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Maintenance

Machine maintenance is the means by which mechanical assets in a facility are kept in working order. Machinery maintenance involves regular servicing of equipment, routine checks, repair work, and replacement of worn or nonfunctional parts.

Professional expertise of the maintenance personnel

The purpose of this section is to give maintenance personnel a reference concerning possible fault symptoms and troubleshooting so that they can repair faults, reduce down time and maintain a smooth and safe operation and use of the machine when faults occur rendering it inoperable. Please do not attempt to repair faults other than the possible faults described in this section. In this case, the customer should immediately be notified, so that repairs can be carried out and the safety of personnel is protected. Due to the consideration for the personal safety of maintenance personnel and in order to extend the life span of the machine,Surui make the following demands for professional expertise and qualifications of the maintenance personnel.

Maintenance List

For Coil feed equipment


1)  Maintenance list.


Maintenance TimingItemsContent
Unscheduled maintenance① Outer cover of the equipments
② Touch screen
① Clean the cover
② Clean the touch screen
Daily maintenance① the photoelectric sensors
② the emergency stop button
③ all the switches
① Check the photoelectric sensors
② Check the emergency stop button
③ Check all the switches 
Weekly maintenance① Width block roll on decoiler
② Gears of straightener feeder
③ Width guiding rolls at the entrance
④ Expansion mandrel of decoiler
① Check the grease on the block roll and lubricate it if neccessary.
② Check and lubricate the gears.
③ Check and lubricate the rolls.
④ Check and lubricate the expansion mandrel. 
Monthly Maintenance① Driving chain of decoiler
② Tension of belt and gasholder of the straightener feeder
③ Gadholder
④ Driving chain of pressing rolls of decoiler
⑤ Bearing of decoiler
⑥ Switches of photoelectric sensors 
① Lubricate the chain and check its tension
② Check the condition and tension of the belt
③ Exhaust water from the gasholder
④ Lubricate the chain and check its tension.
⑤ Lubricate the bearing of decoiler
⑥ Fasten the screws and clean them

     

2) Error code display and handling methods:

The errors can be diagnosed through the error codes displayed on touch panel.The error codes help solve corresponding errors of the equipment.


No.Displayed ContentCorresponding Errors
1Finish countingIt will show up when finish required feeding times which means the feeder will stop running at that time.To make it run again,bigger datas should be set or clear previous datas and reset it .
2No materialThe equipment will stop running when the material run out which will be detected by the sensor.To make it run again,loading another material is neccessary.
3Emergency stopThe equipment will stop emergently when you press Emergency Stop Button.
4Abnormal servo driverThe servo driver will be abnormal when the driver alarms.Check and maintenance the driver is neccessary .
5Abnormal decoiler inverterThe decoiler inverter will be abnormal when the inverter alarms.Check and maintenance is neccessary.
6Abnormal phaseIt will alarm when the wires of three phases are misconnected or disconnected
7The speed of press is to0 fastIt happens with wrong feeding angle or abnormal feeding start signal during feeder.Please refer it to feeding angle instructions for handling methods.
8Motor of oil pump is overheatedThe motor of oil pump may be misconnected or overloaded.
9Lift motor is overheatedThe lift motor may be misconnected or overloaded.


For Stamping Press
Possible fault symptoms and repair methods



NOReason of AbnormalityMethod of Troubleshooting
01Press down Emergency Stop button.Reset Emergency Stop button.
02Abnormal pneumatic pressureCheck if pneumatic pressure is normal.
03Abnormal hydraulic pressureCheck if hydraulic pressure is normal.
04Abnormal photoelectric inputClear obstacles in front of the photoelectric detector.
05Abnormal twin-valve detectorCheck electromagnetic valve of the clutch and relay to boost the clutch.
06Abnormal overloadCheck if overload detector is normal.
07Abnormal misdeed A2 inputCheck if misdeed A2 is normal.
08Abnormal misdeed B2 inputCheck if misdeed B2 is normal.
09Abnormal misdeed A1 inputCheck if misdeed A1 is normal.
10Abnormal misdeed B1 inputCheck if misdeed B1 is normal.
11Abnormal relay shutoff to boost clutchCheck if the relay of the clutch is broken.
12Abnormal relay start to boost clutchCheck if the relay to boost clutch is broken.
13Abnormal phases A, B of decoderCheck if phases A, B of decoder is normal and any broken wire.
14Abnormal phase Z of decoderCheck if phase Z of decoder is normal and any broken wire.
15Broken over-run limit switchCheck if over-run limit switch is normal and any broken wire.
16Memory 1 damagedChange the main board.
17Memory 2 damagedChange the main board.
18Abnormal CPU 1Change the main board.
19Abnormal CPU 2Check if the wire connecting the panel and the main board is broken. If not, change the panel. If it still fails, change the main board.
20Abnormal maximum brake angleChange the lining of the brake or enlarge the maximum brake angle (SE-4).
21Exceed maximum start-up interval;Abnormal phases A, B of decoderCheck if the maximum start-up interval (SE-2) is set too little and if phases A, B of decoder are normal.
22Safety interlock limit switch damagedCheck if the safety interlock limit switch is normal and any broken wire.
23Abnormal over-runCheck if the over-run limit switch and decoder are normal.
24Abnormal clutch motionCheck if decoder and relay to boost clutch are normal.
25Abnormal pass-thru detector inputCheck if material is stuck and if the pass-thru detector is normal.
26Abnormal multi-sectional change-over switchCheck if operation mode of the multi-sectional change-over switch is normal.
27Abnormal over-run (slip)Calibrate the brake sliding angle of each velocity.
28Slide adjustmentReset the slide adjustment switch.
29Abnormal Q.D.C.S operationCheck Q.D.C.S switch and pressure detector switch.
30Abnormal electric grease detectorCheck if the electric grease motor and the distribution valve are normal.
31Abnormal grease volumeCheck if grease for motor is sufficient.
32Electric grease motor overloadCheck if electric grease motor and lover relay are normal.

 

NOReason of AbnormalityMethod of Troubleshooting
01Press down Emergency Stop button.Reset Emergency Stop button.
02Abnormal pneumatic pressureCheck if pneumatic pressure is normal.
03Abnormal hydraulic pressureCheck if hydraulic pressure is normal.
04Abnormal photoelectric inputClear obstacles in front of the photoelectric detector.
05Abnormal twin-valve detectorCheck electromagnetic valve of the clutch and relay to boost the clutch.
06Abnormal overloadCheck if overload detector is normal.
07Abnormal misdeed A2 inputCheck if misdeed A2 is normal.
08Abnormal misdeed B2 inputCheck if misdeed B2 is normal.
09Abnormal misdeed A1 inputCheck if misdeed A1 is normal.
10Abnormal misdeed B1 inputCheck if misdeed B1 is normal.
11Abnormal relay shutoff to boost clutchCheck if the relay of the clutch is broken.
12Abnormal relay start to boost clutchCheck if the relay to boost clutch is broken.
13Abnormal phases A, B of decoderCheck if phases A, B of decoder is normal and any broken wire.
14Abnormal phase Z of decoderCheck if phase Z of decoder is normal and any broken wire.
15Broken over-run limit switchCheck if over-run limit switch is normal and any broken wire.
16Memory 1 damagedChange the main board.
17Memory 2 damagedChange the main board.
18Abnormal CPU 1Change the main board.
19Abnormal CPU 2Check if the wire connecting the panel and the main board is broken. If not, change the panel. If it still fails, change the main board.
20Abnormal maximum brake angleChange the lining of the brake or enlarge the maximum brake angle (SE-4).
21Exceed maximum start-up interval;Abnormal phases A, B of decoderCheck if the maximum start-up interval (SE-2) is set too little and if phases A, B of decoder are normal.
22Safety interlock limit switch damagedCheck if the safety interlock limit switch is normal and any broken wire.
23Abnormal over-runCheck if the over-run limit switch and decoder are normal.
24Abnormal clutch motionCheck if decoder and relay to boost clutch are normal.
25Abnormal pass-thru detector inputCheck if material is stuck and if the pass-thru detector is normal.
26Abnormal multi-sectional change-over switchCheck if operation mode of the multi-sectional change-over switch is normal.
27Abnormal over-run (slip)Calibrate the brake sliding angle of each velocity.
28Slide adjustmentReset the slide adjustment switch.
29Abnormal Q.D.C.S operationCheck Q.D.C.S switch and pressure detector switch.
30Abnormal electric grease detectorCheck if the electric grease motor and the distribution valve are normal.
31Abnormal grease volumeCheck if grease for motor is sufficient.
32Electric grease motor overloadCheck if electric grease motor and lover relay are normal.