Manroland R705 direct drive

[abed roro]

I'm having a problem with all my print modules not working with Direct Drive. These messages appear every time I try to start them, and this problem started suddenly. The messages are: Module 4, inking unit coupling, not engaged correctly
Printing module 3, inking unit coupling, not engaged correctly
Printing module 2, inking unit coupling, not engaged correctly
Printing module 1, inking unit coupling, not engaged

 

[Asim Shehzad]

Hi
You need to fix error from uwr first that station 7 faulty input data. Station 7 is your printing unit 4, here you need to check safety relay board slot 2 and exchange it if needed.
Once you fixed that error repeat the command for coupling again report the results and if you need more support

 

[abed roro]

Dear Asim,

This fault “Monitoring Computer Station 7” was already present before, and the machine was performing ink coupling engage normally.

Note that the fault diagnosis on the computer indicates a problem with the ink sensor B002. However, the sensor is working properly. After checking the sensor and the input board, it was found that the signal is present and the LED on the board is lit.

In addition, this model has an extra safety relay board called Slot /01, and the sensor signal is also present on this board and its LED is lit as well.

 

[Sergey_Ivanov_1963]

Check the operation of B002 in all sections according to the table
PU1 288
PU2 12
PU3 96
PU4 180
PU5 264
PU6 348
You also need to check the operation of the B434 sensor - А350/5 8:0 (PU1) and А359/5 2:7

 

[abed roro]

Dear Sergey,

Do you mean that the value PU1 = 288° is the encoder position for the printing unit in the ideal ink coupling (engage) position, and that it indicates the sensor position relative to the cam of that sensor?

Regarding the B434 sensor, I am not completely sure about this information because I am not on site to check the diagrams. However, I believe it is present on all units, and as far as I remember it is the ink vibrator sensor. Do you mean that I should check only the first unit, and if it is present on the other units as well, should I also check it after tracing it on the diagrams?

 

[Asim Shehzad]

Dear Asim, This fault “Monitoring Computer Station 7” was already present before, and the machine was performing ink coupling engage normally. Note that the fault diagnosis on the computer indicates a problem with the ink sensor B002. However, the sensor is working properly. After checking the sensor and the input board, it was found that the signal is present and the LED on the board is lit. In addition, this model has an extra safety relay board called Slot /01, and the sensor signal is also present on this board and its LED is lit as well.

Dear Asim,
This fault “Monitoring Computer Station 7” was already present before, and the machine was performing ink coupling engage normally.
Note that the fault diagnosis on the computer indicates a problem with the ink sensor B002. However, the sensor is working properly. After checking the sensor and the input board, it was found that the signal is present and the LED on the board is lit.
In addition, this model has an extra safety relay board called Slot /01, and the sensor signal is also present on this board and its LED is lit as well.

Dear Asim,

This fault “Monitoring Computer Station 7” was already present before, and the machine was performing ink coupling engage normally.

Note that the fault diagnosis on the computer indicates a problem with the ink sensor B002. However, the sensor is working properly. After checking the sensor and the input board, it was found that the signal is present and the LED on the board is lit.

In addition, this model has an extra safety relay board called Slot /01, and the sensor signal is also present on this board and its LED is lit as well.

For monitoring computer error from safety relay board it’s common that with these errors machine works but not specific functions and over time those boards stop functioning anymore.

For inking unit coupling and in your case it’s not possible that all B002 detectors are defective and you confirmed their functionality too, so B434 at first unit need to be checked and it’s important to know how machine is behaving during coupling process.
1. Coupling command executed and machine goes into coupling mode?
2. Machine moves and at which speed?
3. Any abnormal stop during process?

I can see there is an error from detector in behind module 6.
There should be no any abnormal stopping during coupling.

Remove these errors first then first carry out the decoupling and then coupling again.

At the end please share machine details it always helps to know about machine errors

 

[abed roro]

Dear Asim,

Regarding the sensor fault behind unit 6, I disabled it and cleared the error, but the problem still remains.

As for the ink coupling process, when I give the engage command to the machine, if the cam at sensor B002 has moved, the machine returns it to a specific position so that the sensor becomes ON. After the startup bell finishes, the machine starts at the creep speed of 1200.

After several revolutions, the machine engages the ink rollers for a very short time, then disengages again. It continues rotating for a while, then stops and shows errors indicating that the process has failed and that the ink coupling operation was not completed correctly.

Regarding sensor B434, I will check and inspect it.

 

[Asim Shehzad]

Dear Asim, Regarding the sensor fault behind unit 6, I disabled it and cleared the error, but the problem still remains. As for the ink coupling process, when I give the engage command to the machine, if the cam at sensor B002 has moved, the machine returns it to a specific position so that the sensor becomes ON. After the startup bell finishes, the machine starts at the creep speed of 1200. After several revolutions, the machine engages the ink rollers for a very short time, then disengages again. It continues rotating for a while, then stops and shows errors indicating that the process has failed and that the ink coupling operation was not completed correctly. Regarding sensor B434, I will check and inspect it

B434 is important to check because it gives the position to the machine engaging an inking unit.

 

[abed roro]

B434 is important to check because it gives the position to the machine engaging an inking unit.

Thank you I will try

 

[abed roro]

Hello, I checked the B434 sensor. I replaced the B434 sensor board - A350/5 8:0 (PU1) - as well as A359/5 2:7, but the problem persists. Are there any steps I can take to troubleshoot it? Thank you.

 

[abed roro]

The problem has been solved

Thank you, Mr. Assem.
I accessed the "make ready" section and followed the steps.
I removed the DirectDrive cover, but I discovered that there was an air hose, number 79, specifically for the ink roller coupling. It always contained air at a pressure of 9 bar, even after disconnecting the Y292 connector. I found that the air continued to flow. I then traced the air hose and found it was coming from another source, so I disconnected that source. After that, I started the machine, made the couplings, and it worked perfectly,

 

[abed roro]

Check the operation of B002 in all sections according to the table
PU1 288
PU2 12
PU3 96
PU4 180
PU5 264
PU6 348
You also need to check the operation of the B434 sensor - А350/5 8:0 (PU1) and А359/5 2:7

Thank you Mr sergey