OMRON _DeviceNet_ (2)

Figure 44

The next step is to proceed to establish the electrical and pneumatic
connections for the station. Before doing this we must make sure that the classroom
meets the pneumatic and electrical requirements mentioned above.

For greater safety, it is wise to cut off voltage to the station using the isolating
switch on the button pad before any electrical connection is made. This is done by
connecting the station plug to the appropriate classroom socket.

In the same way, it is recommendable to carry out the pneumatic connection
with the station air tap turned off. A six-diameter pipe must be connected from the
classroom socket to the air treatment group intake for the station.

4.3.2 CELL

As for the cell, the first step is to proceed to installing the transfer unit. This
means following a similar process to that described above, as if we were dealing with
an individual station. In this case the pneumatic connection will have to be performed
using an eight-diameter pipe.

The stations are provided with anchoring angle brackets and a supporting leg.
The station must first be placed in front of the bars that project from the transfer unit
in the position in which it is going to be sited. The station is then lifted and placed
onto the outermost part of the bars, so that the table can be directly slid and pushed
until it touches the transfer unit.

The next move is to regulate the height of the table and immobilise it. This is
what the angle bracket is for, with its adjustable supporting leg screwed into the
bottom part of the table. This fastening must first be loosened and placed vertically,
then situated again, while the support leg has to be adjusted until it achieves a
horizontal position. In the case of station 8 (store), there is no need to put the station
onto the bars, although its four support legs do have to be adjusted.

45

The angle bracket anchoring pieces must now be screwed down to fix the table
to the transfer unit. When the assembly operations have been executed as indicated,
the wiring connection can be set up. The recommendation is to perform and complete
the wiring and assembly process on each single station before moving on to the next
one.

The transfer unit has connectors for communications, air and electricity,
located on the station positions. Before establishing the wiring connection it is
advisable to disconnect the transfer voltage and air (using the isolating switch on the
side of the unit for the former and the air tap for the latter).

4.4 START-UP

4.4.1 INDIVIDUAL STATION

When installation is completed, we proceed to unit start-up. Shown below is
the procedure for each station. It is advisable to read the entire procedure prior to
carrying out these operations.

General procedure (Stations 1, 2, 3, 4, 5, 6 and 8):

1. As a result of incidents during the transportation of the unit, it is always possible
that mechanical components become unbalanced. This will be detected in the first
working cycle. Before starting, check that the fastening elements are properly
tightened.

2. Feed the loader with the pieces that correspond to each station (1, 2, 4, 5 and 6).
3. Set the air input pressure regulator at above 3 Kg/m3. In the case of station 3

(press), the hydraulic supply regulator must also be set, in this case at 80 Kg/m3.
4. Carry out a visual inspection of the station to verify that there are no elements that

might distort the functioning of the system. With station 8 (store), it is necessary
to check that the fairing protection gates are closed.
5. Ensure that the magnetic circuit breaker situated on the electrical control panel is
in the "on" position.
6. Set the cycle selector switch on the button pad at step-by-step mode.
7. Move the sectionalising switch on the button pad to the "on" position.
8. Make sure that the emergency stop mushroom head on the button pad is
unblocked.
9. Press the button pad reset but ton to ensure that the process begins in start mode
conditions. Every time the process is halted, either during start-up or during a
cycle, if the machine is not in start mode condition the defect pilot light on the
button pad will blink.
10.In the cases of stations 4 and 5 (shafts and covers), if there is a need to perform a
division plate evacuation cycle before beginning, the stop button on the control
pad must be pressed for five seconds.

46

11. When the start button is pressed the first step in the process will be executed.
Since we will be working in step-by-step mode, it will be necessary to press the
start button each time we want to take a new step.

12. If any imbalance in the unit is detected, take appropriate corrective action and
repeat the cycle until it functions correctly.

13. Once the cycle is over, set the cycle switch, situated on the button pad, in
continuous mode. When the start button is pressed it will now perform
uninterrupted cycles until the feeder runs out. At that point the pilot light will
come on to indicate that there is no material in place on the table (1, 2, 4, 5 and 6).

14. The process can be halted at any moment by pressing the stop button or the
emergency stop mushroom head. If the latter is pressed, once it has been
deactivated it is necessary to return to initial mode conditions (reset button). After
this we only have to press the start button.

Station 7 (robot):

1. Carry out a visual inspection of the station to check that there are no elements that
might distort the functioning of the system.

2. Make sure that the fairing protection gates are closed.
3. The robot drive switch at the back of the unit and the magnetic circuit breaker

situated on the electrical control panel must be in the "on" position.
4. Set the cycle switch on the button pad to step-by-step mode.
5. Move the load switch on the button pad to the "on" position.
6. Check that the emergency stop mushroom head on the button pad is unblocked.
7. Press the reset button on the button pad to ensure that the process begins in start

mode conditions. Each time the process is halted, either during start-up or during
a cycle, if the station is not in start mode condition the defect pilot light on the
button pad will start blinking. In addition the drive unit error led lights up
accompanied by the sound of a buzzer.
8. When the start button is pressed the first step in the process will be executed.
Since we will be working in step-by-step mode, it will be necessary to press the
start button each time we wish to take a new step.
9. If any imbalance in the unit is detected, take appropriate corrective action and
repeat the cycle until it functions correctly. It is quite likely that slight
modifications have to be made to the robot's screwing movements so that it
performs its duty correctly. To do this the robot manual must be consulted.
10. When the cycle is over, set the cycle switch on the button pad to continuous
mode. When the start button is pressed it will now execute an uninterrupted cycle.
11. The process can be halted at any time by pressing the stop button or the
emergency stop mushroom head. If the latter is pressed, once it has been
deactivated it will be necessary to return to initial mode conditions (reset button
on the button pad and drive unit). After this we only have to press the start button
on the button pad.

47

4.4.2 CELL

In the case of the cell, before proceeding to starting up the stations it is
necessary to start the transfer unit running, since both the electrical and pneumatic
feed for each station are obtained from their connection to it.

Start- up procedure

1. Due to incidents during the transportation of the unit, it is always possible that
some imbalance is produced in the mechanical components. Before beginning, it
is advisable to check that the holding elements are well tightened.

2. Set the air input pressure regulator at above 4 Kg/m3: should the pressure drop
below this value the defect pilot on the transfer unit will start blinking.

3. Carry out a visual inspection of the system to be certain there are no elements that
might distort its functioning.

4. Check that the magnetic circuit breaker on the unit is in the "on" position.
5. Move the load switch on the side of the unit to the "on" position. The voltage

indicator pilot light in the transfer unit will light up.
6. Make sure that the emergency mushroom heads are unblocked.
7. When the start button is pressed the transfer unit will start to function.
8. Should any imbalance be detected in the unit, take the appropriate corrective

measures and repeat the cycle until it functions correctly.
9. The process can be ha lted at any time by pressing the stop button or the

emergency stop mushroom head. Afterwards we only have to press the start
button for the process to be renewed.
10. Once the transfer unit is running and the stations have been correctly installed, we
proceed to initiate the start- up of each station, ascertaining that each one is
functioning correctly, firstly in manual and then in automatic mode.
11. Finally, the functioning of the system must be checked with all the stations in
automatic mode, feeding the transfer unit with the pallets.
12. Due to reasons mentioned earlier, it is very likely that some imbalance be
produced between the transfer unit and the station: to resolve this problem slight
adjustments will have to be made before achieving optimum performance.

48

4.5 PROCEDURE FOR USE

The start-up procedure for the first cycle of functioning after installation has
been described above. We now proceed to explain the process for normal use.

4.5.1 INDIVIDUAL STATION

General procedure (Stations 1, 2, 3, 4, 5, 6 and 8):

1. Feed the loader with the pieces that correspond to the station (1, 2, 4, 5 and 6).
2. See that the station's air input pressure regulator is registering above 3 Kg/m3. In

the case of station 3 (press), check that the hydraulic supply regulator is indicating
above 80 Kg/m3.
3. Carry out a visual inspection of the station to see that there are no elements that
might distort the functioning of the system. In the case of station 8 (store) check
that the fairing protection gates are closed.
4. Ensure that the magne tic circuit breaker situated on the electrical control panel is
in the "on" position.
5. Set the cycle switch on the button pad to the desired mode.
6. Move the load switch on the button pad to the "on" position.
7. Make sure that the emergency stop mushroom head is unblocked.
8. Press the reset button on the button pad to ensure that the process begins in
starting mode conditions. Every time the process is halted, whether during start-
up or during the cycle, if the station is not in starting mode condition the defect
pilot light on the button pad will start blinking.
9. In the case of stations 4 and 5 (shafts and covers), if there is a need to perform a
division plate evacuation cycle before starting, the stop button on the button pad
must be pressed in for five seconds.
10. If the manual cycle has been selected, each time it is required to execute a step in
the process the start button must be pressed. If automatic has been selected it is
only necessary to press once.
11. If the feeder runs out, the warning pilot light will come on to indicate there is no
material in position on the table (1, 2, 4, 5 and 6).
12. The process can be halted at any time by pressing the stop button or the
emergency stop mushroom. If the mushroom is pressed, once it is deactivated it is
necessary to retur n to starting mode conditions (reset button). Afterwards it will
be sufficient to press the starter button.

49

Station 7 (robot):

1. Carry out a visual inspection of the station to check that there are no elements that
might distort the system's performance.

2. Ensure that the fairing protection gates are closed.
3. The switch at the back of the robot drive unit and the magnetic circuit breaker on

the electrical control panel must be in the "on" position.
4. Set the cycle switch on the button pad to the desired mode.
5. Move the load switch on the button pad to the "on" position.
6. Make sure that the emergency stop mushroom head is unblocked.
7. Press the reset button on the button pad to ensure that the process will begin in

starting mode conditions. Each time the process is halted, whether during start-up
or during a cycle, if the station is not in starting mode conditions the defect pilot
light on the button pad will start blinking. In addition the unit's drive error led will
light up, accompanied by the sound of a buzzer.
8. If the continuous cycle has been selected, when the starter button is pressed the
cycle will be executed. If we are working in step-by-step mode, it will be
necessary to press the starter button each time we wish to perform a new step.
9. The process can be halted at any point by pressing the button or the emergency
stop mushroom. If the mushroom head is pressed, once it has been deactivated it
will be necessary to return to starting mode conditions (reset buttons on the button
pad and the drive unit). Afterwards it will be sufficient to press the starter button
on the button pad again.

4.5.2 CELL

Procedure for use

1. Carry out a visual inspection of the system to check that there are no elements that
might distort its performance.

2. Check that the defect indicator pilot light is not blinking (insufficient pressure).
3. Move the load switch on the side of the unit to the "on" position. Make sure that

the voltage indicator pilot light on the transfer unit lights up.
4. Make sure that the emergency stop mushroom heads are unblocked.
5. When the starter button is pressed the transfer unit will begin to function.
6. The process can be halted at any time by pressing the stop button or the

emergency stop mushroom. Afterwards it is sufficient to press the starter button
again in order for functioning to be renewed.
7. When the transfer unit is functioning, the running procedure for the stations is
carried out.
8. Feed the transfer unit with empty pallets, placing them at the beginning of the
cell.
9. When the units are stored in the last station, the empty pallets are re- fed, since the
transfer unit constitutes a closed circuit. The stations will stop when the material
from their stores finishes, this circumstance being detected by the desktop
warning pilot lights which will light up to indicate this. With the cell stopped, we
now move on to extract the assembled units, disassemble them and distribute
them among the different stores.

50

5. LOCATING AND CORRECTING FAULTS

STATION 1

No. Symptom Possible cause Remedy

1.1 The station does 1) The station is unplugged or 1) Plug the station in or

not start after the the classroom is without supply voltage to the

start button is voltage classroom

pressed 2) The magnetic circuit 2) Close the switch (ON), if

breaker is open it breaks again when

3) The emergency stop button restarted then the power

is locked installed is insufficient

4) The air intake is not 3) Unlock the emergency

connected or the air valve is stop button and press reset

open 4) Connect the air intake or

5) The line breaker is open close the air valve

6) Switch inside the fault box 5) Close line breaker

producing the failure 6) Close off the fault box

activated switch

7) Cell unplugged 7) Plug cell in

8) Transfer unit magnetic 8) Shut off switch (ON) on

circuit breaker open transfer unit, if it breaks

9) Transfer unit emergency again when restarted then the

stop button is locked power supply installed is

10) Cell air supply not insufficient

connected or transfer unit air 9) Unlock emergency button

valve open 10) Connect air intake or

close transfer unit air valve

1.2 Station does not 1) The station is not operating 1) Press reset

start up after the under starting mode 2) Unlock button and press

start button has conditions reset

been pressed and 2) The emergency stop button

the defect pilot is locked and the station is

light on the button not operating under start

pad is blinking mode conditions

1.3 The station will 1) The material feeder is 1) Feed the station store with

not start when the empty the appropriate pieces

start button has 2) The material feeder is 2) Unclog the feeder

been pressed and clogged

the desktop pilot

light comes on

1.4 The station starts 1) Not enough air is reaching 1) Set the station air pressure
but after a short
time it stops the actuators at 3 Kg/m3 and the cell air

2) The pneumatic installation regulator at 4 Kg/m3

in the classroom does not 2) Use a bigger compressor

meet minimum requirements or transfer to a more suitable

classroom

1.5 An actuator is 1) The speed controllers are 1) Regulate the flow until
reaching the desired speed
moving at excessive set at minimum

speed

51

1.6 An actuator is 1) The speed controllers are 1) Regulate the flow until it

moving far too set at maximum acquires the speed desired

slowly 2) The station air regulation 2) Set the station air pressure
does not reach the minimum at 3 Kg/m3

value required 3) Change gaskets or cylinder

3) The cylinder gaskets are as circumstances dictate

worn

1.7 The station always 1) Switch inside the fault box 1) Shut off the switch in the

stops when it producing the failure activated fault box

reaches the same 2) Detector faulty 2) Replace detector

point 3) Solenoid valve faulty 3) Substitute valve

1.8 Piece to be set 1) Detector faulty 1) Replace detector

wrongly placed by 2) Holding elements loose 2) Tighten loose screws

one of the station 3) Station pieces poorly 3) Adjust pieces

components adjusted 4) Shut off switch in fault box

4) Switch inside the fault box

producing the failure activated

1.9 The vacuum pads 1) Vacuum ejector damaged 1) Substitute ejector

do not have 2) Station air regulation does 2) Set the station air pressure

sufficient force to not reach the minimum at 3 Kg/m3

hold the piece required

52

STATION 2

No. Symptom Possible cause Remedy

2.1 The station does 1) The station is unplugged 1) Plug station in or supply

not start when the or the classroom is without classroom with voltage

start button has voltage 2) Shut switch off (ON), if it

been pressed 2) The magnetic circuit breaks again when restarted

breaker is open then the power supply

3) The emergency stop installed is insufficient

button is locked 3) Unlock the emergency stop

4) Air intake is not connected button and press reset

or air valve open 4) Connect the air intake or

5) The line breaker is open close air valve

6) Switch inside the fault box 5) Close line breaker

producing the failure 6) Shut the fault box switch

activated off

7) Cell unplugged 7) Plug cell in

8) Transfer unit magnetic 8) Shut off transfer unit

circuit breaker open switch (ON), if it breaks

9) Transfer unit emergency again when restarted then the

stop button locked power supply installed is

10) Cell air not connected or insufficient

transfer air valve open 9) Unlock emergency stop

button

10) Connect air intake or

close off transfer unit air

valve

2.2 The station will not 1) The station is not 1) Press reset

start when the start operating under start mode 2) Unlock emergency stop

button has been conditions button and press reset

pressed and the 2) The emergency stop

defect pilot light on button is locked and the

the button pad is station is not operating under

blinking start mode conditions

2.3 The station will not 1) The material feeder is 1) Feed the station store with

start when the start empty the appropriate pieces

button has been 2) The material feeder is 2) Unclog the feeder

pressed and the clogged

desktop pilot light

comes on

2.4 The station starts 1) Not enough air is getting 1) Set the station air pressure
but stops after a
short while to the actuators at 3 Kg/m3 and the cell air

2) The pneumatic installation regulator at 4 Kg/m3

in the classroom does not 2) Use a bigger compressor or

meet minimum requirements transfer to a more suitable

classroom

2.5 An actuator is 1) The speed controllers are 1) Regulate the flow until
reaching the speed desired
moving excessively set at minimum
53
fast

2.6 An actuator is 1) The speed controllers are 1) Regulate the flow until

moving far too slow set at maximum reaching the speed desired

2) The station air setting does 2) Set the station air pressure
not reach the minimum value at 3 Kg/m3

required 3) Change gaskets or cylinder

3) The cylinder gaskets are as circumstances dictate

worn

2.7 The station stops 1) Switch inside fault box 1) Shut off the fault box switch

whenever it reaches producing the failure activated 2) Replace detector

the same point 2) Detector faulty 3) Substitute valve

3) Solenoid valve faulty

2.8 Piece to be set 1) Detector faulty 1) Replace detector

wrongly placed by 2) Holding elements loose 2) Tighten loose screws

one of the station 3) Station pieces incorrectly 3) Adjust pieces

components adjusted 4) Shut off the fault box switch

4) Switch inside fault box

producing the failure activated

54

STATION 3

No. Symptom Possible cause Remedy

3.1 The station will not 1) The station is unplugged or 1) Plug the station in or feed

start when the start the classroom is without the classroom with voltage

button has been voltage supply supply

pressed 2) The magnetic circuit 2) Close the switch (ON), if it

breaker is open breaks again when restarted

3) The emergency stop button then the power installed is

is locked insufficient

4) Air intake not connected or 3) Unlock emergency stop

air valve is open button and press reset

5) The line breaker is open 4) Connect up air intake or

6) Switch inside fault box close air valve

producing the failure 5) Close line breaker

activated 6) Shut down the fault box

7) Cell unplugged switch

8) Transfer unit magnetic 7) Plug cell in

circuit breaker open 8) Close the transfer unit

9) The emergency stop button switch (ON), if it breaks

on the transfer unit is locked again when restarted then the

10) Cell air not connected or power installed is insufficient

air valve on transfer unit open 9) Unlock emergency stop

button

10) Connect up air intake or

close off air valve on transfer

unit

3.2 The station will not 1) The station is not operating 1) Press reset

start when the start under start mode conditions 2) Unlock emergency stop

button has been 2) The emergency stop button button and press reset

pressed and the is locked and the station is

defect pilot light on not operating under start

the button pad is mode conditions

blinking

3.3 The station starts 1) Insufficient air is reaching 1) Set the station air pressure

but stops again the actuators at 3 Kg/m3 and the cell air

after a short while 2) The pneumatic installation regulator at 4 Kg/m3

in the classroom does not 2) Install a bigger compressor

meet minimum requirements or transfer to a more suitable

classroom

3.4 An actuator is 1) The speed controllers are 1) Regulate the flow until
moving at
excessive speed set at minimum reaching the desired speed

55

3.5 An actuator is 1) The speed controllers are 1) Regulate the flow until

moving far too set at maximum reaching the desired speed

slowly 2) The station air regulation 2) Set the station air pressure
does not reach the minimum at 3 Kg/m3

value required 3) Change gaskets or cylinder

3) The cylinder gaskets are as circumstances dictate

worn

3.6 The station always 1) Switch inside the fault box 1) Close off fault box switch

stops when it producing the failure activated 2) Replace detector

reaches the same 2) Detector faulty 3) Substitute valve

point 3) Solenoid valve faulty

3.7 Piece to be set 1) Detector faulty 1) Replace detector

wrongly placed by 2) Holding elements loose 2) Tighten loose screws

one of the station 3) Station pieces wrongly 3) Adjust pieces

components adjusted 4) Close off fault box switch

4) Switch inside fault box

producing the failure activated

3.8 The vacuum pads 1) Vacuum ejector damaged 1) Substitute ejector

do not have 2) Station air regulation does 2) Set the station air pressure

sufficient force to not reach the minimum at 3 Kg/m3

hold the piece required

56

STATION 4

No. Symptom Possible cause Remedy

4.1 The station will no t 1) The station is unplugged 1) Plug station in or supply

start when the start or the classroom is without classroom with voltage

button has been voltage supply 2) Close the switch (ON), if it

pressed 2) The magnetic circuit breaks again when restarted

breaker is open then the power installed is

3) The emergency stop insufficient

button is locked 3) Unlock emergency stop

4) Air intake not connected button and press reset

or air valve is open 4) Connect up air intake or

5) The line breaker is open close air valve

6) Switch inside fault box 5) Switch off line breaker

producing the failure 6) Switch off fault box switch

activated 7) Plug cell in

7) Cell unplugged 8) Turn the transfer unit

8) Transfer unit magnetic switch (ON) off, if it breaks

circuit breaker open again when restarted then the

9) The emergency stop power installed is insufficient

button on the transfer unit is 9) Unlock emergency stop

locked button

10) Cell air not connected or 10) Connect up air intake or

transfer unit air valve open close transfer unit air valve

4.2 The station will not 1) The station is not 1) Press reset

start when the start operating under start mode 2) Unlock emergency stop

button has been conditions button and press reset

pressed and the 2) The emergency stop

defect pilot light on button is locked and the

the button pad is station is not operating in

blinking start mode conditions

4.3 The station will not 1) The material feeder is 1) Feed the station store with

start when the start empty the appropriate pieces

button has been 2) The material feeder is 2) Unclog the feeder

pressed and the clogged

desktop defect pilot

light is blinking

4.4 The station starts up 1) Insufficient air reaching 1) Set the station air pressure

but stops after a the actuators at 3 Kg/m3 and the cell air

short while 2) The pneumatic installatio n regulator at 4 Kg/m3

in the classroom does not 2) Install a bigger compressor

meet minimum requirements or transfer to a more suitable

classroom

4.5 An actuator is 1) The speed controllers are 1) Regulate the flow until

moving at excessive set at minimum reaching the speed required

speed

4.6 An actuator is 1) The speed controllers are 1) Regulate the flow until

moving far too slowly set at maximum reaching the speed required

2) The station air regulation 2) Set the station air pressure
does not reach the minimum at 3 Kg/m3

57

value required 3) Change gaskets or cylinder

3) The cylinder gaskets are as circumstances dictate

worn

4.7 The station always 1) Switch inside the fault box 1) Turn off switch in fault box

stops when it reaches producing the failure 2) Replace detector

the same point activated 3) Substitute solenoid valve

2) Detector faulty

3) Solenoid valve faulty

4.8 Piece to be set 1) Detector faulty 1) Replace detector

wrongly placed by 2) Holding elements loose 2) Tighten loose screws

one of the station 3) Station pieces wrongly 3) Adjust pieces

components adjusted 4) Turn off switch in fault box

4) Switch inside the fault box

producing the failure

activated

4.9 The vacuum pads do 1) Vacuum ejector damaged 1) Substitute ejector

not have sufficient 2) Regulation of station air 2) Set station air pressure at 3
force to hold the does not reach the minimum Kg/m3

piece value required

4.10 Sometimes correct 1) Capacity detector 1) Adjust capacity detector

pieces are expelled displaced 2) Turn off switch in fault box

2) Switch inside the fault box

producing the failure

activated

4.11 The division plate has 1) Locking cylinders seized 1) Manually activate the

stopped and will not corresponding slenoid valve so

move despite that the cylinders return to

attempts to restart it their position

58

STATION 5

No. Symptom Possible cause Remedy

5.1 The station will not 1) The station is unplugged 1) Plug station in or supply

start when the start or the classroom is without voltage to classroom

button has been voltage supply 2) Close the switch (ON), if it

pressed 2) Magnetic circuit breaker breaks again when restarted

open then the power installed is

3) The emergency stop insufficient

button is locked 3) Unlock emergency stop

4) Air intake not connected button and press reset

or air valve is open 4) Connect air intake or close

5) The line breaker is open air valve

6) Switch inside fault box 5) Switch off line breaker

producing the failure 6) Turn off switch in fault

activated box

7) Cell unplugged 7) Plug cell in

8) Transfer unit magnetic 8) Close the transfer unit

circuit breaker open switch (ON), if it breaks

9) The emergency stop again when restarted then the

button on the transfer unit is power installed is insufficient

locked 9) Unlock emergency stop

10) Cell air not connected or button

transfer air valve open 10) Connect air intake or

close transfer unit air valve

5.2 The station will not 1) The station is not 1) Press reset

start when the start operating under start mode 2) Unlock emergency stop

button has been conditions button and press reset

pressed and the 2) The emergency stop

defect pilot light on button is locked and the

the button pad is station is not operating in

blinking start mode conditions

5.3 The station will not 1) Material feeder is empty 1) Feed the station store with

start when the start 2) Material feeder is clogged the appropriate pieces

button has been 2) Unclog feeder

pressed and the

desktop defect pilot

light is blinking

5.4 The station starts 1) Insufficient air reaching 1) Set the station air pressure

but stops again after actuators at 3 Kg/m3 and the cell air

a short while 2) The pneumatic installation regulator at 4 Kg/m3

in the classroom does not 2) Use a bigger compressor or

meet minimum requirements transfer to a more suitable

classroom

5.5 An actuator is 1) The speed controllers are 1) Regulate flow until

moving at excessive set at minimum reaching the desired speed

speed

5.6 An actuator is 1) The speed controllers are 1) Regulate the flow until

moving far too slowly set at maximum reaching the speed desired

2) The station air setting 2) Set the station air pressure
3 59

does not reach the minimum at 3 Kg/m3

required value 3) Change gaskets or cylinder

3) Cylinder gaskets are worn as dictated by circumstances

5.7 The station always 1) Switch inside fault box 1) Turn off switch in fault box

stops when it reaches producing the failure 2) Replace detector

the same point activated 3) Substitute valve

2) Detector faulty

3) Solenoid valve faulty

5.8 Piece to be set 1) Detector faulty 1) Replace detector

wrongly placed by 2) Holding elements loose 2) Tighten loose screws

one of the station 3) Station pieces poorly 3) Adjust pieces

components adjusted 4) Turn off switch in fault box

4) Switch inside fault box

producing the failure

activated

5.9 The vacuum pads do 1) Vacuum ejector damaged 1) Substitute ejector

not have sufficient 2) Station air setting does not 2) Set station air pressure at 3
force to hold the
reach minimum value Kg/m3

piece required

5.10 Sometimes correct 1) Capacity detector 1) Adjust capacity detector

pieces are expelled displaced 2) Adjust optical detector

2) Optical detector displaced 3) Turn switch in fault box off

3) Switch inside fault box

producing the failure

activated

5.11 The division plate has 1) Locking cylinders seized 1) Manually activate the

stopped and will not corresponding solenoid valve

move despite an so that the cylinders return to

attempt to restart it their position

60

STATION 6

No. Symptom Possible cause Remedy

6.1 The station will not 1) The station is unplugged 1) Plug station in or supply

start when the start or the classroom is without classroom with voltage

button has been voltage supply 2) Close the switch (ON), if it

pressed 2) Magnetic circuit breaker breaks again when restarted

open then the power installed is

3) The emergency stop insufficient

button is locked 3) Unlock emergency stop

4) Air intake not connected button and press reset

or air valve open 4) Connect air intake or close

5) Line breaker open air valve

6) Switch inside fault box 5) Turn line breaker off

producing the failure 6) Turn off switch in fault

activated box

7) Cell unplugged 7) Unplug cell

8) Transfer unit magnetic 8) Close the transfer unit

circuit breaker open switch (ON), if it breaks

9) The emergency stop again when restarted then the

button on the transfer unit is power installed is insufficient

locked 9) Unlock emergency stop

10) Cell air not connected or button

transfer air valve open 10) Connect air intake or

close transfer air valve

6.2 The station will not 1) The station is not 1) Press reset

start when the start operating in start mode 2) Unlock emergency stop

button has been conditions button and press reset

pressed and the 2) The emergency stop

defect pilot light on button is locked and the

the button pad is station is not operating under

blinking start mode conditions

6.3 The station will not 1) The material feeder is 1) Feed the station store with

start when the start empty the appropriate pieces

button has been 2) The material feeder is 2) Unclog the feeder

pressed and the clogged

desktop defect pilot

light is blinking

6.4 The station starts 1) Insufficient air reaching 1) Set the station air pressure
but after a short the actuators at 3 Kg/m3 and the air

while stops again 2) The pneumatic installation regulator for the cell at 4

in the classroom does not Kg/m3

meet minimum requirements 2) Use a bigger compressor or

transfer to a more suitable

classroom

6.5 An actuator is 1) The speed controllers are 1) Regulate the flow until

moving at excessive set at minimum reaching the desired speed

speed

6.6 An actuator is 1) The speed controllers are 1) Regulate the flow until

moving far too slowly set at maximum reaching the desired speed

61

2) The air station setting 2) Set the station air pressure

does not reach the minimum at 3 Kg/m3

value required 3) Change gaskets or cylinder

3) The cylinder gaskets are as circumstances require

worn

6.7 The station always 1) Switch inside fault box 1) Turn off switch in fault box

stops when it reaches producing the failure 2) Replace detector

the same point activated 3) Substitute valve

2) Detector faulty

3) Solenoid valve faulty

6.8 Piece to be set 1) Detector faulty 1) Replace detector

wrongly placed by 2) Holding elements loose 2) Tighten loose screws

one of the station 3) Station pieces poorly 3) Adjust pieces

components adjusted 4) Turn off switch in fault box

4) Switch inside fault box

producing the failure

activated

62

STATION 7

No. Symptom Possible cause Remedy

7.1 The station will not 1) The station is unplugged 1) Plug station in or supply

start when the start or the classroom is without classroom with voltage

button has been voltage supply 2) Close the switch (ON), if it

pressed 2) Magnetic circuit breaker breaks again when restarted

open then the power installed is

3) The emergency stop insufficient

button is locked 3) Unlock emergency stop

4) Line breaker open button and press reset

5) Cell unplugged 4) Shut down line breaker

6) Transfer unit magnetic 5) Plug cell in

circuit breaker open 6) Close the transfer unit

7) The emergency stop switch (ON), if it breaks

button on the transfer unit is again when restarted then the

locked power installed is insufficient

8) Cell air not connected or 7) Unlock emergency stop

transfer air valve is open button

8) Connect air intake or close

transfer air valve

7.2 The station will not 1) The station is not 1) Press reset

start when the start operating under start mode 2) Unlock emergency stop

button has been conditions button and press reset

pressed and the 2) The emergency stop

defect pilot light on button is locked and the

the button pad is station is not operating

blinking under start mode conditions

For faults associated with the robot consult the robot manual

63

STATION 8

No. Symptom Possible cause Remedy

8.1 The station will not 1) The station is unplugged 1) Plug station in or supply

start when the start or the classroom is without classroom with voltage

button has been voltage supply 2) Close the switch (ON), if it

pressed 2) Magnetic circuit breaker breaks again when restarted

open then the power installed is

3) The emergency stop insufficient

button is locked 3) Unlock emergency stop

4)Air intake not connected button and press reset

or air valve open 4) Connect air intake or close

5) Line breaker is open air valve

6) Cell unplugged 5) Shut line breaker down

7) Transfer unit magnetic 6) Plug cell in

circuit breaker open 7) Close the transfer unit

8) The emergency stop switch (ON), if it breaks

button on the transfer unit is again when restarted then the

locked power installed is insufficient

9) Cell air not connected or 8) Unlock emergency stop

transfer air valve open button

9) Connect air intake or close

transfer air valve

8.2 The station will not 1) The station is not 1) Press reset

start when the start operating under start mode 2) Unlock emergency stop

button has been conditions button and press reset

pressed and the 2) The emergency stop

defect pilot light on button is locked and the

the button pad is station is not operating

blinking under start mode conditions

8.3 The station starts up 1) Insufficient air reaching 1) Set the station air pressure

but after a short the actuators at 3 Kg/m3 and the cell air

while it stops again 2) The pneumatic regulator at 4 Kg/m3

installation in the classroom 2) Use a bigger compressor or

does not meet minimum transfer to a more suitable

requirements classroom

8.4 An actuator is 1) The speed controllers are 1) Regulate the flow until

moving at excessive set at minimum reaching the desired speed

speed

64

8.5 An actuator is 1) The speed controllers are 1) Regulate the flow until

moving far too set at maximum reaching the speed desired

slowly 2) The station air setting 2) Set the station air pressure

does not reach the minimum at 3 Kg/m3

value required 3) Change gaskets or cylinder

3) Cylinder gaskets worn as circumstances dictate

8.6 The station always 1) Detector faulty 1) Replace detector

stops when it 2) Solenoid valve faulty 2) Substitute valve

reaches the same

point

8.7 Piece to be set 1) Detector faulty 1) Replace detector

wrongly placed by 2) Holding elements loose 2) Tighten loose screws

one of the station 3) Station pieces poorly 3) Adjust pieces

components adjusted 4) Modify the corresponding

4) Imbalance between co-ordinate in the PLC

transfer and station program

8.8 The vacuum pads 1) Vacuum ejector damaged 1) Substitute ejector

do not have 2) Station air setting does not 2) Set the station air pressure

sufficient force to reach the minimum value at 3 Kg/m3

hold the piece required

65

CELL

No. Symptom Possible cause Remedy

9.1 The station will not 1) The cell is unplugged or 1) Plug cell in or supply

start when the start the classroom is without voltage to classroom

button has been voltage supply 2) Close the switch (ON), if it

pressed and the 2) Magnetic circuit breaker breaks again when restarted

voltage pilot light is open then the power installed is

off 3) The emergency stop insufficient

button is locked 3) Unlock emergency stop

button and press reset

9.2 The cell will not 1) Air intake not connected 1) Connect air intake or close

start when the start or air valve is open air valve

button has been

pressed and the

defect pilot light on

the unit is blinking

9.3 The cell starts up but 1) Insufficient air reaching 1) Set the cell air pressure at

after a short while it actuators 4 Kg/m3

stops again 2) The pneumatic 2) Use a bigger compressor or

installation in the classroom transfer to a more suitable

does not meet minimum classroom

requirements

9.4 An actuator is 1) The speed controllers are 1) Regulate the flow until

moving at excessive set at minimum reaching the desired speed

speed

9.5 An activator is 1) The speed controllers are 1) Regulate the flow until

moving far too set at maximum reaching the speed desired

slowly 2) The cell air setting does 2) Set the cell air pressure at

not reach the minimum 4 Kg/m3

value required 3) Change gaskets or cylinder

3) The cylinder gaskets are as circumstances dictate

worn

9.6 The cell always 1) Detector faulty 1) Replace detector

stops when it 2) Solenoid valve faulty 2) Substitute valve

reaches the same

point

9.7 The cell frequently 1) There are more pallets 1) Remove excess pallets

comes to a halt but than there should be in the

not always in the cell (no. stations –2)

same place

66

6. MAINTENANCE AND INSPECTION

6.1. INTRODUCTION

It is imperative that the procedures for maintenance and inspection outlined on
these pages be scrupulously observed in order to guarantee the best performance from
the cell over a long period of time. As well as the daily inspections, periodic
inspections should also be carried out.

6.2 INSPECTION POINTS

6.2.1 DAILY INSPECTION Corrective action
Remove
Inspection point
Be sure that there are no obstacles in the Take appropriate corrective action
station that might distort the system's See "Locating and Correcting Faults"
performance See "Locating and Correcting Faults"
Check to see that no components are
loose, out-of-true or wrongly positioned
Make sure sufficient air is reaching the
station/transfer unit
Ascertain that voltage is reaching the
station/transfer unit

6.2.2 PERIODIC INSPECTION

Inspection point Corrective action
Check that the filter condensate level does Bleed: see maintenance procedures 6.3.1
not go beyond the marks
Make sure that the filter pressure does not Replace cartridge filter: see maintenance
drop below a bar procedures 6.3.1
Look at the screws and nuts in case they Tighten using the appropriate tool
are slack or have come loose (6 months)
See that the cylinders are functioning Change the gaskets if needs be: see
correctly (6 months) maintenance procedures 6.3.1
Lubrication of station 8 shafts (6 months) Lubrication: see maintenance
procedures 6.3.2
Examine the state of the shaft belts on the Change the belts: see robot manual
robot (6 months)
Check for disk brake-pad wear on the Change the pads: see robot manual
robot shafts (6 months)
Check for wear on the robot shaft Change brushes: see robot manual
servomotor brushes (6 months)
Clean cell (6 months) Clean: see maintenance procedures 6.3.4

67

Check for wear on the robot's beginning Change gears: see robot manual
and end of travel limit switch gear (1 year)
Check the robot bearings (2 years) Change bearings: see robot manual
Examine the motor reduction gears on each Lubricate gears: see robot manual
robot shaft (2 years)
Check the robot to see if there are damaged Change cables: see robot manual
cables (2 years)

6.3 MAINTENANCE PROCEDURES

6.3.1 PNEUMATIC COMPONENTS

- In general, the pneumatic components of the FMS200 are lubricated for life and there
is no need to carry out any maintenance of this kind on them. It is possible that, over a
long period of time, the internal gaskets of the cylinders may suffer from attrition. In
this eventuality, if the cylinder is detachable the gaskets have to be replaced. If it is
not detachable it will have to be replaced by another cylinder.

- It is recommendable every so often to carry out periodic bleeding of the water that
accumulates in the cell's air conditioning units. The filter condensate level should
never go over the maximum indicated on the filter bowl.

- If a filter pressure drop higher than a bar is detected, the cartridge filter must be
replaced with a new one.

6.3.2 ELECTRICAL SHAFTS

The electrical shafts on station 8 require periodic inspection: after every six
months of continuous work or after a month at standstill. This inspection must involve
a check on the unit holding elements, such as screws and nuts, in case they are loose. It
is also necessary to clean the feed shaft with the right kind of grease, moving the
carriage backwards and forwards. The linear guide runners have to be greased as well,
using an appropriate tool. Important Note: The grease used must not contain fluorine.

6.3.3 CLEANING

For the periodic cleaning operations on the FMS200 a clean cloth that leaves
no fibre traces can be used, whilst it is not advisable to use any cleaning product, in
particular those containing alcohol, solvents or chlorinated compounds.

68

7 SAFETY

7.1 GENERAL SAFETY PRECAUTIONS

- Once the process has begun, care must be taken to avoid adding pieces to, or
removing pieces from, the respective stores or pallets in circulation.

- In general, the stations should not be manipulated with whilst the machine is
running.

- When proceeding to the disassembly of the mechanism, do not leave any pieces
behind inside the main body.

- Under no circumstances must the protection and safety devices described below be
tampered with.

- If the stations have to be physically dealt with after a halt, to extract a fallen piece,
for instance, always press the emergency stop mushroom head down until the
intervention is completed. If some damaged element has to be replaced, we must
open either the sectionalising switch on the button pad or the one on the transfer unit,
as circumstances require.

- In order to safeguard the cell components, care must be taken to stop foreign bodies
or obstacles from entering the stations.

7.2 PROTECTION AND SAFETY DEVICES

All the stations and the transfer unit are equipped with emergency stop
mushroom heads for stopping the process at any moment in order to prevent accidents.
If the emergency stop mushroom is used, once the incident that caused the stop has
been overcome, make sure, before reactivating the cell or station, that the situation will
not recur, by taking appropriate measures. Furthermore, it is advisable to take away
pieces that are in the middle of a cycle whenever possible. After freeing the emergency
stop mushroom it will be necessary to press the reset button so that the components
return to their starting mode positions.

There is also a pneumatic device at the general air input, which causes a
gradual increase in air pressure when the air is first connected, thus avoiding accidents
produced by the sudden input of air in the circuit.

Station 3 (press) has a protection fairing to prevent accidents occurring with
the press. It descends when the latter is working and goes up when the task is finished.

Stations 7 and 8 (robot and store, respectively) there is a protection fairing that
covers the entire station. We must be sure that all the gates are closed before running
these stations. The gates should never be opened with the station running.

69

8. FAULT SIMULATION SYSTEM

All the stations incorporate a Fault Simulation System fitted to the side of each station.
The system consists of a lockable metal box containing 16 switches which, when operated,
cause a fault in the station.
There is also a connector to use the Fault Diagnosis and Virtual Repair Interactive System
instead, via computer.

70

9. SETS OF PARTS FOR ASSEMBLING

This refers to the sets of parts which are handled by the cell in the assembly process. Six sets
are supplied, each consisting of:
- 1 Body
- 2 Bearings of different height
- 2 Shafts of different height
- 1 Aluminium cover
- 1 Black plastic cover
- 1 White plastic cover
- 4 Screws

71

10. EC SELF-CERTIFICATION

ALECOP S.COOP., hereby declares that model FMS 200 of serial nº 10/99 complies with
the standards and essential requirements of directives:

- D 89/392/EEC (Royal Decree 1435/1992)-8/93.
- D 73/23/EEC-D93/68 EEC.
- D 89/392/EEC-D93/68 EEC RD 444/1994.

72

11. SUPPORT MATERIAL

1. FMS-200 Operating Manual.
2. FMS-200 Practical Activities Manual
3. Pneumatic Technology Study Manual.
4. Electro-pneumatic Technology Study Manual.
5. FX Automaton Programming Manual.
6. FX-2N Automaton Manual.
7. 485 Communications Card Manual
8. MEDOC Program Manual.
9. MEDOC PLUS software.
By way of guidance, a list is given below of the Practical Activities aimed at developing the
skills associated with the various technologies integrated into the Cell, with an explanation of
their training focus..

73

ANNEX A

FAULTS GENERATION

ANNEX A: FAULT GENERATION

Note: The information shown in this Annex refers to the different dysfunctions/ failures that can
be provoked in the Flexible Integrated Assembling System FMS - 200. This part of the
manual should not be given to the students, s o they won´t be able to associate the fault
symptom with its cause.

FAULT GENERATION

The Flexible Integrated Assembling System FMS- 200 offers the possibility of generating 16
different dysfunctions for each station. This means that for a complete cell with 8 stations a total
of 128 faults can be generated.

There are two ways of causing this faults/ dysfunctions in each station.

The first way is the traditional method, by means of switches. The only way to accede to these
switches is by opening the li d of the faults box present in each station, with its appropriate key.
Each switch, when activated, will make a dysfunction in some components of the station. Then,
the appropriate red led diode will light up.

There is no limit in the number of faults tha t can be activated at the same time.

After the fault is activated, the student has to analyze the system to find out which the broken
component is. Then he/she will write a report, but the last step of every repairing will not be
done. This would be the substitution of the broken component and the verification of the system
in order to make sure that the dysfunction has been repaired correctly.

This last step, as well as other possibilities, can be done with a connection of a computer to the
system. The computer can be connected by the RS-232C serial line or by the CENTRONICS
parallel. There are two different cables for this purpose. The connection port is located on the
right side of the fault box.

The SIRVAFMS program allows the programming of the faults from the PC. This program
allows the following functions:

- Personalized work for each student. Every student has a personal password to have
access to the program.

- Possibility of committing a dysfunction in the system in order to analyze its effects.
- Possibility of committing faults in the system, introducing a code into the program.

These codes can be easily changed by the teacher.
- Possibility of making a virtual reparation of the component that´s suspicious of being the

cause of the fault.
- Registration of the work made by the student in a historical of reparations, in which

comments for each operation can also be included.

In the SIRVAFMS User´s manual you can find further information about this program.

1

STATION 1: BO

Nº FAULT SYNTHOM SUSPICIOUS COM

1 The station can not be switched on • ON Push-button
• OFF Push- button
• Wiring
• PLC

2 The station does no work in • Manual Automated switc
automated mode • Wiring
• PLC (Programme)

3 The sensor does no go down • Cylinder of sensor
• Solenoid valve Cylinder
• Magnetic switch of senso
• Magnetic switch of feede

4 The vertical cylinder of body • Vertical cylinder of body
manipulator does no go up • Solenoid valve of vertical

• Vacuum switch detector
• Upper magnetic detector

• Wiring
• PLC

ODY SUPPLY

MPONENT BROKEN COMPONENT
On Push Button (XO)

ch Manual /Automated switch (X2)

Magnetic switch of feeder (X16)

or
er

manipulator Vacuum switch detector (X11)
l cylinder

r of vertical cylinder

2

STATION 1: BO

Nº FAULT SYNTHOM SUSPICIOUS COM

5 The body is always rejected • Magnetic detector of sen
• Wiring
• PLC

6 The station can no be switched on • ON Push-button
• OFF Push- button
• Wiring
• PLC

7 The Transfer cylinder does no return • Transfer cylinder
• Solenoid valve of transfe
• Magnetic detector of tran
• Wiring
• PLC

8 The body is left without going down • Vertical cylinder of body
• Solenoid valve of vertical

manipulator

• Solenoid valve of vacuum
• Botton magnetic detector

of body manipulator

• Wiring
• PLC

ODY SUPPLY

MPONENT BROKEN COMPONENT
nsing cylinder Magnetic detector of sensing cylinder

OFF Push-button (X1)

er cylinder Magnetic detector of transfer cylinder.
nsfer cylinder

manipulator Botton magnetic detector of vertical cylinder of bosy
l cylinder of body manipulator (X10)

m pads
r of vertical cylinder

3

STATION 1: BO

Nº FAULT SYNTHOM SUSPICIOUS COM

9 The horizontal cylinder of the body • Horizontal cylinder of the
manipulator does not go ahead and • Solenoid valve of horizon
leave the body in the initial position
manipulator
• Front magnetic detector o

cylinder of body manipula
• Wiring
• PLC

10 The horizontal cylinder does not go • Horizontal cylinder of bod
back • Solenoid valve of horizon

manipulator
• Rear magnetic detector o

cylinder of body manipula
• Wiring
• PLC

11 The vertical Cylinder of the body • Vertical cylinder of transf
manipulator does no go up and the • Solenoid valve of vertical
body crash against the rejector
manipulator
• Upper detector of vertica

manipulator
• Wirirng
• PLC

ODY SUPPLY

MPONENT BROKEN COMPONENT

e bosy manipulator Front magnetic detector of horizontal cylinder of
ntal cylinder of bosy body manipulator (X6)

of horizontal
ator

dy manipulator Rear magnetic detector of horizontal cylinder of
ntal cylinder of body body manipulator

of horizontal
ator.

fer manipulator. Upper detector of vertical cylinder of body
l cylinder of body manipulator (X7)

al cylinder of body

4

STATION 1: BO

Nº FAULT SYNTHOM SUSPICIOUS COM

12 The Led of the detector of feeder • Magnetic detector of man
cylinder does no light on • Wiring

13 The body is no transfered and the • Transfer Cylinder
vertical cylider goes down • Solenoid of transfer cylin

• Wiring
• PLC

14 The vacuum is no made at the pady • Vacuum pods solenoid v
• Wiring
• PLC

15 The hori zontal cylinder does no go • Horizontal cylinder of the
ahead • Solenoid valve of horizon

manipulator.

• Wiring
• PLC

ODY SUPPLY

MPONENT BROKEN COMPONENT
nipulator Detector wiring (X15)

nder Solenoid valves wiring (Y3-Y7)

valves Vacuum pods solenoid valves (Y4)

e body manipulator Solenoid valve of horizontal cylinder of body
ntal cylinder of body manipulator (Y1)

5

STATION 1: BO

Nº FAULT SYNTHOM SUSPICIOUS COM

16 The vertical cylinder of the body • Vertical cylinder of body
manipulator does no go up • Solenoid valve of vertical

manipulator
• Botton detector of vertica

manipulator
• Wiring
• PLC

ODY SUPPLY

MPON ENT BROKEN COMPONENT

manipulator Inputs wiring (X7-X10)
l cylinder of body

al cylinder of body

6

STATION 2: BEARING

Nº FAULT SYNTHOM SUSPICIOUS COM

1 The station can no be switched on • ON Push-button
• OFF Push- button
• Wiring

• PLC

2 The rotary manipulator does not • Rotary actuator
move until the lift platform • Solenoide valve of rotar
• Magnetic detector of su
• Magnetic detector of ro
• Wiring
• PLC

3 The grippers of rotary manipulator • Grippers
do not open • Solenoid valve of grippe
• Magnetic switch of rotar
• Wiring
• PLC

The microswitch does provide any • Microswitch
4 signal when the bearing is there • Wiring
• PLC

G SUPPLY MODULE

MPONENT BROKEN COMPONENT

On Push Button (XO)

Magnetic detector of supplying cylinder (X5)

ry actuator
upplying cylinder
otary actuator

• Magnetic switch of rotary actuator (X11)

ers
ry actuator

• Microswitch (X6)

7

STATION 2: BEARING

Nº FAULT SYNTHOM SUSPICIOUS COM

5 The grippers of rotary manipulator • Grippers
do not close • Solenoid valve of grippe
• Magnetic switch of rotar
• Wiring
• PLC

6 The station can no be switched on • ON Push-button
• OFF Push- button
• Wiring
• PLC

7 The potentiometer is measuring • Potentiometer
wrongly the height of the bearing • Wiring
• PLC

8 The potentiometer is measuring • Potentiomete r
wrongly the height of the bearing • Wiring
• PLC

G SUPPLY MODULE

MPONENT BROKEN COMPONENT

Magnetic switch of rotary actuator (X11)

ers
ry actuator

OFF Push-button (X1)

Potentiometer (Analog input)
Potentiometer (Analog input)

8

STATION 2: BEARING

Nº FAULT SYNTHOM SUSPICIOUS COM

9 The station can not be switched in • Selector step-automatic
to the step mode • Wiring
• PLC

• Gripper solenoide valve

10 The grippers of the manipulator • Bottom magnetic switch

open before they should and crash manipulator

against the bearing • Wiring

• PLC

• Solenoide valve of rotar

11 The manipulator turns before it lifts manipulator

• Upper magnetic detecto

manipulator

• Wirirng

• PLC

12 The Led of the detector of lift • Magnetic detector of lift
cylinder does not light on • Wiring
• PLC

G SUPPLY MODULE

MPONENT BROKEN COMPONENT

c • Selector step-automatic (X2)

e • Bottom magnetic switch of the manipulator
h of the (X13)

ry actuator of the
Upper magnetic detector of the manipulator (X1)

or of the

t cylinder

Detector wiring (X12)

9

STATION 2: BEARING

G SUPPLY MODULE

10

STATION 3: HYDRAUL

Nº FAULT SYNTHOM SUSPICIOUS COMPON

1 The protection cover does not • Protector cylinder
go up • Solenoid valve of protecto
• Upper magnetic detector

cylinder

• Wiring
• PLC

2 The body transfer manipulator • Rotary actuator
does not turn • Solenoide valve of rotary
• Vacuum switch detector
• Magnetic detector of trans
• Magnetic detector of rotar
• Wiring
• PLC

3 The protection cover does not • Protection cover cylinder.
go down • Solenoid valve of protecti
• Back Magnetic switch of e

transfer cylinder
• Wiring
• PLC