Station Operating Procedure

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This procedure explains how to start up a station that is currently locked out and place it in automatic cycle mode.

PROCEDURE:

1. Check that the Rod Lock Bypass Valve on the Air Preparation Package is in the closed position. The valve is closed when it is perpendicular to the pipe.
   
2. Remove the lockout from the Main Air Disconnect valve and pull the red handle out to turn the air on.
   
3. Remove the lockout from the Main Power Disconnect for the Operation that you are currently in.
   
4. Push the Main Power Disconnect up into the “ON” Position.
   
5. Check to make sure all station doors are closed. This can be done visually and can be checked electrically from the Prepare Screens.
   
6. Go to the HMI and pull out the Emergency Stop pushbutton. The Emergency Stop pushbutton will be continuously lit if it is still pushed in.
   
7. Turn the Mode Selector Switch to the MANUAL position.
   
8. Push the POWER ON pushbutton and wait until the flashing light turns solid.
   
9. Confirm the air pressure is at 50 to 60 PSI on the Machine Air Pressure Controller to the air manifold.
   
10. From any screen on the HMI, push the (K1) Diagnosis key to bring up the Alarm Screen.
    
11. Next, push the FAULT RESET pushbutton until all faults are cleared. Any fault conditions that do not clear must be corrected before continuing.
    
12. Verify that the station is in its “Home" position. This can be done in a couple of ways. The first way is to see if the green RETURN HOME pushbutton is continuously lit. The other way is to look at the Home block on the control screen to see if it is green and says Home.
    
    If the station is not in its home position, push and hold the RETURN HOME pushbutton until it stops flashing. The RETURN HOME pushbutton will slowly flash as the machine homes itself. When the machine is homed, the RETURN HOME pushbutton stops flashing and remains lit.
    
    The station can only be homed when in Manual Mode.
    
13. Turn the Mode Selector Switch to the AUTO position.
    
14. Push and momentarily hold down the CYCLE START pushbutton. Once the CYCLE START pushbutton is released, the Machine enters Auto Cycle. Check that the Mode block in the upper left corner of the HMI is green and in Auto.
    
    The CYCLE START pushbutton will flash slowly when the Machine is ready to Start Cycle. It will flash quickly when the Machine is going to stop at the end of the current cycle.
    
    CYCLE START cannot be initiated unless the station conveyors are running.