Azco SUR-PAK FG400 User manual

Operation Manual
MODEL: FG400
SERIAL #: 203104

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Table of Contents
Introduction......................................................................................................................... 2
Specifications...................................................................................................................... 3
Installation .......................................................................................................................... 4
Advanced Setup ..................................................................................................................5
Operations........................................................................................................................... 7
Machine Operations Modes:........................................................................................... 7
How to Set Up an Automatic Cycle................................................................................ 9
How to Setup the FG to Run in Eye Mode ................................................................... 11
Eye Registration Setup.................................................................................................. 14
Setup Instructions for Four-Wire “One Shot” Wiring .................................................. 15
Screen Functions............................................................................................................... 16
General Maintenance ........................................................................................................ 26
Blade Replacement Instructions ................................................................................... 26
Blade Setting Instructions ............................................................................................. 26
Preventative Maintenance................................................................................................. 27
Troubleshooting ................................................................................................................ 28
Recommended Spare Parts ............................................................................................... 29
Parameter Default Settings ............................................................................................... 30
Mechanical and Electrical Drawings ................................................................................ 31

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Introduction
The AZCO SUR-PAK™, MODEL FG, is a motor fed precision cutting machine.
It is designed to cut and dispense a wide variety of materials of varying thickness fed
from a continuous web. An optical sensor is used to detect a registration mark on the
product web. The location of the registration mark is then used to determine the location
of the cut. The unit requires 110 VAC, 50/60 Hz, single phase and a 40 to 60 PSI supply
of compressed air, unless marked for 220VAC near the AC input receptacle.
This manual describes how to install, operate and maintain your unit. Please read
the manual thoroughly before starting the unit to insure long, safe and efficient operation.
If you have any questions about the machine, call us at [phone]. Our technical
staff will offer prompt assistance with any questions you might have.
Additional Features for the Model FG:
1. Eye Registration: Allows product to be cut relative to a registration mark.
2. Jam (Verification) Sensor: Stops the machine if product jams at the knife. Also
allows the machine to signal an external controller if no product is dispensed after
the unit cycles.
3. One Shot Mode: Allows the machine to act as a slave to another controller or
indexer, triggered by a remote contact closure (such as a relay or switch). May
also be used to trigger the unit using a limit switch or photo-eye, such as when a
container is detected under the exit chute.
Options Available on the Model FG:
1. No Product Sensor: Stops the machine if end-of-product condition is sensed at
the in-feed end of the unit.
Instructions for these features and options listed above are included in this
manual. AZCO Corporation warrants all its products against defects in materials or
workmanship for one year. Parts subject to normal wear (such as blades, rollers and
bearings) or damage due to abuse, tampering, neglect or accident are excluded from
the warranty.

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Specifications
Supply voltage 110VAC, 50/60 HZ, single phase
(220VAC, 50/60 HZ, single phase available on some models)
Supply current Standard (5-phase) units: 10A
Air required 40-60 PSI compressed, filtered (non-lubricated) air
Accuracy +/ - .047 in. (1.2mm)
WARNING:
THE UNIT MUST BE PROPERLY GUARDED BEFORE OPERATING!
DISCONNECT POWER AND AIR BEFORE SERVICING!

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Installation
1. Secure the unit to a workbench or a table where it will be operated.
2. Make sure that all guards are on and closed.
3. Verify that the main power switch on the side of the machine is in the OFF
position (in the OFF position, the switch is toggled to the right).
4. Connect 40 to 60 PSI of FILTERED (non-lubricated) air to the machine by
inserting ¼” airline into the quick connect fitting on the back of the machine.
To remove airline, push in on airline tubing with one hand, push in on fitting
ring with other hand, then pull airline out.
5. Plug the power cord into an outlet appropriate for the particular machine. On
standard units, the required power supply is 110 VAC, 15AMP. If the unit is
designed for 220VAC operation, this will be indicated on a label near the AC
input receptacle and the machine MUST be connected to a 220V supply.
6. If the unit will accept a trigger from another piece of equipment in the One-
Shot Mode for wiring instructions.

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Advanced Setup
WARNING: ONLY AN EXPERIENCED PERSON SHOULD ENTER THE
ADVANCED SETUP. IMPROPER SETUP MAY CAUSE DAMAGE OR INJURY.
Normally, these settings do not need to be changed. However, in the event some
parameters need to be adjusted or changed, proceed as described below.
Note:
In order to return your machine to the same operating condition in the case of a memory
error, please write down the values from the Advanced Setup on the “Parameter Default
Set and Factory Set” included at the rear of this manual; once the machine has been set
up.
1. To Enter the Advanced Setup press the ADVANCED SETUP button. While in
the Advanced Setup mode, the operator may return to the main menu
immediately, without going through the rest of the setup by pressing main menu.
Those values already entered will remain in the memory.
2. Enter The Password: The Default Password is will be given to the supervisor of
the company
3. Set High Speed: The High Speed is the maximum speed that the step motor can
go. The servomotor always accelerates from low speed to high speed and
decelerates from high speed to low speed before stopping. So the maximum speed
setting depends on the pulling force required to move the material. The range
available is a 100 to 5000ppm.
4. Set Knife-Down Dwell Time: The Dwell Value determines how long the knife
solenoid should stay on, for the knife to complete the cut. The shorter the time,
the more products that can be run. The time interval is set in milliseconds (ms).
Note: If the timer is set to zero (“0”), the knife solenoid will be disabled, and the
knife will not operate at all.
5. Set Knife-Up Dwell Time: On a standard machine, the web advance is
controlled with the knife home sensor. If additional waiting time is necessary the

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knife-up dwell timer can be adjusted in (ms). The timer starts counting after the
knife solenoid is de-energized. Normal setting is (“0”) zero.
6. Set Acceleration Slope: The Slope Value controls how fast the motor accelerates
from low speed to high speed and decelerates from high speed to low speed. The
higher the value of the slope, the faster the motor will accelerate and decelerate.
Most equipment is set at 250.
7. Set Jog Speed: The Jog Speed is the speed that the web advances when the jog
buttons are pressed. The normal range of the speed is 20 to 300ppm.
8. Set The End Of Cycle Signal Duration Timer: When the knife finishes cutting,
this timer will create a delay that allows the jam eye to have the proper amount of
time to determine whether or not the product piece has fallen through the chute
properly. Note: If the timer is set to zero (“0”), the signal will be disabled (0 =
off, on the display), and no output will occur.

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Operations
Machine Operations Modes:
Continuous Mode:
In the counter mode the rollers will index, feed material to the preset length and
then the knife will cut what was feed. The machine will stop after cutting the
preset number of pieces.
Eye Mode:
The eye mode operation uses a registration mark and a sensor to determine where
the knife will cut. The rollers will index the web until the eye detects the
registration mark, then counts a preset offset length, stops and cuts. The machine
will run a preset number of pieces.

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One Shot Mode:
In the single shot mode, the knife will cut to length when it received an external
signal. The rollers will index a cut a preset length upon receiving a remote signal.
Machine will stop at the end of the preset number of pieces. The one shot signal is
a dry contact closure going from normally open to closed or optional from zero
volts to 110 VAC (AZCO will install a mechanical relay in control unit). One-
shot mode is found used in systems that require the AZCO unit as a subordinate
machine.
Features:
Jam Sensor:
The Jam Sensor can be used with any one of the above four modes. If the sensor
fails to detect product within a time period after a cut has been made, the cycle
will pause. The operator must then clear the jam (usually by removing a piece
which has become jammed at the knife or in the belts) and reset the alarm before
cycling can continue. If the End Signal Timer is enabled a verification signal will
be sent once the Jam Sensor detects product.
Options:
No Product Sensor:
The no-product sensor can be used with any one of the above four modes. If
product is not sensed at the in feed end of the FG within a time period the
machine will pause. The operator must then remedy the no-product condition
(usually by adding product to the machine) and reset the alarm before cycling can
continue.
WARNING
THIS UNIT MUST BE PROPERLY GUARDED BEFORE USE!!!
COVER MUST REMAIN CLOSED WHILE UNIT IS RUNNING

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How to Set Up an Automatic Cycle
(The FG is factory set to work in the Continuous mode):
1. Prepare the machine and adjust guides if necessary. See Machine Installation and
Product Threading.
2. With the E-stop button in the “OUT” position and the power switch in the “ON”
position, the LCD will illuminate and display the welcome/setup screen:
To start cycling using current settings (cut length or max length, cut offset and search
offset), simply press the machine run screen button. The FG will then display current
mode and setting information. You will then be asked to press cycle start to begin
cycling. To change settings, press cycle stop then main menu. After that enter the
standard setup and enter new values when prompted.

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3. If you entered the standard setup the following will be displayed:
Here, the length to be cut may be entered. See Advanced Setup for information on
changing units, if desired. For example, to cut a one-inch piece, the number entered
should be 001.000; for 100 inches, the number should be 100.000. If a wrong number is
entered press cancel and begin again. The entered digits will scroll across the display
from right to left. After the length is entered, press enter to continue.
SET CUT OFFSET:
[###] (Unit)
The Cut Offset is the distance the web will be fed after the registration mark is detected.
When the mark is detected, the web will probably not be in proper position to be cut. The
Cut Offset distance must feed it in order to position the desired cut location under the
knife. This offset is the distance from the blade’s edge to the desired cut location when
the eye first detects the mark. Enter this value and pres enter to continue.
SEARCH OFFSET:
[###] (Unit)
The Search Offset value helps the machine ignore any false eye signals between
registration marks. This distance should be less than the web’s repeat.
NOTE: For best performance, the Search Offset should be larger than the Cut
Offset. Otherwise, the motor may not accelerate to high speed.

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4. For All Modes
TOTAL CYCLES:
[###] (0=infinity)
Enter the number of pieces to be cut, and then press enter. To run continuously (i.e., to
cut to infinity) enter ‘0’. Note: If the machine is set to run continuously, IT WILL NOT
STOP until the cycle is stopped by the operator
How to Setup the FG to Run in Eye Mode
When operating an AZCO unit in the Eye mode, the operator must set three (3) values.
These are: Cut Offset, Max Length and Search Offset.
1. Cut Offset
The Cut Offset is the distance the web must be fed after the registration eye senses the
registration mark in order to position the desired cut location under the knife. By using
this offset no mechanical adjustments are needed when cutting different lengths of
material. When the mark is first sensed, the knife will most likely NOT be in the proper
position to make a cut, as shown:

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One way to determine the value of the Cut Offset is to set the Cut Offset to zero and run
one piece. After the cut is made, measure from the edge of the cut to the desired cut
location (which is usually at the center of the registration mark).
2. Max Length
The Max Length is a parameter, which prevents a “run-away” condition, where the
machine might continue searching indefinitely without seeing a mark. If such a condition
occurred, the machine could feed an entire web of material through the rollers without
making a single cut! This type of problem could occur for a variety of reasons including
eye failure, dirty optics, improper eye adjustment and web or mark drift. In order to
prevent this situation, the machine is programmed to search no further than a given
distance, which is called the MAX LENGTH. If no mark has been detected when the
web has been fed this distance, an alarm is generated and feeding stops.

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3. Search Offset
The final parameter, SEARCH OFFSET, determines how far the web will feed before
the program starts searching for a registration mark, as shown in Fig. 5:This parameter
prevents the registration eye from being false triggered. In the example in Fig. 5, the
program will ignore the stray mark shown in the Search Offset region, and the eye will
register off the edge of the registration mark instead. The Search Offset is very useful for
eliminating various sources of false triggering, including web flutter and stray marks. It
also keeps the machine from registering twice off the same mark in cases where the Cut
Offset is less than the mark size (in this case, the eye will still be on the same mark when
the next cycle is started).
Tip:
To determine the best value for the Search Offset, a measurement can be made on the
product itself as shown in Fig. 6.
Fig. 6 HOW TO MEASURE SEARCH OFFSET
Search Offset
of web
"infeed" end
example of a stray mark which may
occur on each piece
Note: The Search Offset is measured from the beginning of the registration mark, not
from the center of the cut location. Also, if the material being sensed has good contrast
(the background is much lighter or darker than the mark and there are no wrinkles or
stray marks to confuse the eye), the Search Offset can be set to a very small value. A
good rule of thumb is to set this value to one half of the piece length.

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Eye Registration Setup
1. All eye settings are set at the factory using customer-supplied materials.
2. Proper alignment of the thru eye beams must be maintained for proper operation
of the unit using eye registration. The heights of the thru eyes are set at the
factory.
3. Make sure proper horizontal alignment and parallelism is maintained.
4. Adjust spacing as follows: Move the product in and out of view of the opposing
eyes. The upper light module indicator (green bar of lights located on the front of
unit) will show the contrast readings. When the location of the mark or indicating
position is found the light bar should be toward the top of the indicator gauge (in
other words, if the light can shine thru from one eye to the other, the green lights
should be near the top of the indicator bar). Areas, which are not to be read
(beam can not shine thru), will appear at the lower positions of the scale. A
minimum of 7-bar difference will be required contrast.
5. By moving the eyes closer or further from each other the amount of sensitivity
can be adjusted making detection of the product more dependable.
6. Now the next step is to go into the calibrate sensor setting. The next prompt asks
for the product to be feed to its cut position so that the eye is looking directly at
the center of the seal. After the eye is looking at the seal the operator will the
press the learn seal button and the machine will store the reading and then it will
ask the operator to feed to the non-cut position. After the material is feed to the
center of the package the operator will then press learn package button. After the
eye is set the machine will be ready to run.
Now the product is ready to run. (Helpful Hint: to prevent unwanted tripping or erratic
operation, avoid excessive web flutter, wrinkles or background variations.)

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Setup Instructions for Four-Wire “One Shot” Wiring
General
With unit OFF and UNPLUGGED, connect the One-Shot input signal wires (red and
green wires on the pigtail, connected to pins 1 and 3, respectively, on P4, as shown on
the wiring diagram) to the controlling equipment. When these wires are connected
electrically, an index signal will be given to start the cycle in One-Shot or One-Shot
and Eye modes. A dry contact (switch, relay contact closure, etc.) is recommended to
generate this index signal. The output dry contact signal lines (black and white wires
on pigtail, connected to pins 2 and 4, respectively, on P4, as shown on the enclosed
wiring diagram) may be used to provide an ‘end-of-cut’ signal to the controlling
equipment. The dry-contact output is rated to handle up to 28V DC or 250V AC
(contacts open; signal ‘off’) and up to 5A (contacts closed; signal ‘on’), with a
maximum surge current of 20A.
Software Setup for One-Shot Operation:
Set software to One-Shot or One-Shot + Eye mode. See Advanced Setup.
If an ‘end-of-cut’ output signal is desired, enter the Advanced Setup, then enter a
value for the “END SIGNAL TIMER”. This value specifies the duration of the ‘end-
of-cut’ output (i.e., how long the dry contact output will remain “closed”). For
example, if the end signal timer is set for 1500 ms (1.5 seconds), the unit will give a
dry-contact (relay closure) output for 1500 milliseconds (1.5 seconds) after each cut
has been made. Setting the timer to zero turns off the ‘end-of-cut’ output, and no
signal will be output. This timer is set to zero at the factory.

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Screen Functions
Main Screen
This is the screen that will appear at the startup of the machine. It allows the operator to
enter six different areas of configuration plus a help screen. Some of the areas require a
password to enter due to the sensitivity of the settings they hold.

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Advanced Setup
The advanced setup screen is reached by pressing the advanced setup button on the main
screen. It also requires a password to gain access (1428). This screen allows the operator
to adjust the speed of the machine by changing the knife and motor parameters. From
this screen you may also view the safety parameters for your unit and calibrate the
registration eye for proper sensing.
Knife Parameters
The knife parameter menu allows the operator to adjust the up and down dwell of the
knife assembly. The down dwell is the amount of time allotted for the knife to make a
cut. With air pressure ranging from 25-40 PSI, the smallest down dwell possible is 50.
Any down dwell that is lower than 50 will result in an incomplete cut. The up dwell is

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the amount of time given for the knife to return to its home position. The up dwell also
acts as a delay such that the program won’t continue until the up dwell has finished.
Therefore the fastest up dwell time possible is 0.
*THE AIR PRESSURE SHOULD NOT EXCEED 40PSI. ANYTHING HIGHER
WILL RESULT IN SHORTHER KNIFE LIFE AND POSSIBLE CYLINDER
DAMAGE.
Manual Operations
The manual operations screen allows the operator to manually jog the material through
the rollers either forward or backward. The speed is also adjustable up to 3000. The
manual cut button causes the machine to make a single cut to clear the exit chute on the
unit. These functions do not work while the unit is operating, they will only work when
the unit is not running.

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System Mode Select
In this screen, the operator can change the mode of operation. All of the other modes
will not give you the proper results. In continuous mode, the machine will just feed a set
length of material and make a cut. It will disregard all registration marks and just cut the
material into equal lengths each time.
a. One shot mode acts just like continuous mode, except it waits for an external
trigger and then it will make a cut determined by a set length. Once again, all
registration marks are disregarded.
b. Eye mode will use the max length, cut, and search offsets to make its cuts. It will
cut the package in the proper place; but the conveyor will not advance causing the
material to jam up the exit chute. In fact, the conveyor will not move in any mode
except in one shot eye mode.
c. In one shot eye mode the machine waits for an external trigger then it advances
until it sees a mark. It will then make a cut and advance the conveyor. After that
the unit will wait for another trigger and it will repeat this process until its cycle
has ended or it has received an error signal.
d. The encoder mode is used when an encoder is implemented with the machine. It
tracks the product and stops when the encoder has moved the maximum length
entered by the operator.
e. In encoder verify mode the encoder tracks the movement of the product and
compares it to the movement of the motor. If the lengths are out of a set value of
error the machine gives an error signal.