GeD Intercept Gen 2.5 Manuals

Manuals and User Guides for GeD Intercept Gen 2.5. We have 1 GeD Intercept Gen 2.5 manual available for free PDF download: User Manual

GeD Intercept Gen 2.5 User Manual

GeD Intercept Gen 2.5 User Manual (332 pages)

Frame Machine

Brand: GeD | Category: Industrial Equipment | Size: 9 MB

Table of Contents

Table of Contents
5
Chapter 1 Overview

11
- Technical Specifications
  12
- Safety Considerations
  14
- Lockout/Tagout Points
  17
- Emergency Stop Switches
  18
- Safety Labels
  18
- Maintaining the Safety Labels
  18
- Electrical and Functional Overview
  19
- Power Distribution
  19
- Power Control
  20
- PC Overview
  20
- Touch-Screen Control Station Overview
  20
- Plc
  21
- Uncoiler
  21
- Loop Control 1
  22
- Feeder Press
  22
- Loop Control 2, Proximity Switches
  23
- Rollformer
  23
- Crimper
  24
- Cutoff
  24
- Transfer Conveyor
  25
- Master Start Circuit
  25
- Emergency Stop Circuits
  25
- Start
  26
- Definitions
  26
Chapter 2 Installation

33
- Introduction
  33
- Important Notes
  34
- Preparing the Site
  34
- Positioning the Equipment
  35
- Electrical Connections
  36
- Making the Pneumatic Connections
  36
Chapter 3 Operation

37
- Switches and Controls
  38
- E-Stop Switches and Sensors
  38
- Recovering from an Emergency Stop Condition
  39
- Main Electrical Cabinet Switches and Controls
  40
- Touch-Screen Controls
  42
- Touch-Screen Main Enclosure Duplicate Controls
  43
- Touch-Screen Sidebar Controls
  44
- Feeder Press Switches and Controls
  45
- Rollformer Switches and Controls
  48
- Crimper Controls
  50
- Cutoff Switches and Controls
  51
- Transfer Conveyor Switches and Controls
  53
- Power up and Power down
  54
- Power up
  54
- Power down
  54
- The Main Screen
  55
- Pre-Operation Procedures
  56
- Pre-Operation Check List
  56
- Material Width Tables
  57
- Replacing a Coil on the Uncoiler
  61
- Threading Material through the Machine
  63
- Threading the Material through the Rollformer and Cutoff
  65
- Running Production
  67
- Material Types, Configuring for
  67
- Operation Sequence
  68
- Understanding the Production List Creator Screen
  74
- Understanding the Schedule Selector Screen
  78
- Selecting Schedules
  79
- Schedule Selector Column Definitions
  79
- How to Show or Hide Columns
  80
- Column Width Control
  80
- Searching for Schedules
  81
- Sorting the Schedule List
  81
- Filtering the Schedule List
  81
- My Favorites
  82
- Recent Files
  83
- Understanding the Production Screen
  84
- Remaking Spacers
  88
- Remaking Spacers from the User Interface Monitor
  88
- Remaking Spacers from the Extruder
  90
- Deleting Schedules
  90
- Selecting a Unit Setting
  91
- Tight Loop and Full Loop Conditions
  91
- MDI (Manual Data Input)
  93
- Creating and Running an MDI Schedule
  93
- MDI Screen Definitions
  94
- Custom Muntins in MDI
  100
- Custom Shapes in MDI
  101
Chapter 4 Setup and Adjustment

107
- Security Levels, Logging On, and Changing Passwords
  108
- Setting up Users with Security Levels
  108
- Adding Users
  108
- Deleting Users
  109
- Changing a Password
  109
- Logging on and Switching to Administrator Level
  110
- PLC Setup
  111
- Setting up the Printer
  112
- Viewing the Messages in the Print Buffer
  115
- Printing on Spacers in MDI
  116
- IG Unit Setup
  116
- Selecting a Unit Setting
  116
- Creating a New Unit Setting
  117
- Changing the Current Unit Setting
  118
- Deleting Unit Settings
  119
- IG Unit Parameters Definitions
  120
- About Undercuts
  126
- Machine Dimensions Screen
  128
- Feeder Press Dimensions Tab of Machine Dimensions Screen
  128
- Punch Offsets Tab of Machine Dimensions Screen
  129
- General Setup Screen
  131
- Remakenow Setup
  133
- Backing up the Controller Data
  134
- Loop Control 1 Setup and Adjustment
  135
- Loop Control 1 Laser Sensor Parameters
  136
- Feeder Press Setup and Adjustment
  138
- Feeder Press Overview
  139
- Pneumatics Overview
  140
- Die Set Removal - Corner, Lead, and Muntin dies
  142
- Lock-Out/Tag-Out/Block-Out
  142
- Removing die Sets
  143
- Cleaning the die Sets
  145
- Oiling the die Sets
  145
- Die Sharpness Evaluation
  146
- Die Set Installation - Corner, Leading Edge and Muntin dies
  147
- Removing die Components from Corner die Sets
  149
- Installing New Corner die Components
  151
- Die Set Removal - Hole Punch die
  152
- About Spacer Corner Fold Quality and Factors that Affect It
  155
- Checking the Corner Fold Quality
  157
- Checking the Crimps
  157
- Checking the Partially Folded Corner
  157
- Checking the Fully Folded Corner
  158
- Checking Punch Depth
  159
- Checking the Fold Force with the Fold Force Gauge
  161
- Setting Clearance of New ULTRA dies
  166
- Precharge Theory and Adjustment
  169
- Precharge Theory
  169
- Precharge Pressure Adjustment
  170
- Quick Exhausts with Flow Controls
  172
- Die Stop Caps
  173
- Die Stop Height Quick Change Feature
  174
- Quick Change Circuit Tester
  180
- Feeder Press Acme Screw Assembly Adjustment
  185
- Identifying Feeder Press Acme Screw Assembly Components
  185
- Preliminary Requirements
  186
- Acme Screw Backlash Adjustment
  187
- Seating the Acme Screws
  187
- Mounting Plate Alignment
  188
- Centering Material in Feeder Press, Roller Gib System
  191
- Aligning the Guide Rollers to the Centering Fixture
  194
- Fine Adjusting the Guide Rollers to Center the Strip
  200
- Punch Depth / die Spacer Adjustment for the Corner and Leading Edge dies
  205
- Feeder Press Width Display Calibration
  207
- Cylinder Up/Down Limit Switch Adjustment
  209
- Up Limit Switch Adjustment
  209
- Down Limit Switch Adjustment
  210
- Feed Roll Adjustment
  211
- Material Present and Material Type Sensors Adjustment
  213
- Material Color Sensor Adjustment
  214
- Width Brake Setup, Feeder Press
  215
- Crimper Setup and Adjustment
  215
- Crimper Overview and Theory
  215
- Crimp Fingers Setup
  216
- Lubricating the Crimper's Ball Screw
  220
- Cleaning and Lubricating the Crimp Finger Ways
  222
- Corner Detection Photoeye Setup
  223
- Photoeye Theory of Operation
  223
- Photoeye Setup and Adjustment
  225
- Crimper Alignment
  230
- Loop Control 2
  231
- Rollformer Setup and Adjustment
  232
- Roll Setup and Adjustment Guidelines
  232
- Roll Former Layout
  233
- Roll Clearance Specifications
  234
- Pass 7B and 8B Loadrunner to Passline Adjustment
  237
- Setting Roll Clearances to GED Defaults for ULTRA Stainless / Thinplate Material
  239
- Pass 7B Side Roll Adjustments for ULTRA Stainless / Thinplate
  239
- Pass 8 Side Roll Adjustments for ULTRA Stainless
  240
- Pass 8B Side Roll Adjustments for ULTRA Stainless
  240
- Adjusting 8B for Spacer Deformities
  240
- Adjusting 8B for Side Bow
  240
- Adjusting 8B for Twist
  241
- Adjusting 8B for Splay
  241
- Adjusting 8B for Up/Down Bow
  241
- Entry Guide Wheel Alignment and Adjustment, Rollformer
  241
- Rollformer Width Display Calibration
  244
- Roll Cleaning, Rollformer
  247
- Chain, Motor Drive, and Roll Drive - Adjustment/Replacement, Rollformer
  248
- Motor Drive Chain Tension, Rollformer
  248
- Motor Drive Chain Replacement, Rollformer
  249
- Roll Drive Chain Tension, Rollformer
  249
- Roll Drive Chain Replacement, Rollformer
  250
- Pacer Encoder, Rollformer
  250
- Width Lock Setup and Adjustment, Rollformer
  251
- Overview of Width Lock System
  251
- Setup and Adjustment Procedure
  253
- Cutoff Setup and Adjustment
  255
- Pneumatics, Cutoff
  255
- Air Pressure Limit Switch, Cutoff
  256
- Width Brake Setup, Cutoff
  256
- Die Removal, Cutoff
  258
- Swage/Crease die Removal
  258
- Die (Swage/Crease) Cleaning/Adjustment, Cutoff
  259
- Tooling Setup (Cutoff)
  260
- Die Installation, All (Cutoff)
  266
- Cutoff Width Display Calibration
  267
- Cutoff Blade Removal
  270
- Fiber Optic Photo Eye (Cutoff)
  272
- Fiber Optic PE Removal/Cleaning
  272
- Fiber Optic Photoeye Re-Installation
  275
- Photoelectric Amplifier Settings/Adjustments, Cutoff
  275
- Limit Switches, Cutoff
  277
- Up Limit Switch Adjustment, Cutoff
  277
- Down Limit Switch Adjustment, Cutoff
  277
- Transfer Conveyor Setup and Adjustment
  278
- Transfer Conveyor Adjustments
  278
- Belt Tension, Conveyor
  278
- Belt Replacement, Conveyor
  279
- Belt Tracking, Conveyor
  279
- Belt Speed, Conveyor
  279
- S/A (Semi-Automatic) Proximity Switch, Conveyor
  280
- Touch-Screen Setup
  280
- Feeder Press Touch-Screen Setup
  280
- Rollformer Touch-Screen Setup
  281
Chapter 5 Periodic Maintenance

283
- Lubrication Notes
  283
- Maintenance Schedule
  284
- Periodic Maintenance Table
  286
Chapter 6 Troubleshooting

291
- Introduction
  291
- On-Line Documentation
  292
- SDM (System Diagnostic Manager)
  292
- Troubleshooting Machine Functions
  293
- I/O Connections and Torque Wrenches
  293
- Troubleshooting Table - Machine Functions
  294
- Troubleshooting Spacer Deformities
  300
- Down-Bow (Spacer Veers Downward as It Exits Rollformer)
  301
- Up-Bow (Spacer Veers Upward as It Exits Rollformer)
  302
- Spacer Twist
  303
- Side of Spacer Wavy
  305
- Horizontal Line Along the Side of Spacer
  305
- Lip(S) of Leg Edge at Crease Bent Downward
  306
- Leading Edge of the Spacer Is Bowed or Wrinkled
  306
- Corner Fold Troubleshooting
  307
- Analyzing the Results of Corner Fold Force Measurements
  307
- Improving Your Process with the Force Gauge
  309
- Corner Fold Force Troubleshooting Table
  311
- Corner Fold Troubleshooting - Symptoms and Solutions
  314
- Maintaining the Databases
  316
- Compacting the Database
  316
- Creating a New Production Database
  316
- Deleting the Database
  316
- Restoring Controller Data
  317
- Daily Run Log
  318
- Input and Output Table
  319
- PLC Data Table
  320
- Remote Diagnostics
  321
Chapter 7 Leannet

323
- Leannet Writer Setup
  324
- Alert Messages
  325
- Index
  327

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