Troubleshooting Guide  (Maintenance Schedule)

Air Cylinders

Cylinder not extending or retracting

• Check air supply
• Check cylinder switches for proper function; the switches should “make” at the ends of the cylinder stroke
• Check flow controls
• Check to ensure cylinder is not bent or broken
• Check valve to ensure it is functioning properly
• Manually cycle valve to ensure cylinder is receiving proper signal

Bearings

Bearing noise

• Check for proper lube
• Check for proper shaft alignment
• Check for broken housings
• Ensure all setscrews are in place and tight

Bearing seized

• Replace

Chain Wear

Excessive chain wear

• Check chain and sprocket alignment
• Check drive requirements
• Check for abnormal tension
• Check for components interfering with the chain

Conveyor

Conveyor not running

• Check bearings, motors and drives
• Check for proper chain lube
• Check drive fuses
• Check E-Stop buttons
• Check for adequate power to the drive or contactor
• Check for VFD faults (reference manufacturer’s documentation)
• Check guard doors
• Check motor starters and contactors for functionality
• Check photo eyes
• Check upstream surge controls, photo eyes etc.
• Clear any jams
• Ensure motor is running
• Ensure product availability

Flaps

Flaps not glued

• Check air supply to tank and glue heads
• Check for clogged nozzles (most common condition)
  • If this machine has in-line filters in the hose at the glue head fitting, these filters should be replaced regularly
• Check for debris in the glue path
• Check for proper nozzle aim and glue placement
• Check glue tank for product and correct temperature
• Ensure glue bead settings have not been changed or altered
• Ensure glue heads are functioning
• Ensure sensor is functioning (if a sensor is used)
• Call for Technical Support

Machine Fault

Fault will not reset

• Clear all fault pop-up messages on message center
• Clear all fault causes
• Ensure all guard doors are closed
• Ensure all guard door switches are functioning properly
• Call for Technical Support

Machine Start or Run

Machine will not start or run

• Check air supply level
• Check magazine levels
• Check message center
• Ensure machine faults have been reset
• Ensure all guard doors are closed
• Ensure E-Stop buttons are not pressed
• Check upstream surge controls
• Ensure adequate vacuum levels exist
• Ensure all guard door switches are functioning properly
• Ensure glue systems are ready
• Ensure servos are in proper start position

Motor (AC or DC)

Motor not running as expected

• Check drive and/or motor starter fuses
• Check Variable Frequency Drive to ensure proper function
• Ensure proper voltage is being supplied to the motor

Photo Eyes

Photo eyes not responding as expected

• Ensure LED cycles when blocked and unblocked
• Ensure photo eye has not been moved or bumped out of position
• Ensure photo eye is clean and its sight path is uninhibited
• Ensure reflector is in place
• Ensure photo eye and cable are correctly connected
• Check the sensitivity level setting
• Check input and output in electrical cabinet(s)

Servo Motors

Servo motor not performing correct motion profile

• Ensure motion path is free from obstructions
• Ensure settings on HMI are correct
• Check motor and feedback cable for damaged or broken wires
• Replace drive
• Replace motor
• Call for Technical Support

Servo motor not in reference or correct position

• Check for jam not allowing motor to finish motion profile
• Check for bent or broken parts
• Check if values for reference positions have changed on HMI
• Ensure mechanical attachment is tight and has not moved, for instance: belt clamp and belt
• Re-reference motor to reference location
• Check if motor is referenced against correct permanent stop
• Check if motor is properly referenced and triggering homing prox

Noisy servo motor

• Check for outside interferences
• Ensure internal brake is off/on at proper times (for most brake motors, the brake engages when power is removed, such as in an E-Stop condition)
• Ensure mechanical coupling is tight and not slipping
• Call for Technical Support

Vacuum

Vacuum cups or heads not picking case, carton, or product

• Check vacuum cups for damage, debris, tears or leaks (place a non-porous material over vacuum cups; the vacuum switch or gauge should show adequate vacuum levels)
• Check vacuum lines
• Ensure vacuum cups contact the case or product (see servo positions)
• Check for plugged lines or orifices
• Check product for areas that may cause leaks or lack of vacuum
• Check system vacuum by activating vacuum valve manually and checking vacuum level

Maintenance Schedule  (Troubleshooting Guide)

These maintenance items should be checked and performed periodically to ensure optimum performance of your system

Every Shift, or Daily

• Check conveyor belts for wear, alignment and cleanliness
• Check gearboxes for leaks
• Check photo eyes and reflectors for proper operation and positioning
• Check vacuum lines, hoses and cups
• Clean dust and debris from photo eyes
• Clean glue from machine
• Drain air filters and regulators
• Inspect machine for unusual component wear or fatigue
• Remove debris, dirt, grime, dust and other foreign materials from moving parts to lengthen life

Every 50 Hours of Operation

• Check chain drive for tension and adjust to ½ to ¾ inch total play between sprockets, if needed
• Grease rod ends, using #1 or #2 food grade grease
• Grease Thompson bearings on magazine, using #1 or #2 food grade grease
• Lightly oil roller chain if it runs continuously (see Every 6 Months for Adjustment Chain recommendations)

Every 100 Hours of Operation

• Check vacuum pump oil level and fill as needed. Refer to Manufacturer’s datasheet for recommended oil and maintenance information

Weekly

• Check air cylinders, replace as needed
• Check and clean or replace vacuum filters
• Check chain and belt tension
• Check chains for wear and proper alignment
• Check for loose fasteners
• Lightly oil v-wheel rollers and rails

Monthly

• Check all safety circuits
• Check cartridge bearings, replace as needed
• Check for bent shafts, screws or other components
• Check V-rollers periodically; tighten if required
• Adjustment chains: lightly oil roller chain

Every Six Months

• Check gear box fluid levels and refill as necessary. Refer to Manufacturer’s data sheet for recommended oil, grease and maintenance information

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