0554351 Westrock - MPS Dallas TX

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What Arrived: Machine not tipping accurately. Usually get about + or - 1/8 inch. This was all over 1/4" some times late as much as 3 inches. Customer swapped Drive Assemblies (bearing housings) checked pulleys in process, Change Shafts, Encoder, Start Sensor, Product Sensor Pair, nothing helped. He said he had good spacing. Machine was already replaced by an IP3, and this machine was in the box, when customer called. Did not have time to check settings. We have seen 2 cases were OPTO for Start Sensor was failing and adding random delays to cause inaccurate placement. Returning machine for evaluation / repair. (Machine Serial Number:1118-08481) Steve Verbally approved $500 expedite fee.
Description of Problem: MFT 250 IP DCC XED HCP Serial Number 1118-08481 (1) 30mm Red Rough non OEM Feed Belt (1) 30mm Stripper Wheel (4) 15mm HCP XED Discharge (1) 25mm Rear Support Curve (1) Product Support Rod ASSY (1) Set 75/90 Mag Side Guide ASSY (1) Set Disch support brackets (1) Set Disch Side Guides (1) 250 FRW Pressure Roller ASSY (2) Extra Disch Table Rod ASSY (1) Signal Light (1) LSE w/ bracket (1) Start Sensor 7013100 w/ bracket (1) box w/ Mag Striper Reader w/ power supply, but no mounting. (1) Bag w/ Manual, bolt mounting kit, and wrench set
Work Done: Machine seems in pretty rough shape. Bolts for bearng block were too long, and may have been rubbing on timing belt. Non OEM Feed Belt did seem too tight, but it was shimed. Added more shims. Was not jogging at correct speed, as gearing was incorecly set to Low. Motor got to 160F. Center Piece Shaft for FB was some wear causing Split Collars to fit weird. Put back together with these parts but will recommend replacements. Cooling Fan had broken blades, machine was missing a few items, and I replaced them. Also found machine has Standard Performance, and Motor Gains were set to MED, and Accell Decel were only 10K, making it hard for it to stop quickly at high speed. Maybe the tipping was only falling apart when they went over 300PPM, and no one reported the 300PPM message. 11/17/21 DTK Accuracy did get worse when 300 PPM message was shown. Nice and stable in + or - 1/8 below 300 PPM. Ran production for 30 minutes, but at 50 / 50 duty cycle as I could not keep up. Tested accuracy again just below 300 PPM, and still looked good. Think the Motor is probably fine. Sent customer email, and left VM. Think 100% gearing, and or Standard Performance attributed to their issue, but want to discuss more, before quoting. Steve got back to me, they only do about 150 PPM, and they like 100% for the repeat distances. We settled on maybe it is the motor and my test did not show the issue. We settled on I add a fan to the motor, and maybe this allows them to get more life out of the Motor, and if it acts up for them they should swap the Motor. Steve said he wanted a spare Motor, and I said I would quote with the RMA, then I just would not install. Quoted RMA, then I realized, if forgot to mention how it was running 25% too slow, because it was on low gearing. 11/19/21 DTK Added Fan, did finial diagnostics. Updated assigned serial numbers. Motor SN A88161. Shipping under SO# 039958 11/24/21 shipping next week due to Thanksgiving holiday. 11/24/21 DTK
Repair Quotation Notes: Completed By: Found one Guide Rod used to connect the cases, Spacers for one side of Discharge Support Brackets, a Adjustable Lever, the Universal Double Joints, 6 of the Collars for Discharge Exit Pulleys, Cover for Gearing in Electrical Side, all missing. A Fan Assembly in the electrical cabinet has missing blades. Two of the Bulbs in the Signal Light are burnt out. Extensive production tests, provided no sure cause of tipping accuracy issues. After discussing with customer, only thind that stands out is Motor may be damaged due to over heating, (temp sticker, supplies evidence Motor reached 160F on outside), and this slight damage has been known to cause Tipping accuracy issues . Adding Cooling Fan should help or even solve placement issues, and if not, would recommend Motor replacement. Motor will not be installed per conversation with customer. Expedite Fee will be waived, due to time needed to evauate.

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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	55568	1206600		GUIDE ROD 250 16	Set Complete		0 hrs	1		$58.00	0.00	$58.00	90
Edit	55569	1361700		SPACER AL 5/8 OD 1/4 ID 1/4 LG	Set Complete		0 hrs	2		$10.00	0.00	$20.00	69
Edit	55570	3002900		M6 X 40 ADJUSTABLE LEVER	Set Complete		0 hrs	1		$22.00	0.00	$22.00	53
Edit	55571	3577805		UNIV DBL JOINT 5 X 6-35	Set Complete		0 hrs	2		$181.00	0.00	$362.00	248
Edit	55572	3581022		COLLAR HCP EZ-APPLY HC	Set Complete		0 hrs	6		$41.00	0.00	$246.00	18
Edit	55573	2112500		BEARING HOUSING COVER PLATE	Set Complete		0 hrs	1		$42.00	0.00	$42.00	45
Edit	55574	7018700		FAN ASSEMBLY 80 X 80 X 15MM 3"	Set Complete		0 hrs	1		$93.00	0.00	$93.00	17
Edit	55575	6826200		BULB 24V 5W 45MM LIGHT	Set Complete		0 hrs	1		$9.00	0.00	$9.00	26
Edit	55576	8128950		MOTOR COOLING FAN ASSY	Set Complete		0 hrs	1		$178.00	0.00	$178.00	0
Edit	55577	7104800		MOTOR W/PLUG 800W 250/350 DCC	Set Complete		0 hrs	1		$3,795.00	0.00	$3,795.00	2
Edit	55578			LABOR	Set Complete		0 hrs	8		$165.00	0.00	$1,320.00

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