Azco SUR-PAK FG400 User manual

Operation Manual
MODEL: FG400
SERIAL #: 203104

Azco Corp. Page 1 10/8/2013
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

Azco Corp. Page 2 10/8/2013
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.

Azco Corp. Page 3 10/8/2013
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!

Azco Corp. Page 4 10/8/2013
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.

Azco Corp. Page 5 10/8/2013
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

Azco Corp. Page 6 10/8/2013
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.

Azco Corp. Page 7 10/8/2013
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.

Azco Corp. Page 8 10/8/2013
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

Azco Corp. Page 9 10/8/2013
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.