Pallet Pool - Troubleshooting Guide - NGC

Introduction

Pallet Pool

  1. Emergency Stop 
  2. Pallet Ready Button
  3. Load Station Door
  4. Load Station
  5. Air Gun
  6. Drip Tray

SENSORS

 
 
  1. PP Lifter Up
  2. PP Lifter Down
  3. PR Axis Home Switch
 
        4. PP Load Door Open
        5. PP Station Lock

 

        6. UMC Pallet Slide Home Switch

         Note: EC-400 Pallet Slide Home Switch is found underneath the ballscrew.

Symptom Table

Symptom Possible Cause Corrective Action

Alarm 15.108 AXIS SERVO OVERLOAD

Alarm 15.103 AXIS SERVO ERROR TOO LARGE

 Binding Transmission The amplifier could be having an issue driving the motor. If you have this problem, please contact our service department.

After zero returning the PS or PR axis, the folloiwng alarms are generated:

Alarm 15.103 AXIS SERVO ERROR TOO LARGE

Alarm 16.103 AXIS SERVO ERROR TOO LARGE

 Faulty Home Sensor Go to the Diagnostics-MOCON tab, search for PR or PS axis home switch inputs. Manually trigger the PR or PS sensors to verify the bits change states from 0 to 1. If the bits do not change states, use the electrical diagram below to determine which componet has failed.
Hydraulic oil leaks or sprays from the pallet locating pins during a pallet change.   Contact Haas Service.
Alarm 974 Pallet Pool Switch Fault Chips accumulated at sensors. Check the Pallet Lifter Down / Up sensors for chips and clean out any that are found. Recover Pallet Pool and try again. Use the illustrations to locate the sensors.
The pallet pool state proximity sensors are not triggering. Check the Pallet Lifter Down / Up sensor states and make sure the sensors are toggling when triggered. Use the Lifter UP/ Lifter Down I/O Status table below to determine the correct states of the sensor.
Alarm 977 Pallet Pool Lifter Up Time Out Insufficient hydraulic pressure or fluid volume. Make sure the pump is turning on and building enough pressure to lift the Pallet Lifter.
Pallet Lifter was not unclamped. Check for any mechanical obstructions that are preventing the pallet lifter from rising.
Damage to the Pallet Pool up switch or wiring. Check the pallet lifter up and pallet lifter down sensors for proper operation. Use the Lifter UP/ Lifter Down I/O Status table below to determine the correct states of the sensor.
Alarm 9887 Pallet Pool Lifter is Up The Lifter is up when attempting to retrieve a pallet. Enter RECOVERY to attempt auto-recovery, or enter the recovery page to verify that the lifter is operational by commanding it up and down. Check PP Lifter Up (INPUT 38) and verify it is operating correctly. Use the Lifter UP/ Lifter Down I/O Status table below to determine the correct states of the sensor.
Alarm 9888 Pallet Pool Lifter is Down The lifter is down while either retrieving a pallet or placing a pallet. Enter RECOVERY to attempt auto-recovery. If auto-recovery fails, enter the recovery page to verify that the lifter is operational by commanding it up and down. Check  PP Lifter Down (INPUT 41) and verify it is operating correctly. Use the Lifter UP/ Lifter Down I/O Status table below to determine the correct states of the sensor.
Pallet pool is displaying the wrong amount of pallets. Parameter 740 Pallet Pool Max Pallet Count is set incorrectly Change Paramter 740 to the correct pallet count 
Pallet pool up & down solenoid are functioning inversely  Up & down solenoid cables are incorrectly labeled   Order 93-3268 or 93-3268, lower and lift solenoid cable kit for correctly labeled cables. 
Pallet Changer Clamp/Unclamp mechanism operates in reverse. The hydrualic lines are reversed. Check at both ends of the hydrualic lift cylinder and hydraulic power unit and verify that they are set correctly.
The pallet clamp/unclamp sensors are reversed. With a Pallet on the receiver.  Command the pallet to clamp and unclamp.  Go to I/O tab and verify that inputs 25 PALLET CHANGER PALLET UNCLMPED and 29 PALLET CHANGER PALLET CLAMPED toggle to the correct state.  Check the terminal block, check that they are connected correctly.
Alarm 9889 Pallet Pool Slider Door Open Timeout The slider door failed to open within the required time limit Verify there is notthing obstucting the door open switch
Adjust the switch to the flag and make sure it toggles when in position
Check to see if the solenoid is funtioning properly
Verify there is notthing obstucting the door open switch
Alarm 9890 Pallet Pool Slider Door Close Timeout The slider door failed to close within the required time limit
Adjust the switch to the flag and make sure it toggles when in position
Check to see if the solenoid is funtioning properly
Alarm 9892 Pallet Pool Slider Door Not Open  The slider door was detected to be closed when it is expected to be open Check the area around the slider door for obstructions
Verify the correct switch is in the correct location
Alarm 9893 Pallet Pool Slider Door Open  The slider door was detected to be open when it is expected to be closed Check the area around the slider door for obstructions
Verify the correct switch is in the correct location

Lifter Up/Lifter Down I/O Status

Machine State

PP Lifter Up

Input #38

PP Lifter Down

Input #41

PP Pallet Lift

Output #166

PP Pallet Lower

Output #167
Pallet Pool Lifter is Up 1 0 1 0
Pallet Pool Lifter is Down 0 1 0 1

Load Door I/O Status

Machine State

PP  Load Door Open

Input #31

PP Station Lock

Input #33
Door is closed and the station lock is at the home position 0 1
Door is open and the station lock is at the home position 1 1
Door is closed and the station lock is not at the home position 0 0

Electrical Diagrams

Pallet Pool Input Status and Solenoid Output

                                          

PR/PS Switch and Servo Motor Connection to MainCon PCB

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