FRAMECAD F300i Operating Manual (FCF2) - Release 10102013

FRAMECAD Factory 2 Edition

Disclaimer This document has been published for the purpose of providing information of a general nature only. Further, no guarantee, warranty, or any other form of assurance is given as to the accuracy, currency or completeness of the information provided. Accordingly, any reliance on, or use, by you of any information contained within this document for any purpose whatsoever shall be entirely at your own risk, and any liability to you is expressly disclaimed to the maximum extent permitted by law. ALL INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE. THIS DOCUMENT SUPERSEDES ALL PREVIOUS DOCUMENTS.

Intellectual Property Notice FRAMECAD and the FRAMECAD logo are trademarks of FRAMECAD Limited. Reproduction of this document and all material included herein is prohibited, except with the prior written consent of FRAMECAD Limited. Copyright 2013 FRAMECAD Limited.

Confidentiality This document and all material included included herein is confidential to FRAMECAD Limited and must not be disclosed to any other party or used to the detriment of or other than as authorised by FRAMECAD Limited. This document and all material included herein shall be returned to FRAMECAD Limited Immediately upon request. This document and all material included herein shall be returned to FRAMECAD Limited Immediately upon request.

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FRAMECAD F300i Operating Manual

1 Contents 1

CONTENTS

3

2

INTRODUCTION

6

2.1 2.2

A Brief Overview ........................................................... ........................................................................................................ .............................................6 Purpose of this Manual .............................................................................................. ..............................................................................................6

3

FRAMECAD WARRANTY TERMS & CONDITIONS

7

4

SPECIFICATIONS

8

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11

Basic Dimensions & Weight.......................................................................................8 Electrical Supply Requirements ...................................................................... ................................................................................. ...........9 Ambient Temperature ............................................................. ..............................................................................................11 .................................11 Steel Strip T hickness & Tensile Strength Stre ngth ................................................................11 ................................................................11 Steel Coil Dimensions............................................................. ..............................................................................................11 .................................11 Steel Strip W idth ..................................................................... ......................................................................................................12 .................................12 Steel Strip Lubricant ................................................................................................12 ................................................................................................12 Steel Strip Cleanliness............................................................ .............................................................................................12 .................................12 Dust & Airborne Contam inants ....................................................................... ................................................................................13 .........13 Hydraulic Oil ............................................................... ............................................................................................................13 .............................................13 Ink & Cleaner Fluid ..................................................................................................14 ..................................................................................................14

5

SAFETY

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8

General Safety Overview ........................................................ .........................................................................................15 .................................15 Steel Management ............................................................................. ...................................................................................................15 ......................15 Ink and Cleaner .......................................................................................................16 .......................................................................................................16 Lubricants and Oils ...................................................................................... ..................................................................................................17 ............17 Emergency Stop Buttons & Reset Procedure .........................................................18 Protective Covers ....................................................................................................20 Electrical Iso lation Switch ........................................................................................22 ........................................................................................22 Danger Zones ..........................................................................................................23 ..........................................................................................................23

6

INTRODUCTION TO THE FRAMECAD FRAMECAD F300I

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11

Key Assemblies of the FRAMECAD F3 00i Machine ...............................................24 ...............................................24 Introduction to the ‘C’ Section Profile .......................................................... ......................................................................26 ............26 The De-coiler ...........................................................................................................29 ...........................................................................................................29 The Roll-forming Section .........................................................................................31 .........................................................................................31 The Drive System S ystem ....................................................................................................3 ....................................................................................................31 1 The Tooling Stations ............................................................... ................................................................................................32 .................................32 The Electrical Controls ............................................................ .............................................................................................33 .................................33 The Hydraulic System ............................................................. ..............................................................................................41 .................................41 The Ink Jet Printer Control System S ystem .............................................................. ..........................................................................42 ............42 Computer System & Operator Screen Controls ......................................................43 FRAMECAD Factor y Software ................................................................................45

7

INSTALLATION

7.1 7.2 7.3 7.4 7.5

Pre-delivery Considerations .............................................................. ....................................................................................47 ......................47 Unpacking the FRAMECAD F300i ..........................................................................51 ..........................................................................51 Positioning the FRAMECAD FRAMECA D F300i and De -coiler ...................................................53 ...................................................53 Levelling the FR AMECAD F300i .............................................................................55 Mounting the FRAMECAD F300i Operator Screen ...... .................................................56 ...........................................56 Release 10102013 ©2013 FRAMECAD Limited 3

15

24

46

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7.6 7.7 7.8

Charging the Hydraulic Accum ulator ........................................................... .......................................................................57 ............57 Checking Hydraulic Reservoir Level & Pump Rotation ...........................................61 ...........................................61 Connecting Power to the FRAMECAD F300i ..........................................................62 ..........................................................62

8

INITIAL SETUP

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8

Lubrication Unit Setup .............................................................................................63 .............................................................................................63 In-feed Unit Setup ......................................................... ....................................................................................................64 ...........................................64 Roll-forming Section Setup ......................................................................................7 ......................................................................................70 0 Adjusting Chain Tension ......................................................... ..........................................................................................73 .................................73 Check Hydraulic Reservoir Level & Pump Rotation ................................................75 Lubricate Shear Blade B lade .............................................................................................76 .............................................................................................76 Insert Ink & Cleaner .................................................................................................77 .................................................................................................77 Loading Coil onto the De-coiler ...............................................................................78 ...............................................................................78

9

POWERING UP THE FRAMECAD F300I

9.1 9.2 9.3 9.4 9.5 9.6

Pre-Power-up Checklist ...........................................................................................81 ...........................................................................................81 Switching on Electrical Power .................................................................................82 Check the Safety Controls .......................................................................................83 .......................................................................................83 Check Calibration of De-coiler De- coiler Dancer Arm ............................................................ .............................................................84 .84 Check Ink Jet Printer System Pressure ....................................................... ...................................................................94 ............94 Purge the Ink Jet Printer System with Ink................................................................95 Ink ................................................................95

10

INTRODUCTION INTRODUCTIO N TO FRAMECAD FACTORY 2

10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8

Software Overview ............................................................................. ...................................................................................................98 ......................98 Start-up an d Shut-down Shut-do wn Procedure .........................................................................99 .........................................................................99 Navigating FRAMECAD Factory Factor y 2 ........................................................................101 Manual, Semi-auto and Automatic Control Modes ................................................104 Schedule Scr een ...................................................................................................112 ...................................................................................................112 Setup Menu Screens Scree ns .............................................................................................119 .............................................................................................119 Info Menu Screens ........................................................ .................................................................................................127 .........................................127 Updating FRAMECAD Factory 2 ...........................................................................133 ...........................................................................133

11

PRODUCTION

11.1 11.2 11.3 11.4 11.5 11.6

Removing Steel from the Machine ........................................................................136 Loading Steel coil onto the De-coiler ........................................................... .....................................................................138 ..........138 Feed Steel Strip into t he Machine .........................................................................141 .........................................................................141 Purging the Ink Jet Printer System S ystem with Ink ...........................................................14 ...........................................................144 4 Loading a Production Job ......................................................................................147 ......................................................................................147 Switching to Automatic Control .......................................................... ..............................................................................153 ....................153

12

MACHINE CALIBRATION CALIBRATION

12.1 12.2 12.3 12.4

Scale-Factor (Strip Encoder) Calibration ..................................................... ...............................................................157 ..........157 Tool Offset Calibration ....................................................................... ...........................................................................................160 ....................160 Setting Tool Cycle Times Tim es ........................................................ .......................................................................................164 ...............................164 Setup and Calibration of the “C” Section Profile . ...................................................165

13

FRAMECAD F300I MAINTENANCE

13.1 13.2 13.3 13.4 13.5 13.6

Lubrication Schedule .............................................................................................183 .............................................................................................183 Recommended Maintenance Schedule ....................................................... .................................................................184 ..........184 Hydraulic Oil/Filter Replacement ...........................................................................187 ...........................................................................187 Ink Jet Printer System S ystem Maintenance ............................................................ ......................................................................189 ..........189 Purging the Ink Jet Printer System S ystem with Ink ...........................................................19 ...........................................................197 7 Printer System Test ...............................................................................................200 ...............................................................................................200 Release 10102013 ©2013 FRAMECAD Limited 4

63

81

98

136

157

181

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13.7 13.8 13.9

Shear Blade Replacement .....................................................................................203 Dimple Fixed Die/Punch Replacement ..................................................................206 Dimple Moving Die Replacement ..........................................................................210

14

TROUBLESHOOTING

14.1 14.2 14.3 14.4

Managing Problems ...............................................................................................213 Identifying Root Cause ..........................................................................................214 Basic Trouble-shooting Chart ................................................................................215 ® FRAMECAD Support ...........................................................................................218

15

RECOMMENDED SPARES

15.1

Requesting Spares ................................................................................................219

213

219

APPENDIX A – STARTER KIT

Release 10102013 ©2013 FRAMECAD Limited 5

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2 Introduction

2.1

A Brief Overview

The FRAMECAD F300i is an advanced manufacturing solution for producing light gauge steel wall and ® truss frames. The FRAMECAD system comprises a suite of design, manufacturing and engineering software products. Together with the FRAMECAD F300i machine these provide a high volume precision frame and truss manufacturing system. Steel strip is fed to the F300i in-feed rollers via a powered De-coiler with a "dancing arm" speed controller. A light film of lubrication fluid is then applied to the steel strip to allow it to process through the FRAMECAD F300i efficiently and with minimal surface and tooling wear. A sequence of punch and forming operations are performed on the steel strip in accordance with information encapsulated in a manufacturing “job” file (.RFD) and interpreted by the machine control system and software. The steel strip then continues into the roll forming section where the "C" profile is formed over a number of rolling stations. At the out-feed end, an Ink Jet printing system marks individual identifying information on each stick (the term used to define various sub-frame components manufactured in the machine). The completed stick is then ejected from the FRAMECAD F300i in a logical assembly order ready to assemble or "flat pack" to efficiently transport to site.

2.2

Purpose of this Manual

This manual provides general safety, installation, operation and maintenance information for the FRAMECAD F300i.

PLEASE NOTE! THIS MANUAL INCLUDES PHOTO’S AND IMAGES THAT MAY DIFFER TO THOSE USED ON SOME MACHINES. WHERE A SETUP AND CONFIGURATION PROCEDURE IS DEFINED, EVERY EFFORT HAS BEEN MADE TO COVER ALL VARIATIONS AND VERSIONS WHERE POSSIBLE.


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3 FRAMECAD Warranty Terms & Conditions Please refer to your Sale and Purchase Agreement for full Terms and Conditions of sale, including warranty on parts and equipment. For further information please contact your regional FRAMECAD office.


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4 Specifications The following Section provides information on the specifications for the FRAMECAD F300i.

4.1

Basic Dimensions & Weight

Specifications FRAMECAD FRAMECAD FRAMECAD FRAMECAD De-coiler De-coiler De-coiler De-coiler

F300i F300i F300i F300i

(3T) (3T) (3T) (3T)

Weight Height Length Width

Weight Height Length Width

1700kg 1260mm (Machine), 1780 (Machine + Screen) 3700mm 800mm 680kg 1780mm 1040 1040mm 1200mm

FRAMECAD F300i and De-coiler Dimensions


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4.2

Electrical Supply Requirements

Specifications Voltage Frequency Current  F3xxi Connection Type Cable Type Cable Sizing

Special Protection Requirements

400VAC 3-Phase +/-5% 50 / 60Hz +/- 1% 25A 3-Phase + Protective Earth (TN-C) 3-Phase + Protective Earth (No Neutral conductor required), Maximum permissible voltage drop along cable <2.5%. Cable to be sized according to current rating above, distance to machine and ambient temperature.  Over-load and Short-circuit Protection  All cables to be mechanically protected from damage (excessive heat, insulation cuts, crush etc)

1) Typical maximum requirements. Full-load current will vary depending on size and type of De-coiler used; diameter and weight of steel coil; steel thickness, machine setup and configuration.

WARNING! THE ELECTRICAL SUPPLY INSTALLATION IS THE SOLE RESPONSIBILITY OF THE CUSTOMER. CONFORMITY OF THE ELECTRICAL INSTALLATION WITH LOCAL SUPPLY REGULATION AND LEGISLATIVE REQUIREMENTS MUST BE CERTIFIED BY AGENTS ACTING ON BEHALF OF THE CUSTOMER AND RECOGNIZED UNDER LAW IN THE COUNTRY OF INSTALLATION. FRAMECAD WILL NOT WARRANT OR ASSUME ANY RESPONSIBILITY THEREIN FOR THE APPROPRIATENESS, SAFETY OR LEGAL FITNESS OF THE ELECTRICAL SUPPLY INSTALLATION. FAILURE TO CONNECT AND/OR CONDUCT SAFE WORKS MAY RESULT IN DAMAGE TO THE MACHINE OR SUPPLY NETWORK, SERIOUS INJURY OR EVEN DEATH. FAILURE TO COMPLY WITH ALL STATUTORY REQUIREMENTS MAY RESULT IN FINES AND/OR PENALTIES BEING IMPOSED BY AUTHORITIES IN THE COUNTRY OF INSTALLATION.


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Earthing Requirements: The machine must be effectively bonded to a suitably sized and low impedance protective earth network. All machines are equipped with protective earth termination points inside the AC-electrical Cabinet. If the machine is to be powered by a generator, it is typical practice to connect the neutral star point to protective earth. As earthing regulations can vary, to ensure compliance please consult with the local electrical supply authority on the approved earthing requirements for 3-phase transformers. Electrical Supply Protection Requirements: Over-load and Short-circuit protection must be installed on the supply to the machine. If an RCD (Residual Current Device) is to be used, this must be of a h i g h i m m u n i t y type and suited to industrial applications (e.g. reference Si-type). Voltage supply fluctuations (dips or spikes in voltage) can cause damage to the FRAMECAD F300i’s electronic equipment. If supply reliability is a concern, seek advice from electricity service provider on protection and/or supply conditioning measures that can be implemented to avoid serious damage. Generator Considerations: If the machine is to be supplied by a generator, it is important to ensure that the generator is sufficiently sized according to the type of load present and n o t just the full-load currents as stated above. All FRAMECAD machines utilize high-speed switching devices such as Variable Speed (Frequency) Controllers (VFC) and also incorporate Direct-Online Induction Motors (DOL) with demand peaks during operation that can vary substantially according to the type of production being undertaken. This equipment by design will introduce non-linear currents and high transient peaks of short duration both during start-up and in normal operation, and it is important to ensure the generator can accommodate these short-burst requirements. The following table is provided to assist generator suppliers with understanding the loading requirements of the machine. Machine Type

Rolling Motor Rating

Type of Load

7.5kW

Switched Mode (VFC)

F3xxi

Hydraulic Motor

De-coiler

Rating

Type of Load

Rating

Type of Load

3kW

D.O.L Induction Motor

4kW

Switched Mode (VFC)

VFC = Variable Frequency Controller D.O.L = Direct Online Start


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4.3

Ambient Temperature

Specifications Temperature Range

0 - 40 OC

Special Requirements

If the ambient temperature is outside this range, it will be necessary to locate the FRAMECAD F300i in a climate controlled room.

4.4

Steel Strip Thickness & Tensile Strength

Specifications Steel Strip Thickness (TCT)

0.6 – 1.2mm

Steel Strip Tensile Strength

350 - 550Mpa

TCT = Total Coated Thickness (base metal + applied top and bottom coating thickness)

WARNING! RUNNING OUT OF SPECIFICATION MATERIAL THICKNESS WILL DAMAGE THE MACHINE. ALWAYS USE A CALIBRATED MICROMETER OR VERNIER CALIPER TO CHECK THICKNESS OF THE SUPPLIED STEEL STRIP.

4.5

Steel Coil Dimensions

Steel coil to be used on the FRAMECAD F300i De-coiler must meet the following requirements: Specifications Maximum Weight (kg)

<3000kg

Inside Diameter (mm) Maximum Outside Diameter

508 – 530mm <1200mm

Maximum Strip Width

<265mm

WARNING! THE MAXIMUM SIZE AND WEIGHT OF COIL THAT CAN BE SAFELY MANAGED ONSITE WILL BE LIMITED BY AVAILABLE STORAGE, LIFTING AND TRANSFER CAPABILITY – NEVER ORDER STEEL COIL THAT EXCEEDS YOUR ABILITY TO SAFELY MANAGE ON-SITE.


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4.6

Steel Strip Width

In order to roll the steel strip into the correct ‘C’ -type profile dimensions, an ideal strip width must be calculated. The profile dimensions required are submitted when ordering the machine and each FRAMECAD F300i is then manufactured to process the matching strip width. Processing a wider or narrower strip width than that recommended for desired ‘C’ profile will cause the lip dimension (see section 6 – Introduction to the FRAMECAD F300i) to vary accordingly. This can result in insufficient lip width or a lip that is ultimately too wide to be processed; the latter potentially leading to steel jam-ups inside the machine. When considering steel strip width it is important to note that the FRAMECAD F300i is deliberately designed with minimal clearance between the forming rollers and tooling operations. The steel strip width must be checked using a vernier caliper or steel rule to ensure its suitability prior to commencing production. The maximum allowable tolerance of the steel strip width is: +0mm / -2mm of the nominal (recommended) strip width.

4.7

Steel Strip Lubricant

Specifications Type Mixture Application

Soluble Oil 30:1 Consistent film across the strip, without oil droplets forming

Typical Example

HOCUT 757 (supplied Houghton International Inc) Refer to Material Safety Data Sheet for full safety information, handling, disposal and composition related detail

4.8

Steel Strip Cleanliness

Specifications General Cleanliness General Notes

Steel strip should be clean and devoid of transferrable dirt, dust and/or other contaminants Dirty steel will eventually lead to contamination build-up on the roller and tooling surfaces inside the machine resulting in premature wearing of components and/or reduced performance. Always ensure your steel coil storage facilities are kept clean and tidy.


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4.9

Dust & Airborne Contaminants

Specifications General Cleanliness

Avoid excessive dust, dirt or other airborne contaminants from building up on the roller and tooling surfaces inside the machine

General Notes

A high degree of cleanliness is required to ensure maximum service life of the FRAMECAD F300i. Failure to keep the machine clean and free of dust, dirt and other contaminants can lead to blocked Ink Jet Printer head nozzles and premature wearing of components and/or reduced performance. Always ensure the FRAMECAD F300 i is operated in a clean environment with a regular maintenance regime.

4.10

Hydraulic Oil

Specifications (1)

Oil Type Oil Capacity (Reservoir) Maximum Oil Temperature Maximum Operating Pressure Accumulator Pressure

ISO46 Hydraulic Oil 60litres 65 OC 195Bar 120Bar

Typical Example

Castrol Hyspin AWS46 Refer to Material Safety Data Sheet for full safety information, handling, disposal and composition related detail

General Notes

Always ensure the FRAMECAD F300i is operated in a clean environment with a regular maintenance regime.

1) Typically all FRAMECAD F300i machines are shipped with Castrol Hyspin AWS46 included. This is a general purpose ISO 46 viscosity h y d r a u l i c o i l that will satisfy most operating environments. Most hydraulic oil suppliers will be able to give advice on an equivalent and locally available alternative as required. The optimal hydraulic oil viscosity is dependent on the operating temperature range. In warmer year round climates it may be advisable to consider an ISO 68 viscosity oil – always consult your local hydraulic oil supplier for the option that best suits your local requirements.


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4.11

Ink & Cleaner Fluid

Specifications Ink Type Cleaner Type Delivery System Pressure IMPORTANT NOTE!

Mathews SCP-700 (FD) Black Mathews SCP-700C Cleaner 10PSI It is a condition of Warranty on all parts related to the Ink and Cleaner Printing System that the above Ink and Cleaner types are used. Use of an unauthorised alternative will void all related Warranty claims on the Printing System equipment.

Visit www.mathewsmarking.com OR contact your regional FRAMECAD office to find a supplier near you.

WARNING! THE SPECIFIED INK AND CLEANER ARE MEK (METHYL ETHYL KETONE) BASED PRODUCTS. THESE PRODUCTS ARE HIGHLY FLAMABLE AND REQUIRE SPECIAL SAFETY PRECAUTIONS WHEN HANDLING. ALWAYS CONSULT THE MATERIAL SAFETY DATA SHEET BEFORE USE. THE INK AND CLEANER DELIVERY SYSTEM IS PRESSURIZED. ALWAYS USE SAFETY GLASSES AND APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT WHEN WORKING ON OR NEAR THE INK AND CLEANER SYSTEM. SEE SECTION 5 - SAFETY FOR MORE INFORMATION.


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5 Safety 5.1

General Safety Overview

The FRAMECAD F300i is a fast, powerful and fully automated machine and should therefore only be operated by fully trained and competent personnel. Whilst every effort has been made to minimise potential risk and harm, Operators must read and familiarise themselves with the information contained within this manual BEFORE installation and commencing production. Failure to follow the instructions and guidelines included herein may result in serious injury to personnel and/or damage to the machine.

5.2

Steel Management

Steel coils of up to a maximum 3000kg are used to feed strip to the FRAMECAD F300i. Specialist coil loading equipment is required to transfer these to/from the production floor. A certified lifting gantry or other such steel coil loading system is highly recommended. Where practical, steel coils should be stored upright in a reinforced rack system to allow for safe storage, removal and transfer to/from the De-coiler unit. Use either 5000Kg rated plastic sheathed strops OR equivalent chains to secure the steel coils to the gantry lifting hook during transfer. When selecting the steel coil weight and diameter to be used, always consider t he available storage, lifting and transfer capabilities of your site; NEVER exceed your ability to safely manage the size and weight of steel coils ordered for production use.

WARNING! APPROPRIATE PERSONAL SAFETY EQUIPMENT SUCH AS CUT-RESISTANT PROTECTIVE GLOVES AND STEEL CAPPED BOOTS MUST BE WORN WHEN HANDLING STEEL PRODUCT. THE MAXIMUM SIZE AND WEIGHT OF COIL THAT CAN BE SAFELY MANAGED ONSITE WILL BE LIMITED BY AVAILABLE STORAGE, LIFTING AND TRANSFER CAPABILITY – NEVER ORDER STEEL COIL THAT EXCEEDS YOUR ABILITY TO SAFELY MANAGE ON-SITE.


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5.3

Ink and Cleaner

The FRAMECAD F300i utilises MEK-based ink and cleaner. Please note the following; 1.

Refer to Material Safety Data Sheet for full safety information, handling, disposal and composition related detail.

2.

The ink and cleaner system is typically under p r e s s u r e . ALWAYS ensure the system is depressurised BEFORE conducting any work on the ink and cleaner system (including changing the ink and/or cleaner bottles). The following procedure describes the correct method to depressurise the ink and cleaner system; PROCEDURE FOR DEPRESSURISING THE INK AND CLEANER SYSTEM Step 1

Press an emergency stop push-button on the machine (see below)

Step 2

Open the Ink and Cleaner Cabinet Door

Step 3

Makes sure there is no display on the Print Compressor display screen

Step 4

Carefully unscrew the black filter cap on either the Ink OR Cleaner bottles to gently relieve pressure in the system

3.

These products are h i g h l y f l a m m a b l e - ALWAYS remove any potential ignition sources.

4.

Always wear Personal Protective Equipment (PPE) when handling ink or working on the Printing System. At a minimum this includes safety glasses and Nitral rubber gloves.

5.

Consult your company’s hazardous materials handling policy on how to store and/or dispose of MEK based inks and solvents.

6.

Show caution when handling the ink. It is a very strong ink and will permanently mark/stain any surfaces it is spilt on.

WARNING! THE SPECIFIED INK AND CLEANER ARE MEK (METHYL ETHYL KETONE) BASED PRODUCTS. THESE PRODUCTS ARE HIGHLY FLAMABLE AND REQUIRE SPECIAL SAFETY PRECAUTIONS WHEN HANDLING. ALWAYS CONSULT THE MATERIAL SAFETY DATA SHEET BEFORE USE. THE INK AND CLEANER DELIVERY SYSTEM IS PRESSURIZED. ALWAYS USE SAFETY GLASSES AND APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT WHEN WORKING ON OR NEAR THE INK AND CLEANER SYSTEM. CONSULT THE MATERIAL SAFETY DATA SHEET FOR MORE INFORMATION.


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5.4

Lubricants and Oils

for specific safety information relating to the type AL WAYS co nsu lt the Material Safety Data Sheet of hydraulic oil and strip lubricant used with the machine. It is important to ensure this information is readily available by all staff operating the machine AND that they are trained in the safe handling, storage and disposal of these products. Typically all FRAMECAD F300i machines are shipped with Catrol Hyspin AWS46 hydraulic oil. Refer to Material Safety Data Sheet for full safety information, handling, disposal and composition related detail. Typically all FRAMECAD F300i machines are shipped with HOCUT 757 steel strip lubricant. Refer to Material Safety Data Sheet for full safety information, handling, disposal and composition related detail. It is important to ensure that safe storage, disposal and accidental spill management policies are in place and in accordance with the data supplied in the Material Safety Data Sheet for these products.

IMPORTANT! ALWAYS CONSULT THE MATERIAL SAFETY DATA SHEET FOR SPECIFIC SAFETY INFORMATION RELATING TO THE TYPE OF HYDRAULIC OIL AND STRIP LUBRICANT USED WITH THE MACHINE. IT IS IMPORTANT TO ENSURE THIS INFORMATION IS READILY AVAILABLE TO ALL STAFF OPERATING THE MACHINE AND THEY ARE TRAINED IN THE SAFE HANDLING, STORAGE AND DISPOSAL OF THESE PRODUCTS.


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5.5

Emergency Stop Buttons & Reset Procedure

All FRAMECAD F300i machines are fitted with 2 emergency stop push-buttons, located on either side of the machine. Another emergency stop push-button is located at the De-coiler unit. Latter generation FRAMECAD F300i machines are also fitted with an emergency stop push-button located on the Operator Screen Cabinet. The machine safety control system is design to immediately stop production whenever an emergency stop push-button is pressed. Testing of the emergency stop push-buttons should be conducted at least once a day . ALL emergency stop push-buttons should be tested individually to ensure the safety control system responds accordingly and that all buttons are functioning. When an emergency stop push-button is pressed: 1. 2. 3.

The emergency stop push-button should remain down in a latched state so that it must be momentarily turned clock-wise in order to release; the FRAMECAD F300i should stop immediately and inhibit all Automatic and Manual functions on the machine (including all rolling and hydraulic operations); An Emergency Stop Alarm message should be displayed on the Operator Screen;

If any of the above is not true when an emergency stop push-button is pressed then the emergency stop push-button test has failed and all production on the FRAMECAD F300i must be suspended until a qualified Technician has re-tested and resolved the issue.

See Note 1 below

If an emergency stop push-button is pressed, the safety control system can only be reset using the following procedure; 1)

Emergency stop push-button on the Operator Screen Cabinet is only available on latter generation machines


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RESET EMERGENCY STOP PROCEDURE

Step 1

Twist and release all emergency stop push-buttons (i.e. so that none remain latched in the pressed-down state)

Step 2

Press the SAFETY RESET control system

1), 2)

push-button located on the screen cabinet to reset the safety

1) Do not confuse the SAFETY RESET push button with the standard SOFTWARE RESET push-button. The latter is used for software resetting only;

Correct - Safety Reset Push-button

Wrong! – Software Reset ONLY Push-button 2) On earlier generation models, the safety control system was reset by pressing the START push-button once. Machines that do not have a dedicated SAFETY RESET push-button utilise this method.

OR

Start Push-button

Step 3

Acknowledge any Emergency Stop alarms displayed on the Operator T ouch Screen

WARNING! EVEN WITH AN EMERGENCY STOP PUSH-BUTTON PRESSED ALWAYS ASSUME THAT THERE IS RESIDUAL HYDRAULIC AND/OR MECHANICAL ENERGY IN THE MACHINE. NEVER RELY ON A SAFETY CIRCUIT TRIP (E.G. EMERGENCY STOP PUSH BUTTON OR GUARD SWITCH) TO PROVIDE ISOLATION FOR MAINTENACE, SERVICE OR REPAIR WORK TO THE MACHINE!


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5.6

Protective Covers

FRAMECAD F300i is supplied with fitted covers to protect Operators of the machine from moving parts that will cause serious injury if bodily contact is made. The machine also has two sliding guard covers (see picture below) at the top to allow for setup access to the machine. Both these sliding guards incorporate safety switches that are electrically interlocked with the machine. Opening the machine sliding guards will cause the machine to halt. Extreme care must always be taken with the sliding guards open. ALWAYS assume that there is residual hydraulic pressure and/or mechanical energy in the machine tooling and rolling sections.

FRAMECAD F300i Top Sliding Cover Safety Switches

WARNING! ALWAYS ASSUME THAT THERE IS HYDRAULIC AND/OR MECHANICAL ENERGY IN THE MACHINE AND TAKE EXTREME CARE WITH THE TOP SLIDING GUARD COVER(S) OPEN. NEVER OPERATE THE FRAMECAD F300i WITH ANY OF THE PROTECTIVE COVERS REMOVED! IMPORTANT NOTE! ON SOME EARLY PRODUCTION MACHINES, THE ROLLING SECTION WAS KEPT ACTIVE FOR UP TO 5MINS AFTER OPENING THE SLIDING GUARDS. THIS WAS TO ALLOW ROLLER MOTION UNDER MANUAL CONTROL. THIS PRACTICE HAS BEEN SUPERCEEDED AND FRAMECAD NOW RECOMMENDS TURNING THIS FEATURE OFF. INSTRUCTIONS ON HOW TO DO THIS ARE AVAILABLE FROM FRAMECAD TECHNICAL SUPPORT.


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The De-coiler is also fitted with a safety plate and x3 service access panels;

Safety Guard

Service Covers De-coiler Safety Guard and Service Panels

Note that the function of the safety guard is to prevent the steel coil from sliding off the De-coiler mandrel during rotation. Additional safety guarding MUST BE included around the De-coiler m achine itself to prevent serious injury to personnel from the rotating mass.

WARNING! NEVER OPERATE THE DE-COILER WITH ANY OF THE COVERS REMOVED! ALWAYS ENSURE THE SAFETY GUARD IS ATTACHED TO PREVENT STEEL COIL FROM SLIPPING OFF THE DE-COILER MANDREL. ADDITIONAL SAFETY GUARDING MUST BE INCLUDED AROUND THE DE-COILER MACHINE ITSELF TO PREVENT SERIOUS INJURY TO PERSONNEL FROM THE ROTATING MASS.

ELECTRIC SHOCK HAZARD! DANGEROUS VOLATGES ARE PRESENT BENEATH THE SERVICE PANELS! ALWAYS ENSURE THAT THE DE-COILER IS UNPLUGGED AND ELECTRICALLY ISOLATED FROM SUPPLY BEFORE REMOVING PANELS FOR SERVICE WORK.


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5.7

Electrical Isolation Switch

The FRAMECAD F300i must be electrically isolated (disconnected) at the either the isolation switch located on the machine (see picture below) OR at the point of supply to the machine when: 1. 2. 3.

Any maintenance or service work is to be undertaken; Once production is complete – NEVER leave the machine p o w e r e d and u n a t t e n d e d ; If the machine is to be moved.

Electrical Isolation Switch

ELECTRIC SHOCK HAZARD! EVEN WITH THE ISOLATION SWITCH MOUNTED ON THE MACHINE IN THE OFF POSITION, DANGEROUS VOLTAGES STILL EXIST INSIDE THE ELECTRICAL CONTROL CABINETS. THE FRAMECAD F300i MUST BE ELECTRICALLY ISOLATED FROM THE SUPPLY SOURCE TO THE MACHINE (E.G. AT THE CUSTOMER’S DISTRIBUTION BOARD) BEFORE ANY ELECTRICAL SERVICE WORK CAN BE UNDERTAKEN. ALWAYS USE A LOCK-OUT TAG SYSTEM WHEN UNDRTAKING ANY SERVICE/MAINTENACE WORK ON THE MACHINE TO PREVENT ACCIDENTAL RECONNECTION. NEVER RELY ON A SAFETY CIRCUIT TRIP (E.G. EMERGENCY STOP PUSH BUTTON OR GUARD SWITCH) TO PROVIDE ISOLATION FOR MAINTENACE, SERVICE OR REPAIR WORK TO THE MACHINE!


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5.8

Danger Zones

The FRAMECAD F300i and De-coiler are fully automated, high-speed machines. Extreme care must be taken to ensure that Danger Zones are highlighted and that all Operators are fully trained in the potential hazards in and around the machine. The following machine floor plan is provided to indicate the Danger Zones. Under no circumstances should access be permitted to the areas indicated during production.

Danger Zones

WARNING! NO ACCESS IS PERMITTED IN THE IDENTIFIED DANGER ZONES WHILE EITHER THE FRAMECAD F300I OR DE-COILER IS IN A RUNNING STATE! ADDITIONAL SAFETY GUARDING MUST BE INCLUDED AROUND THE DE-COILER TO PREVENT SERIOUS INJURY TO PERSONNEL FROM THE ROTATING MASS. EXTREME CARE MUST BE TAKEN WHILST STANDING NEAR THE OUT-FEED END OF THE FRAMECAD F300I. FRAMING CAN BE EJECTED FROM THE MACHINE AT HIGH-SPEED WHICH WILL CAUSE SERIOUS INJURY TO PERSONS ENTERING THIS AREA DURING MACHINE OPERATION.


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6 Introduction to the FRAMECAD F300i 6.1

Key Assemblies of the FRAMECAD F300i Machine

The FRAMECAD F300i machine is a highly automated and advanced steel processing machine. By integrating the latest computer technology with advanced hydraulic, roll-forming, punch-tooling and ink-jet printer control systems, the FRAMECAD F300i is essentially a complete roll-forming factory in one package. The following highlights some of the key assemblies on the machine.

The F300i Machine

Item 1 2 3 4 5 6 7 8

Description Lubricator Unit Pre-Punch Tool Block Assembly DC Electrical Control Cabinet AC Electrical Control Cabinet Hydraulic Power Pack Cover Access Side Cover Push-button Controls Ink Jet Printer System Roll-forming Section

Item 9 10 11 12 13 14 15 16

Description Lip Box Control Assembly Pinch Roller Set #1 Dimple Tools + Over-from Roller Assemblies Pinch Roller Set #2 Swage Tool Assembly Shear Tool Assembly Operator Screen and Controls Printer Heads


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The basic process of rolling steel strip into a “C” section profile is shown below;

Steel Strip Lubrication (applies lubricant to steel strip)

In-feed Guide Assembly (centralises steel strip; also where steel strip position encoder is located)

Pre-punch Tool Assembly (houses the hydraulic tooling to punch required cut-outs in the steel strip)

Roll-forming Assembly (Rolls the steel strip into ‘U’-section profile shape)

Lip Control Box Assembly (forms the lips to produce the final ‘C’-section profile shape)

Dimple Tools & Over-form Assembly (allows dimple screw holes and adjustable over-form to be added)

Swage Tool (allows the ‘C’-section profile width to be reduced for easy insertion into other framing parts)

Shear Tool (cuts the processed steel to the required length)


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6.2

Introduction to the ‘C’ Section Profile

The FRAMECAD F300i is designed to roll steel strip into a “C” section profile. As the steel strip is progressed through the roll-f orming section, the strip is incrementally folded into the typical “C” section.

“C” Section Profile Progression

“C” section Parts: The diagram below highlights the terminology used when referencing the various dimensions (or “parts”) of the “C” section profile, including;   

Web Lip(s) Flanges(s)

“C” section Profile Parts


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Boxable vs. Symmetrical “C” section: The FRAMECAD F300i can be ordered to produce either “ B o x a b l e” or “S y m m e t r i c a l ” “C” section profiles. The Boxable configuration allows one “C” section profile to be overlapped with another to form a uniform boxed section as shown below;

Boxable Configuration

In order to achieve a boxable configuration, one of the flanges is folded slightly longer than the other. This is to allow one “C” section profile to be overlapped with the second. The standard configuration has one flange (Flange A) 2mm longer than the other (Flange B). In a s y m m e t r i c a l configuration the two flanges are equal length (hence the term symmetrical) and cannot be overlapped together. “U” section Profile: The FRAMECAD F300i can also manufacture “U” section profile . This is achieved by disengaging the Lip operation (i.e. turning the lip folds OFF) and all FRAMECAD F300i machines can be configured this way.

“U” Section Profile


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Tooling Operations: The FRAMECAD F300i will also perform the various hydraulic tooling operations required as defined in the job file and interpreted by the machine control system. These tooling operations will punch the steel in the shape of the cut-out required. Standard FRAMECAD F300i tool functions include;       

Service Hole Bolt Hole (or 3x3.8mm Web holes) Web Notch Lip Cut Chamfer Cut Dimple Hole Shear (cutting blade)

The figure below shows the typical cut-out shapes as performed by the various tooling options.

IMPORTANT NOTE! THE BELOW TOOLING OPTIONS ARE SHOWN FOR INFORMATION ONLY. THESE MAY VARY DEPENDING ON THE CONFIGURATION/MACHINE TYPE SPECIFIED. PLEASE REFER TO THE SPECIFICATION SHEET SUBMITTED AT ORDER PLACEMENT FOR THE EXACT OPTIONS INCLUDED ON YOUR MACHINE.

Typical “C” Section Tooling Options


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6.3

The De-coiler

The FRAMECAD F300i uses a powered De-coiler unit to supply the steel strip to the in-feed of the machine. The De-coiler is electrically connected to the FRAMECAD F300i by a cable and plug system. This supplies electrical power to the De-coiler along with various control signals to manage the De-coiler’s operating state.

Safety Guard Mandrel Shoe Plate Mandrel Assembly

Motor & Gearbox Dancing Arm

Typical FRAMECAD F300i De-coiler Unit

Each De-coiler is fitted with a VFC (Variable Frequency Controller) that is used to control the speed of De-coiler’s rotation and therefore the feed-rate into the FRAMECAD F300i. The Dancing Arm set-up is designed to move up and down with the steel strip.

Dancing Arm Rotation

As the Dancing Arm is raised, the speed at which the De-coiler will rotate the steel coil increases . As the Dancing Arm is lowered, the speed at which the De-coiler will rotate the steel coil will decrease . In this way the De-coiler will speed up and down depending on the demand from the FRAMECAD F300i. For example, as the FRAMECAD F300i speeds up the steel strip at the in-feed to the machine will tend to lift and in doing so raise the De-coiler Dancing Arm and therefore the De-coiler speed.


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To make sure the De-coiler Dancing Arm system operates correctly the De-coiler must be calibrated (see section 9 - Powering the Machine for the First Time). De-coiler Electrical Controls: The De-coiler incorporates Stop, Start and Emergency Stop push button controls as shown below;

De-coiler Stop/Start/Emergency Stop Controls

The FRAMECAD F300i is prevented from starting until the De- coiler has been started. An “Emergency Stop” alarm will be present on the Operator Interface Screen until the De-coiler is started. Inside the De-coiler the VFC unit is mounted as shown below;

De-coiler VFC (Variable Frequency Controller)

ELECTRIC SHOCK HAZARD! DANGEROUS VOLATGES ARE PRESENT BENEATH THE SERVICE PANELS! ALWAYS ENSURE THAT THE DE-COILER IS UNPLUGGED AND ELECTRICALLY ISOLATED FROM SUPPLY BEFORE REMOVING PANELS FOR SERVICE WORK.


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6.4

The Roll-forming Section

Roll-forming Section

The FRAMECAD F300i forms a "C" section profile by passing the flat steel strip through 6 driven roll forming stations. These progressively bend the material to the exact dimensions specified at the time of order. There is an additional 4 non driven rollers that form the lips of the “C” section. These are mounted in a lip control box that can be configured to either produce a lipped or un-lipped section ("C" or "U" section). A set of adjustable pinch rollers are fitted at the out-feed of the roll-form ing section allowing the “C” section profile to be fine-tuned and to compensate for different tensile strength steel strip.

6.5

The Drive System

The drive system is based upon a high-torque, synchronous AC servo motor utilising a highly efficient low-backlash bevel gearbox. The geared servo motor is capable of delivering in excess of 600Nm of rolling torque at its output shaft. The power from the servo motor is then transmitted via multi chain drive system to the lower roll shafts. The top roll shafts are driven via meshing gears.


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6.6

The Tooling Stations

The tooling stations punch the forms, holes and cut outs required by the design to allow the simple assembly of walls, joists and trusses. The tool stations are split into two fundamental sets; the first is located at the start or in-feed of the machine and housed in an assembly termed the p r e - p u n c h block. These tools are located before the roll forming section and therefore process the steel strip while it is still flat (hence the term “pre punch”). The pre-punch tools consist of the service hole, web notch, lip notch, chamfer, lip-cut and web hole tools.

The Pre-Punch Block Assembly (Housing the Pre-Punch Tooling)

1

The dimple tools, swage and shear are located at the out-feed end and operate on the profile after the roll forming section. The shear is a "crimp shear" type, meaning that side “crimps” hold the “C” section profile whilst the shear (cut-off) operation is completed. This side-crimping shear operation is designed to reduce the natural tendency of the side flanges to want to “flare” outwards during the cut sequence, allowing for easier and more efficient assembly of the “C” section parts. 1)

The swage tool does not actually cut the steel but rather re-forms the section at the swage point to reduce the web width for easy insertion into other steel sections

The Swage and Crimp-Shear Assembly


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6.7

The Electrical Controls

The electrical controls for the FRAMECAD F300i are located behind the electrical cabinet doors as shown below;

Electrical Cabinet Doors

The left-side cabinet houses the 400VAC electrical controls. The right-side cabinet houses the DC electrical controls.

Typical AC Electrical Cabinet (Left) and DC Electrical Cabinet (Right)

WARNING! EVEN WITH THE ISOLATION SWITCH MOUNTED ON THE MACHINE IN THE OFF POSITION, DANGEROUS VOLTAGES STILL EXIST INSIDE THE ELECTRICAL CONTROL CABINETS. THE FRAMECAD F300i MUST BE ELECTRICALLY ISOLATED FROM THE SUPPLY SOURCE TO THE MACHINE (E.G. AT THE CUSTOMER’S DISTRIBUTION BOARD) BEFORE ANY ELECTRICAL SERVICE WORK CAN BE UNDERTAKEN. ALWAYS USE A LOCK-OUT TAG SYSTEM WHEN UNDRTAKING ANY SERVICE/MAINTENACE WORK ON THE MACHINE TO PREVENT ACCIDENTAL RECONNECTION. NEVER RELY ON A SAFETY CIRCUIT TRIP (E.G. EMERGENCY STOP PUSH BUTTON OR GUARD SWITCH) TO PROVIDE ISOLATION FOR MAINTENACE, SERVICE OR REPAIR WORK TO THE MACHINE!


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AC Electrical Cabinet: The primary components of AC electrical cabinet are highlighted below;

Hydraulic Pump Phase Rotation Relay

24VDC Power Supply

24VDC Power Supply Circuit Breaker

VFC

400VAC Supply Isolation Switch

24VDC Hydraulic Cooling Fan Relay Motor Control Circuit Breakers VFC (Left), Hydraulic Motor (Centre), De-coiler (Right) Hydraulic Motor Contactor VFC Breaking Resistor AC Electrical Cabinet Components

VFC (Variable Frequency Controller) Controls the position, speed and acceleration of the roll-forming servo motor and thereby the steel strip. The VFC receives its control instructions from the computer system via an Ethernet interface built-into the VFC. 24VDC Power Supply 24VDC power Supply. The power supply unit supplies the 24VDC control voltage for both AC and DC electrical cabinets as well as the computer and touch screen. The power supply uses a 400VAC input and provides a 24VDC output. Hydraulic Pump Phase Rotation Relay This relay is used to prevent the 3-phase hydraulic pump motor from rotating in the wrong direction and causing damage. As the direction of rotation is determined by the phase sequence of the incoming 3-phase supply, this relay will prevent the hydraulic motor/pump from starting if the sequence is reversed. 24VDC Power Supply Circuit Breaker This circuit breaker provides overload protection for the 400VAC/24VDC power supply 400VAC Isolation Switch Main electrical power supply Isolation switch.

WARNING! EVEN WITH THE ISOLATION SWITCH IN THE OFF POSITION, DANGEROUS VOLTAGES STILL EXIST INSIDE THE ELECTRICAL CONTROL CABINETS. THE FRAMECAD F300i MUST BE ELECTRICALLY ISOLATED FROM THE SUPPLY SOURCE TO THE MACHINE (E.G. AT THE CUSTOMER’S DISTRIBUTION BOARD) BEFORE ANY ELECTRICAL SERVICE WORK CAN BE UNDERTAKEN.


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24VDC Hydraulic Fan Cooling Interface Relay This relay controls the hydraulic cooling fan at the out-feed end of the machine. This relay turns ON the hydraulic cooling fan whenever the hydraulic motor is started. Motor Control Circuit Breakers VFC motor circuit breaker: this circuit breaker provides overload and short-circuit protection for the VFC unit and is set to 15Amps. Hydraulic motor circuit breaker: this circuit breaker provides overload and short-circuit protection for the hydraulic pump motor and is set to 7.5Amps. De-coiler circuit breaker: this circuit breaker provides overload and short-circuit protection for the De-coiler and is set to 7.5Amps. Hydraulic Motor Contactor The hydraulic motor start contactor is fitted to the bottom of the hydraulic motor circuit breaker to allow stop/start control via the 24VDC Input/Output control system. VFC Breaking Resistor The braking resistor is used to adsorb any excess energy in the servo motor system (and therefore the VFC) during rapid deceleration of the roll-former section. This excess energy must be dissipated via this resistor to prevent damage to the VFC.


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DC Electrical Cabinet: The primary components of DC electrical cabinet are highlighted below;

Safety Controller & Relay

24VDC Uninterruptable Power Supply (UPS)

DC Input / Output Controller DC Electrical Cabinet Components

Safety Controller & Relay The safety controller monitors the state of both the emergency stop push-button circuit and the top sliding cover safety switches. If one or other of these circuits is interrupted (i.e. a sliding cover is opened or an emergency stop push-button is pressed), the safety controller will disable the safety relay which in turn shuts of the DC control voltage to the hydraulic motor, valves and VFC. The safety controller can only be reset once the VFC and hydraulic motor have been shutdown and the safety controller reset push-button has been pressed from the screen cabinet. 24VDC Uninterruptable Power Supply (UPS) The UPS provides 24VDC power to computer system in the event of a mains power supply failure. If the UPS detects a power supply failure, it will signal the computer to do an orderly shut-down. The UPS will maintain the 24VDC circuit for the computer and screen just long enough to allow the system to fully shut-down then it will switch off. DC Input/Output Controller The Input/Output controller is actually comprised of a number of individual components that are assembled together to form the primary interface between the computer system and the FRAMECAD F300i digital inputs and outputs, including all hydraulic valves, VFC stop/start management, sensors and push-button controls. The complete system comprises;   

An Ethernet Controller to interface with the computer system, Digital Input modules to provide the state of all sensor and push-button inputs on the machine; Digital Output modules to actuate all valves, stop/start the VFC and hydraulic motor, and control the various status lights on the screen push-buttons


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PLEASE NOTE! On some earlier machines, the Operator touch screen and computer were separate, with the computer housed in the DC Electrical Cabinet as shown below;

Some earlier generation F300i machines had a separate Computer Board – located in DC Electrical Cabinet


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Ethernet Connections: The computer system controls the VFC and Input/Output controller via an Ethernet connection. The Ethernet network on the FRAMECAD F300i is shown below;

Ethernet Network


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Encoder Connections: High resolution encoders provide position and speed feedback to the VFC for both the steel strip running inside the machine and the servo motor. The steel strip encoder is mounted on the in-feed unit of the machine. There have been two types of in-feed unit used on the FRAMECAD F300i. The mounting arrangement of the strip encoder will vary depending on the type of in-feed unit used. Type 1 uses a belt-coupled encoder while type 2 uses a direct-coupled encoder;

Strip Encoder – Type 1 in-feed unit (left) uses a belt-couple steel strip encoder while Type 2 (right) uses a directcoupled steel strip encoder

The VFC also requires the speed and angular position of the roll-forming section servo motor. A high resolution encoder (resolver) is mounted inside the cooling fan end of the servo motor to provide this feedback;

Servo Motor Encoder (Resolver) mounted in the cooling fan end of the motor

Servo Motor Encoder/Resolver


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Side Cover Controls: 1)

Mounted on both sides of the FRAMECAD F300i are button controls for inching the steel strip both FORWARD and in Reverse, performing a Shear Down operation (DOWN) and Emergency Stop. The steel strip FORWARD push-buttons are also mounted on the side at the in-feed and out-feed of the machine.

Inch FORWARD push-button – located on each side of the machine and at either end (i.e. In-feed and Out-feed ends)

Shear DOWN push-button, Emergency Stop push-button and Inch FORWARD and REVERSE Selector Switch – mounted each side of the machine 1)

The term i n c h i n g here relates to the method of applying a signal via the push-button or selector switch to the computer control system which in turn will drive the roll-forming servo motor in either the forward or reverse direction (depending on the function being actuated). The following conditions will be present; The speed at which the roll-forming motor will operate at is reduced;  the motor will continue to rotate while the FORWARD push-button or INCH selector switch is activated – this  is to allow accurate positioning of the steel strip using the inching method; Inching is only possible while the FRAMECAD Factory 2 control software is in Manual control mode. 

WARNING! EXTREME CARE MUST BE TAKEN WHEN USING THE SHEAR DOWN PUSH-BUTTON. WHEN THIS BUTTON IS PRESSED DURING MANUAL CONTROL THE SHEAR TOOL WILL ACTIVATE.


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6.8

The Hydraulic System

Pre-Punch Tool Block Hydraulic Cylinders and Solenoid Valves Return Filter

Hydraulic Accumulator Tank

Hydraulic Pump Motor

Hydraulic Tank

Unloader Block Hydraulic Cylinders (Actuators) Hydraulic System Components

The hydraulic tools are operated by solenoid activated, double acting hydraulic cylinders. The 3kW FRAMECAD F300i hydraulic motor generates pressure via a gear pump. A nitrogen pressurised 5litre accum ulator tank provides additional capacity during tooling operations to allow the hydraulic system to run at higher efficiency and speed. The hydraulic tank (reservoir) stores surplus oil. This excess volume assists with cooling the oil due to the increased surface area provided by the tank. The system has a Hydraulic Cooling Radiator situated at the lower shear end (out-feed) of the machine. This provides additional cooling for the hydraulic oil by means of an electrically operated fan. The fan will run continuously in conjunction with the hydraulic oil pump. The FRAMECAD F300i hydraulic system has an adjustable pressure unloader valve located in a mono-block housing on top of hydraulic tank. This is pre-set at the factory and has been tested during commissioning of the machine. No maintenance is necessary and the settings should not be altered under any circumstances. If in doubt, please contact FRAMECAD service for further details.


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6.9

The Ink Jet Printer Control System

Ink Jet Printer Delivery System and Print Controller Cabinet (Left) and the Ink Jet Printer Heads (Right)

The FRAMECAD F300i is fitted with a pressurised printing system that incorporates a print controller (which provides the interface between the computer system and the printer heads) and two 16 port printer heads placed either side of the stick. This system prints individual identification information on every stick. User configured text can also be printed and this might be the manufacturers/customers website, contact information or manufacturing date.

PLEASE NOTE! Latter generation machines use a longer printer head type than that shown above. The longer print heads do need the externally mounted solenoid valve(s) (also shown above) as these are mounted internally. Both types are functionally the same only the mounting arrangement differs.


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6.10

Computer System & Operator Screen Controls

ALL FRAMECAD F300i machines use a touch sensitive screen for the Operator control interface. The Operator Screen allows the FRAMECAD F300i to be configured and jobs to be managed along with other various setup and control options. The main computer controller is typically housed in the rear of the Operator Screen. On some earlier generation machines, a separate computer board was mounted in the DC electrical cabinet. Whilst the computer mounting arrangement differs, the functionality remains the same.

Computer Board

Early Generation FRAMECAD F300i Machines had the Computer Mounted in the DC Electrical Cabinet (Top) whilst latter generations have the Computer integrated into the Operator Screen (bottom)

The computer system incorporates solid-state technology to both simplify the system architecture and improve reliability. The computer system communicates with the VFC and Input/Output controller via an Ethernet network. This network allows the computer to manage speed and position, receive the input state of all the push buttons and sensors, and control the hydraulic valves/motor and indicator lights on the machine. Release 10102013 ©2013 FRAMECAD Limited 43

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There have been two types of Operator Screen used on the FRAMECAD F300i. The push button functions provided on both are shown below;

Start Push-Button Pause Push-Button Software Reset Push-Button Automatic / Semi-Automatic / Manual Selector USB Port

Pause Push-Button Software Reset Push-Button Manual Control Push-Button Automatic / Semi-Automatic Push-Button

Start Push-Button Emergency Stop Push-Button Safety Control System Reset Push-Button USB Port

Screen Cabinet Push Buttons & Functionality – Type 1 (Top) and Type 2 (Bottom)


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6.11

FRAMECAD Factory Software

The FRAMECAD F300i is controlled by licensed and proprietary FRAMECAD Factory Software. A job “project” that is comprised of frame assembly and manufacturing data (.RFD) is loaded via a USB memory stick or network connection into the machine computer. This information is then translated by the software into the various tooling operations and stick lengths to produce the required framing components. The FRAMECAD Factory software also allows the operator to: 

Reconfigure the manufacturing order of panel assemblies in the “ job” schedule



Add / Remove tooling operations



Collect diagnostic information on items such as material produced, waste produced, tool operation counts and an operation log



Calibrate the machine for stick length accuracy and tool operation placement accuracy



View the shape and status of the current frame being produced



Manage the overall speed and acceleration of the machine



Manually operate the machine and all of its tooling operations



View the status of the electrical Input/output for troubleshooting purposes



Set the up/down times for each tool operation



Trend various operating parameters in near real time.

Example of a FRAMECAD Factory 2 Automatic Production Job

IMPORTANT NOTE! ONLY FRAMECAD FACTORY 2 IS COVERED IN THIS MANUAL. FOR OPERATING INSTRUCTIONS ON OTHER VERSIONS PLEASE CONTACT YOUR REGIONAL FRAMECAD OFFICE FOR SUPPLEMENTARY INSTRUCTIONS.


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7 Installation This Section details the installation requirements of the FRAMECAD F300i machine. It also includes pre-delivery considerations that will assist with initial planning and longer term management of your FRAMECAD F300i solution.

WARNING! ALL PROCEDURES DETAILED IN THIS SECTION ARE DESIGNED TO BE COMPLETED WITH ELECTRICAL POWER ISOLATED TO THE MACHINE AND WITHOUT STEEL STRIP INSERTED. IT IS HIGHLY RECOMMENDED THAT A FRAMECAD TECHNICIAN IS PRESENT TO ASSIST WITH THE PROCEEDURES DESCRIBED HEREIN. DAMAGE DONE TO THE MACHINERY AND/OR DELAY’S IN PRODUCTION STARTUP DUE TO INCORRECT INSTALLATION IS THE RESPONSIBILITY OF THE CUSTOMER OR CUSTOMER’S AGENTS.


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7.1

Pre-delivery Considerations

Prior to the machine being delivered, you will have been sent a pre-delivery manual . The primary objective of the pre-delivery manual is to avoid any unnecessary delays in the installation and commissioning of the FRAMECAD F300i machine. It also acts as a guide to the kind of things that must be planned and managed post-commissioning. Essential questions around resource training and raw materials, consumables and the like are all critical to the success of any long term production plan. Some of the items that must be considered prior to taking delivery of the FRAMECAD F300i machine are; PRE-DELIVERY CONSIDERATIONS Steel Coil

Has the correct specification steel been ordered? Is the steel strip width correct for the machine specification? Is the thickness and tensile strength correct for the machine specification? Has enough steel stock been ordered and will it be available in time for commissioning the machine (depending on location there can be significant delays between order and delivery of steel)?

Fastenings & Consumables

Typically a Starter Kit (see Appendix A for a standard list of items) will be supplied with the machine that includes a sample of fasteners and other consumables (examples may include screws and plastic grommets for electrical cable protection inside of wall panel service holes) as an initial guide to the type recommended for general purpose frame assembly. However, the correct quantity and type will depend on the projects being undertaken and preference by those assembling. It is important to ensure the right type and quantity is available to suit your purposes. For further information, please consult with you local FRAMECAD Office or contact our support Helpdesk.

Framing Tools

Typically a Starter Kit (see Appendix A for a standard list of items) will be supplied with the machine that includes a number of frame assembly tools as an initial guide to the type recommended for general purpose frame assembly. This is a very basic kit that with experience may need to be developed and extended to suit your requirements and/or preference. The following is an example of the type of tools that should be considered as part of a extensive framing tool-kit; NOTE! Some of these items are n o t included in the Starter Kit . 



        

Sheet steel shears (“tin snips”). These need to be high quality and capable of cutting the steel thickness being used. For steel >0.8mm thick, electric cutting shears are recommended; Cordless (battery-powered) Impact Drivers, one per Assembler is required. These should be high torque, reliable and lightweight (good examples are Hitachi WH14DL / WH18DL); Calibrated and high accuracy vernier caliper, digital or manual, capable of measuring up to 200mm; 100mm Engineers Square; 8-meter Measuring Tape; 300mm Steel Rule; Steel Scribe; Snub-nose Pliers Chalk-line, String-line Engineers Steel Hammer; 2.4m Spirit Level.


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Steel Coil Management

How will steel coil stock be stored? Ho w will the steel coil stock be m oved around the factory and loaded onto the De-coiler? Without the right kid of storage and lifting equipment, managing steel coil can be extremely dangerous. FRAMECAD recommend a certified rolling gantry with block and tackle setup for the safe lifting of steel coil. The gantry should be rated to safely lift the heaviest steel coil to be used. Due consideration should also be given to the lifting height and transference of coil to/from the De-coiler.

Electrical Supply

Ensure that the Electrical Supply has been installed and is appropriately sized. Cables should be protected from mechanical damage and/or interference; this includes the connection cable between the De-coiler and FRAMECAD F300i. Make sure that safe earthing practice has been followed and the installation has been certified compliant to local standards by a registered Electrician.

Factory Layout

One of the most frequently overlooked considerations is the factory layout. The location and orientation of the FRAMECAD F300i and De-coiler needs to be properly allowed for to ensure efficient operation. The physical foot-print of the machines and equipment along with the length of the assemblies to be made all need to be allowed for. Safe access to the De-coiler for loading steel coil is another key consideration. The De-coiler for example, can be ordered as either left or r i g h t loading. The following machine floor plan highlights the basic machine layout configuration; NOTE! Allowance must be made safe working access. Recommended clearance to boundary walls and space around the machine is shown below:

Length A (distance De-coiler to FRAMECAD F300i in-feed): Length A for <1mm Steel Thickness = 3000mm Length A for =>1mm Steel Thickness = 4000mm Length B (out-feed distance): Length B is dependent on the length of frame assemblies being manufactured


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and Right loading orientation for De-coiler Left Full machine dimensions are shown below;

Lubricants

Ensure lubricant for steel strip has been provided (typically a 20litre drum mixture is sufficient). Also ensure that you have the following general maintenance lubricants available;  Chain Lubricant;  Grease;  General Machine Oil


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Ink & Cleaner

Make sure sufficient Ink and Cleaner is available and is of the correct specification (see section Specifications).

Machine Tools

A basic tool kit is supplied with every FRAMECAD F300i for general day to day service and maintenance. It is important to replace these tools as they wear. It is also recommended to have a source of compressed air to assist with keeping the machine clean and free of debris.


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7.2

Unpacking the FRAMECAD F300i

Unpacking Tools Required

Safety

Unpacking FRAMECAD F300i



Fork Hoist with a lifting capacity of at least 2000kg



Claw Hammer



Impact Driver and Phillips-head drive bits

The FRAMECAD F300i and De-coiler will typically arrive in two crates (one for each machine).  ALWAYS unpack the machines in a clean and dry location, free of dust, moisture, dirt or other airborne contaminants that become entrapped inside the equipment;  ENSURE that any Fork Hoist Operators are fully licensed and experienced in moving heavy loads  Take extreme care when moving/lifting machines and/or crates  Use caution when extracting packaging screws/nails  Where possible, FRAMECAD will use recyclable packaging – do not dispose to landfill – always consider the environmental im pact of waste material 1.

Move the FRAMECAD F300i crate as close as practical to the final installation area – be sure the floor area is flat;

2.

Start by removing the top wooden cover of the FRAMECAD F300i crate, followed by each of the walls;

3.

There are typically 6 bolts threaded through the bottom pallet and into the bottom base plate of the FRAMECAD F300i. Unscrew these bolts so that the FRAMECAD F300i can be lifted off the bottom pallet;

4.

Using the Fork Hoist, carefully lift the FRAMECAD F300i at the lifting points indicated below just high enough to clear the bottom pallet;

Fork Hoist Lifting Points 5.

Gently reposition the machine back down onto the pallet so as to allow access to the mounting feet holes located as shown below ( CAUTION – take extreme care to not unbalance the machine – keep the FRAMECAD F300i loaded onto the Fork Hoist forks as added protection during this procedure) and screw in ALL 6 mounting feet supplied with the machine;


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Mounting Feet

Unpacking the De-coiler

6.

Carefully place the FRAMECAD F300i down on the floor so that it is supported by the 6 mounting feet.

1.

Move the De-coiler crate as close as practical to the final installation area – be sure the floor area is flat;

2.

Start by removing the top wooden cover of the De-coiler crate, followed by each of the walls;

3.

There are typically 4 bolts threaded through the bottom pallet and into the bottom base plates at each corner of the De-coiler and tightened in place with nuts. Remove the bolts and nuts so that the De-coiler can be lifted off the bottom pallet;

4.

Carefully lift the De-coiler using the eye-bolt mounted on top of the main body, using a shackle and chain rated to 1Tonne and place on the floor.

De-coiler Lifting Eye Bolt

WARNING! NEVER LIFT THE DE-COILER WITH A STEEL COIL LOADED ONTO THE MANDREL!


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7.3

Positioning the FRAMECAD F300i and De-coiler POSITIONING THE FRAMECAD F300i AND DE-COILER

Tools Required

       

Safety

 

Positioning FRAMECAD F300i & Decoiler

Screwdriver Chalk lines Anchor Bolts suitable for fixing De-coiler corner plates down Electric hammer drill 16mm masonry drill bit 4x 12mm x 60mm expanding anchor bolts Metric Socket set Metric spanner set ENSURE that any Fork Hoist Operators are fully licensed and experienced in moving heavy loads Take extreme care when moving/lifting machines

1.

Mark up the intended location of the FRAMECAD F300i and De-coiler using a centre chalk line;

2.

Position the FRAMECAD F300i and De-coiler using the chalk line to align the machines. The chalk-line should mark the centre of the steel strip as it comes off the De-coiler. This means the De-coiler needs to be positioned such that the centre of the steel coil as it will be loaded onto the De-coiler mandrel, is centred above the chalk-line. Like-wise the FRAMECAD F300i should be positioned so that the in-feed guide is centred above the chalk-line. There should be a gap of at least 3m between the De-coiler and the FRAMECAD F300i. >3000mm

3.

Place the supplied corner brackets on each corner of the De-coiler base and bolt them to the floor using concrete bolts. The brackets should be located 1-3mm off the corner. These brackets ensure that the De-coiler will remain aligned with the FRAMECAD F300i.

4.

Connect the De-coiler power cable to the plug on the FRAMECAD F300i AC Electrical Cabinet. CAUTION: The exposed cable (between the De-coiler and the FRAMECAD F300i) must be protected by either a cable trench or a protective cap.


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De-coiler Plug

ELECTRIC SHOCK HAZARD! NEVER INSERT OR REMOVE DE-COILER PLUG WITH MAINS ELECTRICAL POWER TO THE MACHINE SWITCHED ON. ENSURE THAT THE ELECTRICAL CABLE BETWEEN THE DECOILER AND FRAMECAD F300I IS PROTECTED BY EITHER A CABLE TRENCH OR PROTECTIVE CAP.


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7.4

Levelling the FRAMECAD F300i LEVELLING THE FRAMECAD F300i

Tools Required



Engineer’s Spirit level



24mm Spanner

Safety



ISOLATE electrical power to the FRAMECAD F300i and implement measures to prevent accidental re-connection;

Levelling FRAMECAD F300i

1.

Start by winding all the mounting feet fully in;

2.

Place the spirit level accurately on top of the lip box or machine bed. Wind in or out the mounting feet using a 24mm spanner until the FRAMECAD F300i is level in both directions (width as well as lengthways);

WARNING! Do not have mounting feet protruding too far out of base as this may cause instability

CAUTION: It is important that the FRAMECAD F300i is accurately levelled to ensure the correct profile is manufactured. CAUTION: If the mounting feet are protruding too far out the machine may become unstable during production.


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7.5

Mounting the FRAMECAD F300i Operator Screen MOUNTING THE FRAMECAD F300i OPERATOR SCREEN

Tools Required



Machine Cabinet Key



10mm Spanner



4mm Hex Key

Safety




Mounting the Operator Screen

The FRAMECAD F300i Operator Screen will be wrapped in protective packaging. Depending on the freighting arrangements the Operator Screen may have be unbolted and laid down inside the machine for safe transportation. The following describes how to re-mount the Operator Screen if required; 1.

Remove the out-feed end cover using the supplied Machine Cabinet Key;

Out-feed End Cover

2.

Remove the protective wrapping from around the FRAMECAD F300i Operator Screen;

3.

Lift the Operator Screen and mounting post into position and fasten the 4 cap screws with accompanying nuts. Remove packaging and lift Operator Screen up onto Out-feed Support

Out-feed Support

Fasten in place using cap screws and nuts


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7.6

Charging the Hydraulic Accumulator

Oil Filled End

Bladder End

The FRAMECAD F300i is fitted with a pressurised hydraulic accumulator. If the machine is to be airfreighted then the accumulator must be discharged for transportation. It is essential that the accumulator is re-charged BEFORE starting the FRAMECAD F300i. Failure to do so will result in damage to the bladder inside the accumulator. If there is a requirement to charge the accumulator, the procedure below s h o u l d o n l y b e c o m p l e t e d by a certified . accumulators

hydraulics

professional

who

is

experienced

in

charging

nit rogen

filled

WARNING! THE PROCEDURE BELOW SHOULD ONLY BE COMPLETED BY A CERTIFIED HYDRAULICS PROFESSIONAL WHO IS EXPERIENCED IN CHARGING NITROGEN FILLED ACCUMULATORS. HYDRAULIC ACCUMULATOR CHARGING PROCEDURE

Step 1 Step 2

Step 3

If removed from the machine, ensure the accumulator side is resting flat on a solid surface. Remove plug or fitting from oil end of accumulator (if fitted) so that port is fully open. With the plug removed, inspect the end of bladder. The steel anti extrusion plug has a 4mm recess in the centre of it. Insert 4mm rod up the centre of the fitting and into recess of anti extrusion ring. The pin should be sitting in the centre of the port. If it is not, try to gently move the plug to the centre. If it will not move, the pressure must be reduced inside the bladder until the plug can be moved into the central position. Remove cap from off the bladder end of accumulator (opposite end to oil end) to gain access to the accumulator bladder valve.

Step 4 Remove End Cap


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Step 5

Check accumulator bladder valve to ensure it is tightened firmly and that it is flush or below the end surface of the face. It should not protrude. Remove accumulator charge unit from protective bag. NOTE: there are two types of accumulator charge unit available; Type B shown in the bottom r i g h t incorporates a tap handle that is used to control the accumulator bladder valve once the charge kit connected. The type A charge kit shown in the bottom left does not (it uses a special fitting instead to control the accumulator bladder valve). Both type A and B do however incorporate a vent valve with a release cap/nut (located on the tee point of each kit). Type A

Type B

Step 6

Left Hand Side – Type A, Right-hand side Type B – vent valves for both types are indicated

Where a particular Step below relates to only one type of charge kit this will be shown.

Step 7

Turn the vent valve nut on the accumulator charge unit fully c l o c k w i s e (as viewed from nut end). This is to CLOSE the vent valve. For Type B accumulator charge kit ONLY: turn the valve tap handle on the accumulator charge unit fully c o u n t e r - c l o c k w i s e (as viewed from handle end). This is to CLOSE the accumulator bladder valve when using this type of charging kit.

Step 8

Step 9

For Type B accumulator charge kit ONLY: check the opposite end (female thread) on the accumulator charge unit to make sure it still has the o-ring is sitting in the recess. If not, check inside bag as it may have fallen out; reinsert if necessary.


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Step 10

Screw the accumulator charge unit charge unit into accumulator and do up hand tight only. DO NOT over tighten.

Step 11

Screw adaptor into the c h a r g i n g n i t r o g e n b o t t l e (the right connection fittings will vary depending on country). The charging nitrogen bottle is the f i l l i n g s o u r c e for the accumulator tank on the machine.

Step 12

Connect the micro bore line and attach it between the accumulator charge unit and adaptor on the charging nitrogen bottle. For Type B accumulator charge kit ONLY: gently turn the tap handle on the accumulator charge unit c l o c k w i s e until it just goes firm. DO NOT force it as it may damage the accumulator valve. If there is any pressure is inside the bladder it will register on the gauge. Accumulator Charge Kit

Step 13 Micro Bore Line connection to Charging Cylinder

Step 14

Step 15

Gently open the v a l v e o n t h e c h a r g i n g n i t r o g e n c y l i n d e r a very small amount and for just a few seconds (nitrogen gas will flow from charging cylinder, through the charge unit and into the accumulator bladder) then close off again. Re-check position of anti extrusion plug in the oil end of accumulator to make sure it is still in the center position – if not, reposition again as per step 3 above. Gently open valve on the c h a r g i n g n i t r o g e n c y l i n d e r . When the desired pressure (120 Bar ) has been reached on the gauge, fully close the valve on the charging nitrogen cylinder .

Wait 10 seconds for the pressure to stabilise and then re-check the accumulator charge unit gauge reading. If the reading is too low (<120 Bar ), admit more nitrogen by opening the valve again on the charging cylinder.

Step 16

If the gauge reading is too high (>120 Bar ), loosen nut on the accumulator charge unit vent valve. This will release the nitrogen and lower the pressure. When the correct pressure is reached, tighten nut again.


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WARNING! DO NOT OVER-PRESSURISE THE ACCUMULATOR BLADDER!

Step 17

For Type B accumulator charge kit ONLY: when the reading is correct, wind the accumulator charge unit tap handle fully c o u n t e r - c l o c k w i s e until it goes firmly against retainer pin. This allows accumulator bladder valve to seat fully when using this type of charging kit. Check position of anti extrusion plug in oil end of accumulator to make sure it is still central within the area of the port, the bladder must be depleted, the position adjusted (as per step 3 above) and the bladder recharged.

Step 18

Step 19

CAUTION! If the anti extrusion plug in the oil end of the accumulator is not central within the area of the port, the accumulator bladder will be damaged during hydraulic operation! For Type B accumulator charge kit ONLY: loosen nut on the accumulator charge unit tee to release pressure in the line. Nitrogen will escape from the bleed holes in the cap. This is normal. DO NOT unscrew it fully while pressure is bleeding off. CAUTION! If you remove the charge unit from the accumulator without releasing the pressure, serious damage or injury may result!

Step 20

Disconnect micro bore hose between the charging cylinder and accumulator charge unit.

Step 21

Disconnect accumulator charge unit from accumulator and place it in protective bag. Ensure any o-ring seals are also returned.

Step 22

Check valve on the end of the accumulator to ensure it is not leaking.

Step 23

Fit and tighten cap to accumulator.

Step 24

Accumulator is ready for use. Test BEFORE commencing full production; 1. Start the machine; 2. Reset the safety control system (see Section 5 – Safety); 3. Press the Inch FORWARD push-button on the side of the machine to start the Hydraulics; 4. Using a test gauge check that the Hydraulic pressure quickly climbs to 120Bar (accumulator pressure) before gradually increasing to full system pressure (195Bar)

IMPORTANT! ALWAYS CHECK THE ACCUMULATOR PRESSURE BEFORE FULL PRODUCTION.


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7.7

Checking Hydraulic Reservoir Level & Pump Rotation

The hydraulic system must be checked prior to running the machine. It is essential that the hydraulic pump is never operated without oil. The Hydraulic Reservoir has a combined sight glass and temperature gauge fitted to the side of the tank. The level must be not less than 60 litres.

Fill Points & Filter Breather The Hydraulic Reservoir has a fill point and filter/breather cap situated on top of the tank. Simply unscrew the cap to remove. The oil level is displayed on the sight glass that is on the side of the when the hydraulic level is at the top of the glass then the tank will be at 60 litres (this is the recommended level), the hydraulic motor must not be running for this check. After running the hydraulic pump, the level may drop by 5%. This is normal.

Hydraulic Tank Fill Point and Breather – Cap Unscrews

Combined Temperature & Level Sight Glass

Rotation of the Hydraulic Motor Before running the machine, it is essential to ensure the hydraulic motor is turning in the correct direction which is clockwise otherwise the pump may be damaged. The correct direction of rotation is Factory set before shipping the machine. However, as the direction of rotation in a 3-Phase induction motor is determined by the phase sequence of the electrical supply, it is possible for a different phase sequence at the point of installation to cause the motor to run in reverse. To prevent damage to the hydraulic pump ALL FRAMECAD F300i machines have a built-in phase detector which will prevent the motor from running in reverse if the phase sequence at the supply is not correct. When the power is first connected, if the hydraulic motor/pump DOES NOT TURN ON have a qualified Electrician swap over any 2 of the 3 incoming supply phase wires to the isolator switch on the machine.


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7.8

Connecting Power to the FRAMECAD F300i

Power connections to the FRAMECAD F300i NOTE! Colour codes shown are for descriptive purposes ONLY – actual colour code may vary depending on region and/or legislative compliance.

The 3-Phase electrical supply to the FRAMECAD F300i machine is connected directly to the Isolation switch as shown above. Cable should be sized to ensure <2.5% voltage drop across the full length. CAUTION! Please pay particular attention to earth requirements.

WARNING! THE ELECTRICAL SUPPLY INSTALLATION IS THE SOLE RESPONSIBILITY OF THE CUSTOMER. CONFORMITY OF THE ELECTRICAL INSTALLATION WITH LOCAL SUPPLY REGULATION AND LEGISLATIVE REQUIREMENTS MUST BE CERTIFIED BY AGENTS ACTING ON BEHALF OF THE CUSTOMER AND RECOGNIZED UNDER LAW IN THE COUNTRY OF INSTALLATION. FRAMECAD WILL NOT WARRANT OR ASSUME ANY RESPONSIBILITY THEREIN FOR THE APPROPRIATENESS, SAFETY OR LEGAL FITNESS OF THE ELECTRICAL SUPPLY INSTALLATION. FAILURE TO CONNECT AND/OR CONDUCT SAFE WORKS MAY RESULT IN DAMAGE TO THE MACHINE OR SUPPLY NETWORK, SERIOUS INJURY OR EVEN DEATH. FAILURE TO COMPLY WITH ALL STATUTORY REQUIREMENTS MAY RESULT IN FINES AND/OR PENALTIES BEING IMPOSED BY AUTHORITIES IN THE COUNTRY OF INSTALLATION.


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8 Initial Setup This Section will introduce the basic setup requirements of the FRAMECAD F300i machine. Typically the process of initial setup commences at the in-feed of the machine and progresses to the out-feed.

WARNING! ALL PROCEDURES DETAILED IN THIS SECTION ARE DESIGNED TO BE COMPLETED WITH ELECTRICAL POWER ISOLATED TO THE MACHINE AND WITHOUT STEEL STRIP INSERTED.

8.1

Lubrication Unit Setup

The lubrication unit is mounted at the in-feed to the FRAMECAD F300i. Steel strip is passed through the lubrication rollers and a thin film of lubricant is applied to the top and bottom surfaces of the steel.

Lubrication Unit

The following procedure details the setup requirements of the lubrication unit. SETUP OF THE FRAMECAD F300i LUBRICATION UNIT Tools Required Safety

Machine Cabinet Key   

Fill Lubrication Tank

Prime Lubrication Unit

ISOLATE electrical power to the FRAMECAD F300i and implement measures to prevent accidental re-connection; Use protective gloves when handling lubricant; DO NOT have steel sheet loaded into the machine;

Mix 30:1 ratio of soluble oil lubricant and fill lubricant tank. This is located under the cover on the opposite side to the electrical cabinets. Use the Machine cabinet key to remove the cover. 1.

Release the two side latches and tilt the top roller assembly back and upwards as shown in the picture below;


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Release lubricator latches (one on each side of unit)

Tilt Top Roller Assembly up and back

CAUTION! Be careful not to pinch or damage any of the connecting tubes or fittings! 2.

Rotate the top roller by hand. This will draw lubricant up and into the roller. Continue to rotate until the roller feels sufficiently wet/damp. The amount of lubricant applied can be adjusted using the flow restrictor mounted on the side of the lubrication pump.

Lubrication Pump Flow Adjustment – wind in to lubricant flow; wind increase o u t to decrease lubricant flow

3. Close up Lubrication Unit & Final Checks

8.2

Further adjustment may be required once steel strip is run through for the first time.

Close up the lubrication unit and re-fasten the two side latches. Check to make sure there are no crimped tubes or damaged fittings.

In-feed Unit Setup

The In-feed unit is mounted just after the lubricator and just prior to the pre-punch block. It provides guidance for the steel strip as it enters the FRAMECAD F300i. The encoder, which provides the position feedback of the steel strip, is also housed in this assembly. The following procedure details the setup requirements of the in-feed unit.


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SETUP OF THE FRAMECAD F300i IN-FEED UNIT Tools Required

Safety



(x1) Set of Metric Hex-keys



(x2) 15mm Spanner



150mm Engineers Ruler



ISOLATE electrical power to the FRAMECAD F300i and implement measures to prevent accidental re-connection; DO NOT have steel sheet loaded into the machine;



Check Height of Steel Strip Sensor

The steel strip sensor is used to detect steel loaded into the FRAMECAD F300i. The sensor is a threaded 12mm barrel-type and is mounted through either the bottom plate of the in-feed unit OR in a separate sensor mounting bracket. There are lock-nuts either side of the bottom plate/bracket that lock the sensor in position.

Steel Strip Sensor If the sensor it is set too low down in the bottom plate/bracket, it may not detect the presence of steel; if set too high it may be damaged during the feeding of steel strip into the machine. To check, open the top roller assembly on the lubrication unit so that steel strip sensor can be seen through the in-feed end cover (see Lubrication Unit Setup procedure above for instructions on how to do this). Check that the tip of the sensor is between 3 and 5mm below the lower in-feed guide(s) surface (this is the surface that the steel strip will slide on). If adjustment is required use two 15mm spanners to loosen the locknuts on either side of the bottom in-feed plate/bracket and reposition the sensor either up or down. Make sure the locknuts are re-tightened.


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Set Steel Strip Sensor height so that 3-5mm B E L O W the lower In-feed Guide surface CAUTION! Always make sure the tip of steel strip sensor is at least 3-5mm below the lower in-feed guide(s) surface to prevent damage to the sensor when feeding steel strip into the machine! Check In-feed Wheel Setup

PLEASE NOTE! FOR CLARITY, SOME OF THE PICTURES IN THE FOLLOWING PROCEDURE ARE SHOWN WITH THE IN-FEED COVER REMOVED. HOWEVER, PLEASE NOTE THAT ALL CHECKS DESCRIBED BELOW CAN BE COMPLETED WITHOUT THE NECESSARY REMOVAL OF THIS COVER.

In-feed End Cover

The in-feed assembly includes a Top and Bottom guide wheel. Both wheels are designed to make contact with the steel strip (top and bottom surface of the steel). The bottom guide wheel is mounted onto a shaft so that as the wheel rotates, so does the shaft. The bottom guide wheel shaft is ultimately coupled to the encoder input shaft. In this way, as steel strip is progressed through the machine, its movement and therefore position is measured by the encoder. The top guide wheel is designed to apply downwards pressure to the top surface of the steel strip which in turn is forced down onto the bottom guide wheel. The surface friction created between the two guide wheels must be such that the steel


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strip cannot slip between them and introduce position measurement errors.

Bottom In-feed Guide Wheel Top In-feed Guide Wheel 1.

Check top guide wheel and shaft is level with the in-feed base;

2.

Hold the bottom guide wheel while rotating the top guide wheel by hand. The top guide wheel should have m o d e r a t e resistance during rotation. This ensures that when steel in inserted between the two it will make positive contact while not slipping or deforming on the steel strip.

3.

Once steel strip is loaded into the machine some minor adjustment may be required to ensure that the top guide wheel does not slip on the steel (or that it is not overly tight). This can be achieved by adjusting the top guide wheel shaft adjustment cap screws. These can be either tightened or loosened depending on the type of adjustment required. It is important to make sure that the top guide wheel shaft remains level to the bottom of the in-feed guide (i.e. both sides are equal height) AND that it is not over tightened which can cause deformation in the steel strip AND/OR in-feed assembly.


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Top Guide Wheel Adjustment Screws

WARNING! DO NOT OVER-TIGHTEN THE TOP GUIDE WHEEL SHAFT AND ENSURE THE SHAFT REMAINS LEVEL WITH THE BASE OF THE INFEED UNIT. Check Encoder Shaft/Belt

To prevent inaccurate position measurements of the steel strip inside the FRAMECAD F300i, it is important to check that encoder is securely coupled to the bottom guide wheel shaft. There are two types in-feed unit used on the FRAMECAD F300i and therefore two types of encoder mounting method; direct-coupled and belt-coupled . The direct-coupled type is shown below. In this method the encoder input shaft is inserted directly into the end of the bottom guide wheel shaft.

Steel Strip Encoder (Direct Coupled Type)

Bottom Guide Wheel Shaft

With the direct-coupled encoder it is important to check that encoder mounting bracket screws are securely tightened and that the grub screw locking the encoder input shaft inside the bottom guide wheel shaft is also securely fastened. Any slippage with either the encoder mounting bracket screws or input shaft will result in position measurement errors. Release 10102013 ©2013 FRAMECAD Limited 68

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The belt-coupled type is shown below. In this method the encoder input shaft has a pulley mounted on the end of it which in turn is coupled to the bottom guide wheel shaft with a toothed belt.

With the belt-coupled encoder it is important to check the belt tension is sufficient to eliminate any slip. The best method to achieve this is by pinching the belt at the o longest point (as shown in the picture above) and twisting 90 . The optimal belt o tension is when the belt is firm to 90 but can’t twist further. If the belt needs to be tensioned, loosen the cap screw on the encoder mounting bracket and rotate anti-clockwise until sufficient tension is reached then re-tighten.

Encoder Bracket Mounting Screw

WARNING! DO NOT OVER-TENSION THE BELT AS THIS MAY RESULT IN DAMAGE TO THE ENCODER.


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8.3

Roll-forming Section Setup

It is important to set the correct clearance between the top and bottom rollers in the rolling section for the material thickness being run in the machine. This is absolutely critical to ensure the “C” section profile is produced to the right tolerances AND to prevent damage to the FRAMECAD F300i. Each combination of top and bottom roller assembly is referred to as a roller station and are numbered sequentially from 1 to 6, starting with the first station directly following the pre-punch tooling block;

The following procedure details the setup requirements of the roller section. SETUP OF THE FRAMECAD F300i ROLL-FORMING SECTION Tools Required

Safety



150mm long, 0.05mm to 1mm metric feeler gauge set (or an imperial equivalent for non-metric sheet steel)



18mm Spanner



6mm Hex-key






Setting the Roller Clearances

1.

The first step is to establish the material thickness of the steel strip to be processed in the machine. The accepted method is to use the Base Metal 1) Thickness (BMT) as the starting reference value. Steel strip is typically ordered on this basis and so the BMT of the steel strip being used should be easy to ascertain; 1)

2.

BMT or Base Metal Thickness defines the uncoated steel thickness and is used as the base reference for all structural design calculations using steel.

Always start with the first roller station (Station 1). Select a feeler gauge that is 0.05mm l e s s t h a n t h e B M T of the steel strip. For example, if the BMT of the steel strip being used is 0.75mm, select a 0.70mm feeler gauge, if BMT is 0.95 use a 0.90mm feeler gauge and so on;


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Inset the feeler gauge between the top and bottom rollers at the forming edges (i.e. the bottom corner edge of the top roller);

The feeler gauge should be a “snug fit”; in other words, the feeler gauge should feel tight to push in and out between the rollers without having to use excessive force. If the clearance is too loose or tight, the roller clearances will need to be reset; 3.

Loosen the lock-nuts on the top bearing cap adjustment screws (there is one on either side of the top roller assembly for each station) using the 18mm spanner and 6mm Hex-key;

4.

Adjust both sides of the top roller until the feeler gauge is a “snug fit”; in other words, the feeler gauge should feel tight to push in and out between the rollers without having to use excessive force.

NOTE! Adjust the clearances on both sides so that they are the same. 5.

Repeat the above steps for the remaining roller stations.


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WARNING! TAKE YOUR TIME! IT IS IMPORTANT THAT BOTH SIDES OF THE TOP ROLLER IN EACH STATION ARE SET THE SAME. IF ONE SIDE IS MORE LOADED THAN THE OTHER IT WILL CAUSE THE TRACKING OF THE STEEL STRIP THROUGH THE MACHINE TO VEER (BE PULLED) TO ONE SIDE. SET ALL ROLLFORMING STATIONS TO SAME TOP AND BOTTOM ROLLER CLEARANCE (BMT – 0.05MM) IF THE ROLLER CLEARANCE IS SET TOO TIGHT FOR THE BMT OF THE STEEL STRIP BEING USED, THIS MAY CAUSE THE MACHINE TO FAULT, PRODUCE OUT OF SPECIFICATION PRODUCT, REDUCE PRODUCTION PERFORMANCE AND/OR IN SEVERE CASES, CAUSE DAMAGE TO THE MACHINE. IF THE ROLLER CLEARANCE IS TOO LOOSE FOR THE BMT OF THE STEEL STRIP BEING USED, THIS WILL CAUSE THE STEEL TO SLIP INSIDE THE ROLLFORMING SECTION AND MAY CAUSE THE MACHINE TO FAULT.


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8.4

Adjusting Chain Tension

The drive chain tension on the FRAMECAD F300i should be checked regularly to make sure that it is not loose.

The following procedure details the drive chain setup requirements. ADJUSTMENT OF THE FRAMECAD F300i DRIVE CHAIN Tools Required

Safety



Machine Cabinet Key



14mm Hex-key



FRAMECAD Custom “C” Spanner (supplied with Toolkit)






Check the Drive Chain Tension

1.

Remove the side covers from the drive chain side of the machine using the machine cabinet key;

Drive Chain Side Covers 2.

There two primary drive chains; one for roller stations 1 to 4 and the other for roller stations 5 and 6 and the lip box unit. Check the tension of both drive chains by moving each chain up and down at the longest point (i.e. just after the motor gearbox output sprocket). The total movement of the either chain should be no more than approximately 10mm.


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Maximum 10mm Chain Deflection

If either drive chain has more than 10mm of movement it will need to be tensioned (tightened). 3.

Loosen the locking bolt on the required chain tensioner using the 14mm Hex-key (there is one tensioner for each of the primary drive chains);

4.

Using the custom FRAMECAD “C” spanner, tighten the required chain tensioner so that there is no more than 10mm of up and down movement in the drive chain – when finished, re-tighten the locking bolt for the chain tensioner; NOTE! Always ensure the tensioners are biased to tighten as shown below so that if the locking bolt was to come loose, the tensioner would tighten rather than loosen the chain tension.


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8.5

Check Hydraulic Reservoir Level & Pump Rotation

The hydraulic system must be checked prior to running the machine. It is essential that the hydraulic pump is never operated without oil. The Hydraulic Reservoir has a combined sight glass and temperature gauge fitted to the side of the tank. The level must be not less than 60 litres.

Fill Points & Filter Breather The Hydraulic Reservoir has a fill point and filter/breather cap situated on top of the tank. Simply unscrew the cap to remove. The oil level is displayed on the sight glass that is on the side of the when the hydraulic level is at the top of the glass then the tank will be at 60 litres (this is the recommended level), the hydraulic motor must not be running for this check. After running the hydraulic pump, the level may drop by 5%. This is normal.

Hydraulic Tank Fill Point and Breather – Cap Unscrews


Rotation of the Hydraulic Motor Before running the machine, it is essential to ensure the hydraulic motor is turning in the correct direction which is clockwise otherwise the pump may be damaged. The correct direction of rotation is Factory set before shipping the machine. However, as the direction of rotation in a 3-Phase induction motor is determined by the phase sequence of the electrical supply, it is possible for a different phase sequence at the point of installation to cause the motor to run in reverse. To prevent damage to the hydraulic pump ALL FRAMECAD F300i machines have a built-in phase detector which will prevent the motor from running in reverse if the phase sequence at the supply is not correct. When the power is first connected, if the hydraulic motor/pump DOES NOT TURN ON have a qualified Electrician swap over any 2 of the 3 incoming supply phase wires to the isolator switch on the machine.


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8.6

Lubricate Shear Blade

Apply neat lubricating oil into the four oil recesses on top of the Shear plate; fill the recesses. DO NOT use hydraulic fluid as it contains little lubricating benefit in this type of application. The Shear blade assembly should be checked and re-filled as required at least 4-times daily.

Shear Tool Top Plate – Lubrication Points

IMPORTANT NOTE! THE SHEAR BLADE ASSEMBLY SHOULD BE LUBRICATED 4-TIMES DAILY DURING PRODUCTION, USING LIGHT GRADE MACHINE OIL.


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8.7

Insert Ink & Cleaner INSERT INK AND CLEANER

Tools Required



Clean rags (to catch any residual ink)



Sharp Knife

Safety




Insert Ink and Cleaner Bottles

1.

Open the printer cabinet door;

Printer Cabinet Location

2.

Locate the empty ink bottle. Carefully unscrew the black filter-cap and withdraw this from the bottle (if the machine has been powered previously, the bottle may be pressurised – remove cap slowly to release pressure), using a clean rag to catch any residual ink. Before removing the bottle completely, close with a spare cap to prevent any accidental spills of residual ink in the bottle;

Ink Bottle Filter Cap Ink Bottle 3.

Carefully remove the empty ink bottle;

4.

Insert replacement ink bottle and remove cap. If the replacement ink bottle is new and has not been opened before, the top will be sealed. DO NOT try to peel the seal off – doing so may leave remnants of the seal stuck to the top of the bottle, causing air leaks when the system is pressurised; NOTE! DO NOT try to peel the seal off the top of new (unopened) ink OR cleaner bottles.

5.

Using a knife, carefully cut the seal in an “X” shaped pattern. CAUTION! Take care not to cut or damage the edges around the bottle opening as this may prevent a reliable seal from being attained when the filter-cap is put back on.

6.

Replace the filter-cap and tighten.

7.

Repeat the above procedure for the cleaner bottle.


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8.8

Loading Coil onto the De-coiler LOADING COIL ONTO THE DE-COILER

Tools Required

Safety



De-coiler Winding Handle



Steel Coil Lifting Equipment



Calibrated and high accuracy vernier caliper OR steel rule



Calibrated and high accuracy Micrometer



Cut-resistant Gloves



ISOLATE electrical power to the De-coiler and implement measures to prevent accidental re-connection;

Turn De-coiler isolation switch to the OFF position    

Use only certified (weight and application) lifting equipment for use on the Steel Coil; Apply extreme care when lifting and transferring coil to the De-coiler; Use cut-resistance protective gloves when handling steel coil strip; Make sure that the steel coil is securely strapped so that the coil cannot spring loose and unwind itself – this is important, failure to do so could result in serious injury as the tightly wound coil will release and tend to unwind once strapping is removed.

Strapped Steel Coil

WARNING! USE EXTREME CAUTION WHEN REMOVING ANY STEEL COIL STRAPPING OR BANDING. STEEL COIL STRIP IS TIGHTLY WOUND AND ONCE ALL STRAPPING IS RELEASED IT WILL WANT TO RAPIDLY UNWIND. WHERE SAFE AND PRATICAL, CLAMP THE END OF THE STEEL STRIP DURING THE REMOVAL OF ALL STAPPING TO ALLOW A CONTROLLED RELEASE.


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Loading Steel Coil onto the De-coiler Mandrel

1.

Remove the De-coiler safety guard by releasing the locking nuts holding it in place;

2.

Using the mandrel winding handle, collapse the mandrel shoe-plates down to below the internal diameter of the steel coil to be loaded; Safety Guard Safety Guard Locking Nuts Mandrel Shoe Plate

Mandrel Shoe Plate

3.

Check the steel coil to be loaded is the correct thickness and strip width using respectively the micrometer and vernier caliper/steel rule;

4.

Using appropriately certified lifting equipment, raise the new steel coil up and onto the De-coiler mandrel, ensuring that; a. b. c.

d.

The steel strip will feed from the top of the coil (not from the bottom); Push the steel coil on so that it is sitting against the De-coiler mandrel backing-plates; Continue to support the weight of the steel coil using the lifting equipment – DO NOT drop the full weight of the steel coil onto the mandrel during this step; Ensure that the steel coil once loaded is in-line with the in-feed to the FRAMECAD F300i machine.

5.

While the weight of the steel coil is still supported by the lifting equipment, use the mandrel winding handle to firmly tighten the mandrel shoe-plates up against the inside diameter of the steel coil;

6.

Remove the lifting equipment and allow the steel coil weight to be fully supported by the De-coiler mandrel;

7.

Remove any banding or strapping that is holding the steel coil together. Where safe and practical use effective clamping means to hold the end of the steel strip to prevent rapid unwinding once the strapping is removed. Carefully remove the clamp while holding the end of the steel strip;

WARNING! USE EXTREME CAUTION WHEN REMOVING ANY STEEL COIL STRAPPING OR BANDING. STEEL COIL STRIP IS TIGHTLY WOUND AND ONCE ALL STRAPPING IS RELEASED IT WILL WANT TO RAPIDLY UNWIND. WHERE SAFE AND PRATICAL, CLAMP THE END OF THE STEEL STRIP DURING THE REMOVAL OF ALL STAPPING TO ALLOW A CONTROLLED RELEASE.

8.

Pull the end of the of the steel coil strip down and under the De-coiler Dancer Arm;


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9.

Re-attach the safety guard and tighten locking nuts to hold in place.


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9 Powering up the FRAMECAD F300i 9.1

Pre-Power-up Checklist

Before switching electrical power ON to ON to the FRAMECAD F300i machine it is good practice to quickly run through the following check-list of items; POWERING THE MACHINE FOR THE FIRST TIME

Check 1

Check the correct steel has been ordered and is available for production; 1.

The correct design thickness;

2.

Correct strip width for the “C”-section “C” -section profile to be run;

3.

Correct surface coating/treatment for the intended application

Check 2

If the machine has NOT been powered before, make sure that the Hydraulic accumulator tank has been fully charged to 120Bar . If you are not sure, please discuss with your regional FRAMECAD office.

Check 3

Check that the ink & cleaner is available.

Check 4

Check the lubricant mix is a 30:1 ratio Check that the lubricant tank is full.

Check 5

Check that the De-coiler is plugged into the FRAMECAD F300i AC electrical cabinet.

Check 6

Ensure that ALL covers are installed and securely fitted to the machine. Make sure that the top sliding covers are fully closed. This includes all covers and guarding on the De-coiler.


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9.2

Switching on Electrical Power

Turn the isolation switch on the side of the machine to the ON position.

FRAMECAD F300i Electrical Isolation Switch

Go to the De-coiler and turn the isolation switch on the side of that machine to the ON position. ENSURE that you stand well away from the spinning mandrel back-plates when power is first connected to the De-coiler.

De-coiler Electrical Isolation Switch

WARNING! STAND WELL BACK FROM THE SPINNING MANDREL BACK-PLATES ON THE DE-COILER WHENEVER THE ISOLATION SWITCH IS TURNED ON FOR THAT MACHINE.


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9.3

Check the Safety Controls

The FRAMECAD F300i safety controls should be regularly checked through-out the course of a given production day. Testing the safety control system operation is achieved by; 1.

Pressing each emergency stop push button respectively and resetting the safety control system before progressing to the next one (including the De-coiler). Each time a safety circuit is tripped by the activation of an emergency stop push button an Alarm Message will appear on the Operator Screen and all Manual and Automatic functions inhibited. The De-coiler mandrel will also be prevented from rotating.

2.

Open each sliding guard cover respectively and resetting the safety control system before progressing to the next one. Each time a safety circuit is tripped by the opening of a sliding guard cover an Alarm Message will appear on the Operator Screen and all Manual and Automatic functions inhibited. The De-coiler mandrel will also be prevented from rotating.

3.

The safety control system should be reset after each test activation (see activation (see Section 5 – 5 – Safety). Safety). NOTE! The safety control system can only be RESET once the De-coiler has been started.

4.

The De-coiler De-coiler also incorporates a “Dancer Arm Too High” safety interlock such that if the Dancer Arm is raised beyond approximately 1.2m (end of Dancer Arm above the ground) then the safety control system will switch to an emergency stop activation state. To test this feature complete the following; a. Press an emergency stop push-button on the FRAMECAD F300i (NOT on the Decoiler) – coiler) – this this will prevent the De-coiler mandrel from turning; b. If the De-coiler Start light is not ON, ON, press the Start push-button with the end of the Dancer Arm resting on the ground; c. Manually lift the end of the De-coiler dancer arm above 1.2m. The De-coiler Start lamp should turn OFF, OFF, indicating that the De-coiler has tripped with a Dancer Arm Too High state. d. Lower the Dancer Arm back down to the ground, re-start the De-coiler, release any emergency-stop push-buttons and reset the safety control system (see Section 5 – Safety).


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9.4

Check Calibration of De-coiler Dancer Arm

Check that the Emergency Stop Push Button on top of the De-coiler is fully released.

With the De-coiler dancer arm end resting on the ground, press the green start button on top of the De-coiler taking care to stand well away from the spinning mandrel back-plates and safety guard cover; Mandrel Back-plate Mandrel Safety Guard


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If the green start push-button lamp does not turn ON OR if the De-coiler starts to rotate with the end of the Dancer Arm resting on the ground then the De-coiler WILL require calibration of the Dancing Arm potentiometer . DANCER ARM POTENTIOMETER CALIBRATION Tools Required



4mm Hex Key



Make sure the De-coiler is powered BUT NOT STARTED

ELECTRIC SHOCK HAZARD! Safety

Calibration Procedure

DANGEROUS VOLATGES ARE PRESENT BENEATH THE DE-COILER SERVICE PANELS! DO NOT TOUCH, MODIFY, REMOVE OR OTHERWISE TAMPER ANY OF THE EXISTING WIRING, TERMINALS, AND/OR CONNECTIONS WITHIN THE DE-COILER.

The De-coiler units utilise a VFC (Variable Frequency Controller) to manage the speed of the mandrel motor. There have been two types of VFC used on the FRAMECAD F300i De-coiler. The following procedures detail the calibration of both types. Please review and select the correct procedure for your machine; Calibration Procedure for MC07B Type:

VFC (Variable Frequency Controller)

1.

Place the end of the Dancer Arm fully on the ground;

2.

If the De-coiler is switched OFF, power-up the De-coiler by turning the isolator switch to the ON position. DO NOT start the De-coiler (i.e. don’t press the Start push button). If the Decoiler was already started (i. e. the green start push-button lamp illuminated), press the Stop push-button OR press the Emergency Stop push-button on top of the De-coiler BEFORE proceeding.

3.

Remove the service panel to gain access to VFC speed controller inside the De-coiler;

4.

Locate the VFC key-pad;


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VFC Key-pad

5.

Press either the arrow UP or DOWN button(s) until Par is selected and P is displayed on the screen;

Use arrow buttons until Par indicator is ON and P is displayed on screen

6.

Press the Enter button;

Press the Enter button

7.

Press the Arrow UP or DOWN button(s) until the display shows P-20 (this is parameter 20);

Use arrow buttons until P-20 is displayed on screen

8.

Press the Enter button;

Press the Enter button


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9.

The value displayed is the feedback voltage (signal) from the Dancer Arm potentiometer. With the end of the Dancer Arm resting on the ground, parameter P-20 should read approximately 1.5 (+/- 0.02); Display should indicate 1.5 (+/- 0.02)

If the value displayed is NOT 1.5 (+/- 0.02) then the potentiometer must be calibrated. Proceed to Step 10;

10. Using a hex key, loosen the two screws that secure the Dancer Arm to the mounting bracket axel. Note that there are two screws; one on the bottom and the other on the side. You will need to lift the Dancer Arm end fully up to gain access to the bottom screw;

Loosen screws that hold the Dancer Arm to the Mounting Bracket Axel Shaft

Lift the Dancing Arm to gain access to the bottom screw

11. Once the Dancer Arm is loose on the mounting bracket axel, use a wrench to turn the axel until the value displayed in parameter P-20 on the VFC reads 1.5 (+/- 0.02) – refer to Step 9.


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Rotate Dancer Arm Axel Shaft until VFC displays 1.5 (+/- 0.02)

Rotate Dancer Arm Axel Shaft until VFC displays 1.5 (+/- 0.02)

12. Re-tighten the screws to lock the Dancer Arm to the mounting bracket axel. Remember to do both screws! Make sure the value at the SEW Drive still reads 1.5 (+/- 0.02) with the Dancer Arm end resting on the ground, otherwise repeat steps 10 and 11.

Retighten screws so the Dancer Arm is not loose on Axel Shaft

13. Turn power back onto the De-coiler and press the Start push-button.

Start the De-coiler

14. Lift the Dancer Arm. Make sure the De-coiler spins in the right direction and that it does not rotate with the Dancer Arm end resting on the ground.

15. The De-coiler potentiometer is now calibrated.


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Calibration Procedure for LTP Type:

VFC (Variable Frequency Controller)

1.

To calibrate the potentiometer feedback, place the end of the Dancer Arm fully on the ground.

Lower Dancer Arm fully to the ground

2.

If the De-coiler is switched OFF, power-up the De-coiler by turning the isolator switch to the ON position but do not start the machine (i.e. don’t press the Start push button). If the De-coiler was already started (i.e. the green start pushbutton lamp illuminated), press the Stop push-button or press the Emergency Stop push-button on top of the De-coiler BEFORE proceeding.

Switch power

ON

BUT DO NOT START

[Press the STOP push-button if already started] 3.

Remove the service panel to gain access to VFC speed controller inside the De-coiler;

4.

Locate the VFC menu control push-buttons;


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VFC Menu Control Push-buttons

5.

Press and hold the centre Navigate [4] button for at least 1 second. The display will now show the parameters list menu. Use the Down [6] or Up [5] arrow buttons to scroll through the parameter list until the parameter P0-02 is shown on the display.

Press & hold the Navigate button for >1 second


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Use the Down or Up arrow buttons to scroll to parameter P0-02

6.

Press and hold the Navigate [4] button for at least 1 second. This will display the actual value inside the parameter. The value displayed is the potentiometer feedback from the Dancer Arm. The potentiometer provides a signal back to the De-coiler VFC that is proportional to the height of the Dancer Arm. With the Dancer Arm resting level with the base of the De-coiler on the ground (see Step 1 above) this value should be reading 15 (+/- 0.5). If the value is correct then the De-coiler potentiometer is calibrated and no further action is necessary. If the value isn’t correct, then the potentiometer on the Dancer Arm needs to be calibrated – proceed to Step 7.

7.

Ensure that the De-coiler is still in the Stopped state (i.e. the green Start pushbutton lamp is NOT illuminated).

Go to the Dancer Arm side of the De-coiler and locate the potentiometer cover.

Potentiometer cover located at the pivot point of the Dancer Arm

8.

Remove the two screws holding the Dancer Arm cover in place and remove the cover.

Remove potentiometer cover

9.

With the Dancer Arm still fully rested on the ground, use a 13mm socket and a 4mm Allen-key tool to loosen the top locking nut and grub screw connecting the Dancer Arm rod to the pivot axel.


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Use a 13mm socket and a 4mm Allen key tool to loosen the top grub screw assembly

10. Lift the Dancer Arm fully UP and rest against the De-coiler frame to gain access to the bottom locking nut and grub screw. Loosen as per the top lock nut and grub screw assembly.

Use a 13mm socket and a 4mm Allen key tool to loosen the bottom grub screw assembly

11. Lower the Dancer Arm DOWN fully on the ground.

12. With the grub screws loosened, gently turn the pivot axel until the value shown in P0-02 on the SEW drive is approximately 15 (+/-0.5).

Turn the pivot axel as shown until parameter P0-02 is showing a value of 15 (+/-0.5)

13. Retighten the top grub screw and lock nut assembly BEFORE lifting the Dancer Arm. Release 10102013 ©2013 FRAMECAD Limited 92

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14. Once the top grub screw assembly has been tightened, lift the Dancer Arm fully up and retighten the bottom grub screw assembly. 15. Confirm the calibration setting by lowering the Dancer Arm fully and checking that the value in parameter P0-02 is still 15 (+/-0.5). 16. Lift the end of the Dancer Arm up off the ground and observe that the value in parameter P0-02 increases. This indicates that the potentiometer polarity is correct. If the value decreases then the polarity needs to be reversed at the interface card on the VFC. Swap over the two wires going to terminals 5 and 7.

If the value in parameter P0-02 decreases when the Dancer Arm is raised, swap over the two wires going to terminals 5 and 7 at the VFC. The value in parameter P0-02 must always increase in value when the Dancer Arm is raised.

17. Start the De-coiler by pressing the green Start push-button. Slowly raise the Dancer Arm, keeping well clear of the rotating parts on the De-coiler. The De-coiler should accelerate cleanly and maintain a uniform speed when the Dancer Arm is held at a fixed height off the ground. If the Dancer Arm is raised too high off the ground, the De-coiler will trip the safety circuit at the roll-former machine and stop the De-coiler. This typically is set to around 1.5m off the ground. NOTE: The Emergency Stop circuit on the roll-forming machine MUST BE reset before the De-coiler will be allowed to rotate. 18. If the calibration is complete with all checks being confirmed the machine can be run in automatic control from the roll-former.

NOTE! DE-COILER DIRECTION OF ROTATION IS SPECIFIED AT ORDER TIME, IF THE DE-COILER MANDREL IS ROTATING IN THE WRONG DIRECTION FOR YOUR INSTALLATION REQUIREMENTS PLEASE CONSULT WITH FRAMECAD ON THE CORRECT REVERSAL PROCEDURE. IF THE POTENTIOMETER CANNOT BE PROPERLY CALIBRATED, OR THE VALUE ERRATIC AND NON-REPEATABLE THEN REPLACE THE POTENTIOMETER.


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9.5

Check Ink Jet Printer System Pressure

Reset all Emergency-Stop Push Buttons and the FRAMECAD F300i safety controller (see Section 5 – Safety for the correct procedure on this). Once complete, open the printer cabinet door and locate the print compressor unit;

Printer Cabinet Door

Print Compressor Unit

The digital display on the print compressor unit should show a value of approximately 10 (PSI). This is the operating pressure of the ink jet printer system. If NO display is present then re-check the machine safety control system (e.g. emergency stop push buttons, sliding cover guard switches and the De-coiler is started) to make sure the system is fully reset. The compressor is de-powered in a safety circuit trip. If the pressure reading is low (<9.5PSI) then check for air leaks in the tubing and ink/cleaner bottle caps.


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9.6

Purge the Ink Jet Printer System with Ink

Before commencing production it is important to ensure the printer system is r e ad y t o p r i n t . In order to achieve this, the printer control system must be p u r g e d with ink. The following procedure defines this; PRINTER INK PURGE PROCEDURE Tools Required



Nil

Safety



Use safety glasses and appropriate personal protective equipment including rubber gloves whenever handling ink or cleaner Nitral


When

Clean Printer Heads

At the start of Production. This procedure will purge the printer system with Ink allowing printed text to be applied during production. 1.

Start the machine and reset the safety control system (i.e. release any Emergency Stop push-buttons, close all sliding covers, and reset the safety control system. See Section 5 – Safety);

2.

Ensure printer Air Compressor pressure is at approximately 10 psi. This can be checked by viewing the compressor digital display inside the printer control cabinet;



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3.

Check the Ink and Cleaner bottles to make sure there is sufficient quantity for the production requirements. Re-fill as required. Check the Waste bottle. If this is full, consult your company ’s hazardous materials handling policy on how to safely dispose of MEK based inks and solvents.

4.

5.

Go to the Setup / Inkjet Screen and press the this will do two things;

[Select Ink] button –

a.

Switch the print control system over to use Ink fluid instead of Cleaner;

b.

Flush the tubes going up to the printer heads and back down to the Waste bottle for a period of 0.5 seconds. This is to remove any residual Cleaner from the lines;

In this next step Ink will be sent up into the printer head and through the nozzles to flush any residual Cleaner/air out of the printer head itself. If there is no steel in the machine, it is a good idea to insert a piece of cardboard in the space between the two printer heads to prevent Ink from one printer head being sprayed onto the other. Press the [Purge] button. This will momentarily send Ink up into the printer heads and eject through the nozzles. Repeat this until there is a consistent spray of Ink from the printer head whenever the [Purge] button is pressed.


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6.

Once steel strip has been threaded through the machine it is a good idea to test the printer control system before commencing full production. Refer to the Printer System Test procedure below for instructions on this.


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10 Introduction to FRAMECAD Factory 2 10.1

Software Overview

This section introduces the main functions and features of the FRAMECAD Factory 2 software. FRAMECAD Factory 2 is the software that ultimately controls all the primary functions of the FRAMECAD F300i. A job “project” that is comprised of frame as sembly and manufacturing data (.RFD) is loaded via a USB flash drive or network connection into the FRAMECAD F300i computer running FRAMECAD Factory 2. This information is then translated by the software into the various tooling operations and stick lengths to produce the required framing components. The FRAMECAD Factory 2 software also allows the operator to: 

Reconfigure the manufacturing order of panel assemblies in the job schedule;



Add / Remove tooling operations;



Collect diagnostic information on items such as material produced, waste produced, tool operation counts and an operation log;



Calibrate the machine for stick length accuracy and tool operation placement accuracy;



View the shape and status of the current frame being produced;



Manage the overall speed and acceleration of the machine;



Manually operate the machine and all of its tooling operations;



View the status of the electrical Input/output for troubleshooting purposes;



Set the up/down times for each tool operation;



Trend various operating parameters in near real time.

Manufacturing and machine performance information is entered via the touch screen controller. Light finger pressure only is required to activate the touch screen commands. Sharp or solid objects should never be used to "tap" or "drag" across the screen. The controller has a USB2 port which can be used to accept USB memory sticks or a keyboard.


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10.2

Start-up and Shut-down Procedure

Whenever the FRAMECAD F300i is powered up, FRAMECAD Factory 2 will automatically load. During this “boot-up” sequence the system will complete general checks and display information text on the Operator Screen; this is normal. Once FRAMECAD Factory 2 has started you will be presented with the Login screen where you will need to select a User and associated password to continue. IMPORTANT SECURITY NOTE! All FRAMECAD F300i machines are shipped by default with Admin user access only. It is highly recommended that a site security policy is developed around user access that meets your requirements. Non-Admin users cannot change many of the machine configuration settings inside the FRAMECAD Factory 2 software. All events and actions initiated from FRAMECAD Factory 2 software will be recorded against the user logg ed in at the time.

FRAMECAD Factory Login Screen

To shutdown FRAMECAD Factory 2 you will need to press from the top right of the main control screens inside FRAMECAD Factory 2. You will be prompted to confirm, if accepted, the system will log off and, as per t he start-up sequence, will display inform ation only text as it fully closes down. Once fully shut-down the electrical power to the machine can be turned OFF. IMPORTANT NOTES! 1) It is always good practice to properly Log out of FRAMECAD Factory 2 whenever you shutdown the software. AVOID switching the electrical power off to the machine without logging-off. Once the software has fully shut-down then you can turn the electrical power OFF to the machine.


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2) All FRAMECAD F300i machines are fitted with an Uninterruptable Power Supply (UPS) unit that is designed to provide a battery backup supply for the computer system in the event that the main electrical power supply to the machine is accidentally disconnected or fails. If the main electrical supply is disconnected for any reason, the UPS unit will switch over to battery backup and issue a shut-down signal to the computer system. The UPS unit will then continue to maintain battery supply for a period long enough to allow FRAMECAD Factory 2 to complete an orderly shut-down.


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10.3

Navigating FRAMECAD Factory 2

The main display of the FRAMECAD Factory 2 software is split into two primary areas; Down the left side is the m enu tree which allows access to the various job scheduling, setup and information screens. The menu is in a tabular format and whenever the Operator selects a screen tab from the menu listing, the associated screen will be shown in the main screen display.

Menu Tree

Screen Display

The menu tree has three primary (or root) screen tabs; 

Schedule – this tab displays the job schedule screen. From this screen the Operator can view the current status, load, edit, delete, re-schedule and move jobs around in the production queue. This is the main screen used during production.



Setup – this tab contains all the screens associated with the setup and configuration of the FRAMECAD F300i machine. Screen access will be dependent on the User security level with only Admin users granted full access.



Info – this tab contains a collection screens that provide feedback and information on the FRAMECAD F300i machine. Here the Operator will find detail on productivity, alarms and service related information.


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When running in Automatic control, the screen display will show the Automatic Home screen with information on the current frame progress. An example is shown below;

When running in Manual control, the screen display will show the Manual Home screen with individual hydraulic punch operation buttons and cycle times. An example is shown below;


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Regardless of whatever screen is currently being displayed, the Operator can return back to the Home screen by pressing the [Return] button. The actual Home screen displayed will depend on the current control mode (i.e. either Automatic or Manual – see elsewhere in this section for more detail).

At the top right of each screen there are 4 buttons; [Return] button – pressing this button will return the Operator back the Home screen for the currently selected control mode (i.e. either Automatic or Manual – see below for more detail). This button will only be highlighted if the Home screen for the current control mode is not already being displayed. [Apply] button – whenever a value or parameter is changed inside FRAMECAD Factory 2, this button will be highlighted prompting the Operator for confirmation of the new setting. Setting changes w i l l n o t b e s a v ed until the [Apply] button is pressed. [Revert] button – once a value or setting change has been entered inside FRAMECAD Factory 2, the Operator can cancel the change and revert back to the original setting by pressing this button. [Logout] button – this will shut-down FRAMECAD Factory 2.


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10.4

Manual, Semi-auto and Automatic Control Modes

The FRAMECAD Factory 2 software has 3 control modes; Manual: In this control mode, the Operator can select individual tool operations to activate and drive the steel strip forward or reverse. In Manual control all operations must be user initiated. Automatic: In this control mode the FRAMECAD Factory 2 software will automatically process all items occurring in the job schedule. This will start with the first item in the job schedule, and will create one frame at a time sequentially down the schedule. At the end of a frame, the job schedule will be re-scanned from the top of the list to find any items which may have been added, moved, or remade since starting. This way it keeps the various job parts together. It will then begin the next job folder it finds with the Pending status. The production rates are shown in the trend graph at the bottom of the screen, displaying the amount of steel produced per hour over the last 8 hours. Semi-Auto: This is a combination of both Automatic and Manual control. In this control mode, the FRAMECAD Factory 2 software will automatically process all items occurring in the job schedule as per the full Automatic control mode BUT the Operator must use the INCH selector switch position mounted on the side of the machine, in order to progress the steel strip (i.e. steel movement is under manual Operator control). The steel strip is progressed through the machine at the reduced Manual (Inch) control speed. This control mode can be useful for running out complicated or troublesome pieces in the machine.

The following procedures describe how to select the required FRAMECAD F300i control modes.

PLEASE NOTE! As there have been t w o types of Operator Screen used on the FRAMECAD F300i machine, the following information will refer to Type 1 and Type 2 Operator Screen controls where there are differences. For more information please see Section 6 – Introduction to the FRAMECAD F300i Machine – Computer System & Operator Screen Controls.


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MANUAL CONTROL MODE Selecting Manual from a Stopped State

For Type 1 Operator Screen: To select Manual control, the Auto/Manual Selector Switch should be placed into the Manual position.

For Type 2 Operator Screen: The default control mode for the FRAMECAD Factory 2 software is Manual. The

[Manual] button lamp should be illuminated when in Manual control mode;

Press the Selecting Manual from Automatic

[Start] button to commence full Manual operation.

For Type 1 Operator Screen: If the FRAMECAD Factory 2 software is running in Automatic control and you wish to switch to Manual control mode use the following method;

If t h e m a c h i n e i s c u r r e n t l y r o l l i n g s t e e l i n A u t o m a t i c m o d e t h e n ;

Press the

[Pause] button to suspend Automatic production;

Place the Auto/Manual Selector Switch into the Manual position; Press the

[Software Reset] button to reset the FRAMECAD Factory 2 software;

For Type 2 Operator Screen: If the FRAMECAD Factory 2 software is running in Automatic control and you wish to switch to Manual control mode use the following method; If t h e m a c h i n e i s c u r r e n t l y r o l l i n g s t e e l i n A u t o m a t i c m o d e t h e n ;

Press the


Press the [Software Reset] button to reset the FRAMECAD Factory 2 software back to its default state which is Manual; The


Press the

[Start] button to commence full Manual operation.

If the machin e is idle (i.e. in Autom atic but no t currently ro lling steel) then;

Press the

[Manual] button;


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The Manual Forward and Reverse

[Manual] button lamp should be illuminated when in Manual control mode.

The FRAMECAD F300i machine is equipped with one INCH selector switch, and two FORWARD only push-buttons mounted on either side of the machine. While the FRAMECAD Factory 2 software is in Manual control, the roller section can be rotated either forward or reverse via the INCH selector switch and forward only via the FORWARD push-buttons. This can occur with or without steel strip in the machine.

Manual operation of hydraulic tool operations – Manual Home Screen

If the Manual Home screen is not currently being displayed press the button.

[Return]

The Manual Home screen will allow direct control of the various hydraulic tools on the machine.

To actuate a tool, select the required tool (Punch) operation, then press the [Execute] button to operate. If the hydraulic pump IS NOT RUNNING when the pressed then:

[Execute] button is first

i.

The hydraulic tool operation will not be performed;

ii.

The hydraulic pump will start and allow pressure to build;

iii.

Once the hydraulic system is at the required pressure the Operator can press the

[Execute] button to operate the hydraulic tool.

If the hydraulic pump IS ALREADY RUNNING AND IS AT THE REQUIRED PRESSURE then the hydraulic tool operation will be performed immediately.


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AUTOMATIC CONTROL MODE Selecting Automatic from Manual Control

For Type 1 Operator Screen: To select Automatic control mode use the following method;

Place the Auto/Manual Selector Switch into the Auto position;

Press the

[Start] button to commence full Automatic operation.

NOTE! Automatic production will only commence if a job file has been loaded and is pending (see Section 10 – Introduction to FRAMECAD Factory 2). For Type 2 Operator Screen: The default control mode for the FRAMECAD Factory 2 software is Manual. To select Automatic control mode use the following method;

The


Press the [Automatic] button to select Automatic control mode. The Automatic button lamp will illuminate; Press the


NOTE! Automatic production will only commence if a job file has been loaded and is pending (see Section 10 – Introduction to FRAMCEAD Factory 2). Pausing Automatic Control

For Type 1 Operator Screen: If the FRAMECAD Factory 2 software is running in Automatic control and you wish to momentarily suspend operations use the following method; Press the


Press the

[Pause] button again to resume Automatic production.



Press the



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Automatic controlled stop

For Type 1 Operator Screen: If the FRAMECAD Factory 2 software is running in Automatic control and you wish to end production after the current Stick being processed is complete then use the following method; Press the [Start] button to commence a controlled production stop. The Start button lamp will flash to indicate a co ntrolled production stop is in process. Once the current Stick has been completed the machine will stop production. For Type 2 Operator Screen: If the FRAMECAD Factory 2 software is running in Automatic control and you wish to end production after the current Stick being processed is complete then use the following method; The [Start] button AND when running in Automatic;

[Automatic] button lamps should both be illuminated

Press the [Start] button to commence a controlled production stop. The Start button lamp will flash to indicate a co ntrolled production stop is in process. Once the current stick has been completed the machine will stop production and return to Manual control (the default control mode). Running a Production Job

To view the jobs being manufactured in Automatic control, select the job schedule screen from the left-side menu tree. Once the FRAMECAD Factory 2 software has been started in Automatic control, the software will start making the first item in the job schedule, and will create one frame assembly at a time. At the end of each frame, the job schedule will be re-scanned from the top of the list to find any items which may have been added, moved, or remade. This way it keeps job batches together. The FRAMECAD Factory 2 software will then begin the next job folder it finds with the Pending status.

Viewing the Automatic Home Screen

If the Automatic Home screen is not currently being displayed press the [Return] button. The Automatic Home screen will display the current status of the job and job sub-parts. The Stick shown in GREEN will be the next Stick to exit the machine; Sticks shown in BLUE are still being processed and are waiting in the queue; Sticks shown in GREY have already been completed and exited the machine.


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Reset Automatic Production

For Type 1 Operator Screen: At any time the Automatic production of the job schedule can be reset by pressing the [Pause] button to suspend followed by the

[Software Reset] button. This will;

1.

Stop the Automatic production sequence;

2.

Reset the production status memory back to the start of the job schedule;

Stop all steel strip motion and hydraulic tooling operations in the machine. For Type 2 Operator Screen: At any time the Automatic production of the job schedule can be reset by pressing the [Pause] button to suspend followed by the


1.


2.


3.

Place the FRAMECAD Factory 2 software back in the default Manual control mode;

Stop all steel strip motion and hydraulic tooling operations in the machine. Automatic Production Speed Adjust

When running in Automatic control mode, the Schedule screen will also display the average production rate (processed steel/hr averaged over the last 8-hours of automatic production) in graphical form at the bottom of the screen.


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To the right of the graph is the FRAMECAD F300i Speed Ratio dial. To increase or decrease the operating speed of the machine, the dial can be turned either left or right respectively. The dial is calibrated in % of Feed-rate as set in the Setup / Motion Control / MDX61B screen (see Setup Menu Screen below for more detail on this). This speed adjustment is only valid for Automatic control has n o e f f ec t on the speed of the machine in Manual control.


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SELECTING SEMI-AUTOMATIC CONTROL MODE Selecting SemiAutomatic Control

For Type 1 Operator Screen: To select Automatic control mode use the following method; Place the Auto/Manual Selector Switch into the Semi position;

Press the

[Start] button to commence full Semi-automatic operation.

NOTE! Automatic production will only commence if a job file has been loaded and is pending (see Section 10 – Introduction to FRAMCEAD Factory 2). Turn the INCH selector switch to the FORWARD position (mounted on the top side covers) to progress the steel strip through the machine. Once the steel reaches the required tool operation position it will automatically stop, actuate the tool, and then wait for the Operator to progress the steel manually through the machine to the next tool position and so on. NOTE! Operators can toggle back and forth between Automatic and Semi-Automatic modes at any time using the Auto/Manual Selector Switch. For Type 2 Operator Screen: To select Semi-Automatic control mode use the following method; Press the [Automatic] button once to select normal Automatic control mode. The Automatic button lamp will illuminate indicating that the machine is now in the Automatic control mode. Press the Automatic button a second time to switch into Semi-Automatic control mode. The Automatic button lamp will flash ON and OFF to indicate the FRAMECAD Factory 2 software is now in the Semi-Automatic control mode; Press the

[Start] button to commence Semi-Automatic operation.

Turn the INCH selector switch to the FORWARD position (mounted on the top side covers) to progress the steel strip through the machine. Once the steel reaches the required tool operation position it will automatically stop, actuate the tool, and then wait for the Operator to progress the steel manually through the machine to the next tool position and so on. Once in the Semi-Automatic control state, pressing the [Automatic] button again will return the FRAMECAD Factory 2 software back to normal Automatic control. NOTE! Operators can toggle back and forth between Automatic and Semi-Automatic modes at any time by pressing the Automatic button.


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10.5

Schedule Screen

The Schedule screen is used to manage the production jobs to be run. From here an Operator can load new production projects, rearrange the order of manufacture, re-schedule jobs, delete jobs and view progress on a job currently being made. To open the Schedule screen, select the Schedule tab from the menu tree.

Once in the Schedule screen the Operator can view the status of the current production job(s) and manage the complete job schedule.

The following procedures explain the various job management functions available within FRAMECAD Factory 2.


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JOB SCHEDULE MANAGEMENT To Load a New Job

Select the Schedule tab from the menu tree to open up the job schedule screen. If the job to be loaded is stored on a USB Flash Memory unit, make sure it is inserted into the USB port on the front of the Operator Screen cabinet. If there is an LED on the USB Flash Memory unit, wait until the LED stops “flickering” - this indicates that it has been recognised by the computer. Press the

button.

Select the source location for the job file; for example USB Find the job File in the source directory and select it, this will move the job file into the components window where you can select the whole job or just parts of it by expanding the job file out (double tap the various sub-folders) and selecting which you want to produce. The frames and individual sub-frame pieces (or “sticks”) that the machine will produce will be checked with a white X next to the name. To select ALL simply check the job root folder in components list.

When the desired jobs (or job sub-parts, e.g. Frames) have been selected press the [Load Job] button to load the job into the production list. Loaded jobs will be displayed in the job schedule shown on the left hand side. If you already have jobs loaded, then by default the newest added job will appear below the existing jobs in the job schedule. Creating a Manual Job

FRAMECAD Factory 2 allows for jobs to be entered directly into the machine without loading from an alternate source. This can be very useful for producing test pieces while calibrating/tuning the machine. To create a manual job, select Create Manual Stick from the Select Source directory. You can then Edit the properties of the stick as described below in Edit Stick Properties.


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Job Status

jobs in the job schedule have 3 states: Pending: The job is queued waiting to be run through the machine. Processing: The job is being run through the machine and is currently being produced. Completed: The job has successfully been produced by the machine. NOTE! If the job file has been designed for a different machine or a different “C” section size to what the machine is configured for, it will be greyed out and highlighted in red.

To Reschedule a Job

Once a job has been completed and you want to repeat (re-schedule) the job, simply press and hold the complete job folder or job sub-part (e.g. a Frame) from the job schedule on the left and drag it over to the Re-schedule bar. The job status will change from completed to pending.


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Deleting a Job

Changing the Job Order

If you would like to delete a job(s), simply select and hold your finger on the job or job sub-part and drag it to the Delete bar.

If you would like to change the order that the jobs will be produced by the machine, simply select and hold your finger on the job or job sub-part and drag it to the n ew desired location in the job schedule.


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Edit Stick Properties

If you want to review or edit the properties (tool operations, length, quantity etc) of a Stick (individual element within a frame assembly) simply select the component from the job schedule and drag it over to the "properties" bar.


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This action will display the Edit Stick screen. The complete list of tool properties used on this Stick will be shown with the various text boxes provided

Stick Length This is the total length of the Stick. If you change this you may also need to adjust some of the other tool positions.

# to Make This is the total quantity to be made.


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# Made This displays the quantity already made.

Available Tools This selection box displays the tools available on the FRAMECAD F300i. From here you can scroll down the tool list and manually Add or Remove tools via the button options beneath. Any tools that are added will then be displayed in the Tool & Position list.

Tool & Position List This is where all the tool operations are listed for this specific Stick. It also lists the position, relative to the end of the Stick, that the tooling function will be placed. To edit the positions select the required position value text box. An on-screen keypad will be displayed allowing you to edit t he value. To remove a tool function simply select the tool and press the under the Available Tools selection box.

button

If a tool position value is entered outside the Stick Length setting the value text box will be highlighted in red.


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10.6

Setup Menu Screens

Selecting the Setup menu tab from the main directory will allow access to the various screens for configuring the FRAMECAD F300i machine. The following introduces the available screens and functions included. CAUTION! Most of the data included in these screens is factory set and will not need editing. These parameters are highlighted below. Always consult an authorised FRAMECAD Technician if you are not sure BEFORE making any changes. It is highly recommended that a site security policy is developed that suits your needs. NonAdmin users cannot change many of the machine settings such as tool offsets or VFC parameters. SETUP MENU Setup / Machine Setting Screen

The Machine Setting Screen is the first screen shown under the Setup menu tab. This screen allows the basic setup and configuration of the FRAMECAD F300i machine. Scrap Length (mm): Whenever the FRAMECAD F300i is first placed into Automatic control, any steel strip inside the machine at commencement will be wasted as scrap. scrap. However, these lengths can be cut up into more usable lengths if required. Often this steel can be used elsewhere and so the Operator can determine a more usable scrap length. length. NOTE! The machine will still produce the same quantity of scrap but will cut it into the length(s) entered in this field. Scrap Length (mm): The Chamfer Scrap Length is used to adjust the length of scrap removed when a stick with end chamfers is manufactured.


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Machine section type: This allows the Operator to choose if the machine will produce “C” or “U” section profile sticks. The selected type will determine if the Lip Box unit is engaged or not. “U” Section Profile: To manufacture “U” section profile, select this option from the box and press the the OR [Soft [Softwa ware re Rese Reset] t] push pushbut butto ton. n. The Lip Lip Box Box will will disen disenga gage ge allowing an un-lipped un- lipped profile (“U” section) to be manufactured. The job schedule will be refreshed and will indicate “U” section as the selected profile. profile . NOTE! An override feature has been allowed for so that the Lip Box can be “manually” engaged by pressing the [Operate] button located directly below the Machine section type box. This will engage the Lip Box whilst operating in Automatic control. However, the Lip Box will disengage again whenever the Software Reset button is pressed. “C” Section Profile: To manufacture “C” “C” section profile, select this option from the box and press the the OR [Sof [Softw twar are e Reset Reset]] push pushbu butt tton on.. The Lip Lip Box will will engag engage e allowing a lipped profile (“C” section) to be manufactured. The job schedule will be refreshed and will indicate “C” section as the selected profile. profile . Setup / Tools Screen

The Tools screen contains setup data on each of the hydraulic tooling operations available on the FRAMECAD F300i machine. This screen defines the physical location of each tool in the machine relative to a fixed datum point AND the speed at which the tool operation will be performed.

Offset (mm): The tool offset value value is the actual physical position of each successive tool relative to the centre of the first tool tool on the machine. On the FRAMECAD F300i machine the first tool is always the Service Hole. Thus the offset value for the Service Hole tool is always Release 10102013 ©2013 FRAMECAD Limited 120

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0 and this becomes the datum point for each successive tool position. Each of the following tools will therefore have an offset value equal to the measured distance in mm from the centre of the Service Hole to centre of the respective tool. Up & Down Delay Times (ms): The sum total of the Up and Down times (in milliseconds) is the time allowed for the tool to complete its operating cycle. The hydraulic solenoid valve will remain energised for the period defined in the Down Delay time. Once de-energised the software will wait for the Up Delay time to elapse before allowing the steel strip to be progressed to the next tool (this is to allow the tool sufficient time to return to its fully retracted position).

WARNING! THE TOOL DELAY TIMES ARE FACTORY SET AND SHOULD ONLY BE ADJUSTED IF DIRECTED TO BY A FRAMECAD TECHNICIAN. INCORRECT ADJUSTMENT COULD CAUSE CATASTROPHIC DAMAGE TO THE MACHINE TOOLING. Setup / Motion Control / MDX61B Screen

The MDX61B Screen contains information about the Variable Frequency Con troller (VFC) which controls the overall speed and positioning of steel strip within the machine. These settings should not be changed unless advised by a FRAMECAD Technician. Incorrect settings can have detrimental effects on the FRAMECAD F300i performance, safety and accuracy.

Scale Factor: In order to accurately position the steel strip during production, the FRAMECAD Factory 2 software needs to be able to precisely convert the electrical pulses received from the strip encoder into a unit of length. This is a function of the number of pulses produced by the strip encoder in a single revolution (i.e. one turn of the encoder input shaft) and the gearing ratio between the strip encoder input shaft and the diameter of the bottom encoder wheel that runs along the surface of the steel strip. Knowing these quantities


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allows the system to accurately calculate the scale factor in mm/pulse. As the number of encoder pulses per revolution or the exact diameter (and theref ore circumference) of the bottom encoder wheel are not always easily determined by direct measurement, the control system can be made to automatically compute the correct scale factor (or mm/pulse). Prior to commencing production the Scale Factor will need to be checked and a calibration completed to ensure accurate positioning of steel inside the machine. Last Length: This is the length of the last Stick made as determined by the FRAMECAD Factory 2 software. Typically this is used during the strip encoder calibration procedure. Measured Length: This is the actual measured length of the last Stick made as determined by the Operator. Typically this is used during the str ip encoder calibration procedure where the Operator will determine the length of the last Stick made using an accurate tape measure and enter the value directly into this text box. Once measured length value has been entered the Operator can press the [Calculate] button to have FRAMECAD Factory 2 automatically calculate the correct Scale Factor. Feed Rate: This is the maximum speed in RPM (revolutions per minute) that the rolling section servo motor will be permitted to rotate at. As the speed of rotation at the rolling section ultimately determines the speed at which the steel strip is progressed through the machine, this value will contribute significantly to the overall production output. The maximum permissible value allowed for here is 3000(RPM). If the Operator adjusts the Speed Ratio dial this will adjust the actual feed rate to a percentage of percentage of this value. NOTE! The Feed Rate value relates directly to the rotation speed of the rolling section servo motor - not the roller section itself. The actual speed of the rolling section will be a derivative of the drive chain gearing, including the servo motor gearbox reduction. Jog Rate: This is the maximum speed in RPM (revolutions per minute) that the rolling section servo motor will be permitted to rotate at whilst in the Manual control mode. Typically this value is set to around 500(RPM). NOTE! The Speed Ratio dial has no impact on the Jog Rate. Ramp Time: This is the time in milliseconds that the FRAMECAD Factory 2 software will attempt to accelerate the rolling section servo motor up to the maximum desired speed (see Feed Rate above). Likewise, the FRAMECAD Factory 2 software will also try to decelerate the rolling section servo motor back down to 0RPM using the same ramp time setting. If this value is set too low too low the the VFC may fault, simply because it cannot ramp the servo motor to the required speed in the given time. If this value is set too high high then the overall production rate will be unnecessarily reduced.


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Lag Window: FRAMECAD F300i machine is equipped with two high resolution encoders; the first for measuring the strip position and the second for determining both the angular position and speed of the rolling section servo motor. Both of the encoder signals are sent back to the VFC unit inside the AC Electrical Cabinet which uses these values to accurately manage the speed and position of steel strip within the machine. Ideally there should be very little difference between the scaled feedback from these two encoders. However, small variations do exist as a result of chain tension, slippage between rollers or even stretch in the steel itself. As one encoder infers position based on the number of servo motor revolutions and the other is reading position directly from the moving steel strip these small variations are inevitable. In fact, the VFC uses these very variations to compensate for any mechanical tolerance within the machine and is the reason why positioning is so accurate. This difference between the encoder feedback values is called the Lag Window . The VFC unit constantly monitors the Lag Window to make sure that the differences between the two encoder values remain acceptable during Automatic control. If the variation becomes too great then the VFC will assume that a problem has occurred and trigger a fault message that will cause the FRAMECAD Factory 2 software to stop the FRAMECAD F300i machine; the most common example being the steel strip “catching” or hitting a tool or guide inside the machine causing the steel strip encoder feedback to slip further behind the servo motor encoder value than allowed. The value in the Lag Window parameter will determine how wide a variation is allowed to exist. Too large a value and the VFC may not respond in time to a steel jam up in the machine; too low a value will make the VFC too sensitive to minor differences. The value represents the number of pulses allowed between the two encoders and is factory set before shipping and should not be changed unless advised by an authorised FRAMECAD Technician. Parameter Index/Parameter Value: The values allow direct access to the VFC internal memory AND SHOULD NOT be used unless under the strict guidance of an authorised FRAMECAD Technician

WARNING! THE MDX61B PARAMETERS/VALUES ARE FACTORY SET AND SHOULD ONLY BE ADJUSTED IF DIRECTED TO BY A FRAMECAD TECHNICIAN. INCORRECT ADJUSTMENT COULD CAUSE CATASTROPHIC DAMAGE TO THE MACHINE TOOLING AND/OR ROLLING SECTION. Setup / Inkjet Printer Screen

This screen allows the Operator to configure the printer control system on the FRAMECAD F300i. Most values displayed here are factory set before the FRAMECAD F300i is shipped and should not need any further adjusting unless instructed to do so by an authorised FRAMECAD Technician. This screen also allows the Operator to select ink (for production purposes) or cleaner (for cleaning the printer heads and tubing) and to test the print system.


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Offset: This value sets the physical location of the printer heads within the FRAMECAD F300i. The value relates to the physical distance in millimetres between the printer head(s) and the centre of the first tool (the datum point) in the machine. The value is factory set prior to shipping and should not need any further adjusting unless instructed to do so by an authorised FRAMECAD Technician. Incorrect settings can cause the print control system to fault or produce poor quality print. Dot Column Width: The text that is printed on each Stick is actually comprised of a series of dots. This value defines the measured width of a single column of dots. It is required by the FRAMCAD Factory 2 software so that it can determine the overall width of the printed text. If the text is too long for the given Stick length, the software will truncate the text so that it will fit. User Text Spacing: This value determines the spacing between the User Text (see below) in millimetres. For example if set to 0, the software will only print the User Text once on each Stick. If set to 200mm, the User Text will be repeated down each Stick with a 200mm gap in between. Dot Size: This value determines the physical size of each ink dot. The FRAMECAD F300i utilises 16-valve Printer Heads, where each valve produces an individual “ink dot”. The size of that dot is actually a function of how long the corresponding valve inside the Printer Head is switched on for. The Dot Size parameter is therefore a time value in periods of 10 microseconds (e.g. if Dot Size value = 80, the Printer Head valve on-time = 80 x 10 = 800microseconds). Flush Time: Whenever the Print Control system is switched between Ink and Cleaner fluid the FRAMECAD Factory 2 software will flush the lines for a short period as defined by this value (in milliseconds).


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Test Button: The [Test] button is used to check the printer system during Manual control mode. Refer to Section 12 – Maintenance for the Printer System Test procedure. Select User Text: The Select user text box displays the available options for the reverse side printing. One side of the Stick (the primary side) will be printed with the Stick identification data, and the other will be printed with the text selected in this field. The text available can be changed by creating a new user text file; on a computer, open up a text editor (Notepad or similar), and enter each user text on its own separate line (each line will be interpreted as a separate User Text message). Save this as a *.txt file to a USB flash memory device and insert it into the machine. Press the `Import new user text file' button, double-tap on the USB folder, select the file you created, and press ‘Load'. You can then choose which user text option you want printed. The User Text can also incorporate Power Fields . A Power Field can be used to insert a default system variable and can be included in any position inside the User Text. There are three Power Variables available in FRAMECAD Factory 2; i.

%date% - this will insert the current system date in the User Text

ii.

%time% – this will insert the current system time in the User Text field

iii.

%newline% - whenever the FRAMECAD Factory 2 software encounters this Power Field it will automatically switch the printed text to a smaller font size and print the User Text in a double line format (i.e. split the User Text into two lines, one on top of the other. This feature is allowed for to save space.

NOTE: each User Text message should be entered in a s i n g l e c o n t i n u o u s l i n e . Each new line will be interpreted as a separate User Text message. Ink Select Button: The [Select Ink] button is used to switch the print control system over to use Ink. Once pressed the Ink Selected check box will be highlighted to confirm the selection. Cleaner Select Button: The [Select Cleaner] button is used to switch the print control system over to use Cleaner (i.e. to flush Ink from the print heads and clean). Once pressed the Clean Selected check box will be highlighted to confirm the selection. Purge Button: The [Purge] button is used to inject a short burst of either ink or cleaner through both the print heads. The fluid used will be dependent on the selection (i.e. Ink or Cleaner). Refer to the check box indicators below the [Purge] button to confirm which fluid has been selected.

IMPORTANT! THE CLEANEAR AND PURGE FUNCTIONS ARE USED DURING THE INKJET PRINTER HEAD CLEANING PROCEDURE. CLEANING OF THE PRINTER HEADS IS IMPORTANT TO MAINTAIN PRINT QUALITY AND OPERATION. REFER TO THE SECTION ON PRINT SYSTEM MAINTENANCE TO ENSURE AN EFFECTIVE CLEANING REGIME IS FOLLOWED.


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Setup / Miscellaneou s Screen

Language Selection: The Language selection list is used to change the factory software language. Users Selection: The User’s section is where you can add, delete or edit user profiles. By default, only an Admin user is loaded. New users can then be created (and chosen at the Login screen). FRAMECAD Factory 2 software will log all events against whichever user is currently logged in. IMPORTANT SECURITY NOTE! All FRAMECAD F300i machines are shipped by default with Admin user access only. It is highly recommended that a site security policy is developed around user access that meets your requirements. Non-Admin users cannot change many of the machine configuration settings inside the FRAMECAD Factory 2 software. All events and actions initiated from FRAMECAD Factory 2 software will be logged accordingly against the user logged in at the time. Operator Pause Reset Reasons: Operator pause and reset reasons occur when the FRAMECAD Factory 2 software detects that the machine is paused or reset . The operator is required to choose a reason from a list of why the machine was paused or reset; these are logged to the event log and allow management to check reasons for machine downtime or steel scrap. By default, these are blank. New reasons can be loaded in a similar manner to inkjet print User Text (see above) by creating a *.txt file with each reason on its own line. These are then loaded by pressing the

[Import pause reasons]

or [Import reset reasons] buttons, followed by the [Load] button. They can be blanked again by pressing either of these buttons again, followed by the [Use Blank] button.


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10.7

Info Menu Screens

Selecting the Info menu tab from the main directory will allow access to various screens that provide information and feedback on the FRAMECAD F300i machine. These screens can be invaluable in diagnosing problems or monitoring performance. The following introduces the available screens and the information provided.

INFO MENU Info / I/O View Screen

The Info Screen displays the logical state of the digital inputs & outputs (I/O) on the FRAMECAD F300i machine. Digital inputs provide the logical state of the various pushbuttons and sensors on the machine. Digital outputs provide the digital state of the solenoid valves, indicator lamps (push-buttons) and motor stop/start contactors. Logic State 1 (input or output is “ON”): Green Logic State 0 (input or output is “OFF”): Grey In addition to the logical state of the I/O, this screen also provides information on the physical connection point inside the DC Electrical cabinet where the input or output is terminated; these can be cross-referenced to the Electrical Circuit diagrams for more detail.

Info / I/O Live Charting Screen

This screen allows the Operator to trend ( chart ) various operations of the machine while it is running. A typical example is displayed here, with a trend of the VFC (MDX61B) output current amps. There are many other machine variables that can be trended, including multiple trends updated at the same time. Trending can be a useful tool in measuring machine performance, determining maintenance/service requirements and monitoring general productivity. Trends can be selected from the drop-down selection list and then added using the [Add Chart] button.


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Info / Alarms Screen

The FRAMECAD Factory 2 software will monitor the machine performance and input state of various sensors on the FRAMECAD F300i machine to determine if there any serious problems that will impact machine performance and/or could compromise safety of the Operator. If an issue is detected then an Alarm condition will be created; typically this will involve stopping machine production. Whenever an Alarm state is activated, the Alarm screen will be automatically displayed. If the Operator navigates away from the Alarm screen while an Alarm is still active the following shortcut will appear in the bottom right-side of the currently displayed screen;

Touching this short-cut will take the Operator directly to the Alarms screen where any active alarm states will be displayed. See example below;


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New and unacknowledged alarms will always be displayed in Red. To acknowledge an alarm state, the Operator must first address the issue that triggered the alarm condition in the first place then press the [Acknowledge All] button. The alarm message will then turn black as per the example below;

If the problem has been addressed (in this instance the emergency stop button needs to be released) then you can remove the notification from the alarm list altogether by pressing the

OR

[Start] button.

If an alarm remains in the list, then the trigger for the alarm has not been resolved and further investigation is required.


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Info / Maintenance Data Screen

The Maintenance Data screen provides information on production, steel consumption and a running count of hydraulic tool operations. This data is invaluable for planning service and maintenance regimes. Time and frequency of tooling operations are two of the most significant indicators in determining when and what service is required. All tools eventually wear and hydraulic oil, filters etc will need replacing with time and use. This screen should therefore be an integral component of the FRAMECAD F300i management strategy. Maintaining an effective service plan is crucial to ensuring the continued performance of the machine. Time Run: This is the total time the FRAMECAD F300i machine has been available for “production”. The time is derived from the number of hours the hydraulic power-pack has been running which is a direct indication of the number of hours the machine has been technically available for production. Total: This is the total length of steel strip processed on the FRAMECAD F300i machine, including all waste (scrap) material processed in either Automatic or Manual control modes. Production: This is the total amount of steel strip processed in Automatic control mode ONLY. In other words, this is technically the amount of usable product run off the machine. Scrap: This is the amount of estimated scrap steel generated on the machine. It is calculated as follows; Scrap (%) = (Total – Production) / Total Tool Counts: This is the number of individual tool operations that have taken place on the machine in both Automatic and Manual control modes. This is useful method for planning scheduled service and maintenance of the tooling.


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IMPORTANT! THE MAINTENANCE DATA SCREEN SHOULD BE AN INTEGRAL COMPONENT OF THE FRAMECAD F300I MANAGEMENT STRATEGY. MAINATAINING AN EFFECTIVE SERVICE PLAN IS CRUCIAL TO ENSURING THE CONTINUED PERFORMANCE OF THE MACHINE.


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Info / Event Log Screen

FRAMECAD Factory 2 has a built-in event log that captures various actions and/or events that take place on the FRAMECAD F300i machine. This screen allows access to this logged data. The data can be segmented and displayed according to the date, the type of event and User.

The type of events to display can be selected via the drop down selection box as shown below;

The event dates can be selected via the drop down Calendar as shown below;


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10.8

Updating FRAMECAD Factory 2 ®

As a company that thrives on innovation, FRAMECAD is committed to the process of continuous improvement and development of all its products, including FRAMECAD Factory 2. As new enhancements or features are introduced, software updates are released that can be installed to ensure that your FRAMECAD F300i is always with the latest version. The following procedure will show you how to update FRAMECAD Factory 2; UPDATING FRAMECAD FACTORY 2 Tools Required



USB Memory Key with the latest FRAMECAD Factory 2 software update file loaded onto it (visit to download)

Safety



Nil

Updating FRAMECAD Factory 2

1.

Shut-down FRAMECAD Factory 2 and switch power OFF to the machine (if already started) – wait for 1 minute then switch power back on to the machine;

2.

During the start-up sequence the following message will be displayed “Tap screen to start admin menu. 5 seconds remaining” “Tap” the screen with your finger before the 5 second count -down has elapsed. This will start the Administration menu.

3.

Once Administration menu has started, plug in the USB Memory Key with the latest FRAMECAD Factory 2 software update loaded into the USB socket located on the front of the Operator Screen;


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4.

Once USB Memory Key has been detected and is ready to use (typically most USB Memory Keys will have indicator lights on them that will flash until recognised by the system), select the option

5.

Select the correct software update file then press the

[Update from USB] [Open] button;

Select the correct software update file

Once selected, press the Open button

6.

Once the update installation process has finished the Operator will be prompted with the message Installation Finished. Press the [OK] to return to the Administration menu screen;


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7.

The Operator can then select [Reboot] from the Administration menu screen to re-boot FRAMECAD Factory 2.


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11 Production This Section details the basic procedures required to commence production on the FRAMECAD F300i. Before starting production ALL Operators will need to have familiarised themselves with this manual, including all safety and initial setup requirements. Failure to do so may result in damage to the FRAMECAD F300i or severe injury.

11.1

Removing Steel from the Machine

Frequently there will be steel already in the machine that must be removed in order to commence production. A typical example of when this might happen is at the end of a steel coil or if the steel strip is cut-off at the in-feed to the machine for whatever reason. The following procedure details the removal of any steel strip left in the machine; REMOVING STEEL STRIP FROM FRAMECAD F300i Tools Required Safety

Removing Steel from Machine






ALWAYS wear cut-resistant gloves during this procedure;



NEVER stand directly in front of the FRAMECAD F300i out-feed unit.

8.

Place the machine into Manual control mode (see Section 10 – Introduction to FRAMECAD Factory 2).

9.

Go to the Setup/Tools screen, and press the [Operate] button for the Lip Box unit until the check box indication lamp is OFF (i.e. grey-colour). This will disengage the Lip Box unit making removal of any steel strip much easier;

10. Use the Inch FORWARD push-button on the side of the FRAMECAD F300i to slowly “inch” the steel out of the machine. When the steel can no longer be driven forward (i.e. it is no longer riding on any driven rollers), it can be removed by hand.


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11. Press the

OR

[Software Reset] button to reset the Lip Box unit.

SAFETY! ALWAYS ENSURE THAT CUT-RESISTANT GLOVES ARE USED WHEN HANDLING STEEL.


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11.2

Loading Steel coil onto the De-coiler

The following procedure details the loading of steel coil onto the De-coiler; LOADING COIL ONTO THE DE-COILER Tools Required

Safety



De-coiler Winding Handle



Steel Coil Lifting Equipment



Calibrated and high accuracy vernier caliper OR steel rule



Calibrated and high accuracy Micrometer






ISOLATE electrical power to the De-coiler and implement measures to prevent accidental re-connection;

Turn De-coiler isolation switch to the OFF position    

Use only certified (weight and application) lifting equipment for use on the Steel Coil; Apply extreme care when lifting and transferring coil to the De-coiler; Use cut-resistance protective gloves when handling steel coil strip; Make sure that the steel coil is securely strapped so that the coil cannot spring loose and unwind itself – this is important, failure to do so could result in serious injury as the tightly wound coil will release and tend to unwind once strapping is removed.

Strapped Steel Coil

WARNING! USE EXTREME CAUTION WHEN REMOVING ANY STEEL COIL STRAPPING OR BANDING. STEEL COIL STRIP IS TIGHTLY WOUND AND ONCE ALL STRAPPING IS RELEASED IT WILL WANT TO RAPIDLY UNWIND. WHERE SAFE AND PRATICAL, CLAMP THE END OF THE STEEL STRIP DURING THE REMOVAL OF ALL STAPPING TO ALLOW A CONTROLLED RELEASE. Release 10102013 ©2013 FRAMECAD Limited 138

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Loading Steel Coil onto the De-coiler Mandrel

1.

Remove the De-coiler safety guard by releasing the locking nuts holding it in place;

2.

Using the mandrel winding handle, collapse the mandrel shoe-plates down to below the internal diameter of the steel coil to be loaded;

Mandrel Shoe Plate Safety Guard Locking Nuts Mandrel Shoe Plate

Mandrel Shoe Plate

3.

Check the steel coil to be loaded is the correct thickness and strip width using respectively the micrometer and vernier caliper/steel rule;

4.

Using appropriately certified lifting equipment, raise the new steel coil up and onto the De-coiler mandrel, ensuring that; a. b. c.

d.

The steel strip will feed from the top of the coil (not from the bottom); Push the steel coil on so that it is sitting against the De-coiler mandrel backing-plates; Continue to support the weight of the steel coil using the lifting equipment – DO NOT drop the full weight of the steel coil onto the mandrel during this step; Ensure that the steel coil once loaded is in-line with the in-feed to the FRAMECAD F300i machine.

5.

While the weight of the steel coil is still supported by the lifting equipment, use the mandrel winding handle to firmly tighten the mandrel shoe-plates up against the inside diameter of the steel coil;

6.

Remove the lifting equipment and allow the steel coil weight to be fully supported by the De-coiler mandrel;

7.

Remove any banding or strapping that is holding the steel coil together. Where safe and practical use effective clamping means to hold the end of the steel strip to prevent rapid unwinding once the strapping is removed. Carefully remove the clamp while holding the end of the steel strip;

WARNING! USE EXTREME CAUTION WHEN REMOVING ANY STEEL COIL STRAPPING OR BANDING. STEEL COIL STRIP IS TIGHTLY WOUND AND ONCE ALL STRAPPING IS RELEASED IT WILL WANT TO RAPIDLY UNWIND. WHERE SAFE AND PRATICAL, CLAMP THE END OF THE STEEL STRIP DURING THE REMOVAL OF ALL STAPPING TO ALLOW A CONTROLLED RELEASE. Release 10102013 ©2013 FRAMECAD Limited 139

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8.

Pull the end of the of the steel coil strip down and under the De-coiler Dancer Arm;

9.

Re-attach the safety guard and tighten locking nuts to hold in place.

10. Carefully turn the De-coiler mandrel back-plates or Safety Guard to allow the steel strip to unwind off the end of the coil and feed this down and through (or under on some earlier De-coiler’s) the end of the Dancer Arm so that the arm will lift up and down with the steel strip as it is pulled through the FRAMECAD F300i. 11. Turn back on the electrical power to the De-coiler; 12. Press the green Start push-button on top of the De-coiler. The start indicator lamp should turn green, if it doesn’t check the Emergency Stop Push-button is not latched in OR the Dancer Arm is not fully raised then retry.

Start the De-coiler

CAUTION! Always make sure the Dancer Arm end is resting on the ground before starting the De-coiler. Stand well clear of the rotating mandrel back-plates. 13. Reset the safety control system (see Section 5 - Safety) and acknowledge any alarms that are active on the FRAMECAD F300i Operator Screen.


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11.3

Feed Steel Strip into the Machine

Once steel coil has been loaded onto the De-coiler threaded through (or under on earlier generation De-coilers) the De-coiler Dancing Arm, the steel strip will then need to be inserted into the in-feed of the FRAMECAD F300i machine. The following procedure details the method for doing this; FEEDING STEEL STRIP INTO THE FRAMECAD F300i Tools Required Safety

Loading Steel into the Machine









NEVER stand directly in front of the De-coiler mandrel back-plates;

1.

If the machine is not already in Manual control mode, press the [Software Reset] button followed by the

2.

OR

OR

[Start] button;

Carefully pull the end of the steel strip down and thread through (or under on some earlier De-coilers) the end of the Dancer Arm so that the arm will lift up and down with the steel strip as it is pulled through the FRAMECAD F300i. NOTE! While the De-coiler is in the ON state (i.e. Start push-button indicator lamp is ON) and the Dancer Arm end is resting on the ground, the De-coiler will tend to resist turning making it difficult to drag the steel sheet off. There are two methods that can be adopted to simplify this; 1.

2.

3.

Gently lift the Dancer Arm to allow the De-coiler to slowly rotate enough and allow the end of the steel strip to be feed down and through (under) the Dancer Arm. Take extreme care to avoid the spinning mandrel back-plates; Stop the De-coiler by either pressing the Stop OR Emergency Stop push-buttons on top of the De-coiler. You can also simply turn OFF the isolation switch on the De-coiler. Stoping the Decoiler will allow the De-coiler mandrel to be rotated by hand.

Carefully feed the end of the steel strip through the Lubricator unit and into the in-feed guides. CAUTION! Always take care not to damage the Steel Strip Sensor mounted in the bottom plate of the in-feed assembly. Make sure the leading edge of the steel strip is free of sharp jagged edges that may hit the top of the Steel Strip Sensor.

4.

When inserting the steel strip, check that the guides are firm on the steel but not tight. You can test this by first inserting the steel and moving it from side to side inside the guides, there should be little to no movement. NOTE! There are two types of FRAMECAD F300i in-feed guide configuration. Choose the one below that suits the type used on your machine;


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In-feed Guide Type 1: This In-feed guide type has two knurled Guide adjustors on either side. If the width needs adjustment simply rotate either adjustor in the required direction. adjustor

Type 1 In-feed Guide Width Adjustment

In-feed Guide Type 2: This type of In-feed Guide has a single Guide Width Adjustor on the right-side (relative to the direction of steel travel). To adjust, loosen the left-side (relative to direction of steel travel) locking screw and wind the right-side knurled adjustment knob (Guide Width Adjustor) in or out until there is a firm fit. Re-tighten the locking screw when complete. Guide Width Adjustor

Locking Screw

Type 2 In-feed Guide Adjustment

Once the in-feed width has been set, close the top sliding cover and reset the safety control system (as one of the top sliding covers was opened, the FRAMECAD Factory 1 software will trigger a Guard Switch alarm event). Restart the machine in Manual control mode as previous. 5.

Continue to push the steel strip through the pre-punch tool block and into the first roller station. Once the steel strip has reached the first roller station, continue to push while at the same time press one of the side cover Inch Forward push-buttons (there is one on either side of the machine at the in-feed end). This will allow the rollers to start spinning and take up the steel strip so that it can be fed through the remainder of the machine.


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6.

The steel strip can now be threaded all the way through using the Inch Forward controls on the side of the machine. Continue to feed until the steel strip has just exited the out-feed end of the machine.

7.

Check to make sure there is sufficient lubricant being applied to the steel strip. The steel strip should have a wet, even film of lubricant across the strip width.

SAFETY! ALWAYS ENSURE THAT CUT-RESISTANT GLOVES ARE USED WHEN HANDLING STEEL.


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11.4

Purging the Ink Jet Printer System with Ink

Before commencing production it is important to ensure the printer system is r e ad . In order ad y t o p r i n t to achieve this, the printer control system must be p u r g e d with ink. The following procedure defines this; PRINTER INK PURGE PROCEDURE Tools Required



Nil

Safety



Use safety glasses and appropriate personal protective equipment including rubber gloves whenever handling ink or cleaner rubber Nitral


When

Clean Printer Heads

At the start of Production. T his procedure will purge the printer s ystem with Ink allowing printed text to be applied during production. 1.

Start the machine and reset the safety control system (i.e. release any Emergency Stop push-buttons, close all sliding covers, and reset the safety control system. See Section 5 – 5 – Safety Safety for more information);

2.

Ensure printer Air Compressor pressure is at approximately10 psi. This can be checked by viewing the compressor digital display inside the printer control cabinet;



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3.


4.

5.

Go to the Setup / Inkjet Screen and press the this will do two things;


a.


b.

Flush the tubes going up to the printer heads and back down to the Waste bottle for the period defined in the Flush Time field (in milliseconds). This is to remove any residual Cleaner from the lines;

In this next step Ink will be sent up into the printer head and through the nozzles to flush any residual Cleaner/air out of the printer head itself. If there is no steel in the machine, it is a good idea to insert a piece of cardboard in the space between the two printer heads to prevent Ink from one printer head being sprayed onto the other. Press the [Purge] button. This will momentarily send Ink up into the printer heads and eject through the nozzles. Repeat this until there is a consistent spray of Ink from the printer head whenever the [Purge] button is pressed.


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6.

Once steel strip has been threaded through the machine it is a good idea to test the printer control system before commencing full production. Refer to the Printer System Test procedure below for instructions on this.


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11.5

Loading a Production Job JOB SCHEDULE MANAGEMENT

To Load a New Job

Select the Schedule tab from the menu tree to open up the job schedule screen. If the job to be loaded is stored on a USB Flash Memory unit, make sure it is inserted into the USB port on the front of the Operator Screen cabinet. If there is an LED on the USB Flash Memory unit, wait until the LED stops “flickering” - this indicates that it has been recognised by the computer. Press the

button.

Select the source location for the job file; for example USB Find the job File in the source directory and select it, this will move the job file into the components window where you can select the whole job or just parts of it by expanding the job file out (double tap the various sub-folders) and selecting which you want to produce. The frames and individual sub-frame pieces (or “sticks”) that the machine will produce will be checked with a white X next to the name. To select ALL simply check the job root folder in components list.

When the desired jobs (or job sub-parts, e.g. Frames) have been selected press the [Load Job] button to load the job into the production list. Loaded jobs will be displayed in the job schedule shown on the left hand side. If you already have jobs loaded, then by default the newest added job will appear below the existing jobs in the job schedule. Creating a Manual Job

FRAMECAD Factory 2 allows for jobs to be entered directly into the machine without loading from an alternate source. This can be very useful for producing test pieces while calibrating/tuning the machine. To create a manual job, select Create Manual Stick from the Select Source directory. You can then Edit the properties of the stick as described below in Edit Stick Properties. Release 10102013 ©2013 FRAMECAD Limited 147

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Job Status

jobs in the job schedule have 3 states: Pending: The job is queued waiting to be run through the machine. Processing: The job is being run through the machine and is currently being produced. Completed: The job has successfully been produced by the machine. NOTE! If the job file has been designed for a different machine or a different “C” section size to what the machine is configured for, it will be greyed out and highlighted in red.

To Reschedule a Job

Once a job has been completed and you want to repeat (re-schedule) the job, simply press and hold the complete job folder or job sub-part (e.g. a Frame) from the job schedule on the left and drag it over to the Re-schedule bar. The job status will change from completed to pending.


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Deleting a Job

Changing the Job Order

If you would like to delete a job(s), simply select and hold your finger on the job or job sub-part and drag it to the Delete bar.

If you would like to change the order that the jobs will be produced by the machine, simply select and hold your finger on the job or job sub-part and drag it to the n ew desired location in the job schedule.


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Edit Stick Properties

If you want to review or edit the properties (tool operations, length, quantity etc) of a Stick (individual element within a frame assembly) simply select the component from the job schedule and drag it over to the "properties" bar.


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This action will display the Edit Stick screen. The complete list of tool properties used on this Stick will be shown with the various text boxes provided

Stick Length This is the total length of the Stick. If you change this you may also need to adjust some of the other tool positions.

# to Make This is the total quantity to be made.


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# Made This displays the quantity already made.

Available Tools This selection box displays the tools available on the FRAMECAD F300i. From here you can scroll down the tool list and manually Add or Remove tools via the button options beneath. Any tools that are added will then be displayed in the Tool & Position list.

Tool & Position List This is where all the tool operations are listed for this specific Stick. It also lists the position, relative to the end of the Stick, that the tooling function will be placed. To edit the positions select the required position value text box. An on-screen keypad will be displayed allowing you to edit t he value. To remove a tool function simply select the tool and press the under the Available Tools selection box.

button

If a tool position value is entered outside the Stick Length setting the value text box will be highlighted in red.


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11.6

Switching to Automatic Control

In this control mode the FRAMECAD Factory 2 software will automatically process all items occurring in the job schedule. This will start with the first item in the job schedule, and will create one frame at a time. At the end of a frame, the job schedule will be re-scanned from the top of the list to find any items which may have been added, moved, or remade. This way it keeps job lots together. It will then begin the next job folder it finds with the Pending status. The production rates are shown by the graph at the bottom of the screen, showing the amount of steel produced per hour over the last 8 hours. AUTOMATIC CONTROL MODE Selecting Automatic from Manual Control

For Type 1 Operator Screen: To select Automatic control mode use the following method;

Place the Auto/Manual Selector Switch into the Auto position;

Press the


NOTE! Automatic production will only commence if a job file has been loaded and is pending (see Section 10 – Introduction to FRAMECAD Factory 2). For Type 2 Operator Screen: The default control mode for the FRAMECAD Factory 2 software is Manual. To select Automatic control mode use the following method;

The


Press the [Automatic] button to select Automatic control mode. The Automatic button lamp will illuminate; Press the


NOTE! Automatic production will only commence if a job file has been loaded and is pending (see Section 10 – Introduction to FRAMCEAD Factory 2). Pausing Automatic Control



Press the



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For Type 2 Operator Screen: If the FRAMECAD Factory 2 software is running in Automatic control and you wish to momentarily suspend operations use the following method;

Automatic controlled stop

Press the


Press the


For Type 1 Operator Screen: If the FRAMECAD Factory 2 software is running in Automatic control and you wish to end production after the current Stick being processed is complete then use the following method; Press the [Start] button to commence a controlled production stop. The Start button lamp will flash to indicate a co ntrolled production stop is in process. Once the current Stick has been completed the machine will stop production. For Type 2 Operator Screen: If the FRAMECAD Factory 2 software is running in Automatic control and you wish to end production after the current Stick being processed is complete then use the following method; The [Start] button AND when running in Automatic;

[Automatic] button lamps should both be illuminated

Press the [Start] button to commence a controlled production stop. The Start button lamp will flash to indicate a co ntrolled production stop is in process. Once the current stick has been completed the machine will stop production and return to Manual control (the default control mode). Running a Production Job

To view the jobs being manufactured in Automatic control, select the job schedule screen from the left-side menu tree. Once the FRAMECAD Factory 2 software has been started in Automatic control, the software will start making the first item in the job schedule, and will create one frame assembly at a time. At the end of each frame, the job schedule will be re-scanned from the top of the list to find any items which may have been added, moved, or remade. This way it keeps job batches together. The FRAMECAD Factory 2 software will then begin the next job folder it finds with the Pending status.

Viewing the Automatic Home Screen

If the Automatic Home screen is not currently being displayed press the [Return] button. The Automatic Home screen will display the current status of the job and job sub-parts. The Stick shown in GREEN will be the next Stick to exit the machine; Sticks shown in BLUE are still being processed and are waiting in the queue; Sticks shown in GREY have already been completed and exited the machine.


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Reset Automatic Production

For Type 1 Operator Screen: At any time the Automatic production of the job schedule can be reset by pressing the [Pause] button to suspend followed by the


3.


4.


Stop all steel strip motion and hydraulic tooling operations in the machine. For Type 2 Operator Screen: At any time the Automatic production of the job schedule can be reset by pressing the [Pause] button to suspend followed by the


4.


5.


6.

Place the FRAMECAD Factory 2 software back in the default Manual control mode;

Stop all steel strip motion and hydraulic tooling operations in the machine. Automatic Production Speed Adjust

When running in Automatic control mode, the Schedule screen will also display the average production rate (processed steel/hr averaged over the last 8-hours of automatic production) in graphical form at the bottom of the screen.


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To the right of the graph is the FRAMECAD F300i Speed Ratio dial. To increase or decrease the operating speed of the machine, the dial can be turned either left or right respectively. The dial is calibrated in % of Feed-rate as set in the Setup / Motion Control / MDX61B screen (see Setup Menu Screen below for more detail on this). This speed adjustment is only valid for Automatic control has n o e f f ec t on the speed of the machine in Manual control.


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12 Machine Calibration The FRAMECAD F300i machine and FRAMECAD Factory 2 software are designed to operate at a very high level of accuracy. However, to ensure positional accuracy is maintained, it is important to check the strip encoder calibration of the machine at least once a week.

12.1

Scale-Factor (Strip Encoder) Calibration SCALE-FACTOR (STRIP ENCODER) CALIBRATION

Tools Required Safety

Check the Last Length Made



Accurate Measuring Tape






NEVER stand directly in front of the FRAMECAD F300i Out-feed;

Select Setup from the menu tree. Now select Motion Control and the MDX61B screen.

To check the scale factor calibration, measure the last stick length made using an accurate tape measure. Compare this with the Last Length value shown in the MDX61B screen; OR Load a manual job (see Section 10 – Introduction to FRAMECAD Factory 2) and create a stick of at least 3000mm in length. Run the Manual job in either Automatic OR Semi Automatic control mode. Measure the actual length made with an accurate tape measure. Compare this with the Last Length value shown in the MDX61B screen. If there is >0.5mm error between the measured length and that displayed in the Last Length value text box then scale-factor calibration may be required.


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Check the Infeed Assembly

One of the most common causes for inaccurate encoder (scale factor) calibration is “slip” at the in-feed unit assembly of the machine. The term “slip” literally means that the strip encoder is “slipping” as the steel strip is progressed through the machine and thereby introducing measurement errors. Typical areas where slippage can occur are (see Section 8 – Initial Setup); 

Some earlier in-feed units incorporated a belt-coupled strip encoder. If this belt is loose then it may slip under speed thereby causing inaccurate measurement – solution, re-tension the belt;



Strip encoders that are directly coupled have a small grub screw that locks strip encoder input shaft inside the bottom guide wheel shaft. If this screw is loose then the strip encoder shaft can slip causing inaccurate measurement – solution, re-tighten grub screw;



Slipping top guide wheel. If the top guide wheel slips on the steel strip as it is being progressed through the machine then measurement errors will be introduced – solution, tighten down top guide wheel shaft.

NOTE! FOR FULL INSTRUCTIONS AND INFORMATION ON SETTING UP THE INFEED UNIT, PLEASE REFER TO SECTION 8 – INITIAL SETUP. Re-calibrating Scale-Factor

Once you have confirmed that there is NO slippage or looseness at the in-feed assembly that may be introducing measurement errors you can re-calculate the strip encoder scale factor by entering the measured length (this is the actual length of the last stick made as measured by an accurate tape measure or steel rule) into the Measure Length text box.

Once entered, press the recalculate the scale-factor.

[Calculate] button. This will automatically

BEFORE you exit the MDX61B screen YOU MUST press the


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[Apply] button to


save any changes, otherwise you will be presented with the following confirmation box;

Checking Scale Factor Calibration During Production

The encoder scale factor calibration can be checked at any time during normal Automatic production using the following method; 1.

Suspend production by pressing the

OR

[Pause] button;

2.

Select the Motion Control / MDX61B screen from under the Setup menu;

3.

Measure the last stick made with an accurate tape measure and compare this with the value shown for Last Length. If the error is >0.5mm, enter the actual measured value in the Measured Length text box and press the [Calculate] button. IMPORTANT NOTE! The longer the measured stick length the more accurate any calculation of Scale Factor will be. If the last stick length made is <3000mm then create a manual job incorporating a 3000mm long stick, measure then enter into the Last Length text box to ensure the greatest accuracy of Scale Factor.

4.

Press the

[Apply] button at the top of the screen to save any changes;

5.

Press the

[Return] button to go back to the job schedule screen;

6. Press the

OR

[Pause] button to recommence Automatic production.


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12.2

Tool Offset Calibration

As discussed previously, the centre of the Service Hole is treated as the Datum or reference point for all the tool positions on the FRAMECAD F300i, including the Shear tool at the out-feed end of the machine. If the offset position of any tool relative to the Service Hole is configured wrong in FRAMECAD Factory 2 then the relative location of the tool will likewise be incorrect. An error in the tool offset values is repeatable and therefore discernable from other measurement errors such as strip encoder slippage (which tend to vary based on speed and or acceleration of the machine). Tool Offset values are factory set prior to shipping and should not require changing. If tool positioning is not accurate always check to make sure there is no other m o v e m e n t or looseness in the various tool assemblies AND confirm the accuracy of the steel strip measurements (i.e. In-feed unit/encoder setup and Scale Factor calibration) BEFORE commencing to make any changes to Tool Offset positions . The following procedure illustrates how to check and/or how to make adjustments to the tool offsets if . The procedure uses a manual job to create a stick that includes Service Holes (as this is the required Datum tool it is important to include) along with dimples (as these are easy to position at either end of the stick for comparative purposes and are also completed at the opposite end of the machine to the other pre-punch tools). Using a sample stick with Service Holes included allows you to check first and foremost the Shear tool offset so that once this is correct other tool offsets can be checked relative to the edges of the stick which is easier to do in most cases than to the centre of the Service Hole.

IMPORTANT NOTE! TOOL OFFSET VALUES ARE FACTORY SET PRIOR TO SHIPPING AND SHOULD NOT REQUIRE CHANGING. IF TOOL POSITIONING IS NOT ACCURATE ALWAYS CHECK TO MAKE SURE THERE IS NO OTHER MOVEMENT OR LOOSENESS IN THE VARIOUS TOOL ASSEMBLIES OR IN-FEED UNIT AND CONFIRM THE ACCURACY OF THE STEEL STRIP MEASUREMENTS (I.E. IN-FEED UNIT/ENCODER SETUP AND SCALE FACTOR CALIBRATION) COMMENCING TO MAKE ANY CHANGES TO TOOL OFFSET POSITIONS. BEFORE WHEN CHECKING THE TOOL OFFSET VALUES, ALWAYS CHECK THE SHEAR OFFSET FIRST. ONCE THE SHEAR OFFSET IS ACCURATE, MEASUREMENTS BETWEEN THE STRIP EDGE AND OTHER TOOL CUTOUTS WILL BE PROPORTIONALLY THE SAME AS REFERENCE CHECKS TO THE SERVICE HOLE DATUM USING THE METHOD DESCRIBED HEREIN. TOOL OFFSET CALIBRATION Tools Required Safety

Check Tool Offset Procedure



Accurate Measuring Tape Engineers Square (Optional) Steel Scribe (Optional)







1.

Load a Manual job that has the following properties (see Section 10 – Introduction to FRAMECAD Factory 2);

 


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2.

Place the machine into Automatic control mode and manufacture the above stick. Mark the leading edge (i.e. the end of th e stick that co mes o ut of th e machine first) so that you can determine the direction of any tooling o f f s e t e r r o r s i f t h e y e x i s t ;

3.

Check the Sick Length: Make sure the measured stick length (from end to end) is accurate. If not then complete the following;


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4.

a.

Check In-feed unit setup (see Section 8 – Initial Setup for instructions);

b.

Re-check Scale Factor calibration (see above) before continuing with this procedure.

Check the Shear Offset: a.

Measure the distance from the e d g e of each Service Hole to the adjacent end of the stick (i.e. the end of the stick closest to each respective Service Hole) and record these measurements as A and B respectively. If A and B measurements for the Service Hole locations relative to their respective ends differ then this indicates that the offset value for the Shear tool position is wrong and will need to be adjusted. This is because the Service Hole is the fixed Datum point for the machine, so all other tool operations are positioned relative to it.

b.

Calculate the degree of offset error and in what direction (i.e. relative to the leading Service Hole tool, does the Shear operation need to be brought closer or further away and if so, by how much?). Here’s an example; suppose the leading Service Hole is located further back from the stick leading edge by approximately 1.5mm. This would mean the trailing edge Service hole would therefore be closer to the stick trailing edge by 1.5mm. This means the Shear offset will need to be increased by 1.5mm. Select the Setup folder from the menu tree. Now select Tools followed by Shear. Enter the new value for the Shear Offset, then the [Apply] button. To re-check that the adjustment made was correct you will need to press the OR sample stick to confirm.

[Software Reset] button, then re-run the


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5.

Check the Dimple Tool Offset: a.

Measure the distance from the e d g e of each Dimple Hole (use the edge of the inner screw hole) to the adjacent end of the stick (i.e. the end of the stick closest to each respective Dimple Hole) and record these measurements as C and D respectively.

b.

If C and D measurements for the Dimple Hole locations relative to their respective ends differ then this indicates that the offset value for the Dimple tool position is wrong and will need to be adjusted. As with Shear offset in 3 above, the position is always relative to the Service Hole tool Datum – this is why the Shear offset must always be checked first so that measurements made to the stick edges are proportionally correct to the Service Hole as well. Calculate the degree of offset error and in what direction (i.e. relative to the leading strip edge, does the Dimple operation need to be brought closer or further away and if so, by how much?). Here’s an example; suppose the leading Dimple Hole is located further back from the stick leading edge by approximately 1.5mm. This would mean the trailing edge Dimple hole would therefore be closer to the stick trailing edge by 1.5mm. This means the Dimple Hole offset will need to be increased by 1.5mm. Select the Setup folder from the menu tree. Now select Tools followed by Dimple. Enter the new value for the Dimple Offset, then the [Apply] button. To re-check that the adjustment made was correct you will need to press the OR sample stick to confirm.

[Software Reset] button, then re-run the


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12.3

Setting Tool Cycle Times

The FRAMECAD Factory 2 software provides the ability to alter the cycle time (in milliseconds) of each hydraulic tool action. The tooling cycle time is the sum total of the time it takes for a tool to complete its downward stroke (including the cutting of the steel strip) AND the time it then takes to fully retract the tool back to its home position during the return upward stroke. This tool cycle timing is critical for three main reasons; 1.

If the downwards stroke time is set too short then the tool may not fully cut the steel strip. This may result in a partial or inefficient cut operation that can then lead to steel jam ups inside the machine;

2.

If the upwards return stroke time is too short then the tool may not have had enough time to fully retract before the FRAMECAD Factory 2 software instructs the VFC unit to progress the steel strip forward in the machine. This will typically result in the edges of the steel strip cut-out catching on the tooling as it retracts, resulting in a jam up inside the machine;

3.

If either the downward or upward times are set too long then this will unnecessarily slow down the FRAMECAD F300i production rate.

If any of the above issues are present the tool cycle times can be adjusted via the Setup folder (see Section 10 – Introduction to FRAMECAD Factory 2). TOOL OFFSET CALIBRATION Tools Required Safety

Change the Tool Up & Down Times



Nil



ALWAYS wear cut-resistant gloves when handling steel during this procedure;




1.

Select the Setup folder from the main directory;

2.

Select Tools followed by the actual tool you wish to adjust the cycle time on;

3.

Change the Up Time value to alter the upward return stroke time of the tool. Change the Down Time value to alter the downward stroke and steel strip cutting time of the tool. The sum of these two values is the Total tool cycle time; NOTE! The time values MUST BE entered in milliseconds

4.

Once you have entered the new values, press the save any changes.

[Apply] button to

5.

It is always good practice to test any new tool cycle times in Manual control mode before running in full Automatic control mode.

WARNING! THE TOOL DELAY TIMES ARE FACTORY SET AND SHOULD ONLY BE ADJUSTED IF DIRECTED TO BY A FRAMECAD TECHNICIAN. INCORRECT ADJUSTMENT COULD CAUSE CATASTROPHIC DAMAGE TO THE MACHINE TOOLING.


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12.4

Setup and Calibration of the “C” Section Profile

Each FRAMECAD F300i is designed to produce dimensionally, a dedicated “C” section profile (and the equivalent a “U” section profile). The dimensions of this profile will have been specified at order placement time to suit the time of framing assemblies required. This means that the roll forming section and all the available tooling will have been factory set to achieve this profile configuration. It is good practice to retain the profile dimension information inside this manual for future reference and training needs. The following diagram and spacing is provided for this;

NOTES: 

You will have specified the type of “C” section profile to be produced at time of order and this cannot be altered without substantial changes to the machine;



The Web and Flange dimensions are pre-set at the FRAMECAD factory. The flanges may be of equal length for a Symmetrical profile (i.e. where the Box Offset value above is 0), or of an uneven length for a Boxable profile (where two “C” section profiles can be fixed together to produce a stronger “boxed” section);



The Lip length is a function of the steel strip width. FRAMECAD will have provided the nominal steel strip width to manufacture the requested “C” section profile. If you reduce this steel strip width, the Lip width will likewise reduce proportionally. If you run a steel strip width wider than recommended, the Lips will grow in proportion.

®

CAUTION! If the Lip width is >14mm, the “C” section profile WILL jam in the dimple punch assembly.


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PRODUCT QUALITY: It is critical that Operators of the FRAMECAD F300i routinely check the quality of the “C” section profile being manufactured. In addition to the accuracy of stick lengths and tool positioning, the following profile issues should be routinely checked for and adjustments made to correct if they occur; 1.

Variations in Lip width from one side of the profile versus the other. An example is shown below. Typically this can be corrected by adjusting the in-feed unit guides;

2.

Bow (or straightness) – this is the amount “bend” in the profile being produced in either an uphill or downhill direction as the product exists the machine. An example of downhill bow is shown below;

3.

Flare or Over-form – this is when the Flanges are no longer 90degress relative to the Web. Flare is when the Flange is bent outwards from the Web; Over-form is when the Flange is bent in towards the Web.

Flare

Over-form


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4.

Twist – this is the difference in angle bet ween each end of the “C” section profile. It can be either “clockwise” or “counter -clockwise” in direction. Twist is most commonly formed by an uneven pressure being applied to one side of the profile versus the other in the roll-forming section. An example is shown below;

5.

Profile Flare Post-Shear Operation: the FRAMECAD F300i incorporates a technique known as side-crimping during each Shear tool operation. The objective of side-crimping is to support the side flanges of “C” section profile during the Shear cut. Without side -crimping, the side flanges will tend to “flare” outwards. Whilst some flare is inevitable, significant flaring may be the result of incorrectly adjusted side-crimps;

This Section will describe the various procedures required to correct and/or manage the above conditions. It is important to note that many “C” section profile issues are as a direct consequence of the type and quality of steel being rolled. Variations in strip width, tensile strength, thickness etc will all have a direct impact on the profile produced. INFEED GUIDE ADJUSTMENT PROCEDURE Tools Required Safety Purpose of the In-feed Guides

In-feed Guide Adjustments

When to Adjust



High accuracy vernier caliper Metric hex-key set Metric spanner set




 

The in-feed guides are a part of the in-feed unit assembly and assist with aligning the steel strip as it is fed into the FRAMECAD F300i. This is to ensure the steel strip is evenly distributed across both sides of the machine as it is progressed through.

The in-feed unit has two adjustments available for the in-feed guides; the first is for adjusting the Lip width relative to each side (Side to Side adjustment) and the second for accommodating different steel strip widths. The in-feed unit guides should always be checked and adjusted if required in the following situations; 1. 2.

3.

After a change in the steel coil (i.e. as it is being fed into the in-feed unit of the FRAMECAD F300i); Whenever there is a variation in the measurement of Lip width from one side of the machine to the other (this can be due to the guides being loose on the strip width OR the sideways Lip adjustment is not correct); Whenever the steel strip does not track evenly through the machine, often resulting in jam ups at the Lip Box unit (typically due to loose in-feed guides on the steel strip);


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4.

Strip Width Adjustment

If the in-feed guides themselves are showings signs of wear (due to the guides being either over-tightened or not correctly set for the steel strip width);

When inserting the steel strip, check that the in-feed guides are firm on the steel b u t . You can test this by first inserting the steel and moving it from side to side not tight inside the guides, there should be little to no movement. In-feed Guide Type 1: This In-feed guide type has two knurled Guide adjustors on either side. If the width needs adjustment simply rotate either adjustor in the required direction.

Type 1 In-feed Guide Width Adjustment

In-feed Guide Type 2: This type of In-feed Guide has a single Guide Width Adjustor on the right-side (relative to the direction of steel travel). To adjust, loosen the left-side (relative to direction of steel travel) locking screw and wind the right-side knurled adjustment knob (Guide Width Adjustor) in or out until there is a firm fit. Re-tighten the locking screw when complete. Guide Width Ad ustor

Locking Screw

Type 2 In-feed Guide Adjustment

Once the in-feed width has been set, close the top sliding cover and reset the safety control system (as one of the top sliding covers was opened, the FRAMECAD Factory 1 software will trigger a Guard Switch alarm event). Restart the machine in Manual control mode as previous. Release 10102013 ©2013 FRAMECAD Limited 168

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Side to Side Lip Adjustment

The Lip width on either side of the profile should be approximately the same. If there is significant variation (>0.8mm) from one side to the other, use the Side to Side Lip Adjustment. The first step is to measure the size of the variance and the direction. Below is an example;

In the above example, the steel strip width is sized to give 11mm Lips on either side. This means that to properly centralise the steel strip tracking in the machine, the steel strip needs to be moved to the left by the in-feed guides (relative to the direction of travel in the machine) by 1.0mm. This is because there is a 2.0mm difference between the two Lip widths, so that moving 1.0mm to the left will allow 11mm symmetry on both Lip widths. To adjust the In-feed guides Side to Side follow the procedure below; Type 1 In-feed Guide Side to Side Adjustment: 1.

Remove the steel strip from the machine. This is the easiest way to adjust the side to side positioning of the guides;

2.

Measure using a digital or vernier caliper the distance from the in-feed shoulder to the left-side guide as shown below and note the measurement;

3.

On the bottom side of the In-feed Guide, there are eight (x8) cap screws that should be loosened to allow the In-feed Guide to be moved either left or right;


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Loosen the bottom eight (x8) cap screws

Type 1 In-feed Guide – bottom view looking up on cap screws

4.

On the either side of the Type 1 In-feed Guide is an adjustment bolt. Access to either bolt is provided by a hole in the side plate. Each adjustment bolt has a lock-nut. Loosen the lock-nut on the side that you want the move the In-feed Guide t o w a r d s and loosen (unwind) the adjustment bolt out by the approximate amount you wish to move the In-feed Guide across by. For example, if you want to move the In-feed Guide 1mm to the right-side (relative to the direction of the steel strip) then loosen the lock-nut on the r i g h t - s i d e adjustment bolt and unwind the bolt out by the approximate distance you want to move the In-feed Guide by. Side adjustment Bolts

Type 1 In-feed Guide – top view looking down on side adjustment bolts

5.

On the opposite side of the In-feed Guide, loosen the lock-nut on the adjustment bolt and then tighten the bolt to move the In-feed Guide assembly across in the direction required. Once complete, check distance moved is sufficient by re-measuring with the vernier caliper (as per Step 1 above). Once set re-tighten both lock-nuts and the cap screws on the bottom of the In-feed Guide;

6.

Now check that the guides are still firm on the steel strip by re-inserting the steel and re-check the width of the guides – adjust if necessary (see above);

7.

Close all sliding covers; reset the safety control system ready to commence production.

Type 2 In-feed Guide Side to Side Adjustment: 1.

Remove the steel strip from the machine. This is the easiest way to adjust the side to side positioning of the guides;

2.

Measure using a digital or vernier caliper the distance from the in-feed shoulder to the left-side guide as shown below;


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3.

Note the measurement then release the clamp bolt and the thread lock screw being careful not to rotate the adjustment shaft; Lock Screw

Clamp Bolt

4.

Using both hands, rotate the left-side adjustor in the direction required to shift the relative position of the steel strip inside the guides while holding the knurled right-side (guide width) adjustor in a fixed position. As you do so, you will see the in-feed guides moving together in one direction. Take your time and move the guides in small incremental steps. After each small adjustment, stop and remeasure using the vernier caliper as shown in 1 until the guides are in the correct position;

Hold Width Adjustor firm

Rotate Side to Side Adjustor

5.

When desired position is reached re-tighten clamp bolt and thread lock screw;

6.

Now check that the guides are still firm on the steel strip by re-inserting the steel and re-check the width of the guides – adjust if necessary (see above);

7.

Close all sliding covers; reset the safety control system ready to commence production.


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OVERFORM ROLLER ADJUSTMENT PROCEDURE Tools Required Safety

Purpose of the Over-form Rollers



Engineers Square 15mm Spanner 10mm Spanner







 

The over form rollers allow you to adjust the angle of the web to flange bend. This 0 should be 90 .

Flare

Over-form

0

The rolling section will roll the steel strip to 90 during roll forming, but because the steel strip is typically has high tensile strength there is a tendency for the steel flanges to want to spring back. The over form rollers compensate for this by allowing some additional forming post the rolling section; this is know as over-forming. The FRAMECAD F300i allows for up to an additional 8 degrees of over form to ensure the 0 profile Flanges are at 90 to the Web.

When to Adjust

The over-form rollers will need adjustment when there is either too much flare (i.e. not enough over-form) or too much over-form (i.e. the machine is over-forming the profile at the over-form rollers);

Location of the Over-form Roller Adjustment

The over-form roller adjustments are located on the Dimple tooling assembly. Each side can be independently adjusted;

Over-form Adjustment – located on the Dimple Assembly

Over-form Adjustment

1.

Using an Engineers Square, check the squareness (how close the angle is to 0 90 ) of the Flanges.


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ALWAYS check squareness of the Flanges relative to the Web at least 300mm from the end of a Stick – the reason for this is that the Shear action will always introduce a degree of flare (opening up) of the Flanges where the Shear cut takes place. 2.

You will find indication marks on the over-form adjustment plates to act as a guide on how much and in what direction to adjust the over-form rollers;

3.

On the back-side side of the Dimple assembly you will find tw o retaining bolts for each of the Dimple tool units (one set for either side, x4 in total). Before any over-form adjustments can be made, the retaining bolts for the side you wish to adjust must be loosened using the 15mm Spanner. This is because the overform adjustment is a part of the Dimple tooling assembly;

Retaining Bolts – two (x2) for each side

4.

Using the over-form roller adjustment nuts, rotate the over-form rollers either in (increasing the amount of over-form) or out (decreasing the amount of overform) for each Flange side. For example, in the picture shown below, to decrease the amount of over-form, loosen nut 2 and tighten nut 1. To increase the amount of over-form, loosen nut 1 and tighten nut 2.

Adjustment Nut 1 Adjustment Nut 2

5.

Re-tighten the Dimple retainer bolts and adjustment nuts;

6.

Close all sliding covers and reset the safety control system. Run out another test Stick and re-check Flange squareness. If required re-adjust.


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CORRECTING BOW PROCEDURE Tools Required

   

Safety

 

Bow Overview

Engineers Square 17mm Spanner 8mm Hex Key 5mm Hex Key ALWAYS wear cut-resistant gloves when handling steel during this procedure; ISOLATE electrical power to the FRAMECAD F300i and implement measures to prevent accidental re-connection;

Bow is the amount of bend in a product. It is either an "up-hill" or "down-hill" bend; typically most bow will tend to be in the down-hill direction. The targeted maximum bow is ± 1.6mm per 2.4m of length (this measurement is carried out on uniform section steel; i.e. with no tooling operation cut-outs in the profile). To check for bow, place two equal stick lengths back to back (i.e. Web to Web). If there is a gap between the centres of the sticks, this is d o w n - h i l l b o w . The Shear unit is the last tool station that the product passes through prior to exiting the machine. This tool is vertically adjustable using jacking bolts. Raising the shear station will tend to counteract any down-hill bow .

When to Adjust Testing for Bow

Correcting Down-hill Bow

1.

Run off two sticks of length 3000mm. There must be no tool operations other than the Shear to cut the length. This is because some tools cause inherently distort the “C” section profile;

2.

Place the two lengths back to back on a smooth level surface and clamp the two ends lightly together;

3.

Using a calibrated vernier caliper measure for a gap between the two webs at the mid 1500mm point.

4.

Divide the measured value by two and the resultant figure will be the total bow in each length;

5.

The maximum allowable bow in a 3000mm length is 7.8mm. Any more than that and the bow will need to be adjusted out. Shutdown and isolate the machine from the electrical power supply to prevent injury when working near the Shear unit;

1.


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2.

Loosen the 4 shear unit mounting bolts using the 8mm Hex Key;

Shear Unit Mounting Bolts (x4)

3.

Loosen the lock nuts on all 4 jack screws using the 17mm Spanner;

4.

Using the 4mm Hex key wind the two jack screws on the in-feed side into the plate to lift the rear of the Shear assembly – make sure this is done evenly on both sides. The in-feed side of the Shear should be raised approximately 25% of the measured bow; e.g. if the measured bow is 4mm then the shear should be raised approximately 1mm;

Shear Unit Jack Screws (x4)

5.

Re-tighten the 4 shear mounting bolts then the jacking screw lock nuts;

6.

Re-power the machine and run two more 3000mm length Sticks and remeasure. If still out of limits, repeat this procedure.


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CORRECTING TWIST PROCEDURE Tools Required

Safety



150mm long, 0.05mm to 1mm metric feeler gauge set (or an imperial equivalent for non-metric sheet steel)



18mm Spanner



6mm Hex-key






Twist Overview

When to Adjust

Setting the Roller Clearances

Twist is the difference in angle between each end of the stick. Twist can be in either clockwise or anticlockwise direction. Twist is caused by one side of the “C” section being stretched more than the other. This is often caused by uneven rolling pressure being applied to either side.

Place the stick web down on a flat surface. Twist at either end should not exceed more than 2-3mm per 1000mm of the stick length relative to the flat surface. If it is greater than this then adjustments will be required to the roller-station clearances in order to counteract. 1.

The first step is to establish the material thickness of the steel strip to be processed in the machine. The accepted method is to use the Base Metal 1) Thickness (BMT) as the starting reference value. Steel strip is typically ordered on this basis and so the BMT of the steel strip being used should be easy to ascertain; 2)

2.

BMT or Base Metal Thickness defines the uncoated steel thickness and is used as the base reference for all structural design calculations using steel.

Always start with the first roller station (Station 1). Select a feeler gauge that is 0.05mm l e s s t h a n t h e B M T of the steel strip. For example, if the BMT of the steel strip being used is 0.75mm, select a 0.70mm feeler gauge, if BMT is 0.95 use a 0.90mm feeler gauge and so on;

Inset the feeler gauge between the top and bottom rollers at the forming edges (i.e. the bottom corner edge of the top roller);


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The feeler gauge should be a “snug fit”; in other words, the feeler gauge should feel tight to push in and out between the rollers without having to use excessive force. If the clearance is too loose or tight, the roller clearances will need to be reset; 3.

Loosen the lock-nuts on the top bearing cap adjustment screws (there is one on either side of the top roller assembly for each station) using the 18mm spanner and 6mm Hex-key;

4. Adjust both sides of the top roller until the feeler gauge is a “snug fit”; in other words, the feeler gauge should feel tight to push in and out between the rollers without having to use excessive force.

NOTE! Adjust the clearances on both sides so that they are the same . 5.

Repeat the above steps for the remaining roller stations.

WARNING! TAKE YOUR TIME! IT IS IMPORTANT THAT BOTH SIDES OF THE TOP ROLLER IN EACH STATION ARE SET THE SAME. IF ONE SIDE IS MORE LOADED THAN THE OTHER IT WILL CAUSE THE TRACKING OF THE STEEL STRIP THROUGH THE MACHINE TO VEER (BE PULLED) TO ONE SIDE AND/OR TWIST IN THE PROFILE. SET ALL ROLLFORMING STATIONS TO SAME TOP AND BOTTOM ROLLER CLEARANCE (BMT – 0.05MM) Release 10102013 ©2013 FRAMECAD Limited 177

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IF THE ROLLER CLEARANCE IS SET TOO TIGHT FOR THE BMT OF THE STEEL STRIP BEING USED, THIS MAY CAUSE THE MACHINE TO FAULT, PRODUCE OUT OF SPECIFICATION PRODUCT, REDUCE PRODUCTION PERFORMANCE AND/OR IN SEVERE CASES, CAUSE DAMAGE TO THE MACHINE. IF THE ROLLER CLEARANCE IS TOO LOOSE FOR THE BMT OF THE STEEL STRIP BEING USED, THIS WILL CAUSE THE STEEL TO SLIP INSIDE THE ROLLFORMING SECTION AND MAY CAUSE THE MACHINE TO FAULT.


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SHEAR SIDE –CRIMP ADJUSTMENT PROCEDURE Tools Required

Safety



High accuracy vernier caliper



18mm Spanner



6mm Hex-key






Profile Flare Post-Shear

When to Adjust

Adjusting Side-Crimps

the FRAMECAD F300i incorporates a technique known as side-crimping during each Shear tool operation. The objective of side- crimping is to support the side flanges of “C” section profile during the Shear cut. Without side-crimping, the side flanges will tend to “flare” ourwards. Whilst some flare is inevitable, significant flaring may be the result of incorrectly adjust side-crimps If there is substantial flare of the flanges post a Shear tool operation (i.e. causing difficulties when assembling frames) then it may be necessary to check and adjust if necessary the Shear tool side-crimps. 1.

Remove any steel strip from the machine and electrically isolate power;

2.

Remove the Out-feed end cover to fully expose the Shear assembly;

3.

Manually press the Shear tool down by applying pressure on the Shear top plate;

Shear Top Plate

4.

Look back through from the out-feed side of the Shear tool and using a flat blade screwdriver gently push the side-crimps back in as far as they will go – the gap between the inner central block and each side crimp should only be 1.5mm; Gently lever the sidecrimps back (on both sides) until movement stops


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Side Crimp Clearance = 1.5mm 5.

If the gap is not 1.5mm, then adjust by loosening lock nut on the outside of the Shear block and adjust each respective side-crimp in or out respectively until a 1.5mm clearance is attained;

Top Lock Nut

Loosen top lock-nut and rotate bottom adjustment nut to bring the side-crimps in or out to achieve 1.5mm clearance relative to centre block

6.

Tighten locknut when 1.5mm gap is achieved.

7.

Re-connect power to the machine and re-check.

WARNING! DO NOT REDUCE THE CRIMP SHEAR GAP TO LESS THAN 1.5MM AS THIS MAY DAMAGE THE SIDE-CRIMP CAM BEARINGS.


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13 FRAMECAD F300i Maintenance Like any high-performance machine, the FRAMECAD F300i needs to be checked and maintained on a regular basis. This section details the type and frequency of maintenance checks required. Machine maintenance should always be completed by qualified and competent technical ®

NOTE: Failure to follow the Maintenance job schedule may null and void the FRAMECAD Warranty

The F300i Machine

Item 1 2 3 4 5 6 7 8

Description Lubricator Unit Pre-Punch Tool Block Assembly DC Electrical Control Cabinet AC Electrical Control Cabinet Hydraulic Power Pack Cover Access Side Cover Push-button Controls Ink Jet Printer System Roll-forming Section

Item 9 10 11 12 13 14 15 16

Description Lip Box Control Assembly Pinch Roller Set #1 Dimple Tools + Over-from Roller Assemblies Pinch Roller Set #2 Swage Tool Assembly Shear Tool Assembly Operator Screen and Controls Printer Heads


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IMPORTANT NOTE! IT IS A CONDITION OF WARRANTY THAT THE PRESCRIBED MAINTENANCE ROUTINES DESCRIBED HEREIN ARE COMPLETED AT THE REQUIRED PERIOD/FREQUENCY. FAILURE TO DO SO WILL RESULT IN REDUCED PERFORMANCE AND QUALITY, PREMATURE COMPONENT WEAR AND SUBSEQUENT FAILURE. DAMAGE RESULTING FROM INSUFFICIENT AND/OR INCORRECT SERVICE/MAINTENANCE WILL VOID FRAMECAD’S WARRANTY TERMS AND CONDITIONS.


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13.1

Lubrication Schedule

ACTION

FREQUENCY

LUBRICANT TYPE

Manually Oil Shear Blade

Every Day before Production and 4 times a day during production

Lightweight Machine Oil

Check Lubricant Level & Top Up as Required

Every Day before Production

30:1 Emulsion Oil Mix (e.g. Hocut 757)

Check Hydraulic Oil Level

Fortnightly

High Grade Hydraulic Oil – ISO46 (General Applications), ISO68 (Continuous High Ambient Applications)

Check Chain Tensions & Lightly Lubricate

Fortnightly

Chain Lubricant, Spray-on Type (Aerosol)

Lightly Lubricate Roller Station Gears

Fortnightly

Light Grease, Spray-on Type (Aerosol)

Lightly Lubricate Pre-punch Tools via Pre-punch Tool Block Side Lubrication Holes

Fortnightly

Lightweight Machine Oil, Spray-on Type (Aerosol)

Lightly Lubricate Dimple Assembly Pivots

Fortnightly

Lightweight Machine Oil, Spray-on Type (Aerosol)


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13.2

Recommended Maintenance Schedule

The following is the recommended maintenance regime for the FRAMECAD F300i machine. For any assistance or advice on the below, please contact your local FRAMECAD regional office or visit our support web-site at http://care.framecad.com

LUBRICATOR ASSEMBLY CHECKS Check Lubricator rollers for build-up of impregnated dirt and contaminants – replace if necessary Lubricator pipes for hardening/kinking – replace/repair as required Lubrication oil for serviceability – refill/replace as required with new

FREQUENCY Fortnightly Fortnightly Fortnightly

IN-FEED ASSEMBLY In-feed guide wheels for tightness (check grub screws and top roller) Sheet sensor for height and damage – adjust height and/or replace sensor as required Encoder belt tension and security (if applicable) – tighten or replace as required Encoder mounting and connections – make sure there are no loose screws/bolts – tighten as required Check in-feed assembly mounting and squareness Check in-feed guides for cleanliness and material build-up – clean/replace as required, adjust to ensure steel strip is central

FREQUENCY Fortnightly Fortnightly

PRE-PUNCH TOOL BLOCK Check hydraulic tool actuator top glands for leakage – replace seals as required Check shoulder bolts for security – tighten as required Check and tighten all attachment bolts and hydraulic tool actuator bolts Check tooling lubrication – lubricate as required Check punch tools (Lift block) – check for damage/wear, replace as required

FREQUENCY Fortnightly 3-monthly Fortnightly Fortnightly 3-monthly

ROLL-FORMING ASSEMBLY Check chain tension and adjust as necessary, lubricate Check condition of all sprockets + gears (meshing), lubricate Check and tighten roll-former assembly (raft) mounting bolts


LIP BOX ASSEMBLY Check all lip rollers for rotation – replace bearings as required Check assembly/rollers for debris or surface build-up – clean or replace as required Check unit alignment to roll-former assembly (raft)


OVER-FORM, DIMPLE ASSEMBLY, PINCH ROLLERS Check and tighten all adjustment bolts as required Check knife rollers for damage and material build-up – clean or replace as required Check all rollers for ease of rotation – replace bearings as required Check dimple assemblies for ease of rotation – lubricate pivot(s) as required Check pinch rollers for material build-up - clean or replace as required Check pinch rollers bearing condition – replace bearings as required

FREQUENCY Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly


Fortnightly Fortnightly Fortnightly Fortnightly

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SWAGE & SHEAR ASSEMBLY Check all swage bolts for security (including lower swage plate) – tighten – tighten as required Check all swage wear plates are in position – position – adjust as required Check all shear assembly bolts for tightness (including mounting bolts) - tighten as required Check condition of shear blade (remove front plate for access) – replace – replace as required Check side crimp clearance and ensure springs are returning Check shear tie rods for wear/deformation – wear/deformation – replace as required Check debris is not passing under lower swage plate – plate – clean and adjust as required Check shear in-feed guilds are tight and in position – clean, – clean, adjust or replace as required HYDRAULICS Check for leaks on all fittings – fittings – tighten as required Check for fretting or cuts along hydraulic hose paths – replace as required Check security of hydraulic tool actuators (shear and swage) – tighten as required Check all hydraulic clamps are tight and maintain hose separation Obtain hydraulic sample for testing (Millipore) Check pressures on main system and both pressure reduction valves (dimple and lip-box) Check settings on pressure switch Check hydraulic leak-down from 195 bar to ascertain if any internal leakage Check hydraulic accumulator pressure Check hydraulic tank level and condition of oil Listen to hydraulic motor running for cavitations or aeration Check heat exchanger for leakage and debris

FREQUENCY Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly

FREQUENCY Fortnightly Fortnightly Fortnightly Fortnightly 3-monthly Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly

PRINTER INK JET SYSTEM Check all pipes for kinking or sediment – sediment – clean and/or replace as required Ensure ink and cleaner filters have not surpassed 60ltrs each (replace after 60ltrs) Operate ink, cleaner and waste directional valves and check both mechanical and electrical functionality Check condition of printer heads their orientation and their spacing

Fortnightly

PRODUCT INSPECTION Calibration on profile length Check pre-punch block alignment to roll-former assembly (raft) Check dimple heights Check tool offsets Check lip width Check over-form Check product for bow, twist and camber Check product for scores nicks and deformity

FREQUENCY Daily Daily Daily Daily Daily Daily Daily Daily



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ELECTRICAL Check supply circuit protection is appropriate and of correct type and capacity Check supply cable is of correct type and current carrying capacity Check machine is adequately earthed Check supply cable and Decoiler supply cables are mechanically protected Check Circuit breaker settings are correct Check Machine and Decoiler isolators , push buttons and switches for secure mounting and check for any damage Check integrity and functionality of Emergency Stop buttons and Guard switches Check operation of push buttons and switches Check visually for any damaged cables, cable glands and cable ducting Clean electrical cabinet fan filters Check operation of AC electrical cabinet fan Ensure electrical cabinets are clean and dust free OFTWARE

FREQUENCY Yearly Yearly Yearly Fortnightly Fortnightly Fortnightly

SOFTWARE Check software version Functionally check all punch and printer operations Record all machine data including punch counts, material run, tool offsets, calibration etc and download onto USB stick

FREQUENCY 3-monthly Fortnightly Fortnightly

GENERAL SERVICE Level the machine Replace hydraulic filter Replace shear blade Replace hydraulic fluid

FREQUENCY Fortnightly 3-monthly Yearly Yearly

DECOILER Check chain tension Check dancer arm calibration (potentiometer) Check motor mounts are secure Check expanding mandrel for tightness/security Check coil guards for functionality Check de-coiler feet for security Check de-coiler alignment with machine

FREQUENCY Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly Fortnightly


Fortnightly Fortnightly Fortnightly 3-monthly Fortnightly Fortnightly

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13.3

Hydraulic Oil/Filter Replacement CHANGE OIL / REPLACE OIL FILTER

Tools Required

Safety



Suction Pump to Remove Oil



New Hydraulic Oil (minimum 60ltrs)



10mm Spanner



Suitably sized container or drum for capturing old oil



ISOLATE electrical power to the FRAMECAD F300i and implement measures to prevent accidental re-connection; Ensure suitably sized container or drum for capturing old oil;



When Replace Oil

Change oil every 12months 1.

Unscrew Filter Breather Cap and remove;

Hydraulic Tank Fill Point and Breather – Breather – Cap Cap Unscrews


Replace Oil Filter

2.

Use suction pump to remove old oil into suitably sized container or drum;

3.

Re-fill with new oil until level at top of sight-glass sight-glass (approximately 60ltrs). BE CAREFUL not to contaminate the oil with dirt or other loose material;

4.

Replace Filter Breather Cap.

1.

Use 10mm Spanner Spanner to remove In-line Filter Cap;

2.

Remove In-line Filter and replace with new. BE CAREFUL CAREFUL not to drop any items into the open tank;


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3.

Replace Filter Cap and tighten bolts.


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13.4

Ink Jet Printer System Maintenance CLEAN PRINTER HEADS PROCEDURE

Tools Required

Safety



Small Paint Brush



Cleaner Fluid



Rags for capturing any residual cleaner/ink



Remove steel from the machine; Activate Emergency Stop state by pressing an Emergency Stop push-button; Use safety glasses and appropriate personal protective equipment including rubber gloves Nitral

 

WARNING! THE SPECIFIED INK AND CLEANER ARE MEK (METHYL ETHYL KETONE) BASED PRODUCTS. THESE PRODUCTS ARE HIGHLY FLAMABLE AND REQUIRE SPECIAL SAFETY PRECAUTIONS WHEN HANDLING. ALWAYS CONSULT THE MATERIAL SAFETY DATA SHEET BEFORE USE. THE INK AND CLEANER DELIVERY SYSTEM IS PRESSURIZED. ALWAYS USE SAFETY GLASSES AND APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT WHEN WORKING ON OR NEAR THE INK AND CLEANER SYSTEM. SEE SECTION 5 - SAFETY FOR MORE INFORMATION. When Clean Printer Heads

Cleaner Printer Heads every 4 hours of use 1.

Remove Steel from the machine and Activate an Emergency Stop state by pressing one of the Emergency Stop push-buttons; NOTE! The print system air Compressor is turned OFF when any of the FRAMECAD F300i safety circuits are tripped (i.e. an Emergency Stop activation OR sliding cover is opened). This is important to allow the print system to de-pressurise.

2.

Clean the nozzle-end of the print heads with a brush dipped in cleaner every 4 hours of operation using rags to remove any dry or contaminated ink.

Printer Head Nozzles


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FRAMECAD F300i Operating Manual SHORT-TERM SHUT-DOWN PROCEDURE Tools Required



Nil

Safety





When Short-term Shut-down Procedure

Perform Short-term Shut-down Procedure at the end of every Production Day 1.

Pause/Stop machine – DO NOT activate an Emergency Stop OR Open the sliding guards;

2.




3.

Go to the Setup / Inkjet Screen and press the button – this will do two things;


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[Select Cleaner]


4.

a.

Switch the print control system over to use Cleaner fluid instead of ink;

b.

Flush the tubes going up to the printer heads and back down to the Waste bottle for a period of 0.5 seconds. This is to remove any residual ink from the lines;

In this next step Cleaner fluid will be sent up into the printer head and through the nozzles to flush any residual ink out of the printer head itself. If there is no steel in the machine, it is a good idea to insert a piece of cardboard in the space between the two printer heads to prevent Cleaner fluid from one printer head being sprayed onto the other. Press the [Purge] button. This will momentarily send Cleaner fluid up into the printer heads and eject through the nozzles. Repeat this until the Cleaner fluid is a clear colour and free of any noticeable ink contamination. Once complete the FRAMECAD F300i can be shut-down.

5.

Check the Ink and Cleaner bottles to make sure there is sufficient quantity for the next day’s production requirements. Re-fill as required. Check the Waste bottle. If this is full, consult your company ’s hazardous materials handling policy on how to safely dispose of MEK based inks and solvents.

6.

When production resumes, the Operator will need to purge the printer system with ink once more by completing the Printer Ink Purge procedure.


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FRAMECAD F300i Operating Manual EXTENDED SHUT-DOWN PROCEDURE Tools Required



A second Cleaner Bottle (full)

Safety





When

Extended Shut-down Procedure

Perform Extended Shut-down Procedure when machine is to be left idle (i.e. no Production) for periods >3days 1.

Activate an Emergency Stop state by pressing any Emergency Stop pushbutton on the machine. This will remove power to the printer Air Compressor;

2.

Slowly unscrew the black filter cap on the Ink bottle to gently relieve pressure in the system. Remove the cap and filter from the ink bottle and insert it into the second Cleaner bottle which must be full of cleaner fluid. Make sure the cap is retightened to prevent air leaks.

3.

Reset the safety control system (i.e. release any Emergency Stop pushbuttons, close all sliding covers, and reset the safety control system. See Section 5 - Safety);

4.




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5.

In the printer cabinet, locate the Waste solenoid valve and press the manual over-ride button on the side of it. This will open up the Waste valve and allow Cleaner fluid from the second Cleaner bottle (now sitting in the ink position) to flush through the ink tubes and back down into the Waste bottle. Continue to do this until tube going into the Waste bottle is no longer dark with ink. Release the override button.

Printer Waste Valve

Printer Waste Valve Over-ride Button

NOTE! The tube going into the Waste bottle will never be completely clear and some discolouration is inevitable. 6.

In this next step Cleaner fluid will be sent up into the printer head and through the nozzles to flush any residual ink out of the printer head itself. If there is no steel in the machine, it is a good idea to insert a piece of cardboard in the space between the two printer heads to prevent Cleaner fluid from one printer head being sprayed onto the other.


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FRAMECAD F300i Operating Manual Go to the Setup / Inkjet Screen;

Press the [Purge] button. This will momentarily send Cleaner fluid up into the printer heads and eject through the nozzles. Repeat this until the Cleaner fluid is a clear colour and free of any noticeable ink contamination. Once complete the FRAMECAD F300i can be shut-down. 7.

Check the Ink and Cleaner bottles to make sure there is sufficient quantity for when production will resume. Re-fill as required. Check the Waste bottle. If this is full, consult your company ’s hazardous materials handling policy on how to safely dispose of MEK based inks and solvents.

8.

When production resumes, the Operator will need to purge the printer system with ink once more by completing the Printer Ink Purge procedure.


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FRAMECAD F300i Operating Manual REPLACE INK FILTER PROCEDURE Tools Required



Replacement Ink Filter

Safety



Use safety glasses and appropriate personal protective equipment including rubber gloves Nitral


When

Replace Ink Filter

Replace the ink filter after every 60ltrs of ink usage OR when the printed text begins to fade 1.

Activate an Emergency Stop state by pressing any Emergency Stop pushbutton on the machine. This will remove power to the printer Air Compressor;

2.

Slowly unscrew the black filter cap on the Ink bottle to gently relieve pressure in the system. Remove the cap and filter from the ink bottle.

3.

Remove old filter and replace with new.

4.

Insert cap and ink filter assembly back into ink bottle. Take care to make sure the ink bottle cap is tightened to enable a good seal.

5.

Reset the safety control system (i.e. release any Emergency Stop pushbuttons, close all sliding covers, and reset the safety control system. See Section 5 - Safety);

6.



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9.

Check the Ink and Cleaner bottles to make sure there is sufficient quantity for when production will resume. Re-fill as required. Check the Waste bottle. If this is full, consult your company ’s hazardous materials handling policy on how to safely dispose of MEK based inks and solvents.

10. When production resumes, the Operator will need to purge the printer system with ink once more by completing the Printer Ink Purge procedure.


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13.5

Purging the Ink Jet Printer System with Ink

Before commencing production it is important to ensure the printer system is r e ad y t o p r i n t . In order to achieve this, the printer control system must be p u r g e d with ink. The following procedure defines this; PRINTER INK PURGE PROCEDURE Tools Required



Nil

Safety




WARNING! THE SPECIFIED INK AND CLEANER ARE MEK (METHYL ETHYL KETONE) BASED PRODUCTS. THESE PRODUCTS ARE HIGHLY FLAMABLE AND REQUIRE SPECIAL SAFETY PRECAUTIONS WHEN HANDLING. ALWAYS CONSULT THE MATERIAL SAFETY DATA SHEET BEFORE USE. THE INK AND CLEANER DELIVERY SYSTEM IS PRESSURIZED. ALWAYS USE SAFETY GLASSES AND APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT WHEN WORKING ON OR NEAR THE INK AND CLEANER SYSTEM. SEE SECTION 5 - SAFETY FOR MORE INFORMATION. When

Clean Printer Heads

At the start of Production. This procedure will purge the printer system with Ink allowing printed text to be applied during production. 7.

Start the machine and reset the safety control system (i.e. release any Emergency Stop push-buttons, close all sliding covers, and reset the safety control system. See Section 5 - Safety);

8.




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9.


10. Go to the Setup / Inkjet Screen and press the this will do two things;


a.


b.

Flush the tubes going up to the printer heads and back down to the Waste bottle for a period of 0.5 seconds. This is to remove any residual Cleaner from the lines;

11. In this next step Ink will be sent up into the printer head and through the nozzles to flush any residual Cleaner/air out of the printer head itself. If there is no steel in the machine, it is a good idea to insert a piece of cardboard in the space between the two printer heads to prevent Ink from one printer head being sprayed onto the other. Press the [Purge] button. This will momentarily send Ink up into the printer heads and eject through the nozzles. Repeat this until there is a consistent spray of Ink from the printer head whenever the [Purge] button is pressed. 12. Once steel strip has been threaded through the machine it is a good idea to test Release 10102013 ©2013 FRAMECAD Limited 198

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FRAMECAD F300i Operating Manual the printer control system before commencing full production. Refer to the Printer System Test procedure below for instructions on this.


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13.6

Printer System Test PRINTER SYSTEM TEST PROCEDURE

Tools Required



Nil

Safety





When

Clean Printer Heads



At the start of Production



At the completion of any purge or cleaning procedure

1.

Start the machine and reset the safety control system (i.e. release any Emergency Stop push-buttons, close all sliding covers, and reset the safety control system. See Section 5 – Safety for more information);

2.

Make sure the machine is in Manual control mode (see Section 10 – Introduction to FRAMECAD Factory 2);

3.

Make sure steel strip has been fully threaded through the machine to the Shear tool;

4.




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5.


6.

Go to the Setup / Inkjet Screen and make sure ink is selected;

7.

Press the [Test] button then using the Inch FORWARD push button on the side of the machine, drive the steel strip forward. The printer control system will print text onto the strip while the FORWARD push-button is being pressed (typically this will be printer head identification; i.e. Head 0 and Head 1).

8.

The printed text should be clearly legible. If the text is too light, not present or illegible complete the following checks; a.

Check the amount of ink in the bottle located in the printer cabinet – refill as required;

b.

Make sure both the Ink and Cleaner bottle caps are tightly sealed, checking the Ink filter for blockages – tighten and clean as required;

c.

Check the Air Compressor pressure is approximately 10PSI;

d.

Check for any kinks or loose connections on the tubing both inside the printer cabinet and going up to the printer heads;


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FRAMECAD F300i Operating Manual e.

Clean and purge the printer heads with Cleaner (see the Clean Printer Heads and Short-term Shut-down procedures above);

f.

Contact your nearest FRAMECAD office for further support if the above does not resolve the printing issue.


®

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13.7

Shear Blade Replacement

The Shear tool is actuated twice on every stick. The shearing action and forces involved are high, for this reason the Shear blade will require frequent lubrication and replacement when worn.

Shear Blade

SHEAR BLADE REPLACEMENT PROCEDURE Tools Required

Safety



Machine Cabinet Key



10mm Hex Key



6mm Hex Key



4mm Hex Key



Metric Socket Set



ISOLATE electrical power to the FRAMECAD F300i and implement measures to prevent accidental re-connection; Remove steel strip from the machine



WARNING! THIS PROCEDURE MUST BE COMPLETED WITH ELECTRICAL POWER ISOLATED TO THE MACHINE AND WITHOUT STEEL STRIP INSERTED. SEE SECTION 5 - SAFETY FOR MORE INFORMATION. When Change Shear Blade

When Shear blade shows signs of wear and/or damage 1.

Remove the Out-feed End Cover;

Out-feed End Cover

2.

In this step we want to swing the Out-feed support frame that the Operator Screen is bolted to, out of the way. There are x4 bolts holding the Support frame in place; x2 on either side. The two rear bolts (relative to the Out-feed end of the Shear) can be accessed from the top. The two front bolts can be accessed via the bottom through access holes cut into the chassis. Remove both of the Support mounting bolts on the left-hand side . Remove only the front mounting bolt on the r i g h t - h an d s i d e as shown below;


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Remove both bolts (rear top and front bottom access) from the left-hand s i d e of Support Frame

Remove the front bolt (bottom access) ONLY from the r i g h t - h an d s i d e of Support Frame 3.

Gently swing the Support frame (including Operator Screen) out of the way;

4.

Loosen (do not remove) the front Shear assembly clamp bolts (x4);

Loosen the Shear assembly clamp bolts (x4) 5.

Remove the top Shear plate bolts (x12) so that the top plate and Shear blade assembly can be lifted upwards; Carefully withdraw the top plate and Shear blade. The Shear blade attachment bolts (x3) can now be removed;


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Shear Attachment Bolts (x3)

6.

Remove the old Shear blade and replace with new. MAKE SURE the replacement blade is the same size and shape as the one being removed.

7.

Re-assemble the Shear by completing the same steps above, only in reverse order.


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13.8

Dimple Fixed Die/Punch Replacement

Inside the Dimple housing is the fixed die/punch that when used in combination with the moving Dimple die, produces the Dimple screw hole and depression in the side flange of the “C” section profile.

Fixed Die/Punch

Given the frequency of operation (generally most sticks will incorporate multiple Dimple operations), the size of the Dimple punch (typically 3.8 to 5.1mm) and the tool location (at the end of the rollforming section which therefore subjects it to interference from other tool cut-outs or profile variations) the Dimple fixed die/punch will require replacing more-often than most other tools. The most frequent need for replacement is when the punch is snapped off the end. DIMPLE FIXED DIE/PUNCH REPLACEMENT PROCEDURE Tools Required

Safety



10mm Hex Key



6mm Hex Key



11/16” Spanner



Replacement Dimple Die/Punch






WARNING! THIS PROCEDURE MUST BE COMPLETED WITH ELECTRICAL POWER ISOLATED TO THE MACHINE AND WITHOUT STEEL STRIP INSERTED. SEE SECTION 5 - SAFETY FOR MORE INFORMATION. When



When Dimple fixed die/punch is damaged or broken

Location

Dimple Die/Punch Location


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FRAMECAD F300i Operating Manual Change Shear Blade

1.

Remove the Pinch Roller Assembly #2 (Out-feed end of Dimple Tools) by removing the two spring loaded cap screws;

Remove Pinch Roller Assembly by removing two spring-loaded cap screws

2.

Disconnect hydraulic hose connection to the Dimple hydraulic cylinder;

Disconnect hydraulic hose connection to Dimple hydraulic cylinder

WARNING! TAKE CARE NOT TO DAMAGE OR LOOSE THE SEALS LOCATED IN THE END OF THE HYDRAULIC HOSE CONNECTOR

3.

Remove the Dimple hydraulic cylinder end plate by removing the four (x4) cap screws;

Remove x4 cap screws holding hydraulic cylinder end plate


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4.

Remove the hydraulic cylinder barrel and Dimple moving die and piston assembly;

5.

Loosen bottom grub screw holding fixed die/punch in place;

Loosen grub screw holding Dimple fixed die/punch in place.

6.

You can now gently push the old Dimple fixed die/punch out of the housing via the access hole on the outside face of the Dimple housing;

7.

Carefully push the new Dimple fixed die/punch through the Dimple housing and into position. Gently press the Dimple fixed die/punch so that it is seated as far back into the Dimple housing recess as it will go;


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8.

Retighten the grub screw then use a steel rule to check and make sure that the Dimple fixed die/punch is not protruding from the inner face – loosen grub screw and push further in if required; TIP! If you need to push the fixed die/punch back further into the recess, use a right-angled Hex key to gently lever it back further.

Check to make sure fixed die/punch is not protruding.

9.

Re-assemble the Dimple cylinder by completing the steps 1 to 4 above, only in reverse order. Take care to do the following; a.

When re-attaching the Hydraulic cylinder end plate, make sure the screws are tightened evenly in a star-pattern;

b.

Be careful not to damage or loose any Hydraulic hose seals;

c.

Make sure all screws/bolts are firmly tightened


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13.9

Dimple Moving Die Replacement

Inside the Dimple housing is the fixed die/punch that when used in combination with the moving Dimple die, produces the Dimple screw hole and depression in the side flange of the “C” section profile. The Dimple moving die should not need frequent changing (unlike the Dimple fixed die/punch). DIMPLE MOVING DIE REPLACEMENT PROCEDURE Tools Required

Safety



10mm Hex Key



6mm Hex Key



5mm Hex Key



11/16” Spanner



Replacement Dimple Moving Die






WARNING! THIS PROCEDURE MUST BE COMPLETED WITH ELECTRICAL POWER ISOLATED TO THE MACHINE AND WITHOUT STEEL STRIP INSERTED. SEE SECTION 5 - SAFETY FOR MORE INFORMATION. When



When Dimple moving die is damaged or broken

Location

Dimple Moving Die Location Change Shear Blade

1.

Remove the Pinch Roller Assembly #2 (Out-feed end of Dimple Tools) by removing the two spring loaded cap screws;


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Remove Pinch Roller Assembly by removing two spring-loaded cap screws

2.

Disconnect hydraulic hose connection to the Dimple hydraulic cylinder;

Disconnect hydraulic hose connection to Dimple hydraulic cylinder

WARNING! TAKE CARE NOT TO DAMAGE OR LOOSE THE SEALS LOCATED IN THE END OF THE HYDRAULIC HOSE CONNECTOR

3.

Remove the Dimple hydraulic cylinder end plate by removing the four (x4) cap screws;

Remove x4 cap screws holding hydraulic cylinder end plate


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4.

Remove the hydraulic cylinder barrel and Dimple moving die and piston assembly;

5.

Remove the end cap screw and split the Dimple moving die;

Remove piston end cap screw and split Dimple moving die from piston 6.

Replace Dimple moving die;

7.

Re-assemble the Dimple cylinder by completing the same steps above, only in reverse order. Take care to do the following; a.

When re-attaching the Hydraulic cylinder end plate, make sure the screws are tightened evenly in a star-pattern;

b.

Be careful not to damage or loose any Hydraulic hose seals;

c.

Make sure all screws/bolts are firmly tightened.


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14 TROUBLESHOOTING 14.1

Managing Problems

The FRAMECAD F300i is a highly advanced and powerful machine. It incorporates electrical, computer, hydraulic and mechanical sub-systems that will require maintenance and troubleshooting from time to time. Most issues can be effectively managed, or even avoided altogether by ensuring the following programmes/plans are in place; 1.

Operator Training; the more effort put into developing employees utilising this equipment, the better the workplace environment will be and the more reliable and effective your production. Complete familiarity with this Operating Manual is an absolute prerequisite to using the FRAMECAD F300i machine;

2.

Effective Maintenance/Service Plans; don’t wait for an issue to occur. Keep the machine well maintained and serviced to maximise productivity and reduce down-time;

3.

Resource Planning; how many Operators/Frame Assemblers will you need? Design and Detailers? If you don’t have on-site expertise in electrical, hydraulic or mechanical disciplines, how will you manage these types of issues if/when they arise? Work out who, how and where you will need to contact and draw resource from when the need arises. This exercise is a simple and fundamental management strategy that should always be in place for any manufacturing environment;

4.

Spare Parts; the FRAMECAD F300i is shipped with a basic assortment of spare parts. These should be deemed the minimum requirement. Depending on location and availability of parts in your region, developing a smart spare part strategy that is specific to your needs and location is a sensible and highly recommended option. The types of things that need to be considered when formulating a spare parts plan are; a.

Electrical power supply integrity; is the supply is prone to frequent dips or surges?

b.

Ambient temperature; extreme ambient temperatures (< 0 C - >40 C) in nonclimate controlled environments will add addition stress to machinery and equipment, resulting in higher wear and tear rates.

c.

Atmospheric dust/contaminate; airborne or surface contaminates that can get inside the machine will result in a higher degree of wear and tear.

d.

Staff competency and training.

e.

Location and general infrastructure; this will have a direct impact on part availability and delivery times, particularly in remote or rural areas.

o

o

®

FRAMECAD has the knowledge and know-how to be able to advise and recommend options on all of the above. From specialised training through to the development of specific spare part ® packages and customised Service Level agreements, FRAMECAD can assist in developing the ® right strategy for your needs. For more information on FRAMECAD support services please ® contact you regional FRAMECAD office or visit our web-site www.framecad.com/care


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14.2

Identifying Root Cause

The following guidelines are supplied to assist in problem diagnosis/solving when using the FRAMECAD F300i machine; 

What has changed? Look for any changes that may have occurred just prior to the problem commencing. Common examples are; o

o

Changes in steel (quality, tensile strength, strip width etc); Change in steel thickness – has the roll-forming section been setup to accommodate the new material thickness?

o

Where there any changes to the set-up and configuration of the machine?

o

Have there been any changes to the FRAMECAD Factory 2 software?

o

If there are problems with tool cut-outs in the final frame assembly, check the job design. Many issues can be resolved by rethinking the layout and configuration of the job file.



Review maintenance records – check to see if there were any adjustments made that may be impacting machine performance.



Check to make sure that routine maintenance checks are up to date and were completed properly; a poor maintenance regime typically means poor performance and product.



Check the basics first; o

o

o

o

o

Check consumable elements on the machine to make sure that they have not simply run out (i.e. does the machine and Ink and Cleaner, is there sufficient lubricant being supplied to the steel strip?) Use the built-in information screens of FRAMECAD Factory 2 (under the Info menu). These are useful for checking the basic state of the digital inputs and outputs, the Variable Frequency Controller and Print System configuration; Look for loose nuts/bolts/screws in or around the problem area and tighten as required; Review the Operating Manual for the correct procedures on setup, calibration and adjustment (this includes the De-coiler); Does the issue occur after a particular tooling operation? For example, is the steel strip catching on a particular tool?



Peculiar or intermittent faults resulting in unexpected machine shut-down, Emergency Stop trips, failure to start the hydraulics etc are often the result of poor electrical supply. Be aware of this and if you suspect a supply related issue, have a registered Electrician investigate.



ALWAYS make sure that all material and services comply with the specifications outlined in this Operation Manual and in accordance with the original specification requested for the machine.



For direct access to our on-line support web-site, go to http://care.framecad.com


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14.3

Basic Trouble-shooting Chart

ISSUE

CAUSE

Display Fault Message “MDX61 Fault Code 06”

RESOLUTION

One of the 3-phases supplying the machine Have a registered Electrician check the – has failed. incoming supply to the machine. Confirm voltages and frequency.

The FRAMECAD F300i or Decoiler shut-down intermittently Display Fault Message “MDX61 Fault Code 08”



The rolling motor failed to reach its target Test the machine in Manual control to – top speed in the required time frame. The investigate the following possible most likely cause will be due to a causes: mechanical hindrance in the machine, either as a result of incorrect setup (i.e. a  Check to make sure there is sufficient misalignment or the roller clearances) or t he lubricant being applied to the steel strip. steel fouling on a tool or guide as it is If the steel strip is too dry this will processed inside the machine. increase the rolling effort required and may result in this error.

The VFC has detected a failure with the – rolling motor encoder (or resolver).

Communications with the master Computer – has failed. NOTE: It is not uncommon to receive this fault just after a machine reset or on powerup as both these conditions reset the VFC and may interrupt the communication link with the Computer.




Check to make sure that the roller station clearances have been properly set for the steel thickness being run. Typically the roller clearances should be set to 0.05mm below the base metal thickness of the steel being run (e.g. if BMT = 0.75mm, roller clearance should be set at 0.70mm).



Check for mechanical obstructions that may be preventing the steel from moving forward (e.g. misalignment or a physical jam-up of the steel).



Check to make sure that no punching tools are stuck down or interfering with the steel movement. I ncrease the UP and DOWN time settings for the suspect tool in the Setup/Tools screen.



Check that no scrap metal is being caught up in the bottom scrap exit points of the tooling pre-punch block/module.



Increase the Ramp time shown in the Setup/MDX61B screen. This will slow the acceleration of the rolling motor down to accommodate for any increase in mechanical loading in the machine. Check all plug connections to the Encoder on the motor and to the VFC inside the AC Electrical Cabinet – make sure all plugs are firmly connected.





Look for a broken or damaged encoder cable and replace if necessary.



f



all connections have been checked and there is no damage to the cable, replace the encoder. If the RESET button was just pressed or the machine was just powered up, press the acknowledge button and ignore.



Check the Ethernet plug connections between the Computer and the VFC in the



AC Electrical Cabinet.

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FRAMECAD F300i Operating Manual Display Fault Message “MDX61 Fault Code 31”


– The motor is too hot.

The VFC detected too large a difference – between the motor encoder signal and the steel strip encoder signal. This fault will often follow or be associated with a fault 08 code. These two faults are typically caused by similar events. The one that is displayed depends on which occurs first. The 08 fault will most likely occur during acceleration while the 42 fault will occur a little latter after the motor has got to speed.

Rollers shudder or oscillate back Chain tension loose OR insufficient and forth during forward motion lubrication on steel strip OR roller station is no longer in contact with steel strip.

Emergency Stop activation De-coiler Dancing Arm has been lifted too without an Emergency Stop high OR De-coiler VFC has tripped. Push-button being pressed The De-coiler is integrated into the safety control circuit, so if the De-coiler has stopped running for any reason the both machines will halt in an Emergency Stop state.




Allow motor to cool.



If excessive production or ambient temperature, additional cooling may be required.



Have a registered Electrician check the state of the motor. The guide wheel(s) at the in-feed of the machine is slipping on the steel strip OR the encoder belt pulley is loose (if applicable) OR the Encoder shaft coupling is loose. Check and re-tighten if necessary. Check to make sure there is sufficient lubricant being applied to the steel strip. If the steel strip is too dry this will increase the rolling effort required and may result in this error.







Check to make sure that the roller station clearances have been properly set for the steel thickness being run. Typically the roller clearances should be set to 0.05mm below the base metal thickness of the steel being run (e.g. if BMT = 0.75mm, roller clearance should be set at 0.70mm).



Check for mechanical obstructions that may be preventing the steel from moving forward (e.g. misalignment or a physical jam-up of the steel).



Check to make sure that no punching tools are stuck down or interfering with the steel movement. I ncrease the UP and DOWN time settings for the suspect tool in the Setup/Tools screen.



Check that no scrap metal is being caught up in the bottom scrap exit points of the tooling pre-punch block/module.



Increase the Ramp time shown in the Setup/MDX61B screen. This will slow the acceleration of the rolling motor down to accommodate for any increase in mechanical loading in the machine.



Tighten chain tension



Check sufficient lubrication on the steel strip



Check to make sure all roller stations are in contact with steel



Restart De-coiler.



Check De-coiler calibration.



Reset power to the De-coiler.

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Dancing

Arm

FRAMECAD F300i Operating Manual Frame component inaccurate

length

is Strip encoder guide wheel at in-feed section of machine is loose OR encoder belt drive (if applicable) is loose OR encoder shaft/coupling is loose. If the length error is inconsistent then this typically indicates “looseness” in the encoder assembly at the in-feed of the machine which is allowing the encoder wheel/shaft or belt to slip whenever steel is moved through the machine.



Check encoder wheel is not slipping on steel strip at in-feed of m achine.



If applicable, check to encoder belt is not loose.



Check all encoder couplings to make sure there is no looseness allowing slip.



Recalibrate the machine

make

sure

If the length error is consistent across all lengths then this typically indicates a machine calibration issue Build Up On Rollers

Machine speed is slow

No or faint printing

Display Fault Message “Hydraulics pressure low”

Clean the residue by either scraping or rubbing the build up with fine emery paper Feed rate setting is too low OR hydraulic pressure is struggling to maintain pressure. If hydraulic tooling actuation is slow then this indicates a hydraulic system issue.



Check Feedrate setting on Setup/MDX61 screen



Check for hydraulic leaks and hot spots in or around the hydraulic cylinders, valves or unloader block that may indicate hydraulic seal leakage (bypassing)



Check hydraulic pump and accumulator ® pressure - contact FRAMECAD for further support.



Check Ink and Cleaner fluid levels – refill as required



Manually clean and purge the printer heads with Cleaner fluid (see Section 12 – Maintenance for applicable procedures)



Check for air leaks and sealing around Ink/Cleaner bottle caps



Check the Ink bottle filter



Look for kinks or loose fittings in or around the tubing, air compressor and printer heads

– The system cannot build and/or maintain hydraulic loading pressure (160Bar).



To confirm hydraulic pressure related issues, a test gauge must be used;

Whilst this can indicate an issue with the hydraulics circuit and/or seals within valves or cylinders, it can also be the result of electrical supply issues to the machine.



Check for hydraulic leaks and hot spots in or around the hydraulic cylinders, valves or unloader block that may indicate hydraulic seal leakage (bypassing) – minimum loaded pressure must be >160Bar (Hydraulic operating pressure range is 160 to 195Bar)



The accumulator vessel is pre-charged to 120Bar – if the hydraulic system pressure is very sluggish to reach 120Bar then replace accumulator bladder



Have a registered Electrician check the electrical supply to the machine (voltage and frequency)



Check hydraulic pump and accumulator ® pressure - contact FRAMECAD for further support.

Blocked or clogged printer heads, blocked, ink filter, air leaks/kinks in the tubing, fittings or Ink/Cleaner bottles


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14.4

FRAMECAD ® Support ®

For further support or assistance please contact your regional FRAMECAD office or visit www.framecad.com/care. ®

For direct access to our FRAMECAD Care support web-site go to http://care.framecad.com, login and raise a support ticket with our Client Services team.

When requesting support, please try to be specific about the issue, investigations already undertaken and include photographs where appropriate. The more information you can provide the faster our Client Services team will be able to answer any questions you may have. Full guidelines ® can be found at our FRAMECAD Care support web-site.


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15 Recommended Spares ®

FRAMECAD recommends the following spare parts inventory. This is a typical list covering basic ® requirements. For extended lists please contact your regional FRAMECAD office for more information. PART NUMBER 003731V 003732V 003020V 006302 006263 301543 002237-SK 002265-SK 002325-SK 002329-SK 002331-SK 002333-SK 002335-SK 002337-SK 002347-SK 002598 005681 004389 300927 005235 304499 004003 005125 302140

DESCRIPTION PUNCH, Dimple Fixed Die, (Machine Variant) PUNCH, Dimple Moving Die, (Machine Variant) BLADE, Shear, (Machine Variant) BEARINGS, Shear In-feed Guide Bearings (6001-ZZ) + Circlip BEARINGS, Shear Side-crimp Cam Bearings (6201 2RS) + Circlip FILTER, Hydraulic Return Oil Filter Cartridge SEAL, Dimple Hydraulic Seal Kit, F300i SEAL, Lip Box Hydraulic Cylinder Seal Kit, F300i SEAL, Swage Cylinder Seal Kit, F300i SEAL, Bolt Hole Hydraulic Cylinder Seal Kit, F300i SEAL, Service Hole Hydraulic Cylinder Seal Kit, F300i SEAL, Lip-Cut Punch Hydraulic Cylinder Seal Kit, F300i SEAL, Chamfer Hydraulic Cylinder Seal Kit, F300i SEAL, Web Notch Hydraulic Cylinder Seal Kit, F300i SEAL, Shear Cylinder Seal Kit, F300i SEAL, F300i Manifold and Hose O-ring Kit VALVE, Hydraulic Directional Valve PRINTER, Waste Bottle Cap PRINTER, High Pressure Ink Cap & Filter, F300i/FL650 SEAL, Valve EPDM Seal (Short Print-heads ONLY) VALVE, 3Way Printer Ink/Cleaner Valve (Short Printheads ONLY) LUBRICATOR, Felt Roller LUBRICATOR, Repair Kit POTENTIONMETER, Potentiometer Plus Cable Assembly (De-coiler)

1

QUANTITY

LEAD TIME

2 2 1

10-15 days 10-15 days 10-15 days

1 Set

5 days

1 Set

5 days

1 Set 1 Set 1 Set 1 Set 1 Set 1 Set

5 days 5 days 5 days 5 days 5 days 5 days

1 Set

5 days

1 Set 1 Set 1 Set 1 Set 1 1

5 days 5 days 5 days 5 days 5 days 20 days

1

20 days

1

5-10 days

1

5-10 days

1 1

20 days 20 days

1

10-15 days

NOTE 1: Lead times may vary beyond FRAMECAD’s control;  Lead times DO NOT include international delivery time; allow additional 3-5 days depending of freight option  Lead times represent the typical time required from placement of order for items if not currently in  ® FRAMECAD stock;

15.1

Requesting Spares

Whenever requesting spare parts, please take note of the following guidelines that will assist our Client Services team in providing a prompt and efficient turnaround of all queries and requests; 1. 2.

Where practical, always request spare parts via a support ticket on our FRAMECAD Care web-site. This allows complete track and traceability of all queries; Always supply the FRAMECAD F300i serial number. This will ensure we have the right machine specification;


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FRAMECAD F300i Operating Manual 3.

4. 5.

Where possible provide the part number for the components required. If the part number is not available, please provide a photo(s) or detailed description of the part you are after and attach to the FRAMECAD Care ticket; Be specific about quantities required; Always include delivery address details, contact information and any specific shipping, customs or packaging requirements.


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FRAMECAD F300i Operating Manual (FCF2) - Release 10102013

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