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Objective:
- At the completion of this training participants should be able to:
Explain what needs to be done for maintenance Demonstrate how to remove and replace a light board Explain different alarm conditions Follow the electrical drawings for the Veritas iC
Alarm Screen
To reset an alarm press the Acknowledge all button. Two types of alarms can occur in the system; Alarms and Latched Alarms
Alarms- Require user intervention to fix and restart the Machine. Alarms are typically more mechanically or electrically related. ie. Main Line Contactor, Safety Relay, Thermal Overloads. Latched Alarms- Some latched alarms stop the machines. These alarms represent data and tracking faults
Latched Alarms
BP1 to BP2 out of Tolerance
- Definition
Bottle slipped or advanced out of the settable tolerance.
- Reasons
Bad Auto Configure Changed quadrat ratio Ware handling Container Sticks to belts Bad belts Bad BP Sensor
- Fix
Latched Alarms
Ware Down Fault
- Definition
One of the two Down ware sensors have been triggered.
- Reason
Fallen bottles Sensor alignment Bad sensor Dirty sensor Improper wiring Clear bottle from sensor and the acknowledge alarm in Supervisor. Make sure the sensor is aligned with the reflector on both sides Verify the wiring and operation of the sensor input PLC I:1/[10] Clean Sensor and reflectors.
- Fix
Latched Alarms
Down Bottle Infeed
- Definition
Down bottle sensor has been activated
- Reason
Fallen bottle prior to the separator Sensor adjustment Faulty sensor
- Fix
Remove fallen bottle Make sure that the sensitivity is adjusted for the bottle in operation. Verify the sensor is working by viewing the input on PLC.
Latched Alarms
Station 1 MX1 Data Fault
- Definition
Data was not received in the data received window point.
- Reasons
Setup for reject result offset not correct
- Fix
ReAuto Configure
Latched Alarms
Station 2 MX2 Data Fault
- Definition
Data was not received in the data received window point.
- Reasons
Setup for reject result offset not correct
- Fix
Re Auto Configure
Latched Alarms
Tracking Fault
- Definition
Bottle was not detectible at one of the BP
- Reasons
Sensor malfunction
- Fix
Verify the operation of both Bp1 and BP2 sensors. Perform Auto Configure
Latched Alarms
BP1 Missed
- Definition
BP2 triggered on a bottle that BP1 did not.
- Reason
Faulty Sensor
- Fix
Verify the operation of both Bp1 and BP2 sensors.
Latched Alarms
BP2 Missed
- Definition
BP1 triggered a bottle that BP2 did not.
- Reason
Faulty Sensor Fallen bottle
- Fix
Verify the operation of both Bp1 and BP2 sensors. Check for fallen obstruction of bottle flow
Latched Alarms
Machine Setup Error
- Definition
Bad Machine Auto Configure (Alarms only during Auto Config.)
- Reason
5 second timer between BP1 to BP2.
- Fix
Make sure the Belt are running at the same speed as the conveyor. Verify the operation of BP1 and BP2.
Latched Alarms
Conveyor Speed too low
- Definition
A Data fault has occurred and the conveyor speed is less than 6 per second.
- Reason
Bad encoder Conveyor has stopped Faulty PLC analog card Low external speed control
- Fix
Make sure conveyor is running Verify the operation of the encoder Verify analog card of the PLC
Latched Alarms
Conveyor Speed too High
- Definition
Conveyor speed exceeds 60 per second
- Reason
External speed reference set too high. .
- Fix
Lower conveyor speed
Latched Alarms
Measures bottle width Out of Range BP1
- Definition
Bottle width exceeded Machine Setup PLC specifications (Alarms only during Auto Config)
- Reason
Sensor malfunction. Bottle fell Bottle not taped properly
- Fix
Verify sensor operation Make sure the bottle is taped high enough for both BP sensors.
Latched Alarms
Measures bottle width Out of Range BP2
- Definition
Bottle width exceeded Machine Setup PLC specifications (Alarms only during Auto Config)
- Reason
Sensor malfunction. Bottle fell Bottle not taped properly
- Fix
Verify sensor operation Make sure the bottle is taped high enough for both BP sensors.
Latched Alarms
Station to Station distance out of ran
- Definition
Variable for Station to Station distance is out of range during an Auto Configuration.
- Reasons
Sensor moved Sensor malfunction Bad encoder
- Fix
Verify sensor BP sensor functionality. Verify encoder signal on I:0/[0] Re Auto Configuration
Alarms
PLC Awaiting Data
- Definition
PLC requesting data from the Supervisor computer.
- Reason - Fix
Only a problem if the alarm stay on Lose Ethernet connection between the PLC and Supervisor Verify the connection to the Ethernet Switch and the two devices. . Make sure power is on the Ethernet Switch. Replace Ethernet cables between the Ethernet switch and the devices.
Alarms
Station 1 MX1 Offline
- Definition
Signal from the MX computer telling the Supervisor that the computer is Offline.
- Reason
Manually turned Offline Signal not reaching the PLC
- Fix
Turn the MX computer online. Verify the connection from MX J13 to Breakout 4 from Breakout 4 pin 9 to PLC inputs I:3/15.
Alarms
Station 2 MX2 Offline
- Definition
Signal from the MX computer telling the Supervisor that the computer is Offline.
- Reason
Manually turned Offline Signal not reaching the PLC
- Fix
Turn the MX computer online. Verify the connection from MX to Breakout and from Breakout to PLC
Alarms
Station 3 MX3 Offline
- Definition
Signal from the MX computer telling the Supervisor that the computer is Offline.
- Reason
Manually turned Offline Signal not reaching the PLC
- Fix
Turn the MX computer online. Verify the connection from MX to Breakout and from Breakout to PLC
Alarms
Low air Pressure
- Definition
Input air pressure below 50PSI.
- Reason
Air supply to low Main cutoff valve turned off. Limit switch not adjusted correct.
- Fix
Verify air supply Make sure valve is turned on. Properly adjust the limit switch on the air pressure sensor.
Alarms
Arm Released Magnets
- Definition
Plc received a signal to release the arm magnets
- Reason
Manually Pressed
- Fix
Secure the swing arm in position and press the arm release button to inactivate it.
Alarms
Station 1 MX1 GIO1 Alarm
- Definition
Programmable alarms set in the Genius software.
- Reason
Consecutive Rejects Excessive rejects No rejects
- Fix
Clean Optics Adjust inspection setup
Alarms
Station 2 MX2 GIO1 Alarm
- Definition
Programmable alarms set in the Genius software.
- Reason
Consecutive Rejects Excessive rejects No rejects
- Fix
Clean Optics Adjust inspection setup
Alarms
Station 2 MX3 GIO1 Alarm
- Definition
Programmable alarms set in the Genius software.
- Reason
Consecutive Rejects Excessive rejects No rejects
- Fix
Clean Optics Adjust inspection setup
Troubleshooting
No Conveyor Encoder
- Should see encoder signal on PLC I/1:0 and MX IO Module 3 input 3.
Bad encoder Bad Splitter Defective Module 3 on MX
Splitter 6 Encoder Splitter 7 PLC I:0/0 CC1B MX1 Mod 3/2 MX2 Mod 3/2 MX3 Mod 3/2
Troubleshooting
Bottle Present Sensor 1 not triggering
- Should see BP1 signal on PLC I/1:1 and MX IO Module 3 input 1.
Bad encoder Bad Splitter Defective Module 3 on MX Arm release active Poor alignment BP1
Splitter 1 Splitter 2
Troubleshooting
Bottle Present Sensor 2 not triggering
- Should see BP2 signal on PLC I/1:1 and MX IO Module 3 input 1.
Bad encoder Bad Splitter Defective Module 3 on MX Arm release active BP2 Poor alignment
Splitter 3 Splitter 4
Troubleshooting
Rejector not firing
- The marching screen is not updating.
PLC not communicating with the Supervisor computer
- For every bottle you should see com1 on the PLC flash
- Make sure that the Serial cable between both devices are connected - Reboot the Supervisor.
Troubleshooting
Rejector not firing
- The marching screen is updating but the rejector is not taking bottles off the line.
Bad Solenoid Insufficient air Offset in the Machine setup - PLC screen not adjusted correct. Poor alignment Poor wiring
- 24VDC - PLC O:0/5 output to solenoid
Troubleshooting
Arm Release will not engage
- Should see BP1 signal on PLC I/1:1 and MX IO Module 3 input 1.
Blown Fuse 9 Bad Control Relay 1 Poor wiring PLC O:5/15 to CR1 Arm release active Poor alignment of BP1
Troubleshooting
Camera not taking pictures
- Trigger Sensor
Troubleshooting
Camera not taking pictures
- GIO Trigger
Card Defective
- Camera
- Ethernet cable - Ethernet Switch - Frame grabber - Camera not assigned correct in software
Troubleshooting
Assigning Cameras.
- Turn the MX Offline
- Go to the Setup screen from the One World Main home screen
Troubleshooting
Assigning Cameras.
- Select the Camera icon and press Edit.
Troubleshooting
Assigning Cameras.
- Located on the left hand side is a drop down box that has all of the camera connected with that MX computer.
- Each camera as a unique Serial Number assigned to it. This number is marked on the camera. View the number and highlight it on the list of cameras.
Assigning Cameras.
Troubleshooting
- The camera should be operational. - Press the camera button and an image should appear - Exit out
Troubleshooting
Lights not acquiring
- Bad connection from MX computer to Light boards
The MX computer sends a signal from IO Mod. 2/[6] to the breakout boards. The trigger cable runs from the Breakout board to the Light driver board.
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Troubleshooting
Initializing the light board
- Turn the MX Offline
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Troubleshooting
Initializing the light board
- Enter the camera setup by pressing the bottle image
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Troubleshooting
Initializing the light board
- Select Sidewall Light Panel in the Exciting Devices window - Press Edit
- Once in the Setup screen select Advanced and enter the advanced setup option.
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Troubleshooting
Initializing the light board
- Select GET to Retrieve the Power setting that is stored in the Light Panel LED Drive Board.
- Once the Power level updates to display the stored settings, press SET to reinitialize the Light board.
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Troubleshooting
Initializing the light board
- The light will operate as they were before the shut down. - Press the camera button and an image should appear - Press X and exit out of the camera setup. - Make sure to Accept changes and continue to the next camera and repeat the initializing process.
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Preventive Maintenance
Daily
- Clear off any broken glass - Clean Bottle Present sensors - Clean Down Ware sensors - Clean Cameras - Clean Mirrors
Preventive Maintenance
Weekly
- Clean conveyor and guide rails - Clean blower filter - Clean Air-condition Filter (If Applicable)
Preventive Maintenance
Monthly
- Inspect and clean inside console.
Routine Maintenance
Cleaning Mirrors and Lightbox Shields
- Use a soft, dry, lint-free cloth, carefully wipe dust and dirt from all mirror surfaces, as well as from the Lightbox Shields that cover the Lightbox Assemblies.
Cleaning Lenses
- Use a soft, dry, lint-free cloth, carefully wipe dust and dirt from all lens surfaces.
Replacing a Mirror
How to remove a mirror
- Disable the electromagnets and swing the optics arm out - Slide the mirror to be replaced up out of its mount then tip the mirror away from the mount and remove