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      Troubleshooting
      • 13 Mar 2023
      • 43 Minutes to read
      • Contributors
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      Contents

      Troubleshooting

      • Updated on 13 Mar 2023
      • 43 Minutes to read
      • Contributors
      • Print
      • Dark
        Light
      • PDF
      Article summary

      Troubleshooting


      1. Overview

       If a mechanical fault has occurred then the machine will have to be shut down and inspected for the probable cause (e.g., loose belt or chain, broken component, loss of air pressure, etc.) 

      1.1 Mechanical Parts Trouble shooting

      FaultsTrouble SymptomsProbable CausesTests & 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 overheats1.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 Overheats1.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 vibration1.Short circuit of windings
      2.Open circuit of rotor      		Factory repair
      Mechanical vibration1.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


      Servo Motor

      OverheatsServo Motor Overheating1.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 FailureUnlubricated BearingGrease lubrication or bearing replacement.

      		Dusty Brakehigh-pitched squeal from your servo motorsoak up the oil, and lead to friction and screeching.
      SmokyProduces Smoke or Burning Odo1.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
      NoiseAbnormal Noise1.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.
      VibrationExcessive Vibration1.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. 

      Pneumatic System

      Actuator Moving Abnormally SlowExcessive air choke1.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 low1.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 UnitAir leak at regulator1.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 problemsIf diaphragm is cracked or brokenA high velocity air leak at the vent hole will occur. Replace diaphragm.
      Filter problemsOver-contaminated, the filter element will create a pressure drop which may affect system operationClean or replace the filter element regularly
      Directional Control Valve Not Changing PositionCoil not picking up.Electric failureFix electric failure and check mechanical spool movement.
      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 CylindersNo movement1.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 movement1.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 leak1.Loose tie rod
      2.Seal deterioration - soft, gummy
      3.Seal deterioration - hard, brittle. Usually due to temperature extremes.      		Repair or replace.
      Rod gland seal leak1.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

      OverheatsGear 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
      NoiseUnusual or excessive noise1.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
      VibrationVibration is excessive1.Gear teeth are worn.
      2.Bearings are worn or damaged
      3.Mounting bolts are loose      		1.Replace wheel
      2.Replace bearings
      3.Tighten
      Oil LeaksOil Leaks1.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.

      Camera

      Not able to track the sachets.Camera lens dusty1.Camera lens covered by the dust.1.Clean the camera lens time to time (refer the camera Maintenance)
      NOTE: When cleaning a camera, the camera stand & camera mounting position cannot be changed or misaligned, clean the inner and outer sides of the camera by using cloth with care.


      2. Equipment's 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: -

      Please find the below Alarms List

      16049 Alarm List

      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 Knocker Cylinder Reed Alarm

      Cylinder Faults

       

       

      Error Code

      Type of Fault

      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.

      110

      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.

      111

      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.

      112

      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.

      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, Rob 1 Rejection Bin Eye Alarm

      Miscellaneous Input Faults

       

       

      Error Code

      Type of Fault

      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.

      402

       Evaluation Error, contact 1 or 2 failed to switch or switched too late

      This is a Fault specific to a Safety Device. For example, a Guard Switch. On a dual channel safety device, the two channels have not switched within the specified time period, or one of the channels has not switched at all.

      • Check the alignment of the safety switch if it is a guard switch.
      • Check the Contacts on the device if it is an E-Stop.
      • Check for cable damage.
      • Check electrical terminations.

      403

       Error in the test pulse wiring.

      This is a Fault specific to a Safety Device. For example a Guard Switch. The power source at the input terminal is from a different source from that configured in the Safety program.

      • Check for cable damage.
      • Check electrical terminations.
      • Check the contacts on the safety device.

      404

      Channel 1 Input Test Pulse Error

      This is a Fault specific to a Safety Device. For example a Guard Switch. The test pulse on a input is different from that configured in the program or has not been received.

      • Check for cable damage.
      • Check electrical terminations.
      • Check the contacts on the safety device.

      405

      Channel 2 Input Test Pulse Error

      This is a Fault specific to a Safety Device. For example a Guard Switch. The test pulse on a input is different from that configured in the program or has not been received.

      • Check for cable damage.
      • Check electrical terminations.
      • Check the contacts on the safety device.

      406

      Triggered while machine Running

      This is a Fault specific to a Safety Device. The Safety Device has been triggered while the machine was running.

      This is used to log if the machine has been E-Stopped, a guard switch has been opened or a light Curtain has been triggered while the machine was in a running state.

      410

      Manual ON Enabled

      The Miscellaneous Input 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.

      411

      Manual OFF Enabled

      The Miscellaneous Input 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.

      2.3 Miscellaneous Output Faults

      All Miscellaneous Output Faults will have an Error Code between 500 and 600. 

      A Typical Miscellaneous Output Alarm is displayed as follows:

      [501] SV2701, MG Vacuum Generator 1 Alarm

      Miscellaneous Output Faults

       

       

      Error Code

      Type of Fault

      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 Motor Faults

      All Motor Faults will have an Error Code between 600 and 700. Motors Alarms are generally only used for Devices that have DOL Control. They can also be used for VFD Drives if the drive is configured for 2 or 3 Wire Control. A Typical Motor Alarm is displayed as follows: 

      [601]   MO3102, Outfeed Conveyor 2 Alarm

      Motor Faults

       

       

      Error Code

      Type of Fault

      Possible Cause

      Solutions

      601

      Forward Feedback OFF Alarm

      The Output to Run the Motor is ON and the Run Feedback to the PLC has been OFF for a period of time greater than the Fault time Preset.

      • If the motor has DOL control Check that the Motor Starter has not tripped.
      • If the motor has VFD control Check that the Drive is not in Fault.
      • Check for mechanical blockages.
      • Check the Wiring.
      • Check the Feedback to the PLC.
      • Check that the Fault time preset has been set correctly. This can be adjusted from the Motor Faceplate screen.

      602

      Reverse Feedback OFF Alarm

      The Output to Run the Motor in reverse is ON and the Run Feedback to the PLC has been OFF for a period of time greater than the Fault time Preset.

      • If the motor has DOL control Check that the Motor Starter has not tripped.
      • If the motor has VFD control Check that the Drive is not in Fault.
      • Check for mechanical blockages.
      • Check the Wiring.
      • Check the Feedback to the PLC.
      • Check that the Fault time preset has been set correctly. This can be adjusted from the Motor Faceplate screen.

      603

      Feedback ON Alarm

      The Outputs to Run the Motor are OFF and the Run Feedback to the PLC has been ON for a period of time greater than the Fault time Preset.

      • If the motor has DOL control Check that the Motor Starter has not tripped.
      • If the motor has VFD control Check that the Drive is not in Fault.
      • Check for mechanical blockages.
      • Check the Wiring.
      •  Check the Feedback to the PLC.
      • Check that the Fault time preset has been set correctly. This can be adjusted from the Motor Faceplate screen.

      604

      External Feedback Alarm

      The External Feedback alarm has been triggered. This can be used for a number of functions, but is normally used to monitor the state of a Local Isolator.

      Check that the Local Isolator has not been switched OFF.

      610

      Manual ON Enabled

      The Motor Manual ON 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.

      611

      Manual Reverse Enabled

      The Motor Manual REVERSE 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.

      612

      Manual OFF Enabled

      The Motor 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.

      2.5 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

      Motor Faults

       

       

      Error Code

      Type of Fault

      Possible Cause

      Solutions

      1

       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.
         


      3.Operations Troubleshooting

      3.1 Once the machine is installed, the machine critical parameters cannot be changed by the operator, BRML team to be involved to make changes to these parameters.

      In case if admin provides these authorities to operator or any other user, the following might be circumstance.

      • The Robots are not homing.
      • Camera & scanner might be inaccurate rejection or acceptance.
      • The machine not able to be homing & run smoothly.
      • Robot collision with surrounding area & might result in permanent damage to the robot.
      • Servo functionality might be affected.

      And Communicate with BRML Team and explain the problems, BRML team solves the problem & run the Machine.

      3.2 If the software is corrupted. BRML team has to be involved make solution of the problem.

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