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Rollstock thermoformer troubleshooting guide

ALARM SCREEN MESSAGES

CHECK WATER

  • Turn on water
  • Water pressure too low / twisted line
  • Check water inlet valve
  • Calcium deposit in dies or lines
  • Check water pressure sensor in pneumatic cabinet

 

CHECK COMPRESSED AIR 

  • Turn on compressed air
  • Air pressure too low / twisted line
  • Check setting on air pressure switch
  • Safety circuit open 

 

CHECK GAS

  • No gas available pressure below 2 bar / twisted line
  • Check gas sensor pressure switch
  • Check gas flush valve
  • Incorrect setting 

 

CHECK HEATERS

  • Turn on heaters
  • Check seal/form temperatures
  • Check electrical connection plug 

 

DIE NOT CLOSED

  • Check proximity switch on lift cylinder
  • Verify pneumatic signal to die lift cylinder
  • Check for lifting system jam
  • Check for foreign object caught in die
  • Check seal die for excessive filler plates

 

DIE NOT OPEN

  • Check proximity switch on lift cylinder
  • Verify pneumatic signal to die lift cylinder
  • Check for lifting system jam

 

CHECK TRIM CANISTER

  • Check overload switch on the bottom of the trim canister
  • Check if trim canister is full
  • Make sure hoses are not blocked
  • Make sure trim canister is plugged in
  • Check electrical plug

 

MAIN DRIVE OVERLOAD

  • Check drive motor
  • Check trim wound around sprockets
  • Check chain for jam or deformation
  • Check contactor and reset it

 

ROTARY KNIFE BREAKER

  • Check knife for jam
  • Check blades for dull edges or nick’s
  • Check rotary knife motor
  • Reset the breaker

 

VACUUM PUMP OVERLOAD

  • Check oil vacuum pump
  • Check motor on vacuum pump

 

E-STOP

  • Reset depressed e-stop
  • Check e-stop switch
  • Loose or broken wire on e-stop

 

ERROR ON 4AD

  • Check for 24V DC to the module
  • Check led input / output

 

ERROR ON 4ADTC

  • Check for 24V DC to the module
  • Check led input / output

ERROR ON PLC

PLC GREEN LIGHT IS FLASHING ON AND OFF

  • Check for short circuit in the 24V DC lead to the interface.
  • Check for possible removal of e-prom during machine cycle.
  • Check 3.6V lithium battery in PLC for low voltage.

 

MTA-G1 INTERFACE GOES BLANK OR SHUTS OFF

  • Check for disconnection or short circuit in the 24V DC power to the interface.

Advance Drive

ADVANCE LENGTH VARIES

  • Make sure die centers are set correctly
  • Check advance length, adjust advance length in program
  • See cycle interruption

 

FORMED POCKET CANNOT BE ALIGNED IN SEAL DIE

  • Check set point in program settings
  • Check die center dimension, information is engraved on the die tops

Cross Cut System

UNEVEN CUT

  • Check advance
  • Move cross cut knife
  • Adjust advance in program
  • Check blade holder
  • Check blade

Cycle Interruption

CHAIN ADVANCE INTERRUPTED

  • Check e-stop
  • Check safeties.
  • If seal die is closed due to trapped vacuum. You must go to the service-manual seal screen on the control panel and vent package.
  •  Turn the vacuum pump on.
  • Push advance arrow one time only to finish the cycle.
  • Put machine back in auto mode for continuous operation

Alarm Codes

          S898     Estop Alarm
          S899     Safety Module Alarm
          S900     Forming Safety Alarm
          S901     Sealing Safety Alarm
          S902     Cutting Safety Alarm
          S903     Zipper Station Safety
          S904     Heat Zone 1 Over Temperature
          S905     Heat Zone 2 Over Temperature
          S906     Heat Zone 3 Over Temperature
          S907     Heat Zone 4 Over Temperature
          S908     Heat Zone 5 Over Temperature
          S909     Heat Zone 6 Over Temperature
          S910     Heat Zone 7 Over Temperature
          S911     Heat Zone 8 Over Temperature
          S912     Low Water Pressure Alarm
          S913     Low Air Pressure Alarm
          S916     Low Gas Pressure Alarm
          S920     Seal Vacuum Fault
          S921     Gas Flush Fault
          S930     Main Drive VFD Fault
          S931     Top Labeler Fault
          S932     Form Die Close Time-Out
          S933     Form Die Open Time-Out
          S934     Seal Die Close Time-Out
          S935     Seal Die Open Time-Out
          S938     Form Blower V/Pump OL
          S939     Seal Vacuum Pump OL
          S940     Trim Canister OL
          S941     Rotary Knife OL
          S942     Discharge Conveyor OL
          S945     Form Plug Time-Out
          S923     Index Blocked By Seal Die
          S924     Index Blocked By Form Die
          S925     Index Blocked By Knives
          S926     Index Blocked By Code Dater
          S972     Seal Die Blocked By Die Locks
          S973     Form Die Blocked By Die Locks
          S963     Guillotine 1 Top Cyl Fault
          S964     Guillotine 1 Botm Cyl Fault
          S965     Guillotine 2 Top Cyl Fault
          S966     Guillotine 2 Botm Cyl Fault
          S967     Guillotine 3 Top Cyl Fault
          S968     Guillotine 3 Botm Cyl Fault
          S969     Guillotine 4 Top Cyl Fault
          S970     Guillotine 4 Botm Cyl Fault
          S919     Guillotine 1 Top Cyl Fault
          S948     Seal Die Lock Fault
          S949     Form Die Lock Fault
          S961    Guillotine Position Cylinder 1
          S962    Guillotine Position Cylinder 2
          S824    Network Alarm – Printer
          S825    Network Alarm – Zipper
          S826    Printer X Axis Fault
          S827    Printer Y Axis Fault
          S828    Printer Limit Switch Fault
          S829    Index Blocked By Printer
          S830    Printer Memory Error
          S834    Zipper Memory Error
          S835    Index Blocked By Zipper
          S836    Zipper Die Lock Fault
          S837    Zipper Die Not Closed Fault
          S838    Zipper Die Not Open Fault
          S844    Zipper Zone 1 Over Temp
          S845    Zipper Zone 2 Over Temp
          S846    Zipper Zone 3 Over Temp
          S847    Zipper Zone 4 Over Temp
          S848    Zipper Zone 5 Over Temp
          S849    Zipper Zone 6 Over Temp
          S850    Zipper Zone 7 Over Temp
          S851    Zipper Zone 8 Over Temp
          S974    Guillotine 5 Top Cylinder Fault
          S975    Guillotine 5 Bottom Cylinder Fault
          S943    Filler Time-Out Fault
          S953    Confirmation Station 1 Not Closed
          S954    Confirmation Station 1 Not Open
          S951    Confirmation Station 2 Not Closed
          S952    Confirmation Station 2 Not Open
          S960    Guillotine Position Cylinder 3
          S976    Slicer Fault
          S927    Shape Cutter OL
          S875    CC Link Master Alarm
          S876    CC Link Master Link Alarm
          S877    CC Link Station 1 Alarm
          S878    CC Link Station 2 Alarm
          S879    CC Link Station 3 Alarm
          S700    Filler Not Ready Fault
          S701    Station 1 Fillers Fault
          S702    Station 2 Fillers Fault
          S703    Station 3 Fillers Fault
          S704    Station 4 Fillers Fault
          S705    Station 5 Fillers Fault
          S706    Station 6 Fillers Fault
          S707    Station 7 Fillers Fault
          S708    Station 8 Fillers Fault
          S709    Station 9 Fillers Fault
          S710    Station 10 Fillers Fault
          S711    Station 11 Fillers Fault
          S720    Filler Timeout Fault
          S721    Network  Filler 1 Timeout Fault
          S722    Network  Filler 2 Timeout Fault
          S723    Network  Filler 3 Timeout Fault
          S724    Network  Filler 4 Timeout Fault
          S725    Network  Filler 5 Timeout Fault
          S726    Network  Filler 6 Timeout Fault
          S727    Network  Filler 7 Timeout Fault
          S728    Network  Filler 8 Timeout Fault
          S729    Network  Filler 9 Timeout Fault
          S730    Network  Filler 10 Timeout Fault
          S731    Network  Filler 11 Timeout Fault
          S732    Network  Filler 12 Timeout Fault
          S733    Network  Filler 13 Timeout Fault
          S734    Network  Filler 14 Timeout Fault
          S735    Network  Filler 15 Timeout Fault
          S736    Network  Filler 16 Timeout Fault
          S737    Network  Filler 17 Timeout Fault
          S738    Network  Filler 18 Timeout Fault
          S739    Network  Filler 19 Timeout Fault
          S740    Network  Filler 20 Timeout Fault
          S741    Network  Filler 21 Timeout Fault
          S742    Network  Filler 22 Timeout Fault
          S977    Heat Zone 1 Auto Tune Error
          S978    Heat Zone 2 Auto Tune Error
          S979    Heat Zone 3 Auto Tune Error
          S980    Heat Zone 4 Auto Tune Error
          S981    Heat Zone 5 Auto Tune Error
          S982    Heat Zone 6 Auto Tune Error
          S983    Heat Zone 7 Auto Tune Error
          S984    Heat Zone 8 Auto Tune Error
          S854    Zipper Zone 1 Auto Tune Error
          S855    Zipper Zone 2 Auto Tune Error
          S856    Zipper Zone 3 Auto Tune Error
          S857    Zipper Zone 4 Auto Tune Error
          S858    Zipper Zone 5 Auto Tune Error
          S859    Zipper Zone 6 Auto Tune Error
          S860    Zipper Zone 7 Auto Tune Error
          S861    Zipper Zone 8 Auto Tune Error
          S995    PLC Memory Error
          S992    Servo Punch Fault
          S993    Servo Punch End of Stroke Fault
          S994    Servo Punch Not Ready
          S991    Servo Punch Home Error

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