Four kinds of diagnosis methods for the fault of INTERBUS bus of Roland rotary printing machine

At present, many domestic newspapers have rotary presses manufactured by Roland, such as Geoman, Colorman, Uniset70, etc. Most of them use BUSSYSTEM95 as the control system. BUSSYSTEM95 is a network integration, and the components are connected by communication cables. According to the function and network type, BUSSYSTEM95 is divided into 3 layers: Ethernet (Ethernet) layer, Arcnet layer and executive layer (Interbus layer). As the closest network to operators and mechanical devices, Interbus has a higher chance of failure. If you can master some fault diagnosis methods and use them flexibly in use and maintenance, you can do more with less.

Interbus is a field bus system developed by Phoenix Corporation of Germany. It is an open serial bus system, which is quite different from the traditional parallel system. This brings maintenance work for maintenance personnel who are accustomed to parallel systems. Some inconvenience. In practice, the author has always used some methods for fault diagnosis of Interbus bus for the reference of colleagues, hoping to play a role.

Roland press bus fault diagnosis method

There are generally two Interbus buses in Roland rotary printing presses: one is the whole bus with G4 control board as the bus controller, which is connected to the input / output (I / O) of the driving part of the whole machine, and each printing department (or Folding machine) operation panel and various paper holders. The other is the local bus using the MS-1000's VMEMCI board as the bus controller, which is connected to various valves, motor controllers, sensors and other devices in the printing department (or folding machine). No matter which part of the bus of the printing machine has a problem, its bus controller will generate a "bus failure" error message, which will be transmitted to the industrial computer of the console through the ARCNET network. come out. When "Interbus bus fault" is displayed on the operation display screen, the fault location can be found in the main control cabinet or printing unit according to its detailed information.

1. Use fault display LED

The Interbus network consists of a bus controller, node devices (Interbus modules) and cables. The possible failures are: damage to the bus controller, damage to the Interbus module, broken cables or poor connections. Because the bus controller and various Interbus modules are equipped with light-emitting diodes for status indication, the door of the control cabinet can be opened when the Interbus bus failure is encountered, and the bus controller and Interbus module fault indication LED. There are multiple LEDs of different colors (mainly red and green) on the VMEMCI board of the Interbus bus controller and the node device (Interbus module). The different states of the LEDs correspond to different Interbus bus conditions. According to the information given by the light-emitting diodes, the fault location of the Interbus bus can be analyzed and judged, and the faulty Interbus module can be replaced to repair the rotary printing press. This method is more suitable for a smaller Interbus network. If this method is used to diagnose a larger network or a network with scattered Interbus modules, it takes time and effort. Of course, this method had to be adopted in the past few years when the diagnostic conditions were not available. It is worth mentioning that some fault indication LEDs can flash at a variety of different frequencies to indicate different fault states, and must be carefully observed and carefully identified.

2. Using the fault display

This method is similar to the method of using fault display LEDs, but because only part of the bus controller of the Interbus network can use this method on the Roland printing machine, and the function of the fault display is far more powerful than the fault indication LED, so it is listed separately Come out and explain.

The bus controller G4 control board in the Siemens S5-155 in the main control cabinet has fault diagnosis and display functions. It can diagnose and display the faults of the connected Interbus network. Under normal circumstances, it is displayed as "RUN" and a circular rectangle, the background light is green (once a fault occurs, its background light turns to red, and displays the fault type, fault location and fault code. The fault type is "LBUS", Indicates a local bus fault; 29.1 is the address information of Interbus; fault code "0D21" indicates that there is a problem with the input of a specific Interbus module. In addition, the types of faults that may be encountered during maintenance are: "CTRL"-bus controller fault; "RBUS"-remote bus failure; "LBUS"-local bus failure; "OUT1", "OUT2"-output failure; "BUS"-a bus loop failure, but cannot be accurately located; "DEV"- -Interbus module failure; "PF"-bus peripheral equipment failure, etc. The failure code can tell further failure information, and may encounter various other failure codes in the work, which will not be repeated here one by one, details You can refer to the Interbus fault diagnosis instruction manual. According to the Interbus address information, you can find detailed information such as the specific module name, location, address and drawing number on the Interbus structure diagram, so as to quickly eliminate the fault .

The G4 control board also has the function of historical fault memory, which can be used to trace the fault that has been reset by the operator or some soft faults. It is worth noting that the Interbus addresses in these historical fault records use 4-digit hexadecimal numbers. This 4-digit hexadecimal number is divided into two parts, the high-order number indicates which bus loop, and the low-order digit indicates the position in the bus loop. It should be converted to a decimal number and then found on the Interbus structure diagram. For example, the fault address 29.1 mentioned earlier is recorded as 1D01 in the historical fault record.

3. XTALK program diagnostic method

XTALK is an early computer-to-computer communication software. The unit computer of the Roland Rotary Press (UnitController) MS-1000 does not have peripherals such as a display and a keyboard. Therefore, the diagnostic program in the MS-1000 requires external commands to be executed. These external commands are issued by the notebook computer with which it communicates. .

The Interbus network of the printing department, the paper holder and the folding machine is controlled by the bus controller on the VMEMCI board of the unit computer MS-1000. This bus controller has no display screen. When the Interbus fails, the failure code cannot be seen. At this time, you can run XTALK to diagnose the network through the unit computer. The specific method is: connect the COM1 port of the notebook computer with the RS232 communication port of the MS-1000 with a special cable, after running XTALK under DOS, type "TIBS" (note that all capital letters) command and press the Enter key , And then type "C" (configuration), you can get a diagnosis similar to Figure 4 and Figure 5. When all node devices are normal, the position of ERR-CODE is OK. When the Interbus is not normal, the location of ERR-CODE displays "0000", and the fault message is given at the bottom of the dialog window: "Error [0d21] atlocation11.1 (DIO-1) [Date = 2002/10 / 16Time = 16:36:32] ", which means that the fault is found at the bus address 11.1, the fault code is" Od21 ". According to the Interbus structure diagram, the module with bus address 11.1 can be found as a digital input / output module. You can find the cause of the fault in and around the input / output module with the fault information. This method can save a lot of fault finding time compared with the method of using fault indication light-emitting diodes, and is especially suitable for use in the printing department and the folding machine where the Interbus module is scattered. However, the fault location given by this method is sometimes not very accurate, which requires finding the fault before and after the location determined by the diagnosis.

The communication between the cell computer and the laptop can also use the "Super Terminal" in Windows or other communication software such as NCTERMINAL95, etc. The specific method of use is similar to XTALK, and will not be detailed here due to space limitations.

4. Diagnose with IBSCMDG4

IBSCMDG4 software is the Interbus application software under the window developed by the company. It can be used to diagnose Interbus: connect the COM1 port of the laptop to the serial port of the bus controller with a communication cable, double-click the IBSCMDG4 icon to run the IBSCMDG4 software, and select Open under the File menu. In the "OpenProject" dialog box, select the name of the Interbus network file to be diagnosed, and then press OK. You can see a window similar to the Interbus structure diagram. In fact, the Interbus structure diagram is printed out using the IBSCMDG4 software. Press function key F3, then select Diagnose in the "OperatingState" dialog box to diagnose the connected Interbus network. When Interbus is normal, all node devices and their connections are green; and when a fault occurs, the faulty node device (Interbus module) turns red. This software can also automatically record historical fault information by making the diagnostic program always Run and connect with the bus controller. The historical fault information is very helpful to locate and find the soft fault of the Interbus bus.

IBSCMDG4 software diagnosis can be used in almost all Interbus networks of Roland printing machine, and can locate the fault more accurately. After installing the software, remember to copy Roland's Interbus graphics file, so as not to display some modules.

Generally speaking, any of the above four methods can be used to find Interbus faults. Only one of them is required to be proficient in one of them, which is enough to cope with various Interbus bus faults. However, using a single fault diagnosis method may only determine the fault in a small range, and cannot lock the fault to a certain module very accurately. When time and conditions permit, it is recommended to try a variety of diagnostic methods and compare the results to achieve the purpose of accurately locating the fault, and also increase the experience of diagnosis.

No matter which method is used to diagnose the Interbus bus fault, you need to be very familiar with the structure of the Interbus network. Because once the fault is diagnosed, the corresponding faulty module can be found immediately. If you can't read the Interbus structure diagram, even if you can quickly diagnose the fault, you can't quickly find the faulty module on such a large rotary offset press, which delays valuable maintenance and printing time.

It is worth noting that each loop of Interbus needs to pass through each node. When one of the node devices (Interbus module) fails, the entire network cannot operate. Using traditional shorting or skipping this node method will not work. After short-circuiting or skipping this node device, it needs to be changed in the setting of the bus controller to make the Interbus bus run again.

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