Power Up From All Sources Off

Cell Power Up Notation

The following procedure covers the power up of the 2V13 Sub Floor Cross Member Cell when the cell has been completely powered down. This procedure provides full power up instruction for the cell and readies the cell for automatic mode of operation. The nature of the cell's "Power Up Procedure" will be conditioned by the manner in which the previous cycling was terminated. In actual operation, some steps may only need to be verified.

Make sure the Pre-Start Check procedure has been performed!

Remove and clear any lockouts throughout the 2V13 Sub Floor Cross Member Cell. Follow procedures outlined in the Lockout / Tagout (LOTO) Placards posted on the Power Distribution Panel.

Follow all plant guidelines and regulations for start-up safety. Follow all safety warning labels posted on the equipment. Refer to the Lockout / Tagout (LOTO) placard for energy source locations. Failure to comply could result in severe personal injury or death, and/or equipment damage.

Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and/or damage to the equipment.

Step 1: ABB Tip Dresser

  • At each ABB Tip Dresser. place the rotary disconnect to the "ON" position.
ABB Tip Dresser Disconnect Switch

Step 2: Brauer Systemtechnik Cap Changers

  • At each Brauer Systemtechnik Cap Changer, rotate the disconnect switch to the "ON" position.
Brauer Systemtechnik Cap Changer Disconnect Switch

Step 3: Pedestal Weld Stands

  • At each Pedestal Weld Stand, rotate the black disconnect switch to the "ON" position on the Festo Panel.
  • At each Pedestal Weld Stand, rotate the E1 ABB disconnect switch to the "ON" position.
Pedestal Weld Stand Disconnect Switches

Step 4: Safety Gates

  • Before closing the safety gate, ensure there are no personnel within the cell performing maintenance, repairs or troubleshooting the equipment. Ensure all tools, carts, rags, etc. are removed from the work area.
  • After all personnel have exited the work area, close and latch the safety gate.
Safety Gate Closed and Latched

Step 5: Power Distribution Panel (PDP) Uninterrupted Circuits

  • If control power had been shut off, open the Power Distribution Panel (PDP) and rotate the uninterrupted power rotary switch to the "ON" position.
  • Close and latch the PDP door.
PDP E2 Uninterrupted Circuit Rotary Disconnect Switch

Step 6: Power Distribution Panel Main Disconnect

  • Power on the Power Distribution Panel (PDP) by placing the Main Electrical Disconnect switch to the "ON" position.
Main Electrical Disconnect Switch

Step 7: Weiss Variable Frequency Drive Controller

  • At each Weiss Variable Frequency Drive Controllers (VFD), place the electrical disconnect switch to the "ON" position.
Weiss VFD Electrical Disconnect Switch

Step 8: ABB IRC5 Robot Controller Single Cabinet

  • At each ABB IRC5 Robot Controller, Rotate the Main Power Selector Switch to the "ON" position.
ABB IRC5 Robot Controller Control Panel

Step 9: ABB Weld Controller

  • At each ABB Weld Controller, rotate the disconnect switch to the "ON" position.
ABB Weld Controller

Step 10: Mig Welder Disconnects

  • Place the two (2) Mig Welder Disconnect Switches to the "ON" position.
Mig Welder Controller Disconnect Switches

Step 11: Mig Weld Controllers

  • At each Mig Weld Controller, place the Main Switch to the "ON" position.
Mig Weld Controller

Step 12: Dust Collector

  • Place the disconnect in the "ON" position.
  • Place the On/Off button in the "ON" position.
  • Ensure that the Emergency Stop (E-Stop) button is reset.
Dust Collector Controls

Step 13: Hydraulic Tank

At the Hydraulic Tank:

  • Place the disconnect switch in the "ON" position.
  • Place the Supply to Pump Ball Valve in the "OPEN" position.
  • Place the Pressure Shut-Off Ball Valve in the "OPEN" position.
  • Press the On pushbutton.
  • Press the Run pushbutton and verify that pressure is showing at the pressure gauge.
Hydraulic Tank Disconnect Switch
Supply to Pump Ball Valve
Pressure Shut-Off Ball Valve
Hydraulic Tank Control Panel

Step 14: Main Air Distribution Panel

  • At the Main Air Distribution Panel, rotate the safety lockout valve to the "OPEN" position.
    • On the pressure regulator unit, verify the incoming air is set to the safe, required operating pressure.
Main Air Distribution Panel

Step 15: Ancillary Air

  • At the Station Level Air Distribution Panels (or Ancillary Air Panels) Place the Safety Lockout Valve to the "OPEN" position.
    • On the pressure regulator or digital pressure switch, verify the incoming air is set to the safe, required operating pressure
    • Ancillary air panels are located at many locations, including tooling and robots.
Ancillary Air Lockout
Robot Air Lockout

Step 16: Water System

  • Place the Plant Water In Ball Valve to the "OPEN" position.
  • Place the To Header Ball Valve to the "OPEN" position.
  • Place the From Header Ball Valve to the "OPEN" position.
  • Place the Plant Water Out Ball Valve to the "OPEN" position.
  • On each ABB Weld Controller, place the To Header and From Header Ball Valves to the "OPEN" position.
Main Water Ball Valves
ABB Weld Controller Water Ball Valves

Step 17: Main Operator Panel (MOP) - Alarm Screen

  • At the Main Operator Panel (MOP), view the Alarm Screen for any faults that have occurred with the 2V13 Sub Floor Cross Member Cell.
  • If any faults have occurred, locate and rectify the fault.
  • Press the "Reset Alarm&qout; button in the top-left corner of the screen to clear the faults from the Alarm Screen. If the Alarm Screen indicates there are still faults within the cell, continue rectifying the faults until all faults have been corrected.
Alarm Screen

Step 18: Main Operator Panel (MOP) - Start Auto Button

  • After all faults have been corrected, place the two-position selector switch into the "AUTO" position.
  • Press and hold the "Start auto" pushbutton for four (4) seconds. The alarm horn will sound alerting personnel that the 2V13 Sub Floor Cross Member Cell is entering Automatic Mode of Operation.
MOP with Control Panel