Photoeye, Encoder, and Interlock Troubleshooting

I/O Board Terminals

Inputs

Troubleshooting

1 - 8

Zone photoeyes or scanners

Photoeyes and scanners are set for breaklight. When a part passes in front of the them, the LEDs for the broken beams should light. If they do not, check the wiring and photoeyes or scanners.

9 -16

Flag photoeyes or scanners, or inputs from customer Part ID system

Photoeyes and scanners are set for breaklight. When a flag passes in front of them, the LEDs for the broken beams, or the LEDs receiving a signal from the customer part ID system should light. If they do not check the wiring and photoeyes or customer part ID system.

20

Encoder

The LED should flash at the same rate as the encoder signal. If it is not flashing when the conveyor is moving check the encoder wiring and encoder.

24

Conveyor interlock

The LED should light as long as the conveyor is on or the keyswitch is in the bypass position. If it is not on check the conveyor interlock wiring. Without this signal the spray guns will not be triggered.

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Relays (DIN rail)

The conveyor interlock relay LED lights when the conveyor is running. The remote lockout relay LED is lit as long as it is receiving a signal (lockout on). The alarm relay LED stays lit until an alarm occurs, then goes out.

1-24

All

Input LEDs should indicate as described above. If none of the LEDs will turn on, then check the following screens:

Zone and Part ID Inputs: Open the Input Status screen. Inputs should display as lighted indicators.

Encoder: On the Main screen, if the encoder is providing a signal then the conveyor speed should be greater than zero.

Conveyor Input: On the Main screen, if the conveyor is running then the conveyor indicator should be green.

If the input indicators on the Main and Input Status screens are lit but the I/O board LEDs are not, then:

• Check the dipswitch and jumper settings on the PC104 I/O board. If settings are correct, replace the PC104 I/O board, ribbon cable, and I/O board. A new cable is shipped with the I/O board.

• If the conveyor interlock LED (24) on the I/O board is operating correctly and all or some of LEDs 1-20 are responding erratically, then check the I/O board inputs common voltage. For sinking inputs, +24 Vdc is applied to all HI terminals on the board as inputs common.

WARNING: Always turn console power off before changing jumper and dipswitch settings on circuit boards. If ribbon cable is not keyed, make sure the colored trace in the ribbon cable is aligned with pin 1 at both connectors.