Strautmann EK 1107 User manual

Remedying FaultsatPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 1–April2005
Frequentlyoccurring faultsand remediesforthem
areexplained in thefollowing tables.
The tablesaredividedup according tomainfaultareas.
•Machine hasnofunction
•Machine doesnot run in automaticmode
•Machine doesnot run in manual mode
•Bale cannotbe ejected
•Press platedropping-oilleakage
•Doordoesnot riseautomatically
•Hydraulicproblems
•Electricalproblems
Thisdocumentationisalsointendedforthe EK1107/1109and
PP 1208
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Remedying FaultsPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 2–April2005
Problem Reason Remedy
1.1Controlhasno
function A. Emergencystoppressed Unlockemergencystop
B. Powersupplycut Restorepower supply
C. Transformer faultyand
transformer fusefaulty(KLM
only)
Test transformer and
replaceif necessary
D. FaultyfuseonPCB
(ABB controlsonly) Checkfusesand replaceif
necessary
E. Connectorsdonotmake
contact Checkand clean plugsand sockets
F. Faultycircuit Checkcircuitandchange if
necessary(inthecaseof
faultycircuiteitherredor
greenLEDslightup; inthe
caseof atotalfault noLED
light up)
1Machine hasno function
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Remedying FaultsPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 3–April2005
A. Unlockemergencystop byturning
clockwise
B. Ensurepresenceof voltage.Checkfuses
1.1Controlhasnofunction
•Emergencystop pressed
•Power supplycut
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Remedying FaultsinPP 1207–ABBcontrol
RemedyingfaultsPP1207
page 4–April2005
1. ABB controls
2. Ensurethatemergencystop
isnotpressed down.Check
fuses.
3. Checkpowersupply;all
phasesmust bepresent.
Emergencystop switchand
fuses
Checkpowersupply
1.1Controlhasnofunction
1. Emergencystop pressed
2. Power supplycut
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 5–April2005
Checkfuses
Check
power
supply
Unlockemergencystop
switch: inthecaseof KLM
controls, theemergencystop
switchmustbe "pulled out".
Pulloutto
release
Klöckner Möller
1.1Controlhasnofunction
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Remedying FaultsinPP 1207
RemedyingfaultsPP1207
page 6–April2005
Checktransformer:
Input voltage 230 -240VAC
Outputvoltage 27 -28 VAC
1.1Controlsnotfunctioning
•Transformer faultyandtransformerfusefaulty(KLMonly)
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 7–April2005
Klöckner Möller control
C. Withthe KLM
transformer, two
voltagesmust be
checked.
1. 24VDC
2. 230VAC
When safetyswitch
S7isequipped,
there mustbe 24Vat
Terminal4
When the safety
switchison, there
must be +24V
voltageat K2,
TerminalA1andat
the TerminalX2on
the PCB.
There must be230V
at Terminal2of
SafetySwitchS7,
when equipped.
1.1Controlhasno function
3. Faultytransformerandfaulty
transformer fuse(KLMonly)
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 8–April2005
CheckPCB
fuses.
Check
connectors
Checkcircuitandif
no LEDlightup
when thereisa
supplyvoltage, or
either red or green
LEDslight up, the
PCBisfaulty.
(There must be
voltageatpins29
and 30anyway)
1.1Controlhasno function
4. PCBfusefaulty(ABB only)
5. Connectorsdo not makecontact
6. PCBfaulty
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 9–April2005
Klöckner Möller
Checkall screw
connections.
CheckPCBandif noLED
light upwhenthere isa
power supply, oreither
red orgreen LEDslight
up, thecircuit isfaulty.
Supplyvoltagemust be
o.k. whilst checking !
1.1Controlhasno function
D. PCBfusefaulty(ABB only)
E. Connectorsdonotmakecontact
F. PCBfaulty
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 10–April2005
Problem Reason Remedy
1.2Motor hasno function
(controlfunctionpresent) A. One or morephases not present Checkif all phasesexist.
B.Motor protection
switchhastripped Checkmotor protection switchand changeif
necessary;checkpower
input
C.Motor contactor faulty Changemotor contactor
D. Leadtomotor faulty Checkpowerleadto
motor
E.Motor faulty Test motor andreplaceif
necessary
1Machine hasnofunction
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 11–April2005
Checkif all thephasesare
present:
Monitorlightsmust glow
and there must be voltage
up tothe contactor.Check
if thereisvoltageup tothe
motor terminalplate.
B. Checkmotor protection
switchand adjust, change if
necessary
C. Checkmotor contactorand
replaceif necessary
1.2Motor hasno function(controlfunction present)
1. One ormore phasesnot present
2. Motorprotection switchhastripped
3. Motorcontactorfaulty
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 12–April2005
Klöckner Möller
A. Checking the phasesequence:
There aretwotypesof KLMcontrolsattached.
Sinceapprox. 2002 theyhavean automatic
rotatingfieldcontrol. It showsvariousfault
signalslisted below, viathe monitoringlights.
When there arecontrolswithout rotatingfield
control, thephasesequencemustbe checked
at the mainswitchandatthe motorcontactor.
Meaning of themonitoring lights:
Green Orange Status
ON OFF OK
OFF ON Phasesequence
inversed
ON ON 1Phasemissing
OFF OFF More than1phaseis
missing
1.2Motor hasno function(controlfunction present)
1. One ormore phasesnot present
2. Motorprotection switchhastripped
3. Motorcontactorfaulty
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 13–April2005
At these
components
there mustbe
voltage.
1.2Motor hasno function(controlfunction present)
•One ormore phasesnot present
• Motorprotection switchhastripped
•Motorcontactorfaulty
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 14–April2005
D. Test motor powersupply
cable:
Applycontinuitytester tosingle
leads.
Ifone or moreleadshaveno
continuityorthemeasured
resistanceismore than 3ohms:
replacecable.
1.2Motor hasno function(controlfunction present)
D. Leadtothe motorisfaulty
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 15–April2005
E.Inordertocheckthe motor, thejumpersand
leadsmustfirstbe disassembledfromthe
terminalplate.
Inorder totestthesinglemotor coils, the
continuitytester mustbe applied toonecoil
sectionat atime.
The followingmust bemeasured separately:
U1-U2
V1-V2
W1-W2
All the coilsmust havethe sameresistance
(less than 100 ohms)inbetween 20%.If the
metered valuesarenotequal, themotormust
be changed.
After the measurementprocess,all thebolts
must be tightened.If there are looseboltsor a
faultypowerconnection, the motorconsumes
too muchpowerandgetsdamaged.
1.2Motor hasno function(controlfunction present)
E.Motor faulty
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 16–April2005
2. Machine doesnot runinautomaticmode
Problem Reason Remedy
2.1Motor isrunning
but machinehasno
function
A.Motor's rotating magnetic
fieldisinversed Reverserotatingmagnetic fieldbychangingtwophase
leadsinthemainplug
B. top homeposition of limit
switch(S4.4ABB)(S8KLM) not
reached orfaultylimit switch
Test limit switchand replace
if necessary
C. Hydraulicvalvesticking Actuatehydraulicvalve
manually
D. Valvecoil plug faulty Checkplug and replaceif
necessary
D. Valvecoil faulty Checkvalvecoil forproper
functioning and replaceif
necessary
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 17–April2005
A. Notemotor's rotating magnetic
field.Motorhastorotateclockwise
fromthissight.
Toinversethe rotating magneticfield,
change2leadsinthemainplug
e.g. L1andL2. (brownand blackwires)
2.1Motor running but machine hasnofunction
1. Motor'srotatingmagneticfieldisinversed
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 18–April2005 B. Checklimit switch(S4.4ABB)(S8KLM).
Checkthe belonging slot onthePCB(12+13 ABB)(X2.7KLM)
2.1Motor running but machine hasnofunction
B. Limit switchhomepositionisnot reached or faultylimit switch
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 19–April2005
C. Actuatehydraulic
valvebypressingina
blunt object, e.g. an
Allen key
Checkvalvefor
smoothmovementand
replaceif necessary
E. Checkvalvecoil
plug and replaceif
necessary
D. Checkvalvecoil by
using an ohmmeter : If
the resistanceismore
than 100kohmsthe coil
isfaulty,tappet isno
longeractuated.
Replacecoil.
2.1Motor running but machine hasnofunction
C. Hydraulicvalvesticking
D. Valvecoil plug faulty
E. Valvecoil faulty
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Remedying FaultsinPP 1207–KlöcknerMöller
RemedyingfaultsPP1207
page 20–April2005
2. Machine doesnot runinautomaticmode
Problem Reason Remedy
2.2Machinebreaksdown
after running for short
period
A.Magneticswitchat press
plateand doormisalignedor
faulty
Checkmagneticswitch
and replaceif necessary.
2.3Machinedoesnot start A. Emergencystopenabled Checkif emergencystop
switchisengaged
B. Fuse(F1.1ABB)(F3
KLM)faulty Checkand replacefuse
C.Magneticswitch
misaligned or faulty. Checkswitchand adjust or replaceif necessary
D. Relay(K1.12 ABB)(K2
KLM)faulty Test relayand replaceif necessary
E. Evaluation unitof the
safetyswitchfaulty Checkand replaceif necessary
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