UNITED CPC 12000, Operation And Service Manual

Page 1: ...CPC 12000 Operation and Service Manual ...

Page 2: ...ng Power 7 4 3 Manual Operation 8 4 3 1 Jog Mode 8 4 3 2 Positioning the Turret 8 Figure 4 3 Jog Controls 8 4 3 3 Barrel Rotation 8 4 3 4 Barrels 9 4 3 5 Opening Barrels 9 Figure 4 4 Lid Cam Lock 9 4 3 6 Heat Precaution 9 4 3 7 Loading Barrels 10 4 3 8 Material Handling 10 Figure 4 5 Error Bookmark not defined 4 3 9 Closing Barrels Error Bookmark not defined 4 3 10 Setting RPM and Cycle Time 11 4 ...

Page 3: ...25 5 1 3 System Tools 25 5 1 4 Password Reset 25 5 1 5 I O Meter 25 5 1 6 Help Menu 26 5 2 Maintenance and Repair 27 5 2 1 Preventative Maintenance Schedule 28 5 2 2 Turret Drive Assembly 28 5 3 3 Adjusting Main Drive Belt 29 5 3 4 Replacing Main Drive Belt 29 5 3 5 Barrel Drive Assembly 30 5 3 6 Inspection 30 5 3 7 Drive Component Removal 31 5 3 8 Adjusting Barrel Chain 32 5 3 9 Bearings 34 5 3 1...

Page 4: ...Page 4 6 4 Desired RPM Not Reached 43 6 5 Barrels Leak 43 6 6 Turret Slips During Loading 44 7 0 Appendix 45 7 1 Handling Compounds 45 ...

Page 5: ...UTIONS LLC immediately 1 2 Selecting Equipment Location The equipment should be conveniently located to the flow of parts The CPC System will require the appropriate electrical power an air line with a minimum of 100 psi a water supply with a minimum of 20 psi and a drain located near the machine If a sump system and water recycling unit is to be used separate power must be provided for those unit...

Page 6: ...60VAC 60Hz but can be ordered in 400VAC 50Hz configuration Applying improper voltage will result in severe damage to the system and will void the warranty Inspect the motor and AC drive to confirm the rated voltage 3 3 Leveling Once the electrical connections have been made it will be necessary to level the unit Do not skip this step of the setup process This unit uses a fluid mass of media to fin...

Page 7: ...nts is necessary for safe and trouble free operation Please refer this figure displaying the various components of the CPC 4 2 Applying Power Before applying power ensure that the electrical control box is closed and secure and that there are no obvious exposed electrical conductors Check that water and air supplies are turned on and are at full pressure To apply power to the CPC12000 turn the saf...

Page 8: ...r door is open the jog and material handling controls will be activated and the operator can safely position the turret for loading and unloading 4 3 2 Positioning the Turret When the shutter door is open the turret may be jogged utilizing the jog button in conjunction with the JOG FWD or JOG REV The Safety Jog Button is located on the right side of the cabinet below the E Stop The JOG FWD and JOG...

Page 9: ...position To open pull the lock pin and hold while rotating the cam handle towards the back of the machine using the lid opening tool provided Refer to Figure 3 3 for component definition WARNING Barrels may become pressurized Some processes can generate super heated steam in as little as 10 minutes Open slowly use caution 4 3 6 Heat Precaution The processes used in the CPC may generate a considera...

Page 10: ...he operator If a process must be continually run that generates an excessive amount of heat raise the water level within the barrel to an inch or more above the media level to help aid in cooling the media On extremely long cycle times 60 minutes or more incorporate what is known as a rinse and recharge into the process In this manner half way through the cycle the system would be stopped and the ...

Page 11: ...latch 4 Visually inspect that all locks are secure and proceed to next barrel To conserve time unload and load each barrel independently Review section on Opening Barrels if necessary 5 If using only one or two barrels use opposing barrels This will balance the turret Approximate barrel weights should be within ten percent of each other 6 Operate the machine with all lids in place even if the barr...

Page 12: ... properly locked 2 Check turret speed 3 Check preset timer 4 Check the desired direction of turret rotation Forward should be used unless specifically stated otherwise on the Process Report 5 Clear the door area and press START The screen will change to a Door Closing Warning If it becomes necessary to stop the start up process use the OPEN DOOR touch key to reverse the door operation and return t...

Page 13: ...ing the first barrel to be unloaded into position Open the barrels as described in 4 3 5 Opening Barrels WARNING Refer to the 4 3 6 Heat Precaution for important safety information 3 Start the Material Handling and Parts Media Rinse Systems as described in 4 3 8 Material Handling The Rinse Controls are located in the lower left hand corner of the screen 4 Empty the barrel by rotating the barrel an...

Page 14: ...ver use the same scooper for more than one compound Doing so will contaminate both products and may result in inferior finishing Keep finishing media as clean and uncontaminated as possible Avoid inadvertently mixing media together If the work pieces are subject to rust a rustproof treatment must be used 4 4 Auto Operation using the CPC Interface In addition to the MAINTENANCE and SYSTEM HELP this...

Page 15: ...outlined with dotted black line By selecting an area the operator will begin any interview asking basic process parameters After entering into any of the process parameter screens data can be input or edited by using the keypad or keyboard within that screen Once data is entered ENTER must be used to save any changes PRESET PROCESSES FIGURE 4 7 UPDATE OR REVIEW PROCESS SELECTION AREA PART NAME MAI...

Page 16: ...l basically start an interview or allow them to view all parameters for a single process The operator can get out of the loop at any time and return to the Process Review screen by pressing RETURN Enter a product description using the screen illustrated in Figure 4 10 to identify the part by either a name or a part number Complete the step by pressing ENTER Process Code Figure 4 9 Use CONTINUE to ...

Page 17: ...d to the next screen NOTE To control part on part impingement use a media height of 80 to 95 percent of the total barrel volume To generate more aggression operate at lower levels approximately 65 percent If the operator has chosen to continue with the interview the following screen Figure 4 12 will be displayed MEDIA DATA FIGURE 4 11 COMPOUND DATA FIGURE 4 12 ...

Page 18: ...e The media fill rate is a speed adjustment for the media pan feeder This adjustment is necessary to insure a steady flow with all media sizes and weights An adjustment of the media flow rate is needed when switching media and works in conjunction to the media fill time to deliver an exact amount of media to the barrel Once set press Enter to save Press CONTINUE to proceed to the next screen NOTE ...

Page 19: ... in Figure 4 15 Through this screen the separator speed and maximum run time can be set The speed should be adjusted so the parts and media flow evenly across the screen deck without bouncing The run time sets the amount of time the separator and elevator operate before automatically shutting down This time should be adjusted to allow the operator time to unload and load all four barrels and clear...

Page 20: ...it the separator The operator should activate the rinse just prior dumping each barrel In this manner the rinse system is not spraying water when the separator is empty such as when the operator is filling the barrel SEPARATOR ELEVATOR CONTROLS FIGURE 4 15 PROCESS REVIEW FIGURE 4 16 PRESS RED KEY TO ACTIVATE AUTO REVERSE TO NAVIGATE TO ANOTHER STEP USE THE STEP KEY ...

Page 21: ...simply select the desired process from the Preset Process screen Figure 4 7 A flashing green light will be displayed behind the Preset Number of the selected process Touch within the Selection Area and press RUN to enter the Loading Instructions screen Figure 4 17 is the Loading Instruction screen This screen appears prior to each process step assisting the operator by displaying the process recip...

Page 22: ...next step or abort the entire process If PROCESS is selected the operator will return to Preset Processes Once the preset time has elapsed the CPC will come to a stop One of two screens will be displayed Continue Process Figure 4 19 will be displayed if there are additional steps to be completed or Process Complete Figure 4 20 if the total cycle has completed AUTOMATIC OPERATION FIGURE 4 18 TO CAN...

Page 23: ...ill be routed to the appropriate instructional screen either to reload barrels for an additional step or to continue processing with the current parameters If NEW PROCESS is selected the operator will be returned to the Preset Process Figure 4 2 ...

Page 24: ...aximum Cycle Time PLC Input Output Utilization Serial Number Model Number Reset Password Program Version System critical functions including maximum cycle time RPM and maintenance alarm reset can be password protected to keep out unauthorized personnel Once the maintenance alarm has timed out a message will be flash for one 1 minute on the CPC interface and repeat every fifteen 15 minutes until th...

Page 25: ...lid Password or the password has been forgotten the system can be reset to the default password as follows 1 Press CLR 2 Press RESET 3 Press ENTER 4 Enter the default password and press ENTER The status box will display Password Correct Press CONTINUE to proceed to System Tools NOTE For information regarding the default password contact United Surface Solutions Technical Support at 877 837 4623 5 ...

Page 26: ...ctive inputs and outputs when speaking with a technician 5 1 6 Help Menu The CPC is designed with help functions to assist the operator on the fly To access the Help Menu press SYSTEM HELP on the Main Menu From the Help Menu Figure 5 5 the operator can retrieve information on system functions By pressing any of the purple keys a non functional screen will be displayed where the operator can touch ...

Page 27: ...Page 27 5 2 Maintenance and Repair Idler Sprocket Cradle Shaft Turret Belt Motor Pillow Block Turret Idler Arm Assy Barrel Drive Sprocket Barrel Drive Turret Shaft MECHANICAL OVERVIEW FIGURE 5 8 ...

Page 28: ...barrel chains lubricate and adjust as needed Inspect and tighten set screws on barrel shaft sprockets Inspect barrel lid linings Every 1000 Machine Hours Inspect electrical connections and tighten as needed 5 2 2 Turret Drive Assembly The turret of the CPC is driven using a double a section v belt that extends from the pulley on the main motor to the flywheel on the turret Under most circumstances...

Page 29: ... 1 Turn OFF the power at the safety disconnect and lock the handle in this position 2 Loosen the four 4 retaining bolts holding the main drive motor to the motor base 3 Use the adjustment bolt on the rear of the motor base to move the motor backwards to tighten the belt or forward to loosen the belt 4 Recheck the tension on the belt and adjust if necessary 5 Tighten four 4 retaining bolts holding ...

Page 30: ...tation of the turret by a 50 series sprocket and chain system The chain type is classified as Diamond Chain and is very resistant to stretching after the brake in period of 30 40 hours of operation During this brake in period some adjustment may be necessary 5 3 6 Inspection A butterfly configuration is used to drive the cradle assemblies that accommodate the barrels Each butterfly configuration d...

Page 31: ...r link Clean with mild solvent if necessary and lubricate with penetrating oil such as Slick 50 One Lube 8 Inspect the Barrel Drive Sprockets and keyways for movement Visually inspect for rust between the sprocket and cradle shaft and physically grasp the sprocket and check for movement on the shaft If movement is evident remove sprocket and examine keyways for wear Replace key shaft or sprocket i...

Page 32: ... in photo 5 4 Motor Brake 4 Position the turret so that the Idler Arm Assembly for the butterfly assembly that needs adjustment is conveniently located and set the motor brake 5 Slightly loosen the two 2 bolts holding the idler arm assembly in place and remove the Idler arm from the turret 6 Using a pry bar gently press down applying 10 to 15 pounds of pressure on the Idler assembly taking up all ...

Page 33: ...Page 33 5 8 Adjusting Idler Assembly ...

Page 34: ...osition 3 Release the motor brake by pulling outward on the brake release knob shown in photo 5 4 Motor Brake 4 Position the turret so that the barrel bearing to be replaced is conveniently located and set the motor brake 5 Remove the two 2 retaining bolts holding the idler arm assembly in place and remove the Idler arm from the turret 6 Loosen the setscrews holding the sprocket to the shaft and s...

Page 35: ...Page 35 11 Lubricate the new bearing according to the instructions given in the section Lubricating 5 9 Bearing 5 10 Bearing Retaining Bolts Zerk Fitting Retaining Bolt Setscrews Zerk Fitting Setscrews ...

Page 36: ... that is being replaced out of its centering grove 10 Remove all six 6 Pillow Block Retaining Bolts four 4 on drive side and two 2 on free side 11 Raise the Turret and remove the Pillow Block from the Center Shaft 12 Loosen the setscrew on the bearing to be removed and slide it off the shaft If replacing the bearing on the Drive Side loosen the Sprocket Setscrews and remove both sprockets followed...

Page 37: ...Page 37 5 12 Turret Free Side 5 13 Turret Drive Side Pillow Block Retaining Bolts 2 Pillow Block Setscrew Turret Center Shaft ...

Page 38: ...technician For further information please contact UNITED SURFACE SOLUTIONS Product Support Team Service Department 877 8374623 Torque Specifications PART DESCRIPTION TORQUE Turret Bearings Retaining Bolts four per bearing 60 ft lbs Barrel Bearings Retaining Bolts two per bearing 80 ft lbs Idler Assembly Retaining Bolts two per idler 80 ft lbs Idler Sprocket Retaining Nut one per idler 50 ft lbs Pi...

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Page 40: ...nterface If there is power to the Drive Inverter and not to the PLC first check fuses then replace the Power Supply if needed No input voltage Check that the main disconnect located on the electrical cabinet door is turned to the On position Make sure that the machine is not being serviced before re energizing the machine Main fuses blown There are three fuses located in the main disconnect With t...

Page 41: ...Always either completely open or completely close the Shutter Door Drive error Check Drive Keypad for error code Refer to the instruction manual for the drive that was supplied with the machine or contact UNITED SURFACE SOLUTIONS for support Loose wire or defective component Turn the main disconnect to the Off position and carefully check and retighten electrical connections beginning at the main ...

Page 42: ...ccidentally pressed If the cycle timer has reset human error is likely the problem If the machine is stopped and the timer is still running human error must be discounted E Stop activated Check the CPC Touch Screen to determine if the E Stop has been activated If the E Stop has been activated the timer will display the remaining time Proceed to Manual Mode Screen to determine time remaining and fi...

Page 43: ...AXIMUM RPM is displayed check the Maximum RPM setting in the System Tools screen Maximum RPM and Cycle Time limits are set to protect the system from operator error These settings can be password proteced 6 5 Barrels Leak Possible Problem Item to Check Remarks Contamination on the sealing surface of the barrel and lid Remove the lid and check for media compound or other obstructions on the sealing...

Page 44: ...s Loose or broken main drive belt Attempt to rotate the turret by hand if it rotates then the belt needs servicing Refer to the Main Drive Belt section for tensioning and replacement instructions Glazed main brake rotor Run the machine at 120 180 rpm empty and then remove power from the machine This will grind a thin layer off the rotor allowing the brake to re seat Due to the requirements of the ...

Page 45: ...neutral a compound becomes whether up or down from seven the more harmful the effects Each container of compound will have an UNITED SURFACE SOLUTIONS label that shows the Hazardous Material Identification Guide HMIG rating of the compound These labels give the level of health risk degree of flammability and the reactivity of the compound Also the protective equipment requirements for handling the...