E2E03 FeederFeedRegister 05

Feeder – Feed Register
Product Training Electronics – ROLAND 200 3
3 Feeder, Feed Register ......................................................................3-3

3.1 Feeder.................................................................................................................. 3-3
Arrangement of the switching elements................................................................ 3-4
Feeder switch cabinet +AB -. Overview................................................................ 3-5
Operation mask - Feeder...................................................................................... 3-6
Seven-segment display on the feeder operation board ........................................ 3-6
Missing sheet detection ........................................................................................ 3-8
I/O-Signals............................................................................................................ 3-9
Program switching unit ....................................................................................... 3-10
Feeder coupling.................................................................................................. 3-11
Setting/Exchange of the angle encoder.............................................................. 3-12
Feeder timing...................................................................................................... 3-13
Air supply............................................................................................................ 3-15
3.2 Feed Register.................................................................................................... 3-17
Electrical double-sheet detection........................................................................ 3-17
Feeder sensors................................................................................................... 3-21
Registering phases............................................................................................. 3-22
© MAN Roland Druckmaschinen AG C 95A 6422 39 - 28.09.2006 3-1

- for certified service technicians only -
3 Product Training Electronics – ROLAND 200
3-2 C95A 6422 39 - 28.09.2006 © MAN Roland Druckmaschinen AG

3 Feeder, Feed Register
3.1 Feeder
1 Pile supporting rails

2 Pile hoist
3 Size adjustment pile stops
4 Suction head
5 Sheet lay down
6 Suction tape feed board
7 Notice board
8 Command board
9 Main switch cabinet
10 Safety area

Arrangement of the switching elements
B134 Y230
S812 S173
S609 Y201
A477:
S604.1 M004
S604.2 M110
S601.1
S601.2
B110 A173 B109 B108 A174 B111 B112 A175
Fig.: Feeder – front view
BMK Description BMK Description

A173 double amplifier M110 suction blower for the suction tape feed
board
A174 double amplifier S173 upper pile limit switch with paper
A175 double amplifier S601.1 lower pile limit switch
A477 program switching unit S604.1 upper pile limit switch
B108 front edge detection, A-side S609 upper pile limit switch
B109 front edge detection, B-side S812 mechanical double sheet detection
B110 side edge detection, A-side S604.2 2nd contact of S604.1
B111 side edge detection, B-side S601.2 2nd contact of S601.1
B112 overrun detection Y201 solenoid valve: feeder clutch
B134 pressure foot sensor Y230 solenoid valve: air supply, feeder
M004 feeder pile motor
until S202: S604.2 = Sxxx

S601.2 = Syyy
S173 = B115

Feeder switch cabinet +AB -. Overview

K015/1 Relay: Pile up (fast, delivery)
K017/1 Relay: Pile down (fast, delivery) X921 X924
K022/2 Relay: Release brake manually
A168
K022/3 Relay: Release brake MD
K022/4 Relay: Release brake by hand (MD)
K063 Contactor: Ventilator, blower, X105 K063
suction tape feed board X001 K097
K079/1 Relay: Crawl speed
K080/1
K081
Relay: Operation
Relay: Main drive inch fwd/back
K101/3 +AB K107
K022/2
K090
K082 Relay: Main drive positioning K015/1
K087
K083 Relay: Main drive forward (mains
contactor) K086 K017/1
K084 Relay: Main drive back (mains K022/4 K091
contactor)
K022/3 K092
K085 Relay: Emergency-Stop (message)
K086 Relay: Main drive stop (RTR) K085 K093
K087 Relay: Main drive Emergency-Stop K084 K108
(RTR)
K083 K103
K090 Relay: Sheet travel active
K091 Relay: Pile up, stop, feeder K080/1 K096/1
K091/1 Time-relay: Pile up, stop, feeder K096
K079/1
K092 Relay: Pile down, feeder
K082 K094
K093 Relay: change pile speed, delivery
K094 Time-relay: Pile down, slow, delivery K081 K091/1
K096 Relay: Pile at top, feeder
X908
K096/1 Relay: Pile at top with sheets, feed. X945 U012
K097 Contactor: Rotation magnet (suction X415
air lock) Fig: Feeder switch cabinet – Overview
K101/3 Monitoring relay: Emergency-Stop
K103 Relay: MV feeder coupling -A168
K107 Relay: Solenoid front lays & cover
X402 X403
guides lock
K108 Relay: Solenoid feeder (air supply)
X400 X401
X001 Terminals
X105 Service plug
U012 Evaluation unit double-sheet-detect. X300 X301
Setting of K107: 55% (version 1)

X200 X201 X202
0 amplification and value
1,1 (version 2)
X110 X111 X112 X113
X106 X107 X108 X109
X102 X103 X104 X015

X001
X002
X003
X004
X005
X101
Fig.: Distributor -–A168 - Overview

Operation mask - Feeder

This mask is used for the preselection of Preselect S/h set act waste
different functions on the feeder. Here it is i 0 100000 5456l 467
possible to preselect or cancel the selection of
NEW ERROR MESSAGE
side edge detection on A-side or B-side. Further,
it is possible to select or cancel the selection of Feeder
ionization, feeder pump and suction blowers.
Side edge A
A line can be selected by the cursor keys. The Feeder pump +
preselection or selection cancellation of a feeder Suction blower +
function takes place via the “+" and “-" keys. Ionization -
The following settings are available:

Print. Feeder Delivery
unit
Side edge: 01-02100-1
“A“ = Side edge detection A-side
“B“ = Side edge detection B-side
“-“ = no Side edge detection
Feeder pump:
“-“ = Automatically on during sheet run or
production
“+“ = Manually on
Suction blower:
“„-“ = Automatically on during sheet run or
production
“+“ = Manually on
Ionization:
“-“ = Cancelled
“+“ = Automatically on during sheet run or
production
Seven-segment display on the feeder operation board

Display of the machine speed or machine angle
The display (1) of the machine speed or
machine angle appears depending on the 1
preselection by the key Angle display on/off and
the operation status of the machine.
v < 600 s/h : Machine angle or speed

v > 600 s/h : Machine speed

Display of sheet arrival A-side / B-side

When the machine is running these displays (2)
show the deviation of the median sheet arrival 2
(the median value is calculated every 5
seconds) from the ideal value.
+22 difference in degrees from ideal

value (early sheet)
-22 difference in degrees from ideal

value (late sheet)
Here an error number is displayed (2) after a

sheet stop. This error number can be deleted by
acknowledging the message by pressing the key
Front guide detection on/off.
Error no. Significance
1 Double-sheet detected by mechanical

double-sheet detection
2 Double-sheet detected by electronic

double-sheet detection
3 Test electrical double-sheet detection
4 Overrun sheet detected
5 Early sheet
6 Late sheet
i Other error numbers from PS 201B1!
The switching status of the different sensors is

displayed (2) in the make-ready mode for paper
run. For this the key "Front guide detection
on/off acknowledge” has to be pressed for more
than 3 seconds. To cancel selection press key
quickly.
The front edge detection sensors are indicated A-side B-side

by the following segments:
The side edge detection sensors are indicated A-side B-side

by the following segments:

The overrun detection sensor is indicated by A-side B-side

the following segments:
The limit switch of the mechanical double A-side B-side

sheet detection is indicated by the following
segments:
The missing sheet detection between the A-side B-side

printing units is indicated by the following
segments: + +
1..6 = transferter 1...6
6 5 4 3 2 1
Missing sheet detection
B116
Fig: Missing sheet detector B116 (until S212)
A new missing sheet detector HRTR 3/44-150-

i S8 (Leuze) with a detection range of 65mm is
used as of S213. The interrogation angle is 40°
earlier than before S213. The cut-out in the
sheet guide for the new sensor has just a
diameter of 20mm.
Fig: Missing sheet detector with the new sheet guide (S213-)

I/O-Signals
CAN-Bus
Switch: STOP safety feeder S015-A596
Switch: Feeder pile up, stop S016-A596 -A330

Switch: Feeder pile down S017-A596
Relay: Feeder pile: up, stop K1.A205 (K091)
Switch release brake S010
ZST Time relay: Feeder pile: up, stop K091/1
Relay: sheet run active K1.A209 (K090)
OUTPUT
Relay: Feeder pile down K2.A205 (K092)
INPUT
Relay feeder up with sheet K3.A205 (K096/1)
Cont.: Blower M110 suct. tapes feed board
Lim. sw.: Feeder pile top limit S604-A477 & K063
K4.A205 (K096)
Contactor: Feeder pump (M200) K028
Limit switch: Feeder pile down S601-A477
Contactor: Ionization system on K250
Contactor feeder pile up K003
Contactor feeder pile down K004
Sensor pressure foot B134
CAN-Bus
Contactor: Solenoid.: Front stop lock K107
Contactor: Solenoid valve feeder coupling

Side edge detect., A- and B-side (B110, B111)
Overrun sheet B112

-A330 K103
Relay: Solenoid feeder air supply K108
OUTPUT
INPUT
Contactor: rot. solenoid (suction air, locking)

Front edge detect. A-side B108, B-side B109
K097
Double sheet detection sensor S812 RTR Dry powdering on
Double sheet detection
Contactor: Sheet run active K1.A209 (K090)

I/O_Anleger.cdr
An additional time relay (K091/1) is used to lock

the pile motors so as to prevent the central
computer from driving the pile motors in
continuous operation. The time relay is pulled in
when the pile motor is activated by the central
computer and released after a maximum cycle
time.
Setting of K091/1: 0,5sec

Program switching unit

Setting:
Set switch S601.1 (and S601.2) lower pile limit

so that it switches, when the L-profile rails (4)
are 30mm above the floor.
I S601.1 Feedback: limit switch main pile

lower (stop)
II S601.2 Limit switch main pile lower I II III IV
(stop)
III S604.1 Feedback: limit switch pile top

IV S604.2 Limit switch pile top
Set switch S604.1 (and S604.2) upper pile limit

so that it switches, when the distance between
guide (1) and the guide rail (2) is 10mm.
1
10mm
(1) Guide
(2) Guide rail
(3) Feeder side frame, B-side
(4) L-profile rail
4
Schalter_S604.cdr

Feeder coupling
The feeder is driven via the drive chains and the
feeder coupling.
The command FEEDER off/on activates the 2
electromagnet of the feeder coupling and the
parts of the coupling lock into position within the
next revolution.
The mechanical connection between the
machine and the feeder is now established.
The feeder coupling (2) is located behind the
angle encoder (1) on A-side.
1
Fig.: Feeder coupling with angle encoder
1 Angle encoder
2 Coupling
3 Pin
4 Spacer disk
5 Bearing cap
6 Shaft
7 Electromagnetic toothed coupling
8 Spacer disk
9 Sprocket
10 Housing
11 Sprocket

Setting/Exchange of the angle encoder

• Switch off machine and disconnect cable on
angle encoder (2; further just AE)
3
• Loosen clamping screws (3) and carefully
pull off AE
• Measure the distance between the coupling

and AE housing and set the same for the
new AE
The AE will be destroyed, if the AE shaft is

! under pressure! Therefore the coupling
should have a backlash of about 0.5...1mm.
2
Fig.: Angle encoder with clamping bolts

• Insert the AE carefully and tighten clamping
bolts (3) slightly.
• Attach cable to the AE and switch on

machine.
• Use the hand crank to turn the machine until

the 16mm pin can be pushed through the
hole in the impression cylinder gear (4) on
DW1into the 16mm hole of the side wall.
• When in this position turn AE to 58° and

tighten the clamping bolts (3).
• Remove the 16mm pin.
Fig: Marking hole on the impression cylinder gear, A-side

Feeder timing
Check feeder timing
• Set the front lays to the highest value of
11mm (6mm gripper bite).
1 2
0
m ,2
m
m ,2
m
0
04-02358-1
Fig.: Front stop adjustment
• Press key [Front lay release ON/OFF] for 3

seconds to activate the test mode
• Press key [Automatic sheet run]. The feeder

and the suction and blast air are activated.
The suction head picks up slowly one sheet.
• Inch several sheets to the feed register.
• Remove first sheet (the subsequent sheets

must be held by the transport rollers) and
continue jogging the machine until the front
edge of the sheet reaches the front lays.
• Read the machine position on the seven-

segment display of the feeder operation
area. Feeder timing is correct if the machine
is set at 168°.

Feeder timing adjustment

• Move several sheets in inching mode to the
feed register and set machine to 168°.
Drive chains (1) must be tensioned correctly

! before checking feeder timing. 1
• Use tensioning pin (2) to hold tape roller so

it does not twist when the bolts (3) are
loosened (clockwise)
• Loosen bolts (3) on the clamping coupling.
• Turn tape rollers until the front edge of the
sheet reaches the front lays.
Fig.: Drive chains
• Use tensioning pin to hold tape roller
(counterclockwise) and tighten clamping bolt
on the clamping coupling.
• Remove the tensioning pin (2).

2
Fig.: Tape roller
Fig.: Clamping coupling

Air supply
• The blast and suction air for the different
blast and suction elements can be adjusted
in several different places.
• The pressure vacuum pump is located
under the feeder.
• Rough adjustment of blast air (1) and
suction air (2) for the feeder and feed
register.
• Air supply for the suction head is on the A-

side.
• Blast air (1) for the front blast nozzles and

auxiliary blast nozzles.
• Suction air (2) for pick-up suckers and
forwarder suckers.
• Lateral pick-up suckers control (3).

• Fine control is possible for the front blast

nozzles and pressure foot (2) as well as for
the auxiliary blast (1) nozzles.

3.2 Feed Register

Electrical double-sheet detection
The evaluation unit of the double-sheet detection is located in the feeder switch cabinet, B-side. It
has the following connections:
(2) DB11Se transmitter double-sheet

detection(-B286)
(3) DB11E receiver double-sheet detection

(B287)
(4) VDB11/4 evaluation unit (-U012)
(6) Connection to machine control

1
2
3
4
5
6
7
8
9
10
11
12
13
Significance of LED’s 1 to 13 on the evaluation

unit (-U012):
LED Significance (LED glows) in Significance (LED glows) in Significance (LED glows) in
number control mode self-test parameter setting mode
1 double-sheet detection ready sufficient level (blinking when
for operation attached capacitive sensor)
2 connection error insufficient level
3 first request
4 second request
5 sheet feed on
6 comparison operating device not
bar-shaped display for the reception
identified (transmitter or
receiver missing)
7 first sheet detected
8 double-sheet detected transmitter or receiver not
level of the optical sensor
identified
9 double-sheet detection
activated and compared
10 missing sheet transmitter not identified
11 error level disturbance to big
(receiver with no ground)
12 second sheet missing capacitive sensor registered
but not identified
13 capacitive sensor identified
K905 Mode: Test

Data exchange double-sheet detection –

Machine control
double sheet detected
double-sheet ready
B286
U012 error message
1st sheet detected -A330

Evaluation
unit
RTR
Double- sheet run - DSD
sheet
detection control single sheet
B287 calibration
control: 2nd sheet
DBK_I_O.cdr
Setting sensors B286 and B287
B286
B287
7,0 +/- 0,5mm

Operation
ON:
• Lay a sheet under the sensor.
14 15 16
• Press the key (16) for approx. 3 seconds.
• The sheet is calibrated and the reference
value is stored.
• The LEDs of the keys (14+16) light up.
2K04_73
• Briefly press the key (14) to switch off the
DBK (double sheet control).
OFF:
• Briefly press the key (14).
• LED switches off.
Setting of the parameter

• Press both keys (14+16) at the same time.
• The key (16) flashes.
14 15 16
• Wait until both keys (14+16) light up.
• Distance between the transmitter and the
receiver is right.
• Switch off the DBK with the key (14).
2K04_73
• Lay a sheet under the sensor.
• Press the key (16) for approx. 3 seconds.
• The sheet is calibrated and the reference
value is stored.
• The LED of the keys (14+16) light up.
• Switch off the DBK with the key (14).
• Press the [Front lay detection on/off] key for
3 seconds.
• Make-ready mode is activated.
• Switch on the DBK with the key (14).
• Lay two sheets under the sensor and press
the [unlock_frontlays] key.
• The key (15) has to flash.
• Push key (15) to confirm.
With stock thicknesses outside the

i measuring range, the LED in the key (16)
blinks.

Feeder sensors
• B108 Front edge detection, A-side (2)

• B109 Front edge detection, B-side (2) 3 4
• B110 Side edge detection, A-side (1)
• B111 Side edge detection, B-side (1)
• B112 Overrun sheet detection (3)
• U012 Double-sheet detection (4)
1
04-02244-1
-A173, -A174, -A175 double amplifier

RTR
I
B111 -A359/3
B.B. 3.5
-A173
I
B109 -A359/3
B.B. 3.2
I
B108 -A359/3
B.B. 3.0
-A174
I
B110 -A359/3
B.B. 3.4
I
B112 -A175 -A359/3
B.B. 3.6

Registering phases
Table registering phases

degree description status
50° * middle suction tape start of suction
100° * blast- and suction elements start of suction
ca. 125° front guides idle position
200° * blast- and suction elements end of suction
230° * middle suction tape end of suction
256° side guides start of pulling
306° - 311° side guides end of pulling
311° swing sucker start of pulling
9° * swing sucker end of pulling
358.5° front guides free
* reference values, resulting from the fabrication


E2E03 FeederFeedRegister 05

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E2E03 FeederFeedRegister 05

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Feeder – Feed Register

Product Training Electronics – ROLAND 200 3

3 Feeder, Feed Register ......................................................................3-3

© MAN Roland Druckmaschinen AG C 95A 6422 39 - 28.09.2006 3-1

3-2 C95A 6422 39 - 28.09.2006 © MAN Roland Druckmaschinen AG

3 Feeder, Feed Register

1 Pile supporting rails

© MAN Roland Druckmaschinen AG C 95A 6422 39 - 28.09.2006 3-3

Arrangement of the switching elements

B110 A173 B109 B108 A174 B111 B112 A175

Fig.: Feeder – front view

BMK Description BMK Description

until S202: S604.2 = Sxxx

3-4 C95A 6422 39 - 28.09.2006 © MAN Roland Druckmaschinen AG

Feeder switch cabinet +AB -. Overview

Setting of K107: 55% (version 1)

X106 X107 X108 X109

X102 X103 X104 X015

Fig.: Distributor -–A168 - Overview

© MAN Roland Druckmaschinen AG C 95A 6422 39 - 28.09.2006 3-5

Operation mask - Feeder

The following settings are available:

Seven-segment display on the feeder operation board

v < 600 s/h : Machine angle or speed

3-6 C95A 6422 39 - 28.09.2006 © MAN Roland Druckmaschinen AG

Display of sheet arrival A-side / B-side

+22 difference in degrees from ideal

-22 difference in degrees from ideal

Here an error number is displayed (2) after a

Error no. Significance

1 Double-sheet detected by mechanical

2 Double-sheet detected by electronic

3 Test electrical double-sheet detection

4 Overrun sheet detected

i Other error numbers from PS 201B1!

The switching status of the different sensors is

The front edge detection sensors are indicated A-side B-side

The side edge detection sensors are indicated A-side B-side

© MAN Roland Druckmaschinen AG C 95A 6422 39 - 28.09.2006 3-7

The overrun detection sensor is indicated by A-side B-side

The limit switch of the mechanical double A-side B-side

The missing sheet detection between the A-side B-side

Missing sheet detection

Fig: Missing sheet detector B116 (until S212)

A new missing sheet detector HRTR 3/44-150-

3-8 C95A 6422 39 - 28.09.2006 © MAN Roland Druckmaschinen AG

Switch: STOP safety feeder S015-A596

Switch: Feeder pile up, stop S016-A596 -A330

Contactor feeder pile down K004

Sensor pressure foot B134

Contactor: Solenoid.: Front stop lock K107

Contactor: Solenoid valve feeder coupling

Overrun sheet B112

Contactor: rot. solenoid (suction air, locking)

Double sheet detection

Contactor: Sheet run active K1.A209 (K090)

An additional time relay (K091/1) is used to lock

Setting of K091/1: 0,5sec

© MAN Roland Druckmaschinen AG C 95A 6422 39 - 28.09.2006 3-9

Program switching unit

Set switch S601.1 (and S601.2) lower pile limit

I S601.1 Feedback: limit switch main pile

III S604.1 Feedback: limit switch pile top