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 Page CHAPTER 1 CHAPTER 2 -Wrapping settings 3-11 -Troubleshooting 13-29 -Wrapping modes 3 -Before starting toubleshooting /safety aspects 13 -Bottom and Top layers 4 -Empty display, no movement 14 -Photocell delay 5 -Horizontal bars in display, no movem. 15 -Film tension 6 -Normal display, no movement 16 -Overlapping 7 -Other problems 17-25 -Turntable speed 8 -Troubleshooting instructions 26-29 -Film carriage speed 9 -Carriage UP manual drive 26 -Photocell settings 10 -MPU-controlled leds 27 -Load stabilizer selection 11 -Power Board leds 28 -Quick operation quide 12 -Manuals available in internet 29 List of Enclosures 30 2
Select the wrapping mode by turning selection switch WRAPPING SETTINGS Wrapping modes 3
WRAPPING SETTINGS Select the number of bottom and top layers using arrow buttons Bottom layers & Top Layers 4
Photocell delay 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 A2 WRAPPING SETTINGS 5
Film tension Adjust the film tension by turning the adjusting nut. Clockwise Anticlockwise = Increase tension = Decrease tension WRAPPING SETTINGS 6
OVERLAPPING DEGREE Overlapping a a WRAPPING SETTINGS TURNTABLE SPEED CARRIAGE SPEED OVERLAPPING DEGREE a = [mm] 10 1 60 % 260 MAX overlapping Measured with Mima Lite film, EUR-pallet (800*1200), medium film tension 10 5 5 10 28 % No Overlapping 120 - (Free space between film 180mm) 5 5 No Overlapping - (Free space between films 35mm) 7
Turntable speed Select the turntable speed 0 = minimum speed 10 = maximum speed WRAPPING SETTINGS 8
WRAPPING SETTINGS Select the film carriage speed 0 = minimum speed 10 = maximum speed 9 Film Carriage speed
Technical Data OBJECT Photocell settings 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) SENSITIVITY (SENS) = MAX - 10º (nearly MAX) Led indicators MODE D.ON L.ON WRAPPING SETTINGS YELLOW = Output Status (ON when no object in range) SENS MIN MAX RED = Fault indicator Weak signal 10
Load Stabilizer selection Activate the Load Stabilizer by turning the selection switch from OFF to ON WRAPPING SETTINGS (Only in Ecomat Easy H / Girotec WRS H) 11
QUICK OPERATION GUIDE Cut the film MACHINE STOPS Wrapping Ready Splash proof- mode Double wrapping 12 Single wrapping Mount the film roll Cut the film Wrapping Ready Wrapping Ready Place the top-sheet Cut the film
Before starting troubleshooting Couple important safety aspects before starting 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! No movement, Nothing in display No movement, Horizontal bars on display No movement, Normal display Page 14 Page 15 Page 16 Other problems Page 17-25 TROUBLESHOOTING 13
No movement, nothing on display 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 14
No movement, horizontal bars on display 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 15
No movement, Normal display 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 damaged Check and replace if necessary (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) TROUBLESHOOTING 16
After START, Turntable is running continously, film carriage does not rise at all,even there is high pallet on turntable Other problems 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 TROUBLESHOOTING 4 mm 17
Other problems After START, Machines makes selected numbers of layers (bottom+top) + 2 additional, and stops. Film 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
Machine works normally untill it has made the top layers After that machine stops. Carriage does not start to move down Other problems 1. Carriage down limit switch can be activated, disconnected or damaged Check the switch and connections TROUBLESHOOTING 19
Machine works normally. When doing the film reel change, the carriage does not stop to correct position, it will go to its upmost position. Other problems 1. Film load position limit switch can be disconnected or damaged Check the switch and connections TROUBLESHOOTING 20
While doing the wrapping, carriage always go to upper limiter and does not stop to the top of the pallet Other problems 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 TROUBLESHOOTING Correct alignment Wrong alignment 21
Carriage does not rise to top of the pallet, it only rises aprox. 150mm. Machine makes selected numbers of layers and stops. Other problems 1. Photocell settings are not correct See instuctions from page 10 TROUBLESHOOTING 22
Carriage always heavily overruns the top of the pallet, even the photocell-delay value is normal (3-5) Other problems 1. Photocell settings or alignment can be wrong See instructions from page 10 TROUBLESHOOTING Correct alignment Wrong alignment 23
Film is breaking / Pallet is not staying on turntable Other problems 1. Film tension setting is too high Loosen the film tension (see page 6) TROUBLESHOOTING 24
Carriage cant go to its reset position (downmost position) Other problems 1. Something inside the mast is blocking the way See instructions from page 25 TROUBLESHOOTING 25
Carriage UP manual drive 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 Doing the film reel change is not possible You cant remove the obstacle, because it is under the carriage Machine does not start Manual drive of U2: Connect LI2 and +15V together using isolated jumping wire Carriage starts to move upwards Keep jumping wire connected untill carriage is up enough that you can remove the obstacle Reset the machine LI1 LI2 LI3 LI4 +15V TROUBLESHOOTING INSTRUCTIONS 26
FUSE 1 MPU-controller 1. 2. Note: 3. FUSE 2 Leds related to Load Stabilizer (1, 10, 13 and 14) are not used in Ecomat Easy 4. 5. TROUBLESHOOTING INSTRUCTIONS 27
TROUBLESHOOTING INSTRUCTIONS Power Board Power Board / Ecomat Easy 28 Power Board / Ecomat Easy H
Manuals available in internet Please find our document pages from internet. http://document.mimaitw.com/doha/index.asp (or www.mimaitw.com machines machine 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 Contains instructions like: -Removing the turn table disc -Lowering the mast -Tensioning of V-Belt & Roller chains -Etc. TROUBLESHOOTING INSTRUCTIONS 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 WRS 680 WRX 690 Ecomat Easy/Girotec WRS Ecomat Easy H/Girotec WRS H Ecomat Plus / Ecomat Plus H turntable rotation turntable rotation turntable rotation turntable rotation turntable rotation turntable rotation
Not default settings : ATV11/0.75kW Turn table rotation 1 ACC 10 2 dec 0,5 3 LSP 12 4 HSP 50 Hz 5 ItH 3,8 6 SP3 12 FUn 7 rrs no 8 rp2 LI LI2 9 AC2 10 10 de2 5 Return to factory setting for ATV11 1 FUn FCS rec 2 FUn FCS InI ENT key must be held down for 2 sec.
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 WRX 690 Ecomat Easy/Girotec WRS Ecomat Easy H/Girotec WRS H Ecomat Plus / Ecomat Plus H film carriage up/down film carriage up/down film carriage up/down film carriage up/down film carriage up/down
Not default settings ATV11/0.18kW Carriage Up/Down 1 ACC 1,0 2 d C 0,1 3 LSP 21 4 HSP 60 Hz 5 ItH 0,7 Return to factory setting for ATV11 1 FUn FCS rec 2 FUn FCS InI ENT key must be held down for 2 sec.
ATV 11/0.18 kw for CARRIAGE
Faults - Causes - Remedies Starter does not start, no fault displayed 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. ENGLISH Fault overcurrent motor short-circuit, insulation fault internal fault configuration fault overspeed drive overload motor overload overvoltage overvoltage during deceleration line phase failure undervoltage charging circuit Remedy Ramp too short, check the settings. 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 settings 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