Welger E-LINK RP 235 User manual

1753-27
RP 235E-LINK
E - LINK
START
STOP
START
STOP
Pr
1729.99.03.02 08.04
from year of manufacture 2004
Operating Manual

WELGER RP 235 • E-LINK 3
E-LINK for RP 235
1INTRODUCTION ............................................................................................................................5
2REQUIREMENTS ON THE MACHINE ..........................................................................................5
3SAFETY INSTRUCTIONS..............................................................................................................6
3.1 WARNING SYMBOLS ...................................................................................................................6
3.2 GENERAL INFORMATION.............................................................................................................7
3.3 INSTRUCTIONS FOR FIRE PROTECTION ........................................................................................7
3.4 PROTECTION OF THE ELECTRONIC CONTROL SYSTEM ..................................................................8
3.5 ELECTROMAGNETIC COMPATIBILITY (EMC).................................................................................8
4THE MENUS...................................................................................................................................9
4.1 OVERVIEW .............................................................................................................................9
4.2 SELECT A MENU.........................................................................................................................9
5"MONITOR" MENU......................................................................................................................10
5.1 THE DISPLAY ...........................................................................................................................11
5.2 TYING MODES .......................................................................................................................... 12
5.3 HYDRAULIC VALVE BLOCK ........................................................................................................13
5.4 OPERATING PARAMETERS ........................................................................................................16
5.5 MACHINE STATUS: BALING .......................................................................................................17
5.6 MACHINE STATUS: TYING .........................................................................................................17
5.7 MACHINE STATUS: OPENING THE TAIL GATE ..............................................................................17
5.8 MACHINE STATUS: TAIL GATE OPEN ..........................................................................................18
5.9 MACHINE STATUS: MACHINE STANDSTILL ..................................................................................18
5.10 OVERVIEW OF THE BUTTON FUNCTIONS IN THE "MONITOR" MENU“ .............................................19
6"SETUP" MENU...........................................................................................................................20
6.1 OVERVIEW OF THE BUTTON FUNCTIONS IN THE "SETUP" MENU:..................................................22
7"SYSTEMINFO" MENU ...............................................................................................................23
7.1 OVERVIEW OF THE BUTTON FUNCTIONS IN THE "SYSTEMINFO" MENU:.........................................24
8"DIAGNOSIS" MENU...................................................................................................................25
8.1 STANDARD DIAGNOSIS .............................................................................................................26
8.2 EXTENDED DIAGNOSIS .............................................................................................................31
8.3 OVERVIEW OF THE BUTTON FUNCTIONS IN THE "DIAGNOSIS" MENU: ...........................................32
9"STATISTICS" MENU.................................................................................................................. 33
9.1 OVERVIEW OF THE BUTTON FUNCTIONS IN THE "STATISTICS" MENU:...........................................34
10 ERROR MESSAGES ................................................................................................................35
10.1 SYSTEM ERROR MESSAGES......................................................................................................36
10.2 SYSTEM ERROR: SHORT CIRCUIT IN SUPPLY OF SENSORS ..........................................................36
10.3 SYSTEM ERROR: OVERLOAD IN SUPPLY OF SENSORS.................................................................36
10.4 SYSTEM ERROR:BATTERY VOLTAGE TOO HIGH..........................................................................37
10.5 STANDARD ERROR MESSAGES..................................................................................................38
10.6 STANDARD ERROR: OVERLOAD.................................................................................................38
10.7 STANDARD ERROR: WIRE BROKEN ............................................................................................38
10.8 STANDARD ERROR: NET KNIFE..................................................................................................38
10.9 STANDARD ERROR: NET KNIFE SET?..........................................................................................39
10.10 STANDARD ERROR: NET KNIFE TRIGGERED? ..........................................................................39
10.11 STANDARD ERROR: NET DOES NOT RUN! ...............................................................................39
10.12 STANDARD ERROR: TWINE RUNS ONE-SIDED.......................................................................... 39
10.13 STANDARD ERROR: TWINE DOES NOT RUN.............................................................................40
10.14 STANDARD ERROR:TWINE RUNS WITHOUT TYING...................................................................40
10.15 STANDARD ERROR: 1 TAILGATE HOOK OPEN ..........................................................................40
10.16 STANDARD ERROR: MAXIMUM BALING DENSITY REACHED .......................................................40

4 WELGER RP 235 • E-LINK
11 "SYSTEM SERVICE" MENU ...................................................................................................41
11.1 CALL-UP „SYSTEM SERVICE“ MENU ..........................................................................................41
11.2 "MONITOR" SUBMENU ..............................................................................................................42
11.3 "SYSTEM SETUP" SUBMENU .....................................................................................................42
11.4 "EEPROM CONTENTS" SUBMENU............................................................................................43
11.5 "SELF TEST" SUBMENU ............................................................................................................43
11.6 OVERVIEW OF THE BUTTON FUNCTIONS IN THE "SYSTEM SERVICE" MENU: .................................44
12 OSCILLOSCOPE......................................................................................................................45
12.1 OSCILLOSCOPE FOR DIGITAL SENSORS AND ACTORS .................................................................46
12.2 OSCILLOSCOPE FOR DISTANCE SENSORS..................................................................................47
12.3 OPERATING THE OSCILLOSCOPE...............................................................................................48
12.4 OVERVIEW OF THE BUTTON FUNCTIONS IN THE "OSCILLOSCOPE": ..............................................51
13 APPENDIX ................................................................................................................................52
13.1 CHRONOLOGICAL TYING PROCESS AT AUTOMATIC TYING............................................................52
Maschinenfabrik GmbH
Gebrüder-Welger-Straße 3 • D-38304 Wolfenbüttel
Phone: (+49) 53 31 / 404-142 • Fax: (+49) 53 31 / 404-143
eMail: w[email protected]

WELGER RP 235 • E-LINK 5
1 Introduction
The control contains (see figures bellow):
•the control box E-LINK (hand set)
•the control unit Balercontrol III
The control box E-LINK serves for operating the machine.
The control unit Balercontrol III is directly attached to the machine in a solid housing.
The control unit and the control box, as well as the respective software contained therein, are provided
with their own serial numbers. Always state the serial numbers for possible requests. Please enter this
numbers here immediately after delivery:
Part Serial number How to find the serial number
E-LINK control box
SW rev. ...........................
dd ...........................
Keep any key on the control box
pressed when connecting the
power supply.
Control unit
Balercontrol III
Serial no. ...........................
SW version ...........................
SW date ...........................
Memory ...........................
Operate button several times
until "Systeminfo" is displayed (see
chapter „"Systeminfo" menu,
page23).
2 Requirements on the machine
•On-board power supply .................... 12 V
•Fuse protection, machine side:......... 20 A
Operation with 24 V power supply is not permissible.

6 WELGER RP 235 • E-LINK
3 Safety instructions
3.1 Warning symbols
Attention!
This symbol stands next to warnings: danger to life, danger of injury, possible serious material
damage.
Caution!
This symbol stands next to safety instructions: malfunctions and impairments of correct operation,
possible material damage.
Note!
This symbol stands next to useful information: special information on how to use the machine most
efficiently.

WELGER RP 235 • E-LINK 7
3.2 General Information
Attention! Read and heed the operating instruction and safety instructions prior to commission
the machine. In this operating instruction all positions required for safety reasons are marked with a
warning sign. Instruct all other operators in safety instructions! The warning- and information signs
located at the machine give information for safe operation. Watch them for safety reasons!
•It is not permissible to enter the working range of the machine or to approach the working range of
the machine as long as the electronics are supplied with power.
•Prior to any kind of assembly, adjustment and maintenance work, the control must be disconnected
from power supply: interrupt electrical connection between tractor and machine.
Moreover : Switch off power take-off shaft. Switch off tractor engine and remove ignition key.
Uncouple power take-off shaft of the machine from the drive shaft of the tractor.
•Check correct setting of all sensors regularly and check that all sensors (proximity switches) and
actors (plugs on hydraulic system, plugs on net tying unit or plugs on twine tying unit) are tightened
properly.
•Power supply of the electronics must only be switched on when the machine is to be operated. After
the end of work, the control system must immediately be disconnected from power supply: interrupt
electrical connection between tractor and machine.
•The housing of the control box is moisture-repellent. Nevertheless: in order to avoid malfunctions, the
control box must not be exposed to excessive moisture (e.g. heavy rain, splashing, steam-jet- or
high-pressure cleaning machine).
•Software- or hardware malfunction can never be totally excluded. Therefore the machine has always
to be handled so that no personal or material damages occur.
•Read the pertinent documentation before commissioning the machine. In case of difficulties in
understanding please contact the customer service department.
3.3 Instructions for fire protection
•In certain conditions the harvested crop is easily inflammable.
•Keep baler always free from crop remains or oil pollution. This note counts especially after finishing
baling.
•The present wiring of the control and of the corresponding machine must not be used for electrical
consumers other than mounted or proofed by the manufacturer. Overloading the electrical lines leads
to excessive heating.
•Always keep a working fire extinguisher within reach.

8 WELGER RP 235 • E-LINK
3.4 Protection of the electronic control system
•All assembly work (connection and disconnection of sensors, valves, control box etc., replacement of
fuses) must be carried out with the power supply switched off.
•The control is designed for 12 Volt operation. Operation with other on-board power supplies is not
permissible!
•The correct polarity of the power supply of the tractor
must not be changed, otherwise the electronic
control could be damaged.
•In case of welding work on the baler:
- Do not permit welding current to flow through the control unit;
- Interrupt power supply between tractor and baler;
- Take heat generation at the welding points into account;
if necessary remove sensitive parts (cables, sensors or the like) prior to welding.
3.5 Electromagnetic compatibility (EMC)
The machine is equipped with electronic components and modules; the function of these electronic
components and modules can be influenced by electromagnetic emissions of other equipment. Such
influences can cause risks to persons, if the following safety instructions are not observed:
In case of subsequent installation of electrical and electronic equipment and/or components into the
machine, with connection to the central mains, it is the user's responsibility to check whether the
installation impairs the vehicle electronics or any other components.
Ensure above all that the electrical and electronic components subsequently installed are in conformity
with the EMC directive 89/336/EEC as amended, and that they are provided with the CE.

WELGER RP 235 • E-LINK 9
4 The menus
4.1 OVERVIEW
Menu Task see chapter
MONITOR
MONITORMONITOR
MONITOR Display and operation in daily machine operation "Monitor" menu
page 10
SETUP
SETUPSETUP
SETUP Setting of machine parameters "Setup" menu
page 20
SYSTEMINFO
SYSTEMINFOSYSTEMINFO
SYSTEMINFO Information about selected system data "Systeminfo" menu
page 23
DIAGNOSIS
DIAGNOSISDIAGNOSIS
DIAGNOSIS Diagnostic functions for checking the machine "Diagnosis" menu
page 25
STATISTICS
STATISTICSSTATISTICS
STATISTICS Machine running time, cumulative counter and daily
counter
"Statistics" menu
page 33
4.2 Select a menu
 Open menu overview : press key .
 Select menu: keys or
 Confirm selection with key .
If no menu is to be selected:
if no key is pressed for 5 seconds, automatic return to
the MONITOR
MONITORMONITOR
MONITOR menu is effected.

10 WELGER RP 235 • E-LINK
5 "Monitor" menu
The MONITOR
MONITORMONITOR
MONITOR menu is the standard menu. This menu
is used for daily machine operation.
The
MONITOR
MONITORMONITOR
MONITOR menu appears automatically as soon
as the control is supplied with power.
 Open menu overview: press key .
 Select MONITOR
MONITORMONITOR
MONITOR menu: keys or
 Confirm selection with key .
The following information are displayed in the menu MONITOR
MONITORMONITOR
MONITOR:
Central main field
•Machine status ( baling, tying, ...)
•Bale diameter with presetting
•Cutting device status
Beside the main field
•Actual daily counter
•Machine working time
•Battery voltage
•PTO speed
Below the main field
•Tying mode
•Hydraulic switch (cutting device, bottom door, pick-up)
•Operating parameter (bale diameter, net layers)

WELGER RP 235 • E-LINK 11
5.1 The display
Tying mode
(see page 12)
Hydraulic switch
(see page 13)
Operating parameter
(see page 16)
manual
twine tying
Adjustment
pick-up Bale density
(here: set value 5)
automatic twine tying Adjustment
bottom door Net layers
(here: set value 1.5)
Manual net tying Adjustment cutting device
(here: 8 knives selected)
Automatic net tying
automatic
combined tying
The PTO speed regulates the optional electric Lubrication pump and the measurement of the machine
working time. Both will be activated at a PTO speed larger than 100 rpm.
A
nimation:
Material flow into the bale
r
Bale counter
(
active dail
y
counter
)
Machine
working time
(active daily counter)
Bar chart
for representation of the bale
density with display of the set
value (arrow)
Battery voltage
PTO speed

12 WELGER RP 235 • E-LINK
5.2 Tying modes
The machine can be equipped with:
•Net tying
•Twine tying
•Net tying and twine tying
The tying modes shown in the following table result from the setup setting (see chapter 6 "Setup"
menu):
Tying mode Machine with
twine tying
Machine with
net tying
Machine with
twine- and
net tying
manual
twine tying
••
automatic twine tying ••
Manual net tying ••
Automatic net tying ••
automatic
combined tying •
 The tying modes can be selected with the left
button.
 Start tying: Press button <START/STOP> .

WELGER RP 235 • E-LINK 13
5.3 Hydraulic valve block
The unit* that is to be moved hydraulically can be selected with the hydraulic switch.
* The machine can – according to the type of the machine – be equipped with the following units:
•Pick-up (see chapter 5.3.1 Hydraulic switch: Pick-Up)
•Bottom door (see chapter 5.3.2 Hydraulic switch: bottom door)
•Cutting device (see chapter 5.3.3 Hydraulic switch: Cutting device)
RP 235 RP 235 S
Pick-Up ••
bottom door ••
Cutting device •
 The units are selected with the centre button. The
selected unit is displayed directly above the centre
button:
Unit Symbol
Pick-Up
bottom door
Cutting device
 The selected unit is moved by means of the
tractor's distribution valve.

14 WELGER RP 235 • E-LINK
5.3.1 Hydraulic switch: Pick-Up
 Press centre button to select the pick-up .
The Pick-Up is displayed directly above the centre button:
 Move Pick-Up with the tractor's distribution valve.
Note!
The valves of the hydraulic switch are not actuated in Pick-Up position .
This setting has to be preferred to minimise the power consumption.
5.3.2 Hydraulic switch: bottom door
 Press centre button to select the bottom door .
The bottom door is displayed directly above the centre button:
 Move bottom door with the tractor's distribution valve.
When the bottom door is opened because of a material jam this condition is displayed in a window
(symbol "Bottom door"; with flashing exclamation mark).

WELGER RP 235 • E-LINK 15
5.3.3 Hydraulic switch: Cutting device
 Press centre button to select the cutting device .
The cutting device is displayed directly above the centre button:
 Move cutting device with the tractor's distribution valve.
The machine can be equipped with a group cutting device of 17 knives or of 25 knives. The setting is
made in Setup (see chapter 6 "Setup" menu).
•The 17-knife cutting device is divided into 2 groups:
A 8-knife group and a 9-knife group.
•The 25-knife cutting device is divided into 2 groups:
A 12-knife group and a 13-knife group.
It can be operated with one knife group or both knife groups at the same time.
The knife group being in cutting position is displayed (here: 12-knife group).
Caution!
Before a knife group can be moved into operating position all knives that are possibly already in
operating position, must be moved out of the operating position.
If it must be operated with an other knife group, first the knife group being in operating position must be
moved into home position before the new knife group can be moved from its home position into
operating position.
Only those knife groups are displayed that can be moved in or out for the current moment, e.g.
(here: 8-knife group).

16 WELGER RP 235 • E-LINK
5.4 Operating parameters
The operating parameters are selected with the right
button.
The operating parameter selected is displayed directly
above the button:
5.4.1 Operating parameter: Setting the bale density
When the operating parameter "Bale density" is selected the set value can be set from 1 ... 10 with the
buttons / .
When the baling density reaches 10 while a manual tying mode is selected "Stop: max. baling density
reached" is displayed (see chapter 10 Error messages).
5.4.2 Operating parameter: Setting net layers
When the operating parameter "Net layers" is selected the set value can be set from 1.5 ... 4.0 with the
buttons / .
When the set net length is through the net knife is triggered and binding is finished.

WELGER RP 235 • E-LINK 17
5.5 Machine status: Baling
The machine status baling is displayed by an animated material flow into the baler, when the PTO
speed is larger than 100 rpm (revolutions per minute).
5.6 Machine status: Tying
The running tying is displayed with two arrows that rotate around a bale.
5.7 Machine status: Opening the tail gate
After tying has been finished, the electronics indicate with a flashing arrow to open the tail gate by
means of the tractor's distribution valve. No more material runs into the baler (stop tractor and
machine).

18 WELGER RP 235 • E-LINK
5.8 Machine status: Tail gate open
The open tail gate is displayed. No more material runs into the baler.
5.9 Machine status: Machine standstill
Machine standstill (after interrupted start of a twine- or net tying) is displayed by the standing material
flow (material flow no more animated). In this condition it is waited for the manual start of a tying when
the error has been removed.

WELGER RP 235 • E-LINK 19
5.10 Overview of the button functions in the "Monitor" menu“
Button Operation
left button
Select tying mode (see chapter 5.2 Tying modes):
•manual twine tying
•automatic twine tying
•Manual net tying
•Automatic net tying
•automatic combined tying)
centre button
Select hydraulic switch (see chapter 5.3 Hydraulic valve block):
•Pick-Up
•bottom door
•8 knives (optional: 12 knives)
•9 knives (optional: 13 knives)
•17 knives (optional: 25 knives)
right button
Select operating parameter (see chapter 5.4 Operating parameters):
•Bale density
•Net layers
Start selected tying mode manually
Increase set value for selected operating parameters
•Bale density
•Net layers
Decrease set value for selected operating parameters
•Bale density
•Net layers
– no function –
Acknowledge fault message (delete) (see chapter 10 Error messages)
Call up menu

20 WELGER RP 235 • E-LINK
6 "Setup" menu
The SETUP
SETUPSETUP
SETUP menu serves for setting various machine
parameters (Language, Machine type, Beep ...).
 Open menu overview: press key
 Select Setup menu: keys or
 Confirm selection with key
 Select parameter: keys and
 Change parameter: keys and
 Either return to menu overview: press key
 Or return to MONITOR menu: press key for
3 sec.
 Scroll the display pages forward and backward:
left and right button.