E-LINK RP 435 MASTER - Trejon · WELGER RP 435 MASTER E-LINK 5 1 Introduction The control contains (see figures bellow): • the control box E-LINK (hand set) • the control unit

1753-27

E-LINK

START

STOP

START

STOP

Pr

1755.99.03.02 09.05from year of manufacture 2005

Operating Manual

RP 435 MASTERE-LINK

WELGER RP 435 MASTER E-LINK 3

E-Link for RP 435 MASTER 1 INTRODUCTION.............................................................................................................................5

2 REQUIREMENTS ON THE MACHINE...........................................................................................5

3 SAFETY INSTRUCTIONS ..............................................................................................................6 3.1 WARNING SYMBOLS....................................................................................................................6 3.2 GENERAL INFORMATION..............................................................................................................7 3.3 INSTRUCTIONS FOR FIRE PROTECTION .........................................................................................7 3.4 PROTECTION OF THE ELECTRONIC CONTROL SYSTEM ...................................................................8 3.5 ELECTROMAGNETIC COMPATIBILITY (EMC)..................................................................................8

4 THE MENUS ...................................................................................................................................9 4.1 OVERVIEW .................................................................................................................................9 4.2 SELECT A MENU..........................................................................................................................9

5 "MONITOR" MENU ......................................................................................................................10 5.1 THE DISPLAY ............................................................................................................................11 5.2 TYING MODES...........................................................................................................................12 5.3 HYDRAULIC VALVE BLOCK .........................................................................................................13 5.4 OPERATING PARAMETERS.........................................................................................................16 5.5 MACHINE STATUS: BALING ........................................................................................................20 5.6 MACHINE STATUS: TYING..........................................................................................................20 5.7 MACHINE STATUS: OPEN TAIL GATE...........................................................................................20 5.8 MACHINE STATUS: TAIL GATE OPENED.......................................................................................21 5.9 MACHINE STATUS: CLOSE TAIL GATE .........................................................................................21 5.10 OVERVIEW OF THE KEY FUNCTIONS IN THE "MONITOR" MENU“.....................................................22

6 "SETUP" MENU ...........................................................................................................................23 6.1 OVERVIEW OF THE KEY FUNCTIONS IN THE "SETUP" MENU: .........................................................25

7 "SYSTEMINFO" MENU................................................................................................................26 7.1 OVERVIEW OF THE KEY FUNCTIONS IN THE "SYSTEMINFO" MENU: ................................................27

8 "DIAGNOSIS" MENU ...................................................................................................................28 8.1 STANDARD DIAGNOSIS ..............................................................................................................29 8.2 EXTENDED DIAGNOSIS ..............................................................................................................35 8.3 OVERVIEW OF THE KEY FUNCTIONS IN THE "DIAGNOSIS" MENU:...................................................37

9 "STATISTICS" MENU ..................................................................................................................38 9.1 OVERVIEW OF THE KEY FUNCTIONS IN THE "STATISTICS" MENU: ..................................................39

4 WELGER RP 435 MASTER E-LINK

10 ERROR MESSAGES ................................................................................................................40 10.1 SYSTEM ERROR MESSAGES.......................................................................................................41 10.2 SYSTEM ERROR: "SHORT CIRCUIT IN SUPPLY OF SENSORS" ........................................................41 10.3 SYSTEM ERROR: "BATTERY VOLTAGE TOO HIGH"........................................................................41 10.4 STANDARD ERROR MESSAGES...................................................................................................43 10.5 ERROR MESSAGE: "OVERLOAD" ................................................................................................43 10.6 ERROR MESSAGE: "WIRE BROKEN" ...........................................................................................43 10.7 ERROR MESSAGE: "SET NET KNIFE !" .........................................................................................44 10.8 ERROR MESSAGE: "NET KNIFE SET ?"........................................................................................44 10.9 ERROR MESSAGE: "1 TAILGATE HOOK OPEN" .............................................................................44 10.10 ERROR MESSAGE: "NO PRESSURE INCREASE !"..........................................................................45 10.11 ERROR MESSAGE: "HYD DEN EXEEDED !" ...................................................................................45

11 "SYSTEM SERVICE" MENU ....................................................................................................46 11.1 CALL-UP „SYSTEM SERVICE“ MENU ...........................................................................................46 11.2 "MONITOR" SUBMENU ...............................................................................................................47 11.3 "SYSTEM SETUP" SUBMENU ......................................................................................................47 11.4 "EEPROM CONTENTS" SUBMENU ............................................................................................48 11.5 "SELF TEST" SUBMENU.............................................................................................................48 11.6 OVERVIEW OF THE BUTTON FUNCTIONS IN THE "SYSTEM SERVICE" MENU:...................................49

12 OSCILLOSCOPE ......................................................................................................................50 12.1 OSCILLOSCOPE FOR DIGITAL SENSORS AND ACTORS ..................................................................51 12.2 OSCILLOSCOPE FOR DISTANCE SENSORS...................................................................................52 12.3 OPERATING THE OSCILLOSCOPE................................................................................................53 12.4 OVERVIEW OF THE BUTTON FUNCTIONS IN THE "OSCILLOSCOPE":................................................56

13 APPENDIX ................................................................................................................................57 13.1 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]


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 How to find the serial number

Control box

SW rev. ...........................

dd ...........................

Keep any key on the control box pressed when connecting the power supply.

Call menu overview.

Select SYSTEMINFO menu.

Control unit

Serial no. ...........................

SW version ...........................

SW date ...........................

Memory ...........................

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.


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.


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.


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.


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.


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)


5.1 The display

Tying mode

(see page 12) Hydraulic switch

(see page 13) Operating parameter

(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


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 Machine with

net tying

manual twine tying •

automatic twine tying •

manual net tying •

automatic net tying •

The tying modes can be selected with the left key.

Start tying: Press key <START/STOP> .


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.


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).


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).


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

Maximumbale diameter

*90 *91 *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).


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

Maximumbaling density

0 1 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).


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.


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

Manynet layers

0.5 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.


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.


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.


5.10 Overview of the key functions in the "Monitor" menu“

Key Operation

left key

Select tying mode (see chapter 5.2 Tying modes): • manual twine tying • automatic twine tying • manual net tying • automatic net tying

centre key

Select hydraulic switch (see chapter 5.3 Hydraulic valve block): • Pick-Up • bottom door • cutting device 8 knives (optional: 12 knives) • cutting device 9 knives (optional: 13 knives) • cutting device 17 knives (optional: 25 knives)

right key

Select operating parameter (see chapter 5.4 Operating parameters): • 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


6 "Setup" menu The SETUP menu serves for setting various machine parameters (Language, Machine type, Beep ...).


Select Setup menu: keys or


Select parameter: keys and

Change parameter: keys and

Either return to menu overview: press key

Or return to MONITOR menu: press key for 3 sec.

Scroll the display pages forward and backward:

left and right key.


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

(Delay of the buzzer while twine tying or net insertion while net tying during the tying process, see chapter 13 Appendix)

0 sec. / 2,5 sec. / 5,0 sec.

Soft center

yes / no „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

(setting according to machine's equipment)

yes / no

Twine tying

(setting according to machine's equipment)

yes / no

Electronic net control

(= electronic monitoring of the set number of net layers)

yes / no "yes" means: • input of the desired number of net layers via E-

LINK 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").

Knives

(only for machine type RP435S)

13, 17 or 25

Beep

0 ... 50


6.1 Overview of the key functions in the "Setup" menu:

Key Operation

left key

Scroll display pages backwards

centre key

– no function –

right key

Scroll display pages forward

– no function –

Change parameter

Change parameter

Select parameter

Select parameter

Open menu overview: short key stroke

Return to MONITOR menu: 3 sec. key stroke


7 "Systeminfo" menu

Open menu overview: press key .

Select SYSTEMINFO menu: key or

Confirm selection with key . SYSTEMINFO menu provides information about important system data: Serial number Software version Software date Memory

The menu SYSTEMINFO is exclusively for information. Data can neither be entered nor selected in the menu SYSTEMINFO.




7.1 Overview of the key functions in the "Systeminfo" menu:

Key Operation

left key

– no function –

centre key

– no function –

right key

– no function –

– no function –

– no function –

– no function –

– no function –

– no function –




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!


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


To previous display page: left key

To next display page: right key



8.1.1 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 Symbol Status Proximity sensors

covered („sees“ metal)

uncovered („sees no metal“)

Switch

opened

closed


On the page DIAGNOSIS DIGITAL SENSORS 1/2 the following sensors are displayed:

Diagnosis Digital Sensors 1/2 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 SENSORS 2/2 the following sensors are displayed:

Diagnosis Digital Sensors 2/2 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

Net tying

Twine tying

Net tying

Twine tying


8.1.2 Standard diagnosis – Analog sensors In DIAGNOSIS ANALOG SENSORS the state of the analog sensors is displayed. On the page DIAGNOSIS ANALOG SENSORS 1/2 the following sensors are displayed:

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 SENSORS 2/2 the following sensors are displayed:

Diagnosis Analog Sensors 2/2 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


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


Standard diagnosis – Actors – Manual To toggle between DIAGNOSIS ACTORS MANUAL and DIAGNOSIS ACTORS AUTOMATIC:

Press key <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 (–).

On the page DIAGNOSIS ACTORS MANUAL 1/1 the following actors are displayed:

Diagnosis Actors Manual 1/1 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)


Net tying

Twine tying


Standard diagnosis – Actors – Automatic To toggle between DIAGNOSIS ACTORS MANUAL and DIAGNOSIS ACTORS AUTOMATIC:

Press key <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.

On the page DIAGNOSIS ACTORS AUTOMATIC 1/1 the following actors are displayed:

Diagnosis Actors Automatic 1/1 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 .


Net tying

Twine tying


8.2 Extended diagnosis

Attention, danger of injury! Extended diagnosis is executed while the machine is running. For trained and instructed service personnel only!

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

Net tying

Twine tying


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.


Call extended diagnosis: Press centre key

and key simultaneously.

Either return to menu selection: press key



8.3 Overview of the key functions in the "Diagnosis" menu:

Key Operation

left key

Page backwards

centre key

Call up oscilloscope

right key

Page forwards

Toggling between automatic and manual actor diagnosis:

Actor channel On

Actor channel Off

Select actor

Select actor




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 Meaning

Total Bale number (total)

#3

Bale number (daily counter)

(here e.g. daily counter number 2)

Total Machine running time (total)

#3

Machine running time (daily counter)

(here e.g. daily counter number 2)

Either return to menu selection: press key



9.1 Overview of the key functions in the "Statistics" menu:

Key Operation

left key

– no function –

centre key

– no function –

right key

– no function –

– no function –

+ Erase selected daily counter: 3 sec. key stroke

Select daily counter (#1, #2, #3, ... #20)

Select daily counter (#1, #2, #3, ... #20)




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.


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.


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).


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.



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).


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.



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.


10.11 Error message: "hyd den exeeded !" After opening of the tail gate, hydraulic pressure is not released. The error message can be acknowledged.



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


11.2 "Monitor" submenu This menu entry terminates SYSTEM SERVICE and causes return to the Monitor menu, see chapter 5 "Monitor" menu, page 10.

Select MONITOR menu: keys or

Confirm selection with button .

11.3 "System Setup" submenu The control can be used on other prepared machine families.

Select SYSTEM SETUP menu: keys or


Select machine family: keys or

Call up selected machine family: Button Now, the control jumps automatically back to the SETUP menu (see chapter 6 "Setup" menu). To safe the changed setting:

Save selection with button


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


Line scrolling: keys or

Page scrolling: press key or

Return to SYSTEM SERVICE: button

11.5 "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


11.6 Overview of the button functions in the "System Service" menu:

Operation Key

System Service System Setup EEPROM contents Self test

left button

centre button

right button

Select machine family Scroll up by one line

Select machine family Scroll down by one line

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

Return to the SYSTEM SERVICE menu

Return to the SYSTEM SERVICE menu


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 leads to the corresponding oscilloscope.


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 Cursor position here: 495.2 sec.


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)

Cursor Cursor position (here: 490.2 sec.)

Actual measurement value (in the HOLD mode the value is displayed at the cursor position) (here: 2.02 V)


12.3 Operating the oscilloscope

12.3.1 Paging through the oscilloscope screens You can page through the oscilloscope screens:

right button page up.

left button 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 and (see dashed circle).

Move cursor to the desired position: buttons

and


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 and


12.3.7 Designation of the sensor channels and actor channels Net tying

Abbreviation Sensors

Channel designation Sensors

AbbreviationActors

Channel designation Actors

DZ Speed B1 Valve B1 B.D. Max. bale diameter B2 Valve B2 D.S. Pressure switch B3 Valve B3 S.W.1 S.W.2

Cutting device B45 Valve B45

BODN Bottom door NETZ Net coupling N.M. Net knife N.L. Net length V.L. Locking device, left N.M. Net motor V.R. Locking device, right BAW Bale ejector Twine tying

Abbreviation Sensors

Channel designation Sensors

AbbreviationActors

Channel designation Actors

DZ Speed B1 Valve B1 B.D. Max. bale diameter B2 Valve B2 D.S. Pressure switch B3 Valve B3 S.W.1 S.W.2

Cutting device B45 Valve B45

BODN Bottom door GARN Twine motor FA.L. Twine run left FA.R. Twine run right V.L. Locking device, left V.R. Locking device, right BAW Bale ejector


12.4 Overview of the button functions in the "Oscilloscope":

Key Operation

left button

Page forwards

centre button

Call-up/terminate oscilloscope

right button

Page backwards

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




Select oscilloscope parameters

- Page shown




– no function –


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

Twine motor

Delay: 0 .. 5.0 sec

8.0 sec

3.0 sec

3.0 sec

Delay: 0 .. 5.0 sec 3.0 sec Net magnet

Buzzer

NET TYING

E-LINK RP 435 MASTER - Trejon · WELGER RP 435 MASTER E-LINK 5 1 Introduction The control contains (see figures bellow): • the control box E-LINK (hand set) • the control unit

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