MP21 Toshiba ISE250N Procedure to Make Screw Return to Full Back Position

MP21 (TOSHIBA ISE250N) Screw Back Position Correction

 

1)   With the power on, open the Main Control Cabinet Doors,

 

2)       On the inside of the LH door, locate a blue tuning pot, with the numbers 0-9,

it is extreme upper LH side of injection control board under a terminal strip, dial the

pot to the #1 position.

 

3)       Under the blue tuning pot, locate and depress, a push button labeled “3SW”.

 

4)       Now, over on the Data Cell Display, punch in code 32 and change the value to 1.0 or .5

Record the original value.

 

5)      Now punch in code 33 and change the value to 40.  Record the original value.

Make sure the value you enter are retained.

 

6)      Turn the tuning pot back to the “0” position.

 

7)  Depress the “3SW” push button.  You are finished.

 

Original Values on July 14, 2010 were Code 32 = 4.0 and Code 33 = 16.

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

7.12.10 D shift

Worked on liquid color pumps that were left on the cart in the shop. Repaired one of them.
One needs a new wheel for the color tube pump.
The other two are probably not worth repairing as they likely have been dropped really hard.
One of them had the tranformer knocked completely from the board.
The other has a short somewhere in the board and also has a bad shaft on the gear housing.
I red tagged them accordingly.

Also worked on water strainers and drained water from some of the water traps that you could see water standing in.

We had some trouble with EOAT on presses #22 and #4 but just parts coming loose.

Left at 4 a.m.

Call if there are any questions or anything I can do to help.

Sean

6.28.10 D shift

Put up the aluminum brackets on all of the presses that Bill Potter requested for the purge checklist sheet he wants to display.

Installed the new core standard on presses #9 and #10.

Replaced the ejector limit switch flag on press#7, it had broken. Made one from stronger materials.

Replaced the handle on the pilot fan tester, it was broken.

I will continue to watch the presses that are down and work from the "tracker"list.

Call if you need to.

Sean

6.24.10 D shift

Finished putting up the EOAT Boards.
Suggest that we put up some guidelines for the techs to see when hanging new tool arms etc., so it will remain organized.

Changed out the bottom core switch on #4 last night.

I think it had come out of adjustment, but the LED was not working.

When I installed the new switch, LED would not work on it either.

The input was reading on menu 41 though.

I checked the switch with my meter and it appears to be good so I will returtn it to MRO.

Installed new core standard plug on MP #3, also installed ejector back limit switch receptacle on junction box (in parallel) so it can be used either way.


Talked to everyone on the D shift and there are 3 guys who want to volunteer for any or all of the 3 work-days of shutdown. They are all mechanically inclined.

1 process tech- Johnny Stamps
1 moldsetter- Cameron Wilson
1 operator- Mike Sells

They understand that it is likely 8 hrs /dayshift ,if they can work. ?

I told them I would let them know by Monday or Tuesday so please get back to me by then.

Thanks

Sean

6.23.10 D shift

GR6- grinder, tore it completely apart and started reassembling it. I still have more plastic to clean out from the screen area (slow going), but it looks like I will only need to do some welding on the pan to complete the repair.

It was welded once before and had new bearings/seals installed last time. They appear to be holding up o.k. for now, so we won't need any new parts for it, unless just want to buy a new pan, etc?

Repalced the nozzle tip and T/C on #13.

Placed a note on the loader for 25. Someone had switch 1 on and 2 off, this was causing the loader to load constantly even though the sensor appeared to be working. I placed a label on it so they would know to use 2 with that sensor cable.

Left at 4:30a.m. puts me at around 40 hrs right now. Plan on working till 6a.m. on Thursday night.

Call if there are any questions.

Sean

6.22.10 B shift

Put up EOAT boards outside of molding office. Will continue the rest of it after I find some wood. I used what Facilities had in their locker area. I made a note on the "Tracker" spreadsheet about what wood I need but I may be able to scratch it up from around the pallet room or something.

Tightened up the filter clamps for the vacuum loader pumps. Looks like they had come out of adjustment.

I plan to tear down the peanut butter grinder Wednesday evening and should have an idea of what parts we will need to get it going again by Thursday morning.

Left at 12:30 a.m.- trying to keep hours down this week. I'll be in the next 2 nights and try to take off Fri-Sat-Sunday.

Call if there are any questions.

Shutdown Attachment

Sorry, I didn’t send attachment.  Here it is..

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Shutdown 2010

Attached is a calendar for shutdown this year.  Also, for anyone who does not already know, we are tracking issues, projects, and parts ordering here-  O:\Molding\MOLDINGSUPPORT\Oreck\Departments\Maintenance\Tracker.xls

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

6.21.10 B shift

Installed new Core wiring standard on presses 6 and 7.

Replaced any switch covers/knobs on all the nissei presses that had stuff missing.

Replaced Nozzle heater band on MP#17 at Darryl's request.

Checked all the machine hoppers for air line leaks, made repairs, replaced some hoses.

Left at 3:30a.m. Be back Tuesday and Wednesday evening to work full shift.

Looks like the board must have worked on #1?

Sean

6.20.10 D shift

Mp#18- sight glass was broken and all of the extruder oil had leaked out. I press fit a peice of plexiglas into it and it is holding for now but need to replace it.

Mp#21- refilled extruder on that one also.

Put together a list of the machines we have completed the core standardization on, robot interface, liquid color plugs, etc. Going to try to combine it with everyone else's machine spreadsheets so we can all be on the same page.

The SB#3- pocket valve has a busted glass in it as well. I sent mark an email to order parts. It was already taped up, but may cause a leak if left unrepaired.

We had some trouble with #22 slider mold. They ran that conductive material on it and had difficulties removing it from the mold consistently.

If there is anything I can do to help prepare for shutdown,...or if any new info about shutdown surfaces, please keep me in the loop, Thanks.

Sean

" C " Shift

• Wiped down & lubed all tie bars before start up. Made sure the chiller & pumps were operating.

 

MP-19  Replaced broken oiler fitting ;bottom  non – operator side.

 

MP-11  Robot not going to home position ; turned off main robot power & rebooted- OK

 

D-32 ( mezzanine )   Alarm 11 -  Adjusted index switch.

 

MP-9  Robot  Z  axis brake not releasing – checked all connections, & cleaned the contacts. Working fine now

 

MP-22  Tech burned his arm while purging out barrel. I checked to make sure we didn’t have a heater problem. The last shift that ran did a mold change &

           didn’t purge the barrel. They went from Santopren to nylon. When the new set up was loaded, it was 200 degrees higher

           than the new material being  loaded.

 

 

 

 R. Upchurch  

6.16.10 Nights

MP#6- Charlie thinks the screw tip may be worn out on it. They ran the big blue Hoky and had short shots off and on all night. We may need to do a static test on that one as well.

Worked on robot PM's all night. Replaced the vacuum generator unit on #20 robot, it was still functional but leaking air really bad. The gasket on the pilot valve was blown. It can be repaired if we can get a new gasket. I think Mark is going to check with Motion Ind.

Sean

" C " Shift

MP-9  Robot wasn’t homing;  the reference block had been moved & one of the home blocks was loose. I got that straightened out & then there was

          no vacuum on the cups. There was water in the system; bled it off & set the vac verify switch—ok to run.

 

MP-17  The nozzle heat controller was in hi - temp alarm & wouldn’t heat.  There was a loose T.C. connection at the controller—Repaired.

 

MP-12  The grinder was making a noise ;  I cleaned it out – the material was hot & just about to start melting. I let it cool down, & had to adjust the rear

           stationary blade. I reassembled the grinder & got them to turn up the regrind load time. OK to run.

 

 

 

 

  R.Upchurch  

6.10.10 D-shift

D shift had 2 process techs out wed/thurs so today I did spend some time assisting with set-ups etc.

MP#9- built and end of arm tool for mold # 78165 and roughed in the parameters.

Made a tool for them to insert the magnet in the fans they were welding at #12.

As it stands, I told Darryl that I will not be working Saturday and Sunday, but if he needed me to come in and fix anything that was down, all he had to do was give me a call. My number is posted in the molding office.

Sean

" C " Shift

MP-3   Left side gate cutters not cutting good; I swapped out cutting tables. I changed out the left side cutters. It’s always harder to cut the polycarb parts.

          We need to order spare cutters.

 

MP-13   I installed the new screw tip . They hung a mold in it.

 

 

 

 

 

 

 

 

R.Upchurch

6.8.10-D shift

Mp#4- changed the thernocouple, reused the heaterband. Darryl requested that I remove the purge that was stuck to the wires.

Mp#15- helped Jeff set-up the Sprue picker. It needed some maintenance and also needs some work on a screw that is stripped out where they adjust the in/out from the mold<>.

MP#21- hot stamp had a blown fuse. Replaced it and it began working fine. Replaced a gage on one of the air regulators, cleaned, lubed and tightened things up on it.

Worked on liquid color pumps that were in the shop. Cleaned, repaired and generally just fixed what needed fixing on them. Still have a few more that may need parts.

Call if there are any questions.

Sean

MP19 Nozzle Touch Alarm

If anyone gets an alarm on MP19 that says “Nozzle Touch PS2 Unconfirmed”, here is the fix-

Go to clamp factory screen by hitting “Shift” and then the “Clamp” screen button.  Go to the page titled “Mold Adjust 1”.  At the top there is a setting named “HPCV”.  Not really sure what it is or what it does, but it controls what the pump loads to for nozzle contact force.  I found it set at 60% the other day when we were getting the alarm and set it to 99% and this fixed the problem.  Evidently they had the problem again over the weekend and I’m assuming the value got set back to 60% when someone reloaded a new process set up.  We changed again from 60% to 99% and this fixed the problem.

Call with any further questions.

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

6.6.10 D shift

Finished repairing the connector nest for vibratory welder. Replaced broken/missing screws loctited them. Cleaned and inspected the tool. It looks like the adjustment method they have been using requires a hammer sometimes.

Lubed all of the tiebars and refilled reservoirs and greased the machines.

We need to get a repair kit for the Milacron machines complete with 3/16" nylon tubing and the ferule type fitting they use.

MP#15- has a broken lube line that needs repaired when it is down.

MP#17- has an extruder hose that is leaking. I tagged and measured it. Made a new hose up and left a note so we can change it when it is between molds.

I left a note on the Fastenal board to restock the "assorted springs" drawer. I used a spring last night to repair one of the gasket locating tools (used on the intake pivots) but didn't really have what was needed.

I left the old clamp tonnage transducer with Mark so we can possibly stock a spare.

Replaced the cabinet fan on robot #3 panel.

Basically fixed little things most of the night and helped the techs because this shift has no tooling person. We repaired the tool on press#22 that broke out all 4 keen-serts. There were only 2 left in the box so we patched it up to get it running.

Let me know how you want to do that blocked nozzle test. I am supposing you want to do a dynamic check ring reliability test for bad screw tips?


I plan to take off this evening but will work on till Friday night. Call tomorrow if there are any questions.

Sean

" C " Shift Weekend

MP-22  Tech said cores not working --  found eject. back switch wasn’t made – they forgot to tie in the knock-outs.

 

MP-2   Mid zone heat kept dropping out;  contactor was bad – replaced

 

MP-22   Checked torque on the screw gun for the valve body. Max torque on the SOP is 14 ;  It is running 12.5 – 12.75.  They had a few

            parts  crack . I think the parts may have just been too hot.

 

MP-5  One of the wheel mounting brackets on the ( small parts ) shelf unit broke off.  I took it to the shop & brazed it back on.

 

MP-5  Getting  the prefill alarm again. Changed settings & offset.  It ran until right before shift change & alarmed out FHD exceeded limit.

          I left it with Sean.

 

Cleaned up oil & changed pads on MP-17 & 21.

 

MP-11  The core pin broke & when they pulled the core cylinder off, they pulled the wires loose. Repaired.

 

 PM’s  on press 2 , 3 , & 4.   MP-3  needs new fan in robot cabinet.

 

 

 

 

R. Upchurch

6.5.10 D shift

Mp #5- the tonnage readout was stuck at 500, even after powering it down, etc.
I changed the tonnage transducer and when I powered it back up, it was a teading negative value (-28). I calibrated the offset and changed the convecs 921, 812, and 813 so they were 150 apart, etc. It worked.
Started it up and ran production at 7:10pm. Has ran good all night so far.

Changed out the screw gun on #22 because it would not stop running. I advised the process techs to monitor the screw bosses so they would notice if they were breaking out. They are doing fine so far.

Assisted Lynn Smith in changing out the welder nest and setting it up. I took the connector tool back into the shop, I have to make some repairs to it where it has been broken.

Sean

Cleaned up out on the floor and in the shop.

6.4.10 D-shift

Mp#5- stopped for the prefill alarm again. I couldn't find any information about what was done to it the other day to get it going. I tried calibrating the tonnage transducer again, but it did not work. Milacron thought there was problem with the FHD board for it to be continuing to have this problem. It is down now.

Jerome never replied to my request to schedule it down to do the screw-tip, so for now I will leave it.

I was able to extract the broken peices out of the screw for MP#13. I think it will be alright to use. Still need a new tip though.

Right now I plan on leaving at 2am Saturday night.

Will work all night Sunday.
Off on Monday.
Will work Tuesday through Friday nights.

Call if there are any questions.

P.S. Leave me some info this time on #5 so I can gain a better understanding of how to patch this thing for production. Thanks.

Sean.

" C " Shift

MP-13   Pulled the screw & screw tip. The rear seat wasn’t there. They continued to run it after it broke, so the threads in the screw were gone.

          Nissei didn’t have a 32mm screw in stock, so I called Chaseland  to make us one. They will fax the quote for the screw & tip Monday.

 

MP-14   Jason said some metal was showing up when he purged it out. Thought I was going to have to tear into that one when I finished 13.

           He got it running, so hopefully this one won’t jam up the check ring.

 

 

 

 

 

  R. Upchurch

6.3.10 B shift

Mp#13-Redid the heater bands on the nozzle. Checked and found that screw tip was indeed broken. Mitch was running it but they were scrapping too many so they eventually shut it down.

Repaired the cannister gate cutter fixture. Tested it out and it works great.

The drill press in the rework area broke the quill return spring. I was able to heat and rebend it and it is working again for now but we need to order another one. I gave Mark a lead with the drill press info.

Cleaned up oil around #17 and #21. Put some new oil absorbent down.

I am sending Jerome an email to see if he will leave #5 down on Saturday nite to do the screw tip change and barrel measurements.

Call if there are any questions.


Sean

Out of plant

I will be out tomorrow, Friday the 4th.
Josh
Sent From My Verizon Blackberry

Thursday A Shift

Suspect screw tip in 13 is broke. I've ordered a new one that will be there tomorrow. 
Josh
Sent From My Verizon Blackberry

6.1.10 D-shift

Mp#5- stopped for "Prefill did not open in time" alarm.
I was able to open the clamp by changing the offset for clamp tonnage on menu 93 from 1799 to 2250,and menu 92/convec 921, from 2000 to 2350 to get the clamp tonnage to zero, but it will not run yet. It now will alarm again but will open if you clear the alarm.
I spoke with Clarence at Milacron service who thought it sounded like the prefill valve was bad. I looked in MRO for another directional valve like it but couldn't locate one. They are using press #3 or I would have tried some parts from it maybe. I wasn't so convinced it was the valve bad yet, and I want to talk with Josh about it first.

Mp#11- Potter asked me to check the cores when I came in, I checked that the machine was working fine, used our test rig to verify switches and hoses. They had the collar tool out working on it and when it was set back in they never worked, it appears to be jammed up internally.

Worked on DME boxes, replaced cooling fan, and installed #3 jumper in all of them so they will work with the new style cards.

Changed the cord plug on liquid colr pump for 13 also.

May want to look over the gate cutting fixture that is for the cannisters. it is in the tool room because it needs another braket made. It looks like it is time for an overhaul of that fixture, I am welcome to any ideas with it.

Be back in at 6pm.

Sean

This week 5/24/10

Ordered new Saskawa servo amp from Nissei for MP1.  Should be here 6/1/10.  Called Saskawa and requested they send us our unrepaired unit and regenerative pack.

Should be here 6/1/10.  Nissei is now set up to accept P.O.’s, net 30.

 

Set up welder ejectors on MP12 for new Edge fan housing ejector cylinders, used outputs 12 and 13, top two single valves.  Firing sequence is top ejectors step 5, bottom ejectors step 6.  When door open part is laying loose for operator to remove.

 

Changed out safety latches in hoist ring hooks in molding production area.  (both hoists)

 

Installed additional 480 outlet on MP18.  Two outlets share a 30A breaker for Thermalators.

 

Fabbed and installed extrusion frame to hang heater wire junction box on MP2.  Mount junction box to new frame.  Replace and label all heater wiring.

 

Install and adjust spare Robot EOAT for fan housing on MP8

 

Replaced  (4)  2” load system hose sections up in mezzanine area with what hose we had on hand.  More hose is coming.  Replaced 2.5” material hose on top of surge bins.  Installed elbows and partially hard piped some drops.  We are trying to eliminate all vacuum leaks.

 

Install sand paper to the bottom of rework fixture for orbiter disks and realign.

 

Worked on color pump signal for MP1.  Parts are here to steal a signal from the output of the servo drive to the motor.

 

 

 

 

 

 

 

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

This week 5/24/10

Ordered new Saskawa servo amp from Nissei for MP1.  Should be here 6/1/10.  Called Saskawa and requested they send us our unrepaired unit and regenerative pack.

Should be here 6/1/10.  Nissei is now set up to accept P.O.’s, net 30.

 

Set up welder ejectors on MP12 for new Edge fan housing ejector cylinders, used outputs 12 and 13, top two single valves.  Firing sequence is top ejectors step 5, bottom ejectors step 6.  When door open part is laying loose for operator to remove.

 

Changed out safety latches in hoist ring hooks in molding production area.  (both hoists)

 

Installed additional 480 outlet on MP18.  Two outlets share a 30A breaker for Thermalators.

 

Fabbed and installed extrusion frame to hang heater wire junction box on MP2.  Mount junction box to new frame.  Replace and label all heater wiring.

 

Install and adjust spare Robot EOAT for fan housing on MP8

 

Replaced  (4)  2” load system hose sections up in mezzanine area with what hose we had on hand.  More hose is coming.  Replaced 2.5” material hose on top of surge bins.  Installed elbows and partially hard piped some drops.  We are trying to eliminate all vacuum leaks.

 

Install sand paper to the bottom of rework fixture for orbiter disks and realign.

 

 

 

 

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

5.27.10 D shift

Replaced wiring to purge sheilds on presses #6 and #12, tied them up neatly and repaired sheilds with new screws and fasteners, etc.

Checked all of the presses that were down for loose safety circuit switches and door latches, fixed whatever I found. Replaced screws as needed.
Checked the lube lines for broken fittings.

MP#8 -Finshed where Ronnie left off on oil pan clean-up.

I left a paper for Mark to see about ordering those vacuum drainage reservoirs for the 500 Cincinatti's clamp drain line. They might give us one as a sample since you order them 48 to a case.?

Mark and I went over the procedure for HMI programming for the AEC robot displays.

Call if there are any questions...have a great weekend. I will be working Tuesday-Friday or Saturday nights next week or until? I sent Darryl an email.

Sean

" C " SHIFT

MP-19-22-23-25   Filled lube reservoirs.

 

MP-19 & 22   Replaced broken tie bar & skate lube fittings

 

MP-21  Robot crashed into mold. All of the gripper mounts were either bent or broken off. Replaced all mounts, tightened the gripper posts, chased

      threads & replaced bolts on eoat mount.

 

MP-6 Vacuumed out oil pan.

 

 

 

R. Upchurch

Molding Maint.

5.26.10 D shift

Mp#260 Changed out the temperature contoller. It quit reading actual temp. Auto-tuned the new one. Checked operation, O.K. to run.

#11-Robot
Would not reference the Z-axis. Went thru the whole z-circuit, found loose connection on break relay module.

Call if there are any questions.
Thanks.
Sean

Molding Support Tracking Spreadsheet

Hey Guys,

I put together a To-Do spreadsheet today and put it on the server.  Attached is a shortcut. 

The spreadsheet has multiple page tabs at the bottom for Issues, Parts, Projects, and ShutDown Projects.

Some of the cells have drop down boxes for your convenience. 

Collin- Don’t let your feelings get hurt because I left your name out of the “Assigned To” drop down box.

 

Thanks

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

5.23.10 Weekend D-shift

Worked on conveyors repairing broken parts and generally looking them over to see if they need anything. There is still one that is going to need the Baldor drive repaired or replaced, but it is working for now.

#3 has a busted reservoir basin for the drain line that draws from the clamp seal. It is mounted under the automatic lube greaser. The words respiratory health care are printed on it so maybe it is something we can get cheaply at a hospital supply place?

#10- Had issues with the ultrasonic welder. The thermolator had been off and the positive stop was adjusted too far down. It was giving an error some of the time that would require you to press the reset button. It is working fine now.

Cal if there are any questions.

" C " Shift Weekend

 

MP-22  Broken glass on control panel—Ordered new one for Saturday delivery

 

MP-2  Tech had core problems--  checked & found sequence was set wrong.  Also DME hooked up wrong; heater was plugged in to zone 1 – TC was plugged in to

            Zone 2.  After correcting it, found it had a bad heater. Tooling to change it out.

 

MP-13  Tech said when sled was run in, the nozzle heat would drop out. When I went to check on it, Bill had started it up & it was OK. He said to let it run.

           ( For future reference )

 

I called Nissei about oiler fittings—They said they would send the right ones & for us to just keep the other fittings.

 

MP-22   The control panel glass & sheet came in---  Installed & checked out.  Also made a cover for it.  I need more hinges to make covers for the other ones.

 

MP-24  Installed a plug for the mold cores to the machine.

 

MP-17 Cleaned up oil jug overflow on clamp end.

 

MP-23  Weak vacuum on eoat suction cups--- tightened up all the fittings—OK

 

MP-23 Replaced the nozzle heater band.

 

MP-22  Could not change the screw back position.  I had to reset the injection scale. ( Press & hold the alarm reset while running the screw all the way back, then all the

           way forward, release reset button, then you can change the setting ).        

           

 

MP- 22  Getting a lot of color swirls in natural bag stiffener.  It wouldn’t purge out. I pulled the nozzle tip & the adapter. The adapter wasn’t seating, so I cleaned it out &  

             had tooling reface it. I reinstalled it & they were starting it up on “ D “ shift.

 

5.18.10 D shift

Mp#1-Put together a water manifold sheild to help direct any future leaks.

Mp#23 robot- Made a sprue gripper extension to pick offset runners (work order request). Helped them get it going.

Mp#21 robot- Replaced a section of tubing that had blown out.

Used 10x6.5mm metric tubing.

Put the new molds in the tool room.

Call if there any questions.

Sean

" C " Shift

  MP-23   Control power kept kicking off.  Mark and I checked it out; found the 3 amp control breaker was bad – replaced.

 

 MP-5 Installed  “T”  for gauge @ pressure transducer port.

 

MP-8  Made a fixture to check for bad ends on fan housings.

 

MP-1 Cleaned up water under clamp. Cleaned & checked operation of cabinet fan.

 

 

R. Upchurch

Molding Maint.

Tuesday

MP01 is still down with the servo drive alarm.  Mark is still doing some investigating before we send the thing in for repair.

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

5.17.10 D shift

Mp#1- Motor power goes off after 1 second, then alarms "5E33" Clamp axis driver error (regeneration abnorm).

Checked it out, found wires burnt open from what appeared to have gotten wet. Repaired regen circuit wiring. Alarm on servo amp cleared but alarm on machine display still comes up as before.

I downloaded the Yaskawa manual for that particular servo amp and motor, it indicated that there were maybe a few solutions to this error.
1. Replace the servo pak
2. Replace the regenerative pak (it could be defective I suspect).
3. Repair wiring to regenerative pak.

After making the repairs and reading further, I found that resistance specs for that servo pak model was 2.4 ohms. We have 3.4 actual now.

This is why I suspect a faulty regen pak.

There is reference to an incorrect pulse count vs. pulse set value, this is supposedly a result of this cause, which may be cleared (with the host controller)if I knew how to do that.

We would likely need that digital operator that we just now ordered to do that?

I turned over everything I had to Mark when he came in and I think he is going to see about making sure that any internal faults get cleared and seeing what else can be done aside from ordering new expensive parts.

Call me if you have any specific questions.

Also worked on the Hot stamp press on #20. It was not reading the down switch and had to be set-up correctly.

Sean

5.13.10 D shift

Mp#4-conveyor quit. Reinstalled chain and readjusted belt tracking.
Working fine now.

Mp#5-overtravelled once and had to be rehomed, problem was a loose cable connection in panel where someone had moved the cabinet.

Mp#6- techs couldn't get the conveyor to work, jumper was not connected.

Mp#19- Nozzle was not working, found loose wiring connection, no further problems.

SB#2- Ran out of material, cap was off of header on catwalk.

Hot stamp press on #21- showing "eater control error". Found bad connection on thermocouple. Replaced the thermocouple (Type J) no further problems.

Call if there are any questions. I did check out the manual on the new star and on behalf of this shift, thanks for the new robot!~

Sean

" C " Shift

 Built & installed three more conveyor trays; only need one more to complete all.

 

MP-22  Checked & set torque on screw gun.

 

MP-1  thru  MP-12   Checked & lubed tie bars—blew out cabinet filters.  (  MP-6 & 8  need new cabinet fans )

 

MP-11  Cleaned up oil under clamp unit – Clamp seal needs to be replaced.

 

MP-17  Discharge line came off of our recirculating pump—blew oil on floor--  cleaned up & replaced hose.

 

 

 

  R.Upchurch

 Molding Maint.

" C " Shift

 MP-24  Oil leaking from tank hatch, where the parts bin track is mounted. Replaced mounting bracket & tightened back down.

 

Surge bin 2 was clogged. Took line apart outside where it 90’s up. Vacuumed out line all the way back to silo. Readjusted flow tube. OK  for now.

 

MP-4  Set up the timer for core 2 & installed a new bolt for one missing from the bottom core 2 cylinder.

 

Trying to locate & tighten some of the fitting leaks.

 

 

 R.Upchurch

 Molding Maint.

The week of May 3rd, 2010

Got Hopper w/ sensor and Jet Loader installed for MP26

 

Added the color port for MP26

 

Installed stainless 90s, new hose, and clamps above the surge bins for plastic load lines

 

Freed up valve under surge bin 1

 

Ordered wands for grinders, short and long.  Will be ready for pick up May 7, 2010

 

Installed the ladder for the feeder bowl on MP10

 

Replaced busted 480VAC plug on grinder on MP2

 

Ordered the mistakeproofing sensors for hole in baseplates (Wheel Press)

 

Ordered 3” Round Black Delrin

 

Picked up 5/8-11 X 4”  SHCS for mold setter

 

 

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

5/1/10

Put the barrel shroud back on MP1 after a bleed off

Core 2 pull quit reading in MP4. the bottom sensor wasn't working. I found another used sensor which would work with a magnet but not on the cylinder. The original senor started working again after I put a magnet to it. It quit one more during the shift so I removed it and stuck the magnet to it again to get it working. I don't know if there are any of these sensors it stock somewhere.

Cleaned the filters in the loader on MP23

Collin

4/30/10

Core 1 wouldn't read the pull switch on MP5. Found a loose connection in the core plug.

When DR18 was started it would index then trip the main breaker to MP25. The process heaters were shorted. I replaced them and started it back up.

The robot on MP25 crashed in the core dummy plug. Straighten the robot arm and set it to rotate above the belt instead of the mold.

Collin Miller

Friday MP05

I finally fixed the problem on MP05 where the screw would drift forward when the pump loaded for Clamp Open/Close and Injection Unit Forward/Retract. Fixing that problem also dramatically made Screw Recover better.
Sent From My Verizon Blackberry

4/29/10

Press 10 ran all night without stopping

Fixed core wiring on MP22

Worked on MP8 robot

Replaced right side push button on fan housing press on MP8

Collin Miller

4-29-10

MP10-  Kept going down all day with the pumps kicking off.  Was getting a 5220 alarm, when indicates “Rear Door”.  On this machine, “Rear Door” does not refer to the Non-Operator side door, but the doors that are to the Rear (away from injection unit) of the machine.  I usually call these doors the “gates”.  Anyway, Mark noticed that the non-operator side rear door limit switch needed to travel a good bit before it was made so he adjusted it.

After this, the machine still kept going down.  We spent a little time troubleshooting it, but it finally got so bad it was doing it every shot they needed to run so I jumped wire #69 to #220.

This should get them running, but it needs to be removed later and the problem fixed.

It only does it when the mold is first closed, so it may be a short in a core wire or something.  The only other inputs grouped with the rear doors all seem to deal with options or the cores.  If something was shorted and dragging the voltage down on the entire group, this is the alarm you would likely see first because it kills the pump.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

4.29.10 D shift

Mp#10 stopped a few times, the techs did not say anything about it until I asked. I caught it once but it was because it had ran out of material and did not make shot size.

Mp#8- looked into redoing the other EOAT in the shop. Could not locate any 5/16 -24 threaded rod to make standoff studs for the disks. Need to get some. I sent Mark an email.
I do have some ideas we could try with the classic fan EOAT.

Began greasing and Pm'ing presses. We need to update press assignments or work out a plan of some kind that works.

Mp#18- I have been looking into the interface details to tie in the sprue picker. I think that one of the interface boxes will work. I have started on some notes that I will submit for Josh's review on Monday.
After looking at the interface schematics, I think it might be likely we can make something similar from scratch to do a few more presses that only require pickers.

Call if there are any questions.

Sean

" C " SHIFT

 MP-21   Replaced pump hydraulic Hose.

 

MP-26  Fabricated top safety door – It’ll work for now.

 

MP-24  Cores not working;  The eject. back common  on the machine side plug wasn’t hooked up. OK now.

 

MP-17  Cleaned up oil , replaced pads, & emptied jug.

 

 

 

 

R.UPCHURCH

MOLDING MAINT.

April 27, 2010

Spent several hours on our favorite two presses today, MP8 and 10

 

It all started with MP10 stopping periodically. (The pump dropping out)  We wanted to rule out machine or robot.

A jumper was placed between pins 19 and 27 in the robot interface plug to bypass the robot estop stuff.

The pump would continue to drop out here and there.  It seems to always drop out when the robot is either on its way to drop a part off or down in the conveyor guard, so basically when the machine is clamping up or building tonnage.  Looked at the control cabinet door switches and added screws to keep control power on solid.  Replaced the bottom safety switch on the back door, fixed the latch on the back door, it was rolling back some after you closed it.  The purge cover door switch cable was just bare wires twisted together, wirenutted and taped it up.  This is where we got to when MP8

Reared its ugly head.

 

MP8 would not pick parts and the EOAT was all out of whack.  So a couple of hours later we started picking parts again on a consistent basis.

We should put our heads together with our tooling and look at some improvements.  Gary and I talked and he brought up some good points that could fix some problems we saw today.  Tie the two discs together at the proper center spacing, fab and mount them so they cannot turn.  Use a single plate across the tool to represent the discs and insert the two tabs into the plate.  Separate the gripper mounts from the disc mount so they could be moved independently.  Just some thoughts, we desperately need to do something.

 

We received our new hydraulic oil today.

 

Poppet valves came in today.

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

4.25.10 D shift

Mp#2- repaired a broken core sensor wire.

Mp#3-repaired the vacuum switch on the robot, somehow the wires got ripped out. I tied them up neatly.

Mp#4-There was purge material all around the nozzle heater wires. Carefully cut away material and taped the wires back up out of the way.

Mp#5- had borrowed the vac switch off that robot to get #3 running and then soldered back the broken one and replaced it on #5 robot. I checked and adjusted the sensor so that it was working good. It is O.K. to run now.

The edge fan that is running in the vibratory welder is in need of ejectors to eject it from sticking in the tool fixture. Even when the parts are cold they can be difficult to remove. They may already have an engineering change planned but if not, someone needs to take another look at it.

Cleaned up and 5-s'd in the shop. Have a good week, call if there are any questions.

Sean

" C " SHIFT

  Mezzanine – Dryers 6, 21, & 32 – All  were in alarm; had to adjust index limit switches.

 

MP-22  Robot dropping parts;  Tightened up all suction cup mounts.

 

MP-16   Nozzle kept freezing off.  Replaced nozzle band.

 

Lubed all tie-bars. Wiped down & lubed tie bars on presses not running.

 

MP-21   Need to order new pump hose – back side- marked with red paint. It’s leaking at crimp.

 

  R.UPCHURCH

  MOLDING MAINT.

" C " SHIFT

 I vacuumed out all the oil pans & emptied all the oil catch bottles. Also cleaned up oil on MP-21.

 

Emptied oil vac.

 

MP-12   Eye wasn’t reading on eagle fan tester; also the air bladder was popping out of the fan when it inflated.  I adjusted the eye & cleaned the bladder

            with alcohol. Working OK.

 

Mark is ordering more hydraulic fluid & some more ½”  female quick connects to install on maifolds for the oil vac.

 

 

    R. UPCHURCH

    MOLDING MAINT.

" C " SHIFT

MP-20    Blow back -  Removed & replaced two nozzle heaters.

 

MP-21   Grinder quit.  Wire came loose from E-Stop.

 

MP-17 Oil running on floor again- jug filled up. Cleaned up. Oil tank was empty. I filled it.

 

 

 

 R. Upchurch

Molding Maint.

4.19.10 D shift

Mp#1- made 4 ejector bars per Bill Potters Request at 16- 3/4" each.
Also finished connecting front water manifold hoses on it.

Repaired the wheel press for the baseplates, it had a sensor out of adjustment and another sensor completely loose. Checked operation and moved back onto floor.

Dryer# 17-alarmed and went into shutdown mode. It did it because it was set-up in the diagnosis pages to fatal out in an overtemp condition. Simply reset it after checking it over, filters, motor operation, contactors, etc. No further problems the rest of the shift.

Hot Stamp press on #12- the process technician (Roy Smith) asked me to assist him in setting it up as he was having difficulty. We got it going after much adjustment. I recommended that using set-up sheets would help him in the future.

Ronnie and I looked over the new Press 1 and discussed lubrication, when the machine manual comes in I would like to have a look at it. I hear Nissei went up on the price of manuals now?

Reminder, I will be out on PTO Tonight as well as next week on Thursday.

Call if there are any questions.

Sean

4/17/10

Replaced the conveyor belt relay in number 4 robot

Worked on the loader on MP22. Had to adjust the sensor and the load timers

Work the rest of the night on number 8 robot. The round back stop on the EOAT broke one of the guides off. I modified another one and got it running again finally.

Collin