Maxcess FIFE-500-XL Manual

FIFE GUIDING SOLUTIONS
FIFE-500-XL
Installation and Service Manual
EN
Medium Web Guiding System
MI 1-917 1 C

CONTENTS
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
INTRODUCTION ....................................................................................1-1
About these operating instructions.......................................................................... 1-1
CE marking .............................................................................................................. 1-1
Product overview ..................................................................................................... 1-2
SAFETY INSTRUCTIONS ..........................................................................2-1
Instructions for use.................................................................................................. 2-1
Safety symbols......................................................................................................... 2-1
Symbols used........................................................................................................... 2-2
Basic safety information........................................................................................... 2-3
INSTALLATION ......................................................................................3-1
Mechanical installation ............................................................................................ 3-1
Mounting dimensions ..................................................................................... 3-3
Guiding parameters ........................................................................................ 3-4
Pneumatic connection to splice table.............................................................. 3-5
Installing the operator interface............................................................................... 3-6
Relocating the operator interface.................................................................... 3-6
Panel mount model......................................................................................... 3-7
Wall mount model .......................................................................................... 3-8
Electrical installation ................................................................................................ 3-9
Power connection ........................................................................................... 3-9
Digital inputs and outputs ............................................................................ 3-10
Wiring diagrams ........................................................................................... 3-13
MAINTENANCE......................................................................................4-1
Sensors........................................................................................................... 4-2
Operator interface screen ............................................................................... 4-2
MODEL NUMBER KEY .............................................................................5-1
SPECIFICATIONS ....................................................................................6-1
General .................................................................................................................... 6-1
Certifications and environmental compatibility ........................................................ 6-1
Inputs and outputs .................................................................................................. 6-2
Maximum cable lengths ........................................................................................... 6-2
SERVICE AND REPLACEMENT PARTS........................................................7-1

1–1
INTRODUCTION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
About these
operating
instructions
All of the information herein is the exclusive proprietary property
of Maxcess International, and is disclosed with the understanding
that it will be retained in confidence and will neither be duplicated
nor copied in whole or in part nor be used for any purpose other
than for which disclosed.
Copyright 2013, all rights reserved.
Periodically there will be updates to this manual. The latest
version is available at www.maxcessintl.com or by calling your
regional office. See back page for phone numbers.
These web guiding systems must not be installed or used in a
machine or system which does not comply with the machinery
directive 2006/42/EC.
These web guiding systems were designed and manufactured to
be installed as Partly Completed Machinery into a machine or
partly completed machine.
The instructions must be read and used by all persons who have
the responsibility of installing and maintaining these web guiding
systems.
These instructions must be retained and incorporated in the
technical documentation for the machine or partly completed
machinery into which the web guiding system is installed.
Language
These are the original instructions, written in English.
CE marking
The FIFE-500-XL complies with the 2006/42/EC Machinery
directive and the 2004/108/EC Electromagnetic Compatibility
directive.
Conventions used
All dimensions and specifications are shown in the format
millimeters [inches] unless otherwise specified.

1–2
INTRODUCTION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Product overview
The FIFE-500-XL web guiding system is a complete offset pivot
guide and controller in a compact package with an IP54
environmental rating. The FIFE-500-XL is available in many
standard roll face, guide span and roller diameters.
The web guiding system is designed for continuous use. The web
guiding system has two sensor inputs, a color touchscreen
operator interface, and parallel inputs and outputs for remote
control and alarms. The web guiding system controls the position
of the web by monitoring the web position with sensors mounted
on the web path and driving an actuator connected to the guide
assembly to steer the web to the desired position. The web
guiding system includes a servo center transducer to position the
guide parallel to the web path for web threading.
The web guiding system works with most Fife sensors.

2–1
SAFETY INSTRUCTIONS
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Instructions for
use
To ensure safe and problem free installation of the web guiding
system, the web guiding system must be properly transported
and stored, professionally installed, and placed in operation.
Proper operation and maintenance will ensure a long service life
of the device. Only persons who are acquainted with the
installation, commissioning, operation, and maintenance of the
system and who possess the necessary qualifications for their
activities may work on the web guiding system.
Note: The safety information may not be comprehensive.
Please note the following:
The content of these operating instructions
Any safety instructions on the device
The machine manufacturer’s specifications
All national, state, and local requirements for installation,
accident prevention and environmental protection
Safety symbols
Information about
safety instructions
The safety instructions and symbols described in this section are
used in these operating instructions. They are used to avoid
possible dangers for users and to prevent material damage.
SIGNAL WORD
Source of danger and its results
Avoiding dangers
The signal word DANGER refers to the danger of death or serious
bodily injuries.
The signal word WARNING refers to the danger of moderate to
severe bodily injuries.
The signal word CAUTION refers to the danger of slight to
moderate bodily injuries or material damage.
The signal word NOTICE refers to the possibility of damage to
equipment.

2–2
SAFETY INSTRUCTIONS
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Symbols used
The following safety identification symbols are used in these
operating instructions.
WARNING/CAUTION –General danger or important note
Reference to general hazards that may result in bodily injuries or
damage to device or material.
WARNING/CAUTION –Danger due to crushing
Reference to danger of injury caused by crushing.
WARNING/CAUTION –Danger due to cutting
Reference to danger of injury caused by cutting.
WARNING/CAUTION –Danger due to voltage, electric shock
Reference to danger of injury caused by electric shock due to
voltage.
WARNING/CAUTION –Danger due to hot surfaces
Reference to risk of injury caused by burning.

2–3
SAFETY INSTRUCTIONS
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Basic safety
information
Proper use
The web guiding system is intended to be used on machines or
systems to guide a web of material.
Indoor operation: see environmental specifications
Improper use
Operation outside the technical specifications
Operation in an Ex-area or intrinsically safe area
Operation as a safety component. The web guiding system does
not hold the web position if power fails.
Outdoor operation
Any other use than the proper use shall be deemed inappropriate.
Installation and commissioning
Any web guiding system which is damaged must not be installed
or put into operation.
Only perform installation, maintenance or repair tasks on the web
guiding system when the machine has been stopped and is
secured from being turned on.
Only perform installation, maintenance or repair tasks on the web
guiding system when there is no electrical power in the system.
The web guiding system must be securely mounted before being
placed in operation.
Only replacement parts obtained from Fife may be used.
No modifications may be made to the web guiding system.
Do not place electrical cables under mechanical strain.
WARNING –Death or injury can result from static electric shocks.
Moving webs of material can produce large static voltage
potentials. Protect against electric shocks by installing a
conductive connection between the terminal marked with the PE
symbol on the power connector and the PE circuit of the building
or machine.
WARNING –The web guiding system contains rotating and moving
parts which could cause injury due to crushing. Appropriate
protective guards must be installed by the user according to his
use of this product.

2–4
SAFETY INSTRUCTIONS
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
WARNING –Death or injury can result from unexpected movement.
Protect against unexpected movement by removing electrical power
from the web guiding system and the machine into which the web
guiding system is being installed.
WARNING –Danger of falling down or muscle or skeletal injury
during installation.
These web guiding systems, especially the larger designs, are heavy.
Appropriate equipment is to be used and the safety rules of the
company must be observed.
Operation
WARNING –The web guiding system contains rotating and moving
parts which could cause injury due to crushing. Do not touch
anything on or in the vicinity of the moving or rotating parts.
Appropriate protective guards must be installed by the user
according to his use of this product.
Maintenance and repair
WARNING –Death or injury can result from unexpected movement.
Protect against unexpected movement by removing electrical power
from the web guiding system and the machine into which the web
guiding system is installed.
WARNING –Danger of injury from crushing.
Maintenance and repair tasks on the web guiding system must be
performed only when the machine has been stopped and has been
secured from being turned on again.
WARNING –Danger of falling down or muscle or skeletal injury
during maintenance and repair.
These web guiding systems, especially the larger designs, are heavy.
Appropriate equipment is to be used and the safety rules of the
company must be observed.
Decommissioning
The web guiding system must be disposed of in accordance with all
the applicable national, state and local regulations.

3–1
INSTALLATION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Mechanical
installation
WARNING –Death or injury can result from unexpected
movement.
Protect against unexpected movement by removing electrical
power from the FIFE-500-XL and the machine into which the FIFE-
500-XL is installed.
WARNING –Danger of injury from crushing.
Maintenance and repair tasks on the FIFE-500-XL must be
performed only when the machine has been stopped and has been
secured from being turned on again.
WARNING –Danger of falling down or muscle or skeletal injury
during maintenance and repair.
These web guiding systems, especially the larger designs, are
heavy. Appropriate equipment is to be used and the safety rules
of the company must be observed.
Install the FIFE-500-XL Web Guiding System in the process
line such that the rollers, when in the Servo-Center position,
are parallel to the entry and exit rollers.
The FIFE-500-XL must be installed on a flat, machined surface
that is flat within 0.5 [0.02] total indicated runout.
Ensure that the WEB DIRECTION ARROW on the guide is
pointed in the direction of web travel.
See Figure Sheet 1-558 for factors to consider on where and
how to install the FIFE-500-XL Web Guiding System for the
best guiding results.
Integrated sensor mounting is provided for wrap styles exiting
towards the base only. Remote sensor mounting must be used
for other wrap styles.
T-nut blocks are delivered in their outermost positions, but
are adjustable. To adjust, loosen the clamping screws, adjust
the location of the T-nut block(s), then tighten the clamping
screws to 3.3 Nm [29 in-lb] of torque after adjustment. See
Figure 1.
Guide will be secured to the machine frame using six
customer supplied M8x1.25 bolts. After securing the T-nut
blocks in the proper location the M8x1.25 bolts will come up
through the machine frame and screw into the T-nut blocks.

3–2
INSTALLATION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Installing the FIFE-500-XL
'X'
'X'
'B'
Ø 'C'
272.5 [10.728]
'A'
'W'
47.5 [1.870]
176.5 [6.949]
'S'
262.5 [10.335]
'C'
'T'
'Z'
16 [0.630]
8.5 [0.335]
12
3
4
6
5
1
T-nut block, 6X
2
T-nut channel, 2X
3
Clamping screw, 6X
4
M8x1.25, 15 [0.59] maximum depth, 6X mounting
5
234.5 [9.232], mounting
6
‘W’-64 [2.520] maximum, mounting
Figure 1. FIFE-500-XL with integrated sensor mounting

3–3
INSTALLATION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Mounting dimensions
Roll Face
‘A’
mm [inch]
(1)
Guide Span
‘B’
mm [inch]
(1)
Roll
Diameter
‘C’
Mm [inch]
Width
‘W’
mm [inch]
Dimension
‘S’
mm [inch]
Dimension
‘T’
mm [inch]
Dimension
‘Z’
mm [inch]
Max
Weight
kg [lbs]
(2)
300
[11.81]
400 [15.75]
80 [3.150]
100 [3.937]
365
[14.370]
82.75 [3.258]
82.75 [3.258]
520
[20.472]
39 [86]
500 [19.69]
132.75 [5.226]
132.75 [5.226]
43 [95]
350
[13.78]
400 [15.75]
80 [3.150]
100 [3.937]
82.75 [3.258]
82.75 [3.258]
570
[22.441]
42 [93]
500 [19.69]
132.75 [5.226]
132.75 [5.226]
46 [101]
400
[15.75]
400 [15.75]
80 [3.150]
100 [3.937]
469
[18.465]
82.75 [3.258]
82.75 [3.258]
620
[24.409]
50 [110]
500 [19.69]
132.75 [5.226]
132.75 [5.226]
55 [121]
600 [23.62]
232.75 [9.163]
132.75 [5.226]
61 [134]
500
[19.69]
400 [15.75]
80 [3.150]
100 [3.937]
82.75 [3.258]
82.75 [3.258]
720
[28.346]
54 [119]
500 [19.69]
132.75 [5.226]
132.75 [5.226]
59 [130]
600 [23.62]
232.75 [9.163]
132.75 [5.226]
65 [143]
600
[23.62]
400 [15.75]
80 [3.150]
100 [3.937]
629
[24.764]
82.75 [3.258]
82.75 [3.258]
820
[32.283]
57 [126]
500 [19.69]
132.75 [5.226]
132.75 [5.226]
63 [139]
600 [23.62]
232.75 [9.163]
132.75 [5.226]
70 [154]
700
[27.56]
400 [15.75]
80 [3.150]
100 [3.937]
82.75 [3.258]
82.75 [3.258]
920
[36.220]
53 [117]
500 [19.69]
132.75 [5.226]
132.75 [5.226]
58 [128]
600 [23.62]
232.75 [9.163]
132.75 [5.226]
64 [141]
800
[31.50]
400 [15.75]
80 [3.150]
100 [3.937]
829
[32.638]
82.75 [3.258]
82.75 [3.258]
1020
[40.157]
60 [132]
500 [19.69]
132.75 [5.226]
132.75 [5.226]
66 [146]
600 [23.62]
232.75 [9.163]
132.75 [5.226]
73 [161]
900
[35.43]
400 [15.75]
80 [3.150]
100 [3.937]
82.75 [3.258]
82.75 [3.258]
1120
[44.094]
68 [150]
500 [19.69]
132.75 [5.226]
132.75 [5.226]
75 [165]
600 [23.62]
232.75 [9.163]
132.75 [5.226]
83 [183]
1) The dimensions A, B, and C may be found from the first three digits of the model
number following the characters “MW”.
2) The weight is a maximum with 100 mm rollers and the splice table. The 80 mm rollers
reduce the weight by 2% and the removal of the splice table reduces the weight by about
10%.

3–4
INSTALLATION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Guiding parameters
Roll Face
‘A’
mm
[inch]
(1)
Guide Span
‘B’
mm [inch]
(1)
Max
Correction
‘X’
mm [inch]
Max
correction
speed
mm/sec
[inch/sec]
300
[11.81]
400 [15.75]
14.61 [0.58]
140 [5.51]
500 [19.69]
15.78 [0.62]
150 [5.91]
350
[13.78]
400 [15.75]
14.61 [0.58]
140 [5.51]
500 [19.69]
15.78 [0.62]
150 [5.91]
400
[15.75]
400 [15.75]
12.99 [0.51]
140 [5.51]
500 [19.69]
14.45 [0.57]
150 [5.91]
600 [23.62]
13.86 [0.55]
137 [5.39]
500
[19.69]
400 [15.75]
19.15 [0.75]
140 [5.51]
500 [19.69]
21.31 [0.84]
150 [5.91]
600 [23.62]
20.44 [0.80]
137 [5.39]
600
[23.62]
400 [15.75]
21.63 [0.85]
140 [5.51]
500 [19.69]
24.87 [0.98]
150 [5.91]
600 [23.62]
24.91 [0.98]
137 [5.39]
700
[27.56]
400 [15.75]
21.63 [0.85]
140 [5.51]
500 [19.69]
24.87 [0.98]
150 [5.91]
600 [23.62]
24.91 [0.98]
137 [5.39]
800
[31.50]
400 [15.75]
21.22 [0.84]
140 [5.51]
500 [19.69]
25.16 [0.99]
150 [5.91]
600 [23.62]
26.41 [1.04]
137 [5.39]
900
[35.43]
400 [15.75]
21.22 [0.84]
140 [5.51]
500 [19.69]
25.16 [0.99]
150 [5.91]
600 [23.62]
26.41 [1.04]
137 [5.39]

3–5
INSTALLATION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Pneumatic connection
to splice table
1. Connect pneumatic lines to the two pneumatic fittings to
allow operation of the pneumatic clamp.
2. Operating pressure range for the pneumatic clamp is
34-552 kPa [5-80 psi].
CAUTION –Damage to the pneumatic clamp due to high pressure.
Do not connect an air source of greater than 552 kPa [80 psi] to the
pneumatic clamp. Use of a pressure regulator is recommended.
5
256.6 [10.100]
313.8 [12.356]
152.4 [6.0] MAX
91.0 [3.58]
1
2
3
4
67
8
1
Tape dispenser
2
6 mm OD pneumatic tube fitting, 2X
3
Adjustable splice table
4
Locking knob
5
50.8 [2.000], tape width maximum
6
1.5 [0.059] maximum web thickness
7
Ø76.2 [Ø3.000] tape core
8
Customer provided tape
Figure 2. Splice table with tape dispenser

3–6
INSTALLATION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Installing the
operator interface
Operator interface
relocation
The Operator Interface may be mounted on either end of the
Base Assembly. If it is desired to relocate the OI from one end of
the Base Assembly to the other, use the following procedure.
1. Disconnect power from the FIFE-500-XL unit.
2. Using a 3 mm Allen wrench, remove the four screws that
retain the OI to the Base Assembly end plate.
3. The shroud, which is the spacer between the OI and the end
plate, should be retained with the OI.
4. Disconnect the cable between the OI and the Base Assembly.
5. Re-direct the cable with the female connector to the opposite
end of the Base Assembly by pulling the cable through the
bottom channel of the extrusion.
6. Reconnect the cable to the OI.
7. Route the sensor cable through the appropriate slot in the
shroud, then mount the OI with the shroud to the end plate
and secure it with the four screws that were removed,
previously.
WARNING –Death or injury due to cutting or crushing.
The operator interface should not be used while the machine is
running. If it is necessary for the operator to use the operator
interface while the machine is running, precautions must be
taken to protect the operator from injury due to moving material
and machinery. This can be accomplished by either surrounding
the operator interface with guarding, or by remote mounting the
operator interface in a safe location.
The operator interface can be mounted through a panel or on a
wall. See the sections on following pages for details on remote
mounting of the OI.

3–7
INSTALLATION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Panel mount model
1. Order mounting kit P/N 215802-001 when mounting the
Operator Interface remotely in a panel.
2. Order an Operator Interface extension cable P/N 215680-XXX.
20 meter maximum length.
CAUTION –Never place electrical cables under mechanical strain.
Always provide mechanical support of wiring with either clamps or
flexible or rigid conduit.
Units are in millimeters [inches].
124[4.882]
R4 [0.157] MAX(4X)





1
Operator interface
2
Panel
3
Mounting bracket
4
Panel jack screws
5
Installation cut-out
Figure 3. Operator interface panel mount kit installation

3–8
INSTALLATION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Wall mount model
1. Use existing hardware (guide mounted) when mounting the
Operator Interface remotely on a wall.
2. Order an Operator Interface extension cable P/N 215680-XXX.
20 meter maximum length.
CAUTION –Never place electrical cables under mechanical strain.
Always provide mechanical support of wiring with either clamps or
flexible or rigid conduit.
Units are in millimeters [inches].
M4 x 0.7 (4X)


111 [4.370]
87.7 [3.453]
1
Operator interface
2
Operator interface shroud
3
Wall
Figure 4. Operator interface wall mount kit installation

3–9
INSTALLATION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Electrical
installation
Reference drawings
Description
Drawing Number
Wiring diagram
217299
Cable selection chart
217914
Power connection
Operating voltage range and current rating are listed in
Specifications (Section 6-1), and shown on the label on the base
housing.
All wiring must comply with the essential requirements of the
appropriate standard(s) and is the responsibility of the installer.
Wiring to the web guiding system must be insulated copper wire
with a temperature rating of at least 80⁰C. The wire size should be
0.82 mm2 (18 AWG).
Note: The negative power connection, pin 2, is internally
connected to the PE connection. This connection is only used for
EMC compliance.
1. Power cable is supplied by the customer. For an assembled
5 m (16.4 foot) power cable with connector and gasket, order
part number 214658-005.
2. Order the power connector based on the outside cable
diameter being used.
Cable Diameter
Connector Order Number
4.5 [0.177] –7.0 [0.276]
91074-001
6.0 [0.236] –10.0 [0.390]
91074-002
8.0 [0.315] –14 [0.551]
91074-003
3. Order the sealing gasket for the power connector, part
number 91074-004.
4. Connect a 24 VDC +/-25% power supply to pins 1 and 2 of
the power connector. Pin 1 should be positive and pin 2
should be negative. See Figure 5.
5. Connect the PE of the building or machine to the power
connector terminal marked with the PE symbol.
See Figure 5.
6. Place the power connector on the mating connector on the
web guiding system and secure with the mounting screw.
Be sure the gasket is installed at the mating interface of the
connectors.

3–10
INSTALLATION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
WARNING –Death or injury can result from static electric shocks.
Moving webs of material can produce large static voltage
potentials. Protect against electric shocks by installing a
conductive connection between the terminal marked with the PE
symbol on the power connector and the PE circuit of the building
or machine.
CAUTION –Never place electrical cables under mechanical strain.
Always provide mechanical support of wiring with either clamps
or flexible or rigid conduit.
1 (+24 V)
24 V GND
+24 V
2 (24 V GND)
3
2
1
3
1
2
AA
3
1
2
Section A-A (rear view)
1
18 AWG wire recommended
2
Gasket
Figure 5. FIFE-500-XL power connection
Digital inputs and
outputs
Digital inputs and outputs are available for remote control and
signalling functions. There are 6 digital inputs allowing control
of the following modes External Lock, Automatic, Manual, Servo-
Center, Jog, RGPC, and sensor selection. There are 4 digital
outputs and are initially configured as alarms for Loss of Null,
Centered, Motor Blocked, and Power OK. See the following page
for the default configuration.
See Figure 6 for terminal connections of the digital inputs and
outputs on the motor controller board located in the base
assembly housing. Figure 7 is the wiring diagram of the
FIFE-500-XL.

3–11
INSTALLATION
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
Table 1. Digital input matrix default configuration
0 = LOW
1 = HIGH
- = IGNORE
Note: To ensure that a command is properly executed, all pertinent
inputs for each command must be switched high or low within
20 ms of each other and maintained for at least 30 ms.
INPUTS
MODE
5
4
3
2
1
0
EXTERNAL LOCK
-
-
-
-
-
1
AUTOMATIC
-
-
0
0
1
-
MANUAL
-
-
0
1
0
-
SERVO-CENTER
-
-
1
0
0
-
JOG Minus *
0
1
-
-
-
-
JOG Plus *
1
0
-
-
-
-
RGPC Minus *
0
1
-
-
-
-
RGPC Plus *
1
0
-
-
-
-
RGPC RESET *
1
1
-
-
-
-
Sensor S1 (Single Edge Guiding) **
-
-
0
1
1
-
Sensor S2 (Single Edge Guiding) **
-
-
1
1
0
-
Sensor S1 –S2 (Center-guiding) **
-
-
1
1
1
-
*
Inputs 4 & 5 are used to provide Jogs while in Manual and Servo Center modes, and RGPC
functions while in Automatic mode.
**
Sensor selection is allowed in Manual and Servo Center modes, only. Sensor selection must
be momentary commands.
WARNING –Death or injury can result from unexpected movement.
If the timing requirements of the digital inputs are not met, unexpected motion
of the guide could result when a sensor selection is misinterpreted as a mode
change to Servo Center or Auto.