Operating Manual Please Read Before Operating Unit

Transcription

1 Always Moving Forward Operating Manual Please Read Before Operating Unit Model IK10 Pre-Stripper Service and All Spare Parts Available The Eraser Company, Inc. PO Box 4961/ Oliva Drive Syracuse, NY 13221, USA Phone: (315) Fax: (315) Website:

2 SPECIFICATIONS Maximum Strip Length " (101mm) Minimum Strip Length " (0.25mm) Material Size AWG ( mmø) Power...115V 60Hz or 230/240 50Hz single phase also requires 60 PSI air supply Cycle Time...Dependent on strip length, wire size and insulation type Feed Rate...Five selectable feed rates Batching...Up to 5 programmable batches Blades...Carbide tipped blades (Special diamond tipped blades available) Display...2 x 16 character LCD display Interface...Contact closure (Start Signal)/ Cycle Complete Signal Size...27 W x 11 D x 12 H (685mm x 279m x 304mm) Weight...43 lbs. (19.5Kg) Decibel Rating...64 db(a) ORDERING INFORMATION AR0991 (IK10)...115V 60Hz US Plug AR0992 (IK10)...230V 50Hz European Plug AR0993 (IK10)...230V 50Hz UK Plug Blades For Four Blade Head Blades for the IK10 must be p urchased separately. If unsure which blades are appropriate for your application send 20 feet of the material to be stripped to us for a FREE application evaluation. IR Strips film and magnet wire AWG ( mmø) IR Strips film and magnet wire AWG ( mmø) IR Strips film and magnet wire AWG ( mmø) IR Strips film and magnet wire AWG ( ) IR Custom stripping blades send material for sizing Optional parts/accessories PR Air Filter, Regulator and Lubricator AR WS1 Wire Straightener Eraser Company Inc. Syracuse, NY USA Ph: info@eraser.com Fax

3 IMPORTANT SAFETY INSTRUCTIONS READ ALL INSTRUCTIONS WARNING DO NOT OPERATE TOOL UNTIL YOU HAVE READ THOROUGHLY, AND UNDERSTAND COMPLETELY, ALL INSTRUCTIONS, RULES, ETC. ON THIS PAGE, AND IN THE OPERATING MANUAL. WHEN USING ELECTRIC TOOLS, BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE RISK OF FIRE, ELECTRIC SHOCK, AND PERSONAL INJURY, INCLUDING THE FOLLOWING: GROUNDING INSTRUCTIONS In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances. Do not modify the plug provided if it will not fit the outlet, have the proper outlet installed by a qualified electrician. Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The green conductor with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal. Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded. Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool s plug. Repair or replace damaged or worn cord immediately. GENERAL INSTRUCTIONS REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning on. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. DON T USE IN DANGEROUS ENVIRONMENTS. Don t use power tools in damp or wet locations, or expose them to rain. Keep work area well lighted. ALWAYS USE SAFETY GLASSES. Everyday eyeglasses only have impact resistant lenses; they are NOT safety glasses. Also use face or dust mask if cutting operation is dusty. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry that might get caught in moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair. DON T OVERREACH. Keep proper footing and balance at all times. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best performance and to reduce the risk of injury. Follow instructions for lubricating and changing accessories. DISCONNECT TOOL before servicing; when changing accessories, such as blades, wheels, cutters, and like. USE RECOMMENDED ACCESSORIES. Consult the operating manual for recommended accessories. The use of improper accessories may cause risk of injury to persons. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced. DO NOT EXCEED THE MAXIMUM MATERIAL SPECI- FICATIONS. DO NOT OPERATED UNIT WITHOUT GUARDS IN PLACE OR GUARDS NOT IN WORKING ORDER. DO NOT PERFORM MAINTENANCE OR ADJUST- MENTS WITH POWER ON. DO NOT PLACE FINGERS OR APPENDAGES IN OR NEAR OPENINGS IN GUARDS. DO NOT RUN UNIT WITH INCORRECT LINE VOLT- AGE. REFER TO LABEL PLACED OVER I/O SWITCH. DO NOT ALLOW UNTRAINED OR UNQUALIFIED PERSONNEL TO OPERATE UNIT. DO NOT DEFEAT ANY OF THE SAFETY FEATURES DESIGNED INTO THE UNIT. Eraser Company Inc. Syracuse, NY USA Ph: info@eraser.com Fax

4 Model IK10 Pre-Stripper OPERATING INSTRUCTIONS SET-UP Unpack the machine and place it on a solid bench with keypad facing the bench edge. Securely fasten the stripper to a stable surface in line with and as close as possible to a coil winder. There are four 17/64 mounting holes to fasten the unit to a bench. Initial set up and blade installation should be made before connecting unit to a coil winder. Do not connect to air or electricity at this time. Caution: Environmental conditions for proper operation should be F (10 C-40 C) and 30-75% relative humidity. The operation of the IK10 should be in a well ventilated clean environment. This machine is rated for continuous use and is protected with one fuse located in the IEC connector. INSTALLATION OF STRIPPING BLADES Blades for the IK10 must be purchased separately (see ordering information for more details). NOTE: It is very important that the proper blades are used for different wire types and sizes to ensure maximum results. See blade selection ordering information for proper blade selection. The IK10 is shipped with the spider (blade holder) attached to the unit. The garter spring, two Allen wrenches and a remote activation plug are packaged separately in a plastic bag. Before beginning write down the number etched on the side of the blades for use in blade calibration. Open the clear plastic guard covering the spider and shaft. Loosen the four set screws on the front of the spider. Remove the four blade pivot pins from the spider. Position one stripping blade in any of the four slots of the spider, making certain the carbide cutting tip points to the center of the spider. Align the hole in the center of the stripping blade with the hole in the spider. Insert the blade pivot pin fully into spider and tighten set screw. Repeat three times to install the remaining blades. Install the garter spring around the bottom of the blades in the retaining groove. The garter spring holds the blades open. Close the blade guard. Adjusting Wire Guide If the wire guides need to be enlarged open the blade guard to access the guide. Open the blades by turning the knob on the stepper motor and loosen set screw in shaft to remove metal guide. Slide the guide to the left until the front of guide is through the hole in the clear plastic guard. Shift the rear of the guide up between the blades. Using smooth pliers grasp the nylon exit bushing on the front of the gripper and pull out of the gripper plate. Remove the four screws that hold the pedestal guard in place and remove the cover. Pull the rear bushing out of the spindle. Using the Allen wrench provided loosen the set screw that holds the wire guide in the spindle. Manually close 2 of the blades until they are almost touching. Slide the wire guide to the left so it is close to the back of the stripping blades. Be sure the blades will not hit the guide when the blades are in the fully closed position as this could damage the blades by chipping the carbide tips. NOTE: When drilling the bushings care should be taken not to raise burrs that could hinder assembly or damage the wire. LOADING THE WIRE Place the wire to be stripped on the right end of the machine. It is recommended that an Eraser dereeler is used to provide easy and level dereeling of wire through the machine. Consult our website for dereeling equipment. Insert the wire through the rear guide bushing, spindle assembly, stripping blades, gripper and exit bushing until it extends approximately 6 beyond the exit bushing. If material is difficult to get through the spindle assembly spin the blades towards you. This will allow material to pass more easily. CAUTION: KEEP HANDS AND LOOSE CLOTHING AWAY FROM MOVING PARTS. USE GUARDING PROVIDED ON THE MACHINE FOR SAFE OPERA- TION. STARTING MACHINE Select direction of rotation by pressing the rocker switch on the back of the unit. The IK10 can rotate clockwise or counter-clockwise, as viewed from the left hand end of the unit looking at the blades. Ensure that the blade guard is closed and connect the machine to the appropriate power and air sources. The machine requires either 115V, 60Hz(Model AR 0991) or 220V, 50Hz electrical power and a minimum of 60 PSI of dry, lubricated compressed air. The customer must provide a fitting with 1/8 male pipe thread to connect the compressed air. The connecting pipefitting will screw into the female air fitting on the rear of the unit. NOTE: The main cylinder airflow control valve on the left of the unit with the graduated scale controls the amount of pressure that goes to the gripping mechanism. The

5 air pressure is preset at the factory. If the amount of gripping force is undesirable pull gently on the knob to release the lock, turn clockwise or counterclockwise until desired pressure is reached. Turn the machine on using the small switch located on the IEC connector on the back of the machine. The machine will activate and the blades and the table will move to their home positions. The table in its home position is all the way forward and the blades in their home position are all the way open. Calibrate the blades. CALIBRATION OF STRIPPING BLADES After machine goes through the start up procedure the keypad screen will read SELECT BATCH. To calibrate the blades: 1. Press the SETUP the screen will display a batch sequence. 2. Press the ENTER the screen will read ANY KEY TO START CALIBRATION. 3. Press CLOSE the screen will read BLADE 0 ADJUST TO WIRE. If the machine was previously calibrated the screen will read CLOSE MOVES TO (previous wire size in steps). 4. Press CLOSE the blades will close. If you hold the close key the blades will close rapidly. If you repeatedly press the close key the blades will close in steps. When the blade tips come close to the wire, it is recommended you use the step method. Each step is on the diameter. Example: blades at their home position are 0 steps, by increasing the number of steps closes the blades accordingly. (The higher the number of steps, the smaller diameter wire will be stripped.) 5. While holding on to the wire from the other side of the gripper, pull the wire slowly while pressing CLOSE using the step method until the wire begins to be stripped by the stripping blades. 6. When the desired strip is reached press ENTER the screen will read BLADE (blade size in steps) ADJUST TO CLEAR. 7. Press OPEN until the desired clearance diameter is reached. Clearance diameter should only be steps ( ) bigger than the wire size. 8. Press ENTER the screen will read BLADE LAND 0.00 Enter in the land of the blades that are installed in the machine. The first four numbers etched on the blades will tell you the size of the land. Refer to the numbers written down earler during blade installation and the chart belcow = land = land = land 9. Press ENTER the blades will return to the home position and the screen will read SELECT BATCH. PROGRAMMING 1. After the blades are calibrated select batch 1 by pressing ENTER A batch sequence will be displayed. 2. Choose a unit of measure by pressing OPEN to toggle between inches and millimeters. 3. Press ENTER Enter the desired strip length. 4. Press ENTER Choose a feed rate 1-5. Feed rates are preset at the factory, if the feed rates are not sufficient please contact your sales representative for assistance. 5. Press RUN W will be displayed in the upper right of the screen. This means the machine is waiting for an exterior signal from the coil winder or cutting mechanism. 6. Press RUN again to run a cycle to ensure depth of cut is sufficient. If the strip quality is insufficient repeat the blade calibration procedure. When the proper quality is achieved attach the remote activation plug. REMOTE ACTIVATION OF STRIPPER The remote activation plug is packaged separately in a plastic bag. This option should be set up prior to loading the wire into the machine. On the back left of the machine is a jack to provide easy connection to the strip switch of a coil winder. The plug is provided for use with this jack. Brief closure of contact points is all that is required. If closure is maintained the unit will continue to cycle. See chart below for wiring sequence. For wiring information refer to electrical interface guidelines section of this manual. Pin 1 = Start input Pin 2 = Start input low Pin 3 = 12V Pin 4 = Done output Pin 5 = External supply 5V-24V Pin 6 = External ground or Board ground. OPERATION The unit is now ready to attach to your coil winder and begin production.

6 INSULATION PARTICLE REMOVAL On the back of the blade guard assembly is a hose nozzle to accept a dust collection system to remove insulation particles. (See Dust Vacuum section of the Eraser Company website for suitable dust collection units.) On the front of the blade guard assembly, there is a nozzle assembly, which supplies a jet of air to the cutting surface of the stripping blades to help keep these surfaces clean. On the left rear side of the machine there is a finger valve protruding through the cover, this valve controls the amount of air going to the air blast nozzle. MAINTENANCE Caution: Remove mains power source prior to servicing the machine. 1. Rotate bushings if grooves appear. 2. Change stripping blades when they become dull. Return to factory in sets of four for precision sharpening. You can double the blade life by reversing the rotation of the motor after one side of the blade set gets dull. 3. Keep blades as clean as possible at pivot point in spider. 4. Lubricate spindle with lightweight oil in accordance with usage. 5. Keep unit as clean as possible. If needed remove mains power supply and wipe down machine with dry cloth. 6. Place a few drops of oil on the linkage connecting to thrust block and spindle. TROUBLE SHOOTING PROBLEM All insulation is not being removed SOLUTIONS 1. Make sure wire is being pulled straight through machine. 2. Check the sharpness of the blades. 3. Make sure all four blades contact the wire at once. 4. Adjust blade depth lower. See CALIBRA- TION OF STRIPPING BLADES earlier. 5.Make sure all four blades are part of a set (the same identification numbers on them). If blades are mismatched, strip quality will be adversely affected. PROBLEM Some of the wire is being removed along with the insulation. SOLUTION 1. Blade depth set too low. See CALIBRATION OF STRIPPING BLADE section. 2. Make sure the wire is straight, no twists or bends. See Eraser website for information on Eraser model WS1 Wire Straightener. PROBLEM Wire Twists SOLUTIONS 1.Check wire guide for proper fit to conductor being stripped. 2. Lower blade depth. 3. Check that blade is not dull. 4. Check that motor rotation is same as lay of wire being stripped. PROBLEM Wire cuts off SOLUTIONS 1. Raise or Lower blade depth. 2. Check that motor rotation is the same as the lay of the strands in the wire being stripped. 3. Check to see if the blade are chipped or dull. SYMBOLS & DECLARATIONS: GROUND LOCATION: This protective Earth Ground Label is located inside the housing beside the ground wire. This wire is connected to the Power Supply Cable and is wired back through the Mains supply to ground. CAUTION LABEL: Refer to operating instructions before using this unit. High voltage is inside this unit and power must be disconnected before servicing. ON/OFF LABEL: This is the ON/OFF switch. Press I for on and press O for off. This switch is also the anti-start switch. In case of a power outage, this switch must be reset for the unit to operate. ROTATION DIRECTION: Rotation of the head may be reversed by pressing this rotation switch. CE MARKING: Indicates compliance with all applicable EU EMC directives. IMPORTANT: No liability will be incurred by the Eraser Company for injury, death, or property damage caused by a product which has been set up, operated, and/or installed contrary to Eraser s written instruction manual, or which has been subjected to misuse, negligence, or accident, or which has been repaired or altered by anyone other than Eraser, or which has been used in a manner or for a purpose for which the product was not designed.

7 SPECIFICATION PHOTOGRAPHS Coil Winder Blade Guard Spider Pedestal Guard Dereeler Keypad Display Keypad Blade Adjusting knob Rotation Selection On/Off Switch Back view Garter Spring Pivot Pin Set Screw Spider

8 Electrical Interface Guidelines The IK10 provides for a start input signal and a done output signal to the host coil winder machine. Both signals can be interfaced in 2 different ways. The signals are available at the interface receptacle [located on the back of the machine, next to the IEC power entry module, an audio connector type]. A mating 6 pin plug is provided with IK10 so that any wiring arrangement can be accommodated. This connector corresponds to the J15 header on the controller board. The pin designations are as follows: Pin# designation description 1 Start input (high) High voltage initiates cycle LED 6 corresponds to this signal (LED on-pin1 high) 2 Start input (low) External voltage source low 3 Internal +24V Source for contact closure input and internal source for done signal 4 Done signal Goes high when stripping complete 5 Done (+) Internal [from pin 3] or external voltage source (+) 6 Done (-) Done return signal Table 1 When setting up the IK10 for start input and done output signal, the end user needs to decide if an internal or external source is to be used with either signal. Both start input and done output can have an external voltage source, both may have the internal 24V source or a combination is possible. Three jumpers on the controller board are used to program these options [J19, J20 and J21]. Refer to figure 1 for the jumper locations.

9 Start input with internal voltage [contact closure signal] J19 pins 2 & 3 shorted [upper most pins] J20 pins 1 & 2 shorted [lower pins] Contact closure connected to pins 1 & 3 of the interface plug. Start input with external voltage source 5,12 or 15 volt source J19 pins 1 & 2 shorted [lower most pins] J20 pins 2 & 3 shorted [upper] 24 volts or higher [up to a maximum of 80 volts] J19 pins 2 & 3 shorted J20 pins 2 & 3 shorted Same connection as above

10 Done signal with internal voltage source [load limited to 50mA max] J21 pins 1 & 2 shorted [lower] On interface connector: soldier a jumper from pin 3 to pin 5 (internal +24V source to supply the collector of the output NPN transistor) Done signal with external voltage source[maximum of 80Vdc applied] J21 pins 2 & 3 shorted [upper] Eraser Company Inc. Syracuse, NY USA Ph: info@eraser.com Fax

11 Declaration of Conformity for IK10: Declaration of Conformity Application of Council directives: 73/23/EEC,98/37/EC, 89/336/EEC, 93/68/EEC Standards to which conformity is declared: EN , EN55014:1991 EN :1995 Manufacturer's name: Type of equipment: Eraser Company, Inc P.O. Box 4961, Oliva Drive Syracuse, N.Y Pre-Stripper Model No. Serial No. Year of manufacture: I, the undersigned, hereby declare that the equipment specified above conforms to the above Directive(s) and Standard(s). Place: Syracuse, N.Y., USA Date: Signature: Full Name: Marcus BeVard Position: Chief Executive Officer CE MARK-Indicates compliance with all applicable EU EMC Directives as descibed above Eraser Company Inc. Syracuse, NY USA Ph: Fax

12 The Eraser Company, Inc. PO Box 4961/ Oliva Drive Syracuse, NY 13221, USA Always Moving Forward Phone: (315) Fax: (315) Website: IR1181 REV 02/05