Rosenthal
30in
AirSpeed 5000
SHEETMASTER
General
Procedures
Troubleshooting
Guide
1
Rosenthal Sheetmaster Components
10
9
8
6
5
12
7
1 Cut Motor
1
2
11
3
7. Power Supply
2. Cut Motor Clutch Brake (not shown) 8. Drive Roller
3. Drive Motor
9. Tension Roller
4. Drive Motor Clutch Brake
10. Foam Rollers
5. Gear Box
11. Blower (not shown)
6. Encoder
12. Blower Switch (not shown)
4
2
Drive Motor
Brushed DC motors
The classic DC motor design generates an oscillating current in a wound
rotor, or armature, with a split ring commutator, and either a wound or
permanent magnet stator. A rotor consists of one or more coils of wire
wound around a core on a shaft; an electrical power source is connected to
the rotor coil through the commutator and its brushes, causing current to
flow in it, producing electromagnetism. The commutator causes the current
in the coils to be switched as the rotor turns, keeping the magnetic poles of
the rotor from ever fully aligning with the magnetic poles of the stator field,
so that the rotor never stops (like a compass needle does) but rather keeps
rotating indefinitely (as long as power is applied and is sufficient for the
motor to overcome the shaft torque load and internal losses due to friction,
etc.)
Many of the limitations of the classic commutator DC motor are due to the
need for brushes to press against the commutator. This creates friction. At
higher speeds, brushes have increasing difficulty in maintaining contact.
Brushes may bounce off the irregularities in the commutator surface,
creating sparks. (Sparks are also created inevitably by the brushes making
and breaking circuits through the rotor coils as the brushes cross the
insulating gaps between commutator sections. Depending on the
commutator design, this may include the brushes shorting together
adjacent sections—and hence coil ends—momentarily while crossing the
gaps. Furthermore, the inductance of the rotor coils causes the voltage
across each to rise when its circuit is opened, increasing the sparking of
the brushes.) This sparking limits the maximum speed of the machine, as
too-rapid sparking will overheat, erode, or even melt the commutator. The
current density per unit area of the brushes, in combination with their
resistivity, limits the output of the motor. The making and breaking of
electric contact also causes electrical noise, and the sparks additionally
cause RFI. Brushes eventually wear out and require replacement, and the
commutator itself is subject to wear and maintenance (on larger motors) or
replacement (on small motors). The commutator assembly on a large
machine is a costly element, requiring precision assembly of many parts.
On small motors, the commutator is usually permanently integrated into the
rotor, so replacing it usually requires replacing the whole rotor.
3
Relay
A relay is an electrically operated switch. Many relays use an
electromagnet to operate a switching mechanism, but other operating
principles are also used. Relays find applications where it is necessary to
control a circuit by a low-power signal, or where several circuits must be
controlled by one signal. The first relays were used in long distance
telegraph circuits, repeating the signal coming in from one circuit and retransmitting it to another. Relays found extensive use in telephone
exchanges and early computers to perform logical operations. A type of
relay that can handle the high power required to directly drive an electric
motor is called a contactor. Solid-state relays control power circuits with no
moving parts, instead using a semiconductor device triggered by light to
perform switching. Relays with calibrated operating characteristics and
sometimes multiple operating coils are used to protect electrical circuits
from overload or faults; in modern electric power systems these functions
are performed by digital instruments still called "protection relays".
Interlock Switch
An interlock switch (micro switch, snap-action switch, etc.) is an electric
switch that is able to be actuated by very little physical force, through the
use of a tipping-point mechanism. They are very common due to their low
cost and extreme durability, typically greater than 1 million cycles and up to
10 million cycles for heavy duty models. This durability is a natural
consequence of the design. Internally a stiff metal strip must be bent to
activate the switch. This produces a very distinctive clicking sound and a
very crisp feel. When pressure is removed the metal strip springs back to
its original state.
The defining feature of interlock switches is that a relatively small
movement at the actuator button produces a relative large movement at the
electrical contacts, which occurs at high speed (regardless of the speed of
actuation). Most successful designs also exhibit hysteresis, meaning that a
small reversal of the actuator is insufficient to reverse the contacts; there
must be a significant movement in the opposite direction. Both of these
characteristics help to achieve a clean and reliable interruption to the
switched circuit.
The interlock switch, which is used to control, regulation, precision
engineering, devices is an electrical switch that is designed to be operated
4
by the physical movement of mechanical devices. The principal
characteristics of the standard interlock switch are that it usually works with
currents from 0.1A to 15A, it resists temperatures between -30 and 80
Celsius degrees.
Encoder
An encoder is a device, circuit, transducer, software program, algorithm or
person that converts information from one format or code to another, for the
purposes of standardization, speed, secrecy, security, or saving space by
shrinking size.
Traditional incremental encoders
A traditional incremental encoder works by providing an A and a B pulse
output which provide no usable count information in their own right. Rather,
the counting is done in the external electronics. The point where the
counting begins depends on the counter in the external electronics and not
on the position of the encoder. To provide useful position information, the
encoder position must be referenced to the device to which it is attached,
generally using an index pulse. The distinguishing feature of the
incremental encoder is that it reports an incremental change in position of
the encoder to the counting electronics.
Clutch Brake
An electromagnetic clutch is a clutch (a mechanism for transmitting rotation) that is
engaged and disengaged by an electromagnetic actuator. Electromagnetic clutches
operate electrically, but transmit torque mechanically. This is why they used to be
referred to as electromechanical clutches and brakes.
A clutch has four main parts: field, rotor, armature, and hub (output). When voltage is
applied the stationary magnetic field generates the lines of flux that pass into the rotor.
(The rotor is normally connected to the part that is always moving in the machine.) The
flux (magnetic attraction) pulls the armature in contact with the rotor (the armature is
connected to the component that requires the acceleration), as the armature and the
output start to accelerate. Slippage between the rotor face and the armature face
continues until the input and output speeds match (100% lockup). The actual time for
this is quite short .02-1.0sec.
There are only three parts: field, armature, and hub (which is the input on a brake).
Usually the magnetic field is bolted to the machine frame (or uses a torque arm that can
handle the torque of the brake). So when the armature is attracted to the field the
5
stopping torque is transferred into the field housing and into the machine frame
decelerating the load. Like the clutch this can happen very fast. If required, and within a
small range, both clutch and brake time to speed and stop can be controlled by varying
the voltage/current applied.
Disengagement is the same for both. Once the field starts to degrade flux falls rapidly
and the armature separates. A spring(s) hold the armature away from its corresponding
contact surface at a predetermined air gap. [6
Typically if a coil fails it is usually due to heat which has caused the insulation of the coil
wire to break down. That heat can be caused by high ambient temperature, high cycle
rates, slipping or applying too high of a voltage. Bushings can be used in some clutches
that have low speed, low side loads or low operating hours. At higher loads and speeds,
bearing mounted field/rotors and hubs are a better option. Like the coils, unless
bearings are stressed beyond their physical limitations or become contaminated, they
tend to have a long life and they are usually the second item to wear out.
The main wear in electromagnetic clutches occurs on the faces of the mating surfaces.
Every time a clutch is engaged during rotation a certain amount of energy is transferred
as heat. The transfer, which occurs during rotation, wears both the armature and the
opposing contact surface. Based upon the size of the clutch, the speed and the inertia,
wear rates will differ. For example a machine that was running at 500 rpm with a clutch
and is now sped up to 1000 rpm would have its wear rate significantly increased
because the amount of energy required to start the same amount of inertia is a lot
higher at the higher speed. With a fixed armature design a clutch will eventually simply
cease to engage. This is because the air gap will eventually become too large for the
magnetic field to overcome. Zero gap or auto wear armatures can wear to the point of
less than one half of its original thickness, which will eventually cause missed
engagements.
6
Rosenthal Sheet Master Time Line
Drive Components
Drive
Clutch-Brake
deactivated
Cut Components
Drive clutchbake relay
deactivated
Auto Off
Drive Clutchbrake relay
activated
Drive motor
engaged
Batch
complete
Drive
Clutch Brake
activated
Length /
footswitch
Automatic
batch
Batch not
complete
Mode
dependent
Start
Cycle
Cut clutch-brake
relay activated
Encoder
calculates
length based
on rotation
Cut motor
engaged
Blade rotates
and deactivates
micro switch
Sheet length
reached
Cut
clutch-brake
deactivated
Blade activation
Blade completes
one cycle and
activates micro
switch
Stop
Cycle
7
Rosenthal 30 inch SHEETMASTER
Troubleshooting Procedures
NOTE: The most important thing to remember about this machine is that all
of its processes (e.g. driving the material, cutting the material, batch
cutting, etc.) are a series of dependant “steps”. If one of the “steps” has not
been completed all remaining “steps” cannot be competed.
NOTE: There are a series of lights located on the right side of the control
panel. Each light corresponds to the various functions of the machine.
Observing these lights during machine operation and understanding their
meaning will often help lessen the time it takes to diagnose a machine
issue.
Problem Description:
MACHINE WILL NOT OPERATE AT ALL - (NO lights on control.)
Possible Causes:
Inadequate power source
Line cord damaged
Main power switch failure
Troubleshooting Steps:
Test for electricity at receptacle to which sheeter is connected. Sheeters
require 115-120 volts, single phase, 60 hertz electrical service unless
otherwise labeled.
Check continuity of line cord.
Test MAIN POWER switch on sheeter control.
8
Resolution:
Obtain a proper power source.
Replace power cord.
Replace main power switch.
Problem Description:
MACHINE WILL NOT OPERATE AT ALL - (Electronic counter is lighted.)
Possible Causes:
Circuit breaker tripped
Faulty power supply
Troubleshooting Steps:
Check AC circuit breaker on face of control panel.
Test DC power output of power supply.
Resolution:
Reset circuit breaker
Replace power supply
9
Problem Description:
MACHINE OPERATES PROPERLY BUT IS INTERRUPTED - (random
pattern)
Possible Causes:
Interlock switch is set too sensitive
Troubleshooting Steps:
Interlock
If an interlock switch is set too sensitively,
switch
machine vibration may be adequate to
cause activation of the interlock. As the
interlock LEDs only work when a switch is actuated, the brief flash may not
be seen and the control panel will appear normal but will not operate after
the interlock light goes off.
If the interruption takes place during the FEED of a LENGTH cycle, the
counter remembers how much material was sheeted. To resume sheeting,
touch the LENGTH button or the AUTOMATIC keypad for the balance of
the sheet.
If the interruption occurs during the CUT cycle, touch the CUT button once
to reset the knife which will permit resumption of operation.
Resolution:
Adjust interlock switch.
Problem Description:
NO LENGTH OPERATION - (Counter display and batch counter are ON)
10
Possible Causes:
Batch is complete
Counter failure
Troubleshooting Steps:
Batch is complete. Reset batch counter or turn batch counter OFF to
restore operation.
Batch not complete but no LENGTH indicates defective batch counter
function
Resolution:
Reset batch.
Replace counter.
Problem Description:
NO LENGTH OPERATION-(Counter display is ON, Batch counter is OFF)
Possible Causes:
Length button failure.
Counter failure.
Troubleshooting Steps:
11
If manual FEED and AUTOMATIC functions operate, test the LENGTH
button switch.
Resolution:
Replace electronic counter.
Replace the LENGTH switch.
Problem Description:
MOVING BLADE CYCLES AND STOPS IN MATERIAL FEED PATH
Possible Causes:
Jam up flap interlock switch set too sensitively. Ideally, the actuating lever
of the switch is formed so that it does not rest against the cam which
activates it. In this way, vibration from the cutting action can not be
transmitted from the machine to the switch contacts and cause premature
opening.
Other interlock switches trip premature.
Troubleshooting Steps:
Inspect interlock switches. Verify proper adjustment.
Resolution:
Adjust interlock switch
Problem Description:
CUT OPERATES CONTINUOUSLY - WILL NOT STOP
12
Possible Causes:
Knife cycle switch misaligned or has
failed.
Clutch brake locked.
Troubleshooting Steps:
Check for proper operation of cam
against knife cycle switch for cycle
cancellation.
Inspect for possibility of locked clutch
armature.
Resolution:
Replace or adjust cycle switch
Replace clutch brake
Problem Description:
LENGTH STARTS BUT WILL NOT STOP
Possible Causes:
Encoder failure
Counter failure
Troubleshooting Steps:
Cam
Cycle switch
13
Check for contact of encoder drive wheel against feed roll. The moving
feed roll must cause encoder wheel movement for material measurement.
Is the encoder plug tightly connected? Encoder cable wire leads secure.
Resolution:
Replace encoder.
Replace electronic counter.
Problem Description:
JAM UPS: (Undesirable fouling of the machine with material that is to be
sheeted.)
WARNING: TURN POWER OFF BEFORE CLEARING ANY JAM!
Possible Causes:
Can be caused by resistance to material travel as it is pushed forward by
the feed roll.
Material too thick for knife opening.
Roll of material not centered and dragging on one side of machine against
guards, etc.
Knife not completely out of material path.
Material is very flimsy.
Pressure roll applies excessive pressure to material causing upward
buckling and therefore rubbing against knife angle.
Pressure roll not parallel to feed roll.
Textured material clings to feed roll.
14
Downward curl of material leading edge can be trapped in space between
paper chute and stainless steel delivery top.
Troubleshooting Steps:
Clean dirty surfaces or replace damaged paper chute covering.
Test CUT brake action or possibly setting of knife cycle cam actuator.
Reduce feed rate.
Resolution:
Clean dirty surfaces or replace damaged paper chute covering.
Reduce feed rate.
Invert material roll.
Problem Description:
Machine will not cut (i.e. cut blade does not cycle)
Possible Causes:
Cut motor failure
Cut motor circuit breaker is tripped
Cut motor relay failure
Cut motor clutch brake failure
Belt is broken or has fallen off
Drive motor failure
15
Drive motor clutch brake failure
Troubleshooting Steps:
First, determine if the problem is related to a component within the
cut mechanism or if it is being caused by something else. For
example:
Relays
If either motor (cut or drive) appears not to be functioning it is always best
to perform a simple test to determine whether the relay is the cause of the
issue. To test the relays, perform the following procedure:
Remove the two screws on the front of the control panel and open the lid.
On the bottom of the counter are the cut and drive motor relays. Remove
the relays by expanding the hold down tabs and gently prying them out
using a small screw driver. Switch the relays from one position to the other
(they are identical). If the issue moves to the other component (e.g. the
drive motor was working, the cut motor was not, now the opposite is true)
the relay has
failed.
Drive motor
relay
Cut Motor
Relay
Diagnosis continued…..
16
On the control pad, press “FUNCTION” then press “CUT”. If the
components are functioning correctly the cut blade will cycle once. If the cut
blade does not cycle the problem is associated with the cut mechanism. If
the cut blade does cycle the problem is associated with another
component.
If the cut blade does not cycle:
Remove machine cover and inspect the cut motor. With the machine
powered on the cut motor should be running, which can simply be identified
by the audible “drone” of the motor or by feeling the motor for vibration.
Verify the cut motor circuit breaker is not tripped by simply pressing it.
(Note: this is a red or grey button on the back of the cut motor housing).
Power Supply
Cut motor
reset button
Verify the cut motor drive belt is intact and is adjusted properly. (Note: the
belt should have approximately 1in of play) Note: Adjustments are made by
loosening the four mounting bolts and moving the motor/clutch brake
assembly (the mounts are slotted).
17
With the machine powered
attempt to cycle the cut
blade by rotating the cut
motor drive belt manually.
Repeat this step with the
machine powered off. With
the machine on you should
not be able to move the belt.
With the machine off you
should be able to move the belt freely and be able to cycle the cut blade
through its entire rotation. If either condition is not met the cut motor clutch
brake is out of adjustment or has failed.
If the cut blade does cycle:
Select (or program- see attached programming guide) the shortest
preset length and press the run (green) button. Visually inspect the drive
roller. If the drive roller is turning and is obviously running longer than it
should (example: with the speed set at 60 the drive roller should take
approximately 1-2 seconds to run 12in) or runs continuously the encoder
has a faulty connection or has failed.
If the roller is not turning remove the rear cover from the machine and
inspect the drive motor.
18
Drive Motor
Clutch Brake
With the machine powered on the drive motor should be running, which can
simply be identified by the audible “drone” of the motor or by feeling the
motor for vibration. Remove the belt cover (drive motor side of the
machine) and verify the belt is intact. With the machine on, manually rotate
the drive roller. Repeat this step with the machine powered off. With the
machine on you should not be able to move the roller. With the machine
off you should be able to move the roller freely. If either condition is not
met the drive motor clutch brake is out of adjustment or has failed.
Resolution:
Reset circuit breaker
Replace cut motor relay
Replace cut motor
Adjust or replace cut motor clutch brake
Replace cut motor drive belt or adjust tension
Replace encoder cable
19
Replace encoder
Replace drive motor
Adjust or replace drive motor clutch brake
Replace drive belt or adjust tension
Problem Description:
All the lights on the control
panel are flashing
Possible Causes:
Hood is not in the down
position
Safety interlock switches are obstructed
Hood safety switch failure
Interlock safety switch failure
Troubleshooting Steps:
First verify the hood is in the down position and unobstructed. Then inspect
the interlock safety switches for obstructions. Note: the interlock switch
that is just forward of the encoder is especially prone to obstruction
due to where it is located in the debris path (cut debris often falls into
the machine) and damage caused by the metal bar that actuates it.
20
Disconnect the hood safety switch and bypass (This is easily
accomplished by disconnecting the wiring harness at the switch and
installing a jumper wire).
Ensure interlock switches are fully
actuated Note: the interlock switch just
forward of the encoder has a long
metal tab that is prone to bending.
This switch can simply be repaired by
readjusting the tab.
Encoder
Interlock Switch
Resolution:
Reposition hood and/or remove obstructions
Replace hood safety switch
Adjust interlock switch(s)
Replace interlock switch(s)
21
Problem Description:
Machine not cutting the material completely (leaving an inch or two uncut)
Possible Causes:
Dull blade
Not enough blade tension
Blade ramp out of adjustment
Troubleshooting steps:
If the blades are damaged or dull
simply remove and replace.
Adjust blade tension by rotating the adjustment bolt on the front of the
machine clockwise. Note: Adjusting blade tension is very subjective.
There is no set scale to determine how much blade tension is needed.
However, a good rule is of thumb is to keep the tension between ½
and ¾ of the adjustment bolt travel.
22
Manually raise the lower blade to where it just comes in contact with the
fixed, upper blade. A properly adjusted blade will contact the leading edge
slightly and then continue in a scissor like motion with the two blades only
fractions of an inch apart. If theses conditions are not met, adjust the ramp
by loosening the set screw (Allen head) and tightening or loosening the
adjustment screw. Once the blade is adjusted properly retighten the set
screw.
Adjustment
Screw
Set screw
Resolution:
Ramp
Assembly
Replace blades
Adjust blade tension
Adjust blade ramp
Problem Description
Machine is cutting material at substantially greater lengths then
programmed
Possible Causes:
Encoder wiring failure
Encoder failure
23
Trouble Shooting Steps:
NOTE: When diagnosing an encoder issue always check the encoder
wiring harness first. The harness is connected to the controller in a
location that makes it very susceptible to damage.
Encoder
harness
Main Wiring
Harness
Verify machine is cutting material at a greater length than expected by
selecting or programming a preset length and running several pieces.
(Note: The lengths, more than likely will be substantially longer than
expected.)
Visually inspect the encoder wiring harness
for damage (broken connecters, frayed
wires, etc.) and ensure that it is plugged in
correctly. Perform a continuity check for
each wire if necessary.
Encoder
Interlock
Switch
24
Resolution:
If the encoder wiring is damaged, replace harness
If the encoder wiring has passed inspection and the machine is still running
greater lengths than programmed, replace encoder.
Problem Description:
Machine is cutting material at intermittent lengths
Possible Causes:
Machine is running too fast for the material type/thickness
Material is slipping
Rollers (foam rollers and drive roller) are dirty or worn
Troubleshooting Steps:
Inspect rollers for wear or debris
Reduce machine speed
25
Resolution:
Clean drive roller
Replace foam rollers
Reduce machine speed and retrain operator
Problem Description:
BLADE NOISE DURING CUTTING
Possible Causes:
If the normal sound of the cutting mechanism changes, discontinue
operation until the noise source is located. The cause of an elevated sound
level may be due to:
Dull Blades
Blade collision!
Worn rod end bearings
Troubleshooting Steps:
The increased radius of dull blade edges! Resharpening of the original
blades or new replacement blades will require properly prepared cutting
edges before they are placed into service.
A freshly sharpened cutting edge formed by the
junction of the bevel and the blade face is too
sharp for practical use. It has no structural
strength and is easily damaged. A slight
decrease of this sharpness is recommended and
quickly accomplished by gentle, uniform rubbing
at a tangent to the edge with a fine grit
26
sharpening stone. Only a very small radius is desired so that sharpness is
preserved. Excessive stoning will dull the blade and shorten its cutting life.
Force applied to the stationary blade edge by the moving blade edge is
determined by tensioning of a single spring (two springs on 60" capacity
machines) that can be adjusted at the front of the machine. New or
resharpened blades cut efficiently so tension should always be reduced to
whatever minimum level is required for complete cutting of the material. As
the blades dull through use, appropriate increases in blade tension are
necessary but should not exceed that required for restoration of cutting.
Blade collision! This highly injurious condition should be corrected
immediately because the moving blade is colliding with the bottom of the
stationary blade as it lifts to cut.
Loosen the laterally positioned, 1/4-28 brass tipped socket set screw in the
guide block at the right side of the machine above the control panel. This
will release the 114-28 x 1-314 socket set screw which positions the guide
spring longitudinally, in and out from the block.
Inspect all bearings associated with blade travel for excessive play. Ideally
there should be very little or no play.
27
Adjustment of the knife guide spring determines the tracking position of
the cam follower attached to the moving blade assembly. By relocating the
spring properly, the elevating edge of the moving blade will contact the
edge of the stationary blade approximately 112" from the right side, outer
edge of the stationary blade. This is the point where cutting starts. Secure
the adjusting screw with the locking screw to preserve this adjustment.
Resolution:
Replace blades
Replace rod end bearings
Adjust blade tension
28
LED DISPLAY INDICATORS:
LENGTH/SLO - When on continuously, this light indicates that a preset
length is in operation or /- that a length is being preset.
CUT - Lights during the cutting cycle.
BATCH - When on continuously, this light indicates that a batch function is
in operation. When it flashes, the preset batch quantity has been satisfied.
If it is off, the batch function is not in use and sheeting can continue without
interruption.
AUTOMATIC- Lights when automatic function is engaged for repetitive
length cycling
SMALL FLASHING LED - at the lower, right comer of the display indicates
encoder input (flashes for each 256 encoder pulses).
ALL LED FLASHING - A safety interlock switch has been actuated. The
machine will not operate until the switch has been restored.
29
ELECTRONIC COUNTER OPERATION - The encoder assembly
generates electrical pulses as movement of the feed roll drives its shaft The
electronic counter will count these pulses and monitor feed roll surface
movement (process is indicated by small, flashing LED at the lower right
hand comer of the display).
"OVERSHOOTING” - When a length preset is entered and the length
button, foot pedal or automatic operation is initiated, the feed roll starts
moving and will do so until the number of pulses counted is the same as
the length preset. At that point the counter signals the machine to stop but,
between the stop signal and the actual halt of the roll, some roll movement
must occur. This will be a function of &e speed of operation and the braking
action. As this extra length is obviously undesirable, it must be deducted
from the sheet length so that the sheeter produces only the length
requested in the length preset. Early model sheeters required the operator
to enter a smaller preset length so the resulting length would be correct.
The electronic counter used in the PACTIV ASTRO-SHEETER is
microprocessor based and can provide a variety of counting functions
including automatic overshoot deduction, if enabled, by setting code 12 at a
value higher than zero.
Before the electronic counter "knows" what the overshoot is, it must be
established. Therefore, the first length sheeted after a length preset change
or after pressing the length reset button twice, will be longer than the
sheets which follow because there was no overshoot to deduct. After that,
with code 12 set at 1, the counter remembers the overshoot of each
preceding sheet and. automatically deducts it from the next.
SCALE FACTOR (CODE 01): This feature can be nullified if set at 1
.OW00 and is not required for proper counter operation. However, if it is
used improperly, it can prevent accurate sheerer results. There is additional
significance to code 01 as it applies to any sheeter shipped to an
installation where the screen displays centimeters rather than inches.
Scaling permits alteration of how the counter will count. At an initial setting
of 1.00000, for domestic use, it counts at the rate of 100 per inch of
material movement. As the screen display is in inches, no scaling factor is
30
required. After, the longest length intended to be dispensed by the
sheerer has been determined, it should be entered into the electronic
counter as a "length preset" Then the length button is pressed to provide a
sheet that will ideally be the same as the preset selected. (Note that the
first sheet will always be slightly longer than those which follow it due to the
automatic overshoot feature. Therefore, the first sheet length must be
disregarded in this test.)
If the output of the sheeter is other than the preset length, (a possibility that
occurs due to variations in component structure) the electronic counter can
be "calibrated" so that output matches the preset. Division of the output
length by the preset produces a ratio (of length to pulses) and by
exchanging the initial value of 1.0000 at code 01 to the new ratio number,
the result will be the counting of the number of pulses required to produce
the desired, preset length.
For metric readout, with no scaling factor entered (1.0000), enter the length
preset as the desired number of centimeters. Dispense one length and
discard it. Then dispense a second length and measure it carefully.
Obviously, the output length will not be correct. However, after dividing that
output length by the length preset and entering that ratio as the new scaling
factor, the resulting sheets will be delivered in centimeters.
OVERSHOOT AVERAGING: Variations in the overshoot of each sheet will
necessarily produce a varying reduction in the projected preset length of
the subsequent sheet. Therefore, with a code 12 value of 1, if a sheeted
length exceeds the preset length by approximately one' inch, the
subsequent sheet will have approximately one inch deducted from it during
the count (measurement) process to produce the desired preset length.
If variations cause variations, they can be disbursed over a greater number
of sheets to promote consistency. As an example, if the code 12 value is
changed to 4, each of the overshoot errors of four previous sheets would
be required before an average of the four would be deducted from the fifth
sheet. However, the theoretical value of this feature is relatively useless
when slippage of the material occurs during sheeting due to poor condition
of the rubber feed roll surface, inconsistent braking of the feed roll drive or
31
because of the nature of the material. Erratic overshoot deductions can
produce a trend of inaccurate sheeter performance so averaging should not
be used to compensate for poor machine maintenance. In this case, a code
12 value of I.
PROGRAM -A sequence of coded instructions in a microprocessor based
electronic counter to predetermine the way it will perform.
The 17 codes and their value options are listed in a separate counter
instruction manual where the function of each code is described.
TO VIEW THE PROGRAM: Press [FUNCTION] + [I]. The first code 01' will
be displayed. As [I] is released, its value appears. Each subsequent push
of [ENTER] will display the next code and then its value when [ENTER] is
released. No alteration to the program is permitted during this scan of the
codes and their values.
TO CHANGE A SINGLE CODE VALUE: Press [ENTER] + [FUNCTION] +
(11 within 4 seconds of each other. A display of 00 indicates the counter is
in the program mode which provides' capability for changing code values.
Then press [FUNCTIONJ + the numbered keys required to access and
display any specific code. To change that code's value, press the
appropriate keys followed by [ENTER].
TO CHANGE A PROGRAM: Press [ENTER] + [FUNCTION]+ [I]. A display
of 00indicates the counter is in the program mode. Pressing [ENTER]
permits scrolling through the codes. As [ENTER] is pressed, the next code
will appear and when [ENTER] is released, its value is displayed. If a
displayed value is to be changed, press the numbered keys required to
create the new value, see it displayed and press [ENTER]. The new value
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will be exchanged for the original value and then the next code will be
displayed.
TO EXIT PROGRAMMING: Press [FUNCTION] + [BATCH ONIOFF]. The
display defaults to the batch counter.
CODES
Depending on when the machine was made, there are three possible
passwords for accessing the codes:
Enter Function 1
Enter Function 9
Enter function 1314
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PREGIS
ASTRO SHEETER PROGRAMMING
Change Length:
1.
2.
3.
4.
5.
Press Recipe# Key 1-8
Press ENTER
Enter Length ( example 12.00)
Press ENTER
Press ENTER (not all controllers require this step)
Set Batch
1.
2.
3.
4.
5.
6.
Press Recipe # Key 1-8
Press ENTER
Press FUNCTION
Press BATCH PRESET (Key # 2)
Enter number of sheets
Press ENTER
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To use Batch
Batch must be reset to be used. This will reset the batch count to “0”
1. Press ENTER
2. Press FUNCTION
3. Press BATCH RESET (key # 4)
The Batch Function must be turned on.
1. Press BATCH ON/OFF (batch Light will be illuminated)
To start batch
1. Press AUTOMATICON/OFF
After Batch completion:
To use current batch and restart machine:
1. Press ENTER
2. Press Function
3. Press BATCH RESET (Key # 4)
If you are not going to use batch:
1. Press AUTOMATIC ON/OFF
2. Press BATCH ON/OFF (batch light will go off)