INTRODUCTION:

Bestpack's random fully automatic machines possess the capability to measure box dimensions and transmit this information to the folding and sealing sections. This ensures that the sections attain the correct height and width for executing the folding and sealing processes, allowing for smooth up-and-down movement. Any instances of hard crashes or unusual behavior fall outside the machine's standard operations.

ISSUE OVERVIEW: 

When an issue arises that interferes with the movement of the folding section or the sealing section to the box height for their respective processes, especially if you observe a hard crash in any of these machine sections, it is essential to examine the settings or potential factors that could be causing these problems.

POSSIBLE CAUSES:

1. Clearlink is not connected: If any of the connections assigned to the clearlink are missing, both the folding area and the sealing area (CSD only) will collapse, and it will not be possible to send the machine to the home position until you reconnect the device.
2. The force of the servo motors' brakes has been disengaged: If you disable the force or encounter a wiring issue with the brake output, the machine will experience a hard crash.
3. Pneumatic/Air issues (CSF only): If the air adjustment for the 'descent of the sealer' is set too high or 'ascending of the sealer' is set too low, the machine will move the sealing section in an abnormal manner, which could result in the boxes being crushed.
4. Box presentation: If the box presentation is incorrect, the machine will read inaccurate height measurements. Consequently, it will adjust the folding and sealing sections to the wrong height. When this occurs, the box may become stuck, or the machine might crush the box.

HOW TO FIX THE ISSUE: 

1. Clearlink: Verify the 3 essential connections that goes to the clearlink:

• Power connection: The Clearlink device must consistently receive 24 volts, except when the machine is turned off. On the power connector, there are three wires: P21 (Positive), N24 (Negative), and E (Ground). If you observe that the Clearlink device is not receiving power, utilize a multimeter to confirm the voltage and check the continuity of the wires.
• Ethernet port: If the machine is not communicating or is exhibiting delayed responses, it is imperative to confirm the functionality of the Ethernet wire connecting the Clearlink device to the Ethernet hub (Switch) on the electrical panel. To check for communication between the Clearlink and the machine, you can connect your computer to the Ethernet hub and attempt to ping the IP address of the Clearlink using the Command Prompt (Default Clearlink IP address: 192.168.1.16).
• Molex cord: This cord connects the servo-motors to the Clearlink. Therefore, if you encounter an issue with this cord, you should examine the continuity of the wires on both sides of the Molex connection. Simultaneously, ensure that the connectors on the wires are properly crimped.               

2. Servo-motors' breaks: If the brakes are encountering issues and not engaging with the servo motors, there are two steps to consider checking:

• Disable/Enable on the HMI Screen: Set the machine in manual and access the manual mode on the HMI Screen, then check the message related to the Servo Brake. If it is indicating 'On,' press the screen button to release it.                                                                                                                   
• Wiring: Inspect the PLC outputs for FA Servo Brake (O:2/8) & SA Servo Brake (O:2/9), which includes examining their positive and negative connections. Afterward, verify whether the wires or connections are in good condition.                                                                                                                                                                    

3. Air pressure (CSF & CSEGA): Each individual machine has recommended air pressure values that should be set on the pneumatic regulators. If you experience a hard crash in the sealing section, check whether the air pressure values are in alignment with these recommended values.

4. Box presentation: The method by which we send the boxes is crucial, as it ensures accurate height and width measurements. Simultaneously, this approach provides additional support to the machine, enhancing the box folding process. Here are the instructions we should adhere to when preparing a box for production:

1. Place the product inside.
2. Fold the minor flaps.
3. Send the box to the machine.

RESET & TESTING: 

After completing any troubleshooting routine, it's important to verify the proper functionality of the equipment. For CSF/CSD/CSEGA machines, press the reset button and hold it for at least 5 seconds. Once you observe the folding section and the sealing section moving to the home position without any faults, this indicates that the machine is ready for operation.