Procedure to unlock Register movement of Regioman Press

1.          Connect service laptop to machine network.

2.          Open Telnet session.

3.          Select REGI Press Enter.

4.          Showing E ( element ) Press Enter.

5.          Showing M.

6.          Type U.for unlock.

7.          Select option to unlock. BW- for Bazzel wheel,

                                               SR  - for Lateral movement,

                                               CR – for Circum movment

8.     Only one unlock at one above procedure.

9.     Do same procedure for every BW, SR, CR all couple.                                                         

Setting of zero position of Folder of Regioman Press

        • If encoder of folder motor (Master) is changed, we have to first latch the encoder with motor by performing latching procedure. Then make zero calibration of folder.

        • If encoder of folder motor (slave) is changed, we have to first latch the encoder with motor by performing latching procedure. No need to make folder zero calibration.

        • If the folder encoder is changed the zero calibration of folder is required.

Latching Procedure:

        1. Switch Off M Drive power (24 V) from drive cabinet

        2. Disconnect Encoder connector from M Drive

        3. Hold roller from other side and remove Encoder

        4. Connect New Encoder and encoder connector

        5. Switch ON power

        6. Go to Baudis PC and restart sercos ring (MLC Section)

        7. Go to the Drive cabinet and Connect Calibration keypad

        8. Switch ON test mode for particular drive

        9. On Calibration keypad, orange light indicates no safe stop and green   light indicates safe stop

        10. Press button for Latch position (bottom button) - sound comes and button light starts flashing

        11. After some time press latch button again

        12. After some time light on latch button goes Off –it means latching finished

        13. Switch of the selector switch and remove the calibration panel

       

 Procedure for zero setting:

        1. Remove the knife where it is mentioned as “0” position

        2. Fix the gauge

        3. Unload the job

        4. Press one safe stop near the knife

        5. Close all the covers

        6. Remove all other stops

        7. Connect the calibration panel

        8. Select switch 1

        9. Remove the safe stop button

        10. No green light means no safe stop

        11. Press safe stop (black push button) on calibration tool – green light starts flashing

        12. Press the triangle button one time for zero setting. It starts flashing

        13. Remove the gauge

        14. Release the black push button on calibration tool. Green light should be off

        15. Press the triangle button one time, there is alarm sound

        16. Press the triangle button one more time, button light starts flashing

        17. After some time the button light goes off

        17. Calibration is completed

        18. Fix the knife with 80 N force tool

        19. Switch of the selector switch and remove the calibration panel

Calibration of Buzal Wheel (BW) of Regioman Press

1. Load the Product.
2. Web up the paper.
3. Make zero at Console.
4. Connect Laptop to machine.
5. Open putty.
6. Connect to PU whose BW has to be calibrated.
7. Type REGI, press enter
8. Type E (Element), press enter.
9. Type C (Calibrate), press enter.
10. Type BW
11. Type 3 or 4 (3 for operating side BW and 4 for gear side BW)
12. Measure voltage at 2 and 4 for BW 3,

        6 and 8 for BW 4 of A621 MCU module.

Keep meter connected for monitoring of values.

13. Type H
14. Meter reading starts to decrease.
15. Press B when meter shows 0.30 Volt for minimum setting (Standard-0.20 Volt).
16. Meter reading starts to increase.
17. Press E when meter shows 9.3 Volt for maximum setting (Standard –9.80 Volt).
18. Meter reading starts to decrease and stops at center i.e. 5.7 Volt or 5.8 Volt.
19. Type Q for quit.
20. Do the mechanical ZERO setting.

Calibration of Turbo Motor of Regioman Press

1. Connect Service Laptop to RS 20 Switch (port no. 8)
2. Open Hyper terminal window by entering correct IP address of Print Unit
3. Hyper terminal window shows Telnet session
4. Press Enter
5. Hyper terminal window shows <Hindustan Times_DE1>
6. OR
   1. Open Putty
   2. Select the Particular Unit which want to Calibrate
   3. Putty window shows <Hindustan Times_DE1>
7. Type TWE to calibrate turbo box i.e. <Hindustan Times_DE1> TWE
8. Press Enter
9. Press C for Calibration and press Enter
10. Window shows DWNR First_Motor Last_Motor ? (DWNR means Print couple number which we want to calibrate, to calibrate turbo box for couple number 4 for motors 1 to 4 then follow next step)
11. DWNR First_Motor Last_Motor ? 4 1 4 (it indicates print couple number 4 and First_Motor is 1 and Last_Motor is 4. if we want to calibrate only motor number 1 then it should be 4 1 1)
12. Press Enter
13. Window shows TWE:Calibration Running
14. After calibration finished window shows TWE:OK
15. Press C to calibrate other turbo motor of same couple or different couple or Q to Quit telnet session

Calibration of Ink Box of Regioman Press

1. Connect Service Laptop to RS 20 Switch (port no. 8)
2. Open Hyper terminal window by entering correct IP address of Print Unit (Unit Controller) Start – Accessories, - Communications – Hyper Terminal
3. Hyper terminal window shows Telnet session – Using TCP - IP
4. Press Enter
5. Hyper terminal window shows <Hindustan Times_DE1>
6. OR
   1. Open Putty
   2. Select the Particular Unit which want to Calibrate
   3. Press Enter
   4. Putty window shows <Hindustan Times_DE1>
7. Type TFA to calibrate ink box i.e. <Hindustan Times_DE1> TFA
8. Press Enter
9. Press C for Calibration and press Enter
10. Window shows DW-NR? (it means select couple number which we want to calibrate, for example if we want to calibrate ink box for couple number 4 then follow next step)
11. DW-NR? 4
12. Press Enter (Calibration Starts)
13. Window shows Calibration Running
14. After some time OK message displayed
15. Press C to calibrate another ink box or Q to Quit telnet session
16. After Ink Box Calibration finished, we need to replace FA_WE_DU.CFG file in our data base.
17. Upload program from UC-100 flash card to our service Laptop and replace the above file in our database for that particular Unit.
18. FA_WE_DU.CFG file name is same for all units but the values inside may be different so save this files separately for each unit.

Calibration of Chuck Potentiometer of Regioman Press

1. Remove the Arm covers
2. Remove Potentiometer and connect new Potentiometer
3. While connecting new potentiometer set potentiometer tip exactly 50 mm outside from the vertical non-movable plate and fix it.
4. Take Chuck out till potentiometer pressed 28 mm backwards and measure the distance of potentiometer tip and vertical non movable plate, it should be exactly 22 mm.
5. Go to Setting mode on the touch screen
6. Select Calibrate option (password-102) and press Enter
7. Select Pot path segment X option ( X indicates Arm position for which we are doing calibration. For example select Pot path segment 2 option for arm-2)
8. Press Start
9. After pressing start button, the value of  Pot path segment changes to zero.
10. It takes its current position as zero position.
11. Zero setting finished
12. Put all the covers.

Procedure to Install the new PPM Server of Regioman Press

1.    Remove the Ethernet connections of the server and connect the monitor and keyboard cables of the PPM server.

2.    Switch on the server

3.    Press F1 as soon as the display comes

4.    Press alt+3 to go to the array settings and BIOS manager

5.    Press any key to continue

Window shows exportable units

2-drive –mirror 139.68GB (DATA) SLOT 5 and 1

2-drive –mirror 139.68GB (SYSTEM) SLOT 3 and 7

6.    Select the drives and delete it

7.    Before installation you have to create drives. To create new drives first select slot numbers and then go to create new.

8.    Assign drive name and click on OK. Now  new partitions were created

9.    Press F8 to done the settings

10. After that Install the LINUX OS. Put the LINUX DVD and start the server.

11. Linux system loading message appears on the screen.

12. After sometime window asks to select some option

13. In this select the 1^st option as PPM with 4 disks (2 logical disks) by pressing 1

14. After installation finishes remove the DVD and press enter. Server restarts automatically and asks system back up disk.

15. Insert the system backup disk and press enter. After finished remove the disk and press enter

16. Remove old server Ethernet connections and connect Ethernet to backup server and restart X-box if display not comes

17. Go to Maintenance menu and insert DATA backup DVD to restore the data

18. Select Data restore MOD and start data restore MOD

19. After completes the restore restart the server. Password is restart.

20. Now Server is ready to operate

Calibration of Arm Encoder (Near Slip ring) of Regioman Press

1. Switch Off power
2. Remove Encoder and connect new Encoder
3. Switch ON power
4. Bring Arm-1 in front position (Always take Arm-1 in front side every time when we replacing or calibrating sleepering encoder)
5. Place level bottle on Arm-2 side
6. Make proper levelling
7. Go to Setting Menu on the touch screen
8. Select Calibrate Option(password 102) and press enter
9. Select Steps angle encoder option
10. Press Start
11. After pressing start button the value of Steps angle encoder option changes to zero and this is the zero position of sleepering encoder

Calibration of Folder DIA Cylinder of Regioman Press

Calibration of Folder DIA Cylinder:  UNLOAD THE PRODUCT

1. After completion of the mechanical work keep the potentiometer out of the machine and check following:

1. Rotate the potentiometer to minimum position (0 volts) and at this position check if the motor can be further rotated to minus side (It should not be possible). Now rotate the pot to maximum position (14.2 volts) and check if the motor can be rotated further to plus position (It should not be possible). 

2. Now ask mechanical persons to set the minimum position of the cylinder to be -2.5 mm on the dial gauge.

3. Set the potentiometer to 1.14 volts and note the hex value (for minimum) on the lap top as follows:
1. Connect the lap top to putty
2. Connect to Folder UC

c.    Type

   MONI <ENTER>

d c0511014 <ENTER> for front folder and  d c0521014 <ENTER> for back folder

4. Note down the hex value

4. Fix the potentiometer in same position

5. Ask the mechanical persons to rotate the motor to plus direction and set the maximum position of cylinder to be + 2.5 mm on the dial. The potentiometer should read 13.06 volts

6. Note the hex value on lap top (for maximum) as per step 3.

7. Close putty

FOR FIX THE MINIMUM AND MAXIMUM VALUE

8. Again connect to putty and enter as follow:

1. Connect to Folder UC

b.    Type

      EICHWERT DM1 ’1a 281 e3D’ <ENTER> for front folder

   

       EICHWERT DM2 ’1a 281 e3D’ <ENTER> for back folder

   281 :  In place of 281 enter the noted minimum hex value

   e3D :  In place of e3D enter the noted maximum hex value

.

FOR CHECK THE ENTER VALUES OF MINIMUM AND MAXIMUM

9.    Check for the entered value as follows:

a.    Connect to putty

b.    Connect to Folder UC

c.    Type:

EICH DM1 for front folder

EICH DM2 for back folder

The entered values are shown

10.Cold start the UC 4 of folder

11. Check the Motor for minimum and maximum position. Also check if the motor

moves further to minus at minimum (It should not be possible) and if it moves  further to plus at maximum (It should not be possible). Check the potentiometer  voltages at both positions. 

Telnet session

<Hindustan_Times_FER1>MONI

ROOT: restarting 'MONI' (#280000), data at $1c12000

FILE: Error in de_cntrl TCGETS: $102

OK >d c0511014

C0511014  07 80 07 84 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511024  00 00 00 00 08 00 01 FA   08 00 01 FC 00 00 00 00   ........ ........

C0511034  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511044  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511054  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511064  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511074  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511084  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511094  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05110A4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05110B4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05110C4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05110D4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05110E4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05110F4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511104  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511114  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511124  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511134  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0511144  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

OK >d c0521014

C0521014  08 89 07 92 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0521024  00 00 00 00 08 00 02 01   08 00 02 00 00 00 00 00   ........ ........

C0521034  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0521044  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0521054  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0521064  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0521074  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0521084  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0521094  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05210A4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05210B4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05210C4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05210D4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05210E4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C05210F4  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0521104  00 00 00 00 00 00 00 00   00 00 00 00 50 00 13 EE   ........ ....P...

C0521114  50 FD D5 F0 00 00 00 00   00 00 00 00 00 00 00 00   P....... ........

C0521124  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0521134  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

C0521144  00 00 00 00 00 00 00 00   00 00 00 00 00 00 00 00   ........ ........

OK >

Telnet session

<Hindustan_Times_FER1>EICHWERT DM2 '1a 145 e3B'

ROOT: restarting 'EICH' (#1f0000), data at $1c2a000

(55 73 1 2): 0000,001a 0000016a 00000e3e

<Hindustan_Times_FER1>EICH DM2

ROOT: restarting 'EICH' (#1f0000), data at $1c2a000

(55 73 1 2): 0000,001a 00000145 00000e3b

Encoder Calibration for Folder Baumuller Motor of Regioman Press

Setting of zero position of Folder
1. Remove the knife where it is mentioned as “0” position
2. Fix the gauge
3. Unload the job
4. Press one safe stop near the knife
5. Close all the covers
6. Remove all other stops
7. Connect the calibration panel
8. Select switch 1
9. Remove the safe stop button
10. No green light means no safe stop
11. Press black push button
12. Press the triangle button one time for zero setting. It starts flashing
13. Remove the gauge
14. Release the black push button. Green light should be off
15. Press the triangle button one time
16. Press the triangle button one more time
17. Calibration is completed
18. Fix the knife with 80 N force tool
19. Switch of the selector switch and remove the calibration panel
• If encoder of folder motor (Master) is changed, we have to first latch the encoder with motor by performing latching procedure. Then make zero calibration of folder.
• If encoder of folder motor (slave) is changed, we have to first latch the encoder with motor by performing latching procedure. No need to make folder zero calibration.
• If the folder encoder is changed the zero calibration of folder is required.

Encoder Calibration for Baumuller Motor (PU) of Regioman Press

1. Switch Off the M Drive power, which we want to change or calibrate (Motor or Encoder). Corresponding MCB – 24 VDC
2. Disconnect Encoder connector
3. Remove old Encoder from motor and connect new Encoder
4. Connect Encoder connector
5. Switch ON M Drive power
6. Restart sercos loop from Baudis PC (Not necessary for calibration but do it only if M Drive is out of network i.e. ERROR 1512)
7. Go to Console
8. Load Job
9. Go to production menu and select that particular tower on which calibration is going on.
10. select correct Couple Number
11. If there is 0 showing on the console screen for lateral and circumference motors then no need to make it zero, but if not then run that couple at washing speed and make it zero
12. Unload Job
13. Do mechanical zero setting (Insert Gauge).
14. Make Impression ON
15. After finishing mechanical zero setting check for no Alarms
16. Connect Calibration Tool
17. Switch ON test mode switch (Bottom for lower motor and upper for upper motor)
18. Green light on Calibration Tool indicates Safe Stop and Orange light indicates there is no Safe Stop
19. Push Safe Stop(Black button)  on Calibration Tool-Green light starts flashing
20. Press Down Arrow button once-button light starts flashing
21. Remove Gauge.
22. Remove Impression
23. Release safe stop (Black Button) on Calibration tool
24. Press Down Arrow Key once-there is Alarm Sound
25. Press Down Arrow Key again-button light starts flashing
26. After some time button light goes off
27. Switch Off test mode switch
28. Take out Calibration Tool
29. Press Safe Stop on Print Unit to ensure that nobody can move the motor.
30. Go to Baudis PC
31. Check Aggregate Information of that particular Motor to check parameter 158
32. Parameter 158 is related to encoder position of the motor and it should be 360 degree (only +1,-1 is allowed)
33. Calibration finished.