Small Piece Folder PF Series Installation and Operation Manual 22-Nov-2013 Revision 1.
Contents 1 Model Identification 1 2 Important Instructions 3 2.1 Before Attempting Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.2 Parts Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.2.1 Nameplate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.3 Key Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.4 Safety Information . . . . . . . .
6 Operation 14 6.1 Powering the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.2 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.3 Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.4 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 6.5 Daily Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 9 Transportation Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 PLC Adjustment 25 9.1 PLC Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 9.1.1 Input Module 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 PLC Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 9.2.1 Output Module 01 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1 Model Identification Information contained in this manual is for the following machines: PF-1 PF-3 Refer to the PF Product Family chart on page 2 for details about the configuration and build of a particular machine. The Product Family Chart ”‘decodes”’ the model information as shown on the serial decal.
Figure 1.
Chapter 2 Important Instructions 2.1 Before Attempting Repairs Moving parts can cause serious injury or death. Before attempting repairs, follow proper shutdown procedures and remove power before commencement of service. Safety is of primary concern with any maintenance or repair operation.
is available to answer any questions you may have about the operation and servicing of your machine. Please call with any questions or concerns about the operation of your machine. 2.2 Parts Ordering Information If you require literature or spare parts, please contact your local distributor. If a local distributor is unavailable, you may contact B&C Technologies directly at (850) 249-2222 for the name of your nearest parts dealer.
Figure 2.1: Serial Decal 2.5 Installation and Operational Safety Instructions 1. Read all instructions prior to operating this equipment. 2. Ensure that the equipment is properly grounded before applying power and operation commences. 3. Do not allow children to play in or around or operate this equipment. 4. Check the operation of all safety interlocks at the start of every shift. If the interlocks do not stop the equipment immediately, the machine must be removed from service.
Figure 2.2: Key Symbols 10. Keep the interior and exterior of the machine clean of lint, dirt, dust and debris. 11. Always disconnect the electrical service from the machine before performing service. 12. This machine must be installed according to the installation instructions. All utility connections must comply with state and local codes and must be made by a licensed installer where required.
Chapter 3 Introduction The PF Series folders are suitable for folding a large variety of textiles. Cotton, terry, and other fabrics can be folded, sized up to 1.8m x 1.5m (72 x 60 inches). The PF Series folders can make lateral and cross-folds. The machine is capable of 1 lateral and 2 cross-fold stations. Lateral folding is done with a template, whose width can be adjusted gradually in order to perform 1/2, 1/3 or 1/4 folds.
3.2 Replacement Parts In the event that literature or replacement parts are required, contact the local distributor of the equipment, or contact B&C Technologies at the above phone numbers/internet addresses.
Chapter 4 General Specifications Figure 4.
Chapter 5 Installation 5.1 Receiving Inspection Upon receipt of the equipment, visually inspect for shipping damage and note any damage with the carrier before signing the shipping receipt, or advise the carrier of the damage as soon as it is noted. If damage is discovered, a written claim must be filed with the carrier as soon as possible. Note: Warranty is VOID unless the equipment is installed according to instructions. The installation must comply with the minimum requirements listed in this manual.
Before servicing any equipment, make certain it is disconnected from the electrical power source. Never allow operation of the machine when any safety device is malfunctioning. Never bypass safety devices. Never insert hands or objects into moving belts. Doing so could result in serious injury. and guards when the machine is operating. If necessary, check the panel safety interlocks for proper operation. Consult with a qualified service technician if necessary.
Do not place volatile or flammable fluids in any machine. Do not clean the machine with volatile or flammable fluids such as acetone, lacquer thinners, enamel reducers, carbon tetrachloride, gasoline, benzene, naphtha, etc. Doing so could result in serious personal injury and/or damage to the machine. Replace all panels that are removed to perform service and maintenance procedures. Do not operate the machine with missing guards or with broken or missing parts. Do not bypass any safety devices. 4.
Always disconnect power and air supplies before a service technician performs any service procedure. 5.2.6 Inverter Drive Machines equipped with AC drives require special attention with regard to the operating environment. 1. An especially dusty or linty environment will require more frequent cleaning of the AC drive cooling fan filter and of the AC drive itself. 2.
Chapter 6 Operation 6.1 Powering the Machine After mains power is applied, wait until the control has fully booted (approximately 3 minutes). As soon as the start screen is visible, the machine can be started. 6.2 Emergency Stop When the emergency stop is activated, power is removed from the outputs of the control. The machine will not operate until the emergency stop button is released and the reset button on the touch screen is pressed.
Figure 6.1: Touchscreen Emergency Stop Display Figure 6.2: Touchscreen Overload Relay Display 6.4 Error Messages Because error messages can cover the screen, they can be minimized. Touch anywhere on the alarm message and the error message will appear as an icon at the botton of the display. To display, touch the error icons at the bottom left of the display. When an error conditionn exists, a red border is displayed around the screen.
6.5 Daily Operation 6.5.1 Start the Machine If there is no error message on the screen, the machine can be started with the green start button on the display. 6.5.2 Stop the Machine The machine can be stoped with the red stop button on the screen. 6.5.3 Feeding Method There are two ways to feed textiles to the conveyor and into the machine. This feed type is set for a particular program. 1. While feeding big and/or complex pieces it is useful for the input conveyor to be stopped.
If the machine is not running the belts can be manually started by pressing the shown button. The belts run as long as the shown button is pressed. 6.6 6.6.1 Control Dispaly Pages Some display modes are built up with pages. These pages can be displayed in turn by pressing left and right arrow icons. 6.7 6.7.1 Settings Password Protection To prevent malfunctions, the parameter settings and manual switching of the control outputs are protected with a password. The control has multiple password levels.
6.7.3 Password reset The password resets (times out) when: 1. If a user presses the button ’Reset Password on the page ’Settings’ 2. If the emergency stop is pressed 3. The password times out after 60 minutes (after the password input is accepted) for the ’Operator’ level. The level ’Engineer’ does not time out - the control must be restarted. If the password times out while in test mode, the activated test mode (see chapter ’Switching Outputs Manually’) terminates. Refer to section 6.8 on page 19. 6.7.
If you change the parameters of the currently running program the new values are used immediately. This means that the new values are used from the next article fed into the machine after the change is made. If you change the program number on the page ’Program Parameters’, the currently running program is not changed. This must be done on the main page. 6.8 Switching Outputs Manually The test mode is for testing the inputs and outputs (with the corresponding functions) of the machine.
Chapter 7 Machine Service 7.1 Daily • Errors that appears on the display of the operation panel must be corrected immediately. • Items stuck or jammed inside of the machinemust be removed first. Any item that interferes with the operation of the photocells must be removed. • If the machine has not operated for a long duration (vacation or other extended idle time), run the machine 5 minutes using the endurance programm. This simulation programm ensures that the machine runs correctly. 7.
7.4 Yearly • Replace the PLC battery. Contact B&C Technologies.
Chapter 8 Mechanical Components 8.1 Machine Drive Refer to figure 8.1 on page 24 and table 8.1 on page 24 and 23. 8.2 Transportation Belts Refer to figure 8.1 on page 24 and table 8.2 on page 24.
Lateral fold No Qty Description 30 1 Break motor 20 1 Pulley 13 1 Driving belt 21 1 Driving roll 23 2 Bearing roll 24 1 Bearing roll 26 2 Bearing roll Crossfold No Qty Description 31 3 Motor 20 3 Pulley 14 2 Driving belt 15 2 Driving belt 22 6 Driving roll 25 1 Bearing roll 27 15 Bearing roll Stacker No Qty Description 30 1 Break motor 20 1 Pulley 14 1 Driving belt 22 1 Driving roll 27 1 Bearing roll Part.-No 51-3080 10-0056 52-0057 10-0256 52-0113 52-0101 52-0100 Part.
No Qty Description 1 6 Cotton belt 88mm L=5500mm 2 1 Cotton belt 50mm L=5500mm 3 2 Polyester belt 180mm perforated L=5505mm 4 2 Cotton belt 50mm L=900mm 4 2 Cotton belt 88mm L=900mm 5 2 Cotton belt 50mm L=1220mm 5 2 Cotton belt 88mm L=1220mm 6 2 Cotton belt 50mm L=1840mm 6 2 Cotton belt 88mm L=1840mm 7 2 Cotton belt 50mm L=1410mm 7 2 Cotton belt 88mm L=1410mm 8 2 Cotton belt 50mm L=1750mm 8 2 Cotton belt 88mm L=1750mm 9 2 Cotton belt 50mm L=2440mm 9 2 Cotton belt 88mm L=2440mm 10 7 Rounthane D1/4 L=1700mm 1
Chapter 9 PLC Adjustment 9.1 9.1.1 PLC Inputs Input Module 01 Table 9.1: Input Module 1 Number DI0111 DI0121 DI0112 DI0122 DI0113 DI0123 DI0114 DI0124 DI0115 DI0125 DI0116 DI0126 9.2 9.2.
Table 9.2: Output Module 1 Number DO0111 DO0121 DO0112 DO0122 DO0113 DO0123 DO0114 DO0124 DO0115 DO0125 DO0116 DO0126 9.2.2 Description Motor inlet LF Motor Transport XF Motor XF 1 Bypass Motor XF 1 not Bypass Motor XF 2 Bypass Motor XF 2 not Bypass Motor stacker Flaps stacker Slider left fast Slider left slow Slider right Option vacuum input conveyor Output Module 02 Table 9.3: Output Module 2 Number DO0211 DO0221 DO0212 DO0222 DO0213 DO0223 DO0214 DO0224 DO0215 DO0225 DO0216 DO0226 9.2.
Table 9.4: Output Module 3 Number DO0311 DO0321 DO0312 DO0322 DO0313 DO0323 DO0314 DO0324 DO0315 DO0325 DO0316 DO0326 9.3 Description Option lamp red Option belt conveyer forward Option belt conveyer backward Option up input conveyor Option down input conveyor PLC Parameter The following parameters are basic settings of the machine. These are geometric data or specify the basic functionalities of the machine. These parameters should not be changed after the implementing.
Table 9.
9.4 Global Parameters The following parameters apply globally for the machine. They are always used no matter which program is currently chosen. Table 9.6: Global Parameters Number 1 2 3 4 5 6 7 8 10 11 12 15 16 17 20 22 23 25 26 70 80 81 85 86 90 95 98 99 9.
Table 9.
Chapter 10 Machine Functions 10.1 Sensors and Outputs The exact position and description of all sensors and outputs are explained in the electric schematics, included with the machine. Refer to the ’Switching Outputs Manually’ section on page 19, showing how all outputs can be tested in their function. 10.2 Feeding of Textiles As described in the input mode section on page 16, there are two ways to feed the machine: 1. Feeding with conveyor stopped 2.
Length piece 3 Figure 10.
10.4 Slider Adjustment The slider can be independently adjusted in their movements with timers. Usually the left slider is activated shortly after the stop in the lateral fold, whereas the right pusher is extended timedelayed. For the 1/4-fold the left pusher is extended longer and taken back together with the right slider. 1/2- folds can be done with only one slider. Parameter 7 determines when the piece is transported out of the lateral fold after the fold is done. 10.
These values can be changed minimally to adjust the overlapping and the folding for different fabric qualities. If a certain folding length is required, an exact end length can be acquired with fixed length: For a fold with fixed length leading edge the value in millimetres has to be entered plus 10000, from trailing edge plus 20000. 10.8 Endurance Run The endurance run is needed to set up the machine.
Chapter 11 Programming Example The following is a brief example outlining the creation or modification of your own folding programs. First consider how the goods will be fed into the machine and how each fold should be made. Procedure: 1. On the main page choose ’Settings’, enter a password (if needed) and choose ’Program’. Select the desired program number. 2. Longitudinal fold: Measure the width of the textile (0.9 m in the example). The required template width is 1/3, which means 300 mm.
Figure 11.
Figure 11.2: Ski programming 8. Fine adjustements of the first crossfold: In this crossfold is built-in a blowtube and a knife. The duration of the blowtube (parameter 13) and of the knife (parameter 16) can be set (in milliseconds). Value 0 means that this function is disabled. Figure 11.3: First Crossfold Adjustment 9. Fine adjustements of the second crossfold: In this crossfold is built-in a blowtube and a knife.
Figure 11.
Figure 11.
Figure 11.
Chapter 12 Service & Parts 12.1 Service Service must be performed by a qualified trained technician, service agency, or gas supplier. If service is required, contact the distributor from whom the equipment was purchased. If the distributor cannot be contacted or is unknown, contact B&C Technologies for a distributor in your area. For technical assistance in the United States, contact B&C Technologies: (850) 249-2222 Phone (850) 249-2226 FAX parts@bandctech.com www.bandctech.
Chapter 13 Decommisioning In the event that the machine must be decommissioned, follow these steps: 1. Clean interior of machine, both basket and shell. 2. Disconnect electrical power. (a) Shut of main power supply at the breaker box or main control panel. (b) Do not attempt to disconnect power supply wires from power supply. Have a qualified electrician disconnect power to machine at its source. 3. Disconnect gas/steam supply. 4. Disconnect exhaust system. 5. Remove the machine from its foundation pad.
