FB10000 Error Messages Troubleshooting

Transcription

1 Error ID: UV UV System Active Alarm (UV will shut down) <date> <time> UV System Active Alarm (UV will shut down). Tap Get Ready. For more details open the Troubleshooting guide This UV error message warns about UV system failure to reach the Standby status required for printing. Error covers practically all major UV errors that caused the UV system to shut down. This document helps interpreting the binary error codes displayed in the UV HMI and locating the faulty UV component that triggered the shut-down. It also provides the recommended troubleshooting action. Possible Causes Power supply damage UV Lamp Damage Contactor Damage Wiring disconnection 1

2 Power Supply damage When a major fault occurs in one of the PSU components, the UV system shuts down. Before the shut-down, each PSU sends an error code to the HMI display: PSU1-Master sends to top row PSU2-Slave1 to mid-row PSU3-Slave 2 to lower row These codes do not mean necessarily that the error occurred in the sender unit but report about a bit alarm that was raised in the sender PSU (each PSU has 2x16 bits). Based on the PSU system internal algorithm, the combination of these three codes help us detecting the faulty component that triggered the shut-down. Note! In case of UV shut-down, the HMI displays the codes for just a few seconds. To recall these error codes, prepare your camera or phone camera beforehand and right after switching on the system, take a quick snapshot of the HMI display. Top The codes displayed in the HMI are binary codes and require conversion and interpretation. For your convenience, we organized the binary code information into three tables titled SW1, SW2 and SW3. Searching in these tables the codes displayed in the HMI will help you detecting the faulty component that caused the UV system shut down and provide a corresponding troubleshooting action. To demonstrate the usage of these tables we used as examples two PSU-related cases that were lately reported from the field. In both cases, the UV system shut-down and the error message was displayed in the machine SW com area. 2

3 Case 1 - Fan 1 fault in PSU 3 (Slave 2) Following a fault in PSU 3 (Slave 2) Fan 1, the UV system shut down and three error codes were displayed in the HMI (Upper row code send by Master, mid by Slave 1 and lower by Slave2). Top PSU 1 (Master) reported error code SW3-B14 (bit 14) indicating a slave fault in either PSU 2 (Slave 1) or PSU 3 (Slave 2) (see Code SW3 B14 highlighted yellow in the SW3 table below) PSU 2 (Slave 1) reported error code SW3-B15 (bit 15) indicating a PS1 Master fault, probably due to the UV shut down that was triggered due to Slave 2 or Slave 3 fault) (see Code SW3 B15 highlighted green in the SW3 table below) PSU 3 (Slave 2) reported error code 2 SW3-B1 (bit1) indicating that Fan 1 in PSU 3 (Slave 2) is faulty (see Code2 SW3 B1 highlighted blue in the SW3 table below). Recommended action: Fan 1 in PSU 3 (Slave 2) is faulty and must be repaired or replaced. 3

4 Case 2 - Fan 1 fault in PSU 1 (Master) Following a fault in PSU 1 (Master) FAN 1 that caused the UV system to shut down, three error codes were sent to the HMI display (upper by master, mid by Slave 1 and lower by Slave2). Top PSU 1 (Master) reported error code 2 SW3-B1 (Bit 1) indicating an internal FAN 1fault. (see Code 2 SW3 B1 highlighted blue in the SW3 table below) PSU 2 (Slave 1) reported error code SW3-B15 (Bit15) indicating a fault in Master unit (see Code SW3 B15 highlighted green in the SW3 table below) PSU 3 (Slave 2) reports error code SW3-B15 (Bit 15) indicating a fault in the Master unit. (see Code SW3 B1 highlighted green in the SW3 table below). Recommended action: Fan 1 in the Master unit is faulty and must be repaired or replaced. 4

5 The tables below constitute a simplified version of the binary alarms code tables provided by the vendor. 1. Search in these tables the three error codes displayed in the UV HMI in the tables below in the correct order (top-down). Every row provides additional information that brings you closer to the faulty component detection. 2. After having searched the third (top-down) code in the table you should by then understood which PSU component is faulty and also read the troubleshooting action recommended by the vendor to resolve this case. Code Status Bit SW1 Nedap Protocol Description Actual Failure and Recommended TS Actions Normal Status 1 SW1 B0 System Ok Master fault status heat sinks, voltage input 1 - ok 2 SW1 B1 Lamp Driver Ok Master fault status internal ballast faults 1 - ok 4 SW1 B2 Lamp Ok Master fault status lamp related faults 1 - ok 8 SW1 B3 Warning Soft fault approaching limits 1 - ok 32 SW1 B5 Lamp Re-ignition Set high during ignition attempts 1 - igniting SW1 B15 Data Out of Range Invalid data request or no data 1 - ok Code Status Bit SW2 Nedap Protocol Description Actual Failure and Recommended TS Actions Normal Status 1 SW2 B0 Heat Sink Temp 1 Fault 2 SW2 B1 Intake Air Temp Fault High temperature (HS1) - Check cabinet air filter, lower the ambient temperature Air inlet temperature high (>40ºC) - Check cabinet air filter, lower the ambient temperature 4 SW2 B2 Input Voltage Fault No AC input present - Check mains input 8 SW2 B3 Heat Sink Temp 2 Fault High temperature (HS2) - Check cabinet air filter, lower the ambient temperature. Return to Test Case 1 Return to Test Case 2 5

6 Code Status Bit SW2 Nedap Protocol Description Actual Failure and Recommended TS Actions Normal Status 16 SW2 B4 Heat Sink Temp 3 Fault 32 SW2 B5 Heat Sink Temp 4 Fault High temperature (HS3) - Check cabinet air filter and Lower the ambient temperature High temperature (HS4) - Check cabinet air filter, Lower the ambient temperature 64 SW2 B6 Input Voltage Phase Fault Missing input phase - Check all mains input lines 128 SW2 B SW2 B8 Lamp Open 512 SW2 B9 Lamp Short 1024 SW2 B10 Nominal Power NOK SW2 B11 Nominal Power NOK2 Lamp not started or open output circuit. Check output circuit and lamp. Short circuit in output circuit and/or Lamp Check output circuit and lamp Driver did not achieve 85% of maximum power during warming up, within 5 minutes after ignition of lamp. Check lamp and lamp cooling Driver above or below set point for power by 15% for a period of 2 minutes. Check lamp and lamp cooling 4096 SW2 B12 GND Fault Driver GND fault - Check output circuit and lamp 8192 SW2 B13 Lamp Rectification Fault Rectifying Lamp. Replace lamp SW2 B14 Lamp Voltage Fault Lamp voltage out of specification (> 1470V) - Replace lamp SW2 B Return to Test Case 1 Return to Test Case 2 6

7 Code Status Bit SW3 Nedap Protocol Description Actual Failure and Recommended TS Actions Normal Status 1 SW3 B0 Lamp Driver Internal Voltages Internal failure - Repair needed, return unit to Nedap 2 SW3 B1 Fan 1 Fault Internal fan 1 failure - Replace fan cassette 4 SW3 B2 Hardware Protection Fault Internal failure - Repair needed, return unit to Nedap 8 SW3 B3 Fan 2 Fault Heat sink fan 2 failure - Replace external fan 16 SW3 B4 Fan 3 Fault Heat sink fan 3 failure - Replace external fan 32 SW3 B5 Fan 4 Fault Heat sink fan 4 failure - Replace external fan 64 SW3 B6 Fan 5 Fault Heat sink fan 5 failure - Replace external fan 128 SW3 B7 Fan 6 Fault Heat sink fan 6 failure - Replace external fan 256 SW3 B8 Module Driver OVP 512 SW3 B9 Lamp Driver Error SW3 B10 Lamp Driver Error SW3 B11 Lamp Driver Error 3 Internal failure - Repair needed, return unit to Nedap Internal failure (DC bus) - Repair needed, return unit to Nedap Internal failure (HF bridge) - Repair needed, return unit to Nedap Internal failure (Freq.) - Repair needed, return unit to Nedap 4096 SW3 B12 Lamp Driver Error 4 Shutdown - Repair needed, return unit to Nedap 8192 SW3 B13 Lamp Driver Error 5 Internal failure (gate) - Repair needed, return unit to Nedap SW3 B14 Slave Fault Fault on slave unit SW3 B15 Master Fault Fault on master unit Return to Test Case 1 Return to Test Case 2 7

8 UV Lamp Damage 1. Press alarm reset to clear alarm. 2. Stop the system and check the UV Lamp. 3. Check that the lamp has no visible damage look for cracks in the quartz tube or if there are burnt marks on the connectors. Contactor Damage 1. Remove covers from the 3 power supplies. 2. Check that power supplies A1, A2 and A3 are powered up (Contactors K1, K2, K3, K4 are energized). 3. If any contactor is not energized, check the voltage across coil terminals (A1 and A2). 4. If supply to the coil is 24VDC but is not energized, the contactor requires replacement (Refer to Baldwin 3.13 Tech Breaker Main N12 Replacement) see also Baldwin Alarm 28 & 29 TS documents). 8

9 Top 5. If power supplies are energized but the alarm is still active. Check High Voltage wiring. 6. Isolate and lock off the electrical supply. Wiring disconnection 1. Check that HV cables covered with red sleeves are connected as shown in the circuits: E15 to K1050 E16 to K Check that the UV lamp Loom is connected to the bottom power supply (A1). 3. Replace Power Supply. Refer to technical bulletin. 9