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wheelblastIT Manual – Troubleshooting

Trolley Continuously Moving Forward #

Potential Causes

  • wheelblastIT PLC Heartbeat pulse is missing

Solution

The wheelblastIT PLC must be power-cycled to return to normal operation.

  • To power-cycle the PLC, toggle off, then on, circuit breaker “300” in the WB controls enclosure.
  • Once the PLC has completed rebooting, the trolleys must returned to the Home position via the ”Force Reverse” command on the HMI.
  • Faults During Trolley Movement
  • Trolley Intermittently Failing To Return To ‘Home’ Position
  • Excess Voltage Fault – Error Codes ‘OU2’ or ‘OU3’ displayed on VFDs
  • Uneven wear on the sides of the belt
  • Water Shaft Spinning Inconsistently

Faults During Trolley Movement #

Potential Causes

  • VFD has experienced a fault

Solution

  • Examine the VFDs for the potential faults below:
    • Motor amperage exceeding a programmed limit (typically 4.0 amps)
    • Excess voltage during/shortly after transition from ‘Reverse Fast Speed’ to ‘Reverse Slow Speed’

Trolley Intermittently Failing To Return To ‘Home’ Position #

Potential Causes

  • Excess amperage fault

Solution

  • Examine the trolley assembly and inspect the wheelblastIT’s moving components for the potential issues below:
    • Motors/pulleys seizing
    • Material binding between gears
    • Failed spur gear

Excess Voltage Fault – Error Codes ‘OU2’ or ‘OU3’ displayed on VFDs #

Potential Causes

  • “OU2” indicates excess voltage during deceleration
  • “OU3” indicates excess voltage when running at constant speed

Solution

  • Reduce ‘Rev Fast Speed’ or ‘Rev Fast Speed’ or increase ‘Rev Slow Speed’

Uneven wear on the sides of the belt #

Potential Causes

Idler and drive pulley shafts are not aligned at right angles (perpendicular) to the rails, causing the belt to rub against the pulley sidewalls

Solution

  • Shaft alignment is adjusted by:
    • Slightly loosening the plastic flanged shaft bearing assemblies with two 9/16” wrenches
    • GENTLY tap the shaft ends with a hammer
    • Tighten the bearing bolts before putting the trolley into test mode “Continuous Move”.
    • Put the trolley into ‘Continuous Move’ mode
    • Observe belt position and ensure there is always at least a small gap between the belt and pullet sidewalls

Water Shaft Spinning Inconsistently #

Potential Causes

  • Misalignment of spur gear and toothed rack

Solution

  • Water shafts assembled with spur gears cannot be switched between driver and passenger sides.
    • When installing a new one-way bearing, ensure the bearing faces the correct direction for its use on the driver or passenger side.
    • A fully assembled spur gear and water shaft assembly has the spur gear key slot facing the vehicle.
    • The key slot side of the spur gear should be 4-3/8” from the 3-nozzle end of the water shaft.
    • The driver side one-way gear should spin freely counterclockwise when viewed from the wall end of the water shaft.
    • The passenger side spur gear should spin freely clockwise when viewed from the wall end of the water shaft.

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