Sterling 882.00722.00 manual Troubleshooting, Introduction

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Chapter 6: Troubleshooting

6-1 Introduction

The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components. All normal trouble-shooting must be accomplished with the power off, line fuses removed, and with the machine tagged as out of service.

The use of good quality test equipment cannot be over-emphasized when troubleshooting is indicated. Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine. Be sure that the voltmeter has at least minimum impedance of 5,000 OHMS-per-volt on AC and 20,000 OHMS-per-volt on DC scales. Popular combination meters, VOM and VTVM can be selected to provide the necessary functions.

Before making haphazard substitutions and repairs when defective electrical components are malfunctioning, we recommend that you check the associated circuitry and assemblies for other defective devices. It is common to replace the obviously damaged component without actually locating the real cause of the trouble. Such hasty substitutions will only destroy the new component. Refer to wiring diagrams and schematics.

Locating mechanical problems, should they occur, is relatively straightforward. When necessary, refer to the parts catalog section.

Figure 53: Typical Troubleshooting Problems and Suggested Corrective Actions

Problem

Corrective action

		Check to make sure that air is hooked up and the regulator gauge
		reads at precisely 60 PSI.
	Nothing happens when I start
	the extruder
	the extruder	Look on the Recipe Screen. If you don’t see a displayed Extruder

		RPM then check the inductive proximity switch. If you do see a
		displayed RPM then check the hopper’s calibration

	“Interface has been Locked” is	Click “Unlock” and enter in your User Password.
	shown	Click “Unlock” and enter in your User Password.
	shown

	I’ve forgotten my User	Contact the Service Department.
	Password	Contact the Service Department.
	Password
	PLC Battery Low	Change out the PLC with your spare and reprogram new unit.
	PLC Battery Low	Send old PLC back to Manufacturer for repair.
		Send old PLC back to Manufacturer for repair.

Chapter 6: Troubleshooting

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Contents GH-M Rate Monitor Allen-Bradley Controller Write Down Your Serial Numbers Here For Future Reference Unpacking and Inspection Shipping InfoEvent of Shipping Damage If the Shipment is Not CompleteWarranty Returns ReturnsCredit Returns Table of Contents Maintenance Safety How to Use This ManualSafety Symbols Used in this Manual Safety Tags and Warning Labels Description Wear Safety Glasses and Work Gloves Follow all Safety CodesResponsibility General ResponsibilityOperator Responsibility Remember Reporting a Safety Defect Maintenance ResponsibilityFunctional Description AccessoriesModels Covered in This Manual General DescriptionCustomer Service Typical Features and Components Mechanical FeaturesController Features Extruder Inductive Proximity Switch System Component DescriptionSurge Hopper Weigh Hopper OpenFunction Typical GH-M Operator Screen Operator Screens Common to all GH Systems Typical Setup Screens Ethernet Module Optional ComponentsSafety Features Pneumatic Slide Gate below surge hopperLow Level Proximity Sensors Mechanical Installation InstallationMounting Configurations Uncrating the EquipmentMachine Mount Electrical ConnectionsPneumatic Connections Initial Set-up Weigh Hopper InstallationMechanical Set-up Extruder RPM connectionDisplay Startup Screen Final ConnectionsController Set-up Recipe Page Start GH Controller Menu StructureWeigh Hopper Load Cell Calibration GH CalibrationDisplay Calibration Menu Screen WTP/RPM Calibration Hopper Size SetupHauloff Setup and Encoder Calibration Extruder SetupNetwork Setup Alarm SetupPanelView Configuration Screen Setting Date and TimeGH-M Operation Procedures OperationOperator Displays Typical Operator Screen for GH Full Control system GH Full Control Operation ProceduresGH-F Gravimetric Feeder Operation Procedures Typical Manual Control Operator Screen Common ScreensAlarm Flags Alarms with DescriptionsPrint Inventory Preventative Maintenance Schedule MaintenanceCorrective Maintenance Preventative MaintenanceElectrical Internal Components of the Control PanelOutput Signals from Programmable Controller Input Signals to Programmable ControllerIntroduction TroubleshootingProblem Problem Corrective actionWarranty Specifications Warranty and Spare PartsWarranty Restrictions Warranty LiabilitiesAnnex B Information Customer ResponsibilitiesTypical Surge Hopper Assembly Parts List Addendum Service Supervisor Information PasswordsProgrammable Settings Typical Engineering Only Setup Screen Extruder Pulse Count Method Percent of hopper Method DefaultFull Hopper Method WTP/RPM FilterMechanical Options Screen Max Allowed WTP/RPMTypical Analog Options Analog options screen Diagnostics ScreenPassword Protection Customer Setup MenuAlarm Log UnitsAllen-Bradley Communications Manual Below are the items that can be accessed for the GH HopperAppendix Reload TOO Long Fixed Decimal Explanation Service Department Sales Department Parts DepartmentContract Department