AQS610-EU/SF (V2 H/W)
DOC 584 Issue A
TECHNICAL GUIDE
Page 20
7. Troubleshooting
7.1 Inconsistent leaktest results
Could be due to:
1. Bad neck sealing. Check that the screw is positioning bottles directly under test heads and that sealing pads
are undamaged.
2. Clamp pressure too low. Causes poor neck seal with bottle neck. Increase clamp pressure regulator
slightly.
3. Clamp pressure too high. Causes bottle necks to distort, releasing air pressure inside. Reduce clamp
pressure regulator slightly.
4. Leaking pneumatic fittings or pipes. Check that joints between fittings are airtight and pneumatic pipes are
not damaged.
5. Sense pipe blocked. Pressure readings will show a sluggish response to pressure changes. Check that
sense pipes from test heads to pressure transducers on main control board are not blocked/kinked,
especially when cabinet front panel is shut.
6. Fill time set too low. Bottle not reaching test pressure in allotted time. Increase fill time Setting.
7. Test pressure set too low. Bottle not being pressurised enough to expose very small holes. Increase test
pressure Setting.
8. Fill regulator set too low. Not enough air flow to fill the bottle to test pressure in allotted time. Increase Fill
regulator.
9. Test time too short. Not enough time allowed for a reliable Leaktest. Increase Test time Setting.
7.2 Failure to reject bad bottles
If the test results indicate that a bottle has been failed but was not rejected from the conveyor:
1. Check screw homing position sensor is operating correctly.
2. Check reject blower OK. Valve can be forced “ON” from the front panel by turning on the function
corresponding to the reject blower output to check the electronics and the valve solenoid. Manually turning
on the valve will check the valve operation. (See Functions section and I/O list and front panel controls for
details).
3. Check that the ‘Reject Time’ setting is et such that the operation time matches the time taken for one screw
revolution.
If the test results do not indicate that a bottle should have been failed:
1. Check the ‘Final P%’ for the bottle tested. Adjust the ‘Min Final P %’ setting if necessary to reject failures but
to pass good containers.
2. Check transducer is not damaged or that pneumatics are connected and intact.
3. Fill regulator set too high. Bottles are over pressurising. Reduce Fill regulator.
4. Test pressure too low. Sometimes a higher test pressure is necessary to expose smaller holes. Increase
‘Test Pressure’ setting.
5. Fill Time too low. Bottle not reaching test pressure in allotted time. Increase ‘Fill Time’ setting.
6. Test time too short. Not enough time allowed for a noticeable pressure drop in the bottle (for a small hole).
Increase ‘Test Time’ Setting.
7.3 Bottles not filling
Occasionally a bottle may not fill correctly if the neck seals and bottle do not line up for any reason, e.g. bottle
wobbling in test station too much .Other factors may cause the bottles not to fill on a regular basis:
1. Test head neck seal damaged. Replace faulty seal.
2. Test head bracket set too high. Cylinders do not reach bottles when extended. Lower test head bracket.
3. Clamp pressure set too high. Bottles distorted and not sealing on test seals. Lower clamp pressure
regulator.
4. Clamp pressure set too low. Head not making a good seal, air leaking around bottle neck. Increase clamp
pressure regulator.
5. Fill pressure too high. Lower test pressure (not below 15mB ( 0.15 psi )), increase fill valve pressure
regulator or increase ‘Fill Time’ setting.
