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