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 conductor
• Check for VFD faults (reference manufacturer’s documentation)
• Check guard doors
• Check motor starters and contractors 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