Guide7
Quick Fault Finder
Find the symptom, check the first causes listed, then open the full answer from its code.
Printing & Labelling
| Code | Problem | First causes to check |
|---|---|---|
| P-01 | Printer Not Printing or Poor Print Quality | Printer offline or wrong message selected; Low ink or ribbon; Dirty print head |
| P-02 | Half Print or Part of the Code Missing | Ribbon running at an angle (not straight) across the print head; Ribbon shifted sideways so it does not cover the full print area; Guide rollers out of line or the adjuster moved |
| P-03 | No Print | Ribbon run out or broken; Ribbon loaded the wrong way (ink side away from the product); Print temperature or energy too low |
| P-04 | Faint, Patchy or Broken Characters | Temperature or energy too low; Print head dirty; Print pressure low |
| P-05 | Ribbon Wrinkling or Creasing | Ribbon not straight on the rollers; Uneven or low tension; Guide rollers not parallel |
| P-06 | Ribbon Breaking or Tearing | Tension too high; Temperature too high (ribbon burns through); Sharp edge or burr on a roller |
| P-07 | Ribbon Wasted or Advancing Too Far | Ribbon advance length set too long; Ribbon save mode off; Take-up slipping |
| P-08 | Wrong Batch Number or Dates Printed | Message not updated at changeover; Data entered incorrectly; Printer clock wrong |
| P-09 | Labels Not Applying, Skewed or Wrinkled | Label web tension incorrect; Label sensor not taught to the label gap; Applicator speed not matched to conveyor |
| P-10 | Missing or Wrong Labels | Splice or missing label on reel; Wrong label reel loaded; Label verification not working |
| P-11 | Print in the Wrong Position on the Bottle | Printer head height not set to the print area at the bottle bottom; Side-grip belts holding the bottle too high or too low; Ribbon not centred on the print head (see P-02) |
| P-12 | Bottles Damaged or Stuck in the Side-Grip Belts | Belt gap set too narrow (grip too tight); Belts not parallel; Belt speeds unequal (bottle twisted) |
| P-13 | Bottles Dropping from the Side-Grip Conveyor | Belt gap too wide; Belt worn or stretched; Width knob loosened by vibration |
| P-14 | Side-Grip Belt Misaligned, Riding Up or Coming Off | Long use: belt stretched or worn; Roller (pulley) not square or loose; Belt tension uneven |
| P-15 | Bottle Twisting or Skewed Print | Left and right belt motors set to different speeds; One motor faulty or slipping |
| P-16 | Inkjet Code Too Far Left or Right on the Bottle | Print position (delay) not set for this bottle; Product detection sensor moved; Conveyor speed changed |
| P-17 | Inkjet Code Too Large or Too Small | Scale (width) setting wrong for the bottle or label; Wrong job selected |
| P-18 | Print Count Does Not Match Product Count | Product detection sensor missing bottles (dirty, misaligned); Bottles too close together; Printer paused or faulted during the run |
| P-19 | Ink or Make-Up Low Warning | Ink or make-up fluid cartridge nearly empty |
| P-20 | Inkjet Print Broken, Scattered or Blurred | Print head dirty (ink build-up); Print head too far from the bottle; Nozzle partly blocked |
| P-21 | Printer Not Running (Will Not Start or Stops) | Printer stopped or paused; Jet start-up fault or blocked nozzle; Fluid empty |
Bottle Feeding & Conveyors
| Code | Problem | First causes to check |
|---|---|---|
| F-01 | Unscrambler / Bottle Feeder Not Feeding Bottles | Bottle jam in the hopper, disc or outfeed; Bottles loaded incorrectly or hopper empty; Guide rails not set for the bottle size |
| F-02 | Bottles Falling Over or Not Upright | Bottle blow time or blow delay incorrect; Conveyor speed mismatch between sections; Guide rails too wide |
| F-03 | Side Belt Slipping / Bottles Not Moving Smoothly | Loose belt tension; Belts not parallel; Worn or contaminated belt |
| F-04 | Bottle Jam Alarm on the Conveyor | Damaged or deformed bottle; Downstream machine stopped; Jam time or delay setting too short |
| F-05 |
Desiccant Inserter
| Code | Problem | First causes to check |
|---|---|---|
| D-01 | Desiccant Cutting in the Wrong Place | Cutting position sensor moved, so its red light spot is no longer on the cut point (main cause); Sensor knob or bracket loosened by vibration or cleaning; Sensor lens dirty |
| D-02 | Desiccant Missing from Bottles | Reel empty or broken; Bottle not detected; Insertion tube blocked |
| D-03 | Double Desiccant or Wrong Length | Sensor misaligned; Sachet pitch varies on the reel; Feed motor overrun |
| D-04 | Desiccant Jamming in the Feed | Reel tension incorrect; Guides misaligned; Damp or swollen sachets |
| D-05 |
Counting & Filling
| Code | Problem | First causes to check |
|---|---|---|
| N-01 | Incorrect Count | Vibrator speed too high (product overlapping) or uneven; Counting sensors dusty or dirty; Area limits (min/max) not set for the product |
| N-02 | Product Jamming in the Channels | Vibrator speed too high; Channels dirty or sticky; Gummies soft or sticky (heat or humidity) |
| N-03 | Low Output | Vibrator speed too low; Hopper level low; Uneven product flow |
| N-04 | No Bottle Alarm at the Counter | Bottle sensor dirty or misaligned; Bottles not reaching the fill position; Upstream feeder stopped |
| N-05 | Product Missing the Bottle / Spilling | Funnel outlet not centred over the bottle neck (main cause); Funnel moved during cleaning or its four black knobs loose; Bottle stopping in the wrong position (bottle stop or change delay) |
Capping
| Code | Problem | First causes to check |
|---|---|---|
| K-01 | Caps Not Feeding | Cap hopper empty; Cap lifter angle incorrect; Jam in the lifter or chute |
| K-02 | Caps Crooked or Cross-Threaded | Bottle not centred under the capping head; Guide rails misaligned; Capping head height incorrect |
| K-03 | Loose Caps / Torque Too Low | Torque setting too low; Worn spindle wheels, rollers or clutch; Cap speed too low |
| K-04 | Caps Over-Tight, Stripped or Cracked | Torque setting too high; Cap speed too high; Head height too low |
| K-05 | Bottles Jamming at the Capper | Bottle separation delay incorrect; Conveyor and machine speed mismatch; Guide rails too tight |
Induction Sealing
| Code | Problem | First causes to check |
|---|---|---|
| I-01 | Seal Missing, Incomplete or Failing Integrity Check | Sealer power too low or too high; Cap torque incorrect (loose cap will not seal); Wrong or missing foil liner |
| I-02 | Weak or Partial Seal | Power too low; Conveyor too fast; Head too high |
| I-03 | Foil Burnt, Scorched or Cap Deformed | Power too high; Conveyor too slow or stopped under the head; Head too low |
| I-04 | Foil Wrinkled | Uneven cap torque; Bottle neck finish damaged or uneven; Too much heat |
| I-05 | Foil Stays in the Cap (Does Not Bond to Bottle) |
Metal Detection & Checkweighing
| Code | Problem | First causes to check |
|---|---|---|
| M-01 | Metal Detector Fails Challenge Test | Sensitivity drift; Wrong product setting; Test piece passed off-centre or at the wrong speed |
| M-02 | Metal Detector False Rejects | Product effect not learned for this product; Sensitivity set too high; Vibration or electrical interference |
| M-03 | Reject Mechanism Not Working | Low air pressure; Reject timing wrong; Reject sensor failure |
| M-04 | Checkweigher Rejecting Good Bottles or Drifting | Not zeroed or calibrated; Vibration or drafts; Conveyor speed changed |
Electrical, Utilities & GMP Events
| Code | Problem | First causes to check |
|---|---|---|
| E-01 | Inverter Failure (All Machines) | Power interruption or phase loss; Motor overload or mechanical jam; Over-current, over-voltage or under-voltage |
| E-02 | Machine Will Not Start | Emergency stop pressed; Guard or door open; Air pressure low |
| E-03 | Sensor Not Detecting | Dirty lens; Misalignment; Loose cable |
| E-04 | Wrong Component Found on the Line | Incomplete line clearance; Wrong material issued; Previous batch materials left on the line |
| E-05 | Reconciliation Discrepancy | Counting or recording error; Unrecorded rejects or samples; Materials lost or mixed |
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