1. E-Stop Active #
CONDITION
The emergency stop input is active.
POSSIBLE CAUSE(S)
- E-Stop push button is pressed.
TROUBLESHOOTING
1
Release the emergency stop button
2
Push RESET push button to clear.
3
If the alarm will not clear
Replace the contacts of the emergency stop button and verify the wiring.
2. Low Gas Pressure #
CONDITION
The low gas pressure switch input is active.
POSSIBLE CAUSE(S)
- This alarm will not activate if the active recipe has a 0 in all of the gas timers.
TROUBLESHOOTING
1
If the alarm will not clear
Verify that gas is hooked up to the machine
2
If gas is hooked up to the machine
Change the gas pressure sensor and verify the wiring.
3. PLC Module 0 Faulted #
CONDITION
The PLC has faulted
TROUBLESHOOTING
1
Set the switch on the PLC to stop and then run twice
2
If the RUN LED does not stay green after resetting twice
The PLC will need to be replaced.
4. PLC Module 1 Faulted #
CONDITION
The digital input card (Slot 1 on the IO rack) has faulted.
POSSIBLE CAUSE(S)
- Failed digital output card
- Shorted or failed field device
- Wiring fault on one of the outputs
TROUBLESHOOTING
1
Remove the terminal strip on the front of the card
And cycle power to the machine to see if the fault clears.
2
If the fault does not clear
Remove the terminal strip from the front of the output card.
3
If the fault does clear
Check the wiring for each of the inputs. Note that a quick way to see which input is causing the issue is to remove them all and put them back one-by-one until the fault reappears to determine which input is causing the fault.
5. PLC Module 2 Faulted #
CONDITION
The safety input card (Slot 2 on the IO Rack) has faulted.
POSSIBLE CAUSE(S)
- Failed digital output card
- Shorted or failed field device
- Wiring fault on one of the outputs
TROUBLESHOOTING
1
Remove the terminal strip on the front of the card
And cycle power to the machine to see if the fault clears.
2
If the fault does not clear
Replace the input card.
3
If the fault does clear
Check the wiring for each of the inputs. Note that a quick way to see which input is causing the issue is to remove them all and put them back one-by-one until the fault reappears to determine which input is causing the fault.
6. PLC Module 3 Faulted #
CONDITION
The analog input card (Slot 3 on the IO Rack) has faulted.
TROUBLESHOOTING
1
Remove the terminal strip on the front of the card
And cycle power to the machine to see if the fault clears.
2
If the fault does not clear
Replace the input card.
3
If the fault does clear
Check the wiring for the RTD and the vacuum pressure sensor.
7. PLC Module 4 Faulted #
CONDITION
The digital output card (Slot 4 on the IO rack) has faulted
TROUBLESHOOTING
1
Remove the terminal strip on the front of the card
And cycle power to the machine to see if the fault clears.
2
If the fault does not clear
Replace the output card.
3
If the fault does clear
Check the wiring for each of the outputs. Note that a quick way to see which output is causing the issue is to remove them all and put them back one-by-one until the fault reappears to determine which output is causing the fault.
8. PLC Module 5 Faulted #
CONDITION
The safety output card (Slot 5 on the IO rack) has faulted.
TROUBLESHOOTING
1
Remove the terminal strip on the front of the card
And cycle power to the machine to see if the fault clears.
2
If the fault does not clear
Replace the output card.
3
If the fault does clear
Check the wiring for each of the outputs. Note that a quick way to see which output is causing the issue is to remove them all and put them back one-by-one until the fault reappears to determine which output is causing the fault.
9. Below Temperature Range #
CONDITION
The temperature is too far below the setpoint value to allow the machine to run
POSSIBLE CAUSE(S)
- The machine takes time to heat up at the beginning (often upwards of 10 minutes), and this alarm will be present until the machine is in range of the temperature setpoint.
TROUBLESHOOTING
1
If the temperature value does not reach the setpoint after a sufficient amount of time
Determine if the bar is physically getting hot (you should be able to determine this by placing hands a few inches away from the outside of the bar, the air should be hot).
2
If the bar is not getting hot
Verify the wiring and function of the heater SSR and heater and replace if necessary
3
If the bar is getting hot and the temperature on the screen is not increasing
check the RTD wiring and replace the RTD if necessary.
10. Above Temperature Range #
CONDITION
The temperature is too far above the setpoint value to allow the machine to run.
POSSIBLE CAUSE(S)
- This alarm is commonly caused by reducing the temperature setting significantly lower than the current temperature value.
TROUBLESHOOTING
1
If the temperature is still increasing after getting this fault
Verify if the LED is on for the heater SSR..
2
If the LED is off and the bar is still hot
Verify the wiring and function of the heater SSR and heater and replace as necessary.
11. RTD Open Wire #
CONDITION
The analog input card is not reading a value from the RTD.
TROUBLESHOOTING
1
Verify the wiring and replace the RTD if the wiring is correct.
2
If the issue still persists
Replace the analog input card.
12. Vacuum Pump Proof Fault #
CONDITION
The input for the feedback from the vacuum pump contactor is not active.
TROUBLESHOOTING
1
Check the wiring of the vacuum pump contactor.
2
If the wiring is correct and the issue persists
Replace the contactor.
13. Vacuum Sensor Open Wire #
CONDITION
The analog input card is not reading a value from the vacuum pressure sensor.
TROUBLESHOOTING
1
Check the wiring of the vacuum sensor.
2
If the wiring is correct and the issue persists
replace the sensor.
3
If the issue still persists
Replace the analog input card.
14. Probe 1 Up Timeout #
CONDITION
The input for the probe 1 up reed switch is not active after a set time while the output to lower the probes is not active.
TROUBLESHOOTING
1
Verify that the probe is up and that the green LED on the reed switch is active.
2
If the probe is up
Ensure that the reed switch is adjusted properly to illuminate the LED when the probe is up.
3
If the LED is on and the probe is up
Check the reed switch wiring and replace if necessary.
4
If the probe is not up
Verify there are no obstructions preventing the probe from rising. Also, check the manifold regulator to verify that there is proper air pressure to lift the probes, and check that the air lines are connected properly to the manifold and air cylinder.
15. Probe 1 Down Timeout #
CONDITION
The input for the probe 1 up reed switch is active after a set time while the output to lower the probes is active.
TROUBLESHOOTING
1
Verify that the probe is down and that the green LED on the reed switch is not on.
2
If the probe is down and the green LED is off
Check the wiring of the reed switch and replace if necessary.
3
If the probe is up
Verify there are no obstructions preventing the probe from lowering. Also, check the manifold regulator to verify that there is proper air pressure to drop the probes, and check that the air lines are connected properly to the manifold and air cylinder.
16. Probe 2 Up Timeout #
CONDITION
The input for the probe 2 up reed switch is not active after a set time while the output to lower the probes is not active.
TROUBLESHOOTING
1
Verify that the probe is up and that the green LED on the reed switch is active.
2
If the probe is up
Ensure that the reed switch is adjusted properly to illuminate the LED when the probe is up.
3
If the LED is on and the probe is up
Check the reed switch wiring and replace if necessary.
4
If the probe is not up
Verify there are no obstructions preventing the probe from rising. Also, check the manifold regulator to verify that there is proper air pressure to lift the probes, and check that the air lines are connected properly to the manifold and air cylinder.
17. Probe 2 Down Timeout #
CONDITION
The input for the probe 2 up reed switch is active after a set time while the output to lower the probes is active.
TROUBLESHOOTING
1
Verify that the probe is down and that the green LED on the reed switch is not on.
2
If the probe is down and the green LED is off
Check the wiring of the reed switch and replace if necessary.
3
If the probe is up
Verify there are no obstructions preventing the probe from lowering. Also, check the manifold regulator to verify that there is proper air pressure to drop the probes, and check that the air lines are connected properly to the manifold and air cylinder.
18. Two Hand Start Buttons Released #
CONDITION
The dome buttons for the two hand start were released before the cycle was completed.
TROUBLESHOOTING
1
Verify that the buttons are clean and dry as the buttons are capacitive and moisture and grease on the surface can interfere with performance.
2
Check button wiring and ensure the cable connection is tight.
19. Internal Use Only #
N/A
20. Left Bag Stretcher Up Timeout #
CONDITION
The input for the probe 2 up reed switch is active after a set time while the output to lower the probes is active.
TROUBLESHOOTING
1
Verify that the left bag stretcher is up and that the green LED on the reed switch is active.
2
If the bag stretcher is up
Ensure that the reed switch is adjusted properly to illuminate the LED when the bag stretcher is up.
3
If the LED is on and the bag stretcher is up
Check the reed switch wiring and replace if necessary.
4
If the bag stretcher is not up
Verify there are no obstructions preventing the bag stretcher from rising. Also, check the manifold regulator to verify that there is proper air pressure to lift the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder.
21. Right Bag Stretcher Up Timeout #
CONDITION
The input for the right bag stretcher up reed switch is not active after a set time while the output to lower the probes is not active.
TROUBLESHOOTING
1
Verify that the right bag stretcher is up and that the green LED on the reed switch is active.
2
If the bag stretcher is up
Ensure that the reed switch is adjusted properly to illuminate the LED when the bag stretcher is up.
3
If the LED is on and the bag stretcher is up
Check the reed switch wiring and replace if necessary.
4
If the bag stretcher is not up
Verify there are no obstructions preventing the bag stretcher from rising. Also, check the manifold regulator to verify that there is proper air pressure to lift the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder.
22. Left Bag Stretcher Down Timeout #
CONDITION
The input for the left bag stretcher up reed switch is active after a set time while the output to lower the bag stretchers is active.
TROUBLESHOOTING
1
Verify that the bag stretcher is down and that the green LED on the reed switch is not on.
2
If the bag stretcher is down and the green LED is off
Check the wiring of the reed switch and replace if necessary.
3
If the bag stretcher is up
Verify there are no obstructions preventing the bag stretcher from lowering. Also, check the manifold regulator to verify that there is proper air pressure to drop the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder.
23. Right Bag Stretcher Down Timeout #
CONDITION
The input for the right bag stretcher up reed switch is active after a set time while the output to lower the bag stretchers is active.
TROUBLESHOOTING
1
Verify that the bag stretcher is down and that the green LED on the reed switch is not on.
2
If the bag stretcher is down and the green LED is off
Check the wiring of the reed switch and replace if necessary.
3
If the bag stretcher is up
Verify there are no obstructions preventing the bag stretcher from lowering. Also, check the manifold regulator to verify that there is proper air pressure to drop the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder.
24. E-Stop Safety IO Fault #
CONDITION
There is a safety IO fault with the E-Stop circuit.
POSSIBLE CAUSE(S)
- This happens when the contacts are in an inconsistent state (meaning one open and the other closed) for too long of a time period.
TROUBLESHOOTING
1
Check the wiring of the E-Stop contact blocks
And replace them if there are no wiring issues.
25. Cycle Start 1 Safety IO Fault #
CONDITION
There is a safety IO fault with the Cycle Start 1 PB circuit.
POSSIBLE CAUSE(S)
- This happens when the contacts are in an inconsistent state (meaning both contacts open or closed) for too long of a time period.
TROUBLESHOOTING
1
Check the wiring of the button
And replace it if there are no wiring issues.
26. Cycle Start 2 Safety IO Fault #
CONDITION
There is a safety IO fault with the Cycle Start 2 PB circuit.
POSSIBLE CAUSE(S)
- This happens when the contacts are in an inconsistent state (meaning both contacts open or closed) for too long of a time period.
TROUBLESHOOTING
1
Check the wiring of the button
And replace it if there are no wiring issues.
27. Jaw Closed Prox Safety IO Fault #
CONDITION
There is a safety IO fault with the Jaw Closed Prox circuit.
POSSIBLE CAUSE(S)
- This happens when the contacts are in an inconsistent state (meaning one open and the other closed) for too long of a time period.
TROUBLESHOOTING
1
Check the wiring of the prox switch
And replace it if there are no wiring issues.
28. MCR Proof Fault #
CONDITION
The input for the feedback on the MCR safety relay is active when the output for the relay coil is energized.
TROUBLESHOOTING
1
Check the wiring of the safety relay.
If the wiring is correct, replace the relay.
29. Jaw Close CR Proof Fault #
CONDITION
The input for the feedback on the jaw close safety relay is active when the output for the relay coil is energized.
TROUBLESHOOTING
1
Check the wiring of the safety relay.
If the wiring is correct, replace the relay.
30. Jaw Close Stage 1 Timeout #
CONDITION
The input for the jaw close stage 1 reed switch is not active when the output for the jaw close stage 1 is energized.
POSSIBLE CAUSE(S)
- The most common reason is that the reed switch is not adjusted properly.
TROUBLESHOOTING
1
Verify that when the jaw is closed in the stage 1 position that the green LED is illuminated on the reed switch.
Adjust the reed switch if necessary.
2
If the green LED is illuminated and the alarm persists
Check the wiring of the reed switch
3
If the jaw is not closing
Verify that there are no obstructions to the jaw. Also verify that the electronic pressure regulator is wired and functioning correctly.
4
Once these are verified, if the issue persists
Verify the air lines are connected properly to the manifold and air cylinder.
31. Jaw Full Close Timeout #
CONDITION
The input for the jaw close stage 2 proximity switch is not active when the output for the jaw close stage 2 is energized.
TROUBLESHOOTING
1
Verify that when the jaw is closed in the stage 2 position that the jaw closed proximity switch is being made.
Adjust the proximity switch if necessary.
2
If the proximity switch is being met and the alarm persists
Check the wiring of the proximity switch.
3
If the jaw is not closing
Verify that there are no obstructions to the jaw. Also verify that the electronic pressure regulator is wired and functioning correctly.
4
Once these are verified, if the issue persists
Verify the air lines are connected properly to the manifold and air cylinder.
32. Jaw Open Timeout #
CONDITION
Either the input for the jaw close stage 1 reed switch or the jaw close stage 2 proximity switch is active while the output to close the jaw is not energized.
TROUBLESHOOTING
1
If the jaw is physically open
Check which input is active.
2
When you find which input is energized
Check the wiring and replace the switch as needed.
3
If the jaw is not opening
Verify that there are not obstructions.
4
Check the functionality and wiring of the electronic pressure regulator
Verify that the air lines are connected properly between the air cylinder and the manifold.
33. Vacuum Pressure Timeout #
CONDITION
The vacuum pressure could not hit the setpoint value for an extended time during the cycle.
TROUBLESHOOTING
1
Check for leaks or clogs in the vacuum lines.
2
Verify the wiring of the vacuum pressure sensor.
34. Third Bag Stretcher Up Timeout #
CONDITION
The input for the third bag stretcher up reed switch is not active after a set time while the output to lower the probes is not active.
TROUBLESHOOTING
1
Verify that the third bag stretcher is up and that the green LED on the reed switch is active
2
If the bag stretcher is up
Ensure that the reed switch is adjusted properly to illuminate the LED when the bag stretcher is up
3
If the LED is on and the bag stretcher is up
Check the reed switch wiring and replace if necessary.
4
If the bag stretcher is not up
Verify there are no obstructions preventing the bag stretcher from rising
5
Check the manifold regulator
Verify that there is proper air pressure to lift the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder.
35. Third Bag Stretcher Down Timeout #
CONDITION
The input for the third bag stretcher up reed switch is active after a set time while the output to lower the bag stretchers is active.
TROUBLESHOOTING
1
Verify that the third bag stretcher is down and that the green LED on the reed switch is not on.
2
If the bag stretcher is down and the green LED is off
Check the wiring of the reed switch and replace if necessary.
3
If the bag stretcher is up
Verify there are no obstructions preventing the bag stretcher from lowering
4
Check the manifold regulator
Verify that there is proper air pressure to drop the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder.