Signode bxt2 ошибки

BXT 2

BXT 2-19

23

12.

12.1.

User Errors

Faults in operating sequence «User errors» are no indication of a tool related defect (except defective

switch). The tool calls the users attention to faulty operation.

During Tensioning:

Nr.

Fault in operating sequence

A11

Tension with rocker lever pulled

A12

Rocker lever is pulled during

tensioning

In Automode:

A13

Rocker lever, tensioning

button or welding button is

activated during tensioning

A14

Tension button is pressed to many

times

A15

Tension time out.

Adjusted tension force could not

be reached

A16

Tensioning with cam switch activated

Welding:

Fault in operating sequence

Nr.

A20

Try to weld without tensioning first

A21

Try to weld with rocker lever pulled

A22

Interrupted welding process by pulling

rocker lever

A23

Interrupted cooling by pulling rocker

lever

A24

Welding time out

cam position could not be detected

(Micro switch Pos. 103)

Failure Codes A22 and A23 are counted by the system. The number of failures is displayed when the

data-cable is used (chapter 5.3)

Error message „empty battery»:

The error code „empty battery» depends on the mode which is currently in use.

Nr.

Battery empty

During welding/tensioning

(Motor end phase switches off)

Into Run Mode

(within 30s)

Into Idle Mode

(within 5min)

Into Sleep Mode (more than 5

min after last usage)

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System reaction

Tensioning is not executed

Tensioning is

interrupted

Tensioning is

interrupted

Tensioning is no longer

executed

Tensioning is

interrupted

Tensioning is not executed

System reaction

Welding is not executed

Welding is not executed

Welding process is completed

but the seal is invalid.

Cooling is interrupted

Welding is interrupted

System reaction

1.

welding/tensioning process is interrupted

2.

Error code E23 is displayed (see chapter 12.4)

1.

4 beep sounds and segment display is blinking

2.

Tool switches off

1.

4 beep sounds and segment display is blinking

2.

Tool switches off

1.

Tool switches off

Error message

Rectification

Beep sound

Release rocker lever

None

Tensioning again

None

Start process again

Execute welding or pull

Beep sound

rocker lever

„E»blinking,

intermittent beep for

Start process again

5s

Beep sound

Pull rocker lever

Error message

Rectification

Beep sound

Press tension button

before welding

Beep sound

Release rocker lever

„E»blinking,

Repeat the strapping,

Intermittent beep for 5s

Seal is not correct

„E»blinking,

Repeat the strapping,

Intermittent beep for 5s

Seal is not correct

„E»blinking,

Repeat the strapping,

Intermittent beep for 5s

Seal is not correct

1
BXT 2
BXT 2-19
Maintenance
Manual
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2
BXT 2
BXT 2-19
Content:
1.
Preface .................................................................................................................................................................. 3
2.
Basic Innovations ................................................................................................................................................... 3
3.
Tool Design............................................................................................................................................................ 4
3.1.
Housing/electrical components: .................................................................................................................... 4
3.2.
Welding unit .................................................................................................................................................. 5
3.3.
Rocker lever and reset .................................................................................................................................. 6
3.4.
Rocker and toothed plate .............................................................................................................................. 6
3.5.
Tensioning gear ............................................................................................................................................ 7
3.6.
Side cover with strap guides ......................................................................................................................... 7
4.
Wear parts ............................................................................................................................................................. 7
5.
Diagnostic aids ...................................................................................................................................................... 8
5.1.
Cycle counter ................................................................................................................................................ 8
5.2.
Problem reports............................................................................................................................................. 8
5.3.
Service Interface ......................................................................................................................................... 11
6.
Tool reset ............................................................................................................................................................. 14
7.
Disassembling ..................................................................................................................................................... 15
7.1.
Housing/electrical components ................................................................................................................... 15
7.2.
Welding unit ................................................................................................................................................ 16
7.3.
Rocker lever and reset ................................................................................................................................ 17
7.4.
Tensioning gear .......................................................................................................................................... 18
8.
Assembly ............................................................................................................................................................. 18
9.
Adjustments ......................................................................................................................................................... 19
9.1.
Adjustment of the welding reset .................................................................................................................. 19
10.
Lubricating chart .............................................................................................................................................. 20
11.
Wiring .............................................................................................................................................................. 21
12.
Error Code List ................................................................................................................................................ 23
12.1.
User Errors .................................................................................................................................................. 23
12.2.
Device Error control system ........................................................................................................................ 24
12.3.
Device error battery..................................................................................................................................... 25
12.4.
Device Error Drive ....................................................................................................................................... 26
13.
Wiring diagramm: ............................................................................................................................................ 28
14.
Explosion drawing ........................................................................................................................................... 29
15.
Product information ......................................................................................................................................... 33
16.
Contact ............................................................................................................................................................ 33
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BXT 2
BXT 2-19
1. Preface
The objective of this maintenance manual is to familiarize a skilled technician with the tools particular
features and enable him to repair and maintain it independently.
Current issues of the operating instructions and the concerning product information sheets are essential
elements of this manual and have to be checked as well.
2. Basic Innovations
Following new technical features have been implemented in this tool generation:
Innovation
Lithium-Ion battery technologie
Brushles DC Motor
Automatic welding
Rocker with floating tooth plate
Revised Tension release pawl
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Advantage
•
•
•
•
•
•
•
•
•
•
Increased energie density
negligible self discharging
no memory effect
Higher Efficiency
Wear-free
Constant high sealing quality
Ergonomic benefits
Increased productivity
Improved characteristics in tensioning
Improved handling
4
BXT 2
BXT 2-19
3. Tool Design
3.1. Housing/electrical components:
The housing is carried out in 3 pieces. All processes are controlled and monitored by the Printed circuit
board (pos. 198). The PCB interacts via the signal cable (pos. 202) with the motor power electronics (pos.
212). The power electronics is required to run the brushless motor. You can find a schematic wiring
diagram in chapter 13.
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BXT 2
BXT 2-19
3.2. Welding unit
The unit is lowering automatically when the welding process is started. Depending on the direction of
motor rotation (freewheels) this is taking place as follows:
1. The cam ring (pos 109) is turning towards the switching cam (pos. 140, 143).
2. This forces the switching cam to go up and to push the welding unit downwards.
3. The eccentric axe (pos.155) is driving the welding shoe via needle bearing (pos.157)
The position of the cam ring needs to be controlled by the PCB. The required information about its
current position (reference point) is provided by the micro switch (pos. 103).
1.
2.
3.
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BXT 2
BXT 2-19
3.3. Rocker lever and reset
The Blocking Pawl (pos. 65) prevents the tension gear from turning backwards during tensioning. After
strapping has taken place, the rocker lever (pos.89) is pulled, the pawl and therewith the tension is
released. The reset cam (pos. 72) brings the welding unit back to its initial position.
The Micro switch (Part of pos. 103) scans the position of the rocker lever. When the lever is pulled, the
PCB does not allow initiating any function.
3.4. Rocker and toothed plate
0-0.1mm
6
46
44
53
The tooth plate (Pos. 53) is not tightened onto the rocker.
This principle has the advantage that regardless the strap
thickness the contact pressure is always consistent. The
gap between tooth plate and the tension wheel (Pos. 46) is
ensured by a bedstop on the cam disk, (Pos.44) notice the
arrow.
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BXT 2
BXT 2-19
3.5. Tensioning gear
There is a free wheel integrated into the bevel gear pinion (Pos. 132). Provided the appropriate turning
direction the free wheel delivers the torque to the 2 stage planetary gear and the tension wheel. To
loose the tension the ring gear (Pos.19) is released by the pawl axle (Pos. 59). See also chapter 3.3).
3.6. Side cover with strap guides
The strap guide (Pos. 179) is integrated into the
side cover. To set up the required strap width
the shims (Pos. 177, 178, 181) have to be
added or removed.
4. Wear parts
Tension wheel, toothed plate and knife are wear parts. In order to reduce costs for the enduser these
parts can easily be replaced by themselves. The operating instructions provide the necessary information
in chapter 7.1 – 7.3.
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BXT 2
BXT 2-19
5. Diagnostic aids
Service technicians are supported in fault finding by the tools firmware. Faults in operating sequence or
system errors are reported by acoustic signals or via the segment display by failure codes. Additionaly a
service interface allows detailed diagnosis with the help of your computer.
5.1. Cycle counter
To readout the number of strapping’s the tool has already accomplished, proceed as follows:
1. Press and hold the “F” button on the panel
2. Pull the Rocker lever
The number of cycles is indicated in the segment display:
- - 1 6 8 3 5 - - = 16‘835 Cycles
5.2. Problem reports
The reporting of events is structured as follows:
Event
Function counter (F-Numbers)
The function counter are counting
certain events during the tool
operation for service purpose. The
user is not affected. Counter
readings are displayed in the
service interface
User Errors (A-Numbers)
The A-Numbers identifie errors in
operating sequence. They are not
an indication of a tool related
defect (except defective switch).
The tool calls the users attention
to faulty operation.
Device Errors (E-Numbers)
These errors are normally not
caused by faulty operation. One or
more parameters are beyond their
valid range. When they occur
repeatedly, the tool needs
repairing.
Storage in the service interface
under „FUNCTION COUNTER“
Storage in the service interface
under „USER ABORTS“
Storage in the service interface
under „ERRORS“
Userinteraction
Userinteraction
You will find a complete list with the failure codes and remedy in chapter 12 “Error codes”.
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9
BXT 2
BXT 2-19
Example of the event readout using the service interface:
As per description above, tool faults are displayed as E-numbers. Following diagram shall help to simplify
the fault finding:
Abort, the tool is in
standby mode again
Stop, the tool shuts down
E10
E11
E23
Replace
battery
Replace
battery
E34
E12
E13
Release
keypad
Pull Rocker
lever
Replace
keypad
Replace
Microswitch
(Pos.103)
Replace printed circuit board (Pos. 198)
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10
Abort, the tool is in standby mode again
E35
E33
Replace the
battery
Let the tool
cool down
E21
E22
Clean mech.
components
E37
E38
E30
Check wirings
Motor to Power
electronics
Abort, the tool shuts down
E31
E32
E36
Check wiring
PCB to power
electronics.
Replace the
motor
E25
E20
E26
Plugg battery
properly
Replace
battery
Plugg battery
properly
Replace
battery
Check wirings
power electronic
to contact plate
Replace
battery
Check wirings
power electronic
to contact plate
Check wiring
PCB to power
electronics.
Check wirings
power electronic
to contact plate
Replace printed circuit board (Pos198.)
Replace power electronics (Pos. 212)
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E24
11
BXT 2
BXT 2-19
5.3. Service Interface
As optional accessory a data cable (Art. Nr: 1821.163.153). for detailed fault diagnosis is available. Using
this data cable allows to readout the most important tool parameters on your computer and helps
debugging. Hyperterminal is required as user interface. Hyper terminal is already installed on every XPComputer. For other operating systems without Hyper terminal get into contact with Orgapack.
To set up Hyperterminal:
1. Start Programm Path: All Programmes accessoriesCommunicationHyper Terminal
2. Type in a name for the
connection on which the set up
will be saved. E.g. Debugger.
Confirm by clicking „OK“ .
3. The window „Connect to“ will open. Chose Comm port,
COM1 in most cases. Confirm by clicking„OK“.
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BXT 2
BXT 2-19
4. Window „COM1 Properties“ will open. Make settings as
enclosed in the illustration. Confirm by clicking „OK“.
5. „Debugger“ Hyper Terminal will open. Cut the connection by clicking on Icon (5).
5
6
6. File/Properties/ASCII-Setup  . Check the box „Echo typed characters locally.
7. Save the settings (File/Save) and close Hyper Terminal.
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13
BXT 2
BXT 2-19
Establish connection:
1. Plug the data cable to the serial interface(RS 232) of your computer.
Plug socket
Should your PC or Laptop not be equiped with a serial interface, you
for data cable
have to purchase a virtual serial interface and connect via USB. Please
follow the instructions of the interface manufacturer.
2. Remove the battery from the tool. Remove the screws of the
motorhousing, untighten it and plug the data cable to data plug socket.
3. Start Hyper Terminal (saved configuration)
4. Insert the battery in the tool. The start screen will now be displayed (See
illustration). All Program steps (e.g. when tension button is pressed) can
now be monitored.
Potential failures in operating sequence are
displayed in plain text.
5. Following options are available by pressing key
2-4:
• 2  Device History
• 3  adjustable Cycle counter B e.g. to
reset after maintenance work.
• 4  Reset of Device History,
recommended after maintenance work.
By pressing key 1 the start screen is displayed
again.
6. Remove the battery before unplugging the tool.
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14
BXT 2
BXT 2-19
6. Tool reset
In some rare cases, it may occur that it is not possible to bring the welding unit back to its initial position
Also the rocker lever is blocked.
Important! Never try to lift the rocker lever with force.
Reason for this behavior may be:
•
•
•
•
Interrupt of power supply during welding process (disconnection of battery?!)
Pulling the rocker lever with force during welding process (to protect the motor, it switches off
due to over-current consumption).
Microswitch (Pos. 103) is defective  reparation is necessary.
PCB or wirings are faulty  reparation is necessary.
To debug the 2 possibilities given on top, the tool is equipped with a reset feature, as also stated in
chapter 6.3 in the operating instructions:
1. Switch to fully automatic mode.
2. Press and hold the welding button, thereafter press the tension button.
The tool will now run the welding function and so turn the cam ring away from its inappropriate position.
But probably the motors torque may not be sufficient to do so. Do not try to execute this process more
than 3 times within a short period. Otherwise the motor may get damaged.
If you have not been successful so far, and the rocker lever is still blocked, proceed as follows:
1. Insert an Allen key (3mm) through the hole in front of the base plate and apply on cylinder head
screw. Pos. 164.
2. Turn 10 revolutions counterclockwise. Moderate effort may be needed to do so.
3. Pull rocker lever  welding shoe must swing up.
1.
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2.
15
BXT 2
BXT 2-19
7. Disassembling
Please consider the explosion drawing which is printed on the last pages of the operating instructions.
Purpose of this manual is only to draw the technician’s attention to the most relevant issues.
7.1. Housing/electrical components
Important! The connectors and cables have to be treated carefully. Never pull on the wiring to
disconnect the connectors.
1. Remove the screws
of the motor cover
(Pos. 191) and pull it
slightly backwards.
3. Disconnect the signal cable
(Pos. 202) from the PCB. If the
harness is secured with a cable
tie, cut tit.
Remove the motor cover.
4. Disconnect and remove the
intermediate cable (Pos. 201).
5. Disconnect the motor from the
power electronics
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6. Remove side cover
(Pos. 175), 4 x Screw M4
(Pos. 41). Loosen the
screws of the housing, 7
x Pos.197.
Disassemble the housing
(notice the picture). Pay
attention to the wiring,
the housing cannot yet
be removed completely.
2. Disconnect
the intermediate
cable (Pos. 201)
16
BXT 2
BXT 2-19
7. Disconnect the
Intermediate cable
(Pos. 201). Remove the
left part of the housing
8. Disconnect the
motor hall sensor
wirings
7.2. Welding unit
1. Remove cable
tensioning (Pos. 103)
2. Remove set screw
and compression
spring (Pos. 86 & 169).
3. Loosen centering screws (2x
Pos. 101) and remove them
completely.
4. The whole
welding unit can
now be pulled
backwards.
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17
BXT 2
BXT 2-19
5. Remove washer (Pos.163). To do so, retain
the excentric axe (Pos.155) with a 5mm
wrench on its back side and loosen the screw
(Pos. 164).
6. Pull out the toothed belt wheel (Pos. 127).
Remove screw (Pos.102) and retaining rings
(Pos. 74). The cover of the motor support (Pos.
126) can now be removed.
Important!: The motor is fixed to the motor support with precote®-coated screws. Should it become
necessary to replace the motor the screws have to be warmed with a hot air fan to 80°C maximum.
7.3. Rocker lever and reset
1. Remove retaining rings (Pos. 66 & 74).
Loosen the blocking pawl with a screw
driver and pull it off the lever. Remove the
bolt (Pos.64).
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18
BXT 2
BXT 2-19
7.4. Tensioning gear
1. Remove retaining ring (Pos. 136). The bevel
wheel complete is now free to be pulled out.
2. Remove the tension wheel, the planetary
wheels and the cam disk (Pos. 44-46 & 18) from
flange complete (Pos.32).
3. Loosen the screw connection
(5xPos.41) and remove retaining ring
(Pos 40). All other gear parts can now
easily be removed.
8. Assembly
To assembly the tool, simply proceed in the opposite way. Please consider the explosion drawing which
is printed on the last pages of the operating and safety instructions. All positions which are marked with
* have to be secured. Most screwings are TufLok ® coated and secured. Do not use these screws several
times. Replace them with new original screws or secure them with loctite.
Moving parts need to be lubricated. Please consider
chapter 10.
Information about how to assemble the wiring and the
housing can be found in chapter 11.
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Screw with TufLok ®coating
BXT 2
BXT 2-19
9. Adjustments
9.1. Adjustment of the welding reset
To avoid play in the reseting parts of the welding unit these parts can be adjusted by the set screw (pos.
73). This screw is adjusted when the tool is assembled in the factory. Normally readjustments are not
necessary. When parts of this unit are replaced, it may become reasonable to check this setting. To do so
proceed as follows:
1.
2.
3.
4.
Unscrew (Pos 73) until it is flush with the reset cam (Pos.72).
Push onto the switching cam (pos. 140) until the welding unit springs completely downwards.
Screw in the set screw until the switching cam starts to lift itself. Unscrew for a quarter revolution.
Check the setting with a feeler gauge (0.05 - 0.1mm).
Must contact each other (Pos.96 & 126)
0.05-0.1mm
19
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BXT 2
20
10.
BXT 2-19
Lubricating chart
Recommended Lubrication:
1
2
3
4
5
6
7
8
Description:
Planetary gear tensioning
Planetary gear welding unit
Freewheels (Pos. 127/ 132) Important! No grease!
Bevel gear
Cam disk, reseting cam, switching cam
Tooth plate, Set screw
All other moving parts.
Ball guides at welding shoe, knife guide, excentric
axle
Lubricant:
Klüber Microlube GBU-Y 131
Klüber Microlube GBU-Y 131
Universal oil e.g. WD 40
Klüber Microlube GBU-Y 131
Klüber Microlube GBU-Y 131
Klüberpaste 46 MR 401
Pressure resistant lubricant
spray, e.g. Würth HHS 2000
Pressure resistant lubricant
spray, e.g. Würth HHS 2000
5
2
3
4
7
5
1
8
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6
Interval:
100‘000 Cycles
100‘000 Cycles
100‘000 Cycles
50‘000 Cycles
50‘000 Cycles
50‘000 Cycles
50‘000 Cycles
25‘000 Zyklen
21
BXT 2
11.
BXT 2-19
Wiring
The cables must be layed very accurate. Misplaced wiring could be damaged by moving parts inside the
tool. Bad connections may lead to tool malfunction.
1. Prepare the power electronics for the assembly.
Connect the hall sensor cables and the signal cable to
the power electronics.
2. Insert the power electronics .into the right half of
the housing. Place the wires
according the picture. Don’t
forget the seal.
3. Mount the right half of the housing to
the tool mechanics. Insert the contact
plate with spring (Pos. 168) Take care
.that the cables are laid accurately.
4. Mount the left side of
the housing and screw
them together. Place the
wires as on the picture.
5. Plug the motor cables. You
don’t need a cable strap as the
motor housing prevents them
from disconnecting.
Place the signal cable and the hall
sensor wires as on the picture.
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22
BXT 2
BXT 2-19
6. Secure cable (Pos.
103) with cable strap.
Pay attention to strain
relief to microswitch!
7. Mount intermediate
cable (Pos. 201) and
secure it at the
retaining bracket.
8. Now the motorhousing with Printed circuit board can
be mounted. Pay attention to accurate fitting at all the
connections.The 2 small pins on the connectors have to
fit into their counterparts.
First the signal cable (Pos. 202) is connected. Best way
to so is to place the tool at the edge of the table. Secure
the cable with cable tie (consider product information 2,
Nov 2010).
9. Put the motor housing over the
motor and move it forward. Connect
the intermediate cable to the PCB, click
the housing into place and screw it on.
Important! Do not set the
connections under tension while
assembling. Connections might
get loose due to vibrations during
operation.
Mount the motor cover in a way
that the signal cable rests in front
of the first vent slot.
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23
BXT 2
12.
BXT 2-19
Error Code List
12.1.
User Errors
Faults in operating sequence “User errors” are no indication of a tool related defect (except defective
switch). The tool calls the users attention to faulty operation.
During Tensioning:
Nr.
A11
A12
Fault in operating sequence
Tension with rocker lever pulled
Rocker lever is pulled during
tensioning
In Automode:
Rocker lever, tensioning
button or welding button is
activated during tensioning
Tension button is pressed to many
times
Tension time out.
Adjusted tension force could not
be reached
System reaction
Tensioning is not executed
Tensioning is
interrupted
Tensioning with cam switch activated
Tensioning is not executed
A13
A14
A15
A16
Error message
Beep sound
Rectification
Release rocker lever
None
Tensioning again
Tensioning is
interrupted
None
Start process again
Tensioning is no longer
executed
Beep sound
Execute welding or pull
rocker lever
Tensioning is
interrupted
„E“blinking,
intermittent beep for
5s
Beep sound
Start process again
Pull rocker lever
Welding:
Nr.
A20
Fault in operating sequence
Try to weld without tensioning first
System reaction
Welding is not executed
Error message
Beep sound
A21
Try to weld with rocker lever pulled
Welding is not executed
Beep sound
Rectification
Press tension button
before welding
Release rocker lever
A22
Interrupted welding process by pulling
rocker lever
Welding process is completed
but the seal is invalid.
„E“blinking,
Intermittent beep for 5s
Repeat the strapping,
Seal is not correct
A23
Interrupted cooling by pulling rocker
lever
Cooling is interrupted
„E“blinking,
Intermittent beep for 5s
Repeat the strapping,
Seal is not correct
A24
Welding time out
cam position could not be detected
(Micro switch Pos. 103)
Welding is interrupted
„E“blinking,
Intermittent beep for 5s
Repeat the strapping,
Seal is not correct
Failure Codes A22 and A23 are counted by the system. The number of failures is displayed when the
data-cable is used (chapter 5.3)
Error message „empty battery“:
The error code „empty battery“ depends on the mode which is currently in use.
Nr.
Battery empty
System reaction
During welding/tensioning
(Motor end phase switches off)
1.
2.
welding/tensioning process is interrupted
Error code E23 is displayed (see chapter 12.4)
Into Run Mode
(within 30s)
1.
2.
4 beep sounds and segment display is blinking
Tool switches off
Into Idle Mode
(within 5min)
1.
2.
4 beep sounds and segment display is blinking
Tool switches off
Into Sleep Mode (more than 5
min after last usage)
1.
Tool switches off
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24
BXT 2
12.2.
BXT 2-19
Device Error control system
Error Reports in conjunction with the control system.
Nr.
E10
System error
Description
DEVICE_UNKNOWN_DEVICE Description:
Device Type (14,4V, 18V) could not be detected
Possible cause:
System reaction
Stop
The tool is switched off.
•
•
Wrong type of PCB (14,4 / 18V)
Wrong Firmware. (The Firmware does not support this
tool type.
•
Hardware failure when reading coding resistors
Rectification:
1. Try again, unplug and plug the battery
2. Replace PCB (Pos.198)
E11
DEVICE_WRONG_BATTERY
Description:
Plugged Battery is known but not valid (Wrong voltage)
Possible cause:
Stop
The tool is switched off.
•
•
•
Wrong battery type.
Wrong type of PCB
Hardware failure on the power electronics.
Rectification:
1. Replace battery
2. Replace PCB (Pos. 198)
E12
DEVICE_KEYPAD_ERROR
Description:
Keypad reports consistent pressure on keys
Possible cause:
•
•
Keys are pressed consistent
Keypad is defective
Rectification:
1. Release keypad
2. Replace Keypad
3. Replace PCB, (Pos. 198)
E13
DEVICE_ORIGIN_ERROR
Description:
Error at cam switch (Pos. 103)
Possible cause:
•
Defective cam switch. (always on/off)
Behebung:
1. Pull rocker lever to reset cam switch
2. Check cables and connections to cam switch
3. Replace cam switch
4. Replace PCB, (Pos 198)
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Interruption
Current process is
interrupted. Tool goes in
standby mode again.
Interruption
Current process is interrupted.
Tool goes in standby mode
again.
25
BXT 2
12.3.
BXT 2-19
Device error battery
Error Reports in conjunction with the battery or the motor
Nr.
E20
System error
BATTERY_OVERTEMPERATURE
Description
Description: Temperature fuse of the battery.
Possible cause:
System reaction
Stop
•
•
•
•
•
The tool is switched off..
Battery Temperatur >60°C
Battery temperature sensor is
Wiring power electronics to battery faulty
Wiring power electronics to PCB faulty
Temperature measurement on the power electronics is
faulty.
•
Loop of temperature sensor via power electronics
faulty
Rectification:
1. Replace the battery or let it cool down
2. Check the wirings battery to power electronics
3. Check the wirings power electronics to PCB
4. Replace the PCB (Pos. 198)
5. Replace power electronics (Pos. 212)
E21
BATTERY_OVERLOAD
Description: Battery Current overload protection.
Possible cause:
•
•
Battery was overloaded
Current measurement on power electronic is faulty
Rectification:
1. Clean tool mechanics
2. Replace power electronics (Pos. 212)
E22
BATTERY_MOTOR_
OVERLOAD
Description: Motor overload protection.
Possible cause:
•
•
The tools mechanics is stucked
Current measurement on on the power electronic is
faulty.
Rectification:
1. Clean / repair the mechanical components
2. Replace power electronics (Pos. 212)
E23
BATTERY_UNDERVOLTAGE
Description:
Undervoltage limit was reached during operation. Current
tension/weld process is invalid.
Error code E34 is bypassed to this error!
Possible cause:
Interruption
Current process is
interrupted. Tool is in
standby mode again.
Interruption
Current process is
interrupted. Tool is in
standby mode again.
Stop
The tool is switched off.
•
•
Battery is empty
Battery temperature to low <-10°C.
Rectification:
1. Replace or load battery
E24
BATTERY_CODING_
RESISTOR
Description: Battery coding resistor has an invalid value
(Disconnection or short circuit)
Possible cause:
•
•
•
Battery is not pluged properly
Batteries coding resistor is faulty
Resistance measurement on power electronics is
faulty.
•
Wiring power electronics to contact plate is faulty
•
Water on the power electronics, tool was exposed to
rain / water.
Rectification:
1. Plug battery properly
2. Replace the battery
3. Check wiring power electronics to contact plate
4. Let the tool dry out
5. Replace the power electronics (Pos.212)
ak 3.11
Stop
The tool is switched off..
26
BXT 2
E25
BXT 2-19
BATTERY_TEMPERATUR_
RESISTOR_ERROR
Description: Battery temperature sensor has an invalid value.
(Disconnection or short circuit)
Possible cause:
Stop
The tool is switched off..
•
•
•
•
Battery is not plugged properly
Batteries temperature sensor is faulty
Wiring power electronic to contact plate is faulty
Loop of temperature sensor via power electronics
faulty
•
Resistance measurement on power electronics is
faulty
Rectification:
1. Plug battery properly
2. Replace the battery
3. Check wiring power electronics to contact plate
4. Replace the PCB (Pos. 198)
5. Replace the power electronics (Pos 212)
E26
BATTERY_UNKNOWN_
BATTERY
Description: Battery coding restistor has an invalid value which
cannot be related to a known battery.
Possible cause:
Stop
The tool is switched off..
•
•
•
Battery is not plugged properly
Batteries coding resistor is faulty
Resistance measurement on power electronics is
faulty
•
Battery is invalid
•
The firmware does not support this battery
Rectification:
1. Plug battery properly
2. Replace the battery
3. Check wiring power electronics to contact plate
4. Replace the PCB (Pos. 198)
5. Replace the power electronics (Pos 212)
12.4.
Device Error Drive
Error Reports in conjunction with the power electronics
Nr.
E30
System error
DRIVE_SENDCRCERROR
Description
Description:
CRC Error in communication with power electronic (send data)
Possible cause:
•
•
Hardwarefailure, Wiring problems
EMV-Disorder
Rectification:
1. Check the wirings power electronics to PCB
2.
Replace the PCB (Pos. 198)
3. Replace the power electronics (Pos 212)
E31
DRIVE_RECEIVECRCERROR Description:
CRC Error in communication with power electronic (receive
data)
Possible cause:
•
•
Hardwarefailure, Wiring problems
EMV-Disorder
Rectification:
1. Check the wirings power electronics to PCB
2. Replace the PCB (Pos. 198)
3. Replace the power electronics (Pos 212)
ak 3.11
System reaction
Interruption
Current process is
interrupted. Tool is in
standby mode again.
Interruption
Current process is
interrupted. Tool is in
standby mode again.
27
BXT 2
E32
BXT 2-19
DRIVE_TIMEOUTERROR
Description:
Time out in communication with power electronics.
Possible cause:
•
•
•
Power electronics is not switched on by the PCB
EMV-Disorder
Hardwarefailure, faulty wiring
Rectification:
1. Check the wirings power electronics to PCB
2. Replace the PCB (Pos. 198)
3. Replace the power electronics (Pos 212)
E33
DRIVE_OVER
TEMPERATURE
Description:
Over-temperatur of power electronic.
Possible cause:
•
•
End-phase-temperatur above 105°C
End-phase-temperatur sensor defective
Rectification:
1. Let tool cool down
2. Replace the power electronics (Pos 212)
E34
DRIVE_UNDERVOLTAGE
Description:
Under-voltage at drive end-phase
This error code is bypassed to E23
Possible cause:
•
Temporary voltage drop (<8.5V) caused by high
current consumption
•
Empty battery during operation
Rectification:
1. See failure code E23
E35
DRIVE_OVERVOLTAGE
Description:
Over-voltage at drive end-phase
Possible cause:
•
•
•
Batterie-voltage to high >24.5V
Voltage peaks
Voltage measurement on end-phase defective
Rectification:
1. Replace Battery
2. Replace the power electronics (Pos 212)
E36
DRIVE_COMTIMEOUT
Description:
Communication time-out with Controller (PCB).
Possible cause:
•
•
Wiring faulty
Hardware defective
Rectification:
1. Check the wirings power electronics to PCB
2. Replace the PCB (Pos. 198)
E37
DRIVE_CURRENTLIMIT
Description:
Short circuit (Overcurrent) during welding
Possible cause:
•
•
Tool is blocked during welding
Current measurement on on the power electronic is
faulty.
Rectification:
1. Clean the tool, remove blockade
2. Replace the power electronics (Pos 212)
ak 3.11
Interruption
Current process is
interrupted. Tool is in
standby mode again.
Interruption
Current process is
interrupted. Tool is in
standby mode again.
Interruption
Current process is
interrupted. Tool is in
standby mode again.
Interruption
Current process is
interrupted. Tool is in
standby mode again.
Interruption
Current process is
interrupted. Tool is in
standby mode again.
Interruption
Current process is
interrupted. Tool is in
standby mode again.
28
BXT 2
E38
BXT 2-19
DRIVE_HALLSENSORERR
OR
Description:
Hallsensor failure at power electronics
Possible cause:
Interruption
•
•
Current process is
interrupted. Tool is in
standby mode again.
Motor hall-sensor defective
Wiring to hall-sensors faulty
Rectification:
1. Check wiring motor to power electronics
2. Replace the motor
3. Replace the power electronics (Pos 212)
welding
13.
tensioning
Wiring diagramm:
EC-Motor
+
Code-R
NTC
-
ak 3.11
Rocker
lever
Cam
signal
29
BXT 2
14.
ak 3.11
BXT 2-19
Explosion drawing
30
BXT 2
ak 3.11
BXT 2-19
31
BXT 2
ak 3.11
BXT 2-19
32
BXT 2
ak 3.11
BXT 2-19
BXT 2
33
15.
BXT 2-19
Product information
Please consider the following product information releases (status April 2011):
•
•
•
Nr.1, May 2010:
•
•
•
•
•
•
1. Optimised housing parts Pos. 186
2. Plug connection to welding button is no longer required (Pos. 77)
3. Firmware update (Pos. 198)
4. Plug connection to power electronics is no longer required (Pos. 212)
5. New bevel wheel (Pos. 161)
6. New Pan head screw (Pos. 54)
•
•
•
•
1. Optimized tooth plate (Pos. 53)
2. New signal cable (Pos. 202)
3. New gasket (Pos. 203)
4. New protection plate (option, Pos. 234)
•
•
1. New Bevel wheel complete (Pos. 132)
2. Optimized Power electronics (Pos. 212)
Nr.2, November 2010:
Nr. 3, April 2011:
16.
Contact
For further technical support please contact:
Andreas Keller
E-Mail: [email protected]
Fax: +41 44 745 54 80
or
Gianni Cordasco
E-mail: gia[email protected]
Orgapack GmbH
Silbernstrasse 14
CH-8953 Dietikon
www.orgapack.com
ak 3.11

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