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Welger Baler Control III Manual

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E-LINK RP 435 MASTER
E - LINK
START
STOP
Pr
1753-27
Operating Manual
from year of manufacture 2005
1755.99.03.02
09.05
E-Link for RP 435 MASTER
1
INTRODUCTION.............................................................................................................................5
2
REQUIREMENTS ON THE MACHINE...........................................................................................5
3
SAFETY INSTRUCTIONS ..............................................................................................................6
3.1
3.2
3.3
3.4
3.5
4
THE MENUS ...................................................................................................................................9
4.1
4.2
5
OVERVIEW OF THE KEY FUNCTIONS IN THE "SYSTEMINFO" MENU: ................................................27
"DIAGNOSIS" MENU ...................................................................................................................28
8.1
8.2
8.3
9
OVERVIEW OF THE KEY FUNCTIONS IN THE "SETUP" MENU: .........................................................25
"SYSTEMINFO" MENU ................................................................................................................26
7.1
8
THE DISPLAY ............................................................................................................................11
TYING MODES ...........................................................................................................................12
HYDRAULIC VALVE BLOCK .........................................................................................................13
OPERATING PARAMETERS .........................................................................................................16
MACHINE STATUS: BALING ........................................................................................................20
MACHINE STATUS: TYING ..........................................................................................................20
MACHINE STATUS: OPEN TAIL GATE ...........................................................................................20
MACHINE STATUS: TAIL GATE OPENED .......................................................................................21
MACHINE STATUS: CLOSE TAIL GATE .........................................................................................21
OVERVIEW OF THE KEY FUNCTIONS IN THE "MONITOR" MENU“ .....................................................22
"SETUP" MENU ...........................................................................................................................23
6.1
7
OVERVIEW .................................................................................................................................9
SELECT A MENU..........................................................................................................................9
"MONITOR" MENU ......................................................................................................................10
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
6
WARNING SYMBOLS ....................................................................................................................6
GENERAL INFORMATION ..............................................................................................................7
INSTRUCTIONS FOR FIRE PROTECTION .........................................................................................7
PROTECTION OF THE ELECTRONIC CONTROL SYSTEM ...................................................................8
ELECTROMAGNETIC COMPATIBILITY (EMC)..................................................................................8
STANDARD DIAGNOSIS ..............................................................................................................29
EXTENDED DIAGNOSIS ..............................................................................................................35
OVERVIEW OF THE KEY FUNCTIONS IN THE "DIAGNOSIS" MENU:...................................................37
"STATISTICS" MENU ..................................................................................................................38
9.1
OVERVIEW OF THE KEY FUNCTIONS IN THE "STATISTICS" MENU: ..................................................39
WELGER RP 435 MASTER E-LINK
3
10
ERROR MESSAGES ................................................................................................................40
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
10.10
10.11
11
11.1
11.2
11.3
11.4
11.5
11.6
12
12.1
12.2
12.3
12.4
13
13.1
SYSTEM ERROR MESSAGES .......................................................................................................41
SYSTEM ERROR: "SHORT CIRCUIT IN SUPPLY OF SENSORS" ........................................................41
SYSTEM ERROR: "BATTERY VOLTAGE TOO HIGH"........................................................................41
STANDARD ERROR MESSAGES ...................................................................................................43
ERROR MESSAGE: "OVERLOAD" ................................................................................................43
ERROR MESSAGE: "WIRE BROKEN" ...........................................................................................43
ERROR MESSAGE: "SET NET KNIFE !" .........................................................................................44
ERROR MESSAGE: "NET KNIFE SET ?"........................................................................................44
ERROR MESSAGE: "1 TAILGATE HOOK OPEN" .............................................................................44
ERROR MESSAGE: "NO PRESSURE INCREASE !"..........................................................................45
ERROR MESSAGE: "HYD DEN EXEEDED !" ...................................................................................45
"SYSTEM SERVICE" MENU ....................................................................................................46
CALL-UP „SYSTEM SERVICE“ MENU ...........................................................................................46
"MONITOR" SUBMENU ...............................................................................................................47
"SYSTEM SETUP" SUBMENU ......................................................................................................47
"EEPROM CONTENTS" SUBMENU ............................................................................................48
"SELF TEST" SUBMENU .............................................................................................................48
OVERVIEW OF THE BUTTON FUNCTIONS IN THE "SYSTEM SERVICE" MENU:...................................49
OSCILLOSCOPE ......................................................................................................................50
OSCILLOSCOPE FOR DIGITAL SENSORS AND ACTORS ..................................................................51
OSCILLOSCOPE FOR DISTANCE SENSORS ...................................................................................52
OPERATING THE OSCILLOSCOPE ................................................................................................53
OVERVIEW OF THE BUTTON FUNCTIONS IN THE "OSCILLOSCOPE":................................................56
APPENDIX ................................................................................................................................57
CHRONOLOGICAL TYING PROCESS AT AUTOMATIC TYING .............................................................57
Maschinenfabrik GmbH
Gebrüder-Welger-Straße 3 • D-38304 Wolfenbüttel
Phone: (+49) 53 31 / 404-142 • Fax: (+49) 53 31 / 404-143
eMail: [email protected]
4
WELGER RP 435 MASTER E-LINK
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
SW rev.
...........................
dd
...........................
Serial no.
...........................
SW version
...........................
SW date
...........................
Memory
...........................
How to find
the serial number
Keep any key on the control box
pressed when connecting the
power supply.
Control box
Control unit
Call menu overview.
Select SYSTEMINFO
menu.
Acknowledge selection.
2 Requirements on the machine
• On-board power supply ....................12 V
• Fuse protection, machine:.................20 A
Operation with 24 V power supply is not permissible.
WELGER RP 435 MASTER E-LINK
5
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.
6
WELGER RP 435 MASTER E-LINK
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.
WELGER RP 435 MASTER E-LINK
7
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.
8
WELGER RP 435 MASTER E-LINK
4 The menus
4.1
Overview
Menu
Task
see chapter
MONITOR
Display and operation in daily machine operation
"Monitor" menu
page 10
SETUP
Setting of machine parameters
"Setup" menu
page 23
SYSTEMINFO
Information about selected system data
"Systeminfo" menu
page 26
DIAGNOSIS
Diagnostic functions for checking the machine
"Diagnosis" menu
page 28
STATISTICS
Machine running time, cumulative counter and daily
counter
"Statistics" menu
page 38
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 menu is effected.
WELGER RP 435 MASTER E-LINK
9
5 "Monitor" menu
The MONITOR menu is the standard menu. This menu
is used for daily machine operation.
The MONITOR menu appears automatically as soon
as the control is supplied with power.
Open menu overview: press key
Select MONITOR menu: keys
or
Confirm selection with key
The following information are displayed in the menu MONITOR:
Central main field
• Machine status (baling, tying, ...)
• Bar graph for present and preselected bale diameter
• Soft-center mode
• Knife in cutting position
Beside the main field
• Day counter
• Machine working time
• Battery voltage
• PTO speed
Below the main field
• Tying mode
• Hydraulic valve block (Cutting device, Bottom door, Pick-Up)
• Operating parameter (Bale diameter, Net layers)
10
WELGER RP 435 MASTER E-LINK
5.1
The display
Tying mode
Hydraulic switch
Operating parameter
(see page 12)
(see page 13)
(see page 16)
manual
twine tying
moving the pick-up
bale diameter
automatic twine tying
moving the bottom door
density (pressure)
manual net tying
moving the cutting device
(here: 12 knives selected)
net layers
(here: set value 1.5)
automatic net tying
WELGER RP 435 MASTER E-LINK
11
5.2
Tying modes
The machine can be equipped with:
• Net tying
• 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
manual
twine tying
•
automatic twine tying
•
Machine with
net tying
manual net tying
•
automatic net tying
•
The tying modes can be selected with the left key.
Start tying: Press key <START/STOP>
12
.
WELGER RP 435 MASTER E-LINK
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)
The units are selected with the centre key. The
selected unit is displayed directly above the
centre key:
Unit
Symbol
Pick-Up
bottom door
Cutting device
The selected unit is moved by means of the
tractor's distribution valve.
WELGER RP 435 MASTER E-LINK
13
5.3.1
Hydraulic switch: Pick-Up
Press centre key
to select the pick-up
The Pick-Up is displayed directly above the centre key:
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 key
to select the bottom door
The bottom door is displayed directly above the centre key:
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).
14
WELGER RP 435 MASTER E-LINK
5.3.3
Hydraulic switch: Cutting device
Press centre key
to select the cutting device
The cutting device is displayed directly above the centre key:
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 / see separate users manual "RP 405 / RP 435").
• 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: 12-knife group).
WELGER RP 435 MASTER E-LINK
15
5.4
Operating parameters
The operating parameters are selected with the right
key.
The operating parameter selected is displayed directly
above the key.
5.4.1 Operating parameters: Set / read bale diameter
Set bale diameter: after selection of the operating parameter "Bale diameter" the value can be set
in 1-digit increments using the keys
/
.
The following overview shows the possible numerical values for the bale diameter display:
Minimum
bale diameter
*90
*91
Maximum
bale diameter
*92
...
*98
*99
00
01
02
...
58
59
60
Read bale diameter: the bale diameter currently reached can be read on the indicating instrument
on the machine (see left figure) or on the display of the control box (see right figure).
16
WELGER RP 435 MASTER E-LINK
5.4.2 Operating parameters: Set / read baling density
Set baling density (= bale density, = pressure): after selection of the operating parameter "Baling
/
density" the value can be set in 1-digit increments using the keys
.
The following overview shows the possible numerical values for the baling density:
Minimum
baling density
0
1
Maximum
baling density
2
3
4
5
6
7
8
9
10
When the baling density reaches stage 10 in a manual tying mode, the message "Stop: Max. baling
density reached" is output (see chapter 10 Error messages).
Read baling density (pressure): the baling density currently reached can be read on the pressure
gauge on the machine (see figure).
WELGER RP 435 MASTER E-LINK
17
Emergency operation: Set baling density
If one of the following error messages appears
ERROR! PRESSURE SENSOR WIRE BROKEN
or
ERROR! NO PRESSURE INCREASE
but the pressure gauge on the machine still indicates a pressure (baling density), a defective pressure
sensor may be the cause of the fault. Nevertheless the baling density can be set in the mergency
operating mode described below:
Set baling density to "0" : press key
.
Press key
and key
simultaneously.
Now an "X" appears in the display (in the place
where usually the baling density is displayed), see
figure.
To set the baling density:
(Valve on machine tail) Turn the handwheel
attached laterally to the machine clockwise up to
the stop. In this position the maximum pressure
(maximum baling density) is set.
If a lower baling density is desired you can turn
the handwheel back in counterclockwise
direction.
18
WELGER RP 435 MASTER E-LINK
5.4.3 Operating parameters: Set net layers
Net layers can only be set on the control box, when electronic net control has been selected in the
"Setup" menu (see chapter 6 "Setup" menu, page 23): EL.NET-CTRL. = YES
Set net layers: After selection of the operating parameter "Net layers" the value can be set in
increments of 0.5 using the keys
/
.
The following overview shows the possible numerical values for the net layers:
Few
net layers
0.5
Many
net layers
1
1.5
2
2.5
3
3.5
4
4.5
5
After the net length (required for the set number of net layers) has passed the machine, the net knife
is automatically activated and tying is finished.
WELGER RP 435 MASTER E-LINK
19
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
Two rotating arrows indicate that tying is being carried out.
5.7
Machine status: Open tail gate
After tying has been finished, the electronics indicate with a flashing arrow and a beep to open the tail
gate. No material flows any more into baler.
20
WELGER RP 435 MASTER E-LINK
5.8
Machine status: Tail gate opened
The open tail gate is displayed in the main window. There is no material flow.
5.9
Machine status: Close tail gate
After the bale has left the baler, the electronics indicate with a flashing arrow to close the tail gate. No
material flows into baler.
WELGER RP 435 MASTER E-LINK
21
5.10
Overview of the key functions in the "Monitor" menu“
Key
Operation
Select tying mode (see chapter 5.2 Tying modes):
left key
•
•
•
•
manual twine tying
automatic twine tying
manual net tying
automatic net tying
Select hydraulic switch (see chapter 5.3 Hydraulic valve block):
centre key
•
•
•
•
•
Pick-Up
bottom door
cutting device 8 knives
cutting device 9 knives
cutting device 17 knives
(optional: 12 knives)
(optional: 13 knives)
(optional: 25 knives)
Select operating parameter (see chapter 5.4 Operating parameters):
right key
•
•
•
Bale density
Baling density (pressure)
Net layers
Start selected tying mode manually
Increase set value for selected operating parameters
•
•
•
Bale density
Baling density (pressure)
Net layers
Decrease set value for selected operating parameters
•
•
•
Bale density
Baling density (pressure)
Net layers
– no function –
Acknowledge fault message (delete) (see chapter 10 Error messages)
Call up menu
22
WELGER RP 435 MASTER E-LINK
6 "Setup" menu
The 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
3 sec.
MONITOR
menu: press key
for
Scroll the display pages forward and backward:
left and right key.
WELGER RP 435 MASTER E-LINK
23
The following machine parameters can be set:
Machine parameter
Setting range
Language
English– German – French – Swedish –
Norwegian – Finnish – Spanish – Italian – Danish
– Dutch
Machine type
RP435
RP435S (with cutting device)
Delay
0 sec. / 2,5 sec. / 5,0 sec.
(Delay of the buzzer while twine
tying or net insertion while net tying
during the tying process, see
chapter 13 Appendix)
yes / no
Soft center
„yes“ means: The bale is to be produced with a
softer center. Therefore the preset pressure in the
baling chamber does not build up completely (up
to the user entered value) before the bale
diameter has reached 75 % of the preset value.
Net tying
yes / no
(setting according to machine's
equipment)
Twine tying
yes / no
(setting according to machine's
equipment)
Electronic net control
yes / no
(= electronic monitoring of the set
number of net layers)
"yes" means:
• input of the desired number of net layers via ELINK control box (see chapter "5.4.3 Operating
parameters: “Set net layers", page 19).
• electronic control / monitoring of the set
number of net layers by the control system.
"no" means:
• emergency function only! Input of the desired
number of net layers by means of the wing nut
in the slotted hole of the net tying unit (see
chapter "Emergency operation: Net tying" in
the separate manual "RP 405/435").
13, 17 or 25
Knives
(only for machine type RP435S)
Beep
24
0 ... 50
WELGER RP 435 MASTER E-LINK
6.1
Overview of the key functions in the "Setup" menu:
Key
Operation
Scroll display pages backwards
left key
– no function –
centre key
Scroll display pages forward
right key
– no function –
Change parameter
Change parameter
Select parameter
Select parameter
Open menu overview:
short key stroke
Return to MONITOR menu:
3 sec. key stroke
WELGER RP 435 MASTER E-LINK
25
7 "Systeminfo" menu
Open menu overview: press key
Select SYSTEMINFO menu: key
Confirm selection with key
menu provides
important system data:
Serial number
Software version
Software date
Memory
SYSTEMINFO
.
or
.
information
about
The menu SYSTEMINFO is exclusively for information.
Data can neither be entered nor selected in the menu
SYSTEMINFO.
Either return to menu overview: press key
Or return to
3 sec.
26
MONITOR
menu: press key
for
WELGER RP 435 MASTER E-LINK
7.1
Overview of the key functions in the "Systeminfo" menu:
Key
Operation
– no function –
left key
– no function –
centre key
– no function –
right key
– no function –
– no function –
– no function –
– no function –
– no function –
Open menu overview:
short key stroke
Return to MONITOR menu:
3 sec. key stroke
WELGER RP 435 MASTER E-LINK
27
8 "Diagnosis" menu
The control contains extensive diagnostic routines for checking the function the electric equipment.
There are two diagnostic routines:
Standard diagnosis
(see chapter 8.1 Standard diagnosis)
Standard diagnosis may only be performed after the
machine has been stopped. In addition, a fully
automatic actor test is possible.
Extended diagnosis
(see chapter 8.2 Extended diagnosis)
Diagnostic functions while machine is in operation.
Observation of all sensor channels and actor
channels possible. Selection via special key
combination.
Attention, danger of injury!
Extended diagnosis is executed while the machine is
running. For trained and instructed service personnel
only!
28
WELGER RP 435 MASTER E-LINK
8.1
Standard diagnosis
Attention, danger of injury!
Standard diagnosis may only be performed after the machine has been stopped: Switch off tractor
engine, wait until machine has stopped, disconnect hydraulic supply to the machine.
Open menu overview : press key
Select DIAGNOSIS menu: keys
or
Confirm selection with key
To previous display page: left key
To next display page: right key
Either return to menu overview: press key
Or return to
3 sec.
8.1.1
MONITOR
menu: press key
for
Standard diagnosis – Digital sensors
Digital sensors are e.g. proximity sensors and
switches. In the DIGITAL SENSORS DIAGNOSIS, the
status of proximity sensors and switches is displayed.
Note!
The number of the sensors shown or of the display
pages depends on the settings in the "Setup" menu
(see chapter 6 "Setup" menu).
The following symbols are used for the sensor status:
Sensor type
Proximity sensors
Symbol
Status
covered
(„sees“ metal)
uncovered
(„sees no metal“)
Switch
opened
closed
WELGER RP 435 MASTER E-LINK
29
Net tying
On the page DIAGNOSIS DIGITAL
following sensors are displayed:
SENSORS
1/2 the
Diagnosis Digital Sensors 1/2
Twine tying
Net tying
Abbreviation
Name
Sensor checks
RPM
revolutions per minute
revolutions of p.t.o
DIAMETER
max. bale diameter
position of the tailgate
wing
PRESS.SW
locking of the cutting
device
pressure in the cutting
device hydraulics
CUTT.DEV.1
knife group 1
(smaller group)
knives in cutting
position?
BOTTOM
bottom (bottom door)
open / closed?
NETKNIFE
net knife
(only for net tying)
home position / cutting
position?
NET RUN
net run
(only for net tying)
revolutions of the net
infeed roll (determination
of the net length)
CUTT.DEV.1
knife group 1
(smaller group)
knives in cutting
position?
On the page DIAGNOSIS DIGITAL
following sensors are displayed:
SENSORS
2/2 the
Diagnosis Digital Sensors 2/2
Twine tying
Abbreviation
Name
Sensor checks
HOOK L.
Locking device, left
open / closed?
HOOK R.
Locking device, right
open / closed?
EJECTOR
Bale kicker
up / down
TWINE L.
Left twine
Twine run left
(only twine tying)
TWINE R.
Right twine
Twine run right
(only twine tying)
In the E-LINK system, an oscilloscope is available in
addition to the various diagnostic functions (see
chapter 12 Oscilloscope). The oscilloscope can be
used to view and analyse the status of all digital
sensors and actors during the last 500 seconds.
Viewing of all signals in real time is also possible:
To the oscilloscope: press centre key
30
WELGER RP 435 MASTER E-LINK
8.1.2
Standard diagnosis – Analog sensors
In DIAGNOSIS ANALOG SENSORS the state of the
analog sensors is displayed.
On the page DIAGNOSIS ANALOG
following sensors are displayed:
SENSORS
1/2 the
Diagnosis Analog Sensors ½
Abbreviation
Meaning
DIAMETER
Voltage value [Volt] shows the position of the
tailgate wing (corresponds to the present bale
diameter).
RP 435: 0,5 Volt (with empty bale chamber)
RP 535: 0,45 Volt (with empty bale chamber)
On the page DIAGNOSIS ANALOG
following sensors are displayed:
SENSORS
2/2 the
Diagnosis Analog Sensors 2/2
WELGER RP 435 MASTER E-LINK
Abbreviation
Meaning
PRESSURE
Measured value [per cent] indicates the
pressure in the hydraulic bale density control
system (corresponds to the current bale
density).
CALIBRATING
Measured value [per cent] indicates the
hydraulic zero point of the pressure sensor.
PRESSURE SENSOR
TYPE
Indicates the recognised pressure sensor
type:
Type 1 / Type 2
31
8.1.3
Standard diagnosis – Actors
Actors are e.g. electro-valves of the hydraulic system.
In the ACTOR DIAGNOSIS, the status of the actor
channels is displayed. The functions can be tested
manually (Diagnosis Manual) or automatically
(Diagnosis Automatic).
Attention, danger of injury!
Standard diagnosis may only be performed after the
machine has been stopped: Switch off tractor engine,
wait until machine has stopped, disconnect hydraulic
supply to the machine.
Note!
The number of the actors shown or of the display
pages depends on the settings in the "Setup" menu
(see chapter 6 "Setup" menu).
See following chapters:
"Standard diagnosis – Actors – Manual" page 33"
"Standard diagnosis – Actors – Automatic" page 34
32
WELGER RP 435 MASTER E-LINK
Standard diagnosis – Actors – Manual
To toggle between DIAGNOSIS
ACTORS MANUAL
DIAGNOSIS ACTORS AUTOMATIC:
Press key
and
<START/STOP>.
Select actor channel: keys
and
Switch actor on: key
Switch actor off: key
The following symbols are used for the actor status:
Symbol
Actor status
Actor has been triggered (+) and has
switched (+).
Actor should be triggered (+), but has not
switched (–). Attention, fault! e. g. actor
channel in control unit defective.
Actor not triggered (–), but has switched (+).
Attention, fault! e. g. short circuit or broken
wire.
Actor has not been triggered (–) and has not
switched (–).
Net tying
On the page DIAGNOSIS ACTORS
following actors are displayed:
MANUAL
1/1 the
Diagnosis Actors Manual 1/1
Twine tying
Abbreviation
Channel designation
VAL.B1
Valve B1*
VAL.B2
Valve B2*
VAL.B3
Valve B3*
VALB45
Valve B45*
PVALVE
Control valve of hydraulic bale density control
system
NET CLUT
Magnetic clutch of the net tying unit
NET KNIFE
net knife tripping device
TWI MOT
Motor twine insertion
* these names are on the plugs or on the hydraulic block (according
to the version of the machine)
Or return to
3 sec.
WELGER RP 435 MASTER E-LINK
MONITOR
menu: press key
for
33
Standard diagnosis – Actors – Automatic
To toggle between DIAGNOSIS
ACTORS MANUAL
DIAGNOSIS ACTORS AUTOMATIC:
Press key
and
<START/STOP>.
In the DIAGNOSIS ACTORS AUTOMATIC, all actors
are automatically triggered and tested in succession.
The following symbols are used for the actor status:
Symbol
Actor status
Actor channel is OK.
Actor channel is faulty.
Net tying
On the page DIAGNOSIS ACTORS
the following actors are displayed:
AUTOMATIC
1/1
Diagnosis Actors Automatic 1/1
Twine tying
Abbreviation
Channel designation
VAL.B1
Valve B1*
VAL.B2
Valve B2*
VAL.B3
Valve B3*
VALB45
Valve B45*
PVALVE
Control valve of hydraulic bale density control
system
NET CLUT
Magnetic clutch of the net tying unit
NET KNIFE
net knife tripping device
TWI MOT
Motor twine insertion
* these names are on the plugs or on the hydraulic block (according
to the version of the machine)
In the E-LINK system, an oscilloscope is available in
addition to the various diagnostic functions (see
chapter 12 Oscilloscope). The oscilloscope mode can
be used to view and analyse the status of all digital
sensors and actors during the last 500 seconds.
Viewing of all signals in real time is also possible:
To the oscilloscope: press centre key
Or return to
3 sec.
34
MONITOR
menu: press key
.
for
WELGER RP 435 MASTER E-LINK
8.2
Extended diagnosis
Attention, danger of injury!
Extended diagnosis is executed while the machine is running. For trained and instructed service
personnel only!
Net tying
Twine tying
The extended diagnosis offers a possibility of viewing
the state of sensor and actors during machine
operation.
Operation of the extended diagnosis is identical to
that of the standard diagnosis (see chapter „8.1
Standard diagnosis). In case of extended diagnosis,
however, the service personnel has exclusively the
function of an observer. Any interference in the
sequence of machine operations (e.g. starting of the
automatic actor diagnosis or switching of a selected
actor channel) will immediately stop machine
operation and thus the extended diagnosis.
Indication for extended diagnosis: the symbol
(AUTOMATIC) flashes.
Net tying
Twine tying
WELGER RP 435 MASTER E-LINK
35
Attention, danger of injury!
While the machine is in operation:
Never climb the machine.
Keep sufficient distance to the range of action of the
machine: Pick-up, tail gate.
Never stay or work below the machine.
Never carry out any adjustment and maintenance
work on the machine while the drive is running.
Before opening the protections: Switch-off tractor's
engine, wait for stand still of the machine, take-out
ignition key of the tractor, interrupt hydraulic supply to
the machine.
Open menu overview: press key
Call extended diagnosis: Press centre key
and key
simultaneously.
Either return to menu selection: press key
Or return to
3 sec.
36
MONITOR
menu: press key
for
WELGER RP 435 MASTER E-LINK
8.3
Overview of the key functions in the "Diagnosis" menu:
Key
Operation
Page backwards
left key
Call up oscilloscope
centre key
Page forwards
right key
Toggling between automatic and manual actor diagnosis:
Actor channel On
Actor channel Off
Select actor
Select actor
Open menu overview:
short key stroke
Return to MONITOR menu:
3 sec. key stroke
WELGER RP 435 MASTER E-LINK
37
9 "Statistics" menu
Open menu overview : press key
Select STATISTICS menu: keys
or
Confirm selection with key
The STATISTICS menu provides an overview of
Bale number
(daily counter)
Bale number
(total)
Machine running time
(daily counter)
Machine running time
(total)
The "total" counters for bale number (example: 42)
and machine running time (example: 44.1 h) are
cumulative counters and cannot be erased. 20 daily
counters are supported (#1, #2, #3 ... #20). The daily
counter selected in each case is used for counting.
Select daily counter (view and activate):
press key
or
Erase selected daily counter: press keys
and
simultaneously for 3 seconds.
Symbol
Total
Meaning
Bale number (total)
Bale number (daily counter)
#3
Total
(here e.g. daily counter number 2)
Machine running time (total)
Machine running time (daily counter)
#3
(here e.g. daily counter number 2)
Either return to menu selection: press key
Or return to
sec.
38
MONITOR
menu: press key
for 3
WELGER RP 435 MASTER E-LINK
9.1
Overview of the key functions in the "Statistics" menu:
Key
Operation
– no function –
left key
– no function –
centre key
– no function –
right key
– no function –
+
Erase selected daily counter:
3 sec. key stroke
Select daily counter (#1, #2, #3, ... #20)
Select daily counter (#1, #2, #3, ... #20)
Open menu overview:
short key stroke
Return to MONITOR menu:
3 sec. key stroke
WELGER RP 435 MASTER E-LINK
39
10 Error messages
Error messages are displayed in a separate window above the current screen. Error messages
consist of:
• the word ERROR
• the error message (text)
• a flashing warning triangle
• the number of errors which occurred (below the flashing warning triangle)
For example:
If several errors occur at the same time, the error message of the highest priority is displayed first.
A distinction is made between:
• System error messages
(see from chapter 10.1 System error messages)
• Standard error messages (see from chapter 10.4 Standard error messages)
Note!
If possible errors cannot be removed: Inform the customer service department.
Tell the customer service about the displayed error messages. The error messages contain important
information about the causes of a possible malfunction to the customer service.
40
WELGER RP 435 MASTER E-LINK
10.1
System error messages
System error messages appear in all menus. Exception: standard diagnosis (where no machine
functions are in operation).
System error messages cannot be acknowledged by pressing a key. They disappear when the cause
of the error has been eliminated.
10.2
System error: "Short circuit in supply of sensors"
While problems during the sensor's power supply
(e.g. during a short circuit in the sensor's power
supply or during bad main power supply) the sensor
and actor supply of the control unit is switched of
automatically, an error window is displayed and an
alarm tone sound from the control box.
This error cannot be acknowledged. It disappears
when the error cause (short circuit or bad main power
supply) has been removed.
Interrupt power supply immediately: pull plug (DIN 9680B)
If the error occurs again after reconnection of the power supply, baling can be processed with
switched off electronics and by means of emergency tying (see users manual of the machine,
chapter "Emergency operation"). Inform customer service!
Use the delivered cable (part no. 0972.20.40.00) to avoid a bad main power supply.
10.3
System error: "Battery voltage too high"
In case of excess voltage in the onboard power
supply (battery voltage > 17 Volt), the sensor and
actor supply of the control unit is switched off, an error
window is opened and a permanent warning signal
sounds in the control box.
This error cannot be acknowledged. The error
message disappears when the cause of the error has
been eliminated. Inform customer service!
Twine tying
Interrupt power supply between tractor and
machine immediately: Pull out plug [1].
If the error occurs again after reconnection of the
power supply baling can be processed with
emergency tying:
Disconnect control unit: pull both 35-pin plugs [3].
Disconnect control box: pull 7-pin plug [2].
Connect power supply: Insert plug [1] into the
socket at the tractor.
See users manual of the machine, chapter
"Emergency operation of the tying": The red
attachment plug for the twine tying is simply
plugged into the empty white socket.
To trigger the twine tying switch on the parking
light (or the low beam or the high beam) for a
short time until the twine is grasped by the bale.
WELGER RP 435 MASTER E-LINK
41
Net tying
Interrupt power supply between tractor and
machine immediately: Pull out plug [1].
If the error occurs again after reconnection of the
power supply baling can be processed with
emergency tying:
Interrupt power supply: Pull plug [1] out of the
socket at the tractor.
See operating manual of the machine, chapter
"Emergency operation": The black attachment
plug of the electric net coupling is simply plugged
into the empty white socket.
See operating manual manual of the machine,
chapter "Emergency operation": Make additional
mechanical adjustments.
To trigger the net tying switch on the parking light
(or the low beam or the high beam) for a short
time until the net is grasped by the bale
(recognisable from the fast rotation of the net roll).
42
WELGER RP 435 MASTER E-LINK
10.4
Standard error messages
Standard error messages can appear in all menus.
Exception: DIAGNOSIS menu. The standard error
messages OVERLOAD and WIRE BROKEN are not
displayed there. Reaction to standard error
messages:
Option 1: press key
to acknowledge the
standard error message. Subsequently, the cause
of the fault must be eliminated.
Option 2: The standard error message disappears
automatically when the cause of the error has
been eliminated.
10.5
Error message: "Overload"
An error has occurred which has caused overload of
an output channel. The output has been switched off.
The error message can be acknowledged, the output
remains, however, blocked until restart of the system
(pull the power supply plug).
Acknowledge fault messages: press key
10.6
Error message: "Wire broken"
A broken wire or a non-connected load has been
recognized.
The error message can be acknowledged or
disappears automatically when the load is connected
again.
Acknowledge fault messages: press key
WELGER RP 435 MASTER E-LINK
43
10.7
Error message: "Set net knife !"
Automatic net wrapping should have been started, but
the net knife sensor is not damped.
After removal of the error message, net wrapping can
be started manually (net knife sensor is ignored).
Acknowledge fault messages: press key
Start manual net tying (see operating manual of
the machine, chapter "Operation / Tying").
10.8
Error message: "Net knife set ?"
Manual net wrapping should have been started, but
the net knife sensor is not damped.
After removal of the error message, net wrapping can
be started manually (net knife sensor is ignored).
Acknowledge fault messages: press key
10.9
Error message: "1 tailgate hook open"
A locking hook is open.
The error message can be acknowledged or
disappears automatically when both locking hooks are
open or both locking hooks are closed.
Acknowledge fault messages: press key
44
WELGER RP 435 MASTER E-LINK
10.10 Error message: "No pressure increase !"
No pressure is built up in the hydraulic tensioning
system during baling.
The error message can be acknowledged.
Acknowledge fault messages: press key
10.11 Error message: "hyd den exeeded !"
After opening of the tail gate, hydraulic pressure is not
released.
The error message can be acknowledged.
Acknowledge fault messages: press key
WELGER RP 435 MASTER E-LINK
45
11 "System Service" menu
Attention!
The following chapter is intended exclusively for trained and instructed service personnel!
The SYSTEM SERVICE menu provides the following
submenus for first commissioning and servicing of the
machine:
Submenu
Task
see chapter
MONITOR
Terminates SYSTEM SERVICE menu and
starts MONITOR menu.
"Monitor" submenu“
page 47
SYSTEM SETUP
Machine model toggling, if several user
interfaces are available.
"System Setup" submenu"
page 47
EEPROM
CONTENT
Display of the EEPROM contents.
"EEPROM Contents" submenu"
page 48
SELF-TEST
Self test of the control (in connection with a
special testing device).
"Self Test" submenu"
page 48
11.1
Call-up „System Service“ menu
Call up SYSTEM SERVICE: hold centre button
depressed (for about 10 seconds) when switching
on the control voltage.
Select submenu: keys
or
Call-up selected submenu: Button
46
WELGER RP 435 MASTER E-LINK
11.2
"Monitor" submenu
This menu entry terminates SYSTEM SERVICE and
causes return to the Monitor menu, see chapter
5 "Monitor" menu, page 10.
11.3
Select MONITOR menu: keys
or
Confirm selection with button
.
"System Setup" submenu
The control can be used on other prepared machine
families.
Select SYSTEM
SETUP
menu: keys
or
Confirm selection with key
Select machine family: keys
or
Call up selected machine family: Button
Now, the control jumps automatically back to the
menu (see chapter 6 "Setup" menu). To safe
the changed setting:
SETUP
Save selection with button
WELGER RP 435 MASTER E-LINK
47
11.4
"EEPROM Contents" submenu
In this submenu the contents of the EEPROM is
shown in hexadecimal form (for diagnostic purposes).
Select
EEPROM CONTENTS
menu: keys
or
Confirm selection with key
Line scrolling: keys
11.5
or
Page scrolling: press key
or
Return to SYSTEM
button
SERVICE:
"Self Test" submenu
A fully automatic self-test can be carried out only in
connection with special test equipment designed for
this purpose. The self-test cannot be started without
this test equipment, and is not described here.
Select SELF-TEST menu: keys
or
Confirm selection with button
Return to SYSTEM SERVICE: press key
48
WELGER RP 435 MASTER E-LINK
11.6
Overview of the button functions in the "System Service" menu:
Key
Operation
System Service
System Setup
EEPROM contents
Select machine family
Scroll up by one line
Select machine family
Scroll down by one line
Self test
left button
centre button
right button
Select submenu
Scroll down by one page
(8 lines)
Select submenu
Scroll up by one page
(8 lines)
Open menu overview
Call-up selected
submenu
Call SETUP of the
selected machine family
WELGER RP 435 MASTER E-LINK
Return to the
SYSTEM SERVICE
menu
Return to the SYSTEM
SERVICE menu
49
12 Oscilloscope
The oscilloscope is used for checking digital sensors, actors, and distance sensors.
• see chapter „12.1 Oscilloscope for digital sensors and actors“
• see chapter „12.2 Oscilloscope for distance sensors“
The oscilloscope mode can be used to view and analyse the status of all sensors and actors during
the last 500 seconds (about 8 minutes). Viewing of all signals in real time is also possible.
In each diagnostic display (see chapter 8
"Diagnosis" menu) the centre button
the corresponding oscilloscope.
50
leads to
WELGER RP 435 MASTER E-LINK
12.1
Oscilloscope for digital sensors and actors
Diagnosis page:
(here: digital sensors)
Measured data recording:
RUN: recording is running
Designation of the
sensor/actor channels
(see chapter 12.3.7).
Page number
Sensor/actor status
High: damped/connected
Low: uncovered/disconnected
Time window
here: 10 sec. set
Measured data recording:
HOLD: recording stopped
Channels not used
Cursor position
here: 495.2 sec.
WELGER RP 435 MASTER E-LINK
Cursor
51
12.2
Oscilloscope for distance sensors
Actual measurement value
(in the RUN-mode, this
value is refreshed all the
time) (here: 2.30 V)
Zoom factor
(here: factor 2.5)
Offset (zero point)
(here: 1.0 V)
Actual measurement value
(in the HOLD mode the
value is displayed at the
cursor
position)
(here:
2.02 V)
Cursor position
(here: 490.2 sec.)
52
Cursor
WELGER RP 435 MASTER E-LINK
12.3
Operating the oscilloscope
12.3.1 Paging through the oscilloscope screens
You can page through the oscilloscope screens:
right button
left button
page up.
page down.
12.3.2 Start or stop recording (RUN mode / HOLD mode)
Recording of the measurement data can be
stopped (HOLD mode) and restarted (RUN mode)
by pressing button
<START-STOP>.
12.3.3 „Time window“ function
The „Time window“ function serves to set the period
of time corresponding to a window size, e.g.:
window size T = 10 seconds
window size T = 20 seconds
window size T = 50 seconds
window size T = 100 seconds
window size T = 200 seconds
window size T = 500 seconds
Position the selection bar (black) on the "Time
Window" function using the buttons
and
(see dashed circle).
Set the value for the window size by means of the
keys
and
12.3.4 „Cursor“ function
When recording has been stopped (HOLD), the
"Cursor" function can be used to view all times of the
course recorded before:
Position the selection bar (black) on the "Cursor"
function using the buttons
dashed circle).
and
(see
Move cursor to the desired position: buttons
and
WELGER RP 435 MASTER E-LINK
53
12.3.5 Function "Zoom" (only for the oscilloscope for analog sensors)
The „Zoom“ function can be used to enlarge the
displayed value range (that means the vertical scale
axis). E. g.:
„Zoom = 1“ means: the displayed value range
comprises 100 % of the measured values.
„Zoom = 2.5“ means: the displayed value range
comprises 40 % of the measured values.
„Zoom = 5“ means: the displayed value range
comprises 20 % of the measured values.
„Zoom = 10“ means: the displayed value range
comprises 10 % of the measured values.
Position the selection bar (black) on the "Zoom"
function using the keys
and
Set zoom factor by means of the keys
and
12.3.6 Function "Offset" (only for the oscilloscope for analog sensors)
The „Offset“ function can be used to shift the origin of
the displayed value range (that means the vertical
scale axis). This function is used when Zoom is used;
that means with a zoom factor larger than 1.
Example „Zoom factor = 5“. Only 20 % of all
measured values are displayed.
Set Offset to 25 %. In this case the measured
values 25 % to 45 % are displayed.
Or, set Offset to 50 %. In this case the measured
values 50 % to 70 % are displayed.
Or, set Offset to 63 %. In this case the measured
values 63 % to 83 % are displayed.
Position the selection bar (black) on the "Offset"
function using the keys
and
Set Offset value by means of the keys
54
and
WELGER RP 435 MASTER E-LINK
12.3.7 Designation of the sensor channels and actor channels
Net tying
Abbreviation
Sensors
DZ
B.D.
D.S.
S.W.1
S.W.2
BODN
N.M.
V.L.
V.R.
BAW
Channel designation
Sensors
Speed
Max. bale diameter
Pressure switch
Cutting device
Abbreviation
Actors
B1
B2
B3
B45
Channel designation
Actors
Valve B1
Valve B2
Valve B3
Valve B45
Bottom door
Net knife
Locking device, left
Locking device, right
Bale ejector
NETZ
N.L.
N.M.
Net coupling
Net length
Net motor
Channel designation
Sensors
Speed
Max. bale diameter
Pressure switch
Cutting device
Abbreviation
Actors
B1
B2
B3
B45
Channel designation
Actors
Valve B1
Valve B2
Valve B3
Valve B45
Bottom door
Twine run left
Twine run right
Locking device, left
Locking device, right
Bale ejector
GARN
Twine motor
Twine tying
Abbreviation
Sensors
DZ
B.D.
D.S.
S.W.1
S.W.2
BODN
FA.L.
FA.R.
V.L.
V.R.
BAW
WELGER RP 435 MASTER E-LINK
55
12.4
Overview of the button functions in the "Oscilloscope":
Operation
Key
Page forwards
left button
Call-up/terminate oscilloscope
centre button
Page backwards
right button
Switch between
RUN mode (recording started) and HOLD mode (recording stopped)
Increase selected oscilloscope parameters
- Page shown
- Time window set (10s - 20s - 50s - 100s - 200s - 500s)
- Cursor position (in HOLD mode only)
- Offset (0..90% measuring range)
(only for oscilloscope for distance sensors)
- Zoom factor (1x - 2.5x - 5x - 10x)
(only for oscilloscope for distance sensors)
Reduce selected oscilloscope parameters
- Page shown
- Time window set (10s - 20s - 50s - 100s - 200s - 500s)
- Cursor position (in HOLD mode only)
- Offset (0..90% measuring range)
(only for oscilloscope for distance sensors)
- Zoom factor (1x - 2.5x - 5x - 10x)
(only for oscilloscope for distance sensors)
Select oscilloscope parameters
- Page shown
- Time window set (10s - 20s - 50s - 100s - 200s - 500s)
- Cursor position (in HOLD mode only)
- Offset (0..90% measuring range)
(only for oscilloscope for distance sensors)
- Zoom factor (1x - 2.5x - 5x - 10x)
(only for oscilloscope for distance sensors)
– no function –
56
WELGER RP 435 MASTER E-LINK
13 Appendix
13.1
Chronological tying process at automatic tying
The value "Delay" can be set in menu SETUP (see chapter 6 "Setup" menu).
TWINE TYING
Buzzer
Delay: 0 .. 5.0 sec
3.0 sec
8.0 sec
Twine motor
NET TYING
Buzzer
Net magnet
3.0 sec
Delay: 0 .. 5.0 sec
WELGER RP 435 MASTER E-LINK
3.0 sec
57
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