the danger zone or work area.
– Interrupt work as long as unauthorised persons are
in the danger zone or work area.
Training The owner must train personnel regularly. Training takes place
annually for safety-relevant aspects. For improved monitoring, a
training record with the following minimum content must be cre-
ated:
n Date of training
n Name of trainee
n Training content
n Name of trainer
n Signatures of the trainee and trainer

Safety
Safety information for replacem...
2.10 Personal protective equipment

Description of personal protective Personal protective equipment serves to protect people from
equipment impairments to health and safety during work.
During different types of work on and with the device, personnel
must wear the personal protective equipment specifically referred
to in the individual sections of this manual.
Protective gloves
Protective gloves serve to protect the hands against friction, abra-
sions, punctures or deep cuts as well as contact with hot surfaces.
Protective work clothing

Protective work clothing is close fitting work clothing with a low tear
resistance, tight sleeves and no protruding parts.
Safety boots
Safety boots protect feet from being crushed, from falling parts and
from slipping on slippery surfaces.
Safety goggles
Safety goggles serve to protect the eyes from flying fragments and
splashing liquids.
2.11 Safety information for replacement parts

Using incorrect replacement parts
WARNING!
Risk of injury due to the use of incorrect replace-
ment parts!
Hazards for personnel, as well as damage, malfunc-
tions or a total failure can occur due to the use of
incorrect or faulty replacement parts.
In the event of uncertainty, always contact our service
team.

Safety
Component-specific safety guidel... > Control cabinet safety
Warranty and guarantee

Invalidation of the warranty and guarantee
The warranty and guarantee become null and void if
unauthorised replacement parts are used.
Acquisition of replacement parts Replacement parts can be acquired from local contact partners or
direct from Baumer hhs. For contact information, see page 2.
2.12 Component-specific safety guidelines

2.12.1 Control cabinet safety
Preventing an unintentional restart
Personnel: n Qualified electrician
Protective equipment: n Protective work clothing
n Safety boots
1. Disconnect the power supply from the control cabinet.
2. Inform those responsible about work in the danger zone.
3. Attach a sign to the control cabinet power supply that indi-
cates work is being undertaken in the danger zone and pro-
hibits the control cabinet being reconnected to the power
supply.
Include the following information on the sign:
n Switched off on:
n Switched off at:
n Switched off by:
n Note: Do not switch on!
n Note: Only switch on after ensuring that there are no
risks to people.
WARNING!
Danger of death due to unpermitted restart!
4. Once all work has been completed. ensure that there are no
risks to people.
5. Ensure that all safety and protective equipment is installed
and functioning correctly.
6. Remove the sign.
7. Reconnect the power supply.

Safety
Component-specific safety guidel... > Linux terminal

Material damage to the terminal
NOTICE!
Material damage due to inappropriate cleaning
agents and cleaning methods!
Inappropriate cleaning agents and cleaning methods
can lead to material damage to the terminal and
external components.
– Only clean the terminal's touchscreen with a damp,
not wet, cleaning cloth.
– Only use gentle pressure on the touchscreen
during cleaning.
– Always use a cleaning agent with a flash point
above 55 °C.
– Always check that the cleaning agent is suitable for
cleaning the surfaces that require cleaning.
– Never use abrasives, solvents or other aggressive
cleaning agents for cleaning.
– Never clean with steam or pressurised air.
– Never clean with a jet of liquid (e.g. pressure
washer).
– Never scratch off dirt with sharp objects.
Cleaning the terminal

NOTICE!
Inappropriate cleaning agents and cleaning methods
can lead to material damage to the terminal and
external components.
– Only clean the terminal's touchscreen with a damp,
not wet, cleaning cloth.
– Only use gentle pressure on the touchscreen
during cleaning.
– Always use a cleaning agent with a flash point
above 55 °C.
– Always check that the cleaning agent is suitable for
cleaning the surfaces that require cleaning.
– Never use abrasives, solvents or other aggressive
cleaning agents for cleaning.
– Never clean with steam or pressurised air.
– Never clean with a jet of liquid (e.g. pressure
washer).
– Never scratch off dirt with sharp objects.

Safety
Component-specific safety guidel... > 3-way blank guide

Pressurised lines
WARNING!
Risk of injury due to pressurised lines and compo-
nents!
Pressurised lines can become disconnected and
cause serious injuries if assembled incorrectly.
– Only have appropriately qualified mechanics/pneu-
matics specialists carry out assembly work on
pressurised lines and components.
– Before commissioning pressurised components,
ensure that the lines are attached securely.
– Always ensure that pressurised material cannot
leak accidentally.
– Always have defective lines and components
replaced immediately by appropriately qualified
mechanics/pneumatics specialists.
Super-ordinate equipment
DANGER!
Risk of serious injury or death due to unintentional
commissioning of the super-ordinate equipment!
The Inliner system with MLT 40 requires an electrical
current for certain installation, maintenance and fault
elimination tasks. This creates a risk that the super-
ordinate machine will start unintentionally.
– Always ensure that the super-ordinate equipment
cannot be commissioned unintentionally.
– Always inform colleagues about work on the
machine.
– Always use a sign to show clearly that work is
being carried out on the machine.
An electrical current is required for the following tasks:

n Rinsing application heads.
n Moving the water bath.
n Checking the light sensor.

Safety
Component-specific safety guidel... > 3-way blank guide
Pressurised components
WARNING!
Risk of injury due to pressurised components!
Pressurised components may move uncontrollably and
cause serious injuries if used improperly. If used
improperly or if there is a defect, pressurised materials
may leak from pressurised components at high pres-
sure, causing serious injuries.
Before beginning work on these components:
– Depressurise and check the components. Also
ensure that any residual energy is discharged.
– All manometers must show 0 bar.
leak accidentally.
– Defective components which are operated under
pressure must be replaced immediately by pneu-
matic or mechanical specialists.
Moving components
CAUTION!
Danger of injury due to moving components!
The super-ordinate machine contains moving compo-
nents. There is a risk of injury when standing or
walking within the equipment due to the movement of
components.
– Do not enter the danger zones designated by the
owner.
– Only start the equipment when the protective cov-
ering and safety equipment are intact.
– When working on components of the Inliner sys-
tems with MLT 40, switch off the super-ordinate
production system and ensure it cannot be
switched back on accidentally.

Safety
Component-specific safety guidel... > Multi-application head
2.12.5 Multi-application head

Disconnected or disassembled
application heads WARNING!
Risk of injury due to uncontrolled spraying of
material when the application heads and hoses are
removed!
Individual working steps require operation with the
application heads or hoses removed or disassembled.
Operation with the application heads and hoses
removed or disassembled can cause serious injuries
e. g. to the eyes, due to the uncontrolled spraying of
material.
– Ensure a second person is ready to stop the
valves or hoses from working immediately.
– Only point disconnected valves and hoses down-
wards.
– Always place a suitable container underneath to
catch the material.
– Wear safety glasses while undertaking all work.
Pressurised lines
WARNING!
nents!
leak accidentally.

Safety
Component-specific safety guidel... > MLT colour filter installatio...
CAUTION!
Fluorescent dyes
The manufacturer of the adhesive defines how the dye
affects foods.
If in any doubt, contact the manufacturer to clarify
whether the dye is suitable for a specific application.
ENVIRONMENT!
Fluorescent dyes
The manufacturer of the adhesive defines how the dye
affects the environment.
If in any doubt, contact the manufacturer to clarify
whether the dye is suitable for a specific application.
Deep blue additional lighting

The blue lighting is very light and energy-intensive. It
therefore wears substantially faster than other light
sources. It is considered a wearing part and must
therefore be replaced in accordance with the duration
and intensity of use.

Safety
Component-specific safety guidel... > Pressure vessel

Pressurised equipment
WARNING!
Risk of injury when working on the pressure
vessel without depressurising it beforehand!
The pressure vessel is pressurised during operation.
Opening the pressure vessel or removing the connec-
tion hoses without first depressurising the equipment
can cause injuries due to splashing material or uncon-
trolled movement of components such as the material
hose.
– Before opening the hose coupling on the material
hose, check the pressure it is under on the vessel
air pressure (material pressure) manometer on the
front side of the equipment.
– Before opening the lid of the pressure vessel,
check the pressure it is under on the vessel air
pressure (material pressure) manometer on the
front side of the equipment.
– Before opening the hose coupling on the material
hose or opening the lid of the pressure vessel,
release the pressure via the vessel air pressure
(material pressure) regulator on the front side of
the equipment.
– Wear safety goggles and gloves during all work.
Pressure vessel operating pressure

WARNING!
Risk of injury and material damage due to high
operating pressure!
The maximum operating pressure of the pressure
vessel and the hoses and connections that carry the
product is 2.5 bar. Higher pressures can cause the
vessel, hoses and connections to burst. This can
cause serious injury and material damage.
– Never set the equipment to a pressure higher than
2.5 bar.
– Check the pressure on the product carrying parts
regularly using the vessel air pressure (material
pressure) manometer.
– Wear safety goggles while undertaking all work.

Safety
Component-specific safety guidel... > Pressure vessel
removed!
material.
wards.
catch the material.
Pressurised lines
WARNING!
nents!
leak accidentally.

Safety
Component-specific safety guidel... > Encoder IE-65-508
Unsuitable liquids
WARNING!
Risk of injury and material damage due to liquids
containing solvents!
The pressure vessel is intended to be used exclusively
with solvent-free liquids. Using liquids containing sol-
vents develops the risk of an explosive atmosphere
being created. Should this happen, the pressure tank
can explode and cause serious injuries and material
damage.
– Never use liquids containing solvents.
– Read and observe the safety data sheet for the
liquid.
– Only use liquids that do not state a flashpoint.
2.12.8 Encoder IE-65-508
CAUTION!
Risk of crushing due to moving parts!
If the encoder is freely accessible while the machine is
running, operate the encoder with a protective cover or
light barrier cover.

Safety
Component-specific safety guidel... > Alert set
2.12.9 Alert set

Improper assembly
CAUTION!
Risk of injury due to improper assembly of the
alert set!
Improper assembly of the alert set can result in haz-
ardous situations, causing serious injuries and consid-
erable material damage.
– Ensure that the base is suitable for supporting the
alert set.
Solid building walls and vibration-free and stable
machine components are also suitable supports.
– Ensure that the assembly location fulfils the oper-
ating conditions.
Ä “Status indicator operating conditions”
on page 530.
– Two people are required to assemble the alert set.
– Lay all connected lines and hoses so that there is
no risk of tripping.
If necessary, lay the lines and hoses in suitable
cable ducts.
Visible assembly location

NOTICE!
Risk of material damage if the status indicator
cannot be read clearly!
The status indicator must be installed in a location
– where the status indicator can be seen easily from
all operator stations and
– the acoustic signal from the horn is not weakened
by adjacent components.
Clear assignment
NOTICE!
Ensure there is clear assignment to the machine
The assembly location must allow the status display
and horn to be clearly assigned to a particular
machine. Multiple status displays or horns in close
proximity may confuse the operator so that he cannot
clearly assign the optical or acoustic signal to a partic-
ular event.

Layout and functional description
Corrugated board blank - definit...
3 Layout and functional description

3.1 Corrugated board blank - definition of terms
Definitions As with most sectors, the corrugated board industry has its own
terminology. This can be specific to countries or even to compa-
nies. Some of the terms used in this operating manual are there-
fore explained in terms of a Fefco 201 folding box, to prevent mis-
understandings.
The flaps
The flaps (Fig. 25/1+2) are used to close the box. The flaps are
divided into top flaps (Fig. 25/1) and bottom flaps (Fig. 25/2).
Fig. 25: Corrugated board blank: the

flaps
The crease lines

The crease lines are aligned parallel (Fig. 26/3) and transverse
(Fig. 26/4) to the running direction through the Inliner. They allow
the corrugated board box to be folded more easily.
The crease lines parallel (Fig. 26/3) to the running direction
through the Inliner are created by the same creasing tool that cuts
the slots.
The crease lines transverse (Fig. 26/4) to the running direction are
created during corrugated board production prior to entering the
Inliner.
Fig. 26: Corrugated board blank: The

crease lines

Corrugated board blank - definit...
The glue flap

Adhesive is applied to the glue flap (Fig. 27/5) before the folding
process. The glue flap connects two opposite panels together.

glue flap
The panels
The side walls of the corrugated board box are referred to as
panels (Fig. 28/6). A rectangular corrugated board box has four
panels. In this example, the height of the panels is defined by the
distance between the two outer crease lines.

panels
The slot depth

The slots on a folding box are the spaces that separate the indi-
vidual flaps. They are normally created using a slotting tool. but
can also be stamped. Slot depth refers to the length of the slot
from the upper or lower product edge to the centre. This can be
controlled by adjusting the slot shaft or the individual tools. The slot
width depends upon the tool being used.

slot depth
The slot width
Fig. 30: Corrugated board blank: The slot width

Functional description
The slot width, or “Gap” , is the slot produced when the first
(Fig. 30/A) and fourth (Fig. 30/D) panels have been brought
together for gluing (Fig. 30/8).
3.2 Functional description

On the Inliner system with MLT 40, stationary application heads
apply adhesive patterns to moving cardboard blanks. To do this,
the front edges of the blanks are detected by a light barrier. Once
the blank reaches the corresponding position in the blank guide,
the controller opens the adhesive application head for a short
period of time. This ensures that the same adhesive pattern is
applied to every blank in serial production. A monitoring unit
checks the quality of the adhesive application in terms of multiple,
definable criteria. Faulty or incorrectly detected blanks are marked
using the optional marking system and can therefore be rejected
easily.
On certain machines, there is the option for the controller of the
Inliner systems with MLT 40 and the Inliner to exchange informa-
tion between one another. If this is done, the Inliner system with
MLT 40 assumes the settings of the super-ordinate machine con-
troller without any further steps required. If needed, the controller
of the Inliner systems with MLT 40 can also stop the Inliner.
Optional equipment such as light displays and acoustic signal gen-
erators advise operators of the current production status or faults.
All figures and settings of the Inliner systems with MLT 40 are
easily and intuitively entered or adjusted on a terminal.
Individual components of the Inliner systems with MLT 40 can be
mounted on both production sides. This means that one-sided or
double-sided adhesive application is possible, depending on the
machine type.
Define adhesive application The control unit converts path and speed information from light
barriers and rotary pulse encoders into electrical impulses to the
application heads. These open and apply a predefined adhesive
pattern to the blank. This pattern is entered via the terminal and
contains details such as the start and end points of the adhesive
application or the length of the adhesive line and the dot spacing.
Save adhesive application pattern Defined adhesive patterns can be stored as a template on the ter-
minal. The settings can be called up, copied and changed as often
as needed. This allows for faster changeover times between dif-
ferent adhesive application patterns.
Preventing adhesive from drying Inliner system with MLT 40 has two methods to prevent drying out:
out
n a pneumatically driven water bath and
n a double-acting piston pump.

Function of the components > Control cabinet description
When the multi-application head is not working, the nozzles on the

application heads dip into the water bath.
The water bath ensures that
n no adhesive dries out in the nozzle,
n Inliner system with MLT 40 is ready for use after breaks in pro-
duction.
Using a double-acting piston pump means that the adhesive is
pumped out of the storage container to the application heads at
high pressure. So any dried out adhesive residues are removed.
Monitor adhesive application Product errors that occur during printing, stamping, folding and
adhesive application must be detected and marked. For this
reason, Baumer hhs systems have optional monitoring equipment
for various parts of the production machine.
The Inliner system with MLT 40 provides real-time measurement at
high machine speeds. All blanks are tracked as they make their
way through the machine and are checked and analysed according
to predefined, fixed parameters. The Inliner system with MLT 40
provides not only efficient monitoring of adhesive patterns, but also
checks areas where no adhesive should be.
Depending on optional, additional components, faulty blanks or
products can be marked or rejected.
3.3 Function of the components

3.3.1 Control cabinet description
Control cabinet
1 Control cabinet
2 Installation space for connection modules
3 Control cabinet door
4 Main switch
5 Door lock
A key component of the Inliner systems with MLT 40 is the control
cabinet. It contains the connection modules and an uninterruptible
power supply (UPS).
Access to the control cabinet is gained via the control cabinet door.
The door can be secured with a lock.
The control cabinet is attached to a wall using 4 screws.
Fig. 31: Control cabinet

Function of the components > Control cabinet description
Main switch
The main switch is used to switch the control cabinet on and off. A
padlock can be used to prevent the switch from being switched
back on by unauthorised persons.
Turning the main switch to "0" switches off the energy supply
immediately. This does not necessarily trigger a emergency stop.
The emergency stop function is controlled by the super-ordinate
equipment!
WARNING!
Danger of death due to uncontrolled restart!
An uncontrolled restart of the unit can result in serious
injuries or death.
Fig. 32: Main switch
– Before switching the unit back on, ensure that
there is nobody within the danger zone and all
safety devices have been mounted and are func-
tioning.
Connection modules Depending on the location of the control cabinet, the prepared
installation spaces on its side can be fitted with various connection
modules to connect system components.
The connection modules plugged into the control cab-

inet are described in separate chapters of this docu-
mentation or separate documentation.
Assembly and internal electrical connection of the con-
nection modules are carried out in-house by Baumer
hhs!

Function of the components > CPU module
3.3.2 CPU module
Fig. 33: 74490015
Connection Description
Status The module's status is indicated via four LEDs. Further information: Ä on page 59
Aux Input: 15-pin Sub-D
Start sensor 1-8, encoder 1/2
This connector can be used to connect further start sensors or encoders. Two
encoders are required if different parts of the super-ordinate machine run at different
speeds.
RS 232 RS 232 serial interface.
RS 485 RS 485 serial interface
Start sensor 1/2/3/4, encoder 1
Up to four start sensors and one encoder can be connected via this input.
Start 1/2/3/4 Input: Start sensor 1/2/3/4
Connection for start sensors 1/2/3/4. These must be assigned accordingly in the
operating software.
ENC 1 Input: Encoder 1
Alternatively, a decoupled 5V TTL signal can be applied that could be provided by
the machine controller for the super-ordinate machine, for example.
Level In Input: Fill level sensor for the material supply
Reset Input: Reset signal for the super-ordinate machine
The response to the reset signal can be set in the operating software.
0..20mA Output: Material pressure
Material supplies with IP converters receive a 0..20 mA signal which depends upon
the material pressure applied. This signal allows the material pressure to be adjusted
relative to the machine speed. See the "Pressure curve" section.

Function of the components > CPU module
Level Out Output: "Fill level alarm" signal
Ready Output: "Ready" signal
This output can be used to transmit a "Ready" signal to the super-ordinate machine.
Flap 1/2 Output: Nozzle sliding sealer 1/2
This output can be used to control two groups of nozzle sliding sealers. The parame-
ters for this must be set in the operating software.
Dual assignment of the inputs

The CPU module provides multiple options for con-
necting the start sensors 1-8 and the encoders 1/2.
Ensure that you only assign one corresponding input
at any one time, as errors can be caused otherwise!
LED status display

The voltage and operating status of the CPU module is
indicated by the LEDs.
LED Condition Meaning

(Colou
r)
1 + 24 V Illuminates as soon as the given
voltage is applied.
(red)
voltage is applied.
(red)
Fig. 34: CPU module status display
3 + 24 V Illuminates as soon as conditions
are fulfilled.
(red) 0...20 mA
short-circuit-
proof
4 Illuminates as soon as the CPU
boots.
(green)
The CPU module contains the connectors for the machine con-
troller. The components are connected to the corresponding con-
nectors on the CPU module as described above.

Function of the components > Terminal interface module
3.3.3 Application head module

37-pin Sub-D Connection for a multi-application head
or: Joint connection for up to 8 applica-
tion heads
with 24 V power supply
For application heads with a rinse
button, the signal for manual activation
of rinse mode in particular is transferred
directly on the application head.
01–08 Connection for application heads 01–08
For application heads with a rinse
button, the signal for manual activation
of rinse mode in particular is transferred
directly on the application head.
Fig. 35: 74490030
Dual assignment of the inputs

The module provides multiple options for connecting
application heads.
Ensure that you only assign one corresponding con-
nection at any one time, as errors can be caused oth-
erwise!
3.3.4 Terminal interface module

Using the "Terminal" connection on the module (Fig. 36)
n the power and signal supply for a terminal can be provided,
n control cabinets can be connected to one another for system
Fig. 36: 75909450 expansions, e.g. the addition of optional glue detection sys-
tems.
The electrical connection varies from system to

system.
Please see the wiring and circuit diagrams in the
appendix!

Function of the components > MLD module description
Voltage output 24 V
The supply voltage is 24 V. Due to the low voltage,
there is no risk to the operator.
3.3.5 MLD module description

The MLD module contains the connections for product monitoring
using an MLT sensor. The components required for sensor-sup-
ported product monitoring are connected here.
RS 232 RS 232 serial interface
SENSOR 1 Connection: MLT sensor
SENSOR 2 Connection: (optional) second MLT sensor
STATUS Connection: Status display
If a module for product tracking is avail-
able, the status display is connected to this
module.
LIGHT BARRIER X Connection: external light barrier or light
sensor (optional)
Fig. 37: 75915120
Signals from light barriers or light sensors
on other modules are normally accessed.
LIGHT BARRIER Y Connection: external light barrier or light
sensor (optional)
Signals from light barriers or light sensors
on other modules are normally accessed.
ENC Connection: Encoder (optional)
An encoder connected here can receive
path-dependant impulses from the
machine. Internal path-dependant
impulses from other modules are normally
accessed.
OPTION 1 Connection for service purposes and cus-
tomer-specific solutions
OPTION 2 Connection for service purposes and cus-
tomer-specific solutions

Function of the components > Linux terminal
3.3.6 Stopp-Link front plate

The Stopp-Link front plate contains the “Machine control” and
“Device connection IN” connectors.
Connector Description
Fig. 38: 75918030
Machine control Machine control provides a signal to the
super-ordinate machine. If there are con-
secutive errors, the signal triggers a feeder
stop. If there is a sensor or controller error,
it triggers a machine stop.
Device connection Device connection IN receives the signals
IN from the optional ejector controller.

3.3.7.1 Linux terminal
The connected system is operated and controlled using the Linux
terminal. The terminal is fitted with a touchscreen.
Fig. 39: 75010350
Linux terminal connections

1 Serial interface 1 (SUB-D socket 9-pin RS 232)
2 Serial interface 2 (SUB-D jack 9-pin RS 232 / RS 485)
3 Serial interface 3 (SUB-D jack 5-pin with Powerpin + CAN)
4 Ethernet connection 1
6 USB port
Fig. 40: Linux terminal connections The Linux terminal is connected to the connection module on the
control unit using serial interface 3 (Fig. 40/3).
A USB stick can be connected to the USB port (Fig. 40/6) for data
storage.
Other specific components can be connected to the other inter-
faces.

Function of the components > Glue delivery unit (KFE)
Linux terminal on/off switch

On/off switch
From the operator side, the on/off switch (Fig. 41/1) is located on
the underside of the device on the right-hand side.
Switching off the terminal using a super-ordinate

controller
If the super-ordinate controller is switched off, the ter-
minal is switched off automatically at the same time.
Leave the terminal's on/off switch in position "1" (ON).
Fig. 41 When the super-ordinate controller is started, the ter-
minal will also be switched on.
3.3.7.2 Terminal holder

The terminal holder is used to attach the Linux terminal.
Fig. 42: Terminal holder

1 KPE9 Piston pump
Ä “KPE9 Piston pump” on page 67
2 High pressure filter
Ä “High pressure filter” on page 70
3 PMDRE6 Pneumatic material pressure regulator
Ä “PMDRE6 Pneumatic material pressure regulator”
on page 69
4 Bracket
5 Pressure regulator
Ä “KFE Pressure regulator” on page 70
Fig. 43: 16940000

5 Pressure regulator
Ä “KFE Pressure regulator” on page 70
1 KPE9 Piston pump
Ä “KPE9 Piston pump” on page 67
3 KPE9 Wall bracket
4 High pressure hose
Ä “High pressure filter” on page 70
6 PMDRE6 Pneumatic material pressure regulator
Ä “PMDRE6 Pneumatic material pressure regulator”
on page 69
7 Bracket for PMDRE6
Fig. 44: 16940005
Functional description The piston pump (Fig. 45/KPE) on the glue delivery unit uses a
suction hose (Fig. 45/A) to draw adhesive out of an external,
unpressurised container (Fig. 45/M).
The piston pump transports the adhesive through hose lines
(Fig. 45/0...35 bar) with the required, regulated output pressure via
the adhesive distributor (Fig. 45/LVT) to the application heads
(Fig. 45/V) on the downstream equipment. A pneumatic material
pressure regulator (Fig. 45/PMDRE) allows adhesive to be made
even and ready to use at the application head according to the
speed. A high pressure filter (Fig. 45/HD) removes any impurities
from the adhesive.
Further components are available on an optional basis

and can be retrofitted individually.
See replacement parts lists.
– 19914000 Container with suction pipe
– 19914005 Container with suction pipe and fill level
sensor
– 19915100 Suction pipe for container
– 19915300 Suction pipe for container with fill level
sensor
– 7719xxx0 Alarm light complete with cable (various
lengths)

Layout diagram (example)
Fig. 45: KFE-KPE9-PMDRE6 Layout diagram (example)

KFE-KPE9- Glue delivery unit
PMDRE6
KPE Piston pump
PMDRE Pneumatic material pressure regulator
A Suction hose
B Incoming air regulator
HD Filter
H Rinsing connector with ball valve
L Material residue container
M Material container
S Control unit
V Application head
LVT Adhesive distributor
FS Fill level sensor
ENC Encoder/Encoder connection cable
0...20 mA Pump pressure control cable
6 bar PMDRE pressurised air supply (not shown)
6...8 bar KFE pressurised air supply
0...35 bar Material pressure
P1 Incoming air manometer (pump input pressure)
P2 Material output manometer
P3 Pressure sensor (actual material pressure
value)
X1 Controller connection (24 V)
X2 PMDRE Pressure sensor connection (P2)
X3 PMDRE Control unit connection
LEVEL IN Connection cable: Fill level sensor
LEVEL OUT Connection cable: Fill level alert light

Glue delivery unit control diagram
Fig. 46: KFE-KPE9-PMDRE6 Control diagram

1 Water separator
2 Incoming air pressure regulator
3 KPE9 Piston pump
4 Material container
6 PMDRE6 Material pressure regulator
7 Adhesive distributor
8 Application head
S Control unit
Ps Control signal
Pi Adhesive pressure
0...6 bar Regulated pressure
6...8 bar Input pressure: Air
0...35 bar Output pressure: Material
eReg Electronic regulation
P1 Air pressure (set to 6 bar)
P2 Output pressure: Material
P3 Pressure sensor

KPE9 Piston pump

1 Pump lid with handle
2 Electronics housing for reversing unit
3 X1 connection (24 V)
4 X2 connection (PDMRE6 Pressure sensor)
5 X3 connection (PDMRE6 Control unit)
6 Adhesive output (pressure side)
7 Adhesive input (suction side)
8 Oil filling screw
9 LEDs (display operating status, faults, software version)
10 Application head connection on the reversing unit
The piston pump draws the adhesive out of an external, unpressur-
ised container via a suction hose1 into the adhesive supply
(Fig. 47/7) and delivers this under pressure through the adhesive
output (Fig. 47/6) into the high pressure filter. The upward and
downward strokes of the piston pump create an even adhesive
pressure. An oil pad separates the air-carrying and adhesive-car-
rying components. This means that adhesive and air never come
into contact, even if the seals are damaged.
1 Suction hose length

Suction hoses must not exceed 5 m in length. Large
suction heights and long suction lines should be
avoided, particularly when using highly viscous adhe-
sives (>10,000 mPa*s). The maximum suction height
decreases as viscosity increases.
Fig. 47: 16012000

KPE9 Air consumption diagram
Fig. 48: KPE9 Air consumption

L Air consumption [l/min]
F Delivery rate [l/min]
H Number of double strokes/min
Average air consumption
Delivery rate
The air consumption diagram serves as a point of reference for cal-
culating the required volume of pressurised air for the piston pump.
The values in the diagram have been calculated using a test oil.
n Test oil viscosity approx. 60 mPa*s
n Incoming air pressure approx. 6 bar, ultimate pressure approx.
35 bar
The measurements were taken when running the piston pump
without counter-pressure. The normal working range of the piston
pump is up to 20 double strokes. Do not exceed this pump output
during continuous operation.
Example:
At a delivery rate of 2 l/min, the pump makes approx. 17 double
strokes. The air consumption here is 130 l/min on average.

PMDRE6 Pneumatic material pres-

sure regulator
1 Pressure sensor (X2 connection from piston pump)
2 Adhesive output (G 3/8)
3 Rinsing connector (6/4 mm)
4 Manometer
5 Control unit
6 Controller connection (X3 from piston pump)
7 Pressurised air connection
8 Adhesive input (G 1/2)
The PMDRE6 pneumatic material pressure regulator with high
pressure filter is installed between the piston pump and the adhe-
sive application heads and regulates the adhesive pressure to the
consumers. The pneumatic material pressure regulator adjusts the
adhesive pressure dynamically to suit the machine speed.
The glue is transferred from the piston pump through the adhesive
input (Fig. 49/8). The adhesive is first passed through a high pres-
sure filter. Impurities and foreign substances are filtered out of the
adhesive. A pressure sensor (Fig. 49/1) detects the adhesive pres-
sure in the system. The control unit (Fig. 49/5) implements the
target values for the reversing unit on the piston pump and adjusts
the adhesive pressure dynamically. The adhesive is passed
through the adhesive output (Fig. 49/2) to the consumers under an
even, regulated output pressure2.
Fig. 49: 19517600

NOTICE!
Damage due to contaminated adhesive!
To prevent damage to the piston pump due to impuri-
ties in the adhesive, the adhesive must be as clean as
possible when filled.
– Always cover adhesive when stored and protect it
from contamination. Always keep the adhesive
container closed.
2 Regulated output pressure

The regulated output pressure decreases due to fric-
tion loss, the properties and viscosities of the adhesive
in use, and the set material withdrawal amount.

High pressure filter

2 Adhesive output (G 3/8)
3 Rinsing connector (6/4 mm)
4 Adhesive input (G 1/2)
The adhesive is delivered under pressure from the piston pump
through the adhesive input (Fig. 50/4) into the high pressure filter
(Fig. 50/1). The high pressure filter filters out impurities from the
adhesive before these are able to reach the pneumatic material
pressure regulator and the adhesive application nozzles via the
adhesive output (Fig. 50/2). This reduces the risk of the nozzles
becoming blocked. The filtration process takes place initially
behind the piston pump on the pressure side of the system.
A filter screen in the suction pipe of the piston pump prevents
larger impurities from being drawn up
Ä Chapter 8.3.2.5.1 “Adhesive container with suction pipe and
hose maintenance” on page 402.
The high pressure filter can be cleaned via the rinsing connector
(Fig. 50/3).
Fig. 50: High pressure filter
KFE Pressure regulator

1 Pressure control knob
2 Air output
3 Inspection glass
4 Condensate drain plug
5 Manometer
6 Air input
The pressure regulator provides a constant air pressure in the
pressurised air system, even if the input pressure or air consump-
tion fluctuate. The pressurised air passed through the air input
(Fig. 51/6) contains small particles of dirt and water which are sep-
arated via the filter and inspection glass (Fig. 51/3) in the pressure
regulator. A manometer (Fig. 51/5) shows the regulated pressure
in the system.
Release the gathered condensate in the pressure reg-

ulator's inspection glass (Fig. 51/3) regularly via the
Fig. 51: 95411129 condensate drain plug (Fig. 51/4).
Ä “Releasing condensate” on page 349

Function of the components > Display and operating elements...
3.3.9 Display and operating elements on the glue delivery unit

Display elements on the KPE9
piston pump
1 LED 1 upper changeover point
2 LED 2 READY
3 LED 3 lower changeover point
Fig. 52 shows the display elements (LEDs 1 to 3) for the current
adhesive piston position in the adhesive cylinder during normal
operation.
Fault messages and version display

In the event of a fault, the corresponding fault is dis-
played via the LEDs Ä “KPE9 Display elements”
on page 453.
When the pump is restarted, the LEDs flash to display
Fig. 52: KPE9 Display elements the installed software version Ä Chapter 9.3.4 “Fault
messages on the KPE9 piston pump” on page 453.
LED Display Description

LED 1 upper changeover point green Upper air chamber is charged with pressur-
ised air.
The piston is on its downward stroke.
LED 2 READY green KFE (with PMDRE pneumatic material pres-
sure regulator) is ready for operation.
other Ä Chapter 9.3.4 “Fault messages on the
KPE9 piston pump” on page 453
LED 3 lower changeover point green Lower air chamber is charged with pressur-
ised air.
The piston is on its upward stroke.

Function of the components > Display and operating elements...
Pressure display for air pressure

regulator
The pressure regulator supplies the piston pump with the required
pressurised air. An electronic pressure regulator detects the
incoming air pressure and creates an even material pressure regu-
lator after the piston pump.
The pressure display (Fig. 53/1) for the pressure regulator displays
the incoming air pressure for the entire glue delivery unit.
Always set the incoming air pressure to 6 bar

(Ä Chapter 8.3.2.2 “Air pressure regulator mainte-
nance” on page 348).
Fig. 53: Air pressure regulator
Pressure display for the pneumatic

material pressure regulator
(PMDRE6)
The pressure display (Fig. 54/1) displays the adhesive pressure in
the pneumatic material pressure regulator (PMDRE6).
Fig. 54: PMDRE6 Pressure display
Fill level display

The fill level display signals that the level of adhesive in the adhe-
sive container has dropped below the minimum level by illumi-
nating the alarm light.
Preventing interruptions to production

To prevent interruptions to production, fill the adhesive
container immediately when the fill level display illumi-
nates.
Fig. 55: Fill level display

Function of the components > Optional components for the gl...
Further operating interfaces

Operation via control unit or equipment controller
Operation via the control unit, super-ordinate equip-
ment controller or control stand is also possible. Their
operation is explained in a separate document.
3.3.10 Optional components for the glue delivery unit

1 Suction hose
2 Lid
3 Adhesive container
4 Suction pipe
The adhesive container is used to prepare adhesive for the glue
delivery unit. The adhesive is drawn up from the adhesive con-
tainer (Fig. 56/3) via the suction pipe (Fig. 56/4) and passed
through the piston pump suction hose (Fig. 56/1). A lid (Fig. 56/2)
helps to prevent foreign substances from entering the adhesive
container and contaminating the adhesive.
A filter screen in the suction pipe prevents large impurities in the
adhesive container from entering the equipment.
Fig. 56: 19914000
Adhesive container with fill level

sensor (19914005) description
1 F1-2 Fill level sensor
2 33 l complete container
The adhesive container (Fig. 57/2) is used to prepare adhesive for
the glue delivery unit. The adhesive is drawn up from the adhesive
container via the suction pipe and passed through the adhesive
hose on the piston pump. A fill level sensor (Fig. 57/1) is used to
determine the adhesive fill level in the adhesive container.
A filter screen in the suction pipe prevents large impurities in the
adhesive container from entering the equipment.
Fig. 57: Adhesive container with fill

level sensor

Function of the components > Optional components for the gl...
Suction pipe for container

(19915100) description
1 Hose fitting (adhesive hose connection)
2 Suction pipe
3 Screw cap
4 Filter mesh housing with non-return valve
The adhesive is drawn up from the customer's adhesive container
through the suction pipe (Fig. 58/2) and is transferred via an adhe-
sive hose to the hose fitting (Fig. 58/1) on the connected glue
delivery unit. A filter screen in the filter mesh housing (Fig. 58/4)
prevents large particles of dirt from reaching the glue delivery unit.
The suction pipe is connected to the adhesive container with the
screw cap (Fig. 58/2) to ensure that it is dust-tight.
Fig. 58: Suction pipe for container
(optional) suction pipe for con-

tainer with fill level sensor
1 Hose fitting (adhesive hose connection)
2 Suction pipe
3 Screw cap
4 Float
5 Filter mesh housing with non-return valve
6 Fill level sensor
The adhesive is drawn up from the customer's adhesive container
through the suction pipe (Fig. 59/2) and is transferred via an adhe-
sive hose to the hose fitting (Fig. 59/1) on the connected glue
delivery unit. A filter screen in the filter mesh housing (Fig. 59/5)
prevents large particles of dirt from reaching the glue delivery unit.
The suction pipe is connected to the adhesive container with the
screw cap (Fig. 59/3) to ensure that it is dust-tight.
A fill level sensor (Fig. 59/6) with a float (Fig. 59/4) is used to deter-
mine the adhesive fill level in the adhesive container.
Fig. 59: 19915300

Function of the components > Fill level sensor
Fill level sensor for container

(15990025)
1 Cable connection
2 Fill level sensor
3 Float switch with permanent magnet
A reed switch is triggered using a float switch containing a perma-
nent magnet (Fig. 60/3). The potential-free connection can be used
as either a closer or an opener. In general, the Baumer hhs control
unit controls a 24 V lamp. The signal can be processed via a PLC
in the parent machine.
Fig. 60: Fill level sensor for container
Fill level display

sive container has dropped below the minimum level by illumi-
nating the alarm light. The fill level in the adhesive container is
detected using a fill level sensor.

The fill level sensor is used to detect the fill level of the material
container. If the fill level falls below a specified level, a signal is
produced via a signal light or another signal generator.

Function of the components > Fill level sensor
F1-2 Fill level sensor (15990021)

1 Fill level sensor
2 Nut (1/2")
3 Float switch with permanent magnet
Fig. 62: F1-2 Fill level sensor
A reed switch is triggered using a float switch containing a perma-

nent magnet (Fig. 62/3). The potential-free connection can be used
as either a closer or an opener (Fig. 63). In general, the Baumer
hhs control unit uses a signal light (24 V) to display the fill level
visually. The signal can be processed via a PLC in the parent
machine.
Fig. 63: F1-2 Fill level sensor circuit

diagram

Function of the components > 3-way blank guide
1 (optional) Adhesive monitoring system

2 3-way multi-application head
3 Pneumatic cylinder
4 Upper guide plate
5 Lower guide plate
6 FHDK light sensor
7 Water bath
8 "Inliner" adapter box
9 Inliner XTS² switchbox
Fig. 64: Example for 27893000
The blank guide ensures that the product is positioned exactly as

adhesive lines are applied to the product. Multi-line adhesive appli-
cation is carried out without direct contact between the multi-appli-
cation head and the product. The light sensor detects the product
being fed in and therefore controls the adhesive application. Adhe-
sive application can be monitored using an optional adhesive moni-
toring system. When stopped, the application heads are moved
into their “resting position” by pneumatic cylinders. As this is done,
the multi-application head nozzles are dipped into a water bath to
prevent the nozzles from drying out.
The switchbox can be used to move the multi-application head and
water bath in manual mode and to activate the multi-application
head nozzles.
The electrical connection for the blank guide is made via the
"Inliner" adapter box.
The blank guide can be mounted on one side (right or

left in the direction of production) or on both sides of
the production line.
Products can run in on both sides of the blank guide.

Fig. 65: 10259300

The guide plates (Fig. 65/1) for the optional guide plate extension
are screwed onto the upper and lower guide plates (Fig. 65/2) of
the blank guide on the side where products enter.
The guide plate extension ensures that thin products feed into the
blank guide correctly, thereby preventing errors caused when prod-
ucts enter at an incorrect angle.
FHDK light sensor
Fig. 66: FHDK light sensor
The light sensor (Fig. 67) detects the blanks in front of the optional
adhesive monitoring system in the blank guide. The light sensor
sends the start signal for adhesive application and adhesive moni-
toring. A second optional light sensor can be used to monitor the
blanks for skew.
The light sensor and the light sensor holder form a

single unit and cannot be replaced separately.

The light sensor has a yellow LED (Fig. 67/1) on its top side which
is used to display the operating status.
The following 3 operating statuses are displayed via this LED.
LED Meaning
Off no object detection
On object detected
Flashing n distance to the object in the critical
Fig. 67: FHDK function display area
n lens surface dirty
n incorrect orientation to the object
For further details, please see the “FHDK light sensor”

section.
Blank guide pressure regulator

1 Way valves
2 Pressurised air diffuser: Inputs and outputs
3 Manometer
4 Pressure regulator (complete)
5 Pressure control knob
The movement of the multi-application head and the water bath in
the blank guide are controlled pneumatically using a pressure reg-
ulator.
A manometer (Fig. 68/3) shows the regulated pressure in the
system.
Always set the air pressure for the pressure regulator

to 1.8 bar Ä “Check pressurised air setting”
on page 416.
The pressure regulator is fitted with a safety valve. If
the response pressure of 2 bar is exceeded, the safety
valve allows the pressurised air to escape into the
atmosphere.
Fig. 68: 27892510
Double-sided adhesive application

When applying adhesive to both sides, each blank
guide (right/left) has a separate pressure regulator.

Function of the components > 3-way multi-application head
Inliner XTS² switchbox
[Button] Description
1 [Rinse] Move application heads into working
position, rinse application heads
2 [UP] Move the water bath towards the appli-
cation heads.
3 [DOWN] Lower the water bath.
4 [AUTO/ Switch between automatic and manual
MANUAL] operation.
5 LED on each There is a yellow LED on each [button]
[button] which displays the activity of the associ-
ated function.
In manual mode, the most important functions of the application

heads and the water bath can be controlled manually using the
switchbox. In manual mode:
n the majority of maintenance work can be carried out and errors
rectified.
Fig. 69: Inliner XTS² switchbox n the position of the water bath is configured.

1 Application heads (module)
2 Electrical connection
3 Adhesive connection
4 Nozzles
5 Main body
6 Stroke regulator
The multi-application head consists of a main body, onto which the
modules with the nozzles are assembled. The multi-application
head is supplied with adhesive from the glue delivery unit provided
via the adhesive connection. It is connected to the control cable via
the electrical connection.
The stroke regulator is fitted to the module to regulate the adhesive
Fig. 70: 28590330 application volume. Depending on the settings, the armature on the
stroke regulator opens the application head to different widths so
that the volume of material delivered can be regulated.
The multi-application head is installed in the blank guide and
allows up to 3 adhesive lines to be applied to the product. A light
sensor on the blank guide detects the products and controls the
adhesive application.

Function of the components > 3-way multi-application head
Functionality of the application

head
The functional elements of the application head are:
n Solenoid coil
n Spring-return armature
n Seal
n Nozzle
n Stroke regulator
The adhesive (or other material) gathers under pressure in the
application head seat.
In an inactive state, the seal uses spring tension to seal the appli-
cation head seat in the nozzle (Fig. 71/1).
Fig. 71: Application head functionality
A pulse of current to the solenoid coil in the application head pulls
the armature against the spring. The nozzle aperture is released
and adhesive is delivered (Fig. 71/2).
When the pulse of current wears off, the armature closes under
spring tension. The flow of adhesive stops.
Operating elements
Fig. 72: Stroke regulator

1 Adjusting screw
2 Clamping ring
Each multi-application head contains individual modules with

stroke regulators as a control element.
The stroke regulator defines the upper stop point for the armature
when the coil is activated (the application head is opened).

Function of the components > MLT sensor
The armature stroke is adjusted by turning the adjusting screw.

The adjusting screw is limited to the stop points using a clamping
ring.
In the open position, the armature stroke is completely released.
This setting is only intended for assembly and disassembly. In the
open position, the application head can no longer be controlled
cleanly, meaning that the applied volume of material may vary. If
the armature stroke is opened too wide, the applied volume of
material may reduce.
In the lower position, all parts are in contact and the application
head can no longer open.
3.3.14 MLT sensor

1 Connection: Signal cable
2 Display: Status
3 Sensor
4 Production running direction
The MLT sensor with integrated lighting is used to detect material
errors and length errors and has the option to detect the edge dis-
tance on products in a production line. The sensor detects the rele-
vant features of the product and transfers this information to the
connected equipment controller. The signal is analysed and pro-
cessed here.
Material application is detected by way of contrast measurement.
The measurement area is illuminated with a line of LEDs. The
Fig. 73: 79020100 receiving lens projects the area for analysis onto the camera line.
The position of the material line is defined dynamically using an
algorithm to locate the edge. The product edge is detected for
additional analyses.
The colour of the material used must contrast with the substrate
and so be distinguishable from the base. Specially developed
external UV or blue lighting systems are required for fluorescent
materials with UV markers.
If the distance between the sensor and the product is 30 mm, the
measuring area covers 50 x 1 mm. The measurement area can be
limited to the right and left in the running direction.
Additional lighting is used to monitor the amount of dirt on the glass
panel and trigger a fault message (dust error) if necessary.
If the ambient light exceeds a certain threshold, a status output and
the extraneous light error LED on the sensor are activated.

Function of the components > MLT sensor
3.3.14.1 MLT sensor display and operating elements

1 LED: Extraneous light error
2 LED: Edge
3 LEDs: Material line detection: 1, 2, 3
4 LED: Object signal
5 Button: Setup
6 LED: Status display
7 LED: Dust error
DANGER!
Securing the super-ordinate machine
Access to the operating space for the super-ordinate
machine is generally required to use the operating ele-
ments of the MLT sensor. There is a risk of touching
moving parts in the super-ordinate machine. This can
cause serious or fatal injuries.
– Applying preferred settings for the MLT sensor via
the terminal.
– Ensure the super-ordinate machine is securely
switched off before entering the operating space.
Fig. 74: MLT sensor
The operating field for the MLT sensor contains the following display and operation options:
Display and operation option Display Description

Extraneous light error red LED illuminates red if the sensor is dazzled by
another light source.
(Fig. 74/1)
Edge (edge error) red LED illuminates red if the material is applied too
close to the edge of the corrugated board.
(Fig. 74/2)
1, 2, 3 (material line detection) yellow LED illuminates yellow if the respective material
line was detected.
(Fig. 74/3)
Object signal green LED illuminates green if the sensor receives a
signal from the light barrier and a product was
(Fig. 74/4) therefore detected.
Setup - If the button is pressed, all of the LEDs illuminate
once each in a clockwise direction.
(Fig. 74/5)
The sensor's measurement area is illuminated
onto the product to assist with setup. The light is
switched off by pressing the button once more.

Function of the components > MLT colour filter installatio...

Status display green LED illuminates green if the measurement is cor-
rect. If there is an error, the LED goes out.
(Fig. 74/6)
Dust error red LED illuminates red if the panel on the underside
of the measuring head is heavily contaminated.
(Fig. 74/7)

1 Mounting bracket
2 Connection
3 UV lights
The optional UV lighting system allows UV fluorescent adhesives
to be detected on difficult substrate surfaces. These include printed
or uneven surfaces, on which conventional or coloured adhesives
do not create sufficient contrast.
UV fluorescent adhesives are also used when the glue flap is
printed. Printed areas can be incorrectly detected as adhesive
when visible light is shone onto the measurement area.
Type of fluorescent adhesive

The detection system is designed as standard for
detecting blue fluorescent adhesives.
Further measures are required to be able to detect
other fluorescent adhesives.
The UV lighting installation kit for the MLT-40 multi-line sensor is

Fig. 75: 10259120 screwed onto the mount on the MLT-40 multi-line sensor and can
be retrofitted.
If you are using a UV light, you require a special cold

glue with UV brighteners!

Optimal fluorescence This fitting is optimised for the inspection of yellow fluorescent
adhesives. Other fluorescent dyes may require different filters and
lighting.

NOTICE!
Other fluorescent markers
Different fluorescent markers require different filters
and lighting.
Please forward the data sheet for the adhesive, which
must contain the emissions spectrum, to the Baumer
hhs service team to determine its suitability. Further
testing may be necessary.
MLT 40 deep blue additional

lighting
1 Mounting bracket
2 Connection
3 deep blue light
The deep blue lighting system enables yellow fluorescent adhe-
sives to be detected on difficult substrate surfaces. This includes
surfaces that are coated with optical brighteners.
Fig. 76: 79029365
3.3.16.1 Fluorescent dyes
If alternative fluorescent markers are suitable for the

relevant production requirements, these can stabilise
adhesive detection enormously.

Blue fluorescent markers

Blue fluorescent markers are traditionally used to improve the
detection of adhesives. The markers reflect a blue light when a UV
light is shone on them. However, these markers are no longer
useful in many areas. Cost pressures have led to the increased
use of recycled fibre materials in the paper and carton manufac-
turing industries. These appear somewhat grey when compared to
"virgin fibres". The surface of this type of paper and carton is there-
Fig. 77: Adhesive dot with blue fluo- fore coated in order to create a high-quality, white surface that is
rescent marker without optical bright- more suitable for printing. Fluorescent markers are added to the
ener surface coating in various amounts in order to intensify the white.
These work according to the same principle as the fluorescent
markers used in the adhesive: They convert invisible UV rays into
visible light. The substrate therefore appears whiter and the nor-
malised degree of white is easier to achieve.
When it comes to detecting the adhesive on coated substrate sur-
faces, this means that as the amount of blue fluorescent whitening
agent added increases, detection quality decreases. If the sub-
strate and adhesive appear as a similar shade of blue under UV
light, the required contrast is lost. The monitoring unit can no
longer detect the adhesive.
Fig. 78: Adhesive dot with blue fluo- The paper and carton manufacturers adjust the amount of
rescent marker with optical brightener whitening agent they use to meet the requirements of the produc-
tion run. This means that while one production batch may allow
detection to run perfectly, it may fail on another batch. Adhesive
application detection becomes unstable.
Alternative fluorescent markers Alternative fluorescent markers remit light in a different colour
range than traditional fluorescent markers. The remitted light there-
fore appears green, yellow or red. One feature of these alternative
fluorescent dyes is that the absorption spectrum (i.e. the range in
which the beams are absorbed by the markers) is closer to visible
light.
Fluorescent dyes are still just as highly effective on bright white
surfaces. The visibility of the adhesive is very helpful for the oper-
ator. However, it excludes all applications of this adhesive in visible
areas, for example on windows.
3.3.16.2 MLT colour filter functionality
Fig. 79: Schematic diagram: Adhesive detection

Function of the components > (optional) Skew
The emissions spectrum of the optical brighteners in the paper

matches that of the blue fluorescent markers. Whether a glue can
be detected on a paper substrate therefore depends solely on
whether the paper or the glue radiates more brightly. Fig. 79 left, a
brown paper substrate without an optical brightener. The beams
from the UV light source are absorbed by the paper. The adhesive
on the other hand, converts the beams into visible blue light that is
detected by the sensor. In the central diagram in Fig. 79, the white
paper substrate has the same properties as the adhesive. The
optical brightener coverts the UV rays into visible blue light. In this
case, the sensor cannot distinguish between the paper and the
adhesive.
Alternative fluorescent markers reflect different colours of light than
the blue fluorescent markers. The colour of the light they reflect dif-
fers clearly from the colour reflected by the optical brightener in the
paper. For example, the light is emitted from a yellow fluorescent
marker at much higher wavelengths than from the optical bright-
ener in the paper. The light reflected by the optical brightener can
be filtered out by using a suitable filter. This means that the sensor
only detects the light reflected from the markers in the adhesive, as
shown in Fig. 79 on the right.
Using these tools allows adhesive to be detected reliably on bright-
ened paper.
shows an example of an image captured with UV lighting:
n Left: Carton without optical brightener with adhesive dots with
blue (left) and yellow (right) fluorescent markers.
n Right: Standard copier paper with a high proportion of optical
brighteners with adhesive dots with blue (left) and yellow (right)
fluorescent markers.
Fig. 80: without a yellow filter
shows an example of an image captured with UV lighting through

a yellow filter. The yellow adhesive dots are much clearer:
n Left: Carton without optical brightener with adhesive dots with
blue (left) and yellow (right) fluorescent markers.
n Right: Standard copier paper with a high proportion of optical
Fig. 81: with a yellow filter brighteners with adhesive dots with blue (left) and yellow (right)
fluorescent markers.
This effect can be intensified further by using alternative lighting.

Skew consists of at least two separate light barriers. Skew is acti-
vated and controlled via the user interface. This function checks if
products are skewed. To be able to use Skew, two light barriers
must be assembled behind one another in the production running
direction. Signals from internal light barriers can also be used for
Skew.

Function of the components > FHDK light sensor

1 Light sensor holder
2 FHDK light sensor
Fig. 82: Individual skew light sensor

A light barrier is an electronic optical sensor which detects interrup-
tions to a light beam. This means that the system can detect
moving objects without touching them. This product detection trig-
gers functions in the system. The terms “light sensor” and “light
barrier” are used synonymously in this operating manual, although
they strictly refer to a reflective light sensor. Where a function of a
light barrier is described, we refer to it as a light barrier. When
describing special functions, we use the term light sensor.
Light barriers are of great importance for the functionality of the
entire system. Without light barriers, many basic functions cannot
be triggered. Quality monitoring sensors often feature an integrated
light barrier.
Light sensor can only be used for individual prod-

ucts
The light sensor is only intended for the detection of
individual products as it detects the edge of the object.
For continuous applications, a different light barrier
must be used that can detect features such as print
marks on the product.
FHDK light sensor function display

The light sensor is fitted with a yellow LED (Fig. 83/1) which dis-
plays the current function status.
Fig. 83: FHDK function display

Function of the components > Marking system
LED status Meaning

Off No object detection
On Object detected
Flashing n Distance to the object in the critical
area
n Lens surface dirty
n incorrect orientation to the object
3.3.20 Marking system

1 Pressure vessel
2, 6 Material hose
3 Cable for spray application head
4 Sprayed air hose
5 Spray application head
The marking system is used to apply materials onto products for
marking purposes.
The marking system marks faulty products with a special marking
fluid during production. These products can then be ejected in a
targeted manner.
The marking fluid is pressurised with pressurised air in the pres-
Fig. 84: 10259295 sure vessel up to a maximum of 2.5 bar. The material hose
(Fig. 84/2) dips into the marking fluid (Fig. 84/6) in the pressure
vessel and the applied pressure transfers it to the spray application
head.
The material application pattern is freely programmable via the ter-
minal. Start and end points for the application can be set here. The
terminal receives information regarding distances and speeds via
optical initiators and a rotary pulse encoder.
Pressure vessel:
Ä Chapter 3.3.21 “Pressure vessel” on page 90
Spray application head:
Ä Chapter 3.3.22 “Marking valve” on page 91

Function of the components > Pressure vessel
Optional sprayed air shut-off

There is the option to fit a sprayed air shut-off into the equipment
(Fig. 85/1).
This is installed between the pressure vessel (Fig. 85/2) and the
spray application head (Fig. 85/3).
It switches the sprayed air supply to the spray application head off
when the application head is inactive. This means that the system
requires less pressurised air.
Ä Chapter 3.3.23 “(optional) Sprayed air shut-off” on page 93
Fig. 85: Sprayed air shut-off position

1 Bulkhead fitting (material hose connector)
2 Pressurised air hose
3 Sprayed air pressure manometer
4 Sprayed air output
5 Sprayed air pressure regulator
6 T-distributor with pressurised air input
7 Vessel pressure (material pressure) regulator
8 Vessel pressure (material pressure) manometer
9 Pressure vessel bracket
10 Pressure vessel
11 Safety valve
The marking fluid in the pressure vessel is pressurised up to a
maximum of 2.5 bar using pressurised air, and transferred to the
connected spray application head via the material hose. The spray
application head also receives sprayed air. The air pressure in the
vessel and the sprayed air pressure can be controlled using pres-
Fig. 86: 12020300 sure regulators. The respective pressures can be read from sepa-
rate manometers.

Function of the components > Marking valve
3.3.21.1 Pressure vessel operating elements

1 Sprayed air pressure manometer
3 Vessel air pressure (material pressure) regulator
4 Vessel air pressure (material pressure) manometer
5 Safety valve
The pressure vessel (Fig. 87) is fitted with 2 pressure regulators
and 2 manometers:
The sprayed air pressure bypasses the vessel and is transferred
directly to the connected spray application head. The sprayed air
pressure is regulated via the pressure vessel. The pressure regu-
lator (Fig. 87/2) on the right can be used to set the sprayed air
pressure for the spray application head. The manometer (Fig. 87/1)
on the right displays the set sprayed air pressure.
The pressure regulator (Fig. 87/3) on the left defines the vessel air
pressure. This is identical to the material pressure, which is used to
Fig. 87: Pressure vessel operating deliver the material to the spray application head and to apply the
elements material via the spray application head. The vessel air pressure
must not exceed 2.5 bar. The manometer (Fig. 87/4) on the left is
used to control the vessel air pressure.
On the far side of the lid from the pressure regulator, there is a
safety valve which activates if the permissible vessel pressure is
exceeded (Fig. 87/5).

The spray application head is an electrically activated valve used
to apply fluids. The application is intermittent and can also be con-
trolled individually. The application head is designed for low to
medium viscosity fluids. The viscosity of the fluid can be up to 1000
mPa*s (Brookfield) and is dependent upon the fluid pressure. It
provides finely spread fluid application by atomising the fluid using
pressurised air. Overspray is possible with spray application, but
can be drawn off if necessary.
Fig. 88: 27480300

Function of the components > Marking valve
Structure
1 Material supply
2 Stroke adjustment (stroke regulator)
3 Sprayed air supply
4 Bracket
5 Nozzle
6 Union nut/air cap
7 Coil
8 Device plug with connection cable
The components of the spray application head are installed into the
bracket. On the upper side of the spray application head you will
find the stroke adjustment, which defines the material volume to be
applied, as well as the connections for the material supply and
pressurised air input.
On the underside are the union nut and air cap with the nozzle
behind.
The electrical connection for the spray application head is made
via the device plug on the coil.
Fig. 89: Spray application head
Function
1 Closed nozzle
2 Pressure spring
3 Open nozzle
4 Sprayed air
The material to be sprayed is pressurised at the application head
seat. The needle is closed into the application head seat and held
in place with spring pressure.
A pulse of current to the solenoid coil pulls the armature against
the spring and opens the nozzle aperture so that material can be
delivered. The armature stroke can be adjusted using a regulator
knob (stroke adjustment). This means that the armature can open
the application head to different widths so that the amount of mate-
Fig. 90: Spray application head func- rial applied can be regulated.
tion
Sprayed air is also emitted from the edge of the nozzle to spread
the material finely as it is applied.
When the pulse of current wears off, the armature closes under
spring pressure. The material stream is interrupted.
The sprayed air shut-off is available as an option and can save
expensive pressurised air under certain operating conditions. The
sprayed air is then controlled via a separate 3/2-way valve. An air
regulator at the sprayed air source adjusts the spray application
exactly as needed. It switches off the sprayed air when there are
no products being processed.

Function of the components > (optional) Sprayed air shut-off
The 3/2-way valve and air regulator are not included in

the delivery.
3.3.22.1 Spray application head operating elements

Stroke adjustment (stroke regu-
lator)
There is a stroke adjustment on the upper side of the spray appli-
cation head.
The material volume can be adjusted using the stroke adjustment.
This means, for example, that multiple application heads can be
aligned with each other.
The stroke adjustment defines the upper stop position for the
armature when the coil is activated. (Opening the application head)
When the armature stroke is completely open, the material volume
cannot be regulated. This position is only intended for assembly
and disassembly.
Fig. 91: Stroke adjustment
Only open the armature stroke far enough to ensure

the material application can be regulated.
At the lower stop point, the armature needle can no longer open
the application head.

Function of the optional sprayed air The sprayed air shut-off is situated between the pressure supply
shut-off and spray application head.
Without the sprayed air shut-off, the spray application head is con-
tinuously supplied with pressurised air. The optional sprayed air
shut-off always switches off the pressurised air supply to the spray
application head when there are no products being worked on.
This saves pressurised air.

Function of the components > IE-65-508 Encoder
1 Sprayed air input

2 Sprayed air output
3 Sound absorber
4 Electrical connector (application head connection plug)
5 T-distributor
The sprayed air shut-off (Fig. 92) has two connections for pressur-
ised air (sprayed air input, Fig. 92/1; sprayed air output Fig. 92/2),
a sound absorber (Fig. 92/3) and an application head connection
plug (Fig. 92/4) to control the application head.
In the housing, there is a solenoid valve that can release or inter-
rupt the sprayed air supply according to an external signal.
Fig. 92: 10259291
Sprayed air shut-off installation kit The sprayed air shut-off installation kit consists of:
n Solenoid valve
n Connection plug with cable (10 m)
n T-distributor
Ä Chapter 12.1.17 “(optional) Sprayed air shut-off” on page 573
3.3.24 IE-65-508 Encoder

An encoder converts the production speed into control pulses for
the control unit.
The speed can be detected in two ways:
n with a friction wheel,
n with a toothed belt.
The machine speed will be displayed in distances per pulse.
Fig. 93: Encoder (example) The distance will be given in mm or inches depending upon the
system settings.
The accuracy of this setting has a direct influence on

the processing accuracy!

Function of the components > Alert set
3.3.25 Alert set

The alert set consists of the status display (Fig. 94/1–4) and the
horn (Fig. 94/5). The operating statuses of the equipment are indi-
cated via optical and acoustic signals.
The status display (Fig. 94/1–4) indicates the current operating
status by way of coloured light signals.
The coloured light signals on the status displays correspond with
the coloured display in the status header in the operating software.
Light signals on the status display
Light signal Description

red Error
Fig. 94/1 n Illuminates if a machine/feeder stop is trig-
gered.
n Flashes if there are active warning mes-
sages.
Fig. 94: 10259250 yellow-orange Setup mode

Fig. 94/2 n Illuminates during setup mode.
green Production
Fig. 94/3 n Illuminates during production (automatic
mode).
blue Teaching cycle
Fig. 94/4 n Illuminates during active teaching cycles
(programming).
If there is an error, an acoustic warning signal is given via the horn

(Fig. 94/5) provided this is activated in the software.
The controller can be used to activate and deactivate

the horn's warning signal and to adjust the duration of
the signal.
There is an option to select whether the horn can be
activated and deactivated via a special button in the
production menu in the operating software.

Function of the components > Alert set

Transport and storage
Transport inspection
4 Transport and storage

4.1 Safety guidelines for transport and storage
WARNING!
Risk of injury to the musculoskeletal system
The weight of the package can be found on the consignment note

or printed on the packaging. Use appropriate transport and lifting
equipment if the proportional weight is greater than 25 kilograms
per person.
Improper transport
NOTICE!
Material damage due to improper transport!
Packages may fall or topple over due to improper
transport. This can result in considerable material
damage.
– Proceed with caution and observe the symbols and
instructions on packaging when unloading pack-
ages during a delivery and during internal trans-
port.
– Do not remove packaging until shortly before
assembly.
4.2 Delivery
The packaging protects the individual components against trans-
port damage, corrosion and other damage until installation. For this
reason, do not destroy the packaging.
The Inliner system with MLT 40 is packed in accordance with the
expected transport conditions. The packaging size and material
can vary depending on the total delivery volume.
4.3 Transport inspection

Check the delivery for completeness and for transport damage
immediately upon receipt.
In the event of visible external transport damage, proceed as fol-
lows:
n Do not accept the or accept the delivery with reservation only.
n Note the extent of the damage on the transport documentation
or on the transporter's delivery note.
n Filing a complaint.

Disposing of packaging materials
File a complaint for every defect as soon as it is

detected. Claims for damage can only be invoked
within the statutory reclamation period.
4.4 Storage of packages

Storage of packages Store packages under the following conditions:
n Do not store outdoors.
n Store in a dry dust-free place.
n Do not expose to aggressive media.
n Protect from direct sunlight.
n Avoid mechanical shocks.
n Storage temperature: 15-40 °C.
n Relative humidity: max. 80%, non-condensing
n If storing for a period of more than 3 months, check the general
condition of all parts and the packaging regularly.
4.5 Disposing of packaging materials

Dispose of packaging materials in accordance with the respective
applicable provisions and local regulations.
ENVIRONMENT!
Risk to the environment due to incorrect disposal!
Packaging materials are valuable raw materials and, in
many cases, can continue to be used or sensibly
reprocessed and reused. The incorrect disposal of
packaging materials can result in risks to the environ-
ment.
– Dispose of packaging materials in an environmen-
tally sound manner.
– Observe the locally applicable disposal regula-
tions. If necessary, instruct a specialist company to
carry out the disposal.
– The recipient is responsible for any costs associ-
ated with the disposal.

Component-specific transport inf...
4.6 Component-specific transport information
WARNING!
Risk of injury to the musculoskeletal system
The weight of the package can be found on the consignment note

or printed on the packaging. Use appropriate transport and lifting
equipment if the proportional weight is greater than 25 kilograms
per person.

Component-specific transport inf...

Assembly and installation
Safety guidelines for assembly a...
5 Assembly and installation

5.1 Safety guidelines for assembly and connection
Improper assembly and installation
WARNING!
Risk of injury due to improper assembly and instal-
lation
Improper assembly or installation can result in haz-
– Have assembly and installation work carried out by
Baumer hhs employees or authorised specialist
personnel only. Personnel requirements can be
found in Ä Chapter 2.9 “Personnel requirements”
on page 40.
– If assembly and installation are to be carried out by
other persons, it must be ensured that these per-
sons
– have read and understood this operation
manual,
– strictly adhere to the information in this opera-
tion manual,
– have the necessary specialist knowledge to
assemble and install the device.
– If assembly and installation are to be carried out by
internal personnel, or by personnel contracted by
the operator, the operator is responsible for
ensuring the assembly and installation are carried
out correctly and safely.
– Ensure sufficient space for assembly before begin-
ning work.
– Make sure that the assembly site is clean and tidy!
Loose components and tools lying around or on
top of each other are sources of accidents.
– Define the assembly location. Always ensure that
the device can be accessed and operated safely.
– Assemble all of the components correctly.
– Always follow the operation and assembly manuals
for additional components.

Safety guidelines for assembly a...
Determining the location for instal- Personnel: n Owner

lation
Determine the location for installation and workspaces using
the following criteria:
n The operator must be able to reach the terminal or oper-
ating display safely.
n The operator must be able to see the information on the
terminal or operating display safely.
n The operator must be able to use the operating elements
for glue delivery safely.
n The operating elements for other components such as
sensors must be able to be operated safely.
n Signalling devices (optional) must be visible from all
workspaces on the machine.
n The operator must be able to safely monitor the adhesive
level in the adhesive container and refill the adhesive.
n The system must not be exposed to strong shocks.
n The system must not be exposed to strong draughts or
temperature fluctuations.
n The installation location must be indoors and dry.
n The installation location must be kept at or above a min-
imum temperature of 15 ºC or 60 ºF throughout the year.
n The temperature at the installation location must not
exceed the maximum operating temperature of the
installed components at any time.
n The installation location must not be close to flammable
or explosive materials.
n All lines and electrical cables must be installed in such a
way that they do not cause any risk or danger to the
operator.
n All lines and electrical cables must be installed in such a
way that they cannot be damaged during operation.
n Components must be assembled outside of the danger
zone / working range of the machine elements of the
super-ordinate machine.
n Potential risks must be recorded using a risk analysis
with reference to the safety information in this operating
manual and be referred to when selecting the installation
location.

Assembling the components > Assembling the control cabinet
5.2 Assembling the components

5.2.1 Assembling the control cabinet
CAUTION!
control cabinet!
Improper assembly of the control cabinet can result in
hazardous situations, causing serious injuries and con-
siderable material damage.
– Ensure that the assembly location fulfils the oper-
ating conditions.
– Ensure that the support is suitable for holding the
control cabinet.
– Solid building walls and vibration-free and stable
machine walls are also suitable supports.
– Never install the control cabinet near water or mag-
netic fields.
– Use the borehole diagram to align the control cab-
inet.
Personnel: n Qualified mechanic

Protective equipment: n Safety boots
1. Use the borehole diagram to produce a drilling template.

2. Mark boreholes onto the support using the drilling template.
3.
CAUTION!
Risk of injury due to careless handling of
tools!
NOTICE!
Risk of material damage due to contamina-
tion during drilling!
Fig. 95: Control cabinet borehole dia-
gram (dimensions in mm) Drill 4 core holes for M8 threads on the markings. Cut M8
threads.
Or if using screws and nuts: drill 4 through holes for M8
screws.
Or if screwing the control cabinet onto a solid building wall:
drill 4 holes for dowels for M8 screws.
Insert 4 dowels into the holes in the solid building wall.

Assembling the components > Assemble modules
4.
CAUTION!
Risk of crushing due to the control cabinet
door falling!
Open the control cabinet:

n Turn the main switch to the "Zero" position.
n Open the control cabinet with a control cabinet key.
5.
CAUTION!
Risk of injury due to the control cabinet
falling!
The selection of the screws depends on the

material that the support is made of.
Hold the control cabinet over the pre-drilled holes on the sup-
port. Have another person screw the control cabinet to the
support using 4 screws and a screw driver.
6. Lock the control cabinet door with a control cabinet key.
ð You can now connect the devices to the control cabinet.
5.2.2 Assemble modules
The modules are installed in the equipment's control

cabinet. Assembly is carried out in-house by Baumer
hhs.
The installation position of the modules within the equi-
pment's control cabinet varies from system to system.
appendix!

Assembling the components > Mounting the Linux terminal on...
5.2.3 Mounting the Linux terminal onto the terminal holder

n Safety boots
CAUTION!
Risk of injury due to the terminal falling!
When assembling the terminal, ensure it is in the

correct position!
The connections on the terminal (Fig. 96/1) must point
down.
Optional accessory
The terminal can be mounted onto the terminal holder
(item number: 89600350).
1. Have another person hold the terminal (Fig. 96/1) over the
holes on the mounting plate (Fig. 96/2) on the terminal
holder.
2. Place the washers (Fig. 96/3) between the terminal and the
terminal holder.
3. Place a spring washer (Fig. 96/4) between the terminal
holder and each nut (Fig. 96/5).
4. Use the 4 nuts (Fig. 96/4) to screw the terminal onto the ter-
minal holder.
ð The terminal is installed and ready for connection.
Fig. 96: Mounting the terminal on the

terminal holder (example).

Assembling the components > Glue delivery unit
5.2.4 Glue delivery unit
CAUTION!
glue delivery unit!
Improper assembly of the glue delivery unit can result
in hazardous situations, causing serious injuries and
considerable material damage.
– Use the borehole diagram to align the glue delivery
unit.
– Check whether the support is suitable for holding
the glue delivery unit.
– The assembly site must fulfil the operating condi-
tions.
– Lay all connected lines and hoses so that they
cannot cause a tripping hazard (if necessary, the
lines and hoses should be run through suitable
cable ducts).
– Two people are required to assemble the glue
delivery unit.

n Qualified electrician
n Safety goggles
n Protective gloves
n Protective work clothing
1. Use the borehole diagram (Fig. 97) to produce a drilling tem-

plate.
2. Mark boreholes (Æ 11) onto the support using the drilling
template.
Fig. 97: KFE-KPE9-PMDRE6 bore-

hole diagram (dimensions in mm)

Assembling the components > Glue delivery unit
3.
CAUTION!
tools!
NOTICE!
Select a method for attachment:
Thread cutting
n Drill a core hole on each of the markings for an M10

thread.
n Cut M10 threads into the core holes.
Through holes
n Drill 4 through holes for Ø 10 mm screws.

Dowels
n Drill 4 dowel holes for M10 screws.

n Place a dowel into each hole.
4.
CAUTION!
Risk of injury due to the glue delivery unit
falling!

1st person: Hold the glue delivery unit over the pre-drilled
holes on the support.
2nd person: Screw the glue delivery unit onto the support
using 4 screws and a suitable tool.

Assembling the components > Glue delivery unit with separa...
5.2.5 Glue delivery unit with separate material pressure regulator
CAUTION!
glue delivery unit!
Improper assembly of the glue delivery unit with sepa-
rate material pressure regulator can result in haz-
– Use the borehole diagram to align the glue delivery
unit.
– Check whether the support is suitable for holding
– The assembly site must fulfil the operating condi-
tions.
– Lay all connected lines and hoses so that they
cannot cause a tripping hazard (if necessary, the
lines and hoses should be run through suitable
cable ducts).
– Two people are required to assemble the glue
delivery unit.


n Safety goggles
n Protective gloves
Fig. 98: KFE-KPE9 with separate PMDRE6 borehole diagram

(dimensions in mm)
1. Use the borehole diagram (Fig. 98) to produce a drilling tem-
plate.
2. Mark boreholes (M8) onto the support using the drilling tem-
plate.

3.
CAUTION!
tools!
NOTICE!
Thread cutting

thread.
Through holes
n Drill through holes for M8 screws.

Dowels
n Drill dowel holes for M8 screws.

n Place a dowel into each hole.
4.
CAUTION!
Risk of injury due to the glue delivery unit
falling!

1st person: Hold the glue delivery unit and separate material
pressure regulator respectively above the pre-drilled holes on
the support.
2nd person: Screw the glue delivery unit and separate mate-
rial pressure regulator onto the support using 4 and 2 screws
respectively and a suitable tool.

Assembling the components > Media supply to the glue deliv...
5.2.6 Media supply to the glue delivery unit

n Safety goggles
n Protective gloves
Materials: n Suction hose (95103100)
n Hose clip (95131125)
n Hose clip (95130920)
n Lubricant (16100001)
The adhesive supply to the glue delivery unit runs from an external
adhesive container through a suction hose on the intake manifold
(Fig. 99/1) on the glue delivery unit.
Connecting the adhesive supply
1. Connect the suction hose (Fig. 99/3) to the intake manifold
(Fig. 99/1).
Ensure that there are two O-rings (Fig. 99/2) on

the intake manifold.
The suction hose should not sag. Shorten the
suction hose accordingly.
2. Secure the suction hose onto the intake manifold with a hose
clip (Fig. 99/4) (95130920).
The adhesive is passed into the adhesive distributor and applica-

tion heads via the adhesive output (Fig. 99/5).
Fig. 99: Connecting the adhesive

supply


Connecting the adhesive output
Connect the adhesive distributor and application heads to the
adhesive output (Fig. 100/1).
To
– fill the glue delivery unit with adhesive,
– rinse the glue delivery unit and
– change the adhesive,
the material can be passed through the rinsing
connector (Fig. 100/2) until it is purely of one
type, clean and contains no trapped air.
Fig. 100: Connecting the adhesive

output

Filling lubricant
1. Unscrew the locking screw (Fig. 101/1) from the filling hole.
2. Fill with lubricant up to the lower edge of the filling hole.
3. Screw in the locking screw.
Fig. 101: Filling lubricant

5.2.6.1 Placing the suction hose

Placement instructions for the suc-
tion hose
1. Place the suction hose so that it always runs upwards from
the point suction begins in the adhesive container up to the
pump.
2. Prevent "kinks" in the suction hose by shortening the suction
hose to the required length.
Fig. 102: Suction hose
Filling the suction hose during In the case of large height differences, long suction hoses and high
commissioning adhesive viscosity, we recommend that you fill the suction hose
with water prior to commissioning.
1. Dip the intake manifold into a container of water.
2. Fill the suction hose completely with water.
If this is not done, the suction process can take a

very long time and the sealing pack can wear
prematurely.
3. Dip the intake manifold into the adhesive to be delivered.
The back pressure ball inside the intake manifold

prevents the water and adhesive from mixing.
4. Deliver the adhesive until it reaches an undiluted state.

Assembling the components > 3-way blank guide
Assemble the FHDK light sensor

onto the blank guide
n Qualified mechanic
Protective equip- n Safety goggles
ment: n Safety boots
Materials: n FHDK light sensor
n 4.5 m cable extension for FHDK light
sensor
DANGER!
the super-ordinate machine and its moving parts!
1. Insert the FHD light sensor and its holder (Fig. 103/1) into the
blank guide.
2. Attach the light sensor holder to the blank guide with the
clamping lever (Fig. 103/2).
The light sensor holder beneath the optional

adhesive detection system is attached with one
cylindrical screw for space reasons.
3. Attach the light sensor holder (Fig. 103/3) for the second
optional light sensor in the same way as described in steps 1
and 2.
4. Connect the light sensor electrically.
See the wiring and circuit diagrams in the appendix.
5. Align the light sensor(s) (Ä “Align the FHDK light sensor”
on page 115).
Fig. 103: Assemble the FHDK light

sensor
Double-sided assembly
Assemble the light sensor on the second side in the
same way as described above.

Align the FHDK light sensor

The light sensor is used to detect the blanks for
n the optional adhesive monitoring system,
n skew control,
n product counts.
The light sensor holder is mounted on the upper guide plate
(Fig. 104/2) of the blank guide. Therefore, the vertical position
(height) of the FHDK light sensor is defined by the position of the
upper guide plate.
The distance between the FHDK light sensor and the

product is approx. 20 mm.
DANGER!
Fig. 104: Align the light sensor the super-ordinate machine and its moving parts!
(example)
1. Switch the equipment to setup mode

ð The light sensor is active.
2. Loosen the knurled screws (Fig. 104/1) on the light sensor
holder (Fig. 104/3).
3. Slide the light sensor holder (Fig. 104/3) sideways until the
light sensor's downward field of view is clear.
The light sensor's downward field of view must

be clear for a minimum of 50 mm. The light sen-
sor's light beam must not be reflected from
neighbouring machine parts!

4. Pass a blank (Fig. 105/1) between the guide plates

(Fig. 105/2) on the blank guide until it is detected by the light
beam (Fig. 105/3) from the light sensor.
ð The LED on the light sensor illuminates.
5. If necessary, slide the light sensor holder (Fig. 105/3) per-
pendicular to the transport direction of the blank until the light
beam from the FHDK-10 light sensor meets an edge of the
blank that is at a right angle to the transport direction.
Check again that the light sensor's downward

field of view is clear for a minimum of 50 mm and
Fig. 105: Align light sensor that the light beam is not reflected from neigh-
bouring machine parts!
6. Align the light sensor holder horizontally so that the light

beam from the light sensor meets the blank vertically.
7. Fix the light sensor holder (Fig. 105/3) in this position with the
knurled screws (Fig. 105/1).
ð The FHDK-10 light sensor is aligned.
Optional light sensor (skew) 8. Align the optional light sensor for skew control as described
above.
When aligning the optional light sensor for skew

control, ensure that the two light sensors are
positioned offset horizontally in the production
direction and not in a row.

Assemble the guide plate extension

ment: n Protective gloves
n Safety boots
Materials: n Rinsing liquid
n Soft cloth
n Guide plate extension installation kit
(10259300)
DANGER!
1. To ensure that the guide plate extension is assembled

exactly, clean
n the upper and lower guide plates (Fig. 106/1),
n the threaded boreholes on the blank guide.
To do this, use a soft, lint-free cloth and warm water.
Fig. 106: Clean the blank guide

2. Hold the guide plates (Fig. 107/1) for the extension with the
holes above the threaded boreholes on the guide plates for
the blank guide (Fig. 107/2).
3. Attach the guide plates (Fig. 107/1) for the extension onto the
guide plates for the blank guide (Fig. 107/2) with the screws
(Fig. 107/3).
The screws (Fig. 107/3) must not protrude from

the rear side of the guide plates for the blank
guide.
Shorten the screws if necessary.
4. Check that the blank guide extensions are attached tightly

and securely.

Assemble the guide plate extension for the second
side as described in steps 1 to 4.
Fig. 107: Assembling the guide plates

Assembling the components > 3-way multi-application head

n Safety goggles
n Protective gloves
Assemble the multi-application head onto the blank guide as fol-

lows:
1. Check the multi-application head for damage that has arisen
during transportation.
2.
NOTICE!
Risk of distorting the guide rods on the pneu-
matic cylinder when working on the multi-
application head!
Move the pneumatic cylinder in the direction of the arrow into

its rear end position so that the guide rods on the pneumatic
cylinder are drawn in.
3. Screw the capstan screws 2 turns into the main body of the
multi-application head.
Fig. 108: Multi-application head, guide

rods/pneumatic
4. From above, fit the multi-application head with the capstan

screws into the slots on the blank guide retainer plate.
5. Fix the multi-application head into the retainer plate by
screwing the capstan screws hand-tight.
ð The multi-application head is assembled mechanically.
Fig. 109: Assemble the multi-applica-

tion head
2 Retainer plate

Assembling the components > 3-way multi-application head
3 Capstan screws
5.2.8.1 Assembling the adhesive supply onto the multi-application head

n Safety goggles
n Protective gloves
Adhesive is supplied to the multi-application head via a high pres-

sure hose from the glue delivery unit.
WARNING!
nents!
leak accidentally.
Connect the adhesive line

Screw the high pressure hose from the glue delivery unit onto
the adhesive connection on the multi-application head.
Gluing on both sides

Connect the adhesive supply to the multi-application
head on the second side as described above.
Fig. 110: Connect the adhesive

supply
1 Adhesive connection

Assembling the components > MLT sensor
5.2.9 MLT sensor

n Safety boots
n Safety goggles
Materials: n MLT sensor
n Mounting screws with washers
1. Clean the mounting surface on the supporting component.
2. Place the MLT sensor (Fig. 111/1) so that its threaded bore-
holes line up with the boreholes (Fig. 111/2) on the sup-
porting component.
Fig. 111: MLT sensor (assembly

example)
3. Attach the MLT sensor (Fig. 112/4) onto the assembly loca-
tion with the mounting screws (Fig. 112/2) and the washers
(Fig. 112/3).
The distance between the MLT sensor and the

surface of the product should be approx. 30 mm!
4. Attach the connection cable (Fig. 112/1) to the MLT sensor.

Ä Chapter 5.3.9 “MLT sensor” on page 144
Fig. 112: Mounting the MLT sensor

Assembling the components > (optional) UV lighting for MLT...

Mounting the UV lighting Personnel: n Qualified mechanic
Materials: n UV lighting installation kit for MLT-40
(10259120)
DANGER!
The UV lighting installation kit for the MLT-40 is screwed onto the
mount on the MLT-40 and can be retrofitted.
DANGER!
Before starting work on the Inliner system with MLT 40
ensure that its power supply has been switched off.
1.
CAUTION!
Fig. 113: UV lighting installation kit tools!
Connect the mounting bracket (Fig. 113/1) and the UV light

(Fig. 113/3) with the mounting screws (Fig. 113/2).
2.
Hold the sensor (Fig. 114/1) with one hand when
removing the mounting screws (Fig. 114/2) to
prevent it from falling!
Release and remove the mounting screws (Fig. 114/2) and

the washers (Fig. 114/3) on the sensor (Fig. 114/1).
3. Clean the surfaces of the mounting bracket with a suitable
cleaning agent.
Fig. 114: Mounting the UV lighting

Assembling the components > MLT colour filter installatio...
4. Position the UV lighting (Fig. 115/3) on the mounting bracket

on the sensor and screw the UV lighting (Fig. 115/3) and the
sensor (Fig. 115/1) together with the washers (Fig. 115/2)
and mounting screws (Fig. 115/4).
5. Connect the UV lighting system to the electricity supply.
Ä Chapter 5.3.10 “Additional lighting for MLT-40”
on page 145

For equipment with double-sided adhesive application,
the mounting process for the UV lighting is carried out
in the same way on the other side.
Fig. 115: Mounting the UV lighting
Switching between fluorescent markers

Switching between different fluorescent markers is
only possible following modifications to the system.
Different markers may require different colour filters or
lighting.
The camera and sensor settings must be optimised
each time a change is made.

Assembling the components > MLT colour filter installatio...
Assembling the deep blue lighting Personnel: n Qualified mechanic

DANGER!
The UV lighting installation kit for the MLT-40 is screwed onto the
mount on the MLT-40 and can be retrofitted.
DANGER!
1.
CAUTION!
Fig. 116: deep blue lighting tools!
Connect the mounting bracket (1) and the UV light (3) with
the mounting screws (2).
2.
Secure the sensor (1) with one hand when
removing the mounting screws (2) to prevent it
from falling!
Loosen and remove the mounting screws (2) and the

washers (3) on the sensor (1).
3. Clean the surfaces of the mounting bracket with a suitable
cleaning agent.
Fig. 117: Disassembling the MLT

sensor

Assembling the components > FHDK light sensor
4. Plug the sensor into the holder with the colour filter (5).
5. Position the deep blue lighting (3) onto the sensor's mounting
bracket.
6. Screw the deep blue lighting, colour filter and sensor together
with the washers (2) and mounting screws (4).
7. Connect the deep blue lighting electrically.

the mounting process for the UV lighting is carried out
in the same way on the other side.
Fig. 118: 10259160 Assembly

To be able to use Skew, two light barriers must be assembled
behind one another in the production running direction. Signals
from internal light barriers can also be used for Skew.
The assembly of an external light barrier is described here as an
example.

1 FHDK light sensor front view
2 LED function indicator
3 FHDK light sensor side view
4 Running direction
5 Light beam
6 Object
Fig. 119: Light sensor

Assembling the components > Marking system
The light sensor is delivered pre-assembled. Its exact installation

position can be adjusted to suit the production conditions on-site.
The light sensor should be mounted with its output opening approx.
20 mm above the object surface (Fig. 119/4).
If using an application head kit, the light sensor may

already be completely assembled. The installation
height is then dependent on the installed position of
the application head kit.
Fig. 120: Installing the light sensor

When an object edge passes through the light sensor's red light
beam (Fig. 119/5), the LED (Fig. 119/2) indicates that it is func-
tioning correctly. If it flashes, there is an error.
The light beam (Fig. 119/5) is emitted from approx. 14 mm behind
the front edge of the light sensor. The light beam must hit the
object surface at a right angle.

Observe the component-specific safety information and operation
instructions.
1. Assemble the pressure vessel.
Ä Chapter 5.2.15 “Pressure vessel” on page 127
2. (optional) Assemble the sprayed air shut-off.
Ä Chapter 5.2.19 “(optional) Sprayed air shut-off ”
on page 130
3. Assemble the spray application head.
Ä Chapter 5.2.17 “Assemble the spray application head”
on page 129
4. Check that all of the connections are tight and secure.

Assembling the components > Pressure vessel

n Safety boots
n Safety goggles
n Protective gloves
1. Disconnect the hose coupling on the lid of the pressure

vessel (Fig. 121/1).
Place the hose in a safe place.
2. Lift the pressure vessel (Fig. 121/2) out of the bracket
(Fig. 121/3).
The pressure vessel is not attached to the

bracket.
Place the pressure vessel in a safe place.
Fig. 121: Assembling the pressure

vessel
Changing the position of the pres-

surised air supply
3.
The pressurised air supply can come from
beneath (Fig. 122/1) or above (Fig. 122/2) the
bracket.
Select the position for the pressurised air supply. Take the
position of the pressure vessel within the super-ordinate
system into account.
4. To change the position of the pressurised air supply, open
the screw connection on the sealing plug (Fig. 122/3) and the
connector (Fig. 122/4).
Mind the seals when doing so.
Fig. 122: Pressurised air supply
5. Swap the sealing plug and connector.
6. Screw the sealing plug and connector in tightly.
7. Fix the pressure vessel bracket (Fig. 121/3) into its installa-
tion position with 4 screws.
8. Place the pressure vessel into the bracket.

Assembling the components > Connecting the pressure vessel...
9. Connect the hose coupling for the pressurised air hose to the
lid of the pressure vessel (Fig. 121/1).
5.2.16 Connecting the pressure vessel material supply

n Safety boots
n Safety goggles
n Protective gloves
1. Connect the pressure vessel bulkhead fitting (Fig. 123/1) to

the material hose (Fig. 123/2) for the spray application head
material supply.
Use a transparent product hose for this.
WARNING!
Risk of injury due to incorrect assembly of pres-
surised lines and components!
2. Check that the connections are tight and secure.
Fig. 123: Material supply to the spray

application head

Assembling the components > Assemble the spray application...
5.2.17 Assemble the spray application head

Spray application head assembly Personnel: n Qualified mechanic
n Safety boots
n Safety goggles
n Protective gloves
1. The connection must:

n Be secure.
n Be vibration-free.
n Have sufficient space for the supply lines.
n Provide easy access for cleaning and maintenance.
2. Screw the application head onto the holder with an M5
screw.
NOTICE!
Risk of material damage due to pushing the
screw into the application head body!
Note the maximum depth of engagement of 6 mm in the

Fig. 124: Install the spray application application head.
head 3. Connect the spray application head to the supply compo-
1 Supply lines nents:
2 M5 screw n Controller:
Ä Chapter 5.3.14 “Spray application head” on page 149
n Sprayed air supply:
Ä Chapter 5.4.5 “Connecting the spray application head
pneumatically” on page 156
n Material supply:
Ä Chapter 5.2.18 “Connecting the material supply to the
spray application head” on page 130

Assembling the components > (optional) Sprayed air shut-of...
5.2.18 Connecting the material supply to the spray application head

n Safety boots
n Safety goggles
n Protective gloves
WARNING!
Connect the material hose from the material source to the

material connection on the spray application head.
n Use a transparent material hose for this.
n Ensure that the material hose is attached tightly and
securely.
Fig. 125: Connecting the material

supply to the spray application head
1 Material connection
2 Material hose
The sprayed air shut-off is installed in the sprayed air path between
the pressure supply and the spray application head.

Assembling the components > IE-65-508 Encoder

n Safety boots
n Safety goggles
n Protective gloves
1. Prepare a drilling template according to the position of the

mounting holes (Fig. 126/1).
2. Drill 2 holes at the mounting point to attach the sprayed air
shut-off.
Ensure that there is space for the cable and pressure hoses
and room to access the sprayed air shut-off regulator.
3. Attach the sprayed air shut-off correctly with 2 suitable
screws (Fig. 126/1).
4. Connect the sprayed air shut off connectors:
Fig. 126: Assemble the sprayed air n Ä Chapter 5.3.15 “Connect the (optional) sprayed air
shut-off shut-off electrically” on page 149
n Ä Chapter 5.4.6 “(optional) Sprayed air shut-off”
on page 157
5.2.20 IE-65-508 Encoder
CAUTION!

Fig. 127: Assembly examples

1 Encoder assembly with friction wheel
2 Encoder assembly with toothed belt
Important requirements for the encoder to function correctly:

n Mount the encoder parallel to the running direction.
n If using a friction wheel:
– Mount the friction wheel on a driven shaft so that it does
not slip or
– mount it onto the conveyor belt near to a driven shaft.
– Ensure the friction wheel only touches it with light contact
pressure. The encoder shaft can be damaged if the contact
pressure is too high.
n If using a toothed belt:
– Ensure that it is aligned in parallel so that the toothed belt
does not run sideways out of the guide.
– Mount the toothed belt onto a driven shaft.
– Ensure that the toothed belt is tensioned correctly. The
toothed belt should only be able to be depressed slightly.

5.2.20.1 Mount the encoder with friction wheel drive

Mount the encoder with friction Personnel: n Qualified mechanic
wheel onto the machine wall
Fit the friction wheel onto the encoder. Mount the friction wheel
onto the conveyor belt on the machine, near to a driven cylinder.
Select the contact pressure for the friction wheel so that the belt
drives the encoder and does not slip.
Mount the friction wheel and
holding plate
1.
The shaft provided to determine the speed must
run at the machine speed. The shaft should be
driven as non-driven drives can slip.
The speed must be calculated exactly to ensure
optimum production results!
Screw the retainer plate (Fig. 128/4) onto the encoder

(Fig. 128/3) with the screws (Fig. 128/2).
2. Plug the friction wheel (Fig. 128/1) into the encoder shaft.
Clamp the friction wheel onto the encoder shaft tightly with
the set screw.
3. Hold the encoder with the friction wheel onto a shaft and
Fig. 128: Encoder assembly mark boreholes on the machine wall or the drive plate.
CAUTION!
Risk of injury due to careless handling of tools!
4. Carefully drill two holes in the machine wall or the drive plate
for the retainer plate.
The holes can be either through holes or

threaded holes depending on your requirements.
5. Screw the retainer plate onto the predrilled holes.

Use the provided screws, washers, nuts and spacers to do
this.
Encoder assembly 6. Screw the encoder on so that the friction wheel is in contact
with the machine shaft.

Slippage
You can identify slippage by observing the speed dis-
play on the control unit.
If there is slippage, the displayed speed will not be
constant.
7. Check that the friction wheel does not slip when running.
8. Check the speed display on the controller. The displayed
speed varies if there is slippage and if the contact pressure is
too high.
NOTICE!
The encoder's axle can be damaged if the con-
tact pressure is too high.
Never use the encoder as a tension device for
the conveyor belt.
9. Correct the assembly if necessary.
5.2.20.2 Mount the encoder with toothed belt drive

Mount the encoder with toothed Personnel: n Qualified mechanic
belt to the machine wall
Assembly of the gear wheels and

retainer plate
1. Screw the retainer plate (Fig. 129/3) onto the encoder
(Fig. 129/2) with the screws (Fig. 129/1).
2. Clamp the toothed belt wheel (Fig. 129/4) onto the encoder
shaft tightly with the set screw.
3. Mount the second toothed belt wheel onto the driven shaft.
This assembly depends upon the construction of the driven
shaft. Please refer to the documentation for the super-ordi-
nate system.
4. Place the toothed belt onto the two toothed belt wheels.
Fig. 129: Encoder assembly 5. Tension the toothed belt.
6. Mark bore holes on the machine wall or the drive plate.

CAUTION!
7. Carefully drill two holes in the machine wall or the drive plate
for the retainer plate.
The holes can be either through holes or

threaded holes depending on your requirements.
8. Screw the retainer plate onto the predrilled holes.

Use the provided screws, washers, nuts and spacers to do
this.
Encoder assembly 9. Screw the encoder on so that the toothed belt is slightly ten-
sioned.
10. Check the tension of the toothed belt.
To test this, press the toothed belt.
DANGER!
Risk of injury due to moving parts!
Only check the tension of the toothed belt when
the machine is stopped.
The toothed belt should only be able to be depressed slightly.

11. Correct the assembly if necessary.

Assembling the components > Alert set
5.2.21 Alert set

Special tool: n Power drill
n Drill bit (steel/concrete)
Materials: n Screws
n Dowels if necessary
1.
CAUTION!
Risk of injury due to the status indicator
falling!
1. person: Hold the alert set onto the intended assembly

location.
2. person: Mark the boreholes (Fig. 130/1).
2.
NOTICE!
Cover sensitive components if necessary.

3.
CAUTION!
tools!
Fig. 130: Alert set assembly
Thread cutting:

thread.
Through holes:
n Drill through holes for M10 screws.

Dowels: (Wall mounting)
n Drill dowel holes for Ø 10 mm screws

n Place a suitable dowel into each hole.

Electrical connection of the com... > Connecting the control cabinet...
4.
CAUTION!
Risk of injury due to the status indicator
falling!
1. person: Hold the alert set onto the predrilled holes.

material that the support is made from and the
attachment method.
2. person: Attach the alert set onto the assembly location

with the corresponding screws and a suitable tool.
5. Check that the alert set is stable and attached securely.
5.3 Electrical connection of the components

5.3.1 Connecting the control cabinet electrically
DANGER!
CAUTION!
5.3.1.1 Connecting the power supply to the control cabinet

n Safety boots
1. Prepare the connection as per the circuit diagram.
The circuit diagram can be found in the

appendix.
2. Guide the connection cable into the housing.

3. Connect the connection cable to the terminals on the main
switch as per the circuit diagram.

Electrical connection of the com... > Linux terminal
5.3.2 Connecting the modules electrically
The module is installed in the equipment's control cab-

inet. The internal wiring is completed in-house by
Baumer hhs!
The electrical connection between the components
and the module varies from system to system. Please
see the wiring and circuit diagrams in the appendix!

n Safety boots
1. Connect the Linux terminal to the connection module on the
control unit using serial interface 3 (Fig. 131/3).
The electrical connection between the ter-

minal and the respective components of the
Inliner systems with MLT 40 varies from
Fig. 131: Linux terminal connections system to system. Please see the wiring and
circuit diagrams in the appendix!
1 Serial interface 1 (SUB-D socket
9-pin RS 232)
2 Serial interface 2 (SUB-D jack 9- 2. Where necessary, connect the remaining connections
pin RS 232 / RS 485) (Fig. 131) on the Linux terminal with the respective compo-
3 Serial interface 3 (SUB-D jack 5- nents as per the wiring and circuit diagrams in the appendix.
pin with Powerpin + CAN)
6 USB port

Electrical connection of the com... > Glue delivery unit

Internal electrical connections
1. The internal electrical connections in the glue delivery unit
are made at the factory. However, check that the internal
electrical connections are positioned correctly before com-
missioning.
Connections:
n X2 Electrical connection (Fig. 132/1) è pneumatic mate-
rial pressure regulator pressure sensor (Fig. 132/3)
n X2 Electrical connection (Fig. 132/2) è pneumatic mate-
rial pressure regulator control unit (Fig. 132/4)
Fig. 132: Check the internal connec-

tions
External electrical connections

2. Make the electrical connection between the glue delivery unit
and equipment by connecting the connection cable to the
"X1" connection (Fig. 133/1).
The external electrical connection for the glue

delivery unit varies from system to system. Please
see the wiring and circuit diagrams in the
appendix!
3. Connect the other end of the connection cable as per the

information in the wiring and circuit diagrams in the appendix!
Fig. 133: Glue delivery unit

Electrical connection of the com... > (optional) fill level display
5.3.5 (optional) fill level display
Electrical current
DANGER!
– Only have work on the electrical systems carried
out by an electrician.
– Before all work on electrical parts of the Inliner sys-
tems with MLT 40 establish a de-energised state
and ensure no voltage is present.
– Keep live parts free of moisture.

cables CAUTION!
tion unit.
hazards arise.
black marking tape.
1 Fill level display

2 Connection cable
sive container has dropped below the minimum by illuminating the
alarm light. The fill level in the adhesive container is detected using
a fill level sensor.

Electrical connection of the com... > 3-way blank guide

n Safety goggles
n Protective gloves
The electrical connection for the fill level display varies

from system to system. Please see the wiring and cir-
cuit diagrams in the appendix!
5.3.6 (optional) fill level sensor

The controller requires a signal from the fill level

sensor in order to produce a warning message and
stop production promptly if there is too little adhesive in
the adhesive container. It also produces a visual
warning message via the "Fill level display" signal light.
Connecting the fill level sensor 1. Connect the connection cable to the fill level sensor.
The electrical connection for the fill level sensor

varies from system to system. Please see the
wiring and circuit diagrams in the appendix!
2. Connect the other end of the connection cable as per the

information in the wiring and circuit diagrams in the appendix!
ð The fill level sensor is ready for operation.

DANGER!

Electrical connection of the com... > Multi-application head
DANGER!
The electrical connection for the blank guide

varies from system to system. Please see the
1. Connect the blank guide electrically.
NOTICE!
Risk of damage to connection lines and cables if
laid incorrectly!
2. Move the super-ordinate machine into its maximum setting.

3. Ensure that no connection lines and cables are under ten-
sion.
CAUTION!
4. Move the super-ordinate machine into its minimum setting.

5. Ensure that all connection lines and cables are laid correctly
and securely.
5.3.8 Multi-application head
Electrical current
DANGER!
– Only have work on the electrical systems carried
out by an electrician.
– Before all work on electrical parts of the Inliner sys-
tems with MLT 40 establish a de-energised state
and ensure no voltage is present.
– Keep live parts free of moisture.

Electrical connection of the com... > Multi-application head

cables CAUTION!
tion unit.
hazards arise.
black marking tape.
Electrical connection
n Safety goggles
n Protective gloves
The electrical connection for the multi-application

head varies from system to system. Please see the

Electrical connection of the com... > MLT sensor
5.3.9 MLT sensor

n Safety boots
1. Screw the plug on the connection cable to the connector
(Fig. 135/1) on the MLT sensor.
2. Attach the connection cable to the assigned module on the
equipment's control cabinet.
The connection cable plug can only be posi-

tioned in one direction corresponding with
the sensor connector.
Fig. 135: MLT sensor electrical con-

nection

Electrical connection of the com... > Additional lighting for MLT-40
5.3.10 Additional lighting for MLT-40

n Safety boots
Materials: n MLT-40 additional lighting adapter
(79029360)
n Adapter cable KAB42M0050
(77742605)
DANGER!
DANGER!
1.
For single-sided adhesive application, lay all of
the cables so that they are long enough if you
need to change sides!
Connect the lighting connector (Fig. 136/1) to the cable

(Fig. 137/7).
Fig. 136: Lighting

2. Connect the "MLT-40 additional lighting" adapter (Fig. 137/4)

to the connector (Fig. 137/5).
3. Connect the connector (Fig. 137/3) for the Y adapter cable
(Fig. 137/2) to the "MLT-40 additional lighting" adapter
(Fig. 137/4).
4. Disconnect the existing MLT-40 connector (Fig. 137/8) if nec-
essary.
5. Connect the MLT-40 connector to the connector (Fig. 137/1)
on the adapter cable (Fig. 137/2).
6. Connect the connector (Fig. 137/9) on the adapter cable
(Fig. 137/2) to the MLT-40 connector (Fig. 137/8).
7. Connect the connection cable to the system.
Observe the circuit diagram.
Fig. 137: Lighting connector
Additional lighting on both sides 8. Connect the connector (Fig. 136/1) for the second lighting
system as described above.
Finishing work 9. Check that all connections are tight.
ð The lighting is connected electrically.

5.3.11 Additional lighting for MLT-40

n Safety boots
Materials: n MLT-40 additional lighting adapter
(79029360)
n Adapter cable KAB42M0050
(77742605)
DANGER!
DANGER!
1.
For single-sided adhesive application, lay all of
the cables so that they are long enough if you
need to change sides!
Connect the lighting connector (Fig. 138/1) to the cable

(Fig. 139/7).
Fig. 138: Lighting

Electrical connection of the com... > FHDK light sensor
2. Connect the "MLT-40 additional lighting" adapter (Fig. 139/4)

to the connector (Fig. 139/5).
3. Connect the connector (Fig. 139/3) for the Y adapter cable
(Fig. 139/2) to the "MLT-40 additional lighting" adapter
(Fig. 139/4).
4. Disconnect the existing MLT-40 connector (Fig. 139/8) if nec-
essary.
5. Connect the MLT-40 connector to the connector (Fig. 139/1)
on the adapter cable (Fig. 139/2).
6. Connect the connector (Fig. 139/9) on the adapter cable
(Fig. 139/2) to the MLT-40 connector (Fig. 139/8).
7. Connect the connection cable to the system.
Observe the circuit diagram.
Fig. 139: Lighting connector
Additional lighting on both sides 8. Connect the connector (Fig. 138/1) for the second lighting
system as described above.
Finishing work 9. Check that all connections are tight.
ð The lighting is connected electrically.

system.
appendix!

Electrical connection of the com... > Connect the (optional) sprayed...
Electrical connections for the components

Ä Chapter 5.3.14 “Spray application head”
on page 149
Ä Chapter 5.3.15 “Connect the (optional) sprayed air
shut-off electrically” on page 149
5.3.14 Spray application head

n Safety boots
n Safety goggles
n Protective gloves
1. Plug the device plug into the coil on the application head.
2. Screw the device plug tightly onto the coil with the screw.
3.
CAUTION!
Danger of tripping due to improperly laid con-
nection lines and cables!
Run the connection cable from the spray application head to

the controller.

system.
Fig. 140: Spray application head Please see the wiring and circuit diagrams in the
appendix!
1 Device plug (connection cable)
2 Coil
3 Screw 4. Screw the union nut on as tightly as you can by hand to con-
nect the connection cable securely.
ð The spray application head is connected electrically.
5.3.15 Connect the (optional) sprayed air shut-off electrically
The sprayed air shut-off is supplied with a 10 m long

cable.

Electrical connection of the com... > IE-65-508 Encoder

n Safety boots
n Safety goggles
n Protective gloves
1. Plug the device plug (Fig. 141/1) into the reel on the sprayed
air shut-off (Fig. 141/2).
2. Attach the device plug (Fig. 141/1) to the reel on the sprayed
air shut-off (Fig. 141/2) with the mounting screws on the rear
side.
The electrical connection for the sprayed air shut-

off varies from system to system. Please see the
Fig. 141: Sprayed air shut-off applica- wiring and circuit diagrams in the appendix!
tion head connection plug
3. Connect the connection cable on the controller side.

4. Screw the union nut as tightly as you can by hand to connect
the connection cable securely.
5.3.16 IE-65-508 Encoder

1 Encoder
2 Cable for encoder
3 (optional) Extension cable for the encoder
4 Connection socket on the control unit module
The electrical connection for the encoder varies from

system to system. Please refer to the information in
the module descriptions and the circuit diagram for the
relevant system.
Fig. 142: Electrical assembly
Connect the encoder to the input socket “ENC” on the con-

trol unit module using the connection cable and, if necessary,
the extension cable.

Pneumatic connection of the comp... > Glue delivery unit
5.3.17 Status indicator

Electrical connection Personnel: n Qualified electrician
The electrical connection between the status indi-

cator and the system control cabinet varies from
system to system. Please observe the information
regarding the control unit and the wiring and cir-
cuit diagrams in the appendix!
5.4 Pneumatic connection of the components

Personnel: n Professional pneumatic engineers
n Safety goggles
Internal pneumatic connections
1. The internal pneumatic connections in the glue delivery unit
are made at the factory. However, check that the internal
pneumatic connections are positioned correctly before com-
missioning.
Connections
n Pressure regulator screw connection (Fig. 143/1) è
reversing unit application head connection block
n Reversing unit application head connection block pneu-
matic connection (Fig. 143/3) è pneumatic material
pressure regulator pressurised air connection (Fig. 143/2)
Fig. 143: Check the internal connec-

tions

Pneumatic connection of the comp... > 3-way blank guide
External pneumatic connection

2. The pressurised air is supplied to the glue delivery unit via a
pressurised air distributor in the super-ordinate equipment.
NOTICE!
The pressurised air must be dry and free
from oil!
Create the pneumatic connection between the glue delivery

unit and the equipment by connecting the air hose from the
external pressurised air supply to the pressurised air input
(Fig. 144/1) on the pressure regulator.
Fig. 144: External pneumatic connec-

tion

Protective equipment: n Safety goggles
n Safety boots
The way-valves (Fig. 145/4) on the pressure regulator (Fig. 145/2)
supply the pneumatic cylinder (Fig. 145/3) of the blank guide
(Fig. 145/1) with pressurised air.
DANGER!

Pneumatic connection of the comp... > 3-way blank guide
WARNING!
1. Connect the air hoses to the pneumatic cylinder (Fig. 145/3)

of the blank guide (Fig. 145/1) as shown in Fig. 145 and to
the way-valves (Fig. 145/4) of the pressure regulator
(Fig. 145/2).
2.
When applying adhesive to both sides, each
blank guide (right/left) has a separate pressure
regulator.
Connect the air hoses for the second blank guide
Fig. 145: Connect the blank guide in the same way as described above.
pneumatically
NOTICE!
Risk of damage to connection lines and cables if
laid incorrectly!
3. Move the super-ordinate machine into its maximum setting.

4. Ensure that no connection lines and cables are under ten-
sion.
CAUTION!
5. Move the super-ordinate machine into its minimum setting.

6. Ensure that all connection lines and cables are laid correctly
and securely.

Pneumatic connection of the comp... > Marking system
Fig. 146: Example pneumatic diagram for the marking system

1 On-site pressurised air supply
3 Sprayed air shut-off (optional)
4 Sprayed air
5 Spray application head
6 Product hose
7 Pressure vessel
8 Material pressure regulator
9 Gate valve
Pressurised air is required to transport the material to the spray
application head (Fig. 146/1, 2, 5) as well as to spray the product
(Fig. 146/3, 4). There are separate air lines for these purposes
(Fig. 146).
The air lines are regulated using their own pressure regulators
(Fig. 146/6 and 7).
An optional sprayed air shut-off (Fig. 146/8) can be installed
between the sprayed air pressure regulator (Fig. 146/6) and the
spray application head (Fig. 146/5) which only switches the
sprayed air on when the spray application head is activated.
Observe the component-specific safety information and operation
instructions.
1.
WARNING!
Risk of injury due to pressurised compo-
nents!
Disconnect the on-site pressurised air supply.

2. Connect the pressure vessel pneumatically.
3. (optional) Connect the sprayed air shut-off pneumatically.

Pneumatic connection of the comp... > Connecting the pressure vessel...
4. Connect the spray application head pneumatically.

5. Check that all of the connections are tight and secure.
5.4.4 Connecting the pressure vessel pneumatically

Connecting the pressure vessel Personnel: n Professional pneumatic engineers
pneumatically
n Safety boots
n Safety goggles
n Protective gloves
Requirement: Disconnect the on-site pressurised air supply.
Fig. 147: Pressure vessel

1. Close the existing pressurised air supply at the pressure
vessel T-distributor (Fig. 147/1).
The connector can be found either underneath or above the
switch panel (Fig. 147/2).
2. Close the pressurised air supply to the consumer at the con-
nector (Fig. 147/3) on the pressure vessel.
Use a suitable pressure hose for this.
3. Check that all connections are secure.

Pneumatic connection of the comp... > Connecting the spray applicati...
5.4.5 Connecting the spray application head pneumatically

Pressure line length
NOTICE!
Risk of errors due to overly long pressure lines!
As the length of the pressure lines increases, so does
the risk of losing pressure within the system. The air
pressure at the spray application head can become too
low, particularly when using multiple spray application
heads.
– Ensure that the lines are no longer than necessary.
Connecting the spray application

head pneumatically
n Professional pneumatic engineers
n Safety boots
n Safety goggles
n Protective gloves
WARNING!
1. Connect the spray application head to the atomised air pres-

sure regulator.
ð Use a suitable pressure hose for this.
2. Install the optional sprayed air shut-off between the spray
application head and the atomised air pressure regulator if
required.
Fig. 148: Connecting the spray appli-

cation head pneumatically

Pneumatic connection of the comp... > (optional) Sprayed air shut-off

n Safety boots
n Safety goggles
n Protective gloves

1. Lay a pressure hose to the pressure supply.
Use a suitable pressure hose for this.
2. Connect the sprayed air supply (Fig. 149/1) to the pressure
supply.
3. Lay a suitable pressure hose to the spray application head.
4. Connect the sprayed air supply for the spray application head
to the sprayed air output on the sprayed air shut-off
Fig. 149: Connect the sprayed air (Fig. 149/2).
shut-off pneumatically
The T-distributor Fig. 149/3 allows serial connection of multiple
application heads with optional sprayed air shut-offs.

Pneumatic connection of the comp... > (optional) Sprayed air shut-off

Commissioning
Safety guidelines for commission...
6 Commissioning
Regulatory framework conditions
for the owner
Personnel: n Owner
In certain countries and regions, inspections must be carried out or
authorisation obtained before commissioning the equipment.
1. Ensure that you are aware of the local regulations.
2. Please refer to the authorities and institutes responsible
before beginning production if authorisation is required
6.1 Safety guidelines for commissioning

Improper commissioning
WARNING!
Risk of injury due to improper commissioning!
Improper commissioning can result in serious injuries
and considerable material damage.
– Before commissioning, ensure that all installation
work has been carried out and completed in
accordance with the information and instructions
set out in this manual and the associated circuit
diagrams.
– Before commissioning, ensure that all safety
equipment is functioning correctly.
– Before commissioning, make sure that nobody is in
the danger zone.
– Commissioning should be carried out preferably by
personnel authorised and trained by Baumer hhs.
If commissioning is to be carried out by other per-
sons, it must be ensured that these persons
manual,
tion manual,
– have the necessary specialist knowledge for
the commissioning process.

Commissioning
Checking the installation before Personnel: n Owner

commissioning n Qualified electrician
Before commissioning, the installation must be checked thoroughly
to prevent damage to people and material items. Please also
observe the component-specific installation information at this
stage. The owner is fully responsible for ensuring the checks are
carried out correctly. The aim of this is for the owner to approve the
installation.
1. Check the electrical installation, particularly connection
values and on-site fuses, according to the component-spe-
cific information. This check must be carried out by a quali-
fied electrician.
ð The Inliner system with MLT 40 is correctly installed.
DANGER!
Before starting work on the Inliner system
with MLT 40 ensure that its power supply has
been switched off.
If the Inliner system with MLT 40 has not been correctly

installed, resolve the faulty installation before commis-
sioning. Continue to check the electrical installation until
the Inliner system with MLT 40 is installed correctly.
2. Check the functions of all of the connected components in
accordance with the component descriptions.
3. Check all lines and couplings that carry liquids for leaks
during a rinse procedure.
ð The Inliner system with MLT 40 has been correctly
installed.
CAUTION!
Always safely depressurise the Inliner
system with MLT 40 before beginning work.
If the Inliner system with MLT 40 is not sealed, resolve

the faulty installation before commissioning.
Replace leaking lines, do not repair them.
Tighten leaking couplings and replace them as neces-
sary.
Remove any liquid that has leaked out.
Only begin commissioning when all leaks have been rec-
tified.

Commissioning
4. Check all lines carrying compressed air for leaks at maximum

operating pressure.
ð The Inliner system with MLT 40 has been correctly
installed.
CAUTION!
Always safely depressurise the Inliner
system with MLT 40 before beginning work.
If the Inliner system with MLT 40 is not sealed, resolve

the faulty installation before commissioning.
Replace leaking lines, do not repair them.
Ensure coupling connections are sealed tightly and
replace them if necessary.
Only begin commissioning when all leaks have been rec-
tified.
5. Start the super-ordinate machine carefully and check
whether components of the Inliner systems with MLT 40 are
damaged by the movement of the machine.
ð No components are damaged.
DANGER!
been switched off.
Should damage arise, replace the damaged components

and adjust the assembly location as necessary.
Only begin commissioning once it is ensured that no
components can be damaged by machine movement.
6. Carefully move all of the positioning elements of the super-
ordinate machine above the maximum working range and
check whether this movement can damage components.
ð No components are damaged.
DANGER!
been switched off and that it is depressur-
ised.
Should damage arise, replace the damaged components

and adjust the assembly location as necessary
Only begin commissioning once it is ensured that no
components can be damaged by machine movement.

Commissioning
Preparing test material for comm... > Preparing adhesive
6.2 Preparing test material for commissioning

6.2.1 Preparing products
Preparing products Personnel: n Owner
In order to ensure that the commissioning process is successful,
you must ensure that sufficient test material is available that is typ-
ical of the operator's production spectrum, for example: printed
sheets or folding carton blanks. These must demonstrate all of the
features that should be checked as part of the commissioning
process. The products must be manufactured to be suitable for
continuous production.
1. For the commissioning process, use products that are repre-
sentative of the product spectrum. Also include borderline
cases, such as the smallest and largest formats.
2. Have a sufficient amount of products ready for the time the
commissioning process begins.
3. Inform the commissioner about the features and quality cri-
teria of these products.
6.2.2 Preparing adhesive
Recommended adhesives list

Baumer tests adhesives for system compatibility at the
request and cost of the adhesive manufacturer. Adhe-
sives that receive good results from testing are added
to the Baumer hhs list of recommended adhesives.
This does not necessarily mean that adhesives that do
not feature on the list are unsuitable.
To test system compatibility, we recommend you use a
recommended adhesive during commissioning.
Baumer hhs commissioners first operate the system
using a known and recommended adhesive before
changing to the customer's adhesive. These means
that the effect of the glue can be determined.
Prepare adhesive Personnel: n Owner

1. Supply a sufficient amount of standard adhesive for the com-
missioning process.
2. Test whether the adhesive is compatible with the system.
3. If necessary, adjust the pressure curve and adhesive applica-
tion parameters to the adhesive.

Commissioning
Commissioning the components > Commissioning the Linux termin...
6.3 Commissioning the components

6.3.1 Commissioning the Linux terminal
Switch-on Personnel: n Operator
n Safety boots
Requirements for commissioning the terminal:

– All of the terminal's cable connections are con-
nected correctly.
– The power supply is secure.
To commission the Linux terminal, switch the on/off switch

(Fig. 150/1) on the rear of the terminal to position "1" (ON).
ð As soon as the system controller is ready for operation,
the start screen appears on the Linux terminal.
Switching off the terminal using a super-ordinate

controller
Fig. 150: Switching on the terminal If the super-ordinate controller is switched off, the ter-
minal is switched off automatically at the same time.
Leave the terminal's on/off switch in position "1" (ON).
When the super-ordinate controller is started, the ter-
minal will also be switched on.

Commissioning
Commissioning the components > Glue delivery unit

6.3.2.1 Filling the piston pump with lubricant
Personnel: n Operator
n Protective gloves
n Safety boots
Materials: n Lubricant (16100001)
Before commissioning the glue delivery unit, the piston pump must
be filled with lubricant.
Filling lubricant
WARNING!
Risk of slipping due to residual oil or lubricant on
the floor!
There is a risk of slipping if there is residual oil or lubri-
cant on the floor. Slipping can cause serious injuries.
– Use suitable containers to fill or empty the oil and
lubricant tanks.
– Do not overfill the oil or lubricant tanks.
– Wear non-slip safety boots.
– Clean spilled oil or lubricant immediately with suit-
able devices and dispose of it correctly.

Commissioning
6.3.2.2 Checking/filling the adhesive container

n Protective gloves
n Safety boots
Materials: n Adhesive
1.
NOTICE!
Risk of material damage due to defective
adhesive!
Using adhesive that has expired or contains con-
taminants can damage the system.
When filling the container, ensure that
– the adhesive does not contain any dirt parti-
cles,
– the adhesive does not contain any mould
particles,
– the adhesive does not have a thick skin.
Also observe the following during the filling
process:
– Stir the adhesive before filling.
– Fill the container using a fine mesh filter.
During the operating life of the adhesive, ensure
that
exceeded,
peratures and

Commissioning
NOTICE!
Risk of material damage due to use of unsuit-
able adhesives!
When filling the system with a different type of
adhesive, there is a risk of material damage due
to the use of unsuitable or incompatible adhesive
types.
– Before filling the system with a different type
of adhesive, carry out tests to ensure that the
adhesive types are compatible and suitable
for the system.
– Adhesive characteristics can be found on the
data sheet or by contacting the adhesive
manufacturer.
– Avoid mixing adhesives from different manu-
facturers.
Fill the adhesive container with adhesive or replace the adhe-

sive container completely.
Attaching the adhesive suction 2. Attach the adhesive suction pipe to the adhesive container.
pipe
Increasing pressure via the pres-
sure regulator
3. Unlock the pressure regulator on the glue delivery unit by
pulling the control knob (Fig. 152/1) upwards, away from the
housing.
4. Slowly turn the control knob (Fig. 152/1) clockwise as seen
from above until the pressure in the system increases slowly
and the manometer (Fig. 152/2) shows 6 bar.
5. Place a sheet or similar item beneath the working position of
the application heads to catch splashes of adhesive.
6. Use the system controller to activate all of the nozzles on the
multi-application head if necessary.
For more information, see the "Control tech-

nology" chapter.
Fig. 152: Pressure regulator

Commissioning
Rinsing application heads

7. Press the [Rinse application head] button (Fig. 153/1) on the
Inliner XTS² switchbox.
ð The application heads on the multi-application head are
rinsed with adhesive.
Rinse until the new type of adhesive is

passed through the nozzles on the multi-
application head without rinsing liquid and
trapped air.
8. Check that all connections are in place and sealed.

ð The equipment is filled with adhesive and ready for oper-
ation.
Fig. 153: Inliner XTS² switchbox Changing the type of adhesive: Ä Chapter
6.3.2.4 “Changing the type of adhesive” on page 169

Commissioning
6.3.2.3 Rinsing the piston pump

n Protective gloves
n Safety boots
To prevent corrosion and contamination of the piston pump during
transportation and storage, the oil cylinder in the piston pump is
filled with a protective liquid. This protective liquid must be rinsed
out of the piston pump prior to commissioning.
1. Check that the electrical, air and adhesive connections are
tight.
2. Slowly turn the pressure regulator screw (Fig. 154/1) on the
pressure regulator clockwise until the manometer (Fig. 154/4)
displays 6 bar.
3. Check that the pressurised air and material pipes are sealed.
4. Hold the drainage hose from the rinsing connector
(Fig. 154/2) pointing into an empty container.
5. Open the ball valve (Fig. 154/3) on the rinsing connector.
6. Use the pump to deliver the material until the connected hose
delivers only one type of material that is clean and contains
no trapped air.
Ä Chapter 6.3.2.5 “Filling and de-aerating the

glue delivery unit” on page 179
7. Close the ball valve on the rinsing connector.

Fig. 154: Rinsing the piston pump 8. Use the pump to deliver the material until only one type of
adhesive exits the application heads without air bubbles.
ð The piston pump is rinsed and filled with adhesive.

Commissioning
6.3.2.4 Changing the type of adhesive

ment: n Protective gloves
n Safety boots
Materials: n Adhesive
n Waste container for adhesive/cleaning
agent
n Container for rinsing liquid
n Rinsing liquid
When changing production to a different product, the adhesive type
in the adhesive container and entire adhesive leading system may
need to be changed.
WARNING!
Risk of injury due to liquid being released at high
pressure!
A hot, highly pressurised stream of adhesive can leak
out during the rinsing process or during operation. This
stream of liquid can cause serious injuries and
scalding.
– Never hold body parts or items into the stream of
liquid
– Make sure that nobody is in the danger zone of the
adhesive application system.
– Never point the stream of liquid at other people.
NOTICE!
See the adhesive manufacturer's data sheet!

Commissioning
When changing the type of adhesive, follow the steps below:

Decreasing pressure via the pres-
sure regulator WARNING!

housing.
2. Slowly turn the control knob (Fig. 155/1) anti-clockwise as
seen from above until the target pressure on the manometer
(Fig. 155/2) shows 0 bar.
ð The residual pressure in the system escapes audibly.
3. Lock the pressure regulator by pushing the control knob
(Fig. 155/1) downwards, towards the housing. The control
knob must lock into place.
ð The compressed air supply for the equipment is depres-
surised.
4. Check the pressure on the manometer (Fig. 155/2).
ð The manometer must show 0 bar.
Reducing the residual pressure via

the Inliner XTS² switchbox
5. Press the [Auto/Manual operation] button (Fig. 156/2) on the
ð The controller switches to Manual mode.
the application heads to catch splashes of adhesive and
rinsing liquid.
ð The application heads move into their working position
and the residual pressure in the system releases via the
application heads.
Fig. 156: Inliner XTS² switchbox

Commissioning
8. Repeat this process until the manometer (Fig. 157/1) on the

pneumatic material pressure regulator (PMDRE6) shows
0 bar.
The system has been depressurised.
Fig. 157: Pneumatic material pressure

regulator
Removing the multi-application

head
10. Remove the multi-application head (Fig. 158/1) from the
blank guide (Fig. 158/2) to prevent damage to the pneumatic
cylinder (Fig. 158/3) when separating the adhesive supply.
Fig. 158: Blank guide with multi-appli-

cation head

Commissioning
Removing the adhesive supply line

NOTICE!
Risk of material damage due to drying out!
When separating or opening adhesive leading lines
and connections, there is a risk of material damage
due to the adhesive drying out on these components.
– Cover adhesive leading lines and connections that
are open and not in use with a damp cloth.
– Carry out work on open systems quickly to prevent
a "skin" building on the adhesive, or adhesive
leading components from drying out.
11. Remove the adhesive supply line from adhesive supply

(Fig. 159/1) to the multi-application head Fig. 159.
WARNING!
Risk of slipping due to leaked liquids the floor!
There is a risk of slipping if there are leaked liquids on
the floor. Slipping can cause serious injuries.
– Use suitable containers to catch the liquids.
– Clean leaked liquids on the floor immediately with
suitable devices.
12. Place the open end of the adhesive supply line into a suitable
waste container.
13. Remove the glue delivery unit's adhesive suction pipe from
the adhesive container.
Fig. 159: Multi-application head 14. Place the adhesive suction pipe into a container with rinsing
liquid.
Only use clean water (max. 40 °C) as the rinsing

liquid.
15. Clean all adhesive-carrying parts thoroughly.

Commissioning

sure regulator
housing.
and the adhesive/rinsing liquid is passed out of the
adhesive supply line.
18. Rinse the equipment with the rinsing liquid completely and for
a sufficient length of time.
Rinse until the rinsing liquid is passed through

the adhesive supply line without any residual
adhesive.
19. Depressurise the system again (see steps 1–4).

line
20. Reassemble the adhesive supply line onto the adhesive
supply (Fig. 161/1) to the multi-application head.
21.
WARNING!
Risk of injury due to liquid being released at
high pressure!
A hot, highly pressurised stream of adhesive can
leak out during the rinsing process or during
operation. This stream of liquid can cause
serious injuries and scalding.
– Never hold body parts or items into the
stream of liquid
– Make sure that nobody is in the danger zone
of the adhesive application system.
– Never point the stream of liquid at other
people.
Fig. 161: Multi-application head Hold the nozzles from the multi-application head pointing into
a waste container.

Commissioning

sure regulator
housing.
Rinsing via the Inliner XTS²

switchbox
ð The nozzles on the multi-application head are rinsed with
rinsing liquid.
26. Rinse the equipment with the rinsing liquid completely and for
a sufficient length of time.
Rinse until the rinsing liquid is passed through

the nozzles on the multi-application head without
any residual adhesive.
27.
Fig. 163: Inliner XTS² switchbox WARNING!
nents!
Depressurise the system again (see steps 1–9).

Commissioning
Removing the adhesive supply line

28.
NOTICE!
Risk of material damage due to drying out!
When separating or opening adhesive leading
lines and connections, there is a risk of material
damage due to the adhesive drying out on these
components.
– Cover adhesive leading lines and connec-
tions that are open and not in use with a
damp cloth.
– Carry out work on open systems quickly to
prevent a "skin" building on the adhesive, or
adhesive leading components from drying
out.
Remove the adhesive supply line from the adhesive supply

(Fig. 164/1) to the multi-application head once more.
Fig. 164: Multi-application head 29.
WARNING!
Risk of slipping due to leaked liquids the
floor!
There is a risk of slipping if there are leaked liq-
uids on the floor. Slipping can cause serious inju-
ries.
– Clean leaked liquids on the floor immediately
with suitable devices.
Place the open end of the adhesive supply line into a suitable
waste container.

Commissioning
30.
NOTICE!
adhesive!
cles,
particles,
process:
that
exceeded,
peratures and
NOTICE!
able adhesives!
types.
for the system.
manufacturer.
facturers.
Fill the adhesive container with the new type of adhesive or

replace the adhesive container completely.
Attaching the adhesive suction 31. Attach the adhesive suction pipe to the adhesive container
pipe with the new type of adhesive.

Commissioning

sure regulator
housing.
and the adhesive is passed out of the adhesive supply line.
34. Completely fill the equipment with adhesive.
Risk of mixing water and adhesive!

Even low volumes of residual water in the
system can thin the adhesive to such an extent
that this can lead to contamination and the incor-
rect quantities being applied.
– Rinse the equipment completely and for a
sufficient length of time until the new type of
adhesive passes through the adhesive
supply line without rinsing liquid.
35.
WARNING!
nents!
Depressurise the system again (see steps 1–4).

line
36. Reassemble the adhesive supply line onto the adhesive
supply (Fig. 166/1) to the multi-application head.
Fig. 166: Multi-application head

Commissioning
37. Reassemble the multi-application head (Fig. 167/1) onto the

blank guide.
Fig. 167: Blank guide with multi-appli-

cation head

sure regulator
housing.
rinsing liquid.
41. Use the system controller to activate all of the nozzles on the
multi-application head if necessary.
For more information, see the "Control tech-

nology" chapter.

Commissioning

rinsed with the new type of adhesive.
Risk of mixing water and adhesive!

Even low volumes of residual water in the
system can thin the adhesive to such an
extent that this can lead to contamination and
the incorrect quantities being applied.
– Rinse until the new type of adhesive is
passed through the nozzles on the multi-
application head without rinsing liquid
and trapped air.
43.
Fig. 169: Inliner XTS² switchbox WARNING!
Risk of injury due to incorrect assembly of
pressurised lines and components!
Check that all connections are in place and sealed.

ð The equipment is filled with the new type of adhesive and
ready for operation.
6.3.2.5 Filling and de-aerating the glue delivery unit

The optional fill level display (Fig. 170) illuminates to signal that the
adhesive fill level in the adhesive container has dropped below the
minimum. The fill level in the adhesive container is detected using
a fill level sensor.

Fill the adhesive container immediately when the fill
level indicator illuminates.
Fig. 170: Fill level display (optional)
n Safety boots
The equipment is connected correctly and commissioned. The con-
nections are sealed.

Commissioning
To (re)fill and de-aerate, follow the steps below:

1. Remove the glue delivery unit's adhesive suction pipe from
the adhesive container.
2.
NOTICE!
adhesive!
cles,
particles,
process:
that
exceeded,
peratures and
NOTICE!
able adhesives!
types.
for the system.
manufacturer.
facturers.

Commissioning
Fill the adhesive container with new adhesive or replace the

adhesive container completely.
Changing the type of adhesive

When changing the type of adhesive Ä Chapter
6.3.2.4 “Changing the type of adhesive”
on page 169.
Attaching the adhesive suction 3. Attach the adhesive suction pipe onto the filled adhesive con-
pipe tainer.
rinsed with adhesive.
Risk of mixing air and adhesive!

Even low residual amounts of air can cause
faults in the system or in the application.
– Rinse until the new adhesive is passed
through the nozzles on the multi-applica-
tion head without trapped air.
– To ensure that even the smallest
amounts of residual air are passed out of
the system, perform the rinsing process
again (approx. 10 rinses).
Fig. 171: Inliner XTS² switchbox 5.

WARNING!
Check that all connections are in place and sealed.

ð The equipment is filled with adhesive and ready for oper-
ation.
The fill level display (optional) goes out.

Commissioning
Commissioning the components > 3-way blank guide

6.3.3.1 Configure the 3-way blank guide
Non-contact application heads
NOTICE!
Risk of material damage due to too small a dis-
tance between the blank and the application
heads!
The cold glue system works with non-contact applica-
tion heads. If application heads touch the blank, the
adhesive will not be applied cleanly. This can damage
the application heads.
Requirement:
– The entry height on the customer's conveyor belt
must be adjusted to the height of the lower guide
plate of the blank guide.
– The application heads must dip a few mm into the
water in the water bath when in their “resting
position” .
– There must be a gap of 5 to 10 mm between the
tip of the nozzle and the lower edge of the upper
guide plate of the blank guide.

n Protective gloves
n Safety boots
Before commissioning the equipment, the guide plates (Fig. 172/1)

for the blank guide must be adjusted to suit the dimensions of the
product.
DANGER!
DANGER!
Fig. 172: Blank guide guide plates

Commissioning
CAUTION!
Always safely depressurise the Inliner system with
MLT 40 before beginning work.
1. Ensure that the machine cannot be turned back on.

Remove cover plate
2. Loosen the screws (Fig. 173/2) on the cover plate
(Fig. 173/1) without removing them completely.
3. Remove the cover plate (Fig. 173/1) from the blank guide.
4. Remove the screws (Fig. 173/2) from the cover plate.
Fig. 173: Remove cover plate
5. Loosen the screws (Fig. 174/1) on the lower guide plate

6. Align the lower guide plate horizontally to the height of the
conveyor belt (Fig. 174/3).
7. Re-tighten the screws (Fig. 174/1) on the lower guide plate.
8. Loosen the screws (Fig. 174/4) on the upper guide plate
9. Place a blank (Fig. 174/6) between the upper and lower
guide plate.
10. Leave a gap of 1 to 2 mm between the upper guide plate
Fig. 174: Configure the blank guide (Fig. 174/5) and the blank (Fig. 174/6).
1 Screws: lower guide plate 11. Re-tighten the screws (Fig. 174/4) on the upper guide plate.
2 Lower guide plate
3 Conveyor belt for the super-ordi-
nate system
4 Screws: upper guide plate
5 Upper guide plate
6 Blank

Commissioning
Fig. 175: Configure the blank guide

12. Loosen the screws (Fig. 175/1) on the multi-application head
13. Set the distance between the nozzle tip (Fig. 175/2) and the
lower edge of the upper guide plate (Fig. 175/3) to 5
(optimum) to 10 mm.
The nozzle tips (Fig. 175/2) must not touch the

blank (Fig. 175/4).
14. Re-tighten the screws (Fig. 175/1) on the multi-application

head (Fig. 175/5).
Ensure that the multi-application head is installed horizontally
when you tighten the screws.
Assemble the cover plate 15. Screw the screws (Fig. 173/2) of the cover plate into the
blank guide with a few turns.
16. Place the cover plate (Fig. 173/1) into the blank guide.
17. Tighten the screws (Fig. 173/2) on the cover plate
(Fig. 173/1).

Commissioning
18. Set the position of the water bath.

To do this, switch the electricity and pressure on.
DANGER!
Risk of injury when entering the operating
space of the super-ordinate machine and its
moving parts!
Follow the instructions:

Ä on page 185

Configure the blank guide on the second side as
described in steps 2 to 18.
6.3.3.2 Prepare the water bath

Set water bath position Personnel: n Qualified mechanic
n Protective gloves
n Safety boots
Materials: n Bottle with spray attachment
The system is fitted with a water bath (Fig. 176/1). Application
heads rest in the water bath when they are not working. The water
bath prevents the nozzles from drying out. The controller moves
the application heads sideways into their resting position. Then the
water bath moves upwards to the stop position. The stop position
for the water bath can be adjusted.
Fig. 176: Water bath position

Commissioning
DANGER!
Set water bath position

1. Activate manual mode.
To do this, press the [MANUAL/AUTO] button (Fig. 177/3).
ð The LED on the button illuminates yellow when manual
mode is active.
2. Move the water bath into its lower end position.
To do this, press the [DOWN] button (Fig. 177/2) until it rea-
ches the end position.
While the water bath is moving, the LED on the

[DOWN] button flashes.
Remove the lid

3. Loosen the knurled nut (Fig. 178/3).
4. Slide the lid (Fig. 178/1) in the direction of the arrow and
remove the lid out from the tray guide (Fig. 178/2).
Fig. 178: Remove the lid
Fill tray
NOTICE!
Risk of material damage to the application heads
and adhesive monitoring system due to improper
filling.
5. Fill the tray with water up to approx. 2 mm beneath the upper

edge of the tray.
Use the included bottle with spray attachment to

fill the tray.

Commissioning
Commissioning the components > 3-way multi-application head
6. Move the water bath up into its resting position.

To do this, press the [UP] button (Fig. 177/1) on the
switchbox until it reaches the resting position.
7. Check that the nozzles dip a few millimetres into the water.
NOTICE!
Risk of corrosion damage to the application
heads if they dip too deeply into the water
bath!
ð Adjust the position of the water bath if necessary.

Adjust water bath position
8. Loosen the screws (Fig. 179/1).
9. Adjust the water bath in the direction of the arrow until the
tips of the nozzles dip a few millimetres into the water.
10. Re-tighten the screws (Fig. 179/1).
To do this, press the [DOWN] button (Fig. 177/2) on the
switchbox until it reaches the end position.
Fig. 179: Adjust water bath position
Replace lid
12. Slide the lid (Fig. 180/1) back into the tray guide (Fig. 180/2).
13. Re-tighten the knurled nut (Fig. 180/3).
ð The position for the water bath is now adjusted.
The water bath is ready for operation.
14. Reconfigure the blank guide if necessary Ä Chapter
6.3.3.1 “Configure the 3-way blank guide” on page 182.
Fig. 180: Replace lid

De-aerate the system
The process of de-aeration is described in the context
of the glue delivery unit.

Commissioning
6.3.4.1 Configure adhesive application

Important parameters that influ- The following parameters affect the amount of adhesive applied:
ence adhesive application
n Nozzle size:
As the nozzle size increases, more adhesive or larger dots are
applied. Nozzles are available with diameters of 0.6 and
0.4 mm.
n Transport speed:
The volume of adhesive applied is also affected by the trans-
port speed of the products. As the transport speed increases,
the applied volume of adhesive decreases.
n Adhesive pressure:
The volume of glue applied is defined by the pressure for the
given nozzle diameter (not for dot operation).
In order to ensure a constant adhesive line is applied at dif-
fering machine speeds, the adhesive pressure is adjusted to
suit the speed. As the speed increases, so must the adhesive
pressure.
n Application head armature stroke:
The dot size can be adjusted using the stroke regulator. The
stroke regulator for the application heads does not provide
reproducible results across the entire range of settings. If the
armature stroke is opened too wide, the applied volume of
adhesive may reduce further.
Reset the armature stroke to fac-

tory settings The multi-application heads are delivered with a fac-
tory-configured armature stroke. Only change the fac-
tory setting if it leads to results outside of the tolerance
range.
If you wish to return to the basic factory setting, proceed as follows:

Commissioning

n Safety goggles
n Protective gloves
Special tool: n Flathead screwdriver
1. Release the set screw on the side of the clamping ring on the
stroke regulator.
2.
NOTICE!
Risk of damaging the nozzle and armature by
over-tightening the stroke regulator!
Only tighten the stroke regulator as tightly as you
can by hand.
Turn the stroke regulator clockwise with a flathead screw-

driver until it stops.
Fig. 181: Configure the armature
stroke 3. Turn the stroke regulator a half turn anti-clockwise from the
point it stops.
1 Threaded pin
2 Stroke regulator 4. Turn the clamping ring clockwise until it stops.
3 Clamping ring
5. Save the setting by tightening the threaded pin.
ð The application head is in its basic setting.
6. Repeat the settings for the remaining application heads.
7. Assess the adhesive application:
Ä “Assessing the adhesive application” on page 189
Assessing the adhesive application

n Safety goggles
n Protective gloves
1. Following a test run, assess the applied volume of adhesive

according to your production requirements.
Changing the applied volume of 2. Change the applied volume of adhesive if necessary:
adhesive
n Ä “Changing the nozzle size” on page 190
n Ä “Adjusting the transport speed” on page 190
n Ä “Adjust the adhesive pressure” on page 190
n Ä Chapter 6.3.4.1.1 “Adjust the armature stroke”
on page 191

Commissioning
Changing the nozzle size Nozzles are available with diameters of 0.6 and 0.4 mm.
To replace the nozzles, see:

Ä Chapter 8.3.5.5 “Replace the nozzle” on page 430
Adjusting the transport speed

Regulating the applied volume of Personnel: n Qualified mechanic
adhesive according to the speed
n Safety goggles
To achieve a constant adhesive line at varying machine speeds,
you can regulate the adhesive pressure according to the speed.
You can also regulate the applied quantity according to the speed.
The following table shows the relationships.
Relationship between adhesive pressure and machine speed

n If the adhesive pressure is constant and the machine speed is
increased, the adhesive line becomes slimmer.
n If the adhesive pressure is increased and the machine speed is
increased, the adhesive line remains constant.
n If the adhesive pressure is decreased and the machine speed
remains constant, the adhesive line becomes slimmer.
n If the adhesive pressure is increased and the machine speed
remains constant, the adhesive line becomes wider.
n If the adhesive pressure remains constant and the machine
speed is decreased, the adhesive line becomes wider.
Adjust the adhesive pressure

Manual adjustments to the adhesive pressure are
made via the glue delivery unit.

Commissioning
6.3.4.1.1 Adjust the armature stroke
NOTICE!
Risk of material damage due to incorrect configu-
ration of the stroke regulator!
If the armature stroke is configured incorrectly, the
nozzles and armature can be damaged.
– Only adjust the stroke regulator during nozzle
testing.
– Do not over-tighten the stroke regulator.
NOTICE!
Possible variations in the applied volume of mate-
rial if the armature stroke opened too widely!
The stroke regulator does not provide reproducible
results across the entire range of settings. If the arma-
ture stroke is opened too widely, the applied volume of
– Maximum setting for the stroke regulator - half
open.
You can make small changes to the applied volume of adhesive

via the settings for the armature stroke.
The armature stroke can be set individually for each of the mod-
ules of the application head.

Commissioning

n Safety goggles
n Protective gloves
The modules are delivered pre-configured. Only

change the factory setting if it leads to results outside
of the tolerance range.
Change the armature stroke setting

1. Release the set screw on the side of the clamping ring on the
stroke regulator.

stroke
1 Threaded pin
2 Stroke regulator
3 Clamping ring
2.
NOTICE!
Risk of damaging the nozzle and armature by
over-tightening the stroke regulator!
Only tighten the stroke regulator as tightly as you
can by hand.
Using the basic setting as a starting point, you can turn the
stroke regulator to regulate the volume of adhesive:
n P To reduce the volume of adhesive, turn the stroke reg-
ulator clockwise.
n P To increase the volume of adhesive, turn the stroke
regulator anti-clockwise.
Fig. 183: Set armature stroke, dia- If there is no satisfactory result throughout the
gram entire range between the stop points, there is a
fault. Proceed as described in the "Fault"
1 Stroke regulator chapter.

Commissioning
Commissioning the components > MLT sensor
3. Turn the clamping ring clockwise until it stops.

4. Save the setting by tightening the threaded pin.
5. Repeat the settings for the remaining application heads.
6.3.5 MLT sensor

Preparation Ensure that the MLT sensor is connected correctly.
Switch-on The MLT sensor is switched on together with the super-ordinate

system.
The settings for the MLT sensor are made via the equi-
pment's terminal.
Adjusting the MLT sensor Personnel: n Operator

n Safety boots
DANGER!
In normal operation, the inspection area for the sensor is not visible
to the human eye.
The [Setup] button activates the MLT sensor's alignment lighting
system to show the monitored scanning area on the product.
1. Press the [Setup] button on the MLT sensor.
2. Adjust the sensor position and required inspection area as
needed.
3. Press the [Setup] button on the MLT sensor once more.
ð The alignment lighting system is deactivated.
Fig. 184: MLT sensor

1 Button: Setup

Commissioning
Commissioning the components > FHDK light sensor
The device is commissioned via the system's user

interface.

At least 2 separate light barriers are required for skew control.
Each light barrier must be commissioned separately to begin with.
Skew control is activated via the controller.

Commissioning information If possible, use the internal start sensors for the individual compo-
nents. If there are gaps in the objects being measured, you can
often avoid using an external light sensor by using window
masking.
Light barriers play an important role in the entire system. They
detect the product and trigger the functions of the assigned compo-
nents via the controller. Components may include adhesive appli-
cation heads, sensors and cameras.
The controller must take into account the distance between the
light barrier and the components. This distance is known as the
offset. The controller can calculate the point in time when the func-
tion should be triggered from the offset value and the machine
speed. The accuracy of the product edge detection therefore has a
direct influence on the function.

Commissioning
Position the light sensor relative to

the object edge
Fig. 185: Positioning relative to the product edge

1 Light sensor
2 Light spot from the light sensor
3 Product transport direction
4 Positioning of the light spot in terms of the product edge
5 Product, represented here by a folding carton blank
NOTICE!
Positioning error due to incorrect placement of the
light sensor
– Always direct the light sensor's light spot towards a
bright, straight edge on the product ().
– Directing it towards a corner, rounded or slanted
section can cause serious positioning errors in the
transport direction. This happens even if there are
only tiny positioning variations transverse to the
running direction.
– This is true for both internal and external light bar-
riers.
NOTICE!
Machine elements can cause faulty detection
Directing the light barrier towards moving machine
parts (cams, rollers, vibrating parts) can lead to func-
tions being triggered incorrectly. The product is not
detected correctly.
– Do not direct the light barrier towards moving or
vibrating machine parts.
– Check that the light barrier can function freely
before beginning production.

Commissioning
Align the light sensor and compo-

nents behind one another
2 Example components, represented here by a sensor
2a Measuring point / output point for the unit
3 Light sensor
3a Light spot from the light sensor
4 Offset value, distance between the light sensor and component
5 Object, represented here by a folding carton blank
6 Running direction
Fig. 186: Alignment of the start sensor

behind the component (represented
here by a sensor)
Calculate offset value Personnel: n Operator

1. Place a product beneath the light sensor assigned to the
component.
2. Stop the product when the edge of the product is positioned
beneath the light barrier and the light barrier activates.
This can generally be detected via the LED display on the
light sensor.
The approximate output position of the light spot is often
marked with an arrow on the light barrier housing.
3. Continue to transport the product until it is positioned
beneath the subsequent component.
ð The distance from the switching point for the start sensor
to this point is the offset.
4. Measure this distance. The unit for this depends upon the
settings in the operating software, either [mm] or [inch].
5. Enter the measured distance into the controller as the offset.
6. Check that the light barrier is correctly assigned to the com-
ponent in the operating software.

Commissioning
Commissioning the components > (optional) Marking system

Spray application head material
supply NOTICE!
Risk of material damage due to insufficient mate-
rial supply to the spray application heads!
The spray application heads can become damaged if
allowed to run dry.
– Before commissioning, ensure that there is a suffi-
cient supply of material or suitable medium.
Adjusting the amount of applied The following factors affect the amount of material applied:
material
n Nozzle size selection,
n Sprayed air and material pressure settings
Ä Chapter 6.3.9.2 “Set material pressure and sprayed air pres-
sure” on page 199
n Armature stroke setting
Ä Chapter 7.2.7.2 “Configure the armature stroke”
on page 332
The nozzle size is defined by the installed nozzle. It can be
changed by changing the nozzle.

Commissioning
6.3.9.1 De-aerate the system

Personnel: n Manufacturer
n Operator
n Safety boots
n Safety goggles
n Protective gloves
Requirement: The equipment is fully installed.

Release pressure
WARNING!
1. Remove the sprayed air pressure regulator (Fig. 187/2).

2. Turn the sprayed air pressure regulator anti-clockwise until it
stops.
ð The pressurised air supply to the spray application head
stops.
3. Check the sprayed air pressure on the sprayed air pressure
manometer (Fig. 187/1).
The manometer must show 0 bar.
4. To save the setting, lock the pressure regulator by pushing it
in.
5. Remove the vessel air pressure (material pressure,
Fig. 187/3) regulator.
6. Turn the vessel air pressure regulator anti-clockwise until it
stops.
ð The pressure is released from the vessel.
7. Check the vessel air pressure on the vessel air pressure
Fig. 187: Setting pressure manometer (material pressure, Fig. 187/4).
in.
9. Disassemble the spray application head associated with the
pressure vessel.
10.
WARNING!
Risk of injury caused by uncontrolled
spraying of cold glue due to disconnected
application heads!
Hold the application head into a suitable container.

Ensure that the application head cannot spray towards
people.

Commissioning

12.
Observe the permissible pressure:
1 to 2.5 bar.
Set the vessel air pressure regulator to the vessel air pres-
sure originally selected.
13. Start the nozzle test for the selected application head.
14. Deliver cold glue as part of the nozzle test until no more air
bubbles appear at the nozzle.
End the nozzle test.
16. Turn the vessel air pressure regulator anti-clockwise until it
stops.
Fig. 188: Setting pressure
17. Check the vessel air pressure on the vessel air pressure
manometer (material pressure, Fig. 188/4).
in.
19. Clean the application head if necessary.
20. Attach the application head back into its original position
within the equipment.
6.3.9.2 Set material pressure and sprayed air pressure

Pressure vessel operating pressure
WARNING!
Risk of injury and material damage due to high
operating pressure!
The maximum operating pressure of the pressure
vessel and the hoses and connections that carry the
product is 2.5 bar. Higher pressures can cause the
vessel, hoses and connections to burst. This can
cause serious injury and material damage.
– Never set the equipment to a pressure higher than
2.5 bar.
– Check the pressure on the product carrying parts
regularly using the vessel air pressure (material
pressure) manometer.

Commissioning
Material pressure You must use pressure to adjust the amount of material for the
given nozzle diameter. For a constant material bead at varying
machine speeds, you must regulate the material pressure
depending on the speed.
As the speed increases, so must the material pressure.
Sprayed air pressure

The sprayed air pressure you need to set depends upon
n the distance to the product,
n the material viscosity and
n the required amount of material per application period.
Fig. 189: Sprayed air period to control When using the optional sprayed air shut-off, the sprayed air
air period (Fig. 189/1) should be initiated before the material begins to be
delivered (opening of the control valve, Fig. 189/2). The sprayed air
must continue to be applied after the control valve closes and the
material output stops in order to keep the nozzle tip clean.
If not using the optional sprayed air shut-off, open the sprayed air
line before beginning production.

Commissioning
n Operator
n Safety boots
n Safety goggles
n Protective gloves
1.
1 to 2.5 bar.
Set the material pressure on the left-hand regulator on the

pressure vessel (Fig. 190/1).
To do this, remove the material pressure regulator and select
a pressure between 1 and 2.5 bar.
2. Check the material pressure on the left-hand manometer on
the pressure vessel (Fig. 190/2).
3. To save the setting, lock the regulator by pushing it in.
4. Set the sprayed air pressure on the right-hand regulator on
the pressure vessel (Fig. 190/3).
To do this, remove the sprayed air pressure regulator and
select a pressure between 1 and 2.5 bar.
The sprayed air pressure must not be higher

Fig. 190: Setting the pressure vessel than the material pressure.
material pressure
5. Check the sprayed air pressure on the right-hand manometer

on the pressure vessel (Fig. 190/4).
6. To save the setting, lock the regulator by pushing it in.
7. Assess the material application
Ä Chapter 6.3.9.3 “Assess material application”
on page 202.
8. If necessary, correct the material application by reconfiguring
the material or sprayed air pressures.
As well as the material and sprayed air pres-

sures, the nozzle size and the armature stroke
(Ä Chapter 7.2.7.2 “Configure the armature
stroke” on page 332) also affect material appli-
cation.

Commissioning
6.3.9.3 Assess material application

n Safety boots
n Safety goggles
n Protective gloves
The air cap can become dirty during setup. Dirt can divert the air
stream. This leads to the sprayed image being seen as faulty.
Therefore, clean the air cap regularly and as needed:
1. Run several models for material application through the
machine.
Then make a visual check of the material application and the
air cap on the spray application head.
2. Assess and correct the result according to the following:
3. Correct the
n Nozzle size,
n Material pressure and/or sprayed air pressure (see:
Material delivery operation) and
Fig. 191: Functional diagram
n Armature stroke
1 Air cap Ä Chapter 7.2.7 “Operating the marking valve”
on page 331
and re-assess the result.
4. If correcting the nozzle size, material and sprayed air pres-
sures and the armature stroke does not result in a satisfac-
tory application image, check:
n the distance between the spray application head and the
paper or carton: The distance must always be the same.
Reconfigure the blank guide if necessary.
n the material for any impurities: Filter or replace the mate-
rial if necessary.
Material application assessment Assessment of the material application is carried out without the
information product moving (during stoppage).
1 Material application with round spray air cap
2 Material application with flat spray air cap
If too much material is applied, the air cap is likely dirty.
Fig. 192: Application image (stopped):

too much material

Commissioning
The air cap is dirty
Description Resolution
The material splashes back Clean the air cap and nozzle tip
from the paper or carton.
Ä Chapter 9.3.16.2 “Check,
replace the nozzle”
on page 486.
Reduce the sprayed air pres-
sure.
Too much material is applied Reduce the material pressure.
during spraying.

Too little material
The material is not being suffi- Increase the sprayed air pres-
ciently mixed with sprayed air sure.
and accelerates towards the
paper or carton.
Fig. 193: Application image (stopped): Too little material is applied Increase the material pressure.
almost no material during spraying.
To set the material pressure and sprayed air pressure:

Ä Chapter 7.2.6.2 “Regulating pressure” on page 330

Uneven application
paper or carton.
uneven application during spraying.

Commissioning
Commissioning the components > Pressure vessel

Where there is
n a sufficient volume of material,
n a fixed distance between the spray application head and the
paper/carton,
n clean material without dirt and thickened areas,
n and the sprayed air is configured correctly,
Fig. 195: Application image (stopped): the application must be full-surface with almost sharp-edged cut
full-surface application offs.

n Operator
n Safety boots
n Safety goggles
n Protective gloves
Requirements: The system is depressurised. The equipment is

fully installed.
1. Fill the vessel with material.
2. Connect the existing pressurised air supply.
3.
1 to 2.5 bar
Remove the vessel air pressure (material pressure,

Set the vessel air pressure regulator to the desired material
pressure between 1 and 2.5 bar.
4. Check the pressure on the vessel air pressure (material pres-
sure, Fig. 196/4) manometer.
in.
6. De-aerate the equipment.
Fig. 196: Pressure regulation

Commissioning
Commissioning the components > Commissioning the marking valve
7. Set the sprayed air pressure on the sprayed air pressure reg-
ulator (Fig. 196/2) to the desired sprayed air pressure
between 1 and 2.5 bar.
The sprayed air pressure should not be higher

than the material pressure.
Check the pressure on the sprayed air pressure (Fig. 196/1)

manometer.
in.
ð The equipment is ready for operation.
6.3.11 Commissioning the marking valve

Spray application head material
supply NOTICE!
Risk of material damage due to insufficient mate-
rial supply to the spray application heads!
The spray application heads can become damaged if
allowed to run dry.
– Before commissioning, ensure that there is a suffi-
cient supply of material or suitable medium.
Influencing the amount of material Before commissioning, set the material application volume in
applied accordance with the production parameters.
The following factors affect the volume of material applied:
n Sprayed air pressure setting
n Material pressure setting
n Armature stroke setting
See the documentation for the application system for

further information on pressure settings and assessing
material application.

Commissioning
Commissioning the components > IE-65-508 Encoder
6.3.12 (optional) Sprayed air shut-off I

n Safety boots
n Safety goggles
n Protective gloves
1. Set the sprayed air pressure on the pressurised air supply.
The sprayed air supply is regulated via the pres-

surised air supply.
Please see the pneumatic diagrams in the
appendix!
2. Check the system for leaks.

3. Check that the system works correctly.
6.3.13 IE-65-508 Encoder
At the maximum machine speed, the impulse fre-

quency at the encoder input must not exceed 20 kHz!
Higher values decrease the measuring accuracy.
Calculating the encoder resolution

The control unit converts the encoder resolution automatically, so
you can enter the lengths for material lines, products or distances
in mm or inches.
The process for calculating the encoder resolution is described
using material application as an example.
1. On the control unit, set the encoder resolution to any value
(Enc0).
2. Program two material lines of any length, one behind the
other, into the control unit.
The only important factor is the programmed spacing
between the start points of the two material lines (Y0).
3. Apply the material lines to a product.
4. Measure the actual spacing between the start points of the
two material lines (Y1).

Commissioning
Commissioning the controller
5. Calculate the new encoder resolution.
Formula: Encoder resolution (Fig. 197)

(actual distance / programmed distance)
Fig. 197: Formula: Encoder resolution x entered encoder resolution
Y1 actual spacing of the start points = new encoder resolution
Y0 programmed spacing of the
start points 6. Divide the actual measured value by the entered nominal
Enc0 entered encoder resolution value and multiply the result by the set encoder resolution.
Enc1 new encoder resolution
7. Enter the calculated encoder resolution into the controller.
Enter the result as the new encoder resolution.
Encoder resolution A frequently used encoder resolution for the IE-65-508 encoder is
0.5 mm/pulse.
6.4 Commissioning the controller

Configure initial basic settings on The Inliner system consists of different, sometimes varying and
the terminal optional, components and parts. The structure depends upon
things such as the machine type of the Inliner. Some parameters
and settings in the Inliner controller are dependent upon the
machine configuration. It is therefore necessary to configure these
settings before commissioning.
Settings before beginning normal operation
n Set language:
Ä Chapter 6.4.2 “Set language, date and time” on page 214
n Check basic service parameter:
Ä Chapter 6.4.3.3 “Configure the settings on the “Data /
Installation / Service” page” on page 222
n Assign the application head type to the application head:
Ä “Select the application head type” on page 229
n Enter application head offset:
Ä Chapter 6.4.4.3 “Configure the settings on the “Application
Head Type - Application Head Mode” page” on page 229
n Adjust encoder resolution:
n Check pressure curve:
Ä Chapter 6.4.5 “Adjusting the pressure curve” on page 234
n Set compensation:
Ä “Determine switch-on/switch-off compensation”
on page 232
Settings on the monitoring unit must be configured to monitor the
adhesive pattern.

Commissioning
Commissioning the controller > System settings for the Inline...
MLT settings
n Check MLT service settings:
Ä Chapter 6.4.3.3 “Configure the settings on the “Data /
Installation / Service” page” on page 222
n Assign the MLT offset and light barriers:
Ä Chapter 6.4.8 “Defining the MLT offset and light barrier”
on page 256
n Configure MLT parameters:
Ä Chapter 6.4.9.3 “Configuring settings on the
“MLT parameters” page” on page 262
6.4.1 System settings for the Inliner systems with MLT 40

Menu navigation for the Inliner sys- The “Data” page acts as the menu for the basic system settings of
tems with MLT 40 the Inliner systems with MLT 40. System settings need only be
configured during initial installation or when changing the parame-
ters, for example if changing the adhesive. The buttons open var-
ious pages of the user interface and the submenu.
Open the “Data” page

On the main page, press the button.

ð The “Data” page opens.

Commissioning
Overview of the “Data” page
Fig. 198: "Data" page

Commissioning
Menu navigation
Button Meaning Settings options

n Change language.
n Set date.
n Set time.
n Calibrate touchscreen.
Opens the “Display” page.

n Configure the adhesive pres-
sure depending on the speed.
n Save and load pressure
curves.
n Adjust dot sizes.
n Set minimum speed vmin.
Opens the “Pressure curve”

page.
n Open the submenu.
Opens the “Data / Installation”

page.

Commissioning
Overview of the Data / Installation

page
Menu navigation for the

“Data / Installation” page
Button Meaning Setting options

n Set inputs and outputs.
n Set the encoder resolution.
n Set consecutive errors.
Opens the “Data / Installation / IO

Signals” page.
n Set MLT parameters
Opens the “Data / Installation /

MLT parameters” page.

Commissioning

n Set the application head
offset.
n Select the application head
type.
n Switch dot/line changeover
on/off.
n Switch minimum speed vmin
on/off.
n Switch switchbox on/off.
n Enter compensation.
Application head types -
Application head mode” page.
n Set the MLT offset.
n Set the marking system offset.

MLT setup” page.
n Set external interfaces.
Opens the “Data / Installation / ”

page.

Commissioning

n Assign user levels.
n Set access codes.

Access codes” page.
n Configure the system.
n Define basic settings.

Service” page.

Commissioning
Commissioning the controller > Set language, date and time
6.4.2 Set language, date and time

6.4.2.1 Open the “Data / Display” page
1. On the main page, press the button. (Fig. 199)
Fig. 199: Open the "Data" page
2. On the “Data” page, press the button. (Fig. 200)

ð The “Data / Display” page opens.
Fig. 200: Open "Data / Display"

Commissioning
6.4.2.2 Configuring the settings on the “Data / Display” page

Select language
Press the corresponding national flag (Fig. 201) to select the
language you require.
Available languages
Greyed out national flags cannot be selected.
ð The flag for the currently selected language is highlighted

in yellow.
Fig. 201: Select language

Commissioning
Setting the date

Depending on the system, you may require an access
code to set the date.
Ä Chapter 7.1.2 “Changing user level” on page 278
1. Enter the access code if necessary.

2. Press the button next to the “Date” display field. (Fig. 202)
ð The calendar opens.
Fig. 202: Setting the date
3. Press the current date. (Fig. 203)
Fig. 203: Calendar
4. To confirm, press the button on the right next to the dis-

play field. (Fig. 204)
ð The new date is set.
5. To exit the “Data / Display” page, press the button on
the lower right.
Fig. 204: Confirming the input

Commissioning
Setting the time

Depending on the system, you may require an access
code to set the time.
1. Enter the access code if necessary.

2.
This section describes how to set the time, using
the hour as an example.
The minutes and seconds are set in the same
way.
Press the hour indicator in the “Time” selection field to set

the hour.
ð The hour indicator is highlighted in blue.
3. Press the arrow keys next to the “Time” selection field to set
the hour.
Fig. 205: Setting the hour
4. Set the minutes and seconds.
5. To confirm, press the button on the right next to the dis-
play field. (Fig. 206)
6. To exit the “Data / Display” page, press the button on
the lower right.
Fig. 206: Confirming the input

Commissioning
Commissioning the controller > Defining basic settings
Calibrate touchscreen
1. Press the button. (Fig. 207)
ð The “Calibrate touchscreen” page opens.
Fig. 207: Open the "Calibrate

touchscreen" page
2. Follow the instructions shown on the user interface.

(Fig. 208)
ð The touchscreen is calibrated.
Fig. 208: Calibrate touchscreen
6.4.3 Defining basic settings

Basic settings for the system are defined on the
“Data / Installation / Service” page.

Commissioning
6.4.3.1 Open the “Data / Installation / Service” page

1. On the main page, press the button.
2. On the “Data” page, press the button.

ð The “Data / Installation” page opens
3. On the “Data / Installation” page, press the button.

ð The “Data / Installation / Service” page opens.

Commissioning
6.4.3.2 Description of the “Data / Installation / Service” page

“Service” page overview
Fig. 209: Inliner MLT "Data / Installation / Service" overview

1 Operating area: Glue column
2 Operating area: MLT column
3 Operating area: Section for further settings
Further service settings Further settings can be configured in the lower section of the oper-
ating area. Pressing the buttons turns the buttons to . The
function is activated.
Fig. 210: Example: Service settings
Service setting Activ Meaning

e
Standby Adhesive application is in standby
when the program starts and must be
started separately
Counter reset for During a teach run, all counters are
teach runs automatically set to zero.

Commissioning
Service setting Activ Meaning

e
No error during No faulty products are marked in setup
setup mode.
Statistics can be On the Statistics page, a button is

reset manually overlaid that allows you to reset the
statistics manually.
Input only during Changes to the program can only be
setup made in setup mode. If the equipment
is in production mode, the input fields
are locked.
Tolerant glue One of three adhesive lines can be
check completely missing without causing an
error.
Request RFID You can also switch between user
(optional) levels using a transponder with an
RFID chip.
Fragment filter Ä “Fragment filter” on page 221
Hole filter Ä “Hole filter” on page 221
Hole filter The hole filter function allows interruptions to start signals to
be ignored up to a preset size.
A value of 0 means that the hole filter is not activated.
Gaps or interruptions in the product can cause the model to be

restarted. Specify a filter area. Provided a gap or interruption in the
product does not exceed the entered length, the system interprets
the interruption as a product passing through.
Note the dependencies:

– The value entered for the hole filter must be
smaller than the offset value.
– The interruption cannot be calculated without the
speed.
– When using the hole filter function, the
Start v=0 selection field must be set to off.
Fragment filter The fragment filter function allows start signals to be ignored
up to a preset size.

Commissioning
A value of 0 means that the fragment filter is not acti-

vated.
Fragments or paper shreds can trigger start signals unintentionally.

Specify a filter area. Start signals are only accepted if they are
larger than the set value for the fragment filter. Paper shreds or
fragments are therefore ignored and not interpreted as start sig-
nals.
Note the dependencies:

– The value entered for the fragment filter must be
smaller than the offset value.
– Fragments cannot be detected without the speed.
– When using the fragment filter function, the
Start v=0 selection field must be set to off.
6.4.3.3 Configure the settings on the “Data / Installation / Service” page

Select production side
1. Press the second selection field in the Gluecolumn.
ð A list opens.
2. Select the relevant fittings according to your system.
Selection list Application area

selectable System fitted on both sides, adhesive
application on one side only.
side 1 only System fitted on side 1.
side 2 only System fitted on side 2.
double-sided System fitted on both sides, adhesive
application on both sides.
Fig. 211: Select production side

Commissioning
Select glue delivery unit

1. Press the third selection field in the Gluecolumn.
ð A list opens.
2. Select [KPE9 + PMDRE].
Fig. 212: Select KFE
Select marking system

1. Press the fourth selection field in the Gluecolumn.
ð A list opens.
2. Select an option depending on the system fittings.
Selection list Application options

No marker System without a marking system
Marker n Marking system available
n manual input of the area to be
marked
Auto marker n Marking system available
n automatic selection of the area to
Fig. 213: Select marking system be marked
n depends upon the product length

Commissioning
Select MLT
1. Press the first selection field in the MLTcolumn.
ð A list opens.

MLT 40 MLT fitted on side 1.
no sensor MLT not fitted on side 1.
Fig. 214: Select MLT side 1
3. Press the second selection field in the MLTcolumn.

ð A list opens.

MLT 40 MLT fitted on side 2.
no sensor MLT not fitted on side 2.
Fig. 215: Select MLT side 2
5. Press the third selection field in the MLT column.

ð A list opens.

selectable System fitted with MLT on both sides.
Monitoring on one side only.
side 1 only System fitted with MLT on side 1.
side 2 only System fitted with MLT on side 2.
Fig. 216: Select MLT application side

Commissioning
Commissioning the controller > Configuring application heads I
6.4.4 Configuring application heads I

6.4.4.1 Open the “Data / Installation / Application Head Types - Application Head Mode” page.

ð The “Data / Installation” page opens.

ð The
“Data / Installation / Application Head Types - Application Head Mod
page opens.

Commissioning
6.4.4.2 Description of the “Data / Installation / Application Head Types - Application Head Mode”
page
Overview of the “Application Head
Types - Application Head Mode”
page
Fig. 217: "Application Head Types - Application Head Mode" page

1 Multi-application head offset 1
Ä “Multi-application head offset” on page 226
2 Multi-application head offset 2
Ä “Multi-application head offset” on page 226
3 Light barrier assignment
4 Water bath offset
5 Application head type
6 Ä “Dot size” on page 226
7 Ä “Dot/line changeover” on page 227
8 Ä “Minimum speed vmin” on page 227
9 Ä “Switchbox” on page 228
10 Ä “Compensation” on page 228
Multi-application head offset Light barriers detect the start edge of individual products and are
therefore mounted in front of the application heads in the running
direction. The offset is the distance from the light barrier light spot
to the application head nozzle on the first application head of the
Dot size The dot size determines the amount of adhesive applied by the
valves on the relevant application head. If this setting is adjusted,
the settings on the “Data / Pressure Curve” page for the volume of
adhesive applied are automatically adjusted and vice versa.

Commissioning
The larger the value, the larger the applied quantity of

adhesive.
Dot/line changeover Dot application heads can apply both adhesive dots and adhesive
lines. In dot/line mode, this feature allows adhesive dots to be
applied at slow production speeds. If the production speed
increases past the dot/line changeover point, it switches to line
application. The general dot spacing value is used in dot/line
mode, which is determined independently of the adhesive pattern.
If the system is not set to dot/line mode, the application head will
work in dot mode continuously.
Dot/line changeover Function

options
The dot application head
switches from dot to line applica-
tion at a set speed.
(on)
The dot application head remains
in dot application mode.
(off)
Dot/line mode can only be used with dot application

heads as line application heads cannot apply adhesive
dots.
Minimum speed vmin Switch minimum speed vmin on/off.

The minimum speed vmin function defines whether detected signals
should only be implemented above a set speed.
Minimum speed vmin Function

options
The adhesive pattern is com-
pleted only at the set minimum
speed and above.
(on)
The adhesive pattern is com-
pleted when the machine speed
is v>0m/min.
(off)

Commissioning
Example application:
If the machine is in setup mode or tip mode, adhesive
application is suppressed. It begins only at or above a
defined minimum speed vmin. You can set the vmin on
the “Pressure curve” page.
NOTICE!
Contamination due to uncontrolled adhesive dis-
charge
You should always assign a minimum speed vmin to
line application heads. If the line application head is
open when the machine stops, adhesive leaks uncon-
trollably from the application heads.
Switchbox The Switchbox button switches monitoring of the end position of

the pneumatic conveyor unit on and off.
Switchbox options Function

The end position is monitored.
The system only applies adhe-
sive when the multi-application
(on) head has reached the end posi-
tion.
The end position of the multi-
application head is not moni-
tored. Adhesive application can
(off) begin independently of the posi-
tion of the multi-application head,
even if it is in the water bath. A
note appears on the main page.
Ä “Note” on page 275
Compensation The controller compensates when the application head is activated

in relation to the machine speed. This is required because each
type of application head has a different switching speed and the
materials have different running speeds.
If the machine runs quickly, the material pattern is moved back-
wards in relation to the machine running direction.
To adjust the compensation, enter the delays for the individual
application heads.
The system differentiates between switch-on and switch-off com-
pensation. Switch-on compensation refers to the start of the mate-
rial line, whereas switch-off compensation refers to the end of the
material line.

Commissioning
For
n Line application heads: The start and end of the material line
are adjusted. They can be configured separately.
n For dot application heads: Each individual dot is adjusted
against the running direction by bringing forward the switch-on
time.
Compensation is given in milliseconds [ms].
Compensation depends upon the:

n Material characteristics
n Distance between the application head and the product
n Time delay using a photocell
n Mechanical inertia of the application head
n Stroke regulation
n Material pressure
n Mask thickness, only for contact application
6.4.4.3 Configure the settings on the “Application Head Type - Application Head Mode” page
Select the application head type
1. Press the first selection field in the Application head
type column.
ð A list opens.

P-Gun Dot Glue application system is fitted on
side 1 or both sides.
No Gun Glue application system is not fitted on
side 1.
Fig. 218: Select side 1 application

head

Commissioning
3. Press the second selection field in the Application head

type column.
ð A list opens.

P-Gun Dot Glue application system is fitted on
side 2 or both sides.
No Gun Glue application system is not fitted on
side 2.
Fig. 219: Select side 2 application

head
Select marking valve (optional)

1. Press the second selection field in the Application head type
column.
ð A list opens.

D-Gun Line Marking valve fitted.
No Gun Marking valve not fitted.
Fig. 220: Select marking valve
Adjust the applied quantity for the You can use the system controller to adjust the applied quantity of
application heads adhesive on the terminal.
The mechanical adjustment of the applied quantity is

made using the stroke adjustment for the application
heads

Commissioning
Entries are made in the same way for every system.

1. Press the selection field in the Level column.
ð A list opens.
2. Select a value.
The larger the value, the larger the applied quan-

tity of adhesive.
Fig. 221: Adjust the applied quantity
Enter the offset between the light The process is explained using side 1 as an example. Depending
barrier and the adhesive applica- on the system fittings, the process is the same for side 2.
tion head
1. Measure the distance between the light barrier light spot and
the adhesive application head.
2. Press the corresponding input field and enter the offset
value.
Enter the offset between the feeder

and the water bath
1. Measure the distance between the feeder and the water bath
for the relevant side.
2. Press the input field and enter the offset value.
Fig. 222: Feeder - water bath offset

value

Commissioning
Determine switch-on/switch-off
compensation
Average values for compensation

Average values for switch-on and switch-off compen-
sation calculated by Baumer hhs are detailed in the
technical data for the fitted application head.
Begin by testing the values in the technical data.
Requirements for configuring compensation

Fig. 223: Configure "Compensation To configure the compensation, the encoder resolution
On (1) / Off (2)" and offset values must be set correctly.
You must have a material pattern loaded to configure
the compensation.
Determine switch-on compensation The switch-on compensation only adjusts the timing for the start of
the material application (Fig. 223/1). It must be set separately for
each application head.
The higher the switch-on compensation value entered, the earlier
the application head will be opened.
1. Apply material to the product at low production speed v1.

2. Measure the distance S1 from the front product edge to the
start of the material line.
3. Increase the production speed by 60 m/min to v2.
Increasing the production speed by exactly

60 m/min means that complicated calculations
can be avoided.
4. Apply the material to the product again.

5. Measure the distance S2 from the front product edge to the
start of the material line.
Fig. 224: Configure "Compensation ð If the distance is identical on both products, no compen-
On" sation is required.
If the lengths of the measured distances differ, proceed
as follows:
6. Calculate the difference (S2 - S1).

Commissioning
7. Add this difference to the value currently entered in

Fig. 223/1.
If you increased the production speed as

described above, you can now ignore the dif-
ferent units when entering the values.
Caution: If you increase the speed by a different
value, you must first calculate the difference in
speed between the measured values before you
add them!
ð The calculated sum is the new value for the switch-on

compensation.
8. Enter the sum as the new value in Fig. 223/1.
9. Set the switch-on compensation for the remaining application
heads.
Configure switch-off compensation The switch-off compensation only adjusts the timing for the end of
the material application (Fig. 223/2). It must be set separately for
each application head.
The higher the switch-off compensation value entered, the earlier
the application head will be closed.
1. Apply material to the product at low production speed v1.

2. Measure the distance S1 between the end of the material line
and the final product edge.
3. Apply the material to the product again.
4. Measure the distance S2 between the end of the material line
and the final product edge.
ð If the distance is identical on both products, no compen-
sation is required.
If the lengths of the measured distances differ, proceed
as follows:
5. Calculate the difference (S1 - S2).
Fig. 225: Configure "Compensation 6. Add this difference to the value currently entered in
Off" Fig. 223/2.
ð The calculated sum is the new value for the switch-off
compensation.
7. Enter the sum as the new value in Fig. 223/2.
8. Set the switch-off compensation for the remaining application
heads.

Commissioning
Commissioning the controller > Adjusting the pressure curve
9. Press the button to save the settings and leave the

page.
6.4.5 Adjusting the pressure curve

The pressure curve provides a range of settings in order to ensure
the even application of material at any machine speed.
If you wish to use a new type of material, normally adhesive, you
must adjust the pressure curve. To do this, you can change the
values for the pressure and speed. These values are affected by a
number of factors and must be calculated using empirical values
and through testing.
Dot/line mode Understanding the differences between an application head's dot

and line modes is important for understanding pressure regulation.
Dot mode
In dot mode, the opening frequency of the application head is
adjusted to conform with the production speed. This ensures a
near constant pressure in the application head. An equal amount of
adhesive is applied each time the application head opens.
Line mode
In line mode, the application head is permanently open and perma-
nently applying glue. If there were a constant pressure at low pro-
duction speeds, this would lead to too much adhesive being
applied, at high speeds there would be too little. The pressure is
therefore adjusted to suit the production speed above the change-
over point using the pressure curve Dot/line changeover (pneu-
matic control principle).
Dot/line changeover
If both the production speed and the pressure are low in line mode,
the pneumatic control principle reaches its limitations. So a special
technique is required that permits a higher pressure despite the
low production speed. Below a selectable limit value for the pro-
duction speed, the changeover point Dot/line changeover, the
device changes from line to dot mode. The advantage of this is that
higher pressure can be used in dot mode than is possible in line
mode. If the changeover point Dot/line changeover is exceeded,
the controller switches to line mode and the pressure is adjusted
according to the pressure curve.

Commissioning
6.4.5.1 Open the “Data / Pressure Curves” page


ð The “Data / Pressure Curve” page opens.

Commissioning
6.4.5.2 Description of the “Data / Pressure Curves” page

Overview of the “Pressure Curves”
page
Fig. 226: "Pressure Curves" page

1 Ä “Overview of the pressure curve” on page 238
2 Ä “Pressure curve selection field” on page 237
3 Ä “Adjust dot size” on page 242
4 Ä “Adjust the pressure curve manually” on page 241

Commissioning
Pressure curve selection field The pressure curve can be adjusted according to the material in
use. The “Pressure Curve” selection field can be used to load,
define and save pressure curves. The “Standard” output value is a
default, factory-installed pressure curve.
Press the “Pressure Curve” selection field to select the following
pressure curves:
Ä “Select pressure curve” on page 240
Pressure curve Function

options
Standard The “Standard” pressure curve is pre-
installed.
User defined The “User defined” pressure curve cannot
be selected. “User defined” will appear
automatically in the selection field if you
adjust the pressure curve manually.
User standard The “User standard” pressure curve is
created and saved by the user.
Service standard The “Service standard” pressure curve is
adjusted by service technicians. The user
can load it, but cannot change it.

Commissioning
6.4.5.3 Description of the pressure curve

Overview of the pressure curve Pressure curve
A pressure curve graphically displays the relationship between var-
ious material pressures and machine speeds.
The pressure settings for the pressure curve are defined by the
material pressure in combination with the machine speed. A pneu-
matic material pressure regulator on the pump is required for this.
To ensure even adhesive application with every material used,
material pressures and machine speeds can be adjusted to suit
one another.
You can enter up to 3 speeds and 3 pressures. The controller cre-
ates a pressure curve from the values entered.
Dot application
The material pressure for dot application Pdot remains the same for
any speed between vmin and vd/l. The material pressure selected
must set be high enough to ensure even adhesive application.
Dot/line changeover
The changeover speed vd/l defines when the controller switches
from dot application to line application.
Line application
The time for which the application head is open is defined automat-
ically by the bead length entered. The higher the machine speed,
the higher the material pressure must be.

Commissioning
Fig. 227: Example: Dot/line changeover pressure curve

1 Pdot: Material pressure for dot application in %
2 Pd/l: Material pressure for dot/line changeover in %
3 Pmax: maximum material pressure in %
4 vmin: Minimum speed
5 vd/l: Dot/line changeover speed
6 vmax: Maximum speed
The small green dot on the pressure curve shows the

current material pressure at the current machine
speed.
You can adjust the pressure curve quickly by dragging
the yellow dots.
Speed units
The unit for the speed is displayed on the lower right of
the Pressure Curve page.
The speed can be given in various units per minute.
Description of the parameters Pdot - material pressure for dot application

Commissioning
Pdot is given in %. This value refers to the maximum pressure of

the pneumatic material pressure regulator. Material pressure is
kept constant for dot application.
Pd/l - material pressure for dot/line changeover
Pd/l is given in %. This value refers to the maximum pressure of the
pneumatic material pressure regulator. The material pressure for
dot/line changeover is the value at which the application head
switches from dot to line application.
Enter a value that prevents excess material being extruded during
the changeover.
Pmax - maximum material pressure
Pmax is given in % and is restricted to 100 %. This value refers to
the maximum pressure of the pneumatic material pressure regu-
lator. The maximum material pressure Pmax is the pressure
required to achieve an even application image on reaching the
maximum speed vmax.
vmin - minimum speed
vmin must be achieved during production so that material is applied.
vmin must be activated on the “Application Head Type” page.
vd/l - dot/line changeover speed
vd/l must be reached during production to ensure that the applica-
tion head switches from dot to line mode. You can only set vd/l in
dot/line mode.
vmax - maximum speed
vmax is the maximum speed at which production can be carried out.
6.4.5.4 Configuring the settings on the “Data / Pressure curves” page

Select pressure curve Saved pressure curves are configured to suit the material in use.
These can be loaded at any time.
1. Press the “Pressure Curve” selection field.
ð A list opens.
2. Select a pressure curve.
ð The selected pressure curve is shown in the graph.
NOTICE!
The selected pressure curve will only be
used once you confirm the selection.
3. To confirm, press the button.

ð The selected pressure curve will now be used.

Commissioning
Adjust the pressure curve manually

“User defined” is displayed in the “Pressure Curve”
selection field as soon as you adjust the pressure
curve manually. You can then only use this pressure
curve if you save it as “User standard” .
Ä “Save the “User defined” pressure curve as “User
standard” ” on page 242
Adjust speed
The values for vmin, vd/l and vmax can be adjusted directly in the
input fields.
The process for adjusting the speed is described

below, using vmin as an example.
vd/l and vmax are adjusted in the same way.
1. To change the minimum speed, press the vmin input field.

ð A number pad opens.
2. Enter a value for vmin.
3. Confirm the input with the [Enter] key.
Adjust pressures using input fields
The process for adjusting pressures is described

below, using Pdot as an example.
Pd/l and Pmax are adjusted in the same way.
1. To adjust the material pressure for dot application, press the

Pdot input field.
2. Enter a value for Pdot.
3. Confirm the input with the [Enter] key.

Commissioning
Adjust pressures using the graphical interface

1. Press and hold one of the yellow circles on the pressure
curve.
2. Drag the yellow dot up or down.
ð The value for the pressure changes to that directly under
the yellow dot.
Fig. 228: Set the pressure curve man-

ually
Save the “User defined” pressure 1. Configure the pressure curve as needed.
curve as “User standard”
Ä “Adjust the pressure curve manually” on page 241
ð “User defined” is displayed in the “Pressure Curve”
selection field.
2. Press the button.
ð The pressure curve is saved as “User standard” and is
displayed in the “Pressure Curve” selection field.
Adjust dot size

You can adjust the applied quantity of adhesive for the respective
production page here. If the setting is adjusted, the setting for the
volume of adhesive applied on the “Data / Installation / Application
Head Types” page is automatically adjusted and vice versa.
Press the desired applied quantity.
The larger the dot displayed, the larger the

applied quantity.
ð The selected dot size is marked in blue. The settings are

adopted as soon as you press the button.
Fig. 229: Adjust the applied quantity

of adhesive

Commissioning
Resolve excess material applica- Switching from dot to line mode can cause excess material to be
tion applied (Fig. 230/A).
Lower the material pressure value for dot/line changeover Pd/l
until you can no longer see any excess material application
(Fig. 230/B).
A Pressure curve and associated material line with excess mate-

rial application.
B Pressure curve with lower pressure for Pd/l and associated
material line without excess material application.
Fig. 230: Material line at different

pressures during dot/line changeover

Commissioning
Commissioning the controller > Defining IO signals
6.4.5.5 Example calculation for material pressure Pdot [%]
You can calculate a guide value for the required mate-

rial pressure as follows:
For the application of a material with a viscosity of 100
mPa*s, a material pressure of 1 bar is required. The
following applies: 1 bar / 100 mPa*s
Note:
Adhesive characteristics such as thixotropy or other
features are not taken into account here.
h Viscosity of the material in use

Pdot [bar] Material pressure for dot application in bar
Pdot [%] Material pressure for dot application in % of Pmax [bar]
Fig. 231: Formula for Pmax [bar] Maximum pressure of the pneumatic material pressure
start value of Pdot [bar] regulator in bar
Example values:
n h [mPa*s] = 1000 mPa*s
n Pmax [bar] = 36 bar
1. Calculate the start value of the material pressure for dot
application in bar.
Fig. 232: Example for start value of Pdot [bar]
2. Use the result to calculate Pdot [%].

3. Calculate the material pressure for dot application in %.
Fig. 233: Formula for Pdot [%]
Fig. 234: Example for Pdot [%]
4. Enter the value into the pressure curve (Fig. 227/1).
6.4.6 Defining IO signals

IO signal functions The IO settings connect your machine to the control unit. On the
“Data / Installation / IO Signals” page, you can define settings for
n control unit inputs,
n control unit outputs,
n encoder resolution,
n the signal horn,
n detailed responses to consecutive errors.

Commissioning
Details regarding the connections can be found in the

descriptions for the connection modules and circuit
diagrams.
6.4.6.1 Open the “Data / Installation / IO Signals” page



Commissioning

ð The “Data / Installation / IO Signals” page opens.
6.4.6.2 Description of the “Data / Installation / IO signals” page
Fig. 235: Overview "Data / Installation / IO Signals"

1 Ä “Define IO signals” on page 247
2 Ä “IO signals for machine speeds 0<v<vmin and v=0”
on page 250
3 Ä “Encoder connection” on page 251
4 Ä “IO signals for faulty products” on page 252

Commissioning
Button Description
Switch to production mode.
Switch to setup mode.
Discard changes and leave the page.
Define IO signals
1 Ä “Selection field: RESET IN” on page 247
2 Ä “Selection field: READY OUT” on page 248
3 Ä “Selection field: Fill level” on page 248
4 Ä “Selection field: Reset” on page 248
5 Ä “Selection field: Ready” on page 249
6 Ä “Input field: Window” on page 250
7 Ä “Input field: Delay” on page 250
8 Ä “Selection field: Flap” on page 249
Selection field: RESET IN The “RESET IN” input is used to connect to your machine. Here
you can set which action should be carried out if there is an active
signal.
Option Function
Gluing off Material application is interrupted for as long as
the signal is active.
Head control The application head moves into and remains
in its working position for the duration of the
active signal.
When the signal decreases, the application
head remains in position until the path to the
feeder is completed. The application head then
moves into its break position

Commissioning
Option Function
Discard product When the signal is active, no material is applied
to the next product.
This option is useful when the ejector is posi-
tioned between the light barrier which activates
material application and the assigned applica-
tion head.
If a product is rejected, the signal is activated
and no material is applied during the gap.
Counter The product counter is reset when the signal is
active.
Selection field: READY OUT The “READY OUT” output is used to connect to your machine.
Here you can set which status activates the signal.
Option The signal is activated when

Rinse the system is switched to test mode or rinse
mode.
Application at least one application head is activated.
head
Fill level there is a fill level warning.
Counter a preset counter figure is reached.
Selection field: Fill level Here, you can select whether the fill level sensor opens or closes if
the tank is empty. The input (Level in) on the control unit then
defines the output (Level out) as a signal to the operator,
depending on the applied setting.
Option Function when the tank is empty

Opener Fill level sensor signal is interrupted.
Closer Fill level sensor signal is activated.
Selection field: Reset Here you can set whether the “RESET IN” input is defined as an
opener or closer.
Option Function
Opener The connection is interrupted by a signal.
Closer The connection is activated by a signal.

Commissioning
Selection field: Ready Here you can set whether the “READY OUT” output is defined as
an opener or closer.
The “READY OUT” output has a switched control

voltage of +24 V.
Option Function
Opener The connection is interrupted by a signal.
Closer The connection is activated by a signal.
Selection field: Flap (optional) For application heads with nozzle sliding sealers.
Here you can determine when the “Flap” outputs are activated. If
the pneumatic conveyor is not controlled by “Reset In” , it moves
into its working position when “Flap” is active.
Here you can define under which conditions the application head
moves into its working position automatically.
Conditions set here are valid in addition to the “RESET IN” condi-
tion.
Please note the following when using the nozzle sliding sealers:
n The optimum delay time (range: 2...25 s) depends upon the
type of material used.
n The sliding sealers are assigned on the “Application head
type / Application head mode” page.
n If “Speed” is selected, the encoders assigned to the applica-
tion heads must send trigger signals.
n Material is only applied to the following product if:
– “Stop Model” is set to “On” and
– “Flap” is set to “Start” .
n If the signal in the “Start” , “Speed” or “Start+Speed” setting is
deactivated, the relevant seal is switched off after the set delay
period.
n Both seal controls are active in test mode.
Option Function
Off No signal via “Flap”
Start The “Flap” outputs are activated when a start
signal is received on any channel on the CPU
module while the machine is running.

Commissioning
Option Function
Speed The “Flap” outputs are only activated when the
machine exceeds the set minimum speed vmin.
Start + speed The “Flap” outputs are only activated when a
start signal is received on any channel on the
CPU module and the machine also exceeds
the set minimum speed vmin.
Input field: Delay (optional) For application heads with nozzle sliding sealers.
The delay period can be 2 - 25 seconds.
The optimum delay depends upon the type of material used.
Input field: Window

The “Window” value must be larger than the product
length but smaller than the distance between the front
edges of two subsequent products.
This value ensures that no further signals after the light barrier start
signal will be processed for the set distance.
The start signal is triggered by the front edge of the product.
Further signals can be triggered by impressions or additional
edges on the product.
IO signals for machine speeds

0<v<vmin and v=0
1 Ä “Selection field: Stop pattern” on page 250
2 Ä “Selection field: Start v=0” on page 251
Selection field: Stop pattern The “Stop model” function defines how to proceed with the model
being processed if the speed drops below vmin.
Options: Machine Function

stop
On The adhesive pattern that has been started
is discarded if the speed drops below vmin.
Off The adhesive pattern that has been started
is interrupted if the speed drops below vmin.
As soon as the machine reaches or
exceeds vmin, the adhesive pattern started
is continued.

Commissioning
Note the dependency:

If “Stop model” is set to “on” , “Start v=0” should be
set to “off” .
Selection field: Start v=0 Switching “Start v=0” on/off.
The “Start v=0” function defines how start signals are to be pro-
cessed when detected during machine downtime.
Options: Start Function

v=0
On The controller completes the signals detected
during machine downtime as soon as the
machine restarts.
If minimum speed vmin is activated, this can
prevent direct control whilst the machine
speed is below vmin.
Off The controller ignores start signals detected
during the downtime.
This prevents error signals such as those
made during cleaning from being processed,
which would otherwise lead to material being
applied incorrectly following a restart.
Note the dependency:

If “Start v=0” is set to “on” , vmin should be set to “off”
if no delay is required. Direct continuation is not pos-
sible if a certain speed must be reached before adhe-
sive is applied.
Encoder connection
1 Ä “Module: Encoder signal assignment” on page 252
2 Ä “Selection field: Connection” on page 252
3 Ä “Input field: Resolution” on page 252
4 Ä “Display: Speed” on page 252

Commissioning
Module: Encoder signal assign- Identification Description

ment
MOD The source of the encoder signal for the CPU
module can be set here.
Ä “Selection field: Connection” on page 252
MLD The source of the encoder signal for the MLD
module can be set here.
Ä “Selection field: Connection” on page 252
Selection field: Connection Option Function

Encoder 1 “ENC 1” connection on the CPU module
MOD
Encoder 2 “ENC 2” connection via the “AUX” joint con-
MOD nection on the CPU module
EXTERNAL “ENC” connection on the MLD module
SKG Bus Encoder connection to another module. The
signal is sent via the internal SKG bus.
Input field: Resolution Here you can define the encoder resolution for the individual mod-
ules independently of one another.
Display: Speed The current speed measured by the encoder is displayed here.
IO signals for faulty products

1 Ä “Horn” on page 252
2 Ä “On/Off: Horn can be switched off” on page 253
3 Ä “ Consecutive errors” on page 253
4 Ä “Time stop” on page 253
5 Ä “On/Off: Automatic time stop release” on page 253
Horn If a signal horn is connected, it can be activated for errors using the
“On/Off” button here.
If this button is activated , an audible signal is given if there is a
faulty product.
The duration of the signal can be defined using the adjacent input
field.

Commissioning
On/Off: Horn can be switched off

If this button is activated , a button appears on the main page
which can be used to mute the signal for faulty products.
Consecutive errors Here you can define how many faulty products can be detected in
succession before a feeder stop is triggered.
Marking system deactivated or not connected

If operating without a marking system, the value can
be set to 1. The feeder will then be stopped for each
faulty product. The faulty product can now be removed
and the cause of the error rectified.
Time stop If the machine is stopped for too long, glued products must be
assessed as faulty as the applied material will dry out over a cer-
tain period of time.
The length of this period depends upon the characteristics of the
material used.
If the machine begins again after a period of time which exceeds
the length set for the time stop, all products between the applica-
tion head and marking valve are marked as faulty.
On/Off: Automatic time stop Description

release
Release following the "Time stop" error message
is automatic once the machine restarts.
The operator must manually action the release fol-

lowing the "Time stop" error message.

Commissioning
Commissioning the controller > Defining interfaces and machin...
6.4.7 Defining interfaces and machine connections
6.4.7.1 Open the “Data / Installation / Interfaces” page



Commissioning
Commissioning the controller > Defining interfaces and machin...

ð The “Data / Installation / Interfaces” page opens.
6.4.7.2 Description of the “Data / Installation / Interfaces” page

Overview of the “Interfaces” page
Fig. 236: "Data / Installation / Interfaces" page overview

1 Machine interface
2 Glue application interface
3 Network details
External interface Fig. 236/1 External interfaces define the machine connection. Details
regarding communication with the Inliner are defined here
Various settings options can be found under External
interface.

Commissioning
Commissioning the controller > Defining the MLT offset and li...
n Protocol
n Interface
n Baud rate
n Address
n Interface type
Protocol In the Protocol selection field, the machine connection is config-

ured according to the machine type.
Interface You can define which interface is used in the Interface selection
field.
Baud rate You can set the transfer speed for the interface in the Baud rate
selection field.
Address The address is assigned in the Address selection field. The 0

address is used for the master.
Interface type The interface standards for data transfer are defined in the
Interface type selection field. The RS232 setting can be used
for cable lengths up to three metres. If using longer cables, you
must use the RS485 setting. This setting also depends upon the
type of serial cable used.
Glue application interface The Use CAN interface button activates and deactivates
Fig. 236/2 whether communication takes place via CAN. If communication
does not take place via CAN, the interface can be defined in the
selection field.
Network details Fig. 236/3 The gateway, IP address and mask are displayed here.
6.4.8 Defining the MLT offset and light barrier

The MLT is connected into the system on the “Data / Installation /
MLD Setup” page. The light barriers for this are selected and the
offset values adjusted.

Commissioning
6.4.8.1 Open the “Data / Installation / MLT Setup” page



ð The “Data / Installation / MLT Setup” page opens.

Commissioning
6.4.8.2 Description of the “Data / Installation / MLT setup” page
Fig. 237: "Data / Installation / MLT Setup" overview

1 Input field: MLT side 2 marking system offset
Ä “Marking system offset” on page 258
2 Input field: MLT side 2 light barrier offset
Ä “MLT light barrier offset” on page 258
3 Selection field: Light barrier side 2 connection
4 Selection field: Light barrier side 1 connection
5 Input field: MLT side 1 light barrier offset
Ä “MLT light barrier offset” on page 258
6 Input field: MLT side 1 marking system offset
Ä “Marking system offset” on page 258
Marking system offset The marking system offset is the distance between the measure-
ment area of the MLT and the spray application head on the
marking system.
MLT light barrier offset The offset is the distance between the light spot from the assigned
light barrier and the MLT.

Commissioning
Commissioning the controller > Entering the parameters for th...
6.4.8.3 Configure the settings on the “Data / Installation / MLT Setup” page
Enter the offset between the light The process is explained using side 1 as an example. Depending
barrier and the MLT on the system fittings, the process is the same for side 2.
1. Measure the distance between the light barrier and the MLT
for the relevant side.
Fig. 238: Enter the MLT light barrier

offset
Enter the offset between the MLT The process is explained using side 1 as an example. Depending
and the marking system on the system fittings, the process is the same for side 2.
1. Measure the distance between the MLT and the marking
system for the relevant side.
Fig. 239: Enter the marking system

offset
6.4.9 Entering the parameters for the adhesive sensor
On the “Data / Installation / MLT parameters” page, you can define

basic parameters for the MLT sensor and see the live image from
the sensor.

Commissioning
6.4.9.1 Open the “Data / Installation / MLT parameters” page



ð The “Data / Installation / MLT parameters” page opens.

Commissioning
6.4.9.2 Description of the “Data / Installation / MLT parameters” page

Overview of the “MLT parameters”
page
Fig. 240: "MLT parameters" page

1 Ä “Live display” on page 261
2 Sensor height input field
Ä “Sensor height” on page 261
3 Light barrier selection field for length control
Ä “Light barrier for length control (optional)” on page 261
4 Light barrier selection fields for skew monitoring
Ä “Light barriers for monitoring skew (optional)” on page 261
5 Line position button
Ä “Line position” on page 262
Live display The live display shows the current analysis by the MLT as a line
graph. The grey areas in the yellow line beneath the curve show
the detected adhesive lines for the respective application head.
Sensor height The sensor height is the distance between the MLT sensor and the
upper edge of the product. This is required for scaling.
Light barrier for length control One light barrier is required for length control. Use the selection
(optional) field to define to which connector the light barrier for length control
is attached.
Light barriers for monitoring skew Two light barriers are required for monitoring skew. Use the selec-
(optional) tion fields to define to which connectors the light barriers for moni-
toring skew are attached.

Commissioning
Line position
To monitor the position of the adhesive lines transverse to the run-
ning direction, the position must be transmitted to the controller
during a teaching cycle. This is required during initial commis-
sioning and after mechanical modifications.
Fig. 241: Button: Teach-in line posi-
tion
6.4.9.3 Configuring settings on the “MLT parameters” page

Entering the sensor height
The line position must be taught in once during commissioning and

after any mechanical modification to the MLT sensor.
1. Place a product in the inspection area of the MLT sensor.
Ä Chapter 6.3.5 “MLT sensor” on page 193
2. Measure the sensor height.
3. Press the Sensor height input field and enter the meas-
ured height.
Fig. 242: Entering the sensor height
Teach-in line position

ð A dialogue window appears.
2. Press [yes].
3. Allow adhesive to be applied to a product and pass it through
the inspection area of the MLT sensor.
ð The controller calculates the lateral position of the adhe-
sive lines. The teaching cycle is complete.
Fig. 243: Teach-in line position

Commissioning
Commissioning the controller > Configuring user levels
6.4.10 Configuring user levels

Locking certain areas prevents unintended entries from being
made. Areas are locked by assigning them to user levels. These
user levels are protected with access codes.
Entries made to define user levels remain in place

even after a restart.
6.4.10.1 Open the “Data / Installation / Access codes” page



Commissioning

ð The “Data / Installation / Passwords” page opens.
6.4.10.2 Description of the “Data / Installation / Access codes” page

Overview of the “Access codes” Locking certain areas prevents unintended entries from being
page made. Areas are locked by assigning them to user levels. These
user levels are protected with access codes.

Commissioning
Fig. 244: "Access codes" page

1 Areas that can be protected from changes using
an access code
Ä “Overview of the lockable areas” on page 265
2 User level 0: Areas that can be changed
without an access code
3 User level 1
4 Input field: Access code for user level 2
5 Amendment rights assigned to user level 1
6 Timer
User level 0 Some functions cannot be locked. These are assigned user level 0
at the factory. These include:
n Change language.
n Start production.
Automatic lock Once a user level is released, the system measures the time in
which no operations are made.
Once the preset time period elapses, the automatic lock activates
user level 0.
Overview of the lockable areas Areas assigned pages

Pattern input “Pattern input” page
Code/Cam “MLT parameters” page

Commissioning
Areas assigned pages

Jam “Jam” page (optional)
Pressure curve “Data / Pressure curve” page
Glue application “Data / Installation / Application head
installation types” page
Code/Cam installa- “Data / Installation / MLT parameters”
tion page
“Data / Installation / MLT setup” page
Inputs/Outputs “Data / Installation / IO signals” page
Protocol/Network “Data / Installation / Interfaces” page
Show install. data all pages that can be called up using the
button.
6.4.10.3 Configuring the settings on the “Data / Installation / Access codes” page
Assigning amendment rights to a Personnel: n Operator
user level
Configuring user levels

Settings on this page can only be changed using
user level 4.
Each area can only be assigned to one user level.

Only one level can be active at any one time.
The user must release at least the assigned user level
to be able to amend settings in this area.
To assign an area to a user level, press the button in the

row for the area and the column for the user level.
ð The button appears.

The selected area is now assigned to the current user
level.

Commissioning
Defining the access code for a user Personnel: n Operator

level

user level 4.
Transponder (optional)
A user level can be unlocked using an RFID chip
instead of an access code.
Ä “ Use transponder (optional)” on page 278
1. Press the Access code input field for a user level.

ð A numeric keypad opens.
The smallest number you can use is 1000.
2. Enter a 4-digit, numerical access code.

3. Press [Enter]to confirm.
ð The access code for this user level has been changed.
Configure automatic lock Personnel: n Operator

user level 4.
1. To define the length of time before the machine returns to the

lowest user level, press the Timer input field.
The maximum period of time is 60 minutes.
2. Enter the time. Press [Enter]to confirm.

Commissioning

page.

Operation
Controller operation > Production mode
7 Operation
7.1 Controller operation
7.1.1 Production mode
The Inliner systems with MLT 40 is mainly controlled via the ter-
minal.
When the terminal is switched on, a start-up image is displayed. A
Inliner system with MLT 40 is displayed schematically on this page.
The most important values and results are shown. You can access
menus, model data and MLT parameters via this page.
The controller works with the most recently used

model until you choose a different model. However,
other patterns can be prepared during production.

Operation
7.1.1.1 Description of the main page
Fig. 245: Example of the "Main page"

1 Ä “Header” on page 271 Ä “Model data button” on page 274
2 Ä “MLT button” on page 273 Ä “Animation: Feeder” on page 275
3 Ä “Input field: Flap length” on page 273 6 Ä “Animation: Feeder” on page 275
4 Ä “Glue flap length input field” on page 274 7 Display: Analysis for the current product
5 Button: Model data and animation: Water bath 8 Ä “Footer” on page 271

Operation
Header The central values for the system are displayed in the header.
Fig. 246: Header

1 User level button
2 The current date is displayed.
3 Entered system time
4 Current job
5 Button: Model selection
6 Current machine speed in metres per minute
7 Current production rate in pieces per hour
8 Display field: good products
9 Display field: faulty products
10 Button: Online help
Fig. 247: Title line

The title line contains the name of the current window.
The background colour of the title line represents the current oper-
ating status.
Colour Meaning
(Fig. 247)
Green Production, everything working correctly.
Yellow Setup mode or standby. Production has not
started.
Red, additional An error has occurred, production not pos-
warning signal on sible
the left hand side
Blue Teaching cycle in progress
Footer Depending on the settings and production mode, the following but-
tons appear in the footer

Operation
Button Description
Opens the “Data” page
Opens the “Test” page
Opens the “Statistics” page
Release following an error, machine

stop or feeder stop.
Ä “Teach-in the adhesive pattern for

the MLT sensor” on page 277
Horn is active. Pressing this button

mutes the horn.
The horn is muted. Pressing this

button activates the horn.
(green) activate material application.
(white) deactivate material application.

Operation
MLT button
The MLT button, Fig. 248, opens the “MLT parameters” page for
the relevant MLT sensor. The basic settings for monitoring the
adhesive pattern are configured here.
Fig. 248: MLT button
Input field: Flap length

Enter the distance from the cut edge to the start of the glue flap
into the Flap length input field, Fig. 249. This figure can be
adjusted if the adhesive pattern remains the same and only the
size of the corrugated board box changes.
Fig. 249: Input the flap length

Operation
Glue flap length input field

The length of the glue flap is defined in the Glue flap length
input field, Fig. 250. This figure can be adjusted if the adhesive pat-
tern remains the same and only the size of the corrugated board
box changes.
Fig. 250: Input glue flap length
Model data button

The Model data button, Fig. 251, opens the “Model data” page
for the respective application head. The adhesive patterns are
defined here.
Fig. 251: Model data button
Animation: Water bath The Water bath animation is a graphical representation of the
position of the adhesive application head in relation to the water
bath.

Operation
The application head is in the water bath.
The application head is outside of the

water bath.
Application head notes Symbols can appear next to the representations of the adhesive
application heads. The notes have the following meanings:
Note
Head position note: The symbol shows

that the end position of the application
head is not being requested. This type of
monitoring is activated on the “Data /
Installation / Application head type” page.
The application head must be in its end
position before adhesive application is acti-
vated.
Manual operation note: This symbol
shows that the corresponding application
head is in a manual mode. It will not move
automatically depending on the feeder
status. This setting can be changed using
the switchbox.
Animation: Feeder The Feeder animation is a graphical representation of the feeder

status.

Operation
Feeder insertion is active.
Feeder insertion is inactive.
MLT display
The display field shows the analysis of the product currently being
checked. Blue bars represent the pre-programmed adhesive pat-
tern. If the product is analysed as good, the detected adhesive
lines are displayed in green. If the product is analysed as bad, they
are in red. An overlaid symbol shows the type of error.
Fig. 252: MLT analysis
Bar colour
The bars on the pre-programmed adhesive pattern will
only be shown in blue if the button (green) is
activated or if (white) is visible.
Error type
Length error
Fig. 253: Inliner MLT error type Edge error
Skew error

Operation
7.1.1.2 Configure settings on the main page

Teach-in the adhesive pattern for Personnel: n Operator
the MLT sensor
Once you have entered a new adhesive pattern, the MLT sensor
has to learn what a good adhesive pattern looks like. Once it is
taught-in, the MLT sensor can detect errors in the adhesive appli-
cation.
1. Enter an adhesive pattern in setup mode.
Ä Chapter 7.1.3.3 “Configure settings on the “Model Data”
page” on page 282
Fig. 254: Start a teaching cycle
ð The controller switches to Programming mode.

The header on the “Program” main page has a blue
background (Fig. 255/1).
A system message opens.
3. Clear the system message by pressing the button.
4. Allow adhesive to be applied to a product and pass it through
the inspection area of the MLT sensor.
ð The controller calculates the correct adhesive pattern.
The controller switches to Production mode automati-
cally.
The teaching cycle is complete.
Fig. 255: Teach the MLT

Operation
Controller operation > Changing user level
7.1.2 Changing user level

Enter access code
In order to change settings on the Inliner systems with
MLT 40, you often need to enter a numeric access
code. You will see a closed lock on the button.
1. Press the button on the left of the header.

2. Enter the 4-digit access code.
3. The button shows an open lock.
Lock changes
The user level is automatically reset after a defined
period of time has elapsed. Ä “Automatic lock”
on page 265
The button then shows a closed lock once again.
Use transponder (optional) Personnel: n Operator

As an alternative to entering an access code, a user level can be
activated by placing an RFID chip on the terminal's antenna.
RFID (radio-frequency identification - identification using electro-
magnetic waves) allows identification to take place automatically.
An RFID system consists of a transponder containing an encoded
chip and an antenna located on the rear left side of the terminal.
Baumer hhs encodes the RFID chip with a user level internally.
The desired user level (1 - 4) must be stated when ordering. The
advantage of a transponder over entering access codes manually
is that this method cannot be passed to another person. This there-
fore reduces the risk of use by unauthorised parties.
Fig. 256: Transponder with RFID chip
1. Press the button on the left of the header.

2. Hold the transponder against the reader on the terminal. For
further details, please see the description of the terminal.
ð The user level encoded onto the chip is activated.
3. The button shows an open lock. The user level is displayed

on the top left, next to the lock (similar to diagram).

Operation
Controller operation > Enter model data
7.1.3 Enter model data

How model data is used The operator defines the adhesive lines for the product using the
model data. This definition controls adhesive application with the
adhesive application heads. The input values for the model data
also act as parameters for optional quality assurance systems.
The following descriptions relate to an adhesive appli-

cation head with three individual valves. Adhesive
application heads with up to six individual valves can
be used with certain machine types and applications,.
In this case, the user interface will display a corre-
sponding number of input fields and adhesive lines.
The inputs are made in the same way as in the fol-
lowing examples.
7.1.3.1 Open the “Model Data” page

The buttons for the symbolised adhesive application

heads that can be selected are displayed in colour and
active. Greyed out areas of the user interface are not
active.
Press the button on the main page.

ð The “Model Data” page opens.

Operation
7.1.3.2 Description of the “Model Data” page

“Model Data” page overview
The following example of the “Model Data” page
shows only one possible display format. The image will
vary depending on the selected glue application
models and which side is selected. However, the basic
composition of the elements remains the same. The
data can always be amended in setup mode.
Depending on the requirements on the “Data /
Installation / Service” page, changes may be disabled
in production mode.
Fig. 257: Model Data page

1 On/Off: individual adhesive lines
2 Input field: Dot spacing
3 Input field: Product length
4 Selection field: Multibox number
5 Display: Adhesive lines with positioning
6 Buttons: Side selection
7 Buttons: Adhesive application appearance
selection
8 On/off and applied length for the marking unit
9 Input field: Length of the glue flap
10 Input field: Flap start

Operation
Overview of buttons Button Description

Select rear side.
Select front side.
Configure “split flap” function.

This function can be combined with
both symmetrical and asymmetrical
adhesive application.
The button is used to define the
type of adhesive pattern:
configure symmetrical adhesive
application
The button is used to define the
type of adhesive pattern:
configure asymmetrical adhesive
application
Adopt changes without leaving the
page.
Discard changes and leave the

page.
Adopt changes and leave the page.

Operation
7.1.3.3 Configure settings on the “Model Data” page

7.1.3.3.1 Select side for adhesive application
Side selection
The selection options for the sides depend upon

the basic settings under
“Data / Installation / Service” .
Fig. 258: Side selection button active Various operation modes for adhesive application are
defined there. These directly affect the selection
options for the position of the adhesive application.
Depending on the settings and fittings on the system,
some buttons may not be active. Inactive buttons are
greyed out.
The glue flap on the corrugated board blank is not always on one
particular side. The side for adhesive application can therefore be
selected using the or buttons if using a double-sided
adhesive application system.
Fig. 259: Side selection button inac-
tive
1. To select side 1, press the button.
ð The button will show as selected . You can enter
the values for adhesive application.
2. To select side 2, press the button.
ð The button will show as selected . You can enter
the values for adhesive application.
Depending on the settings, the buttons may not always

be active. It is not always possible to select between
side 1 and side 2. However, the selection process is
identical for each side.

Operation
7.1.3.3.2 Define product lengths for simple and multiple blanks

Enter product length for simple
adhesive application
1. Press the input field.
ð A number pad appears.
2. Enter the product length and confirm with [Enter].
Fig. 260: Enter product length
3. Select [1] in the selection field.
Fig. 261: Enter number of multiboxes
Enter product length for multiple

blanks
Some machine types allow you to print, die-cut and/or slot multiple
products together. The aim of this is to increase product output.
The individual products enter the blank guide connected with a per-
forated section before being separated at a later time.
For model data definition, this means that the Inliner system with
MLT 40 only receives one start signal, but needs to apply adhesive
to up to three corrugated board blanks.
Fig. 262: Corrugated board: Multiple
blanks

Operation
1.
When entering the product length, use only the
length of the product from the front edge to the
first perforation.
Press the input field.

ð A number pad appears.
2. Enter the product length and confirm with [Enter].
Note the product length and number of products

– All products connected with perforated sections
must be of equal length.
Fig. 263: Enter product length – A maximum of 3 connected products can be
defined.
3. Enter the number of connected products into the selection

field.
NOTICE!
Enter the exact number of multiple products
If the number of connected products is entered incor-
rectly, this can lead to faulty adhesive application and
contamination of the machine. Ensure that you enter
the correct number of products. For a simple, single
corrugated board blank, set the value to 1.
Fig. 264: Select the number of mul-

tiple blanks

Operation
7.1.3.3.3 Adjust the adhesive pattern to suit contour of the glue flaps
Enter crease line values for sym-

metrical adhesive application
If all adhesive lines on the glue flap are of equal length, the adhe-
sive is applied symmetrically. This has the following effects on the
screen display:
n button is selected.
n Parallel adhesive application lines of equal length are dis-
played.
n Measurements need only be entered once
Fig. 265: Example: symmetrical adhe-

sive application
The values that define the positioning for adhesive application
must be entered into the corresponding input fields on the “Model
Data” page. There is also the option to transfer this model data
through another external system, for example a machine controller.
The position of the input fields depends upon the defined machine
running direction and the selected side.
The adhesive line length must not exceed the

product length
If the entered maximum adhesive line length is longer
than the product length, an error message will be dis-
played when you leave the “Model Data” page.
1.
The length of the flap is the distance between the
front edge of the sheet and the first crease line.
Press the input field and enter the length of the flap. If there
is no flap, enter the value 0.
Fig. 266: Enter flap length

Operation
2.
The length of the glue flap is the distance
between the first and last crease line or between
the front edge of sheet and the last crease line, if
there is no flap in the forward running direction
(flap dimension input = 0).
Press the input field and enter the length of the glue flap.
Fig. 267: Enter glue flap length
3.
The offset for adhesive application is the dis-
tance between the start of the glue flap and the
start of the adhesive application.
Press the input field and enter the offset for the adhesive
application.
Fig. 268: Enter the adhesive applica-

tion offset
4. Press the input field and enter the distance between the end
of the adhesive line and the last crease line.
5. When all values have been entered correctly, press the
[Confirm] button .
ð The data is applied.
Fig. 269: Enter the adhesive applica-

tion end value

Operation
Enter values for asymmetrical

adhesive application
Asymmetrical adhesive application occurs when the adhesive is
applied to the glue flap in lines of varying length. Asymmetrical
adhesive application is often used when the glue flaps are trape-
zoidal. As a rule, the outer adhesive lines are shorter and become
longer towards the centre. Asymmetrical adhesive application
makes it possible to glue right to the edge even on trapezoidal glue
flaps. This has the following effects on the screen display:
n button is activated.
n Adhesive lines of different lengths are displayed.
n Measurements must be entered for each adhesive line.
Fig. 270: Asymmetrical adhesive

application example
The values that define the positioning for adhesive application
must be entered into the corresponding input fields on the “Model
Data” page. There is also the option to transfer this model data
through another external system, for example a machine controller.
The position of the input fields depends upon the defined machine
running direction and the selected side.
The adhesive line length must not exceed the

product length
If the entered maximum adhesive line length is longer
than the product length, an error message will be dis-
played when you leave the “Model Data” page.
1.
The length of the flap is the distance between the
front edge of the sheet and the first crease line.
Press the input field and enter the length of the flap. If there
is no flap, enter the value 0.
Fig. 271: Enter flap length

Operation
2.
The length of the glue flap is the distance
between the first and last crease line or between
the front edge of sheet and the last crease line, if
there is no flap in the forward running direction
(flap dimension input = 0).
Press the input field and enter the length of the glue flap.
Fig. 272: Enter the length of the glue

flap
3.
The offset for adhesive application is the dis-
tance between the start of the glue flap and the
start of the adhesive application.
Press the input field and enter the offset for the adhesive
application.
4. Repeat this for all other adhesive lines.
Fig. 273: Enter offset
5. Press the input field and enter the distance between the end
of the adhesive line and the last crease line.
6. Repeat this for all other adhesive lines.
7. When all values have been entered correctly, press the
[Confirm] button .
ð The data is applied.
Fig. 274: Distance: End of the adhe-

sive line and last crease line

Operation
7.1.3.3.4 Enter dimensions for split flaps

Split flap
The term "split flap" is often used to describe a glue flap that con-
tains multiple gaps (Fig. 275). Up to four partial lines or partial sec-
tions can be configured. This means that the glue flap, as in the
example shown, can contain up to three gaps or die-cut sections.
The “split flap” function can be combined with either the
“symmetrical or the asymmetrical adhesive application” function.
Fig. 275: Glue flap with multiple gaps
Select “split flap” function Personnel: n Operator
Press the “split flaps” button (Fig. 276),

ð Input fields for the individual partial lines appear
(Fig. 276).
Fig. 276: Select split flap function
Enter two partial lines Here, we describe how you define an adhesive pattern for two par-
tial lines, i.e. a gap in the glue flap.
Screen display
The operating software always displays input options
for the maximum number (4) of partial lines. The fol-
lowing example shows how you can apply between
two and four partial lines. Ensure you note the
machine running direction (left to right or reverse). All
entries begin with the front edge of the corrugated
board blank. The front edge can be identified by the
dimensioning arrows. These point towards the front
edge of the corrugated board blank.
Overlaps and product edges

The values for the individual partial lines must not
overlap.
When entering the partial lines, ensure that you do not
enter a value that is larger than the glue flap length.

Operation
The diagram (Fig. 277) shows an example for entering two partial
lines. The first partial line begins 20 mm after the front edge of the
blank and ends at 60 mm. The second partial line begins at 90 mm
and ends at 130 mm. The gap is in the area between
60 and 90 mm.
Input symmetrical / asymmetrical

Where the adhesive lines are structured symmetrically,
the values need only be entered once for all partial
lines. These values are therefore valid for all active
adhesive lines. Where the structure is asymmetrical
(adhesive lines of unequal length), individual values
must be entered for each active adhesive line.
Fig. 277: Example with two partial

lines 1. Enter the start value for the first partial section into the first
input field.
2. Enter the end value for the first partial section into the second
input field.
3. Enter the start value for the second partial section into the
third input field.
4. Enter the end value for the second partial section into the
fourth input field.
5. Set all other input fields to 0
ð Two partial adhesive application lines for a simple split
flap are now defined

page.

Operation
Enter four partial lines

The diagram (Fig. 278) shows an example for entering four partial
lines. The first partial line begins 20 mm after the front edge of the
blank and ends at 60 mm. The second partial line begins at 90mm
and ends at 130 mm. The third partial line begins at 160 mm and
ends at 200 mm. The fourth partial line begins at 230 mm and ends
at 270 mm. Gaps are found in the areas 60-90 mm, 130-160 mm
and 200-230 mm.
Input symmetrical / asymmetrical

Where the adhesive lines are structured symmetrically,
the values need only be entered once for all partial
lines. These values are therefore valid for all active
adhesive lines. Where the structure is asymmetrical
(adhesive lines of unequal length), individual values
Fig. 278: Example with four partial must be entered for each active adhesive line.
lines
1. Enter the start value for the first partial section into the first
input field.
2. Enter the end value for the first partial section into the second
input field.
3. Enter the start value for the second partial section into the
third input field.
4. Enter the end value for the second partial section into the
fourth input field.
5. Enter the start value for the third partial section into the fifth
input field.
6. Enter the end value for the third partial section into the sixth
input field.
7. Enter the start value for the fourth partial section into the sev-
enth input field.
8. Enter the end value for the fourth partial section into the
eighth input field.
ð Four partial lines for a flap with three splits have been
defined.

page.

Operation
Controller operation > Editing the model list
7.1.4 Editing the model list

On the Model List page, models can be
n created,
n loaded from a USB stick,
n copied,
n activated,
n deleted.
werden.
7.1.4.1 Open the "Model List" page


ð The “Model List” page opens.
7.1.4.2 Description of the "Model List" page

Overview of the “Model List” page
1 Model number
2 Input field: Search
3 Model name
4 Date / time that the model was created
Order list
The model list can be ordered by number, name and
creation time by pressing the corresponding table
headings.
Search
Pressing the “Search” input field opens an on-screen
Fig. 279: "Model List" overview keyboard.
You can use this to enter keywords to search for in the
model list.

Operation
Button Description
Load model from USB stick.
Delete model with blue background.
Copy marked model.
Create new model.
Discard changes and leave the page.
7.1.4.3 Configuring settings on the “Model list” page

Creating a new model Personnel: n Operator
ð A dialogue opens for you to enter the model name.
Fig. 280: Creating a new model

Operation
2. Press the # input field (Fig. 281).

ð An on-screen keyboard opens.
3. Enter a number for the model.
4. Press the Name input field (Fig. 281).
Fig. 281: Entering the number and ð An on-screen keyboard opens.
description
5. Enter a description for the model.
6. Confirm your entry by pressing the [Done] button (Fig. 281).
7. To cancel, press the [ESC] button (Fig. 281).

page.
Creating a model based on model

#9999 Model #9999
Model #9999 contains fundamental, constant settings.
We recommend that you edit these together with the
service technician responsible. This file can be used
as a template for creating new model data. Errors
during creation can be avoided and rectification costs
reduced.
You must activate model #9999 for use as a template on the

“Service” page.
If model #9999 is activated, the dataset for #9999 is automatically
loaded when you start to create a new model.
Ä “Creating a new model” on page 293
Loading a model from a USB stick Personnel: n Operator

1. Connect a USB stick to the terminal.

ð A list of the models stored on it is displayed.
3. Select the model that you would like to load from the list.
4. Enter a code number for the model.
6. Enter a name for the model.
7. Enter the code number and name for the model. Confirm
your entry by pressing the [Done] button (Fig. 281).
8. To cancel, press the [ESC] button (Fig. 281).

Operation

page.
Copying a model Personnel: n Operator

Instead of creating new models, you can copy and then edit stored
model data.
1. In the model list, press the model that you wish to copy.
ð The background of the marked model turns blue.
Only one model can be copied at any one time. If you
have marked multiple models, press one of the models
marked in yellow again. The marker is removed.
Fig. 282: Marking a model

ð A dialogue opens for you to enter the model name.
Fig. 283: Copying a model
3. Press the # input field (Fig. 281).

4. Enter a number for the model.
Fig. 284: Entering the number and ð An on-screen keyboard opens.
description
6. Enter a description for the model.
7. Confirm your entry by pressing the [Done] button (Fig. 281).

Operation
8. Press the new model in the list to open it.

page.
Load model Personnel: n Operator

Previously saved models can be loaded at any time.
1. Press the desired model in the list.
ð The selected model is shown in the list with a blue back-
ground.
The model is loaded when you save and leave the page.
Fig. 285: Select model

page.
Deleting a model Personnel: n Operator

Any models you no longer require can be deleted. Multiple models
can be deleted simultaneously.
1. In the model list, press the models that you wish to delete.
ð The background of the selected models turns blue.
Fig. 286: Marking a model

ð A dialogue opens.
3. Confirm the deletion with [Yes].

Operation
Controller operation > Monitoring the adhesive line

page.
7.1.5 Monitoring the adhesive line

The MLT sensor detects both the product and the adhesive line
optically. To do this, there must be a colour contrast between the
product and the applied adhesive.
The MLT sensor checks whether
n adhesive has been applied in the desired areas,
n adhesive has been applied in undesired areas.
aufgetragen wurde. To do this, a number of different monitoring cri-
teria can be used. If the given tolerance is exceeded, the product is
detected as faulty.
7.1.5.1 Open the “MLT parameters” page

The buttons for the MLT sensors that can be selected

are displayed in colour and active. Greyed out areas of
the user interface are not active.
Press the button on the main page.

ð The “MLT parameters” page opens.

Operation
7.1.5.2 Description of the “MLT parameters” page

Overview of the “MLT parameters”
page
Fig. 287: "MLT parameters" page

1 Button: Selecting the MLT sensor (optional, only if multiple sen-
sors are connected)
2 Display: Piece counter (good products, bad products, length
errors)
3 Settings for lighting and monitoring criteria
Ä “Light” on page 299
Ä “Monitoring criteria” on page 300
4 Adhesive application display
Ä “Monitoring: Display” on page 302
Button Description
Save settings, remain on the page
Switch to production mode
Discard changes and leave the page

Operation
Units
The unit for all values on this page can be seen on the
top right of the page. The unit can be set on the
“Data / Installation / Service” page.
Light
Fig. 288: Light

1 Ä “Selection field: Lighting profile” on page 299
2 Ä “Selection field: Gain” on page 300
3 On/off: Invert the line graph
4 On/off : red lighting
Only for "special" lighting profile
5 On/off : green lighting
6 On/off : blue lighting
The lighting must be adjusted to suit different colour combinations
between the adhesive and product. Pre-set lighting profiles and an
individual setting are available.
Selection field: Lighting profile Lighting profile Description

white Preset lighting for dyed adhesive on a
white product.
brown Preset lighting for light adhesive on a
brown product.

Operation
Lighting profile Description

UV (optional) Preset lighting setting for UV lighting
(optional, item number 10259120)
The UV lighting activates UV markers in
the adhesive.
UV lighting is also particularly suitable
for monitoring adhesive application on
products printed in more than one
colour.
Special The lighting is configured individually by
the user. The on/off buttons for the col-
ours and the button for inverting the
measurement curve are only active in
this lighting profile.
Ä “Configure lighting” on page 303
Selection field: Gain The higher the contrast between the applied adhesive and the
product, the better the results measured by the sensor will be. If
the contrast is too low, the received signal can be amplified.
For the lighting profiles white, brown and special the amplifica-
tion can be set to 1 or 2.
For the UV lighting profile, the amplification can be set between 1
and 4. The higher the value, the greater the amplification.
Monitoring criteria
Fig. 289: Monitoring criteria

1 Ä “Input fields: tolerated deviation” on page 301
2 Ä “Display: Reference length” on page 301
3 Ä “Input fields: Start/stop only, Edge, Skew” on page 301
4 Ä “On/off: Length” on page 301
5 Ä “On/off: Anti-glue” on page 301
6 Ä “On/off: Glue application” on page 301
7 Ä “(optional) On/off: Skew” on page 302
8 Ä “(optional) On/off: Edge” on page 302
9 Ä “On/off: Start / stop only” on page 302
Products are detected as faulty if the set deviation tolerances for
activated monitoring criteria are exceeded.

Operation
Input fields: tolerated deviation The values for tolerated deviations refer to the selectable moni-
toring criteria on the right.
What the tolerated deviations refer to is described in more detail in
the descriptions of the monitoring criteria.
Input fields: Start/stop only, Edge, n Start/stop only: the checked area of a material line
Skew n (optional) Edge: minimum distance between the adhesive line
and the product edge
n (optional) Skew: maximum skew
On/off: Length If this monitoring criterion is active, the total length of the product is
checked by the light barrier, and is defined on the “Data /
Installation / MLT parameters” page.
Incorrectly fed or damaged products are detected in this way.
If the given tolerance is exceeded, the product is detected as
faulty.
Display: Reference length The reference length is the total length of the product.
This length is calculated by the light barrier assigned for length
monitoring during the teaching cycle.
On/off: Anti-glue If this monitoring criterion is active, the adhesive line can be longer
than the given length for the adhesive line, but only by the entered
tolerated deviation.
faulty.
On/off: Glue application The tolerated deviation entered here refers to multiple monitoring
criteria:
n Interruptions in the adhesive line must not be shorter than the
tolerated deviation.
n Adhesive dots or the adhesive line must not be misplaced by
more than half of the tolerated deviation.
faulty.

Operation
(optional) On/off: Skew

Products can only be monitored for skew with the Skew installation
kit (item number 10259205).
If this monitoring criterion is active, the system checks whether a
product is straight. To do this, two light barriers are placed next to
each other, transverse to the running direction. During a teaching
cycle, the system records when the product reaches the light bar-
riers. If the product is skewed, the light sensor detects a delay in
the product's arrival compared to the teaching cycle. The system
analyses this distance (Fig. 290/A). If the given tolerance is
exceeded, the product is detected as faulty.
Fig. 290: Skew control
(optional) On/off: Edge If this monitoring criterion is active, it compares the distance
between the applied adhesive and the side product edge in the
running direction, with the predefined minimum distance. If the
given tolerance is not reached, the product is detected as faulty.
On/off: Start / stop only If this monitoring criterion is active, only the start and end of the
adhesive line are checked over the given distance.
Monitoring: Display
1 Ä “Input fields: Monitoring width” on page 303
2 Ä “Display: Normal” on page 302
Ä “Display: Live” on page 303
3 Selection field: Display (Normal or Live)
Fig. 291: Example: Normal display
Display: Normal In this display, the signals received from the MLT sensor are dis-
played graphically as adhesive lines in relation to the entered
model data:
n Blue: Model data for the adhesive line,
n Green: Measured values for the adhesive line within the toler-
ance,
n Red: Measured values for the adhesive line outside of the tol-
erance.
n Gray: Adhesive application is deactivated.

Operation
Display: Live
This display (Fig. 292) shows the signals received from the MLT
sensor as a line graph.
The higher the amplitude on the line graph, the greater the con-
trast between the adhesive and the surface detected by the
sensor. Example: For the Fig. 292, a dark product with a light
applied adhesive was checked.
Beneath the line graph is a yellow bar with grey sections. This bar
corresponds with the cross-section of the product in relation to the
Fig. 292: Example: Live display running direction. The controller interprets the signals received
from the MLT sensor and defines which signals belong to the
product and which belong to the applied adhesive.
The product is shown in yellow, the adhesive lines in grey.
The differences between the signals that the MLT sensor receives
from the product surface and the adhesive lines depend upon the
selected lighting profile.
The greater the difference between the signals, the more precisely
the product and adhesive lines can be monitored.
Input fields: Monitoring width

The measurement area of the MLT sensor can be limited. This can
make the measurements more precise.
left input field:
Limitation of the measurement area to the left side of the display in
%.
right input field:
Limitation of the measurement area to the right side of the display
in %.
Fig. 293: Example: Monitoring width
7.1.5.3 Configure settings on the “MLT parameters” page
Configure lighting Personnel: n Operator

To be able to use the monitoring functions of the MLT sensor, you
must ensure that the MLT sensor can interpret the image recorded,
i.e. that it can distinguish between the adhesive line and the
product.
To be able to configure the lighting, a product with the

adhesive applied must be placed under the MLT
sensor during setup.
Carry out the following steps while the machine is stopped.

Operation
Adopt changes
After each change you wish to adopt, press the
button.
Changes are only saved when you leave the page if
you press the button.
1. Use the Display selection field to select the live display.

ð A line graph is shown such as that in Fig. 294.
2. Check the difference between the amplitude of the line graph
in the area of the adhesive line and in the area of the product
(Ä “Display: Live” on page 303).
The greater this difference, the more precise the results of
the measurements taken as part of the monitoring criteria will
Fig. 294: Example: Live display be during operation.
Test the preset lighting profiles or adjust the lighting individu-
ally:
Preset lighting profiles 3. Select a preset lighting profile from the Ä “Selection field:
Lighting profile” on page 299.
4. Increase the amplification (Ä “Selection field: Gain”
on page 300) if necessary.
5. Select the setting that provides the greatest difference
between the amplitude of the line graph in the area of the
adhesive line and in the area of the product.
If the result is not satisfactory, create an individual

lighting profile.
Individual lighting profile Personnel: n Operator

To be able to use the monitoring functions of the MLT sensor, you
must ensure that the MLT sensor can interpret the image recorded,
i.e. that it can distinguish between the adhesive line and the
product.
To be able to configure the lighting, a product with the

adhesive applied must be placed under the MLT
sensor during setup.
Carry out the following steps while the machine is stopped.

Operation
Controller operation > Fault messages
Adopt changes
After each change you wish to adopt, press the
button.
Changes are only saved when you leave the page if
you press the button.
1. Select the Speciallighting profile from the Ä “Selection

field: Lighting profile” on page 299.
ð The On/off buttons for the colours red, green and blue
and inverse are shown in colour and can be selected
(Ä “Light” on page 299).
2. Test different combinations of the three colours.
3. Increase the amplification (Ä “Selection field: Gain”
on page 300) if necessary.
Check whether the displayed line graph and the

assignment of the areas for the product and
adhesive lines shown below it match.
The lighter the product, the higher the ampli-
tude on the line graph. For a light product, the
grey sections for the adhesive lines must there-
fore be under the low points on the line graph.
Invert the line graph 4. Beneath the line graph is a yellow bar with grey sections.
This bar corresponds with the cross-section of the product in
relation to the running direction. The product is shown in
yellow, the adhesive lines in grey.
If you would prefer the product to be grey and the adhesive
lines yellow, switch the inversion on for the line graph.
(Fig. 288/3)
5. You can now select and adjust the monitoring criteria.

page.
7.1.6 Fault messages

Some faults are shown to the user in clear text on the operating
unit. The background of the header on the respective page also
turns red.

Operation
Controller operation > Fault messages
If a fault message is displayed, production can only be

continued once the fault has been acknowledged and
the cause has been rectified.
Example of a fault message
Fig. 295: Encoder error
Error message Plug monitor encoder

Meaning Encoder error
Possible causes Encoder is not connected correctly
Resolution n Check the encoder connection
n Fix if necessary
Acknowledging a fault
A fault has occurred. The page header has a red background.
1. Press the button in the footer.

ð The fault message is displayed.

Operation
Controller operation > Locating the source of a fault
2. Follow the information in the fault message (Ä “Example of a

fault message” on page 306) and eliminate the fault accord-
ingly.
Fig. 296: Encoder error message
3. Acknowledge the fault by pressing the button.

ð The fault resolution process is complete.
To close the fault message without elimi-

nating the fault, press the button. In
this case, the header background remains
red and production cannot be restarted.
Fig. 297: Acknowledging an encoder

error message
7.1.7 Locating the source of a fault

On the “Test - Diagnosis” page
n the individual application heads can be rinsed manually.
n the function of the inputs and outputs on the control unit can be
checked.
n the sources of faults can be located.
n the software versions of the individual components can be read
out.
Page locked (optional)

In order to change settings on the controller, you often
need to enter a numerical access code. You will see a
closed lock on the button.
You can find a detailed description in the Ä Chapter
7.1.2 “Changing user level” on page 278section.

Operation
7.1.7.1 Open the “Test - Diagnosis” page


ð The “Test - Diagnosis” page opens.

Operation
7.1.7.2 Description of the “Test - Diagnosis” page

Overview of the “Test - Diagnosis”
page
Fig. 298: "Test - Diagnosis" page

1 Buttons 1-3 side 1/2:
Activation of the adhesive application heads on side 1/2 (left/
right)
2 Display: Installed software versions
Ä Table on page 310
3 Diagnosis: CPU module
4 Diagnosis: MLD module
5 Test parameters: Pressure, frequency
Ä “Test parameters: Pressure, frequency” on page 312
6 Button: Change the filter
Ä “Changing the filter” on page 312
7 Button: Activate marking valves
Ä “Description of the buttons” on page 310

Operation
Description of the buttons
Button Description
Button: Test mode
If this button is activated, the individual application heads can be
controlled manually.
In test mode, the application heads apply dots depending on the
set frequency.
Button: Rinse mode
If this button is activated, the individual application heads can be
controlled manually.
The application heads are opened for as long as the "Rinse" test
mode is active and they are activated.
Button: "Marking system" test mode
If this button is activated, the next product will be marked as
faulty.
This marking is made regardless of whether the product is actually
faulty. The position of the mark on the product is checked.
Button: Call up information about the connected component.
Fig. 298/7 Button: Activate marking valve

The marking valve is opened for as long as this button is acti-
vated.
Installed software versions
Display Installed software versions on:

BG Terminal
IBG Switchbox side 1 / Switchbox side 2
MOD/CAN CPU module / CAN converter
MLD MLD module

Operation
Assignment of the connections on

the CPU module
The circles next to each position correspond with the LEDs that are
located directly on the CPU module.
If these circles illuminate yellow, there is an active signal.
Position Connection to the CPU

module
S1 - S4 Start 1 - Start 4
S5 - S8 Aux
ENC 1 Enc 1
ENC 2 Aux
RESET Reset
> LEVEL Level in
LEVEL > Level out
FLAP 1/2 Flap 1/2
MLD module diagnosis
Position Description
1 Sensors connected to the SENSOR 1/2 connection
on the MLD module.
2 The connection assigned to the respective sensor
for the triggered light barrier.
3 (optional) Internal light barrier for the respective
sensor.
4 (optional) Display: LB A/B
corresponds with the connection to the MLD
module: Light barrier X/Y
5 (optional) Display: ENC A/B
Path-dependant pulse display for an encoder con-
nected to the MLD module.
6 (optional) Button: Selection of a mounted module

Operation
Test parameters: Pressure, fre-

quency
Position Description
1 Input field:
For testing purposes, the current material pressure
can be adjusted in % of the maximum material
pressure.
The maximum material pressure depends upon the
device and can be found in the technical data.
2 Display: Current material pressure in bar
The display updates when the material pressure is
adjusted via the input field (1).
3 Input field:
For testing purposes, the current material pressure
for the second pressure output can be adjusted in
% of the maximum material pressure.
The maximum material pressure depends upon the
device and can be found in the technical data.
4 Selection field: Clock frequency for test mode.
7.1.7.3 Maintenance and eliminating faults
Eliminate faults
Once you have located the source of the fault, follow
the information in the fault table for the affected com-
ponent.
Changing the filter Personnel: n Qualified mechanic
The [Filter change] function can only be used with a

Baumer hhs piston pump. The pump must be defined
correctly on the controller.
When the filter change is activated, the pump pressure is com-

pletely released.

Operation
You will be guided through the process by the controller.

1. Press the [Rinse mode] button.
Fig. 299: Activate Rinse mode
2. Press the [Filter change] button.
Fig. 300: Activate filter change
ð A dialogue window opens.

3. Confirm with [yes].

4. Follow the instructions in the dialogue window.
Open the application heads in Rinse mode.
ð The residual pressure is released.
5. Confirm with [Ok].
6. Open the filter housing and carry out the mechanical mainte-
nance on the depressurised system.
Also read the “Maintenance” section for the material pres-
sure regulator.
7. Ensure that the filter housing is closed tightly once you have
changed the filter.

Operation
Controller operation > Statistics
8. Press the [Filter change] button again.

9. Confirm with [yes].
ð The [Filter change] maintenance mode ends.
The pump pressure returns to the target pressure.
7.1.8 Statistics
The Statistics page provides an overview of faulty products. These
are listed by the type of error.
7.1.8.1 Open the “Statistics” page

ð The “Statistics” page opens.

Operation
7.1.8.2 Description of the “Statistics” page

Overview of the “Statistics” page
Fig. 301: "Statistics" page

1 Sensor that detected the error
2 Display: Error type
3 Button: Statistical details
4 Graphical representation of the error
5 Display: Error type (optional)
6 Button: Production protocols
7 Button: Reset counters
Error Description
Total occurrences of the error
Assignment error
faulty edge
too little material
too much material

Operation
Error Description
Skew (optional)
Length error
Reset statistics
ð A dialogue field appears.
Fig. 302: Reset "Statistics"
2. Confirm with [Yes].

ð The statistics are reset.
Statistical details
Open the “Statistical details” page
Press the button.
ð The “Statistical details” page opens.
Fig. 303: Open "Statistical details"
Overview of the “Details” page On the “Statistical details” page, errors are shown by the applica-
tion head. Application head 1 is the farthest application head from
the blank guide.

Operation
Controller operation > Saving statistics
1 Application heads
2 Production page
3 Graphical representation of the error
Fig. 304: "Statistics / Details" page
7.1.9 Saving statistics

You can save and export the statistics and production protocols on
this page.
7.1.9.1 Open the “Statistics / Output” page

ð The “Statistics” page opens.

Operation
2. On the “Statistics” page, press the button.

ð The “Statistics / Output” page opens.
7.1.9.2 Description of the “Statistics / Output” page
Fig. 305: "Output" page

1 Display: current statistics output
2 Button: Increase the display size of the output
3 Button: Decrease the display size of the output
4 Ä “Export statistics to a USB stick” on page 320
5 Ä “Save statistics” on page 319
6 Ä “Adjust user data” on page 319

Operation
7.1.9.3 Configure the settings on the “Statistics / Output” page
Adjust user data Personnel: n Operator

Each output contains user data that you can adjust.
ð The User data input window opens.

2. Press the line you wish to change.
3. Enter the desired data.
4. Press [Enter]to confirm.
Fig. 306: Enter user data 5. Adjust the remaining lines in the same way if necessary.

page.
Save statistics Personnel: n Operator

You can save the current status of the statistics at any time. You
can access the saved statistics if you export them.
1. Adjust the user data if necessary (Ä “Adjust user data”
on page 319).

ð The current statistics will be stored as a PDF with the
entered user data in the background.

page.

Operation
Export statistics to a USB stick Personnel: n Operator

You can export production protocols that you have saved in PDF
format to a USB stick via the USB connection on the terminal.
Fig. 307: Open Export to USB
ð If no USB stick is connected or the connection between

the terminal and the USB stick is faulty, an error message
is displayed. Confirm with [OK] and ensure that the USB
stick is connected correctly. Press the button
again.
The page from which stored production protocols can be

exported to a USB stick opens.
2. On the left hand column on the page, you will see the saved
production protocols, and on the right you will see the pro-
duction protocols that are already on the USB stick.
Select the production protocols on the list that you wish to
export to the USB stick. To do this, press the entries in the
left hand column.
You can select multiple production protocols simultaneously.
ð The selected production protocols will have a blue back-
ground.
Fig. 308: Export production protocols

to a USB stick

Operation

ð The selected production protocols will be exported to the
USB stick.
Duration of the export

Large data volumes may take longer to
export. You can see the progress of the
export in the green bar in the footer.
Delete saved production protocols 4. You can delete saved production protocols using the ter-
minal. The files stored on the USB stick are not affected.
Select the production protocols on the list that you wish to
export to the USB stick. To do this, press the entries in the
left hand column.
You can select multiple production protocols simultaneously.
ð The selected production protocols will have a blue back-
ground.

6. Confirm the deletion of the selected production protocols with
[Yes].
Fig. 309: Delete production protocols ð The selected production protocols are deleted.

8. Confirm with [OK] and remove the USB stick.
Fig. 310: Remove the USB stick

Operation
Operation of the components > Glue delivery unit
7.2 Operation of the components

7.2.1 Operating the Linux terminal
Switch on/off Personnel: n Operator
n Safety boots
Switch the Linux terminal on and off using the on/off switch
(Fig. 311) on the rear side of the device.
Switching off the terminal using a super-ordi-

nate controller
If the super-ordinate controller is switched off,
the terminal is switched off automatically at the
same time. Leave the terminal's on/off switch in
position "1" (ON). When the super-ordinate con-
Fig. 311: Switching the terminal on troller is started, the terminal will also be
and off switched on.
User interface The user interface on the touchscreen is used to carry out further
operations.
The user interface is explained in its own section of the

documentation.

7.2.2.1 Setting the system pressure for the glue delivery unit
Setting pressure
n Safety boots
To ensure that the glue delivery unit runs correctly, the pressure
regulator must be set to the correct pressure.

Operation
Operation of the components > Glue delivery unit
The air pressure on the pressure regulator should

always be set to 6 bar.
1. Check the set pressure on the manometer (Fig. 312/2).

2. If the pressure has varied, correct the target pressure using
the control knob (Fig. 312/1) on the pressure regulator valve.
Fig. 312: Check pressure setting
Correct target pressure 3. Unlock the pressure regulator valve by pulling the control
knob upwards, away from the housing.
4. Turn the control knob until the required target pressure is dis-
played on the manometer.
Q Decrease target pressure

P Increase target pressure
5. Lock the pressure regulator valve by pushing the control

knob downwards, towards the housing. The control knob
must lock into place.
ð The target pressure is set.

Operation
Operation of the components > 3-way blank guide
Set target pressure

n Safety boots
The pressure must be set correctly. The application head and the
blank guide water bath will not move correctly if the pressure is
incorrect.
DANGER!

to 1.8 bar.
the pressure exceeds 2 bar, the safety valve allows the
pressurised air to escape into the atmosphere.
2. If the pressure has varied, correct the set pressure using the
control knob (Fig. 313/1) on the pressure regulator.
Correct target pressure 3. Unlock the pressure regulator by pulling the control knob
upwards (away from the housing).
4. Turn the control knob until the required target pressure of
1.8 bar is displayed on the manometer.
Q Decrease pressure
P Increase pressure

towards the housing. The control knob must lock into place.
ð The required pressure is set.

Operation
Operation of the components > 3-way multi-application head

Each blank guide (right/left) has a separate pressure
regulator.
Set the air pressure on the second pressure regulator
as described above.
Configure blank guide guide plates Ä Chapter 6.3.3.1 “Configure the 3-way blank guide” on page 182
Set water bath position Ä Chapter 6.3.3.2 “Prepare the water bath” on page 185
Fill or replace the water bath Ä Chapter 8.3.4.4 “Replace and fill the water bath ” on page 413
Before beginning production

n Safety boots
n Safety goggles
n Protective gloves
Before beginning each production run:

1. Clean the nozzles with a damp cloth.
2. Remove any dried on adhesive residues with a soft, non-met-
allic tool if necessary.
For more intensive cleaning, see:
For cleaning the nozzles, see: “Clean hardened adhesive
from the multi-application head” .

Operation
Operation of the components > MLT sensor
3. Set the volume of adhesive if necessary.
To set the volume of adhesive, see:

– Ä Chapter 6.3.4.1 “Configure adhesive appli-
cation” on page 188
– Configure armature stroke:
Ä Chapter 6.3.4.1.1 “Adjust the armature
stroke” on page 191
– Replacing the nozzles:
Ä Chapter 8.3.5.5 “Replace the nozzle”
on page 430
– Adhesive pressure:
see “Glue delivery unit” section
7.2.5 MLT sensor
The settings for the MLT sensor are made via the equi-
pment's terminal.

Operation
Operation of the components > Pressure vessel
7.2.6.1 Filling the pressure vessel
Release pressure Personnel: n Operator

n Safety boots
n Safety goggles
n Protective gloves
Requirement: The equipment is fully installed.

1. Make a note of the values on the sprayed air pressure
(Fig. 314/7) and vessel air pressure (Fig. 314/3) manome-
ters.
2.
WARNING!
nents!
Remove the material pressure (Fig. 314/1) regulator.

3. Turn the material air pressure regulator anti-clockwise until it
stops.
4. Check the material air pressure on the material pressure
(Fig. 314/3) manometer.
Fig. 314: Operate the pressure vessel
in.
6. Remove the sprayed air pressure (Fig. 314/6) regulator.
7. Turn the sprayed air pressure regulator anti-clockwise until it
stops.
ð The spray application head is no longer supplied with
pressurised air.
This saves pressurised air that would other-

wise escape during filling.
8. Check the sprayed air pressure on the sprayed air pressure

(Fig. 314/7) manometer.

Operation

in.
Opening and filling the vessel Personnel: n Operator

n Safety boots
n Safety goggles
n Protective gloves
WARNING!
1. Remove the material hose from the bulkhead fitting

(Fig. 314/2).
2. Remove the hose coupling from the pneumatic hose.
3. Unscrew the lid (Fig. 314/4) and remove it.
4. Remove the vessel container.
5. Fill the vessel container.
Maximum fill level for all vessels: 2 l.
Closing the vessel Personnel: n Operator

n Safety boots
n Safety goggles
n Protective gloves
1. Place the vessel container into the pressure vessel.

2. Check that the lid is sealed:
The sealing ring must be undamaged and free from dirt.
3. Place the lid so that the material hose (Fig. 314/5) is within
the vessel container with the material.
4. Screw the lid closed.

Operation
5.
WARNING!
Connect the material hose to the bulkhead fitting (Fig. 314/2)

on the pressure vessel.
Ensure that the connection is tight and secure.
6. Plug the hose coupling for the pneumatic hose into the nipple
Finishing work Personnel: n Operator

n Safety boots
n Safety goggles
n Protective gloves
WARNING!
1. Check that all pressure lines are tight and secure.

2.
1 to 2.5 bar
Regulate the material pressure on the left-hand pressure reg-

ulator (Fig. 314/2).
To set the material pressure, remove the pressure regulator
and turn it to the desired pressure.
3. Check the material pressure on the left-hand manometer
(Fig. 314/3).
in.
5. De-aerate the equipment.
6. Regulate the sprayed air pressure on the right-hand pressure
regulator (Fig. 314/4).
To set the sprayed air pressure, remove the pressure regu-
lator and turn it to the desired pressure.

Operation

(Fig. 314/7).
in.
7.2.6.2 Regulating pressure

n Safety boots
n Safety goggles
n Protective gloves
WARNING!
1. Check that all pressure lines are tight and secure.

2. Check the material pressure on the left-hand manometer
(Fig. 315/1).
3.
1 to 2.5 bar
Regulate the material pressure on the left-hand pressure reg-

ulator (Fig. 315/2).
To set the material pressure, remove the pressure regulator
and turn it to the desired pressure.
in.
(Fig. 315/3).
Regulate the sprayed air pressure on the right-hand pressure
Fig. 315: Regulating pressure regulator (Fig. 315/4).
To set the sprayed air pressure, remove the pressure regu-
lator and turn it to the desired pressure.
in.

Operation
Operation of the components > Operating the marking valve
7.2.7 Operating the marking valve

7.2.7.1 Preparing the marking valve for production
n Safety boots
n Safety goggles
n Protective gloves
Requirement: The system is depressurised.

Before beginning each production run:
1. Clean the nozzles with a damp cloth.
2. Remove any dried-on material residues with a soft, non-met-
allic tool.
For more intensive cleaning, see:
n Clean nozzle
Ä Chapter 9.3.16.2 “Check, replace the nozzle”
on page 486
n Clean air cap
Ä Chapter 9.3.16.2 “Check, replace the nozzle”
on page 486
3. Set the material volume if necessary.
To set the material volume, see:

– Set material pressure and sprayed air pres-
sure
– Configure the armature stroke
Ä Chapter 7.2.7.2 “Configure the armature
stroke” on page 332
– Replace the nozzle
Ä Chapter 9.3.16.2 “Check, replace the
nozzle” on page 486
– Assess material application
See the documentation for the application
system for further information on pressure set-
tings and assessing material application.

Operation
7.2.7.2 Configure the armature stroke
NOTICE!
Risk of material damage due to incorrect configu-
ration of the stroke regulator!
If the armature stroke is configured incorrectly, the
nozzles and armature can be damaged.
– Only adjust the stroke regulator during nozzle
testing.
– Do not over-tighten the stroke regulator.
NOTICE!
Possible variations in the applied volume of mate-
rial if the armature stroke opened too widely!
The stroke regulator does not provide reproducible
results across the entire range of settings. If the arma-
ture stroke is opened too widely, the applied volume of
– Maximum setting for the stroke regulator - half
open.
Configure the stroke adjustment The stroke adjustment provides additional regulation of the mate-
(armature stroke) rial volume, for example by coordinating multiple application heads
working in parallel.
n Safety boots
n Safety goggles
n Protective gloves
Basic settings
1. Carefully turn the stroke adjustment clockwise until it stops.
Open the stroke adjustment as described in “Assessing
material application” .

stroke

Operation
1 Stroke adjustment
Adjust the stroke adjustment 2. Assess the material application.

3. Adjust the stroke adjustment:
n to reduce the applied quantity, turn clockwise.
n to increase the applied quantity, turn anti-clockwise.
If the applied material quantity is already rela-

tively low, first decrease the glue pressure to fur-
ther decrease the applied material quantity
before restricting the needle stroke to 1 to ½ rev-
olutions.
4. Reassess the material application.

5. Correct the material application if necessary by reconfiguring
the stroke adjustment.
As well as the stroke adjustment, the nozzle size,

material pressure and sprayed air pressure also
affect the material application.
7.2.7.2.1 Assess material application

n Safety boots
n Safety goggles
n Protective gloves
The air cap can become dirty during setup. Dirt can divert the air
stream. This leads to the sprayed image being seen as faulty.
Therefore, clean the air cap regularly and as needed:
1. Run several models for material application through the
machine.
Then make a visual check of the material application and the
air cap on the spray application head.
2. Assess and correct the result according to the following:
3. Correct the
n Material pressure and/or sprayed air pressure (see:
Material delivery operation) and
n Armature stroke (Ä Chapter 7.2.7 “Operating the marking
Fig. 317: Functional diagram
valve” on page 331)
1 Air cap
and re-assess the result.

Operation
4. If correcting the material pressure, sprayed air pressure and

armature stroke does not result in a satisfactory application
image, also check:
n the distance between the spray application head and the
paper or carton: The distance must always be the same.
Reconfigure the blank guide if necessary.
n the material for any impurities: Filter or replace the mate-
rial if necessary.
Material application assessment Assessment of the material application is carried out without the
information product moving (during stoppage).
If too much material is applied, the air cap is likely dirty.
The air cap is dirty
The material splashes back Clean the air cap and nozzle tip
Fig. 318: Application image (stopped): from the paper or carton.
too much material replace the nozzle”
on page 486.
Reduce the sprayed air pres-
sure.
Too much material is applied Reduce the material pressure.
during spraying.

Too little material
paper or carton.
almost no material during spraying.
To set the material pressure and sprayed air pressure:

Ä Chapter 7.2.6.2 “Regulating pressure” on page 330

Operation

Uneven application
paper or carton.
uneven application during spraying.

Where there is
n a sufficient volume of material,
n a fixed distance between the spray application head and the
paper/carton,
n clean material without dirt and thickened areas,
n and the sprayed air is configured correctly,
Fig. 321: Application image (stopped): the application must be full-surface with almost sharp-edged cut
full-surface application offs.

Operation

Maintenance
Safety guidelines for maintenance
8 Maintenance
8.1 Safety guidelines for maintenance
DANGER!
Improper maintenance
WARNING!
Risk of injury due to improper maintenance!
Improper maintenance can result in serious injuries
– Before beginning maintenance, ensure that all pre-
vious maintenance work has been carried out and
completed in accordance with the information and
instructions set out in this manual and the associ-
ated circuit diagrams.
– Before beginning maintenance, ensure that
nobody is in the danger zone.
– Maintenance must only be carried out by per-
sonnel trained and authorised by the owner.
These personnel must:
manual,
tion manual,
– have the necessary specialist knowledge for
the maintenance work.

Maintenance
Maintenance table
8.2 Maintenance table

Interval Maintenance work Personnel
at the start of the shift MLT sensor: Operator
Check that the cable connection is tight.
MLT sensor: Operator

Check that the attachment is fitted correctly and securely.
Pressure vessel: Qualified mechanic

Check that the safety valve on the pressure vessel is working
correctly.
Carefully increase the material pressure on the pressure reg-
ulator to above 2.5 bar. Monitor the material pressure on the
manometer constantly. Never set the pressure above 3 bar.
The valve must trigger at 2.8 bar.
Pressure vessel: Operator

Refill the material in the pressure vessel:
Ä Chapter 7.2.6.1 “Filling the pressure vessel” on page 327
Spray application head: Operator

Check functionality.

Qualified mechanic
Check for external dirt, clean if necessary.
Visual checks of the electrical, material and sprayed air lines
for external damage and leaks.
Replace damaged lines.

Maintenance
Maintenance table

three times per day Glue delivery unit: Operator
n Visual inspection: Check electrical lines, pressure pipes,
material pipes for damage.
n Leakage: Check material delivery area, material connec-
tion.
n Check that the components of the equipment are in place
and secure.
n Check material for contamination following a material
change.
n Container: Check fill height.
n Container: Clean filter mesh in the suction pipe.
Ä Chapter 8.3.2.5.1 “Adhesive container with suction pipe
and hose maintenance” on page 402
n Delivery unit: Clean high pressure filter.
Ä Chapter 8.3.2.3.3 “High pressure filter maintenance”
on page 364
n Water separator: Release condensate.
Ä “Releasing condensate” on page 349
n Delivery unit: Check that the safety valve is working cor-
rectly.
n Check that the application head is working correctly.
n Clean the application head if dirty.
at the start of the shift 3-way multi-application head: Operator

Check that the multi-application head is working correctly.
See “Glue delivery unit” section
at the end of the shift Glue delivery unit: Operator

n Visual inspection: Check electrical lines, pressure pipes,
material pipes for damage.
n Leakage: Check material delivery area, material connec-
tion.
n Check that the components of the equipment are in place
and secure.
3-way multi-application head: Operator

Check multi-application head for external dirt.
Clean the outside of the multi-application head if necessary.
3-way multi-application head: Qualified mechanic

Visual checks of the electrical and material lines for external
damage and leaks.
Repair lines if necessary.

Maintenance
Maintenance table

Clean the outside of the spray application head.

Qualified mechanic
Visual checks for external damage and leaks.
Replace O-rings if necessary.
Ä Chapter 9.3.16.4 “Check, replace the coil” on page 495
at the beginning and (optional) Marking system: Operator

end of the shift Qualified mechanic
Check hoses, seals and connections are sealed and replace if
necessary.
Pressure vessel: Qualified mechanic

Check that the hoses, seals and connections on the pressure
vessel are completely sealed.
(optional) Sprayed air shut-off: Qualified mechanic

Check that the hoses, seals and connections on the sprayed
air shut-off are completely sealed.
daily Control cabinet: Operator

Check that the main switch on the control cabinet moves
freely and functions correctly every time you switch the con-
trol cabinet on and off.
Have it replaced if necessary.
Linux terminal: Operator

Clean the touchscreen:
Ä Chapter 8.3.1.1 “Cleaning the Linux terminal” on page 344
3-way blank guide: Operator

Change the water in the blank guide water bath.
Ä Chapter 8.3.4.4 “Replace and fill the water bath ”
on page 413

Test the application heads in the multi-application head and
rinse if necessary.
Ä Chapter 8.3.4.3 “Test and rinse the application heads”
on page 411

Maintenance
Maintenance table

Check the target pressure on the blank guide pressure regu-
lator.
Ä Chapter 8.3.4.5 “Blank guide pressure regulator mainte-
nance” on page 416

Carry out visual checks before the start of the shift and after
the shift ends:
Check the blank guide for dirt. Clean if necessary.

Qualified mechanic
Carry out visual checks before the start of the shift and after Qualified electrician
the shift ends:
Check electrical lines, pressure pipes, material pipes for signs
of damage or leaks. Repair if necessary.
UV lighting for MLT-40 (optional): Operator

Clean the lens with a soft, damp cloth. Avoid leaving streaks.
UV lighting for MLT-40 (optional): Operator

Check that the electrical connection is connected tightly.
MLT colour filter installation kit: Operator

Clean the lens with a soft, damp cloth. Avoid leaving streaks.
MLT colour filter installation kit: Operator

Check that the electrical connection is connected tightly.
weekly Control cabinet: Operator

Check that all connection cables are attached tightly and
securely.
Control cabinet: Operator

Check all connection cables for damage and replace if neces-
sary.
Control cabinet: Operator

Qualified mechanic
Check that all screws and attachments on the control cabinet
are fitted correctly.
Tighten if necessary.

Maintenance
Maintenance table

Check that the cable connections are attached securely.

Check the connection cable for damage and replace if neces-
sary.

Qualified mechanic
Check that all screws and attachments on the Linux terminal
are fitted correctly.
Tighten if necessary.

Clean FHDK light sensor with a soft cloth.
FHDK light sensor: Operator

Clean FHDK light sensor with a soft cloth.
Alert set: Operator

Carry out a function test on the alert set.
Alert set: Operator

Check that the connection to the alert set is tight and secure.
Alert set: Operator

Check connection cables on the alert set for damage and
replace if necessary.
before breaks of Glue delivery unit: Operator

more than 14 days
n Clean equipment
n Rinse the equipment with a suitable cleaning agent.
Ä Chapter 6.3.2.5 “Filling and de-aerating the glue
delivery unit” on page 179
n Fill the equipment with a cleaning agent, de-aerate.
n Application head: Basic cleaning.

Basic cleaning of the stroke regulator, armature and nozzle:
Ä Chapter 8.3.5.2 “Disassemble the 3-way multi-application
head” on page 420

Maintenance
Maintenance table

Spray application head: Qualified mechanic
Basic cleaning:
Ä Chapter 9.3.16.4 “Check, replace the coil” on page 495
monthly Control cabinet: Qualified electrician

Check all interfaces for visible corrosion or dirt.
Clean or replace if necessary.
Control cabinet: Qualified electrician

Check interfaces for mechanical damage such as bent con-
tacts.
Repair or replace if necessary.
CPU module: Operator

Carry out an LED test for the status indicator on the CPU
module.
Glue delivery unit: Piston pump Operator

Check oil fill level, refill oil if necessary. Ä Chapter
6.3.2.1 “Filling the piston pump with lubricant” on page 164
Fill level sensor: Operator

Clean float.

Check the armature needles on the multi-application head
module:
Ä Chapter 8.3.5.4 “Check the armature needle” on page 429
3-way multi-application head: Operator

Check that the multi-application head is working correctly:
See “Glue delivery unit” section
MLT sensor: Operator

Clean the lens with a soft, lint-free cloth.
Spray application head: Qualified mechanic

Check the nozzle and armature needle for leaks and signs of
wear:
Ä Chapter 9.3.16.3 “Check, replace the armature needle”
on page 490

Maintenance
Maintenance of the components > Linux terminal

IE-65-508 Encoder: Qualified mechanic
Check that the encoder is positioned correctly:
n Contact between the friction wheel and the drive shaft,
n Toothed belt tension.
Ä More information on: Encoder IE-65-508
IE-65-508 Encoder: Operator
Check encoder resolution:
Ä “Calculating the encoder resolution” on page 206
before breaks of Marking system: Operator
more than 14 days Qualified mechanic
Drain the system. Rinse the system.
Pressure vessel: Operator

Drain pressure vessel and hoses. Rinse pressure vessel and
hoses.
8.3 Maintenance of the components

8.3.1.1 Cleaning the Linux terminal
n Safety boots
Materials: n Cleaning cloth
n Cleaning agents
If the Linux terminal's touchscreen becomes dirty, it may no longer
be clear to read or use. Therefore, the Linux terminal's touchscreen
must be cleaned regularly.

Maintenance
Maintenance of the components > Linux terminal
NOTICE!
Ä “Material damage to the terminal” on page 44
Cleaning the touchscreen

NOTICE!
Unintentional inputs!
Wiping the touchscreen can cause inputs to be made
unintentionally.
– Always deactivate the terminal via the on/off switch
before beginning cleaning.
1. To deactivate the Linux terminal, switch the on/off switch

(Fig. 322/1) on the rear of the terminal to position "0" (OFF).
ð The Linux terminal is deactivated.
2. Wipe the Linux terminal touchscreen with a dry, soft cloth.
3. If you cannot remove the dirt, spray a cleaning agent onto a
soft cloth.
Do not spray the cleaning agent directly onto the
touchscreen.
Fig. 322: Terminal on/off switch
4. Wipe from the edge of the touchscreen to the centre.
5. To reactivate the Linux terminal once cleaning is complete,
switch the on/off switch (Fig. 322/1) on the rear side of the
terminal to position "1" (ON).
ð The Linux terminal is ready for operation.

Maintenance
Maintenance of the components > Glue delivery unit
8.3.2.1 Depressurise the glue delivery unit

Depressurise the equipment
WARNING!
leak accidentally.

Maintenance
n Safety goggles
n Safety boots
Decreasing pressure via the pres-
sure regulator
1. Switch the pressurised air supply from the super-ordinate
equipment off.
2. Unlock the pressure regulator by pulling the control knob
(Fig. 323/1) upwards, away from the housing.
3. Slowly turn the control knob (Fig. 323/1) anti-clockwise as
seen from above until the target pressure on the manometer
(Fig. 323/2) shows 0 bar.
ð The residual pressure in the system escapes audibly.
(Fig. 323/1) downwards, towards the housing. The control
knob must lock into place.
ð The pressurised air supply for the equipment is depres-
surised.
Decreasing pressure via the Inliner The residual pressure in the application heads is decreased using
XTS² switchbox the equipment's Inliner XTS² switchbox.
application heads.

Maintenance

0 bar.

regulator
8.3.2.2 Air pressure regulator maintenance

Check pressurised air setting
To ensure that the glue delivery unit runs correctly, the pressure
regulator must be set to the correct pressure.
The air pressure on the pressure regulator should

always be set to 6 bar.

the pressure regulator valve (Fig. 326/1).

Maintenance


Releasing condensate
n Safety goggles
n Safety boots
Materials: n Waste container for condensate
Release the gathered condensate in the pressure regulator's water
seperator (Fig. 327/2) regularly via the condensate drain plug
(Fig. 327/1).
NOTICE!
The condensate must be released at the point the con-
densate level reaches approx. 10 mm beneath the
filter element if not before.
WARNING!
Risk of slipping due to leaked liquids the floor!
There is a risk of slipping if there are leaked liquids on
the floor. Slipping can cause serious injuries.
– Clean leaked liquids on the floor immediately with
Fig. 327: Releasing condensate suitable devices.
1. Hold a suitable waste container for the condensate beneath

the water seperator (Fig. 327/2).
2. Open the condensate drain plug (Fig. 327/1) on the under-
side of the water seperator (Fig. 327/2).
3. Release the water into the waste container.
4. Close the condensate drain plug on the underside of the
water seperator.

Maintenance
8.3.2.3 Material pressure regulator (PMDRE6) maintenance

8.3.2.3.1 Disassembling the material pressure regulator (PMDRE6)
Disassembling the PMDRE6 mate-
rial pressure regulator
n Safety goggles
n Protective gloves
The material pressure regulator (Fig. 328/1) is positioned beneath
the bracket (Fig. 328/2) next to the piston pump (Fig. 328/3).
1. Turn down the air pressure on the piston pump (Fig. 329/1)
regulator.
Ä Chapter 8.3.2.1 “Depressurise the glue delivery unit”
on page 346
2. Check the material and air pressure on the manometers.
WARNING!
Fig. 328: Material pressure regulator
position Risk of death due to pressurised compo-
nents!
Pressurised components may move uncontrol-
lably and cause serious injuries if used improp-
erly. If pressurised components are used improp-
erly or are defective, liquids may be released at
high pressure, and could serious injuries or
death.
– Depressurise the system. Also ensure that
any residual energy is discharged.
– Always ensure that liquids cannot leak acci-
dentally.
– Always ensure that specialist personnel
immediately replace defective components
which operate in a pressurised state.

Maintenance
3. Release all of the air and electrical connections (Fig. 329).
Fig. 330: Unscrewing the material pressure regulator from the

Fig. 329: Releasing the air and elec- piston pump
trical connections 4. Unscrew the material pressure regulator (Fig. 330/1) from the
L Pressurised air connection from piston pump (Fig. 330/2).
the piston pump to the material To do this, unscrew the screw connection for the double
pressure regulator nipple component (Fig. 330/4) beneath the bracket
X2 Cable connection from the (Fig. 330/3).
reversing unit/piston pump to the
pressure sensor
X3 Cable connection from the
reversing unit to the control unit/
material pressure regulator

Maintenance
5.
CAUTION!
Risk of injury due to falling components
during disassembly!
Components may fall during disassembly,
causing serious injury.
– Only have such work carried out by trained
specialists.
– Always ensure components cannot fall during
disassembly.
– Wear personal protective equipment e. g.
protective gloves and boots.
Ensure that the material pressure regulator cannot fall.

Next, release the attachment between the material pressure
regulator and the bracket (Fig. 331/1).
6. Remove the material pressure regulator beneath the console,
following the direction of the arrow.
Fig. 331: Attaching the material pres-

sure regulator to the bracket
7. Unscrew the elbow coupling plug connection (Fig. 332/1) if

you wish.
This is not absolutely necessary for the following

steps.
Fig. 332: Elbow coupling plug connec-

tion

Maintenance
Disassembling the lower part

8. Release the 2 screws (Fig. 333/1) on the control unit
(Fig. 333/2).
9. Remove the control unit. Mind both of the seals (Fig. 333/3)
when doing so.
10. Release the 4 screws on the cylinder base (Fig. 333/4).
11. Remove the cylinder base (Fig. 333/5).
12. Remove the O-ring (Fig. 333/6) and the air cylinder
(Fig. 333/7).
13. Remove the air piston (complete, Fig. 333/8) together with
the socket (Fig. 333/9) out of the upper part (Fig. 333/10).
Fig. 333: Disassembling the lower part
Disassembling the air piston (com-

plete)
14. Disassemble the air piston (complete) by releasing the screw
on the base (Fig. 334/1).
15. Disassemble the air piston into
n Washer (Fig. 334/2)
n Air piston (piston, Fig. 334/3)
n O-ring (Fig. 334/4)
n Piston rod (Fig. 334/5)
Fig. 334: Air piston (complete)

Maintenance
Disassembling the upper part

16. Disassemble the adhesive piston (complete) by releasing the
4 screws on the upper part (Fig. 335/1, Fig. 336/1).
Fig. 335: Upper part screws

Maintenance
17. Remove the cylinder cover (Fig. 336/2).

18. Disassemble the sound absorber (Fig. 336/3) if you wish.
This is not absolutely necessary for the following

steps.
19. Remove the cylinder tube (Fig. 336/4) and the adhesive
piston (complete, Fig. 336/5).
20. Ensure that the pressure spring (Fig. 337/1) and the ball
(Fig. 337/2) cannot fall out.
Fig. 336: Disassembling the upper

part

Maintenance
21. Disassemble the adhesive piston (complete, Fig. 337):

n Pressure spring (Fig. 337/1)
n Ball (Fig. 337/2)
n Spacer (Fig. 337/3)
n Guide socket (Fig. 337/4)
n Push rod (Fig. 337/5)
n Adhesive piston (piston, Fig. 337/8)
n Screw M5x8 (Fig. 337/9)
n Piston guide ring (Fig. 337/10)
n O-ring and spring lip seal (Fig. 337/11 and 12)
n O-ring (Fig. 337/13, 14 and 15)
Fig. 337: Disassembling the adhesive Disassembling the guide socket (Fig. 337/4) is
piston (complete) not absolutely necessary for the following steps.
To do this, proceed as follows:

Disassembling the adhesive piston 22. Loosen the M5x8 screw (Fig. 337/9, Fig. 338/1) on the base
(complete) of the adhesive piston (piston, Fig. 337/8, Fig. 338/2).
23. Remove the push rod (Fig. 338/3).
24. Release the 3 mounting screws (Fig. 338/4) on the washer
(Fig. 338/5).
25. Remove the O-ring beneath the washer (Fig. 338/6).
26. Remove the upper O-ring (Fig. 338/8) and the spring lip seal
(Fig. 338/7) around it (Fig. 338/9).
27. Remove the lower O-ring (Fig. 338/10) and the spring lip seal
(Fig. 338/11) around it (Fig. 338/9).
28. Remove the piston guide ring (Fig. 338/12).
Fig. 338: Adhesive piston (piston)
lower part

Maintenance
29. Remove the pressure spring (Fig. 339/1) and the ball
(Fig. 339/2) if you have not already done so.
30. Remove the guide socket (Fig. 339/3) on the previously dis-
assembled push rod (Fig. 339/4) on the underside of the
spacer (Fig. 339/5) if you wish.
31. Remove the O-ring (Fig. 339/6) on the upper side of the
spacer (Fig. 339/5).
32. Remove the O-ring (Fig. 339/7) on the underside of the
33. Remove the O-ring (Fig. 339/8) in the centre of the spacer
(Fig. 339/5).
Fig. 339: Adhesive piston (piston)

upper part
8.3.2.3.2 Assembling the material pressure regulator (PMDRE6)

Assembling the PMDRE6 material
pressure regulator
n Safety goggles
n Protective gloves
Assembling the adhesive piston

(complete)
1. The adhesive piston (complete) consists of:
n Pressure spring (Fig. 340/1)
n Ball (Fig. 340/2)
n Spacer (Fig. 340/3)
n Guide socket (Fig. 340/4, previously disassembled)
n Push rod (Fig. 340/5)
n Adhesive piston (piston, Fig. 340/8)
n Screw M5x6 (Fig. 340/9)
n Piston guide ring (Fig. 340/10)
n O-ring and spring lip seal (Fig. 340/11 and 12)
n O-ring (Fig. 340/13, 14 and 15)
Assemble the adhesive piston (complete) as follows:
Fig. 340: Adhesive piston (complete) 2. First assemble the spacer (Fig. 340/1 to 4 and 13 to 15).

Maintenance
3. Attach the O-ring (Fig. 341/1) in the centre of the spacer

(Fig. 341/4).
4. Attach the O-ring (Fig. 341/2) on the underside of the spacer
(Fig. 341/4).
5. Attach the O-ring (Fig. 341/3) on the upper side of the spacer
(Fig. 341/4).
6. If the guide socket (Fig. 341/5) on the push rod (Fig. 341/6)
was disassembled, attach this to the underside of the spacer
(Fig. 341/4).
Fig. 341: Assembling the adhesive

piston, upper part
7. Place the piston guide ring (Fig. 342/1) onto the adhesive
piston (piston, Fig. 342/2).
8. Assemble the lower O-ring and lower spring lip seal together:
9. Place the lower O-ring (Fig. 342/3) and the spring lip seal
(Fig. 342/4) around it (Fig. 342/5) onto the adhesive piston
(piston, Fig. 342/2).
10. Assemble the upper O-ring and upper spring lip seal
together:
Fig. 342: Assembling the adhesive 11. Place the upper O-ring (Fig. 342/6) and the spring lip seal
piston, lower part (Fig. 342/7) around it (Fig. 342/5) onto the adhesive piston
(piston, Fig. 342/2).
12. Place the O-ring (Fig. 342/8) in the centre of the adhesive
piston (piston, Fig. 342/2) and attach the washer (Fig. 342/9)
on top with 3 screws (Fig. 342/10).
Tighten the 3 screws (Fig. 342/10).

Maintenance
13. Guide the push rod (Fig. 342/11, Fig. 343/1) into the adhe-
sive piston (piston, Fig. 342/2 Fig. 343/2).
14. Guide the push rod (Fig. 342/11, Fig. 343/1) through the
guide socket (Fig. 341/5, Fig. 343/3) on the underside of the
15. Attach the adhesive piston by tightening the screw (M5x8,
Fig. 343/5).
16. Place the pressure spring (Fig. 341/8) and ball (Fig. 341/7)
onto the spacer.

piston

Maintenance
Assembling the upper part

17. Place the ball (Fig. 344/1) and pressure spring (Fig. 344/2)
onto the adhesive piston (complete, Fig. 344/3).
18. Slide the adhesive piston (complete, Fig. 344/3) into the cyl-
inder tube (Fig. 344/4).
19. Attach the sound absorber (Fig. 344/5) onto the cylinder
cover (Fig. 344/6).
20. Slide the cylinder cover (Fig. 344/6) against the cylinder tube
(Fig. 344/4) with the adhesive piston (complete, Fig. 344/3).
21. Attach the cylinder cover (Fig. 344/6) and cylinder tube (4)
with the adhesive piston (complete, 3) onto the upper part
(Fig. 344/8) with 4 screws (Fig. 344/7).
Fig. 344: Assembling the upper part
Assembling the air piston (com-

plete)
22. Place the O-ring (Fig. 345/4) onto the ledge on the piston rod
(Fig. 345/5).
23. From above, place the piston rod (Fig. 345/5) into the bore-
hole on the air piston (piston, Fig. 345/3).
24. Place a washer on from beneath (Fig. 345/2).
25. Place a screw on from beneath (Fig. 345/1).
Tighten the screw.
Fig. 345: Air piston (complete)

Maintenance
Assembling the lower part

26. Insert the O-ring (Fig. 346/1) into the cylinder base
(Fig. 346/2).
27. Place the air cylinder (Fig. 346/3) onto the O-ring in the cyl-
inder base.
28. Place the air piston (complete, Fig. 346/4) into the air cylinder
(Fig. 346/3).
Fig. 346: Lower part
29. Slide the cylinder base (Fig. 347/1) with its O-ring
(Fig. 346/1), air cylinder (Fig. 347/2) and air piston (complete,
Fig. 347/3) in place, carefully against the upper part
(Fig. 347/5).
Be aware that the socket (Fig. 347/4) into which the air cyl-
inder runs must be positioned correctly.
30. Attach the cylinder base (Fig. 347/1) to the upper part with 4
screws.
31. Check that the seals (Fig. 347/7) on the control unit
(Fig. 347/8) are in perfect condition and are positioned cor-
rectly.
Replace the seals if necessary.
32. Place the control unit (Fig. 347/8) onto the cylinder base
(Fig. 347/1) and attach it with 2 screws (Fig. 347/9).
Fig. 347: Lower part

Maintenance
33. Attach the elbow coupling plug connection (Fig. 348/1).
Fig. 348: Elbow coupling plug connec-

tion
Attaching the material pressure

regulator to the bracket
34. Slide the material pressure regulator into the bracket
(Fig. 349/1), following the direction of the arrow.
The part beneath the filter (Fig. 349/3) with all of the connec-
tors must be positioned below the bracket.
35.
CAUTION!
during assembly!
Components may fall during assembly, causing
serious injury.
specialists.
assembly.

36. Attach the material pressure regulator to the bracket with 2

Maintenance
Fig. 350: Attaching the material pressure regulator to the piston

pump
37. Connect the material pressure regulator (Fig. 350/1) to the
piston pump (Fig. 350/2) by screwing the connection for the
double nipple component (Fig. 350/3) closed.
38. Reconnect the air and electrical connections (Fig. 351).
39. Rinse the completely assembled glue delivery unit before re-
commissioning Ä on page 179.
Fig. 351: Creating the air and elec-

trical connections
L Pressurised air connection from
the piston pump to the material
pressure regulator
X2 Cable connection from the
pressure sensor/material pressure
regulator

Maintenance
X3 Cable connection from for the

control unit/material pressure reg-
ulator
8.3.2.3.3 High pressure filter maintenance
WARNING!
leak accidentally.

n Safety goggles
n Safety boots
Special tool: n Hook wrench (29110017)
Materials: n Assembly paste (16100015)
n F3 O-ring (92053602)
n F4 O-ring (92052004)
n F5 Round filter mesh/filter (95510104)
n Cleaning cloth
Rinsing the filter with water 1. Dip the suction hose intake manifold into a container of
water.
2. Fill the suction hose completely with water.

Maintenance
There is a rinsing connector (Fig. 352/1) in the material

output from the material pressure regulator.
It contains a plastic hose to allow the glue delivery unit
to be rinsed or de-aerated quickly (Ä Chapter
6.3.2.5 “Filling and de-aerating the glue delivery unit”
on page 179).
3. Connect the plastic hose to the rinsing connector

(Fig. 352/1).
4. Hold the end of the plastic hose into a suitable waste con-
tainer.
5. Deliver water through it.
6. Slowly open the ball valve (Fig. 352/2).
ð The filter is rinsed.
7. Close the ball valve (Fig. 352/2) as soon as the water exits
the plastic hose without containing adhesive residues.
Fig. 352: Rinsing the filter
Depressurising the equipment via

the Inliner XTS² switchbox
rinsing liquid.
application heads.

Maintenance
0 bar.
WARNING!
Risk of death due to pressurised compo-
nents!
Ensure that there is no residual pressure.

regulator The system has been depressurised.
Opening the filter cap 13. Clean large areas of dirt from the glue delivery unit, particu-
larly the filter housing, from the outside with a cloth.
14. Open the cap (Fig. 355/1) on the filter housing (Fig. 355/2)
with a hook wrench.
Fig. 355: Opening the filter cap

Maintenance
Cleaning/replacing the round filter

mesh/filter
15. Remove all parts:
n O-ring (Fig. 356/F3)
n Ball (Fig. 356/F6) and
n Round filter mesh/filter (Fig. 356/F5)
16. Clean each part as soon as it is removed.
If parts are defective, replace them.

Always replace the O-ring (Fig. 356/F3) when
replacing the round filter mesh/filter (Fig. 356/
F5).
17. Replace all of the parts.

Keep to the following order:
n Round filter mesh/filter (Fig. 356/F5)
n Ball (Fig. 356/F6)
Fig. 356: Cleaning/replacing the round
filter mesh/filter n O-ring (Fig. 356/F4) and
18. Brush the threads on the filter cap (Fig. 357/1) with assembly
paste.
19. Screw the filter cap (Fig. 357/1) into the filter housing
(Fig. 357/2) and tighten the filter cap with a hook wrench.
Fig. 357: Screwing on the filter cap

Maintenance
Set target pressure

20. Unlock the pressure regulator valve by pulling the control
knob (Fig. 358/1) upwards, away from the housing.
21. Turn the control knob until the required target pressure of
6 bar is displayed on the manometer (Fig. 358/2).


knob (Fig. 358/1) downwards, towards the housing. The con-
trol knob must lock into place.
Fig. 358: Pressure setting
Rinsing the filter with adhesive 23. Dip the suction hose intake manifold into a container of adhe-
sive.
24. Connect the plastic hose to the rinsing connector
(Fig. 359/1).
25. Hold the end of the plastic hose into a suitable waste con-
tainer.
26. Slowly open the ball valve (Fig. 359/2).
ð The filter is rinsed.
27. Close the ball valve (Fig. 359/2) as soon as pure adhesive
exits the plastic hose.
Fig. 359: Rinsing the filter

Maintenance
8.3.2.3.4 Replacing the material pressure regulator pressure sensor

n Safety goggles
n Protective gloves
Special tool: n Open-ended wrench (for sensor)
Materials: n Pressure sensor type 1 (96316123)
n Pressure sensor type 2 (96316124)
1.
WARNING!
nents!
Depressurise the glue delivery unit Ä “Depressurise the

equipment” on page 346.
Ensure that there is no residual pressure.
3. Remove the plug (Fig. 360/1) from the pressure sensor
(Fig. 360/2).
NOTICE!
Risk of damage to the sensor!
Only assemble/disassemble the sensor on the spanner
flat with an open-ended wrench.
4. Unscrew the pressure sensor (Fig. 360/2) from the material

pressure regulator housing (Fig. 360/3) with an open-ended
wrench.
5. Screw the new pressure sensor (Fig. 360/2) into the material
pressure regulator housing (Fig. 360/3) with an open-ended
wrench.
6. Connect the plug (Fig. 360/1) to the pressure sensor
(Fig. 360/2).
7.
WARNING!
Fig. 360: Pressure sensor/material pressurised lines and components!
pressure regulator
Check that all connections and screws are sealed and tight.

Maintenance
8.3.2.3.5 Replacing the material pressure regulator control unit

n Safety goggles
n Protective gloves
Materials: n Control unit (19517605)
n 2x seals (82050006)
1. Release the electrical connection (Fig. 361/1) from the mate-
rial pressure regulator control unit (Fig. 361/2).
ð The control unit is disconnected from the power supply.
Fig. 361: Releasing the connection

Maintenance
2. Release the 2 screws (Fig. 362/3) on the control unit

(Fig. 362/2).
3. Remove the control unit. Mind both of the seals (Fig. 362/1)
when doing so.
4. Place the new control unit (Fig. 362/2) with new seals
(Fig. 362/1) in.
5. Attach the control unit with the 2 screws (Fig. 362/3).
Fig. 362: Replacing the control unit
6. Connect the electrical connection (Fig. 363/1) to the material

pressure regulator control unit (Fig. 363/2).
Fig. 363: Making connections

Maintenance
8.3.2.4 Piston pump maintenance

8.3.2.4.1 Disassembling the piston pump
Disassembling the KPE9 piston pump and replacing parts
n Safety goggles
n Safety boots
Special tool: n Combination wrench SW 22
n Combination wrench SW 27
n Hook wrench
n Socket head wrench (Allen wrench)
Materials: n Container for catching oil
1. Rinse the pump with water (warm, without cleaning agent)
until it runs clean (Ä on page 168).
2. Turn the air pressure on the pressure regulator (Fig. 364/6)
down until no more water comes out of the application heads.
3. Check the material and air pressure.
WARNING!
nents!
Pressurised components may move uncontrol-
lably and cause serious injuries if used improp-
erly. If used improperly or if there is a defect,
pressurised materials may leak from pressurised
components at high pressure, causing serious
injuries.
– Depressurise and check the components.
Also ensure that any residual energy is dis-
charged.
Fig. 364: Releasing the connections – Always ensure that pressurised material
cannot leak accidentally.
– Defective components which are operated
under pressure must be replaced immedi-
ately by pneumatic or mechanical specialists.

Maintenance
4. Release all of the air and electrical connections.

n (Fig. 364/X2) piston pump reversing unit X2 connection
è material pressure regulator pressure sensor.
n (Fig. 364/X3) piston pump X3 connection è material
pressure regulator control unit.
n (Fig. 364/3) piston pump reversing unit pressurised air
line è material pressure regulator pressurised air input.
5. Unscrew the maintenance unit (Fig. 365/3) from the piston
pump (Fig. 365/2).
To do this, release the screw connection (Fig. 365/1) on the
maintenance unit with an SW 22 combination wrench.
Fig. 365: Unscrewing the mainte-

nance unit from the piston pump
Fig. 366: Unscrewing the material pressure regulator from the

piston pump
6. Unscrew the material pressure regulator (Fig. 366/1) from the
piston pump (Fig. 366/2).
To do this, unscrew the screw connection for the double
nipple component (Fig. 366/4) beneath the bracket
(Fig. 330/3) with an SW 30 combination wrench.

Maintenance
7.
CAUTION!
during disassembly!
Components may fall during disassembly,
causing serious injury.
specialists.
disassembly.

Next, release the mounting screws (Fig. 367/1) from the
material pressure regulator on the bracket.
8. For easier access, you can remove the material pressure
regulator underneath the bracket in the direction of the arrow.

9. Disassemble the piston pump (Fig. 368/1) from the bracket

(Fig. 368/2).
n To do this, release the screws beneath the bracket.
Fig. 368: Separating the piston pump

from the bracket

Maintenance
10. Place a container for catching oil (Fig. 369/2) beneath the
piston pump oil filler plug (Fig. 369/1).
WARNING!
the floor!
Fig. 369: Releasing lubricant
lubricant tanks.
11. Remove the oil cap screw from the oil filler plug (Fig. 3691).
12. Hold the pump tilted over a waste container.
ð Allow all of the lubricant to run out.
ENVIRONMENT!
Dispose of the oil in accordance with the
legal regulations!
13. Screw the oil cap screw into the oil filler plug (Fig. 3691).

Maintenance
Separating the air motor from the

adhesive part
14. Clamp the air motor into a vice if you wish.
Release the 4 screws (Fig. 370/1) and remove the screws
with the spring washers (Fig. 370/2).
Fig. 370: Removing screws

Maintenance
15. Lift the air motor (Fig. 371/1) slightly.

16. Slide the air motor sideways until the slave connection
(Fig. 371/2) releases.
17. Separate the air motor (Fig. 371/1) from the adhesive part
(Fig. 371/3).
Clean each part as soon as it is removed!

Use a suitable cleaning agent for this.
In most cases, a suitable cleaning agent is water
(max. 40 °C) or an appropriate solvent.
Fig. 371: Separating the air motor (oil

cylinder not shown)
Disassembling the adhesive part

18. Remove the oil cylinder (Fig. 372/1) and the O-ring
(Fig. 372/2).
Fig. 372: Disassembling the oil cyl-

inder

Maintenance
19. Use a hook wrench to unscrew the sealing pack (Fig. 373/1)
from the adhesive cylinder (Fig. 373/2).
20. Remove the O-ring (Fig. 373/3) from the adhesive cylinder
(Fig. 373/2).
Fig. 373: Disassembling the sealing

pack
21. Remove the adhesive piston (Fig. 374/1) from the adhesive
cylinder (Fig. 374/2).
Fig. 374: Disassembling the adhesive

piston

Maintenance
Disassembling the sealing pack

When disassembling the sealing pack, observe the
installation positions of the individual components!
22. Disassemble the sealing pack (Fig. 375/1):

n Sealing body (Fig. 375/2)
n Sleeve set (Fig. 3753)
n Spring (Fig. 375/4)
n Supporting ring (Fig. 375/5)
Fig. 375: Disassembling the sealing

pack
23. Place the sealing pack with the new sleeve set (Fig. 375/3)
back together.
When assembling the sleeve set (Fig. 375/3),

note the installation positions of the individual
components!
è Fig. 376
Sleeve set:
n Female adaptor ring (Fig. 376/1)
n Sleeve type 2 (Fig. 376/2)
n Counter ring (Fig. 376/4)
Fig. 376: Sleeve set

Maintenance
Disassembling the hose fitting

24.
Only disassemble the hose fitting (Fig. 377/4) on
the material outlet if necessary (e. g. heavy con-
tamination or damage). Proceed as follows:
Unscrew the hose fitting (Fig. 377/4).

25. Remove the seal (Fig. 377/2) from the adhesive cylinder
(Fig. 377/1).
26. Remove the seals (Fig. 377/3) from the hose fitting
(Fig. 377/4).
Fig. 377: Disassembling the hose fit-

ting
Disassembling the base valve

27. Use an open-ended wrench to unscrew the base valve
(Fig. 378/2) from the adhesive cylinder (Fig. 378/1).
28. Remove the O-ring (Fig. 378/3) from the base valve
(Fig. 378/2).
Fig. 378: Disassembling the base

valve

Maintenance
Disassembling the back pressure

ball
29.
The threaded pins (Fig. 379/3) are glued into the
base valve (Fig. 379/4).
Only disassemble the back pressure ball
(Fig. 379/1) if necessary (e. g. heavy contamina-
tion or damage). Proceed as follows:
Carefully warm the area around the threaded pins

(Fig. 379/3) with a hot air gun.
Fig. 379: Disassembling the back

pressure ball CAUTION!
Warning - hot surface.
The stream of hot air heats the surface to such
an extent that the hot air and the heated metal
can cause burns.
Once they are warm, turn the threaded pins (Fig. 379/3) and
remove them from the base valve (Fig. 379/4).
30. Carefully warm the area around the cylinder pins (Fig. 379/2)
with a hot air gun.
31. Remove the cylinder pins (Fig. 379/2) by sliding them out
from the inside with needle-nosed pliers.
Disassembling the adhesive piston
32.
The adhesive piston connector (Fig. 380/1) is
glued to the adhesive piston rod (Fig. 380/2).
Only disassemble the adhesive piston connector
(Fig. 380/1) if necessary (e. g. heavy contamina-
tion or damage). Proceed as follows:
Carefully warm the connector (Fig. 380/1) with a hot air gun
to release the adhesive connection. The actuator can be
unscrewed from the adhesive piston rod (Fig. 380/2) when it
is warm.
Fig. 380: Disassembling the con-

nector

Maintenance
33. Disassemble the adhesive piston. Proceed as follows:

34. Unscrew the ball seat (Fig. 381/6) from the adhesive piston
rod (Fig. 381/1).
35. Remove the ball (Fig. 381/4), spring (Fig. 381/3) and adhe-
sive piston (piston seal) (Fig. 381/2) from the adhesive piston
rod (Fig. 381/1).
36. Remove the O-ring (Fig. 381/5) from the ball seat
(Fig. 381/6).

piston
1 Adhesive piston rod
2 Adhesive piston with seals
3 Spring
4 Ball
5 O-ring
6 Ball seat
37. Disassemble the adhesive piston seals and clean the indi-
vidual parts with warm water.
NOTICE!
Risk of damage to the sealing elements and
edges.
Do not use sharp-edged tools to disassemble or
clean the sealing elements.
piston seals
38. Replace damaged parts.
1 Adhesive piston complete
2 Piston guide ring
3 O-ring
4 Glyd ring
Disassembling the air motor and replacing parts
Replace the air piston and sealing elements as

needed.
Only open the air motor if you suspect there to be
leaks.

Maintenance
n Safety goggles
n Safety boots
Disassembling the air motor
1. Unscrew the mounting screws (Fig. 383/1) from the reversing
unit (Fig. 383/2).
2. Separate the reversing unit (Fig. 383/2) from the air motor
(Fig. 383/3).
Fig. 383: Disassembling the reversing

unit
3. Open the air motor (Fig. 384/1). To do this, remove the

Fig. 384: Opening the air motor

Maintenance
4. Disassemble the air motor.

When disassembling the air motor, check the sealing ring
(Fig. 385/9) and O-rings (Fig. 385/2 + 5) for wear.
5.
Even wear on sealing elements!
Replace the sealing ring (Fig. 385/9) and O-rings
(Fig. 385/2 +5) if you detect wear.
Always replace the entire sealing set!
Fig. 385: Air motor (opened)

1 Air motor cover
2+5 O-ring
3 Air piston (complete)
4 Air cylinder
6 Air motor base
7 Socket
8 Slave screw
9 Sealing ring
Disassembling the air piston

6. Only disassemble the air piston if necessary (e.g. heavy con-
tamination or damage). Proceed as follows:
Release the nuts (Fig. 386/2) on the air piston rod
(Fig. 386/7).
7. Disassemble the air piston and clean the individual parts with
warm water.
Fig. 386: Disassembling the air piston

2 Nut, counter nut
3+6 Washer
4 Air piston (piston)

Maintenance
5 O-ring
7 Air piston rod
8.3.2.4.2 Assembling the piston pump

Assembling the air motor
n Safety goggles
n Safety boots
Materials: n Assembly paste (16100015)
n O-ring and pneumatic grease
(45999914)
n Sealing set (92911370)
Assembling the air piston
Before assembly, clean the individual parts with warm
water and dry them carefully.
1. Place the washer (Fig. 387/6) onto the threaded ledge on the
air piston rod (Fig. 387/7).
2. Lightly grease the O-ring (Fig. 387/5) and place it in the O-
ring slot on the air piston rod (Fig. 387/7).
3. Place the air piston (Fig. 387/4) onto the air piston rod
(Fig. 387/7).
NOTICE!
Ensure it is installed in the correct direction:
"TOP" engraving = top
4. Place the washer (Fig. 387/3) onto the air piston rod
(Fig. 387/7).
5. Screw the first nut (Fig. 387/2) onto the air piston rod so that
the air piston (Fig. 387/4) cannot turn.
Fig. 387: Assembling the air piston 6. Screw the counter nut (Fig. 387/2) onto the air piston rod and
1 Air piston (complete) so lock the first nut.
2 Nut, counter nut
3+6 Washer
4 Air piston
5 O-ring
7 Air piston rod

Maintenance
Assembling the air motor

7. Grease the inside of the sealing ring (Fig. 388/9) and place
the sealing ring into the air motor base (Fig. 388/6).
8. Lightly grease the O-rings (Fig. 388/2 + 5) and place them
into the O-ring slot on the air motor base (Fig. 388/6) and air
motor cover (Fig. 388/1).
9. Check the sockets in the air motor base (Fig. 388/7) for
damage.
The socket (Fig. 388/7) is compressed.
Replace the socket if damaged:

n Request an air motor base without a compressed socket
from Baumer hhs or
n have a specialist replace the damaged socket with a new
one.
Fig. 388: Air motor (opened)
10. Carefully slide the air piston (Fig. 388/3) through the sealing
1 Air motor cover ring (Fig. 388/9) and the socket (Fig. 388/7) in the air motor
2+5 O-ring base.
4 Air cylinder 11. Screw the slave screw (Fig. 388/8) into the air piston rod on
6 Air motor base the air piston (Fig. 388/3).
7 Socket 12. Moisten the sealing lips on the air piston (Fig. 388/3) with
8 Slave screw pneumatic oil.
9 Sealing ring
13. Carefully slide the air cylinder (Fig. 388/4) over the air piston
(Fig. 388/3).
14. Place on the air motor cover (Fig. 388/1).

Maintenance
15. Screw the air motor (Fig. 389/1) together with the two M6
Fig. 389: Closing the air motor
Assembling the reversing unit

16. Position the reversing unit (Fig. 390/2) onto the air motor
(Fig. 390/3).
17. Attach the reversing unit (Fig. 390/2) onto the air motor
(Fig. 390/3) with the two mounting screws (Fig. 390/1).
Fig. 390: Assembling the reversing

unit
Assembling the adhesive part
Check all seals and the adhesive piston rod for

damage.
Replace damaged parts.

Maintenance
Protective equip- n Protective work clothing
ment: n Safety goggles
n Safety boots
Special tool: n Hook wrench (29110017)
Materials: n O-ring and pneumatic grease
(45999914)
n Assembly paste (16100015)
n Adhesive
n O-ring/ball seat (92052401)
n O-ring/base valve (92064301)
n O-ring/hose fitting (92051701)
n O-ring/adhesive cylinder (92056301)
n O-ring/oil cylinder (92067202)
n Seal/hose fitting (16016134)
n Sleeve set/sealing pack (16012020)
Assembling the adhesive piston
1. If you removed the connector (Fig. 391/1), sparingly brush
the clean thread on the connector with adhesive and screw
the connector into the adhesive piston rod (Fig. 391/2) com-
pletely.
Fig. 391: Assembling the connector
2. Moisten the O-ring (Fig. 392/3) and Glyd ring (Fig. 392/4)
with O-ring grease and pneumatic grease.
3. Place the O-ring (Fig. 392/3) and Glyd ring (Fig. 392/4)
together onto the lower part of the adhesive piston
(Fig. 392/1).
4. Lightly grease the piston guide ring (Fig. 392/2) and place it
into the slot provided on the piston.

piston with seals
1 Adhesive piston complete
2 Piston guide ring
3 O-ring

Maintenance
4 Glyd ring
5. Grease the O-ring (Fig. 393/5) and place it in the O-ring slot
on the ball seat (Fig. 393/6).
6. Place the adhesive piston with seals (Fig. 393/2) onto the
adhesive piston rod (Fig. 393/1).
7. Brush the threads on the ball seat (Fig. 393/6) with assembly
paste.
8. Place the spring (Fig. 393/3) into the spring seat on the adhe-
sive piston rod (Fig. 393/1).
9. Place the ball (Fig. 393/4) onto the ball seat (Fig. 393/6).
10. Screw the ball seat (Fig. 393/6) into the adhesive piston rod
(Fig. 393/1).
Ensure that the ball (Fig. 393/4) is positioned

correctly and that the spring (Fig. 393/3) is posi-
tioned correctly in the spring seat on the adhe-
sive piston rod (Fig. 393/1).
piston
1 Adhesive piston rod
2 Adhesive piston with seals
3 Spring
4 Ball
5 O-ring
6 Ball seat
Assembling the base valve

11. Place the ball (Fig. 394/1) into the base valve (Fig. 394/4).
12. Sparingly brush the ends of the cylinder pins (Fig. 394/2) with
adhesive.
13. Slide the cylinder pins (Fig. 394/2) into the boreholes on the
base valve.
14. Secure the cylinder pins by screwing the threaded pins
(Fig. 394/3) into the boreholes on the cylinder pins.
Fig. 394: Assembling the back pres-

sure ball

Maintenance
15. Grease the O-ring (Fig. 395/3) with O-ring grease.

16. Place the O-ring into the O-ring slot on the base valve
(Fig. 395/2).
17. Brush the clean threads on the base valve (Fig. 395/2) with
assembly paste.
18. Screw the base valve (Fig. 395/2) into the adhesive cylinder
(Fig. 395/1).
Fig. 395: Assembling the base valve
Assembling the hose fitting
20. Brush the clean threads on the hose fitting (Fig. 396/4) with
assembly paste.
21. Lightly grease the O-rings (Fig. 396/3) and place them into
the O-ring slots on the hose fitting (Fig. 396/4).
22. Place the seal (Fig. 396/2) into the base valve (Fig. 395/2)
and screw in the hose fitting.
Fig. 396: Assembling the hose fitting

Maintenance
Inserting the adhesive piston

23. Insert the adhesive piston (Fig. 397/1) into the adhesive cyl-
inder (Fig. 397/2).
Fig. 397: Inserting the adhesive piston
Assembling the sealing sleeve

24. Reassemble the sealing pack with the new sleeve set.
When assembling the sleeve set, note the instal-

lation positions of the individual components!
Sleeve set
n Female adaptor ring (Fig. 398/1)
n Counter ring (Fig. 398/4)
Fig. 398: Sleeve set

Maintenance
Assembling the sealing pack

25. Assemble the sealing pack (Fig. 399/1) as follows:
When assembling the sealing pack, note the

installation positions of the individual compo-
nents!
n Sealing body (Fig. 399/2)

n Sleeve set (Fig. 3993)
n Spring (Fig. 399/4)
n Supporting ring (Fig. 399/5)
26. Place the sleeve set (Fig. 399/3) together with the spring
(Fig. 399/4) and supporting ring (Fig. 399/5) into the sealing
body (Fig. 399/2) by hand with a small amount of lubricant
Fig. 399: Assembling the sealing pack and without tools.
27. Place the O-ring (Fig. 400/3) into the O-ring slot on the adhe-
sive cylinder (Fig. 400/2).
28. Brush the clean threads on the sealing body (Fig. 400/1) with
assembly paste.
29. Screw the sealing body (Fig. 400/1) into the adhesive cyl-
inder (Fig. 400/2) as tightly as you can by hand without using
tools.
30. Gently tighten the sealing body with a hook wrench.
Fig. 400: Assembling the sealing body

Maintenance
Assembling the oil cylinder

31. Place the lightly greased O-ring (Fig. 401/2) into the O-ring
slot on the sealing body (Fig. 401/3).
Fig. 401: Assembling the oil cylinder
32. Slide the oil cylinder (Fig. 402/1) over the sealing body
(Fig. 401/3).
As you do this, point the oil filler plug (Fig. 402/2)

on the oil cylinder forwards (90° to the screw
connection Fig. 402/3).
Fig. 402: Aligning the oil filler plug

Maintenance
Assembling the air motor with adhesive part

n Safety goggles
n Safety boots
Special tool: n Combination wrench SW 22
n Hexagon socket screwdriver
Materials: n Lubricant (16100001)
1. Slide the air motor (Fig. 403/1) sideways so that the air
motor's slave connection (Fig. 403/2) grips into in the con-
nector (Fig. 403/3) on the adhesive piston.
2. Lower the air motor (Fig. 403/1) onto the adhesive part
(Fig. 403/4).
3. Align the air motor (Fig. 403/1) centrally with the operating
device pointing forwards.
Fig. 403: Connecting the air motor (oil

cylinder not shown)

Maintenance
4. Position the 4 screws (Fig. 404/1) with the spring washers

(Fig. 404/2) into the boreholes on the air motor/adhesive part
and screw the air motor and adhesive part together.
Fig. 404: Inserting screws
Filling lubricant
WARNING!
the floor!
lubricant tanks.


Maintenance
9. Place the piston pump (Fig. 406/1) onto the bracket

(Fig. 406/2).
10. Attach the piston pump to the bracket from underneath using
the screws.
CAUTION!
Risk of injury due to falling components during
assembly!
Components may fall during assembly, causing
serious injury.
– Only have such work carried out by trained special-
ists.
assembly.
Fig. 406: Assembling the piston pump – Wear personal protective equipment e. g. protec-
onto the bracket tive gloves and boots.
11. Place the material pressure regulator (Fig. 407/1) into the
bracket (Fig. 407/2).
12. Attach the material pressure regulator onto the bracket with
the mounting screws (Fig. 407/3).
Fig. 407: Assembling the material

pressure regulator

Maintenance
13. Screw the maintenance unit (Fig. 408/3) and piston pump
(Fig. 408/2) together.
To do this, attach the screw connection (Fig. 408/1) on the
maintenance unit to the piston pump using an SW 22 combi-
nation wrench.
Fig. 408: Screwing the maintenance

unit and piston pump together
Fig. 409: Screwing the material pressure regulator and the piston
pump together
14. Screw the material pressure regulator (Fig. 409/1) and piston
pump (Fig. 409/2) together.
To do this, attach the screw connection for the double nipple
component (Fig. 409/4) beneath the bracket (Fig. 409/3) with
an SW 30 combination wrench.
15. Attach all of the air and electrical connections.
n (Fig. 410/X2) piston pump reversing unit X2 connection
è material pressure regulator pressure sensor.
n (Fig. 410/X3) piston pump X3 connection è material
pressure regulator control unit.
n (Fig. 410/3) piston pump reversing unit pressurised air
line è material pressure regulator pressurised air input.
16. Rinse and de-aerate the equipment (Ä Chapter
6.3.2.5 “Filling and de-aerating the glue delivery unit”
on page 179) and check that all of the components are
sealed.
Fig. 410: Connecting the air and elec-

trical connections

Maintenance
8.3.2.4.3 Replacing the piston pump reversing unit

n Safety goggles
n Protective gloves
Special tool: n Open-ended wrench SW 22
Materials: n Reversing unit (76010500)
1. Depressurise the glue delivery unit Ä “Depressurise the
equipment” on page 346.
2. Release the electrical connections
n (Fig. 411/X1) reversing unit/piston pump è control cab-
inet/adhesive application
n (Fig. 411/X2) reversing unit/piston pump è material
pressure regulator pressure sensor
pressure regulator control unit
from the piston pump reversing unit.
3. Separate the pressurised air supply from the maintenance
unit (Fig. 412/3).
Fig. 411: Releasing the connections
4. Separate the maintenance unit (Fig. 412/3) from the

reversing unit (Fig. 412/2).
To do this, release the screw connection (Fig. 412/1) on the
maintenance unit with an SW 22 open-ended wrench.
Fig. 412: Separating the maintenance

unit from the reversing unit

Maintenance
5. Unscrew the double nipple (Fig. 413/1) from the application

head connection block on the reversing unit.
6. Release the pressurised air line from the push-in fitting
(Fig. 413/2) on the application head connection block.
Fig. 413: Application head connection

block
7. Unscrew the mounting screws (Fig. 414/1) from the reversing

unit (Fig. 414/2).
8. Separate the reversing unit (Fig. 414/2) from the piston pump
(Fig. 414/3).
9. Place the new reversing unit (Fig. 414/2) onto the piston
pump (Fig. 414/3).
10. Attach the reversing unit onto the piston pump (Fig. 414/3)
with the mounting screws (Fig. 414/1).
Fig. 414: Disassembling the reversing

unit

Maintenance
11. Screw the double nipple (Fig. 415/1) into the application head
connection block on the new reversing unit.
12. Connect the pressurised air line with the push-in fitting
(Fig. 415/2) on the application head connection block.
Fig. 415: Application head connection

block
13. Connect the maintenance unit (Fig. 416/3) to the reversing

unit (Fig. 416/2).
To do this, attach the screw connection (Fig. 416/1) on the
maintenance unit to the double nipple (Fig. 415/1) on the
reversing unit using an SW 22 open-ended wrench.
Fig. 416: Connecting the maintenance

unit to the reversing unit

Maintenance
14. Connect the electrical connections

n (Fig. 417/X1) reversing unit/piston pump è control cab-
inet/adhesive application
pressure regulator pressure sensor
pressure regulator control unit
to the piston pump reversing unit.
15. Connect the pressurised air supply to the pressurised air
input on the maintenance unit.
Fig. 417: Releasing the connections
16.
Always set the air pressure on the pressure reg-
ulator to 6 bar.
Check the pressure on the manometer (Fig. 418/2).

the control knob (Fig. 418/1) on the pressure regulator valve.


21. Check that all connections on the piston pump are sealed
and tight.

Maintenance
8.3.2.5 Optional component maintenance

8.3.2.5.1 Adhesive container with suction pipe and hose maintenance
n Safety goggles
n Safety boots
n Protective gloves
Special tool: n Circlip pliers
Materials: n Circlip (19916105)
Disassembling the suction pipe
1. Open the adhesive container (Fig. 419/11) lid (Fig. 419/1).
2. Clean the filter hood (Fig. 419/3).
3. Remove the circlip (Fig. 419/9).
4. Remove the filter mesh (Fig. 419/8) and clean it in a water
bath.
5. Unscrew the ball seat (Fig. 419/7) from the pipe (Fig. 419/2).
6. Remove the ball (Fig. 419/6), spring (Fig. 419/5), spring seat
(Fig. 419/4) and filter hood (Fig. 419/3) and clean all of the
parts in a water bath.
Check all of the parts for damage and replace

Fig. 419: Adhesive container with suc- defective parts.
tion pipe
1 Lid
2 Pipe
3 Filter hood
4 Spring seat
5 Spring
6 Ball
7 Ball seat
8 Filter mesh
9 Circlip
10 Suction pipe (complete)
11 Adhesive container
Assembling the suction pipe 7. Place the filter hood (Fig. 419/3), spring seat (Fig. 419/4),
spring (Fig. 419/5) and ball (Fig. 419/6) into the pipe
(Fig. 419/2).
8. Brush the thread on the ball seat (Fig. 419/7) with assembly
paste and screw the ball seat into the pipe (Fig. 419/2).
9. Place the filter mesh (Fig. 419/8) into the filter hood.
10. Secure the filter mesh by placing the circlip (Fig. 419/9) into
the filter hood.

Maintenance
11. Close the adhesive container (Fig. 419/11) lid (Fig. 419/1).
8.3.2.5.2 Fill level sensor for container maintenance

1 Fill level sensor
2 Float
3 Suction pipe
4 Spring seat
5 Spring
6 Ball
7 Filter mesh housing
8 Ball seat
9 Filter mesh
10 Retaining ring
n Safety goggles
n Safety boots
Materials: n Retaining ring (93133201)
1. Remove the suction pipe from the container.
Disassembling the suction pipe 2. Remove the retaining ring (Fig. 420/10).
bath.
4. Unscrew the ball seat (Fig. 420/8) from the suction pipe.

Maintenance
5. Remove the filter mesh housing (Fig. 420/7), ball

(Fig. 420/6), spring (Fig. 420/5) and spring seat (Fig. 420/4)
and clean all of the parts in a water bath.

defective parts.
6. Remove the float (Fig. 420/2).

7. Clean the float in the water bath.
Assembling the suction pipe
NOTICE!
During assembly, the surface of the float with the
"oben" label must point upwards.
8. Insert the float.

9. Place the spring seat (Fig. 421/4), spring (Fig. 421/5), ball
(Fig. 421/6) and filter mesh housing (Fig. 421/7) into the suc-
tion pipe.
paste and screw the ball seat into the suction pipe
(Fig. 421/3).
11. Place the filter mesh (Fig. 421/9) into the filter mesh housing
(Fig. 421/7).
12. Secure the filter mesh by placing the retaining ring
(Fig. 421/10) into the filter mesh housing (Fig. 421/7).
13. Place the suction pipe back into the container.

Maintenance
8.3.2.5.3 Suction pipe for container maintenance

n Safety goggles
n Safety boots
n Protective gloves
1. Open the container lid so that the suction pipe is easily
accessible.
2. Clean the suction pipe (Fig. 422/1).
3. Remove the retaining ring (Fig. 422/8).
bath.

defective parts.

1 Suction pipe
2 Spring seat
3 Spring
4 Ball
6 Ball seat
7 Filter mesh
8 Retaining ring
Assembling the suction pipe 7. Place the spring seat (Fig. 422/2), spring (Fig. 422/3), ball
tion pipe.
(Fig. 422/1).
(Fig. 422/5).

Maintenance

11. Close the container lid.
8.3.2.5.4 Suction pipe for container with fill level sensor maintenance
n Safety goggles
n Safety boots
n Protective gloves
1. Open the container lid so that the suction pipe is easily
accessible.
2. Clean the suction pipe (Fig. 423/1).
3. Remove the retaining ring (Fig. 423/8).
bath.

defective parts.

with fill level sensor
1 Suction pipe
2 Spring seat
3 Spring
4 Ball
6 Ball seat
7 Filter mesh
8 Retaining ring

Maintenance
Maintenance of the components > F1-2 Fill level sensor mainten...
Assembling the suction pipe 7. Place the spring seat (Fig. 423/2), spring (Fig. 423/3), ball
tion pipe.
(Fig. 423/1).
(Fig. 423/5).
11. Close the container lid.
8.3.3 F1-2 Fill level sensor maintenance

Cleaning the fill level sensor
The cleaning process is described below using the
example of a fill level sensor with a single float switch.
If the fill level sensor has multiple float switches, these
must all be cleaned.
n Safety goggles
n Safety boots
1. Open the adhesive container lid (Fig. 424/1).
Fig. 424: Adhesive container

Maintenance
Maintenance of the components > 3-way blank guide
Removing the float

2. Remove the lock washer (Fig. 425/2) beneath the float
(Fig. 425/1) with a set of lock washer pliers.
3. Remove the float.
4. Clean the float in the water bath.
Fig. 425: Removing/inserting the float
Inserting the float

NOTICE!
During assembly, the engraved arrow (Fig. 425/3) on
the float housing must point upwards.
5. Insert the float.

6. Secure the float with the retaining ring.
7. Close the adhesive container lid (Fig. 424/1).
8.3.4.1 General information for any work on the multi-application head

Observe the information below during all work on the blank guide
multi-application head:

Maintenance

n Protective gloves
n Safety boots
DANGER!
CAUTION!
1.
NOTICE!
Fig. 426: Multi-application head, guide Risk of distorting the guide rods on the pneu-
rods and pneumatics matic cylinder when working on the multi-
application head!
Use the switchbox to move the pneumatic cylinder

(Fig. 426/1) in the direction of the arrow into its back end
position until the guide rods on the pneumatic cylinder are
drawn in.
To do this, press the [MANUAL/AUTO] button (Fig. 427/3).
ð The LED on the button illuminates in yellow. Manual
mode is active.
3. Press the [UP] button (Fig. 427/1) until the guide rods on the
pneumatic cylinder are drawn in.
Attach fixing elements 4. n Only tighten the Phillips head screws (Fig. 426/2) that
attach the multi-application head as tightly as you can by
hand.

Maintenance
NOTICE!
The guide rods on the pneumatic cylinder can
bend
Never use a lever to increase the torque.
Detach the multi-application head for all further work
on the blank guide by loosening the Phillips head
screws (Fig. 426/2) and removing the multi-application
head.
8.3.4.2 Clean the blank guide

n Safety boots
DANGER!
DANGER!
CAUTION!
1. Ensure that there are no paper fragments in the area around

Follow the safety guidelines when removing these.

Maintenance
2. Regularly check the application head tips for adhesive resi-

dues.
Remove adhesive residues with a soft, dry or slightly damp
cloth.
If necessary, remove the application head from

the blank guide.
Rinse the application head.
Follow the safety guidelines!
3. Check the remaining parts of the blank guide for paper and
glue residues. Pay particularly close attention to
n the adhesive monitoring system and
n the light sensor.
Follow the safety guidelines when removing contaminants.
For more information on cleaning the light

sensor, see:
Adhesive-carrying components
When disassembling adhesive-carrying components,
cover all neighbouring components with a damp cloth.
This prevents glue residues from drying out on the
neighbouring components.
8.3.4.3 Test and rinse the application heads

n Protective gloves
n Safety boots
Materials: n Waste container or a sheet of paper
DANGER!

Maintenance
All products must be removed from the equipment

while the application valves on the application heads
are cleaned and rinsed.
Set water bath position

To do this, press the [MANUAL/AUTO] button (Fig. 428/4) on
the switchbox.
mode is active.

Fig. 428: Inliner XTS² switchbox [DOWN] button flashes.
3. Position a suitable waste container or sheet of paper beneath

the application valves on the application heads.
4. Rinse the application heads.
To do this, press and hold the [Rinse] button (Fig. 428/2).
CAUTION!
Risk of injury due to splashing liquids.
Liquids exit the material nozzle at high pressure.
Always wear safety goggles when working on the
application head!
ð All application valves on the application heads spray

adhesive while the button is pressed.
The LED on the [Rinse] button illuminates during the
rinsing process.

Maintenance
5. Press the [Rinse] button multiple times until all application

heads produce an even spray.
ð The application heads have now been rinsed.
If the spray of adhesive is still not even after you have
pressed the [Rinse] button multiple times, the nozzles on
the application heads must be cleaned mechanically or
replaced.
For more information, see the maintenance

table in the “Multi-application head” section.
6. Press the [UP] button (Fig. 428/1) until the water bath moves
upwards and stops.
ð The LED on the [UP] button flashes whilst the water bath
is moving.
7. Press the [AUTO/MANUAL] button (Fig. 428/4).
ð The LED on the button goes out.
Automatic mode is activated.
8.3.4.4 Replace and fill the water bath
CAUTION!
Risk of slipping due to overflowing or spilled
water!
If water is allowed to overflow or spill, there is a risk of
injury due to slipping!
– Wipe away or soak up overflowing or spilled water
immediately.
– Wear safety boots with non-slip soles.
n Safety boots
Materials: n Bottle with spray attachment
DANGER!

Maintenance
To ensure that the nozzles on the multi-application head do not dry

out during breaks, they are automatically dipped into a water bath
as soon as the signal is no longer generated by the product guide.
This only works with clean, fresh water.
Change water daily!

Change the water in the blank guide water bath every
day.

To do this, press the [MANUAL/AUTO] button (Fig. 429/3) on
the switchbox.
mode is active.

Fig. 429: Inliner XTS² switchbox [DOWN] button flashes.
Remove water bath

3. Unlock the water bath by pulling the locking bolt (Fig. 430/1)
underneath the water bath down (away from the water bath).
4. Slide the water bath to the centre of the machine and remove
the water bath from the guide plate (Fig. 430/2).
Fig. 430: Water bath

Maintenance
Remove the lid

5. Loosen the knurled nut (Fig. 431/3).
6. Slide the lid (Fig. 431/1) in the direction of the arrow and
remove the lid out from the tray guide (Fig. 431/2).
7.
CAUTION!
Risk of slipping due to overflowing or spilled
water!
Wipe away or soak up any overflowing or spilled water imme-

diately.
Fig. 431: Remove the lid
Empty the water bath 8.

ENVIRONMENT!
Environmentally hazardous substances
Adhesive residues in water contain environmen-
tally hazardous substances. These must not be
allowed to enter the environment. Dispose of
adhesive residues in an environmentally friendly
manner.
Drain the water bath tray and wipe away adhesive residues
with a cloth.
Replace the water bath
9. Pull the locking bolt (Fig. 432/3) down and slide the water
bath tray (Fig. 432/1) onto the guide plate (Fig. 432/2).
The locking bolt (Fig. 432/3) must lock into place

in the tray's (Fig. 432/1) locking bolt hole.
Fig. 432: Replace the water bath tray
Fill tray 10. Fill the tray with water up to approx. 2 mm beneath the upper
edge of the tray.
Use the included bottle with spray attachment to

fill the tray.

Maintenance
Assemble lid
11. Slide the lid (Fig. 433/1) into the tray guide (Fig. 433/2).
12. Attach the lid with the knurled nut (Fig. 433/3).
13. Ensure that all components are installed correctly.
14. Switch the equipment back on.
For further information on switching the equip-

ment back on, please see the control documen-
tation for the entire system.
Fig. 433: Assemble lid
8.3.4.5 Blank guide pressure regulator maintenance

Check pressurised air setting
n Safety boots
DANGER!
To ensure that the multi-application head and water bath in the

blank guide move correctly, the pressure regulator on the blank
guide must be set to the correct pressure.

to 1.8 bar.
the response pressure of 2 bar is exceeded, the safety
valve allows the pressurised air to escape into the
atmosphere.

2. If the pressure has varied, correct the set pressure using the
control knob (Fig. 434/1) on the pressure regulator.
Correct target pressure 3. Unlock the pressure regulator by pulling the control knob
upwards (away from the housing).

Maintenance
4. Turn the control knob until the required pressure of 1.8 bar is
displayed on the manometer.
Q Decrease pressure
P Increase pressure

downwards (towards the housing). The control knob must
lock into place.

Each blank guide (right/left) has a separate pressure
regulator.
Set the air pressure on the second pressure regulator
as described above.
8.3.4.6 Configure proximity sensor

n Safety boots
DANGER!
CAUTION!
The proximity sensor (Fig. 435/1) signals the position of the piston
in a pneumatic cylinder. It detects a ring magnet in the cylinder
piston when it passes the position of the sensor, and signals this
with an LED (Fig. 435/3).
Fig. 435: Configure proximity sensor

Maintenance
Maintenance of the components > 3-way multi-application head
Mounting the cylinder in close proximity to magnetis-

able components can affect the switching behaviour of
the sensor.
1. Insert the proximity sensor (Fig. 435/1) into the slot on the
pneumatic cylinder.
When doing so, position the active zone (centre of the prox-
imity sensor) at the approximate end position of the piston.
2. Move the pneumatic cylinder into the "retrieval position".
3. Position the proximity sensor with the aid of the LED display
(Fig. 435/3).
ð The LED illuminates as soon as the cylinder piston is
detected.
4. Fix the proximity sensor into the slot in this position with a
clamping screw (Fig. 435/2).
Further proximity sensors

Repeat the process for all further pneumatic cyl-
inders with proximity sensors in the same way as
described above.
8.3.5.1 General information for any work on the multi-application head

Observe the information below during all work on the multi-applica-
tion head:

Maintenance
3 Capstan screws
Fig. 436: Multi-application head, guide

rods/pneumatic
1.
NOTICE!
application head!
Move the pneumatic cylinder in the direction of the arrow into

its rear end position so that the guide rods on the pneumatic
cylinder are drawn in.
Attaching fixing elements 2. n Only tighten the capstan screws that attach the multi-
application head as tightly as you can by hand.
n Disassemble the multi-application head for all further
work by releasing the capstan screws and lifting out the
NOTICE!
Under no circumstances use a lever to
increase the torque as this can cause the
guide rods on the pneumatic cylinder to dis-
tort!

Maintenance
WARNING!
Risk of injury caused by uncontrolled spraying of
adhesive due to disconnected valves and hoses!
Certain working steps in connection with the glue
delivery unit require the equipment to operated with
the valves or hoses disconnected or disassembled.
Operating with the valves or hoses disconnected/dis-
assembled can cause serious injuries, e.g. to the eyes,
due to adhesive being sprayed uncontrollably.
wards.
collect the cold glue.
8.3.5.2 Disassemble the 3-way multi-application head

n Safety goggles
n Protective gloves
The multi-application head must be disassembled for cleaning and

maintenance work. To do this, proceed as follows:
1.
NOTICE!
application head!
Move the pneumatic cylinder into its rear end position so that
the guide rods on the pneumatic cylinder are drawn in.
WARNING!
2. Depressurise the system.

3. Remove the multi-application head.

Maintenance

head
1. Release the power supply and adhesive supply from the
2. Release the capstan screws.
3. Pull the multi-application head upwards out of the retainer
plate on the blank guide.
Fig. 437: Removing the multi-applica-

tion head
2 Power supply
3 Retainer plate
4 Capstan screws
5 Blank guide
6 Adhesive supply

Maintenance
Removing the module

1. Release and remove the screws.
2. Remove the module from the main body.
3. Remove the O-ring from the borehole on the main body.
Fig. 438: Removing the module

1 Screw
2 Main body
3 O-ring
4 Module
5 Screw
Opening the stroke regulator

1.
NOTICE!
Risk of damage to the application head and
armature due to incorrect configuration of the
stroke regulator!
Release the threaded pin on the side of the stroke regulator.

2. Turn the stroke setting screw with a screwdriver until it stops.

1 Threaded pin
2 Stroke regulator screw
NOTICE!
Clean individual parts immediately!
Otherwise the material will dry out. Removing dried-on
material residues is difficult and may cause damage.

Maintenance
NOTICE!
Suitable cleaning agents!
Use a suitable cleaning agent.
(max. 40 °C) or a suitable solvent.
1.
Mind the armature and pressure spring when
removing the nozzle!
The armature and pressure spring may fall out.
Turn the nozzle to remove it from the armature housing.

2. Remove the armature together with the pressure spring from
the armature housing.
Fig. 440: Removing the armature

1 Armature housing
2 Armature
3 Nozzle
3. Turn the stroke regulator with a flathead screwdriver to

remove it from the regulator housing on the module.
4. Remove the O-ring from the stroke regulator.
Fig. 441: Removing the stroke regu-

lator
1 Stroke regulator

Maintenance
2 Module
3 O-ring
1. Release and remove the 4 screws.

2. Disassemble the module housing into:
n Armature housing
n Solenoid coil
n O-ring and
n Regulator housing
Fig. 442: Disassembling the module

housing
1 Regulator housing
2 O-ring
3 Solenoid coil
4 Armature housing
5 Screw

Maintenance
8.3.5.3 Assemble the 3-way multi-application head

n Safety goggles
n Protective gloves
Before assembly, clean the individual parts with warm

water (max. 40 °C) and dry them carefully.
Observe the information below during all work on the multi-

application head:
NOTICE!
application head!
Assembling the module

1. Assemble the module housing:
n Armature housing
n Solenoid coil
n O-ring and
n Regulator housing
2. Screw on the module housing with the 4 screws.
Fig. 443: Assembling the module

housing

Maintenance
1 Regulator housing
2 O-ring
3 Solenoid coil
4 Armature housing
5 Screw
1. Place a new O-ring into the O-ring slot on the stroke regu-
lator.
ð Grease the O-ring with a little O-ring grease.
2. Assemble the stroke regulator.
Fig. 444: Installing the stroke regu-

lator
1 Stroke regulator
2 Module
3 O-ring

3.
NOTICE!
stroke regulator!
You can destroy the armature and nozzle when
screwing in the nozzle if the stroke regulator is
not completely open.

1 Threaded pin
2 Stroke regulator 5. Check that the stroke regulator is completely open.

Maintenance
6. Place the armature together with the pressure spring into the
armature housing.
7. Screw the nozzle into the armature housing on the module.
Fig. 446: Installing the armature

1 Armature housing
2 Armature with pressure spring
3 Nozzle
Installing the module

1. Place the lightly greased O-ring (92050301) into the borehole
on the main body.
2. Hold the module onto the main body and attach it with the
screws.
Fig. 447: Installing the module

1 Screw
2 Main body
3 O-ring
4 Module
5 Screw

Maintenance
Installing the multi-application

head
1. From above, guide the multi-application head with the cap-
stan screws into the slots on the retainer plate.
2. Attach the multi-application head onto the retainer plate in
the blank guide with the capstan screws.
3. Connect the power supply and adhesive supply to the multi-
application head.
4. Configure the armature stroke on the module:
Ä Chapter 6.3.4.1.1 “Adjust the armature stroke”
on page 191
Fig. 448: Installing the multi-applica-

tion head
2 Power supply
3 Retainer plate
4 Capstan screws
5 Blank guide
6 Adhesive supply

Maintenance
8.3.5.4 Check the armature needle

n Safety boots
n Safety goggles
n Protective gloves
1. Rinse the installed application head with water.

See maintenance chapter under "Glue delivery unit".
3. Remove the application head.
Open the stroke regulator
4.
NOTICE!
stroke regulator!
Release the set screw on the side of the stroke regulator.


1 Threaded pin
Checking the armature needle

1.
Mind the armature during removal!
The armature can fall out.
Place something underneath to catch falling parts or hold the

module with the armature needle pointing upwards.
2. Remove the nozzle.
3. Carefully check the protruding armature needle.
The armature needle must be able to move gently to and fro
in the direction of the axis.
4. If the armature needle moves gently, continue with step 9.
If the armature needle is stiff, proceed as follows.
Fig. 450: Checking the armature n Check and clean the module.
needle n Disassemble the module if necessary. Check it for
1 Nozzle defects. Replace defective parts.

Maintenance
2 Armature needle
Finishing tasks
1. Install the nozzle.
2. Install the application head.
3. Configure the armature stroke on the module.
8.3.5.5 Replace the nozzle

n Safety boots
n Safety goggles
n Protective gloves
1. Rinse the installed application head with water.

See maintenance chapter under "Glue delivery unit".
3. Remove the application head.
Open the stroke regulator
4.
NOTICE!
stroke regulator!
Release the set screw on the side of the stroke regulator.


1 Threaded pin

Maintenance
Replacing the nozzle

1.
Mind the armature with pressure spring
during removal!
The armature with pressure spring may fall out.
Unscrew the nozzle from the armature housing on the

module.
2. Remove the armature together with the pressure spring.
3. Check the removed parts for wear.
Fig. 452: Replacing the nozzle 4. Replace defective parts.
1 Armature housing 5. Place the clean/new armature with pressure spring back into
2 Armature with pressure spring the module.
3 Nozzle
6. Screw the new nozzle into the module.
Finishing tasks
1. Install the nozzle.
2. Install the application head.
3. Configure the armature stroke on the module.

Maintenance
Maintenance of the components > MLT sensor
8.3.6 MLT sensor
Clean MLT sensor

n Safety boots
n Safety goggles
n Protective gloves
Special tool: n soft cleaning cloth / glasses cleaning
cloth
Check the MLT sensor lens (Fig. 453/1) for dirt.

Clean the MLT sensor lens as needed with a soft, damp cloth
or soft glasses cleaning cloth.
NOTICE!
The glass surface of the lens can be damaged.
Do not use cleaning agents that contain solvents
or alcohol.
Fig. 453: MLT sensor lens

Maintenance
Maintenance of the components > Pressure vessel

8.3.7.1 Opening the pressure vessel
Opening the vessel Personnel: n Operator

n Safety boots
n Safety goggles
n Protective gloves
WARNING!
Before beginning any work, follow the instructions on
Ä on page 327.
1. Remove the material hose from the bulkhead fitting

(Fig. 454/2).
2. Remove the hose coupling from the pneumatic hose.
3. Unscrew the lid (Fig. 454/4) and remove it.
4. Remove the vessel container if necessary.
Fig. 454: Operate the pressure vessel
Closing the vessel Personnel: n Operator

n Safety boots
n Safety goggles
n Protective gloves
1. Place the vessel container into the pressure vessel.

2. Check that the lid is sealed:
The sealing ring must be undamaged and free from dirt.
3. Place the lid so that the material hose (Fig. 314/5) is within
the vessel container with the material.
4. Screw the lid closed.

Maintenance
Maintenance of the components > Pressure vessel
5.
WARNING!
Connect the material hose to the bulkhead fitting (Fig. 314/2)

Ensure that the connection is tight and secure.
6. Plug the hose coupling for the pneumatic hose into the nipple

n Safety boots
n Safety goggles
n Protective gloves
Increasing pressure
1. Remove the material pressure (Fig. 455/3) regulator.
2.
1 to 2.5 bar
Set the material pressure regulator to the material pressure

originally selected.
3. De-aerate the system if necessary.
4. Re-set the previously selected sprayed air pressure.
Fig. 455: Setting pressure

Maintenance
Maintenance of the components > Status indicator
8.3.8 Status indicator

Replacing the light bulb Personnel: n Operator
Materials: n Cut-proof protective gloves
1. Turn the defective diode until the white marking lines
(Fig. 456/1) on the defective and the connected diode are
positioned above one another.
ð The bayonet socket on the diode can now be opened.
2. Remove the defective bulb and replace it with a new bulb.
Only use the bulbs intended for this purpose.
Ä “Light bulb” on page 575
3. Turn the bayonet socket on the diode until the diodes and the
socket are tightly connected together again.
4. Check that all elements of the status display are attached
Fig. 456: Diode securely.
Function test If there is a fault in the electrical supply, a warning message will
appear in the operating software.
The most common error is that a light bulb has failed. A diode must
always illuminate once the power supply is switched on.
Replacing a diode Personnel: n Operator

If there is damage to the outer casing of the diode, the defective
casing must be replaced.
1. Turn the defective diode until the white marking lines
(Fig. 456/1) on the defective and the connected diode are
positioned above one another.
ð The bayonet socket on the diode can now be opened.
2. Open the bayonet socket for further diodes if necessary.
3. Remove the defective diode and replace it with a new diode.
Insert a new bulb if necessary.
4. Turn the diode until the diodes are beneath one another and
they and the socket are tightly connected together again.
5. Check that all elements of the status display are attached
securely.

Maintenance
Maintenance of the components > Status indicator

Fault elimination
Safety guidelines for fault elim...
9 Fault elimination
9.1 Safety guidelines for fault elimination
DANGER!
Improper fault elimination

WARNING!
Risk of injury due to improper fault elimination!
Improper fault elimination can result in serious injuries
– Before beginning fault elimination, ensure that all
repair work is carried out in accordance with the
information and instructions set out in this manual
and in the associated circuit diagrams.
– Before beginning fault elimination, ensure that
nobody is in the danger zone.
– Fault elimination must only be carried out by per-
sonnel trained and authorised by the owner.
These personnel must:
manual,
tion manual,
– have the necessary specialist knowledge to
eliminate the fault.
Possible causes for faults and fault correction tasks are described
in the following chapter.
If faults increasingly occur, shorten the maintenance interval
according to the actual load.
If there are faults that cannot be corrected through the instructions
below, contact the manufacturer, see contact data on page 2.
Conduct with regard to faults

The following always applies:
1. In the event of faults that pose an immediate danger to
people or material assets, bring the Inliner system with MLT
40 into a safe state immediately.
2. Also observe the information regarding faults in the operation
manual for the super-ordinate machine.
3. Identifying the cause of the fault.

Fault elimination
Fault table
4. If work in the danger zone is required in order to eliminate the

fault, deactivate the Inliner system with MLT 40 and ensure
that it cannot be switched back on.
Inform those responsible at the site about the fault immedi-
ately.
5. Depending on the type of fault, either have it eliminated by
authorised specialist personnel or rectify it yourself.
The following fault table provides information as to who

is authorised to eliminate the fault.
9.2 Fault table

Fault description Cause Remedy Personnel
Control cabinet: not func- Main switch set to "off" Switch main switch on. Operator
tioning
No power provided. n Check power line. Qualified
n Check fuse. electrician
Control cabinet fuse Replace control cabinet fuse. Qualified

has triggered. electrician
CPU module: One or more A connected module is Ä Chapter 9.3.2 “Rectifying faults Qualified
LEDs on the status indicator causing a fault. on the CPU module” on page 451 electrician
do not illuminate.
Terminal interface Connection plug not Insert the plug securely and tighten Operator
module: Power supply connected securely. the screws.
inconsistent, screen display
disappears partially or fully. Cable has a break. Replace cable. Qualified
electrician
Terminal interface Interference in the data Check how the cables are laid. Do Qualified
module: Screen display cable. not lay them together with power electrician
flickers. lines.
Cable shielding defec- Replace cable. Qualified

tive or insufficient. electrician
Linux terminal: Cable connections are Check that the cable connections Operator
Touchscreen elements are disconnected. are attached securely. Qualified
not activating correctly. electrician
Touchscreen is dirty. Clean the touchscreen. Operator
Qualified
Ä Chapter 8.3.1.1 “Cleaning the electrician
Linux terminal” on page 344

Fault elimination
Fault table

Linux terminal: Control cabinet is Switch control cabinet on. Operator
Touchscreen and LED do switched off.
not light up.
Linux terminal is Switch Linux terminal on. Operator
switched off.
Ä on page 163
Power supply cable n Connect the power supply Operator

connections are dis- cable connections. Qualified
connected. n Check that the cable connec- electrician
tions are attached securely.
Fig. 131
Power supply connec- Replace the power supply connec- Qualified

tion cable is defective. tion cable. electrician
Control cabinet is not Supply power to the control cabinet. Qualified

receiving power. electrician
Linux terminal: Cursor Dirt between housing Clean away the dirt. Operator
does not move. frame and
touchscreen.
Cable connections n Connect the connection cable. Operator
between the control n Check that the cable connec- Qualified
cabinet and Linux ter- tions are attached securely. electrician
minal are discon-
nected.
Connection cable is Replace the connection cable. Qualified
defective. electrician
Linux terminal: Cursor The corner of the Contact manufacturer to repair.
appears in the wrong place. housing is com-
pressed.
Linux terminal: Screen dis- Backlight is defective. Contact manufacturer to repair.
plays something but the
backlight is dark.
Glue delivery unit: No Material container Refill material. Operator
material. empty.

Fault elimination
Fault table

Ball valve on distributor Open ball valve. Operator
closed.
Material pipes are sep- Connect pipes. Qualified
arated. mechanic
Electrical connections Create connections. Qualified
are separated. electrician
Application head does See “Test mode” on controller. Operator
not receive control sig-
See Faults on the application head.
nals.
Back pressure ball Remove hose from nozzle. Push Qualified
stuck (if present). the ball loose through the hose fit- mechanic
ting using a blunt object (e. g.
wood). Connect the hose.
Pump does not start (if See Faults on the piston pump. Qualified
present). electrician
Qualified
mechanic
Glue delivery unit: Too Material pressure too Settings: Check and correct system Operator
little material. low. pressure, maintenance unit and
controller.
Suction hose dam- Shorten or replace suction hose. Qualified

aged. mechanic
Filter on the suction Clean filter.
and/or output side
See Maintenance on the piston
dirty.
pump.
Application head See Maintenance or Faults on the

blocked. application head.
Sound absorber on the Clean, de-ice the sound absorber. Operator

reversing unit dirty or
icy.
Glue delivery unit: Pump Defective or missing O- Assemble new O-rings. Qualified
switches unevenly. rings on the hose fit- mechanic
ting.
Glue delivery unit: Air bub- Defective or missing O- Assemble new O-rings. Qualified
bles in the material. rings on the hose fit- mechanic
ting.
Glue delivery unit: Short Defective or missing O- Assemble new O-rings. Qualified
interruptions to the material rings on the hose fit- mechanic
application. ting.
Glue delivery unit: Material Sealing pack defective. Change the pack. (see Mainte- Qualified
escaping from the borehole nance on the piston pump). mechanic
above the oil plug.

Fault elimination
Fault table

Glue delivery unit: Nozzle Nozzle dirty. Clean nozzle (see Maintenance on
on multi-application head the multi-application head).
dripping.
Nozzle defective. Replace nozzle (see Maintenance
on the multi-application head).
Spring defective or Replace armature (see Mainte-

worn. nance on the multi-application
head).
unsuitable material. use a suitable material (see mate-

rial description).
Glue delivery unit: Nozzle Nozzle dirty. Clean nozzle (see Maintenance on
sprays at an angle. the multi-application head).
Nozzle defective. Replace nozzle (see Maintenance

on the multi-application head).
Glue delivery unit: Fill level Power supply or anal- see description of the controller or Qualified
display does not work (if ysis does not work. fill level sensor. electrician
present).
Float does not move. Remove, clean float (see Fill level Operator
sensor).
Glue delivery unit: Fill level Minimum fill level in the Refill adhesive container with adhe- Operator
display illuminates. adhesive container not sive.
reached.
Fill level sensor: Float Float sticking to riser Clean float and riser pipe. Operator
does not move. pipe.
Fill level sensor: Signal is Electrical connection Check plug and cable and replace if Qualified
not transmitted. interrupted. necessary. electrician
3-way blank guide: Blanks Guide plate configured Configure guide plates for blank Qualified
are fed incorrectly. incorrectly. format: mechanic
Ä Chapter 6.3.3.1 “Configure the 3-
way blank guide” on page 182
3-way blank guide: No Light sensor dirty. Clean light sensor with a soft cloth. Operator
adhesive is applied.
Light sensor configured Align light sensor: Qualified
incorrectly. mechanic
Ä “Align the FHDK light sensor”
on page 115
Light sensor defective. Replace light sensor: Qualified

electrician
Ä Chapter 9.3.8.1 “Replace the
FHDK light sensor” on page 462

Fault elimination
Fault table

3-way blank guide: Multi- Fill level of the blank Fill water bath: Operator
application head nozzles dry guide water bath too
out. low. Ä Chapter 8.3.4.4 “Replace and fill
the water bath ” on page 413
Water bath positioned Correct water bath position: Qualified

Ä Chapter 6.3.3.2 “Prepare the
water bath” on page 185
3-way blank guide: Blank Light sensor dirty. Clean light sensor with a soft cloth. Operator
guide does not work in auto-
matic mode. Light sensor configured Align light sensor: Qualified
Ä “Align the FHDK light sensor”
on page 115
Light sensor defective. Replace light sensor: Qualified

electrician
Ä Chapter 9.3.8.1 “Replace the
FHDK light sensor” on page 462
Proximity sensor on Adjust the proximity sensor on the Qualified

the pneumatic cylinder pneumatic cylinder: mechanic
configured incorrectly.
Ä Chapter 8.3.4.6 “Configure prox-
imity sensor” on page 417
Pressurised air supply Configure pressurised air supply on Operator

configured incorrectly. the pressure regulator:
Ä “Check pressurised air setting”
on page 416
3-way blank guide: Error in Main supply line for the Check main supply line. Professional
the pressurised air supply. pressurised air supply pneumatic
disconnected. engineers
Pressurised air supply Configure pressurised air supply on Operator
configured incorrectly. the pressure regulator:
Ä “Check pressurised air setting”
on page 416
3-way blank guide: Glue Multi-application head Clean multi-application head noz- Operator
application faulty. nozzles blocked or zles:
dried out.
Ä Chapter 8.3.4.3 “Test and rinse
the application heads” on page 411
3-way multi-application No adhesive supply. Check adhesive supply: Qualified

head: Too little or no adhe- mechanic
sive is applied. n See “Maintenance” section for
n Check lines for bends, block-
ages and leaks.

Fault elimination
Fault table

Multi-application head Clean hardened adhesive from the Qualified
blocked with hardened multi-application head: mechanic
adhesive.
Ä Chapter 9.3.9.1 “Cleaning hard-
ened adhesive from the multi-appli-
cation head” on page 464
Armature stroke Configure armature stroke: Qualified

closed. mechanic
Armature stiff. Check armature: Qualified
mechanic
Application head does n Check controller settings: Qualified
not receive control sig- see “Controller” section mechanic
nals. n Check cabling.
3-way multi-application O-ring defective. Replace O-ring: Qualified

head: Stroke regulator not mechanic
sealed: Ä Chapter 9.3.9.1 “Cleaning hard-
3-way multi-application Nozzle dirty. Clean nozzle: Qualified

head: Nozzle dripping mechanic
although the application Ä Chapter 9.3.9.1 “Cleaning hard-
head is not activated. ened adhesive from the multi-appli-
Nozzle defective. Replace nozzle: Qualified

mechanic
Spring defective or Replace armature: Qualified

worn. mechanic
3-way multi-application Nozzle dirty. Clean nozzle: Qualified
head: Nozzle sprays at an mechanic
angle. Ä Chapter 9.3.9.1 “Cleaning hard-

mechanic
3-way multi-application Nozzle partially or fully Clean nozzle with a damp cloth. Qualified
head: Application image not blocked. mechanic
Clean nozzle if necessary:
clean.

Fault elimination
Fault table
Distance between Change distance: Qualified

application head and mechanic
See “Commissioning” section for
product too small or
the blank guide.
too large.
MLT sensor: Products are MLT sensor parame- Configure MLT sensor parameters. Operator
not detected. ters set incorrectly.
MLT sensor lens dirty. Clean MLT sensor lens. Operator
Ä “Clean MLT sensor”
on page 432
MLT sensor positioned Correct sensor position. Qualified

Connection cable to Attach connection cable. Operator
the MLT sensor has
disconnected.
Too much extraneous Screen the MLT sensor from extra- Qualified
light. neous light coming in from the mechanic
sides.
Prevent light reflecting from the
base.
MLT sensor: “Dust error” MLT sensor lens dirty. Clean MLT sensor lens. Operator
LED illuminates.
Ä “Clean MLT sensor”
on page 432
MLT sensor: “Extraneous Too much extraneous Screen the MLT sensor from extra- Qualified
light error” LED illuminates. light. neous light. mechanic
Prevent light reflecting from the
base.
MLT sensor: “Edge” LED Product with incorrect If the error message repeats, check Qualified
illuminates. spacing between the the line spacing between the adhe- mechanic
adhesive line and the sive application nozzles and the
carton edge detected. carton edge and adjust the line
spacing via the controller if neces-
sary.
UV lighting for MLT-40 Cable connection dis- Reconnect cable connection.

(optional): Lighting has connected.
failed.
UV lighting defective. Replace UV lighting.
Ä Chapter 9.3.12.1 “Replacing the
UV lighting” on page 476
MLT colour filter installa- Cable connection dis- Reconnect cable connection.
tion kit: Lighting has failed. connected.

Fault elimination
Fault table

Lighting defective. Replace lighting.
Ä Chapter 9.3.12.1 “Replacing the
UV lighting” on page 476
FHDK light sensor: Object Object outside of the Move the light sensor closer to the Qualified
edge not detected. scanning area. object. Target distance: 20 mm to mechanic
object surface.
Light sensor dirty. Clean light sensor. Operator
Light sensor defective. Replace light sensor. Qualified

mechanic
Ä Chapter 9.3.14 “FHDK light
sensor” on page 480
FHDK light sensor: Object Cable connection to Replace cable connection. Qualified
edge is detected but the the controller damaged electrician
function assigned on the or defective.
controller is not triggered.
Cable plug is faulty. Check plug and tighten if neces- Qualified
sary. electrician
Light sensor is not Check assignment and correct if Operator

assigned correctly in necessary.
the operating software.
Window mask is set Check window mask and object Operator
too large in the oper- size in the operating software and
ating software. correct if necessary.
Marking system: Products Pressure vessel in the Fill pressure vessel: Operator
with skewed glue applica- marking system is
tion are not ejected. empty. Products with Ä Chapter 7.2.6.1 “Filling the pres-
skewed glue applica- sure vessel” on page 327
tion are not marked.
The spray application Check spray application head and Operator
head in the marking replace if necessary: Qualified
system is not func- mechanic
tioning correctly. Prod-
ucts with skewed glue
application are not
marked.
Marking is not carried Check marking (see Application Operator
out correctly. head operation)
Marking system: Applica- Material application Check material application: Operator

tion uneven, applied quan- faulty.
See Assessment advice in
tity too large or too small.
Ä Chapter 7.2.7 “Operating the
marking valve” on page 331

Fault elimination
Fault table

Pressure vessel: No adhe- Pressure vessel Ensure pressure vessel is standing Qualified
sive applied, but material is crooked. straight: mechanic
in the vessel.
Ä Chapter 5.2.15 “Pressure vessel”
on page 127
Fill level too low. Fill pressure vessel: Operator

Ä Chapter 7.2.6.1 “Filling the pres-
sure vessel” on page 327
Compressed air hose Attach compressed air hose cor- Qualified

attached incorrectly. rectly: mechanic
on page 127
Compressed air hose Replace compressed air hose: Qualified

faulty. mechanic
on page 127
Pressure vessel: Permis- Safety valve defective. Contact manufacturer to repair.

sible vessel pressure
exceeded.
Spray application head: Material container Refill material. Operator
Material is not applied. empty.
Ä Chapter 7.2.6.1 “Filling the pres-
sure vessel” on page 327

Fault elimination
Fault table

Material supply discon- Check lines for bends, blockages Operator
nected. and leaks.
Armature stroke Configure armature stroke: Operator

closed.
Ä Chapter 7.2.7.2 “Configure the
armature stroke” on page 332
Armature stiff. Check armature: Qualified

mechanic
Ä Chapter 9.3.16.3 “Check, replace
the armature needle” on page 490
Spray application head Clean spray application head exter- Qualified

blocked. nally: mechanic
Clean nozzle:
the nozzle” on page 486
Clean air cap:
Spray application head n Check terminal settings: Operator

is not activated. see "Terminal" operating Qualified
manual mechanic
n Check cabling:
see "Material delivery unit"
operating manual
n Test coil:
replace the coil” on page 495
Replace coil:
replace the coil” on page 495
No compressed air. Check the settings for the com- Operator

pressed air source:
on page 204
Check the on-site compressed air
supply.
Spray application head: Material pressure too Check set system pressure, correct Operator
Too little material is applied. low. if necessary:
on page 204

Fault elimination
Fault table

Spray application head Clean spray application head exter- Qualified
blocked. nally: mechanic
Clean nozzle:
Clean air cap:
Sprayed air pressure Decrease sprayed air pressure: Operator

too high.
n Sprayed air pressure must not
be higher than the material
pressure.
n Ä Chapter 6.3.10 “Pressure
vessel” on page 204
Spray application head: O-ring defective. Replace O-ring: Qualified

Stroke adjustment is not mechanic
sealed. Ä Chapter 9.3.16.1 “Check, replace
the stroke adjustment”
on page 482
Spray application head: O-ring in coil defective. Replace O-ring: Qualified

Coil is not sealed. mechanic
the coil” on page 495
Spray application head: Nozzle dirty. Clean nozzle: Operator

Nozzle dripping although
the application head is not Ä Chapter 9.3.16.2 “Check, replace
activated. the nozzle” on page 486
Nozzle defective Replace nozzle: Qualified

mechanic
Spring defective or Replace armature needle. Qualified

worn. mechanic
the armature needle” on page 490
Spray application head: Nozzle dirty. Clean nozzle: Operator

Nozzle sprays at an angle.

mechanic

Fault elimination
Fault table

Spray application head: Contamination from the Clean the air cap and nozzle with a Operator
Spray image not clean. air cap and nozzle. damp cloth.
Disassemble and clean if neces-
sary:
Distance between Adjust distance. Operator

application head and
product too small or
too large.
Sprayed air pressure Coordinate sprayed air pressure Operator
and material pressure and material pressure appropri-
not coordinated well. ately.
Ä Chapter 6.3.11 “Commissioning
the marking valve” on page 205
Spray application head: Loaded application pat- Check the settings on the con- Operator
Application heads work in tern does not include troller, correct if necessary.
test mode but not in produc- the application head.
tion mode.
Entered minimum Check the settings on the con- Operator
speed is too high. troller, correct if necessary.
Vmin is activated. Check whether active, switch off if Operator

necessary.
The application head is Check the settings on the con- Operator

not activated. troller, correct if necessary.
Speed display does not Check the settings on the con- Operator
change. troller, correct if necessary.
The application head Check the settings on the con- Operator

does not receive a start troller, correct if necessary.
impulse.
Check the sensor.
(optional) Sprayed air Electrical cables or Check cables and connections to Qualified
shut-off: Sprayed air is not connections to the the sprayed air shut-off for defects electrician
switched on or off by the sprayed air shut-off are or disconnections. Qualified
optional sprayed air shut-off. defective. mechanic
Repair cables and connections if
necessary.
Incorrect setting on the Change the settings on the con- Operator

controller. troller.
(optional) Sprayed air No external sprayed air Check the supply to the optional Operator
shut-off: No sprayed air supply. sprayed air shut-off. Qualified
mechanic

Fault elimination
Fault table

Restore the supply to the optional
sprayed air shut-off if necessary.
IE-65-508 Encoder: No Cable has loosened. Check, fix cable connection. Qualified
speed display. mechanic
Ä More information on: Encoder
IE-65-508
Encoder friction wheel Re-position the encoder. Qualified
is not touching the mechanic
drive shaft. Ä More information on: Encoder
IE-65-508
Encoder defective. Replace encoder. Qualified
mechanic
IE-65-508
IE-65-508 Encoder: Incorrect encoder reso- Reset encoder resolution: Operator
lution.
Ä “Calculating the encoder resolu-
tion” on page 206
IE-65-508
Alert set: Status display on Error (see Error mes- Resolve error. Operator
the alert set illuminates red. sages on the terminal). Qualified
electrician
Qualified
mechanic
Professional
pneumatic
engineers
Emergency stop trig- Rectify the cause of the emergency Operator
gered. stop. Qualified
electrician
Unlock the emergency stop sensor Qualified
or close the safety barrier. mechanic
Put the equipment back into opera- Professional
tion. pneumatic
engineers
Alert set: No signal light Connector on the con- Check connection. Qualified
illuminates. trol unit not connected. electrician
Cable to the control Replace cable. Qualified
unit defective. electrician
Bayonet socket on the Lock the diodes in correctly. Operator
diodes not locked in
correctly.
Alert set: One signal light Light bulb is defective. Replace light bulb. Operator
does not illuminate.

Fault elimination
Component-specific fault elimina... > Rectifying faults on the CPU m...
9.3 Component-specific fault elimination

9.3.1 Fault messages on the CPU module
LED status display

The voltage and operating status of the CPU module is
indicated by the LEDs.
LED Condition Meaning

(Colou
r)
voltage is applied.
(red)
voltage is applied.
(red)
Fig. 457: CPU module status display
3 + 24 V Illuminates as soon as conditions
are fulfilled.
(red) 0...20 mA
short-circuit-
proof
4 Illuminates as soon as the CPU
boots.
(green)
The CPU module contains the connectors for the machine con-
troller. The components are connected to the corresponding con-
nectors on the CPU module as described above.
9.3.2 Rectifying faults on the CPU module
LED 1, 2 or 3 does not illuminate Personnel: n Qualified electrician

1. Switch the control cabinet off.

2. Open the control cabinet.
See the "Control cabinet" section in the Operation chapter.

Fault elimination
Component-specific fault elimina... > Rectifying faults on the CPU m...
3. Check the associated fuse on the CPU. See the following

table:
LED failed Fuse

LED (red) +24V Fuse F2 (8AT)
(Fig. 458/1)
Fig. 458: LED status LED (red) +54V Fuse F1 (4AT)

(Fig. 458/2)
LED (red) +24V 0..2 mA Fuse F3 (1AT)
(Fig. 458/3)
4. Replace the defective fuse if necessary.

Use the Baumer hhs fuse set for this.
5. Release all of the external connection cables on the power

module.
6. Switch the control cabinet on.
Observe the LED as you reconnect the power

module connection cables.
Reconnect the power module connection cables one by one.

As soon as the LED goes out, proceed as follows:
n Disconnect the equipment from the power supply.
n Check the last cable you connected and the associated
components for faults and damage.
n Rectify the faults or replace the damaged components.
n Replace the fuse again.
n Begin the process again at step 5.
ð The fault is rectified as soon as all power module connec-
tion cables are connected and all of the LEDs illuminate.
LED 4 does not illuminate Personnel: n Operator

(Fig. 458/4)
Ensure that the CPU module is connected to the power supply.

1. Check whether LED 1 (Fig. 458/1) is illuminated.
ð If LED 1 is off, follow the steps in section Ä “LED 1, 2 or
3 does not illuminate” on page 451.
If LED 1 is illuminated, continue with step 2.

Fault elimination
Component-specific fault elimina... > Fault messages on the KPE9 pis...
2. Check again whether LED 4 (green) (Fig. 458/4) is illumi-

nated.
ð If LED 4 is off, the software must be reloaded.
3. Reload the software.
ð If the fault is not rectified by reloading the software,
replace the CPU module.
Further faults on the CPU module Further faults are displayed in clear text via the terminal.
9.3.3 Fault messages on the Linux terminal

The fault messages appear via the touchscreen's user interface.
The user interface is explained in its own section of the

documentation.
9.3.4 Fault messages on the KPE9 piston pump

KPE9 Display elements
1 LED 1 upper changeover point
2 LED 2 READY
3 LED 3 lower changeover point
The KPE9 piston pump features 3 LEDs. The information is
encoded differently depending on the software version:
n Software version 1.24 and later: Ä “Legend (version 1.24 and
later)” on page 454
n Software version 1.23 and earlier: Ä “Legend (version 1.23
and earlier)” on page 454
The following signals are possible:
Fig. 459: KPE9 Display elements

Fault elimination
n Software version signal on restart (version 1.24 and later):

Ä “Different signals for delivery units - version 1.24 and later”
on page 456
n Standard signal, the pump is in control mode and ready for
operation:
– version 1.24 and later:
Ä “Standard signal - pump in control mode, ready for oper-
ation” on page 455
– version 1.23 and earlier:
Ä “Standard signal - pump in control mode, ready for oper-
ation using version 1.23 or earlier” on page 457
n Different signals for delivery units (version 1.24 and later):
– version 1.24 and later:
Ä “Different signals for delivery units - version 1.24 and
later” on page 456
– version 1.23 and earlier:
Ä “Different signals for delivery units - version 1.23 or ear-
lier” on page 458
The following legend is used to explain the signals:
Legend (version 1.24 and later) GF green flashing

RF red flashing
G green constant
O orange constant
_ LED out
Legend (version 1.23 and earlier) GF green flashing

OF orange flashing
RF red flashing
RFF red flashing fast
G green constant
O orange constant
_ LED out

Fault elimination
Version signal on restart When the pump is restarted, the LEDs flash to display the software
version (version 1.24 and later).
LED display is the pump Message/Signal Cause/Troubleshooting

working?
GF no no error
GF Software version signal: e. g.:
1.24
GF
upper LED flashes 1x
middle LED flashes 2x
lower LED flashes 4x
Standard signal - pump in control

mode, ready for operation
LED is the pump Message/ Cause/Troubleshooting

signal working? Signal
G _ yes Controlled operation with target pressure value above 7 %
and air pressure set correctly (6 bar).
G G
no error.
_ G
or yes Reverse operation
G G no error (equipment without pressure regulation)
O O or
_ G incorrect settings for equipment with "PMDRE" pressure regu-
lator:
before switch-on, the following is stored in the control unit:
n Target pressure value below 7 %.
n Control unit incorrectly set to KPE9 + MDR, when it should
be KPE9 + PMDRE.

Fault elimination
Different signals for delivery units -

version 1.24 and later
LED dis- is the Message/ Cause/Troubleshooting

play pump Signal
working?
no 0 ...20 mA/X1 cable connection between control unit and pump
disconnected/defective.
or only after Pressure Set incoming air pressure is too low. Target pressure setting is
an error below target above the reachable material pressure (at this air pressure) e. g.
G _ has been value. 2 bar air pressure - 37 % target pressure setting.
RF RF acknowl-
edged
_ G
or no Pressure Solenoid valve on reversing unit - cable connection disconnected
below target or defective.
G _ value.
!!! No light signal on the solenoid valve !!!
RF RF
_ G
or no Pressure X3 cable connection/control unit disconnected/defective.
below target
G _ !!! No light signal on the control unit LEDs !!!
value.
RF RF
_ G
or no Pressure n Sound absorber on the reversing unit blocked or icy.
below target n Hose (black) to the pressure regulator bent or blocked.
G _ value. n Sensors in the reversing unit do not detect the end position.
RF RF
!!! Pump stays in the end position !!!
_ G
or yes Pressure n Adhesive container empty.
below target n Pump draws in air.
G _ ! at high value. n Suction line blocked.
fre-
RF RF quency ! n Ball in the intake manifold does not move.
_ G !!! Pressure does not increase !!!
no Pressure n X2 cable connection/pressure sensor disconnected or defec-
sensor defective.
tive. n Pressure sensor defective.

Fault elimination

play pump Signal
working?
__ no Pressure n X2 and X3 plugs are inverted.
above target n Ball seat leaking.
RF value. n Adhesive pressure too high.
__ n Sound absorber on bottom of material pressure regulator
blocked.
n If the outlet valve is activated 10x within 15 min at a stable
target value (no material withdrawal), without the inlet valve
being activated during this period.
!!! Pump goes into standby mode !!!
RF no Hose leak,
runs dry.
__
RF
_ no If the following settings are made during operation:
G Standby n Set target pressure below 7 %.
_ n Control unit set to KPE9 + MDR but should be KPE9 +
PMDRE.
!!! Pressure does not increase !!!
!!! Pump returns to normal in controlled operation when
material is withdrawn !!!
RF KFE is in filter change mode.
RF Pressure >2 bar - not ready for filter change.
RF !!! Increase pressure via valves !!!
GF KFE is in filter change mode.
GF Pressure <2 bar - ready for filter change.
GF
Standard signal - pump in control

mode, ready for operation using
version 1.23 or earlier
LED is the pump Message/ Cause/Troubleshooting

signal working? Signal
or yes Controlled operation with target pressure value above 7 %
and air pressure set correctly (6 bar).
G _
no error.
G G
_ G

Fault elimination
Different signals for delivery units -

version 1.23 or earlier

play pump Signal
working?
no 0 ...20 mA/X1 cable connection between control unit and pump
disconnected/defective.
or only after Pressure Set incoming air pressure is too low.

an error below target
G _ Target pressure setting above the reachable material pressure
has been value.
(at this air pressure).
OF OF acknowl-
edged e. g. 2 bar air pressure - 37 % target pressure setting.
_ G
or no Pressure Solenoid valve on reversing unit - cable connection disconnected
below target or defective.
G _ value.
!!! no light signal on the solenoid valve !!!
OF OF
_ G
or no Pressure X3 cable connection/control unit disconnected/defective.
below target
G _ !!! No light signal on the control unit LEDs !!!
value.
OF OF
_ G
or no Pressure n Sound absorber on the reversing unit blocked or icy.
below target n Hose (black) to the pressure regulator bent or blocked.
G _ value. n Sensors in the reversing unit do not detect the end position.
OF OF
!!! Pump stays in the end position !!!
_ G
or yes Pressure n Adhesive container empty.
below target n Pump draws in air.
G _ ! at high value. n Suction line blocked.
fre-
OF OF quency ! n Ball in the intake manifold does not move.
_ G !!! Pressure does not increase !!!
or no n Target pressure value below 7 %.
G _ n Control unit incorrectly set to KPE9 + MDR, when it should be
KPE9 + PMDRE.
O O
_ G
___ no Pressure n X2 cable connection/pressure sensor disconnected or defec-
sensor defective.
RFF tive. n Pressure sensor defective.
___

Fault elimination

play pump Signal
working?
__ no Pressure n X2 and X3 plugs are inverted.
above target n Ball seat leaking.
RF value. n Adhesive pressure too high.
__ n Sound absorber on bottom of material pressure regulator
blocked.
!!! Pump goes into standby mode !!!
RF no Hose leak,
runs dry.
RF
RF
_ no If the following settings are made during operation:
G Standby n Set target pressure below 7 %.
_ n Control unit set to KPE9 + MDR but should be KPE9 +
PMDRE.
!!! Pressure does not increase !!!
!!! Pump returns to normal in controlled operation when
material is withdrawn !!!
OF KFE is in filter change mode.
OF Pressure > 2 bar - not ready for filter change.
OF !!! Increase pressure via valves !!!
GF KFE is in filter change mode.
GF Pressure < 2 bar - ready for filter change.
GF

Fault elimination
Component-specific fault elimina... > Eliminating faults in the glue...
9.3.5 Fault messages on the fill level display

The fill level display illuminates to signal that the adhesive fill level
in the adhesive container has dropped below the minimum. The fill
level in the adhesive container is detected using a fill level sensor.

To prevent interruptions to production, fill the adhesive
container immediately when the fill level display illumi-
nates.
Fig. 460: Fill level display As soon as the adhesive container is filled above the
minimum level, the alarm light on the fill level display
goes out.
9.3.6 Fault messages on the terminal
Please see the operating manual for the terminal and

the fault messages for the machine controller!
9.3.7 Eliminating faults in the glue delivery unit

General actions to eliminate faults in the glue delivery unit:
n Depressurise the equipment
Ä “Depressurise the equipment” on page 346
Specific actions to eliminate faults in the glue delivery unit:
n Air pressure regulator
Ä Chapter 8.3.2.2 “Air pressure regulator maintenance”
on page 348
n Open high pressure filter, clean
Ä Chapter 8.3.2.3.3 “High pressure filter maintenance”
on page 364

Fault elimination
Component-specific fault elimina... > Eliminating faults in the glue...
n Disassemble/assemble the KPE9 piston pump

Ä Chapter 8.3.2.4.1.1 “Disassembling the KPE9 piston pump
and replacing parts” on page 372
and Ä Chapter 8.3.2.4.2.2 “Assembling the adhesive part”
on page 387
n disassemble/assemble the PMDRE6 material pressure regu-
lator
Ä “Disassembling the PMDRE6 material pressure regulator”
on page 350
and Ä “Assembling the PMDRE6 material pressure regulator”
on page 357
9.3.7.1 Commissioning after fault elimination

Ä Chapter 6.3.2 “Glue delivery unit” on page 164

Fault elimination
Component-specific fault elimina... > 3-way blank guide
9.3.8.1 Replace the FHDK light sensor

Protective equip- n Protective work clothing
ment: n Safety boots
n Safety goggles
Materials: n FHDK light sensor
n 4.5 m cable extension for FHDK light
sensor
DANGER!
DANGER!
CAUTION!
Fig. 461: Position of the FHDK light
sensor
The light sensor (Fig. 461/2) is located in front of the application
heads in the direction of production.

Fault elimination
Component-specific fault elimina... > 3-way blank guide
A second light sensor (Fig. 461/1) is required for

product detection when operating with an adhesive
monitoring system.
The second light sensor is used to check for “skew” or
to count products.
1. Disconnect the light sensor from the connection module on

the equipment's control cabinet.
Replace the FHDK light sensor
2. To replace the light sensor (Fig. 462/1), release the clamping
lever (Fig. 462/2) on the light sensor holder.
Remove the light sensor with the light sensor holder.
3. Place the new light sensor with light sensor holder in.
4. Close the clamping lever (Fig. 462/2) on the light sensor
holder.
5. Connect the light sensor electrically.
See wiring and circuit diagrams in the appendix!
Fig. 462: Replace light sensor
Align the FHDK light sensor 6. Align the light sensor:

Ä “Align the FHDK light sensor” on page 115
Replace the second FHDK light 7. Replace the second light sensor (Fig. 462/3) in the same way
sensor as described above.

Fault elimination
Component-specific fault elimina... > 3-way multi-application head
9.3.9.1 Cleaning hardened adhesive from the multi-application head

n Safety goggles
n Protective gloves
The multi-application head must be disassembled for cleaning and

maintenance work. To do this, proceed as follows:
1.
NOTICE!
application head!
WARNING!

3. Remove the multi-application head.

Fault elimination

head
1. Release the power supply and adhesive supply from the
2. Release the capstan screws.
3. Pull the multi-application head upwards out of the retainer
plate on the blank guide.
Fig. 463: Removing the multi-applica-

tion head
2 Power supply
3 Retainer plate
4 Capstan screws
5 Blank guide
6 Adhesive supply

Fault elimination
Rinsing the application head with

water
1. Unscrew the adhesive line from the adhesive connection
nipple.
2. Connect the adhesive connection nipple to a water connec-
tion.
Water temperature for most effective cleaning:

40 °C
3. Rinse the application head with water to remove large impuri-

ties.
Fig. 464: Adhesive connection nipple 4. Depressurise the system following the rinsing process.
Ensure that the system is depressurised.
5. Remove the water connection.
Removing the module

1. Release and remove the screws.
2. Remove the module from the main body.
3. Remove the O-ring from the borehole on the main body.
Fig. 465: Removing the module

1 Screw
2 Main body
3 O-ring
4 Module
5 Screw

Fault elimination

1.
NOTICE!
stroke regulator!


1 Threaded pin
NOTICE!
NOTICE!
Removing/cleaning the nozzle

1.
Mind the armature with pressure spring when
removing the nozzle!
The armature can fall out.
Unscrew the nozzle from the armature housing on the

module.
2. Clean the nozzle under running water.
Fig. 467: Removing/cleaning the Remove tougher impurities with a suitable cleaning agent.
nozzle
1 Armature housing Ask your adhesive supplier to recommend a suit-
2 Armature able cleaning agent for your adhesive.
3 Nozzle

Fault elimination
3.
NOTICE!
Risk of material damage if the incorrect tool
is used!
Use a soft brush to clean the outside of the nozzle tip.

4. Carefully clean the nozzle aperture from the inside with a
cleaning needle if necessary.
Do not use heavy metal objects.
5. Thoroughly clean the nozzle with pressurised air.
6. Repeat the process until all impurities are removed.
7. Use a torch to check that the cleaning process has been suc-
cessful. Check that the nozzle aperture in particular is clear.
If the nozzle shows signs of wear, replace it.
Cleaning the armature
8. Remove the armature together with the pressure spring from
the armature housing.
9. Clean the boreholes on the armature and check that they are
clear.
10. Clean all parts thoroughly with pressurised air.
Fig. 468: Cleaning the armature

1 Armature housing
2 Armature
3 Boreholes
4 Spring

Fault elimination
Removing the stroke regulator

1. Turn the stroke regulator with a flathead screwdriver to
remove it from the regulator housing on the module.
Fig. 469: Removing the stroke regu-

lator
1 Stroke regulator
2 Regulator housing
3 O-ring
Cleaning the stroke regulator

2. Clean the stroke regulator with the brush from the service
set.
3. Pay particular attention to the boreholes on the stroke regu-
lator when cleaning.
4. Check the O-ring on the stroke regulator for signs of wear.
Replace the O-ring if necessary.
Fig. 470: Cleaning the stroke regu-

lator
1 Stroke regulator
2 Boreholes
3 O-ring

Fault elimination
1. Release and remove the 4 screws.

2. Disassemble the module housing into:
n Armature housing
n Solenoid coil
n O-ring and
n Regulator housing
Fig. 471: Disassembling the module

housing
1 Regulator housing
2 O-ring
3 Solenoid coil
4 Armature housing
5 Screw
Assembling the module

1. Assemble the module housing:
n Armature housing
n Solenoid coil
n O-ring and
n Regulator housing
2. Screw on the module housing with the 4 screws.
Fig. 472: Assembling the module

housing

Fault elimination
1 Regulator housing
2 O-ring
3 Solenoid coil
4 Armature housing
5 Screw
1. Place a new O-ring into the O-ring slot on the stroke regu-
lator.
ð Grease the O-ring with a little O-ring grease.
2. Assemble the stroke regulator.
Fig. 473: Installing the stroke regu-

lator
1 Stroke regulator
2 Module
3 O-ring

3.
NOTICE!
stroke regulator!
You can destroy the armature and nozzle when
screwing in the nozzle if the stroke regulator is
not completely open.

1 Threaded pin
2 Stroke regulator 5. Check that the stroke regulator is completely open.

Fault elimination
6. Place the armature together with the pressure spring into the
armature housing.
7. Screw the nozzle into the armature housing on the module.

1 Armature housing
2 Armature with pressure spring
3 Nozzle
Installing the module

1. Place the lightly greased O-ring (92050301) into the borehole
on the main body.
2. Hold the module onto the main body and attach it with the
screws.
Fig. 476: Installing the module

1 Screw
2 Main body
3 O-ring
4 Module
5 Screw

Fault elimination
Installing the multi-application

head
1. From above, guide the multi-application head with the cap-
stan screws into the slots on the retainer plate.
2. Attach the multi-application head onto the retainer plate in
the blank guide with the capstan screws.
3. Connect the power supply and adhesive supply to the multi-
application head.
4. Configure the armature stroke on the module:
Ä Chapter 6.3.4.1.1 “Adjust the armature stroke”
on page 191
Fig. 477: Installing the multi-applica-

tion head
2 Power supply
3 Retainer plate
4 Capstan screws
5 Blank guide
6 Adhesive supply

Fault elimination
Component-specific fault elimina... > Replacing the MLT sensor
9.3.10 Replacing the MLT sensor

n Safety boots
n Safety goggles
1. Disconnect the connection cable (Fig. 478/1) from the MLT
sensor.
2.
Hold the MLT sensor with one hand when
removing the mounting screws (Fig. 478/2) to
prevent it from falling!
Release and remove the mounting screws (Fig. 478/2) with

the washers (Fig. 478/3) and remove the MLT sensor
(Fig. 478/4).
3. Clean the mounting surface for the sensor on the supporting
component.
4. Attach the new MLT sensor with the mounting screws
(Fig. 478/2) and the washers (Fig. 478/3).
5. Attach the connection cable (Fig. 478/1) to the MLT sensor.
Fig. 478: Replacing the MLT sensor 6. Check that all connections are tight and functioning correctly.

Fault elimination
Component-specific fault elimina... > Fault messages on the MLT sens...
9.3.11 Fault messages on the MLT sensor

1 LED: Extraneous light error
2 LED: Edge
3 LED: Status display
4 LED: Dust error
DANGER!
Securing the super-ordinate machine
Access to the operating space for the super-ordinate
machine is generally required to use the operating ele-
ments of the MLT sensor. There is a risk of touching
moving parts in the super-ordinate machine. This can
cause serious or fatal injuries.
– Applying preferred settings for the MLT sensor via
the terminal.
– Ensure the super-ordinate machine is securely
switched off before entering the operating space.
The operating field for the MLT sensor (Fig. 479) contains the fol-
lowing fault messages:
Fig. 479: Fault messages

Extraneous light error red LED illuminates red if the sensor is dazzled by
another light source.
(Fig. 479/1)
Edge (edge error) red LED illuminates red if the adhesive is applied too
close to the edge of the corrugated board.
(Fig. 479/2)
Status display green LED illuminates green if the measurement is cor-
rect. If there is an error, the LED goes out.
(Fig. 479/3)
Dust error red LED illuminates red if the panel on the underside
of the sensor is heavily contaminated.
(Fig. 479/4)

Fault elimination
Component-specific fault elimina... > (optional) UV lighting for MLT...

9.3.12.1 Replacing the UV lighting
n Safety boots
DANGER!
DANGER!
Disassembling the lighting 1. Remove the connection cable from the lighting system.
CAUTION!
2.
Ensure that the lighting system (3) and the
sensor (1) cannot fall when you remove the
mounting screws (4)!

washers (2).
3. Remove the lighting system.
Fig. 480: Disassembling the lighting

Fault elimination
Component-specific fault elimina... > MLT colour filter installation...
4. Loosen the mounting screws (2) on the lamp (3).

5. Separate the lamp from the mounting bracket.
ð The lighting system is disassembled.
6. Assemble a new or repaired lighting system as described in
Ä Chapter 5.2.10 “(optional) UV lighting for MLT-40”
on page 122.
Fig. 481: Disassembling the lamp

9.3.13.1 Replacing the lighting
n Safety boots
DANGER!

Fault elimination
DANGER!
Disassembling the lighting 1. Remove the connection cable from the lighting system.
CAUTION!
2.
Ensure that the lighting system (3) and the

washers (2).
3. Remove the lighting system.
Fig. 482: Disassembling the lighting
4. Loosen the mounting screws (2) on the lamp (3).

5. Separate the lamp from the mounting bracket.
ð The lighting system is disassembled.
6. Assemble a new or repaired lighting system as described in
Ä Chapter 5.2.10 “(optional) UV lighting for MLT-40”
on page 122.
Fig. 483: Disassembling the lamp

Fault elimination
9.3.13.2 Replacing the colour filter

n Safety boots
DANGER!
DANGER!
Disassembling the lighting and 1. Remove the connection cable from the lighting system.
filter
CAUTION!
2.
Ensure that the lighting (3), the filter (5) and the

washers (2).
3. Remove the lighting and the filter.
4. Assemble a new or repaired filter.
5. Assemble the lighting.
6. Connect the lighting and sensor electrically.
Fig. 484: 10259160 Disassembly

Fault elimination
Component-specific fault elimina... > Troubleshooting faults on the ...

Replace light sensor
DANGER!
1. Release the plug connection on the light sensor.

2. Secure the light sensor with one hand during removal to
ensure it does not fall.
3. Loosen the screw (Fig. 485).
4. Remove the defective light sensor.
5. Clean the installation site.
Fig. 485: Remove light sensor

(example with and without holder)
6. Hold the new light sensor onto the installation site.

7. Screw the light sensor on tightly with the screw (Fig. 486).
8. Check that the light sensor is fixed tightly in place.
9. Connect the plug connection on the light sensor.
10. Use the controller to check that the light sensor is functioning
correctly.
Fig. 486: Attach the light sensor

(example with and without holder)
9.3.15 Troubleshooting faults on the pressure vessel

Escaping pressurised air Personnel: n Qualified mechanic
n Safety boots
n Safety goggles
n Protective gloves
Depressurise the system 1.

WARNING!
nents!
Depressurise the system. To do this, follow the instructions

on Ä on page 327
2. Check the system for any residual pressure.

Fault elimination
Component-specific fault elimina... > Spray application head trouble...
3. If pressurised air is escaping (sprayed air switched off),

check that all screws are attached tightly.
4. Replace the lid seal and sealing rings if necessary.
5. Shorten the end of the product hose to create a clean con-
nection to the bulkhead fitting if necessary.
9.3.16 Spray application head trouble-shooting
NOTICE!
NOTICE!
removed!
material.
wards.
catch the material.

Fault elimination
9.3.16.1 Check, replace the stroke adjustment
NOTICE!
NOTICE!

n Safety boots
n Safety goggles
n Protective gloves
WARNING!
nents!
Depressurise the system.

To do this, follow the instructions in the “Operating the
pressure vessel” section.

Fault elimination
Opening the stroke adjustment
NOTICE!
Risk of damage to the nozzle and armature if the
stroke adjustment is configured incorrectly!
If the stroke adjustment is not completely open during
disassembly, you can destroy the armature and nozzle
when screwing in the nozzle.
Turn the stroke adjustment until it stops.
Fig. 487: Opening the stroke adjust-

ment
Release the material and air connections from the spray

application head.
Fig. 488: Releasing connections

1 Material supply
2 Atomised air supply
Removing the stroke adjustment

1. Unscrew the stroke adjustment from the application head on
the flat with an open-ended wrench.
Fig. 489: Removing the stroke adjust-

ment

Fault elimination
2. Remove the stroke adjustment.

3. Remove the O-ring.
Fig. 490: Replacing the O-ring on the

stroke adjustment
1 Stroke adjustment
2 O-ring
Installing the stroke adjustment

Ensure you do not damage the new O-ring when tight-
ening it.
Do not use a sharp-edged tool to tighten the O-ring.
Lightly grease the new O-ring with O-ring and pneu-
matic grease.
1. Tighten the new O-ring into the O-ring slot in the stroke
adjustment.
2. Place the stroke adjustment back into the application head.
Fig. 491: Tightening the O-ring

1 Stroke adjustment
2 O-ring
3. Tightly screw the stroke adjustment into the application head

on the flat with an open-ended wrench.
Fig. 492: Installing the stroke adjust-

ment

Fault elimination

head
1. Connect the material and air connections to the spray appli-
cation head.

1 Material supply
2. Plug the device plug into the coil and attach the device plug
with the screw.
Fig. 494: Plugging in the device plug

1 Device plug
2 Coil
3 Screw
Finishing work
WARNING!
Note the maximum permissible pressure for the
system!
Set the spray image:

1. Set the container pressure.
2. Set the sprayed air pressure.
3. Adjust the applied quantity via the armature stroke.
4. Optimise the spray image.

Fault elimination
9.3.16.2 Check, replace the nozzle
NOTICE!
NOTICE!

n Safety boots
n Safety goggles
n Protective gloves
WARNING!
nents!


Fault elimination
NOTICE!

ment
Releasing the electrical connection

Release the screw and remove the device plug from the coil.
Fig. 496: Unplugging the device plug

1 Device plug
2 Coil
3 Screw

application head.

1 Material supply

Fault elimination
Removing the nozzle

1. Release the union nut.
2. Remove the air cap.
Fig. 498: Union nut and air cap

1 Union nut
2 Air cap
3.
Mind the armature when removing the nozzle!
The anchor can fall out.
Unscrew the nozzle using an open-ended or socket wrench.

4. Only if necessary!
Clean the nozzle aperture from the inside with a cleaning
needle.
5. Repeat the process until all impurities have been removed.
Fig. 499: Unscrew the nozzle ð Check the result with a torch.
1 Nozzle 6. Replace damaged or worn parts.
2 Armature
Installing the nozzle

Screw the clean, undamaged or new nozzle into the arma-
ture housing.
Fig. 500: Screwing in the nozzle

1 Nozzle

Fault elimination
2 Armature
Inserting the air cap

1. Place the air cap beneath the armature housing.
2. Screw the air cap in tightly with the union nut.

1 Union nut
2 Air cap

head
cation head.

1 Material supply
with the screw.

1 Device plug
2 Coil

Fault elimination
3 Screw
Finishing work
WARNING!
system!

9.3.16.3 Check, replace the armature needle
NOTICE!
NOTICE!

n Safety boots
n Safety goggles
n Protective gloves
WARNING!
nents!


Fault elimination
NOTICE!

ment


1 Device plug
2 Coil
3 Screw

Fault elimination

application head.

1 Material supply
Removing the nozzle


1 Union nut
2 Air cap
3.

needle.
2 Armature

Fault elimination
Checking the armature needle

1. Carefully check the protruding armature needle.
ð The armature needle must be able to move gently to and
fro in the direction of the axis.
Fig. 509: Checking the armature

needle
Removing the armature

1. Remove the entire armature.
2. Clean the armature.
3. If you are unable to remove all of the impurities, use a sharp
object to open the retaining ring on the pre-tensioned spring.
ð Be aware that parts may spring out.
4. Clean all parts.
5. Replace damaged or worn parts.
Fig. 510: 2748 Removing the arma-

ture
1 Armature complete
2 Spring complete
Inserting the armature 1. Put the armature back together if you have taken it apart.
2. Place the clean, undamaged or new armature into the arma-
ture housing.
Fig. 511: Inserting the armature

1 Armature complete

Fault elimination

ture housing.

1 Nozzle
2 Armature


1 Union nut
2 Air cap

head
cation head.

1 Material supply

Fault elimination
with the screw.

1 Device plug
2 Coil
3 Screw
Finishing work
WARNING!
system!

9.3.16.4 Check, replace the coil
NOTICE!
NOTICE!

Fault elimination

n Safety boots
n Safety goggles
n Protective gloves

WARNING!
nents!



1 Device plug
2 Coil
3 Screw
Checking the coil

1. Measure the coil resistance by measure the resistance
between contacts 1 and 2.
Check the resistance value in the “Technical

data” .
Fig. 517: Coil contacts

2. If your measurement differs from the given value, replace the
coil.

Fault elimination
NOTICE!

ment

application head.

1 Material supply
Removing the nozzle


1 Union nut

Fault elimination
2 Air cap
3.

needle.
2 Armature
Removing the armature

1. Remove the entire armature.
2. Clean the armature.
3. If you are unable to remove all of the impurities, use a sharp
object to open the retaining ring on the pre-tensioned spring.
ð Be aware that parts may spring out.
4. Clean all parts.
5. Replace damaged or worn parts.
Fig. 522: 2748 Removing the arma-

ture
1 Armature complete
2 Spring complete
Removing the stroke adjustment

1. Unscrew the stroke adjustment from the application head on
the flat with an open-ended wrench.
Fig. 523: Removing the stroke adjust-

ment

Fault elimination
2. Remove the stroke adjustment.

Fig. 524: Replacing the O-ring on the

stroke adjustment
1 Stroke adjustment
2 O-ring
Removing the armature housing

1. Unscrew the armature housing with the pin type face wrench.
2. Remove the O-rings.
3. Clean the armature housing.
Fig. 525: Removing the armature

housing
1 Armature housing
2 Pin type face wrench
Removing the coil

1. Remove the coil.
3. Clean the bracket.
Fig. 526: Removing the coil

Fault elimination
Installing the coil

ening it.
matic grease.
1. Place the new O-ring into the O-ring slot on the bracket.
2. Place the coil into the bracket.
Fig. 527: 2748 Installing the coil

1 Coil
2 O-ring
Installing the armature housing

ening it.
matic grease.
1. Place the new O-rings into the O-ring slots on the armature
housing.
2. Screw the armature housing into the bracket with a pin type
face wrench.

housing
1 Armature housing
2 Pin type face wrench
3/4 O-rings

Fault elimination
Installing the stroke adjustment

ening it.
matic grease.
1. Tighten the new O-ring into the O-ring slot in the stroke
adjustment.
2. Place the stroke adjustment back into the application head.
Fig. 529: Tightening the O-ring

1 Stroke adjustment
2 O-ring
3. Tightly screw the stroke adjustment into the application head

on the flat with an open-ended wrench.
Fig. 530: Installing the stroke adjust-

ment
Inserting the armature 1. Put the armature back together if you have taken it apart.
2. Place the clean, undamaged or new armature into the arma-
ture housing.
Fig. 531: Inserting the armature

1 Armature complete

Fault elimination

ture housing.

1 Nozzle
2 Armature


1 Union nut
2 Air cap

head
cation head.

1 Material supply

Fault elimination
with the screw.

1 Device plug
2 Coil
3 Screw
Finishing work
WARNING!
system!


Fault elimination
Component-specific fault elimina... > Fault messages on the alert set
9.3.17 Fault messages on the alert set

The status display (Fig. 536/1) on the alert set signals an error by
illuminating the red light signal. The corresponding error message
is displayed in clear text on the terminal. An additional warning
signal will also be given via the horn (Fig. 536/2) if there is an error.
Fig. 536: Alert set

Disassembly and disposal
Inliner system with MLT 40 dispo...
10 Disassembly and disposal

10.1 Inliner system with MLT 40 disposal
Disposing of waste electrical and The WEEE Directive 2002/96/EC and the recast WEEE Directive
electronic devices 2012/19/EU govern the handling of waste electrical and electronic
equipment. Not all products fall under these directives, however for
environmental reasons and for simplicity, we treat all electronic
waste in accordance with them. By adhering to the directives, we
ensure that all of our electronic waste is disposed of correctly and
in an environmentally friendly manner.
In order to protect the environment and to ensure that electronic
waste is disposed of correctly, Baumer hhs accepts voluntarily and
at its discretion electronic and electrical waste devices for dis-
posal under the following conditions:
n The customer delivers the waste devices to Baumer hhs with
any shipping charges pre-paid. Baumer hhs does not accept
any costs for shipping and packaging.
n The delivery note must show that the waste device is to remain
with Baumer hhs for scrapping.
n The customer will receive no compensation for the scrap.
n The waste device is free from all liquids.
Otherwise, the Baumer hhs GmbH terms and conditions shall
apply unrestricted (extract):
Disposal of electronic waste devices
n The operator assumes the responsibility for disposing of the
goods provided once they are taken out of use, at their own
cost and in accordance with the legal regulations.
n The operator releases the supplier from the obligations and the
associated requirements of a third party in accordance with §
10 Para. 2 of the German Electrical and Electronic Equipment
Act (ElektroG) (manufacturers' obligation to accept returned
devices).
n Should the operator pass the goods to a commercial third
party, the operator must ensure by way of a contract that the
third party will dispose of the goods at their own cost and in
accordance with the legal regulations once they are taken out
of use, and that this obligation is passed on to the new owner
should the goods be passed on again.
n Should the operator fail to contractually oblige the third party to
whom he has passed the goods to assume the responsibility
for disposal and to pass on this obligation, the operator is
obliged to take the goods back at his own cost once they are
taken out of use, and to dispose of them in accordance with the
legal regulations.
n The supplier's entitlement to the assumption of/release from its
obligations by the operator does not lapse until at least two
years after the device is finally taken out of service. The two
year statute of limitations begins at the time the manufacturer
receives notification in writing from the operator that the device
has been taken out of service, at the earliest.

Disassembly and disposal
Inliner system with MLT 40 dispo...
Baumer hhs undertakes to dispose of its electronic and electrical

waste devices correctly. Send the devices to the following address
for disposal with shipping pre-paid:
Baumer hhs GmbH
Adolf-Dembach-Str. 19
47829 Krefeld Germany
Disposing of components
ENVIRONMENT!
Risk to the environment due to incorrect disposal!
Incorrect disposal can result in risks to the environ-
ment.
Dispose of the components in accordance with the rel-
evant guidelines or local requirements to minimise
ecological damage and protect the environment.

Technical data
Technical data for the components > Control cabinet
11 Technical data
11.1 Technical data for the components
11.1.1 Control cabinet
Control cabinet dimension sheet
Fig. 537: Control cabinet dimension

sheet
Control cabinet dimensions Data Value Unit

Length 450 mm
Width 210 mm
Height 450 mm
Electrical connection values Data Value Unit

Supply voltage min. 90 – V AC
max. 264
Supply voltage, nominal range 100–240 +/- V AC
10 %
Frequency 47–63 Hz
Connected load 700 VA
Fuse 6.3 AT
Protection class IP 20
Operating conditions
For use in enclosed spaces only!
Data Value Unit

Ambient temperature 10 – 40 °C

Technical data
Technical data for the components > Application head module (PME8 ...
Data Value Unit

Maximum relative humidity 70 %
Type plate The type plate is located on the control unit and contains the fol-
lowing information:
n Manufacturer
n Type
n Serial number
n CE mark
n Supply voltage
n Frequency
n Connected load
n Fuse
n Protection class
11.1.2 CPU module (CPU circuit board 50MHz)

CPU module connection values, Data Value Unit
electrical
Voltage 24 / 24 / 54 V
Current consumption, maximum 0.03 / 3.5 / 4.5 A
Power consumption, maximum 0.05 / 4.4 / 0.3 W
Fuse 1 / 8 / 4 AT
11.1.3 Application head module (PME8 Power module)

Application head module, connec- Data Value Unit
tion values, electrical
Voltage 54 V
Current consumption, maximum 4.5 A
Power consumption, maximum 0.27 W
Fuse 4 AT

Technical data
Technical data for the components > Xtend² BG15-ALU-Linux terminal...
11.1.4 Terminal interface module (front plate MFRW-X2ALUTHERM single)
Terminal interface module, connec- Data Value Unit

tion values, electrical
Voltage 24 V
11.1.5 Xtend² BG15-ALU-Linux terminal (Linux terminal)

Linux terminal dimension sheet
and dimensions
1 Antenna for optional RFID chip
Data Value Unit

Length 370 mm
Width ~ 60 mm
Height 295 mm
Weight ~ 4.5 kg
Fig. 538: Linux terminal dimension

sheet [mm]
Linux terminal connection values, Data Value Unit

electrical
Voltage 24 V
NOTICE!
Incorrect configuration of the connections on the
terminal!
Incorrectly configuring the connections on the terminal
can cause material damage.
– Only use the cable intended to connect the power
supply via the terminal interface.
– Please see the wiring and circuit diagrams in the
appendix which define the configuration of the con-
nections.

Technical data
Technical data for the components > Xtend² BG15-ALU-Linux terminal...
Linux terminal operating conditions Data Value Unit

Temperature range 5-40 °C
Relative humidity, maximum 70 %, non-
con-
densing
Linux terminal type plate

The type plate (Fig. 539) is found at the top of the rear side of the
Linux terminal and contains the following information in the order
provided:
MAC address of the internal network connection 1

MAC address of the internal network connection 1
Fig. 539: Type plate
Manufacturer produc- Baumer hhs serial number: Y-xxxxx
tion batch
Manufacturer serial number, also as a 2D matrix code
Manufacturer description

Technical data
Technical data for the components > Glue delivery unit KFE-KPE9-PM...
11.1.6 Glue delivery unit KFE-KPE9-PMDRE6
16940000
Fig. 540: Dimensions of the entire system
Components 16940000 Item number Item description

16940000 KFE-KPE9-PMDRE6 Glue delivery
unit
16012000 KPE9 Piston pump
19517600 PMDRE6 Pneumatic material pres-
sure regulator
Dimensions and weights 16940000 Data Value Unit

Weight 32 kg
Length 525 mm
Width 210 mm
Height 631 mm

Technical data
Dimension sheet 16940005
Fig. 541: Dimensions of the entire system
Components 16940005 Item number Item description

16940005 KFE-KPE9-PMDRE6 Glue delivery
unit with separate material pressure
regulator
16012000 KPE9 Piston pump
19517600 PMDRE6 Pneumatic material pres-
sure regulator
Dimensions and weights 16940005 Data Value Unit

Weight 32 kg
Length 525 mm
Width 210 mm
Height 631 mm
Connection values Electrical
Data Value Unit

Voltage 24 V

Technical data
Data Value Unit

Voltage tolerance, max. ± 10 %
Frequency 50 Hz
Frequency tolerance + 1/- 2 Hz
Power consumption, maximum 12 W
Fuse (not for Baumer hhs controllers) 630 mA
Pneumatic
Data Value Unit

Operating pressure 6 bar
Intake, max. 9.6 m³/h
Temperature 0–50 °C
Lubrication, maximum 0.01 mg/m³

Technical data
Operating values Data Value Unit

Regulated output pressure (max.)1 35 bar
Theoretical max. reachable output 54 bar
pressure at 6 bar incoming air pres-
sure
Delivery rate per double stroke 125 cm³
Max. delivery rate 2.5 l/min.
Piston pump pressure transmission 9:1
ratio
Material pressure regulator transmis- 6.1
sion ratio approx.
Adhesive viscosity with standard suc- 25000 mPa*s
tion hose length
Suction hose length (standard)2 2 m
Suction height (water) approx. 6 m
Suction height (adhesive, viscosity 3.5 m
1000 mPa*s) approx.
Max. suction hose length 5 m
Pressurised air connection (oil-free, 6–8 bar
dry)
1 Regulated output pressure

The regulated output pressure decreases due to fric-
tion loss, the properties and viscosities of the adhesive
in use, and the set material withdrawal amount.
2 Suction hose length

Suction hoses must not exceed 5 m in length. Large
suction heights and long suction lines should be
avoided, particularly when using highly viscous adhe-
sives (> 10,000 mPa´s). The maximum suction height
decreases as viscosity increases.
Fill level sensor for container Data Value Unit

(optional) technical data
Fill level sensor for container 15990025
Material 1.4571
Minimum liquid density 0.64 g/cm³
Temperature resistance -10 to 80 °C

Technical data
Technical data for the components > Fill level sensor F1-2
Data Value Unit

Contact load 10 VA; 0.5 A; Opener
250 V NC
Maximum operating pressure 10 bar
Protection class IP 54n
The electrical connection is made via a 3-pin angled

connector in accordance with DIN 43650.
Type plate
1 Type plate position
Information on the type plate:
n Manufacturer
n Type
n Year of construction
11.1.7 Fill level sensor F1-2

F1-2 Fill level sensor (optional) Data Value Unit
technical data
F1-2 Fill level sensor 15990021
Material 1.4571
Minimum liquid density 0.75 g/cm³
Temperature resistance -20 to 100 °C
Contact load 50 VA; Opener
0.5 A ; 250 V NC/
Closer
NO

Technical data
Technical data for the components > FFG-BG-3P-7,5-L/R-W 3-way blan...
Data Value Unit

60 VA; 1 A; Change-
220 V over con-
tact
The electrical connection is made via a 3-pin angled

connector in accordance with DIN 43650.
11.1.8 FFG-BG-3P-7,5-L/R-W 3-way blank guide

3-way blank guide dimension sheet
Fig. 543: Blank guide dimensions (in mm)
Connection values, pneumatic Data Value Unit

Operating pressure 1.8 bar
Temperature 0–50 °C
Lubrication, maximum 0.01 mg/m³

Technical data
Technical data for the components > Multi-application head PL5-316...
11.1.9 Multi-application head PL5-316-7.5 R/L
Multi-application head dimension

sheet
Fig. 544: Multi-application head dimensions
Multi-application head dimensions Data Value Unit

and weight
Weight 1.4 kg
Length 75 mm
Width 55 mm
Height ~115 mm

Technical data
Technical data for the components > SMLT-40 Multi-line sensor
3-way multi-application head oper- Data Value Unit

ating values
Number of application heads 3
Connection (adhesive) G3/8
Pressure (adhesive) 1.0–50.0 bar
Viscosity (adhesive) approx. 3000 mPa*s
(Brook-
field)
Application width (total) 50 mm
Spacing between adhesive lines 25 mm
Diameter of the nozzles 0.4 / mm
0.6 (standard)
Operating conditions Data Value Unit

Temperature range 0–70 °C
Relative humidity, maximum (non-con- 70 %
densing)
11.1.10 SMLT-40 Multi-line sensor

MLT sensor dimensions and
weights
Data Value Unit

Length 60 mm
Width 40 mm
Height 100 mm
Weight 0.3 kg
Fig. 545: Dimension sheet
MLT sensor connection values, Data Value Unit

electrical
Voltage 24 V (DC)
Voltage tolerance, max. ± 10 %

Technical data
Technical data for the components > UV lighting installation kit f...
MLT sensor specification Functional principle:

Contrast measurement
The internal RGB lighting illuminates the measurement area. 3
material lines and a product edge are detected from the received
signals.
Minimum detectable application:
1 mm adhesive application at a product speed of max. 100 m/min.
Data Value Unit

Read cycle 1 ms
Distance between the lower edge of 30 mm
the MLT sensor and the product sur-
face
Scanning width 50 ´1 mm
MLT sensor outputs Outputs + 24 V pnp

n Adhesive line 1
n Adhesive line 2
n Adhesive line 3
n Distance between glue flap and outer adhesive line
11.1.11 UV lighting installation kit for MLT-40 multi-line sensor
Dimensions and weights
Data Value Unit

Depth 44 mm
Width 60 mm
Height 83 mm
Weight 0.550 kg
Fig. 546: 10259120 Dimension sheet

[mm]
Supply data, electrical Data Value Unit

Voltage 24 V

Technical data
Technical data for the components > MLT colour filter installation...
Data Value Unit


Temperature range 10 - 40 °C
11.1.12 MLT colour filter installation kit Colour filter and additional lighting
Dimensions and weights
Fig. 547: MLT colour filter - dimension sheet
Data Value Unit

Depth 44 mm
Width 64 mm
Height 71.5 mm

Technical data
Technical data for the components > Inliner light sensor installat...
Supply data, electrical Data Value Unit

Voltage 24 V

Inliner light sensor installation kit:
Dimensions
Fig. 548: 27894200, all dimensions in mm

Technical data
Technical data for the components > Marking system Heavy duty vers...

FHDK light sensor: Dimensions
Fig. 549: FHDK dimensions [mm]
Technical data Data Value Unit

Type FHDK light
sensor
Scanning area (adjustable) 30 mm
Operational voltage range 10-30 V
max. switching current 100 mA
Output pnp antiva-
lent
Short-circuit-proof yes
Particular features of the light sensor:

n Background masking

Temperature range -25 - +65 °C
11.1.15 Marking system Heavy duty version

Marking system connection values, Data Value Unit
pneumatic
Pressurised air connection (oil-free, 6 bar
dry)
Quality class as per ISO 8573-1:2010 Class 5
[7:4:4]

Technical data
Technical data for the components > DB-2-S VA Pressure vessel
Marking system operating condi- Data Value Unit

tions
Relative humidity, maximum 80 %
Material viscosity up to approx. 1000 mPa*s
(Brook-
field)
Marking system components

For a complete overview of the technical data for the
marking system, please also refer to the descriptions
for the components:
– Pressure vessel
– Spray application head
as well as
– optional sprayed air shut-off if necessary
11.1.16 DB-2-S VA Pressure vessel

Pressure vessel dimension sheet
Fig. 550: Dimension sheet (all measurements in mm)

Technical data
Technical data for the components > DB-2-S VA Pressure vessel
Pressure vessel dimensions and Data Value Unit

weights
Length 220 mm
Width 170 mm
Height approx. 300 mm
Weight approx. 2 kg
Pressure vessel general data Data Value Unit

Vessel container volume 0.75 L
Vessel volume: 2 L
Vessel material Stainless
steel
Medium the medium
must not cor-
rode stain-
less steel
Pressure vessel connection values, Data Value Unit

pneumatic
Compressed air connection (oil-free, 6 bar
dry)
Working pressure range 1.0 – 2.5 bar
Vessel max. operating pressure 2.5 bar
Pressure vessel operating condi- Data Value Unit

tions
Temperature range 5 – 50 °C
densing)

Technical data
Technical data for the components > Marking valve DSR-403
Pressure vessel type plate

The type plate is located on the panel wall shown and contains the
following information:
n Manufacturer: Baumer hhs
n Type: DB-2-S cpl.
n Serial number: xxxxxx
n maximum operating pressure (PS): 2.5 bar
11.1.17 Marking valve DSR-403

Spray application head dimensions
Data Value Unit

Length 65 mm
Width 23.5 mm
Weight 0.367 kg
Fig. 552: Dimension sheet [mm]
Spray application head dimensions Data Value Unit

and weights
Length 65 mm
Width 23.5 mm

Technical data
Technical data for the components > Marking valve DSR-403
Data Value Unit

Weight 0.367 kg
Spray application head connection Data Value Unit

values, electrical
Nominal voltage +6 V
Nominal capacity 5 W
Fuse via controller *
Spray application head connection

values, pneumatic
[l/min] Air consumption in l/min
[bar] Set sprayed air pressure in bar
0.3... 1.0 SR Air cap size 0.3... 1.0 SR
1.2... 1.5 SR Air cap size 1.2... 1.5 SR
Data Value Unit

Working pressure 1.0 - 6.0 bar
Pressurised air demand, minimum 20 l/min
(approx., see also Fig. 553)
Pressurised air demand, maximum 120 l/min
(approx., see also Fig. 553)
Air quality oil-free, dry
Fig. 553: 2748xx00 Spray application

head air consumption

densing)
Spray application head material Data Value Unit

viscosity
Material viscosity up to approx. 1000 mPa*s
(Brook-
field)

Technical data
Technical data for the components > Sprayed air shut-off installat...
11.1.18 Sprayed air shut-off installation kit
(optional) Dimension sheet and

dimensions for the sprayed air
shut-off
Data Value Unit

Length ~ 45 mm
Width ~ 105 mm
Height ~ 100 mm
Fig. 554: Sprayed air shut-off dimen-

sion sheet
(optional) Sprayed air shut-off con- Data Value Unit

nection values, electrical
Voltage 24 V
Power consumption, maximum 8.5 W
(optional) Sprayed air shut-off con- Data Value Unit

nection values, pneumatic
Operating pressure 2.5 bar
Temperature 20 °C
Quality class as per ISO 8573-1 Class 5
Oil-free, dry
(optional) Sprayed air shut-off type

plate
1 Sound absorber
The type plate is located beneath the sound absorber and contains
the following information:
Manufacturer (MAC)
Model: xxxx-xxxxx
Voltage: 24 V (DC) Power consumption max. 8.5
W
Variant: xxxx maximum pressure: ~ 17 bar
Circuit diagram

Technical data
Technical data for the components > Encoder IE-65-508
11.1.19 Encoder IE-65-508

Dimension sheet
Dimensions and weights Data Value Unit

Length 84 mm
Diameter Ø 58 mm
Centring seat Ø 36 mm
Shaft diameter Ø 10 mm
Weight 270 g
Encoder IE-65-508 technical data Data Value Unit

Resolution 508 Impulse/
revolu-
tion
Operational voltage 10 - 30 VDC
Short-circuit-proof yes
Reversed polarity resistant yes
Output signals 2 square
pulse repeti-
tions, elec-
trical phase
shift 90°
Maximum revolution speed £ 12000 min-1
Permissible shaft load axial £ 40 N
Permissible shaft load radial £ 60 N
Starting torque for the shaft (at 20°C) £ 0.01 Nm

Technical data
Technical data for the components > Encoder IE-65-508
Data Value Unit

Critical frequency 120 kHz
Output load current £ 70 mA
Power consumption (without load) £ 100 mA
Output circuit Push-pull

Temperature range -20 - +70 °C
Relative humidity, maximum 90 %, non-
con-
densing
Encoder IE-65-508 type plate

The type plate is located on the encoder and contains the following
information:
Baumer hhs logo CE mark

12 digit serial number:
S: 700 000 9xx xxx
Item number: Internal designation:
96313103 hhs-508-AB
Pulses per revolution: 508 ppr Pin assignment:
minimum and max- maximum current 2-channel encoder: Power supply
imum current Channel A
Output signals 2-channel encoder: GND
Channel B
Supplier information
Baumer hhs address

Technical data
Technical data for the components > Status display + horn for Inli...
11.1.20 Status display + horn for Inliner (alert set)

Alert set dimension sheet
Status indicator operating condi- Data Value Unit

tions
Temperature range -20 – +50 °C
densing)

Replacement parts
12 Replacement parts
Wearing parts A wearing part is part of a component, or a component itself, that is
designed in such a way that it will wear in time if used correctly.
This increases the service life of the system itself substantially.
These parts must be replaced regularly. The statutory warranty
period or contractually agreed guarantee conditions are not valid
for wearing parts, unless explicitly agreed otherwise.
The following components are considered wearing parts:
n moving parts of an application head (e.g. armature)
n seals and O-rings of an application head
n nozzle and needle seat of an application head
n seals in an adhesive delivery pump
n LED bulbs
n fluorescent tubes
n cleaning brushes
n cleaning rubbers
n Sliding sealer for application heads
n filter inserts
Hook wrench (29110017)
To screw in the sealing body
Circlip pliers
Combination wrench SW 22
Drill bit (steel/concrete)
Flathead screwdriver
Hexagon socket screwdriver
Hook wrench
Hook wrench (29110017)

To open the filter housing
Open-ended wrench (for sensor)
Open-ended wrench SW 22
Power drill
The power drill is used to drill the holes for assembling the compo-
nents.
Socket head wrench (Allen wrench)

Replacement parts
soft cleaning cloth / glasses cleaning cloth

2x seals (82050006)
4.5 m cable extension for FHDK light sensor

4.5 m cable extension (77130450) for FHDK light sensor.
Adapter cable KAB42M0050 (77742605)
Adhesive
Cold glue
Assembly paste (16100015)

Assembly paste for screw connections
Bottle with spray attachment

n Bottle (16100005)
n Spray attachment (16100007)
Circlip (19916105)
Cleaning agents
Cleaning cloth
Container for catching oil
Container for rinsing liquid
Control unit (19517605)
Cut-proof protective gloves
Dowels if necessary
F3 O-ring (92053602)
For the filter cap
F4 O-ring (92052004)
For the round filter mesh
F5 Round filter mesh/filter (95510104)

Fine filter
FHDK light sensor

FHDK light sensor (96310151) with 0.5 m cable.
Guide plate extension installation kit (10259300)
Hose clip (95130920)
Hose clip (95131125)
Lubricant (16100001)
Filling medium for oil cylinder on the piston pumps

Replacement parts
MLT sensor
MLT-40 additional lighting adapter (79029360)
Mounting screws with washers
O-ring and pneumatic grease (45999914)

For temperatures < 60 °C.
O-ring/adhesive cylinder (92056301)
O-ring/ball seat (92052401)
O-ring/base valve (92064301)
O-ring/hose fitting (92051701)
O-ring/oil cylinder (92067202)
Pressure sensor type 1 (96316123)
Pressure sensor type 2 (96316124)
Retaining ring (93133201)
Reversing unit (76010500)
Rinsing liquid
Water (max. 40 °C)
For rinsing and cleaning components and equipment which have
become blocked with glue.
Screws
Seal/hose fitting (16016134)
Sealing set (92911370)

Air motor sealing set
Sleeve set/sealing pack (16012020)
Soft cloth
Soft, lint-free cloth for cleaning lenses and glass covers.
Suction hose (95103100)
UV lighting installation kit for MLT-40 (10259120)
Waste container for adhesive/cleaning agent
Waste container for condensate
Waste container or a sheet of paper

Replacement parts
Replacement parts > Linux terminal replacement par...
The following replacement parts lists may contain other compo-

nent-specific definitions of wearing parts.
12.1 Replacement parts

12.1.1 Linux terminal replacement parts list
Terminal
Dia- Item number Quan- Item description

gram/ tity
posi-
tion
Fig. 559 75010350 1 Linux terminal (Xtend²
BG15-ALU-Linux terminal)
Fig. 559: Linux terminal
Terminal holder
Dia- Item number Quan- Item description

gram/ tity
posi-
tion
Fig. 560 89600350 1 Terminal holder
Fig. 560: Terminal holder

Replacement parts
Replacement parts > Glue delivery unit
16940000
Pos Item number Quan- Item description

tity
1 16012000 1 KPE9 Piston pump
2 16910028 1 Bracket
3 19517600 1 PMDRE6 Material pressure
regulator
4 95411129 1 Air filter regulator
X2 77355030 1 4-pin cable for KPE9 660 mm
X3 77355031 1 4-pin cable for KPE9 720 mm
Connection cable (X1)
Item number Quan- Cable length

tity
Fig. 561: Glue delivery unit (KFE) 77355022 (1) 2.0 m
77355023 (1) 3.0 m
77355025 (1) 5.0 m
77355029 (1) 10.0 m

appendix!

Replacement parts
76010500
Reversing unit

tity
1 16012030 1 Application head connection
block for KPE9 complete
2 76010501 1 Electronics housing for KPE9
complete
77355022 1 Cable (X1) to connect the glue
delivery unit to the Baumer hhs
control unit
(included in item number:
76010501)
Fig. 562: KPE9 Reversing unit Extension cable for 77355022
Item number Quan- Item description

tity
77355023 Option Extension cable 3 m
Cable to connect 24 V DC for pumps with a manual material pres-

sure regulator
Ä on page 139
Connection cable (cable end open)

tity
77355055 Option Cable 5 m, cable end open.
To connect the pump to 24 V
77355059 Option Cable 10 m, cable end open.
To connect the pump to 24 V

appendix!

Replacement parts
16012030

tity
1 16012009 1 Application head connection
block
2 82020300 1 Solenoid valve
3 92010904 2 O-ring
4 16012012 2 Diaphragm for fast de-aeration
5 16012011 2 De-aeration screw
Fig. 563: Application head connection 6 95430104 2 Sound absorber
block for KPE9
7 95172703 1 Detachable double nipple
8 95210102 1 Push-in fitting
9 93020611 2 Screw M6x25
10 93020614 2 Screw M6x40
Option for delivery units without a
pneumatic material pressure
regulator
92610551 1 Sealing ring
95170801 1 Locking screw
16012000
KPE9 Piston pump complete

tity
16012000 1 KPE9 Piston pump complete
Fig. 564: KPE9 Piston pump

Replacement parts
Reversing unit

tity
81 76010500 1 KPE9 Reversing unit complete
Fig. 565: Reversing unit
Connection elements

tity
9 93010624 2 Screw DIN912 M6
68 93051002 4 */** Spring washer DIN88121
M10
69 16012028 4 Screw M10
* Air motor sealing set 92913970
** Material pump sealing set 929193971
Fig. 566: Connection elements

Replacement parts
Air motor + air piston

tity
1 16012008 1 Air motor cover
2 16012007 1 Air cylinder
3 16012035 1 Air motor base compl.
4 92112001 1 * Sealing ring
6 92019904 2 * O-ring
7 94110205 1 Bow-type handle
8 93010607 2 Screw DIN912 M6x20
10 16012015 1 Air piston rod
11 16012013 2 Washer
Fig. 567: Air motor 12 92011601 1 * O-ring
13 16012014 1 * Air piston
14 93079014 2 Nut
15 16012016 1 Slave screw
* Air motor sealing set 92913970
Fig. 568: Air piston

Replacement parts
O-ring sealing body

tity
53 92067202 1 */** O-ring
* Air motor sealing set (92913970) / ** Material pump sealing set
(929193971)
Fig. 569: O-ring sealing body
Sealing body + sealing pack

tity
48 16012027 1 Supporting ring
49 93514501 1 Spring
50 16012020 1 ** Sealing pack
A - (1) Counter ring
B - (2) Sleeve Type2
C - (1) Sleeve Type1
D - (1) Female adaptor ring
51 16012004 1 Sealing body
** Material pump sealing set (929193971)
Fig. 570: Sealing body

Replacement parts
Fig. 571: Sealing pack
Base valve and adhesive output

tity
40 16012001 1 Base valve
41 16016134 1 ** Seal
42 19912006 1 Hose fitting with O-rings
42a 92051701 2 O-ring
43 93581601 1 Ball
44 93150315 2 Cylinder pin
45 93250404 2 Threaded pin
46 92054301 1 ** O-ring
47 16012002 1 Adhesive cylinder
52 92056301 1 ** O-ring
Fig. 572: Base valve and adhesive
output 63 16012003 1 Clamping ring
64 93160402 3 Locking pin
65 16016117 1 Sealing ring
66 95182766 1 Double nipple component
67 95182751 1 Union nut

Replacement parts
Oil cylinder

tity
30 16012005 1 Oil cylinder
31 16011007 1 Oil plug
32 92061201 1 O-ring
33 16011021 1 Locking screw
34 92060802 1 O-ring
35 93010305 2 Screw DIN912 M3x16
Fig. 573: Oil cylinder
Adhesive piston

tity
54 16012025 1 Adhesive piston
55 92053401 1 ** O-ring
56 92314501 1 ** Glyd ring
Fig. 574: Adhesive piston with seals
57 92264501 1 ** Piston guide ring
Adhesive piston rod

tity
54 16012025 1 Adhesive piston
43 93581601 1 Ball
58 16012019 1 Ball seat
59 92052401 1 ** O-ring
60 93511202 1 Spring
61 16012018 1 Adhesive piston rod
62 16012017 1 Connector
Fig. 575: Adhesive piston rod

Replacement parts
Installation accessories
Item number Item description

16100001 Lubricant
16100015 ** Assembly paste 20 g
45999914 */** O-ring and pneumatic grease for
temperatures below 60 °C
* Air motor sealing set (92913970)
Sealing sets (complete)
Pos Item number Item description

* 92913970 Air motor sealing set for KPE9
** 92913971 ** KPE9 material pump sealing set
95411119
Air pressure regulator
Pos Item number Quantity Item description

95411119 1 Filter regulator 3/8
0.5‑8.5 bar 5 µm
1 95440221 1 Manometer 10 bar
2 92610553 1 Sealing ring 3/8"
3 95170204 1 Screw-in reducing
nipple 3/8–1/4
4 95210304 1 Elbow coupling plug
connection 1/4–8x6
5 92610551 1 Sealing ring 1/8
6 95020107 1 Safety valve 7 bar
95172703 1 Detachable double
nipple 3/8"
Fig. 576: Air pressure regulator

Replacement parts
19517600
PMDRE6 Material pressure regulator

tity
1 95445008 1 Manometer
92010504 1 O-ring
19517632 1 Manometer casing
92050601 1 O-ring
2 95182767 1 Double nipple component G1/2
3 Please note the model type
96316123 (1) Type 1 – pressure sensor with
electrical connection
Cube plug
77355030 (1) Cable (X2) to type 1 pressure
sensor
96316124 (1) Type 2 – pressure sensor with
electrical connection
M12x1 - Plug
77355033 (1) Cable (X2) to type 2 pressure
sensor
5 95210302 1 Rotatable elbow coupling plug
connection 1/8 – 8x6
6 95182330 1 Double threaded nipple R1/4" –
6x4
7 95011101 1 Ball valve G1/4
8 95110503 1 Elbow coupling R1/4" – 6x4
10 19517633 1 Double nipple
Fig. 577: PMDRE6 Material pressure 11 95183703 1 T-piece
regulator
12 95183303 1 Elbow piece 3/8"
13 95180510 2 Double threaded nipple G3/8
14 93571201 1 Ball
15 95171303 1 Union nut

Replacement parts
Material pressure regulator

tity
21 93010620 4 Screw DIN912 M6x65
22 92019904 1 O-ring
23 19517625 1 Air cylinder
24 19517605 1 Control unit
25 82050006 2 Seal
26 93010609 2 Screw DIN912 M6x16
27 19517626 1 Cylinder base
31 93590220 1 Socket
32 19517628 1 Piston rod
33 92011601 1 O-ring
34 19517631 1 Air piston
35 19517627 1 Washer
Fig. 578: PMDRE6 Material pressure 36 93021001 1 Screw M10x16
regulator

tity
41 19517624 1 Cylinder cover
42 93010625 4 Screw DIN912 M6x90
43 95430202 2 Sound absorber
44 19517614 1 Cylinder tube
Fig. 579: PMDRE6 Material pressure

regulator

Replacement parts

tity
51 19517616 1 Glue piston
52 93020503 1 Screw M5x8
53 92050601 1 O-ring
54 92264001 1 Piston guide ring
55 92052601 1 O-ring
56 92214001 2 Spring groove ring
61 19517617 1 Washer
62 93350301 3 Screw M3x6
63 19517618 1 Push rod
64 19517619 1 Guide socket
71 19517613 1 Spacer
Fig. 580: PMDRE6 Material pressure
regulator 72 92053301 1 O-ring
73 92054001 1 O-ring
74 92052001 1 O-ring
75 93581201 1 Ball
76 19517421 1 Pressure spring
Assembly accessories

16100015 Assembly paste 20 g
45999914 O-ring and pneumatic grease for temper-
atures below 60 °C
Sealing set

92913981 PMDRE6 Glue part sealing set

Replacement parts
PMDRE6 Filter/material pressure regulator

tity
81 95510104 1 Round filter mesh
82 93572001 1 Ball
83 92052004 1 O-ring
84 19517612 1 Filter cap
85 92053602 1 O-ring
19517611 1 Filter block

16100015 Assembly paste 20 g
Fig. 581: PMDRE6 Filter/material

pressure regulator
92913980 Filter replacement parts list
92913980
Filter replacement parts list
Pos. Item number Quantity Item description

1 95510104 1 Round filter mesh 0.2
2 92052004 2 O-ring
3 92053602 2 O-ring
16100015 1 Assembly paste, 20 g
Fig. 582: Filter replacement parts list

Replacement parts
92913970
KPE9 Air motor sealing set
Pos Item number Quantity Item description

1 93051002 4 Spring washer
DIN88121 M10
2 16012014 1 Air piston for KPE9
3 92011601 1 O-ring
5 92019904 2 O-ring
Fig. 583: KPE9 Air motor sealing set
6 92067202 1 O-ring
7 92010904 2 O-ring
8 16012012 2 KPE9 Diaphragm for
fast de-aeration
45999914 1 O-ring and pneumatic
grease for tempera-
tures below 60 °C
92913971

1 92067202 1 O-ring
2 16012020 1 Pack for KPE9 glue
part
consists of:
n A Counter ring (1x)
n B Sleeve Type2
(2x)
n C Sleeve Type1
(1x)
n D Female adaptor
ring
Fig. 584: ** KPE9 material pump 3 92056301 1 O-ring

sealing set
5 92314501 1 Glyd ring
6 92053401 1 O-ring
7 92052401 1 O-ring
8 92054301 1 O-ring
9 16016134 1 Seal

Replacement parts

10 93051002 4 Spring washer
DIN88121 M10
16100015 1 Assembly paste 20g
45999914 1 O-ring and pneumatic
grease for tempera-
tures below 60 °C
92913981

tity
1 92214001 2 Spring groove ring
2 92052601 2 O-ring
4 19517421 1 Conical pressure spring
5 92052001 1 O-ring
6 92054001 1 O-ring
7 92053301 1 O-ring
8 92050601 1 O-ring
16100015 1 Assembly paste, 20 g
45999914 1 O-ring and pneumatic grease
for temperatures below 60 °C
Fig. 585: Glue part sealing set for
PMDRE6

Replacement parts
Replacement parts > Optional accessories
12.1.3 Optional accessories

19914000
Container with suction pipe for suction hose complete

1 19914301 1 Container
2 - 1 Lid
3 - 1 Suction pipe
4 - 1 Suction hose with hose
clips
Fig. 586: Container with suction pipe

for suction hose complete
Lid

1 19914341 1 Lid
1.1 96163209 1.2 m Edge protector
2 94110202 2 Bow-type handle
2.1 93030601 4 Washer
2.2 93010610 4 Screw M6
3 19916511 1 Threaded nipple
4 93079030 1 Nut 1/2"
5 95183104 1 Elbow piece 1/2"
6 92412101 1 Sealing ring 1/2"
7 19912005 1 Hose fitting complete
Fig. 587: Lid
with O-rings
7.1 92051701 2 O-ring
8 - 1 Lid for filler plug

Replacement parts
Lid for filler plug

1 96162808 1 Hinged lid
2 94110101 1 Star grip
3 93031002 1 Washer
4 93011004 1 Screw M10
Fig. 588: Lid for filler plug
Suction pipe

1 16910036 1 Suction pipe
2 19916107 1 Filter hood
3 19916112 1 Spring seat
4 93511801 1 Spring
5 93571501 1 Ball
6 19916104 1 Ball seat
7 95511102 1 Filter mesh
8 19916105 1 Circlip
Fig. 589: Suction pipe
Suction hose with hose clips

1 95103100 2m Suction hose
2 95131125 2 Hose clip
3 95130920 1 Hose clip
Fig. 590: Suction hose with hose clips

Replacement parts
19914005
Container complete with fill level sensor

1 19914000 1 33 l complete container
2 15990021 1 F1-2 Fill level sensor
Fig. 591: Container complete with fill

level sensor
19915100
Suction pipe for container

1 16910035 1 Suction pipe for con-
tainer
2 95111995 1 Screw cap
3 1493452201 1 Retaining collar
4 95183304 1 Elbow piece 1/2"
5 92412101 1 Sealing ring 1/2"
6 19912005 1 Hose fitting 1/2" with O-
rings (pos. 17)
7 95130920 1 Hose clip
11 93511801 1 Spring
Fig. 592: Suction pipe for container 12 93571501 1 Ball
13 19912007 1 Filter mesh housing
14 19916104 1 Ball seat
16 93133201 1 Retaining ring
17 92051701 2 O-ring for hose fitting

Replacement parts

18 95131125 1 Hose clip
19 95103100 2.5 m Suction hose
19915300
Suction pipe for container complete with fill level sensor

tity
1 16910035 1 Suction pipe for container
2 19912007 1 Filter mesh housing
4 93133201 1 Retaining ring
5 93511801 1 Spring
7 93571501 1 Ball
8 19916104 1 Ball seat
9 95182313 1 Double threaded nipple
10 95183704 1 T-piece
Fig. 593: Suction pipe for container 11 92412101 2 Sealing ring
complete with fill level sensor
12 15990025 1 Fill level sensor with float
13 19912005 1 Hose fitting with O-rings
14 1493452201 1 Retaining collar
15 95111995 1 Screw cap
16 92051701 2 O-ring for hose fitting
95103100 2.5 m Suction hose
95131125 2 Hose clip
95130920 1 Hose clip
Connection cable

tity
77170150 (1) 1.5 m
77170200 (1) 2.0 m
77170300 (1) 3.0 m

Replacement parts

tity
77170319 (1) 3.5 m
77170500 (1) 5.0 m
77171000 (1) 10.0 m
77172000 (1) 20.0 m

appendix!
15990025
Fill level sensor for container

1 15990025 1 Fill level sensor con-
tainer with float com-
plete
2 7717xxxx 1 see "Connection cable"
table
Connection cable (Ä “ 15990025” on page 554)

tity
77170150 (1) 1.5 m
77170200 (1) 2.0 m
Fig. 594: Fill level sensor for container 77170300 (1) 3.0 m
77170319 (1) 3.5 m
77170500 (1) 5.0 m
77171000 (1) 10.0 m
77172000 (1) 20.0 m

appendix!

Replacement parts
77190xx0 alarm light

tity
77190050 (1) Alarm light complete with cable
0.5 m
1.0 m
2.0 m
Fig. 595: Alarm light 3.0 m
5.0 m
10.0 m
20.0 m
16940005
KFE-KPE9 with separate PMDRE6

3 19517600 1 PMDRE6 Material pres-
sure regulator
4 see order 1 High pressure hose
(KPE9 - PMDRE6)
1 Installation material
X1 see order 1 Cable from pump
reversing unit to control
unit for KPE9
Fig. 596: KFE-KPE9 with separate reversing unit to pres-
PMDRE6 sure sensor for KPE9
reversing unit to mate-
for KPE9

Replacement parts
12.1.3.1 Assembly material for glue delivery unit with separate material pressure regulator
16940005
Assembly material for KFE-KPE9 with separate PMDRE6

4 16930012 1 KPE9 Wall bracket
5 16050105 1 Bracket for PMDRE6
6 93010806 6 Screw DIN912 M8x16
7 93030801 6 Washer DIN125 M8
10 93010805 2 Screw DIN912 M8x12
11 93030801 2 Washer DIN125 M8
Fig. 597: Assembly material for KFE-
KPE9 with separate PMDRE6 12 95180513 1 Double nipple
12.1.3.2 Glue delivery unit with separate material pressure regulator

Replacement parts 16940005
KFE-KPE9 with separate PMDRE6

3 19517600 1 PMDRE6 Material pres-
sure regulator
4 see order 1 High pressure hose
(KPE9 - PMDRE6)
1 Installation material
reversing unit to control
unit for KPE9
Fig. 598: KFE-KPE9 with separate reversing unit to pres-
PMDRE6 sure sensor for KPE9
reversing unit to mate-
for KPE9

Replacement parts
Replacement parts > Fill level sensor
12.1.3.2.1 Assembly material for glue delivery unit with separate material pressure regulator
Assembly material 16940005
Assembly material for KFE-KPE9 with separate PMDRE6

4 16930012 1 KPE9 Wall bracket
5 16050105 1 Bracket for PMDRE6
6 93010806 6 Screw DIN912 M8x16
7 93030801 6 Washer DIN125 M8
10 93010805 2 Screw DIN912 M8x12
11 93030801 2 Washer DIN125 M8
Fig. 599: Assembly material for KFE-
KPE9 with separate PMDRE6 12 95180513 1 Double nipple

15990021
F1-2 Fill level sensor

tity
1 15990021 1 F1-2 Fill level sensor
2 93079030 1 Nut 1/2" for fill level sensor
3 93330112 1 Lock washer
Connection cable

tity
77170150 (1) 1.5 m
77170200 (1) 2.0 m
77170300 (1) 3.0 m
Fig. 600: F1-2 Fill level sensor
77170319 (1) 3.5 m
77170500 (1) 5.0 m

Replacement parts
Replacement parts > 3-way blank guide (FFG-BG-3P-...

tity
77171000 (1) 10.0 m
77172000 (1) 20.0 m

appendix!
12.1.5 3-way blank guide (FFG-BG-3P-7,5-R/L-W)

27893000
Fig. 601: 3-way blank guide (right)
Pos Item number Quan- Description

tity
1 27893140 1 Blank guide
Consists of: Pos. 1.1 - 1.13
1.1. 27893135 1 Guide plate with notch I
1

Replacement parts

tity
1.1. 27893136 1 Guide plate with notch II
2
1.2 27893118 1 Base plate
1.3 27893117 1 Junction box plate
1.4 27893124 1 Water bath
1.5 27893123 1 Water bath lid
1.6 27893122 1 Water bath plate
1.7 27893121 1 Multi-application head retaining
plate
1.8 27893112 1 Light sensor holder
1.10 27893115 1 Cylinder retaining plate
1.11 27893113 1 Lower part base plate
1.12 27893114 4 Junction plate
1.13 27893125 1 Proximity sensor strain relief
2 28590330 1 PL5-316-7.5-R/L multi-applica-
tion head
3 96310151 1 Light sensor
3.1 93310305 1 Screw DIN963 M3x16
4 95041102 4 Check valve with choke 1/8-6
5 94130108 1 Clamping lever M5x20
6 95090610 1 Cylinder 40/50
7 95090611 1 Cylinder 32/80
8 93381403 1 Knurled nut DIN467 M4
8.1 93020406 1 Screw DIN 7984 M4x16
12 96312906 3 Proximity sensor for cylinder
13 94111301 1 Locking bolts M10x1 with lock
nut
14 94140815 2 Phillips head screw M8x1/15
15 72890720 1 Inliner adapter box
16 96167162 3 Sleeve for cable guide 18.5 mm
17 27893140 1 Blank guide spray protection
sheet
96167162 3 Sleeve for cable guide 18.5 mm
(reserve)

Replacement parts

tity
27892510 1 Inliner pneumatic accessories
29110800 1 Service set 8 for P-500
16100005 1 Lubricant for piston pumps
(bottle)
16100007 1 Spray attachment for bottle
10259300
Item number Quan- Description

tity
10259300 1 Guide plate extension installa-
tion kit
Consists of:
n Extension sheet (2x)
n Mounting screws (6x)
Fig. 602: Guide plate extension instal-

lation kit

Replacement parts
Replacement parts > Inliner pneumatic accessories
12.1.6 Inliner pneumatic accessories

27892510
Fig. 603: Pneumatic accessories

tity
1 19919103 1 Air diffuser 3-way 1/8"
2 79199759 1 Pressure regulator valve com-
plete
3 95082010 1 3-2 way valve
4 95086011 1 5-3 way valve
5 79199772 1 Pressure regulator attachment
bracket kit
6 95210303 1 Angled screw coupling
7 95210301 4 Angled screw coupling
8 95430102 4 Sound absorber
9 77410500 3 Application head cable
10 95172701 2 Detachable double nipple 1/8"
11 95020112 1 Safety valve 2 bar G1/8
12 92610551 2 Seal ring G1/8

Replacement parts
Replacement parts > 3-way multi-application head (...

tity
13 92610552 1 Seal ring G1/4
14 95170505 1 Double threaded nipple G1/8-
G1/4
15 93010402 4 Screw DIN912 M4x8
12.1.7 3-way multi-application head (PL5-316-7,5 R/L)

28590330
Fig. 604: PL5-316-7,5 R/L Multi-application head

tity
1 28590331 1 Main body
2 28590332 1 Cover plate
2.1 93350301 4 Screw DIN7991 M3x6
3 96111306 1 6-pin built-in plug
3.1 93310208 2 Screw DIN963 M2.5x6
5 95180510 1 Double threaded nipple
6 93010305 6 Screw DIN912 M3x16

Replacement parts
Replacement parts > 3-way multi-application head (...

tity
7 72260091 1 Circuit board
8 27595206 3 PL-506-SC Module
9 93010408 6 Screw DIN912 M4x25
Connection cable

tity
77292309 (1) 9.0 m
77292350 (1) xx m (max. 15 m)
See the wiring and circuit diagrams in the

appendix in relation to the connection cables!
27595206
Pos. Item number Quantity Description

1 27005220 1 Solenoid coil
2 27005202 1 Armature housing
3 93010317 1 Screw DIN912 M3x45
4 27005209 1 Regulator housing
4.1 92051002 1 O-ring
5 27005260 1 Stroke regulator, com-
plete
5.1 92050502 (1) O-ring (already
included in 27005260)
6 27005231 1 Armature complete
Fig. 605: PL-506-SC Module
7a 85361006 1 PL-06 Nozzle
7b 85361004 (1) PL-04 Nozzle
8 92050301 1 O-ring

Replacement parts
Replacement parts > (optional) UV lighting for MLT...
12.1.8 MLT sensor

MLT sensor

tity
79020100 1 MLT sensor
(SMLT-40 Multi-line sensor)
Fig. 606: 79020100

UV lighting installation kit for
MLT-40

tity
10259120 1 The UV lighting installation kit
for MLT-40 consists of:
n Mounting bracket
(Fig. 607/1)
n UV light (Fig. 607/2)
Fig. 607: UV lighting installation kit for

MLT-40

Replacement parts
Replacement parts > MLT colour filter installation...
Cable and adapter

tity
1 77742605 1 KAB42M0050 Adapter cable
2 79029360 1 MLT-40 additional lighting
adapter

you will need to order two each of the UV lighting
installation kit for MLT-40 (Fig. 607) and cable and
adapter (Fig. 608).
Fig. 608: Cable and adapter: UV

lighting for MLT-40

10259160 MLT colour filter installation kit
consists of:
79029110 Holder with yellow MLT colour filter
79029365 MLT 40 deep blue additional lighting
Fig. 609: 79029110

Replacement parts
Replacement parts > MLT colour filter installation...
Fig. 610: 79029365
Cable and adapter

tity
1 77742605 1 KAB42M0050 Adapter cable
2 79029360 1 MLT-40 additional lighting
adapter

Systems with double-sided adhesive application
require two each of the MLT colour filter installation kit,
cables and adapters.
Fig. 611: Cable and adapter: UV

lighting for MLT-40

Replacement parts
Replacement parts > FHDK light sensor

10259205

tity
27894200 2 Inliner light sensor installation
kit
Fig. 612: Skew

27894200 Inliner light sensor installation kit
Fig. 613: 27894200
Define product type

Your exact product types can be found on the delivery
note.

Replacement parts
Replacement parts > FHDK light sensor
FHDK light sensor with holder and

assembly kits

tity
96310109 1 Complete FHDK light sensor
0.5 m
Assembly kit 96310102

tity
Fig. 614: 96310109 96310109 1 Complete FHDK light sensor

0.5 m
77130150 1 Extension cable 1.5 m

tity
0.5 m

tity
0.5 m

Replacement parts
Replacement parts > (optional) Marking system
FHDK light sensor and assembly

kits

tity
96310151 1 FHDK 10 light sensor 0.5 m

tity
96310151 1 FHDK light sensor 0.5 m
Fig. 615: 96310151

tity

tity

tity
1 12020300 1 Pressure vessel com-
plete
2 2748xx00 1 Spray application head
Ä “Spray application
head varieties”
on page 570
3 95101402 4m Material hose 6/4 nat-
ural
Fig. 616: Marking system

Replacement parts
Replacement parts > (optional) Marking system

tity
4 95101106 4m Sprayed air hose 6/4
black
5 89311019 1 Adapter
6 77235xxx 1 Connection cable
Ä “Connection cable”
on page 570
Spray application head varieties
Classification Item number Nozzle diameter

DSR-403-6V 27480300 0.3 mm
DSR-405-6V 27480500 0.5 mm
DSR-408-6V 27480800 0.8 mm
DSR-403-24V 27485300 0.3 mm
DSR-405-24V 27485500 0.5 mm
DSR-408-24V 27485800 0.8 mm
Connection cable

tity
77235200 1 2m
77235300 3m
77235500 5m
77235900 9m
Connection cable

tity
27290100 1 1m
27290200 2m
27290300 3m
27290500 5m
27291000 10 m

Replacement parts
Replacement parts > Pressure vessel
See the wiring and circuit diagrams in the

appendix in relation to the connection cables!

tity
12020300 1 DB-2-S-VA Pressure vessel
Fig. 617: 12020300

Replacement parts
Replacement parts > Marking valve

Ite Item number Quan- Item description
m tity
1 27000014 1 Bracket
2* 27000023 1 Stroke adjustment complete
3* 92050402 1 O-ring
4* 27001501 1 Armature housing
5* 85745103 1 Nozzle S Ø 0.3 mm
6* 27003703 1 Armature complete 0.3 mm
8 85792110 1 Air cap round stream Ø 0.3...
1.0 mm
9 85792001 1 Union nut
10 92011802 1 O-ring
11 92011205 1 O-ring
12 92010901 1 O-ring
13 27000052 1 Coil 6 V
14 96102111 1 Device plug
14a 77235x00 1 Connection cable Ä “Connec-
tion cable” on page 572
Fig. 618: 27480300 14b 7729xx00 1 Connection cable Ä “Connec-
tion cable” on page 573
15 95124303 1 Material connection nipple
16 92010903 1 O-ring
17 95120402 1 Sprayed air connection nipple
complete
* Wearing parts
If changing the nozzle diameter (pos. 5), you must

also replace the armature (pos. 6)!
Connection cable

tity
77235200 (1) 2.0 m
77235300 (1) 3.0 m

Replacement parts
Replacement parts > (optional) Sprayed air shut-off

tity
77235500 (1) 5.0 m
77235900 (1) 9.0 m
Connection cable

tity
77290100 (1) 1.0 m
77290200 (1) 2.0 m
77290300 (1) 3.0 m
77290500 (1) 5.0 m
77291000 (1) 10.0 m
Connection cables
See the wiring and circuit diagrams in the appendix in
relation to the connection cables!

10259291
Pos. Item number Quan- Item description

tity
Fig. 619 10259291 1 The sprayed air shut-off
installation kit consists of:
n Solenoid valve (1)
n Connection plug with
cable (10 m) (2)
n T-distributor (3)
See the wiring and circuit diagrams for the connec-

tion cables in the appendix!
Fig. 619: Sprayed air shut-off installa-

tion kit

Replacement parts
Replacement parts > IE-65-508 Encoder
12.1.18 IE-65-508 Encoder
Connection cable for encoder Item number Item name

77110300 Cable for encoder 3 m
77119500 Cable for encoder with angled jack 5 m
77120150 Encoder extension cable 1.5 m
77120300 Encoder extension cable 3 m
Define product type

Your exact product types can be found on the delivery
note.
Further replacement parts

Replacement parts for the encoder attachment kits are
covered in the appendix.

Replacement parts
Replacement parts > Status display + horn for Inli...
12.1.19 Status display + horn for Inliner (alert set)

Alert set
Pos. Item number Quan- Item description

tity
Fig. 620 10259250 1 The alert set component
group consists of:
(10254082)
n Status display red,
green, orange, blue
(Fig. 620/1)
n Horn (Fig. 620/2)
n Mounting bracket
(Fig. 620/3)
n Mounting screws
See the wiring and circuit diagrams for the connec-

tion cables in the appendix!
Fig. 620: Alert set
Light bulb

96270103 Filament bulb for status display
Fig. 621: 96270103
Diodes
Colour Item number Description

Red 96271123 Red diode for status display
Green 96271122 Green diode for status display
Yellow/ 96271121 Yellow/orange diode for status
Orange display
Blue 96271120 Blue diode for status display
Fig. 622: 9627112x

Replacement parts
Replacement parts > Status display + horn for Inli...
Further replacement parts

96216206 Horn external
27892907 Status display bracket
93040607 Lens head screw
93070601 Nut
93030601 Washer

Index
13 Index
1, 2, 3 ... Symmetrical . . . . . . . . . . . . . . . . . . . . . . . . . 285
Adhesive container
(optional) adhesive container
checking/filling . . . . . . . . . . . . . . . . . . . . . . . 165
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Adhesive container with suction pipe
(optional) fill level sensor
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Description . . . . . . . . . . . . . . . . . . . . . . . 75, 76
Adhesive filter
cleaning or replacing . . . . . . . . . . . . . . . . . . 364
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
rinsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adhesive pattern
(optional) suction pipe
monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Adhesive supply connection
3-way blank guide
3-way multi-application head . . . . . . . . . . . . 120
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Air cap . . . . . . . . . . . . . . . . . . . . 202, 203, 333, 334
clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Air motor
Component-specific safety . . . . . . . . . . . . . . . 45
assembling . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Configuring the guide plates . . . . . . . . . . . . . 182
disassembling . . . . . . . . . . . . . . . . . . . . . . . 382
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Air pressure regulator
Electrical connection . . . . . . . . . . . . . . . . . . 141
Pressure display . . . . . . . . . . . . . . . . . . . . . . . 72
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
Alarm light
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 408
Replacement parts list . . . . . . . . . . . . . . . . . 555
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Alert set
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Pneumatic connection . . . . . . . . . . . . . . . . . 152
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Replace the water bath . . . . . . . . . . . . . . . . 413
Dimension sheet . . . . . . . . . . . . . . . . . . . . . 530
Replacement parts . . . . . . . . . . . . . . . . . . . . 558
Fault messages . . . . . . . . . . . . . . . . . . . . . . 504
Set target pressure . . . . . . . . . . . . . . . . . . . . 324
Function test . . . . . . . . . . . . . . . . . . . . . . . . 435
Technical data . . . . . . . . . . . . . . . . . . . . . . . 516
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 435
3-way multi-application head
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Adhesive supply connection . . . . . . . . . . . . . 120
Replacement parts list . . . . . . . . . . . . . . . . . 575
Assembly . . . . . . . . . . . . . . . . . . . . . . . 119, 425
Replacing the light bulb . . . . . . . . . . . . . . . . 435
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Technical data . . . . . . . . . . . . . . . . . . . . . . . 530
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 420
Application head
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 418
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Operating elements . . . . . . . . . . . . . . . . . . . . 81
Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Application head cleaning
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Replacement parts . . . . . . . . . . . . . . . . . . . . 562
Application head module
Resolve errors . . . . . . . . . . . . . . . . . . . . . . . 464
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Stroke regulator . . . . . . . . . . . . . . . . . . . . . . . 81
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Technical data . . . . . . . . . . . . . . . . . . . . . . . 508
A Application head type . . . . . . . . . . . . . . . . . . . . 229
Access codes Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
assign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Automatic lock . . . . . . . . . . . . . . . . . . . . . . . 267 Application head type - Application head mode
lockable areas . . . . . . . . . . . . . . . . . . . . . . . 265 Determine switch-off compensation . . . . . . . 232
open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Determine switch-on compensation . . . . . . . 232
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Application heads
Acknowledging a fault . . . . . . . . . . . . . . . . . . . . 306 test and rinse . . . . . . . . . . . . . . . . . . . . . . . . 411
Adhesive Armature needle
Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Armature stroke
Recommendation list . . . . . . . . . . . . . . . . . . 162 Factory settings . . . . . . . . . . . . . . . . . . . . . . 188
unusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Adhesive application 3-way blank guide . . . . . . . . . . . . . . . . . . . . 114
Asymmetrical . . . . . . . . . . . . . . . . . . . . . . . . 285 3-way multi-application head . . . . . . . . 119, 425

Index
Adhesive part of the piston pump . . . . . . . . . 387 Commissioning

Air motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 385 IE-65-508 Encoder . . . . . . . . . . . . . . . . . . . . 206
Air motor with adhesive part of the piston Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . 163
pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 MLT colour filter . . . . . . . . . . . . . . . . . . . . . . 194
Alert set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . 193
Control cabinet . . . . . . . . . . . . . . . . . . . . . . . 103 Multi-application head . . . . . . . . . . . . . . . . . 187
FHDK light sensor . . . . . . . . . . . . . . . . . . . . 114 Pressure vessel . . . . . . . . . . . . . . . . . . . . . . 204
Glue delivery unit . . . . . . . . . . . . . . . . . . . . . 106 Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Glue delivery unit with separate material Skew control . . . . . . . . . . . . . . . . . . . . . . . . 194
pressure regulator . . . . . . . . . . . . . . . . . . . . 108 Sprayed air shut-off . . . . . . . . . . . . . . . . . . . 206
Guide plate extension . . . . . . . . . . . . . . . . . . 117 Compensation
Light sensor . . . . . . . . . . . . . . . . . . . . . 125, 480 determine . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . 105 Component-specific safety
Material pressure regulator . . . . . . . . . . . . . 357 3-way blank guide . . . . . . . . . . . . . . . . . . . . . 45
MLT 40 deep blue additional lighting . . . . . . 124 MLT colour filter . . . . . . . . . . . . . . . . . . . . . . . 48
MLT colour filter . . . . . . . . . . . . . . . . . . . . . . 123 Configure lighting
MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . 121 MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . 303
Pressure vessel . . . . . . . . . . . . . . . . . . . . . . 127 Configure the armature stroke
Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Spray application head . . . . . . . . . . . . . . . . . 332
Skew control . . . . . . . . . . . . . . . . . . . . . . . . 125 Connection
Spray application head . . . . . . . . . . . . . . . . . 129 Adhesive supply . . . . . . . . . . . . . . . . . . . . . . 111
Sprayed air shut-off . . . . . . . . . . . . . . . . . . . 130 MLD ENC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Suction pipe . . . . . . . . . . . . . . . . . . . . . . . . . 402 MLD LIGHT BARRIER X . . . . . . . . . . . . . . . . 61
UV lighting for MLT-40 . . . . . . . . . . . . . . . . . 122 MLD LIGHT BARRIER Y . . . . . . . . . . . . . . . . 61
Assess material application MLD OPTION 1 . . . . . . . . . . . . . . . . . . . . . . . 61
Marking valve . . . . . . . . . . . . . . . . . . . . . . . . 333 MLD OPTION 2 . . . . . . . . . . . . . . . . . . . . . . . 61
Spray application head . . . . . . . . . . . . . . . . . 202 MLD RS 232 . . . . . . . . . . . . . . . . . . . . . . . . . 61
Automatic lock . . . . . . . . . . . . . . . . . . . . . . . . . . 267 MLD SENSOR 1 . . . . . . . . . . . . . . . . . . . . . . 61
MLD SENSOR 2 . . . . . . . . . . . . . . . . . . . . . . 61
B Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . 60
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Connection cable . . . . . . . . . . . . . . . . . . . . . . . . 38
Blank guide Connection cables . . . . . . . . . . . . . . . . . . . . . . . . 32
Test and rinse the application heads . . . . . . 411 Connection lines . . . . . . . . . . . . . . 32, 38, 140, 143
Blank guide pressure regulator Connection modules
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Installation space . . . . . . . . . . . . . . . . . . . . . . 56
Bottom flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Connection values
Button Control cabinet . . . . . . . . . . . . . . . . . . . . . . . 507
Switchbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
Buttons pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . 513
Main page . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Connections
0...20 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
C Aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Device connection IN . . . . . . . . . . . . . . . . . . . 62
Calculate start value ENC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Material pressure . . . . . . . . . . . . . . . . . . . . . 244 Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
calibrate Flap 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Level in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . 218 Level out . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Changing the filter Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . . 62
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Machine control . . . . . . . . . . . . . . . . . . . . . . . 62
Cleaning Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3-way blank guide . . . . . . . . . . . . . . . . . . . . 408 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . 344 RS 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cold glue RS 485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
unusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Start 1/2/3/4 . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SUB-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Index
USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Layout diagram (KFE) . . . . . . . . . . . . . . . . . . 65

Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . . 62
Reporting hazards . . . . . . . . . . . . . . . . . . . . . . 3 Marking system . . . . . . . . . . . . . . . . . . . . . . . 89
Control Marking valve . . . . . . . . . . . . . . . . . . . . . . . . . 91
Menu navigation . . . . . . . . . . . . . . . . . . . . . 208 Material pressure regulator . . . . . . . . . . . . . . 69
Control cabinet MLD module . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 MLT colour filter installation kit . . . . . . . . . . . . 84
Dimension sheet . . . . . . . . . . . . . . . . . . . . . 507 MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Pressure vessel . . . . . . . . . . . . . . . . . . . . . . . 90
Technical data . . . . . . . . . . . . . . . . . . . . . . . 507 Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Controller Skew control . . . . . . . . . . . . . . . . . . . . . . . . . 87
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Sprayed air shut-off . . . . . . . . . . . . . . . . . . . . 93
Software version . . . . . . . . . . . . . . . . . . . . . 309 Stopp-Link front plate . . . . . . . . . . . . . . . . . . . 62
Copyright protection . . . . . . . . . . . . . . . . . . . . . . . 4 Terminal interface module . . . . . . . . . . . . . . . 60
CPU module UV lighting for MLT-40 . . . . . . . . . . . . . . . . . . 84
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Determine switch-off compensation . . . . . . . . . . 232
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 Determine switch-on compensation . . . . . . . . . . 232
Fault messages . . . . . . . . . . . . . . . . . . . . . . 451 Dimension sheet
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Alert set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
Status display . . . . . . . . . . . . . . . . . . . . . 59, 451 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . 507
Crease lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Glue delivery unit . . . . . . . . . . . . . . . . . 511, 512
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . 4 IE-65-508 Encoder . . . . . . . . . . . . . . . . . . . . 528
Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . 509
D Marking valve . . . . . . . . . . . . . . . . . . . . . . . . 525
Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . 518
Data Multi-application head . . . . . . . . . . . . . . . . . 517
open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Pressure vessel . . . . . . . . . . . . . . . . . . . . . . 523
Date Spray application head . . . . . . . . . . . . . . . . . 525
set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Sprayed air shut-off . . . . . . . . . . . . . . . . . . . 527
Declaration of conformity . . . . . . . . . . . . . . . . . . 609 Dimensions
Define adhesive lines Marking valve . . . . . . . . . . . . . . . . . . . . . . . . 525
(model data) . . . . . . . . . . . . . . . . . . . . . . . . . 279 Spray application head . . . . . . . . . . . . . . . . . 525
Definition Disassembly
Corrugated board blank . . . . . . . . . . . . . . . . . 53 3-way multi-application head . . . . . . . . . . . . 420
Corrugated cardboard . . . . . . . . . . . . . . . . . . 53 Air motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Light sensor . . . . . . . . . . . . . . . . . . . . . . . . . 480
Description Material pressure regulator . . . . . . . . . . 350, 372
(optional) adhesive container . . . . . . . . . . . . . 73 Piston pump . . . . . . . . . . . . . . . . . . . . . . . . . 372
(optional) fill level sensor . . . . . . . . . . . . . 75, 76 Pressure regulator . . . . . . . . . . . . . . . . . . . . 372
(optional) Guide plate extension . . . . . . . . . . . 78 Suction pipe . . . . . . . . . . . . . . . . . . . . . . . . . 402
(optional) suction pipe . . . . . . . . . . . . . . . . . . 74 Display
3-way blank guide . . . . . . . . . . . . . . . . . . . . . 77 calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3-way multi-application head . . . . . . . . . . . . . 80 open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Adhesive container with suction pipe . . . . . . . 73 Display/operating elements
Alert set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Application head module . . . . . . . . . . . . . . . . 60 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Blank guide pressure regulator . . . . . . . . . . . . 79 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . 56 Dot application heads
CPU module . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Dot/line changeover . . . . . . . . . . . . . . . . . . . 227
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Dot size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
FHDK light sensor . . . . . . . . . . . . . . . . . . . . . 78 adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Glue delivery unit (KFE) . . . . . . . . . . . . . . 63, 64 Dot/line changeover
High pressure filter . . . . . . . . . . . . . . . . . . . . . 70 Dot application heads . . . . . . . . . . . . . . . . . . 227
Inliner light sensor installation kit . . . . . . . . . . 88 Pressure curve . . . . . . . . . . . . . . . . . . . . . . . 238
Inliner XTS² switchbox . . . . . . . . . . . . . . . . . . 80 Dyes
Fluorescence . . . . . . . . . . . . . . . . . . . . . . . . . 85

Index
E Error
Material application . . . . . . . . . . . . . . . . . . . 243
E8 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Material line . . . . . . . . . . . . . . . . . . . . . . . . . 243
Electrical connection
Error message . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3-way blank guide . . . . . . . . . . . . . . . . . . . . 141
Error messages
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
MLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Fill level display . . . . . . . . . . . . . . . . . . . . . . 140
Example calculation
Glue delivery unit . . . . . . . . . . . . . . . . . . . . . 139
Material pressure . . . . . . . . . . . . . . . . . . . . . 244
Lighting for MLT-40 . . . . . . . . . . . . . . . 145, 147
Exchange
Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . 138
Light sensor . . . . . . . . . . . . . . . . . . . . . . . . . 480
Marking system . . . . . . . . . . . . . . . . . . . . . . 149
External interfaces . . . . . . . . . . . . . . . . . . . . . . 255
MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . 144
Multi-application head . . . . . . . . . . . . . . . . . 142
Spray application head . . . . . . . . . . . . . . . . . 149 F
Sprayed air shut-off . . . . . . . . . . . . . . . . . . . 150 Fault
Status indicator . . . . . . . . . . . . . . . . . . . . . . 151 3-way blank guide . . . . . . . . . . . . . . . . . . . . 462
Electrical current . . . . . . . . . . . . . . . . . . . . . . . . . 31 CPU module . . . . . . . . . . . . . . . . . . . . . . . . . 451
Electrical parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MLT colour filter . . . . . . . . . . . . . . . . . . . . . . 479
Encoder Fault displays . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Calculating the resolution . . . . . . . . . . . . . . . 206 Fault elimination
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Glue delivery unit . . . . . . . . . . . . . . . . . . . . . 460
Electrical connection . . . . . . . . . . . . . . . . . . 150 Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . 305
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Alert set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Encoder attachment kit 50 CPU module . . . . . . . . . . . . . . . . . . . . . . . . . 451
Replacement parts . . . . . . . . . . . . . . . . . . . . 591 Fill level display . . . . . . . . . . . . . . . . . . . . . . 460
Encoder attachment kit 51 Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . 453
Replacement parts . . . . . . . . . . . . . . . . . . . . 592 MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . 475
Encoder attachment kit 52 Piston pump . . . . . . . . . . . . . . . . . . . . . . . . . 453
Replacement parts . . . . . . . . . . . . . . . . . . . . 593 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
Encoder attachment kit 53 Feeder
Replacement parts . . . . . . . . . . . . . . . . . . . . 594 Animation . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Encoder attachment kit 54 FHDK light sensor
Replacement parts . . . . . . . . . . . . . . . . . . . . 595 alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Encoder attachment kit 60 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Replacement parts . . . . . . . . . . . . . . . . . . . . 596 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Encoder attachment kit 90 Function display . . . . . . . . . . . . . . . . . . . . . . . 88
Replacement parts . . . . . . . . . . . . . . . . . . . . 598 replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
Encoder attachment kit 91 Technical data . . . . . . . . . . . . . . . . . . . . . . . 522
Replacement parts . . . . . . . . . . . . . . . . . . . . 599 Fill level display
Encoder attachment kit 92 Electrical connection . . . . . . . . . . . . . . . . . . 140
Replacement parts . . . . . . . . . . . . . . . . . . . . 600 Fault messages . . . . . . . . . . . . . . . . . . . . . . 460
Encoder attachment kit 93 Replacement parts list . . . . . . . . . . . . . . . . . 555
Replacement parts . . . . . . . . . . . . . . . . . . . . 601 Fill level sensor
Encoder attachment kit 94 clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Replacement parts . . . . . . . . . . . . . . . . . . . . 602 electrical connection . . . . . . . . . . . . . . . . . . . 141
Encoder attachment kit 95 for container cleaning . . . . . . . . . . . . . . . . . . 403
Replacement parts . . . . . . . . . . . . . . . . . . . . 603 Filling
Encoder attachment kit 96 Pressure vessel . . . . . . . . . . . . . . . . . . . . . . 327
Replacement parts . . . . . . . . . . . . . . . . . . . . 604 Flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Encoder attachment kit 97 Flap length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Replacement parts . . . . . . . . . . . . . . . . . . . . 605 Fluorescent dyes . . . . . . . . . . . . . . . . . . . . . . . . . 85
Encoder attachment kit 99 Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
Replacement parts . . . . . . . . . . . . . . . . . . . . 607 Function test
Encoder IE-65 Alert set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
Technical data . . . . . . . . . . . . . . . . . . . . . . . 528 Status display . . . . . . . . . . . . . . . . . . . . . . . . 435
Entanglement hazard . . . . . . . . . . . . . . . . . . . . . 33 Functional description
Glue delivery unit (KFE) . . . . . . . . . . . . . . . . . 64

Index
Functionality Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MLT colour filter . . . . . . . . . . . . . . . . . . . . . . . 86 Replacement parts . . . . . . . . . . . . . . . . . . . . 567
Inliner system
G Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Inliner XTS² switchbox
Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Glue application interface . . . . . . . . . . . . . . . . . 256 Inspection area
Glue delivery unit MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . 193
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Installation
Changing the type of adhesive . . . . . . . . . . . 169 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Commissioning . . . . . . . . . . . . . . . . . . . . . . . 165 Encoder with friction wheel . . . . . . . . . . . . . . 133
Control diagram . . . . . . . . . . . . . . . . . . . . . . . 66 Encoder with toothed belt wheel . . . . . . . . . . 134
de-aerating . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Installation kit
Description . . . . . . . . . . . . . . . . . . . . . . . . 63, 64 Sprayed air shut-off . . . . . . . . . . . . . . . . . . . . 94
Dimension sheet . . . . . . . . . . . . . . . . . . 511, 512 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Display elements . . . . . . . . . . . . . . . . . . . . . . 71 Interfaces
Electrical connection . . . . . . . . . . . . . . . . . . 139 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Fault messages . . . . . . . . . . . . . . . . . . . . . . . 71 Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . . 62
filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 IO Signals
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 346 define . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Speed below v[min] . . . . . . . . . . . . . . . . . . . 250
Pneumatic connection . . . . . . . . . . . . . . . . . 151 Stop pattern . . . . . . . . . . . . . . . . . . . . . . . . . 250
Replacement parts list . . . . . . . . . . . . . . . . . 535 IP address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
rinsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Technical data . . . . . . . . . . . . . . . . . . . . . . . 511 L
Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . 515 Language
Version display . . . . . . . . . . . . . . . . . . . . . . . . 71 available . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Glue film select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
cleaning or replacing . . . . . . . . . . . . . . . . . . 364 Light barrier
rinsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Glue flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 522
Glue flap length . . . . . . . . . . . . . . . . . . . . . . . . . 274 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Guide plate extension Function display . . . . . . . . . . . . . . . . . . . . . . . 88
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Replacement parts . . . . . . . . . . . . . . . . . . . . 560 Positioning in terms of the product edge . . . 195
Technical data . . . . . . . . . . . . . . . . . . . . . . . 522
H Light sensor
High pressure filter Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Adhesive input/output . . . . . . . . . . . . . . . . . . . 70 Assembly . . . . . . . . . . . . . . . . . . . . . . . 125, 480
cleaning or replacing . . . . . . . . . . . . . . . . . . 364 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 522
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 480
rinsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
I Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Positioning in terms of the product edge . . . 195
IE-65-508 Encoder Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Commissioning . . . . . . . . . . . . . . . . . . . . . . . 206 Lighting for MLT-40
Dimension sheet . . . . . . . . . . . . . . . . . . . . . 528 Electrical connection . . . . . . . . . . . . . . 145, 147
Replacement parts . . . . . . . . . . . . . . . . . . . . 574 Maintenance . . . . . . . . . . . . . . . . . . . . . 476, 477
Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . 529 replace . . . . . . . . . . . . . . . . . . . . . . . . . 476, 477
Improper assembly . . . . . . . . . . . . . . . . . . . . . . 101 Line position . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Improper fault elimination . . . . . . . . . . . . . . . . . 437 teach-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Improper maintenance . . . . . . . . . . . . . . . . . . . 337 Line width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Inliner light sensor installation kit adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Index
Linux terminal Material connection

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Spray application head . . . . . . . . . . . . . . . . . 130
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 Material pressure
Commissioning . . . . . . . . . . . . . . . . . . . . . . . 163 Calculate start value . . . . . . . . . . . . . . . . . . . 244
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 62 configure . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Dot application . . . . . . . . . . . . . . . . . . . . . . . 239
Dimension sheet . . . . . . . . . . . . . . . . . . . . . 509 Dot/line changeover . . . . . . . . . . . . . . . . . . . 239
Electrical connection . . . . . . . . . . . . . . . . . . 138 Dot/line speed . . . . . . . . . . . . . . . . . . . . . . . 239
Fault messages . . . . . . . . . . . . . . . . . . . . . . 453 Example calculation . . . . . . . . . . . . . . . . . . . 244
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Maximum pressure . . . . . . . . . . . . . . . . . . . . 239
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 344 Maximum speed . . . . . . . . . . . . . . . . . . . . . . 239
On/off switch . . . . . . . . . . . . . . . . . . . . . . . . . 63 Minimum speed . . . . . . . . . . . . . . . . . . . . . . 239
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 Material pressure regulator
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 assembling . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Replacement parts list . . . . . . . . . . . . . . . . . 534 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Technical data . . . . . . . . . . . . . . . . . . . . . . . 509 disassembling . . . . . . . . . . . . . . . . . . . 350, 372
Terminal holder . . . . . . . . . . . . . . . . . . . 63, 105 Pressure display . . . . . . . . . . . . . . . . . . . . . . . 72
Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . 510 Replacing the control unit . . . . . . . . . . . . . . . 370
Replacing the pressure sensor . . . . . . . . . . . 369
M Menu navigation
Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . 57 open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 MLD module
3-way blank guide . . . . . . . . . . . . . . . . . . . . 408 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3-way multi-application head . . . . . . . . . . . . 418 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Alert set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435 MLD Setup
Glue delivery unit . . . . . . . . . . . . . . . . . . . . . 346 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Lighting for MLT-40 . . . . . . . . . . . . . . . 476, 477 MLT 40 deep blue additional lighting
Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . 344 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . 432 MLT colour filter
Status display . . . . . . . . . . . . . . . . . . . . . . . . 435 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Marking Commissioning . . . . . . . . . . . . . . . . . . . . . . . 194
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Component-specific safety . . . . . . . . . . . . . . . 48
Marking system Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Electrical connection . . . . . . . . . . . . . . . . . . 149 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Pneumatic connection . . . . . . . . . . . . . . . . . 154 MLT colour filter installation kit
Replacement parts . . . . . . . . . . . . . . . . . . . . 569 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Sprayed air shut-off . . . . . . . . . . . . . . . . . . . . 90 Fluorescent dyes . . . . . . . . . . . . . . . . . . . . . . 85
Technical data . . . . . . . . . . . . . . . . . . . . . . . 522 MLT 40 deep blue additional lighting . . . . . . . 85
Marking valve . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Optimal fluorescence . . . . . . . . . . . . . . . . . . . 84
Assess material application . . . . . . . . . . . . . 333 Replacement parts . . . . . . . . . . . . . . . . . . . . 565
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Technical data . . . . . . . . . . . . . . . . . . . . . . . 520
Dimension sheet . . . . . . . . . . . . . . . . . . . . . 525 MLT display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 MLT parameters . . . . . . . . . . . . . . . . . . . . . . . . 261
Replacement parts . . . . . . . . . . . . . . . . . . . . 572 open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Technical data . . . . . . . . . . . . . . . . . . . . . . . 525 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Masking out the fault message . . . . . . . . . . . . . 306 adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Material application Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Assessment advice . . . . . . . . . . . . . . . 202, 334 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Material application assessment information clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
202, 334 Commissioning . . . . . . . . . . . . . . . . . . . . . . . 193
configure . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Configure lighting . . . . . . . . . . . . . . . . . . . . . 303

Index
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Nozzle
Dimension sheet . . . . . . . . . . . . . . . . . . . . . 518 replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Display/operating elements . . . . . . . . . . . . . . 83
Electrical connection . . . . . . . . . . . . . . . . . . 144 O
Fault messages . . . . . . . . . . . . . . . . . . . . . . 475 Offset
Inspection area . . . . . . . . . . . . . . . . . . . . . . . 193 enter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 432 FHDK-10 light sensor . . . . . . . . . . . . . . . . . . 194
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 MLT light barrier . . . . . . . . . . . . . . . . . . . . . . 259
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 MLT marking system . . . . . . . . . . . . . . . . . . 259
replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474 Multi-application head . . . . . . . . . . . . . 226, 231
Replacement parts . . . . . . . . . . . . . . . . . . . . 564 On/off switch
Technical data . . . . . . . . . . . . . . . . . . . . . . . 518 Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . . 63
MLT Setup Operating conditions
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . 507
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 UV lighting for MLT-40 . . . . . . . . . . . . . . . . . 520
Model Operating elements
copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 3-way multi-application head . . . . . . . . . . . . . 81
create . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 Pressure vessel . . . . . . . . . . . . . . . . . . . . . . . 91
delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 Operating statuses
load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 Alert set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
load from USB stick . . . . . . . . . . . . . . . . . . . 294 Operating values . . . . . . . . . . . . . . . . . . . . . . . . 514
Template . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 Operation
Model data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 3-way blank guide . . . . . . . . . . . . . . . . . . . . 324
Adjust the adhesive pattern . . . . . . . . . . . . . 285 3-way multi-application head . . . . . . . . . . . . 325
Multiple blanks . . . . . . . . . . . . . . . . . . . . . . . 283 Inliner system . . . . . . . . . . . . . . . . . . . . . . . . 269
split flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . 322
Symmetrical adhesive application . . . . . . . . 285 MLD Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 MLT parameters . . . . . . . . . . . . . . . . . . . . . . 259
Model list MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . 326
open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 MLT Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 Model data . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Module Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Armature stroke . . . . . . . . . . . . . . . . . . . . . . 191 Pressure vessel . . . . . . . . . . . . . . . . . . . . . . 327
Basic setting . . . . . . . . . . . . . . . . . . . . . . . . . 191 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Stroke regulator . . . . . . . . . . . . . . . . . . . . . . 191 Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Moving components . . . . . . . . . . . . . . . . . . . 32, 46 Optional sprayed air shut-off 22, 93, 130, 150,
Multi-application head 157, 206, 527
Armature stroke . . . . . . . . . . . . . . . . . . . . . . 188 Other applicable documents . . . . . . . . . . . . . . . . . 4
Check the armature needle . . . . . . . . . . . . . 429 Output
Commissioning . . . . . . . . . . . . . . . . . . . . . . . 187 export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Dimension sheet . . . . . . . . . . . . . . . . . . . . . 517 save to USB stick . . . . . . . . . . . . . . . . . . . . . 319
Electrical connection . . . . . . . . . . . . . . . . . . 142 Overview
Factory settings . . . . . . . . . . . . . . . . . . . . . . 188 (optional) Guide plate extension . . . . . . . . . . . 18
Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 3-way blank guide . . . . . . . . . . . . . . . . . . . . . 17
Replace the nozzle . . . . . . . . . . . . . . . . . . . . 430 3-way multi-application head . . . . . . . . . . . . . 18
Stroke regulator . . . . . . . . . . . . . . . . . . . . . . 188 Alert set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Technical data . . . . . . . . . . . . . . . . . . . . . . . 517 Application head module . . . . . . . . . . . . . . . . 14
test and rinse . . . . . . . . . . . . . . . . . . . . . . . . 411 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . 13
Multiple blanks . . . . . . . . . . . . . . . . . . . . . . . . . 283 CPU module . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Multiple boxes . . . . . . . . . . . . . . . . . . . . . . . . . . 283 Fill level sensor . . . . . . . . . . . . . . . . . . . . . . . 17
Glue delivery unit . . . . . . . . . . . . . . . . . . . . . . 16
N Inliner light sensor installation kit . . . . . . . . . . 21
Note Light sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Main page . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . . 15
Marking system . . . . . . . . . . . . . . . . . . . . . . . 21

Index
Marking valve . . . . . . . . . . . . . . . . . . . . . . . . . 22 open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

MLD module . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
MLT colour filter . . . . . . . . . . . . . . . . . . . . . . . 20 Service standard . . . . . . . . . . . . . . . . . . . . . 237
MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
MLT Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 258 User defined . . . . . . . . . . . . . . . . . . . . . . . . . 237
Pressure regulator . . . . . . . . . . . . . . . . . . . . . 70 User standard . . . . . . . . . . . . . . . . . . . . . . . 237
Pressure vessel . . . . . . . . . . . . . . . . . . . . . . . 22 Pressure regulator
Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check pressure setting . . . . . . . . . . . . . 348, 416
Skew control . . . . . . . . . . . . . . . . . . . . . . . . . 20 Correct target pressure . . . . . . . . . . . . . 348, 416
Sprayed air shut-off . . . . . . . . . . . . . . . . . . . . 22 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Stopp-Link front plate . . . . . . . . . . . . . . . . . . . 15 disassembling . . . . . . . . . . . . . . . . . . . . . . . 372
Terminal interface module . . . . . . . . . . . . . . . 14 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
UV lighting for MLT-40 . . . . . . . . . . . . . . . . . . 19 Releasing condensate . . . . . . . . . . . . . . . . . 349
Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Setting pressure . . . . . . . . . . . . . . . . . . . . . . 322
Owner duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Pressure vessel
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
P close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
Packaging Commissioning . . . . . . . . . . . . . . . . . . . . . . . 204
disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Dimension sheet . . . . . . . . . . . . . . . . . . . . . 523
Personal protective equipment . . . . . . . . . . . . . . 42 filling . . . . . . . . . . . . . . . . . . . . . . . . . . . 327, 328
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 open . . . . . . . . . . . . . . . . . . . . . . . . . . . 328, 433
Piston pump Operating elements . . . . . . . . . . . . . . . . . . . . 91
Air consumption diagram . . . . . . . . . . . . . . . . 68 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
assembling . . . . . . . . . . . . . . . . . . . . . . . . . . 394 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assembling the adhesive part . . . . . . . . . . . 387 Regulating pressure . . . . . . . . . . . . . . . . . . . 330
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Release pressure . . . . . . . . . . . . . . . . . . . . . 327
disassembling . . . . . . . . . . . . . . . . . . . . . . . 372 Replacement parts . . . . . . . . . . . . . . . . . . . . 571
Fault messages . . . . . . . . . . . . . . . . . . . . . . 453 Technical data . . . . . . . . . . . . . . . . . . . . . . . 523
Filling lubricant . . . . . . . . . . . . . . . . . . . . . . . 164 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Releasing lubricant . . . . . . . . . . . . . . . . . . . . 372 Pressurised air
Replacing the reversing unit . . . . . . . . . . . . . 398 Requirements . . . . . . . . . . . . . . . . . . . . . . . . 513
rinsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Pressurised components . . . . . . . . . . . . . . . . . . . 34
PL-506-SC Module Pressurised materials . . . . . . . . . . . . . . . . . . . . . 34
Replacement parts . . . . . . . . . . . . . . . . . . . . 563 Product monitoring
Pneumatic configure . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Requirements . . . . . . . . . . . . . . . . . . . . . . . . 513 Production protocol
Pneumatic accessories save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Replacement parts . . . . . . . . . . . . . . . . . . . . 561 Protective equipment . . . . . . . . . . . . . . . . . . . . . 42
Pneumatic connection Proximity sensor
3-way blank guide . . . . . . . . . . . . . . . . . . . . 152 configure . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Marking system . . . . . . . . . . . . . . . . . . . . . . 154 Q
Spray application head . . . . . . . . . . . . . . . . . 156 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Sprayed air shut-off . . . . . . . . . . . . . . . . . . . 157
Pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 R
Position Reasonably foreseeable misuse . . . . . . . . . . . . . 28
Water bath . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Recommendation list
Power module . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Pressure curve Regulating pressure
Dot application . . . . . . . . . . . . . . . . . . . . . . . 239 Pressure vessel . . . . . . . . . . . . . . . . . . . . . . 330
Dot/line changeover . . . . . . . . . . . . . . . 238, 239 Replace
Dot/line speed . . . . . . . . . . . . . . . . . . . . . . . 239 Light sensor . . . . . . . . . . . . . . . . . . . . . . . . . 480
Maximum pressure . . . . . . . . . . . . . . . . . . . . 239 Replacement parts . . . . . . . . . . . . . . . . . . . . . 3, 42
Maximum speed . . . . . . . . . . . . . . . . . . . . . . 239 3-way blank guide . . . . . . . . . . . . . . . . . . . . 558
Minimum speed . . . . . . . . . . . . . . . . . . . . . . 239 3-way multi-application head . . . . . . . . . . . . 562

Index
Acquisition . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Sensor height . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Encoder attachment kit 50 . . . . . . . . . . . . . . 591 enter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Encoder attachment kit 51 . . . . . . . . . . . . . . 592 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Encoder attachment kit 52 . . . . . . . . . . . . . . 593 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Encoder attachment kit 53 . . . . . . . . . . . . . . 594 set
Encoder attachment kit 54 . . . . . . . . . . . . . . 595 Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Encoder attachment kit 60 . . . . . . . . . . . . . . 596 Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Encoder attachment kit 90 . . . . . . . . . . . . . . 598 Setting material pressure
Encoder attachment kit 91 . . . . . . . . . . . . . . 599 Spray application head . . . . . . . . . . . . . . . . . 201
Encoder attachment kit 92 . . . . . . . . . . . . . . 600 Setting sprayed air pressure
Encoder attachment kit 93 . . . . . . . . . . . . . . 601 Spray application head . . . . . . . . . . . . . . . . . 201
Encoder attachment kit 94 . . . . . . . . . . . . . . 602 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Encoder attachment kit 95 . . . . . . . . . . . . . . 603 Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Encoder attachment kit 96 . . . . . . . . . . . . . . 604 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Encoder attachment kit 97 . . . . . . . . . . . . . . 605 Commissioning . . . . . . . . . . . . . . . . . . . . . . . 194
Encoder attachment kit 99 . . . . . . . . . . . . . . 607 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Guide plate extension . . . . . . . . . . . . . . . . . . 560 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
IE-65-508 Encoder . . . . . . . . . . . . . . . . . . . . 574 Replacement parts . . . . . . . . . . . . . . . . . . . . 567
Inliner light sensor installation kit . . . . . . . . . 567 Technical data . . . . . . . . . . . . . . . . . . . . . . . 521
Invalidation of the guarantee . . . . . . . . . . . . . 43 Skew control
Invalidation of the warranty . . . . . . . . . . . . . . 43 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Marking system . . . . . . . . . . . . . . . . . . . . . . 569 Commissioning . . . . . . . . . . . . . . . . . . . . . . . 194
Marking valve . . . . . . . . . . . . . . . . . . . . . . . . 572 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
MLT colour filter installation kit . . . . . . . . . . . 565 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . 564 Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
PL-506-SC Module . . . . . . . . . . . . . . . . . . . . 563 Slot depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pneumatic accessories . . . . . . . . . . . . . . . . 561 Slot width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pressure vessel . . . . . . . . . . . . . . . . . . . . . . 571 Split glue flap . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567 Spray application head
UV lighting for MLT-40 . . . . . . . . . . . . . . . . . 564 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Replacement parts list Assess material application . . . . . . . . . . . . . 202
Alarm light . . . . . . . . . . . . . . . . . . . . . . . . . . 555 before production begins . . . . . . . . . . . . . . . 331
Alert set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575 Configure the armature stroke . . . . . . . . . . . 332
Fill level display . . . . . . . . . . . . . . . . . . . . . . 555 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Glue delivery unit . . . . . . . . . . . . . . . . . . . . . 535 Dimension sheet . . . . . . . . . . . . . . . . . . . . . 525
Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . 534 Electrical connection . . . . . . . . . . . . . . . . . . 149
Sprayed air shut-off . . . . . . . . . . . . . . . . . . . 573 Material connection . . . . . . . . . . . . . . . . . . . 130
Replacing the control unit . . . . . . . . . . . . . . . . . 370 Pneumatic connection . . . . . . . . . . . . . . . . . 156
Replacing the pressure sensor . . . . . . . . . . . . . 369 Setting material pressure . . . . . . . . . . . . . . . 201
Replacing the reversing unit . . . . . . . . . . . . . . . 398 Setting sprayed air pressure . . . . . . . . . 200, 201
Reporting hazards . . . . . . . . . . . . . . . . . . . . . . . . . 4 Stroke adjustment . . . . . . . . . . . . . . . . . . . . 332
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Technical data . . . . . . . . . . . . . . . . . . . . . . . 525
Resolution Spray application head stroke adjustment
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 configure . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Resolve errors Spray application head stroke regulator
6-way multi-application head . . . . . . . . . . . . 464 Stroke adjustment . . . . . . . . . . . . . . . . . . . . . 93
RFID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Spray application head trouble-shooting
Risk of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Check, replace the stroke adjustment . . . . . 482
Checking the armature needle . . . . . . . . . . . 493
S Checking the coil . . . . . . . . . . . . . . . . . . . . . 496
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Connecting the spray application head 485,
Safety marking . . . . . . . . . . . . . . . . . . . . . . . . . . 29 489, 494, 502
Screen Depressurise the equipment . 482, 486, 490, 496
Title line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Finishing work . . . . . . . . . . . . 485, 490, 495, 503
select Inserting the air cap . . . . . . . . . . . 489, 494, 502
Language . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Inserting the armature . . . . . . . . . . . . . 493, 501
Installing the armature housing . . . . . . . . . . 500

Index
Installing the coil . . . . . . . . . . . . . . . . . . . . . . 500 Suction pipe

Installing the nozzle . . . . . . . . . . . 488, 494, 502 assembling . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Installing the stroke adjustment . . . . . . 484, 501 Clean filter mesh . . . . . . . . . . . . . . . . . . . . . 402
Opening the stroke adjustment 483, 487, disassembling . . . . . . . . . . . . . . . . . . . . . . . 402
491, 497 Suction pipe for container
Releasing connections . . . . . 483, 487, 492, 497 clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Releasing the electrical connection 487, Suction pipe for container with fill level sensor
491, 496 clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Removing the armature . . . . . . . . . . . . 493, 498 Surroundings
Removing the armature housing . . . . . . . . . 499 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Removing the coil . . . . . . . . . . . . . . . . . . . . . 499 Switchbox
Removing the nozzle . . . . . . . . . . 488, 492, 497 Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Removing the stroke adjustment . . . . . 483, 498 Symbols
Removing the stroke regulator . . . . . . . 483, 498 in the manual . . . . . . . . . . . . . . . . . . . . . . . . . 25
Sprayed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Main page . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Sprayed air pressure . . . . . . . . . . . . . . . . . 203, 334 System settings
configure . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 configure . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Sprayed air shut-off . . . . . . . . . . . . . . . . . . . . . . . 90
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 T
Commissioning . . . . . . . . . . . . . . . . . . . . . . . 206 Target pressure
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Dimension sheet . . . . . . . . . . . . . . . . . . . . . 527 Technical data
electrical connection . . . . . . . . . . . . . . . . . . . 150 3-way blank guide . . . . . . . . . . . . . . . . . . . . 516
Installation kit . . . . . . . . . . . . . . . . . . . . . 94, 573 Alert set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Application head module . . . . . . . . . . . . . . . 508
Pneumatic connection . . . . . . . . . . . . . . . . . 157 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . 507
Replacement parts list . . . . . . . . . . . . . . . . . 573 Encoder IE-65 . . . . . . . . . . . . . . . . . . . . . . . 528
Technical data . . . . . . . . . . . . . . . . . . . . . . . 527 Glue delivery unit . . . . . . . . . . . . . . . . . . . . . 511
Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . 527 Light barrier . . . . . . . . . . . . . . . . . . . . . . . . . 522
Start sensor Light sensor . . . . . . . . . . . . . . . . . . . . . . . . . 522
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . 509
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Marking system . . . . . . . . . . . . . . . . . . . . . . 522
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Marking valve . . . . . . . . . . . . . . . . . . . . . . . . 525
Function display . . . . . . . . . . . . . . . . . . . . . . . 88 MLT colour filter installation kit . . . . . . . . . . . 520
Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 MLT sensor . . . . . . . . . . . . . . . . . . . . . . . . . 518
Positioning in terms of the product edge . . . 195 Multi-application head . . . . . . . . . . . . . . . . . 517
Statistics Pressure vessel . . . . . . . . . . . . . . . . . . . . . . 523
delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Spray application head . . . . . . . . . . . . . . . . . 525
resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Sprayed air shut-off . . . . . . . . . . . . . . . . . . . 527
save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Terminal interface module . . . . . . . . . . . . . . 509
Status display UV lighting for MLT-40 . . . . . . . . . . . . . . . . . 519
Alert set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Terminal
Function test . . . . . . . . . . . . . . . . . . . . . . . . 435 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 435 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Replacing the light bulb . . . . . . . . . . . . . . . . 435 Terminal holder
Status indicator Linux terminal . . . . . . . . . . . . . . . . . . . . . 63, 105
Electrical connection . . . . . . . . . . . . . . . . . . 151 Terminal interface
Stopp-Link front plate Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Terminal interface module
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Technical data . . . . . . . . . . . . . . . . . . . . . . . 509
Stroke adjustment Test - Diagnosis
Spray application head stroke regulator . . . . . 93 Changing the filter . . . . . . . . . . . . . . . . . . . . 312
Suction hose Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Index
Time Automatic lock . . . . . . . . . . . . . . . . . . . . . . . 267

set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Defining access codes . . . . . . . . . . . . . . . . . 267
Title line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 lockable areas . . . . . . . . . . . . . . . . . . . . . . . 265
Top flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Transponder . . . . . . . . . . . . . . . . . . . . . . . . . 278
Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 UV lighting for MLT-40
calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Replacement parts . . . . . . . . . . . . . . . . . . . . 564
Transponder . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Technical data . . . . . . . . . . . . . . . . . . . . . . . 519
Transport devices . . . . . . . . . . . . . . . . . . . . . . . . 33
Transport inspection . . . . . . . . . . . . . . . . . . . . . . 97 V
Trip hazards . . . . . . . . . . . . . . . . . . . . . . . 140, 143 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
Trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Type plate W
IE-65-508 Encoder . . . . . . . . . . . . . . . . . . . . 529 Water bath
Linux terminal . . . . . . . . . . . . . . . . . . . . . . . . 510 fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Pressure vessel . . . . . . . . . . . . . . . . . . . . . . 525 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Sprayed air shut-off . . . . . . . . . . . . . . . . . . . 527 replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Set position . . . . . . . . . . . . . . . . . . . . . . . . . 185
Wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . 531
U Work areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
User level 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
User levels
adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Index

Appendix
Appendix

IE-65-508 Encoder
A IE-65-508 Encoder
Name Data
Designation Encoder
Type IE-65-508
Number 96313103
Type of manual
Manufacturer

IE-65-508 Encoder
A.A Encoder attachment kit 50 replacement parts

96313150
Ite Item number Quan- Description

m tity
1 96313103 1 IE-65-508 Encoder
2 96313003 1 Friction wheel R-200
3 77110500 1 Encoder cable 5 m
93250405 2 Set screw DIN913 M4x8
Fig. 624: Replacement parts

IE-65-508 Encoder
A.B Encoder attachment kit 51 replacement parts

96313151
Ite Item number Quan- B

m tity
1 96313103 1 IE-65-508 Encoder
2.1 77121000 2 Encoder extension 10 m
3 96313953 1 Toothed belt wheel n=72 (bore-
hole = 30 mm)
3.1 93123001 1 Retaining ring DIN471 30x1.5
hole = 10 mm)
5 96313986 1 Toothed belt 190XL 95 teeth
482.6 long
6 94156312 4 Spacer bolts M8 73 mm long
7 96313041 1 Encoder retaining plate
8 93350403 3 Screw DIN7991 M4x12
9 93250807 4 Set screw DIN913 M8x25
10 93030801 4 Washer DIN125 M8
11 93010806 4 Screw DIN912 M8x16

IE-65-508 Encoder
A.C Encoder attachment kit 52 replacement parts

96313152
Ite Item number Quan- Item name

m tity
1 96313103 1 IE-65-508 Encoder
1.1 93350403 3 Screw DIN7991 M4x12
2 77119500 1 Encoder cable with angled jack
5m
hole = 40 mm)
hole = 10 mm)
5 96313986 1 Toothed belt 190XL 95 teeth
482.6 long
6 96313020 1 Holder H-400-A
7 96313042 1 Encoder attachment bracket
8.1 93010803 2 Screw DIN912 M8x25
8.2 93030802 2 Washer DIN9021 M8
8.3 93030801 2 Washer DIN125 M8
8.4 93050801 2 Spring washer DIN127 M8
8.5 93070801 2 Nut DIN834 M8
9.1 93010806 2 Screw DIN912 M8x16
9.2 93030801 2 Washer DIN125 M8

IE-65-508 Encoder
A.D Encoder attachment kit 53 replacement parts

96313153

m tity
1 96313103 1 IE-65-508 Encoder
1.1 93350403 3 Screw DIN7991 M4x12
1.2 77119500 1 Encoder cable with angled jack
5m
Fig. 630: Replacement parts 2 96313987 1 Toothed belt 270XL/037 135
teeth 685.8 long
hole = 10 mm)
4 96313020 1 Holder H-400-A
5.1 93010807 2 Screw DIN912 M8x20
5.2 93030802 2 Washer DIN9021 M8
5.3 93050801 2 Spring washer DIN127 M8

IE-65-508 Encoder
A.E Encoder attachment kit 54 replacement parts

96313154
Ite Item number Quan- Item name

m tity
1 96313103 1 IE-65-508 Encoder
2 96313046 1 Encoder shaft coupling TCY
Inliner
3 94210200 1 Multi-beam coupling for
encoder
4 96313047 1 Encoder retainer plate TCY
Inliner
5 94156315 4 Spacer bolts M12 a/a 72 mm
6 93020605 2 Flat head cylindrical screw
7 93031201 4 Washer
8 93072131 4 Hex nut

IE-65-508 Encoder
A.F Encoder attachment kit 60 replacement parts

96313160

m tity
1 94156314 1 Encoder wheel spacer sleeve
2.1 96313986 1 Toothed belt 190 XL 95 teeth
482.6 long
2.2 96313982 1 Toothed belt 230 XL 115 teeth
584.2 long
3 93350403 3 Screw DIN 7991 M 4 x 12
4 96313103 1 IE-65-508 Encoder

IE-65-508 Encoder

m tity
5 77119500 1 Cable for encoder with angled
jack 5 m
6 94156313 2 Spacer SW 17 x 116
7 93250807 2 Set screw DIN 913 M8x25
hole 10 mm)
9 93250405 4 Set screw DIN 913 M4x8
10 93010807 2 Screw DIN 912 M8x20
11 93031002 4 Washer DIN 125 M8
12 96313021 1 Holder H-400
93010809 1 Screw DIN 912 M8x35

IE-65-508 Encoder
A.G Encoder attachment kit 90 replacement parts

96313190 Encoder attachment kit 90 consists of encoder attachment kit 92
(Ä Appendix “Encoder attachment kit 92 replacement parts”
on page 600) and additional connection cables.

tity
96313192 1 IE-65 Encoder attachment kit
complete
72893900 1 ENC/IP2 adapter
77121000 1 Encoder extension 10 m

IE-65-508 Encoder
A.H Encoder attachment kit 91 replacement parts

96313191

m tity
1 96313103 1 IE-65-508 Encoder
2 96313004 1 Friction wheel 20mm knurled
3 96313020 1 Holder H-400-A
jack 5 m
5 93350403 3 Screw DIN7991 M4x12

IE-65-508 Encoder
A.I Encoder attachment kit 92 replacement parts

96313192

m tity
1 96313103 1 IE-65-508 Encoder
2 96313006 1 Friction wheel R-300-A 10mm
knurled
3 96313021 1 Holder H-400
jack 5 m
5 93350403 3 Screw DIN7991 M4x12
6 93030802 2 Washer DIN9021 M8
7 93010803 2 Screw DIN912 M8x25

IE-65-508 Encoder
A.J Encoder attachment kit 93 replacement parts

96313193

m tity
1 96313103 1 IE-65-508 Encoder
2 94156310 2 Spacer SW 22 x 63
3 96313021 1 Holder H-400
jack 5 m
5 93350403 3 Screw DIN7991 M4x12
6 96313981 1 Toothed belt 160 XL 80 teeth
Fig. 640: Replacement parts 406.4 long
hole 12 mm)
hole 10 mm)
93011006 2 Screw DIN912 M10x25
93031002 4 Washer DIN440 M10
93251035 2 Set screw DIN913 M10x35

IE-65-508 Encoder
A.K Encoder attachment kit 94

96313194

m tity
1 96313103 1 IE-65-508 Encoder
2 96313004 1 Friction wheel, 20mm, knurled
3 96313021 1 Holder H-400
jack 5 m
5 93350403 3 Screw DIN7991 M4x12
Fig. 642: Replacement parts 93250403 1 Set screw DIN913 M4x4
93011004 2 Screw DIN912 M10x16
93071001 2 Nut DIN934 M10
93031001 4 Washer DIN125 M10
93011020 2 Screw DIN912 M10x60

IE-65-508 Encoder
A.L Encoder attachment kit 95

96313195

m tity
1 96313103 1 IE-65-508 Encoder
2 96313003 1 Friction wheel
3 96313021 1 Holder
4 93350403 3 Countersunk screw M4
5 96313095 1 Encoder extension
Fig. 644: Replacement parts 93250405 2 Set screw M4x8
93250404 1 Set screw M4x6
93250403 1 Set screw M4 4

IE-65-508 Encoder
A.M Encoder attachment kit 96 replacement parts

96313196
Fig. 645: Dimensions

m tity
1 96313023 1 Encoder holder
2 96313103 1 IE-65 Encoder
3 93350403 3 Screw DIN7991 M4x12
4 93020803 2 Screw M8x25
5 96313004 1 Friction wheel R-200-A
6 96313006 1 Friction wheel R-300-A b=16
7 93070801 2 Nut DIN934 M8
jack 5 m
8.1 77120500 1 Encoder extension cable 5 m
8.2 77120300 1 Encoder extension cable 3 m
11 93030802 2 Washer DIN9021 M8
12 93010809 2 Screw DIN912 M8x35
13 93250405 4 Set screw DIN913 M4x8

IE-65-508 Encoder
A.N Encoder attachment kit 97 replacement parts

96313197

m tity
1 96313103 1 IE-65-508 Encoder
1.1 93350403 3 Screw DIN7991 M4x12
1.2 93250405 2 Set screw DIN913 M4x8
2 96313007 1 Friction wheel R-400-A 31.5
Fig. 648: Replacement parts mm knurled
3 96313021 1 Holder H-400
4.1 77119500 1 Cable for encoder with angled
jack 5 m
4.3 77734202 1 Adapter cable 34
4.4 77737202 1 Adapter cable 37
5.1 93010809 2 Screw DIN912 M8x35
5.2 93030802 2 Washer DIN9021 M8

IE-65-508 Encoder

m tity
5.3 93070801 2 Nut DIN934 M8
93010803 2 Screw DIN912 M8x25

IE-65-508 Encoder
A.O Encoder attachment kit 99 replacement parts

96313199

IE-65-508 Encoder

m tity
1 96313027 1 Encoder bracket
2 93030801 2 Washer DIN 125 M8
3 93012803 2 Screw DIN 912 M8x25 8.8
4 96313028 1 Encoder retaining plate
5 93010403 3 Screw DIN 912 M4x10
6 96313994 1 Toothed belt
7 93011006 1 Screw DIN 912 M10x25
8 96313956 2 Toothed belt wheel
8.1 93250404 4 Set screw DIN 913 M4x6
9 96313103 1 IE-65-508 Encoder
11 93030601 2 Washer DIN 125 M6
12 93010609 2 Screw DIN 912 M6x16
13 77121000 1 Encoder extension cable 10 m

Declaration of conformity
B Declaration of conformity
Individual, order-specific EC declaration of con-
formity
An individual, signed EC declaration of conformity will
be provided for each entire system. This will either be
sent to you by post or included in the delivery of the
system. If this declaration of conformity is missing, you
can request a copy at any time by providing the
Baumer hhs order number. For contact information,
see Contact.

Circuit diagrams
C Circuit diagrams

10259130-EN-20150615 Operating Manual

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Operating instructions

Inliner with MLT 40

Read the instructions prior to performing any task!

© Baumer hhs GmbH 2015

2 Inliner with MLT 40 19.06.2015

Help us Help us make Baumer hhs products even safer!

Contact Please report any hazardous situations to the following email

19.06.2015 Inliner with MLT 40 3

Customer service Baumer hhs GmbH

Reporting hazards Email: Hazardous@baumerhhs.com

Documentation Email: dokumentation@baumerhhs.com

4 Inliner with MLT 40 19.06.2015

19.06.2015 Inliner with MLT 40 5

2.7.7 Danger due to adhesive........................................... 35

6 Inliner with MLT 40 19.06.2015

3.3.24 IE-65-508 Encoder................................................. 94

19.06.2015 Inliner with MLT 40 7

5.3.9 MLT sensor............................................................ 144

8 Inliner with MLT 40 19.06.2015

6.4.7 Defining interfaces and machine connections....... 254

19.06.2015 Inliner with MLT 40 9

9.3.6 Fault messages on the terminal............................. 460

10 Inliner with MLT 40 19.06.2015

12.1.3 Optional accessories........................................... 550

19.06.2015 Inliner with MLT 40 11

12 Inliner with MLT 40 19.06.2015

1.2 Components at a glance

Fig. 1: Example: Control cabinet

19.06.2015 Inliner with MLT 40 13

1.2.2 CPU module

Item number Description

1.2.3 Application head module

1.2.4 Terminal interface module

14 Inliner with MLT 40 19.06.2015

1.2.5 MLD module

1.2.6 Stopp-Link front plate

1.2.7 Linux terminal

19.06.2015 Inliner with MLT 40 15

1.2.8 Glue delivery unit (KFE)

Fig. 8: 16940000, 16940005

For glue delivery unit with:

16 Inliner with MLT 40 19.06.2015

1.2.9 Fill level sensor

1.2.10 3-way blank guide

Item number Description

Fig. 10: 27893000

19.06.2015 Inliner with MLT 40 17

(optional) Guide plate extension

Item number Device

Fig. 11: 10259300

1.2.11 3-way multi-application head

Fig. 12: 28590330

18 Inliner with MLT 40 19.06.2015

1.2.12 MLT sensor

Item number Description

Fig. 13: 79020100

1.2.13 (optional) UV lighting for MLT-40

Fig. 14: 10259120

19.06.2015 Inliner with MLT 40 19

1.2.14 MLT colour filter installation kit

Item number Description

Fig. 15: 79029110 (mounted on the