Instruction manual

35
MAINTENANCE AND TROUBLE SHOOTING
MAINTENANCE
Very little maintenance is required to keep the CES
stamping press controller in service. Periodically, we
suggest that you check the controller to make sure all
terminal screws and other connections are tight. Look
for signs of trouble, such as burn spots on the boards,
loose parts, worn out switches, pushbuttons or LEDs,
and any other abnormal condition. Correct any
deficiency found. If you have a question, call
DSI/Dynamatic at 1-800-548-2169, fax [phone] or
E-mail [e-mail].
The relays in the controller have a definite life, as do
potentiometers and switches. They are designed for
many years of average use; however, if your operation
calls for more frequent switching, we suggest you stock
replacements based on your type of operation. If you
need help in deciding which parts to stock, our Renewal
Parts Department will help you. A Master Parts List, with
recommended spare parts noted, is included on page 5-
2 for your specific controller. This is based on average
conditions.
TROUBLESHOOTING
The possibility of a component failure or other problem
always exists. This section of the manual is provided to
assist you in finding the fault and expediting the repair.
Our design philosophy is based on assembly
replacement. Trying to find a component failure on a
printed circuit board is not economical when you
compare the cost of labor and down time with the cost of
a replacement PCB assembly. Therefore, this manual
limits troubleshooting to the sub-assembly level. Always
check the obvious. Are the plug and switches in the
right position and the power ON?
CAUTION: Turn ac power to the Motor and controller
OFF before making tests, except when voltage
measurements are necessary. Only qualified
personnel acquainted with proper safety
procedures should service this equipment.
If the press drive will not run, we suggest you complete
the following tests to check out the controller operation.
With ac power removed, connect your multimeter set on
500 VAC range. Measure controller terminals 1L1, 1L2
and 1L3. With power OFF you should read zero volts.
Do not proceed until a zero reading is obtained. Then
pull fuses FU1, FU2 and FU3 (on the main PCB
assembly) and check for blown fuses. Replace if
required and re-install FU1, FU2 and FU3 in the
controller.
If a fuse blows on a cold start, there may be a short or
ground in the coil lead wires. Disconnect both leads at
the controller terminal strip and check the resistance of
the coil and resistance to ground. Check the drive
nameplate or contact the Field Service Department at
the factory for the coil resistance. Resistance to ground
should be about 20 megohms. When using a megger,
make sure both coil leads are disconnected from the
controller. Do not megger any portion of the controller.
If the drive is erratic or hunts, we suggest you check for
loose connections, proper brush seating, a good slip ring
surface and load pulsations that can reflect erratic load
to the controller. If no external cause is found, replace
the main PCB assembly.
Generator: The approximate generator coil resistance
for the 37 series of press drive mechanical units to 94
ohms and for the 49 series is 22 ohms.
There are two generator coils on each mechanical unit.
If one in ever lost, the other one may be connected in its
place. The connection diagram calls for both generator
coils to be connected to the terminal block in the control
enclosure. Therefore, the second coil leads should be
readily available should a failure occur.
INTERCHANGING ASSEMBLIES
The DMR assemblies (15-820-*) are similar to one
another. The EPROM’s are programmed differently and
the Absolute Position Resolver board on the DMR
assembly may be a 15-779-112 or a 15-779-113. It will
vary depending on whether the power to the resolver is
provided by Dynamatic (15-779-113) or is provided by
others (15-779-112). The only difference is the
presence or absence of the W7 jumper on this board. If
Dynamatic is providing the power, it is required. If not, it
must be removed with this in mind one DMR assembly
may be used as a back up for more than one press.
When making any substitution of the DMR assembly, the
following items must be checked:
1. The contact that calls for either single stroke or
continuous running of the press must be closed to
cause the press to run continuous and open to
cause the press to run in single stroke. That way an
open wire or a poor contact connection will cause
the press to single stroke.
2. The EPROM located in the DMR assembly has
several parameters that are programmable. These
must be properly programmed before operating the
press after changing DMR’s. Therefore, before
removing the defective DMR, record all of the
variable parameters. It is advisable to record this
data when the press is first put into operation for,
depending on what the problem is in the defective
DMR, this data may be lost when the DMR first
becomes defective.
3. In the typical DMR the following parameters must be
programmed:
26 Maximum Speed
27 Line Voltage
28 Clutch Current