SLD250 Magazine Loader I/O Troubleshooting Guideline

Clear field guide for checking the Magazine Loader I/O interface, identifying sensor faults, output faults, actuator problems, wiring issues, and mechanical jams.

Contents:

Safety Before Troubleshooting
I/O Reference
General Troubleshooting Method
Troubleshooting by Function
Symptom-Based Quick Guide
Final Check Before Production

1. Safety Before Troubleshooting

Important: Output testing may directly move cylinders, motors, conveyors, or the push rod. Keep hands, tools, and loose objects away from all moving areas.

Set the machine to Manual Interface / Manual Mode.
Remove PCB boards if there is risk of pushing, collision, or jamming.
Keep clear of the magazine, tray area, push rod, conveyor, lifting axis, and clamping cylinder.
Do not force multiple movement outputs at the same time.
For motor or cylinder outputs, use short jog operation only.
After testing, turn OFF all manual outputs before returning to Auto Mode.

2. I/O Interface Reference

Input Signals - X

Input	Signal Name	Function	Common Fault If Abnormal
`X0`	Position counting	Detects magazine/tray step position counting.	Lift axis moves but position is not counted.
`X1`	Principal axis upper limit	Main lift axis upper limit sensor.	Axis cannot move up or stops early.
`X2`	Principal axis lower limit	Main lift axis lower limit sensor.	Axis cannot move down or stops early.
`X3`	Loaded board inspection	Detects PCB loaded / board presence.	Machine does not push board out.
`X4`	Out-of-container inspection	Detects board or tray out of container position.	Tray-out sequence stops or gives false alarm.
`X5`	Tray inlet	Detects tray entering the machine.	Tray cannot load in automatically.
`X6`	Tray in place	Detects tray / magazine correctly positioned.	Machine cannot start loading sequence.
`X7`	Push rod displacement	Push rod forward / displaced position.	Push-out action has no completion feedback.
`X10`	Push rod return	Push rod home / retracted position.	Machine cannot start, tray cannot move, push cycle blocked.
`X14`	Emergency stop	Emergency stop signal.	Machine cannot run or reset.
`X16`	Post-loading inspection	Detects board after loading process.	Board transfer confirmation fails.
`X17`	Boards available for the front loader	Signal from upstream / front machine.	Machine waits for board or handshake signal.

Output Signals - Y

Output	Signal Name	Function	Expected Action
`Y0`	Boards needed by the current loader	Board request signal.	Signal is sent to upstream machine.
`Y1`	Conveyor transmission	Conveyor motor running.	Conveyor belt moves.
`Y2`	Principal axis up	Main lift axis moves up.	Lift platform rises.
`Y3`	Principal axis down	Main lift axis moves down.	Lift platform lowers.
`Y4`	Tray loaded out	Tray moves out.	Tray/magazine moves outward.
`Y5`	Tray loaded in	Tray moves in.	Tray/magazine moves inward.
`Y6`	Upper layer loaded out	Upper layer tray/board out.	Upper layer loading-out action.
`Y7`	Lower layer loaded in	Lower layer tray/board in.	Lower layer loading-in action.
`Y10`	Container clamping	Magazine/container clamping action.	Container clamp closes.
`Y11`	Push board out	Push rod pushes PCB out.	Push rod extends forward.
`Y12`	Push board return	Push rod returns home.	Push rod retracts.

3. General Troubleshooting Method

Sensor / Switch / Limit

→

PLC Input X
HMI I/O Monitor

→

Confirm ON / OFF Change

Step 1 - Check Inputs First

Inputs confirm whether the machine can “see” the real condition.

Move the sensor target or mechanical part.
Watch the related X signal on the HMI.
If the real action happens but the input does not change, check sensor, wiring, power, or PLC input.

Step 2 - Check Outputs Second

Outputs confirm whether the PLC can command actuators.

Turn ON one Y output manually.
Check if the motor, cylinder, or signal responds.
Check the related feedback input.
Turn OFF the output immediately after the test.

Standard logic: Output ON but no movement → Check actuator, air pressure, motor, relay, wiring, mechanical jam Movement OK but input wrong → Check sensor, sensor position, cable, PLC input Input always ON or OFF → Check dirty sensor, wrong alignment, short circuit, broken cable, wrong NO/NC logic

4. Troubleshooting by Function

A. Machine Cannot Start / No Auto Operation

X14X10X6X1/X2

Check Item	Normal Condition	If Abnormal
Power / PLC RUN	HMI ON and PLC RUN indicator ON.	Check power supply, fuse, breaker, PLC power.
`X14` Emergency stop	Emergency stop released and signal normal.	Release E-stop, check button contact and safety circuit.
`X10` Push rod return	Push rod fully retracted.	Return push rod manually using `Y12`; check return sensor.
`X6` Tray in place	Magazine/tray correctly positioned.	Adjust tray position, rail width, and sensor.
`X1/X2` Axis limits	Limit status matches real axis position.	Check limit sensor stuck ON/OFF or axis over-travel.

Machine cannot start ↓ Check emergency stop X14 ↓ Check push rod return X10 ↓ Check tray in place X6 ↓ Check lift axis limits X1 / X2 ↓ Read HMI alarm and correct the abnormal condition

B. Tray / Magazine Cannot Move In

X5X6Y5Y10

Enter Manual Interface.
Check if the tray is physically at the inlet.
Confirm X5 Tray inlet changes when the tray enters.
Turn ON Y5 Tray loaded in shortly.
Tray should move into position.
When tray is in position, X6 Tray in place should activate.
Test Y10 Container clamping if clamping is required.

If tray does not move in: check Y5 output, motor/cylinder, air pressure, rail obstruction, tray width, X5, X6, and mechanical jam.

C. Tray / Magazine Cannot Move Out

X4X6X10Y4

Confirm the machine is in Manual Mode.
Confirm the push rod is returned: X10 active.
Make sure the tray is not clamped or blocked.
Turn ON Y4 Tray loaded out shortly.
Tray should move out.
Check X4 Out-of-container inspection.

If tray does not move out: check push rod home X10, clamp output Y10, tray jam, Y4 output, and X4 sensor.

D. Lift Axis Cannot Move Up

X0X1X2Y2

Confirm there is no mechanical obstruction.
Check whether X1 Principal axis upper limit is already active.
If X1 is active, the axis may already be at the upper limit or the sensor may be stuck.
Turn ON Y2 Principal axis up shortly.
The lift platform should rise.
During movement, X0 Position counting should pulse/change.

If axis does not move up: check upper limit sensor X1, Y2 output, lift motor, driver, relay, chain/screw/belt jam, overload alarm, and X0 counting sensor.

E. Lift Axis Cannot Move Down

X0X1X2Y3

Check whether X2 Principal axis lower limit is already active.
If X2 is active, the axis may already be at the lower limit or the sensor may be stuck.
Turn ON Y3 Principal axis down shortly.
The lift platform should lower.
X0 Position counting should change during movement.

If axis does not move down: check lower limit sensor X2, Y3 output, lift motor/driver, mechanical jam, magazine seating, and safety interlock conditions.

F. Push Board Out Failure

X3X7X10X16Y11Y12

Confirm push rod is at home: X10 active.
Confirm board is available: check X3 Loaded board inspection.
Turn ON Y11 Push board out shortly.
Push rod should move forward.
X7 Push rod displacement should activate.
Board should transfer out.
Check X16 Post-loading inspection.
Return push rod using Y12 Push board return.
Confirm X10 Push rod return is active again.

Problem	Likely Cause	Action
Push rod does not move out.	No air, bad solenoid, no `Y11`, jam, no home signal.	Check air pressure, `Y11`, cylinder, mechanical guide, and `X10`.
Push rod moves but PCB does not transfer.	PCB stuck, magazine slot misaligned, push height wrong.	Check PCB thickness, warpage, magazine slot, rail width, and push rod height.
Push-out completes but machine alarms.	Feedback missing from `X7` or `X16`.	Clean/adjust sensors and check wiring.

G. Push Rod Cannot Return

X7X10Y12

Turn ON Y12 Push board return shortly.
Push rod should retract.
X10 Push rod return should activate.
X7 Push rod displacement should turn OFF after return.

If push rod does not return: check Y12, return solenoid valve, air pressure, cylinder jam, PCB jam, return sensor X10, and guide rail lubrication.

H. Conveyor Does Not Run

X3X16Y1

Turn ON Y1 Conveyor transmission shortly.
Conveyor belt should run.
Place a PCB on the conveyor.
Check if X3 and X16 change normally.

If conveyor does not run: check Y1, motor power, motor driver, relay, belt tension, belt jam, PCB jam, and sensor logic.

I. Board Not Detected

X3X16X17

Place PCB at the sensor location.
Observe whether the related input changes on the HMI.
Remove PCB and confirm signal changes back.
Clean the sensor surface.
Adjust sensor position if detection is unstable.

If signal does not change: check dirty sensor, detection distance, sensor angle, PCB color/reflection, loose cable, missing sensor power, or damaged PLC input.

J. Upstream / Handshake Signal Problem

Y0X17

Current loader needs board ↓ Y0 turns ON ↓ Upstream machine receives board request ↓ Upstream machine sends board available signal ↓ X17 turns ON ↓ Loader starts transfer sequence

If the machine waits and does not load, check whether Y0 turns ON.
Confirm the upstream machine receives the request.
Confirm the upstream machine sends the signal back.
Confirm X17 changes on the HMI.
Check handshake cable, connector, and NO/NC signal logic.

5. Symptom-Based Quick Guide

Symptom	Check First	Then Check
Machine cannot start.	`X14` emergency stop.	`X10`, `X6`, HMI alarm message.
Tray cannot enter.	`X5`, `X6`.	`Y5`, rail jam, tray width.
Tray cannot exit.	`X10`, `Y4`.	Clamp, tray jam, `X4`.
Lift cannot move up.	`X1`, `Y2`.	Motor, driver, `X0`.
Lift cannot move down.	`X2`, `Y3`.	Motor, driver, `X0`.
Push board fails.	`X10`, `X3`, `Y11`.	Cylinder, board jam, `X7`.
Push rod cannot return.	`Y12`, `X10`.	Air pressure, cylinder, jam.
Conveyor not running.	`Y1`.	Motor, belt, driver.
Board not detected.	`X3`, `X16`.	Sensor cleaning and adjustment.
Machine waits for board.	`Y0`, `X17`.	Upstream signal / handshake cable.

6. Standard Troubleshooting Sequence

1. Read alarm message on HMI 2. Enter I/O Interface 3. Check emergency stop X14 4. Check home conditions: - Push rod return X10 - Tray in place X6 - Axis limits X1 / X2 5. Check related input sensor 6. Manually test related output 7. Confirm actuator movement 8. Confirm feedback input changes 9. Check mechanical jam or adjustment 10. Turn all manual outputs OFF 11. Run single-cycle test 12. Return to Auto Mode

7. Example Troubleshooting Cases

Case 1 - Loader Does Not Push PCB Out

Check X10 Push rod return.
Check X3 Loaded board inspection.
Turn ON Y11 Push board out.
Check push rod movement.
Check X7 Push rod displacement.
Check X16 Post-loading inspection.
Return using Y12 and confirm X10.

Case 2 - Lift Axis Stops Unexpectedly

Check X1 upper limit and X2 lower limit.
Check whether X0 changes during movement.
Test Y2 up and Y3 down in Manual Mode.
Check mechanical lift system for jam.
Check motor/driver alarm.

Case 3 - Loader Keeps Waiting for Board

Check whether Y0 turns ON.
Confirm upstream machine receives the request.
Confirm upstream sends board available signal.
Confirm X17 turns ON.
Check signal cable and NO/NC logic.

8. Final Check Before Returning to Production

Return-to-production rule: Do not switch back to Auto Mode until all manual outputs are OFF and the machine is in a safe home condition.

All manual outputs are OFF.
Push rod is returned, X10 active.
Tray/magazine is in position, X6 active.
No emergency stop or alarm is active.
No PCB is jammed inside the magazine or conveyor.
Run 3-5 boards in slow/manual observation.
Confirm stable transfer before full production.

9. Field Technician Rule

Input tells you: "The machine knows it." Output tells you: "The machine commands it." Actuator movement: "The device works." Feedback input: "The action completed."

If output is ON but there is no movement, check actuator, power, air, and mechanics. If movement is correct but input does not change, check sensor, wiring, and PLC input.