TROUBLESHOOTING
This manual is for helping you through the possible
malfunction solving process.
Because most common cause of troubles are wrong kind
of machine settings, in chapter one we shortly go trough
the machine settings and operation of machine.
Ecomat EASY / Girotec WRS
Ecomat EASY H / Girotec WRS H
V2.0
1
TROUBLESHOOTING
Page
CHAPTER 1
-Wrapping settings 3-11
-Wrapping modes 3
-Bottom and Top layers 4
-Photocell delay 5
-Film tension 6
-Overlapping 7
-Turntable speed 8
-Film carriage speed 9
-Photocell settings 10
-Load stabilizer selection 11
-Quick operation quide 12
Page
CHAPTER 2
-Troubleshooting 13-29
-Before starting toubleshooting /safety aspects 13
-Empty display, no movement 14
-Horizontal bars in display, no movem. 15
-Normal display, no movement 16
-Other problems 17-25
-Troubleshooting instructions 26-29
-Carriage UP manual drive 26
-MPU-controlled leds 27
-Power Board leds 28
-Manuals available in internet 29
List of Enclosures
List of Enclosures
30
30
2
Wrapping modes
Select the wrapping mode by turning selection switch
WRAPPING SETTINGS
3
Bottom layers & Top Layers
WRAPPING SETTINGS
Select the number of bottom and
top layers using arrow buttons
4
Photocell delay value, sets up the time how long film
carriage still goes upwards after loosing the pallet
upper edge.
You can select the number between 1-9
1 = minimum delay
9 = maximum delay
WRAPPING SETTINGS
Photocell delay
A2
5
Film tension
WRAPPING SETTINGS
Adjust the film tension by turning the
adjusting nut.
Clockwise = Increase tension
Anticlockwise = Decrease tension
6
OVERLAPPING DEGREE
WRAPPING SETTINGS
Overlapping
Measured with Mima
Lite film, EUR-pallet
(800*1200), medium
film tension
TURNTABLE
SPEED
CARRIAGE
SPEED
a
OVERLAPPING
DEGREE
a =
[mm]
26060 %110
12028 %510
-No Overlapping105
-No Overlapping55
a
MAX overlapping
(Free space between film 180mm)
(Free space between films 35mm)
7
Turntable speed
WRAPPING SETTINGS
Select the turntable speed
0 = minimum speed
10 = maximum speed
8
Film Carriage speed
WRAPPING SETTINGS
Select the film carriage speed
0 = minimum speed
10 = maximum speed
9
Technical Data
Sensing Range = 2000mm
Blind Range = ≤75mm
Operational Voltage = 12VDC...240VDC ± 10 %
= 24VAC...240VAC ± 10 %
Power consumption = 3VA
Correct Potentiometer Settings:
MODE = D.ON (Dark ON)
OBJECT
WRAPPING SETTINGS
SENSITIVITY (SENS) = MAX - 10º (nearly MAX)
Photocell settings
Led indicators
YELLOW = Output Status
(ON when no object in range)
RED = Fault indicator
Weak signal
D.ON L.ON
MODE
MIN MAX
SENS
10
WRAPPING SETTINGS
Load Stabilizer selection
Activate the Load Stabilizer by turning the
selection switch from OFF to ON
(Only in Ecomat Easy H / Girotec WRS H)
11
Single wrapping
Splash proof- mode
Cut the film
QUICK OPERATION GUIDE
Wrapping Ready
Cut the film
Double wrapping
Mount the film roll
MACHINE STOPS
Place the top-sheet
Wrapping Ready
Cut the film
Wrapping Ready
12
Couple important safety
aspects before starting
No movement,
Page 14
Nothing in display
Before starting troubleshooting
troubleshooting:
Before any service action,
make sure that main switch
is turned to OFF-position.
When working with
electrical components, work
must be done by
professional electrician!
Other problems
No movement,
Horizontal bars
on display
No movement,
Normal display
TROUBLESHOOTING
Page 15
Page 16
Page 17-25
13
No movement, nothing on display
1. Power plug is not connected Connect the plug
2. Main switch is on 0 position Switch on the power
3. Glass-tube fuse on power board can be blowed Replace the fuse (see page 28)
4. Fuse F1 can be blowed Replace the fuse
5. Glass-tube fuse no.2 on MPU-controller can be blowed Replace the fuse (see page 27)
6. Connector 3 on MPU-controller can be disconnected Connect the plug (see page 27)
7. Connector 4 on MPU-controller can be disconnected Connect the plug (see page 27)
8. Connector 7 on Power Board can be disconnected Connect the plug (see page 28)
TROUBLESHOOTING
No movement, nothing on display
14
No movement, Horizontal bars on display
1. Emergency Stop button can be activated Unlock the button
2. Film loading door can be open Close the door
3. Automatic fuses AF2-AF3 can be tripped Un-trip the fuse/s
4. Connector 2 on MPU-controller can be disconnected Connect the plug (See page 27)
5. Glass-tube fuse no.1 on MPU-controller can be blowed Replace the fuse (See page 27)
TROUBLESHOOTING
No movement, horizontal bars on display
15
No movement, Normal display
1. Machine is not in home position Press the reset button
2. Carriage cant move to its home position See instructions from page 26
3. Carriage down limit switch can be damaged or disconnected Check the switch, connectors and cables
4. Turntable rotation V-belt or roller chain can be dam aged Check and replace if neces sary (see page 29)
5. Connector 5 on MPU-controller can be disconnected Connect the plug (see page 27)
6. Connector 6 on power board can be disconnected Connect the plug (see page 28)
7. Connector 8 on power board can be disconnected Connect the plug (see page 28)
No movement, normal display
TROUBLESHOOTING
16
Other problems
After START, Turntable is running continously, film
carriage does not rise at all,even there is high pallet
on turntable
TROUBLESHOOTING
1. Table home proximity can be disconnect, damaged or have a bad alignment Check the proximity alignment and connections
2. Carriage up limit switch can be activated, disconnected or damaged Check the switch and connections
-X4
4 mm
17
After START, Machines makes selected numbers of
layers (bottom+top) + 2 additional, and stops. Film
Other problems
carriage does not rise at all
even there is high pallet
on the turntable
1. Carriage lifting motor can be disconnected Check the cable and connectios
2. Carriage up limit switch can be disconnected or damaged Check the switch and connections
TROUBLESHOOTING
18
Other problems
Machine works normally untill it has made the top
layers Æ After that machine stops. Carriage does not
start to move down
TROUBLESHOOTING
1. Carriage down limit switch can be activated, disconnected or damaged Check the switch and connections
19
Other problems
Machine works normally. When doing the film reel
change, the carriage does not stop to correct position,
it will go to its upmost position.
TROUBLESHOOTING
1. Film load position limit switch can be disconnected or damaged Check the switch and connections
20
Other problems
While doing the wrapping, carriage always go to
upper limiter and does not stop to the top of the pallet
TROUBLESHOOTING
1. Photocell settings or alignment can be wrong See instuctions from page 10
2. Photocell delay setting is not correct See instructions from page 5
3. Photocell can be disconnected or damaged Check the photocell, cables and connections
Correct alignment
Wrong alignment
21
Other problems
Carriage does not rise to top of the pallet, it only rises
aprox. 150mm. Machine makes selected numbers of
layers and stops.
TROUBLESHOOTING
1. Photocell settings are not correct See instuctions from page 10
22
Other problems
Carriage always heavily overruns the top of the pallet,
even the photocell-delay value is normal (3-5)
TROUBLESHOOTING
1. Photocell settings or alignment can be wrong See instructions from page 10
Correct alignment
Wrong alignment
23
Other problems
Film is breaking /
Pallet is not staying on turntable
TROUBLESHOOTING
1. Film tension setting is too high Loosen the film tension (see page 6)
24
Other problems
Carriage cant go to its reset position (downmost
position)
TROUBLESHOOTING
1. Something inside the mast is blocking the way See instructions from page 25
25
In case there is obstacle dropped inside the mast
Carriage tryes to go to home position but cant reach the limiter
(after couple seconds of trying, OLF- fault message can appear to inverter U2 display)
Reseting of machine is not possible Machine does not start
Doing the film reel change is not possible
You cant remove the obstacle, because it is under the carriage
Carriage UP manual drive
TROUBLESHOOTING INSTRUCTIONS
Manual drive of U2:
ÆConnect LI2 and +15V together
using isolated jumping wire
ÆCarriage starts to move upwards
ÆKeep jumping wire connected
untill carriage is up enough that you
can remove the obstacle
ÆReset the machine
LI1 LI2 LI3 LI4
+15V
26
FUSE 1
TROUBLESHOOTING INSTRUCTIONS
1.
2.
3.
FUSE 2
MPU-controller
4.
5.
Note:
Leds related to Load
Stabilizer (1, 10, 13 and
14) are not used in
Ecomat Easy
27
Power Board / Ecomat Easy
Power Board / Ecomat Easy H
Power Board
TROUBLESHOOTING INSTRUCTIONS
28
Please find our document
pages from internet.
http://document.mimaitw.com/doha/index.asp
(or www.mimaitw.com Æ machines Æmachine documents)
(Registration required for these pages)
Sign in, and you will get the username and password via email.
Usefull manual for using together with troubleshooting:
Maintenance instructions V2.0
TROUBLESHOOTING INSTRUCTIONS
Contains instructions like:
Manuals available in internet
-Removing the turn table disc
-Lowering the mast
-Tensioning of V-Belt & Roller chains
-Etc.
29
List of enclosures
Inverter parameters, Turntable rotation U1
Inverter parameters, Carriage movement U2
Inverter fault messages, ATV11 (U1+U2)
31
PARAMETER LIST
Item 62001871, ATV11HU18M2E, 0,75kW
Applications:
WR 650 turntable rotation
WRS 680 turntable rotation
WRX 690 turntable rotation
Ecomat Easy/Girotec WRS turntable rotation
Ecomat Easy H/Girotec WRS H turntable rotation
Ecomat Plus / Ecomat Plus H turntable rotation
Not default settings :
1
2
3
4
5
6
FUn
7
8
9
10
ACC 10
dEC 0,5
LSP 12
HSP 50 Hz
ItH 3,8
rrS nO
rP2 LI LI2
AC2 10
dE2 5
ATV11/0.75kW
Turn table
rotation
SP3 12
Return to factory
setting for ATV11
1
2
ENT key must be held down for 2 sec.
FUn FCS rEC
FUn FCS InI
ATV 11/0.75kW
for CAROUSEL
page 1
ATV 11/0.75kW
for CAROUSEL
page 2
PARAMETER LIST
Item 62001872, ATV11HU05M2E , 0,18kW
Applications:
WRS 680 film carriage up/down
WRX 690 film carriage up/down
Ecomat Easy/Girotec WRS film carriage up/down
Ecomat Easy H/Girotec WRS H film carriage up/down
Ecomat Plus / Ecomat Plus H film carriage up/down
Not default settings
1
2
3
4
5
ACC 1,0
dȿC 0,1
LSP 21
HSP 60 Hz
ItH 0,7
ATV11/0.18kW
Carriage
Up/Down
Return to factory
setting for ATV11
1
2
ENT key must be held down for 2 sec.
FUn FCS rEC
FUn FCS InI
ATV 11/0.18 kW
for CARRIAGE
Faults - Causes - Remedies
Starter does not start, no fa ul t di splayed
• Check that the run command input(s) have been actuated in accordance with the chosen control mode.
• When the drive is switched on, at a manual fault reset, or after a stop command, the motor can only be
powered once the "forward" and "reverse" commands have been reset. If they have not been reset, the drive
will display "rdY" or “nSt” but will not start.
Faults displayed
The cause of the fault must be removed before resetting.
Faults SOF, OHF, OLF, OSF, ObF, and PHF can be reset via a logic input if this function has been configured.
Faults OHF, OLF, OSF, ObF, and PHF can be reset via the automatic restart function, if this function has been
configured. All faults can be reset by switching the drive off then on again.
Fault Remedy
• Ramp too short, check the settings.
overcurrent
motor short-circuit,
insulation fault
internal fault
ENGLISH
configuration fault
overspeed
drive overload
motor overload
overvoltage
overvoltage
during deceleration
line phase failure
undervoltage
charging circuit
• Inertia or load too high, check the size of the motor/drive/load.
• Mechanical locking, check the state of the mechanism.
• Check the cables connecting the drive to the motor, and the insulation of the motor.
• Check the environment (electromagnetic compatibility).
• Replace the drive.
• Return to factory se ttings or call up the backup configuration, if it is valid. See
parameter FCS in the FUn menu.
• Instability, check the motor, gain and stability parameters.
• Driving load too high, add a braking module and resistor and check the size of the
motor / drive / load.
• Check the motor load, the drive ventilation and the environment. Wait for the drive to
cool before restarting.
• Check the setting of the motor thermal protection, check the motor load. Wait for the
drive to cool before restarting.
• Check the line voltage.
• Braking too harsh or driving load. Increase the deceleration time, add a braking
resistor if necessary and activate the brA function if it is compatible with the
application.
This protection only operates with the drive on load.
• Check the power connection and the fuses.
•Reset.
• Check the line supply / drive compatibility.
• If there is an unbalanced load, inhibit the fault via IPL = nO (FUn menu).
• Check the voltage and the voltage parameter.
• Replace the drive.
24
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