Do not touch any part in motion. x Before operating the Blaze Air and the lathe in automatic cycle, always close the main cover of the Blaze Air. x Do not wear any loose fitting clothing near any part in motion.
This information must be included with the order or a new Vacuum Liner must be manufactured. x Lower the leveling screws so that when the Blaze Air is set in place, the forks can be extracted.
4.2 Description of Components Refer to the drawings at the end of this manual for detailed cross reference labels and components with machine locations. Vacuum Tube Rotary Actuator Vacuum Liner Forward Engage Cylinder Moves forward to engage back Height Adjusting Screw Base Valves on...
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Valves (located on inside of base side door) Valve that when enabled provides the main air pressure to the rest of the manifold SOL1 SOL2 Valve that when enabled moves the Vacuum tube forward to meet the back of the spindle liner and also closes the Hinged Valve in the base to allow vacuum to be drawn through the Vacuum Tube Valve that when enabled causes the rotary actuator to rotate the Vacuum Tube to the...
Move spindle to home position and open the chuck (unload position is when spindle is all the way back towards the rear guard). x Install the Blaze Air Vacuum Liner (There is no longer two separate pieces - See Section 6.1 Changeovers for more detailed instructions). To install the Liner, remove the Tube Connector Pin out of the rear of the tube.
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Push the Blaze Air tube to the back position. If this is not done the Blaze Air may be setup too far back from the end of the spindle liner! Spiral Ring Blaze Air Vacuum Tube: Should be in the home position –...
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Blaze Air. Double-check the alignment. x Push the Blaze Air tube forward so that it contacts the back of the spindle liner. Take the longest part available in the setup diameter and push it through the spindle and into the Blaze Air.
4.4 Anchoring After the alignment is completed, it is recommended to secure the Blaze Air to the floor to maintain stability and alignment. 4 X M10 (1/2”) minimum diameter anchoring bolts are required (dimension can vary according to the floor).
Blaze Air will be supplied with an interface cable and a connector. If the standard connector is not available in the lathe, the Blaze Air is provided with an interface cable that must be wired to the lathe by a qualified electrical technician.
(less than 50 Rpms). If a programming mistake is made and the spindle rotates at a faster speed, there may be damage to the back end of the spindle liner and the front end of the Blaze Air Vacuum Tube. The damage will occur because these two parts contact each other during the unload cycle (they have mating chamfers to align the tubes).
The standard Discharge Tray consists of a 1083 mm (42.6”) wide tray. A photoeye pair (PE1), is mounted to the side of the tray to verify that the part has exited the Blaze Air and to detect when the tray is full. The detection type opposed, with the receiver on the opposite side of the tray. The tray is lined with plastic to protect the parts from damage.
MODE SELECTION: The Blaze Air has three mode selections: x OFF - The Blaze Air will be in this mode whenever power is re-applied to the machine. From this mode nothing can be activated. x AUTO - This mode will allow the operator to put the Blaze Air into automatic cycle.
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x JOG - This mode will allow the operator to jog the Rotating Tube, Contact Cylinder (Front Seal) and the blower vacuum. CHANGING MODES: To change modes, press the MENU function key. Press the ENTER function key when ‘MODE select’ is displayed. Use the ‘up arrow’...
BLOWER ON/OFF & ENTER function keys: Pressing both of these keys at the same time will cause the Blaze Air to start the unload cycle. This can be used to test the Blaze Air and also to finish an unload cycle if it was stopped in the middle from a machine fault.
Pressing the red STOP function key while in AUTO mode will cause a fault and take the machine out of automatic cycle. If the Blaze Air is in the middle of an unload cycle it will wait until the part has been completely unloaded before stopping. Holding the STOP pushbutton for 2 seconds will cause it to stop even if it is in the middle of an unload cycle.
5.5 Display – Menu Tree The Blaze Air Menu Tree: Note: Menu selections are disabled while the Blaze Air is in automatic cycle. MODE Select AUTO SETUP P00: Password Entry P0: Chuck Open P1: Lathe in Auto cycle P2: Spindle Home...
1 cycle. If the signal is set for a delay, the Blaze Air will continue to run for 1 more cycle even though the ramp photoeye is continually blocked. The display will warn of the problem and the Ramp Full output will signal the lathe that there is going to be a problem.
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P11: Ignore Tray PE Y/N: If this parameter is set to a value =1, the Blaze Air will not use the tray photoeyes to detect the part as it rolls down the tray after being unloaded. This may be...
Exit Setup: Exit the SETUP menu structure. 5.7 Menu: Information (This information is for display purposes only and can not be changed) To change view the INFORMATION functions, press the MENU function key. Use the ‘up arrow’ and ‘down arrow’ function keys to index through the different selections. Press the ENTER function key when ‘INFORMATION’...
In some cases, especially large diameter parts, it is desirable to slow down how quickly the part is unloaded from the Lathe. By slightly slowing down the part, the Blaze Air will have less shock from stopping the part and the internal shock absorber will have a longer life.
Spindle Liner Rails for moving Tube Assembly out of the way for Spindle Liner Removal To Changeover the Blaze Air use the following steps: Open the Guard Door to gain access for removing the Vacuum Tube and also put the Blaze Air in an emergency stop state.
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If needed, clean out chips and contamination on the inside of the Vacuum Tube. With the Vacuum Liner out of the Blaze Air, move the Top Tube Assembly out of the way of the rear of the lathe to access the spindle liner. First, loosen the...
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The Top Tube Assembly must be pushed and held against the (2) Stop Blocks while the (2) Stop Clamps are tightened. Load the new Blaze Air Vacuum Liner from the rear opening of the Vacuum Tube. To push the Vacuum Liner into the final position, the operator may have to pull the Liner forward from the front of the Vacuum Liner.
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Install the Tube Connector Pin by pressing on the button and pushing the pin through the lined up holes in the Vacuum Tube, the Vacuum Tube End Cap and the Rotary Actuator. Close the Guard and re-enable the Blaze Air ...
Part Stop Shock Absorber: This shock absorber is located in the Vacuum Tube End Cap and absorbs the impact of the part being vacuumed back into the Blaze Air. The shock absorber that is used in the Blaze-Air is adjustable. Remove the shock absorber from the Vacuum Tube End Cap.
Blaze Air Vacuum Liner: The Blaze Air Vacuum Liner is inserted through the rear of the Blaze Air. It is then attached at the front of the Blaze Air with two screws. The Vacuum Liner reduces the ID of the Blaze Air enabling the vacuum source to pull the part back through the Spindle Liner and Vacuum Liner until it is stopped at the end of the Vacuum Liner.
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A6104-V-LL-X.XXX LL = Length of the extension from the front end of the Blaze Air Vacuum Tube to the front end of the Blaze Air Vacuum Liner when installed. If this value is not specified, a 24” extension will be included.
7. AIR ADJUSTMENTS 7.1 Main Air Pressure For trouble free operation of the Blaze Air, a minimum air pressure of 5 bar (75 psi) is required and should not exceed 6 bar (90 psi). Adjustment: Pull up the adjusting knob (2) to unlock. To increase the pressure turn the knob clockwise, turn counterclockwise to decrease the pressure.
7.2 Valve Descriptions and Settings The Blaze Air Unloader has an air manifold that consists of 3 valves. These valves are located on the inside of the hinged door located on the side of the base. BLOCK DIAGRAM OF PNUEMATIC COMPONENETS:...
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Vacuum Liner ‘bottoms out’ on the back of the spindle liner. This pressure must not be too high because it may push the Blaze Air back instead of just making contact with the spindle liner and also to allow the spindle liner to rotate (less than 50 rpms!) while unloading and thus in contact with the non-rotating Vacuum Liner.
The Blaze Air has been designed with a filter system that will stop metal chips and coolant from being drawn into the blower. The filter is located at the rear of the Blaze Air base (16”x 14”x 6” with a hinged cover). This filter should be visually checked every day and if chips build up should be cleaned.
If there is a problem with the Part in Tube Photoeye (PE1), the Blaze Air can be set to use a timer instead of this sensor. This will allow the Blaze Air to operate until a replacement can be purchased.
9.2 Troubleshooting Unloading Failures If the part fails to be unloaded or only is partially pulled back into the Blaze Air, then check the for the following: Vacuum Leaks: Move the lathe spindle head forward so that the front of the Blaze Air Vacuum Liner can be blocked.
Spindle Liner. Note that this movement may be as short as ¼” depending on how close the Blaze Air was installed to the back of the Spindle Liner. It is important that the mating chamfers of the Spindle Liner and the Blaze Air Vacuum Liner touch with just enough force to stop vacuum leaks but not to much to create a problem when the lathe spindle inches during the unload cycle.
5 years. When the battery is low or not working, a fault message will be displayed on the operator station. As long as power is on the Blaze Air the variable memory will not be lost. The CPU also contains a capacitor that will retain the variable memory for a limited amount of time when power is removed.
When these conditions are met, the lathe will then send an Unload signal to the Blaze Air. The Blaze Air will extend its vacuum liner to meet the back end of the spindle liner and send the Inch Spindle signal. This will cause the lathe spindle to slowly rotate...
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Blaze Air Alarm (Normally Energized) Signal from the Blaze Air that is ON when the Blaze Air is in Auto or Jog Mode and there are no faults. If there is a fault, this signal will turn OFF until the fault is cleared and the Blaze Air is reset.
Accumulator is not ready. This fault will not be indicated on the Blaze Air when it is in Manual Mode or Off. If the Accumulator has a fault when the operator tries to start the Blaze Air, it will not start and the fault message will be displayed.
13. BASE ASSEMBLY PARTS LIST 13.1 6104-A Base Assembly Parts List Item Qty Part Number Description Manufacturer 6104-AA Base 6104-AB Top Plate 6104-AC Tray Support 6104-AD Height Adjuster Screw 6104-AE Discharge Tray 6104-AF Support Bracket-Panel 6104-AG Tube Assy Cover 6104-AH Spacer Plate 6104-AJ Vacuum Valve...
14. TUBE ASSEMBLY PARTS LIST 14.1 6104-B Tube Assembly Parts List Item Qty Part Number Description Manufacturer 6104-BA Slide Plate 6104-BB Front Tube Support 6104-BC Rear Tube Support 6004-2CE Vacuum Tube 6104-BE Rotary Actuator Support 6104-BF Stop Clamp 6104-BG Plunger Rail 6104-BH Cam Rail 6104-BJ...
15. ELECTRICAL PARTS LIST Item Part Number Description Manufacturer D2-04BDC-1 DL205 base, 4 slot, 24vdc Automation Direct D2-240 DL205 CPU Automation Direct D2-16ND3-2 DL205 16pt dc source input Automation Direct D2-08TD1 DL205 8pt dc sink input card Automation Direct F2-08TRS 8pt relay board Automation Direct D2-BAT...
16. RECOMMENDED SPARES 6104 BLAZE AIR UNLOADER RECOMMENDED SPARE PARTS (PRICES ARE NET TO LNS) Item Part Number Description Manufacturer 6104-A DR606CK72M/038526 Regenerative Blower, Model DR606CK72M Ametek 98410A115 Retaining Ring, .312 dia shaft McMaster-Carr TA-MF1-1 1/2X1-KK3 Air Cylinder, 1.50" bore x 1.00" stroke 6104-AR Poly Tray Liner - .38"x23.50"x39.50"...