FAQ

Solution temperature outside of range defined by alarm set points (machines equipped with PLC/HMI only).

• Refer to machine manual for target solution operating temperature and alarm set point.

Access doors or covers not properly closed causing safety limit switches to prevent washer operation.

• Close.

Solution level too low causing low solution level alarm control to prevent washer from starting.

• Refill solution tank.

• Verify float switch operation and clean, re-adjust, repair or replace as required.

Drip pan or pit float switch activated (machines equipped with a drip pan or mounted in a pit).

• Remove excess liquid from pit or drip pan.

• Verify float switch operation and clean, re-adjust, repair or replace as required.

Limit switches misaligned or defective.

• Re-align or replace as required..

Power turned off.

• Turn on power supply.

Pump motor breaker or overload tripped/fuse blown.

• Reset breaker/overload or replace fuse. If problem persists, have a qualified electrician verify the equipment.

• Pump motors overdrawing current due to worn or missing nozzles. Replace nozzles.

Timer for first stage set to zero.

• Reset timer.

Bag or cartridge filter cover limit switches misaligned or defective.

• Re-align or replace.

Bag or cartridge filter cover not properly closed, causing pressure switch to prevent washer operation.

• Close.

Filter bag or cartridge clogged, causing pressure switch to prevent washer operation.

• Replace filter bag or cartridge.

Solution diverter not in correct position.

• Check for object blocking diverter and remove if necessary.

• Check diverter position limit switches, and adjust or replace as required.

  Electric actuator

• Check actuator and replace.

  Pneumatic diverter

• Check for adequate compressed air supply and condition of air hoses.

• Check air valve and replace if faulty.

• Check diverter cylinder and replace if faulty.

Door lock not confirmed.

• Check locking mechanism for proper operation.

• If lock is pneumatic, check for adequate air supply.

Air intake filter clogged 

• Replace.

Blower electrical connections faulty.

• Have a qualified electrician verify the equipment.

Blower malfunctioning.

• Repair or replace.

Airknife is clogged.

• Clean.

Compressed air nozzles clogged.

• Remove and clean. Re-install in original orientation.

Compressed air pressure not adjusted.

• Adjust with pressure regulator on machine.

Inadequate air supply.

• Check air supply.

Solenoid valve malfunctioning.

• Check voltage at solenoid coil and replace if defective.

Oscillation mode set to OFF or CNP delay set to 0.

• Set CNP to ON mode or program delay for 5.00 seconds to test.

CNP drive system malfunctioning or damaged.

• Inspect and verify operation. Re-adjust, repair, or replace components as required.

Access doors or covers not properly closed, causing safety limit switches to prevent conveyor movement.

• Close all access doors/covers.

Conveyor START/STOP button not in ON position.

• Pull conveyor START/STOP button to ON (green light should stay on).

Too much weight on conveyor or conveyor jammed triggering the overload protection.

• Remove jammed workpiece or try again without any load.

Drive clutch slipping.

• Adjust clutch tension. For instructions, consult the MAINTENANCE section of your PROCECO manual or contact us.

Drive gearmotor breaker or overload tripped/fuse blown.

• Reset breaker or overload/replace fuse. If problem persists, have a qualified electrician verify the equipment.

Conveyor variable frequency drive improperly adjusted or malfunctioning.

• Verify operation and re-adjust or replace if defective.

Workpiece detected at unloading station needs to be removed.

• Remove workpiece.

No antifoam being used.

• Add antifoam to control foaming (consult your chemical supplier).

Incorrect solution concentration.

• Titrate solution and adjust chemistry as required (consult your chemical supplier).

Plant water too soft (Less than 4 GPG).

• Adjust with the help of your chemical supplier.

Plant Water too hard (greater than 7 GPG).

• Perform a descaling operation with the help of your chemical supplier.

Plant water too hard and reacting with alkaline cleaner.

• Contact you chemical supplier for more information.

Exhaust blower outlet damper not open far enough.

• Increase damper opening.

  NOTE: Always set the exhaust damper to the minimum required opening to avoid excessive heat loss and to maintain low solution heating costs.

Insufficient gas supply.

• Ensure that gas supply is adequate for intended consumption.

7-day timer clock presently in a period programmed as inactive.

• Wait for programmed activity or change 7-day solution heating timer settings.

Solution level too low causing the solution level control to prevent burner start.

• Make sure there is sufficient solution in the tanks.

No flame.

• Press reset switch to restart burner. In case of a 400,000+ Btu burner, verify spark plug or UV sensor. If problem persists, have a qualified combustion specialist verify the equipment.

7-day coalescer timer programmed for no skimmer activity at this moment.

• Wait for programmed activity or change 7-day coalescer timer settings.

Missing or damaged floating skimmer in solution tank.

• Replace the floating skimmer.

Skimming weir not properly adjusted.

• Adjust. For instructions, consult the MAINTENANCE section of your PROCECO manual.

Coalescers may be interlocked with solution level controls.

• Check solution level and verify operation of solution level controls.

Pneumatic diaphragm pump not working due to inadequate air supply.

• Check air supply.

Air inlet valve to pneumatic diaphragm pump closed.

• Open valve.

Pneumatic diaphragm pump's solenoid valve malfunctioning.

• Repair or replace.

7-day skimming timer programmed for no skimmer activity at this moment.

• Wait for programmed activity or change 7-day skimming timer settings.

Skimmer power cable not plugged in.

• Plug power cable into designated outlet.

Scraper blades worn or damaged.

• Replace.

Skimmer belt or disk worn or damaged.

• Remove cover and replace belt or disk.

No oil buildup.

• If skimmer consistently fails to remove oil because none is present, change 7-day skimming timer settings to reduce duration or frequency of skimmer operation.

Skimmer operational while pump is running.

• Skimmers are most effective when the solution is still and the oil has a chance to rise to the surface.

Hydraulic pump breaker tripped.

• Check mechanism for free movement, for any loose electrical wires or other damage, and then reset breaker. If problem persists, have a qualified electrician verify the equipment.

Flow control valve at cylinder inlet and outlet misadjusted.

• Adjust flow control valves as required.

Air in the hydraulic system.

• Loosen hose connections at pump outlet and bleed.

Hydraulic unit filter dirty.

• Replace.

Hydraulic pump oil level too low.

• Add hydraulic oil to proper operating level.

Loose wire raising amperage.

• Tighten wires.

Problem with pump motor.

• Have a qualified electrician verify the equipment.

Loose piping union inside cabinet.

• Tighten union.

Spray nozzles clogged.

• Remove and clean thoroughly.

Spray nozzle plumbing clogged.

• Remove plugs and flush thoroughly.

Spray nozzles missing or worn out.

• Replace.

Spray nozzles clogged.

• Remove and clean thoroughly.

Spray nozzles missing or worn out.

• Replace.

Spray nozzle plumbing clogged.

• Remove plugs and flush thoroughly.

Remove plugs and flush thoroughly.

• Refill solution tank.

Clearance between the suction side of the impeller and the pump volute is not correct.

• Adjust.

Excessive leakage.

• Repair.

Missing or worn spray nozzles or excessive leakage at the pipe joints can cause a pressure drop indicated by the pump motor overdrawing current by more than 15% above initial measurements.

• Check for missing nozzles. If all nozzles are in place, they may be worn out and should be changed. Replace nozzles with same quantity, type, and capacity.

Low solution level.

• Refill the tank.

Chip filters clogged with debris.

• Remove and clean.

Foaming in solution tanks.

• Unless it is caused by too low an operating temperature or contaminated solutions, this can be corrected with a defoaming additive. Leave some oil on top of the solution to maintain foam control.

Foreign object such as a rag drawn into pump inlet.

• Remove the pump and check the inlet.

Pump cavitating because solution temperature is too high.

• Reduce temperature.

Excessive leakage from pump plumbing.

• Verify and correct accordingly.

Pressure gauge faulty or snubber clogged with dirt.

• Clean snubber and replace pressure gauge as required.
  Note: Do not remove or rotate snubber relative to gauge.

Conveyor jammed.

• Unjam conveyor by removing any debris stuck under scraper bar.

Drive clutch slipping.

• Adjust clutch tension. For instructions, consult the MAINTENANCE section of your PROCECO manual or contact us.

7-day sludge conveyor timer programmed for no activity at this moment.

• Wait for programmed activity or change 7-day sludge conveyor timer settings.

Conveyor drive motor or overload tripped/fuse blown.

• Reset breaker/overload or replace fuse. If problem persists, have a qualified electrician verify the equipment.

Solution diverter not in correct position.

• Check for object blocking diverter and remove if necessary.

• Check diverter position limit switches, and adjust or replace as required.

  Electric actuator

• Check actuator and replace.

  Pneumatic diverter

• Check for adequate compressed air supply and condition of air hoses.

• Check air valve and replace if faulty.

• Check diverter cylinder and replace if faulty.

Solution level too low.

• Ensure that all water valves are open and that the solution make-up solenoid valve is functioning correctly.

Low solution-level alarm control malfunctioning or requiring adjustment.

• Repair or replace.

Exhaust blower set to run during cleaning cycle and damper improperly adjusted, causing excessive heat loss.

• Set blower to run "after cycle" only or adjust damper to minimum setting.

Solution make-up solenoid valve not sealing properly, letting fresh water in continuously.

• Repair or replace solenoid.

Temperature controller setpoint too low.

• Adjust temperature controller setpoint to desired temperature.

7-day solution heating timer programmed for no heating activity at this moment.

• Wait for programmed activity or change 7-day solution heating timer settings.

Excessive scale build-up on heating elements, gas pipes, or steam/water coils.

• Drain liquid from tanks and clean using a brush.

ELECTRICALLY-HEATED SYSTEMS

Electrical contactor defective or not activated.

• Repair or replace.

Heater breaker tripped/fuse blown.

• Reset breaker/replace fuse. If problem persists, have a qualified electrician verify the equipment.

GAS-HEATED SYSTEMS

Gas burner malfunctioning.

• Have checked by a qualified combustion specialist.

Gas supply inadequate.

• Check gas supply.

STEAM-HEATED SYSTEMS

Electric or pneumatic inlet valves malfunctioning.

• Repair or replace. If inlet valve is pneumatic, check for adequate air supply.

Inadequate steam supply.

• Check steam supply.

Steam condensate return blocked.

• Remove obstruction.

Steam traps malfunctioning.

• Repair or replace.

let strainer or filter clogged.

• Turn off main water supply, remove filter and clean/replace as required. Flush water line before reassembling.

Solution level make-up control faulty or requires adjustment.

• Verify that mechanism moves freely. Clean float balls and adjust, repair, or replace as required.

No water supply.

• Check the water supply.

Power turned off.

• Turn on the power supply.

Solution make-up solenoid valve malfunctioning.

• Check voltage at solenoid coil and replace if defective.

Solution make-up solenoid valve protection fuse blown.

• Replace fuse.

Solution make-up timer currently counting down.

• Set solution make-up to 0 for initial tank fill-up or press the REFILL NOW button on the HMI Setup screen.

Drainage interval between stages too short causing solution to remain on workpieces instead of returning to tank.

• Set a long interval time.

Solution diverter not in correct position.

• Check for object blocking diverter and remove if necessary.

• Check diverter position limit switches, and adjust or replace as required.

  Electric actuator

• Check actuator and replace.

  Pneumatic diverter

• Check for adequate compressed air supply and condition of air hoses.

• Check air valve and replace if faulty.

• Check diverter cylinder and replace if faulty.

Drainage interval duration between stages too short.

• Set a longer interval time.

Solution level make-up control faulty or requires adjustment.

• Adjust, repair, or replace.

Solution make-up solenoid valve malfunctioning.

• Repair or replace.

Solution that has not fully drained from inside workpieces continues to spill into the tank.

• Position the parts to allow for complete drainage.

Overflow pipe clogged.

• Remove obstruction.

Solution diverter not in correct position.

• Check for object blocking diverter and remove if necessary.

• Check diverter position limit switches, and adjust or replace as required.

  Electric actuator

• Check actuator and replace.

  Pneumatic diverter

• Check for adequate compressed air supply and condition of air hoses.

• Check air valve and replace if faulty.

• Check diverter cylinder and replace if faulty.

Workpiece dropped through the turntable web and jamming turntable movement.

• Remove jammed workpiece. Inspect turntable and drive system for damage and repair or replace components if necessary.

Drive chain is too loose.

• Check chain tension and adjust as required.

Turntable rotation disabled (washers with PLC/HMI option only).

• Enable turntable rotation using HMI setup screen.

Drive gearmotor breaker or overload tripped/fuse blown.

• Reset breaker or overload/replace fuse. If problem persists, have a qualified electrician verify the equipment.

Turntable variable frequency drive improperly adjusted or malfunctioning.

• Verify operation and re-adjust or replace if defective.

Too much weight on turntable.

• Keep the total weight of all workpieces being processed below the maximum load capacity specified on the nameplate affixed to electrical panel.

CNP not in UP position (washers equipped with Center Nozzle Pipe).

• Move CNP to UP position.

Cleaner concentration too low

• Increase cleaner concentration.

Cycle time not long enough.

• Increase cycle duration until desired cleanliness is achieved.

Spray nozzles misaligned.

• Adjust nozzles. Consult the MAINTENANCE section of your PROCECO manual or contact us.

Low pump pressure.

• See PUMP PRESSURE LOW.

Turntable not rotating (turntable washers) or conveyor not moving (conveyor washers).

• See TURNTABLE NOT ROTATING or CONVEYOR NOT MOVING.

Workpiece poorly positioned.

• Reposition workpieces for optimal impingement and drainage. Avoid shadowing from other workpieces.

Solution temperature too low.

• Check temperature controller settings and adjust if necessary. Allow sufficient time for solution heat-up. The process can take up to 3-4 hours.

• Check heater operation.

• Electric immersion heating elements covered with mineral buildup. Clean elements. Also check for buildup on temperature probes.

• Give sufficient time for heat-up. The solution heating process can take up to three-four hours.

Spray nozzles clogged.

• Remove and clean thoroughly.

Spray nozzle plumbing clogged.

• Remove plugs and flush thoroughly.

Spray nozzles missing or worn out.

• Replace.

Filter bag or cartridge clogged.

• Check the inlet & outlet pressure. If there is a difference greater than 15 psi (100 kPa or 1 bar) between the two pressure gauges, change the filter bag or cartridge.