UNITED CPC 12000 Operation manual

CPC 12000 Operation and Service Manual

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Table of Contents
1.0 Receiving Equipment........................................................................................................................................................5
1.1 Inspection ........................................................................................................................................................................5
1.2 Selecting Equipment Location.................................................................................................................................. 5
2.0 System Dimensions...........................................................................................................................................................5
3.0 Equipment Setup ...............................................................................................................................................................6
3.1 Isolation Pads .................................................................................................................................................................6
3.2 Electrical............................................................................................................................................................................ 6
3.3 Leveling............................................................................................................................................................................. 6
4.0 Operation..............................................................................................................................................................................7
4.1 Component Overview.................................................................................................................................................. 7
4.2 Applying Power.............................................................................................................................................................. 7
4.3 Manual Operation.........................................................................................................................................................8
4.3.1 Jog Mode ................................................................................................................................................................. 8
4.3.2 Positioning the Turret.......................................................................................................................................... 8
Figure 4.3 Jog Controls..................................................................................................................................................8
4.3.3 Barrel Rotation .......................................................................................................................................................8
4.3.4 Barrels........................................................................................................................................................................ 9
4.3.5 Opening Barrels.....................................................................................................................................................9
Figure 4.4 Lid Cam Lock ................................................................................................................................................9
4.3.6 Heat Precaution ..................................................................................................................................................... 9
4.3.7 Loading Barrels ....................................................................................................................................................10
4.3.8 Material Handling ...............................................................................................................................................10
Figure 4.5 ................................................................................................................Error! Bookmark not defined.
4.3.9 Closing Barrels............................................................................................Error! Bookmark not defined.
4.3.10 Setting RPM and Cycle Time ........................................................................................................................11
4.3.11 Starting Process.................................................................................................................................................12
4.3.12 Unloading the System.....................................................................................................................................13

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4.3.13 Operating Tips ...................................................................................................................................................13
4.4 Auto Operation using the CPC Interface............................................................................................................14
4.4.1 Store or Update Process...................................................................................................................................15
4.4.2 Separator Controls..............................................................................................................................................19
4.4.3 Rinse Timer............................................................................................................................................................20
4.4.4 Auto-Reverse ........................................................................................................................................................21
4.4.5 Run a Preset Process..........................................................................................................................................21
5.0 Maintenance......................................................................................................................................................................24
5.1 Maintenance in CPC Interface ................................................................................................................................24
5.1.1 System Information............................................................................................................................................24
5.1.2 System Tools Password.....................................................................................................................................25
5.1.3 System Tools.........................................................................................................................................................25
5.1.4 Password Reset....................................................................................................................................................25
5.1.5 I/O Meter................................................................................................................................................................25
5.1.6 Help Menu.............................................................................................................................................................26
5.2 Maintenance and Repair ..........................................................................................................................................27
5.2.1 Preventative Maintenance Schedule............................................................................................................28
5.2.2 Turret Drive Assembly .......................................................................................................................................28
5.3.3 Adjusting Main Drive Belt ................................................................................................................................29
5.3.4 Replacing Main Drive Belt................................................................................................................................29
5.3.5 Barrel Drive Assembly........................................................................................................................................30
5.3.6 Inspection ..............................................................................................................................................................30
5.3.7 Drive Component Removal .............................................................................................................................31
5.3.8 Adjusting Barrel Chain.......................................................................................................................................32
5.3.9 Bearings..................................................................................................................................................................34
5.3.10 Barrels ...................................................................................................................................................................38
6.0 Troubleshooting...............................................................................................................................................................40
6.1 Interface Not Functioning........................................................................................................................................40
6.2 Will Not Begin Cycle ..................................................................................................................................................41
6.3 Premature System Halt .............................................................................................................................................42

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6.4 Desired RPM Not Reached ......................................................................................................................................43
6.5 Barrels Leak ...................................................................................................................................................................43
6.6 Turret Slips During Loading ....................................................................................................................................44
7.0 Appendix.............................................................................................................................................................................45
7.1 Handling Compounds ...............................................................................................................................................45

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1.0 Receiving Equipment
1.1 Inspection
Upon receipt of the Centrifugal Barrel System with integrated Computerized Process Controller (CPC),
please perform a thorough inspection of the shipment. Compare what is received to the packing list
to be sure all the components, including any ordered supplies are present. Check for any damage to
the equipment. If damage is found, notify the delivering freight company and UNITED SURFACE
SOLUTIONS, LLC immediately.
1.2 Selecting Equipment Location
The equipment should be conveniently located to the “flow of parts.” The CPC System will require the
appropriate electrical power, an air-line with a minimum of 100 psi, a water supply with a minimum of
20 psi, and a drain located near the machine. If a sump system and water recycling unit is to be used,
separate power must be provided for those units as well. It is suggested to leave at least three (3) feet
on each side of the machine for maintenance purposes. Sufficient work and storage space is also
required.
2.0 System Dimensions
Height
121”
Width
125”
Depth
78”
Approx.
Weight
7000lbs.

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3.0 Equipment Setup
3.1 Isolation Pads
While setting up the CPC, make certain that high-capacity rubber isolation
pads (rated at a min. of 1500 psi) are installed under each leg of the unit.
These pads are used to level the equipment and will extend the service life
of the machine. The leveling procedures will be explained later in this
section.
3.2 Electrical
With the CPC in position, a licensed electrician will be required to connect electrical power. The power
requirements for your new equipment are printed on the data plate, which is located on the upper
left-hand corner of the machines left side panel. Refer to included schematics for setup details.
UNITED SURFACE SOLUTIONS, LLC personnel are not authorized to make connections to your
building’s electrical system. Likewise, non-UNITED SURFACE SOLUTIONS personnel are not authorized
to make any modifications or adjustments to the equipment without written authorization. Doing so
may compromise operator safety as well as your warranty.
Caution: Be sure to connect only the specified voltage to the machine. These systems are built with standard
voltage 460VAC / 60Hz, but can be ordered in 400VAC / 50Hz configuration. Applying improper voltage will result
in severe damage to the system and will void the warranty. Inspect the motor and AC drive to confirm the rated
voltage.
3.3 Leveling
Once the electrical connections have been made, it will be necessary to level the unit. Do not skip this
step of the setup process. This unit uses a fluid mass of media to finish your parts and if the machine
is not level, this fluid mass will favor one side of the barrel, effectively reducing the available working
volume of the barrel. This may result in an increase in part-on-part damage. The following instructions
will aid you in leveling the CPC:
1. Install High-Capacity Rubber Isolation Pads (rated at 1500 psi) under each leg of the
unit. Recommended pad size is 6” X 6” X ½”.
2. Turn on the power for the CPC at the disconnect the switch located on the right side of
the machine. The shutter door should open automatically once the Red Beacon stops
flashing and the System Initialization is complete. If the shutter door does not open
please check the incoming air supply.
3. Select ‘Manual Operation’ from the CPC Touch Screen Interface. Using the Jog controls,
position the cradles so you have access to the center axle of the turret.
4. Place a magnetic beam level on the center axle of the turret.

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5. If adjustment is needed, shim under the isolation pad with varying thicknesses of sheet
metal. If large adjustments are necessary use thicker padding, standard sizing is ¾” and
1”.
DO NOT BOLT DOWN SYSTEM. The CPC uses a rotating turret that puts stress on the machine. Being
on isolation pads, the machine is allowed to “flex” and absorb this stress. If the machine is bolted
down and not allowed to flex, additional stress would be placed on the bearings. The added stress on
the bearings will cause premature bearing failure. The warranty stands in effect only when the CPC is
on the isolation pads. If the CPC is bolted to the floor, the warranty on bearings, barrels and belts will
be void.
4.0 Operation
4.1 Component Overview
A brief explanation of the systems major components is necessary for safe and trouble-free operation.
Please refer this figure displaying the various components of the CPC.
4.2 Applying Power
Before applying power, ensure that the electrical control box is closed and secure, and that there are
no obvious exposed electrical conductors. Check that water and air supplies are turned on and are at
full pressure.
To apply power to the CPC12000, turn the safety disconnect switch (located on the electrical
enclosure on the right side of the machine) to the ON position. The display will show the initialization
screen and the red beacon will start flashing. Once initialization is complete, the door will
automatically open, the beacon will stop flashing, and the System I.D. Screen will appear. Simply touch
the screen to proceed to the main menu.
WARNING: The touch screen is built to NEMA 4 standards and is resistant to water but can be easily damaged by sharp hard
objects. DO NOT use any such objects to operate the interface terminal.

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4.3 Manual Operation
To begin operating the CPC manually choose MANUAL OPERATION
from Main Menu. This will bring up the Manual Operation screen of
the CPC. At this level, all necessary functions can be controlled to
operate the CPC. Simply press any touch key to operate the related
function. Individual functions will be explained throughout this
chapter. If at any time the operator needs a brief explanation
regarding the function of a touch key they may do so by using the
Help option in the Main Menu.
4.3.1 Jog Mode
The CPC has two basic modes of operation: jog mode and run mode. The mode of operation is
determined by the position of the shutter door. Once the shutter door is open, the jog and material
handling controls will be activated and the operator can safely position the turret for loading and
unloading.
4.3.2 Positioning the Turret
When the shutter door is open, the turret may be jogged utilizing the jog button in conjunction with
the JOG FWD or JOG REV. The Safety Jog Button is located on the right side of the cabinet below the
E-Stop. The JOG FWD and JOG REV are located on the touch screen interface.
4.3.3 Barrel Rotation
While in Jog Mode the barrels may be rotated to load or unload contents and media by utilizing the
hands-free safety jog button in conjunction with the BARREL FWD or BARREL REV touch key (Figure
3.2)
Pressing JOG FWD will rotate the turret forward
Pressing JOG REV will rotate the turret backward
BARREL REV will rotate the barrel backwards
BARREL FWD will rotate the barrel forward
Figure 4.3 Jog Controls

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WARNING: Never jog the turret while any body part is in contact with either the barrels or the turret, or is anywhere within
the confines of the machine cabinet. Serious injury could occur.
4.3.4 Barrels
The CPC12000 has four barrels held perpendicular to the axle shaft that rotate at a 1:1 ratio relative to
the turret. The barrels are constructed of 304-stainless steel with aluminum lids with attached
hardened steel and stainless steel hardware and locking assemblies. Within the barrel sits a removable
liner of various configurations including compartmental dividers for total part segregation. This barrel
and liner assembly holds work pieces, media, compounds, and water during the finishing process.
4.3.5 Opening Barrels
The barrels use an over-centering cam operation to create an airtight seal between the lid and the
base of the barrel. A spring and pin locking mechanism is used to hold the cam in the locked position.
To open, pull the lock-pin and hold while rotating the cam handle towards the back of the machine
using the lid-opening tool provided. Refer to Figure 3.3 for component definition.
WARNING: Barrels may become pressurized. Some processes can generate super-heated steam in as little as 10 minutes.
Open slowly, use caution.
4.3.6 Heat Precaution
The processes used in the CPC may generate a considerable amount of heat. Since the barrel is
sealed, some heat is converted to pressure inside the barrel. Use caution when opening the barrel; be
prepared for hot, soapy liquid to spray out from between the barrel and the barrel lid. Be sure to
position the barrel so that any foam or liquid from the barrels is contained within the turret
shrouding. Use the following procedure as a guideline to safely open a heated barrel:
1. Jog the turret so that the barrel is 1 to 2 inches below the lower door frame.
2. Rotate the barrel 15 to 20 degrees so that the front seam between the lid and barrel are
facing downward towards the shrouding and the rear seam is facing upward away from
the operator.
Locking-Pin
Cam
Figure 4.4 Lid Cam Lock

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3. Pull the locking-pin outward and slowly release the cam assembly by rotating the cam
handle towards the back of the machine. If pressure begins to release stop until
pressure dissipates. Continue until cam is completely relaxed and then proceed to
opposite side.
4. Rotate barrel BARREL REV until level. Jog turret JOG REV 1-2 inches upwards until seam
is even with lower door frame. Release center latch. Do Not release prior to dissipating
pressure.
5. Slide the cam assemblies in toward each other and remove the lid by sliding the lid
across the lower door fame into the lid cradle. Do Not lift the lid injury could result.
The use of a pressure relief valve: It is not suggested to use any form of pressure relief valve on the
barrel assembly due to the nature of the process. The processes used in the CPC typically grind metal,
ceramic or plastics in a soapy water mixture. Once this mixture dries it quickly cakes and becomes
hard similar to the composition of cement. This would disable any type of pressure relief valve.
Consequently, an operator might feel comfortable that the pressure is relieved and open the barrel
without taking the precautions required, only finding that the valve had malfunctioned and the barrel
was still under pressure. By following the above procedure, the CPC poses little risk to the operator.
If a process must be continually run that generates an excessive amount of heat, raise the water level
within the barrel to an inch or more above the media level to help aid in cooling the media. On
extremely long cycle times, 60 minutes or more, incorporate what is known as a rinse and recharge
into the process. In this manner, half way through the cycle the system would be stopped and the
barrels could be flushed with water (without removing any parts or media) and recharged with soap
or compound. This helps keep the water temperature from reaching dangerous levels.
NOTE: Excessive heat will reduce the service life of the barrel linings. Highly aggressive processes should have periodic
intervals during which the barrels are flushed with cool water to minimize the heat generated within the barrel. A compound
recharge will also be added at this time to maintain the cleaning capabilities throughout the remainder of the process.
4.3.7 Loading Barrels
Load the predetermined production part lot into the barrel. Press MATERIAL HANDLING in the upper
right hand corner of the Manual Mode screen (Figure 4.2). The
interface will change to the screen illustrated below. NOTE:
Generally the production parts are loaded into the barrel prior
to any media or compound. In some cases such as extremely flat
parts water locking or sticking to the barrel lining could occur. If
this is the case it maybe necessary to load in reverse order.
4.3.8 Material Handling
Once in the Material Handling screen the operator can load

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media and water into the barrel from the hopper via the loading hose. To accomplish this place the
hose over the barrel to be loaded and press the MANUAL touch key on both the Media Fill and Water
Fill. This will activate the media feed system, to stop once the barrel is to the predetermined capacity
simply press both MANUAL touch keys again.
It is important to ensure that the sealing surfaces of the barrel and the barrel lid are clean and free
from media, compound, and parts that could disrupt the seal. Please follow the guidelines below for
closing the barrels.
1. Clean the sealing surfaces of the barrel and lid of all media, compound and/or parts.
Rinse the lid using the hose reel provided while it is still in the lid cradle.
2. Slide the lid onto the barrel via lower door frame. Do Not lift the lid; continual lifting
could cause strain on the lower back.
3. Secure the cams using the Wrench provided. Be certain that the Locking Pins are in
place. Secure the center latch.
4. Visually inspect that all locks are secure and proceed to next barrel. To conserve time,
unload and load each barrel independently. Review section on Opening Barrels if
necessary.
5. If using only one or two barrels, use opposing barrels. This will balance the turret.
Approximate barrel weights should be within ten percent of each other.
6. Operate the machine with all lids in place, even if the barrel is empty. Failure to do so
may cause abnormal vibration or damage due to the machine being out of balance.
NOTE: It is usually most efficient to unload and reload one barrel at a time.
Once all barrels are loaded and safety latches are secure use the RETURN touch key to return to the
Manual Operation screen to set process parameters.
4.3.10 Setting RPM and Cycle Time
To set either the turret RPM or the cycle timer while in the manual mode of operation, touch either
command on the display screen. This will activate a pop-up window with a numeric keypad. Once the
keypad is displayed, turret RPM and preset time can be adjusted within the system limits (see System
Tools to adjust limits). Press CLOSE SCREEN to hide keypad once the proper adjustments are made.
Turret Direction

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To set turret direction simply
press the FORWARD or
REVERSE on the Manual
Operation screen. A green
indicator will light one of the
directional keys, displaying the
current direction of turret
rotation. The ‘Auto’ touch key
automatically reverses the turret
direction halfway through the
cycle by dividing the cycle time in half. When activated, this touch key will flash red.
NOTE: Refer to your Process Report for specified time, direction of rotation, and RPM requirements.
4.3.11 Starting Process
It is best to run through a series of safety checks prior to starting the CPC. By organizing the start-up
process in a sequential order, an operator can easily remember a set routine. We suggest that the
following to be a minimum list of safety checks. Appoint any additional operations as needed.
1. Re-check each barrel to be sure that all barrels are secure and properly locked.
2. Check turret speed.
3. Check preset timer.
4. Check the desired direction of turret rotation. Forward should be used unless specifically
stated otherwise on the Process Report.
5. Clear the door area and press START. The screen will change to a Door Closing Warning.
If it becomes necessary to stop the start-up process, use the OPEN DOOR touch key to
reverse the door operation and return to the Manual Operation screen. Once the door is
completely closed, the beacon light will turn green indicating that the CPC will begin the
processing cycle.
NOTE: When the unit is running, the shutter door will lock shut and will release only after the
specified time has elapsed or the stop key is pressed and the turret RPM has decreased to zero.
Do not attempt to open the shutter door until the machine is fully stopped.
Once the system starts, the interface will return to the Manual Operation screen. The START key will
be illuminated green and will start counting down. To stop the process use the STOP touch key.
Speed /
Press within the boxes
to activate keypad

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Remaining Cycle Time
Below the Preset Time display on the Manual Operation screen is a
countdown timer labeled in blue lettering. This timer will display the time
remaining until the cycle is complete. If the CPC is stopped during a cycle the Remaining timer
will retain the remaining cycle time until the shutter door is opened, at which time the display
will reset to the preset time. By pressing the touch key next to the remaining timer the timer can be
reset to the PRESET TIME while the system is in operation.
4.3.12 Unloading the System
When the system has completed the process cycle, the turret will automatically decelerate and stop,
the STOP touch key will be illuminated red, and the shutter door will automatically open. At that time,
follow these operations to safely unload the CPC.
1. The system goes into Jog Mode once the shutter door is completely open.
2. Use the jog controls (Figure 4.3) in conjunction with the Jog button to bring the first
barrel to be unloaded into position. Open the barrels as described in 4.3.5 Opening
Barrels.
WARNING: Refer to the 4.3.6 Heat Precaution for important safety information.
3. Start the Material Handling and Parts/Media Rinse Systems as described in 4.3.8
Material Handling. The Rinse Controls are located in the lower left hand corner of the
screen.
4. Empty the barrel by rotating the barrel and dumping the contents onto the forward
splash panel. This will allow the parts to lay flat before sliding onto the separator screen.
5. Reload the barrel for the next process or step of operation as described in 4.3.7
Loading Barrels.
6. Replace the barrel lid and secure the locking pin as described in 4.3.9 Closing Barrels.
7. Repeat the unloading and reloading sequences for the next barrel.
4.3.13 Operating Tips
Here are a few additional tips for working with your CPC that should make production easier and
more consistent:
Always use a soap or detergent in every process. Otherwise the media will soon take on a glazed
appearance and will no longer cut properly.
Rinse parts after each step of the process. Do not let the compound dry on the parts.

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Do not let parts sit for an extended period after finishing. Some materials, especially aluminum and
zinc alloys will develop corrosion spots if left in the machine for as little as 10 minutes after the end of
the process. If the parts have sat in the barrel, operate the CPC for a few extra minutes before
unloading the barrels. This may help eliminate spotting that may have developed.
Never put compound directly on work pieces. Always load media and water on top of parts before
adding compound or compound residue may be found on the parts.
Thoroughly rinse the empty barrels between process steps.
Never use the same scooper for more than one compound. Doing so will contaminate both products
and may result in inferior finishing.
Keep finishing media as clean and uncontaminated as possible.
Avoid inadvertently mixing media together.
If the work pieces are subject to rust, a rustproof treatment must be used.
4.4 Auto Operation using the CPC Interface
In addition to the MAINTENANCE and SYSTEM HELP this chapter will cover the AUTO mode of
operation and recipe storage for the CPC. Please refer to the previous chapter 4.3 Manual Operation
for operation procedures when using the manual mode of operation.
Select AUTO OPERATION to display the Preset Processes screen shown in Figure 4.7 on the next page.
This control screen allows the operator to store, edit, review or run any of the 30 allowable preset
processes.

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4.4.1 Store or Update Process
To store a new process select any available or unused process by pressing within the Selection Area
and selecting REVIEW. The Process Review screen will appear allowing the operator to both enter a
new process or review and edit an existing process. (Figure 4.8)
The Process Review screen will allow the operator to edit any process parameter simply by selecting
the associated area (outlined with dotted black line). By selecting an area the operator will begin any
interview asking basic process parameters.
After entering into any of the process parameter screens, data can be input or edited by using the
keypad or keyboard within that screen. Once data is entered ↵ENTER must be used to save any
changes.
PRESET PROCESSES
FIGURE 4.7
U
PDATE OR
R
EVIEW
P
ROCESS
S
ELECTION
AREA
P
ART
N
AME
M
AIN
M
ENU
R
UN
P
RESET
P
RESETS
11-20
P
RESET
NUMBER
P
ROCESS
CODE
PROCESS REVIEW
FIGURE 4.8
TOUCH WITHIN THIS AREATO
DISPLAY ASSOCIATED SCREEN
P
RESS THIS KEY TO ACTIVATE THE
AUTO REVERSE FUNCTION
ON WILL FLASH IN THE RED AREA

Using the screen illustrated in Figure 4.8, the operator can enter a process code generated by
United’s Lab or insert a tracking number for easy reference.
By pressing CONTINUE the operator can enter a program loop that will basically start an interview or
allow them to view all parameters for a single process.
The operator can get out of the loop at any time and return to the Process Review screen by pressing
RETURN
Enter a product description using the screen illustrated in Figure 4.10 to identify the part by either a
name or a part number. Complete the step by pressing ↵ENTER
Process Code
Figure 4.9
Use CONTINUE to proceed
with interview

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Utilize Media Data screen (Figure 4.11) to input media information (shape, type, size and height or
level of media within the barrel). Press CONTINUE to proceed to the next screen.
NOTE: To control part on part impingement use a media height of 80 to 95 percent of the total barrel
volume. To generate more aggression operate at lower levels approximately 65 percent.
If the operator has chosen to continue with the interview the following screen (Figure 4.12) will be
displayed.
MEDIA DATA
FIGURE 4.11
COMPOUND DATA
FIGURE 4.12

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This screen is similar to the Media Data screen shown in Figure 4.8. It contains information about the
compound such as type and amount used. Input the necessary information and press Enter ↵to save
it. Press CONTINUE to proceed to the next screen.
Enter the maximum amount of parts per barrel and desired fill times for the water and media (Figure
4.13). These fill times will keep the process consistent by filling each barrel with the exact amount of
media every time. The media fill rate is a speed adjustment for the media pan feeder. This adjustment
is necessary to insure a steady flow with all media sizes and weights. An adjustment of the media flow
rate is needed when switching media and works in conjunction to the media fill time to deliver an
exact amount of media to the barrel. Once set, press Enter ↵to save. Press CONTINUE to proceed to
the next screen.
NOTE: Standard water level is the height of the media; raise the water level 1 to 2 inches above the media for long or
aggressive processes. This will help to cool the contents of the barrel. To reduce part impingement, use a lower water level.
Fill Times and Capacities
Figure 4.13

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The next step is to set the turret RPM and cycle time. To accomplish this, input the number from the
keypad and press ENTER. The arrow keys allow scrolling between RPM and time. Pressing CONTINUE
will display the separator and elevator controls. This is final screen of the interview.
4.4.2 Separator Controls
To control the parts/media separator and rinse systems, utilize the screen illustrated below in Figure
4.15. Through this screen, the separator speed and maximum run time can be set. The speed should
be adjusted so the parts and media flow evenly across the screen deck without bouncing. The run
time sets the amount of time the separator and elevator operate before automatically shutting down.
This time should be adjusted to allow the operator time to unload and load all four barrels and clear
the separator of any parts and media (approximately 10 to 20 minutes). Once the separator shuts
down, the elevator will continue to operate for 20 seconds to empty the buckets completely.
RPM &TIME
FIGURE 4 .14

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4.4.3 Rinse Timer
The parts/media rinse timer is used to conserve water. This should be set to equal the amount of time it
takes for a barrel’s contents to exit the separator. The operator should activate the rinse just prior dumping
each barrel. In this manner, the rinse system is not spraying water when the separator is empty, such as when
the operator is filling the barrel.
SEPARATOR &ELEVATOR
CONTROLS
FIGURE 4.15
PROCESS REVIEW
FIGURE 4.16
P
RESS
R
ED KEY TO
ACTIVATE AUTO REVERSE
T
O NAVIGATE TO ANOTHER
STEP USE THE STEP KEY