Washer 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 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 mode.
SOLUTION: Check Washer screen on nearby operator interface screens for any alerts.
1. Machine power not on. See above.
2. AUTO / MANUAL selector switch not set to "Auto." Switch to "Auto."
3. Line set to "Wash Only Mode." Go to the parameter screen of the Spacer Applicator Machine operator interface and disable "Wash Only Mode."
4. Water level low. Check level sensors and display. Fill tank as needed.
5. Wash water not up to temp. Check heaters, RTD and displays.
6. Water impurity (PPM) too high. Check, drain and fill tank. Replace filters as needed.
7. Motor starter overload tripped. Check displays and mail electrical panel.
8. Some other fault has occurred. Press reset.
9. Line network down. Check status of ethernet switches, bulk-heads and cables.
PROBLEM: Glass won't outfeed from Washer
SOLUTION: 1. Shuttle station not in auto. Check status at push button box and HMI.
2. Shuttle Infeed full. Check Shuttle Infeed Staged sensor.
3. Data missing or faulty. Check Line Status on nearby operator interface.
PROBLEM: Glass won't infeed from Edge Delete
SOLUTION: 1. Washer or Edge Delete station not in auto. Check status at push button box and HMI.
2. Washer full, waiting for outfeed. Check status on Line Status screen.
3. Data missing or faulty. Check Line Status on nearby operator interface.
4. Line set to "Wash Only Mode." Go to the parameter screen of the Spacer Applicator Machine operator interface and disable "Wash Only Mode."
PROBLEM: Glass hits glass on washer infeed. Washer and Infeed conveyors are running but the glass does not go into the Washer from the Infeed.
SOLUTION: 1. Infeed Conveyor misaligned to Washer; check and adjust by moving or levelling line.
2. Rollers in washer sticking in spring floats. Check, clear and adjust.
3. Glass debris blocking entrance. Clear jam.
PROBLEM: Glass hits glass on washer infeed, Washer conveyor is not running.
SOLUTION: 1. Confirm that Washer conveyor is not running when second piece of glass comes in.
2. Check to make sure machine is in normal Auto mode.
3. Washer conveyor is in fact running. See above.
PROBLEM: Glass piles up / overlaps in Washer.
SOLUTION: 1. Make sure that glass is not getting stuck going from Infeed Conveyor to Washer conveyor. See above.
2. Check to make sure machine is in normal Auto mode.
3. Glass debris blocking entrance. Clear jam.
4. Glass coming loose, not well conveyed in washer. Rollers in washer sticking in spring floats. Check, clear and adjust.
5. SHUTTLE INFEED LOADED sensor misreading. Check and adjust.
6. Shuttle Infeed conveyor faulted. Check and adjust.
PROBLEM: Multiple pieces of glass slipping through and being sent to next station.
SOLUTION: 1. Make sure that glass is not getting stuck going from Infeed Conveyor to Washer conveyor. See above.
2. Check to make sure machine is in normal Auto mode.
3. Glass debris blocking entrance. Clear jam.
4. Glass coming loose, not well conveyed in washer. Rollers in washer sticking in spring floats. Check, clear and adjust.
5. SHUTTLE INFEED LOADED sensor misreading. Check and adjust.
6. Shuttle Infeed conveyor faulted. Check and adjust.
7. Part present sensor dirty. Clean with a clean dry cloth.
8. Glass loaded too close together on Infeed Conveyor. Distance from light to light should be an absolute minimum of 6".
PROBLEM: Wash water does not reach maintain desired temperature.
SOLUTION: 1. Confirm that HEATER selector switch is set to "On."
2. Confirm that desired heat is set to reasonable temperature.
3. Confirm that heater coil fuses have not blown or overloads tripped.
4. Confirm that heater coils have not burnt out.
5. Check to make sure that blower is not pushing too much air back into the wash chamber.
PROBLEM: Water level drops or is not maintained.
SOLUTION: 1. Check that valves to drain lines are closed and supply valve is open.
2. Check that filters are not clogged to the point of restricting flow. Replace as needed.
3. Check functioning of float valves.
PROBLEM: Water leaks from washer.
SOLUTION: 1. Glass debris built up, preventing seals from closing properly on doors or glass infeed area. Clean and remove any glass. Examine seals and flaps.
2. Doors not properly shut. Check. Shut.
3. Seals and rubber flaps worn or damaged. Check and replace as necessary.
4. Other leak has developed. Examine, trace and seal.
PROBLEM: Water impurity (PPM) too high.
SOLUTION: 1. Drain, clean tanks. Re-fill.
2. Check water filters. Replace as necessary.
3. Drain rinse tank. Remove PPM sensor and check in standardized solutions against another meter. Replace if not performing adequately.
Do NOT use soap or detergent in washer unless instructed by manufacturer.
PROBLEM: Glass spotted or shows water marks.
SOLUTION: 1. Drain, clean tanks. Re-fill.
2. Check blower filters, replace as necessary.
3. Check water temperature and make sure that it is running above minimum.
PROBLEM: Glass not dry upon exiting.
SOLUTION: 1. Check blower filters, replace as necessary.
2. Check water temperature and make sure that it is running above minimum.
3. Check water purity. Replace filters as necessary.
PROBLEM: Glass breaks in washer.
SOLUTION: 1. Glass getting stuck at infeed of Washer, next glass hitting it and pushing it in. See above.
2. Rollers in washer sticking in spring floats. Check, clear and adjust.
3. Glass coming loose, not well conveyed in washer. Rollers in washer sticking in spring floats. Check, clear and adjust.
4. Glass debris from earlier breakage blocking conveyor. Check; clear.
5. SHUTTLE INFEED LOADED sensor misreading. Check and adjust.
6. Shuttle Infeed conveyor faulted. Check and adjust.
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: Anything you can't figure out.
SOLUTION: CALL ERDMAN AUTOMATION AT 763-389-9475