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The Sandretto Molding Machine Mechanic Helper

Troubleshooting guides

This page will contains technical information regarding the Series 8 Sef 100 Injection molding machine.

 

Troubleshooting Sandretto Molding Machines is simple.  Just remember to troubleshoot the machine with a logic approach.  You have to determine if the problem is mechanical, electrical, hydraulic and processing related. 
 
With the Sandrettos, I found that the most problems with the machines are caused by poor maintenance practices.
 
 

Troubleshooting Guide

Sef 100 Electronic troubleshooting chart
Problem Possible cause Possible solution Notes
Internal error 45.1 1. Machine options not selected on  A. Select the options on the  
  the Configuration screen Configuration page and save.  
  2. Firmware options not selected. B. Select the Mirco AB dip switches  
    to select the options  
  3. Software verision installed on the  C. Replace the software and replace  
  Mirco AB is not the correct verision it with the correct verision  
  4. Corrupt Eeprom on Mirco AB D. Replace the Eeprom chip d. If you replace the Eeprom chip 
      you must reconfigure the Config-
      uration page and save
  5. "Manual Communcation Line  e. Check for the 24vdc power supply e. 
  Breakdown" alarm is generated to the Manual Control panel  
    E1. Check for a loose or broken  e1. Check cables J2(Sef 100 MMI)
    cable connection for the Manual  J2 (Mirco C, middle edge connector)
    Control panel J16 (on the rear of the sef 100
    E2. Replace the Manual Control cabinet going to Mirco C).
    Panel   
  6. Missing or Defective I/O board F. Replace the missing or defective  
    I/O board  
  7    
Internal error 45.2 1. Mirco C is not responding G. Replace the Mirco C board g. Check the Configuration page 
    G1. Replace the Mirco C eproms  
       
       
Internal error 45.3 1. Mirco B doesn't respond to Mirco H. Replace the Mirco AB board refer to Note g
  A.    
       
       
Internal error 45.4 1. I/O board failure  I. Replace the faulty I/O board I. It could be board #13 or #14 on 
      a Mega T, TE, H
  2. Mirco C to Mirco B interface cable J. Replace the Mirco C & B cable j. Edge connectors J1(mirco C) to 
  is Loose or defective   J11(mirco B)
  3. Sef 100 I/O card-rack failure  K. Remove and inspect the card-rack  
       
No video display but, 1. Bad video interface board  L. Replace the video interface board l. Check all cables and connectors
Manual Control Panel does pn#08110110   before replacing any boards
have lights and works 2. Bad Mirco AB board H. Replace the Mirco AB board  
  pn#08110006    
  3. Bad video RS 422/TTL convertor  M. Replace the video convertor board M. Check the cables and power 
  board pn#05110111   connector to the RS422.
  4. Bad video cables N. Replace the video cable n. Check the ribbon cable from Mirco
      AB to video interface board.
No video display and no  1. Check the main power supply O. Check the 220volts for the Sef  o. Check for the 220 voltage on TR1
Manual Control Panel voltages  100 power supply. Fuse FU7 on Mega T, TE
functions or lights     Fuse FU6 on Series 8 AT
  2. Bad Sef 100 power supply P. Replace the Sef 100 power supply  
  3. Bad Mirco AB board Refer to H.  
  4. Faulty or missing I/O card Refer to I.   
  5. Faulty or loose interface cables Refer to J.  
  between Mirco AB & C and the  Refer to K.  
  I/O back-rack.    
  6. Bad Mirco AB eproms  Q. Replace the Mirco AB eproms q. Check the software version and 
      options
  7. Bad Configuration Eeprom chip Refer to D. d. Check the correct Eeprom version
      and tonnage.
  8. Missing or defective I/O cards Refer to I.   
  9. Missing or broken Manual  R. Check the connection between   
  Control Panel connector from the  the Sef 100 MMI and Sef 100   
  Sef 100 MMI panel to Sef 100  Electronic control cabinet  
  10. Hareware of Software Conflict  S. Check the software and Hardware s. Check the dip switches config-
    version uration.
      s Check for the correct software and
      Eeprom version
      s. Check for the correct configuration
      file for that software version.
       
       
The Eprom test stops while 1. Detected missing or bad eproms T. Replace the faulty eproms t Try reseating the chips and boards
the test is running  2. Wrong versions of Eproms U. Replace with the correct version  
  3. Bad eprom carrier boards V. Replace the carrier boards  
       
       
The Sef 100 executes and  1. Hareware/Software conflict  X. Check for options that may be   
completes the eprom test    selected by the dip switches on the  
but, video display blanks out   mirco AB board that the software  
    may not support.  
    X1. Check for options that may be  
    selected on the configuration page  
    that the hardware or software may   
    not support.  
  2. I/O boards could be missing or W. Check the condition of the boards w. Boards 6 & 7 disconnected could
  defective in slot 1 - 9 cause this problem.
  3. Mirco C ribbon cable is missing Y. Replace the ribbon cable y. Ribbon cable missing from the 
  or broken.   Mirco AB and mirco C
  4. Mirco B ribbon cable is missing  Y. Replace the ribbon cable y. Ribbon cable missing from the 
  or broken.   Mirco AB and mirco C
  5. I/O back-rack to mirco C ribbon Y. Replace the ribbon cable y. Ribbon cable between the back-
  cables are missing or are broken.   rack and mirco C 
       
Notes **** If Mirco C ribbon cable is disconnected from the back-rack to Mirco C, multiple alarms will occur but the video display will appear
       
Menu page is displayed but  1. Hareware/Software conflict refer to S, X, X1,  
no page select. 2. Key-Lock is activated Z. Unlock or replace the key-lock  
  3. Faulty P1-P8 key pad AA.Replace the key pad   
  4. Faulty F0 - F8 keyboard BB. Replace the Function key pad  
  5. Faulty Auxiliary keyboard CC. Replace the Auxiliary keyboard  
  6. Faulty Numeric/alpha key-pad DD. Replace the N/A board  
  7. Faulty video interface board Refer to L.  
  8. Faulty Mirco AB board Refer to H.  
       
       
Notes **** A constantly depressed button on the any one of these keyboards could cause the page selection function to freeze.  You could       
troubleshoot this problem by disconnected one keypad or keyboard at a time.  Also a constantly beeping emitting from the Keyboard/video      
interface board PN#08110113 could indicate that a button is constantly depressed.      
       
       
       
       
There is a video display, and  1. Key lock is activated Refer to Z.  
page selection but no cursor 2. Faulty numeric/function keypad Refer to AA.  
movement or data selection  3. Faulty video display interface  EE. Replace the interface board  
  board.      
  4. Faulty Mirco AB board Refer to H.  
       
       
       
Scrambled video on the video  1. Faulty Video display unit FF. Replace the Video display unit  
display 2. Faulty Sef 100 power supply GG. Replace the power supply  
  3. Faulty Video interface board HH. Replace the Video interface  
    board.  
  4. Corrupted or bad eprom chips Refer to T.  
  5. Loose or broken video or power II. Check all power and video   
  connectors on the boards connectors for security.  
  6. Electronic noise on the video  JJ. Check the shield and ground jj. Check the machine ground 
  cables  connections. connection.
       
       
       
There's a flashing "N" on the 1. I/O board failure in slots 1-9 KK. Replace the faulty I/O board.  
video display panel. 2. Mirco B hardware failure Refer to H.  
  3. Problems with the Sef 100 LL. Check out or replace the power   
  power supply supply  
  4. Robot board failure in slot 2 MM. Replace the Robot board  
  5. Software/Hareware failure NN. Check for the correct version   
    of software and hardware   
       
       
The pumps proportional valve 1. Wrong Eeprom version for that  OO. Replace the Eeprom version  
remain energized after the  software    
manual function has       
terminated. 2. Corrupt data in ram memory PP. Delete and totally clear the   
    ram memory.  
       
       
       
The Sef 100 will not reset from 1. Corrupt data in ram memory  Refer to PP.  
Start to Normal mode.      
       
       
All pressure and speed para- 1. Corrupt data in ram memory Refer to PP.  
meters defaulted to highest      
values in memory regardless      
what the parameter is showing      
on the screen.      
       
       
Actual positions varying on the  1. Oscillations of the actuators RR. Check the null on the proportional valves 
Sef 100 video screen. 2. Dirty or faulty transducers SS. Clean or replace the transducer  
  3. Faulty transducer cable  TT. Replace the the cable.  
  4. Fauly transducer interface board UU. Replace the faulty interface board 
  5. Electronic noise VV. Check the cable shielding connection or replace the cable.
  Also do not route your low voltage signal wires close to high voltage, 
    high current line.   
     
     
       
No Manual Control Panel  1. "Manual line breakdown",alarm WW. Check the 24volts going to the Manual control panel.  
(No lights, no functions) 2. "Manual control communication XX. Check the communication cable going to Sef 100 MMI   
  error ", alarm. XX1. Change the Manual control panel.  
  3. Mirco C board failure YY. Change the Mirco C board.  
  4. Mirco AB board failure ZZ. Change the Mirco AB board.  
  5. Firmware problem with Sef 100 AAA. Change the firmware on the Sef 100.  
       
       

sandretto.jpg

Sandrettousa Technical bulletin

 

Machine type: Series 7 or 8

Controller type: Sef 90

Procedure: Calibration problems with LVDT transducers for all linear actuators.

 

Problem one: Transducer zero adjustment will not adjust the transducer position to zero.

 

Possible solutions:

1. The transducer rod is too short to reach the zero position.

            2. The adjustment pot on the I/O board is broken.

            3. The cable is broken or has large amount of internal resistance.

            4. Loose or bad connections

 

 

Problem two: The transducer actual position reads zero after the transducer rod has traveled a short distance from the zero position. 

                 

Possible solutions:

1.     The transducer rod is too long and it’s surpassing the zero position.

2. The adjustment pot on the I/O board is broken.

            3. The cable is broken or has amount of internal resistance.

            4. Loose or bad cable connections.

 

Problem three: The transducer reads but skip or jumps from one position to a higher (or lower) position without any actuator movement, for only one transducer input.

 

Possible solutions:

1.     The rod is mechanically loose.

2.     The case of the transducer body is cracked.

3.     The cable is broken, has a bad connection or there are bad splicing along the length of the cable.

4.     The connections on the I/O board are loose.

5.     Faulty channel on the I/O board.

 

Problem three: The transducer reads but skip or jumps from one position to a higher (or lower) position without any actuator movement, for more than one (or all) transducer reading.

 

Possible solutions:

1.     Check the incoming power to the I/O board. 

2.     Check the different power supplies on the I/O board +15volts, -15volts.

3.     Check the J7 and J9 connectors on the I/O board.

4.     On the Series 8s, check the P1, P2, and the P3 connectors in the back of the sef 90 electronic cabinet.

5.     On the Series 8s check the SMC and SM1 interface boards for connections.

6.     On the Series 7s disconnect one transducer at time and check for ground faults with the cables running through the frame.

7.     Check the ribbon cable from the I/O board to the CPU board.  Check for cracks and broken traces.

 

Problem four: The transducer does not read actual positions.  All displays are zero except for the Ejector transducer which displays a reading of 4095.  Also, a “Press not operating” alarm is display initially at boot up.

 

Possible solutions:

1.     Check the operation of the transducers. 

2.     Check the voltage on the I/O board (+15volts).

3.     Check the dip switches settings on the CPU board.

4.     Check the dip switches settings on the I/O expansion board.

5.     Check the J7 and J9 connectors for security.

 

 

Note: When replacing the old device with its replacement.  Try to route the cable back to the controller’s connections or terminal strip without any splices.  Always use as much of the replacement transducer cable as possible, any splices could cause potential problems with erratic transducer operation.

NONE

Tools and Materials

The nice thing about Sandretto is , you don't need alot of specialized tools to work on these machines.  Basic tools (allen wrenches, phillip screwdriver, adjustable wrench and a good volt meter) is all you need. 

 

Terminology

In this area I'll define any specialized vocabulary that it's helpful to know in order to perform the tasks described on this page.