operating manual - lely manual balercontrol iii ... device when connecting the power supply control...

1753-27

1724.99.03.03 05.04from year of manufacture 2004

O PERATING M ANUAL

BALERCONTROL IIIRP 220 / RP 320

GRAPHIC DISPLAY

Balercontrol III with Graphikdisplay for RP 220 • RP 320 1 Initiation........................................................................................................................................ 1

2 Requirements............................................................................................................................... 1

3 It's a matter of your safety ... ...................................................................................................... 2 3.1 Protection of the electronic control system ......................................................................... 3 3.2 Protection of the electronic control system ......................................................................... 3

4 Monitor.......................................................................................................................................... 4 4.1 Machine status: feeding ...................................................................................................... 4 4.2 Machinery status: Tying ...................................................................................................... 5 4.3 Machinery status: tailgate to be opened ............................................................................. 5 4.4 Machinery status: tailgate is open....................................................................................... 5 4.5 Machinery status: Baler stopped......................................................................................... 6 4.6 Preselection of the density for automatic tripping ............................................................... 6 4.7 Function of the buttons in mode „Monitor“ .......................................................................... 7

5 Menu ............................................................................................................................................. 8

6 Set up............................................................................................................................................ 9

7 Systeminfo ................................................................................................................................. 11

8 Diagnostic .................................................................................................................................. 12 8.1 Standard diagnostic........................................................................................................... 12 8.2 Functions of the buttons in Diagnostic .............................................................................. 16

9 Statistics..................................................................................................................................... 17

10 Fault indications ........................................................................................................................ 18 10.1 System fault: Short in the power supply............................................................................ 18 10.2 System faults: Voltage too high......................................................................................... 19 10.3 Fault indication: „Overload“ ............................................................................................... 19 10.4 Fault indication: Wire broken............................................................................................. 19 10.5 Fault indication: „Set Net knife !“ ....................................................................................... 20 10.6 Fault indication: „Net knife set?“........................................................................................ 20 10.7 Fault indication: „Twine runs one-sided!“ .......................................................................... 20 10.8 Fault indication: „Twine does not run!“ .............................................................................. 21 10.9 Fault indication: „Twine runs but no tying“ ........................................................................ 21 10.10 Fault indication: „1 tailgate hook open“ ............................................................................. 21 10.11 Fault indication: „Maximal pressure reached“ ................................................................... 22

11 Annex.......................................................................................................................................... 23 11.1 Button functions................................................................................................................. 23 11.2 Tying times ........................................................................................................................ 24

Manufacturer: Maschinenfabrik GmbH Postfach 1965 • 38289 Wolfenbüttel Telephone: (05331) 404-0 • Fax: (05331) 404-312 e-mail: [email protected]

WELGER RP 220 • RP 320 BALERCONTROL III 1

1 Initiation The handset for the Balercontrol is attached directly to the baler in a sealed housing. The handset is used to select baler control functions. Both the handset and the black box, together with the programs incorporated in them, are assigned their own serial number. To give any information or to answer questions it may be required to have the Serialnumbers. Please fill in the SERIAL NUMBERS in the columns below after receiving your Baler.

Component Serial number Where do I find the serial number?

Control box

SW.Rev ...........................

Dd ...........................

Hold down any key on the control device when connecting the power supply

Control unit

Serial. ...........................

SW Version ...........................

SW Datum ...........................

Memory

Press button „Systeminfo“ appears

2 Requirements • Power supply ................................... 12 V • Fuse size:.......................................... 20 A Attention: Operation on others than 12 V units is prohibited

2 WELGER RP 220 • RP 320 BALERCONTROL III

3 It's a matter of your safety ...

Read and observe the instruction manual before putting the machine into operation! In this manual, we have inserted the warning sign next to all points which relate to safety. Pass on all safety instructions to other operators! The warning and information plates attached to the machine give important advice on safe operation. Observe this advice for your own safety!

• It is not permitted to enter or to approach the working circle of the machine as long as the electronic unit is powered.

• For any kind of repair or maintenance work the power supply has to be disconnected.

• Check the correct adjustments of all sensors regularly. Check the fittings of all sensors (proximity switches) and actors (cube-shaped plug on hydraulic unit, plug on net tying unit or plug on twine tying unit) regularly.

• The electronic unit should only be powered if the baler is to used for work. After work the power has to be disconnected immediatly.

• If cleaning work has to be carried out the electronic unit should not come in direct contact with water, be very carefully with high pressure cleaners.

• Read all documentation supplied with the machine before the baler starts work. If you cannot understand some details, contact the Service Dept.

• The Balercontrol III control system has been developed and manufactured with the greatest possible care. Every unit is checked for correct functioning before delivery. Despite every precaution, malfunctions occasionally occur. The Balercontrol III control system and associated baler should therefore be operated at all times in such a way that no harm can be caused to persons or property.

• Never carry out adjustments and repairs, or maintenance and service work on the BALERCONTROL whilst the drive is running. Always first disengage the power take-off shaft and withdraw the drive shaft from the end of the power take-off shaft before working in the proximity of moving parts of the machine.


3.1 Protection of the electronic control system • Under certain conditions, harvested crop is easily ignited.

• Always keep the baler free of crop matter and oil leakages. This note applies especially after baling work is completed.

• The cabling provided for the Balercontrol II and the associated machine must not be used for electric consumer devices other than those fitted or approved by the factory. Overloading of electric cables will result in overheating.

• Avoid smoking and always keep a suitable fire extinguisher to hand.

3.2 Protection of the electronic control system • All assembly and maintenance work (connection and disconnection of sensors, valves, control

device etc., replacing of fuses) must be carried out with the power supply disconnected.

• BALERCONTROL is designed to operate with a 12 volt power supply. The system must not be connected to other on-board power supplies!!

• The correct polarity of the power supply on the tractor must not be changed, since otherwise the electronic control unit might be damaged.

• In the event of welding work on the baler:

- Do not allow the welding current to pass through the control unit; - Disconnect the power supply between the tractor and baler; - Be careful of heat generated at welding points; detach any sensitive components

(cables, sensors etc.) before commencing welding.


4 Monitor The monitor is the indication of the standard work functions of the baler. It appears as soon as the power supply is connected. The following information will be shown on the display: Central screen:

• machinery status ( feeding, tying, ...) • bale density existing in the baler • preselected density for auto tying tripping

Sidewards of central screen • Daily bale count in work • Machine working time • Battery power supply

Below the central screen • tying mode • hydraulic function • knife position • bottom door position

4.1 Machine status: feeding The machine status „feeding“ is indicated by an animated material flow into the baler.

Tying mode Valveblock Chopper dev. Bottom gate

manual tying

Operation bottom door

Knive in work

Bottom gate open

auto. Twine tying

Operation pick up

Knive out of work

Bottom gate closed

auto net tying

Operation chopping device

Chopping device not available

Combi tying


4.2 Machinery status: Tying When the tying unit is in operation it is indicated by two rotating arrows.

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Bale3

Hour0.2

Batt.11.9

RPM

4.3 Machinery status: tailgate to be opened After tying is finished the electronics indicate to open the tailgate. Material flow is no longer indicated.

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Bale4

Hours0.3

Batt.11.9

RPM

4.4 Machinery status: tailgate is open The open tailgate is indicated on the main screen. There is no material flow shown.


4.5 Machinery status: Baler stopped If the start of a tying system (net or twine) has failed, the material flow stops, this indicates “baler stopped”. In this status the electronics waits for a fault repair and manual tripping of a tying device

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Batt.11.9

RPM

Bale3

Hours0.2

4.6 Preselection of the density for automatic tripping

Press button or to enter the menu „bale density“. In here the density can be preselected to trip the automatic tying. Approximately 3 s after the last press the monitor changes back to the last screen.

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RPM

Bales17

Hours1.8

Bale densityPreset: 5

Batt.12.0


4.7 Function of the buttons in mode „Monitor“ Button Functions of „Monitor“

Select Menu

Setting of bale density

Setting of bale density

Hydr. valveblock: Operation bottom door

Hydr. Valveblock: Operation pickup

Hydr. valveblock: Operation chopping device

Manual tripping of net tying device

Preselection of tying mode

Manual tripping of twine tie unit


5 Menu

• „Menu“ indicates the available modes.

• Call up from mode „Monitor“ by pressing button

• Selection of the required mode by pressing button or

• Confirm with • If no selection is made then the system returns to mode „Monitor“ after 3 sec.

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Menue: Monitor

SysteminfoDiagnoseStatistics

SetupMenu

Functions of buttons in „Menu“ Button Function in Menü

Call up selected Menu

Move marker down

Move marker up


6 Set up „Set up“ allows the selection of different machine parameters.

Select the required parameter with a short push on the button and change the

preselected value by pressing or . A long press on button returns to Monitor.

The display on page 2 in Setup changes depending on the selection of the Twine tie unit (intern =Twine tie unit; extern = only for Service)

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Setup 2 / 2Net tying: yesTwine tying: intern

Setup 2 / 2Net tying: noTwine tying:Tying prog..: 6Edge clear: 4

extern

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The following Parameter and settings are available in mode „set up“: Set up-Parameter Settings Language English – French – German - ... [other languages]

Machinery-type

RP 220 RP 220 S (with Chopping device) RP 320 RP 320 S (with Chopping device)

Delay (in tying unit) 0 s. / 2.5 s / 5 s

Net tying device yes/no

Twine tie unit

intern: = VARIOTWIN (standard twine tie unit) extern: = only for Service no: no twine tie unit installed


Button functions in „Setup“:

Button Function in „Setup“

Short press on :Select setup Parameter Long press on : Return to Monitor

Set up Parameter up

Set up Parameter down


7 Systeminfo

The „Systeminfo“ supplies information about important System datas, as for example the

Software-Version. A long press on returns to „Monitor“.

Functions of buttons in „Systeminfo“:

Button Fuction in Systeminfo

Returns to monitor


8 Diagnostic The Balercontrol-Software includes a lot different Diagnostic functions to test and check the electronical equipment. Standard diagnostic:

• Diagnostic functions with the baler static • The machinery functions are completely switched off. • Fully automatic valve test is possible.

The standard diagnostics should only be carried out statically and the handset out of the tractor cab!

8.1 Standard diagnostic • In Diagnostic there are no machine functions. • Operate only statically! • Holding the Mode button returns to „Monitor“. • Short press on the Mode button opens the next Diagnostic page.

8.1.1 Diagnostic Digital sensor In the Diagnostic Digital sensors the status (i.e. seeing or not seeing metal) is indicated in symbols. The number of sensors or pages depends on the setting in mode setup ( i.e.machine with chopper or without). A long press on the Mode button returns to Monitor.

The following symbols are used to indicate the sensor status: Sensortype Symbol Status

Sees metal Sensor

Doesn`t see metal

open Switch

closed


The following sensors are indicated in machinery types:

Digital sensors Page 1

Standard machine

Standard machine

with Chopping device

Net knife (only if „net tying“ has been selected) • • Bottom door • • Lock left • • Lock right • • Twine left (only if „twine tying” has been selected) • • Twine right (only if „twine tying“has been selected) • • Pressure switch • Chopping device •


8.1.2 Diagnostic Valves In the Diagnostic for the valves the status of the valve wiring / solonoids is indicated in symbols. The functions can be tested manually or automatically. Therefore the required valve line should be selected by pressing either the<+>/<-> button and switch it by pressing the <Twine tie unit> or. <Net tying device> button on or off. The number of indicated valves or pages is depending on the settings in mode “set up. A long press on the <Mode> button returns to Monitor.

To indicate the status of the valve line the following symbols are shown: Symbol Valve status

Valve is operated and solonoid has switched Valve is operated, but hasn`t switched (fault i.e. solonoid or line damaged) Valve has not operated, but has switched (fault i.e. short against chassis) Valve has not operated and has not switched

Following actors are shown:

Valve Page 1 Standard machine

Magnet Net (only if „net tying“ has been selected) • Motor Twine (only if „twine tying“ has been selected) • Valve A • Valve A1 • Valve A2 • Valve A4 •


A short press on the <Tying mode> button switches over from automatic to manual. In automatic mode all lines will be operated and tested one by one automatically.

For the valve status the following symbols are used:

Symbol Status Valve line is OK Valve line is faulty

Page 2 of the „actordiagnostic“ appears only, if in „Setup“ „Twine tie unit: extern“ is choosen (only for Service).

8.1.3 Diagnostic Analogsensors In this display „Diagnose analog sensors“ the signals of the density sensors are indicated, numerically and as bar graph .

Diagnoseanalog sensors

1 / 1

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1.0 1.5 2.0 2.5 3.0 3.5

distance left:

distance right:

2.83V

1.85V


8.2 Functions of the buttons in Diagnostic Button Functions in „Diagnose“

Short press: next diagnostic page Long press: Returns to Monitor

Page Diagnose valves: Marker moves down

Page Diagnose valves: Marker moves up

Enter or exit osciloscope

Page diagnostic valves, switch off valve line

Page diagnostic valves, switches over between manual and automatic test

Page diagnostic valves, switches on valve lines


9 Statistics The Statistic display indicates baler worktimes and different daily and lifetime counters. In the present software three daily counters are indicated. They can be called up and selected by pressing the <+>/<-> buttons and with a long hold on the <Tying mode> button deleted. A hold down of the <Mode> button returns to Monitor.

Function of buttons in statistics:

Button Function in “statistics”

Return to monitor

Select daily counter

Select daily counter

Hold down button for three seconds to delete selected daily counter


10 Fault indications Fault indications come up in their own windows above the present display. They can only be deleted with the <Mode> button (not system faults). Fault indication does appear in all modes but not in the standard diagnostic, because there is no machinery function working. If more than one fault is indicated the highest priority appears at the display first.

The following faults are shown in their priority order.

10.1 System fault: Short in the power supply • If a short or power over supply are registered the power supply to the valves and sensors will be

switched off by the blackbox, a fault window appears and the buzzer sounds continously. • Systemfaults can not be cancelled by pressing the <Mode> button. • Interrupt power supply immediately: Pull plug (DIN 9680B) • If the error occurs again when power supply is reconnected, work can be continued with the

electronics switched off using the ermegency tying function (see operating manual of the machine „Emergency operation of the tying unit “). Then inform the customer’s service!

Bale3

Hours0.2

Batt.11.9

RPMSTOP

Emergency stopshort circuit in

supply of sensors

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10.2 System faults: Voltage too high. • If the power supply from the tractor becomes too high (more than 17 V) the power supply to the

valves and sensors is switched off by the blackbox, a fault window is opened on the display and the buzzer sounds continuously.

• System faults cannot be cancelled by pressing the Mode button.

Bale3

Hours0.2

Batt.11.9

RPMSTOP

Emergency stopBattery voltage

is too high !

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10.3 Fault indication: „Overload“ • A fault occurs, which leads to much power being supplied to the twine motor line (example). The

line has been switched off. • This fault indication can be cancelled by pressing the Mode button, but the line will be locked until

the power is disconnected and then reconnected.

10.4 Fault indication: Wire broken • A break in a cable or a unknown power consumer is located. • This indication can be cancelled by pressing the Mode button or it will disappear automatically as

soon as the problem is solved (cables reconnected).


10.5 Fault indication: „Set Net knife !“ • Auto trip of the net tying device is required but the net knife sensor does not see metal. • After the fault indication has been cancelled (pressing the Mode button), the net or the twine tie can

be started manually. The net knife sensor has been overridden.

10.6 Fault indication: „Net knife set?“ • Manual net tying should have started, the net knife sensor does not see metal. • After the fault indication has been cancelled (pressing the Mode button), the net or twine tie can be

started manually. The net knife sensor has been overridden.

10.7 Fault indication: „Twine runs one-sided!“ • Twine runs only on one side (one twine spool empty). • The fault indication can be cancelled by pressing the Mode button, or it will disappear itself if both

twines have stopped.

Bale17

Hours1.2

Batt.12.0

RPM

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Errortwine runsone-sided !2


10.8 Fault indication: „Twine does not run!“ • The twine tie unit has been started, but after the twine motor has stopped feeding one twine or both

twines are not running. • After the fault indication has been cancelled by pressing the Mode button, the net or twine tie can

be started manually.

Bale17

1.2

Batt.12.0

RPM

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Errortwine

doesn’t run !

10.9 Fault indication: „Twine runs but no tying“ • A minimum of one twine runs without the tying being started (manually or automatically). • The fault indication can be cancelled by pressing the Mode button, or it will disappear itself if both

twines have stopped

Bale17

Hours1.2

Batt.12.0

RPM

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Errortwine runs

but no tying

10.10 Fault indication: „1 tailgate hook open“ • One tailgate hook is open. • The fault indication can be cancelled by pressing the Mode button, or it will disappear itself if both

tailgate hooks are open or both closed.

Bale17

Hours1.2

Batt.12.0

RPM

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Error1 tailgate

hook open


10.11 Fault indication: „Maximal pressure reached“ • In „manual tying model“ the density of 10 has been exceeded, but no tying has started. • The start of a net or twine tie unit will cancel this fault. • The indication can be cancelled by pressing the Mode button, the buzzer will only stop if a tying

unit is tripped.

Bale3

Hours0.2

Batt.11.9

RPM2

STOPMax. Press.

reached

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11 Annex

11.1 Button functions

Button Monitor Menü Setup System-info

Diagnose Sensoren

Diagnose Actors Statistik

Call up Menu Call up selected Menu

short: Select Set up parameter select Long: Return to Monitor

Return to Monitor

Short press Diagnose Page Long: Return to Monitor

Short press Diagnose Page Long: Return to Monitor

Return to Monitor

Pre selected density

Move marker down

Selected Set up Parameter up

Move marker down

select daily counter

Pre selected density

Move Marker up

Selected Set up Parameter down

Move marker up

select daily counter

Hydraulic Valve block: Operating Bottom door

Hydraulic Valve block: Operating pick up

Hydraulic Valve block: Operating Chopping device

Manual tripping net tying device

Switch off valve motor line

Select tying mode

Switch over between auto. And manual valve / motor test

Press longer than 3 sec. To delete bale counter

Manual tripping twine tie unit

Switch on valve / motor line


11.2 Tying times

Density reached: Start tying

Twine tie unit

Delay: 0sec, 2.5sec or 5.0sec

3secBuzzer

Twinemotor

Net tying device

Buzzer

Magnet Net

8.0sec

Combi Tying

Buzzer 8.0sec

Magnet Net

Twinemotorr

3.0sec + Delay

Delay: 0sc, 2.5sc or 5.0sc

3s

Delay 0sc, 2.5sc or 5.0sc

3sec

operating manual - lely manual balercontrol iii ... device when connecting the power supply control...

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