Conveyor faults intermittently on speed feedback

Inspect

• Ask the operator what happened3 minhint
• Read the HMI alarm banner2 min
• Read the HMI alarm history4 minhint
• Walk the belt path and inspect for obstruction5 minrequires zero energyhint
• Check belt tracking and tension6 minrequires zero energy
• Rotate the drive by hand4 minrequires zero energyhint
• Inspect the motor5 minrequires zero energy
• Inspect the gearbox6 minrequires zero energy
• Inspect the contactor5 minrequires zero energy
• Inspect the overload relay3 minhint
• Inspect the photoeye lens and alignment4 minhint
• Inspect the encoder wiring and connector7 minrequires zero energyhint
• Walk the E-stop stations5 minhint

Measure

• Measure incoming line voltage6 min
• Check the branch breaker3 min
• Measure control transformer secondary5 min
• Measure voltage at the contactor coil5 minhint
• Measure motor current on all three phases7 minhint
• Check the PLC run output5 min
• Check PLC speed feedback against command6 min
• Read the VFD status and fault log5 min
• Watch the photoeye output as product passes5 min
• Scope the encoder signal8 min

Operate

• Reset the overload and restart3 min
• Clear the alarm and restart the conveyor3 min

Safety

• Apply lockout/tagout and verify zero energy8 minhint
• Remove lockout and restore power5 min

Repair

• Clear the obstruction from the belt path10 minrequires zero energy
• Release the latched E-stop station and reset the string4 min
• Clean the photoeye lens and reflector6 min
• Replace the motor contactor25 minrequires zero energy
• Reseat and secure the encoder connector9 minrequires zero energy
• Replace the drive motor90 minrequires zero energy
• Replace the overload relay20 minrequires zero energy
• Replace the photoeye20 minrequires zero energy
• Replace the encoder30 minrequires zero energy

Verify

• Restart the conveyor and run a full cycle6 minhint