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TAK PROGRAMMABLE SERVO FEED OPERATION MANUAL

Power On & Confirmation of Settings: General – The power input point for the TAK Servo System is located in the main utility cabinet and channeled to the operating devices and operator interface. Power necessary is 208/220 VAC 3Ph on a 20A circuit. Upon first power up of the system the Operator Interface Screen will display any system fault messages and wait until the faults are corrected and the operator touches the “reset” section on the touch screen. Due to the extreme versatility of this feed system and software all instructions are written to convey the most general operation of the system. Many options and add-on features are available and not described or addressed in this manual but personal assistance is available from TAK on all features or applications. Warning - Be sure to check all program settings for the current job before allowing the Servo System to proceed with any operations! If this is a new job please see the section on entering job sequence steps.


System Operation; Threading up the Servo System:

1. Check to be sure that the power is “on” and there is 80 psi of air pressure to the system. 2. From the main startup screen “Reset” all error messages & press the “setup” screen button. 3. Alternately press the drive roll clamping “Open or Close” screen button and observe that the top two rolls

move from open to closed and leave the rolls in the up or “open” position. 4. Remove the plastic safety interlock cover in front of the drive rolls. When in the “setup” screen the plastic

safety interlock cover fault messages are not displayed. 5. Move the wire out sensor arm to the open or “up” position. 6. Remove any remaining wire from the system by carefully pulling it back ( towards the wire straightener ) out

of the servo drive section of the system. 7. If required attach a new spool of material to the system payoff. 8. It may be necessary to file a “nose” on the wire prior to trying to thread it through the system. Any burr or

other deformity may cause the wire to get “hung up” during the threading process since each of the tooling pieces ( guides, drive rolls, quills, etc. ) are machined to precise tolerances.

9. If a wire straightener has not been set up for the wire diameter then the procedures outline for the straightening device should be followed before proceeding to the next step.

10. When used, check the TAK wire straightener “offset values” to ensure that nothing has “migrated” since the run of wire through the system.

11. Proceed to thread the wire through the straightener by hand feeding the wire and inch or so at a time. 12. Continue with feeding the wire through the drive guides, between the drive rolls and on into the system cutter

head or other attached devices. 13. Once the wire is through the system, activate the drive roll clamping to “close” so that the upper 2 drive

wheels come down onto the wire and adjust the pressure as required. 14. If the wire did not “hang up” during threading then you can continue to feed it forward or reverse through the

system using the “electronic hand wheel” or “jog” functions until it is observed in a starting position for the process being performed.

15. All attached external devices can be cycled for operation by activating the “Remote” screen buttons down the left side of the screen by depressing the appropriate button.

16. Recheck the wire path all the way back to the payoff spool to ensure that the wire is free to be fed. 17. Rotate the wire out sensor arm down to ride on the wire entering the feed unit.

Replace the plastic safety cover. The system is now ready to run.


SCREEN DESCRIPTIONS FOLLOW:

MAIN SCREEN:

This is the first screen visible after the system is powered up or has encountered a power interruption. On this screen you will be able to access the remainder of the system. The red bar/text area at the top of the screen will display any error/alarm messages from the system. Starting from left to right:

1. Login/Logout; lower left corner is the touch button to access the login screen. All operations to operate this system will require a login.

2. Metric Pgm.; will access all screens required to program the system to function in a metric mode.

3. Inch Pgm.; will access all screens required to program the system to function in an inch mode.

4. Auto; will bring you to the main “auto” run screen where all part program and running information is viewed.

5. Setup; will bring you to the screen where system operational parameters are viewed and input.

6. Alarms; will bring you to the screen to view existing and logging of past system and device alarm messages.


LOGIN/LOGOUT SCREEN W/ENCODER OPTION:

On this screen you will be able to access the following parts of the system; Login; touch here to access the keypad to enter the login password. Master Rights to operate the system: See separate Security levels sheet.


Once the password is entered and accepted, you will be returned to the previous screen. Other items on this screen are; Maint Counter; is a numeric display showing the number of parts produced since the last time the “Counter Reset” was pushed. Life Count; is the number of parts produced since the machine was assembled or rebuilt by the factory and is only re-settable by TAK. Wheel Dia. Comp.; is the master setting for the drive wheel diameter that the machine uses in all calculations. This machine is designed to operate correctly @ a (2.5000”) diameter. If a wheel of different size is used due to wear or regrind the actual calculated diameter to the center of the material line should be entered here. ENCODER OPTION: These optional accessory settings are only available to Admin rights personnel and have to be initially installed by TAK.

1. Encoder Enable: a. This button will toggle on/off to enable/disable the accessory encoder function.

2. Encoder Wheel Diameter: a. This is the entry for the actual encoder wheel diameter. This entry will directly

impact the accuracy of the feeding system. 3. Cut Wheel Width:

a. This will compensate for the width of the actual cutoff wheel or tool that is used to part the material. If a shear or blade is used the entry will be “0”.

View I/O; from this screen you can access other screens showing the current operating status of various I/O detailed/described on the electrical schematics.


SETUP SCREEN:

This screen is the center of the system operational parameters. From this screen it is possible to setup the machine to function manual or input key values that the machine needs to work correctly. Down the left side of the screen it is possible to manually activate each of the remote outputs if the system is so equipped. By pressing the button of choice it will activate the remote until you release the button. Drive Wheels; is the button to either open the grip on the drive wheels or close them. Wire Diameter; is where the operator must input the value for the actual wire diameter being used for the job. If this value is not entered correctly the feed length will not be correct. By pressing the button a keypad will pop up so values can be entered. Position; This is the actual movement of the material after a manual cut. This value will zero out when the local output #0 is activated. Any movement will be shown either by handwheel or jog. Accessory TAK Cutter; is used to activate local output #0. Although it is named as it is, if the cutter is not attached, any appropriate accessory can be used. The output will activate (one shot) only for the time entered in the next button to the right. The default minimum time is 25ms for the TAK cutter. ACC/DEC Override; is engaged or disengaged by pressing this button. This feature is where you can pick an acceleration ramping value. These values range from 0 (most aggressive) to 6 (softest) these values are entered by the next button to the right. This is a system wide ramp change and will affect all feed operations in any program until it is disengaged on this screen. Handwheel; is engaged or disengaged by pressing this button and then picking an increment of movement dictated by each detent on the remote handwheel unit. By choosing a value in the next button to the right, each detent movement will move the feed wheels appr the value picked.


Jog Mode; is engaged or disengaged by pressing this button. The speed for the jog function is picked by entering a value in the next button to the right and is in “inches per minute”. To the buttons to the far right are the direction buttons for the feed wheels to move. Facing the machine rolls, “Jog Reverse” will cause the wheels to move in counterclockwise direction and “Jog Forward” will cause the wheels to move in clockwise direction. Alarm Notice; The red bar/text area of the screen will display any error/alarm messages from the system. Main; button will open the main intro screen. View I/O; from this screen you can access other screens showing the current operating status of various I/O detailed/described on the electrical schematics. Edit Pgm; button will open the currently loaded program screen. Auto; button will open the system auto run program screen. Reset; pressing this button will reset the system after an alarm stoppage. Alarms; will bring you to the screen to view existing and logging of past system and device alarm messages.


AUTO SCREEN:

This screen comprises the main operational viewing of the system while running. From this screen you will be able to input run values and monitor the current status of the job/program. Upper left section of the screen shows the currently running “part sequence #” & “batch sequence #”. The next lower line gives the actual running speed in parts per minute the system is producing at the current settings. PGM # shows the current program number being produced. Part Description shows the current program description being produced. Upper right section of the screen has a switch button to turn on “Speed Override”. This button when activated will give the operator the capability to increase or decrease the feed speed from the speed set in the program on an as needed basis. This speed will not affect or change the actual speed in the program. Total Parts is the running total parts made on the current job. This count can only be cleared by pressing the “Clear All” button on the right side of the screen. Batch Parts is the running total parts made on the current batch. This count can only be cleared by pressing the “Clear Parts” button on the right side of the screen. Batches Done is the running total of batches made on the current job. This count can only be cleared by pressing the “Clear All” button on the right side of the screen. Part preset Qty is where you will input the quantity of parts you wish to produce for a given job. Pressing the button will pop up a keypad to enter a quantity. Batch preset Qty is where you will input the number of batches you wish to produce for a given job. Pressing the button will pop up a keypad to enter a quantity. This function will use the part preset value as the amount of parts in each batch. Alarm Notice is where you will get a message if the system encounters a stop error or malfunction from a remote sensored accessory. Operational Message is where you will get messages from the system on its status while running.


OPERATIONAL BUTTONS: Across the bottom of the screen are the operational buttons that can activate all system running functions and access most screens needed to perform running adjustments. Stop will cause the system to suspend/stop immediately and discard the count of the currently running part. Basically the system will not count a part until the system completes all the part sequences successfully. When start is pressed the system will proceed at the beginning of a part sequence. Start will engage the system to run from a stop condition. Pause will cause the system to suspend/stop immediately and hold in the program sequence until stop or resume is pressed. Resume will cause the system to resume operation from the point it was paused. NOTE: The functions of “Stop” & “Start”, “Pause” & “Resume” are also available from I/O for remote operation. Single is a function that will cause the system to move thru the program in sequence one step at a time. By pressing this button the system will only do the next step in the program and wait for the Start button to be pressed. At any time the Single Step button can be pressed again to disengage this feature and then by pressing start the system will run automatically. Main button will open the main intro screen. Metric button will open the main metric program screen. Inch button will open the main Inch program screen. Setup button will open the system setup program screen. Alarms will bring you to the screen to view existing and logging of past system and device alarm messages.

TAK PROGRAMMABLE SERVO FEED OPERATION MANUAL From the “main” screen you will be able to access the following parts of the system;

INCH SCREEN:

This is the main screen to view the steps entered into the current program that is loaded. “Part Program” area will show the current program ID & “Part Description” will show the description saved with the program. From here you will be able to; “Edit” any of the steps shown by touching the button corresponding to the series of steps that you wish to edit and one of the following screens will be shown. Programming Accessory Functions: “Accessory Function #1:” When using a Type #1 motion step; by placing a device # in the device column of the motion step, this will engage it simultaneously with the feed and latch the device specified. Later in the program insert a step type #2 or #4 and call the same device used in the motion step. If you wish to stop the device immediately, do not enter a time in the time column. If you wish to have the device continue functioning for a period of time, just enter a time in the time column and the device will continue functioning for the set time before the next step will process in the program. “Accessory Function #2:” This function is only available for “Seq. Type #5” on “Remote #8” and in “Batch Mode”. This function changes the standard sequence of the sensors from “Home-Away-Home” using (2) separate sensors to (1) sensor with a different sequence. The sequence is, the system must see the sensor” Closed” then “Open” then Closed” in that order. This function is used to establish a positional ready signal so the SERVO system will know when an index has completed.

TAK PROGRAMMABLE SERVO FEED OPERATION MANUAL Edit. “1-13”

or “14-25”

On these screens you will be able to enter values into each block as desired on each step of the program. Basic guidelines for entry are listed on the right side of the screen.

TAK PROGRAMMABLE SERVO FEED OPERATION MANUAL The column explanations are as follows: “SEQ”: A number sequence followed by the program. All steps are followed in a strict sequential order. All entries of a sequence step are completed before moving to the next. “TYPE”: Defines the action desired for the step. The actions available are listed on the right side of the screen. “DEVICE”: Is the accessory or electro mechanical assembly you wish to address in this step. A standard system has (1) addressable device connection having “home” & “away” sensor input. The expanded system has (8) outputs & (16) inputs that are addressable. “DISTANCE”: Is the desired movement for a type #1 step. “IPS”: Is the speed desired for a type #1 step. “X10 MS”: A time or dwell is entered for a type #0, #2, #4 or #6 step. This entry is in milliseconds and is based on a multiplier of 10. Examp; 2 = 20ms, 5 = 50ms, etc. The sequence type explanations are as follows: “TYPE #0”: Is a skip or move to next step. If a step has a type #0 and no other entry the program will loop @ that point. “TYPE #1”: Is a motion step and will require a distance & speed entry. “TYPE #2”: Is a timed step for the local output and will require a “X10 Ms” entry. “TYPE #3”: Is a sensor controlled step for the local output. When a sensor controlled step is used, the sensor for the selected local device must return signal to the processor in this order; (Home > Away > Home) before proceeding to the next step. “TYPE #4”: Is a timed step for the remote outputs and will require a “X10 Ms” entry. “TYPE #5”: Is a sensor controlled step for the remote outputs. When a sensor controlled step is used, the sensor for the selected remote device must return asignal to the processor in this order; (Home > Away > Home) before proceeding to the next step. “TYPE #6”: Is a sensor controlled step for the remote outputs. When a sensor controlled step is used, the sensor for the selected remote device must return a signal to the processor on the (Home input) before proceeding to the next step. “Exit”; will bring you back to the main program viewing screen.


INCH SCREEN:

“Save Pgm”; From this main screen you have the option to “Save” the program just edited or created new. When entering the program number, enter “I-“ as the first (2) characters in the part program number and the program number can’t exceed a total of (8) characters. This will designate the program as a “Inch” based program. “Part Description;” By touching this you will have the ability to enter a program description of up to (25) characters. This should be done prior to saving the program. “Load Pgm.”; Will give you the option to load programs saved and stored previously. A small screen listing will pop up that you can scroll thru to pick the program desired. “Delete Pgm.”; Will give you the option to delete programs saved and stored previously. A small screen listing will pop up that you can scroll thru to pick the program desired. “Edit Batch”; Will bring you to a screen where you can enter various functions in each step of a batch handling program. A batch handling program can have up to (25) steps as shown and basic guidelines for entry are shown on the right of the screen. In definition a batch as referenced here means a series of steps that are performed on a preset number of parts as a grouping or “batch”.


BATCH SCREEN:

On this screen you will be able to enter values into each block as desired on each step of the batch. Basic guidelines for entry are listed on the right side of the screen.

Example System Part Program Sheet

Program No. Part Name / No. Metric English Description / Material Sequence # Seq. Type Remote Device Distance in/mm Speed IPS Time x 10ms

1 Feed/Conv

1 FEED

2 CONVEYOR

“ON”

FEED LENGTH

30.00

FEED SPEED

10 -

2 Cut 3 - - - -

3 4 2

CONVEYOR “OFF”

- - EXTRA TIME

50

4 4 DUMP PART 1 - - TILT TIME

100 (1 SEC) 5 0 0 0 0 0 6 0 0 0 0 0 7 0 0 0 0 0 8 0 0 0 0 0 9 0 0 0 0 0

10 0 0 0 0 0 11 0 0 0 0 0 12 0 0 0 0 0 13 0 0 0 0 0 14 0 0 0 0 0 15 0 0 0 0 0 16 0 0 0 0 0 17 0 0 0 0 0 18 0 0 0 0 0 19 0 0 0 0 0 20 0 0 0 0 0

System Part Set-up Notes: “Accessory Function #1:” When using a Type #1 motion step; Placing a device # in the device column of the motion step, this will engage it simultaneously with the feed and latch the device specified. Later in the program insert a step type #2 or #4 and call the same device used in the motion step. If you wish to stop the device immediately, do not enter a time in the time column. If you wish to have the device continue functioning for a period of time, just enter the time in the time column and the device will continue functioning for the set time before the next step will process in the program.

Type 0 = Go to next Sequence. Type 1 = Motion Sequence. Type 2 = Timer Controlled Cutter Sequence.

Type 3 = Sensor Controlled Cutter Sequence. Type 4 = Remote Device Timed Sequence. Type 5 = Remote Device Signal required.

TAK PROGRAMMABLE SERVO FEED OPERATION MANUAL From the “main” screen you will be able to access the following parts of the system;

METRIC SCREEN:

This is the main screen to view the steps entered into the current program that is loaded. “Part Program” area will show the current program ID & “Part Description” will show the description saved with the program. From here you will be able to; “Edit” any of the steps shown by touching the button corresponding to the series of steps that you wish to edit and one of the following screens will be shown. Programming Accessory Functions: “Accessory Function #1:” When using a Type #1 motion step; By placing a device # in the device column of the motion step, this will engage it simultaneously with the feed and latch the device specified. Later in the program insert a step type #2 or #4 and call the same device used in the motion step. If you wish to stop the device immediately, do not enter a time in the time column. If you wish to have the device continue functioning for a period of time, just enter a time in the time column and the device will continue functioning for the set time before the next step will process in the program. “Accessory Function #2:” This function is only available for “Seq. Type #5” on “Remote #8” and in “Batch Mode”. This function changes the standard sequence of the sensors from “Home-Away-Home” using (2) separate sensors to (1) sensor with a different sequence. The sequence is, the system must see the sensor” Closed” then “Open” then Closed” in that order. This function is used to establish a positional ready signal so the SERVO system will know when an index has completed.

TAK PROGRAMMABLE SERVO FEED OPERATION MANUAL Edit. “1-13”

or “14-25”

On these screens you will be able to enter values into each block as desired on each step of the program. Basic guidelines for entry are listed on the right side of the screen.

TAK PROGRAMMABLE SERVO FEED OPERATION MANUAL The column explanations are as follows: “SEQ”: A number sequence followed by the program. All steps are followed in a strict sequential order. All entries of a sequence step are completed before moving to the next. “TYPE”: Defines the action desired for the step. The actions available are listed on the right side of the screen. “DEVICE”: Is the accessory or electro mechanical assembly you wish to address in this step. A standard system has (1) addressable device connection having “home” & “away” sensor input. The expanded system has (8) outputs & (16) inputs that are addressable. “DISTANCE”: Is the desired movement for a type #1 step. “MM/SEC”: Is the speed desired for a type #1 step. “X10 MS”: A time or dwell is entered for a type #0, #2 or #4 step. This entry is in milliseconds and is based on a multiplier of 10. Examp; 2 = 20ms, 5 = 50ms, etc. The sequence type explanations are as follows: “TYPE #0”: Is a skip or move to next step. If a step has a type #0 and no other entry the program will loop @ that point. “TYPE #1”: Is a motion step and will require a distance & speed entry. “TYPE #2”: Is a timed step for the local output and will require a “X10 Ms” entry. “TYPE #3”: Is a sensor controlled step for the local output. When a sensor controlled step is used, the sensor for the selected local device must return signal to the processor in this order; (Home > Away > Home) before proceeding to the next step. “TYPE #4”: Is a timed step for the remote outputs and will require a “X10 Ms” entry. “TYPE #5”: Is a sensor controlled step for the remote outputs. When a sensor controlled step is used, the sensor for the selected remote device must return signal to the processor in this order; (Home > Away > Home) before proceeding to the next step. “TYPE #6”: Is a sensor controlled step for the remote outputs. When a sensor controlled step is used, the sensor for the selected remote device must return a signal to the processor on the (Home input) before proceeding to the next step. “Exit”; will bring you back to the main program viewing screen.


“Save Pgm”; From this main screen you have the option to “Save” the program just edited or created new. When entering the program number, enter “M-“ as the first (2) characters in the part program number and the program number can’t exceed a total of (8) characters. This will designate the program as a “Metric” based program. “Part Description;” By touching this you will have the ability to enter a program description of up to (25) characters. This should be done prior to saving the program. “Load Pgm.”; Will give you the option to load programs saved and stored previously. A small screen listing will pop up that you can scroll thru to pick the program desired. “Delete Pgm.”; Will give you the option to delete programs saved and stored previously. A small screen listing will pop up that you can scroll thru to pick the program desired. “Edit Batch”; Will bring you to a screen where you can enter various functions in each step of a batch handling program. A batch handling program can have up to (25) steps as shown and basic guidelines for entry are shown on the right of the screen. In definition a batch as referenced here means a series of steps that are performed on a preset number of parts as a grouping or “batch”.

BATCH SCREEN:

On this screen you will be able to enter values into each block as desired on each step of the batch. Basic guidelines for entry are listed on the right side of the screen.

TAK PROGRAMMABLE SERVO FEED OPERATION MANUAL Program sheet overview; On the enclosed filled in sheet is an example of a simple program to make a formed part using a remote device (forming press) #1 and a remote cutoff head device #2. Seq #1 Type #1 -initial positive move of 6.000” @ 50 IPS. Seq #2 Type #4 -time pulse remote #1 for 45ms. Seq #3 Type #1 -next move of positive 1.000” @ 30 IPS. Seq #4 Type #4 -time pulse remote #1 for 45ms. Seq #5 Type #1 -next move of positive 1.000” @ 30 IPS. Seq #6 Type #4 -time pulse remote #1 for 45ms. Seq #7 Type #1 -next move of positive 6.000” @ 50 IPS. Seq #8 Type #5 -initiate sensor controlled remote #2 for cutoff. Seq #9 Type #1 -final negative move of 12.000” @ 70 IPS. To return to start position. Examp.: A simple feed & cut operation would be only (2) lines. Seq #1 Type #1 -initial positive move a length as required @ 50 IPS or other speed as required. Seq #2 Type #3 -initiate sensor controlled cutter on local output #0. Program Batch sheet overview; This sheet will act the same as the main program except that no movement commands can be used. The part is made by using the part program sheet and is made in a quantity as chosen. After the system has produced the quantity specified, it will look to see if you have specified anything in the batch program. Examp:. Make a quantity of 100 parts then index a packaging machine. Input quantity: 100 Batch Quantity: 3 PART: Seq #1 Type #1 -initial positive move a length as required @ 50 IPS or other speed as required. Seq #2 Type #3 -initiate sensor controlled cutter on local output #0. BATCH: Batch Seq #1 -Type #5 -Device #3 --This line initiates Device #3 in a sensor controlled action. Following the completion of this action the system will make this loop (2) more times for a total of (3) or 300 parts in (3) batches of (100). Any part program or batch can be single line simple or (25) line complex as required.

System Part Program Sheet Program No. I-23587 Part Name / No. Rectangle Metric English XDescription / Material .04 mild steel wire Sequence # Seq. Type Remote Device Distance in/mm Speed IPS Time x 10ms 1 1 0 +6.000 50 0 2 4 1 0 0 45 3 1 0 +1.000 30 0 4 4 1 0 0 45 5 1 0 +1.000 30 0 6 4 1 0 0 45 7 1 0 +6.000 50 0 8 5 2 0 0 0 9 1 0 -12.000 70 0 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 System Part Set-up Notes:


Type 3 = Sensor Controlled Cutter Sequence. Type 4 = Remote Device Timed Sequence. Type 5 = Remote Device Signal required.

System Part Program Sheet Program No. Part Name / No. Metric English Description / Material Sequence # Seq. Type Remote Device Distance in/mm Speed IPS Time x 10ms

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

System Part Set-up Notes:


Type 3 = Sensor Controlled Cutter Sequence. Type 4 = Remote Device Timed Sequence. Type 5 = Remote Device Signal required. Type 6 = Remote Device Signal required

System Batch Program Sheet Program No. Part Name / No. Description / Material Sequence # Seq. Type Remote Device Time x 10ms

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

System Batch Set-up Notes:

Type 0 = Go to next Sequence. Type 4 = Remote Device Timed Sequence.

Type 5 = Remote Device Signal require


Basic Troubleshooting List. This list is intended to guide you to some common solutions and all the following checks should be read and or tried prior to contacting technical support. The proper function of this machine depends upon, but not limited to, the following (4) categories. NOTICE: Any attempt to access or modify inner components or modify the operation of the basic machine without the express consent or direction of technical support will result in restrictions stated in the disclaimer shown elsewhere in this manual. Basics:

1. Check for proper air supply and recommended 80 PSI pressure. 2. Check for proper electrical connection. 3. Check that all components are in their proper place and secured correctly. 4. Check that the safety cover is on and in the proper position.

Pneumatics: Q: Will the machine make a complete cycle ?

A: 1. Check for proper air supply and recommended 80 PSI supply pressure.

Q: Where in the cycle does the machine stop?

A: 1. Check that all components are in their proper place and secured correctly. 2. Check for binding in the machine or on the wire line. 3. Check for proper sensor operation by referring to electrical section.

Q: Does the machine cycle but not cut?

A: 1. Check for proper 80 PSI air supply and recommended 70/80 PSI cutter pressure. 2. Manually check the function of the cut-off cylinder air valve by depressing the

small button located on the valve. Q: Does the machine cycle but not feed?

A: 1. Check for proper 80 PSI air supply and recommended drive wheel pressure. 2. Manually check the function of all the air valves by depressing the small button

located on each valve. 3. Check for proper gripper operation by referring to mechanical section.

Q: Does the machine deform the wire during feeding?

A: 1. Reduce or adjust the air pressure on the grip / drive rolls. Q: Does the machine feed correctly for the first few pieces then feed erratic?

A:


1. Check for proper 80 PSI air supply and recommended system pressures. 2. Check and increase supply air line size if necessary. 3. Check for proper drive wheel operation by referring to mechanical section. 4. Check to be sure that the exhaust is not restricted at all ports.

Q: Does the machine feed correctly then start feeding short?

A: 1. Check for proper 80 PSI air supply and recommended drive wheel pressure. 2. Check and increase supply air line size if necessary. 3. Check for proper drive wheel operation by referring to mechanical section. 4. Check to be sure that the exhaust is not restricted at all ports.

Q: Does the machine run correctly then stop?

A: 1. Check error messages on screen for indicated condition. 2. Check the safety cover interlock.

Electronics: Q: Was the machine running before the problem, or did the problem arise when turning on the machine.?

A: 1. Check for proper electrical connection. 2. Check the fuse inside the control box if you suspect power problem. 3. Check the safety cover interlock. 4. If the screen is backlit and the display is functional, assume the control power is

OK Q: Why won’t the system produce the correct length piece? A:

1. Check to be sure that the drive wheels are not slipping and ensure that the system supply pressure is at 80 PSI

2. Ensure that the wire diameter is within the proper size and tolerance range. Mechanical: Q: Will the machine make a complete cycle ?

A: 1. Verify that there are no excessive back pressures in the wire decoiling system. 2. If the machine stops during the cycle, check for binding through out the system.

Q: Does the machine cycle but not cut?

A: 1. Verify the operation of the cutter head.

Q: Does the machine cycle but not feed?

System Manual www.takenterprises.com

SHARPENING & SETTING PROCEDURES FOR

QUILL ON QUILL Straighten, Feed & Cut Off Machine

NOTE: Wire hole cutting edge, and any surface leading to wire hole cutting edge should be free of all tool marks and/or grinding lines. (Figures 1, 2 ) Step 1: Grind Traveling Quill(#56) Grind end (A) of Quill (opposite wire lead side) flat and perpendicular to body (B) within .0002. Remove enough material to clean and acquire sharp edge for the full diameter of the wire hole. See Fig #1 NOTE: After grinding, surface (A) must be lapped to ensure longevity. (Step 3) Step 2: Grind Stationary Quill(#12) Grind end (A) of quill (opposite wire exit side) flat and perpendicular to body (B) within .0002. Remove enough material to clean and acquire sharp edge for the full diameter of the wire hole. See Fig #1 Step 3: Lapping Procedure a. Use diamond lapping compound to remove all grinding lines. b. Radius break the wire hole cutting edge approx. .002 for hard wire only.


Quill on Quill Setting Procedure Step 1: Stationary Quill (#12) Set stationary quill (#12) with surface (A) (Fig 1) flush to surface (B). (Fig 2) Do not extend above surface (B). Step 2: Traveling Quill (#56) Set traveling quill (#56) with surface (A) (Fig 1) flush or below the quill block surface (D). (Fig 3) Do not extend out from surface (D). NOTE: Properly set quills should have clearance between surface (A) on stationary quill (#12) and surface (A) on traveling quill (#56) dependent on the wire type and hardness.

Illustration:


Illustration:

Installation/Sharpening of square quills:

System Manual Addendum www.takenterprises.com

If your purchased unit was ordered with square quills or you have added this option to an existing machine, the following instructions and included drawings will guide you thru the removal, sharpening & replacement of the quill sets. ATTENTION: Remove the air supply and shut off the power to the unit. The following instructions make reference to item numbers shown in drawings in the user manual and this addendum. DISASSEMBLY:

1. Remove the (2) screws holding the cutter cylinder (#28) to the cutter body (#25). 2. Lay the cylinder to the side out of the way. There is no need to disconnect the air lines

from the cylinder. 3. Remove the (2) screws holding the cutter body assembly to the base (#20). 4. You will observe that the gas spring (#21) under the cutter assembly will push the

assembly up appr. .06 from the seated position, this is normal. 5. Remove the cutter arm cover (#26) from the cutter body. 6. Remove the cutter quill body block (#23) from the cutter body. 7. Remove the stationary quill (#30) from the cutter body. 8. Remove the traveling quill (#22) from the quill body block.

SHARPENING: The cutting quills are marked and are different lengths. The stationary quill will have the smaller wire hole and will be shorter in length than the traveling quill. One face is closer to the alignment pin, this face will be the cutting end and the other will have a tapered entry or exit depending which quill is being sharpened. When sharpening the cutting quills be sure to keep the alignment pin in its groove and the (2) halves square and aligned in a “V” block or other fixture.

1. Grind the cutting face until the worn/dull section of the shape is gone. 2. Lap the face of the quills until the surface is smooth and grind lines are gone. 3. Use a small piece of brass or wood with fine lapping compound and very lightly

remove the sharp edge around the shape or hole. RE-ASSEMBLY: Please refer to the enclosed addendum drawing.

1. Orient the quills so that the (2) halves are on top and bottom. 2. Place the stationary quill into the cutter body with the just sharpened face (#1)

extended into the groove shown as (#2) then adjusted as follows. 3. The face of this quill must be placed flush with the inside surface of (#2) and tightened

into place. A block or a dial indicator placed in this groove can be used to assure that the quill is not sticking out or depressed below the surface.

Installation/Sharpening of square quills:

System Manual Addendum www.takenterprises.com

4. Place the traveling quill into the quill body block with the just sharpened face (#4) extending out past face (#3) this face is also identified by the chamfers on (2) of the vertical edges.

5. This is the quill that needs be adjusted to provide the correct amount of clearance to achieve the “break” required for the material being cut. This clearance value will have to be determined by the operator by experimentation. The correct value will give a cut with a clean square surface with no burr. If the clearance is set too tight, tool edge life will be shortened and if set too large the material will have burrs or not cut off correctly.

6. The best method of setting this clearance is to use a dial indicator that has a resolution of .0001 inch.

7. Place the quill body block on a surface plate or other suitable surface with the face (#3) facing up.

8. Indicate the face (#4) of the quill and place it below the face (#3) a predetermined amount that was recorded previously or at a point you wish to use to evaluate a cut.

9. Slide the quill body block back into the groove shown as (#2) with the sharpened faces of the quills facing each other.

10. Replace the cutter arm cover. 11. Place the cutter assembly back over the gas spring and tighten in place. 12. Replace the cut cylinder and tighten in place. 13. Re-initialize the unit and proceed making trial cuts to verify cut quality.

This instruction is very similar across the complete SF&C line of machines, independent of the quill or material shape or size.

1 | P a g e 30 April 2008

WARNING

The operator of the equipment offered herein must not be in or near the point-of–operation of any such machine or operating parts of any equipment installed on a machine, or bodily injury could result. The EMPLOYER must conspicuously display adequate warning signs on the machine with proper warnings for the machine and the specific application to which the machine and equipment are being applied.

OSHA Sections 1910.147, 1910.211, 1910.212 and 1910.217 contain installation information on the required distance between danger points and point-of-operation guards and devices. No specific references have been made to which paragraph of OSHA 1910.147, 1910.211, 1910.211, 1910.217 or any other applicable sections because the paragraphs may change with each edition of the publications of OSHA provisions.

All equipment manufactured by TAK Enterprises is designed to meet the construction standards of OSHA in effect at the time of sale, however, the EMPLOYER ultimately installs the equipment and is therefore responsible for installation, use, application, training and maintenance, as well as ensuring that adequate warning signs are visible on the machine onto which the equipment will be installed.

OSHA states that the EMPLOYER must ensure that safe operating methods designed to control or eliminate hazards to operating personnel are developed and employed, and that operators are trained in safe operation of the equipment.

It shall be the responsibility of the EMPLOYER to establish and follow a program of periodic and regular inspections and maintenance of machinery to insure that all their parts, auxiliary equipment and safeguards are in a safe operating condition and adjustment. Each machine should be inspected and tested no less than weekly to determine and confirm that the operating condition of the machine meets safety standards. Necessary maintenance or repairs to machinery, auxiliary equipment and safeguards shall be performed and completed before the machine is operated. The EMPLOYER shall maintain accurate records of these inspections and maintenance work performed.

It is not the responsibility of TAK Enterprises to provide notification to the user of this equipment concerning future changes in State or Federal laws, or construction standards.

SAFETY PROGRAM

Accident free operation will result from a well developed, management sponsored and enforced safety program. Of vital importance to the success of a safety program is the proper selection of guards and devices. However, there is no safety device that will insure “automatic” or “fool proof” safety to your operation.

Of equal importance to the proper selection of machine guards and devices is effective training of operating personnel. Each individual must be trained in the proper operation in accordance with established standards developed for the guards or safety devices employed, with emphasis on why specific guards and safety devices have been provided on the equipment. Rules for safe operation should be in writing, available to company personnel and enforced at all times.

An effective safety program must include regularly scheduled inspections and maintenance of all equipment, with accurate records to reflect the successful completion of inspections and maintenance.

To ensure that a safe working environment is maintained at all times, management, supervisors, safety engineers and all production employees must assume their proper share of responsibility to establish and maintain an effective safety program. All members of the company community should be involved so that an accurate view of the specific areas within the facility that require attention are addressed.

To assist you in the development of and maintenance of an effective safety program, many trade groups and safety related organizations provide guidelines and recommendations that are available to you. However, you must know when and how to apply these guidelines. The equipment manufacturers provide information to assist you in properly adjusting and maintaining your equipment. It is recommended that the employer comply with these guidelines at all times.

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