Operating Manual

PECOM Press Center

Reporting System
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Operating Manual – PECOM Press Center Newspaper Presses – Reporting System

 ■ manroland AG
Stadtbachstraße 1
86219 Augsburg
Germany
■ Telephone +49(0)82 14 24-0
Telefax +49(0)82 14 24-33 03
Telegramme Manro Augsburg

■ www.manroland.com

The copyright of this technical documentation

remains with manroland AG.

All rights, in particular the right to reproduction and

distribution as well as translation, remain with
manroland AG. No part of this documentation may
be reproduced in any way (print, photocopy,
microfiche or others) without written consent of
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manroland or be stored, processed, reproduced or

distributed by means of electronic systems.

Any misuse will be prosecuted and offenders be

held liable for the payment of damages.

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 1 Reporting of machine events.....................................................................................4
1.1 Overview ........................................................................................................................... 4
1.2 Elements of the console mask "Alarm tables" on information screen ............................... 5
1.3 Event categories ............................................................................................................... 6
1.4 Operating locks ................................................................................................................ 8

2 Acknowledging alarms .............................................................................................10

2.1 Need to acknowledge...................................................................................................... 10
2.2 Acknowledgment key ...................................................................................................... 12
2.3 Fault message field ........................................................................................................ 13

3 Operation ...................................................................................................................14

4 Display of alarms and operating reports ................................................................15

4.1 "Current alarms" table ..................................................................................................... 15
4.2 "Stored alarms" table ...................................................................................................... 16
4.3 Operating messages ....................................................................................................... 17
4.4 Output of the internal coding of a message .................................................................... 18
4.5 Fast problem identification .............................................................................................. 19
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 Reporting of machine events 1

1 Reporting of machine events

1.1 Overview
During operation of the MAN Roland printing press,
events take place that are either caused by the
operator or occur spontaneously in the press or in
the PECOM automation system.
The events and the effect they have on the operating
condition of the press are displayed on each console
assigned to the press concerned. Depending on
their significance, the events are classified as
• Alarm
• Warning
• Locking event or
• Operating message.
All these events displayed at the console are
described generally as "messages".
Alarms, warnings and locking events are logged in
two alarm tables -
• a "current alarms" table and
• a "stored alarms" table.
The "current alarms" table contains only those
problems and locks currently effective, while the
"stored alarms" table contains a list of the last 100
alarms, warnings and locking events.
Operating messages are separately recorded in the
"messages" table.
To keep the operator permanently aware of current
alarms, the most serious ones are displayed in the
general info block that appears on the monitor in
every selected function.
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 Reporting of machine events 1

1.2 Elements of the console mask "Alarm

tables" on information screen

General
info block

General
info block

2 5

1 3 4

[1] Verbal description of the event and where on the machine it occurred; colour coding to
indicate the gravity of every event (=allocation to an event category)
[2] Machine lock condition
[3] Effect of the event on the operating condition of the machine
[4] Information regarding necessity of acknowledging the event

[5] Alarm message field

Tab 1 Elements of the console mask "Alarm tables" on information screen

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 Reporting of machine events 1

1.3 Event categories [1]

Events are subdivided into categories depending on
their effect on the machine and further makeready
or production; decisive here is the operating
condition of the machine when the event occurs.
The categories indicate the importance of the event.

Occurrence of an event In operating Effect

Category
Caused by operator On the machine condition Console entry
Opening a grill guard - Machine Inch forward lock Lock event
stopped Fault message
field, fault table
Closing a grill guard - Machine Cancels inch -
stopped forward lock1
Deletes the fault
message field and
the entry in the fault
table
Opening a grill guard - Production Safe stop, inch Alarm
speed forward lock
Fault message
field, fault table
- Oil pump fault Production Warning
speed Fault message
field, fault table
- Expiry of response Production Safe stop
time speed Fault message Alarm
field, fault table
Pressing the - Reel change Press speed does Lock event
acceleration key not increase
If applicable, fault
message field, fault
table
Pressing the - (Production Impression ON Operating message
impression ON key speed) Message table
Pressing any of the - Machine Total lock Lock event
safe stop keys - stopped Fault message
field, fault table
Pressing the safe Production Safe stop, total lock Alarm
stop key speed Fault message field,
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fault table

Tab 2 Event categories

1. As long as there is no other current lock event

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 Reporting of machine events 1

If a problem occurs on a non-coupled press

component, this is categorised as an event with
minor importance.
A problem occuring on a press component that can
be optionally assigned to two machine sections
(folding units) is reported at the consoles of both
machines, provided that neither machine is in
production.
The importance of the message is determined by
the current coupling status of the press component
to the two machines.
If a machine section is in production coupled to an
optionally assignable component, any problems
occurring with this component are displayed only on
the consoles of these coupled components and not
on the consoles of the other machines.
Problems occasionally lead to subsequent
problems. When such problems lead to machine
"safe stop", the original problem (→first down report)
is highlighted.
The importance of an event (= categorisation) is
indicated by different colours used for the event
messages displayed at the control console.

Colour Event importance

dark red First down report;
the event was the original cause for a machine stop (alarm).
Example: pressing a "safe stop" key.
red An event that caused the machine to shut down via "safe stop" or "run down
stop" (alarm).
Example: web break.
orange An event that will soon cause the machine to shut down via "safe stop" or
"run down stop" (warning).
Example: dirty oil filter.
ochre An event that activated a lock for (washing), acceleration, webbing-up or
inching forward (lock event).
Example: webbing-up is locked when the inking rollers are in the ON
position.
grey A fault event without lock effect (alarm).
Example: bay window motor fault.
black Other events (operating messages).
Example: ink presetting completed.

Tab 3 Importance of an event and its display colour

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 Reporting of machine events 1

1.4 Operating locks [2], [3]

Events on the machine can lock it and prevent
further operation. Every message entered in the
alarm table includes information on the lock effect
this has ("individual lock condition").
Depending on the coupling status, the lock effect
can apply to only one press component (e.g. printing
unit) or to all coupled components.
If the lock effect applies to all coupled components,
this is also indicated in global "machine lock
condition". If several events are causing the lock
condition, the global machine lock condition
indicates the most serious one. The machine lock
condition indicates which operations (inching
forward, webbing-up, production run) are enabled or
locked.
The individual lock condition is indicated alongside
the related message in the alarm table and the
global machine lock condition is displayed in a
separate symbol in the general Info block that is
visible in every selected function.
Graphic colour-coded symbols are used to indicate
the individual lock conditions resulting from the
individual messages as well as the global machine
lock condition.
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 Reporting of machine events 1

Machine lock Individual lock

Lock indicated Comments
condition condition
no lock
green

washing locked lock does not apply to all

ochre coupled components
acceleration locked
green red

webbing-up locked
green red (crawl speed locked)

automatic webbing-up lock applies only for the

green red locked webbing-up operation
concerned, not for all
coupled components.
inching forward locked
green red

inching backward locked because inching backward

green red is only possible for
uncoupled printing units, it is
logical that the lock only
applies to uncoupled
printing units.
total lock
red (caused by safe stop)

Tab 4 Lock conditions

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 Acknowledging alarms 2

2 Acknowledging alarms

2.1 Need to acknowledge [4]

The press control system will only release a
machine operation lock after the cause of the
problem has been eliminated.
The PECOM system can automatically recognise
that certain problems have been eliminated. Closing
a grill guard is one example.
With such problems, the operator does not have to
expressly acknowledge to the control console that
the problem has been eliminated; once the problem
has been corrected the messages automatically
disappear from the alarm message field and from
the "current alarms" table.
The elimination of other problems however must be
acknowledged by the operator. This is necessary
when the PECOM system cannot automatically
recognise that the problem has been eliminated
(e.g. if the oil filter has been changed following the
message "dirty oil filter", this message must be
acknowledged at the control console); when it must
be ensured that the operator has been made aware
of the problem; or when the problem must be
acknowledged at another part of the machine (e.g.
in the switch cabinet) instead of at the control
console.
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 Acknowledging alarms 2

Whether acknowledgement is needed and where

this must be must be done is indicated by a colour
allocated to each message in the Q field:

blue acknowledgement needed at

external unit or computer
yellow acknowledgement needed at a
console
green acknowledgement can be done at
a console or at external unit/
computer
black no need to acknowledge

Tab 5 Need to acknowledge

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 Acknowledging alarms 2

2.2 Acknowledgment key

Should a problem need to be acknowledged at the
PECOM Press Center, this is done by pressing the
"alarm acknowledged" key on the right side of the
touch screen.
This deletes all messages in the "current alarms"
table; unresolved problems are entered again;
resolved problems or problems accepted through
acknowledgement no longer appear in the table.
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 Acknowledging alarms 2

2.3 Fault message field [5]

The fault message field is part of the "general Info
block" in the console masks.
As with the entire Info block, it is visible in every
function. When there are no problems, the field is
empty. Otherwise the most acute current fault is
displayed here. If there are two or more problems all
equally acute, then the one that occurred first is
shown.
The fault message field contains an entry in the
case of events that lead to
• stop message (safe stop or run down stop),
• fault message with lock effect or
• fault message without lock effect.
In the event of a machine stop, it is ensured that the
original event (first down report) is shown in the fault
message field.
The most acute of the current messages is always
shown in the fault message field.
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 Operation 3

3 Operation
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 Display of alarms and operating reports 4

4 Display of alarms and operating

reports

4.1 "Current alarms" table

The "current alarms" table can be called up in the
main menu "alarms" by pressing menu key
"CURRENT ALARMS".

The table contains all problems or lock events that

are current at that very moment:
• stop message (safe stop or run down stop),
• fault message with lock effect,
• fault message without lock effect and
• lock events.

With every message, the time the event occurred,

the type of acknowledgement needed and the lock
resulting from the event (individual lock condition) is
noted.
The "current alarms" table displayed on the
console monitor reacts dynamically to changes in
machine condition. Newly arriving messages are
immediately entered and can be seen by the user,
while the disappearance of conditions not needing
acknowledgement causes the relevant message to
be deleted.

The complete alarm table can accommodate 100

messages. 20 are grouped on each monitor page.
The monitor pages can be changed using the clear
text keys "previous page" and "next page".
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 Display of alarms and operating reports 4

4.2 "Stored alarms" table

This table can be called up in main menu "Alarms"
by pressing the menu key "STORED ALARMS.

The table contains a record of the last 100 stop and

fault events. Its form is identical to the "current
alarms" table.

20 messages are grouped on each monitor page,

which can be changed using the clear text keys
"previous page" and "next page".

The "stored alarms" table works as a loop store:

the oldest entries are written over by newly arriving
messages.
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 Display of alarms and operating reports 4

4.3 Operating messages

The "Messages" table can be called up in main
menu "Alarms" by pressing the menu key
"MESSAGE".

The table contains all messages that are not

classifed as alarms, warnings or lock events. The
time the message was entered is always included.
The table can accommodate up to 200 messages.
The oldest messages are overwritten by newly
arriving ones.

20 messages are grouped on each monitor page,

leafing forward or backward can be done using the
clear text keys "previous page" and "next page".
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 Display of alarms and operating reports 4

4.4 Output of the internal coding of a message

The PECOM Press Center system uses
unambiguous internal coding for the messages.
Access to the code numbers is important for the
operator when
• the operator cannot understand a message text
or
• an empty message line appears, which occurs
when no text has been assigned to an event.
With the aid of the code numbers, MAN Roland can
clearly identify the message and where necessary
take the appropriate action.

The internal coding can be accessed as follows:

– press the clear text key "Help" to open the
"coded message field" (white field with the
internal code number) on the monitor with the
code number of the top message visible on
the monitor. A magenta-coloured arrow
appears simultaneously in this line.

– use the vertical arrow keys to move to the

desired message line.

The code number for the message in the line where

the magenta arrow stands now appears.
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 Display of alarms and operating reports 4

4.5 Fast problem identification

The machine lock condition in the general Info

block informs the operator at all times about which
machine operating conditions are locked. Detailed
information on the reason for the lock can be
obtained by calling up the current alarms table. This
will contain at least one message in which the
individual lock condition corresponds to the global
machine lock condition - and this will be the cause
of the machine lock.
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