Page 1 Operating Manual...
Page 2 Relevance in print When buying the Vector Revolution 180 you decided in favour of a model with an individual composition. We ask for your understanding that there may be mentioned addi- tional devices which you did not chose. The high standard of quality and security is guaranteed by continual development.
Page 3: Table Of Contents
CHAPTERS Technical data Characteristic Data 1 - 1 Weight 1 - 1 Scope of application, operation and intended use 1 - 1 1.3.1 Scope of application 1 - 1 1.3.2 Operation 1 - 1 1.3.3 Intended use 1 - 1 Machine dimensions 1 - 2 Working dimensions...
Page 4 Contents CHAPTERS Transport, offloading, setting up General instructions 4 - 1 Space requirement 4 - 1 Setting up area 4 - 1 Sensitivity 4 - 1 Ambient conditions 4 - 1 Transport routes 4 - 1 Interim storage 4 - 2 Cleaning 4 - 2 Transport from packaging to location...
Page 5 Contents CHAPTERS Start up Putting the basic machine into service 8 - 1 8.1.1 Switching on 8 - 1 8.1.2 Switching off 8 - 3 8.1.3 Emergency cut-out 8 - 4 8.1.4 Power failure 8 - 4 General Reset 8 - 4 Setting up basic machine Preparation for Operation 9 –...
Page 6 9.3.4 Advanced Controls: Feed 9- 63 9.3.5 Advanced Controls: 360 Panel 9- 65 9.3.1 Advanced Controls: Panel Shapes 9- 66 Cycle Functions 9 – 67 9.4.1 Standard Conditions 9 - 67 9.4.2 Convex (external) Corner 9 - 67 9.4.3 Concave (internal) Corner 9 - 72 9.4.3.1 Aggregate pushed back by Bump Bar...
Page 7: Technical Data
Technical Data ________________________________________________________________________________________ Characteristic Data Machine designation: Contour Edgebander Model Revolution 180 Manufacturer Vector Systems Ltd P O Box 78 331 Grey Lynn AUCKLAND, NEW ZEALAND Serial Number ________________________ Year of Manufacture ________________________ Weight Model Revolution 180 Weight (kg) 2500kg Scope of application, operation and intended use.
Page 8: Machine Dimensions
Technical Data ________________________________________________________________________________________ Machine Dimensions MODEL VECTOR Revolution 180 WIDTH 2606mm HEIGHT 2450mm LENGTH 4600mm _______________________________________...
Page 9 Technical Data ________________________________________________________________________________________ _______________________________________...
Page 10: Working Dimensions
Technical Data ________________________________________________________________________________________ Working Dimensions CAUTION ! Pay attention to the restrictions for the working dimensions. See chapter - Technical Data - for the related operating instructions. Model VECTOR Revolution 180 Workpiece thickness min (mm) (mm) External radius (mm) Internal radius...
Page 11: Safety
Safety _____________________________________________________________ ___________________________ Symbol and explanation of directions DANGER You will find this symbol next to all working safety directions given in these instructions for use that concern risks to the health and safety of personnel. Take note of these directions and be particularly careful in such cases.
Page 12: Qualified Personnel
Safety _____________________________________________________________ ___________________________ 2.2.5 Qualified personnel Qualified personnel are persons who are expert or who have been sufficiently instructed. 2.2.6 Protective clothing, goggles and heat protection gloves Protective clothing is personal protective equipment intended to protect the body from the residual risks entailed by the working process.
Page 13 Safety _____________________________________________________________ ___________________________ The operator must help to ensure that no unauthorised personnel use the machine /unit. The operator undertakes to report immediately any changes occurring at the machine/unit that affect safety. The user must undertake to operate the machine/unit only when it is in fault-free condition. The user’s factory must ensure that the machine/unit workplace is kept clean and unobstructed by means of appropriate and checks.
Page 14: Protective Devices
Safety _____________________________________________________________ ___________________________ Protective devices The provision of safety hoods prevents the user from any danger of accident through contact with rotating tools. Electric interlocks prevent incorrect operation. EMERGENCY-OFF facility Residual risks Our machines harbour residual risks that are unavoidable despite the care taken in their design and manufacture, and that are inherent to operation of the machine.
Page 15: Emergency Measures
Safety _____________________________________________________________ ___________________________ Shattering of the air filter drain bowl (normally enclosed in rear core) if affected by substances such as cleaning fluids (see manufacturers recommendation supplied with this manual). Noise and dust emission. Oak and beech dust are under suspicion of causing cancer of the nose. Since these timbers can be worked using this machine/unit, the provisions of the German regulations governing hazardous substances dated 26.08.1986 must be met, As a general principle, the machine/unit must never be operated without a dust extraction system.
Page 16: First Aid
Safety _____________________________________________________________ ___________________________ 2.6.3 First aid The user is responsible for: 1. Provision of the facilities required for first aid measures, especially reporting facilities, stretcher, first aid facilities and equipment, as well as resuscitation equipment. 2. Provision of equipment required for the purpose of saving life and health of affected personnel especially rescue and recovery facilities.
Page 17: General
General ________________________________________________________________________________________ Introduction This information has been written to be read, understood, and complied with in • every respect by all personnel responsible for this machinery. The complete technical documentation must be kept at all times in the vicinity of •...
Page 18: Copyright
+64 9 950 4792 Warranty Our general terms of business shall apply with regard to warranty. Spare parts are available either from your dealer or from the manufacturer. Only genuine VECTOR spare parts may be used in VECTOR machines for warranty reasons. _______________________________________...
Page 19: Transport, Offloading, Setting Up
Transport, offloading, setting up ________________________________________________________________________________________ General instructions When the machine arrives please check both the packaging and the machine itself. Note down any damage in the presence of the forwarding agent; if the machine proves to be damaged in any way not recorded in the forwarding agent’s documents, we must assume that the machine was damaged on site, which automatically rules out any claim for damages.
Page 20: Interim Storage
Transport, offloading, setting up ________________________________________________________________________________________ Interim storage If interim storage of this machine/unit is necessary directly after delivery, it must be stored carefully at a protected spot, and also covered properly to keep out dust and moisture. Cleaning When the transportation time is greater than 2 weeks, the machine/unit is supplied with a preservative coating on its bright metal parts that will protect them for one year.
Page 21 Transport, offloading, setting up ________________________________________________________________________________________ Fig 1 Fig 2 The machine should be pushed between 500 – 1000mm into the container clear of the doors so as to give the strops a good purchase. At the rear of the container, three strops are used. One ties from the rear left of the container, forward and across behind the rear horizontal cross-member and looping back to the corner tie point.
Page 22 Transport, offloading, setting up ________________________________________________________________________________________ CAUTION ! The centre of gravity of the machine is at the outer end of the machine. Keep supported at all times. It is preferable to jack the machine up onto suitable rolling skates to facilitate easy removal from the container.
Page 23 Transport, offloading, setting up ________________________________________________________________________________________ (3). The strops should be drawn as high as possible above the machine so as to ensure no contact with any part of the arm and aggregate. All additional components including the control console are tied onto the top of the machine so will be removed when the machine is removed.
Page 24: Levelling
Transport, offloading, setting up ________________________________________________________________________________________ If a forklift and/or skates are being used, when the feet (6) are almost out of the container, the forklift can be brought in from the side to lift the entire machine and carefully negotiate the machine out of the container. Alternatively the machine can be jacked onto skates positioned at (7) and rolled clear.
Page 25: Assembly
We cannot accept any liability for damage resulting from incorrect action. The Vector Revolution 180 contour edgebander machine is usually supplied partially disassembled. This is to facilitate fitting the machine into the transport container. Machine Assembly 5.2.1 Re-fitting of components removed for transportation The following items are removed for the purpose of transporting the machine in a container.
Page 26 Assembly ________________________________________________________________________________________ The unit is bolted up underneath the Y arm rear upright (15) and is pushed up against the adjusting points (16). This has been factory set and should require no adjustment for alignment provided the adjusting screws are touching their reference surface (17).
Page 27 Assembly ________________________________________________________________________________________ 5.2.1.2 X Axis Cable Chain and Support The X Axis cable chain support (20) should be unbolted from it’s transportation position on the rear of the machine. A plastic bag contains the bolts used to fix it to the fixing points on the rear of the machine.
Page 28 Assembly ________________________________________________________________________________________ _______________________________________...
Page 29 Assembly ________________________________________________________________________________________ 5.2.1.3 Fitting X Axis Drive Belt The X Axis drive belt (27) can now be fitted. It remains connected to the X –ve belt clamp (28) at the end of the machine during transportation and should be unrolled and aligns in a tooth down orientation.
Page 30 Assembly ________________________________________________________________________________________ NOTE: It is important to ensure the belt is engaging correctly into the toothed sprocket with one belt tooth per sprocket tooth. Failure to do this will result in damage to the belt. Now the fixing bracket (29) at the left hand end can be fitted and the belt tensioned. This is achieved by loosely fixing the bracket and then tensioning is achieved by winding the adjusting screw (30) at the left hand end until the belt is tight.
Page 31 Assembly ________________________________________________________________________________________ Y Axis belt fixing rear end. Y Axis belt fixing front end Y Axis belt fixing in position Y Axis belt fixing front in position _______________________________________...
Page 32: Fitting X Axis Counter
Assembly ________________________________________________________________________________________ 5.2.1.5 Fitting X Axis Counter The X Axis counter which is still connected to the electrical box can now be fitted. This consists of 2 proximity switches which are aligned to measure off the teeth of the pulley. They count in a quadrature pattern (up, up, down, down) so that they up and down count.
Page 33 Assembly ________________________________________________________________________________________ In the event the counter is reading in the wrong direction (as per the control screen [15]), the counters can be reversed in the electrical box – refer wiring diagram). 5.2.1.6 Fitting X Axis Positive and Negative Limit Switches The X and Y axis positive (37)and negative (38) limit switches and the crossover switch (41) can now be fitted.
Page 34: Fitting Emergency Stop Pullwire
Assembly ________________________________________________________________________________________ 5.2.1.7 Fitting the Emergency Stop Pullwire The emergency stop pullwire brackets must be fitted to each corner of the machine and the pullwire strung around and tensioned so that the switch locks when the reset button is pushed as indicated by a green band through the indicator lens. NOTICE: The pullwire extends all the way around the machine and connects back onto the plate which supports the switch mechanism.
Page 35: Fitting Edgeband Coil Support
Assembly ________________________________________________________________________________________ 5.2.1.8 Fitting edgeband coil support The edge-band coil support (42) is fixed to the side of the cover guard for the head using the screw at point (43). Run the pneumatic hoses which protrude from the side of the cover guard, through the cable ties and connect as per the pictures below.
Page 36 Assembly ________________________________________________________________________________________ The 4mm diameter hose (44) connects to the rear of the actuating cylinder (45) and the larger diameter 6mm hose (46) connects into the rod end of the cylinder (45). The Cylinder extends and retracts to drive a ratchet which rotates the tape coiler. The side curtain (51) is also fitted to the side cover (52).
Page 37 Assembly ________________________________________________________________________________________ 5.2.2 Removing Axis Transportation Brackets At this point it is possible to remove the axis transportation brackets after first checking that the axis end limits (33) IMPORTANT!!! These should be stored for any future transportation requirement. Brackets are shown below: There are brackets on the X rails (41), either side of the y-arm at the front and rear as well as brackets either side of the head on the y rails (42).
Page 38: Machine Connections
Assembly ________________________________________________________________________________________ Once the axis brackets are removed and all electrical connections are made by a qualified technician, it is now possible to connect power to the machine. Machine Connections 5.3.1 Electrical DANGER ! Work on electrical equipment or systems may only be performed by a qualified electrician, or by trained personnel under the direction and supervision of an electrician, in accordance with electrical engineering rules.
Page 39: Testing End-Limit Switches
Assembly ________________________________________________________________________________________ 5.3.3 Testing End-Limit Switches It is important to check that the end limit switches are working properly. This should be done before checking the counters, as the X negative limit switch is also the X Axis zero reset for the counter. To test the inputs for the end limit switches, go to the control screen and press the troubleshooting button (16) When in the troubleshooting page it is now possible to access the wiring diagrams...
Page 40: Testing Axis Counting Direction (X + Y)
Assembly ________________________________________________________________________________________ It is possible to move forwards and backwards through the wiring and pneumatic drawings using the forward key (21) and back (20) Check both X (+/-) and Y (+/-) limit switches Thus it is possible to activate the switches manually or by pushing the Y arm onto the respective limits to check their function.
Page 41: Preparations For No-Load Tests Without Workpieces
Assembly ________________________________________________________________________________________ Now move the machine back until it almost (but doesn’t quite touch the zero switch) and then move all the way back to the right position. Check the number again to ensure no counts have been lost. Note it is important not to touch the zero switch as otherwise it will re-zero (even if counts have been lost).
Page 42: Checking The Direction Of Rotation
Assembly ________________________________________________________________________________________ 5.4.2.1 Checking the direction of rotation All motors have been switched by the factory to the correct direction of rotation. To check the direction of rotation for the entire machine, jog the vacuum pump and check the fan direction to match the arrow on the fan cover. Front Pump motor rotation clockwise when viewed from front CAUTION!
Page 43: General Description
Design ________________________________________________________________________________________ General Description This machine is based on years of practical experience and incorporates the results of extensive studies in research and development. Design Feet Plinth Emergency Stop Mushroom Control Console Worktable Emergency Stop Pullwire Aggregate Vacuum Pods Tape Coil Y Gantry Arm Field Controls Machine Base...
Page 44: Mode Of Operation
Design ________________________________________________________________________________________ Mode of Operation The VECTOR Revolution 180 is intended exclusively for the applying of edging materials to pre-shaped panels having been previously shaped by other machines such as CNC machining centres. The workpiece is placed on vacuum pods which are fixed to the worktable via a vacuum system.
Page 45: Operation Panel
Operating Panel ________________________________________________________________________________________ 7.1 Control fields / control elements Definition of control elements Back to home page Vacuum pump control Troubleshooting Z Lift (after em stop) Functions page access Start with glue off Load/Save page access Scraper control Trimmer control Glue control Start positions setting access Panel types setting access...
Page 46 Operating Panel ________________________________________________________________________________________ By touching the control screen below each icon (732) it is possible to enter the advanced controls page for that icon. For example, by touching on the words GLUE below the Glue icon, it will open the page Advanced Controls Glue. The description of the Advanced controls functions is detailed in section 9.0 _______________________________________...
Page 47 Status (such as glue temperature) and other settings are shown below the icon descriptions (733) This image shows the advanced controls page for the Glue settings. Touch on the VECTOR logo (730) to return to the home screen or the Back arrow (734) to go back one page. _______________________________________...
Page 48 Operating Panel ________________________________________________________________________________________ The following image shows the control elements for vacuum and emergency stop on the machine frame. Vacuum control switch(es) Vacuum status display incorporating Vacuum OK output Emergency stop pullwire _______________________________________...
Page 49: Start Up
Start Up ________________________________________________________________________________________ Putting the basic machine into service 8.1.1 Switching on Set the working pressure using the pressure control valve on the servicing unit (9) to the • pressure gauge reading of 6 bar (0.6mpa). Ensure the machine is plugged into the supply socket and switched on. •...
Page 50 Start Up ________________________________________________________________________________________ _______________________________________...
Page 51: Switching Off
Start Up ________________________________________________________________________________________ Clear all error messages by pushing the screen RESET button (828). • The machine is now ready to start. If starting from power up, a General Set will be required to set the axes (refer 8.2 General Reset). If re-starting after an Emergency Stop Error the machine is now ready to run (no General Reset Required.
Page 52: Emergency Cut-Out
Start Up ________________________________________________________________________________________ 8.1.3 Emergency cut-out Control panel emergency switch-off (823) mounted on front door of control cabinet • Emergency Pull wire (806) mounted at front right hand corner of the machine with pull wire • extending all the way around the machine. In case of emergency, stop machine by switching off and disconnecting machine at wall •...
Page 53 Start Up ________________________________________________________________________________________ Press the General Set screen button (819). Each of the axes will move slowly in a negative direction until they reach the zero switch for each axis. Upon reaching the appropriate zero limit switch, the axis will move slowly forward until it just comes off it’s switch. This is the trigger point for setting the axis.
Page 54: Preparation For Operation
________________________________________________________________________________________ 9 .1 Preparation for operation 9.1.1 Loading tape coil, feeding tape, setting guide height, setting infeed top bar. Select the tape required for the job to be performed. Place the tape coil on the tape tray (901) such that the tape unwinds off the tray in an anti-clockwise direction when viewed from above.
Page 55 ________________________________________________________________________________________ There are two ways to prepare The C Axis position, in preparation For loading a new roll of band. Either by using the control switch (988) (see 07 Control Panel), rotate the C Axis fully until it reaches it’s clockwise limit (when viewed from above).
Page 56 ________________________________________________________________________________________ Push the end of the edgeband into the tape winder ring (903) and rotate the head anti- clockwise to bring this band end around behind the winder. Lead the band from the tape coil directly through the loop (904), through the guide (905), behind the corner sensor guide (6) and into the infeed guide (7) –...
Page 57 ________________________________________________________________________________________ Note, the top infeed guide may require loosening to allow the band into the guide system. The top infeed guide (908) should be adjusted using the adjuster screw (909) to allow the tape a free movement in the guide but such that the spring pressure of the tape guide keeps pressure down on the tape to allow for variations in tape width.
Page 58: End Trimming Band
________________________________________________________________________________________ Note: it is possible to lift the top tape guide (908) by pulling up on the adjuster screw (909) against the spring pressure without unwinding it to allow the tape to be feed in. This is achieved by lifting the screw (909). 9.1.2 End trimming tape When the band is slid into the guides, the adjuster (909) is wound down (anti-clockwise when viewed from above) until a positive amount of spring pressure is applied to the top of...
Page 59 ________________________________________________________________________________________ It is also possible to check that this infeed roller (910) is set correctly by watching as the band feeds across the nozzle. It should just brush across the top of the guide pin (911) which is positioned just after the nozzle. If the top tape guide (908) is too loose, or if the infeed roller (910) is pushing down too hard, the tape will not track perfectly along the top of this guide pin (975) If the next workpiece has a butt join (ie.
Page 60 ________________________________________________________________________________________ The functions page is accessed via the Function icon (89) on the main page Saw mode is then activated by pressing the Saw Mode button (992) on the functions page. DANGER ! Danger of injury to personnel. Ensure all hands a clear of trimmer before performing manual trim operation! _______________________________________...
Page 61 ________________________________________________________________________________________ If a non-360 degree panel is to be performed, it is usually unnecessary to pre-trim the tape as the condition of the end of the tape is not important provide it is square. For either cycle (360 or non-360) the tape should always start in line with the cut line (932) of the end trim.
Page 62: Turning On The Glue And Setting Height To Match Panel Thickness
________________________________________________________________________________________ 9.1.3 Turning on the glue and setting glue height to match panel thickness. The glue nozzle comprises: Cartridge Cylinder for pressing the cartridge of glue into the nozzle. Element 1 Comb element for melting the cartridge Element 2 Nozzle element Dosing cylinder for controlling the glue flow Dosing bar...
Page 63 ________________________________________________________________________________________ First check the temperature settings for the two elements. These should be set according to the characteristics of the glue used. Typically element 1 is set 5 degrees lower than the nozzle element which controls the final temperature of the glue onto the panel. The temperature settings (923) are displayed on the control screen but are set in the advance controls for glue (993).
Page 64: Setting Glue Height To Match Panel Thickness
________________________________________________________________________________________ The icon will indicate with a tick when positive Temperature can be set by touching the bottom of the glue icon (993) which will take you to the Glue Advanced Controls page. comb temperature (994) is the temperature of the comb element against which the glue cartridge is pressed.
Page 65: Setting Glue Start And Stop Adjustments
________________________________________________________________________________________ 9.1.4 Setting glue start and stop adjustments. During a running cycle, the edge band material is fed across the glue nozzle. Immediately prior to it passing over the nozzle, it activates the tape present switch (911). There are two sets of settings on the control screen for adjusting the delay between the activation of this switch (911) and when the...
Page 66 ________________________________________________________________________________________ The Glue Start timer (996) and (997) is in 0.1mm counts and is the delay between when the tape present switch is activated and the glue is turned on. Increasing this distance makes the glue start later and hence moves the glue start back from the front edge of the tape.
Page 67: Setting Glue Pressures And Tape Presser
________________________________________________________________________________________ 9.1.5 Setting Glue Pressures and Tape Presser. There are two regulators which control the pressure of the glue cartridge cylinder. Low pressure (926) and high pressure (927). These control the amount of glue applied to the edge material. Low pressure is automatically switched on when the speed reduces for corners.
Page 68: Setting The Nozzle Wiper
________________________________________________________________________________________ 9.1.6 Setting the Glue Nozzle Wiper A pneumatically operated wiper (20) passes a blade across the nozzle after each cycle and prior to the start of a new cycle. This is to remove any residual glue which could get on the front edge of the tape as it passes the nozzle and also serves to keep the nozzle free of burnt glue.
Page 69: Loading A Glue Cartridge
________________________________________________________________________________________ This opens the Functions page. The nozzle wiper (990) can now be turned on (note the nozzle temperature must be over 150 deg C for this to operate. 9.1.7 Loading a Glue Cartridge Now that the tape is set and the glue settings are made a glue test can be run. This is a manual test which is used to ensure that the glue is flowing and the tape is feeding correctly.
Page 70 ________________________________________________________________________________________ IMPORTANT! It is important to use a glue of high quality. Failure to do so can result in problems with edge bond and glue nozzle function. Below is a list of performance characteristics important to the function of the machine which will perform better in higher quality glues: Glue bond strength Dimensional tolerance of glue cartridges (diameter)
Page 71 ________________________________________________________________________________________ 9.1.7.1 Running a glue-tape test Load the tape (see 9.1.1) and turn on the glue (9.1.2). Enter the Functions pageusing the icon (989) Ensure the Glue (926) is turned on and at temperature (ie now low glue temp alarm) Turn on the Tape Feed (994) The tape will be fed across the glue nozzle, triggering the tape present switch (911) and starting the glue.
Page 72 ________________________________________________________________________________________ From this it is possible to check that the glue is flowing correctly, is the correct width and that the tape is sitting correctly on the exit guide pin (975) (to ensure laying on the panel at the correct height). The edge material should just brush this pin. When sufficient tape has been run, the feed can be stopped by pressing the tape feed (994) on the Functions page again.
Page 73 ________________________________________________________________________________________ The image above shows a poor glue line with glue build-up on the nozzle at the point where the edge material leaves the nozzle. This is caused by insufficient glue pressure at the cartridge and is usually due to the cartridge not being free to move in the teflon infeed guide (73) of the cartridge heater.
Page 74: Manually Purging Glue Cartridge
________________________________________________________________________________________ 9.1.7.2 Manually purging glue cartridge. Ensure the glue heating is turned on and at the desired temperature (within the range of the glue manufacturers specification). Enter the Functions page using the icon (989) This opens the Functions page. Swing the 3 roller forward using the function (950).
Page 75 ________________________________________________________________________________________ The tape presser shoe (919) should be released by removing the pin (925) and pushed back or removed Nozzle face Ensure the glue is turned on (926) Make a V-shaped piece of cardboard to pump the glue into. Corrugated box cardboard is good because if forms a V easily if folded along the corrugations and is firm enough to support the hot glue.
Page 76: Selecting 360 Degree Setting For Butt Joint Or Open Board
________________________________________________________________________________________ NOTE If the glue does still not flow correctly, it may be due to poor glue quality or nozzle maintenance issues. Refer trouble shooting glue nozzle Section 11. When you are satisfied with the glue flow, run another glue-tape test (ref 9.1.7) to confirm. 9.1.8 Selecting 360 degree setting for butt joint or open board.
Page 77: Degree Operation
________________________________________________________________________________________ 9.1.8.1 360 Degree Operation When in 360 degree mode, the machine is set to start against the edge of the panel such that the tape start will begin in the desired place. When the aggregate has aligned itself against the panel, feed motor will begin progressing it around the panel. Tape feeding will commence immediately.
Page 78 ________________________________________________________________________________________ There are 3 digits on the digital counter. They correspond to 1/100ths of a millimeter. It is appropriate however to ignore the right hand column and adjust in 10ths of a millimetre. The left hand digit represents millimetres. Digital Counter Image shows counter set at 1.8mm.
Page 79 ________________________________________________________________________________________ This following table contains approximate digital counter (940) settings for different radii. These are similar for all machines but exact settings need to be calculated and noted for each machine. Radius (mm) Radius (inches) Counter setting Straight 1.00 1200mm 3.60 1000 4.00...
Page 80 ________________________________________________________________________________________ 9.1.8.2 Open Board (non-360 degree) Mode This mode of operation is used where the contoured edge to be banded has square starting and finishing corners. It is selected on the control screen via the 360 Panel Icon (933) In this mode of operation it is necessary to use the Starting and Finishing pods. Starting Pod showing Lead Block attached.
Page 81 ________________________________________________________________________________________ banding, trimming and scraping all to complete their process on the workpiece before the head retracts and lifts. These blocks must be the same thickness as the workpiece. This ensures that prevents the trimmer cutters removing excess material when running onto and off of the workpiece. Lead block with panel butted up against it.
Page 82 ________________________________________________________________________________________ A universal pod plate (963) can be fitted to these pods to act as a Start of Finish pod in most circumstances. The universal single piece pod plate is 16mm thick. It can be used as a pattern to make pod plates of different thicknesses. It is shown here positioned as a Start block.
Page 83 ________________________________________________________________________________________ The following drawing shows a template for a universal Pod Plate (967) which can be manufactured as a blank with the 8 diameter holes and notches for end trimming. There is also on the drawing a dotted line (968) representing the EndPOD on which the Universal Pod Plate sits.
Page 84 ________________________________________________________________________________________ This drawing is available in dxf format on request. The reason that there are 3 holes (964) for fixing is that this plate is universal. The left hand side of the plate above is straight and is used when needed as a start block. Therefore only the two left hand 8mm holes (964) are required and in fact the entire right hand side can be cut off if unnecessary or obstructing in some way.
Page 85 ________________________________________________________________________________________ In non-360 DEGREE MODE, the cycle has some differences to when running in 360 DEGREE MODE. Firstly, on pressing the Start Cycle button, the tape will commence feeding at the same time as the z axis is lowering. This pre-feeds the tape into the tape guide so that if feeds earlier onto the panel (requiring a shorter starting block).
Page 86 ________________________________________________________________________________________ When LENGTH CUT “OFF” is selected, the butt join sensing arm (938) swings out and remains out (though it will retract automatically when the convex sensor is off) running along the edge of the panel feeling for the sensing cam (966) on the finishing pod. This sensing trigger (966) is a plastic screw which screws into the M6 hole in the FINISHING BLOCK.
Page 87 ________________________________________________________________________________________ This distance of travel for the trimmer and scraper can be controlled by the operator (refer section 9.3) If the finish point of the tape cut is to be changed, this is effected by moving the position of the cam. When LENGTH CUT “ON”...
Page 88: Commencing A Cycle
________________________________________________________________________________________ 9.2 Commencing a cycle 9.2.1 Setting vacuum cups and lead –in and lead – out pods. The machine can operate in single or pendulum mode. When in single mode, the vacuum systems operates as one large field 3550mm x 1830mm. The vacuum control switches at each end of the machine perform the same function of raising the panel lifters and switching on the vacuum (it does not matter which switch is operated).
Page 89 ________________________________________________________________________________________ To facilitate positioning the pods and workpiece, lifting pins (944) built into a number of the pods. These are automatically controlled by the control switch (945) and lower when the vacuum is turned on. This control switch (945) has two “spring return” positions. In its central position, the vacuum and panel lifters remain in their existing state.
Page 90 There is no requirement for absolute accuracy in positioning the panel as the principle of operation of the Vector Revolution senses the edge of the panel. When placing the panel on the machine, it is important to consider the rotational capability of the aggregate to ensure that it will not exceed it’s clockwise or anti-clockwise limits...
Page 91: Saving Start Positions
________________________________________________________________________________________ If the retract distance reaches the axis limit, the head will automatically lift provided none of the board sensor, convex sensor, bump bar or bump switch is activated at the time (indicating the head is not clear of the panel). This should also be taken into account when setting the panel positon.
Page 92 ________________________________________________________________________________________ CAUTION ! Ensure that all axes are free of obstruction and personnel are clear of the machine before pressing the Move to Position key! It is possible to change the start position settings two ways. Method 1: One is by modifying the settings in the appropriate target field (944 or 945). This can be done by modifying the number(s) in the field by touching the field number and modifying using the popup keyboard.
Page 93 ________________________________________________________________________________________ These scales are calibrated to match the position of the central axis of the C shaft which corresponds to the second pressure roller (951). Thus for example, if an X position of 150 is set, Y position 100 and C 0 degrees, the head will move so that the C roller (951) will move to this position and the head will rotate to the 0 degrees position which is facing the right hand side of the panel.
Page 94 ________________________________________________________________________________________ This method enables either for two panels to be loaded in pendulum with the aggregate automatically moving to the second panel on completion of the first (cycling back and forth thereafter. Alternatively for large panels, a park position can be set for position 2 that will move the head away from the panel on completion to allow unloading and loading a new panel.
Page 95: Single Or Pendulum Operation
________________________________________________________________________________________ 9.2.3 Single or Pendulum The machine is equipped with two vacuum manifolds which can either be used as a large single field or as two individual fields to allow one to be loaded/unloaded while the other is still working. If the box ( 941) is set to SINGLE, then both vacuum fields operate as one with either vacuum control switch (945) working both fields.
Page 96: Start Cycle
________________________________________________________________________________________ 9.2.4 Start Cycle. When the panel is sucked down onto the vacuum pods, the aggregate is in the start position and all the settings are as desired (including glue temperature reached), a cycle can begin. To start a cycle, upon pressing the Start cycle pushbutton (960), provided all of the “Start Prevent”...
Page 97: Start Prevent Messages
________________________________________________________________________________________ 9.2.4.1 Start Prevent Messages The following is a list of the Start Prevent Messages which will appear when the Machine State is START WHEN READY but when the Start Button (960) is pressed, there are conditions required for operation which are not met. NOTE: If the cycle does not start, push an hold the start pushbutton (960) and a message (947) will appear on the screen status bar advising the reason.
Page 98 ________________________________________________________________________________________ 9.2.5 Applying edge material only (without trimming or scraping) Refer to section 9.1.2.1 for how to turn on the glue. For the purposes of this test, turn the glue on, trimming off, 360 degree cycle – YES, scraping off (note if the trimmer is turned off, the scraper is automatically disabled.
Page 99 9.4, it is now possible to start the cycle with the glue turned off for the purpose of testing the trimming setup. The Vector Revolution has a patented trimming unit which travels with the gluing and taping aggregate and performs the top and bottom radius trimming in the same pass as the tape application.
Page 100 ________________________________________________________________________________________ It is also possible to start and stop the feed rollers by pressing the start button (960) while traversing the panel. Pressing the start button again will re-commence the feed. NOTE: if this is done during a gluing cycle, the pause must be very short because the heat from the glue nozzle will deform the band material depending on the characteristics of the band.
Page 101: Setting Trimmer Shoes
________________________________________________________________________________________ 9.2.7 Setting Trimmer Shoes 9.2.7.1 Setting the horizontal tracer shoe The horizontal shoe (928) controls the horizontal position of the cutters and operates for both the top (932) and bottom (931) cutter heads. The horizontal tracer shoe (928) serves to control the basic shape of the radius. Moving the show outward past the end of the cutter will reduce the amount of radius which is formed on the edge material.
Page 102 ________________________________________________________________________________________ Linear rail. Adjuster block pushed against face and shoulder edge (985) . Move shoe this way reduce amount of radius on external corner (986) Contact point on small external radius corner (987) Contact point on Move shoe out to straight edge (988) reduce amount of radius (989)
Page 103 ________________________________________________________________________________________ It is also a simple matter to measure the setting using callipers as in the image below. Adjustment can be made to the set screws and a measurement taken to check the change in setting. Now release the two locking screws (981) on top of the horizontal shoe, replace the adjuster block (with it’s new set screw settings) and push the horizontal shoe back against the two screws and sideways against the single lateral screw.
Page 104 ________________________________________________________________________________________ Adjusting the vertical shoe upwards allows the cutter block to cut closer to the panel. Conversely, moving the shoe downwards lifts the cutter away from the panel leaving more overhanging edge material. To adjustment system for both the upper and lower blocks is the same but operates in opposite directions due to one being on top and one under the panel.
Page 105 ________________________________________________________________________________________ There are 2 locking screws (990) on each block, one fixed pin (992) and an upper (991) and lower (993) adjusting screw. The shoe is restrained from tilting by a machined tongue and groove arrangement on their mating faces. Firstly release the locking screws (990) and then finger tighten them so they provide some resistance to movement.
Page 106 ________________________________________________________________________________________ The trimmer blocks can be brought together by going into the functions page and activating the Trimmer Vertical button. (976). 9.2.8 Performing a complete cycle with trimming and scraping but without gluing. (used to test setup of scraper). Using the panel created when testing the gluing and edge material application in section 9.4, it is now possible to start the cycle with the glue turned off for the purpose of testing the scraping setup.
Page 107: Setting The Glue Joint Scraper
________________________________________________________________________________________ 9.2.8.1 Setting the Glue Joint (surface) Scraper The glue joint surface scraper (901) is a unit suspended from the trimming unit with a pneumatic cartridge cylinder (902) pressing the scraper knife arm down onto the panel. (900) The knife has adjustments which allow it’spressure, flatness to the panel and angle of attack to be adjusted.
Page 108 ________________________________________________________________________________________ 1. Ensure that the travel limiter screw(s) (903) are not preventing the scraper knife applying pressure to the workpiece. The knife should be able to travel 0.5 – 1mm past the surface of the workpiece. 2. The pressure for the vertical pneumatic cylinder (902) is controlled by the regulator (905).
Page 109 ________________________________________________________________________________________ Typically this pressure is set at 3 bar. If the scraper is not performing correctly, the first adjustment is to increase this pressure to say 4 bar. Harder banding materials may require a little more pressure. Note however, that increased pressure could also cause the knife to damage fragile surface materials.
Page 110 ________________________________________________________________________________________ 3. If the scraper is still not scraping correctly, next check the horizontal angle of the knife in relation to the panel. The knife (906) makes contact with the panel at the glue joint but should be slightly raised at the inside end so a visible light gap is present (approximately 0.25mm).
Page 111 ________________________________________________________________________________________ 4. If the scraping performance is still not satisfactory, it is possible to adjust the attack angle of the knife. This is achieved by adjusting the two set screws (906) to tilt the knife block (904) on a greater angle causing the knife to cut more aggressively into the glue edge. NOTE! The scraper is designed to remove the squeezed glue bead and a small sliver of edgeband material.
Page 112: Advanced Controls
________________________________________________________________________________________ Advanced Controls. There are a set of Advanced Controls for each icon on the control screen. These advanced controls give extra ability for the operator to make setting adjustments according to specific conditions. Usually these advanced controls remain hidden as they are not required for machine running and they are accessed as needed.
Page 113: Advanced Controls: Glue
________________________________________________________________________________________ 9.3.1 Advanced Controls: Glue These settings are: Set Temp Comb Set temperature for the comb (cartridge) element Nozzle Set temperature for the nozzle element Actual Temp Comb Display of the actual comb temperature Nozzle Display of the actual nozzle temperature Glue Start 360 (0.1mm) Distance from tape present switch to glue start.
Page 114: Advanced Controls: Trimmer
________________________________________________________________________________________ 9.3.2 Advanced Controls: Trimmer These settings are: Trim Forward Pressure When set to OFF, trimmer advance pressure is OFF when trimmer is turned OFF. This can be useful if producing shapes outside specification where the banding can be performed but the trimmer will interfere.
Page 115: Advanced Controls: Scraper
________________________________________________________________________________________ 9.3.3 Advanced Controls: Scraper These settings are: Concave Scrape When this is set to OFF, the scraper will automatically lift off when the curve becomes concave. It will automatically recommence when the edge straightens again or goes convex. On internal radii less than 300mm, the scraper will move over the panel away from the edge and on fragile surfaces, this may mark the surface, hence it is possible to turn the scraper off in this situation.
Page 116: Advanced Controls: Feed
________________________________________________________________________________________ 9.3.4 Advanced Controls: Feed These settings are: Start Speed Feed speed when laying tape at commencement of cycle Fast Speed Maximum speed attained on straight edges Hold count bump bar Distance after bump bar is released before speed, bias and roller pressure return to standard.
Page 117 ________________________________________________________________________________________ Standard Bias Bias is the force applied by the patented VECTOR Revolution process in the direction of travel. This assists the head along the workpiece. Start Bias Bias along the direction of travel as the band is first being laid on the workpiece.
Page 118: Advanced Controls: 360 Panel
________________________________________________________________________________________ 9.3.5 Advanced Controls: 360 Panel These settings are: Auto Length Cut When “ON”, the distance travelled in a non-360 degree (open) panel is controlled by Auto Cut L1 for the left field, and Auto Cut R1 for the right field. See section 9.3 Autocut L1 Distance travelled before automatically stopping and end trimming.
Page 119: Advanced Controls: Panel Shapes
________________________________________________________________________________________ 9.3.6 Advanced Controls: Panel Shapes Enable Concave Sensor Turning this on enables the concave sensor which is required to be activated for tight concave (internals corners) less than 70mm. Refer section 9.4.3 Retract on Bump Bar Turning this on makes the bump bar retract when touched.
Page 120: Cycle Functions
Special conditions are deemed to be tight convex (external) corners, tight concave (external) corners and large radius concave corners. The design of the Vector Revolution 180 is such that little operator setting is required to handle these conditions. The settings which are required are set from the control screen (refer section 9.2.2).
Page 121 ________________________________________________________________________________________ The bump bar/switch mechanism has two motions. The first is simply to push the bump bar back causing it to release the sensor (915 – bump bar). This releases the glue station for shallow internal corners. The second mechanism is when the bump bar/switch is contacted end on causing the end of the bump bar/switch to slide.
Page 122: Standard Conditions
________________________________________________________________________________________ 9.4.1 Standard Conditions When progressing along a straight edge where the convex sensor (911) is detecting the panel and the bump bar (915) and bump switch (914) are not activated, fast speed is maintained as are the standard pressures against the edge. 9.4.2 Convex Corner The convex sensor (911) is a photo-eye which senses the panel at all times except when a convex corner of sufficient radius is reached.
Page 123 ________________________________________________________________________________________ Image showing convex corner almost complete with convex sensor (911) swinging back over the top of the panel. Usually it is not necessary to make any machine setting changes for convex corners. However the following highlights some possible operator changes: _______________________________________...
Page 124 ________________________________________________________________________________________ Convex corner speed (refer 9.3.4 Advanced Controls Feed). This is the speed of the laying of the band on a convex corner. Typically this is set at approximately 2000 – 2500 which is a good universal speed which allows the banding time to set before the rollers move on, even on smaller radius corners.
Page 125: Concave (Internal) Corner
________________________________________________________________________________________ This ensures the convex sensor does not detect a round workpiece such as a 600mm diameter and treat it as a convex corner. However there are certain shapes such as wireways which require the convex detector to be retracted so that they fall inside the wireway and cause the feed to slow. Fig 2.
Page 126: Aggregate Pushed Back By Bump Bar
________________________________________________________________________________________ 9.4.3.1 Aggregate pushed back by bump bar. If the angle is sufficient (about 45 degrees) then the panel will aggregate (920) will push back naturally and it is recommended to set the “enable concave sensor” setting (970) to NO. Refer 9.3.6 Advanced Controls: Panel Shapes This disables the bump switch (914) and prevents inadvertent operation during a cycle.
Page 127: Aggregate Retracted By Bump Bar
________________________________________________________________________________________ If the internal curve is large (say greater than 300mm radius) then it is not necessary to slow the feed on bump bar particularly so a speed of say 3500 to 4500 is common. If the internal curve is tighter such as the small radius internal as shown in figures 3 and 4, then a slower speed will be necessary to ensure the band sits tightly in the small radius.
Page 128 ________________________________________________________________________________________ 9.4.3.3 Aggregate pushed back by bump switch (914) If the shape of the panel is such that the aggregate will not be pushed back naturally by the shallow shape of the panel, it is necessary to Enable the Concave Sensor (970). Refer 9.3.6 Advanced Controls: Panel Shapes.
Page 129 ________________________________________________________________________________________ Upon activation of the bump switch (914), a sequence of events takes place. Firstly the aggregate (920) swings back. The feed automatically slows until the glue station has swung back to about a 45 degree angle at which point the Glue back 45 sensor (935) is activated. Now the glue station is floating.
Page 130 ________________________________________________________________________________________ A CONCAVE CORNER message will also appear on the status bar on the screen. The speeds and pressures will automatically be controlled until the trimmer has been brought through the concave corner. It is also advisable to turn the Concave Scrape OFF in this cycle (refer 9.3.3 Advanced Controls: Scraper) so that the scraper is automatically lifted as it goes through this corner.
Page 131 ________________________________________________________________________________________ Fig 5 Shows situation where concave corner cannot be detected by bump switch slide lever being depressed on its end NOTE: There is an infinite number of possible combinations of Concave followed by Convex such as one might find in a wireway. Which combination of Enable Concave and Retract on bump bar is used is dependent on the shape so it if you are having trouble with a shape, then it is ok to try different combinations.
Page 132: Special Sequences
Because there are an infinite number of possible shapes for a non-rectangular panel, there can in some instances be a desire to over-ride the internal algorithms which control the patented VECTOR Revolution process. For example, when there is a complex series of convex and concave corners in a short space, it may be very difficult to bend the banding to conform naturally to the shape.
Page 133: Setting Trigger Points
________________________________________________________________________________________ 9.4.4.1 Setting Trigger points for Special Sequences To set up a new special sequence, we firstly run around the workpiece with no gluing or trimming turned on. Refer 9.2.7 Starting with Glue Off. It is now possible to run around the workpiece and press the Start/Pause button (960) again to pause the feed.
Page 134: Setting Up Special Sequences
________________________________________________________________________________________ method is less accurate as it depends on the position of the panel on the pods as to exactly where the count starts. The Raw Count or Bump Bar/Switch options are usually used only when the specific panel shape precludes the use of the Convex Sensor option. 9.4.4.2 Setting up Special Sequences Once the trigger points have been set, open the Special Sequences page by touching on...
Page 135 ________________________________________________________________________________________ By turning on any combination of the options in this column, the corresponding row value will over-ride the existing machine settings. For example, by turning on the Glue Back function (992), the Glue Station will retract until further notice. Similarly by turning on Speed 1 at (993), the speed will be over-ridden by the value you enter into the Speed field at (994).
Page 136: Functions Page
________________________________________________________________________________________ Functions Page The functions page allows manual override of some functions. To access the Functions Page, touch the Functions ICON, Enter the Functions page using the icon (989). This opens the Functions page. _______________________________________...
Page 137 ________________________________________________________________________________________ Available functions are: Glue On Off Tape Feed Starts feed rollers. If Glue is turned on, tape will feed and apply glue to band. Roller 3 Fwd Swings third roller forward to allow access to glue unit Tape Change Brings head to front of machine and rotates C axis into tape load position Nozzle Wiper...
Page 138: Save/Load Settings
________________________________________________________________________________________ Save / Load settings. It is possible to save screen settings into settings folders via the Save Load Settings page. This is accessed by touching the Save /Load settings icon which is found in the top right corner of most pages such as (970) on the Functions page above. This will open the following page: Touching the header (978) drops down a menu of 3 options.
Page 139 ________________________________________________________________________________________ To send an exiting settings programme to the PLC, simply select the desired setting programme and touch the Send to PLC button. To create a new programme with settings which you have made on the Main screen or any of the Advanced Controls screens; Touch Create New (981) Type the name you wish to call the new setting programme in the heading box (982)
Page 140: Alarms
________________________________________________________________________________________ Alarms There is an alarm banner (919) at the bottom of most screen pages. When the cause of the alarm is cleared, in most instances it is required that the RESET button (974) is pressed to remove the screen alarm message. Common operation alarms able to resolved by operators are: Alarm Cause...
Page 141: Care And Maintenance
Care and Maintenance ________________________________________________________________________________________ 10.1 General instructions DANGER ! Refer to the chapter “Safety” during maintenance and inspection work. The power must be disconnected from the machine at its supply socket before work is started on the machine. Depressurise the pneumatic supply system! Clean the machine/unit daily.
Page 142: Maintenance Chart
Care and Maintenance ________________________________________________________________________________________ 10.2 Maintenance chart In single-shift operation, the operating hours correspond to a certain lubrication cycle. 2000 hrs ---------- Every year 1000 hrs ---------- Every six months hrs ---------- Every month hrs ---------- Every week hrs ---------- Every day Item Maintenance...
Page 143 Care and Maintenance ________________________________________________________________________________________ Axis bearings X 160 hrs Lubricate grease Kluber axis, Y axis and Z nipples on all 4 linear ISOFLEX axis. motion bearings on NBU15 each axis X, Y and Z. Top tape guide 160 hrs Lubricate guide bars Guide must spring with light oil.
Page 144 Care and Maintenance ________________________________________________________________________________________ _______________________________________...
Page 145 Care and Maintenance ________________________________________________________________________________________ _______________________________________...
Page 146 Care and Maintenance ________________________________________________________________________________________ _______________________________________...
Page 147: Troubleshooting And Remedies
Troubleshooting and remedies ________________________________________________________________________________________ DANGER ! Repairs to electrical equipment must not be performed except by an electrician, or by trained personnel under the direction and supervision of an electrician, in accordance with electrical engineering rules. 11.1 SIMPLE FAULT SCHEDULE This table is intended for rectification of simple problems.
Page 148 Troubleshooting and remedies ________________________________________________________________________________________ Circuit breaker tripped Check for faults and Trimmer will not start reset VSD showing fault Turn off power and restart. If fault doesn’t clear call technician Mechanical fault with drive Repair or replace spline Circuit breaker tripped Check for faults and Feed motor will not start reset...
Page 149: List Of Alarms
Troubleshooting and remedies ________________________________________________________________________________________ set correctly (continued next page) Tape not feeding Password protected (continued) refer technical support Screen setting is set too Reset Glue remaining on after long tape has passed Glue and debris is Clean switch obstructing the tape present switch holding it Cartridge sticking to inside Use purge function until...
Page 150: Start Prevent Alarms
Troubleshooting and remedies ________________________________________________________________________________________ clear of panel. Machine will not run until General Set General set required performed. Z Axis down and needs to be lifted to set for a Head Lift Required cycle. Axis limit reached during cycle. Reset cycle X Axis negative limit and move panel within machine limits Axis limit reached during cycle.
Page 151: Notes
Notes ________________________________________________________________________________________ _______________________________________ 12-1...

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