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UNITED CPC 12000 Operation And Service Manual

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CPC 12000 Operation and Service Manual

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  • Page 1 CPC 12000 Operation and Service Manual...

  • Page 2: Table Of Contents

    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....................................
  • Page 3 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 ..................................
  • Page 4 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 Page | 4...

  • Page 5: Receiving Equipment

    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.

  • Page 6: Equipment Setup

    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.

  • Page 7: Operation

    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”...

  • Page 8: Manual Operation

    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.

  • Page 9: Barrels

    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.

  • Page 10: Loading Barrels

    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.

  • Page 11: Closing Barrels

    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.

  • Page 12: Starting Process

    To set turret direction simply Press within the boxes press the FORWARD or to activate keypad 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 Speed / direction halfway through the...

  • Page 13: Unloading The System

    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...

  • Page 14: Auto Operation Using The Cpc Interface

    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.

  • Page 15: Store Or Update Process

    RESET ROCESSES IGURE RESET PDATE OR EVIEW ROCESS RESETS 11-20 RESET UMBER ROCESS ELECTION 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.
  • Page 16 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.
  • Page 17 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. EDIA 4.11 IGURE NOTE: To control part on part impingement use a media height of 80 to 95 percent of the total barrel volume.
  • Page 18 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).

  • Page 19: Separator Controls

    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. RPM &...

  • Page 20: Rinse Timer

    & E EPARATOR LEVATOR ONTROLS 4.15 IGURE 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.

  • Page 21: Auto-Reverse

    4.4.4 Auto-Reverse When using a fixturing device, divided compartments, or holding a part in a stationary position within the barrel, multi-directional turret operation may be required. The AUTO REVERSE function will divide the cycle time and change direction automatically, to activate press the touch key. Some processes require more than a single operational step.
  • Page 22 This screen is similar to the Manual Operation screen shown in Figure 4.2 except that the parameters are preset. It O CANCEL THE is displayed while the process is CURRENT running. To exit Automatic Operation without HESE SETTINGS beginning the current process or step, ARE PRESET AND use ABORT OPERATION.
  • Page 23 Select an option and the operator will be routed to the appropriate instructional screen, either to reload barrels for an additional step or to continue processing with the current parameters. If NEW PROCESS is selected the operator will be returned to the Preset Process (Figure 4.2). Page | 23...

  • Page 24: Maintenance

    5.0 Maintenance 5.1 Maintenance in CPC Interface By pressing MAINTENANCE on the Main Menu, the operator will be able to view and set basic maintenance functions for the CPC. These functions include: • Total Operational Hours • PLC Input / Output Utilization •...

  • Page 25: System Tools Password

    1. Press CLR 2. Press RESET 3. Press ↵ ENTER 4. Enter the default password and press ↵ ENTER The status box will display “Password Correct.” Press CONTINUE to proceed to System Tools. NOTE: For information regarding the default password contact United Surface Solutions Technical Support at (877) 837-4623. 5.1.3 System Tools The System Tools screen controls system critical settings and allows the operator to troubleshoot the system.

  • Page 26: Help Menu

    Please refer to ISPLAYED IN the CPC I/O Meter (Figure 5.4) REEN NOTE: When contacting United Surface Solutions for support, please note active inputs and outputs when speaking with a technician. 5.1.6 Help Menu The CPC is designed with help functions to assist the operator on the fly. To access the Help Menu press SYSTEM HELP on the Main Menu.

  • Page 27: Maintenance And Repair

    5.2 Maintenance and Repair Turret Barrel Drive Sprocket Idler Sprocket Turret Belt Cradle Shaft Idler Arm Assy. Barrel Drive Motor Pillow Block Turret Shaft ECHANICAL VERVIEW IGURE Page | 27...

  • Page 28: Preventative Maintenance Schedule

    5.2.1 Preventative Maintenance Schedule Every Shift • Inspect cradle over-centering latches. • Inspect cradle hinges and barrel seats. • Inspect barrel lock bars and barrel tabs. First 50 Machine Hours • Inspect turret double-v belt and tighten as needed • Inspect barrel chains, lubricate and adjust as needed •...

  • Page 29: Adjusting Main Drive Belt

    V-Belt drive is the lowest tension at which the belts will not slip under the highest load condition. In this manner the method that is used by United’s technicians is the twist method. The tension of the turret belt should allow the technician to twist the belt to the halfway point.

  • Page 30: Barrel Drive Assembly

    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.

  • Page 31: Drive Component Removal

    5.3.7 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.

  • Page 32: Adjusting Barrel Chain

    5-7 Align Sprockets 5.3.8 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.
  • Page 33 5-8 Adjusting Idler Assembly Page | 33...

  • Page 34: Bearings

    5.3.9 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.
  • Page 35 11. Lubricate the new bearing according to the instructions given in the section Lubricating. Zerk-Fitting Retaining Bolt Zerk-Fitting Setscrews Setscrews Retaining Bolts 5-9 Bearing 5-10 Bearing Page | 35...
  • Page 36 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.
  • Page 37 Turret Center Shaft Pillow Block Setscrew Pillow Block Retaining Bolts (2) 5-12 Turret Free Side 5-13 Turret Drive Side Page | 37...

  • Page 38: Barrels

    See photo’s 5-10 Profiles and 5- 11 Lockbar. Shaft If repair is needed it is recommended that it be performed by a qualified United technician. For further information please 5-11 contact UNITED SURFACE SOLUTIONS Product Support Team, Service Department, (877) 8374623.
  • Page 39 Page | 39...

  • Page 40: Troubleshooting

    6.0 Troubleshooting 6.1 Interface Not Functioning Possible Problem Item to Check Remarks Control voltage fuse Check for blown fuses. If the door interlock has shorted out, it is blown usually because someone attempted to open the shutter door while in Run Mode. Check the interlock before re-energizing this circuit.

  • Page 41: Will Not Begin Cycle

    Check Drive Keypad for Refer to the instruction manual for the drive error code. that was supplied with the machine or contact UNITED SURFACE SOLUTIONS for support. Loose wire or Turn the main disconnect If you are certified to work with high voltage defective component to the “Off”...

  • Page 42: Premature System Halt

    Refer to the instruction manual for the drive that overload error code. was supplied with the machine or contact UNITED SURFACE SOLUTIONS for support. Human error Attempting to open the If the cycle timer has reset, human error is likely Shutter Door while the the problem.

  • Page 43: Desired Rpm Not Reached

    6.4 Desired RPM Not Reached Possible Problem Item to Check Remarks Machine overloaded If the acceleration of the Loading the barrels with more material will not machine slows before the overload the machine. With the CPC, the desired RPM is reached, the greatest load condition occurs at approximately machine is attempting to 60% fill height.

  • Page 44: Turret Slips During Loading

    Worn barrel tabs Inspect the barrel tabs on Refer to the section “Lockbar” for detailed each end of each Lock bar instructions. and adjust as necessary. Worn linings Inspect the barrel linings Refer to the section “Inspecting Barrel Lining” instructions. 6.6 Turret Slips During Loading Possible Problem Item to Check...

  • Page 45: Appendix

    The following information for the CPC12000 finishing system is intended to assist personnel with the basic operations of the system. Some or all of the information may not be current. If updated information is required, please contact our technical support team. Thank you for choosing UNITED SURFACE SOLUTIONS, LLC for your finishing solutions.

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