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Short Version Troubleshooting Guide

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Information about Short Version Troubleshooting Guide
Education

Published on March 7, 2009

Author: metaprinter

Source: slideshare.net

Description

Troubleshooting guide created summer of 2008 for the washington post company's MHI offset printing presses to diagnose splice failure and web tension issues.
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Abridged Presentation

Troubleshooting With Paster Logger & RTP CCS Malfunction Faults MHI Offset Press

Purpose Of This Guide Minimize the frequency of “unexplained” paster failures. Increase runability by minimizing paster related down time. Enhance communication between press operators and maintenance department.

Minimize the frequency of “unexplained” paster failures.

Increase runability by minimizing paster related down time.

Enhance communication between press operators and maintenance department.

Reading The Logger 1. Select “press” 2. Select “reel” 3. Select “last failure” 4. Check the date and time If the Logger is not recording events, call 6-1945 and ask I.T. to restart/ reboot. This example shows a successful paster for comparison

1. Select “press”

2. Select “reel”

3. Select “last failure”

4. Check the date and time

What Are We Looking At? 10-second snapshot within the paster cycle The first 5 seconds show old roll tension and new roll paster signal The zero point is marked by the PLC’s calculation of minimum roll diameter and triggers: knife fire, brush release, core brake, and A/B change The last 5 seconds shows new roll tension This is the expiring Core Millisecond Pulse Count (Black Tape) Off On Brake/ Knife A/B change New Roll Pulse Old roll reel tension new roll reel tension

10-second snapshot within the paster cycle

The first 5 seconds show old roll tension and new roll paster signal

The zero point is marked by the PLC’s calculation of minimum roll diameter and triggers: knife fire, brush release, core brake, and A/B change

The last 5 seconds shows new roll tension

SCREEN ELEMENTS Notice that the screen only allows for viewing of the last successful paster and the last three failures. The print function currently prints to a printer in the pressroom office. Notice that this successful paster begins at 28kg’s and returns to 28kg’s within this 10 second snapshot. This is Ideal.

Notice that the screen only allows for viewing of the last successful paster and the last three failures.

The print function currently prints to a printer in the pressroom office.

Paster Signal Elements Black tape signal always shows up as a series of 1 or 2 millisecond width pulses on the paster logger. Commutator shows up slightly wider as 2 or 3 millisecond width pulses. The frequency of the pulses is what matters most here. They should be EVENLY spaced. Good Surface Sensor Signal Bad Signals Good Commutator Signal

Black tape signal always shows up as a series of 1 or 2 millisecond width pulses on the paster logger.

Commutator shows up slightly wider as 2 or 3 millisecond width pulses.

Paster Logger Troubleshooting

Elements of a Good Paster 1. Paster signals evenly spaced 1. 2. 3. 4. 5. These are the elements you must focus on when troubleshooting with the logger 2. Old roll tension reading at the correct tension 3. Old roll tension is steady 4. Slight tension rise during brush contact 5. Slight tension correction after splice

Failure Description Probable Causes: Most Likely Specific component Less Likely Specific component Least Likely Specific component Description of the above failure Failure causes More information for troubleshooting Call to action Picture of related component Paster Logger Example Highlights the area of focus The following pages are ordered so that the beginning of the section is at the beginning of the paster cycle and the last page is a failure at the end of the paster cycle

Probable Causes:

Most Likely

Specific component

Less Likely

Specific component

Least Likely

Specific component

Description of the above failure

Failure causes

More information for troubleshooting

Call to action

No Paster Signals example 1 Press Stopped !! Web May Still Be In !! Probable Causes: CCS Malfunction Push Button Stop Other Press Shut Down While in paster cycle The specific failure above was found to be the result of: Shut down during paster cycle Proximity Sensor Fault Use the CCS Fault Quick Guide in the next section to assist with troubleshooting Notice there Are NO Signals

Press Stopped

!! Web May Still Be In !!

Probable Causes:

CCS Malfunction

Push Button Stop

Other

Press Shut Down While in paster cycle

The specific failure above was found to be the result of:

Shut down during paster cycle

Proximity Sensor Fault

Use the CCS Fault Quick Guide in the next section to assist with troubleshooting

Erratic Paster Signal Press Stopped !! Web May Still Be In !! Probable Causes: Slip Ring Failure Oil Contamination Brushes worn out Check for CCS malfunction faults The specific failure above was found to be the result of: Oil leaking into the Slip Ring Housing Causing electrical problems If you notice oil leaking onto / into the slip ring housing, call maintenance . Slip Rings Inside DR Ignore This Problem is in here

Press Stopped

!! Web May Still Be In !!

Probable Causes:

Slip Ring Failure

Oil Contamination

Brushes worn out

Check for CCS malfunction faults

The specific failure above was found to be the result of:

Oil leaking into the Slip Ring Housing

Causing electrical problems

If you notice oil leaking onto / into the slip ring housing, call maintenance .

Rising / High Tension Before Brush Probable Causes: Floating Roller Incorrect setting Losing setting (air leak) Reel Tension Components The specific failure above was found to be the result of: Floating roller incorrect setting resulting in high OR tension (40kg’s) Go to the back of this guide for proper floating roller setting Call maintenance to check reel tension components if floating roller setting is good

Probable Causes:

Floating Roller

Incorrect setting

Losing setting (air leak)

Reel Tension Components

The specific failure above was found to be the result of:

Floating roller incorrect setting resulting in high OR tension (40kg’s)

Go to the back of this guide for proper floating roller setting

Call maintenance to check reel tension components if floating roller setting is good

Failure at Brush Signal ( black tape surface sensor ) Probable Causes: Brush Air pressure incorrect Mechanical movement Incorrect gate distance Speed Mismatch Paster Make Up Nose turned over Incorrect pattern Floating Roller Timing Humidity (seasonal) should be 45%-75% The specific failure above was found to be a result of incorrect brush timing due to: Brush pressure too high, destroyed paster on new roll Is the paster tail at incorrect distance from paster? -Indicates timing problem Is the nosetab still on the new roll? -listen for weak or violent brush fire Notice there is no tape signal for the knife to fire. Indicates the paster was destroyed at brush contact.

Probable Causes:

Brush

Air pressure incorrect

Mechanical movement

Incorrect gate distance

Speed Mismatch

Paster Make Up

Nose turned over

Incorrect pattern

Floating Roller

Timing

Humidity (seasonal)

should be 45%-75%

The specific failure above was found to be a result of incorrect brush timing due to:

Brush pressure too high, destroyed paster on new roll

Is the paster tail at incorrect distance from paster? -Indicates timing problem

Is the nosetab still on the new roll? -listen for weak or violent brush fire

Notice there is no tape signal for the knife to fire.

Indicates the paster was destroyed at brush contact.

Tension Spike Probable Causes: Floating Roller Incorrect setting Stuck - unable to move Bellofram Cylinder Unable to maintain air pressure Roll Speed Mismatch New Roll diameter sensor Out of adjustment Dirty / oily The tension spike above was found to be a result of: Floating roller not centered Also check NR size NR size above 1270mm is suspicious NR size above 1290mm is impossible Problem is in here OP DR Ignore This

Probable Causes:

Floating Roller

Incorrect setting

Stuck - unable to move

Bellofram Cylinder

Unable to maintain air pressure

Roll Speed Mismatch

New Roll diameter sensor

Out of adjustment

Dirty / oily

The tension spike above was found to be a result of:

Floating roller not centered

Also check NR size

NR size above 1270mm is suspicious

NR size above 1290mm is impossible

Failure After Brush Contact superstructure Probable Causes: Slitter Worn / damaged Not fully engaged Incorrect depth Missed Cutout Mill Defect Paster Make Up Tape too close to roll edge Too much tape Loose Blankets Wrinkles The failure above occurred in the superstructure and was found to be a result of: A worn slitter Also be aware of a good paster that encounters: Loose blankets Wrinkles Problem is at this moment

Probable Causes:

Slitter

Worn / damaged

Not fully engaged

Incorrect depth

Missed Cutout

Mill Defect

Paster Make Up

Tape too close to roll edge

Too much tape

Loose Blankets

Wrinkles

The failure above occurred in the superstructure and was found to be a result of:

A worn slitter

Also be aware of a good paster that encounters:

Loose blankets

Wrinkles

Retrieving RTP CCS Faults & Troubleshooting

Press Status Monitor Screen 1. Shows faults by highlighting the area in red. Below, reel 7 is illuminated in red indicating a problem. Select this reel to bring you to the reel status screen.

Reel Status Screen “STOP” Active faults highlighted >>! Example !<< From the stop screen, when the “other” category is illuminated in yellow this is indicating there is more specific information about the malfunction. Select “other” and read through the list to find faults highlighted in red. 2.

Active faults highlighted >>! Example !<<

From the stop screen, when the “other” category is illuminated in yellow this is indicating there is more specific information about the malfunction.

Select “other” and read through the list to find faults highlighted in red.

Reel Status Screen “SLOW” The “slow” category only has three possible faults stored in it, with the OR Pulse Error being the most prevalent. 3. Continue scrolling through to the “other” category to find more faults.

The “slow” category only has three possible faults stored in it, with the OR Pulse Error being the most prevalent.

Continue scrolling through to the “other” category to find more faults.

Reel Status Screen “OTHER” The “other” category has two screens of malfunction reports. Any number of these faults may be highlighted depending on the components involved in your failure To get to the second page select the >> button 4a.

The “other” category has two screens of malfunction reports. Any number of these faults may be highlighted depending on the components involved in your failure

To get to the second page select the >> button

Reel Status Screen “OTHER” This is the second page contained within the “other” category. It is important to note all the failures so accurate troubleshooting can be performed by press operators, machinists, and electricians. 4b.

This is the second page contained within the “other” category.

It is important to note all the failures so accurate troubleshooting can be performed by press operators, machinists, and electricians.

RTP CCS Faults Troubleshooting

Fault Category Specific Fault- Description Most likely cause / component Less likely cause / component Least likely cause / component What to look for (corrective action) Additional information Picture of related component

Specific Fault- Description

Most likely cause / component

Less likely cause / component

Least likely cause / component

What to look for (corrective action)

Additional information

Common RTP “STOP” Faults Proximity Sensor Fault- Black Tape Surface Sensor No black tape or wrong location Dirty or obstructed sensor (Call maintenance to clean optical surface sensor) Hub/ Slip Ring problem (Paster Logger displaying erratic paster signals?) Oil / Debris leaking into slip ring housing (Call maintenance) Electrical resistance out of range Slip ring brushes worn out Roll not spinning NR accelerator not engaging (call maintenance) Paster gate out of position (paster arm sensor fault)

Proximity Sensor Fault- Black Tape Surface Sensor

No black tape or wrong location

Dirty or obstructed sensor (Call maintenance to clean optical surface sensor)

Hub/ Slip Ring problem (Paster Logger displaying erratic paster signals?)

Oil / Debris leaking into slip ring housing

(Call maintenance)

Electrical resistance out of range

Slip ring brushes worn out

Roll not spinning

NR accelerator not engaging (call maintenance)

Paster gate out of position (paster arm sensor fault)

Common RTP “STOP” Faults NR Sensor Fault- Commutator Paster Signal Hub/ Slip Ring problem (Paster Logger displaying erratic paster signals?) Oil / Debris leaking into slip ring housing (Alert maintenance) Electrical resistance out of range Slip ring brushes worn out Roll not spinning NR accelerator not engaging (call maintenance) Paster gate out of position (paster arm sensor fault) Slip Rings Inside

NR Sensor Fault- Commutator Paster Signal

Hub/ Slip Ring problem (Paster Logger displaying erratic paster signals?)

Oil / Debris leaking into slip ring housing (Alert maintenance)

Electrical resistance out of range

Slip ring brushes worn out

Roll not spinning

NR accelerator not engaging (call maintenance)

Paster gate out of position (paster arm sensor fault)

Common RTP “SLOW” Faults OR Pulse Error- Communication Error When the PLC receives an unexpected signal from the old roll commutator hub, it sets this fault. Hub/ Slip Ring problem (Paster Logger displaying erratic paster signals?) Oil / Debris leaking into slip ring housing (Alert maintenance) Electrical resistance out of range Slip ring brushes worn out

OR Pulse Error- Communication Error

When the PLC receives an unexpected signal from the old roll commutator hub, it sets this fault.

Hub/ Slip Ring problem (Paster Logger displaying erratic paster signals?)

Oil / Debris leaking into slip ring housing (Alert maintenance)

Electrical resistance out of range

Slip ring brushes worn out

Common RTP “OTHER” Faults Paster Arm Sensor Error- Paster Gate R.T.P. relies on electric eye sensor to position gate into pasting position Sensor dirty, oily (call maintenance to clean sensors) Sensor out of alignment (call maintenance to check sensors) Mechanical movement of gate is incorrect Call maintenance to check movement and gate position

Paster Arm Sensor Error- Paster Gate

R.T.P. relies on electric eye sensor to position gate into pasting position

Sensor dirty, oily (call maintenance to clean sensors)

Sensor out of alignment (call maintenance to check sensors)

Mechanical movement of gate is incorrect

Call maintenance to check movement and gate position

Common RTP “OTHER” Faults Brake Output Error- NR/OR Brakes Indicates the RTP tension cannot be controlled by brake output Brake pads worn out Oil leaking onto brake pads Air pressure problem Every time a web is lost, this fault will set. This is normal and does not indicate a problem.

Brake Output Error- NR/OR Brakes

Indicates the RTP tension cannot be controlled by brake output

Brake pads worn out

Oil leaking onto brake pads

Air pressure problem

Every time a web is lost,

this fault will set. This is

normal and does not indicate

a problem.

Component Locator

Slip Ring Location Slip rings are a series of copper bands connecting the electrical components on the rotating reel arms to the stationary electrical components in the reel-stand via brushes. Beware of oil leaking into housing (notify maintenance Dept. if you see oil on the outside of the housing) Slip Rings Inside Oil Leaking Into Housing Housing Removed DR side reel-stand

Slip rings are a series of copper bands connecting the electrical components on the rotating reel arms to the stationary electrical components in the reel-stand via brushes.

Beware of oil leaking into housing (notify maintenance Dept. if you see oil on the outside of the housing)

Floating Roller Bellofram Location By controlling floating roller movement, the bellofram maintains reel tension during pasting cycle. Common causes of floating roller failure are: Incorrect operator setting Air leak from bellofram cylinder Floating Roller Bellofram Cylinder Close up Hole in Diaphragm DR

By controlling floating roller movement, the bellofram maintains reel tension during pasting cycle.

Common causes of floating roller failure are:

Incorrect operator setting

Air leak from bellofram cylinder

Rotary Valve Location The rotary valve is a manifold which distributes air from the stationary air lines in the reel-stand to the rotating reel arms. Tend to notice air leak / tension loss while reel arms index All pneumatic components on the arms are affected Valve is inside here Rotary valve OP side reel-stand

The rotary valve is a manifold which distributes air from the stationary air lines in the reel-stand to the rotating reel arms.

Tend to notice air leak / tension loss while reel arms index

All pneumatic components on the arms are affected

Electro-Pneumatic Valve Location The EP valve receives electronic signals from the RTC to control air pressure to the brakes. Controls air flow through the rotary valve Failure of this component will affect brake performance Call maintenance to check this device OP side reel-stand

The EP valve receives electronic signals from the RTC to control air pressure to the brakes.

Controls air flow through the rotary valve

Failure of this component will affect brake performance

Call maintenance to check this device

Reel Tension Sensor Locator The reel tension sensor roller measure tension from the roll to the infeed nip point. The roller has a load cell supporting it on either side The load cells measure downward pressure on the roller and transmit that signal to the Reel Tension Controller OP side reel-stand

The reel tension sensor roller measure tension from the roll to the infeed nip point.

The roller has a load cell supporting it on either side

The load cells measure downward pressure on the roller and transmit that signal to the Reel Tension Controller

Reel Tension is a Closed Loop System RTC EP Valve Reel Tension Controller 2 on reel tension roller One component failure affects the behavior of the others. Pasting Floating Roller Bellofram Cylinder Brakes Air pressure Rotary Valve LOAD CELL

OUTLET TENSION RTP TENSION REEL TENSION CONTROLLER PASTER LOGGER DISPLAY REEL TENSION SENSOR SURFACE SENSOR COMMUTATOR HUB BRUSH / KNIFE SOLENOIDS Signal Sources • REEL TENSION SENSOR (2 Load Cells) • SURFACE SENSOR • COMMUTATOR • BRUSH SIGNAL • KNIFE SIGNAL REPORT TO PASTER LOGGER PLC (2 Load Cells) (RTC) LOGGER PLC

Supporting Information

Using Paster Signals To Determine Press Speed In the example at right, the press is running at 55k impressions/ hour We can tell this because there are 11 paster signals visible

In the example at right, the press is running at 55k impressions/ hour

We can tell this because there are 11 paster signals visible

Prepare Pattern to Mitsubishi Spec.

Floating Roller Setting Baseline air settings: ADJUSTING 1.Pull out knob 2.Set air pressure 3.Push in knob 4.Check setting Floating roller not able to hold this position? Air pressure bleeding off during press run? Call a machinist to inspect for problems. (Settings may be modified in the future)

Humidity Effect on Tape Humidity affects the tack of the double stick tape as well as the elasticity of the paper Seasonal problem during the dry months approx. January to April Manifests as a failure during brush contact Call building engineer at 6-1960 if humidity is not between 45% and 70% Indications you have a humidity problem: Paper feels brittle Tape not strongly adhering to paper Concrete floors look shiny / feel slick from condensation Condensation forming on tape Close-up Tape peeling off paster

Humidity affects the tack of the double stick tape as well as the elasticity of the paper

Seasonal problem during the dry months approx. January to April

Manifests as a failure during brush contact

Call building engineer at 6-1960 if humidity is not between 45% and 70%

Indications you have a humidity problem:

Paper feels brittle

Tape not strongly adhering to paper

Concrete floors look shiny / feel slick from

condensation

Condensation forming

on tape

Created summer 2008 through the collaborative effort of press operators, machinists, electricians, and management to aid in their pursuit for continuous improvement at:

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