PK-3 stops mid-cycle saying the clamp never closed

Inspect

• Ask the operator what changed3 minhint
• Read the HMI alarm banner2 min
• Read the sequence step display3 minhint
• Read the alarm and event history4 min
• Check what work has been done on this machine4 min
• Check the cycle time trend3 minhint
• Listen along the manifold and actuators for leaks5 minhint
• Inspect the filter, regulator and lubricator5 minhint
• Check the dump valve and soft-start4 min
• Watch the clamp cylinder through a cycle4 minhint
• Watch the pick head through a cycle4 minhint
• Inspect the clamp switch mounting and cable5 minhint
• Inspect the suction cups6 minrequires zero energy
• Check the guard interlock3 min
• Check the e-stop circuit3 min

Measure

• Measure supply pressure at the drop3 min
• Measure regulated pressure while the machine cycles5 minhint
• Measure vacuum at the gripper4 min
• Check the vacuum switch output4 min
• Check the PLC clamp extend output4 minhint
• Check the PLC clamp extended input4 min
• Check the clamp switch output at the switch5 minhint
• Measure voltage at the clamp valve pilot5 minhint
• Measure the clamp coil resistance6 minrequires zero energy

Operate

• Press the clamp valve manual override4 minhint
• Jog the clamp from the operator panel3 min
• Reset the alarm and restart the cycle2 min

Safety

• Lock out power, lock the air isolation and bleed down stored pressure10 minhint
• Remove locks, re-pressurise and restore power6 min

Repair

• Replace the clamp extended switch12 minrequires zero energy
• Reposition the clamp extended switch on the barrel8 minrequires zero energy
• Rebuild the clamp cylinder with a seal kit40 minrequires zero energy
• Replace the filter element and service the bowl15 minrequires zero energy
• Adjust the regulator setting5 min
• Replace the clamp valve solenoid coil14 minrequires zero energy
• Replace the clamp valve body25 minrequires zero energy
• Replace the suction cups12 minrequires zero energy

Verify

• Run a full cycle and watch it complete8 minhint