Service manual W Service manual for OptoPalm
Contents
1. 15 mm 0 59 The centre of the optical sensor must be centered to the edge of clothing Mount the SH 9002 edge sensor on the same machine side as the FR 3811 optical edge sensor The space should be roughly 40 mm 1 75 away from the edge of the clothing Consider uneven edges of the clothing W page 2 BEA 250437 EN 03 3 4 Mounting of FE 0721 me chanical edge sensor 3 5 Mounting of solenoid valve in DP pneumatic switching unit 3 6 Commissioning of DC 761 digital control unit 3 7 Commissioning of entire system 4 Change of felt or wire Service manual for OptoPalm FRA 3803 T N Mount the FE 0721 run off alarm on the machine side opposite to optical FR 3811 optical sensor and SH 9002 Hall sensor The space should be roughly 40 mm 1 75 away from the edge of the clothing Consider uneven edges of the clothing Switch off air supply reduce pressure to 0 bar O psi Connect air piping air supply to solenoid valve Connect air piping from solenoid valve to servo cylinder guide Adjust air pressure and check for leaks Switch solenoid valve manually to left and right side Check if guide is moving to its final position Disconnect power supply clamp 1 and 2 on NK 3501 Commission following DC 761 operation manual Following a program routine the solenoid will be switched and the guide will move to both ends of its stroke Switch paper machine to crawl speed lt 30 m min 100 fpm Check action of the2. V DC 0 1 V Damage of line between FR 3811 optical edge sensor and DC 761 digital control unit transmitter gt check the transmitter signal of FR 3811 optical edge sensor NK 3501 in DC 761 terminal X1 clamp 37 40 42 43 transmitter signal and 36 GND SZ 2204 terminal X1 clamp 9 10 11 12 transmitter signal and 1 GND Damage of line between FR 3811 optical edge sensor and DC 761 digital control unit receiver gt check the signal level of SH 9002 Hall sensor see point 9 2 BEA 250437 EN 03 W page 7 Service manual for OptoPalm FRA 3803 T N 9 4 Failure optics 9 4 1 Possible causes for alarms gt check the receiver signal of FR 3811 optical edge sensor The distance of clothing to sensor lenses should be 115 mm 4 56 5 mm 0 19 For optimal reflexion put a white paper on clothing NK 3501 in DC 761 terminal X1 clamp 44 45 46 48 receiver signal and 36 GND SZ 2204 terminal X1 clamp 5 6 7 8 receiver signal and 1 GND FR 3811 optical edge sensor is too much contaminated gt check and clean Mounting distance between FR 3811 optical edge sensor and clothing is not correct must be 115 mm 4 56 5 mm 0 19 gt check and adjust Paper has wrapped around the sensor gt check and clean SH 9002 Hall sensor or FE 0721 run off alarm are too close to the edge of the clothing distance should be roughly 40 mm 1 75 de pending on edge variation gt check and
3. adjust Effects on guiding The DC 761 control unit is no more operating in optical mode The edge sensing and guiding is performed by the SH 9002 Hall sensor The edge position is offset to the position of the optical sen e sor when performing with Hall sensor The optic has failed or is hidden Guiding is performed by FE 0701 run off alarm Paper has wrapped around the sensor gt check and take away paper FE 0721 run off alarm too close to the clothing s edge gt check and position in correct distance normally 40 mm 1 75 Watch for uneven edges If alarm remains gt Check receiver signal of FR 3811 see point Back up mode Effects on guiding The DC 761 control unit is not operating in optical edge sensing mode The control is performed by FE 0721 run off alarm A clothing run off towards the opposite side of FR 3811 can t eo be detected when optics are hidden W page 8 BEA 250437 EN 03 9 5 Failure SH 9002 9 5 1 Possible causes for alarms 9 6 Failure FE 0721 9 6 1 Possible causes for alarms Service manual for OptoPalm FRA 3803 T N The FE 0721 run off alarm has been contacted at the same time as the SH 9002 Hall sensor Spring of SH 9002 is broken lengthened or loose i e the spring don t place the feeler paddle to the starting position gt check and replace or fix SH 9002 Hall sensor or FE 0721 run off alarm too close to edge of clothing gt check and position
4. guide increase step by step the machine speed If required adjust the following parameters switching delay control optimization optimization degree dead zone amplification guide actuating path infrared actuating path Switch off power supply of DC 761 digital control unit Take care of not damaging sensors and wiring when changing the clothing After putting the new clothing in the machine position the clothing in the centre of the paper machine following the clothing supplier s instruction Check the position of FR 3811 optical edge sensor Position the SH 9002 Hall sensor roughly 40 mm 1 75 away from clothing edge Consider an uneven position of clothing edge Position the FE 0721 mechanical edge sensor roughly 40 mm 1 75 away from clothing edge Consider an uneven position of cloth ing edge Switch on DC 761 digital control unit BEA 250437 EN 03 W page 3 Service manual for OptoPalm FRA 3803 T N 5 Change of soft ware 6 Change of digi tal control unit 7 Change of sole noid valves 7 1 3 2 directional valve 7 2 5 3 directional valve Check function during machine crawl When speeding up adjust control parameters if required Switch off DC 761 digital control unit Change EEPROM chip on control board RK 4202 on back side of display unit Switch on DC 761 digital control unit All parameters have been saved in EEPROM Read and note all programmed parameters
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6. 1 At the same time the red alarm LED is flashing and the alarm output is switched on terminal NK 3501 clamp 32 The respective alarm is erased when the causes of the alarm have been cleared The output signal of the FE 0752 stroke sensor is out of range regis tered during initialization Minimal output voltage 3 5 V DC 0 1 V Maximum output voltage 6 5 V DC 0 1 V The power supply 10 V DC of FE 0752 stroke sensor has failed gt check input signal of FE 0752 stroke sensor NK 3501 in DC 761 terminal X1 clamp 15 10 V DC and 16 GND DP 1005 DP 1006 terminal X1 clamp 6 9 10 V DC and 4 7 GND The signal must be 10 V DC 0 1 V DC The line between FE 0752 stroke sensor and DC 761 control unit is damaged or troubled gt check output signal of stroke sensor NK 3501 in DC 761 terminal X1 clamp 38 output signal voltage and clamp 16 GND DP 1005 DP 1006 terminal X1 clamp 8 output signal voltage and clamp 4 7 GND The signal must be as following FE 0752 right position 3 5 V 0 1 V FE 0752 center position 5 0 V 0 2 V FE 0752 left position 6 5 V 0 1 V BEA 250437 EN 03 W page 5 Service manual for OptoPalm FRA 3803 T N 9 2 Line fault SH 9002 No mechanical link between FE 0752 stroke sensor and guide gt check if FE 0752 stroke sensor is linked by connection rod to the bearing support of guide Mechanical clamp of control lever of FE 0752 stroke sensor is loose gt check if t
7. Service manual W Service manual for OptoPalm FRA 3803 T N Addendum to Description DC 761 1 Instructions 2 Assembly 3 Start up 3 1 Mounting of FE 0752 stroke sensor 3 2 Mounting of FR 3811 optical edge sensor 3 3 Mounting of SH 9002 electro mechanical edge sensor 3 4 Mounting of FE 0721 mechanical edge sensor 3 5 Mounting of solenoid valve in DP pneumatic switching unit 3 6 Commissioning of DC 761 digital control unit 3 7 Commissioning of entire system Change of felt or wire Change of software Change of digital control unit Change of solenoid valves 7 1 3 2 directional valve 7 2 5 3 directional valve 8 Change of pneumatic guide 9 Alarm displays 9 1 Line fault FE 0752 9 2 Line fault SH 9002 9 3 Back up mode 9 4 Failure optics 9 5 Failure SH 9002 NJS or OSODINIDO A al a Pr 2 2 BRI W WI WI WI WIM NM M NM NM NM 9 6 Failure FE 0721 9 9 7 Movements h 10 9 8 Contamination alarm 10 10 Spare parts 11 BEA 250437 EN 03 Service manual for OptoPalm FRA 3803 T N 1 Instructions 2 Assembly 3 Start up 3 1 Mounting of FE 0752 stroke sensor 3 2 Mounting of FR 3811 opti cal edge sensor 3 3 Mounting of SH 9002 elec tro mechanical edge sen sor This manual is designed as an aid to clear simple malfunctions or in correct operation Your E L service technicians supply full support for all problems We suggest the i
8. and clamp 6 GND SZ 2204 terminal X1 clamp 16 micro and clamp 14 GND 9 3 Back up mode 9 3 1 Possible causes for alarms Service manual for OptoPalm FRA 3803 T N The output signal of SH 9002 must be 5 3 V 0 3 V NK 3501 in DC 761 Terminal X1 clamp 17 signal and clamp 6 GND SZ 2204 Terminal X1 clamp 15 signal and clamp 14 GND gt check the position of fully activated feeler paddle lead paddle manually The output signal of microswitch must be 7 0 V DC 0 3 V NK 3501 in DC 761 Terminal X1 clamp 39 micro and clamp 6 GND SZ 2204 Terminal X1 clamp 16 micro and clamp 14 GND The output signal of SH 9002 must be 4 0 V 0 3 V NK 3501 in DC 761 Terminal X1 clamp 17 signal and clamp 6 GND SZ 2204 Terminal X1 clamp 15 signal and clamp 14 GND SH 9002 Hall sensor is defect and must be changed Effects on guiding The control unit is able to perfom only in the optical edge detection mode The back up mode is switched off Tail threading support is not possible and will be deactivated Guiding is performed either by SH 9002 Hall sensor or by FE 0721 run off alarm because of optic failure No power supply from DC 761 digital control unit to FR 3811 optical edge sensor gt check the input signal of FR 3811 optical edge sensor NK 3501 in DC 761 terminal X1 clamp 41 5 V DC and clamp 36 GND SZ 2204 terminal X1 clamp 2 3 4 5 V DC and clamp 1 GND The signal must be 5
9. he mechanical clamp is tightly linked to the stroke sensor Stroke sensor is defect and must be changed Effects on guiding The control unit will perform with standard parameters without elec tronic feedback Guiding is possible but the clothing will run less stable The number of guiding movements will raise Either one of the output signals is out of the range registered during initialization 9 2 1 Possible causes for alarms W page 6 BEA 250437 EN 03 The power supply of the SH 9002 Hall sensor has failed gt check input signal of Hall sensor SH 9002 NK 3501 in DC 761 terminal X1 clamp 5 10 V DC and 6 GND SZ 2204 terminal X1 clamp 13 10 V DC and 14 GND The signal must be 10 V DC 0 1 V DC The line between SH 9002 Hall sensor and DC 761 control unit is damaged or troubled gt check that the feeler paddle is not activated The output signal of microswitch must be 3 5 V DC 0 3 V NK 3501 in DC 761 terminal X1 clamp 39 micro and clamp 6 GND SZ 2204 terminal X1 clamp 16 micro and clamp 14 GND The output signal of SH 9002 must be 6 4 V 0 3 V NK 3501 in DC 761 terminal X1 clamp 17 signal and clamp 6 GND SZ 2204 terminal X1 clamp 15 signal and clamp 14 GND check the signal voltage while the paddle is in center position fix paddle manually The output signal of microswitch must be 7 0 V DC 0 3 V NK 3501 in DC 761 terminal X1 clamp 39 micro
10. in correct distance normally 40 mm 1 75 Watch for uneven edges Felt or wire tension is too low guiding is not possible clothing runs less stable gt check tensioning SH 9002 Hall sensor is damaged gt check see point Line fault SH 9002 Effects on guiding The control unit is not operating in optical edge sensing mode The control is performed by FE 0721 run off alarm The FE 0721 run off alarm is switched even though the FR 3811 opti cal sensor is working correctly Spring of FE 0721 run off alarm is broken lengthened or loose i e the spring don t place the feeler paddle to the starting position gt check and replace or fix Feeler paddle of FE 0721 run off alarm is jammed or its mounting is extremely dirty gt check and move clean if required Feeler paddle of FE 0721 run off alarm is positioned too close to the clothing s edge gt check and position in correct distance normally 40 mm 1 75 Watch for uneven edges Inductive switch of FE 0721 run off alarm is defect gt check the signals NK 3501 in DC 761 Terminal X1 clamp 24 24 V DC 22 GND 8 signal and 22 GND terminal box clamp 1 24 V DC 2 GND 4 signal and 2 GND Power signal 21 26 V DC Signal not contacted lt 1 V DC Signal contacted 21 26 V DC Effects on guiding Edge sensing and guiding is done in optical mode The back up system is working electro mechanical edge sensor SH 9002 Tail
11. nstallation of the electrical and mechanical compo nents following the wiring diagram and under consideration of the surrounding conditions in the paper machine Electrical lines should be laid in protective piping The guide must be fixed in its centre position The electrical equipment must be mounted free of electrical power and the wiring must be checked with appropriate means after instal lation The maximum cable length between the edge sensor e FR 3811 and the digital control unit DC 7 must not exceed 50 m 54 68 yards This cabling must be done with special low capacity cable pair twisted and shielded Stop the paper machine Position the guide in the centre of its stroke Mount the FE 0752 stroke sensor Adjust the stroke sensor in its cen tre position Connect the connection rod to the bearing support Fix the control lever Check guide stroke and turn angle of stroke sensor and fix all screws The FR 3811 optical edge sensor should be mounted behind the guide roll before the next following roll If tail threading support will be activated the optical sensor must be mounted on tending side To avoid dirt alarms mount the edge sensor in an area where no direct water stock or dirt projections are thrown on the lenses of the optical sensor Mount the FR 3811 optical edge sensor on sensor support with sen sor distance of 115 mm 4 52 5 mm 0 19 to the edge of the cloth ing absolute visual range 115 mm 4 52
12. of existing DC 761 con trol unit Switch off power Disconnect cable between keyboard unit and NK 3501 connector board Exchange control unit Take off EEPROM of old control unit and plug it into new control unit Plug in cable between NK 3501 and control unit Switch on power Switch off power supply of DC 761 digital control unit Switch off air or water for IR sensor optical cleaning system Disconnect cable on solenoid valve and exchange valve Connect cable on new valve on previous position Switch on power and air or water Switch off power supply of DC 761 digital control unit Switch off air of guiding system Disconnect cables on solenoid valve and exchange valve Connect cables on the new valve on previous position Switch on power and air for guide W page 4 BEA 250437 EN 03 8 Change of pneu matic guide 9 Alarm displays Actual cc la Reg h O0 T IR Info 0000 gt Act Middle 9 mm Fault 9 1 Line fault FE 0752 9 1 1 Possible causes for alarms Service manual for OptoPalm FRA 3803 T N Switch off power supply of DC 761 digital control unit Switch off air of guiding system Disconnect air piping to the guide Exchange guide and connect air piping to the guide on previous posi tion Adjust air pressure and check for leaks Switch on power and check guiding Faults of the systems are displayed in the 5 line of the display of the digital control unit DC 76
13. s performed without objections The felt or wire may os cillate If the number of oscillations is extremely high well above e 000 please check real movements of guide If this number is very high too and the stroke too big there s danger of long term damage of the clothing abrasion The actual value of reflection is out of range of programmed value The programmed limit is too high gt check and adjust Mounting distance between FR 3811 optical edge sensor and clothing is not correct gt the mounting distance must be 115 mm 4 56 5 mm 0 19 W page 10 BEA 250437 EN 03 10 Spare parts Service manual for OptoPalm FRA 3803 T N Optics contaminated gt check and clean FR 3811 optical edge sensor defect gt check signal level Effects on guiding None guiding is done perfectly Part no Description 305188 FR 3811 T optical edge sensor for dry application 326565 FE 0752 U electronic stroke sensor 326494 SH 9002 U edge sensor Hall for infrared sensing 328427 FE 0721 U alarm device with 1 switching point 303550 DC 7610 digital control unit 304312 Solenoid valve 5 3 way directional G connection 307350 Solenoid valve 3 2 way directional G connection Technical data are subject to modification BEA 250437 EN 03 W page 11 Erhardt Leimer GmbH Postfach 10 15 40 D 86136 Augsburg Telephone 0821 24 35 0 Telefax 0821 24 35 6 66 Internet http
14. threading assistance is available BEA 250437 EN 03 W page 9 Service manual for OptoPalm FRA 3803 T N 9 7 Movements h 9 7 1 Possible causes for alarms 9 8 Contamination alarm 9 8 1 Possible causes for alarms The number of solenoid valve pulses for guiding is out of range of the programmed threshold The programmed value is too low gt a value of 600 movements h should be standard For short wires at high speed machines a value up to 3000 movements h may be programmed as standard value Air leakage on the guide or piping gt check and repair Dead zone too small gt adjust to 6 mm 0 24 3 mm 0 12 In case a smaller dead zone than 6 mm 0 24 is required start reducing it by steps of 1 mm 0 039 to the desired value After each adjustment wait 2 to 4 minutes to evaluate performance Switching delay is too short f e if wire edge is very uneven gt adjust switching delay to standard value of 0 2 0 4 sec Optimization switched off or optimization level insufficient gt increase optimization level to 10 switch on optimization Gain level too high The guide makes a big step forward and almost immediately a smaller step backwards gt reduce gain level standard value 0 50 Gain level too small The guide makes several small steps in the same directions all almost immediately one after the other gt increase gain level standard value 0 50 Effects on guiding The guiding i
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