TL;DR

Main drive overload usually means a mechanical jam, a broken punch, or a drive fault. Inspect the turret and punch set before attempting a restart.

What you might see

main drive overload fault on HMI
press stopping mid-run
drive current spike at fault time
jam or unusual noise before fault

Likely causes

Tap to mark as ruled out

Broken punch or die causing a jam in the turret
Tablet jam at the ejection ramp or discharge chute
Overcompression from incorrect fill depth cam setting
Drive inverter fault or phase loss

Required tools

Inspection flashlight
LOTO kit
Punch inspection tools and gauge
Manual turret rotation tool (if applicable)

Safety first

Never reach into the die table or punch area with the turret in an unknown state. Lock out completely before any internal access.
Pharmaceutical dust is present inside the press casing. Wear respiratory PPE per product SOP during internal inspections.
Broken punch tips can launch with significant force. Do not stand directly over the die table when a punch failure is suspected.

Procedure

7 steps · ~30 min

1
Stop the press immediately. Lock out and tag out the main drive.
2
Inspect the discharge chute and tablet ejection area for a tablet jam or fragment accumulation.[1]
3
Manually index the turret (if provided by the press design) by one station at a time. Check for binding.
4
Inspect each punch and die in the turret for a broken lower punch tip or a cracked upper punch.[1]
5
Check the fill depth cam setting against the process order. Overfill causes excess compression force.
6
Review the drive inverter fault log on the press HMI for current limit trip codes.
7
After clearing any mechanical jam and confirming no broken tooling, restore power and attempt a jog start at low speed to verify free rotation before resuming production.

Sources

Fette Compacting Fette FE 1200i / 3090 Tablet Press general technical documentation, Fette Compacting
Fette FE 1200i / 3090 tablet press general drive overload and punch jam procedures (general)

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