SECTION 6 TROUBLE-SHOOTING - Sea
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1. causing a Photo Eye Fail alarm once too much contamination occurs This fault can also be caused by a damaged fiber optic cable causing low gain or if the Reject Photo Eye gain potentiometer is set too low Output Code 101 Tester did not Reject Defective Can This message indicates that the Reject Verification sensors in the reject chute did not detect a can rejected when the reject blow off was activated This indicates that a problem with the blow off solenoid air or blow off photo eye may exist Verify the operation of the blow off solenoid by depressing the Test Blow off key on the HSMLT module while the machine is running A single can should be rejected when the key is depressed If not trouble shoot the reject blow off system Output Code 110 Can Presence Sensor Failure This message is generated when the Reject Photo Eye detects a significantly greater number of cans coming out of the machine than the Can Presence Sensor sees coming in Generally this occurs when the Can Presence Sensor fails no change of state or when it misses cans set too far out to detect all the cans or is missed timed sees leading edge of can coincident with Sync timing In some cases this can be caused by the Reject Photo Eye simply double clocking damaged fiber cables or miss adjusted lenses Verify the machine set up be performing the steps in the section 6 2 Output Code 111 SYSTEMS Electronics Grou2. the lenses must be able to see thru the valley created by the two necks b Verify the lenses cannot see over the top of the can when the can is pushed or tilted toward the dome c Verify the gain potentiometer on the body of the Q23SP6 Photo Eye is fully clockwise max gain This is a turn pot 10 With the machine running in normal production verify the positions that the critical inputs come in see section 2 10 7 These inputs include the Reject Receiver Array Fault Receiver Can Presence Sensor and Vision Reject signal None of these signals should come in within 60 degrees of the Sync timing otherwise FIFO errors may occur SYSTEMS Electronics Group 89 SECTION 6 TROUBLE SHOOTING ASL LTA LTS User s Manual 11 For aluminum can installations Verify that the can flow from the discharge is smooth and that the cans are not intermittently bouncing back into the discharge Since the Reject Photo Eye is used to calculate the speed of the can as it is rejected and thus lead the blow off based on this speed the can must flow past the sensor and reject port at a constant rate If a can goes past the sensor and then is knocked back by the previous can the reject port will not fire at the right time and a clean reject will not occur Also in severe cases instability in the discharge can flow can cause FIFO error corrections because the Reject Photo Eye may be double clocked when cans bounce bac
3. HSL LTA LTS User s Manual SECTION 6 TROUBLE SHOOTING The following is provided as a quick reference to aid in the trouble shooting of the HSL LTA LTS Definitions and causes of the various alarm messages displayed by the HSMLT module is provided as well as a general step by step trouble shooting process 6 1 HSMLT ALARM MESSAGE DEFINITIONS In addition to the default and set up messages described in the previous sections alarm and status messages are displayed on the HSMLT display These messages correspond to the binary code output on B101 5 bit0 through B101 7 bit2 The definitions of these messages are as follows Leak Detection Array Fault This message occurs when a fault in a leak detection array head occurs Array Fault Receiver did not detect array head LED when array head passed by Output Code 001 Can Jam or Back up at Discharge This message is displayed if either a jam occurs at the discharge of the tester Reject Photo Eye covered continuously or if the Reject Photo Eye fails In general if cans are running into the machine but the Reject Photo Eye does not see individual cans coming out this alarm occurs Output Code 010 Timing Resolver Fail The timing resolver fail occurs when any of the four timing signals generated in the PLS section fail to change state periodically while the machine is running Motion must be detected on all four timing signals six seconds after the Machine Run inpu
4. assumed by the system and is used as part of the speed calculation to lead when to activate the blow off Changing this distance will change where the air hits the can Verify and if necessary adjust the Reject Solenoid Pulse time see section 3 5 2 2 Set Reject Blow off Parameters Verify and if necessary adjust the Can Neck Size see section 3 5 2 2 Set Reject Blow off Parameters The Can Neck Size parameter can be used to compensate for the response time of the blow off solenoids To advance the blow off activate solenoids earlier make the Can Neck Size larger To retard the blow off activate the solenoids later make the Can Neck Size smaller SYSTEMS Electronics Group 92 SECTION 6 TROUBLE SHOOTING Steel Can Installations 1 Verify that both reject solenoids are firing Verify a pulse of air from the both the nozzle and manifold when the Test Blow off key is depressed 2 Verify air pressure to reject system is 90psi or greater 3 Verify that the length of the air line from the reject solenoid to the reject manifold is less than 4 Air line longer than this will increase the response time solenoid activation to air out manifold and reduce the pressure at the exit of the manifold 4 Verify vortex nozzle of upper reject solenoid points down at an angle into the can This maximizes the reject force 5 Verify the distance from the centerline of th
5. e Reject Photo Eye fiber lenses to the centerline of the reject manifold and nozzle is 5 This distance is assumed by the system and is used as part of the speed calculation to lead when to activate the blow off Changing this distance will change where the air hits the can 6 Verify and if necessary adjust the Reject Solenoid Pulse time see section 3 5 2 2 Set Reject Blow off Parameters 7 Verify and if necessary adjust the Can Neck Size see section 3 5 2 2 Set Reject Blow off Parameters The Can Neck Size parameter can be used to compensate for the response time of the blow off solenoids To advance the blow off activate solenoids earlier make the Can Neck Size larger To retard the blow off activate the solenoids later make the Can Neck Size smaller HSL LTA LTS User s Manual SYSTEMS Electronics Group 93
6. id check out OK but the pocket to pocket 0 location is still not right replace the RSV34 MS1 resolver HSL LTA LTS User s Manual SYSTEMS Electronics Group 88 HSL LTA LTS User s Manual SECTION 6 TROUBLE SHOOTING 8 Verify the Can Presence Sensor The Can Presence Sensor is used 9 to clock the cans into the FIFO so the set up of the sensor is critical Verify the following a Verify the Can sensor sees a can when positioned in front of it b Verify the Can sensor is set at about 125 from the body of can positioned in front of the sensor Adjust if necessary c Determine the position the Can Presence Sensor turns on With a can in a pocket rotate the machine forward until the Can Presence Sensor just turns on This position cannot be within 60 degrees of the Sync timing Adjust the sensor if necessary to achieve this Verify the Reject Photo Eye The fiber optic lenses of the Reject Photo Eye must be mounted such that the neck of the can breaks the beam Knowing the neck size the time the neck of the can breaks the beam of the Reject Photo Eye is used to calculate the speed of the can and thus lead the blow off solenoid correctly at all speeds In addition the Reject Photo Eye is used to clock the cans out of the FIFO so the set up of the Reject Photo Eye is critical Verify the following a Verify the fiber optic lenses see the neck of the can With two cans side by side
7. k into the machine 12 For steel can installations For steel food cans that do not have a neck make sure the distance between cans on the magnetic conveyor at the tester top speed is 3 8 or more The Reject Photo Eye has to see the individual cans beam must be able to pass between individual cans 13 If after performing the previous steps 1 thru 12 the system is still not functioning correctly perform all the steps in the set up section 2 5 14 If after performing step 13 the system is still not functioning correctly replace the HSMLT M4503 module and try again See section 2 11 for details on replacing the module SYSTEMS Electronics Group 90 HSL LTA LTS User s Manual SECTION 6 TROUBLE SHOOTING 6 3 CAN REJECT PROBLEMS TROUBLE SHOOTING If the system is having problems cleanly rejecting cans from the discharge conveying into the reject chute perform the following Note The reject can be verified at full production speeds using the Test Blow Off key on the keypad of the HSMLT M4503 module Depressing this once will cause one can to be rejected just as a normal reject would occur Also this key can be pressed with the machine stopped to verify the reject solenoids The solenoids will be pulsed for the same time when the key is hit just as if the machine was running Aluminum Can Installations 1 Verify that both reject solenoids are firing Disconnect the air lines from b
8. oth solenoids and verify a pulse of air from each solenoid when the Test Blow off key is depressed 2 Verify air pressure to reject system is 90psi or greater 3 Verify that the length of the air lines from the reject solenoids to the reject manifold is less than 4 Air lines longer than this will increase the response time solenoid activation to air out manifold and reduce the pressure at the exit of the manifold 4 Verify the distance between the face of the reject manifold and can is 1 4 If the manifold is placed closer to the can than this less reject force occurs because air induction to the stream of air at the exit of the manifold is reduced 5 Verify the manifold is pointed perpendicular or slightly into the flow of cans Pointing the manifold slightly into the flow of cans increases the angle that a can will be rejected Pointing the manifold slightly with the flow of cans will decrease the angle that a can is rejected 6 Verify the distance opening in discharge track work from the centerline of the manifold to the lip of the funneling plate is 8 In general an opening of less than 8 will not allow the can to cleanly reject at high speeds SYSTEMS Electronics Group 9 SECTION 6 TROUBLE SHOOTING ASL LTA LTS User s Manual 7 Verify the distance from the centerline of the Reject Photo Eye 8 9 fiber lenses to the centerline of the reject manifold is 5 This distance is
9. p 86 SECTION 6 TROUBLE SHOOTING 6 2 CAN TRACKING ERRORS TROUBLE SHOOTING If the system is intermittently rejecting the wrong can or incurring Excessive FIFO Correction faults perform the following to trouble shoot the system 1 Verify the FIFO Error Correction is calibrated correctly Perform all the steps in section 2 10 6 If after calibrating the FIFO correction the system is still not functioning correctly perform the following steps 2 thru 4 2 Check the RSV34 MS1 Resolver mounting and resolver coupler for obvious damage broken or loose coupler or mount 3 Check the Can Presence Sensor for obvious damage bent mounting bracket sensor damaged etc 4 Check Reject Photo Eye and fiber cables for obvious damage damaged L2 lenses on fiber cables crushed or broken fiber cables fiber cable mounting in Q23SP6 photo eye loose or damaged Q23SP6 sensor failed etc 5 Ifno obvious damage is detected in steps 2 thru 4 above perform the following steps 6 thru 13 6 Position the machine at machine zero see section 2 10 4 From the 3 Set Machine Timing selection of the Set up menu verify the position reads 000 degrees 20 degrees If not re zero the resolver HSL LTA LTS User s Manual SYSTEMS Electronics Group 87 SECTION 6 TROUBLE SHOOTING 7 Verify 360 degrees per pocket Position the machine at 0 degrees A pocket should be aligned with the
10. reset lamp centered in the reset photo diode of a pocket By hand move the machine forward one pocket such that the next pocket is centered on the reset lamp the position should count up thru 359 and again be at 0 degrees Do this for all the pockets Note The position may deviate 20 degrees from pocket to pocket This is normal and is not a problem If it does deviate significantly more than 20 degrees perform the following a Using a DVM in AC mode measure the voltage between R1 and R2 on the HSMLT M4503 resolver connector This should read 1 0 to 1 5 VRMS AC voltage If no voltage is read replace the HSMLT M4503 module see section 2 11 Be sure the DVM is in AC mode this is not a DC voltage b Again using the DVM in AC mode verify the voltage between S1 and S3 on the HSMLT M4503 module resolver connector while slowing rotating the machine forward one pocket The voltage should vary between 0 and 2 0 VRMS If the voltage always stays at zero as the machine is moved forward check the resolver wiring for a loose connection If the wiring is OK replace the RSV34 MS1 resolver c Check the voltage between S2 and S4 on the HSMLT M4503 module resolver connector just as was done for S1 and S3 above It should read just as S1 and S3 should read d If steps a thru c above check out OK check the resolver coupler Make sure the key in the resolver shaft is installed and the coupler is tight e If a thru d d
11. t B110 0 turns on in order to avoid this fault Output Code 011 Excessive FIFO High Corrections This fault occurs when more than five FIFO high corrections see section 2 10 6 occur within 5 minutes of accrued run time Normally no more than a few corrections per hour should occur A High correction occurs when either the Can Presence Sensor double clocks a can unlikely or the Reject Photo Eye misses a can Verify the machine set up be performing the steps in section 6 2 Output Code 100 SYSTEMS Electronics Group 85 SECTION 6 TROUBLE SHOOTING HSL LTA LTS User s Manual Excessive FIFO Low Corrections This fault occurs when more than five FIFO low corrections see section 2 10 6 occur within 5 minutes of accrued run time Normally no more than a few corrections per hour should occur A Low correction occurs when either the Can Presence Sensor misses a can or the Reject Photo Eye double clocks a can Verify the machine set up be performing the steps in section 6 2 Output Code 100 Clean Blow off Photo Eye Lenses Dirty This message indicates that the lenses of the Reject Photo Eye fiber optic cable mounted on the Reject Blow off assembly should be cleaned This occurs when an excess film deposit of contaminants has formed over the fiber optic lenses of the Reject Blow off Photo Eye reducing the gain of the eye If the lenses are not cleaned the eye will cease to function correctly
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