Root cause · Line 4 · Conveyor 3
Lens cleaning overdue
312 h since the last one, against 240
- The conveyor stops Program line 48
- %I4.3 is the light barrier Drawing sheet 217
- A dirty lens drops OSSD1 Manual p. 7
- The cleaning was overdue Journal Apr 12
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Before the analysis
14 stopsin 3 weeks, about $24K
Root cause found in
7 h 35 minafter the files arrived
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The root cause, within 48 hours
Why it stopped and where the cause sits, with the source for each step.
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Conveyor 3 Light Barrier Troubleshooting
Incident Analysis
Conveyor 3 stops a few times a shift. Light barrier alarm, nothing in the beam. Restart works.
Line4_TIA_V17.zap1714.2 MBConveyor3_Elektro.pdf6.8 MB
Incident update
Root cause: lens cleaning on -B34 overdue
The light barrier on conveyor 3 drops out because its lens is overdue for cleaning: the manual asks for every 240 hours, and it has been 312. When OSSD1 of -B34 falls, FB_Conv3_Control stops the conveyor.
How it stops
FB_Conv3_Control stops the conveyor the moment input %I4.3 drops. FB_Conv3_Controlline 48 %I4.3 is OSSD1 of receiver -B34, on core 4 of cable -W34 through terminal -X9:4. Conveyor3_Elektro.pdfp. 217
Why it is the lens
The manual asks for the lenses to be cleaned every 240 operating hours. Conveyor 3 manualp. 7 They were last cleaned on April 12, 312 hours before this stop. Maintenance journalApr 12
Next steps
Choose a step to prepare a follow-up. Add your observations below, then continue.
- 1 Clean both lenses of the light barrierHigh Receiver -B34 and transmitter -B32. Add the date to the maintenance journal.
- 2 If it trips again inside 240 hoursMedium Check terminal -X9:4 and cable -W34 for a loose core before anything else.
- 3 Put the lens cleaning into the preventive planMedium Every 240 operating hours, as the manual asks.
Evidence gaps (1)
- No photo of the lens itself. Cleaning it and noting the date in the journal confirms the cause.
Investigation activity
- Read TIA Portal project 412 blocks
-
Read EPLAN drawings 402 pages - Read Conveyor 3 manual 88 pages
- Read Maintenance journal 34 entries
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Results from manufacturing groups using Edmund
Flexible packaging plant in Nový Bydžov, part of Amcor plc (NYSE: AMCR). Measured over one year.
26%
faster repairs
€190K
a year back at the plant
Corrugated and solid board packaging, four Czech locations, part of the Swiss Model Group.
up to30%
potential for shorter breakdowns
300K+
pages of documentation at the machine
“We use Edmund AI as an ‘invisible co-worker’: it fills the missing know-how, supports our technicians’ decisions, and speeds up finding and fixing faults.”
Frequently asked questions
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Who is behind Edmund?
Edmund s.r.o., from Ostrava in the Czech Republic. The company came out of an industrial consulting practice, and Edmund now runs on 130+ machines across four countries.
See how AI can solve your manufacturing line fault.
Send us the hardest error that your team is still chasing. We put it through our AI incident module and give you the root cause within 48 hours, no strings attached.
NDA on request · Used only for your analysis · Never used to train AI
