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