Service Training Elektronic Roland 700

Communication systems 3
3 Communications systems
3.1 SPS-Loop

3.1.1 SPS Loop structure

3.1.2 Jumper positions in the SPS Loop
3.1.3 Fibre optic modules
3.1.4 Error diagnosis SPS Loop
3.1.5 Fibre optic cable test
[Link] Test procedure for SPS Loop
[Link] Test procedure for Process Loop
[Link] Measuring
3.1.6 News at the Leitstand computer from series 716/717
3.1.7 From SPS to MMS
3.1.8 Jumper positions on the MMS master board
3.1.9 Diagnosis program STATUS 7
3.1.10 Creating STATUS 7 (*.ANZ) files

3.2 Process Loop

3.2.1 Process Loop structure

3.2.2 RCI (Remote Controled Inking)
3.2.3 MAVO rack
3.2.4 Color rack
3.2.5 Error diagnosis Process Loop

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3 Communication systems

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 Service Training Elektronic Roland 700

Communication systems 3
3.1.1 SPS Loop structure

Leitstand computer
-D001 in +Fx
Glass fibre optical conductor
Station 22, SPS/LSR (orange insulation)
MMS with
SPS bus master -Slave-

Slot 5 Slot 6

Caution:
All further optical conductors
are made of homogenous plastic
(light gray insulation)

B12

Station 21, UWR

-A358
-Slave-

Station 2, delivery Slot 8

-A353
-Slave-

Slot 6

B12

Station 14.. 16, coating module

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

Slot 8

Station 5...13, middle machines

-A350 Station 3, general
-Slave- -A354
-Slave-
Slot 6
Slot 6

Station 4, feeder
Station 1, feeder
-A350
-A356
-Slave-
-Slave-

Slot 6
Slot 6

SPSLOOP2_E.PRZ

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3 Communication systems

3.1.2 Jumper positions in the SPS Loop

station station name designation location

1 feeder -A352 +AB
2 delivery -A353 +EA
3 general -A354 +AC
4 feeder machine -A350 +BA
5 center machine -A350 +CA
6 center machine -A350 +CB
7 center machine -A350 +CC
8 center machine -A350 +CD
9 center machine -A350 +CE
10 center machine -A350 +CF
11 center machine -A350 +CG
12 center machine -A350 +CH
13 delivery machine -A350 +DA
14 coating module 1 -A548 +JA (from series 717)
15 coating module 1 -A356 +EB (up to series 716)
15 second extension -A356 +EB (from series 728)
16 coating mudule 2 -A548 +JB (from series 717)
17 perfecting device -A459 +KA
20 RTR -A359 +AA
21 UWR -A358 +AD
22 slave in Leitstand -W001 +Fx

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Communication systems 3
3.1.3 Fibre optic modules

Fiber optic system up to series 713 (and for all R600D machines):

Fiber optic module: Hewlett-Packard

B 37V 0196 70 (R8 =182 Ohm) for cable length 2 to 15
B 37V 0639 70 (R8 = 52 Ohm) for cable length15 to 30

For spare parts (R8 can be different):

A 37V 1253 70 for cable length 2 to 15 m,
A 37V 1254 70 for cable length 15 to 28 m.

Receiver
(blue)
Transmitter
(grey)
R10
R9
R8

Fiber optic system as of series 714:

Fiber optic cable:

For the connection between main switch cabinet (+Ax) and the console (+Fx) glas fiber is used (orange insulation,
imprint: SIEMENS).
Other connections made out of plastic fiber (black insulation, imprint: SIEMENS).
Fiber optic module: Toshiba
. 37V 1005 70 for any cable length

LED on for
receive O.K.

Receiver

J1 plugged in Transmitter

General:
For trouble shooting a service set to measure the attenuation
of the fiber optic loop components can be ordered (order no.: 0 37X 2829 90).

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3 Communication systems

3.1.4 Error diagnosis SPS Loop

Switch on current
(main switch)

Possible causes:
- Slave computer defect
- LWL module defect (only on RTR, UWR)
- DPR slave computer defect
- Power supply slave computer missing
LED's on slave computer - SPS bus master (MMS board, slot 5) defect,
address
no flashing to interrupted if no LED flashing
assignment
position , - LWL cable defect
successful?
LED's of subsequent slaves
off Test tools:
- RODIMO: SPS bus master, state, status O.K...?
- RODIMO: SPS bus slave, view, visualize log
yes
- Damping measuring:
Check LWL cable by Fiber optic power meter

LED's on slave computer Bus system is

are permanently on in loop mode

yes

Possible causes:
- Wrong slave sequence in the loop
- Wrong mounting of the slave rack(s)
Comparison - Digital/analog I/O boards in address part defect
SPS Output does not
of nominal-actual no
- Wrong nominal configuration (MMS Program)
function in active mode,
configuration
SPS loop is in idle mode
O.K.? Test tools:
- RODIMO: SPS bus master, state, Configuration ?
- RODIMO: SPS bus master, other, log

yes

Possible causes:
- MMS program: is correct version 'loaded' ?
'Bell signal' O.K. ?, - MMS board defect, power supply ?
no
SPS output O.K. ? yellow LED on MMS
board flashing ? Test tools:
- RODIMO: SPS bus master, other, log
......, error
- RODIMO: SPS bus master, state, status
- Status 9: Check configuration

SPS loop 'running',

Data communication between
master and slaves O.K.

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Communication systems 3
3.1.5 Fibre optic cable test

Necessary tools

A service set for measuring levels on a fiber optic cables (0 37X 2829 90) consisting of:

Measuring device "fiber optic meter 18XTA"

HP adapter for fiber optic cables with HP connector (used in all R600D presses and R700 presses to series
713)
TOSHIBA adapter for fiber optic cables with TOSHIBA connector (used in all R700 presses starting from
series 714)
Test EPROM
96-pole adapter board for HP fibre optic cables (A 37V 1239 70)
96-pole adapter board for TOSHIBA fibre optic cables (A 37V 1244 70)
(HP = Hewlett Packard)

[Link] Test procedure for SPS loop

1. Insert test EPROM in SPS-Bus-Master

> to series 716:

Replace EPROM in location U30 on SPS-Bus-Master board; +F*, -A365, slot7
and restart the system.

> from series 717:

Replace EPROM in location U18 on MMS board ; +F*, -W001, slot 5, and
restart system.

2. Disconnect receiving fibre optic cable at the next following SPS bus slave (see loop cable diagram) and plug into
the specially designed socket of the measuring device 18XTA.

3. Measuring! See that measuring takes place in correct measuring range.

4. Disconnect SPS bus slave processor from the next SPS bus slave (see loop cable diagram) and replace by HP
adapter board or TOSHIBA adapter board. Connect both fibre optic cables. Disconnect at the next following SP
bus slave (see loop cable diagram) the receiving fibre optic cable and plug into the socket of the measuring device.

Caution:
In the end the SPS bus slave in the central console (+F*, -W001, slot 6) must not be forgotten. The EPROM
location U15 is replaced for measuring purposes by the test EPROM.

5. Repeat points 2., 3. and 4. until the whole SPS loop has been measured.

6. Replaces the original components in there right position.

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3 Communication systems

[Link] Test procedure for process loop

1. Replace EPROM in location U20 by TEST EPROM on process bus master in +F*, -W001, slot 6 and restart
system.

2. Disconnect receiving fibre optic cable at the next following process bus slave (see loop cable diagram) and plug
into the specially designed socket of the measuring device 18XTA.

3. Measuring! See that measuring takes place in correct measuring range.

4. Disconnect process bus slave processor from the next process bus slave (see loop cable diagram) and replace
by HP adapter board or TOSHIBA adapter board.
Connect both fibre optic cables. Disconnect at the next following process bus slave (see loop cable diagram) the
receiving fibre optic cable and plug into the socket of the measuring device. Measuring.

5. Repeat points 2., 3. and 4. until the whole process loop has been measured.

6. Replaces the original components in there right position.

[Link] Measuring

1. Switch on measuring device and set wave length by selection key.

> HP fibre optic cable: 660 nm (for glass and plastic)

> TOSHIBA fibre optic cable: 670 nm (for glass and plastic)

If it is impossible to select 670 nm pressselection key for at least 3 sec. and then select the right wave length.

2. Preset dBm measuring dimension by selection key dBm/Watt.

3. Measure fibre optic cables as described on pages 1 and 2.

> limit values for H fibre optic devices:

min. level -22.5 dBm max. level -17.5 dBm

> limit values for TOSHIBA fibre optic devices:

min. level -26.5 dBm max. level -11.0 dBm

If the actual value are below or above the limit value then check:

fibre optic module

location of the fibre optic cables (min. bend radius: 50 mm)
the +5V power supply voltage of the rack must be within the range of +5.0V and +5.15V (important with the
HP system)
check the fibre optic plu

Note:
When using the supplied reference cable it is also possible to measure the transmitting output of the fibre optic
modules.

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1
Slot:

+ 5V

+ 12V
- 12V

+ 5V
+12V

GND
2

+ 5V

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

Reserve

3
Option: Multifunctionboard (same as in Slot 8)

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4
SPS Bus Slave 22 (LED upper left)

Data Base Documentation

Prozeß Bus Master (LED upper right)

COM1 STATUS7 RODIMO

5

from series 717 : MMS (Modular Maschinen Steuerung) with integr. SPS Bus Master

Process FO SPS FO
6

RODIMO
V24
SPS Proz

Interfaceconverter (SPS Bus Slave and Process Bus Master)

Token Ring Interface

with PS2 adapter

V24
V24

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7

IBM Token-Ring (Option, connection via serielle interface

to other machines or TPP)

IBM compatible keyboard

8

LPT1 COM5 COM4 COM3 COM2

HDD

Multifunctionsboard
Zugriff

RODIMO
9

F VGA
VGAOut digital VGA OUT
F
COM1
LSR CPU with integrated graphic-controller
COM4 =

VIDEO IN
COM3 = FDM

VGA OUT VGA IN

10
LPT1 = Printer

Fast sreen machine 2 (Option, for Videomagnifier)

COM5 = Kassette
COM2 = Rollerball

Floppy Disk Drive (FDD)

2 HDD (each 270 MB)
HDD 1 HDD2

COM1= Foilkeyboard
C:\ D:\
11

E:\ G:\
F:\ H:\
Communication systems
Service Training Elektronic

3
Roland 700

3.1.6 News at the Leitstand computer from series 716/717

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3 Communication systems

3.1.7 From SPS to MMS (from series 717)

From series 717 there is no SPS rack (Klöckner-Möller) in the Leitstand of the R700 machines anymore.

The machines are now controled by by a so called MMS (Modula Maschinen Steuerung = Modula machine
control). The MMS master board is plugged in slot 5 of the new Leitstand PC (by company Eckelmann).
The MMS master is a board with a 80386 DX CPU with 25MHz.
The machine Program is stored on flash Eproms (512 kB) and has to be loaded via floppy disc drive.
The fibre optic cable connection now is going to the MMS master board.
For service there is an Interface on the MMS master board for the RODIMO program (-X28) and for diagnostic
program STATUS 7 (-X29). Both connections with RODIMO cable.

yellow LED: program is running

red LED: power supply
green LED: SPS-loop
X27 X26

X26: fibre optic cable receiver (SPS-bus-master), system Toshiba

X27: fibre optic cable transmitter (SPS-bus-master), system Toshiba

X28

X28: interface to SPS-bus-master (RODIMO)

X29

X29: interface to machine control program (STATUS 7)

X30

X30: COM1 (of SPS-bus-master) for direct storing of machine control program vi
Notebook

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Communication systems 3
3.1.8 Jumper positions on the MMS master 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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3.1.8 Jumper positions on the MMS master board

Jumper connected PINs

J1 plugged in
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 plugged in

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Communication systems 3
3.1.9 Diagnosis program STATUS 7

Installation disk

MAN Roland Druckmaschinen AG

Mühlheimer Straße 341
D-63075 Offenbach am Main

0 35 D XXXX 35 [Link]-x
SPS-MMS Status 7

(C) MAN Roland 1998

note:

this program depends on MMS program version. Make sure, that the Status 7 version is the same like on MMS
program floppy disks.

Installation of STATUS 7 to hard disk

Insert floppy disk in drive A: of the notebook an type in

A:\install

and confirm it by pressing the Enter-key.

The installation program creates a directory called STA7 on the hard disk drive and copies all necessary files and
subdirectories to it.

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3.1.9 Diagnosis program STATUS 7

File structure of STATUS 7 (example of V04.56)

C:\STA7

04_5 ANZ
1_conf.anz
1_io.anz
REF 1_statio.anz
2e_air.anz
2e_deliv.anz
[Link] 2e_feedr.anz
[Link] 2e_mrdy1.anz
[Link] 2e_mrdy2.anz
2e_prod.anz
io01_ab.anz
io02_ea.anz
[Link]
io16_jb.anz
[Link] 1_conf.lis
[Link] 1_io.lis
r700shrt.m8
[Link]
[Link] io16_jb.lis

C:\STA7\04_56: Contains all necessary files fo

the program run

C:\STA7\04_56\REF: Contains reference files to manage

the access to program variables
(e.g. I/O signals)

C:\STA7\ANZ: Contains diagnostic files of machine

control (ASCII files)

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Communication systems 3
3.1.9 Diagnosis program STATUS 7

1_conf.anz = machine configuration

1_io.anz = general overview I/O-signals
1_statio.anz = Overview I/O-signals (select station
no. by +/- keys
2e_air.anz = Air supply
2e_deliv.anz = Delivery
2e_feedr.anz = Feede
2e_mrdy1.anz = Release of machine run (part 1)
2e_mrdy2.anz = Release of machine run (part 2)
2e_prod.anz = Production
io01_ab.anz = I/O-list standard rack (station) +AB
io02_ea.anz = I/O-list standard rack (station) +EA
.
.
.
.
io16_jb.anz = I/O-list standard rack (station) +JB

How to start the diagnostic program STATUS 7

- Install the interface connection with the "RODIMO cable" (F 98L 1000 90)

COM 1
MMS board in LSR
LAPTOP
PC

X28

X29

X30

- Start the program by enter:

C:\STA7\0X_XX\start

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3.1.9 Diagnosis program STATUS 7

- Automatical initialisation of the interface:

Initialize: connection to MMS by COM1, 38400 Baud

Possible error message:

No connection to MMS-board

Okay

Possible reasons:
a) Interface connection wrong established
b) MMS program does not run (yellow LE
on MMS-board is off

- Menu if initialisation is successfull:

ONLINE - State display

F1 - State display
F2 - File selection ...\1_conf.anz

ESC - Exit

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Communication systems 3
3.1.9 Diagnosis program STATUS 7

After pressing F1 the program part "machine configuration" is displayed (The file [Link] is loaded
automatically after program start)

Hex Dec Bin All Start Pause View Trig Right Find Goto
25.12.98 [Link]

Certain functions are selectable by entering the emphasized letters:

Hex All actual values are displayed in hexadecimal mode

Dec All actual values are displayed in decimal mode

Bin All actual values are displayed in binary mode

(useful if byte values are displayed)

All Simultaneous display of actual values in hex, dec and

bin mode

Start active automatically after selection of a program part

with F1; Online display (also the status counter /-memory
is active (counter in lower left corner of the screen));
The status counter is reset after cursor up/down

Pause no more online display; status counter /-memory

is frozen

View Actual value display off/on

Trig No function yet

Right By enter cursor right/left the status memory counter is

polled, if Start is deactivated

Find Used for searching text portions and to select the block
number (e.g. block no. 00005)

Goto To select a line number in a block

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3.1.10 Creating STATUS 7 (*.ANZ) files

We recommend to use the Norton Commander (NC) but any other editor is also possible.

With the example of the water level sensors at the training R702 with coating module we create the following
testprogra

| search with the help of the circuit diagram the necessary addresses (contained in DPR) out
from the I/O-listings (Status 7 program)

BMK component IO04_BA.ANZ IO05_C1.ANZ

-B003 Sensor: min. water fountain level I [0063.4] I [0081.4]

-F502 Water fountain roller: drive, trouble I [0063.0] I [0081.0]
-K052 Contactor water fountain roller Q [0088.1] Q [0112.1]

| go to directory C:\STA7\ANZ
(if you use NC)
create an ANZ-file (for example [Link]),
call up with edit (F4)
write your program, e.g.: -1- I [0063,0] comments
nominal value without space here you can type your own comment-text
add the other I/Os
and save (F2)

| go to directory C:\STA7\ANZ
take any I/O*.LIS file and copy (F5) to a file named like the new ANZ file.

| start STATUS7 e.g. C:\STA7\04_72\[Link]

F2 (file selection) [Link]
F1 (state display)

| now you see your created file!

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Communication systems 3
3.2 Process Loop

3.2.1 Process Loop structure

Fibre optics conductor loop Process:
(it is absolutly necessary to observe the correct sequence)

Leitstand computer
-D001 in +Fx

Process Bus Master

Slot 6

Glass fiber optical conductor

(orange insulation)
Color Rack in
Leitstand desk
-A367
-Slave-
Slot 1

Caution:
All further optical conductors
are made of homogenous plastic
Process Rack in delivery
(light gray insulation)
-A355
-Slave-
'OLD' design
Slot 1

MAVO Rack in
delivery
-A371
-Slave-
Slot 5

Process Rack in feeder

-A357
-Slave-

Process Rack in coating module(s) Slot 1

-A352
-Slave(s)-

Slot 1

Process Rack in printing tower

feeder machine
-A351
-Slave-
Process Rack in printing tower(es)
Slot 1
middle machine(s)
-A351
-Slave(s)-
Slot 1

PROLOOP1_E.PRZ

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3.2.2 RCI (Remote Controled Inking)

5 3 1

6 4 2
8 RCI_Tast.PRZ

Inking unit selection

If ink control does not take place press keys 1 and 2 at the same time. This protects the control system against
accidental change.

Setting standard values: relative adjustment (in per cent) of the ink slides / rake function
If keys 3 and 4 are pressed at the same time:
- a relative adjustment in a preselected inking unit with set standard values (max. setting +/- 25 %);
- the rake function is activated if no standard value for relative adjustment is set.

Rake function: offers the printer the possibility, after the activation of the keys ( 3 and 4) that change ductor roller
strip width and/or ink slides, to return to the value originally set before the activation of this function by pressing
again the keys (3 and 4).

Ductor roller strip standard value setting

The adjustment (0...99%) of the ductor roller strip in the preselected inking unit. Press at the same time key 5 and 6
to lock adjustments in preselected inking unit. Press the keys again to cancel the lock.

Ink slide nominal value setting

Control possibilities:
- Individual adjustment of ink slides on a selected printing unit;
- The adjustment of all ink slides or of a block of ink slides by a relative value (percentage) - keys 5 and 6:
To do so select a block: press at the same time and hold for about two seconds keys 7 and 8 for the first and last
ink slide in the block; marking symbols "<" and ">" appear.
To cancel block selection: Press briefly keys 7 and 8 for the first and last ink slides. The marking symbol "-"
appears. Press again keys 7 and 8 to cancel lock.

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Communication systems 3
3.2.3 MAVO rack

MAVO = machine preparation, i.e. possibility to control auxillary equipment via interface

Dampening
solution
refrigarator Dry sprayer

Voltage
42V 3~

25 pol. D-Sub
25 pol. D-Sub

25 pol. D-Su
25 pol. D-Su
25 pol. D-Su
25 pol. D-Su
25 pol. D-Su

B1 B5 B6 B7 B8 B9 B10 B11

V24 V24
for 2x V24 (not used in standard configuration)

(optical cable direct into connector Bus Slave)

V24
Subnode 3 B2

Node computer (Process Bus Slave)

25 pol. D-Sub

+15V / 0,5 A
Subnode 4 B3 V24

Power supply +5V / 3 A

25 pol. D-Sub
V24 Interface board

B4
25 pol. D-Sub

-A371 MAVO_E.PRZ

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3.2.4 Color rack

Rack Colour desk :

Voltage supply
Ribbon cable to
Colour desk
Colour deskt-keyboard

Service
Voltage
B1 B3 B4

25 pol. D-Sub
42V 3~

25 pol. D-Sub
26 pol. Latch
9 pol. D-Sub.
B5
B2
Optical conductors to
Process Bus

(optical cable direct in connector Bus Slave)

Power supply 5V / 12 A (GOSSEN)

Node computer (Process Bus Slave)

(Colour desk controller)

Subnode computer 1

-A367 RS 232

COLPULT_E.PRZ

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Communication systems 3
3.2.5 Error diagnosis Process loop

Switch on curren
(main switch)

Possible causes:
LED's on slave computer - Slave computer defect
address
no flashing to interrupted - Power supply slave computer missing
assignment
position, - Process Bus Master (LSR-board, Slot 6) defect,
sucessful?
LED's of subsequent if no LED flashing
slaves off - LWL cable defect

yes
Test tools:
- messages in menu Diagnoses : example
Process Bus: Loop interrupted
- RODIMO: Process Bus Master, Status, Bus status o.k.?
LED's on slave computer Bus system is - RODIMO: Process Bus Master, Log, Log Process master
are permanently on in loop mode - RODIMO: Process Bus Master, Log, Log Process slave
- RODIMO: Process Bus Master, Protocol, Error message
- Damping measuring:
yes Check LWL cable by Fiber optic power meter

Possible causes:
Initialis- no Process loop in
ation o.k. idle mod - Wrong slave sequence in the loop
- Wrong nomonal configuratio
- Wrong actual configuration
- Defective subnode computer
- Defective node computer

yes Test tools:

- messages in menu Diagnoses : example
Pos-Ctrl: Node 4, Subnode 1; didn't answer or
Process Bus: transmit failure (Node 3-2)
- RODIMO: Process Bus Master, Protocol, Data transfer
- RODIMO: Process Bus Master, Log, Log Process master
- RODIMO: Process Bus Master, Log, Log Process slave
- LSR program, in 'Configuration': Process Nodes: ID, Version
- Handterminal
*

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Service Training Elektronic Roland 700

3 Communication systems

3.2.5 Error diagnosis Process loop

Possible causes:
- Wrong firmware in Master/Slaves
machine can be activated
LSR pro- no - wrong nominal configuration
in menu 'water/ink' with
gram o.k. ? - defectivesubnode computer
working position ?
- EEPROM defective, or wrong ID/ Version

Test tools:
- messages in menu Diagnoses : examples
yes Process Bus: Color desk didn 't answer or
Pos-Ctrl: wrong positioning datas (Node 4, ID 11)
- RODIMO: Process Bus Master, Protocol, Data transfer
- RODIMO: Process Bus Master, Protocol, Error message
LSR program 'runs', - RODIMO: Process Bus Master, Log, Log Process master
data exchange between - RODIMO: Process Bus Master, Log, Log Process slave
Master and Slaves are o.k. - messages in 'Last Alarms'
- Firmwareversions in: 'Production', 'General', 'Service', Version'
- erase EEPROM (only with Keydisc) in:
'Production', 'General', 'Service', 'erase EEPROM'
- record on PMD-disc

Explanations to RODIMO Process Bus Master:

BUS STATUS Indication, that Loop is o.k., or LSR (Eckelmann-Computer) Output is o.k.
LOG error messages in hexadecimale code
CLEAR LOG Erase all logbooks
ERROR MESSAG Error is indicated with hex. number and text, possibility to record these datas (called: Display)
DATA TRANSFER Possibility to record (Display) the data transfer between Process Bus Master
and Process Bus Slaves

[Link]

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