SM52 Perfecting changeover error, Monitoring of reversing drum - storage drum synchronization

Discussion in '4-Color Offset Presses +' started by Connerj91, Feb 23, 2022.

  1. Connerj91

    Connerj91 Member

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    2001 Heidelberg SM 52-5P, CP2000

    Need help please. The press was running in perfect mode, and I started the changeover to straight mode. The press sounded like it was doing all the correct moves and no errors were thrown, but after I ran the process the console still showed it was in perfect mode. So I ran the process twice more, but the console still showed in perfect mode. Still no errors at this point. I then rebooted the press, and after the press came online it showed it was now in straight mode, so I began ran the "Press Start" sequence to ink up for the next job, the press moved very slightly and now shows the error "Monitoring of reversing drum - storage drum synchronization". The press won't move with the controls. I can move the press with the Hand crank and the brake released, the press will rotate 100% (forward and reverse) with the hand crank and there doesn't appear to be any mechanical binding or problems.
    The press appears to still be in perfect mode, but the console shows straight mode, so it is confused.
    When I go into the printing material screen, the green check mark is grayed out, and I cannot select it or the perfecting drum size buttons.
    I checked the level of the intensifier oil (top allen head screw on intensifier) and that seems to be full still. I have rotated the press forward to 0.0 degrees, but still no check box on the printing material screen.
    Looking at the reversing drum, and the gear on the DS, it still shows that the press is physically in perfect mode, but again the console thinks the press is in straight mode. The only error we have is the synchronization error.
     
  2. ashok kumar

    ashok kumar Senior Member

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    Is it fully automatic perfection
    Or semi automatic??
     
  3. Connerj91

    Connerj91 Member

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    The press is fully automatic perfecting changeover.
     
  4. Adil

    Adil Senior Member

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    Please show me the image of the synchronization error,
    Also take me the init test and dyn test of the eak cards.
    To make a good diagnosis because there are several causes for this problem, (connection fault, faulty eak card, faulty format change engine, faulty sum module, faulty sensor)
    To find out what happened take me some pictures that I asked for.
     
    ABDALLH SANDAFI likes this.
  5. Connerj91

    Connerj91 Member

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  6. Adil

    Adil Senior Member

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    Did this problem occur after a new installation, or during production?
     
  7. Connerj91

    Connerj91 Member

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    Thank you for your assistance.
    This happened during production. The machine has been installed and running great for 4 years.
     
  8. Grant B

    Grant B Senior Member

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    Location:
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    I experienced a similar issue years ago. There's a solenoid in the perfector area, it's on the gear side wall. The solenoid housing fills with oil. I can't remember if just draining it helped or replacing the solenoid was the fix.
    Ours was a 102, I'm not sure if you'd have a selanoid located in the same location.
     
    Last edited: Feb 25, 2022
  9. Connerj91

    Connerj91 Member

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    The problem has been solved, with the help of a technician. Here is what eventually fixed it.
    -Put in the crank handle.
    -locked the reversing drum via the service menu
    -rotated press with crank until the pawl locked in the double gear
    -then we tried to release sheet reversing device clamping (storage drum and reversing drum button) via the service menu, but they wouldn't release
    -so we unlocked the reversing drum, removed crank, shut down the press, and reset (initialized) the SAK board. Before resetting we recorded all press presetting values and variant code information, along with any other settings that might have been lost like characteristic curves and such.
    -rebooted, the press now showed it was in perfect mode (which is good because it was originally showing it was in straight mode, even though it was still in perfect)
    -the press now showed new error to put the press back into straight printing. So we tried the sequence again, the clampings released this time, we rotated the press forward (counter-clockwise at crank) to straight mode by hand
    -then on the console re-engaged the clamps, released the locking pawl/reversing drum, then tried to run the changeover sequence from the console, but nothing would happen, so we shut down again, reset the SAK again, rebooted
    -this time the changeover button was available, and when pushed it started the automatic changeover, the press did stop and had us insert the crank to rotate until the pawl locked into the double gear, then after removing the crank, we hit the green check box to continue, and the press ran through the rest of the process automatically.

    I don't know if the SAK board actually initialized all the way the first time, or if the press was just so confused ("lost in perfect") about where it was in the process that it just needed to be reset a few times to get its bearings, and eventually got back on the right track.
     
    asem alsafady likes this.

  10. Adil

    Adil Senior Member

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    Good job, doing this synchronization procedure and getting the machine back to working order. It's not sufficient
    If you have freed the machine now it is very good but if the problem recurs you must check the sensors of the regrouping and turning drums the connections and the pneumatic cylinders of the flange and the hydraulic sum module (input and output signals ) ....
    One day I had the same problem on a sm102 and each time I mechanically put the machine back in good condition and I reset the sak but finally we found that there is a flange cylinder which is defective and each time it breaks. blocks the flange does not move to its position when changing modes and the machine stops giving the same problem (a line between the two drums) anyway good luck and congratulations to the technician
     
    ABDALLH SANDAFI likes this.
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