Scott Scotty 5000 User manual

Copy No.:
Instruction Manual
Model No. : Scotty 5000.................
Year of Manufacture : 2006.......
Manufactured by :..........
Document Number : F--9999--8........
Issue : 1.....................
Date of Issue : August 2006..............

ISSUE NOTE
This is Issue 1; Date of Issue: August 2006
Copyright 2006

I
F--9999--8 Issue 1
TABLE OF CONTENTS
1 INTRODUCTION AND SAFETY 1--1........................................................
1.1 Introduction 1--3....................................................................
1.1.1 Scotty 5000 Machine Specifications and Utility Requirements 1--4.......................
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 Compressed Air Valve 1--8........................................................
1.3.5 Guards and Covers 1--9...........................................................
1.3.6 Safety Devices 1--9...............................................................
1.4 Warnings, Cautions & Notes 1--10.....................................................
1.4.1 Warnings 1--10....................................................................
1.4.2 Cautions 1--10....................................................................
1.4.3 Notes 1--10.......................................................................
1.5 Warnings 1--11.......................................................................
1.5.1 Heat Hazards 1--11................................................................
1.5.2 Electrical Shock Hazards 1--11......................................................
1.6 Safety Procedures 1--12..............................................................
1.6.1 Compressed Air Valve 1--12........................................................
1.6.2 Safety Devices 1--12...............................................................
1.6.3 Appropriate Dress 1--12............................................................
1.6.4 Keep Area Clean 1--13.............................................................
1.6.5 Grease and Oil 1--13..............................................................
1.6.6 Manual Usage 1--13...............................................................
2 INSTALLATION 2--1......................................................................
2.1 Installation Requirements 2--3........................................................
2.1.1 Pre-Installation Requirements 2--4..................................................
2.1.2 Uncrating & Placement 2--5........................................................
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 Scotty 5000 with Telemecanique PLC Control 3--12....................................
3.3 Preliminary Inspection and Start-Up Procedure 3--13....................................
3.3.1 Preliminary Set-Up 3--13...........................................................
3.3.2 Adjust Hub Roller 3--26............................................................
3.3.3 Adjust Drive Roller 3--26...........................................................

II F--9999--8 Issue 1
3.3.4 Side Guide Set--Up 3--27...........................................................
3.3.5 Kick Out Solenoid Set--Up 3--28.....................................................
3.3.6 Sheet Hold Down Straps 3--28......................................................
3.3.7 Set Up For Production 3--29........................................................
3.3.8 Run Production 3--30..............................................................
3.4 Handwheel and Tab Set-Up 3-34..........................................................
3.4.1 Hand Wheel and Tab Set-Up Definitions 3-35.........................................
HANDWHEEL SET-UPS FOR 5” SHEET WITH 3/16” MARGINS 3-36...............................
HANDWHEEL SET-UPS FOR 6” SHEET WITH 3/16” MARGINS 3-37...............................
HANDWHEEL SET-UPS FOR 7-1/4” SHEET WITH 3/16” MARGINS 3-38...........................
HANDWHEEL SET-UPS FOR 7-1/4” SHEET WITH 1/4” MARGINS 3-39.............................
HANDWHEEL SET-UPS FOR 7-3/4” SHEET WITH 3/16” MARGINS 3-40...........................
HANDWHEEL SET-UPS FOR 7-3/4” SHEET WITH 1/4” MARGINS 3-41.............................
HANDWHEEL SET-UPS FOR 8” SHEET WITH 3/16” MARGINS 3-42...............................
HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH 3/16” MARGINS 3-43...........................
HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH 1/4” MARGINS 3-44.............................
HANDWHEEL SET-UPS FOR 8-1/2” SHEET WITH 1/2” MARGINS 3-45.............................
HANDWHEEL SET-UPS FOR 9” SHEET WITH 3/16” MARGINS 3-46...............................
HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH 3/16” MARGINS 3-47...........................
HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH 1/4” MARGINS 3-48.............................
HANDWHEEL SET-UPS FOR 9-1/2” SHEET WITH 1/2” MARGINS 3-49.............................
HANDWHEEL SET-UPS FOR 11” SHEET WITH 1/8” MARGINS 3-50...............................
HANDWHEEL SET-UPS FOR 11” SHEET WITH 3/16” MARGINS 3-51..............................
HANDWHEEL SET-UPS FOR 11” SHEET WITH 1/4” MARGINS 3-52...............................
HANDWHEEL SET-UPS FOR 11” SHEET WITH 1/2” MARGINS 3-53...............................
HANDWHEEL SET-UPS FOR 12” SHEET WITH 3/16” MARGINS 3-54..............................
HANDWHEEL SET-UPS FOR 12” SHEET WITH 1/4” MARGINS 3-55...............................
HANDWHEEL SET-UPS FOR 12” SHEET WITH 1/2” MARGINS 3-56...............................
HANDWHEEL SET-UPS FOR 14” SHEET WITH 3/16” MARGINS 3-57..............................
HANDWHEEL SET-UPS FOR 14” SHEET WITH 1/4” MARGINS 3-58...............................
HANDWHEEL SET-UPS FOR 14” SHEET WITH 1/2” MARGINS 3-59...............................
METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 297 MM MARGIN: 0 MM 3-60
METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 210 MM MARGIN: 0 MM 3-61
METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 297 MM MARGIN: 1 MM 3-62
METRIC HANDWHEEL SET-UPS FOR A4 (297mm x 210mm) TAB SIDE: 210 MM MARGIN: 1 MM 3-63
4 MAINTENANCE 4--1......................................................................
4.1 Maintenance 4--3....................................................................
4.1.1 Machine Lubrication 4--3..........................................................
4.1.2 Vacuum Pump Maintenance 4--6...................................................
4.1.3 Machine Timing 4--8..............................................................
4.1.4 Preparation for Timing Procedures 4--10..............................................
4.1.5 Timing Procedures 4--11...........................................................
4.1.5.2 Plastic Feed & Cut Operating Arm 4--12..............................................
4.1.6 Reinstall Chains 4--15..............................................................
4.2 Calibration 4--16.....................................................................
4.2.1 Preparation for Calibration Procedures 4--16..........................................
4.2.2 Handwheel Settings 4--17..........................................................
4.2.3 Handwheel Calibration Procedures 4--18.............................................
4.2.4 Pile Feeder 4--22
..................................................................

III
F--9999--8 Issue 1
4.2.5 Paper Stocks 4--26................................................................
4.2.6 Procedure To Set Tab Cutting Knives 4--28............................................
4.2.7 Set Tab Cut Cylinder 4--30..........................................................
4.2.8 Kick Out Solenoid Set Up 4--30......................................................
4.2.9 Plastic Tip Die 4--32...............................................................
4.2.10 Paper Stop Adjustment 4--34........................................................
4.2.11 Plastic Reel Holder Adjustment Procedure 4--36.......................................
4.3 Fiber Optics 4--37....................................................................
4.3.1 Fiber Optic Sensor Locations 4--37..................................................
4.3.2 Fiber Optic Adjustment 4--38........................................................
4.3.3 Fiber Optic Sensor Cleaning 4--40...................................................
4 MAINTENANCE 4--1......................................................................
4.1 Maintenance 4--3....................................................................
4.1.1 Machine Lubrication 4--3..........................................................
4.1.2 Vacuum Pump Maintenance 4--6...................................................
4.1.3 Machine Timing 4--8..............................................................
4.1.4 Preparation for Timing Procedures 4--10..............................................
4.1.5 Timing Procedures 4--11...........................................................
4.1.5.2 Plastic Feed & Cut Operating Arm 4--12..............................................
4.1.6 Reinstall Chains 4--15..............................................................
4.2 Calibration 4--16.....................................................................
4.2.1 Preparation for Calibration Procedures 4--16..........................................
4.2.2 Handwheel Settings 4--17..........................................................
4.2.3 Handwheel Calibration Procedures 4--18.............................................
4.2.4 Pile Feeder 4--22..................................................................
4.2.5 Paper Stocks 4--26................................................................
4.2.6 Procedure To Set Tab Cutting Knives 4--28............................................
4.2.7 Set Tab Cut Cylinder 4--30..........................................................
4.2.8 Kick Out Solenoid Set Up 4--30......................................................
4.2.9 Plastic Tip Die 4--32...............................................................
4.2.10 Paper Stop Adjustment 4--34........................................................
4.2.11 Plastic Reel Holder Adjustment Procedure 4--36.......................................
4.3 Fiber Optics 4--37....................................................................
4.3.1 Fiber Optic Sensor Locations 4--37..................................................
4.3.2 Fiber Optic Adjustment 4--38........................................................
4.3.3 Fiber Optic Sensor Cleaning 4--40...................................................
4.4 Machine Cleaning 4--41...............................................................
4.4.1 Clean Platen Unit 4--41............................................................
5 SCOTTY 5000 PARTS 5-1.................................................................
5.1 ASSEMBLY LOCATOR 5-4...............................................................
5.2 PILE FEED - REGISTER BOARD ADJUSTMENT 5-6........................................
5.3 PILE FEED - DRIVE ROLLER ASSEMBLY 5-8
..............................................
5.4 PILE FEED DRIVE 5-10...................................................................
5.5 PILE FEED DRIVE & TENSIONER 5-12.....................................................
5.6 PILE FEED - VACUUM BAR DRIVE 5-14....................................................
5.7 PILE FEED - VACUUM BAR 5-16..........................................................
5.8 PILE FEED - PAPER GUIDE 5-18..........................................................

IV F--9999--8 Issue 1
5.9 PILE FEED - OPTIC MOUNTING 5-20......................................................
5.10 PILE HEIGHT ASSEMBLY 5-22...........................................................
5.11 PILE LIFT DRIVE 5-24...................................................................
5.12 PILE LIFT FRAME 5-26..................................................................
5.13 PILE LIFT HANDWHEEL 5-28............................................................
5.14 PILE FEED - SHEET SEPARATOR 5-30...................................................
5.15 PILE FEED -- STACK GUIDE 5-32.........................................................
5.16 PILE FEED - PNEUMATIC FITTINGS 5-34.................................................
5.17 PILE FEED - GUARDS, COVERS 5-36....................................................
5.18 PILE FEED - OPTIC MOUNTING 5-38.....................................................
5.19 PILE FEED - PNEUMATIC CONTROLS “A” 5-40............................................
5.20 PILE FEED - PNEUMATIC CONTROLS “B” 5-42............................................
5.21 PILE FEED - BELT & CHAIN LAYOUT 5-44.................................................
5.22 PLATEN UNIT 5-46.....................................................................
5.23 REGISTER BOARD - HOLD DOWN PLATE 5-48............................................
5.24 REGISTER BOARD - CONVEYOR 5-50...................................................
5.25 MIDDLE REGISTER - HOLD DOWN PLATE 5-52...........................................
5.26 MIDDLE REGISTER - CONVEYOR 5-54...................................................
5.27 MIDDLE REGISTER BOARD UNIT 5-56...................................................
5.28 MIDDLE REGISTER BOARD DRIVE (A) 5-58...............................................
5.29 MIDDLE REGISTER BOARD DRIVE (B) 5-60...............................................
5.30 TAB CUTTER - KNIFE CARRIER (L.H.) 5-62...............................................
5.31 TAB CUTTER - KNIFE CARRIER (R.H.) 5-64...............................................
5.32 TAB CUTTER (A) 5-66...................................................................
5.33 TAB CUTTER (B) 5-68...................................................................
5.34 TAB CUTTER DRIVE LINKAGE 5-70......................................................
5.35 TIP DIE UNIT 5-72......................................................................
5.36 HANDWHEEL UNIT/ PLASTIC POSITION/ TAB POSITION 5-74..............................
5.37 HANDWHEEL UNIT/ PLASTIC SIZE 5-76..................................................
5.38 HANDWHEEL UNIT/ TAB SIZE 5-78.......................................................
5.39 HANDWHEEL LOCATOR 5-80............................................................
5.40 PLASTIC FEED UNIT ASSEMBLY (A) 5-82.................................................
5.41 PLASTIC FEED UNIT ASSEMBLY (B) 5-84.................................................
5.42 PLASTIC FEED ASSEMBLY (C) 5-86......................................................
5.43 PLASTIC FEED UNIT - ROLLERS 5-88....................................................
5.44 PLASTIC FEED - SLIDE 5-90.............................................................
5.45 PLASTIC FEED - DRIVE 5-92............................................................
5.46 PLASTIC FEED - COVERS & GUARDS 5-94...............................................
5.47 PLASTIC CUT - BASE 5-96..............................................................
5.48 PLASTIC CUT ASSEMBLY 5-98..........................................................
5.49 PLASTIC REEL HOLDER 5-100...........................................................
5.50 PNEUMATIC CONTROLS --1 5-102........................................................
5.51 PNEUMATIC CONTROLS --2 5-104........................................................
5.52 PAPER TRAY ASSEMBLY 5-106...........................................................
5.53 GUARDS & COVERS 5-108...............................................................
5.54 BASE & DRIVE 5-110....................................................................
5.55 MAIN MOTOR & VACUUM PUMP 5-112....................................................
5.56 HOLD DOWN BAR 5-114.................................................................
5.57 DRIVE BELT & CHAIN ASSEMBLY 5-116...................................................
5.58 CHIP REMOVAL VACUUM 5-118..........................................................

V
F--9999--8 Issue 1
6 ELECTRICAL AND PNEUMATICS 6-1...

1 Introduction and Safety
1--1
F--9999--8 Build 8 Issue 1
1 INTRODUCTION AND SAFETY

1 Introduction and Safety
1--2 F--9999--8 Build 8 Issue 1
Important Warranty Information
All Scott machines require clean, dry air. The warranty does not cover damage to machines due to
impurities or water in the air supply system. An optional coalescing filter with auto drain is available.
Contact your Scott representative for details.

1 Introduction and Safety
1--3
F--9999--8 Build 8 Issue 1
1.1 Introduction
Fig. 1-1. Scotty 5000t
The Scotty 5000tuses a vacuum feeder for accuracy with many stocks, a platen mylar applicator which
only heats the tab extension, tab cutting knives, and efficient receiving stacker 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. As the tab widens, or the tab position moves toward the center of the sheet, the
sheet size capability increases accordingly.

1 Introduction and Safety
1--4 F--9999--8 Build 8 Issue 1
1.1.1 Scotty 5000 Machine Specifications and Utility Requirements
Model Scotty 5000t
Speed Up to 5000 tabs cut per hour
Up to 4200 tabs laminated and cut 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 -- 999999
Motor 1HorsePower
Electrical Requirements 30 Amps, 220VAC single phase, 50 or 60 Hz
Air Requirements 6 ScFm @ 80 P.S.I. (170LPM @ 5.3 bar)
Air Quality Clean Dry Air filtered to 5 micron
Decibel Rating 94db
Dimensions L--85” W--52” H--63” (L--2159mm W--1320.8mm H--1600.2mm)
Shipping Weight 2000 lbs (910 Kg)
Warranty One year against defects in parts and workmanship
Note ! All Scott Machines require clean, dry air.
Optional air filters are available, contact your Scott representative for more details.

1 Introduction and Safety
1--5
F--9999--8 Build 8 Issue 1
PAPER
SUPPORT
PAPER
CATCHER
OPERATORS
PANEL
PILE
FEEDER
TIP DIE
TAB
CUTTER
ELECTRICAL
BOX
PAPER LIFT
HANDWHEEL
PLASTIC
POSITION
HANDWHEEL
PLASTIC SIZE
HANDWHEEL
TAB POSITION
HANDWHEEL
TAB SIZE
HANDWHEEL
Fig. 1-2. Machine Front View
FILM
GUIDES
VACUUM
UNIT
TRANSFORMER
MAIN POWER
SWITCH
REEL HOLDER
PLASTIC
FEEDER
VACUUM
GAGE
DRIVE
MOTOR
AREA
AIR INLET
VALVE
TAB CUTTER OFF
Fig. 1-3. Machine Back View

1 Introduction and Safety
1--6 F--9999--8 Build 8 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 and Safety
1--7
F--9999--8 Build 8 Issue 1
1.3 Safety Features
EMERGENCY
STOP
MAIN POWER
SWITCH
KEY SWITCH
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.
RUN
SAFE
STOP
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 and Safety
1--8 F--9999--8 Build 8 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.
VALVE
CONTROL
PLANT
AIR
SUPPLY
Fig. 1-8. Compressed Air Can Be Turned Off.
1.3.4 Compressed Air Valve
The compressed air line at the main AIR IN
features a ON/OFF valve for safety. The valve is
constructed to lockout down stream air pressure
when in the OFF position.
●The valve shuts off plant supplied compressed
air to the machine.
●Place the valve in the closed position when the
machine is not in use and prior to washing or
servicing the machine.

1 Introduction and Safety
1--9
F--9999--8 Build 8 Issue 1
Fig. 1-9. Cover Warnings
1.3.5 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. 1-10. Safety Devices
1.3.6 Safety Devices
The covers of the machine are connected to safety
devices for your protection.

1 Introduction and Safety
1--10 F--9999--8 Build 8 Issue 1
WARNING!
Fig. 1-11. Warnings Indicate Personal Danger
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.
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. 1-12. 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. 1-13. Notes Indicate Essential Information
1.4.3 Notes
An Operating Procedure, Condition,
etc. Which is Essential To Highlight.
Note !

1 Introduction and Safety
1--11
F--9999--8 Build 8 Issue 1
Fig. 1-14. Heat Hazard
1.5 Warnings
1.5.1 Heat Hazards
Forexample,thereisHOTSURFACEsignontop
of the Plastic Press assembly. Look for warning
signs throughout the machine. They are there to
alert you to hazards.
Fig. 1-15. 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 and Safety
1--12 F--9999--8 Build 8 Issue 1
VALVE
CONTROL
PLANT
AIR
SUPPLY
Fig. 1-16. Compressed Air Valve.
1.6 Safety Procedures
1.6.1 Compressed Air Valve
Assemblies which are air actuated may have
pressure remaining in the air lines. Turn OFF
valve before working on pneumatic circuits to
release air trapped in the system.
DRAIN LINES OF COMPRESSED AIR TO
PREVENT ACCIDENTAL ACTIVATION OF
AIR DRIVEN ASSEMBLIES.
WARNING!
SAFETY
SWITCH
Fig. 1-17. Do Not Disable Safety Devices
1.6.2 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. 1-18. Wear Proper Clothing
1.6.3 Appropriate Dress
Personnel working in the machine operation area
must remove jewelry and neckties. Personnel
must wear clothing appropriate for the work area.

1 Introduction and Safety
1--13
F--9999--8 Build 8 Issue 1
Fig. 1-19. Keep Work Area Clean and Neat
1.6.4 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. 1-20. Clean Up Oil and Grease Spills
1.6.5 Grease and Oil
Clean up all oil and grease spills around the
machine work area.
Fig. 1-21. Read Manuals First
1.6.6 Manual Usage
Read and understand the instructions in the
manual before operating, adjusting or servicing
machine.