4H SF&C User Manual
Contents
1. ING SS RELA Y AUX O6 Spare AUX OS Spare System Manual www takenterprises com Intro Screen System Screens ER TIRIS ES Bristol CT 06010 Ph 560 553 0517 Fax 85U 585 D473 takitakenterprises coam S r gt El SETUP When the system starts up this will be the first screen showing From this screen you will be able to access Administration functions System running functions System alarm information and the Program running section To access any of the screens from here just touch the appropriate screen button If the screen you are trying to access is password protected you will be shown a keypad to enter the code The Supervisory password is 3333 TAK Admin Screen ADMIN SCREEN MAINTENANCE COUNTER LIFE COUNTER 123 123 123 123 123 123 SCREEN p From the Main Intro screen a Supervisory password will be necessary to access this screen Maintenance Count Reset Supervisory password will be necessary to reset this counter This counter can be used to track any system maintenance feature you wish to track based on parts produced System Manual www takenterprises com ENTENERIE ELS System Screens Life Count Reset A Factory Only password is necessary to reset this counter OIT Screen Configure A Factory Only password is necessary to access this feature OIT CONFIGURATION VOLUME CON2. POWER INDICATOR E STOP NC O CPU INDICATOR TxD RxD PLC COMMUNICATIONS LOOP RESUME LOOP PAUSE BATCH HANDSHAKE REMOTE ERROR 9 RESUME e n REMOTE PAUSE e REMOTE STOP OPTION MATERIAL REQ D START LOOP CONTROL CLOSE 6 BATCH END CYCLE RUN 9 CLOSE 6 CYCLE START AUDIBLE ALERT AMBER LIGHT GREEN LIGHT COMMON 24VDC RED LIGHT SPARE CUTTER CYLINDER SNAG SENSOR BAND CYLINDER FEED AWAY FRONT GRIP FEED HOME SNAG SENSOR CUT AWAY CUT HOME WIRE OUT LOW AIR SENSOR 86 SPARE a SAFETY COVER CONTROL POWER OPTION CHE LOW AIR MICROLOGIX 1100 VALVE BODY NOIES ALL PHOTO SENSORS ARE NPN DARK ON ON 3 WIRE SENSORS USE BLACK ON 4 WIRE SENSORS USE WHITE 24 VDC ALL DRY CONTACTS ARE TO BE NO ENTERFRISES i B 12308 GDH 072707 TOLERANCE UNLESS DRAWING PART NO OTHERWISE STATED 9111 101 DWN GDH ioe ls PART NAME X Gis STANDARD TOUCH SCREEN 05 LOCALE CUSTOMER 0005 DATE 010307 TAK 86 NOTES 3 UNIBODY 4 amp 5 UNIBODY 4 amp 5 QUICK RE
3. Enterprises Inc PSI TII ES Visit us on the web PNEUMATIC FEED amp OFF SYSTEM QUILL ON QUILL CUTTER 70 Enterprise Drive Bristol 06010 7400 Ph 860 583 0517 Fax 860 585 0479 E mail tak takenterprises com www takenterprises com ENTEREERKIEEE Feed amp Cut off System General Introduction The TAK family of feed and cutoff systems is designed to produce straightened precisely cut and close tolerance length pieces from wire shapes or narrow strip material Each of the styles of cutoff systems offered is a precision crafted device that provides every user with an extremely versatile machine that is compact easy to operate and cost effective Versatility Plus There are four major elements of versatility that these systems apply to every application Any combination of these makes these systems very justifiable 4 Very wide range of materials quick change over of the cassette style tooling allows every unit to be able to accommodate a range of materials The Ist shift could be running gold plated copper the 2nd shift could run stainless steel and the 3rd a paper wrapped tempered steel Any diameter up to 375 Each of our cutoff systems has a very wide range of operation that allows for many different size diameters to be run Variable cut lengths Our pneumatic systems can cut lengths up to 300 feet while our servo systems are
4. Note Before proceeding check the setting of your Fine Adjustment Device FAD if so equipped Set the position to zero Step 1 Set the desired number of samples you wish to cut to validate proper cut length by using the counter buttons on the face of the Program Screen by going to it from the Run Screen after starting at the Main Screen Once the quantity is entered press the Return button which will take you back to the Run Screen Push START to run the sample parts and check the lengths for accuracy Safety Warning BEFORE PROCEEDING Disconnect the air supply line coming from the source DO NOT re connect the air supply until the unit is completely adjusted and ready to run according to the following instructions Remove lexan safety cover Step 2 Measure the distance from the rear shaft support or a clamp placed on the accumulating guide rod to the back of the rear stop block This reference dimension will be used to adjust the rear stop block to achieve the correct blank length you desire The use of precisely ground gage blocks are recommended for cut lengths of 002 Step 3 For fine adjustment loosen the four clamping screws on the rear stop block Move the rear stop block either towards the cutter end to get a shorter blank or towards the rear shaft support for a longer blank Use the reference dimension found in the previous step along with the error in the blank length to a
5. CUT NOT AWAY The touch buttons along the bottom edge will bring you to the screens as described for viewing or actions you wish to initiate System Manual www takenterprises com ENTENERIE ELS System Screens Alarm Detail Touching this button will open the alarm detail screen where the chosen alarm event can be viewed in detail Alarm History Details Entry 1 Message PRESSURE LOW Activated 05 JAHM 2007 12 50 13 Cleared Actual Value On HighiLowiDis Discrete Low High Confirm Cleared Alarm Count Touching this button will open the alarm count screen where the alarm events can be viewed based on the number of occurrences Alarm Court Alarm Mo Cnt Message SAFETY DOOR AIR PRESSURE LO WIRE QUT CUT MOT HOME CUT RIOT AAY FEED HOME FEED AWAY aNAGGELD System Manual www takenterprises com System Screens System setup screen For explanation of operation of each timer Please see the appropriate section of the Screen and Operational information explanations This screen is supervisory password protected SETUP SCREEN TO1 PRESET R T02 FRESET PRESET R GRIP ON F GRIP DH BAND ON 12345 11 12345 III 12345 4 PRESET TOS PRESET TUS PRESET F RIP OFF R GRIP OFF BAND OFF 12345 12348 12345 CUT TOG PRESET T10 PRESET DWELL CUT BATCH CELA TIMED 12345 12248 Cut Selec
6. 9100 013 MAGNET SCS T 1 H5 PWS 2 PLANE ASSY REF 1005 012 amp BRKT 4004 172 4 9010 01 PLASTIC 6 5 4100 107 LEXAN covek 1 5 PWS 2 PLANE QR ASSY REF 1005 002 amp BRKT 4004 150 6 3010 0060 EYEBnLT SCS 7 4004 101 FRONT SUPPHRT C C ij B 9008 013 SHIM WASHER C 6 9 4004 9XX ACCUMULATING GUIDE PLATE 4 io 921 001 DILITE BUSHNG gs 12 4004 58XX FEED GUIDE C 1 i 13 2004 1002 REAR GRIPPER BODY C 1 14 4004 194 SENSOR ADJUSTER C 8 15 9100 044 SENSOR 3 16 4004 165 FRONT PHOTO BRACKET C I 17 4004 155 NUT FRONT PHOTO BRKT 1 8 18 4004 183 TRAVELING STOP SPACER 1 19 2004 124 TRAVELING STOP PIN 2 0 4004 168 TARGET STOP PLATE 1 21 901 020 STOP BUTTON 1 221 2100 0587029 UPPER LOWER SENSHR I 2 23 9401 001 shock STOP C C C C gs 24 9100 013 MAGNETIC REED SWITCH I 25 4004 100 REAR SUPPORT C i 251 9802 007 NYLON TIP 271 9007 024 DOWEL PIN REAR SENSOR 8 28 4004 169 WO SENSOR ARM 1 129 4000 090 W PIVOT BUSHING 1 30 9002 118 BHCS ATTACH i 4000 088 WU SENSOR PLAE 1 38 4004 170 SENSOR MOUNT BRACKET 1 33 9800 008 CERAMIC INSERT C 2 34 9011 015 HEX STAND DOFF 120 35 3011 008 CHLLARGSPLITD 2 36 4004 104 C
7. This is a view only indication of how many batches have been made in the current run This initiates the system to run This will Stop the system For detailed information please see the Cause amp Effect section of this manual This button will clear reset an alarm condition This button will silence the audible alert if the system has this option This will pause the system For detailed information please see the Cause amp Effect section of this manual This button will bring you to the edit screen where you can set the parameters for the job run This will resume the system For detailed information please see the Cause amp Effect section of this manual This button will bring you to the Main intro screen By momentarily pressing this button it will clear the Run Actual parts count By holding this button for more than 5 seconds it will clear the Total and the Batch Actual also Reference Screen Shots View with alarm condition System Manual RUNSCREEN ShIP PRESET PART PRESET 000 DDD ALARM PRESENT RUN ACTUAL PARTS 000 000 ZEE MAIN EDIT SEQO READY www takenterprises com M ENTENERIE ELS System Screens View while normal running condition RUN SCREEN SKIP PRESET PART PRESET 123 123 123 RUN ACTUAL PARTS 123 123 TOTAL 123 123 SPEED PPM BATCH PRESET BATCH ACTUAL 1234 123 123 123 123 View wi
8. only limited by the amount of material on the coil or spool Various Shapes Again the use of cassette style tooling allows an operator to quickly change from one shape material to another Quality amp Precision Every TAK cutoff system is capable of providing close tolerance length cuts some within 0005 as well as cut ends that are clean burr free and square If the system utilizes our precision grade wire straighteners then the user is assured to get the straightest parts For the application that requires no marks or material distortions the tooling items can be fabricated from special materials and fashioned in such a manner to maintain the pristine condition of the material Options There are a number of system options available that provide extended performance characteristics for all the TAK cutoff systems The Fine Adjustment Device Production Performance Package and Data Display options are just a few that are available Available option descriptions are listed in section 4 of this manual System Manual www takenterprises com EN T6EIIIEES TAK Feed amp Cut off System Application Set up Threading the Material Setting the Length safety Warning Before Proceeding Read These Safety Points Unplug the unit from both the power input source and air supply line before attempting any adjustments or attempting to thread up the system with material When the power and air is connected to the sy
9. English version Allen wrench or hex key Step 11 Reinstall the stationary quill flush to the inner surface of the cutter body tighten the quill retaining set screw with your Allen wrench Re Install the raveling quill and recess it from the face of the traveling quill block a predetermined amount for the clearance for the type and diameter of material being cut Tighten the quill retaining set screw with your Allen wrench Reinstall the traveling quill block into the cutter body Replace the cutter arm cover Step 12 Re mount the cutter body to the cutter base and the cutoff cylinder to the cutter body Step 13 Replace safety cove and plug the unit into a standard 120 volt AC 60 Hz grounded outlet Connect the air line to a source of clean dry air at approximately 60 to 80 psi NEVER exceed 120 psi Safety Warning BEFORE PROCEEDING Remove any tools or objects from the feed area Momentarily press the manual activation button located on the air valve assembly that controls the cutoff cylinder and test for the proper cutter movement System Manual www takenterprises com ENTENERIE ELSE SHARPENING PROCEDURE For QUILL ON QUILL Type Straighten Feed amp Cut Off Machine NOTE Wire hole cutting edge and any surface leading to wire hole cutting edge should be free of all tool marks and or grinding lines Figures 1 2 Step 1 Grind Traveling Quill Grind end A of Quill opposite wire exit side flat and perpen
10. INPN dry contact NO remote activation AUX II Remote Stop INPN dry contact NO remote AUX 12 Remote Pause INPN dry contact NO remote AUX I3 Remote Resume INPN dry contact NO remote AUX 14 Remote Device Error NPN dry contact NO remote activation AUX I5 Batch Handshake INPN dry contact NO remote activation AUX I6 Loop Pause INPN dry contact NO remote activation AUX I7 Loop Resume INPN dry contact NO remote activation Micrologix Outputs Some features optional equipped 00 Spare Rear uuu uu u u ING SS RELA Y EE Front grip s SS RELAY Band cylinder valve NE SS RELAY Cut cylinder valve ace SS RELAY Red Light Stack error IN o SS RELAY AUX OO Green Light Stack error SS RELAY AUX O1 Amber Light Stack error SS RELAY AUX O2 Sonic Alert Stack error INO S SS RELAY AUX O3 Close Cycle Start INO r SS RELAY AUX OA Close During Cycle run IN 0 SS RELAY AUX 35 Close Batch End
11. cylinders 3 Remove the grippers and check for wear or contamination that would prevent them from closing 4 Check for material variation System Manual www takenterprises com 24 0 V 24 VDC PLC INPUTS LOOP RESUME LOOP PAUSE BATCH HANDSHAKE REMOTE ERROR REMOTE RESUME REMOTE PAUSE REMOTE STOP REMOTE START SPARE SNAG SENSOR CUT HOME WIRE OUT LOW AIR SENSOR SAFETY COVER CONTROL POWER 24 0 V NZ N Oe N N 7 wc 24 VDC 24 VDC 24 VDC PLC OUTPUTS 24 VDC 24 VDC 24 VDC 24 VDC AUX AUX 0 7 0 6 24 VDC AUX AUX AUX AUX AUX AUX 0 5 0 4 0 3 0 2 0 1 0 0 0 5 0 4 0 5 0 2 0 1 0 0 GROUND 24 VDC ENTERFRISES MATERIAL REQ D Rc 24 VDC SPARE SPARE VALVE COMMON 24 VDC CLOSE BATCH END CYCLE RUN CLOSE CYCLE START AUDIBLE ALERT AMBER LIGHT GREEN LIGHT RED LIGHT CUTTER CYLINDER BAND CYLINDER FRONT GRIP REAR GRIP SPARE SYSTEM GROUND dd o plo _ si Rev ecn 6 6 BY DATE TOLERANCE UNLESS ID 0 a zd NO OTHERWISE STATED 101 IO FRACT 1 16 DWN PART X 032 28 s SYSTEM IO t t XXX 005 SCALE CUSTOMER 0005 DATE 010507 110 VAC SWITCH SYSTEM GROUND
12. run until the cover sensor makes contact Step 8 Plug unit into a standard 120 volt AC 60 Hz grounded 2 amp outlet If unit is configured for non USA voltage connect to proper rated outlet Connect the air line to a source of clean dry air and set the system regulator to approximately 80 psi NEVER exceed 120 psi Connection of the air will cause the front gripper cylinder to activate and grip the material firmly so it will not move Step 9 Take one of the smaller size Allen hex wrenches supplied as part of the tooling package and momentarily press the manual activation button located on the air valve assembly that controls the cutoff cylinder so that the material just threaded through the system will be cut off Step 10 Turn on the system by flipping the red rocker switch on the top of the controller box Using the touch screen on the controller see screen description page select the run program Set the desired number of samples you wish to cut to validate proper cut length by using the counter buttons on the face of the touch screen Push START to run the sample parts and check length Please refer to the screen amp operational section for a complete description of all system and screen functions System Manual www takenterprises com ENTENERIE ELS TAK Feed amp Cut off System Adjusting the Length Speed Changing to a Different Size Shape or Type of Material Adjusting the Length
13. D STOP CONDITION IMMEDIATE STOP amp RESET TO STAND BY COUNT ACTUAL MANUAL CLEAR REQUIRED IF DESIRED BATCH ACTUAL MANUAL CLEAR REQUIRED IF DESIRED CURRENT BATCH COUNT MANUAL CLEAR REQUIRED IF DESIRED SKIP ACTUAL AUTOMATIC CLEAR ON STOP CONDITION ERROR CONDITION CHOICES CONTINUE System Manual www takenterprises com sa ENTERESE ELS Screen and Operational information explanations PLC and Operational information explanations Micrologix Inputs Some features optional equipped TO cune Control power INPN dry contact NO system sensor IL oss Safety Cover NPN dry contact NO system sensor Min air pressure INPN dry contact NO third party unit Wire OU i os system sensor I4 en Cut home NPN NO system sensor Cut away NEN 0 system sensor Feed hom e NPN NO system sensor IL us Feed away NPNN O kasanqa system sensor IMicrologix Remote System inputs Some features optional equipped Snag NPN dry contact NO third party unit P INPN dry contact remote AUX IO Remote Start
14. ILL ADJUSTMENT SHM 175 4004 8XX TRAVELING QUILL 1 77 9311 006 DILITE BUSHING 1 78 4004 160 CUTTER ARM Ti 7 80 4004 7XX STATIUNARY QUILL 1 81 4004 137 CUTTER ARM PIVOT SHAFT 1 sa 9007 085 DOWEL DIA 250 175 LG 1 83 4004 159 CUTTER BHDOY 11 84 4004 73 SLEEVE T 3 7 85 4004 132 QUILL BACKER 1 86 4004 129 CUTTER BASE 1 1 EE TOLERANCE UNLESS DRAWING PART OTHERWISE STATED 4004 062 CAD 3 FRACT 1 16 WN GDH PART NAME 00003 X 032 dilt SF amp C QUILL ON QUILL 12 ASSY amp PARTS TAR 9 x 5 fow SF amp C 4H ASSY 5ENTERICKRISES 00005 005 SCALE CUSTHMER 00005 XXXX 0005 120205 EXPLODED VIEW ae aoe PART LISTING DESCRIPTION EE Ew 38 58 LL TOLERANCE UNLESS DRAWING PART NO OTHERWISE STATED 4 SF amp C GDH PART NAME 015 GENERIC 4H CUT HEAD ENTEREFRISES i GE 005 CUSTOMER 0005 DATE 082207 082207 3 TERRIS EE The operator of the equipment offered herein must not be in or near the point of operation of any such machine or operating parts of any equipment installed on a machine or bodily injury could result The EMPLOYER must conspicuously display adequate warning signs on the machine with proper warnings for the machine and the specific application t
15. LAMPING REAR I 39 9007 041 DOWEL PIN GRIPPE 4 40 4000 093 MAIN MOUNT PLATE I 41 4000 001 CUNTRUL 1 1 4e 3100 108 PUSH E STOP BUTIN 1 43 4000 094 AIR MOUNTING PLATE 1 44 4004 113 GRIPPER WEAR PLATE 8 45 4004 6XX GRIPPER lt 2 PCS PER SED 8 48 4000 077 GRIPPER PIN 800M T 1 49 4001 535 ACCULULATING GUIDE SHAFT 8 50 4004 103 FRHNT GRIPPER BODY 1 51 9400 518 GRIPPER CYLINDER 63MM 1 52 4000 076 GRIPPER PIN 63MM 1 53 4000 057 CONTROL ADAPTER PANEL 1 54 4000 096 UPRIGHT CONTROL BRACKET 8 55 9403 024 MAC 400 SERIES VALVE ASSY 1 55 9402 008 AIR REGULATOR 3000 1 57 9402 006 AIR REGULATOR GAGE J 1 58 9405 010 EXHAUST SILENCER 2 59 4000 095 CHNTRHL BUX BRACKET C 2 601 4000 083 STACK LIGHT BRACKET I let 3103 008 STACK LIGHT 1 7 E eS 7 P 7 7 7 U P 64 9402 000 DUMP VALVE 65 9405 040 SILENCER 1 66 9404 038 1155 1 2 67 9400 531 BIMBA TRIPLE ACTING CC 1 68 4004 136 CYLINDER ADAPTER PLATE 1 69 4010 805 CYLINDER PIVOT lt 1 70 4004 134 CUTTER ARM LINK i 71 9007 020 0125 X 50 LG DDVEL PIN 1 175 4004 193 FRONT SENSOR BRACKET 1 73 4004 131 CUTTER ARM COVER 1 174 4004 135 CUTTER ARM QUILL BACKER CAP 1 75 9008 009 GU
16. LEASE DIM S ARE APPROXIMATE 3 PWS 2 ASSY REF 1005 002 amp BRKT 4004 126 DIM S IN X X ARE IN MM 3 PWS 4 PLANE ASSY REF 1005 004 amp BRKT 4004 1171 184 48 5 PWS 2 PLANE ASSY REF 1005 012 amp BRKT 4004 172 5 PWS 2 PLANE QR ASSY REF 1005 002 amp BRKT 4004 150 4 PWS 2 PLANE ASSY REF 1004 012 amp BRKT 4004 158 4 PWS 2 PLANE QR ASSY REF 1004 002 amp BRKT 4004 146 19 7 16 2 499 67 412 73 4 LJ 2 nl i s re H m oy O 9 mU Lu 3 1 CE o 9 E 2 lt 9 9 c c LE 35 9 912 35 4 999 20 27 582 28 19 57 514 74 466 60 OO 166 75 0 48 12 25 90 04 1431 04 o T r ones E HAH SFC QUILL ON QUILL 12 ASSY 005 ca 12 4H ovs ENTERICKRISES 565 CUSTOMER 0005 DATE 6 11 03 ga se NOTES 3 UNIBHDY 4 amp 5 UNIBUDY 4 amp 5 QUICK RELEASE 3 PWS 2 PLANE ASSY REF 1003 002 amp BRKT 4004 126 3 PWS 4 PLANE ASSY REF 1003 004 amp BRKT 4004 171 4 PWS 2 PLANE ASSY REF 1004 012 amp BRKT 4004 158 1 4004 458 MAIN BASE PLATE 1 4 PWS PLANE QR ASSY REF 1004 008 amp BRKT 4004 146 2 9400 406 BAND 18585 1 3
17. Lapped A I a Y ey N J N N x Y Ec w 3 X x Z NAN No d rs A ie T V e E E mE t A J jding to tne JO nm 7 e Ok JAZ ane i aft Ipping fo e only B 2 TE IS Si CUTIE 1 a AC pt Y 2 b TATION I Qu QUIL O SHIM GRIND CUTTER SHIM G a TRAVELLING QUILL B 3 cnm INSTALLATION OF SWING IN ACCUMULATING GUIDE PLATES Install the new swing in guide plates with the larger chamfered hole side towards the wire side as shown Separate the first set of washers and insert one end of a new plate so that the cutout portion slips over the shaft and between the washers Separate the corresponding washers on the other shaft and pull them apart far enough to swing the other end of the guide plate between the shafts and slip the cutout end of the plate over the shaft fig 1 Release the springs washers and guide plate The result should be a washer on each side of the accumulating guide plate backed by a spring fig 1 ERT PLATE ELAXED NORMAL POSITION gt P
18. TROL ADJUST DISPLAY 10 E CLOCK INC DEC HOUR SCREEN SAVER AV Activate Exit Returns you the Main TAK Intro screen System Alarm Screens Alarm Count Alarm Message SAFETY DOOR OFEN AIR PRESSURE LOWY WIRE OUT ALARM HISTORY AUDIBLE SILENCE On this screen you can view the last 3 alarm conditions and the of times that the specific alarm has been triggered System Manual www takenterprises com System Screens If an alarm 15 active this will be shown on the screen This Alarm Present pop up will show on all system screens 11 an alarm condition is detected Touching OK will remove the pop up if the condition has been fixed or it will return after a few seconds if the condition is still present The actual alarm description will be shown in the lower left portion of the screens to make identification of the problem easier to detect Alarm count Alamo Message 4 yurari EhI ALARM PRESENT ALARM CONDITION DETECTED ALARM AUDIBLE RESET SILENCE Alarm History Touching this button will open the alarm history screen where all un cleared alarm events can be vlewed Alarm History Total of Alarms Entry Ma Alarm Mo Message AIR PRESSURE Lowy WIRE QUT FEED HOME SAFETY DOOR OPEN FEED AWAY r anfirm
19. USH A A A fA A A UM BERRE BARRE LARGE CHMF D SIDE W OF GUIDE PLATE RE IN DIRECTION 5 SWING A A A A A A BUREAU PLATE VY YY 1 PUSH ENTENERIE ES Screen and Operational information explanations ERROR Messages Some features apply to optional equipment But not limited to the following Wire out Feed not Home Feed not Away Cut Fail Optional equipped Loss of Air Optional equipped Snag on De Coil Optional equipped Remote device Error Optional equipped System Timeout Error Safety Cover Missing 29090 ps C des oues Stack Light Sequence Only with optional Pro Pack RED Steady Jinise System Idle Sitting GREEN Steady System Running GREEN AMBER Alternatine System Paused AMBER RED Alternating System Error Paused Audible Alert Pulsing System Error Paused If enabled AMBER Flashine End of Job Timers Ue Rear grip energize to Front grip energize a Front grip energize to Band cylinder energiz
20. chieve the correct spacing between the rear shaft support or the clamp and the rear stop block Step 4 Gently move the rear stop block to the new calculated dimension and tighten the four clamping screws on the rear stop block Step 5 Push the floating clamp mount firmly against the rear stop block replace the lexan safety cover and reconnect the air supply Cycle the system to cut a couple of pieces and repeat steps 2 thru 5 until successful Note The set cut length may be multiplied before a cut is made by any quantity up to 300 times by adjusting the skip value from the run screen on the system controller Adjusting the Speed System Manual www takenterprises com ENTENERIE LS The speed is adjusted on the Program screen Changing to a Different Size Shape or Type of Material Tooling Components Typically Involved Hand Tools Required 1 Traveling Quill Allen Wrenches Hex Keys English 1 Stationary Quill Needle Nose Pliers or Pencil Magnet 4 Feed Grippers Dial Indicator or Micrometer Depth Gauge amp Surface Plate 4 Feed guides ONLY IF NEEDED Quality bearing grease amp cleaning items 8 Accumulating guide plates ONLY IF NEEDED Each component has the diameter size etched into it Note 1 There are many occasions where some tooling items guides amp quills may be used for smaller sized material and therefore may not have to be changed out In about all cases the grippers mus
21. dicular to body B within 0002 Remove enough material to clean and acquire sharp edge for the full diameter of the wire hole See Fig 1 NOTE After grinding surface A must be lapped to remove any grinding lines and to ensure longevity Step 3 Step 2 Grind Stationary Quill Grind end A of quill opposite wire entry side flat and perpendicular to body B within 0002 Remove enough material to clean and acquire sharp edge for the full diameter of the wire hole See Fig 1 Step 3 Lapping Procedure a Use diamond lapping compound to remove all grinding lines b Radius or break the wire hole cutting edge approx 002 for hard wire only B 1 Mr ENTENERIE ELSE Quill on Quill Setting Procedure Step 1 Stationary Quill Set stationary quill with surface A Fig 1 flush to surface B Fig 2 Do not extend above surface B Use appropriate shim grind rings to set surface A of the stationary quill flush to surface B of the cutter body Step 2 Traveling Quill Set traveling quill with surface A Fig 1 flush or below the cutter arm surface C Fig 3 do not extend out from surface C Use appropriate shim grind rings to set surface A of the travelling quill flush or below surface C of the cutter arm NOTE Properly set quills should have clearance between surface A on stationary quill and surface A on traveling quill dependent on the wire type and hardness e Illustrations
22. e Band cylinder energize to Front grip de energize Front grip de energize to Rear grip de energize Ua Rear grip de energize to Band cylinder de energize UU Cut cylinder energize to cut cylinder de energize Speed delay timer O08 Rear Home Sensor to Rear grip energ1Ze UE Cut cylinder de energize to rear grip de energ1Ze End of batch to start of next batch Life count The total of cut cycles produced on the machine since manufacture or rebuild Reset by only Maintenance count A re settable counter showing the of cut cycles since the last manual admin re set Admin reset Dwell timers System timers used to delay PLC actions to compensate for air movement Admin reset Timed cutl The choice of using a set dwell time in milliseconds for the cut actuation Operator Job setup Sensor cut The choice of using actual positional sensors for the cut actuation Operator job setup Sonic Alarm Audible alarm switching for On or Off Operator job setup Batch mode cut A cutting mode where the operator can choose the number of batches to cut Operator job setup Batch mode clear To clear the count in a curr
23. eck for binding in the machine or on the wire line 3 Check for proper sensor operation by referring to electrical section Does the machine cycle but not cut 1 Check for proper air supply and recommended 80 PSI pressure 2 Manually check the function of the cut off cylinder air valve by depressing the small button located on the valve Does the machine cycle but not feed 1 Check for proper air supply and recommended 80 PSI pressure 2 Manually check the function of all the air valves by depressing the small button located on each valve 3 Check for proper gripper operation by referring to mechanical section Does the machine feed correctly for the first few pieces then feed erratic A Check for proper air supply and recommended 80 PSI pressure 1 2 Check and increase supply air line size if necessary 3 Check for proper gripper operation by referring to mechanical section 4 Check to be sure that the exhaust is not restricted at all ports System Manual www takenterprises com M ENTENERIE ELS Q Does the machine feed correctly then start feeding short Check for proper atr supply recommended 80 PSI pressure 1 2 Check and increase supply air line size if necessary 3 Check for proper gripper operation by referring to mechanical section 4 Check to be sure that the exhaust is not restricted at all ports Does the machine run correctly then stop A Check f
24. ence check wiring Why When the machine is turned on are the buttons on the run screen dark A3 l If the system is turned on and it is in an error condition this happens 2 Fix the error condition 3 Turn off the system using the power rocker switch then turn back on System Manual www takenterprises com ENTENERIE ELS Mechanical Will the machine make a complete cycle 7 A 1 Verify that there no excessive back pressures in the wire decoiling system 2 If the machine stops during the cycle check for binding through out the system Q Does the machine cycle but not cut 1 Verify the operation of the cutter head Q Does the machine cycle but not feed A 1 Check that all components are in their proper place and secured correctly 2 Verify the operation of the grippers and cylinders 3 Remove the grippers and check for wear or contamination that would prevent them from closing 4 Check for material variation Part Quality amp Condition Q Inconsistent lengths 1 Verify that there no excessive back pressures in the wire decoiling system 2 If the machine stops during the cycle check for binding through out the system Q Cut pieces have marks on them A 1 Verify the operation of the cutter head Q My end cut is not good Check that all components are in their proper place and secured correctly 2 Verify the operation of grippers and
25. ently running batch to start the current batch over Operator run mode System Manual www takenterprises com ENTENERIE ES Screen and Operational information explanations Single lot mode A cutting mode where the operator can choose the total number of parts to cut T TE Operator Job setup Batch number The operator will choose the number of batches to cut In a Job Operator Job setup Batch run quantity The operator will choose the number of parts to cut In each batch E EEE Operator job setup Job quantity The operator will choose the total number of parts to cut In the current Job Operator Job setup Skip number of feed strokes before cut cycle H M Operator job setup NN start running in determined operational mode Pause Stop To suspend runnin of a Job for any reason other than a complete Job restart Resume To resume running after clearing an error or a pause command System Reset To stop all job functions and clear all part count displays Neutral System Startup condition 1 valves non energized 2 Rear sensor engaged 3 Cover Safety engaged 4 Counter set or reset 5 Band cylinder slide w gripper body in the rearmost posi
26. ess Q What is the maximum length the machine can run A Our standard machine has a maximum 12 stroke but it is capable of feeding multiple times before the cut off action occurs It can feed up to 300 strokes before the wire is cut Q Can my system which is set up for round material be able to straighten something like a hex shape A The TAK SF amp C systems can be easily re configured to accommodate various shapes of material to include square hex D rectangular triangular and many more Q Will still need a 12 machine when my part length is never over 4 A No the TAK series SF amp C systems are available in several standard stroke lengths The series 02 is available in a 1 3 6 and 12 stroke length The series 03 is not available in a 4 stroke length The series 4L amp 4H are available in 6 and 12 stroke length only Usually the shorter stroke system will provide a little faster production rate than the 12 stroke unit on smaller length parts Q What types of options and configurations are available on the TAK feed and cut off systems A The TAK feed and cut off systems can be fitted with many special items amp options Call to discuss yours Overseas power requirements Process line interface with remote mounting of controller Motorized wire payoffs de coilers Customized simple end forming stations Cut piece collection and packaging Wire straighteners Cleaner Lubricators Fine Ad
27. f the material to be cut push the floating clamp mount to the extreme right side against the internal stop at the cutter end of the stroke To adjust your required length measure from the rear traveling end plate on the rear of the floating clamp mount to the stop button face located in the rear stop block Loosen the 4 clamping screws and move the rear stop block to the desired stroke length required Retighten the 4 clamping screws being careful not to use too much torque Push the floating clamp mount with rear gripper body as far to the left as possible This will position the floating clamp mount against the rear stop block Be sure to push it far enough to collapse the gas shock stop and bottom out against the stop button Make sure the material is still sticking out of the cutter body as described in Step 6 Safety Warning Before proceeding remove any tools or objects from the Feed and Cut System DO NOT put hands in front of the cut off area or near any moving parts The material will exit at a fast rate and could cause severe injury during the operating mode If step 8 is attempted without pushing the floating clamp mount to the far left position against the stop button the unit might jump to its starting position If the rear stop block was not securely clamped to the accumulating guide shafts the floating clamp mount may travel further than expected and again possibly causing severe injury Replace lexan safety cover since the unit will not
28. intenance and reset the counter Step 4 Place the wire out sensor in the up position Wire Out Sensor Special Notes If your feed and cut system has a straightening unit attached roll type or rotary type completely read the Instructions for straightening before proceeding The material should be straightened prior to setting the feed and cut section elements If your system employs a TAK Wire Cleaner Lubricator completely read the instructions for its use If your system employs a loop control device be sure to completely read the instructions for its use If you are utilizing a wire payoff or de coiler device be sure to have read the instructions for that item Step 5 Thread the material through any of the ancillary equipment such as wire straighteners wire guides cleaner lubricators etc as required prior to threading it into the TAK feed and cutoff system In so doing make sure that there will be no mechanical restrictions that will keep the material from running freely once the TAK system is activated Step 6 Thread the material from the left hand side through the hole in the rear gripper body the feed guides all the accumulating guide plates the front gripper body all the way through the cutter body and pull out approximately 2 to 3 inches from the cutter head System thread up is now complete System Manual www takenterprises com ENTENERIE ELS Step 7 To roughly estimate the length o
29. justment Device etc See section 4 for some standard items System Manual www takenterprises com Basic Troubleshooting List This list is intended to guide you to some common solutions and all the following checks should be read and or tried prior to contacting technical support The proper function of this machine depends upon but not limited to the following 4 categories NOTICE Any attempt to access or modify inner components or modify the operation of the basic machine without the express consent or direction of technical support will result in restrictions stated in the disclaimer shown elsewhere in this manual Basics Before proceeding check the following primary items first HEF Check the touch screen for any error messages first Correct identified problems Check to ensure that proper tooling items amp sizes correctly correspond to the application attempting to be run Check for proper electrical connection and power values Check that all components are in their proper place orientation and secured correctly Check to ensure that any integrated ancillary items are all running properly Pneumatics Q Will the machine make a complete cycle 1 Check for proper air supply recommended 80 PSI pressure Where in the cycle does the machine stop 1 Check that all components are in their proper place and secured correctly 2 Ch
30. nd touch enter Batch quantity entry Is entered the same as the part quantity entry System Manual www takenterprises com ENTENERIE ELS Frequently Asked Questions Q If have various applications that encompass different types of materials to be fed and cut do need another machine to do this A No The cassette tooling design of the TAK SF amp C system allows for the replacement of all the tooling components The tooling can be fabricated using many different materials and or processes to accommodate just about any stringent application needs Q If my application parameters go beyond a particular operation range of one of the SF amp C series does that mean that must purchase two different systems A Not necessarily Typically the series with the larger size capability can employ smaller sized tooling to run a smaller size material Q What type of cutting application is best suited for a servo based system as opposed to the pneumatic type A Usually the two main differences are price and performance A servo system can produce any cut length but is best used for very long cut lengths if speed is important Secondly servo systems typically employ more sophisticated controls and usually have very easy key in set up and control panels The pneumatic style systems are still considered the best for high speed close tolerance short length application The pneumatic styles are very reliable and usually cost l
31. o which the machine and equipment are being applied WARNING OSHA Sections 1910 147 1910 211 1910 212 and 1910 217 contain installation information on the required distance between danger points and point of operation guards and devices No specific references have been made to which paragraph of OSHA 1910 147 1910 211 1910 211 1910 217 or any other applicable sections because the paragraphs may change with each edition of the publications of OSHA provisions All equipment manufactured by TAK Enterprises is designed to meet the construction standards of OSHA in effect at the time of sale however the EMPLOYER ultimately installs the equipment and is therefore responsible for installation use application training and maintenance as well as ensuring that adequate warning signs are visible on the machine onto which the equipment will be installed OSHA states that the EMPLOYER must ensure that safe operating methods designed to control or eliminate hazards to operating personnel are developed and employed and that operators are trained in safe operation of the equipment It shall be the responsibility of the EMPLOYER to establish and follow a program of periodic and regular inspections and maintenance of machinery to insure that all their parts auxiliary equipment and safeguards are in a safe operating condition and adjustment Each machine should be inspected and tested no less than weekly to determine and confirm that the operating conditi
32. on of the machine meets safety standards Necessary maintenance or repairs to machinery auxiliary equipment and safeguards shall be performed and completed before the machine is operated The EMPLOYER shall maintain accurate records of these inspections and maintenance work performed It is not the responsibility of TAK Enterprises to provide notification to the user of this equipment concerning future changes in State or Federal laws or construction standards SAFETY PROGHAM Accident free operation will result from a well developed management sponsored and enforced safety program Of vital importance to the success of a safety program is the proper selection of guards and devices However there is no safety device that will insure automatic or fool proof safety to your operation Of equal importance to the proper selection of machine guards and devices is effective training of operating personnel Each individual must be trained in the proper operation in accordance with established standards developed for the guards or safety devices employed with emphasis on why specific guards and safety devices have been provided on the equipment Rules for safe operation should be in writing available to company personnel and enforced at all times An effective safety program must include regularly scheduled inspections and maintenance of all equipment with accurate records to reflect the successful completion of inspections and maintenance To en
33. or excessive heat anywhere on the machine Check for excessive bouncing on the wire out sensor arm Check for loss of air pressure in lines Check for loss of power Check the safety cover interlock The magnet in the cover should be positioned over the switch od zd s Electronics Was machine running before the problem or did the problem arise when turning on the machine A Check for proper electrical connection 2 Check the fuse inside the control box if you suspect power problem 3 Check the safety cover interlock The magnet in the cover should be positioned over the switch 4 If the screen is backlit and the display is functional assume the control power is OK Will the machine make a complete cycle I Make sure the cylinder is In the rearmost position prior to any cycle 2 With the safety cover in place observe the rearmost sensor If your machine has photo electric sensors the indicator light will be off 3 If the light stays on check for proper alignment and slide position to break the light beam 4 Adjust or replace as required 5 Remove the safety cover and disconnect the air supply Manually push the slide to the forward most position and replace the safety cover Observe the front sensor See previous step Does the machine cycle but not cut or feed properly 1 During cycling observe the indicator lights on the valve for each cylinder 2 If each does not light In sequ
34. stem the front gripper automatically clamps down This will deny the passage of material through the system by hand Almost all cylinders used on this system have a low thrust value so extreme care is required in the tightening of the attaching screws Use a minimum amount of torque on the attaching screws to keep from stripping the threads as the majority of the threads are into aluminum Step 1 Select the proper tooling items for the application and check the condition of each item for operational use Feed Guides Accumulating Guide Plates Cutting Quills Fig 1 Series 02 tooling shown Tooling Note Typically the tooling provided is as pictured in figure 4 1 above Applications for material sized 020 and under will employ a set of Square Shaped cutting quills The square quills will only fit into the Square Cutting Block Assembly In the series 402 system the short quill is the stationary and the long one is the traveling Also in the series 02 one guide is shorter and is always placed in the Front Gripper Tooling configuration is similar in appearance throughout the SF amp C product lines System Manual www takenterprises com ENTENERIE ELS Step 2 Remove lexan safety cover by unscrewing the 4 plastic knobs Step 3 Remove any existing material from the system Remove any installed tooling and check system for signs of wear Check maintenance count number on admin screen and if needed perform scheduled ma
35. sure that a safe working environment is maintained at all times management supervisors safety engineers and all production employees must assume their proper share of responsibility to establish and maintain an effective safety program All members of the company community should be involved so that an accurate view of the specific areas within the facility that require attention are addressed To assist you in the development of and maintenance of an effective safety program many trade groups and safety related organizations provide guidelines and recommendations that are available to you However you must know when and how to apply these guidelines The equipment manufacturers provide information to assist you in properly adjusting and maintaining your equipment is recommended that the employer comply with these guidelines at all times 1IPage 30 April 2008
36. t Touching this button will give the option of a sensor controlled cut action or the default time based cut T06 Preset Select Touching this button will open a keypad to enter the cutter time for the default time based cut System Run Screen This screen is the main monitoring screen to run or view the system operation RUN SCREEN SKIP PRESET PART PRESET 123 123 123 RUN ACTUAL PARTS 122 723 TOTAL 123 123 SPEED PPM BATCH PRESET BATCH ACTUAL 1234 123 123 123 123 ALARM T ALARM STOP EDIT SEQ NOT READY 5122 Skip Preset This is a view only indication of how many skips were preset in the program setup on the edit screen System Manual www takenterprises com ENTENERIE ELS Part Preset Run Actual Parts Run Actual Total Speed Batch Preset Batch Actual Start Stop Alarm Reset Alarm Silence Pause Edit Resume Main Clear System Screens This 15 a view only indication of how many parts were preset in the program setup on the edlt screen This 15 a view only indication of how many parts have been made in the current batch This is a view only indication of the total parts that have been made in the current job This 15 a view only indication of the parts per minute that the system 15 producing at the current settings This is a view only indication of how many batches were preset in the program setup on the edit screen
37. t always be changed to the size of the material in order for the system to be able to feed the material correctly Note 2 Always check each tooling item for wear and damage Set aside for cleaning amp maintenance Safety Warning BEFORE PROCEEDING Disconnect the air supply line coming from the source DO NOT re connect the air supply until the unit is completely adjusted and ready to run according to the following instructions Remove lexan safety cover Step 1 Remove all material from feed mechanism Step 2 Skip this step s procedure if the new size doesn t require a guide change Remove accumulating guide plates by rotating them to remove them from between the spring washers on the accumulating guide shafts Replace the accumulating guide plates with the proper size for the new material being processed Step 3 Remove rear gripper cylinder by removing the four retaining cap screws on top Step 4 Remove the upper and lower feed grippers positioned within the rear gripper body Loosen the two set screws retaining the feed guides in the rear gripper body located at both the entry and exit ends Push the feed guides out of the rear gripper body and remove Note All lead in holes with counter sinks on the feed guides must be facing to the feed in side Step 5 Take the feed guides for the size and shape you are switching to and insert it into the hole in the rear gripper body The lead in counter sunk hole end of the feed g
38. th cleared alarm pop up condition RUA ACTUAL SEIF PRESET FART PRESET non PARTS 0 DO 000 i TOTAL 000 000 SPEEDO BATCH FRESET BATCH ACTUAL DDD DDD 000 DDD SIART ALARM View with system Daused condition SEQ NOT READY System Manual www takenterprises com System Screens View with run complete condition RUN SCREEN RUN ACTUAL SHIP PRESET PART PRESET Baars 000 000 RUN COMPLETE System Edit Program Screen This screen is where the presets for parts batch and skip quantities are entered The machine speed factor can be entered here The only entry on this screen that can be changed during operation is the speed delay PART SET BATCH SET QTY 1 234 512 1 234 512 SKIP VALUE AUDIBLE SPEED DELAY 1 Min 00 FAST 100 SLOW 123 SEQUENCE RETURN Audible Alarm If the system 15 equipped the audible alarm be turned on or off for use during the Job being setup Sequence reset This button will clear all counts and reset the system to the beginning of the program run Return This button will return you to the run screen System Manual www takenterprises com ENTENERIE ELS System Screens Part quantity entry By touching the number section on the part set quantity section of the screen a keypad will popup Enter the desired quantity to produce a
39. tion 6 Front gripper holding stock This condition puts air pressure on the main band cylinder forcing it to the rear away from the cutter end the cut off cylinder to the retract position the front gripper cylinder in the engaged gripping position the traveling gripper cylinder in the retract open position System Manual www takenterprises com EW TEMERS CE Screen and Operational information explanations SF amp C CONTROL CAUSE amp EFFECT 1 RUNNING SINGLE STROKE PARTS PAUSE CONDITION STAYS IN SEQUENCE amp STOPS 2 NEXT FEED HOME STOP CONDITION IMMEDIATE STOP amp RESET TO STAND BY COUNT ACTUAL MANUAL CLEAR REQUIRED IF DESIRED 2 RUNNING SKIP MULTIPLE STROKE PARTS PAUSE CONDITION STAYS IN SEQUENCE amp STOPS 2 NEXT FEED HOME STOP CONDITION IMMEDIATE STOP amp RESET TO STAND BY COUNT ACTUAL MANUAL CLEAR REQUIRED IF DESIRED SKIP ACTUAL AUTOMATIC CLEAR ON STOP CONDITION 5 RUNNING SINGLE STROKE PARTS IN BATCH MODE PAUSE CONDITION STAYS IN SEQUENCE amp STOPS 2 NEXT FEED HOME STOP CONDITION IMMEDIATE STOP amp RESET TO STAND BY COUNT ACTUAL MANUAL CLEAR REQUIRED IF DESIRED BATCH ACTUAL MANUAL CLEAR REQUIRED IF DESIRED CURRENT BATCH COUNT MANUAL CLEAR REQUIRED IF DESIRED 4 RUNNING MULTIPLE STROKE PARTS IN BATCH MODE PAUSE CONDITION STAYS IN SEQUENCE amp STOPS 2 NEXT FEE
40. uides must be facing toward the left DO NOT force the feed guides against the free moving feed grippers System Manual www takenterprises com ENTERPRISE Step 6 Place a feed gripper into the center of the rear gripper body with the ground groove traversing from left to right the same as the material feed line Place the second feed gripper on top of the first aligning the radii or V groove A material sized for the grippers should move freely through the feed grippers until pressure is applied Note Some systems which have been configured for applications under 020 0 5mm in diameter may have small springs set in the corners of the feed grippers Take care to ensure that all springs are in place when placing the top feed gripper onto the bottom one Step 7 Replace the rear gripper cylinder Step 8 Replacement of feed grippers and feed guides for the front gripper body is the same as the procedure outlined in steps 3 7 Step 9 Cutter Change Over Remove the cutoff cylinder by removing the two retaining cap screws that hold the cutoff cylinder to the cutter body Step 10 Remove the cutter body by removing two cap screws that hold it to the cutter base Then slide the cutter body to the right to remove Remove the cutter arm cover then remove the traveling quill block Remove the traveling quill Now you can remove the stationary quill from the cutter body by loosening the retaining set screw with an
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