Service Training Electronics Roland 300

Washing devices
7
7 WASHING DEVICES .........................................................................................................................................7-3

7.1 BLANKET WASHING DEVICE (GTW) / ROLLER WASHING DEVICE (WW) ............................................................7-3

7.1.1 Overview of the electrical components...............................................................................................7-3

7.1.2 Connections of the hoses ...................................................................................................................7-4

7.1.3 Overview I/O in +AX ...........................................................................................................................7-5

7.1.4 Overview I/O (DW) .............................................................................................................................7-6

7.1.5 Washing program run .........................................................................................................................7-7

7.1.6 Abortion of the washing program........................................................................................................7-7

7.1.7 Disturbances.......................................................................................................................................7-7

7.1.8 Reservoir container ............................................................................................................................7-8

7.1.9 Wiring of the float-switch of the washing agent container ..................................................................7-9

7.1.10 Washing programs .......................................................................................................................... 7-10

7.2 IMPRESSION CYLINDER WASHING DEVICE (DZW).......................................................................................... 7-13

7.2.1 Overview of the electrical components............................................................................................ 7-13

7.2.2 Overview I/O (DW) .......................................................................................................................... 7-14

7.2.3 Function description ........................................................................................................................ 7-15

7.2.4 Example of a DZW program ............................................................................................................ 7-17

7.2.5 Setting the control disk .................................................................................................................... 7-19

7.3 DESCRIPTION OF THE WASHING PROGRAMS (UNTIL PS 335D3) .................................................................... 7-20

7.4 DESCRIPTION OF THE WASHING PROGRAMS (AS OF PS 335E1) .................................................................... 7-21

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7 Washing devices

This page is empty for technical reasons.

7-2 C 95A 6424 39 - 27. Jan. 2004

 7.1

7.1.1
main switch cabinet +AX
7 Washing Devices

Overview of the electrical components

M 217 M 015 M 015 M 015 M 015 M 015

S 879 B105 B105 B105 B105

S 880

Y 116 Y 107 Y 030 Y 031 Y 107 Y 030 Y 031 Y 107 Y 030 Y 031 Y 107 Y 030 Y 031 Y 107 Y 030 Y 031

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Y 108 Y 044 Y 045 Y 108 Y 044 Y 045 Y 108 Y 044 Y 045 Y 108 Y 044 Y 045 Y 108 Y 044 Y 045
Y 194

delivery +EA +DA +CC +CB +CA +BA feeder

Blanket washing device (GTW) / Roller washing device (WW)

M 217: used fluid pump GTW B 105: sensor GTW installed (as of S337)
M 015: GTW main drive
S 879: floating switch for used fluid water GTW
high level (low active) Y 107: GTW swivel
Y 108: WW-ductor blade on/off
S 880: floating switch for used fluid GTW
low level (low active) Y 030: solenoid valve GTW-washing agent
Y 031: solenoid valve GTW-water
Washing devices

Y116: solenoid valve return GTW/DZW

Y 044: solenoid valve WW-washing agent
Service Training Electronics

console +FA Y194: solenoid valve washing agent

Y 045: solenoid valve WW-water
suction GTW/DZW (as of S333)
7

7-3
Roland 300
7-4
7
7.1.2
GTW/ WW connections

operating side
Service Training Electronics

Washing devices

Connections of the hoses

Roland 300

PU 5 PU 4 PU 3 PU 2 PU 1

delivery feeder

3 1 3 1 3 1 3 1 3 1

4 2 4 2 4 2 4 2 4 2

C 95A 6424 39 - 27. Jan. 2004

1: GTW water c. nr. 0028 thick blue hose

2: GTW-washing agent c. nr. 0042 thick white hose

3: WW water c. nr. 0028A thin blue hose

4: WW-washing agent c. nr. 0043 thin white hose

 7.1.3
I I I I I I I I I
safety -A 354/3 -A 354/3 -A 354/3 -A 354/4 -A 354/5 -A 354/5 -A 354/5 -A 354/5 -A 354/5
circuit Byte 3 Byte 3 Byte 3 Byte 5 Byte 8 Byte 8 Byte 8 Byte 9 Byte 1
Bit 4 Bit 5 Bit 6 Bit 5 Bit 4 Bit 5 Bit 6 Bit 6 Bit 7

-A 345 -A 345

-A 524 13 -A 524 -A 525

S 873 S 874 S 875 Q 217* S 876 S 877 S 878 S 879 S 880
Overview I/O in +AX

14

I -24V.X50 I -24V.X50 I -24V.X20 I -24V.X53 I -24V.X53 I -24V.X1 I -24V.X1

-A 345:10 -A 345:10 -A 345:3 -A 345:5 -A 345:3 -A 345:1 -A 345:3

GTW

(M 217)

O O O P.O. P.O. P.O. P.O.

-A 354/10 -A 354/10 -A 354/10 -A 354/13 -A 354/13 -A 354/13 -A 354/13
Byte 10 Byte 14 Byte 14 Byte 17 Byte 17 Byte 16 Byte 18
Bit 0 Bit 1 Bit 2 Bit 9 Bit 4 Bit 3 Bit 7

C 95A 6424 39 - 27. Jan. 2004

-A 345 -A 345

3x380V
H 403 H 404 H 405 -Y116 -Y194***
-A 524 +EA +EA
+AX/34.A Q 217*
Washing devices

K 217**
Service Training Electronics

0V
* up to the S314: Q237, ** up to the S314: K158, *** as of S333
7

7-5
Roland 300
7-6
7
7.1.4
I I I P.O. P.O. P.O. P.O. P.O. P.O. P.O.
-A 350/7 -A 350/7 -A 350/3 -A 350/14 -A 350/14 -A 350/13 -A 350/13 -A 350/13 -A 350/13 -A 350/13
Byte 11 Byte 11 Byte 2 Byte 19 Byte 19 Byte 17 Byte 17 Byte 18 Byte 18 Byte 17
Bit 4 Bit 4 Bit 3 Bit 6 Bit 7 Bit 5 Bit 6 Bit 0 Bit 1 Bit 2
Service Training Electronics

Overview I/O (DW)

safety circuit safety circuit

Washing devices
Roland 300

-A 335 -A 335 -A 335

emergency
stop (+AX)

14 22 8
-A095 Q 234 K 44 Y 108 Y 107 Y 031 Y 045 Y 030 Y 044 3x380V K 13

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13 21

0V 0V 0V 0V 0V 0V emergency
Q 234
stop (+CA)

B105* I - 24V I - 24V

X23:1 X74:1
K 44

sensor motor handshake WW-ductor GTW solenoid valve solenoid valve solenoid valve solenoid valve
GTW installed protection GTW blade on/off swivel GTW-water WW-water GTW washing WW washing
switch agent agent 0V
GTW-drive
M 015
+BA
GTW
drive
* as of S337 and only in PUs +Cx, +DA
 Service Training Electronics Roland 300

Washing devices
7
7.1.5 Washing program run

Statuses of variables StatusWaschenGtw

a) WaschenNull: waiting for the Start of washing

b) WaschenStart: loading the preselected washing table

c) WaschenWait: waiting for washing rev speed (6000 sheets/h for GTW and WW)

d) WaschenBusy: preselected washing program run

e) Waschenende: preselected washing program successfully completed

f) Waschenabbruch: preselected washing program not successfully completed (abort)

7.1.6 Abortion of the washing program

The washing program is aborted when

• the key SpontanDruckAb is pressed,

• the key EmergencyOff is pressed,
• a Slow-Stop (and Machine rotating) or
• a Fast-Stop is active

7.1.7 Disturbances

The following errors messages are sent to the LSR:

• Gtw Min-Stand (solvent in container)

• Ww Min-Stand (solvent in container)
• WwGtw Water level min. (water in container)
• Motor protection switch

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7 Washing devices

7.1.8 Reservoir container

Machine

V4

Waste Solution Pump A L1 A L2 A L3 L1

GTW H2O WW L2
Waste Solution container
L3
A S1 A S2 A S3
V1 V2 V3

T Connector Tank Compressor 1

3K12_10

Indicator lamp: L1 = WW L2 = H2O L3 = GTW

V1 = valve GTW AS1 = closing tap GTW AL1 = draining tap GTW
V2 = valve H2O(GTW) AS2 = closing tap H2O AL2 = draining tap H2O
V3 = valve WW AS3 = closing tap WW AL3 = draining tap WW
V4 = valve H2O (WW)

Waste container: Water and GTW solvent residue after washing

Waste pump: The Waste pump (M 217) starts pumping the liquid out of the return container when the
Waste container is full and the max. float switch (S 879) within it is activated.
The Waste pump stops pumping as soon as the min. float switch (S 880) in the return
container is activated.

Pressure in the reserve tank: a) GTW p =2.5...3 bar (via V1)

b) H2O p(GTW) = 2.5...3 bar (via V2)

p(WW) = 0.8...1 bar (via V4)

c) WW p = 0.8...1 bar (via V3)

i As of S343 the machine is equipped with no more than one washing solution tank for GTW, DZW and WW.
A second tank can be activated in the MMS configuration as of software version 335H1 (new MMS-
configurations-disk from MRB required).

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Washing devices
7
7.1.9 Wiring of the float-switch of the washing agent container

1. 50l tanks

a) The max. and min. levels in the 50l tanks are interrogated via the float switches.
Both switches are designed as changeover contacts.

Max. level: color code: common: green

normally open: brown
normally closed: yellow

Min. level: color code: common: red

normally open: white
normally closed: blue

Caution: It occasionally happens that the manufacturer wrongly connects the color codes for
min. level – the normally closed contact to white and the normally open contact to
blue.

Caution: It occasionally happens that the 50l tanks are fitted with the wrong float switches
(two normally open contacts, color code: top: blue/black
bottom: brown/gray)
In this case it is necessary to order the correct switches from MRO under item
No.: 0 37B 4910 44.

b) The normally closed contacts (cable brake safe) of the float switches for min. and max. level are
interrogated starting from software version 315A1.

In the case of updates to 315A1 it is necessary to change the wiring in plug X1.A524 to the
normally closed version.

2. 33l tanks

a) The 33l tanks have just one switching point, that is used for the min. level (normally closed
contact with color code blue/black).

b) The normally closed contacts (cable brake safe) of the float switches for min. and max. level are
interrogated starting from software version 315A1.

Since the 33l tanks do not have a max. level signal it is necessary to change the wiring in plug
X1.A524 of the 315A1 updates as follows:

Contacts 1-7, 2-8 and 3-9 have to be jumpered.

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7 Washing devices

7.1.10 Washing programs

; FILE: GTW0001.PRG;
;
; Date | Name | Comment
; ---------- +----------+--------------------------------------------------------------------------------
; 09.06.94 |MHOE | New design according to instructions from Mr. Dürrnagel of 20.01.94
; 04.06.94 |MHOE | Program name change GTW0002.PRG -> GTW0001.PRG
; 27.06.94 |MHOE | Program name change after test with Mr. Dürrnagel on
; | | software machine 27476B on 24.06.94
; 25.06.94 |MHOE | Time to stop 90 seconds
;
;**************** GTW timing in 100msec. cycle ******************
;
; Time |Water |Solvent |Roller |Roller |W.-mot |Resv. |Resv. |
; | | |motor |valve |direction |BOOL2 |CARD |
; (sec.) |(trig) |(trig) |(stat) |(stat) |(stat) | | |
; --------- |------------- |---------- |---------- |---------- |---------- |----------- |---------- |
0000 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
0010 | 0 | 0 | 1 | 0 | 0 | 0 | 0 |
0030 | 0 | 1 | 1 | 1 | 0 | 0 | 0 |
0080 | 0 | 1 | 1 | 1 | 0 | 0 | 0 |
0230 | 0 | 1 | 1 | 1 | 0 | 0 | 0 |
0330 | 0 | 1 | 1 | 1 | 0 | 0 | 0 |
0430 | 0 | 1 | 1 | 1 | 0 | 0 | 0 |
0620 | 0 | 0 | 1 | 0 | 0 | 0 | 0 |
0650 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
; Time to stop 90 seconds
1550 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
; --------- |------------- |---------- |---------- |---------- |---------- |----------- |---------- |
0FFFFh
; End identification

; FILE: GTW0099.PRG
;
; Date | Name | Comment
; ------------ +--------- +-----------------------------------------------------------------------------
; 09.06.94 |MHOE | New design brush washing program;
; 04.06.94 |MHOE | Program name change GTW0001.PRG -> GTW0099.PRG
; 25.06.94 |MHOE | Time to stop 90 seconds
;
;**************** GTW timing in 100msec. cycle ***************
;
; Time |Water |Solvent |Roller |Roller |W.-mot |Resv. |Resv. |
; | | |motor |valve | direction |BOOL2 |CARD |
;(sec.) |(trig) |(trig) |(stat) |(stat) |(stat) | | |
; --------- |---------- |-------- |---------- |---------- |---------- |---------- |--------- |
0000 | 0 | 1 | 1 | 0 | 0 | 0 | 0 |
0150 | 0 | 1 | 1 | 0 | 0 | 0 | 0 |
0300 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
; Time to stop 90 seconds
1200 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
; --------- |---------- |-------- |---------- |---------- |---------- |---------- |--------- |
0FFFFh
; End identification

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Washing devices
7
FILE: WW0001.PRG
;
;Date | Name | Comment
;----------- +----------+---------------------------------------------------------------------------------
;14.06.94 |MHOE | Standard program with up to 5 degrees of contamination
;
;********* WW timing in 100msec. cycle (max. 50 entries possible) ***********
;
;Time |Cont. |Water |Sol- |Rake |Inking |Water |Resv |Resv |Resv |Resv |
; |deg. | |vent | |roller |Extra |BOOL1 |BOOL2 |BOOL3 |CARD |
; | <= | | | | | | | | | |
;------- |------- |---------- |------- |-------- |-------- |-------- |---------- |---------- |---------- |---------- |
;------------------------------------------------ Starting block ----------------------------------------------
;4 Solvent thrusts,
;------------------------------------------------------------------------------------------------------------
0000 | 1 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
0002 | 1 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
0200 | 1 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
0202 | 1 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
0550 | 1 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
0552 | 1 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
0750 | 1 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
0752 | 1 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
;------------------------------------------------------------------------------------------------------------
;Rake on,
;------------------------------------------------------------------------------------------------------------
0800 | 1 | 0 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
;-------------------------------------------------- Middle part ---------------------------------------------
;The degrees of contamination 1 .. 5 are processed at the Leitstand in keeping with the selection.
;A solvent thrust is ejected for each degree every 48 seconds.
;-----------------------------------------------------------------------------------------------------------
1150 | 1 | 0 | 1 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
1152 | 1 | 0 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
1630 | 2 | 0 | 1 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
1632 | 2 | 0 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
2110 | 3 | 0 | 1 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
2112 | 3 | 0 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
2590 | 4 | 0 | 1 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
2592 | 4 | 0 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
3070 | 5 | 0 | 1 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
3072 | 5 | 0 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
;------------------------------------------------- End block ----------------------------------------------
;2 Solvent thrusts,
;1-2 Water thrusts, (depending on selection with/without plate washing)
;Inking rollers on (depending on selection with/without plate washing)
;------------------------------------------------------------------------------------------------------------

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7 Washing devices

;Time |Cont. |Water |Sol- |Rake |Inking |Water |Resv |Resv |Resv |Resv |
; |deg. | |vent | |roller |Extra |BOOL1 |BOOL2 |BOOL3 |CARD |
; | <= | | | | | | | | | |
;------- |------- |---------- |------- |-------- |-------- |-------- |---------- |---------- |---------- |---------- |
3073 | 1 | 0 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
3400 | 1 | 0 | 0 | 1 | 1 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
3550 | 1 | 0 | 1 | 1 | 1 | 0 | 0 | 0 | 0 | 0 |
3552 | 1 | 0 | 0 | 1 | 1 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
4000 | 1 | 0 | 1 | 1 | 1 | 0 | 0 | 0 | 0 | 0 |
4002 | 1 | 0 | 0 | 1 | 1 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
4300 | 1 | 1 | 0 | 1 | 1 | 0 | 0 | 0 | 0 | 0 |
4303 | 1 | 0 | 0 | 1 | 1 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
4600 | 1 | 0 | 0 | 1 | 1 | 1 | 0 | 0 | 0 | 0 |
4603 | 1 | 0 | 0 | 1 | 1 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
4800 | 1 | 0 | 0 | 1 | 0 | 0 | 0 | 0 | 0 | 0 |
; | | | | | | | | | | |
4900 | 1 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
;------------------------------------------------------------------------------------------------------------
; End identification
;------------------------------------------------------------------------------------------------------------
0FFFFH

i Increasing of the GTW spray time for spray pipes

Setting at the LSR 1 2 3 4

Spray impulse duration up to PS 335F3 100ms 200ms 300ms 400ms

Spray impulse duration as of PS 335G1 200ms 300ms 400ms 500ms

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 7.2

7.2.1
main swtch cabinet +AX

Overview of the electrical components

B406 B406 B406 B406 B406

B408 B408 B408 B408 B408
B429 B429 B429 B429 B429
Impression cylinder washing device (DZW)

M 217 M409 M409 M409 M409 M409

S 879

S 880

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Y 116 Y 406 Y 407 Y 408 Y 406 Y 407 Y 408 Y 406 Y 407 Y 408 Y 406 Y 407 Y 408 Y 406 Y 407 Y 408

Y 194

delivery +EA +DA +CC +CB +CA +BA feeder

M 217: used fluid pump GTW/DZW-TZW B 406: wash-up device DZW-TZW disengaged M 409: DZW-TZW motor

B 408: wash-up device DZW-TZW engage/disengage Y 406: solenoid valveDZW-TZW engaged-disengaged

S 879: floating switch for
used fluid GTW/DZW-TZW Y 407: solenoid valve DZW-TZW water
high level (low active) B 429: protective switch
Washing devices

Y 408: solenoid valve DZW-TZW washing agent

S 880: floating switch for Y116: solenoid valve return GTW/DZW
Service Training Electronics

used fluid GTW/DZW-TZW

low level (low active) Y194: solenoid valve washing agent suction GTW/DZW
(as of S333)
console +FA
7

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Roland 300
 7

7-14
7.2.2
I I I I I I P.O. P.O. P.O. P.O. P.O.
-A 350/7 -A 350/3 -A 350/3 -A 350/3 -A 350/5 -A 350/5 -A 350/13 -A 350/13 -A 350/13 -A 350/13 -A 350/13
Byte 11 Byte 2 Byte 2 Byte 1 Byte 9 Byte 9 Byte 20 Byte 18 Byte 18 Byte 17 Byte 17
Bit 4 Bit 4 Bit 5 Bit 7 Bit 2 Bit 3 Bit 4 Bit 4 Bit 5 Bit 7 Bit 3
Service Training Electronics

safety safety safety

Overview I/O (DW)
circuit circuit circuit
Washing devices
Roland 300

-A 335 -A 335 -A 335 -A 335 -A 335

14 emergency emergency
stop (+AX) stop (+AX)
Q 409
-A 599
13 evaluation
22 22 of the 8 1
protective
K 409 K 410 B 406 B408 Y 406 Y 407 Y 408 K 14 3x400V K 14
switch
14
21 21 7 2

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Q 234 0V -24V

13 emergency emergency
0V 0V 0V 0V 0V
B 429 stop (+CA) Q 409
stop (+CA)
inductive -24V -24V
-24V -24V -24V protective
switch
-A 335

K 410 K 409

MPS for acknowledge acknowledge TZW-DZW sensor sensor soleniod solenoid solenoid
GTW and message message installed wash-up wash-up valve valve valve
DZW-TZW- DZW-TZW DZW-TZW device device DZW-TZW DZW-TZW DZW-TZW
DZW-TZW DZW-TZW 0V 0V
motors motor motor engage/ water washing
disengaged engage/ disengage contactor DZW-TZW
forward reverse agent M 409 contactor DZW-TZW
disengage motor reverse +BA motor forward
DZW-TZW-
motor
All printing units

circuit diagram: +BA page 45-48

circuit diagram: +C*, +DA page 32-35
 Service Training Electronics Roland 300

Washing devices
7
7.2.3 Function description

Preliminary notes:

This documentation describes the function of the impression cylinder washing device.
The DZW must be configured on the Leitstand and in the "KONFxxx.DAT" of MMS.

Definition of terms:

Pictograms:

DZW Druckzylinder-Waschanlage (impression cylinder washing device)

MMS Modulare Maschinen Steuerung (Modular Machine Control)
high active signal coming
high active signal going

Inputs / Outputs:

DZW ==> MMS

DzwAusgeschwenkt : MMS-DW: A350/5 Input-Byte 9.2
DzwAnFahren : MMS-DW: A350/5 Input-Byte 9.3

MMS ==> DZW

MvDzwSchwenken : MMS-DW: A350/12 Output-Byte 20.4

Y406 B408 B406

Out 20.4 In 9.3 In 9.2

Impression Cyclinder

DZW

1. Transfer Cylinder

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7 Washing devices

Function run DZW

a.) Allow machine to run.

b.) Enter the required DZW washing program (0001 ... 0099) into the mask "Impression/Pre-
selection/DZW" on the Leitstand.
For each printing unit separately it is possible to determine whether the washing process should take
place in it and how long the water and solvent spraying impulse should be (100ms .. 400ms).

c.) The menu point "DZW" in the mask "Impression /Machine" on the Leitstand is switched to "+".
This "+" then briefly changes to '-'. The MMS loads the washing program specified on the Leitstand in
form of a table from the ROM disk of the MMS.
The menu point on the Leitstand computer changes back to "+" after the successful loading and start
of the washing program.

d.) The machine rev speed is reduced to 200 rev/h.

To S336: The starting angle for each printing unit is determined by the initiator "DzwAnFahren" (B408)
on the impression cylinder in the course of the first revolution.
From S337: The washing bar is activated by software.

e.) As soon as the starting angle is determined the processing of the washing table in each printing unit
begins.

f.) The menu point on the Leitstand computer changes to "-" when the washing program comes to an end
in all the preselected printing units. Rev is again increased to basic rev speed.

Disturbances:

a.) Failure of the DZW signal "Swing out" (B406):

A continuous check tests whether the DZW with switched off output "MvDzwSchwenken" (Output byte
20.4) is in the rear position. For this purpose the initiator signal "DzwAusgeschwenkt" (Input byte 9.2)
must be set within three seconds after the switching off of the output. If this is not so, a Fast-stop is
triggered and an error message dispatched.

b.) To S336: Failure of the DZW signal "DzwAnfahren" B408):

A continuous check tests whether the signal "DzwAnfahren" appears cyclically. In this case this signal
(Input byte 9.3) must have changed its status at least once within two machine revolutions. If this is not
so, an error message appears and the washing program is aborted or will not start.

c.) Stopping the machine:

The DZW swings off if the machine is stopped using the keys "NotAus" (Emergency Off) or
"StopHaltSichern" (Stop-Halt-Safe) or if the washing program is cancelled while running.

These functions are monitored via a single channel (only MMS) since they only provide protection to
the machine (injury to people is excluded).

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Washing devices
7
7.2.4 Example of a DZW program

; FILE: DZW0001.PRG ;
;
; Date | Name | Comment ;
;----------+-------+----------------------------------------------
; 07.02.95 |MHOE | Newly created for a test, cycle in degrees
; 18.03.95 |MHOE | Modification with IB
;
; **** DZW-Timing in 1-degree cycle, max. 100 lines *******
;
; Angle |Water |Sol- |Wash- |Wash- |W.mot.|W.mot.|Resv. |
; | |vent |motor |bar |Rückw.|Rü. L.|BOOL4 |CARD |
; |(trig)|(trig)|(stat)|(stat)|(stat)|(stat)| |
; ------|------|------|------|------|------|------|------|
;0. Revolution |------|------|------|------|------|------|
0000 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
0090 | 0 | 1 | 1 | 1 | 0 | 1 | 0 |
0150 | 1 | 0 | 1 | 1 | 0 | 1 | 0 |
0290 | 0 | 0 | 1 | 1 | 1 | 0 | 0 |
;1. Revolution |------|------|------|------|------|------|
0360 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
0450 | 0 | 1 | 1 | 1 | 0 | 1 | 0 |
0510 | 1 | 0 | 1 | 1 | 0 | 1 | 0 |
0655 | 0 | 0 | 1 | 1 | 1 | 0 | 0 |
;2. Revolution |------|------|------|------|------|------|
0720 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
0810 | 0 | 1 | 1 | 1 | 0 | 1 | 0 |
0870 | 1 | 0 | 1 | 1 | 0 | 1 | 0 |
1010 | 0 | 0 | 1 | 1 | 1 | 0 | 0 |
;3. Revolution |------|------|------|------|------|------|
1080 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
1170 | 0 | 1 | 1 | 1 | 0 | 1 | 0 |
1230 | 1 | 0 | 1 | 1 | 0 | 1 | 0 |
1375 | 0 | 0 | 1 | 1 | 1 | 0 | 0 |
;4. Revolution |------|------|------|------|------|------|
1440 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
1530 | 0 | 1 | 1 | 1 | 0 | 1 | 0 |
1730 | 0 | 0 | 1 | 1 | 1 | 0 | 0 |
;5. Revolution |------|------|------|------|------|------|
1800 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
2095 | 0 | 0 | 1 | 1 | 1 | 0 | 0 |
;6. Revolution |------|------|------|------|------|------|
2160 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
2450 | 0 | 0 | 1 | 1 | 1 | 0 | 0 |
;7. Revolution |------|------|------|------|------|------|
2520 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
2815 | 0 | 0 | 1 | 1 | 1 | 0 | 0 |
;8. Revolution |------|------|------|------|------|------|
2880 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
3175 | 0 | 0 | 1 | 1 | 1 | 0 | 0 |
;9. Revolution |------|------|------|------|------|------|
3240 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
;10. Revolution|------|------|------|------|------|------|
3600 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
;11. Revolution|------|------|------|------|------|------|
3960 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |

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; Angle |Water |Sol- |Wash- |Wash- |W.mot.|W.mot.|Resv. |

; | |vent |motor |bar |Rückw.|Rü. L.|BOOL4 |CARD |
; |(trig)|(trig)|(stat)|(stat)|(stat)|(stat)| |
; ------|------|------|------|------|------|------|------|
; 12.Revolution|------|------|------|------|------|------|
4320 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
;13. Revolution|------|------|------|------|------|------|
4680 | 0 | 0 | 1 | 1 | 0 | 1 | 0 |
4900 | 0 | 0 | 0 | 0 | 0 | 0 | 0 |

0FFFFh ; End identification

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7.2.5 Setting the control disk

Observe the following point when setting the Control disk for swinging to/away the DZW:

a) The Control disk must be set in single side printing position of the machine!

b) The table below contains degree values which correspond to the given switching point of the signal
"Swing-to DZW". The values are shown on the display of the 1. printing unit.

c) The switching point is determined as follows:

The sensor is positioned in the window of the Control disk. The diode is "Off". The switching point is
reached when the diode comes on while the machine is moving forward (see drawing below).

view from drive side

plate cam
plate cam

sensor B408
sensor B408

plate cam installed at the impression cylinder plate cam installed at the blanked cylinder
(up to S324) (from S325 to S336)

Switching position of the Control disk with signal "Swing-to DZW"

PU 1. and between PU Last PU Tolerance

1 187.5° ---
2 92.5° 69°
3 357.5° 334°
4 262.5° 239°
+ 0.15°
5 167.5° 144°
6 72.5° 49°
7 337.5° 314°
8 --- 219°

As of S337 the signal for the Wash roller "Swing On and OFF" is
controlled solely by the Software

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7.3 Description of the washing programs (until PS 335D3)

Washing programs for GTW

Program Program
No.
1 Standard washing program
2 Standard washing program A3 and washing agents
with higher boiling point
67 MAN Roland test program
70 Additional program A3 and washing agents with
higher boiling point (with higher water supply than
program 0002 used especially after a longer
production break, e.g. final cleaning)
99 Self-cleaning of the washing device

Washing programs for DZW

Program Program
No.
1 Standard washing program
57 MAN Roland test program
61 Additional program A3 and washing agents with
higher boiling point (with lower water supply than
program 0063)
63 Standard program A3 and washing agents with higher
boiling point
98 Self-cleaning of the washing device
99 Self-cleaning of the washing device (opposite
direction of revolution of the washing brush than in
program 0098)

The washing programs are in the menu AGGREGATE-GTW or -DZW.

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7.4 Description of the washing programs (as of PS 335E1)

The wash-up programs can be selected in the LSR menu [MACHINE] as follows:

• preselection WW + GTW ⇒ wash-up speed = 6000 S/h (GTW-brush does not lift-off when the channel
passes)
• preselection DZW + GTW ⇒ wash-up speed = 200 S/h (GTW- and DZW brush lift-off when the channel
passes)
• preselection GTW ⇒ wash-up speed = 200 S/h (GTW-brush lifts-off when the channel passes)
• preselection DZW ⇒ wash-up speed = 200 S/h (DZW-brush lifts-off when the channel passes)
• preselection WW ⇒ wash-up speed = 6000 S/h
• WW + gumming (program 0201) can be selected alone only (without GTW)

The following programs are available

Washing programs for GTW and DZW (printing units)

Program Program
No.
0001 slightly contaminated
0002 contaminated
0003 very contaminated
0004 paper build-up
0005 biological solvent
0099 self-cleaning of the washing device

Washing programs for GTW and DZW (coating module)

Program Program
No.
0101 slightly contaminated
0102 contaminated
0103 very contaminated
0104 paper build-up
0105 biological solvent
0199 self-cleaning of the washing device

Info: The wash-up program for the ink roller wash-up device is started 0,5s delayed from unit to unit.

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Notes:

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