JP2000 Jam Preventer Installation and Operation Manual. Manual Number: MC006

Transcription

1 JP2000 Jam Preventer Installation and Operation Manual Manual Number: MC006 Revision Date: September 2007

2 2007 All Rights Reserved. This manual is furnished with the JP2000 Jam Preventer and may only be used or copied in accordance with the terms of purchase. No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Valco Cincinnati, Inc. The information in this manual is furnished for educational purposes only, is subject to change without notice, and should not be construed as a commitment by This manual was written and designed at, 411 Circle Freeway Drive, Cincinnati, Ohio Part Number: MC006 Printed in the USA Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati, Ohio 45246, USA TEL: (1) FAX: (1) Melton S.L.U. Pol. Industrial Agustinos calle G, n Orcoyen, Navarra, Spain TEL: (34) FAX: (34) Valco Cincinnati, Ltd. Unit 7-8 Hortonwood 32 Telford TF1 7YN England TEL: (44) FAX: (44) Valco Cincinnati GmbH Storkower Strasse 6 D Gallun, Germany TEL: (49) FAX: (49)

3 TABLE OF CONTENTS Section 1 - Introduction About this Manual Product Description Section 2 - Safety Information General Information Specific Information Section 3 - Wiring Guidelines Routing Low-Voltage Leads Connecting the Supply of Electrical Power Section 4 - Front Panel & Internals Front-Panel Internal Components Mother Board Master Logic Power Supply (MLPS) Card Scanner Input (JPA Circuit) Card Section 5 - Installation Introduction Mounting the JP Mounting the Product Sensors Mounting the JP Mounting the Product Sensors Adjusting Sensor Sensitivity Testing the Scanner Connecting the Shaft Encoder Connecting the JP Section 6 - Initial Setup Introduction Calculating the Tolerable Sheet Length Conducting Initial System Check Testing the Product Sensors TOC-1

4 Table of Contents MC006 - JP2000 Jam Preventer Manual Section 7 - Operation Introduction System Startup Clearing a Jam Resetting the Product Counter Testing the JP2000 During Operation Section 8 - Maintenance Introduction Interior Maintenance Exterior Maintenance Section 9 - Troubleshooting Introduction Section 10 - Specifications Introduction Section 11 - Part Number List How to Order Parts USA: England: Germany: Spain: Section 12 - Warranty Cold Glue Equipment and Electronic Controls Hot Melt Units, Hoses, Valves, Guns, and Related Equipment Section 13 - Service TOC-2

5 SECTION 1 - INTRODUCTION About this Manual Valco Cincinnati has prepared this manual as an aid for installing, operating, and servicing the JP2000 jam preventer. This manual provides specific information about the unit, and general guidelines and references when discussing other equipment such as glue systems, scanners, encoders, and dispensing valves. If you need more information, contact your Valco Cincinnati sales representative. Product Description The JP2000 jam preventer monitors the relationship of one product to the next as the products move through a machine. The JP2000 s solid-state electronic components and field-replaceable PC boards are housed in a dust-proof, metal cabinet. A signal generator (encoder) provides machine information. This generator is either shaft-driven or driven by the product belt. Retro-reflective product sensors are mounted in jam-susceptible machine locations. The JP2000 uses product location data from these sensors and machine information from a machine-mounted encoder to detect product slippage and butted or overlapped product units. If product positioning and slippage won t cause a product jam, the jam preventer allows machine operation to continue. However, when product slippage or other conditions exceed a preset product slippage allowance, the jam preventer will interrupt product feed and stop the machine. If machine operation is interrupted, lights on the control panel will indicate which product sensor was responsible for triggering the machine-stop circuit. The jam preventer will automatically re-arm when the machine is re-started. The JP2000 will provide jam protection with only one product sensor mounted along the product path. However, jam protection can be expanded and customized on each machine by placing as many as six product sensors in jam-sensitive locations. Since the sensors operate independently of one another, sensors can be placed in any areas where jams are likely to occur. A relay-interrupt test switch inside the control cabinet allows the JP2000 to be functionally tested during machine operation without interrupting production. A system test button on the control panel, when pressed in, will verify the operation of the control circuitry by shutting the machine down. Figure 1-1. JP2000 Jam Preventer 1-1

6 SECTION 2 - SAFETY INFORMATION General Information It is the purchaser s responsibility to ensure that all local, county, state, and national codes, regulations, rules, and laws relating to safety and safe operating conditions are met and followed. The best safeguard is trained personnel. The purchaser is responsible for providing personnel who are adequately trained to install, operate, and maintain Valco components and systems. This section contains information that is essential to the safety of personnel. The following safety conventions are used to indicate potential safety hazards: This symbol indicates the presence of un-insulated dangerous voltage within the product s enclosure. This voltage may cause electrical shock or fire. Failure to observe precaution may result in death, personal injury, and/or equipment damage. This convention is used to alert the user to important installation, operation, and/or maintenance information. Failure to observe precaution may result in personal injury or death. This convention is used to alert the user to important installation, operation, and/or maintenance information. Failure to observe precaution may result in damage to equipment. Specific Information All personnel involved with the installation, operation, and maintenance of the equipment must read and thoroughly understand the following safety information: When making adjustments or performing checkout procedures, stay clear of any moving mechanical parts and do not touch exposed electrical equipment or electrical connectors. Keep pump cover and electrical enclosures closed except during setup, service, and checkout procedures. Promptly repair or replace all worn or damaged parts. Promptly repair or replace all worn or damaged electrical wiring and equipment wires to avoid danger to personnel. Properly route all electrical wires to avoid danger to personnel and damage to moving parts of machine. Disconnect all power before opening the control. Only qualified personnel should open and service the control. 2-1

7 SECTION 3 - WIRING GUIDELINES Routing Low-Voltage Leads Electrical installation should be accomplished only by experienced service personnel! When routing low-voltage leads, follow these guidelines: Do not route low-voltage leads in the same conduit as wires carrying a high-current load. Do not route low-voltage leads adjacent to, or across wires carrying a high-current load. If low-voltage leads must cross or run parallel to wires carrying high current, keep the leads at least 6" (152 mm) from high-current wires. Do not splice or solder leads. Trim leads to the required length. Leads should be only as long as necessary for installation. All wiring should be in conduits or wireways. Connecting the Supply of Electrical Power Electrical connections should be made only by experienced service personnel! The control must be connected to a clean supply of electrical power. Use a dedicated circuit if possible if a dedicated circuit is not available, do not connect the control to a circuit that supplies high-amperage equipment. Use another circuit such as a lighting circuit. 3-1

8 SECTION 4 - FRONT PANEL & INTERNALS Front-Panel The features of the JP2000 s front panel are described in Table Table 1. Front Panel Features Figure 4-1. Front Panel of JP2000 Item # Name Description 1 POWER switch Input power on/off switch 2 1-amp fuse Main power fuse (1-amp, SLO-BLO) 3 ON LED Power lamp that illuminates when power is on 4 PRODUCTION COUNT window 5 TOLERABLE SHEET LENGTH window 6 ARMED LED 7 STOP TEST button 8 JAM LOCATION LEDs 9 PERCENT OF ALLOWABLE SHIPPAGE Window that displays the number of products counted by the product counter Contains thumbwheel switches used by the operator to set jamprevention parameters for each product. These switches are also used to increase or decrease jam-prevention sensitivity. Indicator light that illuminates to indicate that the jam-prevention system is operational Test button that is used to verify that the jam-preventer circuitry is operational. Pressing the STOP TEST button stops the parent machine. Six indicator lights, one of which will illuminate when conditions that might produce a jam are detected at that sensor location Currently not used. (On JP2000C units, the product counter will be mounted in this location.) 4-1

9 Section 4 - Front Panel & Internals MC006 - JP2000 Jam Preventer Manual Internal Components The JP2000 contains the following internal components: Mother board Master Logic Power Supply (MLPS) card Scanner input card (also called JPA circuit card) The MLPS card (Figure 4-3) and the scanner input card (Figure 4-4) both contain circuitmonitoring LEDs. Mother Board Figure 4-2. Mother Board Item # Name Description 1 Master Logic Power Supply (MLPS) card 2 Scanner input (JPA circuit) card 3 Scanner and encoder inputs 4 Stop-circuit and feed-interrupt circuit Supplies power to JPA circuit cards, and controls the relay circuit. Card containing two input LEDs that illuminate when product is under the product sensor. There is one JPA circuit card for each two product sensors. A maximum of three JPA circuit cards can be installed in each control. Place where scanners and encoder are connected to the JP2000. Place where signal from parent machine is connected to the JP2000 to actuate the stop-circuit and feedinterrupt features. 4-2

10 MC006 - JP2000 Jam Preventer Manual Section 4 - Front Panel & Internals Master Logic Power Supply (MLPS) Card Figure 4-3. MLPS Card Item # Name Description 1 +12V power-supply LED 2 +15V power-supply LED 3 Minimum-speed LED 4 English/Metric mini-jumper 5 Pulse-generator mini-jumper Illuminates when the power is on and the 12-volt regulator is working. Illuminates when the power is on and the 15-volt regulator is working. When illuminated, indicates that machine is operating and that pulses are being received from the pulse generator. Minimum speed is factory-set at the lowest possible setting and is not field-adjustable. Allows either English (inch) or Metric (mm) measurements to be used and displayed. Allows either a line-shaft encoder or a belt-driven pulse generator to provide machine information to the JP

11 Section 4 - Front Panel & Internals MC006 - JP2000 Jam Preventer Manual Scanner Input (JPA Circuit) Card 1 Figure 4-4. Scanner Input Card Item # Name Description 1 Input LEDs Illuminate when product is under the product sensor. The LED for sensor number 1 on the first JPA card will have a slight glow even though the sensor on the machine is not activated. The LED will get brighter when sensor number 1 is activated. 4-4

12 SECTION 5 - INSTALLATION Introduction This section contains both mechanical and electrical installation instructions for the JP2000 jam preventer. Read the Safety Information section and the Wiring Guidelines section of this manual before performing the following procedures. Electrical work should be done only by experienced service personnel! Otherwise, death, personal injury, or equipment damage could occur. Mounting the JP2000 To mount the JP2000 unit, follow these steps: Mount the control cabinet to a stationary (non-vibrating) support, using both upper and lower mounting flanges (4 bolts). The control cabinet should be located in a place that minimizes the length of the electrical cables, allows the operator to easily see the front panel indicator and have ready access to the unit, and lets the cabinet door open fully without interference. Mounting the Product Sensors To mount the product sensors, follow these steps: 1. Place product sensors in jam-sensitive areas on the parent machine. If a Valco Flexoseal gluing system is controlling the gluing operations of the parent machine, Valco recommends connecting the existing Flexoseal product sensor to the JP2000 unit. This is because if scrap builds up under the Flexoseal product sensor, it generally inhibits the application of glue. However, if the JP2000 receives the same information from the Flexoseal product sensor, it will interpret the information as a slipped board and will shut the parent machine down before any unglued units are processed through the parent machine. For most applications, a universal sensor-mounting bracket is available from Valco. However, in unusual situations, brackets may have to be field-fabricated. 2. Mount the sensors so that they are pointing downward, and so that the face of each sensor is 1-1/2 to 2 inches from the product. Sensors are mounted pointing downward so that dust does not accumulate on the lens. Accumulated dust can interfere with proper sensor operation. 5-1

13 Section 5 - Installation MC006 - JP2000 Jam Preventer Manual 3. Adjust sensor sensitivity so that sensor will not detect objects 1-1/2 inches beyond the product. (See procedure on following page.) If sensor is 2 inches from the product, sensitivity should be adjusted so that it will not detect objects 3-1/2 inches from the face of the sensor (2 inches from sensor to product, plus 1-1/2 inches for allowance beyond the product). Mounting the JP2000 To mount the JP2000 unit, follow these steps: 1. Mount the control cabinet to a stationary (non-vibrating) support, using both upper and lower mounting flanges (4 bolts). The control cabinet should be located in a place that minimizes the length of the electrical cables, allows the operator to easily see the front panel indicator and have ready access to the unit, and lets the cabinet door open fully without interference. Mounting the Product Sensors To mount the product sensors, follow these steps: 1. Place product sensors in jam-sensitive areas on the parent machine. If a Valco Flexoseal gluing system is controlling the gluing operations of the parent machine, Valco recommends connecting the existing Flexoseal product sensor to the JP2000 unit. This is because if scrap builds up under the Flexoseal product sensor, it generally inhibits the application of glue. However, if the JP2000 receives the same information from the Flexoseal product sensor, it will interpret the information as a slipped board and will shut the parent machine down before any unglued units are processed through the parent machine. For most applications, a universal sensor-mounting bracket is available from Valco. However, in unusual situations, brackets may have to be field-fabricated. 2. Mount the sensors so that they are pointing downward, and so that the face of each sensor is 1-1/2 to 2 inches from the product. Sensors are mounted pointing downward so that dust does not accumulate on the lens. Accumulated dust can interfere with proper sensor operation. 3. Adjust sensor sensitivity so that sensor will not detect objects 1-1/2 inches beyond the product. (See procedure on following pages.) If sensor is 2 inches from the product, sensitivity should be adjusted so that it will not detect objects 3-1/2 inches from the face of the sensor (2 inches from sensor to product, plus 1-1/2 inches for allowance beyond the product). 5-2

14 MC006 - JP2000 Jam Preventer Manual Section 5 - Installation Two types of sensors can be used to detect product: Adjusting Sensor Sensitivity Fixed-field sensor Detects all colors, including black; non-adjustable sensitivity, maximum range is 4 inches (100 mm) Scanner with 18-inch lead assembly Detects only light colors, adjustable sensitivity, maximum range is 12 inches (304 mm). To adjust sensor sensitivity on the scanner with 18-inch lead assembly, follow these steps: 1. Remove the clear plastic cover. 2. Turn the potentiometer clockwise (CW) to increase sensitivity or counterclockwise (CCW) to decrease sensitivity. To test the scanner, follow these steps: Testing the Scanner 1. Connect the scanner to the power source and hold an object three inches from the sensor. (The LED on top of the sensor should light up). 2. Move the object so that it is 3-3/4 to 4 inches from the sensor. (The LED on top of the sensor should go out). Connecting the Shaft Encoder A mini jumper on the Master Logic Power Supply (MLPS) card (Figure 5-1) allows either a line-shaft encoder or a belt-driven pulse generator to provide machine information to the JP2000. For a signal input from a stand-alone wheel-driven encoder, the mini jumper must be set to the A side. For a signal input from the Valco Flexoseal pattern controller s shaft-driven or wheel-driven encoder, the mini jumper must be set to the B side. Electrical work should be done only by experienced service personnel! Otherwise, death, personal injury, or damage to equipment could occur. mini jumper Figure 5-1. MLPS Card 5-3

15 Section 5 - Installation MC006 - JP2000 Jam Preventer Manual To connect the shaft encoder, follow these steps: Valco Flexoseal Systems: 1. When the JP2000 is used on a machine equipped with a Valco Flexoseal gluing system, wire the machine information signal from the Flexoseal control into the JP2000 control. 2. Ensure that the mini jumper on the MLPS card is positioned to the B side. Non-Flexoseal Systems: 1. When the JP2000 is used on a machine that is not equipped with a Valco Flexoseal gluing system, install a pulse generator. 2. Connect the pulse generator to the JP2000 control. 3. Ensure that the mini jumper on the MLPS card is positioned to the A side. Connecting the JP2000 Electrical work should be done only by experienced service personnel! Otherwise, death, personal injury, or damage to equipment could occur. To connect the JP2000, follow these steps: 1. Wire the JP2000 (120 VAC or 240 VAC) as shown in Figure 5-2 (JP200 with time delay) or Figure 5-3 (JP200 withou time delay). 2. Connect the JP2000 to a clean power supply. Whenever possible, use a dedicated circuit. If a dedicated circuit is not available, do not connect control to a circuit that operates highamperage equipment. Use another circuit such as a lighting circuit. 3. Place the encoder lead, the product-sensor leads, and the machine and product-feed interrupt wiring near the JP2000 unit. Before cutting entry holes in cabinet, ensure that the drill will not hit internal components. Otherwise, damage to equipment could occur. Remove printed circuit cards if necessary. 4. Cut the required number of entry holes in the JP2000 cabinet. Leads and wires should enter the control cabinet through holes cut in the bottom of the cabinet. Entry holes may be cut on top or in sides, but this is less desirable. Entry holes should be cut in the top only when absolutely necessary, and then positive sealing connectors must be used. 5-4

16 MC006 - JP2000 Jam Preventer Manual Section 5 - Installation 5. Connect the Flexoseal encoder as shown in Figure 5-2 or Figure 5-3. Certain older Flexoseal units will require minor re-wiring if they are to be used with the JP Connect the product-sensor leads as shown in Figure 5-2 or Figure Connect the machine and product-feed interrupt wiring as shown in Figure 5-2 or Figure Check wiring to ensure that proper connections have been made, and that all wires and leads are securely connected. 5-5

17 Section 5 - Installation MC006 - JP2000 Jam Preventer Manual Figure 5-2. Customer Connections for JP2000 with Time Delay (999DX077-59) 5-6

18 MC006 - JP2000 Jam Preventer Manual Section 5 - Installation Figure 5-3. Customer Connections for JP2000 without Time Delay (999XC077-23) 5-7

19 SECTION 6 - INITIAL SETUP Introduction This section contains procedures for conducting initial setup of the JP2000 system. Calculating the Tolerable Sheet Length The first thing you need to do is calculate the tolerable sheet length. To calculate the tolerable sheet length, follow these steps: 1. Select a sample of the product to be run, and measure its length. 2. Calculate the tolerable sheet length by adding 3 inches (8 centimeters) to the product length. This formula should be used to set up an average sensitivity to potential jamming conditions. If greater or less sensitivity is desired, the tolerable sheet length setting on the control can be increased or decreased in increments of 1 inch (or 1 centimeter) until desired sensitivity is reached. Increasing the tolerable sheet length will decrease the sensitivity of the jam preventer. This may result in some machine jams because the jam preventer will allow marginal conditions to pass without shutting the machine down. Decreasing the tolerable sheet length will make the system more sensitive to conditions that might cause product jams. This may result in more machine shutdowns. 3. Using the thumbwheel switches, enter the tolerable sheet length in the TOLERABLE SHEET LENGTH window on the front panel of the JP2000. Controls will typically be shipped with two thumbwheel switch-banks for units set up for English measurements, and three thumbwheel switch-banks for units set up for metric measurement. 4. Ensure that English-Metric jumper on MLPS card (Figure 6-1) is correctly positioned. 5. Ensure that the pulse-generator mini jumper (Figure 6-1) on the MLPS card is correctly positioned. 6. Ensure that the relay interrupt switch inside the JP2000 cabinet (Figure 6-2) is set to the ON position. 6-1

20 Section 6- Initial Setup MC006 - JP2000 Jam Preventer Manual English/Metric mini jumper Pulse-generator mini jumper Figure 6-1. MLPS Card Relay-interrupt switch Figure 6-2. Relay-Interrupt Switch inside JP2000 Cabinet 6-2

21 MC006 - JP2000 Jam Preventer Manual Section 6 - Initial Setup Conducting Initial System Check After calculating the tolerable sheet length, you need to conduct a system check. To conduct an initial check of the system, follow these steps: 1. With the parent machine not operating, turn on the power to the JP Ensure that the power light on the front panel, and the +12-volt and +15-volt LEDs inside the cabinet are all illuminated. 3. Turn the parent machine on and operate at low speed. (The Armed light on the control panel should illuminate.) Testing the Product Sensors Each product sensor should be tested by simulating a product jam. To test the product sensors, follow these steps: 1. With the parent machine running, hold a piece of paper in front of the product sensor until the JP2000 detects a jam. 2. Ensure that the parent machine shuts down, and that the appropriate jam location indicator light on the front panel of the JP2000 illuminates. If the parent machine does not shut down, see the Troubleshooting section of this manual 3. Restart the parent machine (the JP2000 re-arms when the parent machine is restarted). 4. Repeat the above steps for each product sensor. 6-3

22 SECTION 7 - OPERATION Introduction After setting up the system and performing the initial check, the JP2000 is ready for operation. This section contains the procedures for operating the system. System Startup To start the JP2000, follow these steps: 1. Turn on the JP Using the thumbwheel switches, enter the tolerable sheet length in the TOLERABLE SHEET LENGTH window on the front panel of the JP2000. A maximum of 3 inches (8 cm) can be added to the total product length. 3. Start the parent machine. The red scanner lights should go out and the green ARMED light should illuminate. Clearing a Jam Jams are caused by butted or overlapped products. To clear a jam, follow these steps: 1. Remove the items that caused the shutdown, or reposition them in order to provide space between the units. Otherwise, the same two overlapped units will shut down the machine again when they get to the next product sensors. Another way to clear a jam is to turn the jam preventer off temporarily until the overlapped or butted boards have passed all of the product sensors. 2. If product jams continue to occur, increase the value of the tolerable sheet length on the control panel thumbwheel switch. This causes the control to be less sensitive to conditions that may cause jams. 7-1

23 Section 7 - Operation MC006 - JP2000 Jam Preventer Manual Resetting the Product Counter The JP2000C includes a product counter, which is mounted in the door of the jam preventer, and is powered by two 1.5-VDC size-n batteries that are installed in the rear of the counter case. (Estimated battery life is 2-5 years.) The product counter input signal is factory-wired. Each time the counter receives a signal, the counter s memory circuit is indexed, and the updated count is presented on the LCD display. The six-digit numerical display will count up to 999,999 before automatically resetting to zero. To reset the product counter for a new production run, follow these steps: 1. Press the red reset button located to the right of the display. (The counter will reset to zero). The counter can also be factory-wired to a keyed reset or to a remote location reset button. Since the counter is battery operated, the counter will stay on even when power to the control is turned off. However, the counter will add an additional one to three units to the displayed total each time the control is turned on or off. 7-2

24 MC006 - JP2000 Jam Preventer Manual Section 7 - Operation Testing the JP2000 During Operation The JP2000 can be tested during operation without interrupting production. Turn the power switch on the front panel of the JP2000 unit to the OFF position before opening the unit. Otherwise, death, personal injury, or equipment damage could occur. Only qualified personnel should open and service the control. Otherwise, death, personal injury, or equipment damage could occur. To test the JP2000, follow these steps: 1. Turn the relay-interrupt switch inside the cabinet (Figure 7-1) to the OFF position. 2. Turn the power switch on the front panel of the JP2000 unit (Figure 7-2) to the ON position. The number of JPA circuit boards in the JP2000 control (that is, 1, 2, or 3) determine the number of red lights that will initially illuminate on the front door assembly. Each JPA circuit board controls two red jam location lights. For example, if your control has two JPA circuit boards, jam location lights 1-4 will illuminate, even if you are using less than four scanners for jam prevention. As soon as the machine starts and the JP2000 receives an encoder signal, the red jam location lights will go out and the green ARMED light will illuminate. (This takes approximately 3 seconds.) 3. Test each product sensor by watching the LED lights on each JPA circuit board. The lights will illuminate each time the scanner is activated and go out when the scanner is deactivated. If a jam occurs during testing, the red JAM LOCATION LED (or LEDs) will illuminate. However, since the JP2000 is in the test mode, the jam preventer will not shut down the parent machine. 4. After testing is complete, turn the power switch on the front panel of the JP2000 unit to the OFF position. 5. Turn the relay-interrupt switch inside the cabinet to the ON position. 6. Turn the power switch on the front panel of the JP2000 unit to the ON position. 7-3

25 Section 7 - Operation MC006 - JP2000 Jam Preventer Manual relayinterrupt switch power switch Figure 7-1. Relay-Interrupt Switch inside JP2000 Cabinet Figure 7-2. Power Switch on Front Panel of JP

26 SECTION 8 - MAINTENANCE Introduction This section contains maintenance procedures for the JP2000. Interior Maintenance To clean the interior of the JP2000, follow these steps: 1. Turn off the main power. 2. Vacuum dust and dirt from the inside of the control box. 3. Wipe the interior of the control box with a soft cloth. The control cabinet door should stay closed when the unit is not being worked on. Exterior Maintenance Never hose or steam-clean the unit. If surrounding area is to be hosed or steam-cleaned, protect the unit by covering it with plastic or other protective material. To clean the exterior of the JP2000, follow these steps: 1. Turn off the main power. 2. Clean the outside of the cabinet with a mild soap-and-water solution. 3. To protect the finish, wax the cabinet with an automotive-type wax. 8-1

27 SECTION 9 - TROUBLESHOOTING Introduction This section contains troubleshooting procedures for the JP2000 jam preventer. Problem Possible Cause Possible Solution 1. Parent machine starts and then shuts down immediately. 1a. Machine is jammed. 1b. An obstruction under the scanner is causing the scanner to shut down the machine. 1c. One of the product sensors is incorrectly sensing a jam. 1d. System is incorrectly wired. 1e. Relay fuse is blown. 1a. Remove jam. 1b. Remove obstruction. 1c. Check contorl panel to identify sensor. Check sensor operation. 1d. Check wiring. 1e. Replace fuse. Jam preventer does not operate: 1. No lights or LEDs are illuminated. 2. The power light is on, but the DC. LEDs in the cabinet are not operating. 3. The power light is on, but the "armed" light is not illuminated. 1a. Unit is turned off. 1b. Power plug is not plugged in. 1c. AC power service is interrupted. 1d. Fuse is blown. 1e. There is a break in wiring circuit. 1f. Wiring is incorrect. 2a. Wiring is incorrect. 2b. Voltage input is incorrect. 2c. Transformer is malfunctioning. 3a. Arming circuit is not armed. 3b. Signal generator (encoder) is malfunctioning. 3c. MLPS PC board is malfunctioning 1a. Turn unit on. 1b. Plug unit in. 1c. Check plant power. 1d. Replace fuse. 1e. Check wiring. 1f. Check wiring. 2a. Check wiring. 2b. Check volltage. 2c. Replace transformer. 3a. Shut machine down and allow it to come to a stop. Restart machine. 3b. Check setup and output of signal generator. 3c. Replace PC board. 9-1

28 Section 9 - Troubleshooting MC006 - JP2000 Jam Preventer Manual Problem Possible Cause Possible Solution Miscellaneous: 1. Jam preventer continuously shuts the machine down. 2. The machine jams but the preventer is not causing the shutdown. 3. Jam preventer product counter does not operate. 1a. Sensor is detecting an object. 1b. Sensor is incorrectly signaling a product jam. 1c. The tolerable sheet length is set incorrectly. 1d. The sensitivity of the tolerable sheet length is set incorrectly. 1e. The English or metric jumper is on the incorrect pins. 1f. Signal generator is malfunctioning. 1g. Wiring is incorrect. 1h. JPA card is malfunctioning. 2a. The tolerable sheet length is set incorrectly. 2b. The sensitivity of the tolerable sheet length is set incorrectly. 2c. Arming circuit is not armed. 2d. Fuse is blown. 2e. The relay interrupt test switch is turned off. 2f. Relay is defective. 2g. Wiring is incorrect. 2h. Sensor or JPA circuit card is malfunctioning. 3a. Batteries are run down. 3b. The signal input lead is disconnected or broken. 3c. Product counter is defective. 1a. Remove object. 1b. Check operation of sensors. 1c. Remeasure product and reset dimension. 1d. Decrease sensitivity by increasing tolerable sheet length. 1e. Reposition mini jumper. 1f. Check signal generator setup and output. 1g. Check wiring. 1h. Replace JPA card. 2a. Remeasure product and reset dimension. 2b. Increase sensitivity by reducing tolerable sheet length. 2c. Shut machine down and allow it to come to a stop. Restart the machine. Check setup and output of signal generator, and encoder signal from pattern control. Replace MLPS circuit board. 2d. Replace fuse. 2e. Turn the switch on. 2f. Replace the relay. 2g. Check wiring. 2h. Check LEDs on JPA card. If not operating properly, replace sensor. If operating properly, replace JPA card. 3a. Replace batteries. 3b. Check lead. 3c. Replace product counter. To test operation of the product counter, touch the black wire to the white wire. The product counter should index each time the wires are touched. To reset the counter, hold the black and yellow wires together and push the reset button. 9-2

29 SECTION 10 - SPECIFICATIONS Introduction This section contains specifications for the JP2000. Model: Enclosure: Width: Height: Depth: Power Requirements: Input: Output: Special Features: JP2000 with product counter Sheet metal cabinet to JIC NEMA type-12 specifications 10.5" (267 mm) 11.5" (292 mm) 6.25" (159 mm) 120/240 VAC Retro-reflective product sensor (1 to 6 sensors can be used) Double-pole mechanical relay (normally open/normally closed) Internal circuit monitoring LEDs Jam location indicator lights on the control panel Internally mounted mini-jumper for English or metric machine operation "Armed" indicator lights on control panel Option to use either shaft-mounted or conveyor-belt-driven pulse generator Optional 6-digit LCD on product counter located on control panel (remote reset button or key reset also available) 10-1

30 SECTION 11 - PART NUMBER LIST How to Order Parts USA: 411 Circle Freeway Drive Cincinnati, OH TEL: (513) FAX: (513) sales@valcomelton.com Web: England: Valco Cincinnati Limited Hortonwood 32 Telford, TFI 7YN, England TEL: (+44) FAX: (+44) sales@valco.co.uk Web: Germany: Valco Cincinnati GmbH Storkower Strasse 6 D Gallun, Germany TEL: (+49) FAX: (+49) info@valcogmbh.de Spain: Melton S.L.U. Pol. Industrial Agustinos calle G, n Orcoyen, Navarra, Spain TEL: (34) FAX: (34)

31 Section 11 - Part Number List MC006 - JP2000 Jam Preventer Manual Part Number Description 077xx403 Jam preventer, 120VAC, inch calibration, one JPA card 077xx407 Jam preventer, 120VAC, metric calibration, one JPA card 077xx405 Jam preventer, 240VAC, inch calibration, one JPA card 077xx409 Jam preventer, 240VAC, inch calibration, one JPA card 077xx410 Jam preventer, 120VAC, inch calibration, one JPA card and delay/stop/relay option 030xx016 Interconnect cable to interface the JP2000 with a Flexoseal control, 66 feet (20m) 155xx009 Pulse generator and wheel for free-standing JP2000, inch calibration, 12 pulses 155xx008 Pulse generator and wheel for free-standing JP2000, metric calibration, 33.3 pulses 578xx403 Pulse generator mounting bracket 030xx017 Pulse generator connector cable, 33 feet (10m) 151xx040 JPA scanner interface board 151xx039 Master logic power supply (MLPS) board 151xx044 Motherboard assembly 481xx006 Thumbwheel switch with ribbon cable, inch calibration 481xx007 Thumbwheel switch with ribbon cable, metric calibration 033xx008 Ribbon cable assembly 551xx003 Transformer 160xx005 Relay, stop/feed interrupt 085xx005 Fuse, 1-amp, SLO-BLO (package of 5) 085xx008 Fuse, 3-amp, SLO-BLO (package of 5) 11-2

32 MC006 - JP2000 Jam Preventer Manual Section 11 - Part Number List Part Number 036xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx537 Description Delay/stop/relay assembly with wiring harness Adjustable relay for delay/stop option Pulse generator, inch calibration, 12 pulses Pulse generator, metric calibration, 33.3 pulses Measuring wheel, inch calibration Measuring wheel, metric calibration Power on/off switch Fuse holder assembly White neon light, 110VAC (power light) Lamp socket Lamp cap LED indicator Fixed-field scanner (normally recommended) Standard scanner Fixed-field scanner bracket Standard scanner bracket Scanner cable, 33 feet (10m) Scanner cable, 66 feet (20m) Production counter Battery, 1.5VDC (for production counter) 11-3

33 SECTION 12 - WARRANTY Cold Glue Equipment and Electronic Controls Liability of the company is limited to repair of the product, or replacement of any part shown to be defective, and does not extend to defects caused by accidents, misuse, abuse, neglect, tampering or deterioration by corrosion. This warranty does not cover those items determined by to be normal wear items such as seals, O-rings, diaphragms, springs, etc. Reconditioned equipment, unless specified otherwise at the time of purchase, will be warranted as described above for a period of ninety (90) days from the date of shipment by Valco Cincinnati. Components purchased by from others for inclusion in its products are warranted only to the extent of the original manufacturer s warranty. In no event shall be liable for indirect or consequential damages arising out of the use of Valco Cincinnati products. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to Valco Cincinnati, Inc. for examination and verification. If claimed defect is verified, repairs or replacements will be made F.O.B. Cincinnati, Ohio, U.S.A. or ex-works Telford, U.K. If the inspection of the equipment does not disclose any defect of workmanship or material, any necessary repairs will be made at a reasonable charge and return transportation will be charged. This is the only authorized warranty and is in lieu of all other expressed or implied warranties, representations or any other obligations on the part of The warranty for cold glue equipment and electronic controls is for a period of one (1) year from the date of shipment by Hot Melt Units, Hoses, Valves, Guns, and Related Equipment All hot melt components except cast-in heating elements are warranted for a period of six (6) months from the date of shipment by Valco Cincinnati. Cast-in heaters carry an additional, pro-rated warranty not to exceed three (3) years from the date of shipment by ValcoMelton, a company. 12-1

34 SECTION 13 - SERVICE If a problem with your system persists, contact a ValcoMelton Technical Support representative. If your need is urgent, we encourage you to contact our corporate office in Cincinnati, Ohio, U.S.A. at (513) If the problem cannot be resolved, Valco Cincinnati will promptly arrange to have a technical representative visit your facility. Any charges for a service call will be quoted at that time. Any part that fails during the warranty period shall be returned prepaid to by the customer for disposition. NOTE: Upon request, ValcoMelton personnel are available to repair or replace such parts at the customer s facility. Charges for this service include travel time and expenses. If an equipment problem is the result of customer abuse, improper installation or operation, all travel time, labor, parts, and expenses will be charged to the customer. If the responsibility for a problem cannot be absolutely determined, the customer will be charged for travel time and expenses only. No charge will be made for parts and labor. 13-1