aik serial number - tigerstop · e1 / 2010 aik serial number -_ aik tigerstop® advanced...

E1 / 2010 AIK Serial Number ____-______________ AIK

TigerStop®

Advanced Interconnect Kit 110 / 220v August 2010 Versions 3.5 ~ 4.72 and 5.03 or higher

Control Box

Tool Control Cable

Foot Switch

IOC6-X Cable

Kill Line Kit

Power Cord

Sensor Bracket Kit

Prox Sensor Set (2)

Solenoid Valve Kit

Safety Connect Cable

Safety Switch

TS Interface Cable

CONTACT: TigerStop LLC, Assembly Plant, 12909 NE 95th St., Vancouver, WA 98682 U.S.A. Tel: 360 448-6102 ● Fax: 360 260-0755 ● Website: www.tigerstop.com ● Email: [email protected]

© 2010 TigerStop LLC

Safety First!

i

Safety First! Any automatic equipment can be dangerous if used improperly, and this includes TigerStop and its line of

automation equipment: TigerStop, TigerPro, TigerFence (standard and SLR), TigerCrossCut, TigerTurbo and HeavyDuty2, and TigerSaw.

But before you put your tape measure away and start making a TigerStop machine your newest best friend, please read and consider the following safety reminders, some of which may relate to the operation of your other power tools as well.

If a warning is also found elsewhere in this manual, or on a label affixed to the machine, the reference is shown in parentheses.

General

Warnings

WARNING: TigerStop, TigerFence, TigerCrossCut, TigerRip Fence, HeavyDuty2 and TigerTurbo are machine components intended for use in conjunction with other potentially dangerous machinery. The use of these components does not make that machinery safe. TigerStop LLC’s products are not intended to substitute, in any manner, for safety requirements in general, or in conjunction with other machinery. These components must be incorporated into machinery by persons qualified to design safety features to make the machine as safe as possible and to ensure that it meets federal, state and local law with respect to safety and all other regulatory requirements. In addition, TigerStop, TigerStop Heavy Duty 2 (HD2) and TigerTurbo are machine components that should only be operated by qualified persons trained in safe operating procedures. Illustrations of TigerStop, TigerStop Heavy Duty 2 (HD2) and TigerTurbo components in use do not show, and are not intended to show, safety features necessary to make the machinery safe to operate. (Label covering end cap of fence extrusions)

Installation Warnings

WARNING: TigerStop (TigerFence SLR, TigerFence, TigerCrossCut, TigerTurbo, HeavyDuty2) must be installed in accordance with all local, state, and federal regulations, as well as common sense safety requirements. Use only trained professionals when installing TigerStop machines with existing equipment to ensure a safe and proper work station that will in no way endanger the operator or any other personnel. Do not operate without proper training, both in TigerStop operation, and in the operation of adjoining equipment. (Installation Guides of: TigerStop, TigerFence, TigerFence SLR, TigerCrossCut, TigerTurbo, HD2) FOUR IMPORTANT CAUTIONS: 1. Do not randomly drill and tap holes in the TigerStop fence beam for mounting or for any other purpose. This might damage the drive system. All fastening or attachment to the fence beam MUST be made by inserting T-bolts or T-nuts WITH washers! 2. It is CRITICAL — especially if NOT using TigerStop attachment brackets (BR3x3) — that if T-nuts are used, the bolts are prevented from tightening through them and into the aluminum fence beam. Again, it is imperative that washers be used! 3. Uneven tightening of the bolts used to fasten down TigerStop to its mounting support can introduce a slight twist or other deformation in the beam. This will result in inaccurate measurement and premature failure of the drive belt or other components. 4. The motor box (compartment) contains DC voltage with potentially FATAL amperage. NEVER attempt any unauthorized actions inside the motor box! (linked from TigerStop Installation, Feed Table Installation, Ledge Stand) CAUTION: NEVER drill holes into the HD2 fence beam for any reason! (HD2 Installation) CAUTION: NEVER drill holes into the TigerTurbo fence beam for any reason! (TigerTurbo Installation) CAUTION: Washers MUST be used to prevent damage to the fence beam by over-tightening! (Mounting TigerStop to a Feed Table)

Interconnects

WARNING: Using a TigerStop interconnect does not relieve you of the responsibility for making sure that your saw or other tool has all the necessary safety equipment in place. (Standard Interconnect Kit, Advanced Interconnect Kit)

Operation

DANGER: This machine can start, move, and stop automatically. Keep hands and loose clothing clear of moving parts while operating. Moving parts can crush and cut. When used with saws or other cutting equipment, bodily injury and death may result if operated without safety guards on all machines. Do not operate with guards removed. Operators must wear adequate eye and ear protection. High voltage DANGER—Do not open motor compartment or controller keypad. No user-serviceable parts inside. (TigerStop Quick Reference Card, ALSO label of motor end plate or amplifier cover)

TigerStop Manual

ii

DANGER! CAUTION! Keep hands and loose clothing clear of moving parts while operating. Moving parts can crush and cut. To comply with ANSI Safety Standard B11-19 paragraph 4.2.1,“The user shall be responsible for ensuring that safeguarding is provided, integrated, installed, maintained and used in accordance with the requirements of this standard.” When used with saws or other cutting equipment, bodily injury and death may result if operated without safety guards on all machines. Do not operate with guards removed. Keep the work area clean and well-lit to avoid accidental injury. Do not use TigerStop in a dangerous environment. Using power tools in wet locations or in rain can cause shock or electrocution! Do not operate near flammable liquids or in gaseous or explosive atmospheres! Wear proper apparel, no loose clothes or jewelry which could get pulled into moving machinery or materials. Wear non-slip footwear, safety glasses, ear protection, and a dust mask. Do NOT operate this machine under the influence of drugs or alcohol! POWER: Use only 3-wire extension cords, 3-prong grounded plugs and 3-pole receptacles. No one should operate this machine except fully qualified personnel. Read the TigerStop Manual for complete instructions. HIGH VOLTAGE DANGER: Do not open motor compartment or controller keypad. DC voltage with potentially FATAL amperage! Disconnect power before servicing. (Label covering motor box or amplifier end cap) CAUTION: The springs are loaded! Do not loosen the clamp at the back end of the buffer tubes without taking precautions. Sudden release of spring tension could result in bodily injury. (Spring Buffer Heavy Duty)

IMPORTANT CAUTIONS - READ AND UNDERSTAND BEFORE OPERATING TIGERSTOP MACHINES!

DANGER! Don't get pinched by the push feeder. Keep your hands away when in motion!

Keep the work area clean and well lit to avoid accidental injury.

Do not use TigerStop machines in a dangerous environment. Using power tools in damp or wet locations or in rain can cause shock or electrocution!

Do not operate near flammable liquids or in gaseous or explosive atmospheres!

Wear proper apparel, no loose clothes or jewelry which could get pulled into moving machinery or materials.

Wear non-slip footwear, safety glasses, ear protection, and a dust mask.

Use only 3-wire extension cords that have 3-prong grounding-type plugs and 3-pole receptacles that accept the tool’s plug. Do NOT operate this or any machine under the influence of drugs or alcohol!

Do not open motor compartment or controller keypad. DC voltage with potentially FATAL amperage! Disconnect power before servicing.

No one should operate this machine except fully qualified personnel. Read the Manual!

© 2010 TigerStop LLC. All rights reserved.

ii

Table of Contents AIK Installation Guide Overview 110/220v....................................................................................3 AIK Model Comparison.................................................................................................................4

Major differences between Model 3 and previous Model 2....................................................4 Advanced Interconnect Kit............................................................................................................5 The Basic Advanced Interconnect 110/220v ................................................................................6

Proximity Sensors..................................................................................................................6 Pneumatic Solenoid...............................................................................................................7 Kill Line & Safety Switch........................................................................................................7 Foot Switch............................................................................................................................8

Advanced Interconnect Components 110/220v ............................................................................9 AIK Subassembly: Kill Line Kit — Part # SB3901..................................................................9 AIK Subassembly: Pneumatic Kit — Part # SB3903 ...........................................................10 AIK Subassembly: Proximity Sensor Bracket Kit — Part # SB3902 ....................................10

AIK Installation 110/220v ............................................................................................................11 Safety Warnings ..................................................................................................................11 Installation Procedures ........................................................................................................11

Control Box Hookups 110/220v ..................................................................................................12 Cable Connections Closeup ................................................................................................13

Install the Safety Switch and Kill Line 110/220v .........................................................................14 Install Safety Connect Cable 110/220v.......................................................................................16 Install the Proximity Sensors 110/220v.......................................................................................17

Install M0334 / 335 Prox Sensor Bracket ............................................................................18 Install M0337 / 338 Prox Sensor Bracket ............................................................................19

Install the Foot Switch 110/220v.................................................................................................20 Install the Pneumatics 110/220v.................................................................................................21

Tools Using Pneumatic Activation to Cycle (Cable U5953) .................................................21 Tools Using Electronic Activation to Cycle ..........................................................................22

Install the Control Box 110/220v.................................................................................................23 Hook Up the Cables, Setup and Test 110/220v..........................................................................24

Hook up all the cables to the control box.............................................................................24 Electronics Troubleshooting .......................................................................................................27

Eliminating System Noise....................................................................................................27 Installing a Snubber.............................................................................................................27

Run Tool Interconnect Type .......................................................................................................29 Run Auto Detect .........................................................................................................................30 AIK Maintenance Schedule ........................................................................................................32

Daily ....................................................................................................................................32 Weekly.................................................................................................................................32

3

AIK Installation Guide Overview 110/220v 1

What is the Advanced Interconnect? Advanced Interconnect Kit

2 How does the Advanced Interconnect work?

The Basic AIK Proximity Sensors Pneumatic Solenoid Kill Line & Safety Switch Foot Switch

3 What's included in the Advanced Interconnect?

Advanced Interconnect Components Kill Line Kit Pneumatic Kit Prox Sensor Bracket Kit

4 How do you install the Advanced Interconnect?

AIK Installation Install the Safety Switch and Kill Line

Install Safety Connect Cable Install the Proximity Sensors Install the Foot Switch Install the Pneumatics Install the Control Box

Hook Up the Cables, Setup and Test

5 How does TigerStop set up for the Advanced Interconnect?

Run Tool Interface Type Run Auto-Detect

Run Auto Detect Versions 4.2 to 4.7 Run Auto Detect Versions 3.5 to 4.1

6 What about maintenance?

AIK Maintenance Schedule

Electronics Troubleshooting Driving Inductive Loads

Advanced Interconnect 110/220v Guide

4

AIK Advanced Interconnect ENABLE CODE Call TigerStop Customer Service for your Enable Code, (360) 448-6102 Mon-Fri 6am~4pm PST. There are two ways to enable your AIK. Be sure to specify your AIK as either…

Standard AIK…………Full-Auto* AIK *Full-Auto is a tool interconnect mode in which the tool cycles automatically in conjunction with TigerStop movement, usually

triggered by the use of a foot pedal. Full-Auto requires the use of comprehensive safety guards on all equipment.

AIK Model Comparison Advanced Interconnect AIK Model 3, 110/220v, was introduced in August, 2010, superceding the AIK Model 2, 110v. Model 3 can be used with either 110v or 220v power (also other local voltages, rated up to 250v).

Major differences between Model 3 and previous Model 2 The increase in number of leads in the safety connection cable from 4 to 6, and in the kill

line e-stop cable from 2 to 4, is to provide double protection when the equipment is shut down due to a hazardous condition.

Double fuses on the incoming power is also for increased protection.

Model 3 - 110/220v Model 2 - 110v

5

Advanced Interconnect Kit Description and Use The Advanced Interconnect is intended to facilitate precise control and coordination of movement between TigerStop and a saw or other tool.

The Advanced Interconnect is a kit consisting of a control box, foot switch, kill line and safety switch, proximity sensors, brackets and cables (Fig. 1). Each of these components is pictured and described in more detail in this guide.

Fig. 1 There are currently two models of the AIK in use.

Model 2 - 110v - Can be connected only to 110v power. Model 3 - 110/220v - Can be connected to 110v or 220v power.

What the AIK does

The Advanced Interconnect… Controls the movement of your saw and other machine tools. Prevents movement of material when the tool is not in the safe position. Prevents the movement of the tool when TigerStop is in motion. Efficiently starts and stops the tool’s action, enhancing its performance by controlling

the supply of air to the tool using the air control solenoid. With proper safety guards on your saw or other machine tool, can be configured for full

automation of your TigerStop work station.

What the AIK does not do

Using a TigerStop Advanced Interconnect does not relieve you of the responsibility of ensuring that your saw or other tool has all the necessary safety equipment in place.

6

The Basic Advanced Interconnect 110/220v Primary functions and operational components

The Advanced Interconnect performs these primary functions, each by means of a set of operational components.

1. Proximity Sensors detect the motion of the saw arbor or other machine tool movement. 2. Pneumatic Solenoid coordinates the motion of the tool with TigerStop movement, to

prevent both from activating at the same time. 3. Kill Line and Safety Switch enable quick shut down of power to the work station to

avoid accidental injury or damage to the equipment. 4. Foot Switch is used instead of pressing the START button on the TigerStop controller.

Proximity Sensors

When used with your TigerStop and saw or other machine tool, the Advanced Interconnect makes possible high speed production, by means of two proximity sensors (Fig. 2).

For example, in an up-cut saw application the sensors are used to detect saw arbor position. The position of the upper proximity sensor is adjusted so it detects the machine arbor only after the machine blade has completed its upward motion through the material to be cut. The arbor is then immediately allowed to fall back down to the resting position. This results in faster production compared to the typical machine where cut duration is based on a fixed time delay usually much longer than necessary.

Fig. 2 Proximity Sensors on up-cut

saw

When installing the Advanced Interconnect on machines other than up-cut saws remember…

1. The sensor connected to the control box as “Top Arbor Sensor”, Bit 4 (Fig. 3, upper input), is mounted so that it is active when the tool (machine, drill, etc.) is in the machining position. On some tools, the machining position is below the resting position! In such a case, the Top Arbor Sensor is mounted below the DM Sensor! The cable is still plugged into the port marked "Top Arbor Sensor."

2. The sensor connected to the control box as “DM Sensor", Bit 2 (Fig. 3, lower input) is mounted so that it is active when the tool is in the resting (parked) position. On some tools, the resting position is above the machining position! In such a case, the DM Sensor is mounted above the Top Arbor Sensor! The cable is still plugged into the port marked "DM Sensor."

Fig. 3 Top Arbor Sensor

DM Sensor

For example, if a drilling operation is being performed, the Top Arbor Sensor should sense the drill chuck when it is in the extended (drilling) position and the DM Sensor should sense the chuck when it is in the retracted (non-drilling) position.

The proximity sensors are metal-sensing and are more sensitive to steel than aluminum.

The Basic Advanced Interconnect

7

They have a red or yellow LED at the rear of the sensor that lights when the sensor has detected a metal target.

Pneumatic Solenoid

A 24VDC pneumatic solenoid provides operator safety (Fig. 4).

For example, in an up-cut saw application… 1. TigerStop pushes the raw material into

position. 2. The solenoid is energized and air passes

through the solenoid to the main air cylinder (Fig. 4, AIR OUT #2), pushing the saw arbor upward.

3. The solenoid remains energized until the machine blade cuts through the material and the saw arbor position is detected by the Top Arbor Sensor.

4. The solenoid is then de-energized (Fig. 4, AIR OUT #1), the arbor falls back into resting position and is detected by the DM Sensor.

5. When the DM Sensor is active the TigerStop is allowed to move again.

Fig. 4

IMPORTANT CONCEPTS!

DM = "Dead Man" DM sensor ACTIVE = SAFE for TigerStop to move

Kill Line & Safety Switch

For safety reasons, regardless of the specific type of machine tool that the Advanced Interconnect is installed on, there must be a way to immediately cut power to the tool in an emergency. To accomplish this, the provided kill line and safety switch must be installed. There are currently two types of safety switches (Figs. 5a and 5b). See AIK Install Kill Line and Safety Switch for tensioning instructions.

1. Typically, the kill line is run along the entire length of the infeed table and down to the machine tool.

2. The safety switch has electrical contacts that are closed after the kill line is tensioned and the blue reset button pushed. If the operator applies pressure to the kill line, both contacts open up, immediately cutting power to TigerStop.

3. If either the kill line or the safety switch is opened, both the kill line and the safety switch must be reset in order to operate the tool.


8

Fig. 5a - Kill Line and Safety Switch

Fig. 5b - Alternate Safety Switch (as available)

Foot Switch From inside a part list

There are two models of foot switch. Both function the same way. The foot switch…

Can be used instead of pressing the START button on the TigerStop controller.

Can be used to pause or resume processing of a part list.

Fig. 6a

Type 1 foot switch

Fig. 6b

Type 2 foot switch

Used with Tiger Optimizer

When the foot switch is initially depressed, the TigerStop Optimizer (if enabled) will compute its solution. The foot switch must be depressed again to begin movement, OR simply hold the foot switch down until the TigerStop moves.

Outside of a part list

The foot switch… Can be used to manually cycle the tool.

The foot switch must be held down until the TA proximity sensor is triggered. Otherwise, the saw will not complete its cycle.

9

Advanced Interconnect Components 110/220v

Part Quantity 1. Foot switch 2. Control box with mounting clips 3. Kill line kit 4. Pneumatic kit 5. Proximity sensor bracket kit 6. Proximity sensor switch with connector 7. Safety switch 8. Safety connect cable 9. AIK-to-TigerStop cable 10. AIK control connect cable 11. AIK-to-TigerStop power cord

1 1 1 1 1 2 1 1 1 1 1

AIK Subassembly: Kill Line Kit — Part # SB3901

Part Part # Qty Tools Used 1. Kill line cable, 26' 2. Kill line bracket 3. Socket cap screw, 10-32 x 1½"4. Hex head bolt, 3/8-16 x 1" 5. Nut, 3/8 UNC 6. Washer, 3/8 7. Eye bolt, 1/4-20 x 3" 8. U-bolt cable clamp 9. Cable thimble

MS7901 M0030-1

F1394 F0110 F0415 F1677 F0120

MS7903 MS7902

1 1 2 3 3 3 5 2 2

Wire cutter -

3/16" hex, 5/32" drill, 10-32 tap 9/16" wrench 9/16" wrench

- 7/16" wrench Phillips driver

Needle nose pliers


10

AIK Subassembly: Pneumatic Kit — Part # SB3903

Part Part # Qty Tool Used 1. Solenoid valve 2. Fitting, 5mm > 1/4" tubing 3. Muffler, 5mm 4. Elbow fitting, 5mm > 4mm tubing 5. Elbow fitting, 5mm > 6mm tubing 6. Fitting plug 7. Hex wrench, 2.5mm 8. Connector/cable assembly 2p DC

A0107A0226A0201A0232A0229A0250T2100J0680

1 3 2 3 2 1 1 1

- 2.5mm hex

- 7mm wrench 7mm wrench

- -

AIK Subassembly: Proximity Sensor Bracket Kit — Part # SB3902

Part Part # Qty Tools Used 1. AIK sensor support bracket 2. AIK prox sensor ring 3. Handle, plastic ratchet 4. Socket cap screw, 1/4-20 x 1/2"5. Washer, 1/4" 6. Hex head bolt, 1/4-20 x 1½"

M0335-1M0334-1

F2190 F1565 F1655 F1280

1 2 2 2 2 2

- - -

1/8" hex, 13/64" drill, 1/4-20 #7 tap -

3/16" hex

11

AIK Installation 110/220v Safety Warnings ALWAYS disconnect BOTH TigerStop AND the saw or other tool from the AC power line BEFORE starting installation of the Advanced Interconnect!

There are no user serviceable parts inside the Advanced Interconnect Control Box U5950. TigerStop must be installed in accordance with all local, state, and federal regulations, as well as common sense safety requirements. Use only trained professionals when installing TigerStop with existing equipment to ensure a safe and proper work station that will in no way endanger the operator or any other personnel. Do not operate TigerStop without proper training, both in TigerStop operation, and in the operation of adjoining equipment.

Installation Procedures Installation of the Advanced Interconnect can be broken down into 7 steps:

1 Install Kill Line and Safety Switch 2 Install Safety Connect Cable 3 Install the Proximity Sensors 4 Install the Foot Switch 5 Install the Pneumatics 6 Install the Control Box 7 Hook Up the Cables, Set Up and Test

7 An optional step is to set up the interface type.

Use one of the methods below: Run Tool Interface Type to manually select the tool interconnect type. Run Auto Detect to set your tool interface type automatically.

8 To set interface type if you are retrofitting an AIK to TigerStop version 4.7 or older:

Run Auto Detect Versions 4.2 to 4.7 Run Auto Detect Versions 3.5 to 4.1

12

Control Box Hookups 110/220v

Control box connections plan view

Every receptacle is clearly marked to help you find the right one for every cable.

Side view, connections 1 - 5

Side view, connection 6


Cable Plug Type Other End 1. Top arbor sensor 4-pin Top arbor proximity sensor

2. DM Safe sensor 4-pin Bottom arbor (DM) proximity sensor

3. AIK control connect cable 6-pin Brown & blue wires to solenoid valve

4. Safety connect cable 6-pin Variable, depending on tool's E-stop or lack of it

5. Safety switch 4-pin Safety switch to kill line

6. Foot switch 3-pin Foot switch

7. AIK-to-TS cable 8-pin TigerStop 6-pin receptacle

8. AIK-to-TS power cord female TigerStop power cord receptacle

9. Power cord (incl. with TS) male Power source (110v 15a grounded)

AIK Install Proximity Sensors

13

Cable Connections Closeup

. 1. Top Arbor Sensor U5952

. 2. DM Safe Sensor U5952

. 3. Control Connect Cable U5953

. 4. Safety Connect Cable U5954

. 5. Safety Switch U5956

. 6. Foot Switch U5951

. 7. AIK-to-TS Cable U5955

. 8. AIK-to-TS Power Cord J0209

. 9. TigerStop Power Cord J0206

Every cable has a unique pin configuration* and cannot be plugged into the wrong receptacle.

*There are 2 sensor cables, however, that must be plugged in correctly, one for the TA sensor, the other for the DM. Pay close attention to which is which.


14

Install the Safety Switch and Kill Line 110/220v Mount the safety switch U5956

The kill line safety switch is bolted to the feed table or other support structure at the end closest to the machine. There are four holes in the safety switch. It is necessary to use only two of them. One hole of each pair is slotted, for adjustability. The hand tools needed for the following procedures are not provided by TigerStop. These instructions are for installation, using TigerStop feed tables. The use of other feed tables may require you to modify these procedures.

You will need: center punch power drill 5/32" drill bit tap driver 10-32 tap

Fig. 1

Fig. 2

Fig. 3

1. With a punch, mark the locations of two holes 1.18" (30mm) apart on center, in the edge of the feed table at the end closest to the saw or other tool (Fig. 1).

2. With a power drill and a 5/32" drill bit, bore two holes at the punch marks (Fig 2). 3. With a tap driver and 10-32 tap, tap both holes (Fig. 3).

You will need: U5956 switch F1394 screws (2) 3/16" hex key MS7902 thimble needle nose pliers

Fig. 4

Fig. 5

Fig. 6

4. Mount the U5956 safety switch, using (2) F1394 screws and a 3/16" hex key (Fig. 4). 5. Remove the small cable thimble that is attached to the switch, using a pair of needle

nose pliers or other tool (Fig. 5). 6. Replace it with one of the MS7902 cable thimbles (Fig. 6). Leave the tines of the thimble

spread slightly apart.

You will need: M0030-1 bracket F0110 bolts (3) F1677 washers (3) F0415 nuts (3) 9/16" wrench

Fig. 7

Fig. 8

Fig. 9


15

Mount the kill line bracket M0030-1 7. Attach the kill line bracket M0030-1 to the far end of the feed table system, using (3)

F0110 bolts, (3) F1677 washers, (3) F0415 nuts, and a 9/16" open end wrench. The three holes in the bracket match the three slotted holes in TigerStop feed tables (Figs. 7, 8, 9). Tighten the bolts firmly. If you are not using TigerStop feed tables, mount the kill line bracket at the far end of your feed table or other structure.

You will need: F0120 eye bolts (2+) 7/16" wrench MS7902 thimble needle nose pliers

Fig. 10

Fig. 11

Fig. 12

Add eye bolts F0120 to the kill line bracket and feed table edge 8. Add an eyebolt F0120 to the kill line bracket, making sure that there is a washer on each

side of the bracket flange (arrows, Fig. 10). Do not tighten firmly. This eyebolt is used to tension the kill line.

9. Add as many eye bolts to the feed table edge as necessary. There are a total of (5) eye bolts in the kit. Use the center hole on the table edge to attach the eye bolts. Tighten the eye bolts on the table edge firmly, and in the orientation shown (Fig. 11).

10. Add one of the MS7902 cable thimbles to the eye bolt in the kill line bracket (Fig. 12). Leave the tines of the thimble spread slightly apart.

You will need: MS7901 cable MS7903 clamps (2) Phillips head driver Wire cutters

Fig. 13

Fig. 14

Fig. 15

Fig. 16

Fig. 17


16

Add the kill line and tension it

11. Run one end of the kill line cable over and around the cable thimble MS7902 at the kill line bracket M0030-1. Slip a cable clamp MS7903 around it and tighten down firmly, using a Phillips head screw driver (Fig. 13).

Fig. 18 - Type 2 safety switch

12. Perform the same procedure with the other end of the cable at the safety switch. Cut off the excess cable, using wire cutters (Fig. 14).

13. Tension the kill line by adjusting the eye bolt in the kill line bracket. Loosen the nut on the cable side of the bracket and tighten the nut on the far side of the bracket, to cinch the kill line tighter. When the kill line is properly tensioned, the black tab will fall within the green band on the switch (Fig. 15, type 1 switch), or the arrow in the tensioning window will be aligned with the indicator line (Figs. 16, 17, 18, type 2 switch), and the blue button can be pushed IN. If it is not, the system will not work.

14. Be sure that all bolts are now tightened firmly. Any tensioning correction must always be done by adjusting the eye bolt in the kill line bracket M0030-1.

Install Safety Connect Cable 110/220v


17

It is strongly recommended that a qualified electrician perform the final setup and test.

The wiring diagram shows how the Safety Connections cable from the control box is wired in the safety chain of the customer's machine or tool. This may require an additional set of contacts to be installed.

Install the Proximity Sensors 110/220v Proximity sensor mounting brackets, adjustable M0334/335 type, fixed M0337/338 type There are two different bracket sets for mounting the proximity sensors. Fixed type has been discontinued.

M0334 / 335

Fig. 1

Inside an up-cut saw

M0334 / 335

Fig. 2

Inside a press

M0337 / 338

Fig. 3

On a cold saw

U5952

Fig. 4

Proximity sensor

The M0334 / 335 type is yellow and has (2) prox sensor rings M0334-1 that are adjustable by sliding them along a slot in the bracket M0335-1 (Fig. 1). The rings can also be mounted flange forward or back (arrows, Fig. 2) for more adjustment. This type requires the drilling and tapping of two holes to secure the bracket to your saw or other tool.

The M0337 / 338 type is red and has a mounting bracket with two openings for the prox sensors at a fixed distance from each other, along with a mounting plate used to clamp the bracket around an internal support within the tool (Fig. 3).

Use the set that best fits your application.

Proximity sensor basics Circuit Status Up-cut saw Press Cold saw

Top arbor sensor Tool actuated Upper sensor Lower sensor Lower sensorDM "safe" sensor Tool at rest Lower sensor Upper sensor Upper sensor

Fig. 5

There are two proximity sensors U5952 (Fig. 4). The purpose of the proximity sensors is to monitor the movement of a tool. This is usually a saw arbor, but it can also be any moving part


18

of a machine tool. For this reason, it's important to understand that the relative position of the two sensors is not an absolute (Fig. 5), in spite of the designation "top arbor."

The Advanced Interconnect was designed with an up-cut saw in mind, where "arbor UP" indicates saw actuated. Such tools like a press or a cold saw, the examples used in this guide, are actuated with "arbor DOWN".

The sensors have yellow LED light emitting diodes that light up (Fig. 6) when the tool arbor is within active sensing range.

CAUTION!

When installing the proximity sensor bracket, to avoid interference with the tool arbor, make sure that both sensors are initially backed off in their movable brackets.

Fig. 6

Install M0334 / 335 Prox Sensor Bracket Mount the sensor support bracket and sensor rings

You will need: center punch power drill 13/64" drill bit tap driver 1/4-20 #7 tap M0335-1 bracket M0334-1 sensor rings (2) F1565 bolts (2) F1655 washers (2) 1/8" hex key

Fig. 7

Fig. 8

Fig. 9

1. Determine a safe and practical location to mount the sensor support bracket M0335-1. With a punch, mark the locations of two holes through the slots in its base.

2. With a power drill and a 13/64" drill bit, bore two holes at the punch marks. 3. With a tap driver and 1/4-20 #7 tap, tap both holes. 4. Mount the bracket, using (2) F1565 bolts, (2) F1655 washers and a 1/8" hex key (Figs. 7,

8). 5. Roughly position the (2) prox sensor rings M0334-1 in the slot of the support bracket (Fig.

9) and hand-tighten them with plastic ratchet handles F2190.

Add the proximity sensors U5952 and position them

You will need: U5952 sensors (2)

Fig. 10

Fig. 11

Fig. 12

In this example, the tool is a press, and is in the resting (not actuated) state when it is raised.


19

Thus, the DM "safe" sensor is mounted as the upper sensor to detect the arbor when it is raised (arrow, Fig. 11). The "top arbor" sensor is mounted as the lower sensor to detect the arbor when it is down (arrow, Fig. 12).

6. The proximity sensors are threaded and secured inside the sensor rings by means of (2) large hex nuts. Back them off as far as necessary to avoid physical contact with any moving part of the tool (Fig. 10).

7. Check the positions of both proximity sensors, ensuring that the LED lights up when the tool arbor is next to them (arrows, Figs. 11, 12). If they do not, the sensors may be too far from the arbor. Adjust both sensors so they light up when the arbor is next to them, and firmly tighten them down.

Install M0337 / 338 Prox Sensor Bracket

You will need: M0338 bracket M0337 mounting plate F1280 bolts (2) 3/16" hex key

Fig. 13

Fig. 14

Fig. 15

1. If there is a tool component next to the saw arbor or other moving part that can be used to anchor the prox sensor bracket M0338 using the mounting plate M0337, position the bracket and plate, using the (2) F1280 bolts and 3/16" hex key. The mounting plate is threaded.

2. The proximity sensors are threaded and secured in holes in the bracket by means of (2) large hex nuts. Back them off as far as necessary to avoid physical contact with any moving part of the tool (Fig. 14).

3. Check the positions of both proximity sensors, ensuring that the LED lights up when the tool arbor is next to them (Fig. 13). If they do not, the sensors may be too far away. Adjust both sensors so they light up when the arbor is next to them, and firmly tighten them down.

Verify which sensor is the DM and which the "top arbor" (Figs. 14, 15)

When installing proximity sensors, it is crucial to know which sensor will be functioning as the "top arbor" sensor, and which will be used as the "DM" sensor.

The sensor that detects the tool when it is at rest will always be the DM sensor. The sensor that detects the tool when it is activated (saw cutting, drill press boring, punch

press punching, etc.) will always be the "top arbor."

20

Install the Foot Switch 110/220v The foot switch supplied with the Advanced Interconnect Kit will replace the foot switch, double palm switches or other activation device on your tool. There are two types of foot switch, but both are connected and function in the the same way. Type 1 is illustrated below.

Fig. 1

Typical tool pneumatic foot switch

Fig. 2 AIK foot switch

U5951

If the example foot switch (Fig. 1) were being eliminated by installing an AIK, the AIR IN line would be disconnected from the foot switch and be reconnected to the AIK solenoid as shown (Fig. 3).

The two AIR OUT lines would be disconnected, being replaced by the AIR OUT lines between the AIK solenoid and the tool's pneumatic cylinder (represented by a pneumatic cylinder, Fig. 3). The pneumatic cylinder is the part of the tool which causes it to cycle.

Fig. 3 - Pneumatic setup

Type 2 Foot Switch

Fig. 4 - Type 2 Foot Switch

Type 2 foot switch is also used with the AIK Advanced Interlock. The only difference is the shape of the device housing.

21

Install the Pneumatics 110/220v If your machine uses pneumatic activation to cycle, you will need to utilize the AIK pneumatic kit. Tools Using Pneumatic Activation to Cycle (Cable U5953)

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Select the appropriate pneumatic fittings

Identify the tubing size that is used on your machine and select the appropriate size fitting. There are three different size fittings, items 2, 4 and 5 (Fig. 5).

Assemble the fittings and mufflers

The mufflers (item #3, Fig. 6) screw into the solenoid as shown (Fig. 3).

The pneumatic fittings screw into the remaining holes, as shown in one of two configurations:

No Pilot Valve type (Fig. 1), or Pilot Valve type (Fig. 3).

Connect the air lines

No Pilot Valve If the solenoid valve will directly control the air cylinder, assemble it with the appropriate fittings as shown in Fig. 1.

1. Air intake line feeds into the bottom fitting between the mufflers (Fig. 1; line "c", Fig. 2). 2. Connect the two (2) outflow lines (lines "d" and "e", Fig. 2) to the pneumatic cylinder used

to cycle your tool (lines #2 and #1, Fig. 7)


22

Fig. 7 - Pneumatic setup (no pilot valve)

Pilot Valve The air flow of a typical pilot valve is similar to that of the solenoid valve. Compare the air flow maps of the solenoid valve (Fig. 2) and a pilot valve (Fig. 5). Air Intake (C) and Air Outflow (D, E) are analogous.

If your tool utilizes a pilot valve, assemble the solenoid valve with one fitting plugged (item 6, part # A0250) as shown in Fig. 3.

1. Run an air line from the pilot valve air intake (line "a", Fig. 5) to the intake fitting on the solenoid valve (fitting "a", Fig. 4).

2. Run an air line from the pilot valve outflow (line "b", Fig. 5) to the outflow fitting on the solenoid valve (fitting "b", Fig. 4).

The pilot valve in actual use in your application may be different from the example shown, but it will operate in the same way. Locate or divert inflow and outflow connections on your pilot valve to correspond to the example, and plug them into the solenoid valve.

Wire in the solenoid to the Control Connect Cable

1. Locate the control connection cable (AIK Components, item 10, part # U5953). It has a 6 pin connector at one end and flying leads at the other. See also AIK Control Box Hookups.

2. The blue [3] and brown [5] wires from the cable (Fig. 8) should be connected to the red and black wires on the solenoid. See also Control Connection cable.

3. Snip and protect the remaining four wires [1, 2, 4, 6] with electrical tape. They will not be used.

Fig. 8

Tools Using Electronic Activation to Cycle

When installing the AIK for use with a tool that is activated electronically instead of pneumatically, the pneumatic components of the interconnect are not used.

The Control Connect Cable (U5953) is wired into the external device, most likely a relay solenoid.

1. The black [4] and gray [6] wires from the cable (Fig. 8) should be connected to the external device.

2. Snip and protect the remaining four wires [1, 2, 3, 5] with electrical tape. They will not be used.

23

Install the Control Box 110/220v The control box U5950 is the "brains" of the Advanced Interconnect. Install the control box in a location…

Where ALL the cables will be able to reach to be plugged in Where you can easily access the reset button (Fig. 1) Where it will not be at risk of being impacted by materials and

damaged Where it is away from contaminants, especially liquids

Fig. 1 - Reset

button

Add the mounting feet

The mounting feet are packaged with (4) screws. They are used to interface with any surface to which the control box will be attached.

You will need: U5950 control box mounting feet (4) mounting screws (4) Phillips head driver

Fig. 2 - Control box Fitting and flange

Fig. 3 - Mounting feet

and screws

Fig. 4 - Control box

Foot attached

1. Lay the control box on its side with the bottom facing you. Locate the four brass fittings at the corners (arrow, Fig. 2).

2. There are four plastic feet and four screws (Fig. 3) in a plastic bag. The feet have a flat side with one countersunk hole and one slotted hole (Fig. 3). The other side of the feet has a raised flange (arrows, Fig. 1). Attach the four feet as shown with the flange resting on the perimeter of the control box (arrows, Fig. 4).

You may need: center punch power drill drill bit tap driver tap screws

Mount the control box to the tool

The control box can be mounted in any position, as long as its location meets the four criteria listed above at the bullet points.

NEVER leave it just lying on the floor!

3. Mark the location of the slotted holes which will be used to mount the control box. 4. Drill and tap holes in the surface to which the control box will be mounted. 5. Securely mount the control box with adequate fasteners, not provided.

24

Hook Up the Cables, Setup and Test 110/220v Hook up all the cables to the control box Every cable plugs in to a receptacle that is clearly labeled. There can be no mistake plugging in the cables because the number of pins or their configuration pattern is different on every plug, with one exception—there are (2) prox sensor cables U5952, one labeled "top arbor sensor", the other "DM sensor." See Proximity Sensor Basics for an explanation of how to distinguish the two sensor functions.

Control box connections plan view

Every receptacle is clearly marked to help you find the right one for every cable.


Side view, connection 6


Cable Plug Type Other End 1. Top arbor sensor 4-pin Top arbor proximity sensor

2. DM Safe sensor 4-pin Bottom arbor (DM) proximity sensor

3. AIK control connect cable 6-pin Brown & blue wires to solenoid valve

4. Safety connect cable 6-pin Variable, depending on tool's E-stop or lack of it

5. Safety switch 4-pin Safety switch to kill line

6. Foot switch 3-pin Foot switch

7. AIK-to-TS cable 8-pin TigerStop 6-pin receptacle

8. AIK-to-TS power cord female TigerStop power cord receptacle

9. Power cord (incl. with TS) male Power source (110v 15a grounded)

AIK Hook Up the Cables, Setup and Test

25

Hooking up the cables to the control box is easy!

Except for the two power cables (8) and (9), the cables all plug into their receptacles, and then are secured by means of a threaded collar that must be tightened to prevent a cable from falling out.

1. Plug the cables into the control box as shown in the picture above. 2. The power cord that shipped with your TigerStop should be unplugged from the motor

box and replaced with the power cord supplied with the AIK. One end of this power cord (J0209) plugs into the control box at [8] and the other end plugs into the TigerStop. TigerStop is powered through the control box.

3. Plug the power cord that shipped with your TigerStop into the control box at [9]. This device has the following electrical specifications.

AC Input voltage / frequency: 100-240 VAC / 50-60 Hz. AC Output voltage / Frequency: 100-240 VAC / 50-60 Hz. Internal voltage: 24 VDC. Internal Fuse: 250V, 8A, Slow blow.

The parameters are set at the factory when an interconnect is ordered with a new TigerStop. If the interconnect is an upgrade to an existing machine, run Auto-Detect!

4. With AC power and air pressure applied to the machine, home the TigerStop. 5. Activate a cut list and depress the foot switch. The machine tool will travel its cycle until

the upper proximity sensor is active, and then the tool will return to its safe position. 6. The position of the upper proximity sensor must now be adjusted to be appropriate for the

thickness of the material being cut. If the machine arbor passes by the upper proximity sensor without the LED lighting up, the sensor face must be repositioned closer to the machine arbor. Be sure to firmly tighten the 30mm sensor nuts when the correct position has been located.

7. Test the kill line switch by pulling the kill line, and observe the TigerStop controller screen. It should go blank and the machine motor should stop if the installation has been completed successfully. Repeat this test using the machine's E-Stop button, the same result should occur.


26

Safety Note

Connections S21 and S22 are powered through the safety relay and must be electrically isolated from the machine's E-Stop circuit.

27

Electronics Troubleshooting Eliminating System Noise

When using a TigerStop interconnect kit (AIK or SIK), problems may develop from system noise causing unexpected behaviors by the TigerStop machine.

Problem

Solenoids attached to the system are generally the prime suspect when system noise seems to be causing a problem within the TigerStop-interconnect system. When a solenoid coil de-energizes, the collapsing magnetic field induces a voltage spike in the wiring. This transient voltage can be inducted to unrelated circuit wiring, causing odd behavior in the system, or even catastrophic failure.

Solution

Avoid routing data-carrying wires, such as the AIK sensor wires, in parallel with wire carrying power, such as the power wires for a solenoid. The farther apart the two sets of wires are, the better. If it is necessary to run power wires in close proximity to data-carrying wires, the wiring should cross perpendicularly to each other, never in parallel.

Fig. 1

Fig. 2

Installing a Snubber

Depending on the system integration between a tool, such as a saw, and the interconnect, there is a risk of damage to the TigerStop amplifier, from the AIK or SIK output being connected to an inductive load.

Problem

When the magnetic field on the solenoid or other relay collapses, an EMF pulse is generated and transmitted back to the TigerStop amplifier, where the U16 outputs are damaged.

Solution


28

The use of an RC snubber circuit will greatly reduce the potential risk of catastrophic failure of the TigerStop amplifier. Frequently, a snubber can consist of just a small resistor (R) in series with a small capacitor (C). This combination can be used to suppress the rapid rise in voltage across a thyristor, preventing the erroneous turn-on of the thyristor; it does this by limiting the rate of rise in voltage (dV/dt) across the thyristor to a value which will not trigger it. Snubbers are also often used to prevent arcing across the contacts of relays (and the subsequent welding/sticking of the contacts that can occur). An appropriately-designed RC snubber can be used with either dc or ac loads. This sort of snubber is commonly used with inductive loads such as electric motors.

Fig. 3

Fig. 4

Snubbers are often used in electrical systems with an inductive load where the sudden interruption of current flow would lead to a sharp rise in voltage across the device that created the interruption.

This sharp rise in voltage might lead to a transient or permanent failure of the controlling device. The preferred configuration is to connect the snubber across the coil of the load (Fig. 4).

IMPORTANT!

Connecting the AIK to an inductive load and failing to connect a snubber device can result in amplifier damage and/or failure and will not be covered under the TigerStop Warranty.

29

Run Tool Interconnect Type This parameter lets the user manually select the tool interconnect type.

Run Auto Detect to set your tool interconnect type automatically. For reasons of safety, it is imperative to select the CORRECT tool

interconnect type when setting this parameter.

At the Ready Screen… Press [A] to access Menu

Press to scroll to menu screen 2.

Press [C] to access System Information

to scroll to Set TIK.

Press [B] or [C] to trigger password prompt.

Tool interconnect type is a list parameter.

The factory default value of this parameter is: NONE.

Enter the password, and press [=]. Press [B] or [C] to scroll through available

tool interconnect types.


30

Press [D] to save selection and exit to the Ready Screen.

Default Tool Interconnect Type value is NONE. Continue… Run Auto Detect

Run Auto Detect Run Auto Detect to set your tool interconnect type automatically.

Tool Interconnect Type can be used to set your tool interface type manually.

At the Ready Screen… Press [A] to access Menu.

At menu screen 1… Press [A] to access Setup

to scroll to Auto Detect.

Press to begin.

Run Auto Detect

31

Press to continue.

Make sure that nothing will impede the tool from activating.

Press to continue.

If the tool is activated by means of a foot switch, keep the foot switch depressed,

and press to continue.

If you have a tool interconnect, it will be detected and type will display in the screen. If no tool is connected, the message "No Tool IK detected!" will appear.

Press [STOP] to exit Menu.

32

AIK Maintenance Schedule Daily

Check kill line and switch (Fig. 1) for functionality.

Weekly Check all cables for wear or damage. Check the proximity sensors (Figs. 2, 3) to ensure they remain tight and in the

correct position.

Fig. 1 - AIK Kill line and safety switch

Fig. 2 - Proximity Sensors on an Up-Cut Saw

Fig. 3 - Proximity Sensors on a Cold Saw

aik serial number - tigerstop · e1 / 2010 aik serial number ____-_____ aik tigerstop® advanced...

Documents

aik serial number - tigerstop · e1 / 2010 aik serial number -_ aik tigerstop® advanced...