Product Training Central control console

Control concept
2

2 Control concept .................................................................3

2.1 Control elements .............................................................................. 3
2.2 Tasks of SPS-level (e.g.: R700) ....................................................... 4
2.3 Tasks of Process level (e.g.: R700)................................................. 5
2.4 Overview hardware componenets control console computer...... 6
2.5 SPS loop............................................................................................ 7
Components of SPS-loop-system (e.g. R702).................................... 7
Overview SPS-loop system ................................................................ 8
Trouble shooting SPS-loop............................................................... 10
Central console computer from series 716/717 ................................ 11
Change PLC system from "SPS" to "MMS" (ab Serie 717) .............. 12
Jumper-positionen on MMS-board ................................................... 13
Jumper positiones at MMS board ..................................................... 14
2.6 Prozeß-Loop.................................................................................... 15
Components Prozeß-Loop-System .................................................. 15
Overview Process-Loop-System ...................................................... 16
Trouble shooting process loop.......................................................... 18
2.7 Overview SPS- and Process-Bus from series 714....................... 20
2.8 Overview SPS-and Process-Bus from series 717........................ 21
Exercises SPS-Loop:........................................................................ 21
Exercises SPS-Loop:........................................................................ 22
Exercises Process-Loop: .................................................................. 22
Exercises Process-Loop: .................................................................. 23

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This page remains free for technical reasons.

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 Product Training Central control console

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2 Control concept

2.1 Control elements

Central console
RCI 2L

LSR

Prozeß SPS

Prozeß SPS
Level I/O - level

MACHINE

LSR - Leitstandrechner (Central console computer Æ PC)

RCI2L - Remote Controlled Inking 2nd. Generation for digital controlled presses
SPS - Speicherprogrammierbare Steuerung (Programmable logical control PLC)
I/O - Input / Output
Prozeß Ebene - Process level
SPS Ebene - PLC level

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2.2 Tasks of SPS-level (e.g.: R700)

Machine release
Run commands
Guard system Monitoring of all safety
Safety circuit Feeder relevant functions.
Pile up / down In case of an error UWR is
Ink fountain roller ON interfering into PLC control
Water fountain roller delivery control and stop drives
Coating roller
Lubrication
Plate change
system
procedure

Control of production Air supply

and paper run
Roller control
UWR
Blanket, roller and
impression cylinder
washing programms Control panels
Monitoring computer

Dryer interface

SPS
Perfect printing computer Real-Time-
(R700 only) computer

SWR RTR
time-critical functions
main drive control
feeder pile control

angle depending functions

Control of change over Impression ON-OFF
procedure single side / Feeder / feeder air ON
perfect printing Quick airation feeder
Front lay control
Front guide locking
Missing sheet control
Spray powder control
Inspection sheet removal (S.719)

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2.3 Tasks of Process level (e.g.: R700)

Positioning drives delivery: Positioning drives feeder:

Suction roller format suction head height / size
Sheet jogger side stops
Gripper opening cam pile supporting plate
feeder timing

Prozeß

MAVO:
Interface spray powder unit
Color console RCI 2L Interface dampening
solution refrigerator
Interface to other
periferical devices

Printing unit
Register
(Circumferential,
lateral, diagonal)
Duktor roller strip
Oszillator timing
Material thickness
Side guide (P.U. 1 only)
Cover guide (P.U. 1 only)
Gripper opening cam
Ink slides

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2.4 Overview hardware componenets control console computer

Kassette drive Job Card Reader

(up to Series 720) (from Series 721)

Monitor and Option: printer

keyboard

SPS
PLC control
LSR Option:
CCI (Computer controlled inking)

Prozeß
Option:
Process control Video magnifier

Option: Modem connection

Token-ring-network board
to MAN Roland servernet

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2.5 SPS loop

Components of SPS-loop-system (e.g. R702)

+EA +DA +BA +AX

Delivery Delivery Feeder Feeder
machine maschine
6

3 4 5 8

2 9

Components
+FA 10 1 MMS, SPS-Bus-Master,LSR
Central 2 SPS-Bus-Slave 1 Delivery
console 3 SPS-Bus-Slave 2 Delivery
4 SPS-Bus-Slave +DA
5 SPS-Bus-Slave +BA
6 SPS-Bus-Slave Feeeder
7 SPS-Bus-Slave General
1 8 SPS-Bus-Slave RTR
9 SPS-Bus-Slave UWR
10 Keyboard / screen

Assignment of tasks

LSR, keyboard, screen Interface between operator and machine

MMS-CPU (386DX) Modular machine control contains the programm to control all machine functions
SPS Bus Master (80188µP) Establishes communication between MMS-CPU and SPS Bus Slaves via fiberoptic
cable using SDLC-transfer protokoll (Synchronous Data Link Control)
SPS Bus Slave Reading input signals and setting output signals in the individual stations,
communication via fiberoptic loop to SPS Bus Master.
UWR Monitoring of safety relevant SPS functions e.g. Guards, E-Stop buttons, main drive
control etc.
RTR Proceeding of time-critical or angle depending functions e.g infeed control,
impression throw-on, main drive control, missing sheet control

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Overview SPS-loop system

Æ with one SPS rack in delivery cabinet (no AirGlide and no automatic residual pile)

Central console Computer

-D001 in +Fx
MMS with Station 22, SPS/LSR Fiberoptical cable
SPS Bus Master -Slave- (orange Isolation)

Slot 5 Slot 6

B12

Station 21, UWR

-A358
-Slave-

Station 2, Delivery Slot 8

-A353
-Slave-

Slot 6

B12

Station 14.. 16, Coater

-A548
Station 20, RTR
-Slave-
-A359
Slot 6 -Slave-

Slot 8

Station 5...13
Center machines
Station 3, General
-A350
-A354
-Slave-
-Slave-
Slot 6
Slot 6

Station 4, Feeder machine

Station 1, Feeder
-A350
-A356
-Slave-
-Slave-
Slot 6
Slot 6

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Lichtwellenleitersysteme
Fiber optic system up to Series 713 (and on all R600D Machines):

Fiber optic module: Hewlett-Packard

B 37V 0196 70 (R8=182 Ohm) cable length 2 to 15 m (6 to 48 feet)
B 37V 0639 70 (R8= 52 Ohm) cable length 15 to 30 m (49 to 100 feet)

For spare part purpose (R8 might be different and is mounted on soldering terminals):
A 37V 1253 70 cable length 2 to 15 m (6 to 48 feet)
A 37V 1254 70 cable length 15 to 30 m (49 to 100 feet)

Receiver
(blue)
Transmitter
(grey)
R10
R9
R8

Fiberoptic system from Series 714:

Fiber optic cable:

Connection in-between main cabinet (+Ax) and Central control console (+Fx) is glass fiber (cable jacket orange,
manufacturer: SIEMENS).
other connections plastic fiber (cable jacket black or grey, manufactuer SIEMENS).

LED lit, if
receive is O.K.

Receive

J1 conected Transmit

General advise:
There is a service kit for trouble shooting on fiber optic loop systems available. It contains a optical level meter to
measure the level of received light-

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Trouble shooting SPS-loop

Power ON
(main switch)

Possible reasons
- Slave computer defective
- F.O. module defective (only RTR, UWR)
- DPR Slave CPU defective
- Power supply slave CPU missing
LEDs at Slave CPU are - SPS Bus Master (MMS-Board, Slot 5) defective,
Adressing No flashint to interrupted if no LED is flashing
successful? position, following Slave - Fiberoptic cable defective
LED's are off.
Test tools
- RODIMO: SPS Bus Master, State, Status o.k.?
- RODIMO: SPS Bus Slave, View, Visualize log
Yes
- Damping behavior
Test F.O. cabel with Fiber optic power meter

LEDs at Slave CPU lit Bus system is

permanently in loop mode

Yes

Possible reasons
- Slave sequence in loop wrong connected
- Slave rack wrongly assembled
Nominal - - Adress part of I/O-board defective
No SPS Output are not active ,
actual configuration - wrong nominal configuration of PLC program
SPS loop is in idle mode
check o.k?
Test tools
- RODIMO: SPS Bus Master, State, Configration ?
- RODIMO: SPS Bus Master, Other, Log

Yes

Possible reasons
- MMS Programm: correct version loaded ?
'Bell signall' o.k. ?,
No - MMS Board defective, power supply?
SPS Output o.k. ? yellow LED on MMS board
is flashing?
Test tools
- RODIMO: SPS Bus Master, Other, Log
......, Error
- RODIMO: SPS Bus Master, State, Status
- Status 3/7/9: Check configuration
Yes

SPS Loop is "running",

Data transmit between
master and slaves

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 1
empty

Slot:

+ 5V

+ 12V
+12V
+ 5V
- 12V

GND
2

+12V
+ 5V

- 12V
AC Line
Power supply +5V; +12V; -12V

3
Reserve

Option: second multifunctional board (like Slot 8)

4
SPS Bus Slave 22 (top left LED)
Prozeß Bus Master (top right LED)

COM1 STATUS7 RODIMO

5

from Serie 717 : MMS (Modular Machinen Control) with SPS Bus Master
V24 Prozeß F.O. RODIMO SPS F.O.
6
SPS Proz

Interface converter board (Process master / SPS slave)

V24

with PS2 connector

7

IBM Token-Ring board (Option from series 717 up to 733)

IBM compatible keyboard

LPT1 COM5 COM4 COM3 COM2

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8
Central console computer from series 716/717

HDD

Multifunctionalboard
Zugriff

COM1 VGA Out digital VGA OUT

9

F
F

LSR CPU with integrated graphic controller

COM4 =

VIDEO IN VGA OUT VGA IN

COM3 = FDM

10
LPT1 = Printer
Product Training

Fast Sreen Machine (Option, only for video magnifier)

COM2 = Rollerball

Floppy Disk (FDD)

COM5 = Cassette/Jobcard
Control concept

COM1= foil keyboard

Hard disk 2x (HDD, each 270 MB) HDD 1 HDD2
11

C:\ D:\
E:\ G:\
F:\ H:\
2

11
Central control console
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Change PLC system from "SPS" to "MMS" (ab Serie 717)

From Sereies 717 the PLC system has changed from Klöckner-Moeller SPS system to the so called MMS
(Modular Machine control).
Therefore the whole PLC rack with Power supply
master plc
slave plc and
SPS bus master
is replaced by a single board in slot 5 of the new console PC (Manufactuer: Eckelmann).
This board is controlled by a 386 CPU with 25 MHz clockrate.
The machine program is stored on flash EPROM and is loadable from the floppy disk drive of the PC.
The MMS board also contains the SPS bus master, therefore the fiber optic cables are connected directly
to the MMS board .
There are three sockets for service purpose:
-X28: Connection to SPS bus master (RODIMO program
-X29: Connection to MMS (Status 3/7/9 program)
-X30: RS232 Interface to load MMS program by laptop
All connections require the RODIMO cable.

Yellow: MMS program is running

Red LED: Power

Green LED: SPS-Loop o.k.

X27 X26

X26: F.O. cabel Receifer (SPS-Bus-Master), System Toshiba

X27: F.O. cabel Transmitter (SPS-Bus-Master), System Toshiba

X28

X28: Interface to SPS-Bus-Master (RODIMO)

X29

X29: Service-Interface to MMS program (STATUS 3/7/9)

X30

X30: COM1 to load / safe a MMS program by notebook

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Jumper-positionen on MMS-board

J2
1 J8
2 1

BUS
LEDs Master
V .....
J3 J4 5 J10
3
J1 1

1 2 1 2
J14 J13 1
1
X26 J9
4
7

X27 1
2

J11
1
J15

386DX
X28 J5
31 33

TMON 5

X29 MMS 7 9
3
1
High 4 6 J12
1 3
1 2
3 4
J6 J7
TMON
X30 MMS
Low

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Jumper positiones at MMS board

Jumper Connected pins

J1 Gesteckt
J2 3–5
4–6
J3 1–2
J4 1–2
J5 2–3
5–6
8–9
11 – 12
13 - 14
16 – 17
19 – 20
22 – 23
31 – 32
J6 1–2
3–4
J7 1–2
3–4
J8
J9 1–2
3–4
5–6
13 – 14
J10 1–2
3–4
5–6
J11 2–3
J13 1-2
4–5
7–8
J15 connected

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2.6 Prozeß-Loop
Components Prozeß-Loop-System

+EA +DA +BA +AX

Delivery Delivery Feeder Feeder
machine machine
6

3 4 5

8
+FA
Console
Components
1 Prozess Bus Slave,Color Rack
2 Prozess-Bus-Slave, Pos.-Controller Delivery
3 Prozess-Bus-Slave, MAVO Rack
4 Prozess-Bus-Slave, Pos.-Controller +DA
1 7 5 Prozess-Bus-Slave, Pos.-Controller +BA
6 Prozess-Bus-Slave, Pos.-Controller Feeder
7 Prozess-Bus-Master, LSR
8 Monitor / Keyboard
Assignment of tasks

LSR, keyboard, monitor Interface between operator and machine.

Color Rack
Prozess Bus Master
Prozess Bus Slave
MAVO Rack
Positioning Controller
The LSR computer contains the main program to control the printing process.
Proceed input from the color desk (ink slide and ink fountain roller commands)
Manages communication between LSR and Prozess Bus Slaves via F.O.cables.
Establish communication between prozess loop and subnode processors.
MAschinen-Vorbereitung (Machine preparation) Interface to peripheric equipment
such as spray powder unit or dampening solution refrigerator
Controlles all positioning drives such as ink slides or stepper motors.

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Overview Process-Loop-System

Central console Computer

-D001 in +Fx

Process Bus Master

Slot 6

Fiberoptical cable
(orange Isolation)

Color Rack (Console)

-A367
-Slave-

Slot 1

Process rack delivery

-A355
-Slave-

Slot 1

MAVO rack in delivery

-A371
-Slave-

Slot 5

Process rack coater Process rack

feeder
-A352
-A357
-Slave-
-Slave-
Slot 1
Slot 1

Process rack
Process rack
center machines
feeder machine
-A352
-A352
-Slave-
-Slave-
Slot 1
Slot 1

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Notes:

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Trouble shooting process loop

Power ON
(main switch)

Possible reasons
- Slave computer defective
- DPR Slave CPU defective
- Power supply slave CPU missing
LEDs at Slave CPU are - Process Bus Master (MMS-Board, Slot 6) defective,
Adressing No flashint to interrupted if no LED is flashing
successful? position, following Slave - Fiberoptic cable defective
LED's are off.
Test tools

- Diagnosis messages (Loop interrupted)

Yes - RODIMO: Process Bus Master, Status, Bus status o.k.?
- RODIMO: Process Bus Master, Log, Log process bus master
- RODIMO: Process Bus Master, Log, Log process bus slave
LEDs at Slave CPU lit Bus system is - RODIMO: Process Bus Master, Protocol, Error message
permanently in loop mode - Damping behavior
Test F.O. cabel with Fiber optic power meter

Yes

Possible reasons
- Slave sequence in loop wrong connected
- Slave rack wrongly assembled (Configuration)
Nominal - SPS loop is in - defective node computer
No
actual configuration idle mode - defective subnode computer
check o.k?
Test tools
- Diagnosis messages (Pos.Ctrl., node x, subnode y: nnn)
- RODIMO: Process Bus Master, Log, Log process bus master
- RODIMO: Process Bus Master, Log, Log process bus slave
Yes
- RODIMO: Process Bus Master, Protocol, Data transfer
- LSR Program: Configuration
- Handterminal on Subnode

Possible reasons
No Machine react , if "Working
LSR program - EEPROM defective, wrong ID/version no.
position" is actuated (menu:
o.k.? dampening/inking) - wrong Firmware in master / slave CPU
- wrong nominal configuration
- defective subnode computer

Test tools
- Diagnosis messages (Pos.Ctrl., node x, subnode y: nnn)
Yes
- RODIMO: Process Bus Master, Log, Log process bus master
- RODIMO: Process Bus Master, Log, Log process bus slave
- RODIMO: Process Bus Master, Protocol, Data transfer
- RODIMO: Process Bus Master, Protocol, Error messages
LSR program is "running",
Data transmit between - Messages in last alarm files
master and slaves - Erase EEPROM (with keydisk only)
- Firmware version (Menu: PRINT / Gerneral / Service / Version)

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Notes:

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2.7 Overview SPS- and Process-Bus from series 714

(e.g.: R702)

KM-BUS ISA-BUS
DPR DPR DPR
Klö-Mö Contr.
SPS-Bus SPS- D Prozeß- console
SPS- Slave P
Master
Master R
CPU 1&2 8 CPU

SPS-Bus Prozeß-Bus
RS232
SMP-BUS Colorpult
SPS- Prozeß-
I/O I/O Slave Slave
1
1
Color-Rack
Delivery

SMP-BUS
RS232
Pos-Ctrl
SPS- Prozeß-
I/O I/O Slave Slave
2
2
Delivery
Delivery machine

SMP-BUS Prozeß- RS232

D.S. Refrigerator
SPS- Slave
I/O I/O Slave 3 RS232
Spray powder
3
SMP-Bus
Feeder machine V24- RS232
board n.u.
Mavo-Rack
SMP-BUS
SPS- RS232
I/O I/O Slave Pos-Ctrl
4 Prozeß-
Slave
Feeder 4 RS485
Duktor R700
Delivery machine
SMP-BUS
SPS-
I/O I/O Slave RS232
Pos-Ctrl
5 Prozeß-
Slave
General
5 RS485
Duktor R700
SMP-BUS Feeder machine
DPR
I/O RTR SPS-
Slave RS232
Prozeß- Pos-Ctrl
6
Slave
6
SMP-BUS
DPR Feeder

I/O UWR SPS-

Slave
7

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2.8 Overview SPS-and Process-Bus from series 717

(e.g.: R702 without Airglide delivery)

ISA-BUS
DPR DPR DPR
Contr.-
MMS-CPU SPS- D Prozeß- console
DPR
Slave P
R
Bus-
8 Master CPU
SPS-Bus-Master
SPS-Bus Prozeß-Bus
RS232
SMP-BUS Colorpult
SPS- Prozeß-
I/O I/O Slave Slave
1 1
Color-Rack
Delivery

SMP-BUS
RS232
Prozeß- Pos-Ctrl
SPS- Slave
I/O I/O Slave
2
2
Delivery
Delivery machine

SMP-BUS Prozeß- RS232

D.S. refrigerator
SPS- Slave
I/O I/O Slave RS232
3 Spr. powder unit
3 SMP-Bus
Feeder machine V24
RS232
board
empty
Mavo-Rack
SMP-BUS
SPS- RS232
I/O I/O Slave Prozeß- Pos-Ctrl
4 Slave
RS485
Feeder 4 Duktor R700
Delivery machine
SMP-BUS

I/O I/O SPS- RS232

Slave Prozeß- Pos-Ctrl
5
Slave
General
5 RS485
Duktor R700
SMP-BUS Feeder machine
DPR
I/O RTR SPS- RS232
Slave Prozeß- Pos-Ctrl
6
Slave
6
SMP-BUS
DPR Feeder

I/O UWR SPS-

Slave
7 (Node)

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2
Product Training

Please work out the missing designations of cabinets, racks designation, Slave numbers (decimal), station number t
and equipment designation. Use the training documents and the machine documentation for assistance
Control concept

Delivery Coater Printingunit 3 Printingunit 2 Printingunit 1 Feeder / Maincabinet

Locationdescription: Locationdescription: Locationdescription: Locationdescription: Locationdescription: Locationdescription:

Central control console

Exercises SPS-Loop:

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

Rack designation: Rack designation: Rack designation: Rack designation: Rack designation: Rack designation: Rack designation: Rack designation:

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

SPSslave no.: SPSslave no.: SPSslave no.: SPSslave no.: SPSslave no.: SPSslave no.: SPSslave no.: SPSslave no.:

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

Station no.: Station no.: Station no.: Station no.: Station no.: Station no.: Station no.: Station no.:

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

Equipmt. desig.: Equipmt. desig.: Equipmt. desig.: Equipmt. desig.: Equipmt. desig.: Equipmt. desig.: Equipmt. desig.: Equipmt. desig.:

C95A 6442 39 - 06. Feb. 2004

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

Rack designation: Rack designation:

Control console ............................................. .............................................

Locationdescription: SPSslave no.: SPSslave no.:

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

Rack designation: Station no.:

Name the exact R700 machine type for this example Station no.: Station no.:

(witout perfecting)
............................................... ............................................. ............................................. .............................................

SPSslave no.: Equipmt. desig.: Equipmt. desig.: Equipmt. desig.:

.....................................................................................................
............................................. ............................................. ............................................. .............................................
 Please work out the missing designations of cabinets, racks designation, Slave numbers (decimal), station number
and equipment designation. Use the training documents and the machine documentation for assistance

Delivery Coater Printing unit 3 Printing unit 2 Printing unit 1 Feeder / Main cabinet

Location description: Location description: Location description: Location description: Location description: Location description:

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

Exercises Process-Loop:

Rack designation: Rack designation: Rack designation: Rack designation: Rack designation: Rack designation: Rack designation:

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

SPS slave no.: SPS slave no.: SPS slave no.: SPS slave no.: SPS slave no.: SPS slave no.: SPS slave no.:

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

No. of subnodes No. of subnodes No. of subnodes No. of subnodes No. of subnodes No. of subnodes No. of subnodes

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

C95A 6442 39 - 06. Feb. 2004

Equipmt. desig.: Equipmt. desig.: Equipmt. desig.: Equipmt. desig.: Equipmt. desig.: Equipmt. desig.: Equipmt. desig.:

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

Control console
Product Training

Location description:

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

Rack designation: No. of subnodes

Name the exact R700 machine type for this example
Control concept

(with perfecting unit after the first printing unit)

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

SPS slave no.: Equipmt. desig.:

.....................................................................................................
............................................. .............................................
2

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Central control console
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Notes:

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