How can I determine if the encoder is causing a fault symptom on my

How can I determine if the encoder is causing a fault symptom on my
November - December 2016 • Volume 25, Number 6
ASK AN ENGINEER
How can I determine if the encoder is causing a
fault symptom on my machine?
Jim Mraz retires
(see page 4)
IN THIS ISSUE
Encoder Causing
Failure Symptoms?
1
Parts Discounts
2
Surplus/Obsolete
Discounts
3
Rebuilt Parts
Discounts
3
Service Tip: Reduce
Converter Failures
4
Jim Mraz Retires
4
Machine symptoms caused by either a
defective encoder or encoder cable may not
always be obvious, but are easy to
troubleshoot. An absolute optical encoder is
used on Evergreen machine models N-8
(SN1525 - SN1712), EQ-5, EH-2 and EH-3
(SN5600 - SN5683) to electronically input the
machine timing position to the PLC. With this
input, the PLC will know when to turn on or
off outputs to the machine, such as bottom or
top seal solenoid valves and vacuum release.
An absolute optical encoder uses a disc with
transparent and opaque areas along with a
light source to generate 360 counts per
revolution of the encoder shaft, and maintains
its position even when power is removed.
It is not uncommon to have a defect in the
encoder disc where the signal may skip or
jump one or more counts. An example would
be if the machine is showing a fault on the
HMI display that the spout clutch is
disengaged on both lines, yet it is not
disengaged. A proximity switch on the spout
welder monitors the position of the anvil shaft
spider. The PLC is looking to see a signal from
the proximity switch within a specific timing
window. If it does not sense a signal within the
timing window, the PLC assumes the clutch is
disengaged or out of position. A defective
encoder may skip counts when the PLC is
looking to see the proximity switch signal,
resulting in a spout clutch fault. This fault will
occur whether the spout system is turned on
or turned off.
To check for a defective encoder, slowly handcrank the machine while someone is watching
the timing screen on the HMI operator
display. The timing numbers should change by
1-degree increments. If the timing skips one or
more numbers, the encoder is likely defective.
Be sure to hand-crank the machine through a
complete 360-degree rotation and verify that
each timing number is displayed. A defective
encoder can also increment backwards or
jump a series of timing numbers.
Contd on page 2
1
PARTS DISCOUNTS
Parts must be ordered between Nov 1 and Dec 31, 2016.
To get the discount, you must ask for the special
Run Time price when you place the order!
Part No.
The Run Time is the
newsletter of the
Evergreen Packaging
Equipment Sales
Services Department. Its
purpose is to provide
customers with
Evergreen Packaging
gable top parts and
service information.
Editor: Sheri Albrecht
sheri.albrecht@
everpack.com
Phone: 319-399-3481
or 800-553-5981
Fax: 319-399-3388
or 800-553-5986
Evergreen Packaging
Equipment
PO Box 3000
2400 Sixth Street SW
Cedar Rapids IA 52406
We welcome comments
and suggestions. Please
send all mailing address
changes to the editor.
Evergreen Packaging
Equipment is proud to be
ISO 9001:2008 certified.
QUALITY POLICY
As employees, we will
perform our jobs in
conformance to
customer and industry
requirements with a
commitment to doing it
right the first time. We
will manufacture and
deliver on time, defectfree products and
services to our
customers.
We are dedicated to
quality and continuous
improvement.
2
Description
Model
Discount
Your Price
3051627
Bottom Oven
EQ4, older quarts
25%
3055921
Sealer Jaw Stationary
N5
25%
$818
3058006
Top Breaker Kit
Q6, Q7, Q11
15%
$5,160
3058035
4 Jaw, Line 2, 6 Pin + Slug Kit
EQ, Q9, Q11
25%
$3,147
3058306
Top Seal 6-Hole Rebuild Kit
Older quarts
15%
$26,610
3285398
Stationary Jaw, Line 1 - PM
EH2, EH3
25%
$1748
3286491
Ribbed Sealer Jaws, Foil And Heavy EH3
Paper
25%
$4,950
3286915
Top Squeezer Guide Block Kit
20%
$738
3473143
Top Breaker Base
Q11, APC11
25%
$1,519
3492370
Electric Heat-Unique Parts
N8
25%
$77,880
7053747
Spider - Inlet
Older quarts, half
gallons
25%
$713
7263914
SM Welder Rebuild Kit
SM spout
25%
$4,790
3281019
Infeed Drive Arm
EH2, EH3
25%
$1,100
EH3
$4,245
When you order parts from an Evergreen quotation, please tell the sales
coordinator the quotation number (200xxxxx) when you place the order.
It will speed up the order entry process and get your parts to you quicker!
Contd from page 1
A defective encoder cable can cause a similar
symptom. Individual wires in the cable are
soldered to pins in the connector. A broken
solder joint or corrosion across pins can cause
incorrect signals to the PLC.
Here are examples of some other symptoms
that might result from a defective encoder or
encoder cable:
• The outfeed vacuum release does not come
on, even though the solenoid is good and
output forcing will energize the solenoid
valve.
• You get an infeed carton jam fault, where the
carton jam detect photoeye is looking to see
the carton within a specific timing window.
• The bottom seal cylinders do not extend,
since the encoder may be jumping the
timing number that the PLC is looking for
to extend the cylinders.
I hope these suggestions provide some
assistance. If you have questions about this or
any other issue, don’t hesitate to “Ask An
Engineer.”
— Dave Olsen
Engineering Technical
Support Manager
SURPLUS/OBSOLETE DISCOUNTS
Take advantage of these huge discounts on overstocked parts. To order, make sure you ask for the
surplus/obsolete price. Stock is limited to the quantities shown, so order now!
Part no.
Description
Model
Qty
List price
DISCOUNT
PRICE
3109265 Carton Lift Rod
Q14
1
$3,400
$1,750
3111334 Mandrel
EQ4, Q11, Q14
4
$3,212
$1,100
3113182 Jaw Sealer Movable-Line 2
Quart
3
$1,140
$525
3114167 Carton Stop Assembly
EQ5
3
$1,197
$650
3150768 Top Breaker Eccentric
N5,Q150
1
$3,000
$1,950
3152780 Mandrel Bearing Kit
EQ5
1
$3,709
$1,750
3153659 Top Breaker Eccentric
EQ4
1
$3,600
$1,950
3157239 Retainer
EQ4, H75, Q80
32
$160
$75
3158285 Oven Housing-Line 1
H5
5
$4,038
$550
3158286 Oven Housing-Line 2
H5
4
$2,475
$550
3285815 Anvil
SA VE3/ALCOA
8
$1,098
$375
3481257 Jaw/dater Movable-Line 1
EQ5
3
$1,298
$750
3481731 Elevator Subassembly
EQ5
2
$3,409
$1,750
7150179 Carton Stop Block
N7
58
$145
$75
7254154 Mounting Slide Bearing
N5, Q11
6
$573
$250
EPE NEWS
From time to time, Evergreen has parts repaired or rebuilt to like-new condition and places them
into stock as “REB” parts. These parts are offered to customers for 25% off our normal list price.
But we are now offering the parts listed below with an additional 15% discount. That’s 40% off the
price of new but with the same 6-month warranty that applies to every new part that we sell.
Please make sure you provide the REB part number and ask for the 40% discount price when you
order. Stock is limited to the quantities shown, so order now!
Description
Model
Qty
Price for
new
Evergreen Packaging is
owned by Reynolds Group
Holdings Ltd, an
investment company that
also owns Reynolds
Packaging, Pactiv
Corporation, Closure
Systems International and
Graham Packaging.
The Evergreen Packaging
product line includes:
Get Rebuilt Parts, Now at BIGGER Savings
Part no.
EVERGREEN PACKAGING
is a global leader in
beverage packaging
systems, serving the dairy,
juice, specialty, and other
liquid food markets. The
Evergreen Packaging
business employs nearly
4,100 people worldwide.
Besides the North
American facilities,
Evergreen Packaging
includes wholly owned
subsidiaries in China,
South Korea and Taiwan,
and joint ventures in Israel,
Latin America, North Africa
and Saudi Arabia.
REB
PRICE
REB3284984
Product Tank Agitator Port
EH3
1
$52,995
$31,800
REB5500965
Regenerative Blower
EH2, EH3, H9, N8
1
$3,824
$2,294
REB5501171
Allen-Bradley Servo Motor
N100, QL70
1
$3,022
$1,813
REB5513982
Temperature Controller
Q16
1
$1,001
$601
REB5522170
Gearbox
Q14
1
$4,590
$2,754
REB5561928
16-Station Former Valve
Manifold
N8, N8 ESL
Stretch
1
$6,500
$3,900
REB5580430
CIP Pump
N8, Q15, QR15
1
$9,180
$5,508
REB5902591
Clutch
H5, N5, QPC11
2
$3,031
$1,819
REB6511142
Power Supply, DCX-4K
Horizontal Ultrasonic
SA Consolidated,
SM Spout
2
$14,320
$8,592
• Gable top packaging
equipment—which forms,
fills, and seals paper
gable top cartons—
available for pasteurized,
ESL (Extended Shelf
Life), ELL (Extended
Long Life), and hot fill
applications. These
machines fill cartons from
4 oz. up to half-gallon
(150 ml up to 2 liter), at
speeds from 30 to 340
cartons per minute.
• SPOUT-PAK® twist-off
closures for most gable
top cartons.
• Gable top materials
available through our
global network of
converting plants.
3
SERVICE TIP
Here’s How to Reduce Converter Failures
3. General converter installation and
maintenance practices should be followed.
When replacing ultrasonic stack
components, it is recommended to replace
the stud that connects the stack
components as well. Also, any fretting on
the components must be cleaned before
reassembly, and a new Mylar washer must
be placed between the stack components.
1. Broken electrode tabs or wires
Finally, be sure to tighten components to
2. Damaged RF connector
the correct torque:
3. Converter fretting, loose stud or converter
• Stud to horn: 450 in-lb (50.84 Nm)
not properly torqued
• Converter to booster and booster to
4. Horn-to-anvil contact for extended
horn: 220 in-lb (24.85 Nm)
period of time
Torque wrench kit PN 3701004 and stack
1. Electrode tabs or wires are usually broken
vise kit PN 3112721 will help in applying
in two ways: from looking inside the
the proper torque and, consequently,
converter to see what is wrong, and
eliminating inconsistent welds and damage
because the converter cooling line is
to components. Find more information in
kinked. Simply inspecting the cooling lines
the instruction manual.
for kinks can eliminate that cause of failure,
and putting a tamper-apparent decal on the 4. Make sure the horn and anvil never come
in contact with each other. There must
converter to indicate if it has been opened
always be a gap between the anvil and the
can discourage looking inside.
horn. Refer to the instruction manual for
2. Damage to the RF connector is generally
additional information on setting the gap
obvious because it will appear bent or
between the anvil and horn.
deformed. To avoid this, be very
Frequent ultrasonic converter failures can be
frustrating for customers as well as for
Evergreen’s service technicians and returned
goods coordinator. What contributes to their
failure? According to product engineer Jim
Goranson, problems with converter
PNs 5517630 and 5518161 usually center
around four areas:
careful when connecting and
disconnecting the cable from the
converter. Converter PN 5518161
comes with an 8-in. “pigtail” that
flexes with the connector, thus
reducing the possibility of damage.
Sales Coordinator Jim Mraz Retires
Jim came to then Cherry-Burrell in 1978--four
years after earning a degree in psychology from
Iowa State University and working in sales for a
company in Chicago where he grew up.
Perhaps that psychological insight is what
helped Jim to positively connect with
TO ORDER PARTS:
Email: evergreenparts@
everpack.com
Phone: 319-399-3399 or
800-553-5981
Fax: 319-774-2194 or
800-553-5986
TO REQUEST SERVICE:
Email:
evergreenfieldservice@
everpack.com
Phone: 319-399-3570 or
800-331-6083
Fax: 319-540-8958
FOR TECH SUPPORT:
Phone: 319-399-3300
EPE NEWS
We’ve all heard the saying that all good things
must come to an end, and so goes Evergreen’s
relationship with Jim Mraz.
Every part you purchase
from EVERGREEN
PACKAGING EQUIPMENT
is backed by our:
• Commitment to quality.
• Technical Service Team
(TST) of engineers to
answer your questions.
• Team of knowledgeable
sales coordinators to
make sure you get the
part you need, when you
need it.
• Emergency parts and
service availability 24
hours a day, 7 days a
week.
• Experienced field service
technicians available to
maintain your filler in peak
operational condition.
• Six-month warranty.
Evergreen customers and coworkers for the
next 38 years.
Jim will work his last day at Evergreen on
December 21, so be sure to wish him well
before he heads to Florida where he’ll spend his
retirement enjoying the sun and sand, and
getting fishing pointers from his 3-year-old
grandson Nolan. Congratulations, Jim!
ANNOUNCEMENT
The Evergreen
Packaging facility will
be closed Nov 24-25,
Dec 23, 26 & 30, and
Jan 2 for the Thanksgiving, Christmas
and New Year’s
holidays. On those
days, we will ship
parts and schedule
service on an emergency basis only.
Happy holidays!
4
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