SM52 Perfecting error

2001 Heidelberg SM 52-5P3, CP2000
CpTronic Modular
Fully automatic perfector

We have run into another perfecting changeover problem. We were running in perfect mode, and initiated the changeover to straight. The press sounded like everything worked fine, there were no errors on the screen, however the screen still showed that the press was in Perfect, so I checked the reversing drum and it was still in perfect mode. I inched the machine slightly to check the position of the drum, but the machine stopped and showed error "Monitoring of reversing drum - storage drum synchronization". This happened a few years ago, but has not happened since.

Last time we ran a learning /"emergency run" by initializing the memory (SAK board), we first tried to release the clampings, but they wouldn't release from the Service screen, so we initialized the board again, and rebooted, and after that the clampings would release, then we were able to complete the emergency run and clear the error. This time the clampings will not release with the screen buttons. After we rebooted the machine shows that it is in straight, but it was still in perfect. When I push the 90 bar button, the machine does sound like it is attempting to send power to the solenoids, but it is not enough to engage them.

We checked the oil level and sensors on the intensifier and they are good. The 35 and 100 bar pressure solenoids will not engage with the buttons on the screen. We can manually engage them though and they work fine, the corresponding sensors on the intensifier do report back that the pressure is good when we manually activate them. The reversing drum latch Pawl does operate normally, and we do have that engaged when we manually operate the solenoids so that the gear segment has not shifted. The EAK board does show 24V on the output for the solenoids, and I do have 24v going into the 15K64a, but zero V coming out. There are 4 wires going into the 15K64a, two have 24V from the EVM board, but the other two i don't know where they come from or run back to, but i think they send a signal to activate the contactor switch? I swapped the contactor with another one in the cabinet, but that didn't have any affect.

I have tried to convert the machine back with the hand crank, and can rotate the press from perfect to straight, and back again manually by engaging the reversing drum pawl Y15, and manually engaging the 90 bar solenoid Y5, but the machine will not recognize that it has been changed, the machine always shows straight now, and never shows perfect mode. Maybe I am not completing the manual process completely, is there another step after manually converting? I have tried to move the press to 0.0 degrees after, and reboot, but no change. The machine never shows perfect even if it is in perfect, and I never get a green check mark on the format change screen, it is always grayed out.

I checked the position of the flags on the storage drum (static and dynamic), they seem to be in the correct positions when watching the Sum9 module (red/green lights). When converting by handcrank, the segment gear does contact the sensor

I am wondering if the problem is with the storage drum, I changed the size (manually with the crank) to a larger sheet size than 280mm (approximately 300mm), when i did this the screen does not reflect the change it still reads the original size.

The machine had been giving us an error when changing sheet sizes (in straight mode), we would get a "Size Mismatch" error, which we could clear/acknowledge on the screen (feeder) area. We do not run in perfect mode very often, only once every few months.

Dyn test is clear, Init Test only has an S-SAK FFEF, but I think that is a battery on the board error only, I did check the 3V on the board and it is low like 1.5V. The machine also does not recognize that the dropped sheet removal door is opened?

In the PT Functionality / Fault Handler overview window:
After reboot i get these, if i start a manual changeover the DW3 error - 1027 stays and the other two disappear.
MAG error - 6076
DW3 error - 1015, 1027

 

Please can you send the pocture of your screen to see which problem is it

 

Short out memory board after manually restoring positioning. It sounds like you’ve got a thorough handle on restoring press to straight printing manually, but the final step in process is to clear memory board. There’s also potential problems that could occur from that last step. Be careful. Good luck,.

 

Thank you, I have shorted that jumper on the SAK board like 20 times, it does not seem to make an affect.
Is the best mode to be in Straight or Perfect for resetting memory? Should I move the press be at 0 degrees before reboot?

Is this the correct order to convert into perfect/straight manually?
-Engage - Reversing pawl
-Rotate press with crank to lockup (counterclockwise)
-Engage 90bar (i have to do this manually because it will not engage from the console).
-I can then move the reversing drum freely and rotate (lining up the "S" hole on the gear to 8mm hole behind for Straight, or "W" for Perfect).
-Then release 90 bar
-Release reversing pawl.
- shutdown, remove SAK, short jumper, wait 30 seconds, reinstall, powerup.

When moving to perfect, the console will not show that the press is in Perfect mode, it always shows Straight mode on the screen.

 

Hi dear sir, please hold the withdrawal symbol and press the emergency stop button and check the oil which is in the pressure multiplier and restart the conversion.

 

Hi sir
Regarding your picture please do that
Change machine to straight mode and shunt 9-10 and 11-12 on the x11 in zsk board like the picture attached there
Good luck

 

Thanks for the advice, but I do not believe this machine has a ZSK board, it is a 52-5 modular.

 

Thank you, this does not seem to do anything for my problem.

 

It's just eliminate the fault and restart the withdrawal.

 

Please send me picture of you electrical cabinet

 

In this case you have yo change the machineto straight mode and then try to reset sak board that all .
Good luck

 

Yes, I have tried resetting SAK board with the machine in straight at 0 degrees, and in perfect at 0 degrees.

 

The Press is FIXED, and is working again!!! Thank you for everyones assistance.

Today, I moved the press to straight manually, then rotated by hand crank to Zero degrees. Shutdown, reset SAK board, rebooted. The machine did not change. Then I pushed and held the error symbol button on the screen and pushed the normal "STOP" button, and that cleared the error. The emergency stop did not work, but the regular/normal stop button cleared the error. I was then able to run the changeover sequence automatically. the press moved itself back to perfect, and then immediately moved itself back to straight.

I did have the service buttons activated from under the console as well, but that might not be necessary.

 

Yes to activate the error on the screen you have to puch stop boutton and clear the error .
Good job

 

Service buttons under console, each opens a different menu.

 

Hello Friend hereby i would like to express my gratitude for your valuable feedbacks which these kind of behaviours are very very rare. most of people come here and narrate a story without the-end part or better to say without telling the remedy way. The world would be a better place with the people such as you that share generously their experiences (Knowledge) with the others. Thank you and wish you all the best. GoodLuck

 

Yes it s sfk card

 

Dear Connerj91, Which cylinder do you mean when (Lining up "S" or "W" hole on the gear to 8mm hole), Is it reversing drum (small) or storage drum (big)