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Fault Recovery Procedure

Alarm Name:
Lubrication Monitoring DKAK =05-PRS02

Alarm Description:
The DKAK Counting Unit proximity switch has not detected the minimum stroke count.
Click here for component location

Possible Causes:
1. Press stopped near Top Dead Center (170 - 190 degrees).
2. Oil volume coming out of Regulator Valve 201.02 is below 505 cm3/min.
3. Distributor Block 201.11 not supplying Distributor Block 201.14 with required 225 cm3/min of oil.
4. Distributor Block 201.14 not supplying DKAK Counter Unit with required 56 cm3/min of oil.
5. Malfunctioning or improperly set Pressure Valve 201.18.
6. Malfunctioning DKAK Counter Unit.
7. Mechanical damage.
8. No input to Controller.

Recommended Action:
  1. Move the Press off Top Dead Center (TDC). Click here for procedure.
  2. Then, bring up the Lubrication Monitoring Screen. Once the Actual count has exceeded the Minimum Pulse Count, the press can be restarted.

    Before continuing with this procedure, visually inspect the DKAK unit to see if it is working. First look at the proximity switch to see if the red LED located on the switch body is turning on and off. If it is, you know the proximity switch itself is working properly. If the LED light is not turning on and off, look through the round sightglass to see if the small metal rod is moving in and out. If it is, you know the DKAK unit is working and should troubleshoot the proximity switch. If it isn't, continue on to the next step in this procedure.
  3. Check the oil volume coming out of Regulator Valve 201.02. The oil volume must be at least 505 cm3/min. Click here for procedure

    1 cm3 = 1 ml.
  4. If the oil volume out of Regulator Valve 201.02 is OK, troubleshoot the Distributor Block 201.11 segment M1.5 supplying oil to the Distributor Block 201.14. Click here for procedure
  5. If the Distributor Block segment is working properly, troubleshoot the Distributor Block 201.11 segment M1 supplying oil to the DKAK Counter Unit. Click here for procedure
  6. Troubleshoot the Pressure Valve. Click here for procedure
  7. Troubleshoot the DKAK Counter Unit. Click here for procedure
  8. No lube counts can be an indicator of internal mechanical damage. The mechanical damage can block the lubrication port, thereby halting the flow of oil. Abnormally high pressure readings are indicators of mechanical damage. The high pressure readings should be detected when the distributor block is tested during step 4. To determine what component is damaged, loosen each lube point fitting one at a time. When you loosen the blocked fitting, the lube pulse counts will begin to increase.
  9. If the DKAK Counter Unit is OK, cover the end of the DKAK Counter Unit proximity switch with a metallic object so it is ON, and then check Input Module S101EA3 to see if indicator light #6 (E32.4) is lit. If it is, the input is OK, but there may be a problem with the Controller. If the light is not lit, check for a broken wire between the proximity switch and the Input Module. If the wiring is OK, replace the Input Module. Click here for drawing