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1.1 Mechanical Parts Trouble shooting

The filled Cartons are entering the Outfeed Conveyor and the Capacitive sensor detect the products inside the Carton. The Cartons are rejected which not have the products and the cartons are moved out.

Faults

Trouble Symptoms

Probable Causes

Tests & the Remedy

Induction Motors

Fail to start without load.

MCB Trips

(Automatic switch trips off, slow start with electro-magnetic noise)

1.Short circuit of circuit switches
2.Incorrect wiring
3.Poor contact at terminals
4.Windings grounded & Broken winding

1.Check circuit switches and replace.
2.Check wiring according to nameplate or refer electrical drawing.
3.Lock tightly
4.Factory Repair

Loading after start

MCB Trip (Fail to restart due to trip-off of automatic switch)

1.Insufficient capacity of fuse
2.High load at low voltage

1.Replace fuse if wiring permits.
2.Check circuit capacity and reduce load

Motor overheats

1.Motor Overloaded or intermittent overload.
2.Motor improperly connected to the Circuit
3.Electric Shock
4.A lack of ventilation
If there is something blocking the ventilation holes for your electric motor, then hot air won’t escape.

1.Remove the Load, run motor Idle. Give it General Inspection. Apply Load Gradually & note characteristics. Inspect for Localized heating.
2.Check Motor Line Connections
3.Check the Earthing of the Motor.
4.Scheduling regular maintenance on your motor can help reduce this risk.

Bearing Overheats

1.High Belt tension.
2.misalignment between motor & machine shaft
3.High Bearing noise

1.Adjust Belt tension.
2.Re-align.
3.Replace the damage bearing

Noise

Electro-magnetic noise induced by electricity.

1.Occurrence from its first operation
2.Sudden sharp noise & smoky

1.coulb be normal.
2.short circuit of windings, Factory repair

Mechanical noise caused by machinery.

1.Loose belt sheave
2.Loose coupling
3.Rubbing as a result of ingression of foreign materials
4.Wind noise
5.Bearing abrasion or they lack lubricating oil. 
6.The rollers are misaligned 

1.Adjust key and lock the screw.
2.Adjust the position of couplings, lock key and screw.
3.Clean motor interior and ventilation ducts
4.Noise induced by air flowing through ventilation ducts.
5. Have the Induction motor serviced:
(i) Change or clean the bearings.
(ii) Change or add the lubricating oil.
6.Realign the rollers 

Vibration

Electro-magnetic vibration

1.Short circuit of windings
2.Open circuit of rotor

Factory repair

Mechanical vibration

1.Unbalanced rotor & Unbalanced fan
2.Unsymmetrical centers between belt sheaves
3.Rollers Central points of couplings do not lie on the same level.
4.Improper mounting installation

1.Factory repair.
2.Align central points
3.Adjust the rollers central points of couplings to the same level.
4.Lock the mounting screws

Vibration

Induction Motors
Pneumatic System

Pneumatic System

Actuator Moving Abnormally Slow

Excessive air choke

1.Flow control valve incorrectly adjusted.
2.Plugged air silencer.
3.Air leak or squeezed tube
4.Plugged filter
5.Damaged cylinder or seal

1.Readjust the valve.
2.Replace or clean silencer.
3.Repair air leak or tube.
4.Replace air filter.
5.Replace cylinder or seal.

Pressure too low

1.Damaged or incorrectly adjusted pressure regulator valve
2.Plugged filter
3.System leaks
4.Directional or other valve open due to dirt or failed pilot circuit.
5.Cylinder pipe, piston or seal damaged

1.Replace regulator or readjust rating as shown in drawing.
2.Replace filter.
3.Fix leaks.
4.Locate damaged part and clean or replace it.
5.Repair or renew damaged parts.

Filter / Regulator / Lubrication Unit

Air leak at regulator

1.Continuous air leak from the small vent hole in the regulator bonnet
2.Failure of the diaphragm

1.The regulator should be scheduled for repair. Overhaul kits with diaphragm and seals are available for most standard regulators.
2.Replace a diaphragm or the seals as soon as possible after the leak is discovered.

Pressure problems

If diaphragm is cracked or broken

A high velocity air leak at the vent hole will occur. Replace diaphragm.

Filter problems

Over-contaminated, the filter element will create a pressure drop which may affect system operation

Clean or replace the filter element regularly

Directional Control Valve Not Changing Position

Coil not picking up.

Electric failure

Clean or replace the filter element regularly

Valve spool stuck

1.Impurities between spool and sleeve 

2.valve pilot not working

1.Replace valve.
2.Replace or clean piloting part.

Proportional valve not responding.

1.Valve not receiving set value from program.
2.Set value received but valve not responding

1.Locate and fix electric failure.
2.Replace the proportional valve.

Air Cylinders

No movement

1.Pressure too low
2.Piston seal leak
3.Scored cylinder bore

1.Check pressure at cylinder to make sure it meets circuit requirements.
2.Operate valve to cycle cylinder.
-Observe fluid flow at valve exhaust ports at end of cylinder stroke.
-Replace piston seals if flow is excessive
3.Replace necessary parts.
-Eliminate contaminants from air supply.

Erratic movement

1.Load misalignment
2.Large difference between static and dynamic friction

1. Re-align cylinder and load.
2.Install flow control valves to provide back pressure to control stroke.

Cylinder body seal leak

1.Loose tie rod
2.Seal deterioration - soft, gummy
3.Seal deterioration - hard, brittle. Usually due to temperature extremes.

Repair or replace.

Rod gland seal leak

1.Torn or worn seal
2.Seal deterioration - hard, brittle. Usually due to temperature extremes.

1.Examine piston rod for dents, gouges or score marks. Repair or replace.
-Check gland bearing for wear. Repair or replace.
2.Replace seals and shield cylinder from temperature extremes.

Gearbox

Gearbox

Overheats

Gear case becomes unusually hot.

1.Overload
2.Insufficient or excessive lubricating oil
3.Contaminated oil
4.Oil viscosity is improper
5.Bearing are improperly mounted
6.Shaft is connected improperly
7.Air vent port is closed
8.Ambient temperature is too high

1.Decrease load or use a larger model.
2.Adjust oil level so it aligns with mark on oil gauge
3.Flush interior and replace oil.
4.Change oil with one having the proper viscosity.
5.Reassemble and tighten properly
6.Align properly
7.Remove rubber plug from oil cap
8.Install cooling fan or move to cooler area

Noise

Unusual or excessive noise

1.Improper meshing
2.Bearings are damaged or worn
3.Overloaded
4. Insufficient oil
5.Oil seal is not wet with oil
6.Bearing are improperly mounted

1.Adjust properly
2.Replace bearings
3.Decrease load or use a larger model
4.Add oil so level aligns with oil gauge
5.Lubricate
6.Adjust the bearing

Vibration

Vibration is excessive

1.Gear teeth are worn.
2.Bearings are worn or damaged
3.Mounting bolts are loose

1.Replace wheel
2.Replace bearings
3.Tighten

Oil Leaks

Oil Leaks

1.Oil seal is defective.
2.Cover mounting bolts are loose
3.Air does not escape
4.Excessive oil

1.Replace oil seal
2.Tighten bolts
3.Check oil cap.
4.Adjust oil level so it aligns with mark on oil gauge.

Servo Motor

Servo Motor

Servo Motor Overheating

1.A very high supply voltage that exceeds the specified maximum value.
2.An overloaded motor or the servo motor is started up too frequently.
3.Worn bearings or the bearings were replaced with an incorrect type.
4.A high ambient temperature within the motor’s working environment. 

1.Reduce the voltage being supplied to the servo motor; for example, by adjusting the tapping point of the servo motors’ supply transformer.
2.Reduce off-peak or peak loads for load shedding
3.Have the servo motor serviced; repair worn-out bearings, replace the wrong type of bearings and reconfigure the rotor.
4.Reduce the ambient temperature in the motor surroundings by adopting appropriate cooling measures.

​Bearing Failure

Unlubricated Bearing

Grease lubrication or bearing replacement.

Dusty Brake

high-pitched squeal from your servo motor

soak up the oil, and lead to friction and screeching.

Smoky

Produces Smoke or Burning Odo

1.Loose servo motor coupling
2.Unbalanced supply voltage, which might be too high.
3.Bearing abrasion or they lack lubricating oil.
4.Presence of impurities like sand in the lubricating oil.
5.Presence of noise on the motor feedback signal wires or the controller speed reference signals

1.Check and fasten the servo motor coupling.
2.Check and adjust the supply voltage accordingly, to ensure that the servo motor is receiving appropriate amount of power.
3.Have the servo motor serviced:
(i) Change or clean the bearings.
(ii) Change or add the lubricating oil.
4.nspect all motor and controller cables, wiring and connections.
5.Verify that the servo motor is grounded properly.

Excessive Vibration

1.Uneven or big air gap caused by worn bearings or bearing abrasion.
2.Misalignment of the servo motor with the load being driven.
3.The rotating shaft of the servo motor is bending.
4.The coaxial of the servo motor coupling is too low, especially where a belt pulley is used.
5.Improper servo motor mounting. 

1.Check, repair or change the bearings if necessary.
2.Check alignment of the motor with driven load, couplings, and for any possible shim movement.
3.Check and correct both motor and load balance issues.
4.If the servo motor is belt coupled, remove the belt pulley and see if the coaxially is still too low or if the motor is still out of balance.
5.Inspect for worn or loose servo motor mounts. 

Overheats

1.Servo motor is overheating.
2.Too much lubricant, overheating or they’re worn.
3.Burning servo motor windings or wiring

1.inspect its ventilation or cooling system. & If it’s blocked by either accumulated dirt or dust particles, be sure to clean it as recommended.
2.Ensure that you service the servo motor or have the bearings repaired/changed.
3.Ensure that the servo motor is grounded properly
- Check all the motor wiring to ensure that the wires are contactless

Noise

Abnormal Noise

Vibration

2. Equipments Alarms Troubleshooting

Should a program or operational fault occur please refer to digital touch screen.  In most cases the screen will detail the cause of the fault and its location.

 Each alarm starts with a 3- or 4-digit number. This is called an Error Code.  The First Part of the Error Code defines the type of device, and the second part defines the type of fault. Each Type of Device will have a range of error Codes. For example, Cylinders have Error Codes ranging from 100 to 200. For most devices we have limited this range to be 100. Below is a list of the Device Types and on the following pages there are tables that can be referenced that specify all the types of alarms associated with a device and actions to solve each fault. 

A Typical Alarm would be displayed as shown below:

For example: -

Device Tag

SC1801 Infeed Servo 1 Motion servo ON Reset Control Fault

Device Description

Type of Fault

Please find the below Alarms Code

2.1 Cylinder Faults

All Cylinder Faults will have an Error Code between 100 and 200.

A Typical Cylinder Alarm is displayed as follows:

[101] CY1801, Minor Flap Folding Cylinder Reed Alarm

Cylinder Faults

Error Code

Type of Faults

Possible Cause

Solutions​

101

Reed Alarm

Cylinder has both Reed switches on at the Same time.

  • Check the Position of Both Reed Switches on the Cylinder. 

  • Check the for-cable damage.

  • Check electrical terminations.

102

Extend Alarm

The Cylinder Extend Solenoid is ON, and the Extend Reed Switch has been off for a period of time greater than the Extend Fault time.

  • Check the Position of the Extend Reed Switch on the Cylinder.

  • Check the Cylinder has not been damaged.

  • Check for cable damage.

  • Check electrical terminations.

  • Check the Extend Fault time preset. This can be adjusted from the Cylinder Faceplate screen.

103

Retract Alarm

The Cylinder Retract Solenoid is ON, and the Retract Reed Switch has been off for a period of time greater than the Retract Fault time.

  • Check the Position of the Retract Reed Switch on the Cylinder.

  • Check the Cylinder has not been damaged.

  • Check for cable damage.

  • Check electrical terminations.

  • Check the Retract Fault time preset. This can be adjusted from the Cylinder Faceplate screen.

130

Manual Extend Enabled

The Cylinder Manual Extend Function has been enabled. This will override all other control.

  • When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.

131

Manual Retract Enabled

The Cylinder Manual Retract Function has been enabled. This will override all other control.

  • When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.

132

Manual OFF Enabled

The Cylinder Manual OFF function has been enabled. This will override all other control.

  • When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.

133

Alarm Mute

The Cylinder Alarm Mutehas been enabled. Not operatable  during machine is running Condition

  • When this is active the Alarm mute of this button will glow .Go to that particular cylinder and turn off the Alarm Mute button

The Cylinder test cycle has been enabled. Not operatable  during machine is running Condition

  • When this is active the Alarm mute of this button will glow .Go to that particular cylinder and turn off the Alarm Mute button

Cycle Enabled

134

2.2 Miscellaneous Input Faults

All Miscellaneous Input Faults will have an Error Code between 400 and 500.

A Typical Miscellaneous Inputs Alarm is displayed as follows:

[401] PE2301, Blister Presence Detect PE Alarm

Miscellaneous Input Faults

Error Code

Type of Faults

Possible Cause

Solutions​

401

Alarm

​This is a general Fault for a miscellaneous Input. It is generally raised when the input is ON when it is expected to be off.

  • Check the operation of the Device. For Example, check that a photocell is switching on and off when objects pass in front of it.

  • Check for cable damage.

  • Check electrical terminations.

  • Check PLC input is switching.

410

Manual ON Enabled

The Miscellaneous Input Manual ON Function has been enabled. Not operatable  during machine is running Condition

  • When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.

411

Manual OFF Enabled

The Miscellaneous Input Manual OFF Function has been enabled. Not operatable  during machine is running Condition

  • When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.

412

Alarm Mute Enabled

The Miscellaneous Input Alarm Mute Function has been enabled. Not operatable  during machine is running Condition.

  • When this is activated the alarm will displayed on current alarm and can be turned off at that particular component  mimic popup .

2.3 Miscellaneous Output Faults

All Miscellaneous Output Faults will have an Error Code between 400 and 500. 

A Typical Miscellaneous Output Alarm is displayed as follows:

[501] SV1501, Plucker Vaccum Alarm

Miscellaneous Output Faults

Error Code

Type of Faults

Possible Cause

Solutions​

501

Alarm

This is a general Fault for a miscellaneous Output.

  • Check the operation of the Device.

  • Check for cable damage.

  • Check electrical terminations.

  • Check PLC input is switching.

510

Manual ON

The Miscellaneous Output Manual ON Function has been enabled. This will override all other control. This can be used to force a signal ON. 

  • When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.

511

Manual OFF

The Miscellaneous Output Manual OFF Function has been enabled. This will override all other control. This can be used to force a signal OFF.

  • When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.

2.4 Air Pressure Fault

Air Pressure low alarm shows when incoming air pressure is low.

A Typical Air Pressure Fault is displayed as follows: 

SV0401, Air Pressure Low Fault

Air Pressure Fault

Error Code

Type of Faults

Possible Cause

Solutions​

501

 Air Pressure Low Fault

Air Pressure low alarm shows when incoming air pressure is not equal or greater than the sated value on the pressure switch.

  • Check the Incoming air Pressure is not less than 5bar/ low.

  • Check the incoming air ON/OFF knob. It will be ON position.

2.5 IRB 4600 Robot Troubleshooting (ABB)

IRB Robot  Faults

Error Code

Type of Faults

Possible Cause

Solutions​

201

Emergency Stop Activated

E-Stop button pressed

  •  Reset all Emergency Stop buttons

  • Check safety circuit status

202

Safety Interlock Active

Guard door open

  •  Close all safety doors

  •  Reset safety relay

  • Be out of Light Curtain Range​

203

Servo Off Fault

Servo power disabled

  • Turn Servo ON from HMI/Teach Pendant

  •  Check servo drive status

204

Robot Collision Detected

Obstruction in robot path

• Remove obstruction

• Reset collision alarm

• Restart robot

205

Program Fault

Program error or stop command

  • Check running program

  •  Restart cycle from HMI

206

Communication Failure

PLC/Robot communication lost

  • Check Ethernet cables

  • Verify IP configuration

  •  Restart PLC & controller

207

Drive Fault

Servo drive error

  •  Check drive alarm message

  • Reset drive faultI

  • nspect motor/drive

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