2. CONTENTS:
1. Maintenance and troubleshooting
a. Replacing new HMI panel in the batch machine of the block plant.
b. Troubleshooting the wrapper machine of the block plant.
c. Troubleshooting the pallet stacker
d. Obtaining proper scaled value in the aggregate bins.
e. Replacing the Load cell on the color machine.
f. Replacing broken safety photo eyes on the pallet transfer cart.
g. Troubleshooting Cuber malfunction.
2. Future Projects
a. Height adjustment for pavers on wet side.
b. Installing cable ladder and cable tray system on the paver plant.
c. Rewiring the Cuber UP/ down control wires.
d. Adjustment of the height sensor on the Hopper 1.
3. A.Replacing new HMI panel in the batch machine of the
block plant.
Cause of the Problem:
No power at the panel.
Possible loss of the program.
Setup not running.
Not able to automatically add color as panel was down.
Troubleshooting:
The power was restored.
It was rebooted and the setup was run.
The setup was not able to run as the program was cleared.
Therefore new panels were ordered and installed.
B. Troubleshooting the wrapper machine of the block plant.
Cause of the Problem:
Conveyor does not start.
Blocks not able to pass forward.
NO power in the SLC power card.
Delay in production cycle.
Troubleshooting:
A broken fuse was found and was replaced.
The SLC power card was reinstalled and a new was ordered.
The SLC processor was reinstalled with the Current program and rebooted.
The conveyor started running.
However wrapper is still waiting on a part after which it could be used in the process.
4. C.Troubleshooting the pallet stacker
Cause of the Problem:
Pallet stacker shows unusual behavior.
Sometimes it just comes down with just 2 or three boards.
Troubleshooting:
The sensor in the middle which is responsible for the number of boards was loose.
Repositioned the sensor.
Adjusted the sensor for the number of boards.
Pallet stacker working fine
D. Obtaining proper scaled value in the aggregate bins.
Cause of the Problem:
Desired Agg bin weight was different than the value obtained.
Caused differences in the product made.
Troubleshooting:
The small jog and the large jog values were altered with the help of Mr. Joe.
Difference in the jog time was also altered.
The exact value was obtained and noted down.
E.Replacing the Load cell on the color machine.
Cause of the Problem:
The weight of color in the color panel was showing as constant.
There was no difference with any color.
Resetting the color program had no effect either.
5. Troubleshooting:
Any loose wire connection was found out. All wires were intact.
The Load cell had no control voltage between the green and the black wires.
The load cell had incoming voltage to it.
This confirmed that the load cell was bad.
The load cell was replaced and was calibrated through the software.
F. Replacing broken safety photo eyes on the pallet transfer cart.
Cause of the Problem:
Broken photo eye
The transfer car sometimes stops in between.
Connection problem with the receiver.
Troubleshooting:
Both the Transmitter and the receiver was replaced and a new set was ordered.
They were aligned to get the maximum signal.
They were all fitted and started with operation.
6. G. Troubleshooting Cuber malfunction.
Cause of the Problem:
Cuber not going up and down.
Manual/ auto operation cannot perform.
Delay in dry side production.
Troubleshooting:
A loose wire was found which was tied up together.
Eventually the fuse had also blown which was also replaced.
The wire is very tight so did come off twice.
New wires are ordered and will be rewired by Wednesday.
