Bag Making Faults

1

PLASTIC BAG MAKING MANUAL

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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THE SYSTEM

COMPLETE SOLUTION TO THE BAG MAKING APPLICATION

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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INDEX SR.N O

DESCRIPTION

PAGE. NO

1.

INTRODUCTION

4

2.

FEATURES

5

3.

MACHINE SPECIFICATIONS

6

4.

EQUIPMENT CONNECTIONS

9

5.

DISPLAY AND OPERATION

10

6.

PARAMETERS

12

7.

COMMUNICATIONS

16

8.

MAINTENANCE AND INSPECTION

19

9.

DIAGNOSTICS

20

SPECIFICATIONS

38

10.

1.0

INTRODUCTION

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

4 If you are looking for the reliable plastic bags making machine which give speed, accuracy, automatic and fully friendly the the solution is here.

COMPANY PROFILE : Gururaj Engineers was set up in 1981. It is in to its 26th year serving the industry. Mr. Mohan R Tilwalli, the founder and the driving force has made Gururaj Engineers a well respected and important player in the industry with his keen interest, expertise and vision. The firm serves various industries like Material handling, Machine tools, Plastics, Paper, Chemical, Pharmaceutical and many more. It holds major expertise in the field of DC Drives (0.5 HP to 75 HP ), Logic Controllers, Pulse Jet Timers, Torque Motor Controllers. The firm is the approved system integrators of GE Fanuc industrial automation products for Vadodara and around, specializing in PLC’s (Programmable Logic Controllers).Gururaj Engineers is set up in a total area of 4000 square feet in GIDC Makarpura, Vadodara and employs around 20 people. Product Range : At Gururaj Engineers, we design, manufacture and commission industrial automation products of various range.These products are customized to suit the industry’s needs. Some of the main products are as below·

• • • • • • • • • • •

Thyrister DC Drives ( up to 75 Hp ) Vibrator Feeder Control Clutch Brake Control Dedicated Machine Controls Solid Stated Heating Controls Zero Speed Switch Units Digital Temperature Controllers Digital Timers Digital Counters Torque Motor Controllers PLC Based Systems

System integrators of GE Fanuc range of industrial Automation :·

• • • • • •

SCADA PLCs Servo Motor Controllers Touch Screen Displays / HMI / MMI AC Drives Embedded Systems (Single board PCs)

2.0

FEATURES

Features: •

High Speed up to 150 strokes/min

•

Servo Motor for Indexing and Accuracy

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

5 •

PLC Controlled with Digital Display

•

Keyboard Setting for speed, Size & Count

•

Backlit Display for Operating Parameters

•

Photocell Control to START and STOP action

•

Vertical Unwinder motor stand with IR proxy

•

Upto six Continuous side or bottom Sealing bags/min

•

User Friendly Single Control Panel

•

Print mark action

•

Conveyor action

Some of these standard features on all the machines not only make them more reliable but also efficient and operator friendly. AC Inverter Drives : The main Motor and unwinder Motor are both AC Drives for speed control. PID Temperature Controller : It maintains accurate sealer temperature to give consistent quality of sealing. Print Registration Photocell : The best quality photocells are used to give accurate print registration.

3.0 MACHINE SPECIFICATION AUTOMATION SOLUTION TO ANY BAG MAKING MACHINES

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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BAG FOLDING MACHINE MACHINE

BOTTOM SEALING CUTTING

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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GLOVE BAG MAKING MACHINE MACHINE

HEAVY DUTY BAG MAKING

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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ROLL MAKING MACHINE MACHINE

T-SHIRT BAG MAKING

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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SIDE SEALING BAG MAKING MACHINE

4.0 EQUIPMENT CONNECTIONS DRIVE TO PERIPHERAL DEVICE

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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5.0 SCREEN

VARIOUS DISPLAY

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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MAIN SCREEN

THIS IS WHERE YOU SEE THE PROCESS DATA IN THE QPT SCREEN

TO SEE NEXT SCREEN PRESS

TO SEE PREVIOUS SCREEN PRESS

AND TO ENTER DATA YOU HAVE TO ENTER WITH NUM PAD

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PARAMETER ENTERING SCREEN-1

TO ENTER BAG LENGTH YOU HAVE TO PRESS FLASHES THEN ENTER THE REQUIRED LENGTH.

AND THEN WHEN IT

PARAMETER ENTERING SCREEN-2

TO ENTER BATCH SIZE AND WARNING, YOU HAVE TO PRESS AND THEN WHEN IT FLASHES THEN ENTER THE BATCH SIZE AND WARNING ALARM.

PARAMETER ENTERING SCREEN-3

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TO ENTER WINDOW WIDTH, ROLLER DIAMETER AND GEAR RATIO, YOU HAVE TO GO TO THE MAIN SCREEN THEN PRESS

AND

WILL ASK FOR PASSWORD THEN GIVE PASSWORD AS

TOGETHER AND IT

2345.

IT WILL OPEN

THE ABOVE SCREEN AND THEN YOU PRESS AND THEN WHEN IT FLASHES THEN ENTER THE WINDOW WIDTH, GEAR RATIO AND ROLLER DIAMETER. ENTER THESE VALUES AFTER MEASURING THE PARAMETERS PROPERLY.

6.0

PARAMETERS

 SERVO PARAMETERS

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ONE SHOULD INSERT THE BELOW PARAMETERS BEFORE STARTING THE MACHINE SPEED AND MODE PARAMETERS P1-01 101

=

DIRECTION SERVO

P1-15

400272

=

FROM PLC COPY REVOLUTION

P1-16

400273

=

EXTRA COUNT FROM PLC

P1-33 P1-34 P1-35 P1-36

1 80 40 20

= ms ms ms

P1-54

400311

=

I/O PARAMETER P2-10 P2-11 P2-12 P2-13 P2-14 P2-15 P2-16 P2-17 P2-18 P2-19 P2-36

101 108 111 37 38 21 0 0 105 107 400549

= = = = = = = = = = =

INCREMENTAL MODE ACC TIME DEACC TIME S-CURVE WINDOW WIDTH COUNT FROM PLC

DI-1 DI-2 DI-3 DI-4 DI-5 DI-6 DI-7 DI-8 DO-1 DO-2

SERVO ENABLE SERVO TRIGGER JOG REVERSE JOG FORWARD EMRG STOP

WINDOW WIDTH SERVO ALARM RPM (MAX-3000)

CN3 COMMUNICATION PARAMETER P3-00 1 P3-01 4 P3-02 8 P3-03 0 P3-04 1

= = = = =

NODE BAUD RATE NO OF BIT PARITY (ODD) STOP BIT

P3-05

=

RS232 COMMUNICATION

OTHERS P4-05

0

10

JOG SPEED

TO SEE WEATHER THE INPUT IS COMING TO THE SERVO OR NOT ONE SHOULD SEE THIS PARAMETER (P4-07)

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TO RESET ALL THE PARAMETERS TO THEIR FACTORY DEFAULTS ONE SHOULD ENTER THE VALUE 10 INTO PARAMETER P2-08 TO MOVE THE SERVO IN THE OPPOSITE DIRECTION ONE SHOULD SEE THE PARAMETER P1-01 AND IF THE VALUE IS 101 AND YOU HAVE TO REVERSE THE DIRECTION OF SERVO MOTOR YOU SHOULD ENTER THE VALUE 1 IN PARAMETER P1-01

MAIN MOTOR & UNWINDER MOTOR FACTORY DEFAULT SETTINGS 0-03

1

3-0.0

0

6-2.2

0.14

0-04

1

*

3-0.2

0

6-2.3

20

0-10

1

*

3-0.3

50

6-2.4

0

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0-11

1

*

3-1.0

0

6-2.5

50

0-12

20

*

3-1.1

5

6-2.6

0.01

0-40

1

3-1.2

0

6-8.1

0

0-41

1

3-1.4

0

6-8.2

50

0-42

1

3-1.5

1

6-9.0

0

0-50

0

3-1.6

2

6-9.1

0

0-51

0

3-1.7

11

6-9.2

0

0-60

0

3-1.8

0

6-9.3

0

3-4.0

0

6-9.4

100%

1-0.0

0

*

3-4.1

3SEC

1-0.1

1

*

3-4.2

3SEC

7-2.0

0

1-0.3

0

3-5.0

0

7-3.0

0

1-0.5

2

3-5.1

3SEC

7-3.1

1

*

1-2.0

0.75HP

3-5.2

3SEC

7-3.2

0

*

1-2.2

230

3-8.0

3SEC

7-3.3

0.01

*

1-2.3

50HZ

3-8.1

3SEC

7-3.4

9999sec

*

1-2.4

3.48

7-3.8

0%

*

1-2.5

1704

7-3.9

5%

*

1-2.9

0

*

4-1.2

0

*

1-3.0

2.63

*

4-1.4

65

8-0.1

0

*

1-3.3

4.58

4-1.6

150%

8-0.2

1

*

1-3.5

91..54

4-1.7

100%

8-0.3

1sec

1-5.0

100%

4-5.0

0

8-0.4

0

1-5.2

0HZ

4-5.1

26

8-0.6

0

1-5.5

0

4-5.8

1

8-3.0

0

1-5.6

0

4-6.1

0

8-3.1

1

1-6.0

100%

4-6.3

0

8-3.2

2

1-6.1

100%

8-3.3

0

1-6.2

100%

1-6.3

0.10SEC

1-7.1

0.0SEC

1-7.2

2

1-7.3

4-1.0

2

5-1.0

8

8-3.5

0.010s

5-1.1

10

8-3.6

5sec

5-1.2

1

8-5.0

3

5-1.3

14

8-5.1

3

0

5-1.5

16

8-5.2

3

1-8.0

0

5-4.0

0

8-5.3

3

1-8.2

0

5-5.5

20

8-5.4

3

1-9.0

0

5-5.6

5000

8-5.5

3

1-9.3

0

5-5.7

0

8-5.6

3

5-5.8

50

8-9.4

0

6-0.0

10sec

13-0.0

0

2-0.0

50%

2-0.1

50%

*

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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*

2-0.2

10SEC

6-0.1

0

13-0.1

39

2-0.4

0

6-1.0

0.07

13-0.2

40

2-1.0

0

6-1.1

10

13-0.3

0

2-1.1

5

6-1.2

0.14

13-1.0

0

2-1.6

100

6-1.3

20

13-1.1

1

2-1.7

0

6-1.4

0

13-1.2

0

2-2.0

0

6-1.5

50

13-2.0

0

2-2.2

0

6-1.6

0.01sec

13-4.0

0

6-1.9

0

13-4.1

0

13-4.2

0

13-4.3

0

13-4.4

0

13-5.1

0

13-5.2

0

FIRST SEET ALL THE PARAMETERS ACCORDING TO THE FACTORY SETTINGS AND THEN ONLY CHANGE THE LISTED PARAMETERS MARKED BY * TO DRIVE YOUR MAIN MOTOR AND UNWINDER MOTOR

7.0 COMMUNICATIONS THE BELOW IS THE DIAGRAM OF DRIVE COMMUNICATION WITH PLC WITH THE HELP OF CN1 CABLE

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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POWER CABLE

54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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ENCODER CABLE

DRIVE TO QPT COMMUNICATION CABLE

8.0 MAINTENANCE AND INSPECTION 54/3-A, G.I.D.C, MAKARPURA, VADODARA-390010

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Warning Be sure to disconnect AC power and ensure that the internal capacitors have fully discharged before performing the maintenance and inspection.

Warning Do not touch any internal or exposed parts of servo drive and servo motor as electrical shock may result. Do not remove the operation panel while the drive is connected to an electrical power source otherwise electrical shock may result. Wait at least 10 minutes after power has been removed before touching any drive or motor terminals or performing any wiring and/or inspection as an electrical charge may still remain in the servo drive and servo motor with hazardous voltages even after power has been removed. Do not disassemble the servo drive or motor as electric shock may result. Do not connect or disconnect wires or connectors while power is applied to the drive and motor. Only qualified personnel who have electrical knowledge should conduct maintenance and inspection. MAINTENANCE & INSPECTION Use and store the product in a proper and normal environment. Periodically clean the surface and panel of servo drive and motor. Make sure the conductors or insulators are corroded and/or damaged. Do not disassemble or damage any mechanical part when performing maintenance. Clean off any dust and dirt with a vacuum cleaner. Place special emphasis on cleaning the ventilation ports and PCBs. Always keep these areas clean, as accumulation of dust and dirt can cause unforeseen failures.

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9.0 DIAGNOSTICS  FAULTS 9.0.0 SERVO FAULTS 9.0.1 MAIN MOTOR FAULTS 9.0.2 UNWINDER FAULTS 9.0.3 ELECTRICAL FAULTS 9.0.4 QPT PROBLEMS 9.0.5 COMMUNICATION FAULTS 9.0.6 AC DRIVE FAULTS 9.0.7 MECHANICAL PROBLEMS 9.0.8 HEATER PROBLEM 9.0.9 PROGRAM ERROR

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9.0.0 ERRORS AND THEIR PREVENTIVE ACTIONS ERRO RS

FAULT NAME

ALE -01

OVER CURRENT

POTENTIAL CAUSE 1. Short circuit

at drive output (U,V,W) 2. Motor wiring

error

3. Control

parameter setting error 4. Control

command setting error

CHECKING METHOD

CORRECTIVE ACTIONS

Check wiring connections between drive ad motor

Repair and avoid metal conductor being exposed

Check wiring steps are all correct when connecting motor to drive

Follow the wiring steps in user manual to reconnect wiring

Check if the setting value exceeds the factory default settings

Set the setting to factory defaults and set parameters again

Check if control input command is unstable (much fluctuation)

Ensure the input command frequency is stable

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE02

OVER VOLTAGE 1. The main circuit voltage has exceeded its maximum allowable value 2. Input power error

Use voltmeter to check whether the input voltage falls within the rated input voltage

Use correct power supply or stabilizing power

Use voltmeter to check whether the input voltage is within the specified limit

Use correct power supply or stabilizing power

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE

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ALE03

UNDER VOLTAGE

1. The main circuit voltage is below its minimum specified value

Check whether the wiring of main circuit input voltage is normal

Reconfirm voltage wiring

2. No input voltage at main circuit

Use voltmeter to check whether input voltage at main circuit is normal

Reconfirm power switch

3. Input power error

Use voltmeter to check whether the input voltage is within the specified limit

Use correct power supply or serial stabilizing power

THIS FAULT MESSAGE IS REMOVED AUTOMATICALLY AFTER THE VOLTAGE HAS RETURNED WITHIN ITS SPECIFICATION ALE04

Z PULSE SHIFT

1. Encoder is damaged

Check encoder for the damage

Repair or replace the motor

2. Encoder is loose

Examine the encoder connector

Install the motor again

3. Earthing is not proper

Check the earthing is given properly or not

Provide panel with proper earthing

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE AL-05

Regeneration error

1. Regenerative Check the wiring resistor is not connection of connected regenerative resistor

Reconnect regenerative resistor

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2. Regenerative switch transistor fault

Check if regenerative switch transistor is shortcircuited

Contact technical support for assistance

3. Parameter setting is in error

Confirm the parameter setting and specifications of regenerative resistor

Correctly reset parameter again

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE06

OVERLOAD

1. The drive has exceeded its rated load during continous operation 2. Control system parameter setting is incorrect

Check if the drive is overloaded

Increase motor capacity or reduce load

Check if there is mechanical vibration

Adjust gain value of control circuit

OR Accel/Deaccel time setting is too fast

Decrease Accel/Deaccel time setting

3. The wiring of Check the wiring of Ensure all wiring is drive and U,V,W and encoder correct encoder is in error TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE07

OVERSPEED

1. Speed input command is not stable (fluctuation)

Use signal detector to detect if input signal is abnormal

Ensure that input command frequency is stable and activate filter function (P1-06, P107, P1-08)

2. Over speed parameter

Check if over speed parameter setting

Correctly set over speed parameter

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setting is value is too low setting (P2-34) defective TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE08

1. Pulse command is higher than rated input frequency TURN ARST (DI signal) ON TO CLEAR FAULT ALE09

ABNORMAL PULSE CONTROL COMMAND

EXCESSIVE DEVIATION

Use pulse frequency detector to measure input frequency

Correctly set the input pulse frequency

OR RESTART THE SERVO DRIVE

1. Maximum deviation parameter setting is too small

Check the maximum deviation parameter setting and observe the position error value when the motor is running

Increase the parameter setting value of P2-35

2. Gain value is too small

Check for proper gain value

Correctly adjust gain value

3. Torque limit is too low

Check torque limit value

Correctly adjust torque limit value

4. There is an overload

Check for overload condition

Reduce external applied load or reestimate the motor capacity

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE10

WATCH DOG EXECUTION TIME OUT

1. Watch dog execution error

Check and reset the If there are any power supply abnormal conditions after resetting the power supply contact technical support

THIS FAULT CAN BE CLEARED ALE11

ENCODER ERROR

1. The wiring of encoder is in

Check if all wiring is correct

Ensure all wiring is correct

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error (OR) Check if the users conduct the wiring by the wiring information in the user manual 2. Encoder is Examine the loose encoder connector

Install the motor again

3. The wiring of encoder is defective

Check if all connections are tight

Conduct the wiring again

4. Encoder is damage

Check the encoder for the damage

Repair or replace the motor

THIS FAULT CAN BE REMOVED BY RESTARTING THE SERVO DRIVE ALE12

ADJUSTMENT ERROR

1. The setting Remove CN1 wiring If the error does not value of drift clear after Execute the drift adjustment executing the drift has adjustment again adjustment contact exceeded its (set P2-08 to 20 technical support maximum first and then set allowable P4-10 to 5) value THIS FAULT CAN BE REMOVED AFTER THE WIRING OF CN1 CONECTOR IS REMOVED AND AUTO ADJUSTMENT FUNCTION IS EXECUTED ALE13

EMERGENCY STOP ACTIVATED

1. Emergency Check if emergency stop switch is stop switch is ON or activated OFF

Activate emergency stop switch

THIS FAULT MESSAGE CAN BE REMOVED AUTOMATICALLY BY TURNING OFF EMGS (DI signal)

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ALE14

REVERSE (CWL) LIMIT SWITCH ERROR

1. Reverse limit switch is activated

Check if reverse limit switch is ON or OFF

Activate reverse limit switch

2. Servo system Check the value of is not stable control parameter setting and load inertia

Modify parameter setting and reestimate motor capacity

3. Servo not stable

Increase this values above 30

Check the values of parameters at P215, P2-16, P2-17.

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE15

FORWARD (CCWL) LIMIT SWITCH ERROR

1. Forward limit switch is activated

Check if forward limit switch is ON or Off

Activate limit switch

2. Dervo system is not stable

Check the value of control parameter setting and load inertia

Modify parameter setting and reestimate motor capacity

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE16

1. The drive has exceeded its rated load during continous operation 2. Short-circuit at drive output TURN ARST (DI signal) ON TO CLEAR FAULT ALE17

IGBT TEMPERATURE ERROR

MEMORY ERROR

1. Data error in memory readout/write-in

Check if there is overload or the motor current is too high

Increase motor capacity or reduce load

Check the drive input wiring

Ensure all wiring is correct

OR RESTART THE SERVO DRIVE Reset parameter or power supply

If the error does not clear after resetting the power supply, contact technical

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support TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE18

DSP COMMUNICATI ON ERROR

1. Control power is in error

Check and reset control power

If the error does not clear after resetting the power supply, contact technical support

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE19

SERIAL COMMUNICATI ON ERROR

1. Communicati on parameter setting is defective 2. Communicati on address is incorrect

Check the communication parameter setting

Correctly set parameter setting

Check the communication address

Correctly set communication address

3. Communicati on value is incorrect

Check the communication value

Correctly set communication value

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE20

SERIAL COMMUNICATI ON TIME OUT

1. Setting value in time out parameter is not correct

Check communication time out parameter setting

Correctly set P3-07

2. Not receive=ing communicati on command for a long time

Check whether communication cable is loose or broken

Tighten the communication cable make sure the communication cable is not damaged and ensure all wiring is correct

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE-

COMMAND

1. Control

Check and reset

If the error does not

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21

WRITE-IN ERROR

power is in error

control power

clear after resetting the power supply contact technical support

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE22

INPUT POWER PHASE LOSS

1. Control power supply is in error

Check the power cable and connections of R, S T. check whether the power cable is loose or the possible loss of phase on input power

If the fault does not clear even when the three phase power is connected correctly contact technical support

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE23

PREOVERLOAD WARNING

1. The drive is going to overload

Check the load connection of the servo motor and drive

Refer to the connection actions of ALE06

Check the setting value of P!-56 check whether the setting value of P156 is to small

Increase the setting value of P1-56 or set P1-56 to 100 and above

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE97

INTERNAL COMMAND EXECUTION TIME OUT

1. An error occurs when internal command is executing

Check and reset control power

If the error does not clear after resetting the power supply contact your distributor for assistance or contact support

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE

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ALE98

DSP COMMUNICATI ON ERROR

1. May be the hardware is damaged

Check and reset control power

If the error does not clear after resetting the power supply contact your distributor for assistance or contact support

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE ALE99

DSP COMMUNICATI ON ERROR

2. May be the hardware is damaged

Check and reset control power

If the error does not clear after resetting the power supply contact your distributor for assistance or contact support

TURN ARST (DI signal) ON TO CLEAR FAULT OR RESTART THE SERVO DRIVE

9.0.1 MAIN MOTOR FAULTS ERRO RS Motor not runnin g

FAULT NAME

POTENTIAL CAUSE

CHECKING METHOD

CORRECTIVE ACTIONS

The power supply is not proper at the main motor drive terminals

Check power supply Give proper supply of Main motor Drive and ensure it is at (R,Y,B) (L,N) according to the manual. Check digital Run Command of motor

The pot voltage is not coming.

Check pot voltage ( variable 0-10V)at terminals 50 and 53.

Ensure the wiring properly, or change the POT.

Check parameter of main motor drive are according to the parameters below

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FOR 2 WIRE SYSTEM for modified freq. I-22

230V

I-23

FREQ.

50HZ

I-24

CURR.

AS MOT.TY

I-25

SPEED

AS MOT.TY

I-29

3.0-03

max ref.

6.0-15

term.53 high

0

I-30

AS MOT.TY

I-33

AS MOT.TY

I-35

AS MOT.TY

3.0-11

Jog

as req.

5.0-10

Start

8

5.0-11

Reversing

1

Do other parameter are set as factory settings WIRING DIA. 12 18

24 OUT START PUL.

NO P.B.

12 19

24 OUT REVERSE

NO P.B.

12 29

24 OUT JOG.

NO P.B.

9.0.2 UNWINDER FAULTS ERRORS

FAULT NAME

POTENTIAL

CHECKING

CORRECTIVE

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CAUSE UNWIND ER MOTOR NOT RUNNIN G

UNWINDER FAULT

The power supply is not proper at the unwinder motor drive terminals

METHOD

ACTIONS

Check power supply of Main motor Drive at (R,Y,B) (L,N)

Give proper supply and ensure it according to the manuals

Unwinder frequency should be set first in the unwinder drive

Install parameters properly

Check the connections are properly given or not and also the parameters are install UNWIND ER NOT STOPPIN G AT ROLL POSITIO N

UNWINDER FAULT

The proxy is Check the proxy at not set properly unwinder motor and ensure that it is properly connected and adjusted near to the roll

Adjust the IR proxy properly

Check parameter of unwinder motor drive are according to the parameters given 9.0.3 ELECTRICAL FAULTS ERRORS

FAULT NAME

POTENTIAL CAUSE

CHECKING METHOD

CORRECTIVE ACTIONS

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SERVO STOP AFTER RUNNIN G FOR FEW MINUTES

ALE 04

MCB TRIPS SEVERAL TIMES

POWER FAILURE

SERVO NOT POWERI NG ON

SERVO NOT ENABLED

Connection not proper causing servo to stop after few minutes

Check all the connection are done with respect to the drawing

Separate the encoder cable from 3-phase supply passing near it.

Earthing problem

Check all the earthings terminals are properly grounded

The 20 no terminal of the ac drive should be grounded to avoid some problems and earthing should be proper

Earthing problem and over voltage or overcurrent problem

Check the supply properly given and fuse used to limit the supply

Use transformer to give supply in case of 1-phase or 3phase supply before giving it to the panel or machine

Servo enable problem

Check the supply given to the servo drive and check the input is coming at P4-07 is coming or not

if input is coming and servo not moves then turn on the servo enable switch and give proper supply

Check the connections of line, neutral and Also keep encoder earthing properly away from the line given or not and other supply to avoid the problem

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9.0.4 QPT PROBLEM ERROR S

FAULT NAME

POTENTIAL CAUSE

QPT not showin g the values

Unknown values

Due to communication problem the values are not displayed in the QPT

QPT taking long time for changing the screen

QPT not able to connect to the plc

Due to cable problem it will not display the values

CHECKING METHOD

CORRECTIVE ACTIONS

Check the cable from the PLC to QPT is properly connected or not.

Tighten the cable and if still problem persist then change the communication cable

Check the cable from the PLC to QPT is properly connected or not.

Reinstall the program in the QPT to resolve the problem

Check the communication cable connecting the QPT to DRIVE (CN3)

Change only if problem is not solved after changing the PLC to QPT cable.

Check the communication by switching OFF the QPT supply and again ON the supply and the mode communication and com will show the communication is ok or not.

If not then tighten the cable and again check and if not then replace the cable.

9.0.5 COMMUNICATION FAULTS

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ERRORS

FAULT NAME

Error No communicat communicatio ing the n program

POTENTIAL CAUSE

CHECKING METHOD

Due to cable faults or due to loosing of cable the coomunication will not be there

Check all the communication cable used are properly connected

CORRECTIVE ACTIONS Change the cables with faults and tighten it properly

Check the proper parameter are install in the drive for communication

9.0.6 AC DRIVE FAULTS ERRORS The motor not running at required speed or frequency

FAULT NAME POTENTIAL CAUSE Frequency required for running not proper

Frequency not sufficient

CHECKING METHOD Check the speed frequency of the motor required

CORRECTIVE ACTIONS Insert proper frequency as per requirement

Check the parameter of the drive as per requirement

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Having trouble running motor

Terminals are not properly connected or loose contact

First of all check the 20 no terminal is properly grounded and parameters are proper

The parameters are install default as factory settings and only the required should be changed

9.0.7 MECHANICAL PROBLEMS ERRORS

FAULT NAME

POTENTIAL CAUSE

CHECKING METHOD

CORRECTIVE ACTIONS

HUMMING OF SERVO

HUMMING SOUND COMING DURING SERVO ROTATION

Due to some parameter values different the error occurs

To reduce sound you have to check parameters in P2-31 and P232

Insert A into P2-31 and 02 into P2-32 OR change as per requirement

TUNING NOT PROPER

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CUTTER NOT PROPER

Improper length of bag

The cutter is cutting the plastic before the servo stops

Check the proximity switch is proper in position

one should adjust the proximity switch accordingly to give start pulse so that the cutter comes down after the servo stops and before the next pulse

KNIFE NOT STOPING AT PROPER POSITION

KNIFE POSITION NOT PROPER

The knife position will be always at the top and its due to proxy.

Check the stop proxy settings

Properly set the position of the stop proxy and according to it the knife will stop

POTENTIAL CAUSE

CHECKING METHOD

In high speed machine above 1500 rpm the use of braking resistor is must

9.0.8 HEATER PROBLEM ERRORS

FAULT NAME

CORRECTIVE ACTIONS

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HEATER NOT HEATED UP AFTER 1 HOUR ALSO

HEATER FAULT

IMPROPER WIRING TO HEATER

Check the wiring of the heater

Check the phase given to the heater with multimeter

One end is connected with phase and other with SSR as respect to the drawing

Provide proper phase to the heater

9.0.9 PROGRAM ERROR ERRORS

FAULT NAME

POTENTIAL CAUSE

CHECKING METHOD

CORRECTIVE ACTIONS

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MACHINE NOT STARTING

Servo not getting pulse

Even after giving the pulse from start proxy the servo does not move

Check the values Enter the required are entered which values in is required Gear Ratio Roller Diameter Bag Length Batch size Batch warning

ENSURE ALL THE WIRING IS PROPER AND SYSTEM IS ENABLED BEFORE STARTING THE MACHINE. OR ELSE CONTACT THE VENDOR

10.0 SERVO SPECIFICATIONS

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