Scott 10,000 User manual

Copy No.:
Instruction Manual
Model No. : Scott 10,000.................
Year of Manufacture : 2004.......
Manufactured by :..........
Document Number : C9999--2........
Issue : 1.....................
Date of Issue : August 2004..............

ISSUE NOTE
This is Issue 1; Date of Issue: August 2004
Copyright 2004

Table of Contents
III
C9999--2 Issue 1
TABLE OF CONTENTS
1 INTRODUCTION & SAFETY 1--1...........................................................
1.1 Introduction 1--3....................................................................
1.1.1 Scott 10,000 Machine Specifications and Utility Requirements 1--5......................
1.2 General Safety Guidelines 1--6.......................................................
1.3 Safety Features 1--7.................................................................
1.3.1 Emergency Stop 1--7.............................................................
1.3.2 Stop and Safe 1--7...............................................................
1.3.3 Main Power Switch 1--8...........................................................
1.3.4 Guards and Covers 1--8...........................................................
1.3.5 Safety Switches 1--8..............................................................
1.4 Warnings, Cautions & Notes 1--9.....................................................
1.4.1 Warnings 1--9....................................................................
1.4.2 Cautions 1--9....................................................................
1.4.3 Notes 1--9.......................................................................
1.5 On Machine Warnings 1--10...........................................................
1.5.1 Heat Hazards 1--10................................................................
1.5.2 Electrical Shock Hazards 1--10......................................................
1.6 Safety Procedures 1--11..............................................................
1.6.1 Safety Devices 1--11...............................................................
1.6.2 Appropriate Dress 1--11............................................................
1.6.3 Keep Area Clean 1--11.............................................................
1.6.4 Grease and Oil 1--11..............................................................
1.6.5 Manual Usage 1--11...............................................................
2 INSTALLATION 2--1......................................................................
2.1 Installation Requirements 2--3........................................................
2.2 Pre-Installation Requirements 2--4....................................................
2.3 Uncrating & Placement 2--5..........................................................
2.3.1 Crate 1 -- Main Machine 2--5.......................................................
2.3.2 Crate 2 -- Additional Assemblies 2--6................................................
2.3.3 Install Tab Cutter Unit 2--6.........................................................
2.3.4 Leveling the Machine 2--8.........................................................
2.3.5 Continue Assembling Machine 2--10.................................................
2.3.6 Install Cross Conveyor 2--15........................................................
2.3.7 Install Steel Balls 2--16.............................................................
2.3.8 Connect Vacuum Canister 2--17.....................................................
2.3.9 Install Vacuum Valve 2--17..........................................................
2.3.10 Install Paper Supports on Pile Feeder 2--18...........................................
2.4 Utility Connections 2--22..............................................................
2.4.1 Electrical Connections 2--22........................................................

Table of Contents
IV C9999--2 Issue 1
3 OPERATION 3--1.........................................................................
3.1 GENERAL INFORMATION 3--3........................................................
3.1.1 Before Operating the Machine 3--3.................................................
3.2 Operating Controls and Indicators Descriptions 3--4...................................
3.2.1 Operator’s Control Panel Layout 3--4................................................
3.2.2 Machine Stopping Device 3--4.....................................................
3.2.3 Main Operator’s Panel Control Descriptions 3--5......................................
3.2.4 Telemecanique PLC Control 3--10...................................................
3.3 Preliminary Inspection and Start-Up Procedure 3--11....................................
3.3.1 Preliminary Set-Up 3--11...........................................................
3.3.2 Pile Feeder 3--13..................................................................
3.3.3 Adjusting the Reregister Unit 3--20...................................................
3.3.4 Machine Start--Up 3--23............................................................
3.3.5 Start-Up for Run 3--35.............................................................
3.4 Handwheel and Tab Set-Up 3-37..........................................................
3.4.1 Hand Wheel and Tab Set-Up Definitions 3-38.........................................
HANDWHEEL SET-UPS FOR 5” SHEET WITH 3/16” MARGINS 3-40...............................
HANDWHEEL SET-UPS FOR 6” SHEET WITH 3/16” MARGINS 3-41...............................
HANDWHEEL SET-UPS FOR 7-1/4” SHEET WITH 3/16” MARGINS 3-42...........................
HANDWHEEL SET-UPS FOR 7-1/4” SHEET WITH 1/4” MARGINS 3-43.............................
HANDWHEEL SET-UPS FOR 7-3/4” SHEET WITH 3/16” MARGINS 3-44...........................
HANDWHEEL SET-UPS FOR 7-3/4” SHEET WITH 1/4” MARGINS 3-45.............................
HANDWHEEL SET-UPS FOR 8” SHEET WITH 3/16” MARGINS 3-46...............................
HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH 3/16” MARGINS 3-47...........................
HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH 1/4” MARGINS 3-48.............................
HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH 1/2” MARGINS 3-49.............................
HANDWHEEL SET-UPS FOR 9” SHEET WITH 3/16” MARGINS 3-50...............................
HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH 3/16” MARGINS 3-51...........................
HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH 1/4” MARGINS 3-52.............................
HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH 1/2” MARGINS 3-53.............................
HANDWHEEL SET-UPS FOR 11” SHEET WITH 1/8” MARGINS 3-54...............................
HANDWHEEL SET-UPS FOR 11” SHEET WITH 3/16” MARGINS 3-55..............................
HANDWHEEL SET-UPS FOR 11” SHEET WITH 1/4” MARGINS 3-56...............................
HANDWHEEL SET-UPS FOR 11” SHEET WITH 1/2” MARGINS 3-57...............................
HANDWHEEL SET-UPS FOR 12” SHEET WITH 3/16” MARGINS 3-58..............................
HANDWHEEL SET-UPS FOR 12” SHEET WITH 1/4” MARGINS 3-59...............................
HANDWHEEL SET-UPS FOR 12” SHEET WITH 1/2” MARGINS 3-60...............................
HANDWHEEL SET-UPS FOR 14” SHEET WITH 3/16” MARGINS 3-61..............................
HANDWHEEL SET-UPS FOR 14” SHEET WITH 1/4” MARGINS 3-62...............................
HANDWHEEL SET-UPS FOR 14” SHEET WITH 1/2” MARGINS 3-63...............................
METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 297 MM MARGIN: 0 MM 3-64
METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 210 MM MARGIN: 0 MM 3-65
METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 297 MM MARGIN: 1 MM 3-66
METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 210 MM MARGIN: 1 MM 3-67
4 MAINTENANCE 4--1......................................................................
4.1 Maintenance 4--3....................................................................
4.1.1 Machine Lubrication 4--3..........................................................
4.1.2 Chain Lubrication 4--4............................................................

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V
C9999--2 Issue 1
4.1.3 Vacuum Pump Maintenance 4--8...................................................
4.2 Machine Timing 4--10.................................................................
4.2.1 Maintenance Mode 4--11...........................................................
4.2.2 Preparation for Timing Procedures 4--12..............................................
4.2.3 ChainA&BRemoval 4--14.........................................................
4.2.4 Feeder Timing 4--15...............................................................
4.2.5 Plastic Feed & Cut Operating Arm 4--16..............................................
4.2.6 Tab Cutter Timing 4--17............................................................
4.2.7 Machine Cycle Cam Timing 4--18....................................................
4.2.8 Position of Kick Back Cam 4--19.....................................................
4.2.9 Reregister Section 4--20............................................................
4.2.10 Rubber Kick Back Roller 4--21......................................................
4.2.11 Tab Cutting 4--22..................................................................
4.2.12 Reinstall Chains 4--23..............................................................
4.2.13 Calibration 4--24..................................................................
4.2.14 Handwheel Settings 4--25..........................................................
4.2.15 Handwheel Calibration Procedures 4--26.............................................
4.2.16 Plastic Size Handwheel 4--27.......................................................
4.2.17 Plastic Position Handwheel 4--29....................................................
4.2.18 Tab Position Handwheel 4--31.......................................................
4.2.19 Tab Position Calibration 4--33.......................................................
4.2.20 Slip Rings and Brushes 4--35.......................................................
4.2.21 Plastic Feed and Fold Mechanism 4--36..............................................
4.2.22 Chip Removal System 4--40........................................................
4.2.23 Tip Die Assembly 4--41............................................................
4.2.24 Reinstalling the Tip Die Assembly 4--44..............................................
4.2.25 Hold Down Strap on Delivery Conveyor 4--45.........................................
4.2.26 Setting Tab Cutter Knives 4--46......................................................
4.2.27 Paper Stocks 4--50................................................................
4.2.28 Hot Roller 4--52...................................................................
4.2.29 Plastic Reel Holder Adjustment Procedure 4--54.......................................
4.2.30 Fiber Optics 4--55.................................................................
4.2.31 Machine Cleaning 4--58............................................................
4.2.32 Feed, Drive, Hold Down & Tension Rollers 4--58.......................................
5 SCOTT 10,000 PARTS 5-1................................................................
5.1 ASSEMBLY LOCATOR 5-4...............................................................
5.2 PILE FEED - REGISTER BOARD ADJUSTMENT 5-6........................................
5.3 PILE FEED DRIVE 5-8...................................................................
5.4 PILE FEED DRIVE & TENSIONER 5-10.....................................................
5.5 PILE FEED - VACUUM BAR DRIVE 5-12....................................................
5.6 PILE FEED - VACUUM BAR 5-14..........................................................
5.7 PILE FEED - PAPER GUIDE 5-16..........................................................
5.8 PILE FEED - OPTIC MOUNTING 5-18
......................................................
5.9 PILE HEIGHT ASSEMBLY 5-20............................................................
5.10 PILE LIFT DRIVE 5-22...................................................................
5.11 PILE LIFT FRAME 5-24..................................................................
5.12 PILE LIFT HANDWHEEL 5-26............................................................
5.13 PILE FEED - SHEET SEPARATOR 5-28...................................................
5.14 PILE FEED -- STACK GUIDE 5-30.........................................................

Table of Contents
VI C9999--2 Issue 1
5.15 PILE FEED - PNEUMATIC FITTINGS 5-32.................................................
5.16 PILE FEED - GUARDS, COVERS 5-34....................................................
5.17 PILE FEED - OPTIC MOUNTING 5-36.....................................................
5.18 PILE FEED - PNEUMATIC CONTROLS “A” 5-38............................................
5.19 PILE FEED - PNEUMATIC CONTROLS “B” 5-40............................................
5.20 PILE FEED - BELT & CHAIN LAYOUT 5-42.................................................
5.21 MAIN MOTOR & VACUUM PUMP 5-44....................................................
5.22 BASE & DRIVE 5-46....................................................................
5.23 BASE & DRIVE 5-48....................................................................
5.24 BASE & DRIVE 5-50....................................................................
5.25 MACHINE GUARDS 5-52................................................................
5.26 CHAIN ASSEMBLY & PG. 8 REF. 5-54.....................................................
5.27 REGISTER BOARD - HOLD DOWN PLATE 5-56............................................
5.28 REGISTER BOARD - CONVEYOR 5-58...................................................
5.29 PLASTIC CUT - BASE 5-60..............................................................
5.30 PLASTIC CUT ASSEMBLY 5-62..........................................................
5.31 TIP DIE UNIT 5-64......................................................................
5.32 PLASTIC FEED UNIT ASSEMBLY (A) 5-66.................................................
5.33 PLASTIC FEED UNIT ASSEMBLY (B) 5-68.................................................
5.34 PLASTIC FEED ASSEMBLY (C) 5-70......................................................
5.35 PLASTIC FEED UNIT - ROLLERS 5-72....................................................
5.36 PLASTIC FEED - SLIDE 5-74.............................................................
5.37 PLASTIC FEED - DRIVE 5-76............................................................
5.38 PLASTIC FEED UNIT - COVERS & GUARDS 5-78..........................................
5.39 PLASTIC REEL HOLDER 5-80...........................................................
5.40 CONTROL PANEL 5-82..................................................................
5.41 HEAT ROLLER SHAFTS 5-84............................................................
5.42 HEAT ROLLER -- BEARING BLOCKS 5-86.................................................
5.43 PAPER SUPPORT PLATE -- TAB WIPER 5-88..............................................
5.44 HEAT ROLLER -- GEARS & SPROCKETS 5-90.............................................
5.45 Slip Ring Assembly 5-92.................................................................
5.46 Heat Roller -- Slip Rings & Brush Blocks 5-94...............................................
5.47 TAB WIPER UNIT 5-96..................................................................
5.48 TAB WIPER -- HOLD DOWN ROLLER 5-98................................................
5.49 HEAT ROLLER -- GUARDS 5-100..........................................................
5.50 REREGISTER UNIT -- REAR FRAME 5-102.................................................
5.51 REREGISTER UNIT -- LINKAGE 5-104.....................................................
5.52 TABCUTTER GUARD 5-106...............................................................
5.53 HOLDDOWN UNIT 5-108.................................................................
5.54 REREGISTER DRIVE 5-110...............................................................
5.55 KICK BACK UNIT 5-112..................................................................
5.56 KICK BACK UNIT 5-114
..................................................................
5.57 GEARBOX & REREGISTER SLIDE ASS’Y 5-116.............................................
5.58 CONVEYOR UNIT 5-118..................................................................
5.59 CONVEYOR UNIT 5-120..................................................................
5.60 PULL BACK UNIT 5-122..................................................................
5.61 PULL BACK UNIT 5-124..................................................................
5.62 PULL BACK UNIT 5-126..................................................................
5.63 REREGISTER DRIVE 5-128...............................................................
5.64 REREGISTER DRIVE 5-130...............................................................
5.65 REREGISTER UNIT -- VIEW -- A (PREV. PG’S.) 5-132........................................

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VII
C9999--2 Issue 1
5.66 REREGISTER UNIT -- VIEW -- B (PREV. PG’S.) 5-134........................................
5.67 INFEED UNIT 5-136......................................................................
5.68 TAPE SUPPORT PLATES 5-138...........................................................
5.69 TAB CUTTER - KNIFE CARRIER (L.H.) 5-140...............................................
5.70 TAB CUTTER - KNIFE CARRIER (R.H.) 5-142...............................................
5.71 TAB CUTTER 5-144......................................................................
5.72 TAB CUTTER 5-146......................................................................
5.73 TAB CUTTER DRIVE LINKAGE 5-148......................................................
5.74 HANDWHEEL UNIT -- REREGISTER/ TAB CUTTER 5-150....................................
5.75 HANDWHEEL UNIT -- PLASTIC POSITION 5-152............................................
5.76 HANDWHEEL UNIT -- PLASTIC SIZE 5-154.................................................
5.77 HANDWHEEL LOCATOR 5-156............................................................
6 ELECTRICAL PAGE 6-1

1 Introduction & Safety
1--1
C9999--2 Issue 1
1 INTRODUCTION & SAFETY
C9999--2 Issue 1

1 Introduction & Safety
1--2 C9999--2 Issue 1

1 Introduction & Safety
1--3
C9999--2 Issue 1
1.1 Introduction
The Scott 10,000tuses a vacuum feeder for accuracy with many stocks, heated bonding rollers, tab
cutting knives and cross conveyor for hands--off operation.
Tab sizes range from 1/2 inch to 5 inches (12.7 mm to 127 mm) by simply rotating the Tab Size handwheel.
The extra long tool steel knives quickly and easily cut a one inch (25.4 mm) tab in the first position on a 14
inch (355.6 mm) long sheet.
CROSS
CONVEYOR
OPERATORS
PANEL
PILE
FEEDER
TIP DIE
ELECTRICAL
BOX
PLASTIC SIZE
HANDWHEEL
PAPER LIFT
HANDWHEEL
PLASTIC
POSITION
HANDWHEEL
TAB
CUTTER PULL BACK
ASSEMBLY
Fig. 1-1. Machine Front View

1 Introduction & Safety
1--4 C9999--2 Issue 1
TAB CUTTER
ASSEMBLY
TAB
SIZE
HANDWHEEL
TAB POSITION
HANDWHEEL
CROSS
CONVEYOR
REREGISTER UNIT
(UNDER CROSS
CONVEYOR)
Fig. 1-2. Reregister / Cross Conveyor
FILM
GUIDES
VACUUM
UNIT
MAIN POWER
INLET
REEL HOLDER
DRIVE
MOTOR
AREA
PLASTIC CHIP
VACUUM
PLUG
TRANSFORMER
Fig. 1-3. Machine Back View

1 Introduction & Safety
1--5
C9999--2 Issue 1
1.1.1 Scott 10,000 Machine Specifications and Utility Requirements
Model Scott 10,000t
Speed Up to 10,000 plastic index tabs per hour
Sheet Size 355.6 mm x 342.9 mm (14” x 13--1/2”) maximum
127 mm x 111.1 mm (5” x 4--3/8”) minimum
Plastic Size 139.7 mm (5--1/2”) maximum
25.4 mm (1”) minimum
Tab Cut Size 127 mm (5”) maximum
12.7 mm (1/2”) minimum
Paper Load Approximately 2000 sheets
Counter 1 -- 999,999
Motor 2 Horsepower
Electrical Requirements 40 Amps, 220VAC single phase, 50 or 60 Hz
Decibel Rating 94db
Dimensions L-- 3200 mm, (126”) includes conveyor
W-- 1219 mm (48”)
W-- 1955 mm (77”) with conveyor
H--1752 mm (69”)
Shipping Weight Approximately 1509.55 kg (3,325 lbs)
Warranty One year against defects in parts and workmanship. Labor Not Included.

1 Introduction & Safety
1--6 C9999--2 Issue 1
1.2 General Safety Guidelines
Providing a safe working environment for operating your machine is the responsibility of the user. The
suggested precautions, material safety data and other suggestions that follow do not have preference over
the user’s own plant practices, regulations or safety committee recommendations.
Personal injury and equipment damage can be avoided by the continued adherence to the safety features
provided with this machine and in keeping with the necessary governmental requirements. The guarding
and interlocking safety switches have been installed on the machine for the operator’s safety. These items
should be maintained in good working order by the user.
It is assumed that the user’s safety department has established a safety program that is in keeping with a
complete analysis of industrial hazards. Before installing and operating or performing maintenance and
clean--up procedures on the machine, it is suggested that the safety program be reviewed to ensure that it
covers the possible hazards that might occur with the operation of this machine.
Due consideration must be given to those hazards which arise from the presence of electrical power, high
temperature, and cleaning materials used in the operational areas of the machine. Proper installation and
care of protective devices and over--pressure protective equipment should be considered an essential part of
any safety program.
Special lock--out features are to prevent the possibility of applying power to the equipment at any time when
maintenance work is in progress.
In general, personnel should be guided by all basic rules of safety associated with the equipment and the
process. It should be further understood that information contained in this manual does not relieve operating
and maintenance personnel of the responsibility of exercising normal good judgment in operating and care of
the machine and its attendant equipment.

1 Introduction & Safety
1--7
C9999--2 Issue 1
1.3 Safety Features
EMERGENCY
STOP
RUN/SAFE/MAINT
KEYSWITCH
STOP
PUSHBUTTON
Fig. 1-4. Safety Feature Locations
E--STOP
Fig. 1-5. Know Where Emergency Stop Button
is Located
These safety features are to be used in conjunction
with the installation, operation and maintenance
instructions contained in this manual.
1.3.1 Emergency Stop
Stops machine drive immediately. This pushbutton
must be manually pulled out to reset.
STOP
RUN
SAFE
MAINT
Fig. 1-6. Know How to Stop Machine & Set Key
Switch to SAFE
1.3.2 Stop and Safe
The machine operator, clean--up and maintenance
personnel MUST be shown how to stop the
machine and place the KEY SWITCH on the
operator’s CONTROL PANEL in the SAFE mode
whenever machine is accessed or clean--up
operations are performed.

1 Introduction & Safety
1--8 C9999--2 Issue 1
Fig. 1-7. Turn Machine Off Before Making
Adjustments
1.3.3 Main Power Switch
If machine is to be shut down for adjustments or
repairs, turn the power supply to the machine off.
Fig. 1-8. Blade Hazard Warning
1.3.4 Guards and Covers
All safety guards, protective screens and covers
MUST be in place and securely fastened before
operating the machine.
Observe Danger warnings. Use extra care around
moving cutting blades.
SAFETY
SWITCH
Fig. 1-9. Safety Devices
1.3.5 Safety Switches
The covers of the machine are connected to
interlock safety devices for your protection.
Machine will stop operating if a safety cover or
guard is opened while the machine is running. The
rollers will continue to maintain unless the rear
machine roller guard is removed.

1 Introduction & Safety
1--9
C9999--2 Issue 1
1.4 Warnings, Cautions & Notes
In order to emphasize certain areas in the interest of personal safety and a properly operated and maintained
machine, you will encounter the words WARNING,CAUTION, and NOTE throughout this manual.
WARNING!
Fig. 1-10. Warnings Indicate Personal Danger
1.4.1 Warnings
AN OPERATING PROCEDURE,
PRACTICE, ETC. WHICH IF NOT
CORRECTLY FOLLOWED, COULD
RESULT IN PERSONAL INJURY OR
LOSS OF LIFE.
WARNING!
CAUTION!
Fig. 1-11. Cautions Indicate Potential Damage
to Equipment
1.4.2 Cautions
AN OPERATING PROCEDURE,
PRACTICE, ETC. WHICH, IF NOT
STRICTLY OBSERVED, COULD RESULT
IN DAMAGE TO OR DESTRUCTION OF
EQUIPMENT.
CAUTION!
Note !
Fig. 1-12. Notes Indicate Essential Information
1.4.3 Notes
An Operating Procedure, Condition,
etc. Which is Essential To Highlight.
Note !

1 Introduction & Safety
1--10 C9999--2 Issue 1
1.5 On Machine Warnings
Fig. 1-13. Heat Hazard
1.5.1 Heat Hazards
Forexample,thereisHOTSURFACEsignontop
of the Tab Wiper assembly. Look for warning signs
throughout the machine. They are there to alert
you to hazards.
Fig. 1-14. Electrical Shock Hazard
1.5.2 Electrical Shock Hazards
Look for warning signs on electrical cabinets and
circuit breaker boxes. They are there to alert you
to hazards of electrical shock.

1 Introduction & Safety
1--11
C9999--2 Issue 1
1.6 Safety Procedures
SAFETY SWITCH
Fig. 1-15. Do Not Disable Safety Devices
1.6.1 Safety Devices
Tampering with safety mechanisms in order to
disable them should not be tolerated.
IT IS EXTREMELY DANGEROUS TO ACCESS
MACHINE WHEN IT IS OPERATING OR
CAPABLE OF OPERATING.
Warning!
Fig. 1-16. Wear Proper Clothing
1.6.2 Appropriate Dress
Personnel working in the machine operation area
must remove jewelry and neckties. Personnel
must wear clothing appropriate for the work area.
Fig. 1-17. Keep Work Area Clean and Neat
1.6.3 Keep Area Clean
Loose materials, tools and equipment, not
essential to the operation of the machine, must be
removed from the machine work area.
Fig. 1-18. Clean Up Oil and Grease Spills
1.6.4 Grease and Oil
Clean up all oil and grease spills around the
machine work area.
Fig. 1-19. Read Manuals First
1.6.5 Manual Usage
Read and understand the instructions in the
manual before operating, adjusting or servicing
machine.

2 Installation
2--1
C9999--2 Issue 1
2 INSTALLATION
C9999--2 Issue 1

2 Installation
2--2 C9999--2 Issue 1