Maintenance
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 Timing | Items | Content |
Unscheduled maintenance | ① Outer cover of the equipments ② Touch screen | ① Clean the cover ② Clean the touch screen |
Daily maintenance | ① 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 maintenance | ① 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 Maintenance | ① 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 Content | Corresponding Errors |
1 | Finish counting | It 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 . |
2 | No material | The 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. |
3 | Emergency stop | The equipment will stop emergently when you press Emergency Stop Button. |
4 | Abnormal servo driver | The servo driver will be abnormal when the driver alarms.Check and maintenance the driver is neccessary . |
5 | Abnormal decoiler inverter | The decoiler inverter will be abnormal when the inverter alarms.Check and maintenance is neccessary. |
6 | Abnormal phase | It will alarm when the wires of three phases are misconnected or disconnected |
7 | The speed of press is to0 fast | It happens with wrong feeding angle or abnormal feeding start signal during feeder.Please refer it to feeding angle instructions for handling methods. |
8 | Motor of oil pump is overheated | The motor of oil pump may be misconnected or overloaded. |
9 | Lift motor is overheated | The lift motor may be misconnected or overloaded. |
For Stamping Press
Possible fault symptoms and repair methods
NO | Reason of Abnormality | Method of Troubleshooting |
01 | Press down Emergency Stop button. | Reset Emergency Stop button. |
02 | Abnormal pneumatic pressure | Check if pneumatic pressure is normal. |
03 | Abnormal hydraulic pressure | Check if hydraulic pressure is normal. |
04 | Abnormal photoelectric input | Clear obstacles in front of the photoelectric detector. |
05 | Abnormal twin-valve detector | Check electromagnetic valve of the clutch and relay to boost the clutch. |
06 | Abnormal overload | Check if overload detector is normal. |
07 | Abnormal misdeed A2 input | Check if misdeed A2 is normal. |
08 | Abnormal misdeed B2 input | Check if misdeed B2 is normal. |
09 | Abnormal misdeed A1 input | Check if misdeed A1 is normal. |
10 | Abnormal misdeed B1 input | Check if misdeed B1 is normal. |
11 | Abnormal relay shutoff to boost clutch | Check if the relay of the clutch is broken. |
12 | Abnormal relay start to boost clutch | Check if the relay to boost clutch is broken. |
13 | Abnormal phases A, B of decoder | Check if phases A, B of decoder is normal and any broken wire. |
14 | Abnormal phase Z of decoder | Check if phase Z of decoder is normal and any broken wire. |
15 | Broken over-run limit switch | Check if over-run limit switch is normal and any broken wire. |
16 | Memory 1 damaged | Change the main board. |
17 | Memory 2 damaged | Change the main board. |
18 | Abnormal CPU 1 | Change the main board. |
19 | Abnormal CPU 2 | Check 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. |
20 | Abnormal maximum brake angle | Change the lining of the brake or enlarge the maximum brake angle (SE-4). |
21 | Exceed maximum start-up interval;Abnormal phases A, B of decoder | Check if the maximum start-up interval (SE-2) is set too little and if phases A, B of decoder are normal. |
22 | Safety interlock limit switch damaged | Check if the safety interlock limit switch is normal and any broken wire. |
23 | Abnormal over-run | Check if the over-run limit switch and decoder are normal. |
24 | Abnormal clutch motion | Check if decoder and relay to boost clutch are normal. |
25 | Abnormal pass-thru detector input | Check if material is stuck and if the pass-thru detector is normal. |
26 | Abnormal multi-sectional change-over switch | Check if operation mode of the multi-sectional change-over switch is normal. |
27 | Abnormal over-run (slip) | Calibrate the brake sliding angle of each velocity. |
28 | Slide adjustment | Reset the slide adjustment switch. |
29 | Abnormal Q.D.C.S operation | Check Q.D.C.S switch and pressure detector switch. |
30 | Abnormal electric grease detector | Check if the electric grease motor and the distribution valve are normal. |
31 | Abnormal grease volume | Check if grease for motor is sufficient. |
32 | Electric grease motor overload | Check if electric grease motor and lover relay are normal. |
NO | Reason of Abnormality | Method of Troubleshooting |
01 | Press down Emergency Stop button. | Reset Emergency Stop button. |
02 | Abnormal pneumatic pressure | Check if pneumatic pressure is normal. |
03 | Abnormal hydraulic pressure | Check if hydraulic pressure is normal. |
04 | Abnormal photoelectric input | Clear obstacles in front of the photoelectric detector. |
05 | Abnormal twin-valve detector | Check electromagnetic valve of the clutch and relay to boost the clutch. |
06 | Abnormal overload | Check if overload detector is normal. |
07 | Abnormal misdeed A2 input | Check if misdeed A2 is normal. |
08 | Abnormal misdeed B2 input | Check if misdeed B2 is normal. |
09 | Abnormal misdeed A1 input | Check if misdeed A1 is normal. |
10 | Abnormal misdeed B1 input | Check if misdeed B1 is normal. |
11 | Abnormal relay shutoff to boost clutch | Check if the relay of the clutch is broken. |
12 | Abnormal relay start to boost clutch | Check if the relay to boost clutch is broken. |
13 | Abnormal phases A, B of decoder | Check if phases A, B of decoder is normal and any broken wire. |
14 | Abnormal phase Z of decoder | Check if phase Z of decoder is normal and any broken wire. |
15 | Broken over-run limit switch | Check if over-run limit switch is normal and any broken wire. |
16 | Memory 1 damaged | Change the main board. |
17 | Memory 2 damaged | Change the main board. |
18 | Abnormal CPU 1 | Change the main board. |
19 | Abnormal CPU 2 | Check 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. |
20 | Abnormal maximum brake angle | Change the lining of the brake or enlarge the maximum brake angle (SE-4). |
21 | Exceed maximum start-up interval;Abnormal phases A, B of decoder | Check if the maximum start-up interval (SE-2) is set too little and if phases A, B of decoder are normal. |
22 | Safety interlock limit switch damaged | Check if the safety interlock limit switch is normal and any broken wire. |
23 | Abnormal over-run | Check if the over-run limit switch and decoder are normal. |
24 | Abnormal clutch motion | Check if decoder and relay to boost clutch are normal. |
25 | Abnormal pass-thru detector input | Check if material is stuck and if the pass-thru detector is normal. |
26 | Abnormal multi-sectional change-over switch | Check if operation mode of the multi-sectional change-over switch is normal. |
27 | Abnormal over-run (slip) | Calibrate the brake sliding angle of each velocity. |
28 | Slide adjustment | Reset the slide adjustment switch. |
29 | Abnormal Q.D.C.S operation | Check Q.D.C.S switch and pressure detector switch. |
30 | Abnormal electric grease detector | Check if the electric grease motor and the distribution valve are normal. |
31 | Abnormal grease volume | Check if grease for motor is sufficient. |
32 | Electric grease motor overload | Check if electric grease motor and lover relay are normal. |