26002

Check System Air Pressure

Navigate to HMI > Diagnostics > PLC > I/O and verify pneumatic pressure reading is within specification (typically 6-8 bar). Check machine data MD11210 for minimum pressure threshold.

Ensure machine is in safe state before checking pneumatic systems

Inspect Gripper Air Lines

Examine pneumatic lines to gripper cylinders for leaks, kinks, or disconnections. Check quick-disconnect fittings and verify proper routing through cable chains.

Use soapy water to detect small air leaks that may not be audible

Test Gripper Valve Operation

In HMI > Commissioning > Actuating drive, manually activate gripper open/close outputs and listen for valve switching. Verify valve coil resistance and check for proper 24VDC supply.

Valve response time should be immediate - delayed switching indicates internal valve wear

Check Sensor Status in PLC

Navigate to HMI > Diagnostics > PLC > Inputs and monitor gripper position sensor inputs (typically I0.x for open/closed positions). Verify sensors change state during manual gripper operation.

Sensor inputs should be mutually exclusive - both on or both off indicates sensor malfunction

Verify Sensor Positioning

Check proximity sensor mounting distance (typically 2-4mm gap) and ensure sensors are not loose or misaligned. Clean sensor faces of metal chips or coolant residue.

Use non-metallic tools when adjusting inductive proximity sensors

Test Sensor Electrical Continuity

Measure sensor supply voltage (24VDC) and output signal with multimeter. Replace sensors showing incorrect voltage levels or intermittent operation.

LED indicators on sensors should illuminate when target is detected - no LED indicates sensor failure

Inspect Gripper Mechanism

Visually examine gripper jaws for chips, coolant buildup, or damaged surfaces. Check for proper jaw alignment and smooth manual operation when air pressure is removed.

Lock out air supply and verify zero energy state before manual manipulation

Clean and Lubricate Components

Remove debris from gripper mechanism using compressed air and appropriate solvents. Apply light machine oil to pivot points and sliding surfaces per manufacturer specifications.

Use way oil rather than general lubricants for better chip resistance and longevity

Check Gripper Jaw Wear

Measure gripper jaw thickness and compare to specifications in machine documentation. Verify jaw faces are parallel and not excessively worn or damaged.

Uneven jaw wear often indicates spindle taper problems or improper tool holder maintenance

Verify Gripper Timeout Parameters

Check HMI > Parameters > Machine Data and verify MD11220 (gripper timeout) is set appropriately (typically 2-5 seconds). Compare with OEM documentation for correct values.

Timeout too short causes false alarms, too long delays production and masks real problems

Confirm I/O Signal Assignment

Navigate to HMI > Commissioning > I/O and verify gripper input/output assignments match PLC program and electrical drawings. Check MD11200-11219 for proper I/O mapping.

Incorrect I/O assignments can cause unexpected machine movements

Reset and Test Configuration

After parameter changes, perform control restart and test gripper operation in single block mode. Monitor alarm buffer for any recurring issues.

Always backup machine data before making parameter changes using HMI archive function