TS800III Power-On Picker In/Out Error Repair Case

Note: The following content is developed based on the English/code error interpretation and distinguishes between 'possible causes' and 'confirmed conclusions'. Do not present possible causes as confirmed root causes.

1. Fault symptom

Field record for TS800III:

• Power-on picker in/out error

2. What the error message means

At startup, the Picker (suction cup/pick-and-place mechanism) reports an in/out error, indicating pneumatic or mechanical motion abnormality.

• Associated module (inferred): motion / Z axis (this classification is based on the alarm text and can be revised according to actual measurements).

3. Possible causes (not conclusions)

The following are possible causes and must not be presented as confirmed fault sources without verification:

1. Possible: Insufficient or fluctuating air source pressure
2. Possible: Incorrectly set or faulty pressure regulator valve
3. Possible: Aged cylinder seals causing internal leakage
4. Possible: Position sensor sensing failure or misalignment
5. Possible: Solenoid valve coil damage or sticking
6. Possible: Tubing bent, blocked, or leaking
7. Possible: Mechanical components binding or lack of lubrication
8. Possible: Poor contact in control signal wiring

4. Diagnostic direction

1. 1. Use a pressure gauge to measure if the main air source pressure is within the standard range (typically 0.5–0.7 MPa).
2. 2. Check if the output pressure of the pressure reducing valve matches equipment requirements.
3. 3. Manually test the Picker cylinder for smooth operation and abnormal noise.
4. 4. Check the cylinder inlet/outlet seals and tubing for leaks.
5. 5. Inspect the position sensor mounting and output signal.
6. 6. Check the solenoid valve coil resistance and confirm proper power supply.
7. 7. Clean or replace the pneumatic filter and water-oil separator.
8. 8. Restart the equipment and observe if the fault recurs and specific alarm code.

• Repair direction: Prioritize checking air source pressure stability and pressure reducing valve settings, then inspect tubing seals and solenoid valve operation. If still undetermined, isolate the cylinder and valve group for segment testing.

5. What was checked (Engineer actions)

• Air pressure, adjusted air pressure

6. Confirmed root cause (traceability)

The repair order and analysis have not been refined into a single traceable root cause (or multiple parallel interpretations exist). This section is not written as a definitive conclusion—the following 'possible causes' are merely common inspection directions, not the sole on-site answer.

• Uncertainty: The engineer resolved the issue only by adjusting air pressure, without in-depth inspection of specific components (e.g., cylinder, sensor, solenoid valve). Therefore, the root cause may be low air pressure or regulator drift, but intermittent interference from sensors or control loops cannot be ruled out.
• Writing perspective: Start with the Picker error, then troubleshoot common pneumatic system faults / impact of abnormal air source pressure on CTP pick-and-place mechanism / how to quickly diagnose pneumatic circuit leaks and blockages / key points of sensor signal and pneumatic actuator coordination / maintenance suggestion: regularly check the regulator and oil-water separator.

7. Repair solution (summary)

(No parts replacement recorded.)

• Final treatment summary: Air pressure, adjusted air pressure

8. Final test result and recheck

• Air pressure, adjusted air pressure

9. On-site image index