Introduction

Product Training Electronics – ROLAND 200 1

1 Introduction.......................................................................................1-3
1.1 Location of Parts ................................................................................................ 1-3
1.2 Operation Panels - Overview ............................................................................. 1-4
Delivery Operation Panel, A-Side ......................................................................... 1-5
Delivery Operation Panel, B-Side ......................................................................... 1-6
Feeder Operation Panel, B-Side........................................................................... 1-7
Feeder Operation Panel, B-Side, Air Supply ........................................................ 1-8
Operation Panel Printing Unit, A-Side .................................................................. 1-9
Operation Panel Printing Unit, B-Side ................................................................ 1-10
1.3 Mask Structure.................................................................................................. 1-11
1.4 Operation Concept ........................................................................................... 1-12
1.5 Arrangement of the Switch Devices ............................................................... 1-13
1.6 Machine documentation................................................................................... 1-17
1.7 MAN Roland Circuit diagrams:........................................................................ 1-18
Page formating: .................................................................................................. 1-18
How to read Circuit diagrams ............................................................................. 1-19
Systematics of the designations ......................................................................... 1-20

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1 Product Training Electronics – ROLAND 200

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Product Training Electronics – ROLAND 200 1

1 Introduction

1.1 Location of Parts

8
A
+AX
B
1

10

+AB 2
+AA
+BA
+CA
+EA
+CB

+DA 3
4

9 5
6
7
01-01895-1

1 Feeder switch cabinet (+AB) AUSL: delivery side

ANL: feeder side
2 Feeder

3 Printing unit 1 (+BA)

4 Printing unit 2 (+CA)

5 Printing unit 3 (+CB)

6 Printing unit 4 (+DA)

7 Delivery (+EA)

8 Main switch cabinet

9 RCI

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1.2 Operation Panels - Overview

5 1

6 2
4
01-01900-1

1 Operation panel feeder, B-Side

2 Operation panel printing unit, B-Side

3 Operation panel printing unit, A-Side

4 Operation panel delivery, B-Side

5 Operation panel delivery, A-Side

6 RCI

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Product Training Electronics – ROLAND 200 1

Delivery Operation Panel, A-Side

1 Switch Stop-Secure delivery pile

2 Key Delivery pile up

3 Key Delivery pile down 1

05-01902-1

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1 Product Training Electronics – ROLAND 200

Delivery Operation Panel, B-Side

2 F1 F2 F3 F4 F5
3 4 5 6 7 8 9 10

11 1-7 1 2 3 4 5 6 7

12 13 14 15
000

16

7 8 9 17

4 5 6 - +
1 2 3 18 19

- 0 . CLR
20 21

22 23 24 25

10-01903-1

1 LCD display 14 Key Job counter on/off

2 Keys F1 to F5 15 Key Feeder coupling on/off
3 Key Job 16 Number field
4 Key Preset 17 Cursor keys
5 Key Printing unit 18 Key Machine speed "-"
6 Key Damping unit 19 Key Machine speed "+"
7 Key Inking unit 20 Key Automatic production on/off
8 Key RCI 21 Key Automatic paper run on/off
9 Key Make-ready 22 Switch Emergency-stop
10 Key Diagnosis 23 Switch Stop-Secure
11 Keys 1 to 7 24 Key Inch forward
12 Key Water form rollers on/off 25 Key run
13 Key Print throw off
feeder off

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Product Training Electronics – ROLAND 200 1

Feeder Operation Panel, B-Side

1 2
3

15
4 5

6 7 8 9
16 17

10 11 18 19

12 13 14

20 21 22

23 24

Anleger.wmf; *.ai

1 7-segment display (sheet arrival A-side) 13 Key Front lay detection on/off /
acknowledge
2 7- segment display (sheet arrival B-side) push the key >3s: test mode

3 7- segment display (machine speed 14 Key Impression off immediately / Feeder off
/ machine angle)
15 Switch Stop-Secure feeder
4 Key Machine speed "-"
16 Key Inch backward
5 Key Machine speed "+"
17 Key Inch forward
6 Key angle display on/off
18 Key Release brake main drive
7 Key Double sheet detection active / inactive
19 Key Feeder pile up
8 Key Double sheet detection acknowledge
20 Switch Emergency-stop
9 Key Double sheet detection comparison
21 Switch Stop-Secure
10 Key Automatic production on/off
22 Key Operation
11 Key Automatic paper run on/off
23 Signal generator
12 Key Feeder coupling on/off
24 Key Feeder pile down

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Feeder Operation Panel, B-Side, Air Supply

1 Setting front lay shaft B-side

2 Setting front lay shaft A-side

3 Size fine setting side lay

4 Suction air adjustment middle suction tape

5 Blast air adjustment feed board

6 Suction air adjustment swing sucker

7 Suction air conversion side lays on A+B side

8 Suction air adjustment side lays

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Operation Panel Printing Unit, A-Side

1 Signal generator

2 Key Crawl speed

3 Key Inch backward 1 2

4 Key Inch forward

5 Switch Emergency-stop

6 Switch Stop-Secure
3 4

5 6

05-01898-1

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Operation Panel Printing Unit, B-Side

1 7-Segment display

E = make ready 1 2
o = inking unit wash-up
F = ink feed 3 4
P = plate change
t = blanket change 5 6

2 Key Impression off immediately / Feeder off

or Impression on/off 7

3 Key Make-ready "-" (for MAN Roland Sales 8

10
and Service partner only)
9
4 Key Make-ready "+" (for MAN Roland Sales
and Service partner only)

5 Key Water fountain roller on

or overdampening on
11 12
6 Key Ink fountain roller auxiliary drive on/off

7 Key Water fountain roller on/off

8 Key Reserve
13 14
9 Key Ink fountain roller on/off

10 Key Crawl speed

05-01901-1

11 Key Inch backward

12 Key Inch forward

13 Switch Emergency-stop

14 Switch Stop-Secure

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Product Training Electronics – ROLAND 200 1

1.3 Mask Structure

The R200 operation masks have the following structure:

1 2 3 4 5
Job | S/h | Nom. | Act. | Waste
| 0 |100000 | 5456 | 467
-------------------------------+--------
Setting range 360 to 1040 | 0.00
----------------------------------------
6 7

----------------------------------------
Print. |Set |Reset |Zero |Card
substr.|counter|counter|posit. |reader
9 10 11 12 13

1 Name of the menu tree

2 Actual machine speed
3 Nominal print run
4 Actual print run
5 Waste
6 Message area with the following functions:
a) Indication of value ranges of the
expected input
b) Indication of error messages
c) Warning, indicating that the double
sheet detection is off
7 Echo of the current input
8 Mask contents
9 Inscription on key F1
10 Inscription on key F2
11 Inscription on key F3
12 Inscription on key F4
13 Inscription on key F5

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1.4 Operation Concept

Job Sheet
No. of sheets
Reset counter
Setting to zero
JobCard reader Read JobCard
Write JobCard
Eject JobCard
Return

Preseting Printing module

Feeder
Delivery

Printing Water fountain roller

module
Ink fountain roller
Circumferential register
Side register
Pressure adjustment

Damping unit Water fountain roller

Characteristic curve

Inking unit Ink fountain roller

Ductor roller
EPS data Adoption
Setting

Ink slides Working position

Job storage
Intermediate storage
Zero position
Zones parallel Zero adjustment (-> chapter 5)

Make-ready Change-over program Plate change

Blanket change
Return
Washing program Washing ink rollers
Washing blanket
Return
Ink-up

Diagnosis Current message

Last message Old message
Trouble alarms
Return
Total sheet
Settings Date
Time
Language
Missing sheet
Return
Maintenance Oil change
Service (-> chapter 8)
Return

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Product Training Electronics – ROLAND 200 1

1.5 Arrangement of the Switch Devices

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Product Training Electronics – ROLAND 200 1

code Designation
A063 Special equipment: Ionization
A166 Switch box: distributor
A173 Two channel amplifier
A174 Two channel amplifier
A175 Two channel amplifier
A385 Dry sprayer
A394 Special equipment: wash-up device
A477 Programmed switching device
A596 Control panel: B-side, feeder side
A597 Control panel: machine commands
A598 Control panel: A-side, delivery side
A599 Control panel: pile control, delivery, A-side
A600 Control panel: B-side, delivery side
B001 Sensor: pile control
B005 Sensor: min. water fountain level
B108 Sensor: front edge control, A-side
B109 Sensor: front edge control, B-side
B110 Sensor: side edge control, A-side
B111 Sensor: side edge control, B-side
B112 Sensor: overrun sheet control
B115 Sensor: pile control (pile top edge)
B116 Sensor: missing sheet control
B134 Sensor: pressure foot (pile control)
B150 Tachometer monitoring: main drive
B160 Angle encoder
B249 Detector: guard in front of plate- & blanket cylinder
B250 Detector: guard in front of inking & water roller unit
B251 Detector: guard over transferter
B285 Detector: guard over delivery
B286 Special equipment: emitter: double sheet control: feed reg.
B287 Special equipment: receiver: double sheet contr.: feed reg.
B293 Detector: guard above the chain track
B294 Detector: guard in front of inking unit, delivery side
E000 Lighting: delivery
F003 Pressure switch: oil circulation lubrication
F452 Temperature control: main drive, warning (120°C)
F453 Temperature control: main drive, disconnection (150°C)
M000 Main drive motor
M001 Motor: ink fountain roller
M004 Motor: main pile (feeder)
M006 Motor: main pile (delivery)
M031 Motor: water form roller
M100 Motor: ... (only R202)
M101 Motor: water fountain roller
M110 Blower: suction tapes feed board
M200 Blower: feeder (suction air)
M206 Oil pump

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code Designation
M210 Blower: delivery (suction air)
M280 Motor: side register
M281 Motor: circumferential register
M301-M324 Ink slides
M336 Motor: ductor strip width
M400 Motor: printing material adjustment, A-side
M401 Motor: printing material adjustment, B-side
S224 Limit switch: guard between cylinder and delivery drum
S514 Limit switch: guard above swing gripper and feed reg. drum
S523 Limit switch: guard between ink form roller and plate cylinder
S600 Limit switch: pile supporting plate (lower end position)
S601-A477 Limit switch: main pile, lower (stop)
S604 Limit switch: main pile, raise (stop)
S609 Limit switch: pile, top (feeder)
S613 Limit switch: pile supporting plate (end position, top)
S620 Limit switch: sheet running back into the press
S621 Limit switch: pile change mark
S636 Float switch: oil tank
S640 Limit switch: guard between blanket and plate cylinder
S641 Limit switch: guard in front of impression – and blanket
cylinder (+BA, +C*)
Limit switch: guard above delivery (+DA)
S804 Limit switch: brake, main drive
S812 Detector: double sheet control
S829 Limit switch: inspection sheet removal (lever activated)
Y022 Solenoid: front guide blocking
Y025 Solenoid valve: impression on
Y105 Solenoid valve: locking of ink ductor roller
Y201 Solenoid valve: feeder clutch
Y230 Solenoid valve: air supply, feeder
Y301 Brake: main drive

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1.6 Machine documentation

Printing machines of MAN Roland are delivered with an extensive documentation. Respective contents of the
individual files are evident at the coloured indication. All files are in 1 - 2 documentation containers:

Maschinendokumentation
Documentation

Documentation

Documentation

Documentation
Data Base

Data Base

Data Base

Data Base

Orange Files Red Files Blue Files Green Files

 Operating  Spare parts  Electrical  Mechanic
instructions catalogues documentation documentation
• Control console • Mechanical and • Current diagrams • Installation plans
• Machine • Electrical spare part • Cable list • Arrangement plans
• Care and catalogues with • Rack assembly • Railing assembly
maintenance pictures of all parts • Assembly of • Cable duct
• Aggregates- switchgears assembly
documentation • Reference module • Documentation
• Transport and Main drive-
Putting into Converter
operation
• Safety rules

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1.7 MAN Roland Circuit diagrams:

Page formating:

Systematics of the MAN Roland circuit diagrams is described the by following example:

A B C D E F G H

1 2 3 4 6
5

TAG: 1 1.1 0 .0 1 STROMLAUFPLAN BUSVERBINDUNGEN: NOT-AUS ORT MASCH.-TYPE N SERIE:

NAME: RHEE CIRCUIT DIAGRAM 1 0 3 9 E5 8 0 0 3 8
FILMSORTKARTE ERSTELLT
BUS CONNECTIONS: EMERGENCY STOP +Ex R7 0 0 M BLATT: 0 2 2 - DIN A3
AM 1 ANSTATT:
A B C D E F G H

Number Description
1 Type of diagram, e.g. circuit diagram, assignment of switchgears
2 Contents of page
3 Location, Switch cabinet e.g. +Ax, +BA etc.
4 Machine type e.g. R700, R300, R200
5 Page number important for cross reference
6 MAN Roland drawing number
7 Current path important for links to find the switch gears.

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How to read Circuit diagrams

A B C D E F G H

- A600/ 02
/ 1 11 .C

10 11 12 13 14 15 - S 00 0
16

- XB1.A998:4
S

+FX
4
9 - XB1.A6 0 0/ 02 4

- X1 3 .A33 4 4 - X11 .A33 4 4

17

- A334
/ 01 6.A
/ 02 3.A
- X10 .A3 34 4 - X2 6 .A3 3 4 8 - X2 6 .A3 3 4 7 - X1 0 .A3 3 4 3

I - 0V.X28.A342:4
/ 0 11 .E
I - 0V.X28.A342:3
/ 0 11 .E

- A353-1.2
8
- A353-1.3

- X2 8 .A3 4 2 3 4 8 - X2 8 .A3 4 2 7
18

/ 017.C
/ 017.C

- XB3 .A3 53 4 - XB3 .A3 5 3 3

- D4.A342

- D12.A342

6B - A342
/ 02 1.A - K4 .A3 4 2 - K12 .A34 2
5B 19
INPUT INPUT
/ 02 3.A
-A353/ 03 -A353/ 03
/ 10 5.A - K10:7 / 1 05 .A
/ 0 25 .C
BYTE:BIT 1 .3 BYTE:BIT 1 .2 20
3 3
NOT-AUS: LEITSTAND NOT-AUS: AUSLEGER
1 2 / 0 2 4B 1 2 / 02 4 B
EMERGENCY STOP: CONTROL CONSOLE DEVICE EMERGENCY STOP: DELIVERY
6 6

4 5 4 5
21
TAG: 1 1.10 .0 1 STROMLAUFPLAN BUSVERBINDUNGEN: NOT-AUS ORT MASCH.-TYPE N SERIE:
NAME: RHEE CIRCUIT DIAGRAM 1 0 3 9 E5 8 0 0 3 8
FILMSORTKARTE ERSTELLT
BUS CONNECTIONS: EMERGENCY STOP +Ex R7 0 0 M BLATT: 02 2- DIN A3
AM 1 ANSTATT:
A B C D E F G H

Number Description
8 Cross reference to page numbers / current path, switch gear is to find on these pages.
9 Switchgear indication (BMK).
10 Border line of the switchgears, here: Circuit board.
11 Plug connector designation with plug number. BMK and pin number.
12 Cross reference to other switchgears on further circuit diagram (here: +FX).
13 Internal junction lines are drawn in dot line.
14 These dots indicate electrical junctions
15 Safety-relevant component, must be replaced by component of same type
16 The wave line is a note of potential branches on circuit boards, exact info. is to find in the
reference module
17 not used on R200
18 Inputs, to find on input board in rack A353, slot 03, cross reference see point 8.
19 Byte and bit number of the input.
20 Description of the function of the current path in German / English.
21 Pin assignment of the relay / contactor, the contact shown here is to find in the circuit
diagram on page 24 current path B (cross reference).

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Systematics of the designations

Electrical resources are marked through indication blocks by signs. Signs are used for the distinction of these
blocks and for a complete indication. Systematics used with MAN Roland orient themselves at the
IEC 1346-1(DIN 40719 part of 2).

Here an example:

= R200 + BA – K 052 : 13
overall allocation Location Type of Counting no. Terminal
(system, machine) switchgear

The indication of the overall allocation is not used in MAN Roland circuit diagrams.

In the following table are the most important switchgear indications:

Letter Description Examples at the printing machine

A Modules Distributor boards, racks
B Sensors Proximity switches, light barriers
E Various devices Switch cabinet ventilation, lighting
F Protection devices Fuses, pressure switches
G Generators, Power supplies Power supplies, main drive rectifier
H Signalling equipment Signal lamps, signal horn
K Relays, Contactors Main contactors, auxiliary contactors
L Inductivity Chokes at frequency converters
M Motors Main drive motor, positioning motors
Q Heavy current switchgears Main switch, motor protection switches (trips)
R Resistances Potentiometer, resistors
S Switches Push buttons, limit switches
T Transformers Transformers for control circuits
U Converters Frequency converter
X, XB Terminals, plugs, sockets Terminal strips, connectors
Y Solenoid operated mechanical mechanisms Solenoid valves, solenoid operated pawls
Z Filters Filters at frequency converters

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