Applicable Models: CSF, CSD, CSS, CSEGA

Overview

The lift cylinder raises the indexer assembly to transfer a carton from the indexing area to the holding area.
If the lift cylinder does not activate, cartons will stall in the indexer and generate alarms.

This article provides a step-by-step guide to diagnose and resolve the issue.

Troubleshooting Steps

1. Reset & Verify Machine Status

• Reset the machine.

• Check the light tower:

  • Green flashing = no error, machine is ready.

  • If another color is showing, resolve the error before continuing.

2. Test Cylinder Through HMI

1. On the HMI, open the Manual Page.

2. Locate Indexer Lift button.

3. Toggle ON/OFF to manually actuate the lift.

Results:

• ✅ Cylinder moves: Air supply, valve, and wiring are good. Problem is likely program logic.

• ❌ Cylinder does not move: Continue to Step 3.

3. Manually Actuate the Solenoid Valve

1. Locate the solenoid valve controlling the lift cylinder.

2. Press the blue manual override button on the valve.

3. Observe cylinder movement:

   • ✅ Moves: Pneumatics and mechanics are fine. Issue is valve signal/electrical logic.

   • ❌ Does not move: Check air supply, leaks, or cylinder damage.

4. Electrical & Valve Check

• Inspect solenoid wiring. Tighten loose wires, look for damage.

• Use a multimeter:

  • Command lift ON via HMI.

  • Check for 24V power at the valve.

Results:

• ✅ 24V present: Replace the solenoid valve (coil failure).

• ❌ No voltage: Trace wiring back to panel. Possible relay issue, loose wire, or short circuit.

5. PLC & Program Diagnostics

• Confirm whether the PLC output light for the lift solenoid turns on.

• If you can force the output ON and the lift works, then:

  • Pneumatics & mechanics are fine.

  • Issue is in the program logic or interlocks (machine may be receiving a “busy” or “hold” signal from conveyors).

Case Example: 

A customer reported the indexer lift not activating. Steps taken:

1. Verified mechanical and pneumatic systems by forcing output → lift worked.

2. Found bad relay causing electrical interruption.

3. Tested successfully; machine returned to normal operation.

Root Cause: Electrical relay failure

Decision Tree Summary

• Cylinder moves in HMI test → Program logic fault.

• Cylinder moves only by solenoid override → Electrical/valve fault.

• Cylinder doesn’t move at all → Pneumatic/mechanical fault.

• Forcing PLC output works → Program/HMI settings or busy signal issue.

Preventive Maintenance Tips

• Inspect and clean solenoid valves regularly.

• Keep spare cylinders, valves, and relays on hand.

✅ Conclusion:
Following this structured troubleshooting path ensures fast diagnosis of whether the issue is mechanical, pneumatic, electrical, or program-related.