2017 Wheel Aligner / Headlamp Aimer Operation & Maintenance Manual Safety Fori Automation Version 1.2 4/21/2017
SECTION 1.0 SAFETY These Safety Requirements Must Be Read And Understood By All Machine Operators, Supervisors And Service (Maintenance) Personnel Prior To Operating Or Servicing The Equipment. Any machine, if operated or serviced improperly, can be dangerous. All personnel operating the equipment must be thoroughly instructed in its safe operation. Failure to do so can result in serious injury. The following instructions must always be followed in addition to all normal safety practices. Although the procedures in this manual have proven safe in use, Fori Automation INC. assumes no responsibility for personal injury or damage to equipment resulting from their application. It is not possible to cover all safety conditions in this manual, therefore, always be alert and work safely. 1.1 Laser Warnings As with any laser: Eye damage may occur. Don t look directly at it. Safety Fori Automation Version 1.2 Page 1
1.2 Personal Safety Personal safety must be the primary concern for all personnel working in an industrial environment. Industrial machinery is capable of causing serious injury or death when operated improperly. Description Personal Protection Wear proper eye protection to reduce the risk of eye injury. Wear proper eye protector when exposed to eye or face hazards that include flying particles, molten metals, liquids, chemicals, acid or caustic liquids, chemical gases or vapors, or potentially hazardous light radiation. Graphics Accidents occur when loose clothing or other personal articles become tangled in moving components of machinery. Loose or hanging clothes must be secured. Do not wear jewelry such as watches, rings, and necklaces around moving machinery. Only wear gloves when handling rough, sharp, or hot parts, or when exposed to chemicals Observe and follow warning signs and safety instructions at all times. Learn before working. Read and understand all instructions before setting up, operating, or servicing machinery. Safety Fori Automation Version 1.2 Page 2
1.3 Fundamental Safety References References in the safety and operating chapters must be considered by the plant maintenance team! Basic conditions for safe handling and the trouble free operation of the equipment requires the knowledge of the fundamental safety references and the safety regulations as outlined in the safety and operating chapters as well as the documentation (operating instructions) of the sub-suppliers. This maintenance chapter contains the most important maintenance criteria required to operate the equipment safely and trouble free. This maintenance chapter, in particular the safety references, are to be read and understood by all persons entrusted with the maintenance of the system / equipment. All work rules and regulations valid regarding accident prevention have to be considered! All work must take into account all legal and other obligatory regulations regarding environmental protection. 1.3.1 Symbol Reference Safety references in this manual are characterized as follows: Safety Fori Automation Version 1.2 Page 3
1.4 Obligation of the Plant Management The plant management and operators must comply with the following: To only allow persons work on the equipment who are familiar with the fundamental regulations regarding industrial safety and accident prevention. To insure that only fully trained personnel are assigned to work within the system / equipment area. To operate the equipment exclusively in safety-relevant and perfect condition. Safety awareness of the workers must be examined in regular intervals. 1.5 Obligations of the Personnel All persons who are assigned maintenance tasks on the system must commit themselves to the following before beginning to work. To consider the fundamental regulations of industrial safety and accident prevention. To read the safety and warning references in the safety and operating sections and to read the maintenance and documentation of the sub-suppliers. Problems of any kind, in particular problems with the safety devices or changes in the operation or function of the equipment must be announced immediately to the responsible person and / or manager. Safety Fori Automation Version 1.2 Page 4
1.6 Dangers in Handling the Equipment The equipment has been built according to the state of the art and the appreciative rules in terms of safety. Nevertheless dangers to life and limb can exist and the user or third parties must be fully aware and follow the guidelines set forth in this documentation when visiting or working within the assembly area. The System / Equipment is to be used: For the intended use. In safety relevant and perfect operating condition. Faults which can impair safety and / or security must be addressed and repaired immediately 1.7 Protection Equipment / Protection Devices Mortal danger exists if the safety / protection devices are bypassed! Bypassed protection devices do not offer protection in the case of danger. This can lead to fatal injuries of plant personnel and / or damage to the equipment or other capital equipment. Protection devices provided with the system cannot under any circumstances are changed, removed or bypassed in their function. Immediately notify the proper authority if any safety / protection device is found to be defective or non-operational. Stop the work in the affected area immediately. If the disassembly of a protection device is necessary for repairing then plant management can, in order to maintain production and at their discretion, implement additional safety procedures / steps that guarantee the operator s safety while the fault is being repaired. The equipment can only be operated if all safety devices are fully functional and operating. Safety Fori Automation Version 1.2 Page 5
1.8 Disconnect Switches Always use the control stop button(s) and/or the selector switches to stop the machine prior to pulling a disconnect. Never stand in front of a disconnect when shutting if off. Turn your head away and stand to the side of the disconnect. If you cannot stand to the side, turn and face away from the disconnect Arc Flash: An arc flash is caused by a reduction of the insulation or isolation distance between energized components. This could be caused by a tool being inserted or dropped into a breaker or service area, or other elements that may be accidentally left behind that could compromise the distance between energized components. Often incidents occur when a worker mistakenly fails to insure that the equipment has been properly de-energized. An arc flash event can cause serious equipment damage and render the equipment no longer usable causing a disruption of a facilities operation for hours or days depending upon the equipment, its age and how quickly service can be restored. The explosion can also bend and distort pieces of the equipment leaving it unsuitable for service as well as causing injury to those near the explosion. The heat from the arc itself can cause severe burns up to 10ft. / 3.3m away. Safety Fori Automation Version 1.2 Page 6
Danger of injury for maintenance personnel can be minimized with contents of the following defaults. Allow only trained and qualified personnel to work on the equipment. 1.9 Welding / Grinding Before welding or burning in the area, the environment has to be cleaned and free from dust and inflammable materials. All surrounding equipment / material must be covered 1.10 Pneumatics / Hydraulics Danger by compressed air / hydraulic oil! The components of compressed air and / or hydraulic system are at high pressure. Under high pressure withdrawing compressed air or spraying hydraulic oil can lead to heavy injuries. 1. Work on hydraulic / pneumatic mechanisms can only be performed by specialists with knowledge and experience in hydraulic / pneumatics. Consideration must be given to the relevant safety regulations. 2. All lines, hoses and screw connections must be checked regularly for leakages and outwardly recognizable damage. Any damage must be repaired immediately. 3. Relieve all pressure on standing components before opening any hose and / or component. Always follow the data in the component manufacturer s documentation. 4. Remember that shutting off the power source, there can be residual energy stored in some components. Only open system sections and hoses / pipes after verifying all residual energy has been relieved. Hydraulic and air supply lines should only be serviced by qualified and trained personnel. Connections, length and quality of the hose lines must correspond to the requirements. Safety Fori Automation Version 1.2 Page 7
1.11 Safety Overview Always know the location and purpose of every safety device on the machine. Check daily at the beginning of each shift to ensure all the safeties are operating. Always report any unsafe condition, defect or irregularity in the machine to your supervisor and/or safety department immediately for correction. Always know the location of the first aid facilities. Report all injuries regardless of the severity of the injury to supervisor immediately. Always practice fire prevention at all times. Know where the fire extinguishers are located in your area. Always use the proper hand tool for repairs. Do not use makeshift or substitute hand tools. Use a tool box or tool belt. Do not carry hand tools, especially those with points and sharp edges in pockets or under trouser belts. Never touch bare wires or terminal if there is the slightest doubt about whether or not they are energized. Proper lockout procedures must always be followed. 1.12 General Safety Guideline Always observe federal, province and plant power lock out standards. Shut off and lockout the power when making any adjustment or repair that requires placing yourself inside the machine's area. Always secure loose clothing, neckties and long hair. Remove items such as rings, necklaces, bracelets and wristwatches to avoid engagement with moving parts. Wear medical alert jewelry with caution. Always wear OSHA / ANSI approved eye protection when servicing the machine. Always keep the floor around your machine clean and free of oil, grease, debris, nonessential materials and other obstructions. Always observe and follow warning signs and safety instructions. 1.13 Safety Guards / Gates Always replace guards after servicing. Always use extreme care and caution when servicing any item inside a guard. Never operate a machine with a safety guard removed. Never allow a guard to be removed by anyone other than authorized service personnel. Never override a safety interlock. Safety Fori Automation Version 1.2 Page 8
1.14 Jammed Parts Hazard Always watch for metal splinters that can cause cuts and puncture wounds. They should only be removed with the proper tools. Always be careful in handling components before and after removal to avoid cuts. Always remember clearing a jammed part may result in sudden movement. Use extreme caution or injury could result. Never attempt to remove a jammed part before turning power, hydraulics and air off. Never attempt to clear blockages of material with metal rods. 1.15 Operating Safety Guidelines Always use extreme caution when manually operating solenoid valves and limit valves. This practice can cause dangerous, unexpected machine movements. Always remember machine guarding is designed to protect against all pinch points (areas where a moving machine component could cause a hazardous pinching condition). Report any observed pinch point to your supervisor and/or safety department so that this unsafe condition can be corrected immediately. Always ensure that the operator work areas are kept clean. Do not work on slippery floors and surfaces. Remove hazardous obstacles Always use extreme caution when manually operating solenoid valves and limit valves. This practice can cause dangerous, unexpected machine movements. Always remember machine guarding is designed to protect against all pinch points (areas where a moving machine component could cause a hazardous pinching condition). Report any observed pinch point to your supervisor and/or safety department so that this unsafe condition can be corrected immediately. Always ensure that the operator work areas are kept clean. Do not work on slippery floors and surfaces. Remove hazardous obstacles. Always stop the equipment by pressing the E-Stop button and then the Power Off palm button before removing a part, tooling tray, batteries or cleaning any exterior of the cart. Always stop the cart completely by disengaging the appropriate electrical and air services before performing any service or maintenance. Always read and observe all signs posted on or near the system. Replace signs that have become illegible. Never place hands / feet between the rail plate and drive wheel until the cart is shut down. Never climb over the equipment at any point. Never reach over or around a safety guard. It is there to protect personnel against bodily injury. Never touch or attempt to stop moving carts with your hands or makeshift devices. Safety Fori Automation Version 1.2 Page 9
1.16 Electrical Guidelines Always be sure to have an up-to-date set of appropriate electrical drawings before troubleshooting or servicing a cart. Always remove metal items such as rings, metal necklaces, watches and jewelry. They are electrical hazards. Medical alert jewelry and glasses with a metal frame should be worn with caution. Always check for voltage before commencing work. Circuits may be powered from multiple sources. Always verify equipment is properly grounded. Always use electrically insulated tools, electrical safety shoes and other shock avoidance techniques. Do not allow your body to complete an electrical circuit. Always turn off main power when servicing any electrical device. Always allow only properly trained personnel access to any electrical enclosure. Never alter circuits unless authorized to do so by the manufacturer. Never alter over-current protective devices 1.17 Pneumatic Guidelines When Equipped Always be sure to have an up-to-date set of appropriate pneumatic circuit drawings before troubleshooting or servicing a station. Always shut off air supply, relieve pneumatic pressure and lock the pneumatic lockout valve in the "OFF" position prior to repairs or maintenance. Always ensure that the compressed air supply has been isolated from the equipment, at the main air supply valve if necessary. Always when a repair is completed, make sure all fittings and connections have been tightened before turning on the air and ensure other personnel are clear of the machine. Never perform any maintenance or repair at a station until the air lock out and exhaust valve have been shut off. This turns off the incoming air and vents the system air. Safety Fori Automation Version 1.2 Page 10
1.18 Safety Devices Basic Maintenance Power Down Procedure Device Location Description Graphics Emergency Stop Push-button PanelView processor, Operator Run Bar, & Steering Wheel Leveler Stand Red, mushroom shaped palm button, Stops the cycle and drops power from the master relay Main Disconnect Main Control Panel Pull Lever, Removes power to the equipment, except the PLC Safety Fori Automation Version 1.2 Page 11
1.19 Power Up / Power Down Procedure Follow all prevailing L.O.T.O Procedures. ECPL Placard is Located on the Main Panel Door. Follow all Plant Safety Procedures. 1.19.1 Powering up the wheel aligner from a complete power down state Power Up Procedure from Complete Power Down State Description Graphics 1. Move the main disconnect to the ON position. 2. Turn the secondary disconnect to the on position. 3. Verify the air is unlocked / open. 4. 5. Wait for all devices to boot / start up. The production screens will be displayed when this is complete. Verify there are no faults on the HMI screen. 6. Press the Power On button on the Panelview Safety Fori Automation Version 1.2 Page 12
1.19.2 Complete Power Down Procedure Description Complete Power Down Procedure 1. Place the system in a No Mode state by pressing Reset Mode on the PLC Screen. Graphics 2. Perform normal Windows shutdown on both the headlamp aimer and wheel aligner computers. 3. On the main panel turn off the main disconnect. Pull the disconnect to the down position. Safety Fori Automation Version 1.2 Page 13
Description Basic Maintenance Power Down Procedure 1. Place the system in a No Mode state by pressing Reset Mode on the PLC Screen. Graphics 2. Perform normal Windows shutdown on both the headlamp aimer and wheel aligner computers. 3. On the main panel turn off the main disconnect. Pull the disconnect to the down position. Power is still supplied to th PLC and Panel lighting. Yellow or Yellow Trace Wiring is NOT De-Energized by this disconnect Safety Fori Automation Version 1.2 Page 14
1.20 Lockouts Safety Fori Automation Version 1.2 Page 15