In/Out Positioner Troubleshooting

Positioner Error Code Troubleshooting

Use the fault messages on the Alarm screen with this table to diagnose and correct in/out positioner problems. Refer to Ethernet Network Troubleshooting if the fault messages indicate a communications problem (Watchdog fault or TCP/IP communications fault).

Each fault message displayed on the iControl screen is accompanied by a device and number identifier. The identifier indicates the faulted machine (for example, IN/OUT Positioner #1, Reciprocator #2). When the fault condition is corrected or cleared, the fault message will indicate a returned-to-normal status.

For all in/out positioner faults, the alarm relay contacts open to signal an alarm condition.

Error Code	Message	Correction
1001	E-Stop Open	In/out positioner or reciprocator E-Stop button pressed. Determine why E-Stop button was pressed and correct if necessary. Reset E-stop button when clear to do so.
1002	Encoder Failure Fault	In/out positioner or reciprocator not moving. Mechanical, motor, or motor controller failure. This fault must be reset from the iControl alarm screen. Change in/out positioner or reciprocator operating mode to Manual and check for proper forward and reverse (up and down) motion. If only one direction of movement, check motor control circuits. If no motion, check the positioner carriage to make sure it moves properly. Make sure that the anti-tip device is adjusted properly a carriage wheel bearing has not failed no obstructions are preventing motion. Check the pulleys, belts, or other mechanical link connecting the gear reducer to the gun moving carriage. If the gear reducer is not rotating but the motor is, replace the reducer. If the drive motor is not rotating, check the motor circuit protection, motor wiring, motor controller, and motor control circuits.
1003	Motor Protector	Circuit protector limiting current to the in/out positioner or reciprocator motor has failed. Check mechanical components of in/out positioner for proper operation. Lubricate, repair, or replace components as needed. Check motor electrical circuit between protector and motor. Repair or replace wiring, terminals, or motor control components as needed. Reset circuit protector after corrections have been made.
1004	Motion Controller Fault	Motor speed controller “ready for operation” feedback signal has failed. Check the status display on the motor speed controller for fault indications. Status can only be displayed while power is applied. Cycling power to the controller will generally reset the fault condition. Determine the probable cause based on the controller fault status information. Correct the problem causing the fault or replace the controller if necessary.
1005	Forward Contactor Fault	Auxiliary contact on the motor forward contactor did not close when the in/out positioner was commanded to move forward. Check forward contactor for proper operation. Repair or replace contactor as needed. Check control circuit and devices that energize the contactor for proper operation. Repair or replace components as needed. This fault must be reset from the iControl alarm screen.
1006	Reverse Contactor Fault	Auxiliary contact on the motor reverse contactor did not close when the in/out positioner was commanded to move in reverse. Check reverse contactor for proper operation. Repair or replace contactor as needed. Check control circuit and devices that energize the contactor for proper operation. Repair or replace components as needed. This fault must be reset from the iControl alarm screen.
1006	Reverse Contactor Fault	If the positioner encoder fails, the positioner will move to the reverse limit position. Check the encoder mechanical and electrical connections, encoder output. Replace if necessary.
1007, 1008	Forward or Reverse End-of-Travel Limit Fault	In/out positioner color change cycle takes too long (Automatic color change system). During an automatic color change cycle the positioner is commanded to make both forward and reverse moves. This fault occurs if the positioner did not reach the limit in a set amount of time (20 seconds for forward and 75 seconds for reverse). For a 1007 Forward fault: Check for an obstruction to forward motion. Check the operation of the forward limit switch. For a 1008 Reverse fault: Check for an obstruction to reverse motion. Check the operation of the reverse limit switch. If there is no obstruction and the reverse limit switch is good, increase the motion speed slightly.
1112	Positioner not in ready state for color change	In/out positioner not in Manual or Auto mode. Color change cycle cannot start unless in/out positioner is in Manual or Auto mode. Set in/out positioner mode to Manual or Auto.
3100	Positioner Watchdog fault	The positioner controller did not respond with a watchdog signal in 1 second. Check the Ethernet cable connections and the positioner controller.
4109	Clean cycle aborted Arch clean operation - waiting on Park release (Euro color change only)	During a SpeedKing booth cleaning cycle, an in/out positioner has moved off its reverse limit switch or the limit switch has failed. All in/out positioner reverse limit switches must be engaged for iControl system to send “OK for Cleaning Arch” signal. Check in/out positioners for position, check limit switches and replace failed switch.
4110	Clean cycle aborted by user action - Park release detected (Euro color change only)	Park button touched causing color change cycle to abort. Touching the Park button to abort the color change cycle is a normal function. If the button was mistakenly touched before the cycle ended, the cycle must be restarted from the beginning.
4111	Clean cycle aborted detected machine lockout/watchdog fault (Euro color change only)	Communication with in/out positioner or reciprocator controller lost during color change cycle. Check the iControl alarm log for Watchdog or TCP/IP faults. Refer to Ethernet Network Troubleshooting.

Other In/Out Positioner Troubleshooting

Problem	Cause	Correction
No movement from in/out positioner in response to move command	A fault has occurred preventing operation	Check the iControl alarm log. Identify the fault and review the fault troubleshooting information in this table.
	Controller configuration jumpers not installed correctly	Refer to in/out positioner or in/out positioner/reciprocator control panel drawings for function identification and jumper placement instructions.
	Positioner is locked out from Configuration screen	Check the In/Out Positioner control screen for the lockout indicator. Lockout is applied from the Configuration screens.
	iControl system locked out with keyswitch	This is a normal condition unless a failure has occurred. Refer to Photoeye, Encoder, and Interlock Troubleshooting.
	Remote disable applied to in/out positioner controller. No status display on iControl screens.	If the system is a Nordson USA ColorMax system, the positioner can be disabled by a remote system control panel switch. In the Disable position, the switch opens the disable input circuit at the in/out positioner control panel. No corrective action is required unless the keyswitch Normal position does not allow motion. Refer to your system drawings for circuit details. If not a Nordson USA ColorMax system, apply a jumper to force ON the remote disable input at the in/out positioner control panel. Refer to system drawings for jumper application.
No in/out positioner response when Auto mode selected	A fault has occurred preventing Auto operation	Check iControl alarm screen. Identify the fault and correct. Review the related faults and corrections listed in this table.
No in/out positioner response when Auto mode selected	iControl in/out positioner configuration settings have not been completed	Refer to Network Configuration and In/Out Positioner Configuration in the iControl Operator Interface manual. Make sure all required settings have been made and are correct. Refer to the in/out positioner/reciprocator control panel drawings and make sure all connections have been made correctly.
Auto mode is selected, homing has completed, but no auto positioning response from in/out positioner	Auto hold action has been applied to the in/out positioner	The in/out positioner is forced to the Retract position. Refer to in/out positioner configuration setting. This is a normal and temporary occurrence when the iControl system does not know the status of the parts on the conveyor between the in/out positioner scanner and the in/out positioner. This condition occurs when the iControl console is powered up or rebooted and part tracking (shift register) information is lost. Auto positioning will commence when parts identified by the in/out positioner scanners arrive at the in/out positioner. Manual positioning is allowed during this period.
	Booth interlock has opened (booth exhaust fan shut off)	The in/out positioner moves to the Park position (refer to in/out positioner configuration settings) if the Auto mode is selected. The in/out positioners can be operated manually while the booth fan is off.
	In/Out Positioner scanner not responding to parts passing by on the conveyor	Conveyor encoder failure. Check encoder function. Refer to Photoeye, Encoder, and Interlock Troubleshooting. If the In/Out Positioner scanners are not detecting parts: Check scanner input values on the Input Status screen. Refer to the Monitoring Operation section of the iControl Operator Interface manual. Check for scanner remote node communication failure on the Network Node Status screen and Node Configuration screens. Refer to Ethernet Network Troubleshooting. Check for electrical power at the scanner controllers. Check for a voltage signal, 0-10 Vdc = length of scanner (0 = maximum), from the scanner controller to the analog input module. Refer to the In/Out Positioner Scanner Junction Box drawings in this manual. If a voltage signal is read at the analog input module, and there is no problem with the Ethernet network connections to the controller node, then replace the analog input module.
	In/Out Positioner preset set to Fixed	Normal operating scenario. Position change will only occur when a new part appears at the in/out positioner.
Auto mode is selected, in/out positioner stays at the reverse limit position	Refer to Problem “Auto mode is selected, homing has completed, but no auto positioning response from in/out positioner.“
	Park/Clean and Retract position values set too high	Set the Park/Clean and Retract position values to less than Reverse Limit switch position value. If the values are greater, the in/out positioner will stop at the reverse limit switch and generate a fault condition during normal operation. NOTE: If the in/out positioner is an analog version, then the Reverse Limit value must equal the position at the reverse limit switch.
In/Out Positioner “jumps” back to a stop after moving to a new position	In/Out Positioner Hysteresis value too small	Open In/Out Positioner Configuration screen and increase the Hysteresis value. The hysteresis value is the allowable over- or under-shoot distance from the target position. If the in/out positioner is within this distance of the desired position when it stops, the iControl system will not move it again to the target position. If the value is not large enough, the in/out positioner will over- or under-shoot its destination and then “jump” back to it (called hunting). A typical setting is 0.5-0.7 inches depending on the in/out positioner speed setting.
In/Out Positioner actual travel distance does not match value shown on iControl screens	In/Out Positioner position calibration not completed, or in/out positioner forward or reverse limit switch moved since last position calibration	In/Out Positioner calibration involves moving the in/out positioner to a stop at the forward limit switch (Zero) and then within 60 seconds moving it to the reverse limit switch (Home). This sets zero at the forward limit switch and Home at the reverse limit switch. Calibration is performed during in/out positioner configuration, but can be performed at any time while in Manual mode. If the physical position of either limit switch has been changed, then positioning will be incorrect. You must recalibrate the in/out positioner if you move the limit switches. NOTE: The first time Auto mode is selected after in/out positioner power up, the in/out positioner moves to the reverse limit switch (Home) and acquires a reverse reference value. This value is used to reset the in/out positioner position for Auto operations.
	Positioner encoder resolution is incorrect	NOTE: Encoder resolution can only be entered or changed by a Nordson representative. Verify encoder resolution (number of pulses output for one inch of travel) and enter that value on the in/out positioner configuration screen. If the number is not know and cannot be mechanically calculated, then a trial and error method can be attempted. Perform this procedure from the in/out positioner configuration screen: Manually move the in/out positioner to the forward limit (zero position). Reverse the in/out positioner slightly off the limit, record the displayed position value, and apply reference marks to the in/out positioner and base. Manually move the in/out positioner in reverse, almost but not all the way to the reverse limit (the greater the distance the more accurate the calculated resolution will be). Use your reference marks to measure the distance moved and compare the measured distance to the displayed position value. The ratio of these two values is used to calculate a new encoder resolution. If the displayed position value is greater than the measured distance, then increase the encoder resolution. If the displayed position value is less than the measure value, then decrease the resolution.
	Encoder mechanical fault	Check the mechanical components and connections linking the encoder rotation to the movement of the in/out positioner.