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Remedying Faults at PP 1207– Klöckner Möller

Remedying faults PP 1207

page 1 – April 2005

Frequently occurring faults and remedies for them
are explained in the following tables.

The tables are divided up according to main fault areas.

•

Machine has no function

•

Machine does not run in automatic mode

•

Machine does not run in manual mode

•

Bale cannot be ejected

•

Press plate dropping - oil leakage

•

Door does not rise automatically

•

Hydraulic problems

•

Electrical problems

This documentation is also intended for the EK 1107/1109 and
PP 1208

PDF wurde mit pdfFactory-Prüfversion erstellt.

www.context-gmbh.de

Summary of Contents for EK 1107

Page 1: ...d up according to main fault areas Machine has no function Machine does not run in automatic mode Machine does not run in manual mode Bale cannot be ejected Press plate dropping oil leakage Door does...

Page 2: ...se faulty KLM only Test transformer and replace if necessary D Faulty fuse on PCB ABB controls only Check fuses and replace if necessary E Connectors do not make contact Check and clean plugs and sock...

Page 3: ...aults PP 1207 page 3 April 2005 A Unlock emergency stop by turning clockwise B Ensure presence of voltage Check fuses 1 1 Control has no function Emergency stop pressed Power supply cut PDF wurde mit...

Page 4: ...2 Ensure that emergency stop is not pressed down Check fuses 3 Check power supply all phases must be present Emergency stop switch and fuses Check power supply 1 1 Control has no function 1 Emergency...

Page 5: ...April 2005 Check fuses Check power supply Unlock emergency stop switch in the case of KLM controls the emergency stop switch must be pulled out Pull out to release Kl ckner M ller 1 1 Control has no...

Page 6: ...P 1207 page 6 April 2005 Check transformer Input voltage 230 240V AC Output voltage 27 28 V AC 1 1 Controls not functioning Transformer faulty and transformer fuse faulty KLM only PDF wurde mit pdfFac...

Page 7: ...n safety switch S7 is equipped there must be 24V at Terminal 4 When the safety switch is on there must be 24V voltage at K2 Terminal A1 and at the Terminal X2 on the PCB There must be 230V at Terminal...

Page 8: ...rcuit and if no LED light up when there is a supply voltage or either red or green LEDs light up the PCB is faulty There must be voltage at pins 29 and 30 anyway 1 1 Control has no function 4 PCB fuse...

Page 9: ...Check PCB and if no LED light up when there is a power supply or either red or green LEDs light up the circuit is faulty Supply voltage must be o k whilst checking 1 1 Control has no function D PCB fu...

Page 10: ...present Check if all phases exist B Motor protection switch has tripped Check motor protection switch and change if necessary check power input C Motor contactor faulty Change motor contactor D Lead...

Page 11: ...tactor Check if there is voltage up to the motor terminal plate B Check motor protection switch and adjust change if necessary C Check motor contactor and replace if necessary 1 2 Motor has no functio...

Page 12: ...ights When there are controls without rotating field control the phase sequence must be checked at the main switch and at the motor contactor Meaning of the monitoring lights Green Orange Status ON OF...

Page 13: ...page 13 April 2005 At these components there must be voltage 1 2 Motor has no function control function present One or more phases not present Motor protection switch has tripped Motor contactor faul...

Page 14: ...er supply cable Apply continuity tester to single leads If one or more leads have no continuity or the measured resistance is more than 3 ohms replace cable 1 2 Motor has no function control function...

Page 15: ...The following must be measured separately U1 U2 V1 V2 W1 W2 All the coils must have the same resistance less than 100 ohms in between 20 If the metered values are not equal the motor must be changed...

Page 16: ...magnetic field by changing two phase leads in the main plug B top home position of limit switch S4 4 ABB S8 KLM not reached or faulty limit switch Test limit switch and replace if necessary C Hydraul...

Page 17: ...c field Motor has to rotate clockwise from this sight To inverse the rotating magnetic field change 2 leads in the main plug e g L1 and L2 brown and black wires 2 1 Motor running but machine has no fu...

Page 18: ...ril 2005 B Check limit switch S4 4 ABB S8 KLM Check the belonging slot on the PCB 12 13 ABB X2 7 KLM 2 1 Motor running but machine has no function B Limit switch home position is not reached or faulty...

Page 19: ...replace if necessary E Check valve coil plug and replace if necessary D Check valve coil by using an ohmmeter If the resistance is more than 100kohms the coil is faulty tappet is no longer actuated R...

Page 20: ...tic switch and replace if necessary 2 3 Machine does not start A Emergency stop enabled Check if emergency stop switch is engaged B Fuse F1 1 ABB F3 KLM faulty Check and replace fuse C Magnetic switch...

Page 21: ...pril 2005 A Check and adjust sensors replace if necessary Good adjustment Bad adjustment 2 2 Machine breaks down after running for short period 1 Magnetic switch between press plate and door misaligne...

Page 22: ...7 page 22 April 2005 ABB controls Kl ckner M ller controls Unlock emergency stop switch by turning clockwise A Unlock emergency switch by pulling out 2 3 Machine does not start 1 Emergency stop enable...

Page 23: ...P 1207 Kl ckner M ller Remedying faults PP 1207 page 23 April 2005 Kl ckner M ller ABB Check fuse F1 1 ABB F3 KLM 2 3 Machine does not start B Fuse faulty PDF wurde mit pdfFactory Pr fversion erstellt...

Page 24: ...h a screwdriver Ensure that the sensor is correctly adjusted If a connection has no function sensor is faulty and must be replaced Apply continuity tester as follows Brown input side Blue output 1 Bla...

Page 25: ...r safety relay D ABB safety relay If sensors and evaluation unit are OK the relay K1 12 ABB K2 KLM must rise and switch on Check relay terminals A1 and A2 for voltage and change relay if necessary 2 3...

Page 26: ...ch sensor has two switches If both switches do not reach the same switching status within three seconds the device disables the machine and both LEDs light up If only one LED lights up change the eval...

Page 27: ...is not present fuse and emergency stop switch must be checked If safety switch is engaged K1 12 ABB K2 KLM must be actuated If the relay does not rise and switches on replace it 230 V 24V Sensors mus...

Page 28: ...s not run in manual mode Problem Reason Remedy 3 1 Machine cannot be operated in manual mode A Push button faulty Test all push buttons and replace if necessary A Check push buttons pay attention to b...

Page 29: ...t switch faulty Test limit switch and replace if necessary C Door limit switch faulty Test limit switch and replace if necessary D Valve sticking Actuate valve manually and replace if necessary E Coil...

Page 30: ...12 KLM must be released Check the switch tappet for smooth axial movability Check if switch has been jammed ABB circuit Slots 10 11 must have continuity when door is open C Check limit switch 4 1 Bale...

Page 31: ...ck limit switches S4 4 ABB S8 KLM When actuated On the ABB PCB the terminals 12 and 13 must not have continuity There must be 24V at the KLM PCB terminal X2 7 4 1 Bale cannot be ejected B Top of press...

Page 32: ...oil faulty C Actuate hydraulic valve by pressing in a blunt object e g an Allen key Check valve for smooth movement and replace if necessary E Check valve coil plug and replace if necessary D Check va...

Page 33: ...ts in PP 1207 Kl ckner M ller Remedying faults PP 1207 page 33 April 2005 D Valve for ejector control 4 1 Bale cannot be ejected D Valve is sticking PDF wurde mit pdfFactory Pr fversion erstellt www c...

Page 34: ...Remedying faults PP 1207 page 34 April 2005 G Check ejector mechanism for broken or bent parts and ensure a smooth movability 4 1 Bale cannot be ejected G Ejector lever broken PDF wurde mit pdfFactor...

Page 35: ...o the cylinder causing press plate to sink down Because now additional oil out of the cylinder flows back the oil tank cannot hold the increased volume and overflows Change valve intermediate plate to...

Page 36: ...t move automatically or tilts while starting A Locking pins or door mechanism faulty or not free moving Convert to new system door mechanism and check free movement and lay on surface of the press pla...

Page 37: ...just if necessary B Check sensor adjustment and readjust if necessary Replace faulty sensors 6 1 Door does not move automatically or tilts while starting 1 A Locking pins or door mechanism faulty or n...

Page 38: ...ve and low pressure pump both faulty Test DFV pressure sequence valve and replace if necessary Test pump and replace if necessary 7 3 Machine does pressure vibrations while moving down A Pressure sequ...

Page 39: ...axial movability Replace stucked valve Actuate hydraulic valve with a blunt object e g Allen key To avoid damage do not use any sharp objects 7 1 Machine does not build up high pressure A Valve stick...

Page 40: ...r is in the home position the low pressure pressure is built up in the system and it can be read off at the manometer The pressure can now be regulated via the pressure sequence valve DFV The pressure...

Page 41: ...domed nut screwed on Adjusting high pressure Gradually turn the DBV1 adjustment screw clockwise Use manual operation to build up pressure to check the pressure values by manometer Adjust 230 bar maxi...

Page 42: ...ing faults PP 1207 page 42 April 2005 DBV 230 bar DFV 60 bar 2 Non Return valves 1 is behind the manometer High pressure pump Low pressure pump The following components must be checked PDF wurde mit p...

Page 43: ...PP 1207 page 43 April 2005 If pressure adjustment has failed the pressure regulator valve DBV and the pressure sequence valve DFV must be checked and changed if necessary DBV 230 bar DFV 60 bar PDF w...

Page 44: ...ing faults PP 1207 page 44 April 2005 If the pressure adjustment has failed again the pumps must be checked and replaced if necessary 230 bar high pressure pump 60 bar high volume pump PDF wurde mit p...

Page 45: ...tion after machine has been switched off a small quantity of oil runs back into the tank The reason is a faulty non return valve Check and replace the non return valves if necessary Non return valves...

Page 46: ...check power input check motor and replace if necessary 8 2 Bale ready signal is triggered constantly A Bale ready signal switch misaligned or faulty Test and adjust switch replace if necessary 8 3 Ba...

Page 47: ...current and adjust trigger level If motor contactor has seized up replace it 8 1 Motor protection switch trips and power supply cable fuses trip A Current value set too low component faulty motor too...

Page 48: ...ssary A Adjust press time with potentiometer optimal time 26 seconds With KLM controls time is adjusted by switch 8 2 Bales ready signal is triggered constantly 1 Bales ready limit switch misaligned o...

Page 49: ...according to demand whereby Switch 1 extends the press time by approx 1 second Switch 4 extends the press time by approx 4 seconds As shown here Switches 1 and 3 are turned on This means 4 additional...

Page 50: ...ge 50 April 2005 Check if motor contact has seized up B Check if limit switch S4 4 ABB S8 KLM is working properly 8 4 Motor does not switch off A Top limit switch not engaged or motor contact has seiz...

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