LELY E-LINK D 6060 Operating Manual

3 PREFACE PREFACE PREFACE PREFACE PLEASE READ THIS OPERATING MANUAL! � This operating manual provides you with important information for the safe operation of your machine. � Pass on this operating manual to every user of this machine! � This manual must always be available wherever the machine is in use. PLEASE READ THE OPERATING MANUAL D 6060 / D 4060! � Observe all safety instructions!

IMPRINT IMPRINT IMPRINT IMPRINT Control unit, control box and control programs (software) have their own serial numbers. Please state the serial numbers in case of inquiries: Part Serial number (please enter) Determine serial number Control box Control program in the control box (software) SW rev. ........................................ dd................................................. Keep any key on the control box pressed when switching on the power supply. Control unit Serial no....................................... SW version................................... SW date....................................... Memory........................................ Appears automatically in the display 2 seconds after switching-on of the power supply and is displayed for 5 seconds. Reprinting without express written approval is not permitted – all rights reserved and subject to technical alterations. Illustrations are not binding on form and design of the machine. © 2003 by Lely Maschinenfabrik GmbH Wolfenbüttel Made in Germany. 1251.99.03.04 Rev 05.03 Print 05.03 Manufacturer: LELY Maschinenfabrik GmbH Gebrüder-Welger-Straße 3 • D-38304 Wolfenbüttel Phone: (+49) 53 31 / 404-142 • Fax: (+49) 53 31 / 404-143 eMail: [email protected]

5 CONTENTS CONTENTS CONTENTS CONTENTS PREFACE 3 IMPRINT 4 WARNING SYMBOLS 6 SAFETY 7 Proper use 7 General Information 8 Electrical equipment/Electronics 9 Welding work 9 Electromagnetic compatibility (EMC) 10 OVERVIEW 11 General Information 11 Requirements on the machine 11 THE MENUES 12 General Information 12 Menue selection 12 MONITOR MENUE 13 Blower control 14 Hydraulic functions 14 Operating parameters 14 Operating status Pressure On/Pressure Off 15 Knotter faults 15 Slip warning 16 Length of bale 16 Cutting device status 16 SETUP MENUE 18 Language 19 Machine type 19 Pressure drop 19 Knotter alarm 19 Beep 20 Worm monitor (D 4060 only) 20 CAN modules 21 SYSTEMINFO MENUE 24 DIAGNOSIS MENUE 26 Standard diagnosis 26 Extended diagnosis 33 STATISTICS MENUE 36 ERROR MESSAGES 38 System error messages 38 Standard error messages 40 APPENDIX 44 System Service 44 Select submenue 44 MONITOR submenue 46 SYSTEM SETUP submenue 46 EEPROM CONTENTS submenue 48 SELF-TEST submenue 50 SCOPE 51

WARNING SYMBOLS WARNING SYMBOLS WARNING SYMBOLS WARNING SYMBOLS Instructions of particular importance in this manual are marked by the following symbols and signal words: Attention! This symbol stands next to warnings: danger to life, danger of injury, possible serious material damage. Caution! This symbol stands next to safety instructions: malfunctions and impairments of correct operation, possible material damage. Note! This symbol stands next to useful information: special information on how to use the machine most efficiently.

7 SAFETY SAFETY SAFETY SAFETY Proper use This E-Link system is exclusively intended for use on the LELY WELGER D 6060 or LELY WELGER D 4060 "Balers". Using the machine for any other purposes does not constitute proper use. The manufacturer cannot be held liable for any damage resulting from such use; the risk of improper use lies entirely with the user. Operating the machine within the limits of its proper use also involves complying with the operating, maintenance and servicing conditions prescribed by the manufacturer. This E-Link system may only be operated by persons who are familiar with the system and instructed on the dangers involved. The relevant accident prevention regulations and all other generally accepted safety rules must be observed. Attachment of additional devices is not permitted. Unauthorized modifications and installation of non-approved parts and equipment preclude any liability of the manufacturer for any damage resulting therefrom.

General Information Even if all warnings and safety instructions are observed the machine involves secondary hazards which cannot be eliminated by constructional measures. Always handle the machine with care to avoid danger to yourself and others! � Read the pertinent operating manual before commissioning the machine. In case of difficulties in understanding please contact the customer service department. � Never carry out any maintenance and repair work on the machine while the drive is running. Never carry out any adjustment and service work on the machine while the drive is running. � Never remove any crop material from the machine while the drive is running, or while the disconnected machine is still moving. First switch off power take-off shaft and tractor motor and then pull off the drive shaft from the power take- off shaft end. � In case of work on movable parts or in the range of action of movable parts: switch off power take-off shaft and pull off the drive shaft from the power take-off shaft end. Apply the flywheel brake. � Riding on the machine is prohibited for the entire machine! � During operation: Never climb the drawbar or any other parts of the machine. Keep sufficient distance to the . Do not reach in the range of action of the conveying elements. � Prior to inserting the wrapping material: switch off power take-off shaft drive and tractor motor, remove the ignition key and insert tying unit locking device. � Never operate the machine with defective or removed protective devices (e. g.: casing sheets and distance brackets)! Before opening the protections: Switch off p.t.o. shaft drive and tractor engine, wait until machine has stopped, remove the ignition key. � Keep fire extinguisher within reach.

9 Electrical equipment/Electronics � Operation with other onboard power supplies is not permissible! Prior to any kind of assembly, adjustment and maintenance work, the E-Link system must be disconnected from power supply (switch off control voltage on switch box). � Check correct setting of all sensors regularly and check that all sensors and actors are tightened properly. � Power supply of the electronics must only be switched on when the machine is to be operated. After the end of work, the control system must immediately be disconnected from power supply. � It is not permissible to enter the working range of the machine or to approach the working range of the machine as long as the electronics are supplied with power. � During cleaning work, the electronics must not be exposed to a direct water jet (in particular: high-pressure cleaning machine). � The existing wiring of the E-Link and of the respective machine may only be used for the consumers installed in the factory and approved by the manufacturer. � E-Link is designed exclusively for 12-volt operation. Welding work � Do not permit welding current to flow through the E-Link system. � Provide for all-polo disconnection of the power supply to the machine (disconnect battery). � Interrupt power supply between tractor and baler. � Take strong heat generation at welding points into account. Dismount sensitive parts (cables, sensors, plastic parts) before welding.

Electromagnetic compatibility (EMC) The machine is equipped with electronic components and modules; the function of these electronic components and modules can be influenced by electromagnetic emissions of other equipment. Such influences can cause risks to persons, if the following safety instructions are not observed: In case of subsequent installation of electrical and electronic equipment and/or components into the machine, with connection to the central mains, it is the user's responsibility to check whether the installation impairs the vehicle electronics or any other components. Ensure above all that the electrical and electronic components subsequently installed are in conformity with the EMC directive 89/336/EEC as amended, and that they are provided with the CE.

11 OVERVIEW OVERVIEW OVERVIEW OVERVIEW General Information The E-Link control system consists of: � control box with display (Figure: 2) � control unit in switch box (Figure: 1) � control program (software) Caution! Prior to any kind of assembly, adjustment and maintenance work, the E-Link system must be disconnected from power supply: Switch off control voltage on switch box, Figure: 1. Caution! The housing of the E-Link control box is moisture-repellent. Nevertheless: in order to avoid malfunctions, the control box must not be exposed to excessive moisture (e.g. pouring rain, splashing, steam-jet or high-pressure cleaning machine). Requirements on the machine Caution! Operation with 24 V power supply is not permissible. Onboard voltage, machine: 12 V Fuse protection, machine side: 30 A Figure: 1 Figure: 2

THE MENUES THE MENUES THE MENUES THE MENUES Note! Unless otherwise stated: The E-LINK figures in this manual relate to the WELGER D 6060. General Information The E-Link system provides the following menues: Menue Task see chapter MONITOR Display and operator control in normal machine operation "MONITOR menue" page 13 SETUP Setting of machine parameters "SETUP menue" page 18 SYSTEMINFO Information about selected system data "SYSTEMINFO menue" page 24 DIAGNOSIS Diagnostic functions for checking the machine "DIAGNOSIS menue" page 26 STATISTICS Machine running time, cumulative counter and day counter "STATISTICS menue page 36" Menue selection � Open menue overview: Press key < >. � Select menue: keys < > and < > � Confirm selection with key < >. If no menu is to be selected: if no key is pressed for 5 seconds, automatic return to the MONITOR menue is effected. Menu: Monitor Menu: Monitor Menu: Monitor Menu: Monitor Systeminfo Systeminfo Systeminfo Systeminfo Diagnosis Diagnosis Diagnosis Diagnosis Statistics Statistics Statistics Statistics Setup Setup Setup Setup

13 MONITOR MONITOR MONITOR MONITOR MENUE MENUE MENUE MENUE The MONITOR menue is the standard menue. This menue is used for daily machine operation. The MONITOR menue appears automatically as soon as the E-Link system is supplied with power. The following information is shown in the display: Central main field � Machine status (slip, knotter sensors, knotter fault, bale length ...) Beside the main field � Bale counter (day counter) � Machine running time (day counter) � Battery voltage � PTO speed Below the main field � Blower (fan) status � Hydraulic valve block � Operating parameters (pressure/combi presetting, mixer, bale length) Field A: Blower (fan) status Field B: Hydraulic System Field C: Operating parameters Disconnected Pick-up Pressure presetting Stand-by (flashing)/ connected Cutting device Combi presetting Support foot Mixer Bottom door Length of bale Battery voltage PTO speed Bale counter (day counter) Machine running time (day counter) Knotter sensors Bar diagram to display the bale length Bales Bales Bales Bales Hours Hours Hours Hours Batt. Batt. Batt. Batt. RPM RPM RPM RPM Pressure Pressure Pressure Pressure

Blower control � Blower ON/OFF: key < > The blower status is indicated in the field above the key A flashing blower symbol indicates the stand-by mode of the blower. In the stand-by mode, the blower � is automatically switched on as soon as the operating speed has been reached. � is automatically switched off as soon as the speed is below the operating speed. Hydraulic functions � Scroll through the hydraulic functions: key < > The hydraulic function active in each case (pick-up, cutting device, support foot, bottom door) is displayed in the field above the key < >. Operating parameters � Select parameter: key < > � Change parameter: keys < > and < > Compression force The compression force is adjustable to 0..100% in steps of 1%. 0% = no pressure; 100% = full pressure Combi presetting Combi can be set to 0..100 in steps of 1. Mixer The mixer can be set to 0..50 in steps of 5. � If mixer = 0 the pressure can be set, not, however, combi. � If mixer <> 0, combi can be set, not, however, the pressure. length of bale The bale length can be adjusted to 80..240 cm.

15 Operating status Pressure On/Pressure Off � Switch hydraulic system to the PRESSURE OFF status: Taste < > (START/STOP) This status is indicated by the flashing pressure-off symbol in the main field. After 30 seconds in the pressure-off status the pressure measuring system is automatically calibrated anew. Knotter faults The knotter monitoring system signals knotter faults by means of the symbol below the circular knotter sensor symbols. The type of knotter fault is indicated by the status of the circular knotter sensor symbols: Knotter faults Description The knotter sensor is damped, no knot has been tied The knotter sensor is undamped, the knot was not drawn off Batt Batt Batt Batt. Bales Bales Bales Bales Hours Hours Hours Hours RPM RPM RPM RPM Combi Combi Combi Combi Bales Bales Bales Bales Hours Hours Hours Hours RPM RPM RPM RPM Combi Combi Combi Combi Batt Batt Batt Batt.

Slip warning The slip warning system warns by means of a baler filled black, when slip occurs in the drive system due to machine overload. Length of bale The bale length is displayed by means of a bar diagram. Cutting device status The connected cutting device is displayed in the main field by scissors. Bar diagram to display the bale length Batt Batt Batt Batt. Bales Bales Bales Bales Hours Hours Hours Hours RPM RPM RPM RPM Combi Combi Combi Combi Batt Batt Batt Batt. Bales Bales Bales Bales Hours Hours Hours Hours RPM RPM RPM RPM B. B. B. B.----length length length length Batt Batt Batt Batt. Bales Bales Bales Bales Hours Hours Hours Hours RPM RPM RPM RPM Combi Combi Combi Combi

17 MONITOR menue key functions - Overview Button Operation Blower ON/OFF Toggle hydraulic switch (pick-up – cutting device – support foot – bottom door) Toggle system presetting (pressure/combi presetting - mixer - bale length (D4060/6060 only) ) Toggle pressure-on / pressure-off status Increase selected system presetting Reduce selected system presetting +/- simultaneously: trigger el. tying cycle (50 cm monitoring active) "Remove" error message Open menue overview

SETUP SETUP SETUP SETUP MENUE MENUE MENUE MENUE The SETUP menu serves for setting various machine parameters (Language, Machine type, etc.). � Select parameter: keys < > and < >. � Change parameter: keys < > and < >. � Return to the menue selection: Press key < >. � Return to MONITOR menue: press key < > for 3 sec. The following setting values can be selected for the parameters: Setup parameter Setting range Language English – German – French Machine type D4060 – D6060 Pressure drop 0..5 s Knotter alarm Off – On Page 1/2 Beep Off – On, length 0..50 ms Page 2/2 CAN-modules 1 and 2 Yes – No D 4060 only: Page 2/2 Worm monitor On – Off D 4060 only Setup 2/2 Setup 2/2 Setup 2/2 Setup 2/2 Worm monitor: on/off Worm monitor: on/off Worm monitor: on/off Worm monitor: on/off Setup 1/2 Setup 1/2 Setup 1/2 Setup 1/2 Language: Language: Language: Language: Machine typ: Machine typ: Machine typ: Machine typ: Pressuredrop: Pressuredrop: Pressuredrop: Pressuredrop: knott.alarm: knott.alarm: knott.alarm: knott.alarm: D6060 D6060 D6060 D6060 1s 1s 1s 1s off off off off english english english english

19 Language The language in the control box display can be adjusted. � German � English � French Dependent on the configuration further languages can be selected. Machine type The machine type can be adjusted: � D 4060 � D 6060 Dependent on the configuration further models can be selected. Pressure drop After tying has been effected, the baling channel can automatically be switched to pressure-off status for a short time (0..5 s) to ensure that the finished knots are easily and correctly withdrawn from the knotters during conveyance of the finished bale. This function is primarily used: � when silage is processed. � if too little material is transported into the machine after the finished bale (i.e. the finished bale is not conveyed speedily). The length of time for the pressure drop in the baling channel can be set between 0 seconds and 5 seconds. Knotter alarm Any knotter alarm is optically indicated in the display, see chapter "Knotter faults", page 15. In addition, an audible knotter alarm can be activated: � Knotter alarm ON: Any knotter alarm occurring is audibly indicated. � Knotter alarm OFF: Any knotter alarm occurring is not audibly indicated.

Beep The beep indicates audibly that a key on the control box has been pressed. The beep can be switched on or off and the length of the beep can be varied (0..50 ms). Worm monitor (D 4060 only) When the control recognizes blocking of at least one of the two worms (worms between rotor and compactor) the PU stop is activated. The PU stop will only be deactivated when the two worms rotate again. Worm monitoring becomes active only from a certain operating speed: approx. 800 U/min.

21 CAN modules Note! To avoid operating errors: adhere to the following procedure When the inquiry as to whether both CAN modules are to be used is answered with "No" and subsequently with "Yes", the inquiry "PROGRAMING NEW ADDRESS?" will be displayed: � (Step 1) Actuate no further keys. � (Step 2) Restore old status: Switch off power supply on switch box, Figure: 1. If by mistake the inquiry "PROGRAMING NEW ADDRESS?" is answered with "Yes" (via the key ), both CAN modules are given the same address, i.e. both CAN modules are addressed by means of the same "name". As a result, the functions controlled by the renamed CAN module are no more available. If this happens: � (Step 3) Switch power supply on switch box off and on again (Figure: 1). The system starts anew. After switching-on again, the message "CAN MODULE #XY IS MISSING" is displayed. If this error message does not appear, the CAN modules can be checked as described under steps 10 to 14. � (Step 4) Disconnect CAN module #2 from control system by pulling the plug (in the switch box). Ignore any error message "CAN MODULE #XY IS MISSING" which might occur, and acknowledge with key < >. � (Step 5) In the Setup on page 2/2, set "CAN module 1" from "NO" to "YES": key < >. � Answer the inquiry "PROGRAMING NEW ADDRESS?" with "YES". If CAN module 1 had already been set to "YES", it must first be set to"NO". CAN module addressing is finished after a few seconds. � (Step 6) Reconnect plug of module 2 and remove plug of module 1, and proceed with module 2 – as described under steps 4 and 5. � (Step 7) Ignore and acknowledge any error messages possibly appearing during this process. � (Step 8) Reconnect CAN module 1. � (Step 9) Switch power supply on switch box off and on again (Figure: 1). The system starts anew.

If 10 seconds after the new start no CAN error message is displayed, you can assume that both CAN modules work correctly again. This can be tested as described in steps 10 to 14. If a CAN error message appears, the procedure must be repeated beginning with step 3. When module x is to be addressed, the plug of module y must be pulled. When module y is to be addressed, the plug of module x must be pulled. To test the CAN modules steps 10 to 14 must be carried out: � (Step 10) In the "Actors" diagnosis, go to page 2/2 (valves 1, 2, 3, 11, 12, 13, 14, 15). � (Step 11) Activate automatic diagnosis by means of the key < > (START/STOP). If some or all valves do not switch, a CAN module is not correctly addressed. � (Step 12) Address both modules once again anew (beginning with step 3). If all valves switch correctly, it is possible that the CAN modules were exchanged by mistake during new addressing. � (Step 13) In the " Digital sensors " diagnosis, go to page 3/4. � (Step 14) Test with the keys for the chute and the bale extractor. If closing of the keys is correctly indicated in the diagnosis, addressing has been successfully finished. If the key changes are not correctly indicated, the two modules have been exchanged and must be addressed anew (beginning with step 3).

23 SETUP menue key functions - Overview Key Operation Page up Page down Change parameter Change parameter Select parameter Select parameter Open menue overview (3 sec.: Monitor menue)

SYSTEMINFO SYSTEMINFO SYSTEMINFO SYSTEMINFO MENUE MENUE MENUE MENUE The SYSTEMINFO menue provides information about important system data (serial number, software version, software date, memory). � Return to the menue selection: Press key < >. � Return to MONITOR menue: press key < > for 3 sec. Systeminfo Systeminfo Systeminfo Systeminfo Serial No.: 101001 Serial No.: 101001 Serial No.: 101001 Serial No.: 101001 SW Rev. : 0.03 SW Rev. : 0.03 SW Rev. : 0.03 SW Rev. : 0.03 SW Date : 02.03.2001 SW Date : 02.03.2001 SW Date : 02.03.2001 SW Date : 02.03.2001 Memory : 128kB/1kb Memory : 128kB/1kb Memory : 128kB/1kb Memory : 128kB/1kb

25 SYSTEMINFO menue key functions - Overview Key Operation Open menue overview (3 sec.: Monitor menue)

DIAGNOSIS DIAGNOSIS DIAGNOSIS DIAGNOSIS MENUE MENUE MENUE MENUE The E-Link system offers extensive diagnostic functions for checking the electrical equipment. There are two diagnostic routines: Standard diagnosis Diagnostic functions with machine stopped. Machine functions completely switched off. In addition, a fully automatic actor test is possible. Extended diagnosis Observe safety instructions! Diagnostic functions while machine is in operation. Observation of all sensor channels and actor channels possible. Selection via special key combination. Standard diagnosis Standard diagnosis may only be performed after the machine has been stopped. If the machine is started while the standard diagnosis is running, no further diagnosis can be selected, and with the next key stroke the control system returns to the MONITOR menue. � To previous diagnostic page: key < > � To next diagnostic page: key < > � Return to the menue selection: Press key < >. � Return to MONITOR menue: press key < > for 3 sec.

27 Standard diagnosis – Digital sensors In the "Digital sensors" diagnosis, the status of proximity sensors and switches is displayed. The following symbols are used for the sensor status: Sensor type Symbol Status Proximity switches damped undamped Key opened closed Diagnosis submenue Page number Diagnosis 1/3 Diagnosis 1/3 Diagnosis 1/3 Diagnosis 1/3 Di Di Di Digital sensors gital sensors gital sensors gital sensors Twine Twine Twine Twine Packer Packer Packer Packer Cutt.dev Cutt.dev Cutt.dev Cutt.dev Worm Worm Worm Worm Diagnosis 2/3 Diagnosis 2/3 Diagnosis 2/3 Diagnosis 2/3 Digital sensors Digital sensors Digital sensors Digital sensors Kn.shaft Kn.shaft Kn.shaft Kn.shaft Knotter1 Knotter1 Knotter1 Knotter1 Knotter2 Knotter2 Knotter2 Knotter2 Knotter3 Knotter3 Knotter3 Knotter3 Knotter4 Knotter4 Knotter4 Knotter4 Knotter5 Knotter5 Knotter5 Knotter5 Knotter6 Knotter6 Knotter6 Knotter6 Diagnosis 3/3 Diagnosis 3/3 Diagnosis 3/3 Diagnosis 3/3 Digital sensors Digital sensors Digital sensors Digital sensors Pto Pto Pto Pto Flywheel Flywheel Flywheel Flywheel Crank Crank Crank Crank RPM RPM RPM RPM RPM RPM RPM RPM RPM RPM RPM RPM D 4060 only

Digital sensors - Overview The following digital sensors are included in the diagnosis: Digital sensors D 4060 D 6060 Knotter shaft � � Pressure switch � � Twine � � Bottom � � Knotter 1 � � Knotter 2 � � Knotter 3 � � Knotter 4 � � Knotter 5 � Knotter 6 � Compactor � � Crank � � Worms (between rotor and compactor) � Cutting device � � Flywheel � � Star wheel 1 � � Star wheel 2 � � Pto � � � : Channels in additional CAN module

29 Standard diagnosis – Actors In the "Actors" diagnosis, the status of the actor channels is displayed. The functions can be tested manually (Diagnosis Manual) or automatically (Diagnosis Automatic): � Select actor channel: keys < > and < > � Actor On or Off: keys < > and < >. The following symbols are used for the actor status: Symbol Actor status Actor has been triggered (+) and has switched (+). Actor should be triggered (+), but has not switched (–). Attention, fault! E. g. actor channel in control unit defective. Actor not triggered (–), but has switched (+). Attention, fault! E. g. short circuit to chassis or broken wire. Actor has not been triggered (–) and has not switched (–). Valve diagnostic Valve diagnostic Valve diagnostic Valve diagnostic 1/2 1/2 1/2 1/2 Manual Manual Manual Manual Val. B Val. B Val. B Val. B Val. C Val. C Val. C Val. C Val. 45 Val. 45 Val. 45 Val. 45 Fan Fan Fan Fan Tying Tying Tying Tying Val. 67 Val. 67 Val. 67 Val. 67 Val. 89 Val. 89 Val. 89 Val. 89 PU STOP PU STOP PU STOP PU STOP Selected actor channel Here: manual diagnosis Because of special properties, the actor channel "Tying" is automatically switched off after an on-time of 0.5 sec..

Attention, danger of injury! Standard diagnosis may only be performed after the machine has been stopped: Switch off tractor engine, wait until machine has stopped, disconnect hydraulic supply to the machine. � Toggling between automatic and manual diagnosis: key < > (START/STOP). In the Diagnosis Automatic mode all channels are automatically triggered and tested in succession. The following symbols are used for the actor status: Symbol Actor status Actor channel is OK. Actor channel is faulty. Actor channel cannot be triggered. Here: Automatic diagnosis Valve diagnostic 1/2 Valve diagnostic 1/2 Valve diagnostic 1/2 Valve diagnostic 1/2 Automatic Automatic Automatic Automatic Val. B Val. B Val. B Val. B Val. C Val. C Val. C Val. C Val. 45 Val. 45 Val. 45 Val. 45 Fan Fan Fan Fan Tying Tying Tying Tying Val. 67 Val. 67 Val. 67 Val. 67 Val. 89 Val. 89 Val. 89 Val. 89 PU STOP PU STOP PU STOP PU STOP Because of special properties, the actor channel "Tying" is not tested in the Automatic Diagnosis.

31 Actors - Overview Note! See hydraulic plan "External supply system" in the operating manual D 6060 / D 4060. The following actors are included in the diagnosis: Actors D 6060 D 4060 Electr. tying � � Fan � � PU Stop � � Valve B � � Valve C � � Valve S1 (main valve, bottom) � � Valve S2 (direction valve 1) � � Valve S3 (direction valve 2) � � Valve S4 S5 (to hydraulic switch) � � Valve S6 S7 (to support foot) � � Valve S8 S9 (to bale extractor) � � Valve S11 (to chute) � � Valve S12 (hydraulic switch A4) � � Valve S13 (hydraulic switch A2) � � Valve S14 (hydraulic switch A1) � � Valve S15 (hydraulic switch A) � � � : Channels in additional CAN module Remark: The chain lubrication pump is supplied with bower via the switch box located in the tying mechanism area. Fan (blower) and chain lubrication pump are diagnosable only together: In diagnosis, any malfunction of the fan is indicated only, if e. g. the broken wire is located between main switch box and fan switch box. A broken wire between switch box/tying mechanism area and fan or chain lubrication pump is not diagnosable, not even if both consumers (fan and chain lubrication pump) are defective. If a fan or the chain lubrication pump does not work, this is in most cases due to a blown fuse in the switch box/tying mechanism area. Each fan is protected by a 10 A flat fuse (red), the fan to which the lubricating pump is connected is protected by a 15 A fuse (blue).

Standard diagnosis – Analog sensors In the "Analog sensors" diagnosis, all analog measuring values are displayed numerically and as a bar graph. The diagnosis screen "1/2" shows - besides the pressure - also the calibration value. When the system is in the pressure-off status, the calibration value is calculated anew after 30 sec.: The diagnosis screen "2/2" shows the output signal of the strain bolt. The displayed voltage drops with increasing strain: Analog channels - Overview The following digital sensors are included in the diagnosis: Analog sensors D 6060 D 4060 Pressure sensor � � Strain bolt � � Diagnosis Diagnosis Diagnosis Diagnosis 1/2 1/2 1/2 1/2 Analog sensors Analog sensors Analog sensors Analog sensors Pressure: Pressure: Pressure: Pressure: Calibrating: Calibrating: Calibrating: Calibrating: Diagnosis Diagnosis Diagnosis Diagnosis 2/2 2/2 2/2 2/2 Analog sensors Analog sensors Analog sensors Analog sensors Strainbolt: Strainbolt: Strainbolt: Strainbolt:

33 Extended diagnosis The extended diagnosis offers a possibility of viewing sensor and actor screens during machine operation. Operation of the extended diagnosis is identical to that of the standard diagnosis. In case of extended diagnosis, however, the operator has exclusively the function of an observer. Any interference in the sequence of machine operations, e. g. starting of the automatic actor diagnosis or switching of a selected actor channel, will immediately stop machine operation and thus the extended diagnosis. Attention, danger of injury! While the machine is in operation: Never climb the drawbar or any other parts of the machine. Keep sufficient distance to the range of action of the machine (support foot, pick-up, conveying elements, bale chute). Never stay or work below the machine. Never carry out any adjustment and maintenance work on the machine while the drive is running. Before opening the protections: Switch off p.t.o. shaft drive and tractor engine, wait until machine has stopped, remove the ignition key. Observe the safety instructions, chapter "General Information", page 8. � Return to the menue selection: Press key < >. � Return to MONITOR menue: press key < > for 3 sec. � Call extended diagnosis: press key < > and key < > simultaneously.

Indication for extended diagnosis: symbol flashing Diagnosis Diagnosis Diagnosis Diagnosis Digital sensors Digital sensors Digital sensors Digital sensors Twine Twine Twine Twine Packer Packer Packer Packer Cutt.dev Cutt.dev Cutt.dev Cutt.dev Worm Worm Worm Worm Val. B Val. B Val. B Val. B Val. C Val. C Val. C Val. C Val. 45 Val. 45 Val. 45 Val. 45 PU STOP PU STOP PU STOP PU STOP Fan Fan Fan Fan Tying Tying Tying Tying Val. 67 Val. 67 Val. 67 Val. 67 Val. 89 Val. 89 Val. 89 Val. 89 Valve diagnostic Valve diagnostic Valve diagnostic Valve diagnostic

35 DIAGNOSIS menue key functions - Overview Key Function in Diagnosis Page up Call up scope Page down Toggling between automatic and manual actor diagnosis: Actor channel On Actor channel Off Select actor Select actor Open menue overview (3 sec.: Monitor menue)

STATISTICS STATISTICS STATISTICS STATISTICS MENUE MENUE MENUE MENUE The STATISTICS menu provides an overview of � Machine running time per day counter � Number of bales per day counter � Total machine running time � Total number of bales The actual software supports 20 day counters. Only 1 day counter can be active at a time. � Return to the menue selection: Press key < >. � Return to MONITOR menue: press key < > for 3 sec. � Select day counter (view and activate): press key < > or < >. � Erase day counter: press keys < > and < > simultaneously for 3 seconds. Bale counter Machine running time Active day counter #3 Statistics Statistics Statistics Statistics

37 STATISTICS menue key functions - Overview Key Function in Statistics + Press both keys for 3 seconds: erase actual day counter. Select day counter Select day counter Open menue overview (3 sec.: Monitor menue)

EEEERROR MESSAGES RROR MESSAGES RROR MESSAGES RROR MESSAGES Error messages are displayed in a window above the current screen. Error messages consist of: � the word "STOP" � the error message in plain text � a warning triangle � the number of errors which occurred If several errors occur at the same time, the error message of the highest priority is displayed first. A distinction is made between: � System error messages � standard error messages System error messages System error messages can appear in all menues. System error messages cannot be removed by pressing a key/acknowledged. They disappear when the cause of the error has been eliminated.

39 System error: Short circuit in the sensor supply In case of short circuit or overload in the sensor supply, the sensor and actor supply of the control unit is switched off, an error window is opened and a buzzer gives a permanent sound. This error cannot be removed by pressing a key. It disappears when the cause of the error has been eliminated. System error: Excess voltage in on-board power supply In case of excess voltage in the on-board power supply (battery voltage > 17 Volt), the sensor and actor supply of the control unit is switched off, an error window is opened and the buzzer sounds permanently. This error cannot be removed by pressing a key. It disappears when the cause of the error has been eliminated. STOP STOP STOP STOP Emergency stop Emergency stop Emergency stop Emergency stop Short circuit in Short circuit in Short circuit in Short circuit in supply supply supply supply of sensors! of sensors! of sensors! of sensors! STOP STOP STOP STOP Emergency stop Emergency stop Emergency stop Emergency stop Battery voltage Battery voltage Battery voltage Battery voltage too high ! too high ! too high ! too high !

Standard error messages Standard error messages can appear in all menues. Exception: "Diagnosis" menue. The standard error messages "Overload" and "Wire broken" are not displayed there. Reaction to standard error messages: � Option 1: Press key < > to remove (acknowledge) the standard error message. Subsequently, the cause of the fault must be eliminated. � Option 2: The standard error message disappears automatically when the cause of the error has been eliminated. Standard error: Overload An error has occurred which has caused electrical overload of an output channel. The output is switched off. The error message can be removed via key; the output, however, remains blocked up to a new start of the system. � Remove/acknowledge error messages: press key < >. Error Error Error Error Overload Overload Overload Overload Val. B ! Val. B ! Val. B ! Val. B !

41 Standard error: Wire broken A broken wire or a non-connected load has been recognized. The error message can be removed by key depression or disappears automatically, when the load is connected again. � Remove/acknowledge error messages: press key < >. Standard error: Overload compactor The overload protection "compactor cut-out" responds in case of compactor overload. In case of compactor overload, the PU stop is activated (PU = pick-up). The error message can be removed by key depression or disappears automatically, when the overload has been removed. � Remove/acknowledge error messages: press key < >. Error Error Error Error Wire broken Wire broken Wire broken Wire broken Val. B ! Val. B ! Val. B ! Val. B ! STOP STOP STOP STOP Overload Overload Overload Overload packer! packer! packer! packer!

Standard error: Overload Worms The "Worms" overload protection responds in case of overload on at least one of the two worms (between rotor and compactor). In case of worm overload, the PU stop is activated (PU = pick-up). The error message can be removed by key depression or disappears automatically, when the overload has been removed. � Remove/acknowledge error messages: press key < >. Standard error: Twine empty The twine monitor signals that twine is missing on one of the tying mechanisms. The error message can be removed by key stroke, or disappears automatically when twine has been reloaded. � Remove/acknowledge error messages: press key < >. STOP STOP STOP STOP Overload Overload Overload Overload Worm Worm Worm Worm STOP STOP STOP STOP Twine Twine Twine Twine empty! empty! empty! empty!

43 Error screen „CAN module is missing“ There is no connection to the CAN module. The error message appears only � in case of faults on one or both CAN modules(s), or � in case of faulty electrical connection to one or both CAN module(s). � Remove/acknowledge error messages: press key < >. ERROR ERROR ERROR ERROR CAN module CAN module CAN module CAN module is missing! is missing! is missing! is missing!

AAAAPPENDIX PPENDIX PPENDIX PPENDIX The following pages are intended only for trained and instructed service personnel! System Service SYSTEM SERVICE provides the following submenues for first commissioning and servicing of the machine: Submenu Task see chapter MONITOR Terminate the SYSTEM SERVICE and start MONITOR menue, page 13. "MONITOR menue" page 13 SYSTEM SETUP Machine model toggling, if several user interfaces are available. "SYSTEM SETUP submenue" page 46 EEPROM CONTENTS Display of the EEPROM contents. "EEPROM CONTENTS submenue" page 48 SELF-TEST Self-test of the E-LINK control unit in connection with test equipment. "SELF-TEST submenue" page 50 Select submenue � Select SYSTEM SERVICE: when switching on the control voltage, keep the key < > depressed for 10 seconds. � Select submenue: keys < > and < >. � Confirm selection with key < >. Syste Syste Syste System setup m setup m setup m setup EPROM co EPROM co EPROM co EPROM connnntent tent tent tent Self Self Self Self----test test test test Monitor Monitor Monitor Monitor

45 SYSTEM SERVICE key functions - Overview Key Operation Select submenue Select submenue Open menue overview

MONITOR submenue This menu entry terminates SYSTEM SERVICE and causes return to the MONITOR menue, page 13. SYSTEM SETUP submenue The E-LINK system can be used on other prepared machine families. � Select machine family: keys < > and < >. � Open SETUP of the desired machine family: Press key < >. System setup System setup System setup System setup D 4000 D 4000 D 4000 D 4000----6060 6060 6060 6060

47 SYSTEM SETUP key functions - Overview Key Operation Select machine family Select machine family Calling of SETUP of the desired machine family

EEPROM CONTENTS submenue In this submenue, the contents of the EEPROM is shown in hexadecimal form (for diagnostic purposes). � Line scrolling: press key < > or < >. � Page scrolling: press key < > or < >. � Return to SYSTEM SERVICE: Press key < >.

49 EEPROM CONTENTS key functions - Overview Key Operation Scroll up by one line Scroll down by one line Scroll down by one page Scroll up by one page Return to SYSTEM SERVICE

SELF-TEST submenue A fully automatic self-test can be carried out only in connection with special test equipment designed for this purpose. The self- test cannot be started without this test equipment, and is not described here. � Return to SYSTEM SERVICE: Press key < >. Self Self Self Self----test test test test Please connect Please connect Please connect Please connect test test test test----appliance! appliance! appliance! appliance!

51 SSSSCOPE COPE COPE COPE In the E-LINK system, a scope is available in addition to the various diagnostic functions. So it is possible to view and analyze the status of all sensors and actors during the last 500 seconds. Viewing of all signals in real time is also possible. In each diagnostic screen, key < > leads to the pertinent scope screen. Digital Scope The digital scope is used for checking digital sensors and actors. When recording has been stopped (HOLD mode), an additional CURSOR function is available. Measured data recording: RUN: cont. recording HOLD: recording stopped Diagnosis page: Digital sensors Page number: 1/9 (presently selected) Designation of the sensor/actor channels Channels not used Time window:10 s Cursor position:490.0 s Digital se Digital se Digital se Digital sennnnsors sors sors sors Valve Valve Valve Valve

List of the abbreviations used: Sensors Actors Abbreviation Channel designation Abbreviatio n Channel designation FAD. Twine PU S Valves A+D PU stop PAC. Compactor B Valve B SW. Cutting device C Valve C BW. Knotter shaft S45 Valve 45 KN.1 Knotter 1 S67 Valve 67 KN.2 Knotter 2 S89 Valve 89 KN.3 Knotter 3 S15 Valve 15 KN.4 Knotter 4 S14 Valve 14 KN.5 Knotter 5 S13 Valve 13 KN.6 Knotter 6 S12 Valve 12 ZR.1 Star wheel 1 S11 Valve 11 ZR.2 Star wheel 2 S3 Valve 3 GL.B Bottom S2 Valve 2 D.S. Pressure switch S1 Valve 1 SCHN. Worm (between rotor and compactor) EL.B Electr. tying Switches Abbreviation Channel designation S.H Chute up S.R. Chute down BA.V Bale extractor forward BA.R Bale extractor backwards

53 DIGITAL SCOPE key functions - overview Key Operation Page up Entry / exit scope Page down Toggling RUN/HOLD mode (start/stop recording) Increase selected scope parameters Reduce selected scope parameters Select scope parameters Options : - Page shown - Time window set (10s - 20s - 50s - 100s - 200s - 500s) - Cursor position (in HOLD mode only) Return to SYSTEM SERVICE

Analog Scope The Analog Scope is used e.g. for checking the pto speed. When recording has been stopped (HOLD mode), an additional CURSOR function is available. Momentary value: 959RPM Offset: 840RPM Zoom factor: 5 Value measured (at cursor position: 977RPM Cursor position: 495.5 s Pto Pto Pto Pto Pto Pto Pto Pto

55 ANALOG SCOPE key functions - overview Key Operation Page down Entry / exit scope Page up Toggling RUN/HOLD mode (start/stop recording) Increase selected scope parameters Reduce selected scope parameters Select scope parameters Options : - Page shown - Time window set (10s - 20s - 50s - 100s - 200s - 500s) - Cursor position (in HOLD mode only) - Offset (0..90% measuring range) - Zoom factor (1x - 2.5x - 5x - 10x) Return to SYSTEM SERVICE