YM:LISIM Installation Guideline

1 Preparation

Prepare all documents at home before you go to the site. For the LISIM lines, there are many PI diagramms. There are PI diagramms for the track system and for the motor cooling and all kind of sensors in and arround the LISIM. It is useful to prepare these diagramms. Also the mechanical drawing for the proximity switches are useful.

When you arrive on site you have to check all cable trays in the LISIM basement.

At most LISIM lines, more special parts are installed, such as the camera inspection system. For more details, please refer to a separate KIWI article: Public:LISIM camera installation

The LISIM part of the line has its own structure numbers.

• 361-1 width adjustment, edge guide
• 361-2 inlet and outlet table , LISIM motors, FDM sensors, IMC system LISIM
• 361-7 safety mats, light barrier, warning lights, warning lamps, jogging switch, lubrication, clip cooling, peumatic cabinets, websteering
• 363 oven with the fans, PT100, heating system, shutter, film break, camera inspection, pyrometer, lightning
• 365 cooling zone
• 367 external airing
• 368 HCUs and utilitys

2 Cable Pulling

Before you start pulling the cables, make sure you know which cable arm and breakthrough you need to use.

2.1 Cable pulling on return track

Pulling the cable on the return track is much easier than on the forward track in the oven.

• Make sure power and date cables are not pulled together in the same hose.
• Do not pull the cables over the joints. If there is no other option than it is (only at the return track) allowed.
• Take care with pulling the FDM sensor cables!

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In case there is not enough place in the black cable hoses you can install a third one rigth next to it. All cable hoses must be movable. (Maybe you have to dismantel one hose on a position where it is not required because there is no spare one.)

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2.2 Cable pulling on the forward track

Pullig the cable is more critical and difficult than on the return track. Don´t pull any cables over the movable joints. Template:Notice bms

• Do not bend the motor cables to much!
• Do not use (metal) cable ties, only if it is really necessary.
• Do not tighten the cable clamps and glands to much.
• Always lay the cables above the water hoses, as they tend to condense.
• Make sure the mechanics installed the water hoses long enough, otherwise there will be no place for the cables.
• You have to install rubber cable entys on the metal sheets on the breakthroughs inside the oven. (The rubber is heat-resistant. Don´t lose any rubber cable entrys because there are no spare ones.)
• Fill the breakthroughs with some insolation material after cable pulling. (Done by mechanics.)
• Take care by pulling the cables for the FDM-sensors. This cables get easily damaged!
• Sometimes the pre-installed cables for the limit switches are too short. However, an additional cable is always provided by the BSK.

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Don´t loose any rubber cable entrys. There are no spare ones and all holes must be closed.

2.3 Cable pulling in the basement

When you pull the cables from the oven to the outside, you need to pass them through two metal plates. Inside the oven, a heat-resistant rubber gland is installed, and on the outside plate, you need to install a metal cable gland.

All unused holes must be closed with appropriate closures.

Don´t tighten the cable glands too much, otherwise the cables will get damaged.

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If the workers don’t pull the cables directly into the cabinets, you must make sure the cables are properly secured and not lying on the floor. Otherwise, the cables will get damaged!

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Most of the time the cabinets of the LISIM are in a basement under the oven. The cables must be properly laid. For this purpose, vertical cable trays are usually installed above the control cabinets.

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If the customer does not wish to use cable trays, C-rails can be installed as an alternative for fastening and routing the cables.

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3 Cable connecting

At LISIM lines, the switchboard room is usually located in the basement. The cable entries in the cabinets are always on the top side of the cabinets.

The shield of the cables must be connected to both the EMC rail and the clamp of the drive. A small piece of PTFE hose must be inserted between the stainless-steel cable shield and the shield clamp of the drive to protect the cable. If this is not done, it could cause problems with the cable insulation.

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If some motor cables have damaged insulation, you can open all clamps, glands and cableties and check again. If there is still a fault, check which phase is damaged. Sometimes it is possible to change the colored phases because there are some spare ones. If this is not possible, then you have to change the cable. Changing cables and soldering is a lot of extra work, so better you find the fault.

The soldering device is included together with the other LISIM spare parts.

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4 Grounding

For LISIM ovens many groudings are required. All groundings must be according the electrical- and the foundation drawings.

All junction boxes on the LISIM track are grounded to the LISIM motors and to each other junction box. Also every track support must be grounded accoding the single foundation drawing.

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Grounding in the return track (cold area)

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Grounding in the froward track (hot area)

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Some spare grounding strips are always sent from the BSK to the site. These strips can be used to extend the existing grounding strip if its not long enough.

​​Grounding for the track supports must be according the single foundation drawing:

For all track-support-stands the mechanical supervisor has some grounding strips.

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5 Special parts around the LISIM

Arround the Lisim line are a lot of speacial machine parts, such as light barrier, safety mats at the inlet, clip cooling sensors, clip controll sensors, limit switches, vacuum pumps, flow sensors and the websteering unit.

All parts are shown in different PI- diagrams.

5.1 Websteering

Every LISIM has one Websteering unit before the inlet.

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For the Profinet connection, an RJ45 coupling is required, otherwise the cable cannot be connected. It’s best to ask the customer for one piece. Brückner does not send any RJ45 coupling to the site.

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5.2 LISIM motor cooling

All LISIM motors are water-cooled. There is a PI diagram for the cooling water system that includes all the flow sensors. Use this PID to precisely identify the location of each flow sensor and compare it with the actual situation on site (usually, some sensors are swapped). If you follow the PID, it’s really easy to find the correct positions of all flow sensors in the piping. PI numbers are indicated in the electrical drawings.

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5.3 Width adjustment

All LISIM lines are equipped with a width adjustment and the corresponding limit switches. The limit switches are shown in a PI diagram. All switches are already preassembled and marked by BSK. All cables are connected and only need to be routed to the correct cabinet. Sometimes the pre-installed cable from the switch is too short and cannot reach the cabinet. For this, BSK always supplies some spare cables together with the LISIM- spare parts from preassembly.

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5.4 Clip position sensors (FDM sensors)

All LISIM lines are equipped with clip position sensors (FDM sensors). The position of the sensors you can find in a PI diagram. Some of the sensors are already preassemblied but they are not labeled. Most of the sensors will be installed on site from the Brückner mechanics. Keep care during cable pulling. The cable is attached on the sensor and cannot be replaced or repaired. The whithe cable on the cable is heat resistant and can not be cutted. The grey cable end after the signal amplifier can be cutted and is not heat resistant.

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In the last zone before the outlet table is the same type of sensor installed, but his sensor is shown in a different PID and belongs to a different machine structure.