TROUBLESHOOTING

This manual is for helping you through the possible malfunction solving process.

Because most common cause of troubles are wrong kind of machine settings, in chapter one we shortly go trough the machine settings and operation of machine.

1

Ecomat EASY / Girotec WRS

Ecomat EASY H / Girotec WRS H

V2.0

TROUBLESHOOTINGPage

CHAPTER 1-Wrapping settings 3-11

-Wrapping modes 3

-Bottom and Top layers 4

-Photocell delay 5

-Film tension 6

-Overlapping 7

-Turntable speed 8

-Film carriage speed 9

-Photocell settings 10

-Load stabilizer selection 11

-Quick operation quide 12

2

Page

CHAPTER 2-Troubleshooting 13-29

-Before starting toubleshooting /safety aspects 13

-Empty display, no movement 14

-Horizontal bars in display, no movem. 15

-Normal display, no movement 16

-Other problems 17-25

-Troubleshooting instructions 26-29

-Carriage UP manual drive 26

-MPU-controlled leds 27

-Power Board leds 28

-Manuals available in internet 29

List of EnclosuresList of Enclosures 3030

Wra

ppin

g m

odes

Select the wrapping mode by turning selection switch

WR

APPIN

G SETTIN

GS

3

WR

APPIN

G SETTIN

GS

Botto

m la

yers

& T

op L

ayer

s

Select the number of bottom and top layers using arrow buttons

4

WR

APPIN

G SETTIN

GSPh

otoc

ell d

elay

Photocell delay value, sets up the time how long film carriage still goes upwards after loosing the pallet upper edge.

You can select the number between 1-9

1 = minimum delay

9 = maximum delay

5

A2

Adjust the film tension by turning the adjusting nut.

Clockwise = Increase tensionAnticlockwise = Decrease tensionFi

lm te

nsio

nW

RA

PPING

SETTING

S

6

Ove

rlapp

ing

OVERLAPPING DEGREE

-No Overlapping55

-No Overlapping105

12028 %510

26060 %110

a = [mm]

OVERLAPPING DEGREE

CARRIAGE SPEED

TURNTABLE SPEED

aa

Measured with Mima Lite film, EUR-pallet (800*1200), medium film tension

WR

APPIN

G SETTIN

GS

7

MAX overlapping

(Free space between film 180mm)

(Free space between films 35mm)

Select the turntable speed

0 = minimum speed10 = maximum speed

Turn

tabl

e sp

eed

WR

APPIN

G SETTIN

GS

8

Film

Car

riage

spe

ed

Select the film carriage speed

0 = minimum speed10 = maximum speed

WR

APPIN

G SETTIN

GS

9

Technical Data

Sensing Range = 2000mm

Blind Range = ≤75mm

Operational Voltage = 12VDC...240VDC ± 10 %

= 24VAC...240VAC ± 10 %

Power consumption = 3VA

Correct Potentiometer Settings:MODE = D.ON (Dark ON)

SENSITIVITY (SENS) = MAX - 10º (nearly MAX)

Led indicatorsYELLOW = Output Status

(ON when no object in range)

RED = Fault indicator

Weak signal

OBJECT

MO

DE

D.O

NL.O

N

SENS

MIN

MA

X

Phot

ocel

l set

tings

WR

APPIN

G SETTIN

GS

10

11

WR

APPIN

G SETTIN

GSLo

ad S

tabi

lizer

sel

ectio

n

Activate the Load Stabilizer by turning the selection switch from OFF to ON

(Only in Ecomat Easy H / Girotec WRS H)

Wra

ppin

g R

eady

Splash proof- mode

MA

CH

INE

ST

OPS

Double wrapping

Mount the film roll

QU

ICK

OPER

ATIO

N G

UID

E

Single wrapping

Cut the film

Cut the film

Wra

ppin

g R

eady

Place the top-sheet

Wra

ppin

g R

eady

Cut the film

12

No movement,

Nothing in displayPage 14

No movement,

Horizontal bars on display

Page 15

No movement,

Normal displayPage 16

Other problems Page 17-25

Before any service action, make sure that main switch is turned to OFF-position.

When working with electrical components, work must be done by professional electrician!

Couple important safety aspects before starting troubleshooting: TR

OU

BLESH

OO

TING

Befo

re s

tarti

ng tr

oubl

esho

otin

g

13

No movement, nothing on display

1. Power plug is not connected Connect the plug

2. Main switch is on 0 position Switch on the power

3. Glass-tube fuse on power board can be blowed Replace the fuse (see page 28)

4. Fuse F1 can be blowed Replace the fuse

5. Glass-tube fuse no.2 on MPU-controller can be blowed Replace the fuse (see page 27)

6. Connector 3 on MPU-controller can be disconnected Connect the plug (see page 27)

7. Connector 4 on MPU-controller can be disconnected Connect the plug (see page 27)

8. Connector 7 on Power Board can be disconnected Connect the plug (see page 28)

TRO

UB

LESHO

OTIN

G

14

No

mov

emen

t, no

thin

g on

dis

play

No movement, Horizontal bars on display

1. Emergency Stop button can be activated Unlock the button

2. Film loading door can be open Close the door

3. Automatic fuses AF2-AF3 can be tripped Un-trip the fuse/s

4. Connector 2 on MPU-controller can be disconnected Connect the plug (See page 27)

5. Glass-tube fuse no.1 on MPU-controller can be blowed Replace the fuse (See page 27)

TRO

UB

LESHO

OTIN

G

15

No

mov

emen

t, ho

rizon

tal b

ars

on d

ispl

ay

No movement, Normal display

1. Machine is not in home position Press the reset button

2. Carriage cant move to its home position See instructions from page 26

3. Carriage down limit switch can be damaged or disconnected Check the switch, connectors and cables

4. Turntable rotation V-belt or roller chain can be damaged Check and replace if necessary (see page 29)

5. Connector 5 on MPU-controller can be disconnected Connect the plug (see page 27)

6. Connector 6 on power board can be disconnected Connect the plug (see page 28)

7. Connector 8 on power board can be disconnected Connect the plug (see page 28)

TRO

UB

LESHO

OTIN

G

16

No

mov

emen

t, no

rmal

dis

play

After START, Turntable is running continously, film carriage does not rise at all,even there is high pallet on turntable

1. Table home proximity can be disconnect, damaged or have a bad alignment Check the proximity alignment and connections

2. Carriage up limit switch can be activated, disconnected or damaged Check the switch and connections

TRO

UB

LESHO

OTIN

G

4 mm

-X4

17

Oth

er p

robl

ems

After START, Machines makes selected numbers of layers (bottom+top) + 2 additional, and stops. Film carriage does not rise at all even there is high pallet on the turntable

1. Carriage lifting motor can be disconnected Check the cable and connectios

2. Carriage up limit switch can be disconnected or damaged Check the switch and connections

18

TRO

UB

LESHO

OTIN

GOth

er p

robl

ems

Machine works normally untill it has made the top layers After that machine stops. Carriage does not start to move down

1. Carriage down limit switch can be activated, disconnected or damaged Check the switch and connections

TRO

UB

LESHO

OTIN

G

19

Oth

er p

robl

ems

Machine works normally. When doing the film reel change, the carriage does not stop to correct position, it will go to its upmost position.

1. Film load position limit switch can be disconnected or damaged Check the switch and connections

TRO

UB

LESHO

OTIN

G

20

Oth

er p

robl

ems

While doing the wrapping, carriage always go to upper limiter and does not stop to the top of the pallet

1. Photocell settings or alignment can be wrong See instuctions from page 10

2. Photocell delay setting is not correct See instructions from page 5

3. Photocell can be disconnected or damaged Check the photocell, cables and connections

TRO

UB

LESHO

OTIN

G

21

Oth

er p

robl

ems

Correct alignment

Wrong alignment

TRO

UB

LESHO

OTIN

G

Carriage does not rise to top of the pallet, it only rises aprox. 150mm. Machine makes selected numbers of layers and stops.

1. Photocell settings are not correct See instuctions from page 10

22

Oth

er p

robl

ems

TRO

UB

LESHO

OTIN

G

Carriage always heavily overruns the top of the pallet, even the photocell-delay value is normal (3-5)

1. Photocell settings or alignment can be wrong See instructions from page 10

23

Oth

er p

robl

ems

Correct alignment

Wrong alignment

TRO

UB

LESHO

OTIN

G

Film is breaking /

Pallet is not staying on turntable

1. Film tension setting is too high Loosen the film tension (see page 6)

24

Oth

er p

robl

ems

TRO

UB

LESHO

OTIN

G

25

Oth

er p

robl

ems

Carriage cant go to its reset position (downmost position)

1. Something inside the mast is blocking the way See instructions from page 25

In case there is obstacle dropped inside the mast

Carriage tryes to go to home position but cant reach the limiter

(after couple seconds of trying, OLF- fault message can appear to inverter U2 display)

Reseting of machine is not possible Machine does not start

Doing the film reel change is not possible

You cant remove the obstacle, because it is under the carriage

Car

riage

UP

man

ual d

rive

Manual drive of U2:Connect LI2 and +15V together

using isolated jumping wire

Carriage starts to move upwards

Keep jumping wire connected untill carriage is up enough that you can remove the obstacle

Reset the machine

LI1 LI2 LI3 LI4 +15V

26

TRO

UB

LESHO

OTIN

G IN

STRU

CTIO

NS

MPU

-con

trolle

r

27

TRO

UB

LESHO

OTIN

G IN

STRU

CTIO

NS

Note:

Leds related to Load Stabilizer (1, 10, 13 and 14) are not used in Ecomat Easy

FUSE 2

FUSE 1

1.

2.

3.

4.

5.

28

Pow

er B

oard

TRO

UB

LESHO

OTIN

G IN

STRU

CTIO

NS

Power Board / Ecomat Easy

Power Board / Ecomat Easy H

http://document.mimaitw.com/doha/index.asp

(or www.mimaitw.com machines machine documents)(Registration required for these pages)

Sign in, and you will get the username and password via email.

Usefull manual for using together with troubleshooting:

Maintenance instructions V2.0Contains instructions like:

-Removing the turn table disc

-Lowering the mast

-Tensioning of V-Belt & Roller chains

-Etc.

Please find our document pages from internet.

Man

uals

ava

ilabl

e in

inte

rnet

29

TRO

UB

LESHO

OTIN

G IN

STRU

CTIO

NS

List of enclosures

Inverter parameters, Turntable rotation U1

Inverter parameters, Carriage movement U2

Inverter fault messages, ATV11 (U1+U2)

31

PARAMETER LIST

Item 62001871, ATV11HU18M2E, 0,75kW

Applications:

WR 650 turntable rotationWRS 680 turntable rotationWRX 690 turntable rotation

Ecomat Easy/Girotec WRS turntable rotationEcomat Easy H/Girotec WRS H turntable rotation Ecomat Plus / Ecomat Plus H turntable rotation

Not default settings :

ATV11/0.75kW Turn table

rotation

1 ACC 10 2 dEC 0,5 3 LSP 12 4 HSP 50 Hz 5 ItH 3,8 6 SP3 12 FUn 7 rrS nO 8 rP2 LI LI2 9 AC2 10

10 dE2 5

Return to factory setting for ATV11

1 FUn FCS rEC 2 FUn FCS InI

ENT key must be held down for 2 sec.

ATV 11/0.75kWfor CAROUSEL

page 1

ATV 11/0.75kWfor CAROUSEL

page 2

PARAMETER LIST

Item 62001872, ATV11HU05M2E , 0,18kW

Applications:

WRS 680 film carriage up/downWRX 690 film carriage up/down

Ecomat Easy/Girotec WRS film carriage up/downEcomat Easy H/Girotec WRS H film carriage up/down Ecomat Plus / Ecomat Plus H film carriage up/down

Not default settings

ATV11/0.18kW CarriageUp/Down

1 ACC 1,0 2 d C 0,1 3 LSP 21 4 HSP 60 Hz 5 ItH 0,7

Return to factory setting for ATV11

1 FUn FCS rEC 2 FUn FCS InI

ENT key must be held down for 2 sec.

ATV 11/0.18 kWfor CARRIAGE

24

EN

GL

ISH

Faults - Causes - RemediesStarter does not start, no fault displayed• Check that the run command input(s) have been actuated in accordance with the chosen control mode.• When the drive is switched on, at a manual fault reset, or after a stop command, the motor can only be

powered once the "forward" and "reverse" commands have been reset. If they have not been reset, the drive will display "rdY" or “nSt” but will not start.

Faults displayedThe cause of the fault must be removed before resetting. Faults SOF, OHF, OLF, OSF, ObF, and PHF can be reset via a logic input if this function has been configured.Faults OHF, OLF, OSF, ObF, and PHF can be reset via the automatic restart function, if this function has beenconfigured. All faults can be reset by switching the drive off then on again.

Fault Remedy

overcurrent• Ramp too short, check the settings.• Inertia or load too high, check the size of the motor/drive/load.• Mechanical locking, check the state of the mechanism.

motor short-circuit, insulation fault

• Check the cables connecting the drive to the motor, and the insulation of the motor.

internal fault• Check the environment (electromagnetic compatibility).• Replace the drive.

configuration fault• Return to factory settings or call up the backup configuration, if it is valid. See

parameter FCS in the FUn menu.

overspeed• Instability, check the motor, gain and stability parameters.• Driving load too high, add a braking module and resistor and check the size of the

motor / drive / load.

drive overload• Check the motor load, the drive ventilation and the environment. Wait for the drive to

cool before restarting.

motor overload• Check the setting of the motor thermal protection, check the motor load. Wait for the

drive to cool before restarting.

overvoltage • Check the line voltage.

overvoltage during deceleration

• Braking too harsh or driving load. Increase the deceleration time, add a braking resistor if necessary and activate the brA function if it is compatible with the application.

line phase failure This protection only operates with the drive on load.• Check the power connection and the fuses.• Reset.• Check the line supply / drive compatibility.• If there is an unbalanced load, inhibit the fault via IPL = nO (FUn menu).

undervoltage• Check the voltage and the voltage parameter.

charging circuit• Replace the drive.