Interface adapter Block diagram

Interface adapter

Block diagram
The interface adapter STA provides electrical
isolation of the signal lines between the central
control cabinet and the additional equipment. The
Additional equipment electrical isolation of the signal lines protects the
CPTronic control system. The following additional
equipment can, for instance, be connected to the
interface adapter:
SAM SEM STA-X1
IR dryer, UV dryer, sheeter, tape inserter, produc-
tion recorder, external powder spray device.
STA
The interface adapter comprises an interface input
STA-X3 ( SM74 only ) STA-X2 module SEM, an interface output module SAM, the
terminal strip STA-X1 and the connector STA-X2
and, for M74, the connector STA-X3.

FAM/ EVM FEM/ EVM Interface input module SEM

On the interface input module, electrical isolation
of the input signals is achieved by an optocoupler.
EAK
Interface output module SAM
On the interface output module, electrical isolation
of the output signals is achieved by relays.
REK2 /
ESK
REK386
Terminal strip STA-X1
CPTronic control system At terminal strip STA-X1, a voltage connection of
AC 220 V and the press cycle signal of position
switch 1S65 are provided for the additional equip-
ment.

Printing press
ÁÁ 1S65
Connector STA-X2
The position switch ”Press cycle” 1S65 is con-
nected to the connector STA-X2.

Connector STA-X3 ( SM74 only )

MID The signal lines from and to the central control
cabinet are led via the connector STA-X3.

In the case of malfunctions, the fault messages

appear in the press display MID and the control
console display ZID ( in the production run display
Fault displays +
messages from and in the fault display ).
external devices

Central control
console

Signal flow

177
 Interface adapter Layout, place of installation

Layout

Interface adapter STA

Interface output module SAM  Connector STA-X2 for position switch ”Press
 Interface input module SEM
cycle” (1S65)

 Housing of interface adapter

 Cable to central control cabinet

 Terminal strip STA-X1

 Connector STA-X3 ( SM74 only )
 Position switch ”Press cycle” 1S65

Place of installation
SM52, SM74
The interface adapter STA is located at the
feeder, below the control console on the O.S.

ÎÎ ÎÎÎÎ
ÎÎÎÎ STA

STA on O.S. of feeder control console

178
 Interface adapter Layout, place of installation

SM102, CD102
The interface adapter STA is located outside on
the back panel of the central control cabinet.
The position switch ”Press cycle” 1S65 is fitted
before the 1st printing unit on the O.S.

STA on back panel of central control cabinet

179
 Interface adapter Connector

Connector

Connector STA-X2

Pin Function

1 NO contact,
2 1 2 switching capacity 230V AC, 1A

3 4 3 NC contact,
4 switching capacity 230V AC, 1A

Connector STA-X2, coming from position switch

”Press cycle” 1S65

Connector STA-X3 (SM74 only)

Pin Function
 
A1 AC 230 V AC
 A2 Neutral conductor AC 230 V
 A3 DC 24 V
 A4 Run
 A5 Dryer on / off
 A6 Radiators on / off
 A7 Paper in PU1
 A8 Emergency stop
A9 Printed sheets in the delivery

B2 Feeder on
B3 Powder spray device on / off
B4 Emergency stop
B5 UV dryer in operation
B6 Malfunction UV dryer
Connector STA-X3, coming from the press B7 –
B8 –
C1 –
C2 –
C3 –
C4 AC 21 V
C5 Neutral conductor AC 21 V
C6 –
C7 –
C8 –
C9 –
PE conductor

180
 Interface adapter SEM Interface input module

SEM Interface input module

Layout and task

The function of the SEM is to isolate inputs leading
to the CP Tronic control system from the additional
AC equipment.
211 21 V
DC
N4 12 V On the SEM, an auxiliary voltage of DC 12 V is
10
 generated from AC 21 V. This voltage is picked up
11
   by the external device and switched back. On the
10 SEM, this voltage is then passed on to an opto-
E1
12 coupler. The optocoupler transmits DC 24 V via the
FEM/ EVM and EAK to the ESK and from there to
E2 10 the REK2.
13

E3 10
14

E4 10
15

E5 10
16

E6 10
17

E7 10
18

E8
X1 X2

Layout of SEM

Block diagram

AC
21 V
DC AC 21 V
12 V

EAK ESK
DC 24 V

REK2 /
REK386
External device SEM FEM / EVM

Principle of SEM

181
 Interface adapter SEM Interface input module

Connections

UV dryer
with shutter

Dryer blocking after

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
washing

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
18

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
10 E8

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
17
E7
Not used 10

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
E6
16
E5

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
* 10
E4

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
15
E3

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
10 E2
14 E1

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Not used 10 +1

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
13
N4

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
10 211

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
12
*
10

Malfunction UV dryer
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
*
11

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
10

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
UV dryer in
operation
* Note:
When connecting additional equipment
– to terminals 10 and 11
– to terminals 10 and 12
Emergency stop
– to terminals 10 and 16
remove the corresponding jumper!

Additional equipment connected to SEM

Terminal strip: SEM-X2; connections of the The cables from the additional equipment are
additional equipment connected to terminal strip SEM-X2 of the inter-
face input module SEM.
 Terminal strip: SEM-X1; connections to the
central control cabinet ZSG

182
 Interface adapter Input signals (SEM)

Input signals (SEM)

UV dryer with shutter UV dryer in operation

The electronic control system recognizes that all Monitoring of gripper bars in the case of UV dryer
installed UV dryers are equipped with a shutter. without shutter.
The ”in-operation” message of the UV dryer is
Dryer blocking after washing required to monitor the gripper bars in the delivery.
If, at press standstill, the gripper bars are in the
After completion of an automatic washup proce- area of the UV lamps, optical and acoustic warning
dure, the signal ”Dryer on / off” ( SAM) is blocked signals are output.
for approx. 180 seconds. In the control console display the symbol ”Gripper
During this time the position code 20 is displayed bars in radiator area” appears in the production run
in the fault display of the MID and ZID ( production display and under the type of fault ”Entire
run display ). press/ warning”. At the same time, a warning signal
sounds at one-second intervals.
Note: If the gripper bars stay in this area for more than
After automatic washup the UV dryer must stay out 1 minute, the electronic control system switches off
of operation for 180 seconds. the signal ”Dryer on / off” ( SAM).
Interlocking the washup device:
Malfunction of sheeter The signal ”UV dryer in operation” is also required to
interlock the washup devices in the printing units.
A malfunction has occurred in the sheeter. In the When the signal ”UV dryer in operation” is present,
MID and ZID ( production run display ) the position automatic washup is not possible. When the signal
code 14 appears in the fault display. ”UV dryer in operation” is no longer present, a
waiting time of 180 s starts.
Sheeter in operation In the ZID the message ”Dryer waiting time”
indicating the current waiting time appears under the
The signal causes the feeder pile control to switch command ”WASHUP”.
off. The pile at the feeder does not move anymore. Note:
Paper is fed in by the sheeter. Before automatic washup starts, the UV dryer must
have been out of operation for at least 180 seconds.
Malfunction of dryer
Emergency stop
A malfunction has occurred in the dryer. The press
is brought to a ”controlled” standstill, i. e. the pres- The emergency stop signal brings the printing press
ent state of the press is taken into account ( ”Run”, to a standstill as quickly as possible.
”Paper run” and ”Production run” ). In the MID and ZID ( production run display ) the
In the MID and ZID ( production run display ) the position code 15 appears in the fault display. In the
position code 20 appears in the fault display. ZID the symbol ”Emergency stop” appears under the
type of fault ”Entire press/press not ready to run”.

183
 Interface adapter SAM Interface output module

SAM Interface output module

Layout and task

The function of the SAM is to isolate the outputs of
the CP Tronic control system from the additional
+1 20 equipment.
DC 24 V 21
22 Through an EAK output to ground a relay is
A1 23
switched on the SAM. Thus switching operations
24
25 are carried out in external devices. Each time two
26 switches are actuated in parallel.
A2 27
28 With the NO contacts of the relays it is possible to
29
30 directly switch AC 230V, 1A.
A3 31
32
33
34
A4 35
36
37
38
A5 39
40
41
42
A6 43
44
45
46
A7 47
48
49
50
A8 51
52
53
54
A9 55
56
57
58
A10 59
X1 X2


 

184
 Interface adapter SAM Interface output module

Block diagram

REK2 /
REK386
DC 24 V
AC 230 V

ESK EAK

Emergency
stop

FAM / EVM SAM External device

 
  

Connections

Attention: To ensure trouble-free functioning of the press

control system, make sure that the additional
equipment to be connected is provided with suit-
able interference suppressors.
For safety reasons, the signals ”Radiators
ON/OFF” and ”Paper in PU1 during production
run” must be appropriately combined with the
signal ”Run” by the dryer manufacturer.
For safety reasons, the washup devices and UV
dryers on printing presses must not be operated at
the same time.
After manual washup it is likewise necessary to
wait an adequate period of time until all vapours
have escaped!

185
 Interface adapter SAM Interface output module

Terminal strip: SAM-X1; connections to

central control cabinet ZSG
20
21  Relays
22
23  Terminal strip: SAM-X2; connections of the
additional equipment
24
25
26
27 The cables from the optional equipment are
28 connected to terminal strip SAM-X2 of the
29 interface output module SAM.
30
+1 31
A1 Connection Additional equipment:
32
A2 33 to terminals max. contact load: AC 230V /1A
34 20 and 21
A3 Run
35 22 and 23
A4
36 24 and 25 Dryer on / off
A5 37
38 26 and 27 (e.g.: IR dryer or UV dryer)
A6 39 28 and 29 Radiators on / off
A7 40 30 and 31 (e.g.: IR dryer or UV dryer)
A8 41 32 and 33 Paper in printing unit 1 during
42
A9 34 and 35 production run ( e.g.: UV dryer )
43
A10 36 and 37 Emergency stop
44
Res 45 38 and 39 ( e.g.: sheeter )
46 40 and 41 Printed sheets in delivery
47 ( e.g.: tape inserter )
42 and 43
48
44 and 45 Feeder on / off
49
50 46 and 47 ( e.g.: HSQ )
51 48 and 49
Powder spray unit on / off
52 50 and 51
53
54 52 and 53
Reserve
55 54 and 55
56 56 and 57
57
Main drive emergency stop
58 and 59
58
59

Interface output module SAM

186
 Interface adapter Output signals (SAM)

Output signals (SAM)

Attention: The signals ”Radiators on / off” and ”Paper in print-

ing unit 1 during production run” must be appropri-
ately linked with the ”Run” signal if a UV dryer is
connected.

For safety reasons washup devices and dryers

must not be operated at the same time. Before
and after washup, UV dryers must stay out of
operation for 180 seconds.

Run Radiators on/off

Control signal for all additional equipment. Control signal e. g. for IR and UV dryers.
The signal is present when printed sheets pass the
The signal is present when the press is on ”Run”
dryer section in the delivery.
( press runs at minimum speed, i.e. 3000 i.p.h.).
If there is an emergency stop during production run,
the signal switches off. When the press is back on
Dryer on/off ”Run”, the signal is present again until all sheets
have reached the delivery.
Control signal e. g. for IR and UV dryers. With the function ”Dryer on / off” in the actual value
The signal is switched on if display the signal can be switched off and on.
– the dryer has been preselected at the control
console
and
Paper in printing unit1 during
the following guards are closed: production run
cylinder guards between the printing units and
guard of printing unit / delivery; Control signal e. g. for inter-unit dryers.
– there is still paper in the press after a press The signal is present when the sheets pass through
standstill and the press goes on ”Run” again. the 1st printing unit during ”Production run”.

The signal is switched off if Emergency stop (of printing press)

– an emergency stop function has been triggered;
Control signal for the additional equipment which is
Note:
to shut off when an ”Emergency stop” button on the
Only in the case of press standstill caused by an
press is actuated.
”Emergency stop” button, a cylinder guard
The signal is present as long as no ”Emergency
between the printing units or the guard printing
stop” button is actuated.
unit/ delivery.
– automatic washup is initiated;
– there is still paper in the press during press
standstill ( does not apply to UV dryer with
shutter);
– the gripper bars in the delivery stay in the
radiator area of the UV dryer for more than
1 minute ( only applies to UV dryer without
shutter).

187
 Interface adapter Output signals (SAM)

Printed sheets in the delivery

Control signal e. g. for tape inserter.
Prerequisite:
The job counter is switched on.
Control is effected when printed sheets reach the
delivery.

Feeder on/off
Control signal e. g. for sheeter.
The control signal is present as long as the feeder is
engaged.

Powder spray device on

Control signal for external powder spray devices.
Prerequisite:
The powder spray device has been preselected at
the control console.
The signal is present as long as printed sheets
leave the last printing unit and reach the delivery.

Main drive emergency stop

Additional ( redundant) control signal for the
additional equipment which is to shut off in the case
of a press emergency stop.
The signal is present as long as the press control
system does not transmit the ”Emergency stop”
signal to the main drive.

188
 Interface adapter EEM Single-fault fail-safe
extension module

EEM Single-fault fail-safe extension module

Layout

Connector X1
connection to backplane of computer plug-in
unit RER2
 Connector X2
ground and connection to SAM

Single-fault fail-safe extension module EEM

Task/function
The EEM transmits the isolated signal ”Main drive
emergency stop” from the REK2 to the SAM. The
signal transmission path is open-circuit-monitored.
This second signal transmission path ( as
compared to the ”Emergency stop” signal which is
transmitted to the SAM via the EAK ) ensures the
single-fault fail-safe condition.
If a wire is broken or the signal ”Main drive
emergency stop” is transmitted by one of the
SEKs, the corresponding relay on the SAM drops
out.

Block diagram

REK2 / RER2 EEM

REK386 SAM
X1 X2

A10

Block diagram of EEM

189
 Interface adapter EEM Single-fault fail-safe
extension module

Pin assignment
Connector X2

Pin Function
1 3
1 Connection to ground ( if two SEKs are
used on presses with
8 PUs; other-
wise not connected )
2 Connection to ground ( if one SEK is
Connector EEM-X2 used on presses with  8 PUs; other-
wise not connected )
3 Relay
– if no emergency stop: ground
– if emergency stop: high-resistance
( no ground)

190
 Interface adapter 1S65 Position switch ”Press cycle”

1S65 Position switch ”Press cycle”

Place of installation
SM52

The position switch ”Press cycle” 1S65 is

located on the D.S. of the feeder.

Position switch ”Press cycle” at feeder, D.S.

SM74

The position switch ”Press cycle” 1S65 is fitted

before the 1st printing unit on the O.S.

1S65

ÎÎÎÎÎ
ÎÎ
ÎÎ ÎÎÎÎ
ÎÎ
ÎÎ
Position switch ”Press cycle” in front of 1st PU, O.S.

SM102, CD102

The position switch ”Press cycle” 1S65 is fitted in

the middle between the D.S. and O.S., under the
feed table. It is connected to the interface adapter
STA.

Printing press, operator side of feeder

191
 Interface adapter 1S65 Position switch ”Press cycle”

Removal and installation

Position the press to press angle
000.0
4.
 Turn off the main switch 15Q66.

Positioning
 Remove the defective position switch 1S65.
Fit the new position switch 1S65.
 When fitting the position switch, make sure to
1S65 position it in such a way that the NC and NO
contacts are actuated.
21 22

13 14

Contacts of position switch 1S65

 Adjust the position switch in such a way that

when it is actuated there is still a gap of
2 mm before the switch contacts the block.
 Tighten the fixing bolts of the position switch.

2mm 1S65

Adjusting the position switch

000.0 ... 050.0  Turn on the main switch 15Q66.

( SM52, SM74 )  Check in inching mode whether both contacts
of position switch 1S65 are actuated between
000.0 ... 080.0
000.0  050.0  .0 ( displayed in the
( SM102, CD102 )
22
press display MID ).
21

21 / 22 = 0
13 / 14 = 1
13 14

Contacts of position switch 1S65

192