UNITED CPC4000 User manual

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CPC4000
Operation and Maintenance Manual

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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 without
written permission of United Surface Solutions LLC
©2017 United Surface Solutions LLC

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Table of Contents
Notice to User ................................................................................................................................................................................................2
1.0 Receiving Equipment & Setup..........................................................................................................................................................4
1.1 Inspection ............................................................................................................................................................................................4
1.2 Selecting Equipment Location .....................................................................................................................................................4
1.3 Isolation Pads .....................................................................................................................................................................................4
1.4 Electrical................................................................................................................................................................................................4
1.5 Leveling.................................................................................................................................................................................................4
2.0 Overview....................................................................................................................................................................................................6
2.1 Specifications......................................................................................................................................................................................6
2.1 Dimensions..........................................................................................................................................................................................7
2.2 Main Components............................................................................................................................................................................8
3.0 Operation..................................................................................................................................................................................................9
3.1 Applying Power .................................................................................................................................................................................9
3.2 Main Menu .............................................................................................................................Error! Bookmark not defined.
3.3 Auto Operation..................................................................................................................................................................................9
3.3.1 Entering a New Process....................................................................................................................................................... 10
3.3.2 Running a Process................................................................................................................................................................. 12
3.2 Manual Operation Screen..............................................................................................................................................................9
3.2.1 Setting Manual Process Parameters..................................................................................................................................9
3.3 Jog Mode .............................................................................................................................................................................................9
Positioning the Turret........................................................................................................................................................................9
Barrel Rotation .....................................................................................................................................................................................9
Barrels................................................................................................................................................................................................... 10
Opening Barrels................................................................................................................................................................................ 10
5.4 Loading Barrels ..................................................................................................................... Error! Bookmark not defined.

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1.0 Receiving Equipment & Setup
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 SUR FACE 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. 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 two (2) feet on each side of the machine for
maintenance purposes. Sufficient work and storage space is also required.
1.3 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.
1.4 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 right 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 230VAC / 60Hz. 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.
1.5 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.
1. Install High-Capacity Rubber Isolation Pads (rated at 1500 psi) under each leg of the unit.
Recommended pad size is 3” X 3” X ¼”.
2. Place a magnetic beam level on the center beam.
3. If adjustment is needed, shim under the isolation pad with varying thicknesses of sheet metal. If
large adjustments are necessary, use thicker padding
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

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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.
1.6 Facility Interconnect
Below is the facility interconnect plate on the rear of the machine used to interface with your facility.
Power In
3/4”
Air In (CPC4000FA Only)
3/8”
Water In
3/4”

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2.0 Overview
2.1 Specifications
Model
CPC4000HD
Description
Centrifugal barrel finishing system with removable barrels.
Maximum Capacity
4 cubic feet (114 L)
Barrel Capacity
1 cubic foot (28 L) x 4 barrels
27.5” wide x 8.5” long x 5.75” deep
CPC Interface
PLC/touchscreen controls
Main Drive
10HP three phase AC motor, inverter controlled
Turret Speed Range
0 - 225 RPM fully adjustable
Barrel Rotation Ratio
1:1
Barrel Construction
Stainless steel with removable urethane lining.
Machine Enclosure
304 Stainless steel.
Compressed Air
None
Dry Floor Compatible
YES
Weight
~3000lbs
Water Connection
¾” NPT
Power Requirements
Voltage
380VAC – 480VAC
Frequency
50Hz – 60Hz
Line Phase
Three Phase
UL-Required Amperage Rating
40 Amps
Motor FLA
12.9 Amps
Warranty
Up to three years, dependent on component type.
Options
Divided barrels with dividers.
Allen-Bradley controls.
Indicator Beacon

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2.1 Dimensions
Width: 86.75” / 2.20m | 134.75” / 3.42m with clearance
Depth: 50.5” / 1.28m | 74.5” / 1.90m with clearance
Height: 58.44” / 1.48m

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2.2 Main Components
10HP
Motor
Jog Button
E- Stop
Electrical Panel
Turret
Barrel
Barrel Lid
Separator
Touch Screen
Door
Jog
Motor
Drive
System
Urethane
Liner
Separator
Motor
Lid Harp

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3.0 Operation
3.1 Applying Power & Main Menu
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 CPC4000HD, simply connect it to a 460VAC
power source. The display will show the initialization screen. Once initialization is complete, proceed to the
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.
3.2 Manual Operation Screen
To begin operating the CPC manually chose the MANUAL OPERATION touch key from the 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. 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.
3.2.1 Setting Manual Process Parameters
After selecting MANUAL OPERATION from the Main Menu, the
Manual Operation screen will appear. et the RPM by pressing the RPM
field and entering a value, then press ENT. Set the Cycle Time by
pressing the Cycle Time field and entering a value, then press ENT.
Press R to reset Cycle Time Remaining if needed. Choose FWD or REV
to specify the direction the turret will spin or press AUTO REV. to split
the process between forward and reverse. To start the cycle, close the
door and press START.
3.2.2 Jog Mode
The CPC has two basic modes of operation, the jog mode and the run mode. The mode of operation is
determined by the position of the door. Once the door is open, the Jog controls will be activated and the
operator can safely position the turret for loading and unloading.
Positioning the Turret
When the Shutter door is open, the turret may be jogged utilizing the Hands Free Safety Button in conjunction
with the JOG FWD or JOG REV. The Safety Jog Button is located on the left side of the cabinet below the E-
Stop. The JOG FWD and JOG REV are located on the touch screen interface.
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.
WARNING: Never jog the turret while any part of your body is in contact with either the barrels or the turret, or is anywhere

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within the confines of the machine cabinet. Serious injury could occur.
Barrels
The CPC4000 has four barrels held perpendicular to the Axle Shaft and 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 seats a removable liner of various
configurations including compartmental dividers for total part segregation. This barrel and liner assembly holds
the work pieces, media, compounds and water during the finishing process.
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 Handle of the cam in a downward manner using the tool provided.
WARNING: Barrels may become pressurized. Some processes can generate super-heated steam in as little as 10 minutes.
Open slowly, use caution.
Closing Barrels
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.
After the Enter Password screen, the
Select a Screen screen appears. Press
ENTER PROCESS, which brings up the
Process Review screen. To begin
entering your new process, press
PROCESS CODE.

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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.

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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 it from the cradle. Do this by pulling the pin,
rotating the lockbar, and pulling it out. To open a barrel, rotate and
remove its lockbar. Then remove the lid. Load it starting with media and
parts, then water, and finally compound. Replace the lid and lock it in place with the lockbar.
Beginning Process
To begin a process, press CONTINUE from the Loading Instructions screen.
To jog the turret, hold the button and press JOG FWD or JOG REV on the
Automatic Operation screen. Before beginning operation, ensure all
information on the screen is correct. If starting a process from the
beginning, ensure the CYCLE TIME REMAINING matches the CYCLE TIME. If
it does not, press R to reset it. To start the cycle, press PRESS TO START.
Stopping a Process
To stop a process before it has been completed, press STOP (takes the place of PRESS TO START). The turret
will slow to a stop. Once stopped, the door will unlock and may be opened. The cycle time remaining will be
saved on the Automatic Operation screen. The process can be continued by pressing PRESS TO START. If the
process will not continue, remove your parts and reset the cycle time.

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Stopping a Process in Emergency Situation
If the machine needs to be stopped immediately in an emergency
situation, press the emergency stop button. This will quickly stop the
machine. The Emergency Stop Activated screen will display and the door
will unlock when the machine has stopped. Inspect the machine and make
adjustments/repairs as necessary. Reset the E-Stop by turning it
counterclockwise and pulling it out. A countdown will appear and unlock
the machine when completed. The cycle time remaining will be the same
as when the machine was stopped.
Unloading Barrels and Cradles
Unload cradles as described in Loading Cradles and remove barrels one cradle at a time. Always ensure barrels
are locked into place when jogging the turret.
5.0 Maintenance
5.1 Preventative Maintenance Schedule
Every Shift
•Inspect and Lubricate Lid Lock Cams
•Inspect Lid Seals.
First 25 Machine Hours
•Inspect turret belt and tighten as needed
•Inspect barrel chains, lubricate and adjust as needed
First 250 Machine Hours
•Inspect turret belt and tighten as needed
•Inspect barrel chains, lubricate and adjust as needed
•Grease turret bearings
•Grease motor bearings
•Inspect barrel & lid linings
•Inspect electrical connections and tighten as needed.
Every 250 Machine Hours
•Grease turret bearings
•Grease motor bearings
•Inspect turret belt and tighten as needed
•Inspect barrel chains, lubricate and adjust as needed
•Inspect barrel & lid linings
•Inspect electrical connections and tighten as needed.
5.2 Maintenance
5.2.1 Replacing Main Drive Belt
1. Empty ALL barrels, insert into the cradles and latch cradle lids.
2. Turn OFF the power at the Safety Disconnect and lock the handle in this position.
3. Release the motor brake by pulling outward on the brake release knob shown in photo 5-4 Motor Brake.

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4. Loosen the motor adjustment nuts and move motor forwards to loosen the main drive belt. Remove the
belt from the motor pulley.
5. Remove the eight (8) bolts from the pillow blocks, four (4) on drive side, two (4 ) on free side.
6. Raise the turret and pillow blocks off the frame and slide the old drive belt out under the pillow block
and the new drive belt in.
7. Tighten the eight (8) the pillow block bolts four (4) on drive side, four (4 ) on free side and torque to 80
ft-lbs.?
8. Adjust the main drive belt per the procedure given above as described in Adjusting the Main Drive Belt.
9. Engage the motor brake by pushing in the brake release knob shown in photo 5-4 Motor Brake.
5.2.2 Drive Component Removal
To remove and replace barrel drive components follow these procedures:
1. Empty ALL barrels, position into the cradles and latch cradle lids.
2. Turn OFF the power at the safety disconnect and lock the handle in this position.
3. Release the motor brake by pulling outward on the brake release knob shown in photo 5-4 Motor Brake.
4. Position the turret so that the drive components to be repaired or replaced are conveniently located
and set the motor brake.
5. Remove the two (2) bolts holding the idler arm assembly in place and remove the Idler arm from the
turret.
6. Check the Idler Sprocket Bearing for ease of movement and side play and inspect the sprocket for wear.
Replace Bearing/Sprocket Assemble if necessary. Torque sprocket retainer nut to 50 ft-lbs.?
7. Remove the chain by means of the master link. Clean with mild solvent if necessary and lubricate with
penetrating oil.
8. Inspect the Barrel Drive Sprockets for wear and movement. . . Replace sprocket if wear is excessive.
9. Install Idler Arm Assembly and any sprockets removed and slightly tighten, do not torque.
10. Align Barrel and Turret Sprocket to Idler Sprocket using a measuring device. First measure the distance
from the turret disc (disc that the Idler Assy. is mounted on) the center of the Idler Sprocket, record the
distance. Next adjust the Barrel and Turret Sprockets so that the centerline of the sprocket equals that
of the recorded distance. Refer to photo 5-7 Align Sprockets for a demonstration view. Torque Turret
and Barrel Sprocket setscrew to 20 ft-lbs.
11. Install the chain and lock the master link using the retainer.
5.2.3 Adjusting Barrel Chain
To adjust the barrel chain, please refer to the following procedure (if continuing from the previous section skip
steps 1-5):
1. Empty ALL barrels, position into the cradles and latch cradle lids.
2. Turn OFF the power at the safety disconnect and lock the handle in this position.
3. Release the motor brake by pulling outward on the brake release knob shown in photo 5-4 Motor Brake.
4. Position the turret so that the Idler Arm Assembly for the butterfly assembly that needs adjustment is
conveniently located and set the motor brake.
5. Slightly loosen the two (2) bolts holding the idler arm assembly in place and remove the Idler arm from
the turret.

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6. Using a pry bar gently press down (applying 10 to 15 pounds of pressure) on the Idler assembly taking
up all slack in the chain. Refer to photo 5-8 Adjusting Idler Assembly for tightening method.
7. Retighten the two (2) bolts holding the idler arm assembly and torque to 80 ft-lbs.
5.2.4 Bearings
Lubricating
The barrel and turret bearings must be periodically lubricated with water-resistant grease, such as Deoplex
Multi-Purpose #2EP, to maintain their service life. Each of the eight (8) barrel bearings (four per side) is
equipped with a zerk-fitting for this purpose. Refer to photo 5-9 and 5-10 for zerk-fitting locations.
When lubricating, add only a small amount of grease at any one time, usually only one or two pumps on a
grease gun. Adding too much will result in damage to the seal, which will allow water and process chemicals to
enter the bearing. If this occurs, the bearing will have to be replaced within a short period of time.
Barrel Bearing - Replacement
1. Empty ALL barrels, position into the cradles and latch cradle lids.
2. Turn OFF the power at the safety disconnect and lock the handle in this position.
3. Release the motor brake by pulling outward on the brake release knob shown in photo 5-4 Motor Brake.
4. Position the turret so that the barrel bearing to be replaced is conveniently located and set the motor
brake.
5. Remove the two (2) retaining bolts holding the idler arm assembly in place and remove the Idler arm
from the turret.
6. Loosen the setscrews holding the sprocket to the shaft, and slide the sprocket off the barrel shaft, using
a bearing puller if necessary.
7. Loosen the two (2) setscrews holding the bearing onto the shaft.
8. Remove the two (2) retaining bolts holding the bearing to the turret and slide the bearing off the shaft.
9. Install the new bearing using the method shown in photo 5-11 Install Barrel Bearing. Measure the
distance from the center shaft to the cradle shaft center point. The distance should equal that of the
existing bearings or exactly 8 inches. Torque bearing retaining bolts to 80 ft-lbs.
10. Proceed to line #9 in Drive Component Removal in the previous section for installation instructions.
11. Lubricate the new bearing according to the instructions given in the section Lubricating.
Turret Bearing - Replacement
1. Empty ALL barrels, insert into the cradles and latch cradle lids.
2. Turn OFF the power at the safety disconnect and lock the handle in this position.
3. Release the motor brake by pulling outward on the brake release knob shown in photo 5-4 Motor Brake.
4. Loosen the motor adjustment nuts and move motor forwards to loosen the main drive belt. Remove the
belt from the motor pulley.
5. If replacing bearing on the Drive Side, remove all Idler Assemblies and both chains.
6. Loosen setscrews on both pillow blocks, Do Not remove the pillow block retaining bolts.

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7. Remove the four (4) Turret Bearing Retaining Bolts for the bearing that is being replaced.
8. Loosen the Turret Bearing Setscrews for the bearing on the OPPOSITE side of the turret.
9. Gentle tap the center shaft, OPPOSITE the side of the bearing being replaced, moving it inward about
3/8 of an inch. This will push the bearing that is being replaced out of its centering grove.
10. Remove all six (6) Pillow Block Retaining Bolts; four (4) on drive side and two (2) on free side.
11. Raise the Turret and remove the Pillow Block from the Center Shaft.
12. Loosen the setscrew on the bearing to be removed and slide it off the shaft. If replacing the bearing on
the Drive Side, loosen the Sprocket Setscrews and remove both sprockets followed by the bearing.
13. Install the new Turret Bearing into the centering grove and tighten the retaining bolts by hand. Install
the Center Shaft Sprockets if replacing the bearing on the Drive Side.
14. Install the Pillow Block and lower the Turret. Torque the Pillow Block Retaining Bolts to 80 ft-lbs.
15. Position the Center Shaft evenly between the Pillow Blocks and torque the setscrews to 20 ft-lbs.
16. Torque the Turret Bearing Retaining Bolts to 60 ft-lbs and torque the setscrews for BOTH Turret
Bearings to 15 ft-lbs.
17. Proceed to line #9 in Drive Component Removal in the previous section for installation instructions.
18. Lubricate the new bearing according to the instructions given in the section Lubricating.

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6.0 Troubleshooting
Interface Not Functioning
Possible Problem
Item to Check
Remarks
Control voltage fuse blown
Check for blown fuses.
If the door interlock has shorted out,
it is usually because someone
attempted to open the shutter door
while in Run Mode. Check the
interlock before re-energizing this
circuit. Replace as necessary.
No power to the machine
Carefully check the three terminal
blocks on the top of the main
disconnect for line power.
Consult with your plant electrician to
determine the source of the power
outage.
PLC Power Supply Blown
Check the lights on the PLC located
inside the control box.
The Power Supply on the PLC also
powers the Interface, If there is
power to the Drive Inverter and not
to the PLC first check fuses then
replace the Power Supply if needed.
No input voltage
Check that the main disconnect
located on the electrical cabinet
door is turned to the “On” position
Make sure that the machine is not
being serviced before re-energizing
the machine.
Main fuses blown
There are three fuses located in the
main disconnect. With the power off,
check for continuity across each of
these fuses.
If a fuse is blown, DO NOT REPLACE
IT until the problem that caused the
fuse to blow has been corrected.
Loose wire or defective
component
Turn the main disconnect to the
“Off” position and carefully check
and retighten electrical connections
beginning at the main disconnect.
If you are certified to work with high
voltage AC, re-energize the
Disconnect and follow the voltage
paths until you find the problem.

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Will Not Begin Cycle
Possible Problem
Item to Check
Remarks
No power to the machine
Verify that the Power Indicator is lit
and the CPC screen is operational.
Follow the procedures under
“Interface Not Functioning”
Shutter Door is not closed
entirely
The Shutter Door must be closed in
order in order to place the machine
in Run Mode.
Always either completely open or
completely close the Shutter Door.
Drive error
Check Drive Keypad for error code.
Refer to the instruction manual for
the drive that was supplied with the
machine or contact AXYS for
support.
Loose wire or defective
component
Turn the main disconnect to the
“Off” position and carefully check
and retighten electrical connections
beginning at the main disconnect.
If you are certified to work with high
voltage AC, re-energize the
Disconnect and follow the voltage
paths until you find the problem.
Premature System Halt
Possible Problem
Item to Check
Remarks
No power to the machine
Verify that the Power Indicator is lit
Follow the procedures under
“Interface Not Functioning”
Drive error or overload
Check Drive Keypad for error code.
Refer to the instruction manual for
the drive that was supplied with the
machine or contact AXYS for
support.
Human error
Attempting to open the Shutter
Door while the machine is running
may result in the cycle being
canceled.
The Stop Button may have been
accidentally pressed.
If the cycle timer has reset, human
error is likely the problem. If the
machine is stopped and the timer is
still running, human error must be
discounted.
E-Stop activated
Check the CPC Touch Screen to
determine if the E-Stop has been
activated.
If the E-Stop has been activated the
timer will display the remaining time.
Proceed to Manual Mode Screen to
determine time remaining and finish
the current process.
Loose wire or defective
component
Turn the main disconnect to the
“Off” position and carefully check
and retighten electrical connections
beginning at the main disconnect.
If you are certified to work with high
voltage AC, re-energize the
Disconnect and follow the voltage
paths until you find the problem.

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Desired RPM Not Reached
Possible Problem
Item to Check
Remarks
Machine overloaded
If the acceleration of the machine
slows before the desired RPM is
reached, the machine is attempting
to avoid an overload condition.
Loading the barrels with more
material will not overload the
machine. With the CPC, the greatest
load condition occurs at
approximately 60% fill height.
Try running your process with more
parts and media to eliminate this
condition.
Exceeds Maximum RPM
If in Manual or Auto Mode Screens
the “EXCEEDS MAXIMUM RPM” is
displayed, check the Maximum RPM
setting in the System Tools screen.
Maximum RPM and Cycle Time limits
are set to protect the system from
operator error. These settings can be
password proteced.
Barrels Leak
Possible Problem
Item to Check
Remarks
Contamination on the
sealing surface of the barrel
and lid
Remove the lid and check for media,
compound or other obstructions on
the sealing surfaces
Review the section “Closing &
Loading Barrels” for procedures to
eliminate this problem.
Process too hot
Verify that the process is not
building up significant heat and
pressure that is causing the seal to
fail.
Refer to the section “Opening the
Barrels” for information and tips
about building up pressure in the
barrels.
Worn barrel tabs
Inspect the barrel tabs on each end
of each Lock bar and adjust as
necessary.
Refer to the section “Lockbar” for
detailed instructions.
Worn linings
Inspect the barrel linings
Refer to the section “Inspecting
Barrel Lining” instructions.
Turret Slips During Loading
Possible Problem
Item to Check
Remarks
Loose or broken main drive
belt.
Attempt to rotate the turret by hand,
if it rotates, then the belt needs
servicing.
Refer to the “Main Drive Belt”
section for tensioning and
replacement instructions.
“Glazed” main brake rotor
Run the machine at 120-180 rpm
empty and then remove power from
the machine. This will grind a thin
layer off the rotor allowing the brake
to re-seat.
Due to the requirements of the
machine, this “glazing” may become
a common occurrence. In which case
add this procedure to your
preventative maintenance schedule.