Input/output control Signal routing

Input/output control

Signal routing

Components
By input/ output control we understand the
handling of all input/ output signals of the
electronic control CPTronic modular.
The following components are connected to the
inputs:
– switches,
– buttons,
– pressure switches,
– sensors,
– position switches,
– electrical subassemblies.

The outputs of the CPTronic modular control the

following subassemblies and components:
– signal lamps,
– audible signal devices,
– solenoid valves,
– contactors,
– relays,
– electronic modules,
– electronic boards.

53
 Input/output control Signal routing

Block diagram of input/output signal routing

Processor Processor
Memory board
board
analog board REK2
REK1
SAK

Input/output
control board
ESK

Input/output board
EAK
Input/output
module
EAM

Flat cable input Flat cable

module output module
FEM FAM
Signal lamps,
buttons,
Switches, Signal lamps, switches, etc.
sensors, contactors,
buttons, etc. relays, etc.
Central control
console ZSP

Components of input/output signal routing

The input and output signals are transmitted to

the input/ output boards EAK and to the
input/output control board ESK via various
input/output modules.
The handling of the signals is then effected on
the processor boards REK1, REK 2 and the
memory analog board SAK.
The input and output signals of the central
control console ZSP are transmitted via the
input/output module EAM. All other input signals
are transmitted via the flat cable input modules
FEM and all output signals via the flat cable
output modules FAM. On these modules (FEM,
FAM) the single cores of the connected
components are grouped together to flat cables.

54
 Input/output control ESK Input/output control board

ESK Input/output control board

Layout
The input/output control board ESK is in the
computer plug-in unit REE.

Layout of the input/output control board ESK

Function
The ESK acquires and processes the signals which
come from the HWI. The input/output control board
ESK provides the electronic control system with
parallel and serial interfaces. All input and output
signals pass through these interfaces. Thus the
different components of the control system
communicate with each other via the ESK.

55
 Input/output control EAK2 Input/output board

EAK2 Input/output board

Layout
The input/output boards EAK 2 are located in the
input/output plug-in unit EAE.
Depending on the number of printing units, up to
12 input/output boards EAK are operated in the
input/output plug-in unit.

Input/output board EAK2

Function
The essential task of the EAK 2 is the acquisition,
conditioning and transmission of signals which are
led to the control electronics (input/output control
board ESK, processor boards REK1 / 2, memory
analog board SAK) or come from there.
The EAK 2 has 128 input/output ports. 120 of
these input/output ports are preprogrammed as
inputs or outputs.
In addition, 8 ports are either defined
– as 8 inputs or
– as 4 differential inputs.

56
 Input/output control AUM Analog conversion module

AUM Analog conversion module

Signal routing

On the analog conversion module AUM, the single

Control electronics cores of sensors which supply analog signals are
(REK1, REK 2, ESK) grouped together to flat cables.
These analog signals are then transmitted to the
memory analog board SAK.

SAK Memory analog board

Memory
analog board AUM Analog conversion module
SAK

Analog con-
version module
AUM

Sensors
(analog signals)
e.g. double-sheet sensor

Signal control via AUM

57
 Input/output control AUM Analog conversion module

Layout and task

Connector X1
 Connector X2
 Terminal strip X3

The analog conversion module AUM is a passive

module, which connects terminal strip X3 with the
connectors X1 and X2.

Connections:

     
    


     
     

Layout of AUM

Connectors X1, X2: 

  
 

Connectors/terminal strip

58
 Input/output control EAM Input/output module

EAM Input/output module

Signal routing
The input/ output module controls the illuminated
Control electronics pushbuttons and signal lamps in the central
(REK1, ESK, SAK) control console ZSP and determines their circuit
states.
The current states of the buttons of the connected
control units are registered and, via a serial
interface, transmitted to the processor board
Processor REK2 for evaluation.
board
The decision as to which of the signal lamps will
REK2
be activated is taken by the connected computer
(REK2). Control of the signal lamp is again
effected by the input/ output module EAM.

Input/output REK2 Processor board

module
EAM Input/output module
EAM
ZSP Central control console

Signal lamps,
buttons,
switches, etc.

Central control
console ZSP

Signal flow via EAM

59
 Input/output control EAM Input/output module

Layout

Input/output module EAM

60
 Input/output control EAM Input/output module

1 X2 Pin base
serial interface ZSK/BEK/REK
2 X3 Pin base / ink zone keys CPC 1
3 X4 Pin base / ink zone keys CPC 1
4 X5 Pin base / ink zone keys CPC 1
5 X6 Pin base / ink zone keys CPC 1
6 X10 Pin base
signal lamps/illuminated pushbuttons
7 X11 Pin base
signal lamps/illuminated pushbuttons
8 X12 Pin base
signal lamps/illuminated pushbuttons
9 X13 Pin base
signal lamps/illuminated pushbuttons
ß X14 Pin base
signal lamps/illuminated pushbuttons
q X15 Pin base
signal lamps/illuminated pushbuttons
w X1 Socket base
power supply EAM
e X20 Plug-in terminals: key-operated switch CPC
ZSP: emergency stop
KSP: jumper

Task
The input/output module EAM operates the
illuminated pushbuttons and signal lamps of any
control unit (central control console, compact
control console, plate image reader CPC 31,
control unit CPC 1).
It registers the circuit states of the buttons and
activates the signal lamps of the control unit.

61
 Input/output control EAM Input/output module

Block diagram

Control unit CPC 1 Input/output module EAM

FZT2
(matrix with
32 inputs)

1FZT2 X3
1...64 and filter
EPROM
ink zones
4FZT2 X6 Temporary
storage
FZT2 and
voltage
(matrix with conversion
32 inputs) RAM

2
24V DC

1
ZSP/KSP/

Computer unit
CPC 31/CPC 1 Micro-
controller Serial
interface

X10
1
Drivers PF5V PF24V
96 and
X15 registers
Voltage
monitoring
2
24V DC

Signal lamps 5V DC
and

1
illuminated Temporary storage

Power supply
and voltage
pushbuttons conversion and filter 24V DC
2 Chopper–type De-
power supply unit coupling

Button matrix
S1 S2
X10
1 Z1 Supply voltage p.c.b.
5V DC
96 Z2
X15

X10...X15 24V DC

Simplified block diagram of EAM

1 Dependent on application
2 Decoupled voltage 24V DC

62
 Input/output control EAM Input/output module

Function
The present circuit states of the buttons of the
connected control unit (central control console,
compact control console, plate image reader
CPC 31, control unit CPC 1) are transmitted to the
connected computer unit (ZSK, BEK, REK) via a
serial interface.
The decision as to which of the signal lamps will be
activated is taken by the connected computer.
Activation itself is again effected by the EAM.

Power supply and chopper-type power supply

unit
The EAM is supplied with 24V DC.
From this voltage, the chopper-type power supply
unit generates 5V DC for the logic section of the
module.
For lamp activation and interrogation of the buttons
24V DC are required.

Voltage monitoring
The input and output voltages of the chopper-type
power supply unit are monitored by voltage
comparators. If the output voltage of the chopper-
type power supply unit drops below 4.75V for more
than 20
s, the signal PF5V 2 is generated and
thus a reset is triggered.

The signal PF24V 3 is generated, if the 24V DC of

the button interrogation/signal lamp activation drop
below 19.5V DC, because the interrogation logic
does not work correctly in the presence of
undervoltage.

Note:
None of the outputs (lamp activation and interroga-
tion signals) are short-circuit-proof.

Signal lamp control

The max. 96 signal lamps are activated in a static
way, i.e. the processor treats the registers one after
the other. One signal lamp is permanently allocated
to each register. The connected signal lamp is
connected to ground via transistors.
The flashing of the signal lamps is achieved by the
cyclic treatment of the registers.
1 Dependent on application

2 Signal is : 0V U
4.75 V DC
5V U  4.75V DC
OK
3 Signal is : 0V U
19.5V DC
5V U  19.5V DC
OK

63
 Input/output control EAM Input/output module

Button interrogation
S1 S8
.
.
.
.
.
.
Z1 Two matrices (1 x 64 inputs, 1 x 32 inputs) are
.
. allocated to the max. 96 inputs of the illuminated
.
. pushbuttons.
.
. S1 S2 S3 The columns of the matrices are formed by the
Z8 interrogation leads (S1 ... S8) and the lines by the
Z1 feedback leads (Z1 ... Z8).

Z2 The microcontroller addresses the columns 1 ... 8

one after the other. Thus 24V DC are only present
Z3 at one of the 8 columns at a time. In the process,
the return signals (Z1 ... Z8) are read and the
buttons pressed are registered.

The cyclic interrogation of the status of the buttons

Diagram of a button matrix is repeated every 10 ms.

Pin assignment

X10 ... X15

X10 X15
c a c a 1

1 1 1 1

13

16
32 32 32 32

Pin bases X10 ... X15

X10 ... X15 Pin bases

illuminated pushbuttons and signal lamps

Note:
For the allocation of the pin bases X10 ... X15 to the
illuminated pushbuttons and signal lamps of the
connected control unit, see circuit diagram.

64
 Input/output control EAM Input/output module

X1 Socket base power supply

X1

1 4 Pin Function
1 24V DC
2 24V DC
3
24V
4
24V
Socket base X1

X20 X20 Plug-in terminals

K3
M Terminal
designation Function
K2
M K1 ...K3 Coding lines
K1 M

96A ... A Voltage applied to outputs
96+
... + 24V DC
96R
96S ... R Return signals (return lines)
95A ... S Interrogation lines (scan lines)
95+
95R Plug-in
95S terminal Function 1
12A ZSP KSP
12+ 63S ”Emergency Jumper
12R 63R stop” button
12S 12S Key-operated switch CPC 1
63A 12R
63+
63R
63S

Plug-in terminals X20

1 Dependent on application

65
 Input/output control EVM4 Input/output distributor module

EVM4 Input/output distributor module

Layout and purpose

X1 XEA1 XEA2 XEA3 XEA4 X1W

X11S
X3E X2A
X5 X1E
X4E X3A
X2E
X4 X1S
X1A X4A

Input/output distributor module EVM4

The input/output distributor module EVM4 is the

link between the electronic control system and the
electric components of the press. The flat cables
from the control system are split up into single
cores which are led to the electric components.
1 Socket bases X1, XEA1, XEA2, XEA3,
XEA4,
2 Socket base X1W
3 Socket base X11S
4 Pin base X1S
5 Pin bases X1E, X2E, X3E, X4E
6 Pin bases X1A, X2A, X3A, X4A
7 Pin base X4
8 Pin base X5

66
 Input/output control SVM Interface distributor module

SVM Interface distributor module

Signal routing
The interface distributor module SVM multiplies
Control electronics the serial interface to the processor board REK2.
(REK1, ESK, SAK) Four serial interfaces can be created per interface
distributor module SVM.
Via the serial interfaces, the processor board
REK2, the press display MID and external devices
with serial interfaces communicate with each
Processor board other.
REK2
REK2 Processor board
SVM Interface distributor module
Interface dis-
tributor module
SVM

Press display Central Powder spray

MID dampening device with
solution supply serial interface

Signal control via SVM

67
 Input/output control SVM Interface distributor module

Layout and task

1 Connector X5, power supply
2 Connector X0, input interface

3


3 Connector X1, output interface
2
1
5V DC 4 Connector X2, output interface

5 Connector X3, output interface

6 Connector X4, output interface

The SVM multiplies the serial interface of the

REK2. 4 interfaces can be established per SVM
(X1...X4).

The serial interfaces control the communication

with the press displays (MID) and the external
Interface distributor module SVM devices with serial interfaces.

Interconnection diagram

Power supply
X1 MID1-X2 Control panel feeder
NTK5 X5
X2 MID2-X2 Control panel delivery
SVM
X3 12E2-X2 Powder spray device
with serial interface
REK2 X0
Serial X4 E40-X2 Central dampening
interface solution supply

Interconnection diagram SVM

68
 Input/output control VSM2 Amplifier module

VSM2 Amplifier module

Signal routing
The outputs of the input/ output board EAK can
switch max. 2.4 W. For consumers with higher
Control electronics
power output the amplifier module VSM is used.
(REK1, REK2, SAK)
The VSM can control consumers with an output of
up to 48 W (e.g. clutches, blowers).

ESK Input/output control board

Input/output EAK Input/output board

control board FAM Flat cable output module
ESK
VSM Amplifier module

Input/output board
EAK

Flat cable
output module
FAM

Amplifier module
VSM

Clutches,
blowers,
fans

Output control via VSM

69
 Input/output control VSM2 Amplifier module

Layout

X1 Pin base power supply,
outputs
 X2 Pin base inputs

Amplifier module VSM2

Task
The amplifier module VSM2 increases the switch-
ing capacity of the standard input / output ICs of
EAK/ EAK/ EAK2/ EWK and ZSK.
EAK2/ FAM/ Power
EWK/ EVM
VSM2 consumer 24V DC
ZSK
The switching capacity of an output of
EAK/ EAK2/ EWK or ZSK is 2.4W and is increased
to 48W (2A, DC 24V) by the VSM2.
Amplifier module VSM2
The VSM2 is used to control power consumers,
e.g. contactors and magnetic clutches.
It may not be used to control motors.

Note:
– The VSM may only be used in combination with
Power
the EAK.
EAK FAM VSM consumer 24V DC – The VSM2 is used for EAK, EAK2, EWK and
ZSK.

Amplifier module VSM with EAK

70
 Input/output control VSM2 Amplifier module

Block diagram

Feed-
back

E1 Compar-
ator 1 A1

Feed-
back

E2
Compar-
ator 2 A2

Feed-
back

E3 Compar-
ator 3 A3

Feed-
back

E4 Compar- A4
ator 4

Feed-
back

E5 Compar-
ator 5 A5

Feed-
back

E6 Compar- A6
ator 6

5V DC
Reference supply voltage
voltage
p.c.b.

Simplified block diagram of VSM2

71
 Input/output control VSM2 Amplifier module

Function

The supply voltage for the module is 5V DC.

The controlling electronic board ( EAK/ EAK2/ EWK/

ZSK) actuates its output driver in order to switch a
power consumer on ( e.g. contactor, magnetic
clutch).
The comparator sees this and controls the output.

Feedback signal:
The feedback signal tells the controlling electronic
board whether a power consumer is connected or
not.

Pin assignment
X1 Pin base power supply, outputs
X1

1 10 Pin Function
1 5V DC
2 Not used
3 Output 1
Pin base X1 4 Output 2
5 Output 3
6 Output 4
7 Output 5
8 Output 6
9
5V1
10
5V1

X2 X2 Pin base inputs

Pin Function
5 1
6 2 1 Input 1
2 Input 2
3 Input 3
Pin base X2 4 Input 4
5 Input 5
6 Input 6
1 For safe functioning both p.c.b. ground contacts must be
connected.

72
 Input/output control SUM6/SUM9 Signal conversion module

SUM6/SUM9 Signal conversion module

Signal routing
The signal conversion modules SUM 6 and SUM 9
Control electronics (REK1, register the signals from the sensors and combine
REK2, REK386, SAK) them for logic operation. Via the FEM, EAK and
ESK the signals are then passed on to the control
electronics (REK1, REK 2, REK386, SAK) and
processed.
SUM6 is designed for SM 102 presses and SUM 9
Input/output
for SM 52 presses only.
control board
ESK On perfector presses sheet turnaround is
monitored by sensors.

SUM6 Signal conversion module

Input/output board
SUM9 Signal conversion module
EAK
FEM Flat cable input module
EAK Input/output board
Flat cable input ESK Input/output control board
module
FEM

Signal
conversion module
SUM6 / SUM9

Sensors for
sheet turning
device

Signal control via SUM6/SUM9

73
 Input/output control SUM6/SUM9 Signal conversion module

Place of installation
The signal conversion module SUM 6 / SUM9 is
located in the distribution box LVT of the corre-
sponding printing unit.

LVT
Place of installation of SUM6/SUM9

Task
The signal conversion module SUM 6 / SUM9
combines different input signals. Two output signals
of the SUM 6 / SUM9 are available for the electronic
control system.

green LED red LED

Signal conversion module SUM6/SUM9

74
 Input/output control SUM6/SUM9 Signal conversion module

Terminal assignment
Terminal Function
A Output signal;
the signal is generated by combining
terminals C, F and G for logic operation.
B Output signal;
the signal is generated by combining
terminals F and G for logic operation.
C Input signal
D
(ground 24V)
E 24V DC
Terminals on SUM6/SUM9 F Input signal (red LED)
G Input signal (green LED)
H Not used

75
 Input/output control BKM Brake coupling module

BKM Brake coupling module

Signal flow
From the control electronics, signals are trans-
Control electronics mitted to the input / output control board ESK via
(REK1, REK2, REK386, SAK) the data bus.
The ESK controls the input / output board EAK in
the central control cabinet.
On the flat-cable output module FAM, the flat
Input/output cable is split up into single cores.
control board The brake coupling module BKM controls the
ESK feeder brake and the feeder clutch.

ESK Input/ output control board

Input/output board EAK Input/ output board

EAK FAM Flat-cable output module
BKM Brake coupling module

Flat-cable
output module
FAM

Brake Feeder brake

coupling module
BKM Feeder clutch

Signal flow of brake coupling module

76
 Input/output control BKM Brake coupling module

Layout and task

The brake coupling module BKM is required to
control the feeder clutch and the feeder brake of
the press.
For installation in the control cabinet the board is
placed in a card holder.

Single-row pin base X1, 6-pole

Layout of brake coupling module

77
 Input/output control BKM Brake coupling module

Block diagram

+12 V +48 V

Actuator KU
+24 V-NTK
Electrical
Control logic
isolation
ST-BK
Actuator BR

+48 V +12 V

+48 V
Power supply unit
Ground

Block diagram of brake coupling module

+24 V-NTK Control voltage DC 24 V

ST-BK Potential-free control signal
brake / clutch
+48 V Power supply DC 48 V
Ground Ground reference (
)
KU Connection of clutch
BR Connection of brake

78
 Input/output control BKM Brake coupling module

Function
The brake coupling module BKM prevents the
running-on of the feeder and consequently
overshooting sheets and paper jams on the feed
table.
A power supply unit provides the required direct
voltages ( DC 12 V and DC 48 V ).
The control signal which comes from the higher-
level electronic system is isolated (electrical
isolation) and then transmitted to the control logic.
In the process, the control signal ST-BK can have
the following circuit states:
ST-BK = 0 V (”Off”) clutch engaged; brake
released.
ST-BK = 24 V (”On”) clutch not engaged; brake
briefly applied (1 second),
then released.
The control logic conditions the signals (clocked
control voltage), which are required to control the
feeder clutch and feeder brake.

Assignment of pin base

Pin Function

1 6 1 DC 48 V
2
(ground)
3 DC 24 V – NTK
4 ST-BK
5 KU
6 BR

Pin base X1 of brake coupling module

79
 Input/output control EAE Input/output plug-in unit

EAE Input/output plug-in unit

Layout
1 NTK Power supply board (slot 5V)
2 SEK Safety input board
3 EAK2 for printing unit 8 or coating unit
4 EAK2 for printing unit 7 or coating unit
5 EAK2 for printing unit 6 or coating unit
6 EAK2 for printing unit 5 or coating unit
7 EAK2 for printing unit 4 or coating unit
8 EAK2 for printing unit 3 or coating unit
Input/output plug-in unit
7 EAK2 for printing unit 2 or coating unit
9 EAK2 for printing unit 1
ß EAK2 for central control cabinet
q EAK2 for central control console
w EAK2 for delivery
e EAK2 for feeder

Components
EAR Backplane of input/output plug-in unit
The EAR is at the back of the input/output plug-in
unit. All pin and socket bases on this backplane are
connected to the relevant components through
cables.

Backplane of input/output plug-in unit

NTK Power supply board

In its board slot the power supply board receives a
reference voltage which informs it about the
output voltage to be generated.

Layout of power supply board NTK

80
 Input/output control EAE Input/output plug-in unit

SEK Safety input board

The signals from all safety inputs and outputs pass
through the safety input board SEK where they are
registered and conditioned.

Layout of safety input board SEK

EAK2 Input/output board

The input/output boards EAK 2 are identical in
design and can be interchanged. Dependent on the
board slot they perform different functions and are
allocated to different printing or coating units of the
press.

Layout of input/output board EAK 2

81