Plate change systems

Product Training Electronics – ROLAND 700 9

9 Plate change systems ......................................................................9-2

9.1 General ................................................................................................................ 9-2
9.2 Explanation of abbreviations............................................................................. 9-2
9.3 Electrical components ....................................................................................... 9-4
Solenoid valves .................................................................................................... 9-4
Sensors ................................................................................................................ 9-5
Motor for plate transport (APL) ............................................................................. 9-5
DC motor control (APL) ........................................................................................ 9-6
9.4 Explanations of symbols used in chains of steps........................................... 9-8
9.5 PPL plate change procedure ............................................................................. 9-9
9.6 PPL – emergency program .............................................................................. 9-12
Machine stops, plate is outside the sliding protection......................................... 9-12
Machine stops, the plate is within the sliding guard............................................ 9-13
Plate not released at DE..................................................................................... 9-14
Plate change procedure PPL.............................................................................. 9-15
Exceeding the time limit when loading the plate DA rail ..................................... 9-15
No I I in the 7-segment display ........................................................................... 9-15

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 Plate change systems
9 Product Training Electronics – ROLAND 700

9 Plate change systems

9.1 General
The positioning for tensioning as well as opening and closing the clamping bar is automatic in all
systems.
Explained below is the exact plate changing procedure presented in form of a so-called chain of
steps. The complete plate change is divided into program steps followed by subsequent switching
conditions. If a program step is completed, subsequent switching conditions must be met before the
next program step can be initiated.

These chains of steps provide a clear presentation of complex processes, facilitate the
comprehension of the function and is particularly helpful for error diagnostics. The immediately
preceding condition for the subsequent switch was not met, if a program step in a certain procedure
is not executed.

9.2 Explanation of abbreviations

The following abbreviations are used in this Chapter:

APL Automatic Plate Loading

DA Druck-Anfang ( leading edge)

DE Druck-Ende (tail edge )

DW Druckwerk; Druckwerke (printing unit(s) )

PPL Power Plate Loading

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Product Training Electronics – ROLAND 700 9

PPL / PPL 2 (Power Plate Loading)

, Semiautomatic plate change;
the used printing plate must be pulled by 2 2
hand from the DA rail, the new one has 1 PPL2 1 APL
to be inserted into the DA rail also by
6
hand.

PPL (to S716) 4 3 4 3

, The closing of the DA rail is triggered by
pressing a button. 5 5
, The positioning to the next printing unit
using the “crawl speed button” is started
as soon as the plate change is
completed in one printing unit.
1. clamping slit
2. releasing slit
PPL 2 (from S717)
3. plate cylinder
, The closing of the DA rail and the 4. inserting tool
positioning to the next printing unit is 5. pressure roller 4 7 5 8
automatic with PPL2. 6. plate transport system (only APL)
7. bending bar
APL (Automatic Plate Loading) 8. swivel lever
, Fully automatic plate change;
the printing plate is pulled into or pulled Note:
out of the DA rail by a motor driven PPL features just one slit for mounting and
plate transporting unit in the sliding ejecting the printing plate. Accordingly, the
guard. design of the sliding protection is different to
that of the PPL2 / APL

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9.3 Electrical components

[1] => 3,5 bar

[2] => 8 bar

Solenoid valves
PPL/APL Description Mounting Operation
location pressure
-Y084 (23) Clamp DA rail (DA position) B-side, outside Max.
Mount DE rail (DE position)
Double function – depending on machine position

-Y085 (32) Open DE rail (DE position) A-side, inside Max.

-Y086 (26/27) Infeed tool ON/OFF (DA position) B-side, inside until S736: Max.
Bending bar ON/OFF (DE position) [1] A-side, inside from S737: 3,5bar
Double function – depending on machine position

-Y087 (24/25) Pressure roller ON/OFF [2] B-side, inside to S739 3,5 bar
(when ejecting or mounting procedure of the printing A-side, inside from S740 8 bar
plate) (box version INOX)

APL
-Y125 (35/36) Transport rollers withdrawal sliding guard until S737: ca 2 bar
(mounting the printing plate in the DA rail) from S738: Max.

-Y126 (42/43) Transport rollers ejection sliding guard until S737: Max.
(ejecting the printing plate from the DA rail) from S738: 6 bar
Note: Solenoid number to S716 (37/38) and from S717 (42/43),
due to double assignment with the coating module
(38= coating form roller)

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Sensors
Mounting Basic position
PPL/PPL2/APL Description
location Signal
-B072 Proximity switch for pneumatic cylinder B-side, outside 1
DA/DE rail clamping/mounting ejected
(-Y084)
In basic position –B072 = 1
-B073 Proximity switch for pneumatic cylinder A-side, inside 1
DE rail open drawn in (-Y085)
In basic position –B073 = 1

-B074 Proximity switch for pneumatic cylinder B-side, inside 1

Infeed tool and bending bar ejected (-Y086) A-side, inside
In basic position –B074 = 1

PPL2/APL

-B135 Register plate interrogation A-side

1

-B136 Proximity switch for pneumatic cylinder B-side 1

APL
-B137 Proximity switch for plate transport B-side, top changing flanks
If the plate is drawn in when the transport rollers are in box
tilted (-Y125, or –Y126) and the motor is on (-M411), as a
result of the flank change at the initiator one may assume
that the plate is transported.

Motor for plate transport (APL)

APL Monitoring
-M411 Motor for plate transport A-side, top by -B137
24V DC micro-motor transports the plate into or out of the in box
DA rail depending on the transport rollers.
(-Y125, or –Y126)

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DC motor control (APL)

Use, Compatibility, Dependencies
The "DC motor control with switchable current limit" pc-board, RS-no. A37V 1821 70, is used for the
first time in the R700 from series 738. An upgrade for machines from series 717 is possible.

In brief:
i • Expected employment as motor control in R700 APL slide protection
• Current control with switchable current limit for 24V DC motor
• Activate-current-boost to increase the start-up torque,
• One direction of rotation
• Overtemperature and short circuit protection with LED display and lock.
Reset by switching off and on again.

Technical specifications:
• Voltage supply: +24VDC +- 10%
• Current limits (typ.)
- Lo (normal) 0.26A
- Hi (’Current limit‘ against –24V jumper): 0.78A
• Reaction time to temperature switching off: 80 sec. typ.
during cold start und Lo current limit
• Temperature range: 0..55°C
• Connections:
- X1 [Motor connection:] 4 pol. module
- X2 [Current supply and current limit control input:] 3 pol. Combicon
- X3 [Mounting and alternative
current limit control input:] 9 pol. D-SUB

Circuit diagram: X2: Supply,

pin assignment:
X1: Motor pin assignment: 1 0V
1,3 Motor + 2 -24V
2,4 Motor – 3 Current limit

X3: Input current limit

switch:
7 To series 742:
Current limit for +BA
Æ J1 on position ’bottom‘
5 To series 742: 1
Current limit for +C*,+DA
Æ J1 on position ‘top‘

From series 743: 1

Current limit for alle
printing units +BA,+C*,+DA
Æ J1 on position ‘top‘

Jumper position ’top‘

Jumper position

LED
’Short circuit / Temperature‘

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Product Training Electronics – ROLAND 700 9

Connecting diagram “tower switch cabinet R700”:

distribution board
A335

to sliding protection
X19

old connection

new line to sliding

protection

new
connection line
Motor control
* 37V 1821 70

X1

X2

X62 Jumper J1 LED

see below ’Short circuit / Temperature‘
“Connections
“

From series 743 always in top position

New connection line between A335 / X19 ÅÆ motor control X2:

Variant 1: Combicon 3pol. (Motor control X2) Modu I 4pol. (A335 / X19)
1 4 Use only to series 742 for DW +BA,
2 3 plug jumper J1 on the bottom
position

Variant 2: Combicon 3pol. (Motor control X2) Modu I 4pol. (A335 / X19)
1 Use to series 742 for DW +C*,+DA,
! 2 2
1
from series use 743 for all DW,
plug jumper J1 on the top position

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 Plate change systems
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9.4 Explanations of symbols used in chains of steps

Function is switched on in self-holding mode, it is switched off in
S Setzen (set)
a later step by reset (R)
R Rücksetzen (reset) Switch off in a previous step activates this function

NS Nicht Setzen (not set) Function is activated for the time of this step

FC Erster Zyklus (first cycle) Function is processed only in the first cycle of the program

T/L Zeitglied (timer) Function is activated or deactivated after a certain period

& UND-link (AND) All listed conditions for subsequent switching must be met
One of the listed conditions for subsequent switching must be
≥1 ODER-link (OR)
met
tw waiting time A subsequent switch takes place only after this time elapses

TV jog forward Machine function: jog operation forward

TZ jog reverse Machine function: jog operation reverse

Start of
sequence
0

Step enabling condition Command

&
Step enabling condition

N
name of step Nr. S
Action / Function 1

S 2

Step enabling condition R 3

name of step Nr.

consecutive
number

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Product Training Electronics – ROLAND 700 9

9.5 PPL plate change procedure

Precondition:
i •
•
LSR: job defined and made-ready
Selection of “Plate change“ mode of operation (Menu Machine)
• Selection of printing units where plates are to be changed (Menu Machine)
• Confirmation of entries with the “ENTER“ key. (Menu Machine)
• Insertion of the plates in the mounting slit of the selected printing units.

Machine ready for plate change 0

!!! Caution: !!!
Push button Autmatic start at the central
If the register are not in zero-position => only button
console or the button crawl speed at the PU
"Automatic start" at the central console can be used. <=

Release 1 N
S
Release button "positioning" when
guard is closed
1
N LED in button pneum. guard blinks,
S when guard is open
2
-Pneumatic guard closed
-Register in zero-position N Release command buttons for jog
forward and reverse: jog possible
3
S
-Button "positioning"

N move to DE position;
Positioning 2 S direction: any
1
Slot 4 N Release command buttons for jog
S forward and reverse: jog possible
2
Locking:
DE reached S 3
Pneum. guard activation is locked

DE- rail 3 S
Tilt in pressure roller;
Y087 (24/25)
1
-B072 -B073 Relax DE- rail;
S
Y084 (23)
2
-B074 -B135
3 (tw) tw Waiting time t1= 1s 3
-B136 -B137
&
-B176 Sensor "DA/DE-rail" B072=0

DE- rail 4 S Open DE- rail; Y085 (32) 1

tw Waiting time t2= 0,8s 2

2 (tw)
&
Sensor "DE-rail open" B073=0

DE- rail 5 R
Tighten DE- rail;
Y084 (23)
1

tw Waiting time t3= 1s 2

Slot 11
2 (tw)
&
Sensor "DA/DE-rail" B072=1

DE- rail 6 R
CLose DE- rail;
Y085 (32)
1

Sensor "DE- rail closed" B073=1

-M411
&
Sensor "DE-rail tightened" B072=1
-Y084 -Y087
N Positioning to DA- rail;
-Y086 -Y085 Positioning 7 S Rotating direction: reverse
1
-Y125 -Y126 N Release command buttons for jog
S forward and reverse: jog possible
2

PPL_Schrittkette_PPL_Teil_1.VSD

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APL:
With APL the used plate is removed and the
new plate is inserted via the small DC-motor
-M411. This is monitored by sensor -B137 DA reached
"Sensor plate transport".

Release 8 S Open DA- rail; Y084 (23) 1

tw Waiting time t4= 1 - 2s 2

2 (tw)
&
Sensor "DA-rail open" B072=0

Tilt-in infeed tool / bending bar

Positioning 9 S Y086 (26/27)
1
N
LED button "make ready plus" blinks 2
S
Sensor "Infeed tool tilt-in" B074=0

remove used plate <===

insert new plate ===> from
to
Register pin interrogation A-side B135=1
& An acoustic signal resounds;
Register pin interrogation B-side B136=1
if the plate has been inserted
correctly within 12s.

DA- rail 10 N
S
Close DA- rail; Y084 (23) 1

Sensor "DA-closed" B072=1

Slot 4 Slot 11

Infeed tool 11 R
Tilt-out infeed tool
Y086 (26/27)
1
N Release crawl speed button: crawl
-B072 -B073 S speed possible
2

-B074 -B135 Sensor "Infeed tool" B074=1

-B136 -B137 -M411

-B176

-Y084 -Y087
DE- rail 12 N
S
Position to DE;
Rotation direction: forward
1
N Release Command button for jog
-Y086 -Y085 forward and reverse: jog possible
2
S
-Y125 -Y126
DE reached

Positioning 13 S
Tilt-in bending bar;
Y086 (26/27)
1

tw Waiting time t5= 1s 2

2 (tw)
&
Sensor "Bending-bar tilt-in" B074=0

PPL_Schrittkette_PPL_Teil_2.VSD

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DE- rail 14 S Open DE- rail; Y085 (32) 1

tw Waiting time t6= 0,8s 2

2 (tw)
&
Sensor "DE-rail open" B073=0

DE- rail 15 S
Relax DE- rail;
Y084 (23)
1

tw Waiting time t7= 1s 2

2 (tw)
&
Sensor "DA/DE-rail" B072=0

DE- rail 16 R Close DE- rail; Y085 (32) 1

tw Waiting time t8= 0,8s 2

2 (tw)
&
Sensor "DE- rail closed" B073=1

DE- rail 17 R
Tighten DE- rail;
Y084 (23)
1

tw Waiting time t9= 0,8s 2

2 (tw)
&
Sensor "DA/DE-rail" B072=1

Bending bar 18 R
Tilt-out bending bar
Y086 (26/27)
1

Sensor "infeed tool" B074=1

End 19 R
Tilt-out pressure roller;
Y087 (24/25)
1
Signal: plate change terminated ;
S
step enabling condition for next PU
2
Sensor "infeed tool" B074=1 Locking:
R 3
Activation of pneu. guard locked

Slot 4 Slot 11

END

Perfecting machines use Sensor -

-B072 -B073 B140 "Plate cylinder zero position" in
-B074 -B135 each PU to interrogate the DA and DE
-B136 -B137 -M411
position.
-B176
When the machine reaches the correct
-Y084 -Y087
DA or DE position Bit 10.2 is "1" (Slot 7).
-Y086 -Y085

-Y125 -Y126

PPL_Schrittkette_PPL__Tei_3.VSD

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9.6 PPL – emergency program

Machine stops, plate is outside the sliding protection

• The machine stops while the plate is being

ejected.

• The plate protrudes over the sliding

protection.

• When stopping, the PPL program switches

automatically to emergency program (7-
segment display shows two blinking
zeros).

• Press crawl speed button

• Machine positions to DA

• The turquoise minus button blinks

• Press the turquoise minus button

• The plate can be removed

• Press Stop/Halt/Safe

• The DA rail closes automatically and the

normal PPL program is again active (two
constant zeros on 7-segment display)

• Restart program procedure for this unit with

crawl speed

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Machine stops, the plate is within the sliding guard

• The machine stops while the plate is being

ejected.

• The plate is still within the sliding guard

• When stopping, the PPL program switches

automatically to emergency program (7-
segment display shows two blinking
zeros).

• Jog the machine forward to DE while the

guard is closed.

• Open sliding guard.

• Hold the plate firmly and press crawl speed
button.

• The machine positions itself automatically to

DA
• The turquoise minus button blinks, press
the minus button, the DA rail opens.
• The plate can be removed.
• Close sliding guard.
• Press Stop/Halt/Safe.
• DA rail closes automatically and the normal
PPL program is active (two constant zeros
on the 7-segment display).
• Restart program procedure for this unit in
crawl speed.

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 Plate change systems
9 Product Training Electronics – ROLAND 700

Plate not released at DE

• The plate does not emerge from the sliding

guard.

• Machine stands at DA.

• Remove new plate from the sliding guard.

• Select emergency PPL program using

Stop/Halt/Safe (two blinking zeros on the
7-segment display).

• Now position machine so far back until the

turquoise plus and minus buttons glow.

• Press 4x the turquoise minus button until the

plate emerges from the DE rail.

Ì 1 = Release the DE rail.

Ì 2 = Open the DE rail.
Ì 3 = Clamp the DE rail.
Ì 4 = Close the DE rail.

• Jog the machine back a little until crawl

speed starts blinking.

• Open sliding guard.

• Hold plate.

• Press crawl speed button, the machine

positions itself automatically at DA.

• Press the turquoise minus button, the DA

rail opens.

• The plate can be removed.

• Close sliding guard and press

Stop/Halt/Safe.

• The DA rail closes automatically and the

normal PPL program is again active (two
constant zeros on the 7-segment display)
Insert plate into the sliding guard.

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Plate change procedure PPL

• Machine positions on DE.

• The pressure roller engages, the DE rail
unclamps, opens, clamps, closes.
• The plate emerges from the sliding guard in
reverse position.
• Machine switches to lower speed just before
DA.
• Machine stops at DA.
• Auxiliary device and bending bar move to
DA rail.
• DA rail opens.
• Turquoise plus button blinks.
• The old plate is pulled out slightly.
• The new plate is placed on the register pins.
• If correctly positioned, the 7-segment
display displays I I and closes DA rail
automatically.
• Auxiliary device and bending swing off.
• Machine moves to DE position.
• Machine switches to lower speed just before
DE.
• The pressure bar swings in at DE and
presses the plate under the DE rail.
• DE rail opens, unclamps, closes and
clamps.
• The pressure roller swings away.
• The plate change on this printing unit is
complete.

Exceeding the time limit when loading the plate DA rail

• 7-segment display displays I I .

• DA rail closes automatically.
• Crawl speed button blinks.
• Start crawl speed.
• The plate mounting procedure will now be
conducted.

No I I in the 7-segment display

• Printing plate not detected by interrogation

(digits – observe display).
• Check how the printing plate fits and correct if
necessary. Plate positioned correctly on the
register pins.
• Close the DA-rail with the turquoise plus
button.
• Start crawl speed.
• Plate loading procedure continues.

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 Plate change systems
9 Product Training Electronics – ROLAND 700

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