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Autoink User Guide

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Autoink User Guide

The Autoink system is a modern replacement for the Hydrair system to automatically monitor and fill the ink ducts across the press. The new design uses the existing Hydrair bars whilst replacing the control system and solenoids. A Siemens PLC controls the system and a unit mounted HMI is utilised to monitor duct levels and alarm messages to allow for more accurate and quicker fault finding. A warning sounder mounted in the quiet room alerts press crew to potential problems.

Control Box

□ Each duct is locally fitted with a control box with one on/off switch per duct.

Ultrasonic sensor:

□ Only one sensor is fitted to each duct. The sensor however is a more accurate ultrasonic version which can control much lower duct levels compared to the existing capacitive type sensor.

□ If duct levels are in a healthy state pressing the green start button will put the duct in auto mode.

□ A white indication LED is fitted into the integrated Start/Stop button

□ When the duct is in auto mode the LED is illuminated

□ When the duct is filling the LED flashes.

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□ To allow the system to operate with only one sensor the Autoink system is connected to the press control system. As the system knows what imposition is selected it will select Op, Drive or both valves accordingly.

□ For example if the unit is running a half web to the drive side, only the drive side valve will operate. Indication of selected valves is provided on the Pre-set screen on the HMI.

HMI (Human machine interface) □ An HMI is fitted to the Operator side panel to allow viewing of duct levels, fault messages as well as selection of manual fill mode and the resetting of the alarm sounder.

□ One sensor is mounted in the centre of each bar.

□ It is mounted flush with the bottom of the bar to reduce possible contamination.

□ If the sensor gets dirty the duct will not go into auto mode and will sound an alarm in the quiet room. A message will also appear on the HMI

□ Duct levels are pre-set and can not be changed by operators.

□ Optimum duct level setting is (50%) as shown on left.

□ This is to reduce waste and possible contamination to the ink in the duct.

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Home page.

Main Page

□ The cylinders on A10 are red to denote that the duct is not in auto mode.

□ The box on the RHS of the screen shows current alarms i.e. A 10 duct not in auto mode

□ Pressing the o for each colour take you to the duct level screen.

Click the “continue” to home page button to move to main information screen.

□ The main information screen shows a mimic of the unit. The cylinders change colour to identify if they are in automatic mode

□ If the cylinder on the mimic are green the duct in question is healthy and in auto mode.

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Duct Level Screen

□ Each level/colour on the tower has a duct level screen which provides a graphical representation of current duct levels.

□ Links to other key screens are also provided as well as information on if the duct is in auto mode.

Manual Override

□ As an overflow precaution the solenoid valves that fill the ducts only operate when they receive a signal from the press to say that it is running.

□ To allow ducts to be filled manually, for example after duct cleaning a manual override facility has been incorporated into the design.

□ As well as feedback on duct levels indication is also provided to show if the solenoids are currently operating.

□ On the manual override screen press the override button.

□ This will allow the ducts to be filled manually via the green start button on the junction boxes.

□ Once the ducts reach a level of 20% they will automatically drop into auto mode.

□ The override function times out after 5 minutes.

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Alarm Logs

□ To assist in fault finding a log of faults is recorded

Fault messages

□ If a duct is in fault mode the current alarm box and alarm log will provide a list of faults.

Examples of faults include:

Duct level too low Duct level too high No feedback from Sensor Duct not in Auto Duct in manual fill mode Press running and no attempt to fill duct Too many requests to fill duct

Each message will display the duct in question and the faults, i.e.: A10 Duct not in automatic A10 duct – No feedback from sensor. In the alarm log the date/time will also be recorded.

Warning Sounder

□ To warn press operators of any faults during the run, a sounder has been fitted in the quiet room. This will sound if any duct drops out of auto mode. The sounder can be silenced by pressing the “reset alarms” button on the main page. At this point the duct then needs checking and putting back into auto or the sounder will go off again after 5 minutes.

□ The alarm log records when and what caused a fault for historical fault finding purposes.

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Spreader bar Taps The taps on the spreader bar are set to optimum positions during commissioning. They should not be altered. By opening up all valves to maximum it could result in parts of the duct overflowing.