0554448 PLI Card Marketing Solutions

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What Arrived: Product Sensor Circuit not working. Went over things on the phone with customer, believe problem is on Motherboard, probably that darn A to D. (Machine Serial Number:0717-06412)
Description of Problem: MFT 250 IP ED Serial Number:0717-06412 4.1.29c-10 with: ED roller discharge with side guides and 7007400 product sensor, new in appearance 4 purple discharge belts 2 non-mft 30 mmsw 2 non0mft 30mm smooth feedbelt baby blue in color 1/2 inch tall stack of sample product cards to run. Approx 3.5" x 4.5" no power cord no magazine side guides no prod support rods no labels on cabinet doors.
Work Done: Power up. Lower fan makes buzzing noise. Upper fan seized and resists rotating manually Attempt to manually advance feeder takes abnormally high torque to rotate the motor driven pulley. believe too small feedbelts are to blame. Leaving tension adjuster screws set as they arrived to take objective torque measurement before reducing customer's tension setting.Will not run motor until mechanical resistance is reduced. DEK 24 Aug 22 Feeder passes electrical tests except for Product Sensor diag. reads low single digits on all drives. A/D convertor input on MB has 4.2 ohm resistance should be 40 Megohm.After solving motor drag problem, will remove MB and replace U7 to verify product sensor diagnosis. Mechanically drive train has major drag issues.Will slacken FB tension and see if root cause. will look for tension damage, bearings,shafts and warn of damage from over tension.likely require our fb on return if to be warrantable Very loose timing belt from idler shaft to feedbelt shaft allows for slop. Also plastic spur gears are worn and allow play between upper and lower discharge shafts. 31 aug 22 Major drag due to bearing failure in bearing blocks. In particular the left upper and lower discharge shaft bearings. almost to the point of seizure.Some indication of corrosion . also lower right discharge split collar corroded. Requires bearing housing rebuild on both sides and belt replacements. Pulleys appear ok except inside idler pulley(1053900) may be wrong size causing belt slack.deep groove cut in upper discharge shaft needs replacement Gouges in non-mft sw. Has non-mft feedbelts overtensioned but not the cause of the drag. Had Vicky remove U7, then we measured R44 resistance at 40.72K so no other secondary problem on Prod Sensor circuit. Vicky replaced U7, put board back into unit and Prod Sensor tests OK and provided Prod.Sensr is good at all 255 when no prod. 13 Sept 22 DEK Updated rt side composite bearing housing with new thick worm shafts. Had to drill out 3577300 universals because ther is no ss to new IM u joint in existence. Replaced all quoted components. Re-squared the machine. Modified a cover to mount on the right side plastic bearing housing. Left side is metal housing. added temp stickers on alpha motor. Changed upper gearbox fraction to 100 from 116 to make tach reading correct (20.18 when set at 20 mpm) Left lower at 100 Ran all diagnostics OK including APL. Started Burn In 6:45 pm Friday and ran fine for 1 hour. Shut off to let David restart monitored burn in 11/21. Set Customer expectation verbally for departure before Thanksgiving Holiday Put into 24 hour burn in, and observed for proper operation. 11/21/22 DTK Passed 24 hour burn in. Went do finial checks. Upper Discharge Height Adjustment was rough, and slipping. Found washers missed for under knobs, went to remove knobs, knob shaft was all burred up from sliping. Went to pry off knob...but was not thinking how other end of U-Joint was just plastic, and snapped the Plastic Worm Shaft. SHIT!!!!! Also bent up the Knob Shaft fierce trying to get it off, and will need to replace it. 11/22/22 Removed right side Bearing housing to replace worm shaft, found nut was too tight on this side for Upper Discharge Height adjustment also leading to the rough adjustment. Corrected issue, and reassembled Feeder. Put in burn in after 1.75 hour burn in, stopped and did diagnostics. Passed all testing. Updated assigned serial numbers COMMENTS "Custom U-Joint for a Metal Knob Shaft (4mm) to a Composite Worm Shaft 1432115 - Use U-Joint 3577400 mod one end to .25" hole". Shipping next week under invoice# 042336 11/23/22 DTK
Repair Quotation Notes: Completed By: Original complaint of Product Sensor malfunction was isolated to Motherboard. Failure can be repaired at the Component level on PCB. Observed MAJOR mechanical drag issue in motor drivetrain. isolated it to bearing failure on both bearing housings. The cause of the majority of the bearing failure, is due to non MFT OEM Feed Belts being uses, and too much belt tension applied to the machine. Feeder is inoperable with this level of bearing failure. Operating may result in motor overtempt failure or worse. All drive train belts worn and need replacement, one drive train pulley and both Spur Gears (suggest Aluminum replacements not composite) are heavily worn. Stripper wheels are heavily worn and have gouges. Feedbelts require replacement with MFT belts which can be properly tensioned. Feedbelt drive pulleys of proper diameter are required. Discharge belts are marginal and should be replaced as well. Lower fan makes noise and filters have crumbled . Double U joints are wrong size for the Stainless version knobs. Quote assumes that missing items such as Product Support rods, magazine side guides, power cord are at the customer site but not shipped with the repair unit.

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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	62000	6092500		IC 8BIT SERIAL I/O ADC 8-MSOP	Set Complete		0 hrs	1		$16.00	0.00	$16.00	10
Edit	62001	1002100		BALL BEARING 173510	Set Complete		0 hrs	10		$59.00	0.00	$590.00	41
Edit	62002	1355600		SPLIT COLLAR M8 20	Set Complete		0 hrs	2		$82.00	0.00	$164.00	315
Edit	62003	3267895		BOLT M8 X 25 SHLPS	Set Complete		0 hrs	16		$8.00	0.00	$128.00	235
Edit	62004	3029200		BELLOW HEIGHT ADJUSTMENT IP	Set Complete		0 hrs	4		$37.00	0.00	$148.00	147
Edit	62005	7018700		FAN ASSEMBLY 80 X 80 X 15MM 3"	Set Complete		0 hrs	1		$98.00	0.00	$98.00	17
Edit	62006	3756800		FAN FILTER 80X80	Set Complete		0 hrs	2		$7.00	0.00	$14.00	71
Edit	62007	4118200		DRIVE PULLEY 304620C	Set Complete		0 hrs	2		$57.00	0.00	$114.00	46
Edit	62008	3577300		UNIVERSAL DBL JOINT 404 SS IM	Set Complete		0 hrs	2		$101.00	0.00	$202.00	10
Edit	62009	1199300		FEED BELT SE 304606S	Set Complete		0 hrs	2		$110.00	20.00	$176.00	33
Edit	62010	4125600		STRIPPER WHEEL ASSY 304620	Set Complete		0 hrs	2		$154.00	20.00	$246.40	33
Edit	62011	1177300		ED DISCHARGE BELT EPDM 204604	Set Complete		0 hrs	4		$83.00	20.00	$265.60	40
Edit	62012	4129400		SPUR GEAR 16 475 525 ALF	Set Complete		0 hrs	2		$184.00	0.00	$368.00	39
Edit	62013	1157300		TIMING BELT 051574	Set Complete		0 hrs	1		$45.00	0.00	$45.00	12
Edit	62014	1150600		TIMING BELT 9521326	Set Complete		0 hrs	1		$22.00	0.00	$22.00	124
Edit	62015	1156600		TIMING BELT 051566	Set Complete		0 hrs	1		$32.00	0.00	$32.00	119
Edit	62016	1154600		TIMING BELT 051546	Set Complete		0 hrs	1		$42.00	0.00	$42.00	128
Edit	62017			LABOR	Set Complete		0 hrs	16		$200.00	0.00	$3,200.00

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