UNITED CPC1500 Manual

United Surface Solutions | 11901 Burke St, Santa Fe Springs, CA 90670 | [email protected] | [phone] Page | 1
Operation & Maintenance Manual
CPC1500

United Surface Solutions | 11901 Burke St, Santa Fe Springs, CA 90670 | [email protected] | [phone] Page | 2
NOTICE TO USER
The user is expressly warned to consider and adopt all safety precautions that might be indicated by
the activities described herein and to avoid all potential hazards. By following the instructions contained
herein, the user willingly assumes all risks in connection with such instructions.
All rights reserved. No part of this work may be reproduced or used in any form or by any means -
graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage
and retrieval systems - without written permission of United Surface Solutions, LLC.
COPYRIGHT 2020
BY UNITED SURFACE SOLUTIONS, LLC

United Surface Solutions | 11901 Burke St, Santa Fe Springs, CA 90670 | [email protected] | [phone] Page | 3
Table of Contents
1.0 First Steps..........................................................................4
1.1 Inspection ....................................................................4
1.2 Selecting Equipment Location .............................4
1.3 Equipment Setup ......................................................4
Isolation Pads ...............................................................4
Electrical..........................................................................4
Leveling...........................................................................5
2.0 Overview............................................................................6
2.1 Specifications..............................................................6
2.2 Component Overview .............................................7
Main Machine...............................................................7
Drive System .................................................................7
3.0 Operation..........................................................................8
3.1 Applying Power .........................................................8
3.2 Main Menu ..................................................................8
3.3 Auto Operation..........................................................8
3.3.1 Entering a New Process..................................8
3.3.2 Running a Process......................................... 10
3.4 Manual Operation.................................................. 12
3.4.1 Setting Manual Process Parameters....... 12
3.4.2 Running a Manual Process......................... 12
3.5 Operating Tips ........................................................ 13
4.0 Process Development................................................ 14
4.1 Process Types .......................................................... 14
4.1.1 Cut....................................................................... 14
4.1.2 Refinement....................................................... 14
4.1.3 Burnishing or Dry Buffing........................... 14
4.2 Compounds.............................................................. 15
4.2.1 Abrasive Compounds................................... 16
4.2.2 Detergent Compounds................................ 16
4.2.3 Burnishing Compounds .............................. 16
4.3 Process Report ........................................................ 17
4.3.1 Media ................................................................. 17
5.0 Maintenance & Repair .............................................. 18
5.1 Overview of Drive System................................... 18
5.2 Preventive Maintenance Schedule .................. 19
Every Shift ................................................................... 19
Weekly Maintenance .............................................. 19
First 50 Machine Hours.......................................... 19
Every 150 Machine Hours ..................................... 19
Every 1000 Machine Hours................................... 19
United Surface Solutions Preventive Maintenance
Program ............................................................................ 19
5.3 Turret Drive Assembly.......................................... 20
Adjusting Main Drive Belt ..................................... 20
Replacing Main Drive Belt..................................... 21
5.4 Barrel Drive Assembly .......................................... 22
Inspection.................................................................... 22
Drive Component Removal.................................. 22
Adjusting Barrel Chain............................................ 23
Bearings ............................................................................ 24
Lubricating.................................................................. 24
Barrel Bearing - Replacement.............................. 24
Turret Bearing - Replacement ............................. 25
Barrels................................................................................ 26
Inspecting Barrel Lining ......................................... 26
Lockbar......................................................................... 27
Lid Block ...................................................................... 27
Torque Specifications .................................................. 27
6.0 Troubleshooting.......................................................... 28
Interface Not Functioning.......................................... 28
Will Not Begin Cycle .................................................... 29
Premature System Halt ............................................... 29
Desired RPM Not Reached........................................ 30
Barrels Leak...................................................................... 30
Turret Slips During Loading ...................................... 30
7. 0 Component List.......................................................... 31

United Surface Solutions | 11901 Burke St, Santa Fe Springs, CA 90670 | [email protected] | [phone] Page | 4
1.0 First Steps
1.1 Inspection
Upon receipt of the CPC1500, perform a thorough inspection of the shipment. Compare what you
received to the packing list to be sure you have all the components, including any supplies you may
have ordered. 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
Placement of the new equipment should be decided before the delivery date. The equipment locations
should be based on the “flow of parts” in your factory. The CPC1500 requires electrical power and
optional water source to operate, although for most applications, fresh water, a wastewater treatment
system, a drain, and a large work surface should be provided near the machine. United carries a full line
of workstations and wastewater treatment systems and is happy to recommend appropriate equipment
to fit your needs.
It is recommended to leave at least three (3) feet on each side of the machine for maintenance purposes.
Sufficient work and storage space is also required.
1.3 Equipment Setup
Isolation Pads
While setting up the CPC1500, 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.
Electrical
A licensed electrician is required to connect electrical power to the CPC1500. The power requirements
are printed on the data plate, located on the machine’s rear panel.
Caution: Be sure to connect only the specified voltage to the machine! These systems are built with standard voltage of
230VAC. They can be ordered in 208, 380, 400, 460, and 480 volt configurations. Applying excessive voltage will result in
severe damage to your system and will void the warranty. If you question the voltage specified on the data plate, inspect
the motor and AC drive to confirm their rated voltage or call United Surface Solutions with the serial number.
A visible-blade safety disconnect is required (supplied by the customer) to connect the appropriate
power to the CPC. Connect incoming power from the safety disconnect to the junction block located in
the electrical control box. Do not connect power to any other location. A conduit is supplied on the
lower left side of the rear panel for routing power from the safety disconnect. Use an appropriate
junction box to connect to this conduit. Do not connect conduits, cables, or any other device to the
removable panels on the CPC, as this will interfere with maintenance. Be advised that the CPC will sway
(front to back) under normal operating conditions and may damage rigid conduit or plumbing attached
to the machine.

United Surface Solutions | 11901 Burke St, Santa Fe Springs, CA 90670 | [email protected] | [phone] Page | 5
United personnel are not authorized to make connections to
your building’s electrical system. Likewise, non-United
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.
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 Switch located inside the rear panel of the
machine. The door safety switch should release once the System Initialization is complete.
3. Select Manual Operation from the CPC Touch Screen Interface. Using the Jog controls position
the cradles to gain access to the center axle of the turret.
4. Place a Magnetic Beam Level on the center axle of the turret.
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 THE SYSTEM. The CPC1500 uses a rotating turret that puts stress on the
machine. Being on isolation pads, the machine is meant to “flex” and absorb this stress. If the machine
is bolted down and not able to flex, additional stress is placed on the bearings, causing premature
bearing failure. The warranty applies only when the CPC1500 is on the isolation pads. If the CPC is
bolted to the floor, the warranty on bearings, barrels, and belts is voided.
WARNING: Whenever maintenance or service is being performed on the machine, a lock must be
installed at the power supply to ensure that power is not applied to the unit.

United Surface Solutions | 11901 Burke St, Santa Fe Springs, CA 90670 | [email protected] | [phone] Page | 6
2.0 Overview
2.1 Specifications
Model: CPC1500
Description: Centrifugal barrel finishing system with removable barrels.
Maximum Capacity
1.5 cubic foot (42.5 L)
0.375 cu.ft. (10.5 L)
Barrel Dimensions
11” (280mm) long
9” (230mm) octagonal flat to flat
Divided Compartment
Up to 4 per Barrel
9” (230 mm) long
2.25” (58mm) Wide
CPC Interface
Touchscreen controls with recipe storage capabilities.
Main Drive
3HP, three phase AC motor, inverter controlled.
Turret Speed Range:
0-250 RPM fully adjustable
Barrel Rotation Ratio:
1:1
Barrel Construction:
304 stainless steel with removable urethane lining.
Machine Enclosure:
304 Stainless steel.
Power Requirements:
208/230 (± 10%) VAC, 50/60Hz, 3Ø, 20A (460 V Available).
Water Inlet
¾” NPT
Compressed Air:
None
Dry Floor Compatible:
YES
Weight
1200 Lbs. (550 Kgs.) approximate
Warranty:
Up to three year warranty
Options:
Extra Liners and Dividers, workstation.
*speed above 250 RPM requires a larger motor and is offered as an option.
51”
51”
44”
Divided Compartment Liner
And Dividers
Complete Barrel

United Surface Solutions | 11901 Burke St, Santa Fe Springs, CA 90670 | [email protected] | [phone] Page | 7
2.2 Component Overview
Main Machine
Drive System
Emergency Stop
Jog Button
Door
Touch Screen
Cradle
Liner
Lock Bar
Isolation Pads
Cradle Harp
Cradle Sprocket
Idler Sprocket
Belt
Motor
Turret Flywheel
Cradle Bearing
Turret Bearing
Drive Chain
Lid Storage

United Surface Solutions | 11901 Burke St, Santa Fe Springs, CA 90670 | [email protected] | [phone] Page | 8
3.0 Operation
3.1 Applying Power
Before applying power, ensure that the electrical control box is closed
and secure, and that there are no obvious exposed electrical
conductors.
To apply power to the CPC1500, switch on the safety disconnect
switch (supplied/ installed by the customer) to the ON position. The
touchscreen will display the boot screen and the LED power indicator
located on the black frame of the touch screen face will be illuminate.
3.2 Main Menu
After boot is complete, the Main Menu shows with buttons for Auto
Operation, Manual Operation, System Tools, and System Help.
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 touchscreen.
3.3 Auto Operation
3.3.1 Entering a New Process
After selecting AUTO OPERATION from the Main Menu, the Process
List screen will appear. To create a new process, choose an empty cell
(if all cells are full, press 11-20 to view the second screen, > to view
the third) then press REVIEW. The Enter Password screen will appear.
To enter a password, press the empty password field
then begin typing the password that was either set by United Surface
Solutions or changed by you (details on changing passwords will be
in a later section of the manual). After typing the password, press ENT
then. If successful, the screen will display PASSWORD CORRECT above
the password field. If this is displayed, proceed by pressing
CONTINUE. To correct any mistakes, press BS (backspace) and
continue typing.

United Surface Solutions | 11901 Burke St, Santa Fe Springs, CA 90670 | [email protected] | [phone] Page | 9
After the Enter Password screen, the
Select a Screen appears. Press ENTER
PROCESS, which brings up the
Process Review screen. To begin
entering your new process, press
PROCESS CODE.
This will recall the Add New Process screen. Press the box next to
Description to enter a new description. Press ENT. Repeat for the
Process Code field. The Process Report given to you by United Surface
Solutions contains all process information, including the process
code. United recommends following all the Process Report data. If a
process needs to be modified to produce different results, contact
United Surface Solutions for no-charge process development. After
entering the process description and code, press CONTINUE to
proceed to the Media Data screen.
Press the Media Type A field to enter the media part number. Add a
space then type the height of the media (measured as inches below
the top of the barrel) and press ENTER.
Example: MC-CACC-18x1132 2”
If two types of media are used, enter Media Type B. Press CONTINUE.
The Compound Data screen is much like the Media Data screen.
Repeat all the steps but instead of height, input the compound part
number and the amount of compound required (1/2 Cup, 0.25 Cup,
etc.). The measurement is for operator reference, so any number
format is acceptable. Press CONTINUE to proceed to the next screen.
The Quantities screen is used to input information about parts and
water in each barrel. Enter Water Level by pressing the empty field.
Enter it as “Level” (just covering the media), or +/- a measurement
(1”) above or below the media. This measurement if per barrel. Next,
enter the Parts/Barrel by pressing the empty field next to the label.
Simply enter the number designated on your Process Report. Press
CONTINUE to proceed to the next screen.

United Surface Solutions | 11901 Burke St, Santa Fe Springs, CA 90670 | [email protected] | [phone] Page | 10
The RPM & Time screen is one of the most important screens in
process storage and is required to save a process. This screen directly
controls machine settings when running a process. Tap on each
empty field to enter the recommended time and RPM. Press ENT after
entering each value. These values are only for the first (or only) step.
Press RETURN when done to review the process.
The process screen has options to press > to add a 2nd step, turn auto
reverse on (reverses the rotation of the turret at the halfway point in
a process), or press RETURN to complete the
process storage. If there are any errors, you
may correct them by pressing on them. You
will be notified if the RPM & Time are missing.
You will be returned to the Process List screen.
3.3.2 Running a Process
Loading Barrels
To run a process, choose a process from the Process List screen and
press RUN. The Loading Instructions screen will appear. Use these
instructions to load each barrel with the correct amount of
compound, water, media, and parts.
To load a barrel, first remove the lid from the barrel.
To open a lid, Pull the Safety pin away from the Lock-bar then rotate athe lockbar way from you, when
loose, pull away from the lid to the side. The lock bar should drop towards the center shaft of the turret
(see figure illustration above). Repeat with opposite side. Then remove the lid risnse and store it in the
Lock-bar
Cradle
Safety Pin
Harp
Lid