Iowa Precision Cornermatic Plus User manual

IPI003V04
CORNERMATIC PLUS
H. WEISS MACHINERY & SUPPLY
H. WEISS MACHINERY & SUPPLY
PHONE: [phone] - www.hweiss.com

H. WEISS MACHINERY & SUPPLY
H. WEISS MACHINERY & SUPPLY
PHONE: [phone] - www.hweiss.com

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CORNERMATIC PLUS
TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY SUMMARY
LOCKOUT GUIDE
ELECTRICAL SCHEMATIC (Back of Manual)
ASSEMBLY DRAWINGS (Back of Manual) Section/Page
1. INSTALLATION.........................................................................................................................1-1
A. SELECTING A LOCATION............................................................................................................... 1-1
B. PNEUMATIC REQUIREMENTS ....................................................................................................... 1-1
C. ELECTRICAL REQUIREMENTS...................................................................................................... 1-1
D. RECEIVING AND UNPACKING THE EQUIPMENT......................................................................... 1-1
E. SAFETY REQUIREMENTS............................................................................................................... 1-2
(1) Safety Precautions before Starting the Machine..........................................................1-2
(2) Safety Precautions When Operating the Machine.......................................................1-2
2. SYSTEM OVERVIEW................................................................................................................2-1
(1) Flange & Corner Requirements...................................................................................2-2
(2) Duct Requirements......................................................................................................2-2
B. TABLE TOP COMPONETS.............................................................................................................. 2-3
C. PNEUMATIC CONTROL PANEL ..................................................................................................... 2-3
(1) Pressure settings.........................................................................................................2-4
(2) Secondary Pressure Setting........................................................................................2-4
D. PROGRAMMABLE LOGIC CONTROL (PLC) OPERATING SEQUENCE ..................................... 2-4
E. CONTROLS....................................................................................................................................... 2-5
(1) POWER OFF...............................................................................................................2-5
(2) POWER ON.................................................................................................................2-5
(3) MAGAZINE LOW.........................................................................................................2-5
(4) Control Sequence........................................................................................................2-5
3. SYSTEM OPERATION..............................................................................................................3-1
A. SAFETY PRECAUTIONS ................................................................................................................. 3-1
(1) Before Starting the Machine ........................................................................................3-1
(2) When Operating The Machine.....................................................................................3-1
B. LOADING CORNERS ....................................................................................................................... 3-2
C. ADDING NEW CORNERS................................................................................................................ 3-3
D. PREPARATION FOR OPERATION.................................................................................................. 3-4
E. SYSTEM SHUT-DOWN..................................................................................................................... 3-4
4. MAINTENANCE.........................................................................................................................4-1
A. TORQUE VALUES FOR GENERAL ASSEMBLY ........................................................................... 4-1
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B. MAINTENANCE SAFETY..................................................................................................................4-4
C. SERVICING........................................................................................................................................4-4
(1) Lubrication, General Requirements .............................................................................4-4
(a) Lubrication Schedule................................................................................................4-4
D. PREVENTIVE MAINTENANCE.........................................................................................................4-4
(1) Preventive maintenance checks: .................................................................................4-5
E. TROUBLESHOOTING.......................................................................................................................4-5
F. ASSEMBLY DRAWINGS & ELECTRICAL SCHEMATICS..............................................................4-7
LIST OF TABLES
Table 4-1. Metric Bolt And Cap Screw Torque Values..........................................................4-2
Table 4-2. Unified Inch Bolt And Cap Screw Torque Values.................................................4-3
Table 4-3. Troubleshooting Chart..........................................................................................4-6
LIST OF FIGURES AND ILLUSTRATIONS
Figure 2-1 Cornermatic Plus .................................................................................................2-1
Figure 2-2 TDC and TDF Duct Fitting Flange Requirements................................................2-2
Figure 2-3 Fitting Height Minimum........................................................................................2-2
Figure 2-4 Table Top Components .......................................................................................2-3
Figure 2-5 Pneumatic Manifold Assembly.............................................................................2-4
Figure 2-6 Control Panel Switches........................................................................................2-5
Figure 2-7 Bottom Head Cycle Start Levers..........................................................................2-6
Figure 2-8 PLC Press & Crimp Timer Adjust Potentiometers (Under Cover)........................2-6
Figure 3-1 Pre-packaged Corners.........................................................................................3-2
Figure 3-2 Presser Cover......................................................................................................3-2
Figure 3-3 Inserting Corners .................................................................................................3-3
Figure 3-4 Duct fittings Placement........................................................................................3-4
Figure 4-1 Electrical Symbols Used On Assembly Drawings (Sheet 1 of 2).........................4-8
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SAFETY SUMMARY
INTRODUCTION
Safety is everyone’s business... Whether you are an equipment operator, a maintenance
person, a supervisor, or business owner, you are directly responsible for the day-to-day safe
operation of the equipment under your control. It is your responsibility to maintain and
operate this equipment in strict compliance with all applicable laws, safety regulations, and
the manufacturer’s recommended procedures.
PROMOTING SAFETY
Institute a company safety program. Management has a moral and legal responsibility for
promoting industrial safety. The formation of an organized safety program is strongly
recommended. This safety program should include the formation of a safety committee to
review and update company safety policies on a regular basis. Establish a firm policy on
safety regulations in the work place. Publish these objectives, spelling out each employee’s
responsibilities. Make certain that each employee knows what is expected of them.
SAFETY PROGRAM
The following steps are suggestions that a company developing, or expanding, a
comprehensive safety program should consider:
1. Industrial equipment manufacturers carefully design safeguards into their product in order
to minimize hazards. However, the manner in which equipment is incorporated into a
manufacturing process may inadvertently create a hazard or otherwise defeat built-in
safeguards. Closely examine the operation of your company’s processing equipment.
Take notice of potential hazards. Install guards or take other appropriate action to
eliminate hazard risks.
2. Make certain equipment operators and maintenance personnel are properly trained.
3. Setup a program of daily, weekly, and monthly machinery inspection. Make a check list.
Keep a historical record of all maintenance work, repairs, and adjustments.
4. Frequently evaluate safety guards and devices during actual product runs. Correct any
unsafe practice or situation immediately.
5. Establish safe, convenient material handling systems. If conveyor equipment is installed
in your facility, it should conform to recommendations published in the ‘American National
Standard, Conveyors and Related Equipment, Safety Standards for ANSI/ASME B20.1’
which is available from the American National Standards Institute (ANSI).
6. Provide personal protective equipment, such as safety glasses with side shields, safety
helmets, tongs, gloves, hand pads, spats, and protective sleeves, as required to suit the
operation.
7. Organize a company safety committee. Schedule periodic meetings on a regular basis to
review and update all safety policies.
8. Establish a firm policy on safety regulations in the work place. Publish these objectives,
spelling out each employee’s responsibilities. Make certain that each employee knows
what is expected of them.
9. Investigate all accidents and close calls. Take immediate action to prevent a recurrence
of the incident. Keep records of the investigation and the corrective measures taken.
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CORNERMATIC PLUS
10. Post a list of names, addresses, and phone numbers of physicians and others who are to
be called in emergency situations.
CUSTOMER'S RESPONSIBILITIES
There are certain hazards associated with the operation of any equipment or system of
machinery that are impractical, if not impossible, for equipment suppliers to safeguard. The
user must address these hazards and be responsible for providing guards or barriers for
establishing appropriate work procedures and for training personnel in the safe operation of
that equipment.
With respect to coil and strip processing equipment, the following hazards should be noted:
•Open pits and depressions or raised areas in the floor.
•Space between machines, where strip edges and ends are exposed during feed-up,
run, and tail-out conditions. This includes carry-over tables and both roller and belt
conveyors.
•Nip and pinch points of machinery, coils, and strip which may be exposed in feed-up,
run, and tail-out.
•Areas surrounding coil handling devices where coils are in motion, such as coil cars,
conveyors, up-enders and turnstiles.
•Areas surrounding payoff reels and re-coilers, where clock-springing strip ends
present a hazard during banding, un-banding, feed-up and tail-out conditions.
•Sheet and pack handling devices (including conveyors) where the motion, as well as
shifting of sheets or packs, may present a hazard.
•The area surrounding sheet stacking devices, which must be approached for setup,
but which should be clear of personnel during operation because of moving
machinery or material.
•Areas associated with high temperatures, high pressure fluids (hydraulic, air, or
water) and electrical devices and connections.
•The vicinity of machinery which moves into or out of the line.
REFERENCE SOURCES
Questions concerning specific hazards or safeguarding of equipment may be addressed to
the equipment manufacturer. For additional information, refer to the sources listed here:
American National Standards Institute (ANSI)
ANSI B11.18, ”Machinery and Machine Systems for the Processing of Coiled Strip,
Sheet and Plate - Safety Requirements for Construction, Care and Use.” ANSI
B11.4, “Shears: Safety Requirements for Construction, Care and Use.” ANSI
B11.14, ”Coil-Slitting Machines/Systems Safety Requirements for Construction, Care
and Use.” ANSI B11.18, ”Machinery and Machine Systems for the Processing of
Coiled Strip, Sheet and Plate - Safety Requirements for Construction, Care and Use.”
National Fire Protection Association (NFPA)
NFPA 79, “Electrical Standards for Industrial Machinery.”
European Union
“Directives on Safety of Machinery” and “CE Marking”
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WARNING LABELS
Warning and safety related informational labels are placed on the Iowa Precision Industries’
equipment at strategic points. It is important that these labels are not removed, covered,
hidden, or defaced. The purpose of these labels is to alert personnel to potential personal
injury hazards or other direct or indirect safety concerns.
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in minor or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
NOTICE indicates a company policy that relates directly or indirectly
to the safety of personnel or protection of property.
“It is important that the meaning of a safety sign is clearly understood
by those who may come in contact with the hazard. To increase the understanding of a safety sign’s
components, the ANSI Z535 committee encourages safety sign manufacturers and owners of
facilities to publish and exhibit the following (above) information on safety posters, safety bulletins or
the like. Doing so will assist in the objective of achieving a national uniform system for the
recognition of potential personal injury hazards and accident prevention.” - ANSI Z535.2, Annex A1
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CORNERMATIC PLUS
WARNING MESSAGES IN THIS MANUAL
Throughout this manual various DANGER, WARNING, CAUTION, and safety
related NOTICE messages appear. The intent is to alert operator and maintenance
personnel to potential hazards. In addition, important operation and maintenance details are
emphasized with the NOTE heading.
SAFETY FIRST
The equipment in this line was designed and manufactured for a specific task. DO NOT use
the equipment for any other function or to process material that is beyond the equipment’s
design specifications. Modifications or additions to this equipment line should not be made
without first consulting MESTEK MACHINERY. Replacement and maintenance parts should
be equal to original equipment. Use of other parts may result in unsafe operating conditions.
If there is a question as to the suitability of a part, MESTEK MACHINERY should be
consulted.
In general, every piece of equipment must be treated as dangerous. While operating or
maintaining this equipment, each person must be aware of their own safety as well as the
safety of all others around the line.
Material Coils
Coils present numerous hazards. They may shift, roll or fall without warning. Some
coils may spring open without warning. Sharp edges of the strip in the coil are
hazardous. Stay clear of coils as they are being moved. Use extreme caution any
time a coil is approached or handled.
Metal Strips
The metal strip may have sharp or ragged edges. The strip is under tension and is
subject to abrupt tension changes. This can result in strip breakage with the ends
flying without warning. Stay clear of the strip whenever possible. When it is necessary
to approach or handle the strip, use extreme caution. Use protective devices such as
tongs, gloves, eye protection, and wrist guards as required for safety. The strip
presents many pinch hazards with the machinery. Stay clear of these. Never step on
or over strip in the line.
Machinery
Never reach into any piece of machinery which is operating or which is capable of
operation. Loose clothing or jewelry should be kept clear of machinery at all times.
When working on one piece of equipment, be aware of hazards of surrounding
equipment. Any item inserted into a machine may be thrown or may cause a
dangerous malfunction or breakage.
Safe Guards
No equipment should be operated unless the safe guards or devices supplied with
the product fittings are securely in place and properly adjusted.
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WARNING
MESTEK MACHINERY has conduct hazard evaluation and risk analysis studies for their
product. Safe guards installed on the equipment are there for a reason. BEFORE
EQUIPMENT IS PLACED INTO SERVICE, ALL SAFE GUARDS OR DEVICES MUST BE IN
PLACE AND PROPERLY ADJUSTED.
Maintenance
Before performing any maintenance on a piece of equipment, insure that all power is
locked off in accordance with your company’s lockout/tagout policy. Be sure that all
movable members (such as rolls, arms, tables, etc.) are securely blocked from
inadvertent motion which might be hazardous. Treat all electrical lines as being live
and all Mestek Machinery as being under high pressure. Ensure that all items are
properly reassembled before placing them into operation. Before equipment is
returned to service, ALL safe guards or devices MUST BE in place and properly
adjusted.
NOTICE
Before doing any WELDING ON EQUIPMENT, the following precautions must
be taken to insure against damage:
1) All power is removed from system.
2) The weld ground is connected to the closest possible location on the unit
where the welding is being performed.
3) All encoders, sense eyes, and controls should be electronically
disconnected if at all possible to avoid possible damage.
Operation
This equipment is capable of speeds, tensions, and adjustments which may be
hazardous for some of the materials within the line specification. For example, thin,
narrow strip may be subjected to tensions sufficient to cause breakage. Never
attempt to process any material unless the safe adjustments for that particular are
known and can be implemented.
Traffic Around Equipment
Care should be taken at all times in moving around the equipment, whether on foot or
in a vehicle. Changes in floor elevation, machine bases and debris around the
equipment are trip hazards. Take care that personnel are not trapped between
vehicles and equipment.
WARNING
Do not attempt to walk or climb on any machine while in operation. Failure to observe this
warning may result in death or serious injury.
HAZARD REMINDER
Use the following HAZARD REMINDER sheet to reinforce awareness of the hazards
associated with coil processing lines. This reminder can be a useful supplement to your
company’s safety program. MESTEK MACHINERY suggests the following steps:
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1. SHOW each individual the HAZARD REMINDER sheet and explain each category of
hazard.
2. POINT OUT EXAMPLES of each type of hazard on the actual equipment the individual
operates or works around.
3. EXPLAIN HOW TO AVOID HAZARDS in the individuals work environment.
4. GIVE a copy of the HAZARD REMINDER sheet to each individual.
Safety is everyone’s business!
H. WEISS MACHINERY & SUPPLY
H. WEISS MACHINERY & SUPPLY
PHONE: [phone] - www.hweiss.com