Bosch ATMO Station, Assembly

Page 1: ...tation 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH EPA assembly line DaeP FA3 STATIONS 60 61 62 Leak Test Dae Assy Dae Flow Test System No 0843 195 960 Station No 0843 195 961 Order No M 3000314 190 Year of construction 2013 Customer DaeP Robert Bosch Spain Madrid Factory S A PA ATMO2 Automations technical Md Hnos García No...

Page 2: ... 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Used symbols These warning signs are printed beside all operational safety instructions contained in this manual and where necessary also on machine areas where...

Page 3: ...Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Classification of the signal words in the safety directions Signal word Use Danger Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Warning Indicates a potentially hazardous situation which if not avoided could result ...

Page 4: ... Station 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Ro...

Page 5: ...4 Station 25 Station 26 Station 27 Station 28 Station 29 Station 30 Station 31 Station 32 Station 33 Station 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230...

Page 6: ...0 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Contents Intended use 2 Operation modes 2 Residual risks 3 Safety devic...

Page 7: ...ot listed in the order confirmation as well as operating with dangerous or hazardous substances is contrary to the regulations For damage resulting from use contrary to regulations the operator assumes liability Notice Installation startup and maintenance must be carried out as described in this manual This is also part of a Intended use of the machine according to the regulations Non permissible ...

Page 8: ...er or third parties and impairments to the machine and other property can still be caused The following residual risks remain despite all precautions Notice Installation startup and maintenance must be carried out as described in this manual This is also part of a Intended use of the machine according to the regulations DANGER In manual mode it is possible to bypass certain guard doors by way of t...

Page 9: ...on 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Intended use Residual risks WARNING Crushing hazard Keep your hands out of the area between the workpiece supports Keep yo...

Page 10: ...4 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Safety devices Installed safety devices The system is equipped with the following safety devices for the protection of the operating personnel the environment and the system No Description 1 Main switch lockable 2 EMERGENCY STOP switch at operating panel control cabinet system 3 Automatic station enclosed with safety covers in the work are...

Page 11: ...ting personnel Safety measures to be applicated No Description 1 Safety gloves 2 Safety shoes Duties of the owner user Necessary safety measures DANGER Danger of accident The owner user is obliged to ensure that the machine is kept and operated in perfect condition Danger zones occurring from a combination of machines must be rendered safe by the owner user Determine and instruct responsible perso...

Page 12: ...person Notes 1 Do not climb on or into the machine during operation 2 Do not remove or change protection covers 3 Immediately inform the responsible superior about troubles or damage at the machine Do not continue production before all problems are eliminated 4 Observe all safety and danger symbols and information on the machine and keep them in a readable condition 5 Before carrying out work at t...

Page 13: ...tion 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Information for operation and work at the machine Electrical electronic installations Note Work on electrical parts subassemblies must only be carried out by a skilled electrician in accordance with the rules of electrical engineering The 5 safety rules 1 Switch off main swit...

Page 14: ...tation 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Information for operation and work at the machine Cleaning Attention Shut down machine before cleaning work and secure against unintended startup The machine is not i...

Page 15: ...tion 24 Station 25 Station 26 Station 27 Station 28 Station 29 Station 30 Station 31 Station 32 Station 33 Station 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Stati...

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Page 17: ...act scope of supply and compare it with the delivery note The dimensions and weights are listed on the delivery papers Check for completeness Compare the entire scope of supply with the order and the shipping note Missing parts or damage as a consequence of faulty packaging or transport must be reported immediately to the carrier and the supplier Packaging The way of transport decides upon the kin...

Page 18: ...n 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Transport Preparation d Properly disconnect the machine from all energy supplies and links to other machines or devices d Remove all tools from the machine and pack them suitably d Remove all fastening brackets d Secure any moving and non fastened parts d Close any open ends of lines d Pump...

Page 19: ... load bearing capacity d Do not put the machine inclined onto the disc type feet The disc type feet will bend and the machine will tip over danger of accident d Lifting gear may be operated by authorized personnel only d Observe the accident prevention regulations DANGER Danger of injury Use suitable lifting devices and fastening means Moving loads can tip drop and trap personnel When lifting the ...

Page 20: ...of the machine on the forks stability have to be taken into consideration Transport by fork lift truck D When lifting the machine ensure that the center of gravity of the machine is between the forks of the truck or low lift platform truck The position of the center of gravity must be determined during unloading and transportation by personnel who have received safety instruction D If an unstable ...

Page 21: ...tation 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Transport Unloading the machine off the pallet Run the fork lift truck under the cross beams of the base frame and lift up the machine The fork lift truck must have sufficient load bearing capacity and a sufficient fork length Pos Measure 1 Unpack the machine and check it for transport...

Page 22: ...n 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Installation and connection Notice Floor requirements For space requirements weights and load bearing capacity of floor see Chapter 3 Technical data Setting up It is recommended that the machine plant should be set up by the Bosch Service personnel Position the indiv...

Page 23: ...R Danger to life Mortal danger from electric voltage and other energies Before dismounting the machine disconnect it from any external energy supply The machine may only be dismounted by specialist personnel observing local safety regulations Appropriately package parts of the machine that could break drain liquids where necessary Waste disposal Protect the environment Dispose of problem substance...

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Page 25: ...n 29 Station 30 Station 31 Station 32 Station 33 Station 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3...

Page 26: ...tion 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH...

Page 27: ...ation 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Functional Description What is being proce...

Page 28: ...tion of function Leak Test Withdraw previous ECU and put a new one into the fixture 1 Data of the ECU Trace Label are being read by the installation via a scanner and being checked as to the right type and as to production progress If it is the right type processing is being started as the ECU is being lowered In this position the ECU is being fixed and adapted via the sealing head Now test operat...

Page 29: ...escription of function Dae Assembly Withdraw previous ECU grip the DAE element and push it into the DAE fixture The DAE element is being held by means of vacuum 1 Insert a new ECU in the corresponding fixture 2 Data of the ECU Trace Label are being read by the installation via a scanner and being checked as to the right type and as to production progress If it is the right type processing is being...

Page 30: ...sch GmbH Description of function Dae flow Test Pick ECU from leak test fixture and insert in DAE mounting fixture 1 Data of the ECU Trace Label are being read by the installation via a scanner 2 and being checked as to the right type and as to production progress If it is the right type processing is being started as the ECU is being lowered In this position the ECU is being fixed and adapted via ...

Page 31: ...Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Technical data Connections Pneumatic connection 5 bar 0 5m Electrical connection 3x400 V 50 Hz also see type plate at control cabinet or wiring diagram i...

Page 32: ... Station 24 Station 25 Station 26 Station 27 Station 28 Station 29 Station 30 Station 31 Station 32 Station 33 Station 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 S...

Page 33: ...n 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bo...

Page 34: ...0 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Commissioning Prior to startup Take heed of the section Safety measures Prior to switching On the machine please ensure that the machine startup will not endanger ...

Page 35: ...n 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Commissioning Switching on the station starting the automatic procedure Condition The station must be duly connected and in technically perfect condition No interference failure may not exist Step Procedure Operating control element 1 D Observe safety instructions It...

Page 36: ...nd in step mode guards can be bridged with switches There is danger of being injured in case of unappropriate proceedings After work with bridged guards always pull out the key and ensure that it is not accessible for unauthorized personnel Automatic operation In this operating mode a cyclical process controlled operation is carried out Automatic operation can only be started from the basic positi...

Page 37: ...tion 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert...

Page 38: ... 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Operator terminal VCP20 OPERATOR INTERFACE The push buttons and operator console help the operator to set all pre conditions for startup to start the Machine The push butto...

Page 39: ...3_EN_PA ATMO2 Robert Bosch GmbH Operator terminal VCP20 SWITCHES OUTSIDE THE VCP20 Emergency switch Emergency Stop The emergency switches are wired witch 2 channels If you push the emergency switch the control relay is off and the switch is locked This will turn off the control power and the main air valve To unlock the e stop turn the switch clockwise Light button white Control on Turns the contr...

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Page 42: ... 31 Station 32 Station 33 Station 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960...

Page 43: ... 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH How to proceed for trouble shooting Preparations and notices How to p...

Page 44: ...mbH Trouble shooting Fault types The troubles within the station are distinguished as follows Warnings A fault message appears in the display The operation of the machine is continued Simple faults The operation of the machine is interrupted The operation is continued when having cleared the fault Enduring faults The operation of the machine is interrupted The fault cannot be eliminated by simple ...

Page 45: ...s Precondition Enduring faults or defects are only allowed to be cleared by skilled personnel with the corresponding training Heed the chapter Safety measures Kind of fault Notice for remedy Plug at proximity switch valves insert cards loose Determine the fault by diagnosis or PLC status Cables squeezed torn damaged Determine the fault by diagnosis or PLC status Proximity switch relaxed in the hol...

Page 46: ...n 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Cause of the fault Possible causes and remedies continued Kind of fault Notice for remedy Indication lamp does not light anymore Lamp t...

Page 47: ...ion 24 Station 25 Station 26 Station 27 Station 28 Station 29 Station 30 Station 31 Station 32 Station 33 Station 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Statio...

Page 48: ...ation 25 Station 26 Station 27 Station 28 Station 29 Station 30 Station 31 Station 32 Station 33 Station 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Sta...

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Page 50: ...n 24 Station 25 Station 26 Station 27 Station 28 Station 29 Station 30 Station 31 Station 32 Station 33 Station 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station ...

Page 51: ...n 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Documentation of sub supplied equipment See next page See separate file Lists o...

Page 52: ...4 Station 25 Station 26 Station 27 Station 28 Station 29 Station 30 Station 31 Station 32 Station 33 Station 34 Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230...

Page 53: ...Station 35 Station 36 Station 37 Station 38 Station 39 Station 40 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch G...

Page 54: ... the manufacurer instructions and the instruction manuals of the individual manufacturers when using bought in parts and sub supplied equipment Preparations D Only appoint skilled personnel D Switch the machine off in accordance with this operating manual and secure it against accidental re starting D Cordon off the maintenance area D Inform operating personnel and appoint a supervisior D Make ava...

Page 55: ...20 1000 2000 4000 1 Complete machine 1 1 General D Clean all machine areas Heed safety measures With suction air or cloth J 1 2 Safety devices D Check function of EMERGENCY STOP switch F D Check warning lamps for function F D Check protective covers for completeness and function F D Check guards and key switches for function F D Check two hand operating device for function F Clean J Check Change F...

Page 56: ... 1000 2000 4000 2 Control cabinet 2 1 Station control system D Check main switch for function F D Replace battery of PLC F D Replace filter mat for the plug in fan unit F 3 Operating panel D Check emergency stop button for function F D Check control lamps for function F D Sensor Clean active surfaces J 3 1 D Laser scanner Clean optics J 3 3 D Laser light barriers Clean optics J Clean J Check Chang...

Page 57: ...ance unit D Drain filter housing Clean filter and housing with b i t l th J D Clean filter housing and cartridge benzine or petroleum ether Housing must be J D Exchange filter Housing must be depressurized J D Drain and clean collecting filter depressurized J 4 2 Lines and connections D Check for untightness and leakages F D Check emergency ventilation for function F D Check pressure gauge F D Che...

Page 58: ...oning devices stops spacers Check if pieces are broken out check wear and tight seat F 6 Guides 6 1 D Ball guides ball bushes Y D Linear guides Y 7 Contactings 7 1 D Check if pieces are broken out check wear and tight seat F D Check tightness and seat of sealings F D Check contact pins F 8 Screw driver inserts 8 1 D Check if pieces are broken out check wear and tight seat F 9 Escorting hoses and c...

Page 59: ... Montaje y Maquinaria Especial Maintenance plan Sub suppliers Position Maintenance point Volume Value Maintenance interval in hours Note 16 80 320 1000 2000 4000 Note Measuring and test appliances must be checked in regular intervals 10 Subassemblies from sub suppliers 10 1 D CETA leak tester CETA 815 Heed separate operating instructions of manufacturers 10 2 D CETA flow tester FCO752 ...

Page 60: ...0 Station 50 Station 60 Station 70 Station 80 Station 90 Station 100 Station 110 Station 120 Station 130 Station 140 Station 150 Station 160 Station 170 Station 180 Station 190 Station 200 Station 210 Station 220 Station 230 Station 240 Station 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Trouble Shooting Pneumatic Failure 1 Check for set pressure ...

Page 61: ...n 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Trouble Shooting Periodic Inspection And Maintenance Chart Sl no Inspection area Inspection Unit Inspection method Judgement Standard Action Inspection frequency 1 Main air pressure gauge Pressure Visual Pressure 6 bar Adjust Daily 2 Air pressure gauge Pressure Visual Pressure 5 bar Adjust Daily 3 Air Filter Soiling Visual Ch...

Page 62: ... 250 Station 260 Station 270 M 3000314 190_0843 195 960 V0 0_0613_EN_PA ATMO2 Robert Bosch GmbH Trouble Shooting Maintenence Data Chart Pneumatics Device Period Action Pneumatic service unit Input pressure daily Check for 5 6 bar Air filter monthly Check for soiling Cleaning if necessary see manual of Bosch Water filter weekly Check water level Draining if necessary see manual of Bosch Pneumatics ...