uge081-0714 powered payoff unspooling crystallizer4...always disconnect and lock out the incoming...

Powered Payoff Unspooling Device

U S E R G U I D E

UGE081-0714

www.conairgroup.com

Corporate Office: 724.584.5500 | Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861

Please record your equipment’smodel and serial number(s) andthe date you received it in thespaces provided.

It’s a good idea to record the model and serial number(s) of your equipment and the dateyou received it in the User Guide. Our service department uses this information, along withthe manual number, to provide help for the specific equipment you installed.

Please keep this User Guide and all manuals, engineering prints, and parts lists together fordocumentation of your equipment.

Date:

Manual Number: UGE081-0714

Serial Number(s):

Model Number(s):

DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental,consequential damages in connection with the furnishing, performance or use of this information.Conair makes no warranty of any kind with regard to this information, including, but not limitedto the implied warranties of merchantability and fitness for a particular purpose.

Copy r i gh t 2014 l Cona i r l A l l r i gh t s r ese r ved

Tab le o f Con ten t s l i

Tab le o f Conten ts1-1 I n t r oduc t i on

Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

How the Guide Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Your Responsibilities as a User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

ATTENTION: Read This So No One Gets Hurt . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

How to Use the Lockout Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2-1 Desc r i p t i onWhat Is the Powered Payoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Powered Payoff Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3-1 I n s t a l l a t i onUnpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Installing the Powered Payoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

4-1 Opera t i onStarting the Powered Payoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

i i l Tab l e o f Con ten t s

5-1 Main tenanceMaintenance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Preventative Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Lubricating the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Machine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Checking Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

6-1 Troub leshoo t i ngBefore Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

A Few Words of Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Identify the Cause of a Problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Operation Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Product Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

A A ppend i xCustomer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

B A ppend i xUltrasonic Sensor instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

I n t roduc t ion

Purpose o f t he Use r Gu ide . . . . . . . . . . . . . . . . . 1 -2

Ho w the Gu ide I s O rgan i zed . . . . . . . . . . . . . . . . 1 -2

You r Respons ib i l i t i e s as a Use r . . . . . . . . . . . . . . 1 -2

ATTENT ION : Read Th i s So No One Ge t s Hu r t . . . . . . 1 -3

Ho w to Use t he Lockou t Dev i ce . . . . . . . . . . . . . . 1 -4

S E C T I O N

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I n t r oduc t i on l 1-1

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Purpose o f the User Gu ideThis User Guide describes the Conair Powered Payoff and explains step-by-step how toinstall and operate this equipment.

Before installing this product, please take a few moments to read the User Guide and reviewthe diagrams and safety information in the instruction packet. You also should review man-uals covering associated equipment in your system. This review won’t take long, and itcould save you valuable installation and operating time later.

How the Gu ide i s O rgan izedSymbols have been used to help organize the User Guide and call your attention to importantinformation regarding safe installation and operation.

Symbols within triangles warn of conditions that could be hazardous to users or could damage equip-ment. Read and take precautions before proceeding.

Numbers indicate tasks or steps to be performed by the user.

A diamond indicates the equipment’s response to an action performed by the user.

An open box marks items in a checklist.

A circle marks items in a list.

Indicates a tip. A tip is used to provide user with a suggestion that will help with the maintenance andthe operation of this equipment.

Indicates a note. A note is used to provide additional information about the steps the user is followingthroughout the manual.

Your Respons ib i l i t y as a UserYou must be familiar with all safety procedures concerning installation, operation, andmaintenance of this equipment. Responsible safety procedures include:

• Thorough review of this User Guide, paying particular attention to hazard warnings,appendices, and related diagrams.

• Thorough review of the equipment itself, with careful attention to voltage sources,intended use, and warning labels.

• Thorough review of instruction manuals for associated equipment.• Step-by-step adherence to instructions outlined in this User Guide.

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1-2 l I n t r oduc t i on

ATTENT ION :Read Th is So No One Ge ts Hur tWe design equipment with the user’s safety in mind. You can avoid the potential hazardsidentified on this machine by following the procedures outlined below and elsewhere in theUser Guide.

WARNING: Improper ins ta l l a t ion , opera t ion , o r se r v-ic ing may resu l t i n equ ipment damage o r pe rsona lin ju r y.

This equipment should be installed, adjusted, and serviced by qualified techni-cal personnel who are familiar with the construction, operation, and potentialhazards of this type of machine.

All wiring, disconnects, and fuses should be installed by qualified electricaltechnicians in accordance with electrical codes in your region. Always maintaina safe ground. Do not operate the equipment at power levels other than whatis specified on the machine serial tag and data plate.

WARNING: Vo l tage hazard

This equipment is powered by three-phase alternating current, as specified onthe machine serial tag and data plate.

A properly sized conductive ground wire from the incoming power supply mustbe connected to the chassis ground terminal inside the electrical enclosure.Improper grounding can result in severe personal injury and erratic machineoperation.

Always disconnect and lock out the incoming main power source before open-ing the electrical enclosure or performing non-standard operating procedures,such as routine maintenance. Only qualified personnel should perform trou-bleshooting procedures that require access to the electrical enclosure whilepower is on.


DANGER: Mo v ing Par ts ; p inch hazard .

An Emergency stop (E-stop) button is located at an accessible point on theoperator side of the machine at the upstream end. When pressed, it will dis-connect power to the Powered Payoff drive. The E-stop must be physicallypulled out to reset the switch. To start the Payoff again after an E-stop hasbeen pressed, the Reset button must be pressed.

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How to Use the Lockout Dev iceCAUTION: Before performing maintenance or repairs on this product, you should disconnectand lockout electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardouselectricity.

Lockout is the preferred method of isolating machines or equipment from energy sources.Your Conair product is equipped with the lockout device shown. To use the lockout device:

1 Stop or turn off the equipment.

2 Isolate the equipment from the electric power. Turn the rotarydisconnect switch to the OFF, or “O” position.

3 Secure the device with an assigned lock or tag. Insert a lock or tag in the holes to prevent movement.

4 The equipment is now locked out.

WARNING: Before removing lockout devices and returning switches to the ON position,make sure that all personnel are clear of the machine, tools have been removed, and allsafety guards reinstalled.

To restore power to the equipment, turn the rotary disconnect back to the ON position:

1 Remove the lock or tag.

2 Turn the rotary disconnect switch to the ON or “I” position.

ON

O

OF

F

Descr ip t ion

Wha t I s t he Po wered Payo f f . . . . . . . . . . . . . . . . . 2 -2

Typ i ca l A pp l i ca t i ons . . . . . . . . . . . . . . . . . . . . . . 2 -2

Ho w I t Wo rks . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -3

Po wered Payo f f Fea tu res . . . . . . . . . . . . . . . . . . 2 -4

S E C T I O N

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Desc r i p t i on l 2-1

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escription

What I s Powered Payo f f (unspoo l ingdev ice )Conair’s Powered Payoff is designed to allow controlled, tensioned payoff of a tubular prod-uct.

Typ ica l App l i ca t ionsConair’s Powered Payoff is typically used for offline cutting from a spool or wheel, wherecontrolled tension is required for precise cut-to-length applications.

This Powered Payoff was configured based on your specific application needs.

Due to the automatic tensioning and calibration of the machine using a sonic loopdevice, when it is placed in the line, the operation is virtually hands-off. This promotessimple operation and less operator involvement.

2-2 l Desc r i p t i on

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EMERGENCY EMERGENCY EMERGENCY EMERGENCY 1LT1LT

Conair Powered Payoff

How I t WorksThe Powered Payoff uses Sonic Loop detection to detect and determine appropriateproduct tension and uncoiling speed to maintain the tension as it uncoils tubing from acoiled spool. A potentiometer is used to set a maximum speed for the Powered Payoff touncoil. There are two basic ways to set the potentiometer: 1. Set to the maximum speed, and simply allow the Sonic Loop detention system toautomatically calibrate the payoff speed necessary to maintain proper tension for cuttingthe product. 2. Set to the desired speed based on your puller, still allowing the Sonic Loop detectionsystem to calibrate the payoff speed, but never allowing unspooling to be faster thanyour desired speed.

As the product unspools, the Sonic Loop detection system monitors the tension of thetubing. If the tubing begins to sag (low tension), the Powered Payoff will slow down toincrease tension. If the tubing is too tight, the Powered Payoff will speed up to decreasetension.

Desc r i p t i on l 2-3

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escription

Sonic Loop detection

Powered Payoff

2-4 l Desc r i p t i on

Powered Payo f f Fea tures

Sonic Loopdetectiondevice

Locking casters

1.5 incharbor shaft

Brake - to hold thePayoff in place duringoperation.

Spool

NOTE: Depending on application andoptions ordered, your model may varyslightly from the description in this userguide.

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Drivemotor

Gearbox andsafety cover

Adjustable drive pin for spool

E-Stop and reset

I ns ta l l a t ion

Unpack ing t he Boxes . . . . . . . . . . . . . . . . . . . . . 3 -2

P repa r i ng f o r I n s t a l l a t i on . . . . . . . . . . . . . . . . . . 3 -3

Ins ta l l i ng t he Po wered Payo f f . . . . . . . . . . . . . . . 3 -4

Tes t i ng t he I ns t a l l a t i on . . . . . . . . . . . . . . . . . . . . 3 -6

S E C T I O N

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I n s t a l l a t i on l 3-1

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3-2 l I n s t a l l a t i on

Unpack ing the Boxes

CAUTION : L i f t ing hazard .

To avoid personal injury or damage to the Powered Payoff, lift the Payoff usinga forklift or hoist with straps that have been positioned at the Payoff center ofgravity. The Powered Payoff is equipped with locking casters, for ease of move-ment on level floors.

1 Carefully uncrate the Powered Payoff and its components. The Payoff typicallycomes fully assembled in a single crate.

2 Remove all packing material, protective paper, tape, and plastic. Compare contents tothe shipping papers to ensure that you have all the parts.

3 Carefully inspect all components to make sure no damage occurred during shipping.Check all wire terminal connections, bolts, and any other electrical connections, whichmay have come loose during shipping.

4 Record serial numbers and specifications in the blanks provided on the back of theUser Guide’s title page. This information will be helpful if you ever need service orparts.

5 You are now ready to begin installation. Complete the preparation steps on the nextpage.

Prepar ing fo r Ins ta l l a t ion

You will install the Powered Payoff in a position where it unspools to a Sonic Loop device,followed by a puller or puller/cutter combo.

1 Make sure the installation area provides:

r A grounded power source supplying the correct current and voltage. Check theserial tag for the correct amps, voltage, phase, and cycles. All wiring should becompleted by qualified personnel and should comply with your region’s electricalcodes.

r Minimum clearance for safe operation and maintenance. Determine the bestdistance from the discharge end of the Powered Payoff to the Sonic Loop device.This can be anywhere from 3 to 10 feet {0.91 to 3.05 m}, depending on the abilityof your product to flex. Any more than 10 feet of distance may interfere with thePayoff’s ability to function.

2 Determine the correct position for the Powered Payoff.The Payoff will be positioned upstream of a puller/cutter. You must consider optionalequipment and product type to determine the best spacing between the equipment.


WARNING : Improper ins ta l l a t ion , opera t ion , o r se r v-ic ing may resu l t i n equ ipment damage o r pe rsona lin ju r y.

This equipment should only be installed, adjusted, and serviced by qualifiedtechnical personnel who are familiar with the construction, operation, andpotential hazards of this type of machine.

All wiring, disconnects, and fuses should be installed by qualified electricaltechnicians in accordance with electrical codes in your region. Always main-tain a safe ground. Do not operate the equipment at power levels other thanwhat is specified on the machine serial tag and data plate.

3In

stallation


I ns ta l l i ng the Powered Payo f f

1 Move the Powered Payoff into position. This unit is supplied for either a right to leftor left to right operation. Check your order to see which direction was purchased.

2 Measure the centerline height of the product as it exits the Payoff spool. Make sureall equipment downstream of the spool is aligned to the this height.

3 Lock the Payoff into place. Lock the Payoff floor lock/caster assemblies so that thePayoff is locked in place. Turn the floor brakes to ensure that the Payoff will not moveduring operation.

IMPORTANT: Never operate the Payoff with the casters unlocked.Always use the caster brakes, and the floor lock assembly to lock the Payoff in place.

CAUTION : L i f t ing hazard .

To avoid personal injury or damage to the Payoff, lift the unit using a forklift orhoist with straps that have been positioned at the center of gravity.

(Cont inued)

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EMERGENCY EMERGENCY EMERGENCY EMERGENCY 1LT1LT


I ns ta l l i ng the Powered Payo f f (cont inued)

The Loop Detector - The loop detector will be positioned halfway between the puller andthe Payoff. Its function is to detect the height of the loop. As the loop lowers it sends a sig-nal to speed up the drive. In likeness, as the loop gets higher it sends a signal to slow downthe drive. When these functions work together, it keeps the loop at a consistent height, min-imizing any stretch that could result from “pulling” the material directly from the upstreamPayoff.

Refer to the Sonic Loop Control addendum in this user guide for height adjustment andoperation instructions.

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Tes t ing the Ins ta l l a t ion

1 Make sure all components are installed according to assembly drawings. Check allbolts on the Powered Payoff for tightness.

2 Check that Payoff is firmly anchored into position with the floor brakes.

3 Check that all wiring conforms to electrical codes, and all wiring covers are in place.

4 Turn on the main disconnect. Plug in the main power cord and turn on the main dis-connect.

5 Check that the E-Stop buttons are in the out, extended position.

6 Press Start button. The arbor shaft should begin to rotate. Ensure that the Payoff isoperating.

If the Payoff is not working properly at any time, turn it off immediately and refer to theTroubleshooting section of this User Guide.

If you do not encounter any problems, proceed to the Operation section.

7 Place a piece of tube in the Sonic Loop sensing tool. Raising and lowering the tubeshould start the arbor shaft rotating.

DANGER: P inch hazard .

Never remove or disable safety devices to sustain production. Operating with-out these devices could lead to hazardous conditions that can cause severeinjury. Take all necessary precautions when working around moving parts toprevent body parts and clothing from being pulled into the machine.


Opera t i on l 4-1

S E C T I O N

44

Op

eration

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Opera t ion

S ta r t i ng t he Po wered Payo f f . . . . . . . . . . . . . . . . 4 -2

4-2 l Ope ra t i on

Star t ing the Powered Payo f f

To start the Payoff:

1 Ensure that all guards are in place.

2 Turn on the main power.

3 Check that the emergency stopbuttons are functioning correctly.

4 Reset the emergency stop circuit ifnecessary.

5 Place the spool on the arbor shaft. Make sure that the spool will rotate in the cor-rect direction to uncoil towards the Sonic Loop device. Leave the spool loose at thispoint, so that you can unwind it by hand.

6 Unwind enough tubing to go through the Sonic Loop device and into thepulling/cutting device.

7 Slide the spool tightlyagainst the adjustablespool pin, making surethat the pin slides intoone of the holes on thespool.

8 Adjust the outside clamp on the arbor shaft so that it holds the spool tightly inplace.

(Cont inued)

Emergency Stopbutton and Resetbutton

NOTE: Refer to the appendix ofthis user guide, or the manual thatcame with your Sonic Loop devicefor operation procedures.

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Opera t i on l 4-3

4O

peration

Star t ing the Payo f f (cont inued)

9 Adjust the speed potentiometer knob to an appropriate level. This knob mayneed adjusted during operation to find the perfect setting. Setting the knob to thetop level will allow a top speed of approximately 250 feet per minute. Typically,you want the payoff to operate at about 10-20% faster speed than the puller speed.

10 Adjust the range of the Sonic Loop control if necessary. Refer to the controlinstructions that came with your equipment, and to the information in the appendixof this user guide. These settings are confirmed at the factory and should typicallynot need adjusted.

11 Follow the instructions for your puller or puller/cutter combo and start thatmachine. As the puller starts to pull the product (tube), the Sonic Loop device willsense the need for more product, and the Powered Payoff will begin unspooling.

0NOTE: Adjustments maybe necessary to thesettings for the speedof the Payoff. TheSonic Loop control isfactory set and shouldnot typically needadjusted.

4-4 l Ope ra t i on

Main tenance

Main tenance Fea tu res . . . . . . . . . . . . . . . . . . . . 5 -2

Warn ings and Cau t i ons . . . . . . . . . . . . . . . . . . . . 5 -2

P reven ta t i ve Ma in tenance Schedu le . . . . . . . . . . . 5 -3

Lub r i ca t i ng t he Un i t . . . . . . . . . . . . . . . . . . . . . . 5 -5

Mach ine Lub r i ca t i on . . . . . . . . . . . . . . . . . . . . . 5 -6

Sys tem I nspec t i on . . . . . . . . . . . . . . . . . . . . . . . 5 -7

Check ing E l ec t r i ca l Connec t i ons . . . . . . . . . . . . . 5 -8

5S E C T I O N

5M

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Ma i n t enance l 5-1

5-2 l Ma in tenance

Main tenance Fea turesThe Powered Payoff needs regular, scheduled maintenance for peak performance. Among the featuresthat require maintenance are:

• Floor locks• Electrical cables and terminals• Gear box

Warn ings and Caut ionsTo maintain the best performance of the Powered Payoff, it must be cleaned and inspected regularly.Maintenance includes a daily, weekly, quarterly, and semi-annual (every 6 months) schedule.

Use this maintenance schedule as a guide. You may need to shorten the time of the maintenanceschedule, depending on how often you use the Powered Payoff, and the types of material for which itis used. Follow all precautions and warnings when working on the equipment.

WARNING: Improper Ins ta l l a t ion , opera t ion , o r se r v ic ingmay resu l t i n equ ipment damage o r pe rsona l in ju r y.This equipment should only be installed, adjusted, and serviced by qualified technical personnel whoare familiar with the construction, operation, and potential hazards of this type of machine.

All wiring, disconnects, and fuses should be installed by qualified electrical technicians in accordancewith electrical codes in your region. Always maintain a safe ground. Do not operate the equipment atpower levels other than what is specified on the machine serial tag and data plate.

DANGER: P inch HazardNever remove or disable safety devices to sustain production. Operating without these devicescould lead to hazardous conditions that can cause severe injury. Take all necessary precautionswhen working around moving parts to prevent body parts and clothing from being pulled into themachine.

Main tenance l 5-3

P reventa t i ve Ma in tenance Schedu le

WARNING : Mo v ing Par ts .Improper se r v ic ing may resu l t i n equ ipment damageor persona l in ju r y.

This equipment should be adjusted and serviced by qualified technical person-nel who are familiar with the construction, operation, and potential hazards ofthis type of machine.

Before performing maintenance or repairs on this product, disconnect and lockout electrical power sources to prevent injury from unexpected energization orstart-up. A lockable device has been provided to isolate this product frompotentially hazardous electricity.

Make sure all safety devices and belt guards are installed before resuming nor-mal operation.

5M

ainten

ance

WARNING: Vo l tage hazardThis equipment is powered by alternating current, as specified on the machineserial tag and data plate. Do not operate the equipment at power levels otherthan what is specified on the machine serial tag and data plate.

A properly sized conductive ground wire from the incoming power supply mustbe connected to the chassis ground terminal inside the electrical enclosure.Improper grounding can result in severe personal injury and erratic machineoperation.

Before performing maintenance or repairs on this product, disconnect and lockout electrical power sources to prevent injury from unexpected energization orstart-up. A lockable device has been provided to isolate this product from poten-tially hazardous electricity.

(Cont inued)

Preventa t i ve Ma in tenance Schedu le(cont inued)

To maintain the best performance of the Powered Payoff, we recommend the followingmaintenance schedule. You may need to shorten the time between servicing, depending onhow often you use the Payoff, and the types of material for which it is used. Maintenanceshould be performed anytime you change materials, lines, or equipment in the extrusionline.

• Daily

r Inspect Powered Payoff for wear.If the arbor shaft, drive pin or any other part of the unit seems worn or loose, takecorrective action to remedy the situation.

r Inspecting unit alignmentProper alignment with other equipment on the line is critical for optimum perform-ance.

r Verify floor lock settings.The weight of the unit should never rest solely on the casters during operation. Forstability during uncoiling, the Powered Payoff should rest on the locked castersAdna the brake pad assembly. Verify that the floor locking mechanism is properlyadjusted before starting the Payoff. If necessary, use an adjustable wrench to turnthe floor locks until the weight is shared between the locks and the caster.

r Clean equipment.Wipe the equipment with a clean dry cloth to eliminate dust and other build-up,which can deteriorate performance.

• Weekly

r Check the Drive pin tightness.

r Check and lubricate all grease fittings.See Machine Lubrication.

• Semi-annual (every 6 months)

r Inspecting electrical terminalsCheck all electrical terminals for tightness; adjust as needed.

5-4 l Ma in tenance

Main tenance l 5-5

Lubr ica t ing the un i tLubricate all shafts and grease fittings as needed.

1 Follow lockout proceduresand disconnect main powerfrom the machine prior tobeginning any maintenance.

2 Remove the two screws fromeach side of the safety guardthat hold it in place. Theyare shown here circled in red.

3 Carefully remove the safetyguard.

4 Visually inspect all compo-nents of the drive unit.

5 Lubricate as necessary.

(Cont inued)

NOTE: Depending on your model or configuration, grease locations may vary from above what is shown inthe manual. Visually locate the grease locations on your machine.

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5-6 l Ma in tenance

Mach ine Lubr ica t ionThe machine is supplied to you completely lubricated. After running the unit for long peri-ods of time, this lubrication will break down and become useless. For this reason, periodiclubrication is required.

Component Type of Lubrication DurationFlange Bearings Chassis Lube 6-9 Months

Gear Reducers Mobil 629 or Equiv. 12 Months

Main tenance l 5-7

5M

ainten

ance

Sys tem Inspec t ionAlthough this unit was designed to require a minimum amount of maintenance, it should beinspected periodically to insure that it remains in top operating condition.

Items to inspect

• Mechanical Components - Approximately once every six months or sooner, if able, allmechanical components should be visibly inspected. While these components shouldstay secure and last a long time, it is always a good idea to check for any excessive wear,damage, and fastener security to these units.

• Coupling - Visually inspect the coupling for wear.

5-8 l Ma in tenance

Check ing E lec t r i ca l Connec t ions

1 Disconnect and lock out the main power.Turn the main power disconnect to the off position before opening the electrical enclo-sure. This is a safety device to prevent you from opening the doors if the power is stillon.

2 Open the electrical enclosure.

3 Inspect all wires and connections. Look for loose wires, burned contacts, and signs ofover-heated wires. Have a qualified electrician make any necessary repairs or replace-ments.

4 Close the electrical enclosure door.

5 Inspect the exterior power cords. Cords should not be crimped, exposed, or rubbingagainst the frame. If the main power cord runs along the floor, make sure it is not posi-tioned where it could rest in pooling water or could be run over and cut by wheels andcasters.

WARNING: E lec t r i ca l hazard .

Before performing any work on this product, disconnect and lock out electricalpower sources to prevent injury. A lockable device has been provided to isolatethis product from potentially hazardous electricity.

WARNING: Improper se r v ic ing may resu l t i n equ ip-ment damage o r pe rsona l in ju r y.

This equipment should only be adjusted and serviced by qualified technicalpersonnel who are familiar with the construction, operation, and potential haz-ards of this type of machine.

All wiring, disconnects, and fuses should be installed by qualified electricaltechnicians in accordance with electrical codes in your region. Always main-tain a safe ground. Do not operate the equipment at power levels other thanwhat is specified on the machine serial and data plate.

Troub leshoot ing

Be fo re Beg inn ing . . . . . . . . . . . . . . . . . . . . . . . 6 -2

A Few Words o f Cau t i on . . . . . . . . . . . . . . . . . . . 6 -2

I den t i f y i ng t he Cause o f a P rob l em . . . . . . . . . . . 6 -3

Ope ra t i on P rob l ems . . . . . . . . . . . . . . . . . . . . . . 6 -4

P roduc t Qua l i t y P rob l ems . . . . . . . . . . . . . . . . . . 6 -6

6S E C T I O N

Troub leshoo t i ng l 6-1

6Trou

blesh

ooting

6-2 l Tr oub leshoo t i ng

Before Beg inn ing

You can avoid most problems by following the recommended installation, operation, andmaintenance procedures outlined in this User Guide. If you have a problem, this sectionwill help you determine the cause and tell you how to fix it.

Before you begin to take diagnostic actions, be sure to:

oFind any wiring, parts, and assembly diagrams that were shipped with your equip-ment. These are the best reference for correcting a problem. The diagrams willnote any custom features or options not covered in this User Guide.

oVerify that you have all instructional materials related to the machine. Additionaldetails about troubleshooting and repairing specific components are found in thesematerials.

oCheck that you have manuals for other equipment connected in the system.Troubleshooting may require investigating other equipment attached to, or connect-ed with the machine.

A Few Words o f Caut ion

WARNING : Improper se r v ic ing may resu l t i n equ ipmentdamage o r pe rsona l in ju r y.

This equipment should only be installed, adjusted, and serviced by qualified tech-nical personnel who are familiar with the construction, operation, and potentialhazards of this type of machine.

All wiring, disconnects, and fuses should be installed and adjusted by qualifiedelectrical technicians in accordance with electrical codes in your region. Alwaysmaintain a safe ground. Do not operate the equipment at power levels other thanwhat is specified on the machine serial tag and data plate.

WARNING: E lec t r i ca l hazard .

Before performing maintenance or repairs on this product, disconnect and lock outelectrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentiallyhazardous electricity.


I den t i f y ing the Cause o f a P rob lem

The Troubleshooting section covers problems directly related to the operation andmaintenance of the standard Powered Payoff. This section does not provide solutions toproblems that originate with other equipment. Additional troubleshooting help can be foundin manuals supplied with the other equipment.

The main problems you will see with the Powered Payoff could include:

• Payoff operation problems, which focus on problems that are clearly related to themechanical components and electrical control system.

• Product quality concerns, which deal with extrudate characteristics that may be relat-ed to Payoff operations. Of course, other sections of the extrusion line also influencethe quality of the extruded product. This section does not provide solutions to problemsoriginating with other equipment on the extrusion line.

Additional troubleshooting help can be found in the component manuals included with thisUser Guide.

6Trou

blesh

ooting


Opera t ion P rob lemsLook in this section when the control or motor is not working properly.

SolutionReplace the bearings.

Pull out the E-Stop buttons.Make sure it clicks into posi-tion.

Check that communicationcables are connected.

Adjust loop control setpoint.

Adjust potentiometer.

Possible cause

The bearings are failing.

The E-stop buttons arepushed in.

Cables between Payoff andloop detect are disconnected.

Loop control out of calibra-tion.

Payoff uncoiling too slowly.

Problem

The Powered Payoff‘creaks’ while run-ning.

The Powered Payoffdoes not start.

Material tension tootight.

NOTE: For some materials,material tension is required tomaintain a straight tube tocut. Adjust the weights on theSonic Loop for adjusting ten-sion to achieve the perfectcut.

0


6Trou

blesh

ooting

Opera t ion P rob lemsLook in this section when the control or motor is not working properly.

Solution


Adjust potentiometer to aslower speed.

Add weight to the loop controlto increase tension.

Verify that the collar is holdingthe spool tightly against theadjustable spool pin. Also ver-ify that the spool pin is adjust-ed and seated into a hole in thespool.

Verify that the product on thespool is free from knots andable to unwind easily.

Possible cause


Payoff is operating too fast.

Collar is loose on arbor.

A “wrapover” or knot in thetube has stopped the Payofffrom uncoiling.

Problem

Material tension tooloose.

Spool is not rotating.


Product Qua l i t y P rob lems

Possible cause


Too much weight on the loopcontrol.

Speed potentiometer onPayoff not adjusted correctly.

Loop control out of calibra-

tion.

Too little weight on the loopcontrol.

Speed potentiometer onPayoff not adjusted correctly.

Solution


Reduce weight to reduce tension.



Increase weight to increase ten-

sion on the loop.


Problem--

Too much tension onthe product - not agood cut.

Too little tension onthe product - not agood cut.

A ppend i x l A-1

We ’ re Here to He lpConair has made the largest investment in customer support in the plastics industry.Our service experts are available to help with any problem you might have installingand operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from mis-application or improper use.

How to Contac t Cus tomer Ser v iceTo contact Customer Service personnel, call:

From outside the United States, call: 814-437-6861You can commission Conair service personnel to provide on-site service by contact-ing the Customer Service Department. Standard rates include an on-site hourly rate,with a one-day minimum plus expenses.

Before You Ca l l . . .If you do have a problem, please complete the following checklist before callingConair:

r Make sure you have all model, serial and parts list numbers for your particularequipment. Service personnel will need this information to assist you.

r Make sure power is supplied to the equipment.

r Make sure that all connectors and wires within and between control systems andrelated components have been installed correctly.

r Check the troubleshooting guide of this manual for a solution.

r Thoroughly examine the instruction manual(s) for associated equipment, especiallycontrols. Each manual may have its own troubleshooting guide to help you.

r Check that the equipment has been operated as described in this manual.

r Check accompanying schematic drawings for information on special considerations.

Additional manuals and prints foryour Conair equipment may beordered through the CustomerService or Parts Department for anominal fee.

NOTE: Normal operating hours are 8:00 am - 5:00 pm EST. After hours emergency

service is available at the same phone number.

0

A-2 l A ppend i x

Equ ipment Guaran teeConair guarantees the machinery and equipment on this order, for a period asdefined in the quotation from date of shipment, against defects in material andworkmanship under the normal use and service for which it was recommended(except for parts that are typically replaced after normal usage, such as filters, linerplates, etc.). Conair’s guarantee is limited to replacing, at our option, the part orparts determined by us to be defective after examination. The customer assumes thecost of transportation of the part or parts to and from the factory.

Per fo rmance War ran tyConair warrants that this equipment will perform at or above the ratings stated inspecific quotations covering the equipment or as detailed in engineering specifica-tions, provided the equipment is applied, installed, operated and maintained in therecommended manner as outlined in our quotation or specifications. Should perform-ance not meet warranted levels, Conair at its discretion will exercise one of the fol-lowing options:• Inspect the equipment and perform alterations or adjustments to satisfy

performance claims. (Charges for such inspections and corrections will be waivedunless failure to meet warranty is due to misapplication, improper installation,poor maintenance practices or improper operation.)

• Replace the original equipment with other Conair equipment that will meet original performance claims at no extra cost to the customer.

• Refund the invoiced cost to the customer. Credit is subject to prior notice by thecustomer at which time a Return Goods Authorization Number (RGA) will beissued by Conair’s Service Department. Returned equipment must be well cratedand in proper operating condition, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and provide a customer receiptand other evidence that a claim is being made.

Warranty L imi ta t ionsExcept for the Equipment Guarantee and Performance Warranty statedabove, Conair disclaims all other warranties with respect to the equipment,express or implied, arising by operation of law, course of dealing, usage oftrade or otherwise, including but not limited to the implied warranties of mer-chantability and fitness for a particular purpose.

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