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What Arrived: Returning MFT 550 for evaluation and repair. Noisy motor. (Machine Serial Number:0143-01989 )
Description of Problem: MFT 550 XED serial number 0143-01989 (5) 30mm R ECG Feed Belt (5) 30mm SW (7) Discharge Belts (pulleys for 10) (3 Belts missing on bottom) (2) 90 degree rod mounting brackets (1) Static String (1) Stack Light (1) E/R pair
Work Done: Motor sounded pretty normal. Motor reached 140F, should be fine for customer's batching application.There is quite a bit of mechanical noise. Heard motor make odd sounds navigating through menu. Saw Motor Settings were off, corrected and didn't hear them any more. Found that Yellow light would come on and stay on when a Multiply was feed an feeder would not fault. Saw MPD IO Ready, and Jam IO Ready were both on. Turned them off, and yellow light didn't come on by Feeder still wouldn't fault. Tried some other settings and did not find the problem. Do not think it is as easy as a changeable setting. Needs APL Test still. 3/3/16 DK Found MPD issue to be caused by a failed computer board. Completed diagnostics. Put in 24 hour burn in, and observed for proper operation. 3/8/16 DK Feeder passed 24 hour burn in. Completed evaluation. Prepared repair quote, and emailed to the customer. 3/9/16 DK Found a WIN SYS Computer board that could detect doubles. Upon installing it in this Feeder, it would not longer boot up. 3/11/16 Went through all of the WIN SYS boards we have recovered (about 6-8) and none could detect doubles. Test fixture lost the ability to detect doubles due to a failure of its WIN SYS board in the process. Sent customer email informing we can not restore MPD Detection, and asking for them to advise on how we should proceed. 3/18/16 DK Harry Kliss give me a call. He asked if there were any options to get double detect working. Presented a used MB box of P/N 8319800. He asked for an email with pricing for options, and stated to go ahead with mechanical repairs, as they would like these done even if the machine cannot detect doubles. Sent customer an email with options for MPD. Continued with mech. repairs. 3/22/16 DK Customer agreed to email quote for used MB Box, and Custom Product Sensor Upgrade. Worked out customer mounting MB box to stand. Completed mechanical repairs. Updated quote to reflect email, and emailed customer revised quote. Neal approved net 30 for the order, if it goes out with a Lease Code. 3/25/16 DK Configured machine for MB Control Box S/N 1408-13399 (the box had an IO board and interconnect cables for product sensors). Tested box (including IO test) it passed. Put Feeder in 24 hour burn in with this box. Enabled Lease Code in MB box to expire 6/1/16. Sent Penny email on this. 3/29/16 DK Updated Assigned Serial numbers for changes. 3/31/16 DK Found issues with new sensor mounting. Sent customer email with options, and looking for input before proceeding. 4/1/16 DK Decided to order up some low profile fibers that are slightly smaller bundle size, and my limit how thick of product it could detect doubles. Vendor agreed to letting us try, and return if they didn't work. (ordered (2) F-A-36RS from Automation Sensors. 4/7/16 DK Completed 80/20 set up mount for Control Box, Keyence Readers, and Smart Eye Fiber MPD Sensor, w/ all hardware, and some spare hardware. 4/11/16 DK Received low profile fibers. Tested fibers found them to have same sensing range as Standard Product Sensor Pair. Used a stack of note pad sheets until both sensors could barley sense a double, the addition of one more post it note was too much for both sensors to detect doubles. Performed this test with both sensors mounted in place, with the same electronics. Vic made customer composite mounts to mount these fibers off the Product Sensor Rods. 4/12/16 DK Completed Sensor Mount for Laser Product Sensor. 4/13/16 Was getting close to completing finial testing, when it appeared Slow Speed was broken in the Software. 4/15/16 DK After discussing in the sales meeting. Found Slow Speed will not work with Min Product Length set to 0, but will work if Min Product Length set to 1. 4/18/16 DK Found that Max Speed for latest IP2 Software of 4.2.37 is limited to 175MPM, even with Factory code acess. Machine previously ran at an equivalent speed of 196MPM. Looked into things and thought this speed limitation came about after 4.2.17B. Set the machine up for this older Software, and found I could not program with a lease code. Talked with software engineering, and found the lease code function broke in 2013, and 4.2.37 software had the fix. Proposed telling the machine it was 2010, and question if leasing would work properly with a older year programed in the machine. 4/20/16 DK Sftware E. worked out lease code issues with 2010 date, conveted info to Penny. Went forward using 4.2.17b. Fond MPD message not available, used Signal Fault A. Found that this version of software has the use Motor Ecnoder as LSE function broken, causing the length threshold for MPD not to work. Sent customer email with 2 choices.1) Have Speed Limited to 175MPM. With the Multiply Product Detect Message, length threshold for Multiply Product Detect, and live speed adjustment. 2) Have similar max speed of 200MPM. Display shows “Signal Fault A” when a Multiply is detected, only a time threshold for Multiply Product Detect, and NO live speed adjustment. 4/21/16 Customer choose option 1. Was have difficulty setting date in 4.2.37 to current, and was confused. 4/22/16 Mike C. confirmed that even with the latest IP2 Software 4.2.37 date cannot be set higher then 2015. Went with 2010 lease code plan and informed Penny of this. Set up needed parameters and tested functionality. Date set for 4/25/10, lease to exp. 6/1/10. Backed Settings up to the network. 4/25/16 Completed finishing work such as labeling sensors. Sent EE hand written drawing for sensors used, for them to put in EE Customer System File. Shipping under SO# 026679 4/26/16
Repair Quotation Notes: Completed By: Found that the Motor Gain Software Settings were set higher then recommended, causing the Motor noise. The machines bearings are worn, End Piece and Center Piece Shaft mating is worn. These two factors are causing a higher load on the electronics, and will cause failures. The motor has gotten close to over heating, and this is likely due to the mechanical drive issues. Collars to align Feed Belts are missing. Three of the Drive Pulleys have deep gauges in them. Stripper Wheels, and Discharge Belts are worn and in need of replacing. The WIN SYS Computer board is causing the machine to be unable to fault when thickness of the product is exceeded. This board is discontinued, and cannot be sourced. We do not have any of these board available that will fault when thickness of the product is exceeded. The replacement Used Motion Control Box is needed to fault when thickness of the product is exceeded. Bracketry will be included with the box, Packaging Graphics has taken responsibility for mounting the box. This Box has a newer platform of electronics that allow for a Custom Product Sensor Upgrade like the new machine Packaging Graphics recently purchased. Repair quote does not reflect final charges for service of this unit. Other problems either mechanical or electrical may arise during the RMA process due to natural causes. Quoted labor is an estimate. Actual labor time will be billed. This quote does not reflect shipping charges, or packaging material. All items will be shipped via UPS ground unless otherwise specified on purchase order. A $295.00 diagnostic/administration/handling fee will be applied to an item the customer deems is uneconomical to repair. All replaced and un-repairable items will be disposed of, unless otherwise stated on purchase order. * A hard copy purchase order that agrees to repair quote charges is required before work can continue.

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Edit	XID	Part Number	Serial Number	Part Name	Complete	Total Hours	Hours Remaining	Qty	Cost	Price	Discount	Cal Price	On Hand
Edit	24841	4103200		REBUILT BRG HSG ASSY SET INT	Set Complete		0 hrs	1		$696.00			0
Edit	24842	1260000		END PIECE THREE PIECE SHAFT	Set Complete		0 hrs	4		$280.00			12
Edit	24843	1355000		SPLIT COLLAR THREE PIECE SHAFT	Set Complete		0 hrs	4		$141.00			13
Edit	24844	1265500		CENTER THREE PIECE SHAFT 550	Set Complete		0 hrs	2		$312.00			0
Edit	24845	4121000		COLLAR FEEDBELT INT 16MM	Set Complete		0 hrs	10		$47.00			34
Edit	24846	4122300		DRIVE PULLEY ASSY 304007	Set Complete		0 hrs	3		$111.00			10
Edit	24847	1096800		STRIPPER WHEEL 3042	Set Complete		0 hrs	5		$117.00			14
Edit	24848	1178400		XED DISCHARGE BELT EPDM 204003	Set Complete		0 hrs	10		$111.00			23
Edit	24849	8319800		MOTION CONTROL BOX	Set Complete	4 Standard Production Build	4 hrs	1		$4,716.00			0
Edit	25058	7020400		ALPHAMOTOR POWER CABLE EXT	Set Complete		0 hrs	1		$158.00			3
Edit	25059	7020500		ALPHAMOTOR ENCODER CABLE EXT	Set Complete		0 hrs	1		$268.00			5
Edit	25060			WIRING AND CONFIGURATION OF MB CONTROL BOX	Set Complete		0 hrs	1		$125.00
Edit	25061			CUSTOM PRODUCT SENSOR UPGRADE	Set Complete		0 hrs	1		$5,102.00
Edit	25062			LABOR	Set Complete		0 hrs	9		$125.00

+ denotes that software settings are available for this piece of equipment.

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