0554517 Brook & Whittle

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What Arrived: Return of Driven Discharge with MB3 Control Box Serial Number 2101-14276, along with new Motor just purchased. Box was just repaired under RMA# 0554514. After they got it back it was getting Major Product Jam, and Overcurrent Jams or maybe just one or the other....really hard to tell with these guys. Customer was advised to check mechanisms as a mechanical issue was a likely cause for the original failure box was returned for. Through remote troubleshooting, sounded like a it could be a Motor. Customer ordered new motor, and same issues. Customer is running on 245V AC without the Trimatt fixes. They then tried 120V with setting Changed, and still had issues. Then they turned up the Motor Jam Time Window from 100 to 500, and the fuse blew. Told them the probably should not run it much more. they said they were going to try and get through production with 6 AMP Fuses. Should update Software and AMP Code, after evaluation. (Machine Serial Number:2101-14276) New motor will not be coming back for credit. They installed this motor on the old 350 1300 they acquired that we original sold WO# 2015012 Now the whole 1300 is coming back. Will need to update Firmware and Software on both. Offered to set up for their books, if the send them back. 2/23/23 2 Books are coming back, one that is 1.25 inch long (Pat K assures me the have ran this with success, and it is a repeat job they do a few times a year) approx. 3" lug belt spacing, 2.125 repeat on Press. Other product is longer with 6" lugs, repeat on web of 4.75. Both product run fold first. 2/28/23 DTK Expedite, with now expedite FEE, possible other warranty consideration.
Description of Problem: 550 - 1300 system from WO# 2020209 MFT 550 IP3 XED HCP Slider SN 2106-10308 (1) 30mm SE S FB (2) 20mm SE S FB (2) 10mm SE S FB (1) 30mm 60D FDA SW (2) 20mm 60D FDA SW (2) 10mm 60D FDA SW Feed Belts Stripper Wheels go 20mm, 10mm, 30mm, 10mm, 20mm (12) 10mm XED HCP Slider Discharge Belt (1) Shaker (1) 100mm Index Support Curve (1) HCP Hopper w/ 4 Stright Supports (1) E/R (1) Jumper Plug (1) Keyence Barcode Reader (they do not use this) (1) Laser Start Sensor (mounted to DD) (1) Line Speed Encoder (mounted to DD) (1) 220V Power Cord - 620 HCP Slider Driven Discharge Serial Number 2101-14276 (12) 10mm XED HCP Slider Discharge Belt (4) Lug Belts B,L,B,B,L,L,B,B,L,B (1) E/R (1) Jumper Plug (1) Fan Box for Motor (1) Set of Motor EXT Cables (1) Fan EXT Cable (1) Set of E/R EXT Cables (2) M12 5pin M to F Cables (1) Wheel Crank ADJ (1) 1300 Frame with large Web Transfer Rollers. No Cover over MECH
Work Done: DD Passed all diagnostics, even with Extension cables. Did find Motor Stop Digital Input on DD MB3 Box set to J3, but Motor Stop was not the reported fault. DD seems to roll nice. Missing cover over MECH of DD. Put DD into overnight burn in, and observed for proper operation. Feeder has broken parts for SW and Discharge Height Adjustment, further investigation needed. Was missing cover for electrical pulleys, and Power Supply added them. Feeder passed all diagnostics, as well as all returned electrical parts. Feed belts were installed without tensioning shims. Backed bolts of 2 full turns. Put Feeder into overnight burn in, and observed for proper operation. Sent email report to customer. 2/28/23 DTK Fixed up height adjustments, Discharge was till a little sticky with new knob, just charge for SW Knob. Plastic bracektf or index had a nut stripped, replaced the whole thing. Added a 35 and 60 shim to Spaning Shaft. Cleanred belts. Set up feeder for product. Added (4) 3" lugged belts, DD already had (4) 6". When jogging the DD, saw issue come up. Then noticed how loose power cable was in Power Entry Module. Was able to wiggle power calbe and see same Major Product jam and Overcurrent faults. Replaced Power Entry Module. This will make it interesting how, we handle RMA warranty, will discusss with management. Need to trim glue of lugs. Sent customer status update in the AM, asking about DD Cover, and Siko Adjustment knobs. Completed trimming lugs, and started product set up. SWs need calibration. 3/2/23 DTK Customer confirmed they did not use the Siko Counters, and said the had the DD Cover there. Ran product nicely at 32MPM > 100 FT a Min. Updated firmware and software on both units. Retained settings, for 32mm long Proctor and Gamble inserts, in Program 7. Ran product well after firmware and software upgrades. Sent score card quote, but before I quoted the customer I saw the Driven Discharge go into a false Overcurrent Motor Fault, for no apparent reason. Informed customer. Put into a 72 hour burn in on 243V AC. 3/3/23 DTK DD passed over 65 hours of burn in test. Overcurrent was only seen in a jog. Talked to Greg C on the issue. I pointed out how the Safety Relay chatter seemed really bad on this one, we thought to try and swap with another Motherboard that had the problem less. Had a conference call with B&W management, they were of the mind that 2 fault in about 85 hours of run time, and not in production or burn in, was a ghost problem, and not that big of a deal, I did mention how that my understating was this was the reported issue machine was returned for, along with firmware and software upgrade of Feeder. Told them how there was symptom that is reliable shown, and look's worse on this Motherboard, and I will hand pick one that is better. Pulled 4 Motherboards, and found one that you had to look really close to see the tiniest amount of RED light on the LED for Safety Relay. After assembling with customer power supply, computer board, and software card saw it a bit more. Put in software card that I was testing with and looked the same as w/ customer software. Installed in box, and saw it just as bad. Saw that the longer the Motor Extension Cables, the worse the chatter. Told customer - I tested 4 Motherboards from stock, and hand picked one that showed the symptom, I discussed on our call today, much less then the other 3, and less than the one on the Driven Discharge. Upon installing this Motherboard in your machine, the symptom was basically the same as before. I ruled out software as a cause, and I found that the longer the Motor EXT cables, the more this symptom is shown. All of our Motherboards are showing this symptom, and is not a known source of a problem. The fact that these faults came up after the a new Motherboard was installed, changing the Motherboard has a good chance to resolve these intermittent Overcurrent and Major Product Jam faults. I now have the machine in another overnight Burn In test. Provided it passes burn in, and finial testing tomorrow, I plan to move to ship, unless there are any objections to this. AND Quoted them, giving them some healthy RMA warranty discount. 3/7/23 They aggreged and sent PO. Ran product at 32MPM 100Ft/Min. Passed all testing. Customer aggreged to 1 day dedicated truck-$1,475.00 freight via attached email. Updated Assigned serial numbers, shipping under SO# 042888 3/7/23 DTK
Repair Quotation Notes: Completed By: Overcurrent / Major Product Jam Motor fault was seen twice, on 2nd Stage Lower Driven Discharge. Ran over 85 hours with only two faults, both while pressing Jog, and not in production run, or simulated production run Burn In. Considering problem occur after new Motherboard was installed, we did switch out the Motherboard, at no charge. Power Entry Module has dents in it, and power cord does not fit in it as tight as it should. Power Supply Shield Cover, and Bearing Housing Cover were missing. 90 DEG X 5" SW Tube Clamp holds the S Curve Scoop, had bolts with stripped nuts, this is the item that Dean mentioned falls on the Feed Belts and damages the belts. The new part will lessen this from happening, and make it easier to adjust. Knob for Stripper Wheel adjustment was broken. Timing Belts are the 3" Lug Belts Pat Requested we put on while it was here.

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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	65196	8161000		POWER ENTRY MODULE	Set Complete		0 hrs	1		$118.00	0.00	$118.00	200
Edit	65197	2270300		POWER SUPPLY SHIELD COVER	Set Complete		0 hrs	1		$49.00	0.00	$49.00	66
Edit	65198	2112500		BEARING HOUSING COVER PLATE	Set Complete		0 hrs	1		$43.00	0.00	$43.00	45
Edit	65199	2021840		90 DEG X .5" SQ. TUBE CLAMP	Set Complete		0 hrs	1		$82.00	0.00	$82.00	11
Edit	65200	4490800		KNOB HEIGHT ADJUSTMENT SW	Set Complete		0 hrs	1		$79.00	0.00	$79.00	191
Edit	65201	1156910		TIMING BELT T5 780L 10W-95LS-10	Set Complete		0 hrs	4		$316.00	0.00	$1,264.00	4
Edit	65202	RMA		LABOR	Set Complete		0 hrs	2		$200.00	0.00	$400.00
Edit	65217	RMA		WARRANTY LABOR	Set Complete		0 hrs	12		$200.00	100.00	$0.00
Edit	65218	RMA		SOFTWARE AND FIRMWARE UPDATES	Set Complete		0 hrs	1		$668.00	100.00	$0.00

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

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