| PROBLEM: | POWER ON LAMP won't illuminate. |
| SOLUTION: | 1. Check E-STOP. |
| 2. Ensure gates are closed and main power is on. The touch screen message banner will display the current status. | |
| 3. Check HMI display and see of Power Off message is displayed. If not, replace indicator light. | |
| PROBLEM: | Machine won't go into AUTO. |
| SOLUTION: | 1. Machine is in an error condition; check display for error, reset or home machine as needed. |
| 2. Control power is not on; see above. | |
| PROBLEM: | Multiple pieces of glass slipping through and being sent to next station. |
| SOLUTION: | 1. Glass loaded too close together on Infeed Conveyor. Distance from light to light should be an absolute minimum of 6". |
| 2. Sensor dirty. Clean with a clean dry cloth. | |
| PROBLEM: | Glass won't transfer from Shuttle Infeed to Shuttle. |
| SOLUTION: | 1. Not in cycle or in cycle stop. Press START button. |
| 2. Glass data missing or incorrect. Check Line Status on nearby operator interface. | |
| 3. Check machine status display message on Line Status screen. | |
| 4. SHUTTLE INFEED or OUTFEED OUTFEED CLEAR sensor is blocked or dirty. Shuttle cannot move to infeed position. Check; clean. | |
| PROBLEM: | Glass won't transfer from Shuttle to Spacer Applicator Infeed |
| SOLUTION: | 1. Not in cycle or in cycle stop. Press START button. |
| 2. Spacer Applicator Infeed not in Auto Mode. Check the Spacer Applicator touch screen; select Auto and press START. | |
| 3. Sensor dirty. Clean with a clean dry cloth. | |
| 4. Glass data missing or incorrect. Check Line Status on nearby operator interface. | |
| 5. Base or Cap glass missing. Check; adjust; update display. | |
| 6. Glass set to feed through front only or back only but glass present both front and back. | |
| 7. Check machine status display message on Line Status screen. | |
| 8. SHUTTLE INFEED or OUTFEED OUTFEED CLEAR sensor is blocked or dirty. Shuttle cannot move to outfeed position. Check; clean. | |
| PROBLEM: | VFD / Blower / Conveyor doesn't run. |
| SOLUTION: | 1. Check function by manually jogging conveyor from HMI after resetting. |
| 2. Cycle e-stop power. | |
| 3. Check for missing data, glass. | |
| 4. Check part present sensors. | |
| 5. Check fuses | |
| 6. Check ethernet cable connections and routers. | |
| 7. On recently replaced hardware, confirm all parameters are correctly entered and the IP address is correct and not overlapping existing active addresses. Check data link parameters (Powerflex 525s: C153-C160) | |
| PROBLEM: | Axes seem to jerk from position to position. |
| SOLUTION: | 1. Check AXIS SPEED, ACCEL or DECEL PARAMETERS, 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. Look for IO faults on PLC's LED indicators. | |
| 4. Make sure that all servo drives controlled by PLC are powered on. Note some servo drives may be in the cabinet of other machines. | |
| PROBLEM: | Frequent Servo Errors. |
| SOLUTION: | 1. Normal on main cabinet 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 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 Accel / Decel / Speed set too high, check & adjust. | |
| 3. Poor Servo Cable connections; check motor cable connections at both the motor and drive sides. | |
| 4. Servo cable failure. Check & replace (if replacing, consider using 'high flex' cables). | |
| 5. Mechanical binding; check & clear. | |
| PROBLEM: | Frequent Servo Errors. Feedback Error; Encoder Fault. |
| SOLUTION: | 1. Poor Servo Cable connections; check 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 or interference during homing; check and clear any binding / blockages. Note: a servo axis must NEVER be able to move so that the home sensor is on the "wrong" side of the home flag. | |
| PROBLEM: | Servo Error: Duplicate address found. |
| SOLUTION: | Another device has been added to the network with the same IP address. Check for recent additions. Isolate and track down using "ping" and other computer tools. Cycle power. |
| PROBLEM: | Anything you can't figure out. |
| SOLUTION: | CALL ERDMAN AUTOMATION AT 763-389-9475 |