Kentucky PD1000 User manual

PD1000_v2008.66
PD1000
Rack & Pinion
Automatic Stop System
*Important to note: PDX (PD1000) systems are customized per
application. The contents in this general gauge manual may vary from
your specific machine details. Please contact factory for guidance or
questions regarding your machine.
INSTRUCTION MANUAL
Hymark Ltd. – 427 Bark Cove – Owensboro, KY 42303
[phone] – Fax [phone]
www.kentuckygauge.com

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Identification Data
Model
PD100
Serial Number
Controller PartNumber
PS312P
Software Number
Controller Serial Number
Customer Data
Inventory-Number
Location
Technical support and Spare
Parts
Hymark Ltd
427 Bark Cove
Owensboro, KY 42303
USA
Phone [phone]
Fax [phone]
Document Number of the Manual
Version
Date
Last changings

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Table of content
1. Product Description 5
1.1 Intended use 5
1.2 Workplace 6
1.3 Danger zones 6
1.4 Technical specifications 6
2. Basic Safety Hints 7
2.1 Notice hints inside manual 7
2.2 Owner obligations 7
2.3 Operator obligations 7
2.4 Intended use 7
2.5 Warranty and liability 8
3. Safety Instructions 9
3.1 Symbol explanation 9
3.2 Organizational measures 9
3.3 Safety devices 9
3.4 Operator training 10
3.5 Position Controller 10
3.6 Safety measures 10
3.7 Danger by electrical power 10
3.8 Special danger zones 11
3.9 Maintenance and trouble shooting 11
3.10 Construction changes at the machine 11
3.11 Cleaning of the machine and disposal 11
3.12 Exposure to noise 11
4. Transportation 12
4.1 Installation location 12
5. Installation 13
5.1 Installation procedure 13-22
6. Intended Gauge Use 23
6.1 Check before power on 23
6.2 Power on 23
6.3 Power off 24
7. Trouble Shooting 24
8. Maintenance 25

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1. Product Description
Note: Carriage length and depth can differ depending on motor and
gearbox type
Operating Procedure (as “go to” stop)
1. Enter length to be cut into the position controller and press the Start
Button. Gauge arm now moves into position.
2. Material is positioned through saw (or drill or punch) to desired length.
3. Engage the saw material clamp.
4. Retract gauge arm by pushing the Retract/Extend button.
5. Cut the material.
6. Remove the material.
7. Disengage the saw clamp.
8. Extend gauge arm by using the push button.
1.1 Intended Use
The only acceptable use for the PD100 is as a length gauging / feed system. Any
other use is not intended and is a misuse of the gauging system.
Adjustable arm
(optional gripper)
Carriage hood
RC conveyor
Double linear
guide and rack
Adjustable
faceplate
Controller
with stand

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1.2 Work Area
Operator work area
When the machine is powered on, the only acceptable operator location in the
work area is standing in front of the control stand on the opposite side of the
conveyor (see picture above) Never place any material on the conveyor except
the piece to be cut.
1.3 Danger Zones
•The carriage
•The area between the face plate or carriage and the saw, drill, puncher
or any other machines
These areas are always dangerous and have the potential to harm the operator
or others. Use safety precautions when working inside these areas.
1.4 Technical Specifications
General Data
Weight
8 lbs per ft measuring length without conveyor
Travel speed
16in/sec (other upon request)
Power supply 115 V AC 60 Hz Input power
24 V DC Operating power
Current
Max 5 A
Fuse positioning controller
6A, slow-blow fuse 20 x 5 mm
Gauge arm extension
12 inches (others upon request)
Operating Temperature
+ 5° C to + 45° C (41°F to 113°F)

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2. Basic Safety Hints
2.1 Read and follow all hints inside the Instruction Manual
This instruction manual, especially the safety hints and precautions must be
followed by every person working with this gauge or machine.
Also follow all general plant safety rules and precautions not mentioned in
this manual.
2.2 Owner Obligations
The owner agrees to only allow the gauge or the machine to be used by qualified
and trained persons who:
Have been instructed in general safety rules and precautions
Have been instructed in the correct use of the gauge and machine
2.3 Operator Obligations
All persons working with this gauge and machine agree before operating:
To follow general safety rules
To read and understand this instruction manual.
2.4 Intended Use
The only acceptable use for this gauge is as a length gauging system. Any other
use is not intended and is a misuse of the gauging system.
Hymark is not liable for any damages resulting from misuse.
Additionally:
Following all general safety rules and precautions mentioned in this manual
Following the maintenance and inspection procedures as mentioned
in this manual.

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2.5 Warranty and Liability
Hymark Ltd Co (henceforth Hymark), warrants this product for a period of
twenty-four (24) months from the date of shipment. During the warranty period,
under authorized return component parts to Hymark freight prepaid, the
company will repair, or at its option, replace any part found to be defective in
material or workmanship, without charge to the owner for parts, service labor, or
associated customary shipping costs.
This same protection will extend to any subsequent owner during the warranty
period. It does not apply to damage caused by accident, misuse, fire, flood or
acts of God, or from failure to properly install, operate, or maintain the product
in accordance with the printed instructions provided.
This warranty is in lieu of any other warranties, expressed or implied, including
merchantability or fitness for a particular purpose, which are expressly included. The owner
agrees that Hymark’s liability with respect to this product shall be set forth in this warranty,
and incidental or consequential damages are expressly excluded
Hymark is not liable in part or in whole for any personal or equipment damage
caused by of the following:
•Unintended use of the gauge
•Improperly mounting, installing, maintaining or operating the gauge.
•Operating the machine when the safety devices are damaged or not
properly installed or if the safety or protection devices are not working
properly.
•Disregarding the hints, notes and warnings concerning the
transportation storing mounting installing using or maintaining the
machine.
•Changing the construction or assembly of the machine.
•Replacing the original motor with a stronger motor or changing the load
bearing components of the machine.
•Not monitoring the machine parts that wear.
•Improper repair or replacement.
•Acts of God or damage caused by impact of materials not involed in
machine operation.

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3. Safety Instructions
3.1 Symbol and Hints Explanation
In this manual the following symbols are used:
Danger!
This symbol means an immediate impending life threating or personal injury possiblity
if caution is not taken.
•Not following these hints can cause major injury.
Danger by electrical power!
This symbols warns of an immediate life threating or personal injury risk by electric
shock if the warning is not followed.
•Not following these hints can cause major injury.
Caution!
This symbol means that there is a possibly dangerous situation may occur.
•Not following these warning may cause personal or device damage.
Important!
These symbols give important hints for proper operation of the machine.
•Not following the these instructions can cause the machine to operated
improperly.
Note!
Under this symbols you get user hints and other special use of the machine for
optimal use of the machine functions.
•Following these hints will help with the optimal machine usage.
3.2 Owner Responsibilities
The owner is responsible for any necessary personal protection equipment
needed for safe operation of the machine.
The owner is responsible for the correct function of any and all safety devices.
3.3 Safety Devices
Before any operation of the machine all safety devices must be installed
properly and tested.

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Safety devices may be removed only
-when the machine is at a standstill
-after making sure that the machine cannot be run (i.e. removing power
to the controller).
When any component of the machine is replaced or removed the safety
devices must be properly installed and tested.
3.4 Operator Training
Only trained personnel can operate the machine.
The training requirements for assembling, operating, maintaining the machine
must be clearly defined. Personnel in training, must be accompanied by
trained personel.
Personnel
Job function
Trained
Operators Mechanically trained personnel
Electrically trained
personnel
Operating
X
--
--
Troubleshooting
X
X
X
Repairing
X
X
X
Maintenance
--
X
X
X...allowed --...not allowed
3.5 Position Controller
•Only trained personnel are allowed to use the position controller.
•Only personnel with electronic training are allowed to open the position
controller.
3.6 Safety Measures for Gauge Use
•Only operate the machine when all the safety devices are working
properly and have been fully tested.
•Before applying power be sure that nobody can be harmed by machine
movement or operation.
•The machine must be checked at least once a day to check for
recognizable damage and proper function of the safety devices.
3.7 Danger by Electrical Power
•Only properly trained and qualified electrical personnel shall work on
the power supply.
•Check electrical devices frequently.
•Immediately replace any loosed connection or cables that show wear.
•All electrical panels keys and controller access codes must be stored in
a secure area with restricted access to unauthorized personel.

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3.8 Special Danger Zones
•The Carriage and gauge arm.
•The interface zone between the machine and the gauge.
3.9 Maintenance and Troubleshooting
•Follow the maintenance and inspection schedule.
•All operating mediums (i.e. air pressure) must be secured against
unintentional activation.
•Unplug power cord any time for maintenance or repair.
•Check all bolts if tightened correctly.
•After finishing with maintenance check all safety devices before running
the machine.
3.10 Machine Design Changes
•Do not change any mechanical or electrical components of the machine
without written manufacturer permittance.
•Replace all non-working or damaged electrical components and
machine parts immediately.
•Use only original parts and equipment from the manufacturer.
•There is no warranty or liability if parts and equipment from different
suppliers are used.
3.11. Machine Cleaning and Disposal
Handle any lubricants properly especially
-When working with grease
-When working with chemicals.
3.12. Exposure to noise
•The noise level produced by the gauging system is less than 70 dB (A).
•Special safety and protection devices such as ear plugs or head phones
are not necessary for the gauge, but saws, drills and punches produce
such noise levels requiring hearing protection.

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4. Transportation of the gauge
Danger!
Danger caused by moving loads. Immediate impending life threating or personal
injury possiblity by moving and dropping the gauge with a crane.
Don’t stay underneath the lifted gauge.
The minimum age for operating personal is 21 years.
•
Personal has to be authorized and trained before using a crane, a forklift
or any other transportation vehicle
Avoid bumping the gauge during transportation damage may occur.
Use a crane or a vehicle with allowed maximum weight of 1500lbs.
Move gauge only at slow speed.
Gauge might topple over if moved too quickly.
Do not drive on any ramp while moving the gauge.
4.1. Installation Location
The load carrying capacity of the floor has to be minimum 300lbs per square
meter.
5. Installation
Danger!
Danger caused by second or additional personal while testing and running the
gauge. Immediate impending life threating or personal injury possiblity if caution is
not taken.
Before installation and while running the machine ensure that no other person is
within the danger areas of the gauge
Note!
Before installation check gauge for any damages or defects
Eliminate any damage or defect before installing or running the gauge. Contact the
manufacturer if required.

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5.1 Installation procedure
Note: carriage length and depth can differ depending on motor and
gearbox type
5.1.1 Packing list
-one or two sections of aluminum guide with double steel rods and
mounted rack (each section with pre-mounted T-nuts and bolts for
missing joint rack)
-one bag with T-nuts, M8 bolts, washers and stand-offs to mount
aluminum extrusion to conveyor
-one long piece of joint rack to connect both aluminum extrusion
sections (only when shipped in two separate sections)
-one 10in long adapter rack piece with two squared metal spacers to
properly align and tighten the separate joint rack with pre-mounted
racks on aluminum guide sections (only when shipped in two separate
sections)
-one motor carriage with yellow hood, stop arm with face plate
-cable track with cable and mating connectors to controller and carriage
-Sections of cable tray and mounting brackets with M8 socket head cap
screws with washers and T-nuts
-free standing control stand (optional)
-Position controller
Important: Please note that in some cases the machines are shipped
fully assembled (or nearly assembled) and require less joining hardware.
Contents may vary as application requires.
Adjustable arm
(optional gripper)
Carriage hood
RC conveyor
Double linear
guide and rack
Adjustable
faceplate
Controller
with stand

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5.1.2 Assemble Kentucky Gauge conveyor series (if
conveyor is purchased)
Place conveyor near saw, drill or punch
Mount each height adjustable leg to the conveyor
Level the conveyor using a level and the height adjustable bolts
Adjust the conveyor so it is leveled lengthwise using a metal guide
set in the saw clamp.
Be sure the conveyor sections are straight and properly aligned.
See below.
Anchor the legs to the floor
Tighten the bolts between the legs and the conveyor.
5.1.3 Mount aluminum guide section to conveyor
Align the aluminum guide with the conveyor using a lift, saw horses,
or some other appropriate means.
Sägeblatt
Fester Backen
Richtschiene
Führungsschiene
Rollenbahn
Saw Blade
Steel guide
Saw clamp
Conveyor
Metal guide
Saw blade
conveyor

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Snap or slide T-nuts into the T-slot facing the conveyor. For the
Kentucky Gauge conveyors series RC or RH use one T-nut every 18
inches (recommended). Note: T-nuts may already be inserted.
Mount aluminum extrusion to conveyor by using M8 socket head cap
screws with washers and stand-offs. Stand-off length is designed
for Kentucky Gauge conveyors series RC and RH .
Note: Do not tighten the screws at this point to be able to align the
T-nuts with the conveyor mounting holes and to align the aluminum
extrusion in X direction when mounted to the conveyor
When all stand-offs of first aluminum guide section are mounted
adjust aluminum extrusion in X direction so that end of conveyor is
aligned with end of aluminum extrusion and tighten socket head cap
screws

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5.1.4 Slide on carriage to aluminum guide
Remove carriage hood by unscrewing the four flange head screws to
have access to spring loaded servo motor with spur gear, motor set
screw and mating connectors to attach cable inside track chain
Unscrew motor set screw to be able to push down motor with spur
gear
Note: motor set screw may look different depending on type of
motor and gear box
Slide carriage carefully on aluminum extrusion so that the two top
and bottom rollers of the carriage are running on the double linear
guides, be sure to lift the wiper to allow for proper sliding
Carriage plate
Servomotor
Mating connector
for reader head
4 pin connector
for motor and
brake
Motor set screw to
prevent spur gear
from jumping off the
rack

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Push down motor with spur gear to not hit pre-mounted rack screws
and rack
Release pushed down motor when spur gear has passed the rack
Tighten motor set screw. Gap between end of screw and planetary
gear box housing should not exceed 1/32in
Systems long in length may require shipment and
subsequent assembly in sections, please follow 5.1.5 and
5.1.6 for instructions (otherwise omit).
Push down motor with one hand
Direction to
slide on carriage
Pre-mounted screws to
mount separate rack to
connect aluminum guide
sections
Pre-mounted
rack on
aluminum
guide section
Reset motor screw
to prevent spur
gear from jumping
off the rack

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5.1.5 Mount 2nd aluminum guide section to conveyor
Align 2nd section of the aluminum guide with the conveyor using saw
horses and shims or some other appropriate means
Snap T-nuts into the T-slot facing the conveyor. For the Kentucky
Gauge conveyors series RC or RH use one T-nut every 18 inches
(recommended). Make sure to slide on enough T-nuts to any section
before mounting to conveyor
Mount 2nd aluminum guide to conveyor by using M8 socket head cap
screws with washers and stand-offs. Stand-off length is designed for
Kentucky Gauge conveyors series RC and RH and might not work
with different types of conveyors
Note: Do not tighten the screws at this point to be able to align the
T-nuts with the conveyor mounting holes and to be able to mount
the extra rack piece properly between both aluminum guide sections
5.1.6 Mount joint rack to aluminum guide sections
Remove pre-mounted rack screws from 1st and 2nd section of
aluminum guide
Mount joint rack to 1st aluminum guide section by using the short
adapter rack piece, the two metal spacers and a clamp
Two spacers to
tighten clamp
properly
Pre-mounted screws to
mount joint rack to
connect aluminum guide
sections
Extra joint rack to
connect both
aluminum guide
sections
Adapter rack
overlaps joint rack
and pre-mounted
rack for precise
alignment
Pre-mounted
rack

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Tighten all socket head cap screws of the joint rack on 1st aluminum
guide section
Release clamp and move adapter rack, spacers and clamp to the
other end of the joint rack on 2nd section of the aluminum guide
Mount joint rack to 2nd aluminum guide section and align joint rack
with rack on 2nd aluminum guide by using again the adapter rack
piece, the two metal spacers and the clamp
Tighten all socket head cap screws of the joint rack on 2nd aluminum
guide section
Mount T-slot connecting plate between 1st and 2nd aluminum guide
section to stabilize both sections. This T-slot connecting plate is
located inside the bottom T-slot of 2nd aluminum guide section
Tighten now all socket head cap screws that connects conveyor with
2nd aluminum guide section
5.1.7 Mount cable tray sections to aluminum guide
Required parts: cable tray sections (3” x 1” channel with brackets),
T-nuts and M8 bolts with washers
1st section
2nd section
T-slot connecting
plate
Rack (bottom side)

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Slide on the brackets and secure loosely by using the bottom T-nuts
in the slots of the aluminum extrusion. Align section 1 with far end
of aluminum extrusion (opposite side of the saw, drill, punch, etc.)
Space brackets properly at 8ft. Where channels meet, brackets will
be placed in close proximity. Sections supplied in 16ft sections max.
Fasten channels to brackets with provided hardware.
Tighten the socket head cap screws of each section from underneath
5.1.8 Assemble cable and cable track to carriage
Connect motor/brake and reader head cable from cable track to
mating connectors on carriage
Mating connector
for reader head
4 pin connector for motor
and brake (tighten screw of
connector housing)