StarLogixs PressMate Service Manual

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PRESSMATE CONTROLLER

SERVICE MANUAL

For Use By Authorised Service Agents

Models covered by this manual:

SL100A1—Single Phase 2.2kW Motor

SL100A3– Three Phase 2.2kW Motor

SL200-Three Phase 4kW Motor

SL400-Three Phase 5.5.kW Motor

27 Young Street

Deepwater. N.S.W. 2371

Australia.

Phone: (02) 67 345 262

Fax:

www.starlogixs.com.au

(02) 67 345 020

Page1

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Page 1 PRESSMATE CONTROLLER SERVICE MANUAL For Use By Authorised Service Agents Models covered by this manual: SL100A1—Single Phase 2.2kW Motor SL100A3– Three Phase 2.2kW Motor SL200-Three Phase 4kW Motor SL400-Three Phase 5.5.kW Motor 27 Young Street Deepwater. N.S.W. 2371 Australia. Phone: (02) 67 345 262...
Page 2 NOTES Page2...
Page 3: Table Of Contents
CONTENTS Owners Manual Introduction…………………………………………………..4 Important Safety Notice…………………………………….5 Location of Controls and Switches………………………..6 Basic Operating Proceedures……………………………..7 Motor Operation…………………………………………….8 Optional Extras……………………………………………...8 Basic Servicing……………………………………………...9 Copyright…………………………………………………...10 Specifications……………………………………………...10 Warranty…………………………………………………..11 Service Manual The Hydraulic Pressure Switch………………………..12 The Full Bale Switch……………………………………..13 The Infra-Red Detection System………………………...14 The Hydraulic Valve Energisation Method……………...14 Machine Protection Features in Controller……………..15 Controller Active LED….………………………………….16 Electric Motor Control……….……………………………...
Page 4: Owners Manual
OWNERS MANUAL Thankyou For choosing a Starlogixs PressMate Controller. For operating this Controller properly, please take some time to read this owners man- ual thoroughly before starting operation of your Autobaler. Keep this manual handy for future reference IMPORTANT NOTICE...
Page 5: Important Safety Notice
Should you leave your Autobaler unattended for a period of time, it is strongly recommended that you switch the power off and remove the key. The StarLogixs PressMate Controller provides vital safety features in your press. • If the Controller has been damaged always have it checked by an approved ser- vice agent before operating the press.
Page 6: Location Of Controls And Switches
LOCATION OF CONTROLS AND SWITCHES Page6...
Page 7: Basic Operating Proceedures
BASIC OPERATING PROCEEDURES IMPORTANT Read this procedure in conjunction with procedures in your press manual. CAUTION 1. Switch on Power Key Switch and check that Emergency Stop Button is not depressed (rotate to release). The Power LED should illuminate. 2. Close press doors. If door is not properly shut the Door LED will remain illuminated and the only function that will work is the bale eject.
Page 8: Motor Operation
In addition it allows for monitoring of a secondary safety door or device, and also pro- vides a full bale light. The standard kit provides 5 meters (15 feet) of cable between the PressMate Controller and the remote operator panel. For more details contact your local sales agent.
Page 9: Basic Servicing
BASIC SERVICING The StarLogixs PressMate Controller is a state of the art electronic control system that is designed for long service free life. No part of the controller is serviceable, and should never be opened because there are dangerous voltages inside.
Page 10: Copyright
StarLogixs Pty. Ltd. SPECIFICATIONS...
Page 11: Warranty
StarLogixs service facility, or transportation costs. StarLogixs is not responsible or liable for indirect, special, or consequential damages arising out of or in connection with the use or performance of the Con- troller or other damages with respect to any economic loss, loss of property, loss of revenues or profit, or cost of removal, installation or reinstallation.
Page 12: The Hydraulic Pressure Switch
THE HYDRAULIC PRESSURE SWITCH The hydraulic pressure switch is pre-adjusted, and field adjustment is not recommended. The switch set-point is adjusted to be about 150psi below the hydraulic system by-pass pressure. There are no mechanical sensors to detect the end of stroke of the main hydraulic cylinders.
Page 13: The Full Bale Switch
THE FULL BALE SWITCH The full bale limit switch is situated on the front left- hand corner of the press, and detects if the left-hand cylinder is fully retracted when the pressure switch closes. If the pressure switch closes before the cylinder fully retracts then the material in the pressing chamber is carrying the total applied load and the bale is full.
Page 14: The Infra-Red Detection System
THE INFRA-RED DETECTION SYSTEM The infra-red detection system detects material in the pressing hopper and if the Controller is active and the bale not full will cause the press to cycle until the beam is cleared (i.e. no material in pressing hopper.) It is a transmissive type system with the IR Transmitter located on the back of the press and the receiver inside the Controller.
Page 15: Machine Protection Features In Controller
MACHINE PROTECTION FEATURES IN CONTROLLER The Controller incorporates a number of features to protect the ma- chine from sensor faults. The two main features are: • Excessive Cycling If the infra-red detection beam becomes obstructed and cycling of the baler does not clear the obstruction, then an unattended baler may continually cycle causing unnecessary machine wear.
Page 16: Controller Active Led
THE CONTROLLER ACTIVE LED The second LED from the top on the Controller is the active LED. This indicates if the Controller is in full automatic mode. If the LED is flash- ing the Controller will start the electric motor and cycle the press if the infra-red detection beam is interrupted.
Page 17: Trouble-Shooting
TROUBLE-SHOOTING NO POWER Plug another machine into the wall socket power Call Electrician Is the socket powered ? Disconnect press plug from wall socket and thoroughly check entire length of power cable and cable to motor for damage Replace/repair Leads cables O.K.? Rotate Emergency Stop Button clockwise to release and check key switch is on...
Page 18: Baler Won't Cycle
TROUBLE-SHOOTING Refer to No Power Power Flow Chart Light On? Shut Press Doors Fault in door switch or Door Emergency Bar Open LED illuminated Press cycle button Wait 5 minutes for auto-resetting overload Motor relay Starts? Motor Starts? Down LED Possible Faulty Control Illuminated Panel/ Motor Wiring or...
Page 19 Wait for hydraulic cylinder to reach the end of its stroke Check hydraulic system pressure- Replace faulty pres- Down LED stays sure illuminated ? Switch Check wiring to pressure switch Press Up or Cycle Button Up LED Possible Controller Illuminated? Fault Check up valve coil Cycles...
Page 20: Baler Continually Cycles
TROUBLE-SHOOTING BALER CONTINUALLY CYCLES Switch power on, shut press doors and press down or cycle button Refer to Baler Won't Press cycles? Cycle Flow Chart Material Press should cycle Blocking until eye beam is Eye Beam? cleared Press Baler O.K. cycles? -Clean eye lens covers -Replace lens covers if...
Page 21: Baler Won't Eject
TROUBLE-SHOOTING B A L E R W O N 'T E J E C T O p e n P r e s s D o o r s D o o r O p e n F a u l t i n D o o r S w i t c h o r L E D E m e r g e n c y B a r S w i t c h I l l u m i n a t e d...
Page 22: Main Wiring Diagram
VALVE COIL DOWN VALVE COIL VALVE COIL EJECT Green Blue Pink MOTOR-3PH 9 WAY D-CON. MAIN HARNESS PLUG MOTOR PLUG MOTOR SOCKET 15 WAY D-CON. OPTIONS PLUG KEY SW. EMERG. STOP PANEL FUSE EMERG. BAR SW. DOOR SW. LIMIT SWITCH INTERLOCKING SW.
Page 23: Connector Pin-Out
Page23...
Page 24: Motor Contactor And Overload Relay Details
MOTOR CONTACTOR AND OVERLOAD RELAY DETAILS All contactors and overloaders are General Electric Brand, and the parts numbers are listed below for the range of Controller models: • 2.2 kW Single Phase 240V Full load Amps = 17 Overload Relay = RTIM (5.5 to 8.5A) Contactor = CL00A310T—24Vac coil Note: all three phases in parallel—only active switched.
Page 25: Spare Parts List
SPARE PARTS LIST Description StarLogixs No. Manufacturer Man. Part Number Full Bale Switch SL-S008 Omron Z15GQ21-B Emergency Stop SL-S001 General Electric P9CER4RN Key Switch SL-S009 General Electric P9XSCD0A95 Spare Keys SL-H026 General Electric 077C3095 Interlocked Door Sw. SL-S006 Omron D4DS-15FS Interlocked Sw.
Page 26: Distributor List
27 Young Street Deepwater. N.S.W. 2371 Phone: (02) 67 345 262 Distributors List General Electric Distributors Bell Electrical 1-5 Carter Street Homebush Bay 2127 Phone: (02) 9364 1700 Fax: (02) 9364 1739 Melbourne 140 Burwood Hwy Burwood 3125 Phone: (03) 9888 8100 Fax: (03) 9888 0280 Brisbane...
Page 27 Melbourne VIC Automation Systems Unit 1/87 Heatherdale Road, Ringwood VIC 3134 Phone: (03) 9874 0888 Fax: (03) 9874 6677 Geelong Factory Controls 65 Douro Street North Geelong VIC 3215 Phone: (03) 5278 8222 Fax: (03) 5278 9761 Brisbane QLD Control Logic 34 Thompson Street Bowen Hills QLD 4006 Phone: (07) 3252 9611...
Page 28 RS Components 25 Pavesi Street Phone: 1300 656 636 Smithfield NSW 2164 Phone: (02) 9681 8588 Fax: (02) 9681 8599 250 Beatty Road Phone: 1300 656 636 Archerfield QLD 4108 Melbourne Phone: 1300 656 636 294 Salmon Street Port Melbourne. VIC 3207 Perth Phone: 1300 656 636 26 Walters Drive...
Page 29: Proceedure To Change Power Block
Proceedure to Change Power Block [Disconnect from power source and completely remove Controller from press] 1. Remove 3 Phase plug from the end of the supply cable. Take note of any cable clamps and wire locations and ensure they are returned to original when re-fitting the plug.
Page 30: Proceedure To Change Interlocked Door Switch
6. Loosen the screw marked A2 on the contactor and remove wire. 7. Loosen the screws in the contact block on the top of the transformer marked 24V. Remove the two wires. Note: That it does not matter which way around these two wires are connected. 8.
Page 31: Proceedure To Change Pcb
6. If necessary remove 4 screws on the top of the NEW switch and rotate the head to the correct orientation. Replace screws. 7. Remove gland nut from OLD switch and fit to the NEW switch. 8. Carefully fit blind hold in NEW switch over the plastic rivet. 9.
Page 32 3. Loosen the two screws and remove the options plug. 4. Using a 5mm nut driver remove the 4 D-connector nuts. 5. Using a 1 point Phillips screw-driver remove the 4 PCB retaining screws. Options Plug PCB Retaining Screws D-Connector Nuts 6.
Page 33: Set-Up Tactile Swtiches In Relation To Touch-Pad
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Page 34: Category Iii Safety Changes
Fax: (02) 67345 020 Email: mark@starlogixs.com.au A.C.N.: 095 551 198 September 2003 PRESSMATE CONTROLLER CHANGES TO SATISFY REQUIREMENTS OF AS4024.1:1996 CATEGORY III SAFETY The following modifications were carried out : 1) A PILZ PNOZ X2.1 safety relay was fitted to monitor both contacts of the door switch.
Page 35: Category Iii Wiring Diagram
CAT III SAFETY—WIRING DIAGRAM Page35...
Page 36 CRITICAL SAFETY COMPONENTS Substitution of other parts may void the safety compliance of this machine. Item/Circuit Manufacturer Type/Model Technical Conformity party Designation Data with marks of following approval standards Door Switch Omron D4DS-1AFS 400Vac 2A EN1088, CE and UL contact EN50047, rating –...
Page 37 STARLOGIXS PTY. LTD. 27 Young Street DEEPWATER. N.S.W. 2371 www.starlogixs.com Page37...