HI, MI, WI-700 service manual - 7 – fault finding

7 Fault finding
Contents-
Operational problems 7-2
On screen error messages - Console software 7-3
On screen error messages - Worldview software 7-4
Labeller problems 7-5
Labeller error codes (lab sw V:40013 &below) 7-6
Labeller error codes - (lab sw V:50019 & above) 7-8
Conveyors 7-10
Pack sensors 7-11
Scale not working 7-12
Fault finding checks on A/D board 7-12
Labeller board LED’s 7-13
How to PING the labeller to check communication 7-14
Sleever interface operation error codes 7-16

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FAULT FINDING – Operational problems

No green L.E.D on screen when launch button is pressed.

• Check isolator switch on control box is turned on and green power light on control box is on.
• Check mains power cable is plugged into mains power.
• Ensure the screen launch button is not pressed for too long. Once the screen L.E.D has lit, (which
should be as soon as the launch button is pressed), release the launch button

Green light in conveyor start button is not lit.

• Check isolator switch is turned on.
• Check emergency stop switch is not pressed in. If pressed in, pull up to release.
• Conveyor safety switch not made – check all conveyors are correctly in place and fitted to the
machine in the correct orientation.
• Check control fuse in electrical cabinet (315mA)
• Is a sleever connected? Sleever must be on and ready for use.

Stays on Digi 700 start up screen

• Check infeed sensor is not blocked and sensor / reflector are clear and clean.

Machine starts up but weight is red on screen and/or not active

• Check infeed sensor is not blocked and sensor / reflector are clear and clean. May need to restart
the machine once sensor fault is rectified.

After start-up, plu cannot be selected

• Check infeed sensor is not blocked and sensors / reflectors are clear and clean. May need to restart
the machine once sensor fault is rectified.
• Is the labeller that is assigned to the plu being selected ready for use and communicating with the
console.

No label when pack passed over scale

• Unstable weight - when pack passes over scale, check the on-screen weight is green. If the weight is
red, the pack is unstable.
• Check pack is within any weight limits set or e-mark tolerances
• Is the correct plu selected with the correct labels loaded onto the labeller?

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ON SCREEN ERROR MESSAGES - Console software

System not ready
System not ready to print, problem(s) with
labeller 1

This error will occur when the labeller is unable to

print a label when a pack is being processed.
This can be due to:
1. Machine just switched on and a label feed
not done – press label feed to prepare
labeller.
2. New cassette installed – press label feed
to prepare labeller
3. Labeller lost communication with console
– if label feed does not fix this, then shut
machine down (including mains isolator)
and restart.

Error 1 labeller – Timeout before extra

application sensor
This error will appear when the optional additional
outfeed pack labelling sensors are being used and
the time window and/or distance set is not correct

Error - scale not at zero.

There is something on the scale.
This error will occur if the scale is not at zero. Ensure
there is nothing touching the scale and there is no
debris on or under the scale.

If the scale needs to be re-zeroed, touch the scale

re-zero button to reset scale to zero

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ON SCREEN ERROR MESSAGES - Worldview software

Error messages that appear in the worldview operation screen have the same meaning and resulting action
as Console software but the messages are displayed in a different way. A section below the weight / price
area flashes red/green when an error occurs. If pressed, detail of the error is displayed and the error can
be cleared at this point.

Typical error messages

When an error occurs, this area will flash

red/green
Basic message is displayed
Press the red area to access addition error
information

Additional error information

In this example, the labeller is not ready for
printing, red light error on labeller
Feed labels to get labeller to correct status
Touch to clear error from list

Other common errors

PLU is not selected / System not ready to
weigh - select PLU for machine operation

Labeller error - Print apply cycle too fast -

Reduce conveyor speed and/or increase
print speed to obtain label in time

System error messages have not been

cleared -
If original error is not cleared and operation
of the machine is tried, this message will
appear, clear all error to restart operation

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LABELLER PROBLEMS
Label not applied on pack correctly.
• Position and function of applicator – adjustments to applicator will depend on applicator type fitted.
• Air pressure too high or too low
• Sub jet bar (blow bar) - check air holes are clean and in correct position, plus check strength of air
blast. (refer to servicing section)
• Check Label is fed out to correct position at the front edge of the thermal head
• Check Labels/backing paper is not fed over the front of sub jet bar.

Incorrect label feed.

• Correct label format / plu is selected for labels being used.
• Labels are feeding through gap sensor and are being read correctly by the sensor.
• Check free running rollers are free to turn and labels are fed through machine correctly.
• Check drive and pinch rollers are clean and set correctly.
• Sensitivity level of gap sensor – check in Service menu/labellers/adc & gap sensor.
• Label path is clean - check the yellow sheet (sheet AF) is free from label debris and is clean and not
damaged so labels have a smooth path to run into thermal head area, (2nd stage labeller).

No print.
• Label format is selected which has print
• Labels are thermal type
• Thermal head is locked down in position and adjusted correctly against the platen roller or wear strip
• Compressed air is connected and set correctly for head cylinder (Signature labeller)
• Thermal head is connected, if disconnected; turn power off machine before reconnecting.
(If disconnected should get Error 22)
• Possible failure of thermal head or labeller board.

Poor quality print

• Thermal head is clean
• Wear strip is clean, undamaged and in serviceable condition (2nd / Signature labellers)
• Platen roller is clean, undamaged and in serviceable condition (classic labeller / Signature labeller)
• Print speed is not too high for quality of label.
• Position of thermal head onto wear strip, 2nd / Signature labeller. (refer to servicing section)
• Position of thermal head on platen roller, classic / Signature labeller. (refer to servicing section)
• Air pressure of head onto wear strip / platen roller, Signature labeller (refer to servicing section)
• Pressure of thermal head onto platen roller, classic labeller (refer to servicing section)

No label produced when expected

• Pack is outside any weight limits set in the plu
• Pack is unstable over scale deck (check weight on screen, if red, pack is unstable)
• Pack has not been seen by sensors (infeed and scale)
• Re-call plu to ensure correct information is sent to labeller.
• Is conveyor speed too fast and/or print speed too slow? (Should get Error 11)
• Are there any error messages on screen when pack passes through?
• If error is shown, refer to error code list on following pages.
• If labeller has stopped communicating with console, power reset labeller board

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Labels not staying central in the labeller (2nd stage labeller only)
• Check label path is clean
• Check label guides are set to the width of the label
• Follow corrective action in servicing section to correct label drift (snaking)
If an error occurs with the labeller, the error is displayed on the operation screen as an error code number
with some description. The table below gives typical error codes
NOTE: this list relates to a labeller with software V:40013 or below
Note: Some of the errors listed below refer to checks to make on the label format (e.g. – error 16, 21, 33).
These types of errors may occur after a new or a modification has been made to a label format.
In some instances it may be necessary to delete the relevant label format and re-make it if the error
persists.

List of labeller errors Reason for error

Error 10: The labels have run out Check label roll
Error 11: The apply timer has expired Increase print speed or decrease conveyor speed
before the label has been fully printed
Error 14: Label image memory elements Console / blow signal error. Too many packs in the system
are full. More labels must be printed be- waiting for blow signal to expire.
fore sending more data
Error 15: Label image memory full for Check label format size, may be too large for available
current type of label memory.
Error 16: Missing image line or lines not Check label format layout in Dr Label, all data must be within
in sequence label area on screen, adjust fields if needed.
Master image may not have been sent, reselect plu.

Error 21: The current image line is not Check gap sensor position (as for error 25)
available for printing Check label format layout in Dr Label, all data must be within
label area on screen.
The console may have been completing a different task when
labeller required data, reselect plu to ensure master image is
sent and retry packs.

Error 22: Thermal head temperature is Check thermal head is clean; also, check ribbon cable is con-
above or below the operational range nected in thermal head correctly.
Head may be too hot, leave to cool down, (may happen if m/c
was run with head in up position.
Fault with thermal head, replace head
Error 23: The labels have run out Check label roll. If label is present refer to solution in error 26

Error 24: There is no label or the stepper Stepper motor may have stalled, feed labels to reset. If labels
has stalled are present but m/c does not detect them, check label are fed
through gap sensor or the gap sensor may need its sensitivity
adjusted
Error 25: No label has been detected Is just backing paper coming through gap sensor? If so feed
after the gap. Please perform label feed labels again until labels are at sensor. If labels are correct,
again check to see if the label gap comes to rest at the gap sensor
position, if so, move gap sensor position (or adjust in soft-
ware) so label gap does not stop at sensor position.
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Error 25: No label has been detected after Is just backing paper coming through gap sensor? If so feed
the gap. Please perform label feed again labels again until labels are at sensor. If labels are correct,
check to see if the label gap comes to rest at the gap sensor
position, if so, move gap sensor position (or adjust in soft-
ware) so label gap does not stop at sensor position.

Error 26: No labels found after five Check label roll for missing labels.
consecutive prints
Error 27: Pack print requested but no blow Will need to power reset the whole m/c. Error may be
start input was received caused by feeding new label roll before new plu is selected.

Error 28: Pack print requested before Check print and conveyor speed is suitable for label size.
label application was complete
Check operation of outfeed pack sensor with pack.

Error 29: Run out of blow timers Multiple blow pulses have occurred. PLC error or sensor is
seeing through pack

Error 32: Unrecoverable error in Dual Port Turn off machine, including isolator and restart.
Ram during transmission of label bitmap
data
Error 33 - Dual Port RAM failure on last Check label format layout, an item, e.g.-barcode may be
label bitmap Ethernet packet over the edge of the label. Move item or increase label width,
(just increasing width in Dr label design will help).
May require restart – if so, power down including isolator and
restart.
Error 34 - Timeout before extra blow Check label gap sensor settings.
sensor
Error 100 - Protocol error Cassette labeller – lost communication with labeller. Shut
down machine, including isolator and restart.
Cassette labeller – if a new label format has been made or a
label width changed, try adding or subtracting 1-2mm from
the programmed label width.
E.G. – if programmed label width is 58, change it to 60.
Also, ensure the format size has not been made with a
fraction size (e.g. – 56.7). must be whole numbers (e.g. –
56)

Ping Test Failure: Unable to ping labeller Check network connection. If console software has just
stopped operating the labeller board will need a power reset.
Ping Test Failure: Unable to ping labeller
with IP address
Socket Open Error: Unable to connect to
labeller socket. Error code
Socket Open Error: Unable to connect to
labeller socket. Error code
Socket Disconnected: The labeller TCP Labeller has received a reset command, may need to power
socket has been disconnected or reset off to re-establish comms.

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High speed 2 labeller software uses some different codes to display any error, these are initially in the form
of a letter. These are listed below

Error code Reason for error

Print error A Asynchronous errors - Unable to load data to serialiser
because the data was not ready
Print error B Unable to load data to the head because it has not yet been
loaded to the serialiser
Print error C The PIC has not finished printing the previous line yet.
Please Check Ramp type and PIC version
Print error D The PIC is ready to print but data has not yet been loaded
into the head
Error E - out of labels No labels detected, out of labels

Error F - no labels detected Label not detected or stepper stalled

Error G - print apply too fast Print/apply cycle is too fast

Error H - head temp Thermal head temperature error

Error I - no pack in window Pack not found in extra sensor window

Error J - timer expired, no print Time to apply label but print not yet started
Error L - labels near end Label roll near end

Error M - out of ribbon Label ribbon has run out

Error N - image not RXD Labeller has not received the label image in time

Error O - label ID mismatch Label ID mismatch

Error P - erase fail Ethernet download - for Erase flash failed. Do not power cycle or reset the labeller,
s/w version 50021 & above please try again
Error Q - program fail Ethernet download - Programming flash failed. Do not power cycle or reset the
for s/w version 50021 & above labeller, please try again
Error R - head open - linerless labeller with Head open
50030 s/w
Error S - no label on cutter - linerless No label on cutter
labeller with 50030 s/w
Error T - label on applicator - linerless Label on Applicator/ not taken
labeller with 50030 s/w
Error U - Arm jam Front label applicator - check debounce timer value, arm
may be hitting pack before fully down or up
Labeller s/w from v:50046
Error V - labeller missed pack Side labeller applicator - applicator has not hit pack in time
to make proximity sensor, check application time value and/
Labeller s/w from v:50046
or pressure setting

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If the labeller have software installed that is V:50019 or higher the following error codes will apply

Error code Reason for error

10 Unknown command Console sent a command not recognised by the labeller (possibly
mismatch of protocol versions)
11 Invalid message Console sent a message that was not the correct type
12 Unexpected length Console sent a message that was of incorrect length
13 Out of range The value for a parameter was out of range (the error message will also
show what the parameter was)
14 No trigger Console has sent an image command but did not send a trigger first (or the
trigger command was rejected and it still sent the image)

15 No image Console sent a trigger but it had not yet sent the image for the previous
label.
16 Queue full The pack queue of the labeller is full. It can queue up to 19 packs (also de-
pendant on image memory). Move the labeller closer to the scale or in-
crease pack spacing.
17 Image memory full The image memory is full. Reduce the size of the label format.

18 Pairs out of range Console has sent the labeller an invalid image command.
19 Line width mismatch The width of one line of image data does not match the master image. Is
console trying to send the image of another label?
20 No master Console sent a pack image but the labeller has not received a master
image.
(can’t actually happen at the moment, the labeller will just print the pack
image it’s been sent)

21 Manual queued There is a manual label queued to be printed (or printing), in this situation it
is only possible to queue more manual prints, not automatics. (this is only
likely to occur when doing pack and total labels on the same labeller with-
out a sufficient gap)

22 Queue time The time that this label would need to be applied is less than the last ele-
ment in the queue (should never happen)
23 Label ID mismatch The label ID of the image that was sent does not match the label ID of the
last trigger that was sent (should never happen)

24 Duplicate successive Console has sent the same label twice (should never happen)
label IDs

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CONVEYORS

Conveyors do not start - If the green light in the button is not lit, the conveyors will not start.
Check - Emergency stop button
Conveyor safety switches (one under each conveyor)
Control fuse in electrical cabinet
Is machine connected to a sleever machine, is sleever machine operational?
Is contactor being energised when start button is pressed?

If green light in switch is lit and conveyors do not run:

Check for loose wires in the back of the conveyor start switch
Check PLC is operational and there are no loose wires / connectors on the three sections
Check – Vexta motor drivers in electrical box for flashing LED error code, see code list below

Two flashes = overload protection - load in excess of rated torque applied to motor.
Check the conveyor that has given the error.
Check for anything that maybe stopping the conveyor / motor from turning.
Check roller / pulleys turn freely

Three flashes = open phase protection – sensor cable within motor cable is disconnected during motor
operation.
Check connection on motor driver and the plug/socket/motor cable to motor.

Four flashes = Over voltage protection – Load in excess of permissible load inertia or voltage applied to
the driver has exceeded the voltage setting (24VDC) by 15% or greater.

Five flashes = Insufficient voltage protection – Applied voltage to the driver is less than the voltage setting
(24VDC) by 25% or greater.

Six flashes = Over-speed protection – motor speed has exceeded 3500r/min.

Green LED

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PACK SENSORS
The pack sensors can be mounted across or above the conveyors. These may be the fibre optic type
(Omron) or the opto-electronic type (Wenglor).

If Wenglor type, to check operation or adjust sensitivity use the teach mode on the sensor. The teach mode
inhibit plug inside the electrical cabinet will need to be unplugged to allow the sensor to be adjusted.
If fibre optic type sensor, the sensor amp for each fibre optic is positioned inside the electrical cabinet

The operation for both type sensors can also be checked in the Console or Worldview software.
For 700 Console go to Service menu / Service plc
Enable the 1st and/or 2nd sensors, the onscreen indicators will turn red
By crossing the sensor, the onscreen indicators should turn green.

For Worldview software, go to Service menu / conveyor settings

When the sensor is covered the indicator on the

screen will change colour from red to green

Typical problems caused by 1st sensor malfunction

No weight displayed on screen
No weighing operation
No pack indexing

Typical problems caused by 2nd sensor malfunction

No label produced for good pack

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SCALE NOT WORKING

Example of errors
1. Error- Scale not at zero
2. Error- unable to start scale communication, scale disabled
3. Error initialising ADC

Error 1 – possible causes

Something on the scale when starting up, check scale assembly and under scale for debris.
If the weight on screen is fixed (red) check ADC connection to load cell.

Error 2 and 3 – possible causes

Normally from start-up, check infeed sensor is working (go to service menu / service plc and check
operation of sensors, infeed sensor must not be covered or out of adjustment when starting scale.
Check serial communication cable and plug from ADC to main board serial port.

Fault finding checks on ADC board

With the ADC cover off, the electronic board is visible.
1. With machine isolator on (but not starting the PC) there should be – 4 red LED’s on near to top of the
board, if not check the power supply for the ADC.
2. A set of 3 green LED’s (near bottom of board) will start to flash after about 10 seconds of the isolator
being powered on. If this does not occur, then possible ADC fault.
3. Start PC – when software has reached operation screen, the set of 3 green LED’s will go out. Above
these LED’s is a single LED that should now be flashing. If the middle one (D7, of the set of three) is
also on then check infeed sensor.
4. Putting hand across infeed sensor the middle and top green LED’s (D7& D8) will come on for around
5 seconds then go out, returning to the single flashing LED. Check infeed sensor if this does not
occur.
5. If you put your hand over the outfeed sensor while the middle and top (D7, D8) green LED’s are on
the middle one should flash once. If this does not occur check outfeed sensor.

These 3 LED’s should be flashing when the isolator switch

is turned on (before the software is started).

The LED’S are numbered

D8 (top)
D7 (middle)
D9 (lower).

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LABELLER BOARD LED’S

When viewing the labeller, the following should occur on start-up of the machine.

The LED’s in the middle of the labeller board are:

LED15
LED16
LED17
LED18
When the machine is powered on at the isolator (software not
started yet) LED16 & 17 should be on.
When the software is running this should change to LED 15 &
17

Board in operation:

The following list is an identification of these LED’s status:

With the board in operation in the 700 machine, the 4 LED’s on the board (15, 16, 17, and 18) will display
their current function, i.e. - if an error occurs, the LED (s) can indicate the error.

LED 15 = listen socket error

LED 15 + 16 = cannot set interface
LED 16 = cannot open interface
LED 17 = TCP server error
LED 16 + 17 = waiting for TCP connection
LED 15 + 17 = TCP connected
LED 15 + 16 + 17 = waiting for free mailbox slot
LED 18 = data waiting in output slot (to pc console)

All flash = wrong software loaded into CPU

All steady = waiting for CPU synchronisation.

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HOW TO ‘PING’ THE LABELLER TO CHECK COMMUNICATION

If the labeller has failed in its communication to the machine software a simple check using the Windows®
command prompt can quickly establish if there is a hardware failure or if the machine software / labeller
software is not communicating.
It is useful to plug in a USB keyboard for this check
To access the command prompt function the machine needs to be at Windows® level or access the
Windows start menu with a Keyboard.
Therefore, when logged in as engineer level,
closed machine down to Windows®

Select the Windows® icon in lower left of

screen

Select Command prompt

When the command prompt box appears, type in:

Ping [Link] (this address is the standard for the 1st labeller (Signature type)
For subsequence labellers the last number of the IP address increases (e.g. - lab 2 = [Link])
Touch – return
Note: after the word ping, always leave a single space before typing in the IP address numbers.

Note: IP address will be different depending on labeller type

Classic / 2nd stage will be: 192.168.0.X (X being 1 for labeller 1, 2 for labeller2 etc.)
Cassette / LC labeller will be: 1.1.1.X (X being 210 for labeller 1, 211 for labeller 2 etc.)

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From the Ping request, one of the two screens below will appear.

Below is a successful communication to the labeller from the console with a reply back from [Link]

On the screen below the communication has failed (timed out and / or Destination host unreachable
check all hardware for fault.
If error is Destination host unreachable this may be due to incorrect Windows® / software setting
• Power reset the labeller board
• Check indication lights on hub and labeller board
• Check Ethernet connection plugs on main board, hub & labeller board.

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From the Ping request, one of the two screens below will appear.

On the left is a successful

communication to the
labeller from the console
with a reply back from
[Link]

On this screen the

communication has failed
(timed out) – check all
hardware for fault
• Power reset the la-
beller board
• Check indication
lights on hub and
labeller board
• Check Ethernet
connection plugs on
main board, hub &
labeller board.

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Error codes when 700 series machine is linked to a Sleever machine

When a pack passes through the 700 machine and onto the sleeving machine, if the pack is not detected
correctly and/or the values in the service menu / labeller are not set correctly an error may appear on the
700 screen.
The possible error codes are below.

Error A
No sleeve movement after print detected. You MUST CHECK last 10 packs and index two sleeves before
continuing!
Reason – the sleever has received all required data correctly, but has failed to index the sleeve for
unknown reason. Check sleever indexing and sleeve movement sensor.

Error B
Communication with the scale didn't finish on time. You MUST index two sleeves before continuing!
Reason - pack has been weighed but the console did not tell the interface that it was a good pack (correct
weight, stable) within the required time (limit 500 milliseconds). The message may have been lost due to a
communications error (electrical). However the console did receive a weight from the ADC and is telling the
interface to add this (now missed) pack to the queue.

Error C
Delay of pack is a negative number. You MUST index two sleeves before continuing!
Reason – would only happen if scale sensor to sleever sensor was too close. This is unlikely to happen
now as the software has a minimal print time.

Error D
Communication with the printer didn't finish on time. You MUST index two sleeves before continuing!
Reason - The confirmation from the console that a pack is ready to be printed has arrived too late. There is
a time limit of 750ms after the pack cuts sensor 2 for the receipt of this message. It could be caused by
communication errors between the console and the ICE or between the console and the interface.

Error E
Not used – replace with error A or I

Error G
Printer didn't accept the pack. You MUST index two sleeves before continuing!
Reason - Two successive good pack messages have been received by the interface without an intervening
'pack is ready to be queued for printing' message. It could be caused by communication errors between
the console and the ICE coder or between the console and the interface.

Error H
No good pack signal received between good pack confirmations. You MUST index two sleeves before
continuing!
Reason - Two successive messages have been received from the console to say that this is a good pack
ready for printing without an intervening good pack message. Possibly there has been a communications
error between the console and interface.

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Error I
No sleeve movement after good pack signal detected. You MUST CHECK last 10 packs and index two
sleeves before continuing!
Reason – the sleever has received all required data correctly, but has failed to index the sleeve for
unknown reason. Check sleever indexing and sleeve movement sensor.

Error J
Pack didn't arrive to printer sensor on time or printing started too soon. You MUST index two sleeves before
continuing!
Reason – pack arrived too soon or too late at the sensor in the sleever. Use the statistics screen to readjust
the timing parameters.

Error K
Printing while pack is crossing printer sensor. You MUST index two sleeves before continuing!
Reason - A second pack is expected before the completion of the good pack signal to the sleever for the
first. The timing parameters are incorrect. Use the statistics display to check and adjust them.

Error L
No sleeve for printing or printing timeout while waiting to finish printing. You MUST index two sleeves
before continuing!
Reason - Printing didn't finish on time (425 milliseconds are allowed) or the sleeve started moving before
printing completed. This is often caused by false movement detection by the sleever sensor, which needs
adjusting. If this is not the case then the sleever may not be able to sleeve the pack at this belt speed and
the belt speed must be reduced. There may be a problem with the ICE coder or its setup (for example too
low a print speed).

Error M
No sleeve for printing or printing timeout while waiting to start printing. You MUST index two sleeves before
continuing!
Reason - The Ice coder was commanded to start printing but it had not done so within the timeout or before
the sleeve moved. The causes of this are as for Error L

Error O
Good pack event didn't occur. You MUST index two sleeves before continuing!
Reason – this error is generated by the 700 console (all others are generated by the interface
communication board). The ICE printer received and confirmed data but the interface did not report receipt
of a good-pack message. This may be caused by a communications error between the console and the
interface.

Error Q
Queue overflow. You MUST index two sleeves before continuing!
Reason – The timing queue in the interface can only hold 9 packs and more than 9 have been seen before
the first is sleeved. This is unlikely to happen on any of the standard machine configurations but could if an
experimental (extra long) one was attempted. Another alternative is that the timing parameters have been
set much too long and an out-feed/top printer conveyor belt is stopped/running too slowly (again only likely
to happen during experimentation).

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