Platen Press and Fourth Corner Sealer Troubleshooting

Common Problems

Last Updated: Friday, October 7, 2022

CAUTION: DISABLE ALL MACHINE POWER AND OBSERVE LOCKOUT PROCEDURES PRIOR TO MAKING ANY ADJUSTMENTS TO THE MACHINE. FAILURE TO DO SO COULD RESULT IN SEVERE EMBARRASSMENT, INJURY OR DEATH.

PROBLEM: POWER ON LAMP won't illuminate.
SOLUTION: 1. Check E-STOP.
2. Ensure gates are closed and power is on.
3. Check for messages on HMI. Power may be on although the button lamp is burnt out.
4. Check fuses.
5. Check for correct voltages.
6. Check for messages on HMI. Servo communication may have failed or drives be disconnected which will prevent the "Servos ready to power on" relay from enabling.
PROBLEM: Machine won't go into AUTO or STEP cycles.
SOLUTION: 1. Machine is in an error condition; check display for error, reset
2. Control power is not on; see above.
PROBLEM: Spacer is not properly wet-out.
SOLUTION: 1. Glass data does not match actual spacer and glass used. Make sure glass is correct thickness (for example single strength glass rather than double strength). Make sure spacer is correct.
2. IG unit sat too long after being heated before being squished. Check process and line throughput to achieve minimum standing time.
3. IG unit not getting proper heat. Measure with handheld temperature sensor. Check heat lamp bulb, intensity settings and servo speeds
PROBLEM: IG Unit thickness incorrect, undersized.
SOLUTION: 1. Glass data does not match actual spacer and glass used. Make sure glass is correct thickness (for example single strength glass rather than double strength). Make sure spacer is correct.
2. Squish Offset parameter set too great. Check and adjust.
PROBLEM: IG Unit thickness incorrect, oversized.
SOLUTION: 1. Glass data does not match actual spacer and glass used. Make sure glass is correct thickness (for example single strength glass rather than double strength). Make sure spacer is correct.
2. IG unit sat too long after being heated before being squished. Check process and line throughput to achieve minimum standing time.
3. IG unit not getting proper heat. Measure with handheld temperature sensor. Check heat lamp bulb, intensity settings and servo speeds
4. Squish Offset parameter set too light. Check and adjust.
PROBLEM: IG Unit thickness incorrect, uneven.
SOLUTION: see also "Spacer is not properly wet-out" above.
1. Platens not parallel. Measure, adjust.
2. Drive belt loose. Check and adjust
3. Platens have become worn; check and fix / replace as necessary.
PROBLEM: Corner is not properly rolled down.
SOLUTION: Roller worn; check and replace.
XY or conveyor positions and parameters out of adjustment. Check and adjust.
PROBLEM: Axes seem to jerk from position to position.
SOLUTION: 1. Check AXIS SPEED PARAMETER, may be too high.
PROBLEM: Servo Communication Error
SOLUTION: 1. Normal on power-up. Home.
2. During regular operation, check logic voltage connections.
3. Check ethernet connections, try different patch cables.
PROBLEM: Frequent Servo Errors.
SOLUTION: 1. Normal on power-up. Home.
2. During regular operation, reset. If the problem persists, see below.
PROBLEM: Frequent Servo Errors. Position Error:
SOLUTION: 1. Position error tolerance set too low; see plc program.
2. Axis Torque Limit set too high; check & adjust - note: if the torque limit is set beneath a certain point (determined by the friction & inertia of the mechanical power-train) the motor will not be able to move.
3. Axis Accel / Decel / Speed set too high, check & adjust.
4. Poor Servo Cable connections; check motor & feedback cable connections at both the motor and drive sides.
5. Servo cable failure. Check & replace.
PROBLEM: Frequent Servo Errors. Position Error:
SOLUTION: 1. Position error tolerance set too low; see plc program.
2. Axis Torque Limit set too high; check & adjust - note: if the torque limit is set beneath a certain point (determined by the friction & inertia of the mechanical power-train) the motor will not be able to move.
3. Axis Accel / Decel / Speed set too high, check & adjust.
4. Poor Servo Cable connections; check motor & feedback cable connections at both the motor and drive sides.
5. Servo cable failure. Check & replace (if replacing, consider using 'high flex' cables).
6. Mechanical binding; check & clear.
PROBLEM: Frequent Servo Errors. Feedback Error; Encoder Fault.
SOLUTION: 1. Poor Servo Cable connections; check feedback cable connections at both the motor and drive sides.
2. Servo feedback cable failure. Check & replace (if replacing, consider using 'high flex' cables which are rated by millions of bend cycles.).
PROBLEM: Frequent Servo Errors. Hall Effect Error
SOLUTION: 1. Poor Servo Cable connections; check feedback cable connections at both the motor and drive sides.
2. Servo feedback cable failure. Check & replace (if replacing, consider using 'high flex' cables).
PROBLEM: Frequent Servo Errors. IPM Motor Fault / Over Temp / Over Current Fault
SOLUTION: 1. Poor Servo Cable connections; check motor cable connections at both the motor and drive sides.
2. Servo cable failure; check & replace (if replacing, consider using 'high flex' cables).
3. Drive failure; check and replace.
4. Stray wires shorting out terminals on drive; check and fix as necessary.
5. Binding during homing; check and clear any binding / blockages.
PROBLEM: Anything you can't figure out.
SOLUTION: CALL ERDMAN AUTOMATION AT 763-389-9475