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FIFE GUIDING SOLUTIONS
FIFE-500-XL
Installation and Service Manual
EN
MI 1-917 1 C
Medium Web Guiding System
CONTENTS
SAFETY INSTRUCTIONS .......................................................................... 2-1
MODEL NUMBER KEY ............................................................................. 5-1
SERVICE AND REPLACEMENT PARTS ........................................................ 7-1
www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
1–1
About these operating instructions
INTRODUCTION
All of the information herein is the exclusive proprietary property of Maxcess International, and is disclosed with the understanding that it will be retained in confidence and will neither be duplicated nor copied in whole or in part nor be used for any purpose other than for which disclosed.
Copyright 2013, all rights reserved.
Periodically there will be updates to this manual. The latest version is available at
www.maxcessintl.com
or by calling your regional office. See back page for phone numbers.
These web guiding systems must not be installed or used in a machine or system which does not comply with the machinery directive 2006/42/EC.
These web guiding systems were designed and manufactured to be installed as Partly Completed Machinery into a machine or partly completed machine.
The instructions must be read and used by all persons who have the responsibility of installing and maintaining these web guiding systems.
These instructions must be retained and incorporated in the technical documentation for the machine or partly completed machinery into which the web guiding system is installed.
Language
These are the original instructions, written in English.
CE marking
The FIFE-500-XL complies with the 2006/42/EC Machinery directive and the 2004/108/EC Electromagnetic Compatibility directive.
Conventions used
All dimensions and specifications are shown in the format millimeters [inches] unless otherwise specified. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
1–2
Product overview
INTRODUCTION
The FIFE-500-XL web guiding system is a complete offset pivot guide and controller in a compact package with an IP54 environmental rating. The FIFE-500-XL is available in many standard roll face, guide span and roller diameters.
The web guiding system is designed for continuous use. The web guiding system has two sensor inputs, a color touchscreen operator interface, and parallel inputs and outputs for remote control and alarms. The web guiding system controls the position of the web by monitoring the web position with sensors mounted on the web path and driving an actuator connected to the guide assembly to steer the web to the desired position. The web guiding system includes a servo center transducer to position the guide parallel to the web path for web threading.
The web guiding system works with most Fife sensors. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
2–1
Instructions for use
SAFETY INSTRUCTIONS
To ensure safe and problem free installation of the web guiding system, the web guiding system must be properly transported and stored, professionally installed, and placed in operation.
Proper operation and maintenance will ensure a long service life of the device. Only persons who are acquainted with the installation, commissioning, operation, and maintenance of the system and who possess the necessary qualifications for their activities may work on the web guiding system.
Note: The safety information may not be comprehensive.
Please note the following:
The content of these operating instructions
Any safety instructions on the device
The machine manufacturer’s specifications
All national, state, and local requirements for installation, accident prevention and environmental protection
Safety symbols
Information about safety instructions
The safety instructions and symbols described in this section are used in these operating instructions. They are used to avoid possible dangers for users and to prevent material damage.
SIGNAL WORD
Source of danger and its results
Avoiding dangers
The signal word DANGER refers to the danger of death or serious bodily injuries.
The signal word WARNING refers to the danger of moderate to severe bodily injuries.
The signal word CAUTION refers to the danger of slight to moderate bodily injuries or material damage.
The signal word NOTICE refers to the possibility of damage to equipment. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
2–2
Symbols used
SAFETY INSTRUCTIONS
The following safety identification symbols are used in these operating instructions.
WARNING/CAUTION – General danger or important note
Reference to general hazards that may result in bodily injuries or damage to device or material.
WARNING/CAUTION – Danger due to crushing
Reference to danger of injury caused by crushing.
WARNING/CAUTION – Danger due to cutting
Reference to danger of injury caused by cutting.
WARNING/CAUTION – Danger due to voltage, electric shock
Reference to danger of injury caused by electric shock due to voltage.
WARNING/CAUTION – Danger due to hot surfaces
Reference to risk of injury caused by burning. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
2–3
Basic safety information
SAFETY INSTRUCTIONS
Proper use
The web guiding system is intended to be used on machines or systems to guide a web of material.
Indoor operation: see environmental specifications
Improper use
Operation outside the technical specifications
Operation in an Ex-area or intrinsically safe area
Operation as a safety component. The web guiding system does not hold the web position if power fails.
Outdoor operation
Any other use than the proper use shall be deemed inappropriate.
Installation and commissioning
Any web guiding system which is damaged must not be installed or put into operation.
Only perform installation, maintenance or repair tasks on the web guiding system when the machine has been stopped and is secured from being turned on.
Only perform installation, maintenance or repair tasks on the web guiding system when there is no electrical power in the system.
The web guiding system must be securely mounted before being placed in operation.
Only replacement parts obtained from Fife may be used.
No modifications may be made to the web guiding system.
Do not place electrical cables under mechanical strain.
WARNING – Death or injury can result from static electric shocks.
Moving webs of material can produce large static voltage potentials. Protect against electric shocks by installing a conductive connection between the terminal marked with the PE symbol on the power connector and the PE circuit of the building or machine.
WARNING – The web guiding system contains rotating and moving parts which could cause injury due to crushing. Appropriate protective guards must be installed by the user according to his use of this product. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
2–4 SAFETY INSTRUCTIONS
WARNING – Death or injury can result from unexpected movement.
Protect against unexpected movement by removing electrical power from the web guiding system and the machine into which the web guiding system is being installed.
WARNING – Danger of falling down or muscle or skeletal injury during installation.
These web guiding systems, especially the larger designs, are heavy.
Appropriate equipment is to be used and the safety rules of the company must be observed.
Operation
WARNING – The web guiding system contains rotating and moving parts which could cause injury due to crushing. Do not touch anything on or in the vicinity of the moving or rotating parts.
Appropriate protective guards must be installed by the user according to his use of this product.
Maintenance and repair
WARNING – Death or injury can result from unexpected movement.
Protect against unexpected movement by removing electrical power from the web guiding system and the machine into which the web guiding system is installed.
WARNING – Danger of injury from crushing.
Maintenance and repair tasks on the web guiding system must be performed only when the machine has been stopped and has been secured from being turned on again.
WARNING – Danger of falling down or muscle or skeletal injury during maintenance and repair.
These web guiding systems, especially the larger designs, are heavy.
Appropriate equipment is to be used and the safety rules of the company must be observed.
Decommissioning
The web guiding system must be disposed of in accordance with all the applicable national, state and local regulations. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–1
Mechanical installation
INSTALLATION
www.maxcessintl.com
WARNING – Death or injury can result from unexpected movement.
Protect against unexpected movement by removing electrical power from the FIFE-500-XL and the machine into which the FIFE-
500-XL is installed.
WARNING – Danger of injury from crushing.
Maintenance and repair tasks on the FIFE-500-XL must be performed only when the machine has been stopped and has been secured from being turned on again.
WARNING – Danger of falling down or muscle or skeletal injury during maintenance and repair.
These web guiding systems, especially the larger designs, are heavy. Appropriate equipment is to be used and the safety rules of the company must be observed.
Install the FIFE-500-XL Web Guiding System in the process line such that the rollers, when in the Servo-Center position, are parallel to the entry and exit rollers.
The FIFE-500-XL must be installed on a flat, machined surface that is flat within 0.5 [0.02] total indicated runout.
Ensure that the WEB DIRECTION ARROW on the guide is pointed in the direction of web travel.
See Figure Sheet 1-558 for factors to consider on where and how to install the FIFE-500-XL Web Guiding System for the best guiding results.
Integrated sensor mounting is provided for wrap styles exiting towards the base only. Remote sensor mounting must be used for other wrap styles.
T-nut blocks are delivered in their outermost positions, but are adjustable. To adjust, loosen the clamping screws, adjust the location of the T-nut block(s), then tighten the clamping screws to 3.3 Nm [29 in-lb] of torque after adjustment. See
Figure 1.
Guide will be secured to the machine frame using six customer supplied M8x1.25 bolts. After securing the T-nut blocks in the proper location the M8x1.25 bolts will come up through the machine frame and screw into the T-nut blocks.
FIFE-500-XL MI 1-917 1 C
3–2 INSTALLATION
Installing the FIFE-500-XL
'B'
Ø
'C'
16 [0.630]
8.5 [0.335]
'A'
272.5 [10.728]
1 2
47.5 [1.870]
'W'
'Z'
3
4
1 T-nut block, 6X
2 T-nut channel, 2X
3 Clamping screw, 6X
4 M8x1.25, 15 [0.59] maximum depth, 6X mounting
5 234.5 [9.232], mounting
6 ‘W’-64 [2.520] maximum, mounting
Figure 1. FIFE-500-XL with integrated sensor mounting www.maxcessintl.com FIFE-500-XL
6
MI 1-917 1 C
3–3 INSTALLATION
Mounting dimensions
Roll Face
‘A’ mm [inch]
(1)
Guide Span
‘B’ mm [inch]
(1)
Roll
Diameter
‘C’
Mm [inch]
Width
‘W’ mm [inch]
Dimension
‘S’ mm [inch]
Dimension
‘T’ mm [inch]
Dimension
‘Z’ mm [inch]
Max
Weight kg [lbs]
(2)
300
[11.81]
350
[13.78]
400
[15.75]
500
[19.69]
600
[23.62]
700
[27.56]
400 [15.75]
500 [19.69]
400 [15.75]
500 [19.69]
400 [15.75]
500 [19.69]
600 [23.62]
400 [15.75]
500 [19.69]
600 [23.62]
400 [15.75]
500 [19.69]
600 [23.62]
400 [15.75]
500 [19.69]
600 [23.62]
80 [3.150]
100 [3.937]
80 [3.150]
100 [3.937]
80 [3.150]
100 [3.937]
80 [3.150]
100 [3.937]
80 [3.150]
100 [3.937]
80 [3.150]
100 [3.937]
365
[14.370]
469
[18.465]
629
[24.764]
82.75 [3.258]
132.75 [5.226]
82.75 [3.258]
132.75 [5.226]
82.75 [3.258]
132.75 [5.226]
232.75 [9.163]
82.75 [3.258]
132.75 [5.226]
232.75 [9.163]
82.75 [3.258]
132.75 [5.226]
232.75 [9.163]
82.75 [3.258]
132.75 [5.226]
232.75 [9.163]
82.75 [3.258]
132.75 [5.226]
82.75 [3.258]
132.75 [5.226]
82.75 [3.258]
132.75 [5.226]
132.75 [5.226]
82.75 [3.258]
132.75 [5.226]
132.75 [5.226]
82.75 [3.258]
132.75 [5.226]
132.75 [5.226]
82.75 [3.258]
132.75 [5.226]
132.75 [5.226]
520
[20.472]
570
[22.441]
620
[24.409]
720
[28.346]
820
[32.283]
920
[36.220]
400 [15.75] 82.75 [3.258] 82.75 [3.258] 60 [132]
800
[31.50]
500 [19.69]
80 [3.150]
100 [3.937]
132.75 [5.226] 132.75 [5.226]
1020
[40.157]
66 [146]
600 [23.62]
400 [15.75]
829
[32.638]
232.75 [9.163]
82.75 [3.258]
132.75 [5.226]
82.75 [3.258]
73 [161]
68 [150]
900
[35.43]
500 [19.69]
80 [3.150]
100 [3.937]
132.75 [5.226] 132.75 [5.226]
1120
[44.094]
75 [165]
600 [23.62] 232.75 [9.163] 132.75 [5.226] 83 [183]
1) The dimensions A, B, and C may be found from the first three digits of the model number following the characters “MW”.
2) The weight is a maximum with 100 mm rollers and the splice table. The 80 mm rollers reduce the weight by 2% and the removal of the splice table reduces the weight by about
10%.
39 [86]
43 [95]
42 [93]
46 [101]
50 [110]
55 [121]
61 [134]
54 [119]
59 [130]
65 [143]
57 [126]
63 [139]
70 [154]
53 [117]
58 [128]
64 [141] www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–4 INSTALLATION
Guiding parameters
Roll Face
‘A’ mm
[inch]
(1)
300
[11.81]
350
[13.78]
400
[15.75]
500
[19.69]
600
[23.62]
700
[27.56]
800
[31.50]
900
[35.43]
Guide Span
‘B’ mm [inch]
(1)
Max
Correction
‘X’ mm [inch]
400 [15.75]
14.61 [0.58]
500 [19.69]
15.78 [0.62]
400 [15.75]
14.61 [0.58]
500 [19.69]
15.78 [0.62]
400 [15.75]
12.99 [0.51]
500 [19.69]
14.45 [0.57]
600 [23.62]
13.86 [0.55]
400 [15.75]
19.15 [0.75]
500 [19.69]
21.31 [0.84]
600 [23.62]
20.44 [0.80]
400 [15.75]
21.63 [0.85]
500 [19.69]
24.87 [0.98]
600 [23.62]
24.91 [0.98]
400 [15.75]
21.63 [0.85]
500 [19.69]
24.87 [0.98]
600 [23.62]
24.91 [0.98]
400 [15.75]
21.22 [0.84]
500 [19.69]
25.16 [0.99]
600 [23.62]
26.41 [1.04]
400 [15.75]
21.22 [0.84]
500 [19.69]
25.16 [0.99]
600 [23.62]
26.41 [1.04]
Max correction speed mm/sec
[inch/sec]
140 [5.51]
150 [5.91]
140 [5.51]
150 [5.91]
140 [5.51]
150 [5.91]
137 [5.39]
140 [5.51]
150 [5.91]
137 [5.39]
140 [5.51]
150 [5.91]
137 [5.39]
140 [5.51]
150 [5.91]
137 [5.39]
140 [5.51]
150 [5.91]
137 [5.39]
140 [5.51]
150 [5.91]
137 [5.39] www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–5
Pneumatic connection to splice table
INSTALLATION
1. Connect pneumatic lines to the two pneumatic fittings to allow operation of the pneumatic clamp.
2. Operating pressure range for the pneumatic clamp is
34-552 kPa [5-80 psi].
CAUTION – Damage to the pneumatic clamp due to high pressure.
Do not connect an air source of greater than 552 kPa [80 psi] to the pneumatic clamp. Use of a pressure regulator is recommended.
1
2
3
4
5
6
1 Tape dispenser
2 6 mm OD pneumatic tube fitting, 2X
3 Adjustable splice table
4 Locking knob
5 50.8 [2.000], tape width maximum
6 1.5 [0.059] maximum web thickness
7 Ø76.2 [Ø3.000] tape core
8 Customer provided tape
Figure 2. Splice table with tape dispenser www.maxcessintl.com FIFE-500-XL
7
8
152.4 [6.0] MAX
91.0 [3.58]
313.8 [12.356]
256.6 [10.100]
MI 1-917 1 C
3–6 INSTALLATION
Installing the operator interface
Operator interface relocation
The Operator Interface may be mounted on either end of the
Base Assembly. If it is desired to relocate the OI from one end of the Base Assembly to the other, use the following procedure.
1. Disconnect power from the FIFE-500-XL unit.
2. Using a 3 mm Allen wrench, remove the four screws that retain the OI to the Base Assembly end plate.
3. The shroud, which is the spacer between the OI and the end plate, should be retained with the OI.
4. Disconnect the cable between the OI and the Base Assembly.
5. Re-direct the cable with the female connector to the opposite end of the Base Assembly by pulling the cable through the bottom channel of the extrusion.
6. Reconnect the cable to the OI.
7. Route the sensor cable through the appropriate slot in the shroud, then mount the OI with the shroud to the end plate and secure it with the four screws that were removed, previously.
WARNING – Death or injury due to cutting or crushing.
The operator interface should not be used while the machine is running. If it is necessary for the operator to use the operator interface while the machine is running, precautions must be taken to protect the operator from injury due to moving material and machinery. This can be accomplished by either surrounding the operator interface with guarding, or by remote mounting the operator interface in a safe location.
The operator interface can be mounted through a panel or on a wall. See the sections on following pages for details on remote mounting of the OI. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–7
Panel mount model
INSTALLATION
1. Order mounting kit P/N 215802-001 when mounting the
Operator Interface remotely in a panel.
2. Order an Operator Interface extension cable P/N 215680-XXX.
20 meter maximum length.
CAUTION – Never place electrical cables under mechanical strain.
Always provide mechanical support of wiring with either clamps or flexible or rigid conduit.
Units are in millimeters [inches].
124 [4.882]
R4 [0.157] MAX (4X)
1 Operator interface
2 Panel
3 Mounting bracket
4 Panel jack screws
5 Installation cut-out
Figure 3. Operator interface panel mount kit installation www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–8
Wall mount model
INSTALLATION
1. Use existing hardware (guide mounted) when mounting the
Operator Interface remotely on a wall.
2. Order an Operator Interface extension cable P/N 215680-XXX.
20 meter maximum length.
CAUTION – Never place electrical cables under mechanical strain.
Always provide mechanical support of wiring with either clamps or flexible or rigid conduit.
Units are in millimeters [inches].
111 [4.370]
M4 x 0.7 (4X)
87.7 [3.453]
1 Operator interface
2 Operator interface shroud
3 Wall
F igure 4. Operator interface wall mount kit installation www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–9
Electrical installation
INSTALLATION
Reference drawings Description
Wiring diagram
Cable selection chart
Drawing Number
217299
217914
Power connection
Operating voltage range and current rating are listed in
Specifications (Section 6-1), and shown on the label on the base
housing.
All wiring must comply with the essential requirements of the appropriate standard(s) and is the responsibility of the installer.
Wiring to the web guiding system must be insulated copper wire with a temperature rating of at least 80⁰C. The wire size should be
0.82 mm2 (18 AWG).
Note: The negative power connection, pin 2, is internally connected to the PE connection. This connection is only used for
EMC compliance.
1. Power cable is supplied by the customer. For an assembled
5 m (16.4 foot) power cable with connector and gasket, order part number 214658-005.
2. Order the power connector based on the outside cable diameter being used.
Cable Diameter
4.5 [0.177] – 7.0 [0.276]
6.0 [0.236] – 10.0 [0.390]
8.0 [0.315] – 14 [0.551]
Connector Order Number
91074-001
91074-002
91074-003
3. Order the sealing gasket for the power connector, part number 91074-004.
4. Connect a 24 VDC +/-25% power supply to pins 1 and 2 of the power connector. Pin 1 should be positive and pin 2 should be negative. See Figure 5.
5. Connect the PE of the building or machine to the power connector terminal marked with the PE symbol.
See Figure 5.
6. Place the power connector on the mating connector on the web guiding system and secure with the mounting screw.
Be sure the gasket is installed at the mating interface of the connectors. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–10 INSTALLATION
WARNING – Death or injury can result from static electric shocks.
Moving webs of material can produce large static voltage potentials. Protect against electric shocks by installing a conductive connection between the terminal marked with the PE symbol on the power connector and the PE circuit of the building or machine.
CAUTION – Never place electrical cables under mechanical strain.
Always provide mechanical support of wiring with either clamps or flexible or rigid conduit.
1 (+24 V)
2 (24 V GND)
3
1
A A
2
24 V GND
1
2
2
1
+24 V
1
2
18 AWG wire recommended
Gasket
Figure 5. FIFE-500-XL power connection
Section A-A (rear view)
Digital inputs and outputs
Digital inputs and outputs are available for remote control and signalling functions. There are 6 digital inputs allowing control of the following modes External Lock, Automatic, Manual, Servo-
Center, Jog, RGPC, and sensor selection. There are 4 digital outputs and are initially configured as alarms for Loss of Null,
Centered, Motor Blocked, and Power OK. See the following page for the default configuration.
See Figure 6 for terminal connections of the digital inputs and
outputs on the motor controller board located in the base
assembly housing. Figure 7 is the wiring diagram of the
FIFE-500-XL. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–11 INSTALLATION
Table 1. Digital input matrix default configuration
0 = LOW
1 = HIGH
- = IGNORE
Note: To ensure that a command is properly executed, all pertinent inputs for each command must be switched high or low within
20 ms of each other and maintained for at least 30 ms.
EXTERNAL LOCK
AUTOMATIC
MANUAL
SERVO-CENTER
JOG Minus *
JOG Plus *
MODE
-
0
1
-
-
5
-
-
1
0
-
-
4
-
1
-
-
0
0
3
INPUTS
2
- -
0
1
0
-
-
0
-
-
1
0
1
-
RGPC Minus *
RGPC Plus *
RGPC RESET *
Sensor S1 (Single Edge Guiding) **
0
1
1
-
1
0
1
-
-
-
-
0
-
-
-
1
-
-
-
1
Sensor S2 (Single Edge Guiding) ** - - 1 1 0 -
Sensor S1 – S2 (Center-guiding) ** - - 1 1 1 -
*
Inputs 4 & 5 are used to provide Jogs while in Manual and Servo Center modes, and RGPC functions while in Automatic mode.
**
Sensor selection is allowed in Manual and Servo Center modes, only. Sensor selection must be momentary commands.
-
-
-
-
-
-
-
-
-
0
1
WARNING – Death or injury can result from unexpected movement.
If the timing requirements of the digital inputs are not met, unexpected motion of the guide could result when a sensor selection is misinterpreted as a mode change to Servo Center or Auto. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–12 INSTALLATION
Table 2. Digital output matrix default configuration
1 = ACTIVE
- = IGNORE
STATUS D
LOSS OF NULL (AUTOMATIC MODE)
CENTERED (SERVO-CENTER MODE)
MOTOR BLOCKED
POWER OK
* Digitial outputs are active low
-
-
-
1
-
-
1
-
OUTPUTS*
C B
-
1
-
-
A
1
-
-
- www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–13
Wiring diagrams
ENCODER
MOTOR
HALL
SENSORS
ENC_A
ENC_B
GND
+5V
HALL_A
HALL_B
HALL_C
GND
+5V
ORANGE
VIOLET
BLACK
RED
YELLOW
GRAY
GREEN
BLACK
ORANGE
INSTALLATION
7
8
5
6
9
3
4
1
2
MOTOR
COILS
MOTOR_A
MOTOR_B
MOTOR_C
POWER
INPUT
+24V
GND
RED
BLACK
WHITE
RED
BLACK
N.C.
1
2
3
1
2
3
F1 FUSE
Figure 6. Motor controller board connections
MOTOR/
ENCODER
DC
POWER
INPUT
5
1
4
2
3
N.C.
ORG
VLT
BLK
RED
YELLOW
GRAY
GREEN
BLACK
ORANGE
4
5
6
7
8
9
1
2
3
RED
BLACK
WHITE
1
2
3
RED
BLACK
1
2
3
ENC_A
ENC_B
GND
+5V
HALL_A
HALL_B
HALL_C
GND
+5V
X103
+24V
GND
N.C.
CONTROLLER PCB ASSY
MOTOR_A
MOTOR_B
MOTOR_C
X102
X101
X104
PAR_O0
+12V
+12V
PAR_I0
PAR_I1
PAR_I2
PAR_13
PAR_I4
PAR_I5
GND
LINESPEED
GND
RGPC_LED
RS485+
RS485-
GND
OI_+24V
GND
+12V
SENSOR_B
SENSOR_A
+12V
GND
GND
ISCT
-12V
PAR_O3
PAR_O2
PAR_O1
13
12
11
10
17
16
15
14
24
23
22
21
20
19
18
29
28
27
26
25
7
6
5
9
8
2
1
4
3
BLACK
RED
WHITE
WHITE
RED
BLACK
BLU
BRN
BROWN
BLACK
BLUE
WHITE
29
28
27
21
20
19
18
26
25
24
23
22
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
BLACK
RED
WHITE
WHITE
RED
BLACK
BLUE
BROWN
BROWN
BLACK
BLUE
WHITE
GND
+12V
SENSOR_B
SENSOR_A
+12V
GND
GND
ISCT
-12V
OUTPUT D
OUTPUT C
OUTPUT B
OUTPUT A
+12V
+12V
INPUT 0
INPUT 1
INPUT 2
INPUT 3
INPUT 4
INPUT 5
GND
LINESPEED
GND
RGPC-LED
RS485+
RS485-
GND
OI_+24V
SENSOR B
SENSOR A
ISCT
OI
OPTIONAL
CONNECTIONS
M9
MALE
M9
MALE
1
2
3
4
TO THE RIGHT SENSOR (AS VIEWED FROM THE
EXIT ROLLER SIDE OF THE GUIDE)
1
2
3
4
TO THE LEFT SENSOR (AS VIEWED FROM THE
EXIT ROLLER SIDE OF THE GUIDE)
INDUCTIVE PROXIMITY SENSOR
FEMALE
M12
1 2 3 4
TO OPERATOR INTERFACE
Figure 7. FIFE-500-XL basic wiring diagram www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–14 INSTALLATION
1
2
3
1
2
3
7
8
9
4
5
6
1
2
3
ENC_A
ENC_B
GND
+5V
HALL_A
HALL_B
HALL_C
GND
+5V
GND
+12V
SENSOR_B
SENSOR_A
X103
MOTOR_A
MOTOR_B
MOTOR_C
+24V
GND
N.C.
CONTROLLER PCB ASSY
X102
X101
X104
+12V
PAR_I0
PAR_I1
PAR_I2
PAR_13
PAR_I4
PAR_I5
GND
LINESPEED
GND
RGPC_LED
RS485+
RS485-
GND
OI_+24V
+12V
GND
GND
ISCT
-12V
PAR_O3
PAR_O2
PAR_O1
PAR_O0
+12V
12
11
10
9
8
17
16
15
14
13
2
1
4
3
7
6
5
22
21
20
25
24
23
19
18
29
28
27
26
BLUE
WHITE
RED
GREEN
ORANGE
ORANGE
YELLOW
BROWN
BLUE
WHITE
RED
GREEN
BLACK
YELLOW
BLACK
BROWN
Figure 8. FIFE-500-XL parallel I/O connections
RGPC-50/F WIRING
3
4
5
6
7
1
2
8
9
1
2
3
1
2
3
ENC_A
ENC_B
GND
+5V
HALL_A
HALL_B
HALL_C
GND
+5V
X103
CONTROLLER PCB ASSY
GND
+12V
SENSOR_B
SENSOR_A
+12V
GND
GND
ISCT
-12V
PAR_O3
PAR_O2
PAR_O1
PAR_O0
+12V
+12V
PAR_I0
MOTOR_A
MOTOR_B
MOTOR_C
+24V
GND
N.C.
X102
X101
PAR_I1
PAR_I2
X104
PAR_13
PAR_I4
PAR_I5
GND
LINESPEED
GND
RGPC_LED
RS485+
RS485-
GND
OI_+24V
3
2
1
6
5
4
11
10
9
8
7
16
15
14
13
12
21
20
19
18
17
24
23
22
29
28
27
26
25
GRAY
BROWN
WHITE
GREEN
YELLOW
GRAY
RGPC-50/F
204547-XXX
Figure 9. FIFE-500-XL RGPC-50 connections
PARALLEL I/O CABLE
217497-XXX
PARALLEL I/O CABLE
217497-XXX www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–15 INSTALLATION
Wiring diagrams
5
6
7
8
9
1
2
3
4
1
2
3
1
2
3
ENC_A
ENC_B
GND
+5V
HALL_A
HALL_B
HALL_C
GND
+5V
X103
MOTOR_A
MOTOR_B
MOTOR_C
+24V
GND
N.C.
CONTROLLER PCB ASSY
X102
X101
X104
+12V
+12V
PAR_I0
PAR_I1
PAR_I2
PAR_13
PAR_I4
PAR_I5
GND
LINESPEED
GND
RGPC_LED
RS485+
RS485-
GND
OI_+24V
GND
+12V
SENSOR_B
SENSOR_A
+12V
GND
GND
ISCT
-12V
PAR_O3
PAR_O2
PAR_O1
PAR_O0
4
3
6
5
10
9
8
7
2
1
15
14
13
12
11
19
18
17
16
29
28
27
26
25
24
23
22
21
20
EXTERNAL LOCK CABLE
215730-XXX
RED
WHITE
USER
DEFINED
{
BROWN
GREEN
BLACK
Figure 10. FIFE-500-XL external lock connections
1
2
3
1
2
3
1
2
3
4
5
6
7
8
9
ENC_A
ENC_B
GND
+5V
HALL_A
HALL_B
HALL_C
GND
+5V
X103
GND
+12V
SENSOR_B
SENSOR_A
+12V
GND
GND
ISCT
-12V
PAR_O3
PAR_O2
PAR_O1
PAR_O0
+12V
+24V
GND
N.C.
CONTROLLER PCB ASSY
MOTOR_A
MOTOR_B
MOTOR_C
X102
X101
X104
+12V
PAR_I0
PAR_I1
PAR_I2
PAR_13
PAR_I4
PAR_I5
GND
LINESPEED
GND
RGPC_LED
RS485+
RS485-
GND
OI_+24V
21
20
19
18
17
26
25
24
23
22
16
15
14
13
29
28
27
4
3
6
5
2
1
9
8
7
12
11
10
BLACK
RED
WHITE
WHITE
RED
BLACK
M9
MALE
3
4
1
2
215513-XXX
M9
MALE
1
2
3
4
215513-XXX
Figure 11. FIFE-500-XL sensor connections for sensors SE-11, SE-17, SE-22, SE-23, SE-31-IP, SE-38,
SE-42R, SE-44R www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
3–16
Wiring diagrams
INSTALLATION
7
8
9
4
5
6
1
2
3
1
2
3
1
2
3
ENC_A
ENC_B
GND
+5V
HALL_A
HALL_B
HALL_C
GND
+5V
X103
CONTROLLER PCB ASSY
GND
+12V
SENSOR_B
SENSOR_A
+12V
GND
GND
X104
ISCT
-12V
PAR_O3
PAR_O2
PAR_O1
PAR_O0
+12V
+12V
PAR_I0
PAR_I1
PAR_I2
PAR_13
MOTOR_A
MOTOR_B
MOTOR_C
+24V
GND
N.C.
X102
X101
PAR_I4
PAR_I5
GND
LINESPEED
GND
RGPC_LED
RS485+
RS485-
GND
OI_+24V
12
11
10
9
8
16
15
14
13
2
1
4
3
7
6
5
23
22
21
20
19
18
17
29
28
27
26
25
24
BLACK
RED
BROWN
WHITE
GREEN
M16
FEMALE
3
4
5
1
2
6
7
8
+12V
-12V
N.C.
N.C.
S2
GND
N.C.
S1
217435-XXX
Figure 12. FIFE-500-XL sensor connections for sensors SE-26A, SE-46A-C, DSE-17 www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
4–1
Maintenance
MAINTENANCE
WARNING – Death or injury can result from unexpected movement.
Protect against unexpected movement by removing electrical power from the FIFE-500-XL and the machine into which the FIFE-500-XL is installed.
WARNING – Danger of injury from crushing.
Maintenance and repair tasks on the FIFE-500-XL must be performed only when the machine has been stopped and has been secured from being turned on again.
WARNING – Danger of falling down or muscle or skeletal injury during maintenance and repair.
These web guiding systems, especially the larger designs, are heavy.
Appropriate equipment is to be used and the safety rules of the company must be observed.
WARNING – To prevent death or injury, always use standard
Lockout/Tagout procedures.
Maintenance schedules are recommended intervals only.
Ambient conditions can influence intervals considerably.
Therefore, adjustments to the recommendations must be made accordingly.
Guide has a protection class rating of IP 54. The “5” defines limited ingress of dust permitted, while the “4” defines protection against water splashed from all directions. Note that the guide is only protected from water splashes and no jets of water are permitted. Adhere to protection class rating IP 54 during all maintenance procedures.
General cleaning of the complete assembly shall be completed once a week, or as required by usage and environmental conditions. Cleaning shall consist of wiping down components as necessary with a clean and dry cloth. Compressed air or a shop vacuum may also be used as necessary.
Rollers are designed to be mechanically maintenance free, including ball bearings. If issues exist with bearings or other roller components contact customer service for further instructions. Surfaces of the rollers should be cleaned every four weeks or as required by usage and environmental conditions. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
4–2
Maintenance
MAINTENANCE
Sensors
Sensors shall be cleaned as necessary in order to ensure lenses, transmitters, and/or receivers have a clear path to detect the web.
Cleaning shall consist of wiping down components as necessary with a clean and dry cloth. Compressed air or a shop vacuum may also be used as necessary.
Operator interface screen
The Operator Interface (touchscreen) should be cleaned as necessary in order to ensure clear visibility of the menus. Cleaning shall consist of wiping down components as necessary with a clean and dry cloth. Commercial liquid cleaner may be used if necessary, but ensure that a small amount of liquid is placed on the cloth before wiping down the screen. Do not directly spray the screen.
Compressed air or a shop vacuum may also be used as necessary. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
5–1
Model number key
MODEL NUMBER KEY
The model number and serial number are shown on the back side of the base housing.
The model number consists of the base model “MW” followed by 9 digits specifying the options.
Format: MW – A B C DD E F G H
See Figure 1 for an illustration of the A, B, and C dimensions.
A = Roll Face dimension
B = Guide Span dimension
C = Roller Diameter
A Roll Face B Guide Span
1 300 [11.81]
2 350 [13.78]
1
2
1
2
400 [15.75]
500 [19.69]
400 [15.75]
500 [19.69]
C
0
3
4
0
3
4
Roller Diameter
NONE
80 [3.150]
100 [3.937]
NONE
80 [3.150]
100 [3.937]
1 400 [15.75]
3 400 [15.75] 2 500 [19.69]
0
3
4
NONE
80 [3.150]
100 [3.937]
3
1
600 [23.62]
400 [15.75]
4 500 [19.69] 2 500 [19.69]
0
3
4
NONE
80 [3.150]
100 [3.937]
3
1
600 [23.62]
400 [15.75]
5 600 [23.62] 2 500 [19.69]
0
3
4
NONE
80 [3.150]
100 [3.937]
3
1
600 [23.62]
400 [15.75]
6 700 [27.56] 2
3
500 [19.69]
600 [23.62]
0
3
4
NONE
80 [3.150]
100 [3.937]
7 800 [31.50]
8 900 [35.43]
1
2
3
1
2
3
400 [15.75]
500 [19.69]
600 [23.62]
400 [15.75]
500 [19.69]
600 [23.62]
0
3
4
0
3
4
NONE
80 [3.150]
100 [3.937]
NONE
80 [3.150]
100 [3.937] www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
5–2
Model number key
MODEL NUMBER KEY
DD = Sensor Type
DD Sensor Type
00 None
01 SE-11 without Air Sweep
02 SE-17 with Air Sweep
03 SE-17 without Air Sweep
04 SE-22 without Air Sweep
05 SE-23 without Air Sweep
06 SE-31-IP (2 in. Gap) without Air Sweep
07 SE-42R with Integrated Air Sweep
08 SE-22 with Air Sweep
09 SE-23 with Air Sweep
10 SE-26A
11 SE-46
12 DSE-17
13 SE-38
14 SE-44
E = Sensor Quantity
0 = None
1 = 1 Sensor
2 = 2 Sensors
F = Type of Sensor Mounting Bracket Assembly
0 = None
1 = Standard
2 = Fine Adjustment
G = Splice Table and Tape Dispenser
G
0
1
2
Splice Table
No
Yes
Yes
H = Roller Coating
H Roll Finish
1 Standard
2 Hard Coat Anodize
3 Dragon Elite II Plasma Coat
4 Rubber Cork Tape
5 11036 Plasma Coat
Tape Dispenser
No
No
Yes
Example Model Number: MW-223052224
This model number specifies a roll face dimension of 350
[13.78], a guide span of 500 [19.69], a roller diameter of 80
[3.150], a quantity of two SE-23 without Air Sweep sensors, a fine adjustment sensor bracket, a splice table with tape dispenser and rollers with rubber cork tape. www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
6–1
General
SPECIFICATIONS
Input voltage range
Current
Internal fuse
Operating ambient
Dimensions
– 24 VDC nominal
18-30 VDC min/max
Proper earth grounding is required.
Note that the negative supply and housing ground are interconnected.
The power supply must have an SELV output, such as Puls CS10.241-S1, or equivalent.
– 7.8 A maximum
– 10 A, slow-blow
– 0° to 50°C [32° to 122°F]
– Height - 274.5 mm [10.81"] maximum
Width - 940 mm [37.01"] maximum
1096.5 mm [43.16"] with splice table
Depth – 600 mm [23.62"] not including sensors
Guide weight
Protection class
Certifications and environmental compatibility
Maximum web tension – 1000 N [250 lbs]
Motor – 24 VDC Brushless
Product certifications – CE
TUV Rheinland of North America to UL61010-1 and
CAN/CSA-C22.2 No. 61010-1 and
CB Certificate to IEC61010-1
– IP 54 (applies only when all connectors are mated) www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
6–2 SPECIFICATIONS
Inputs and outputs
Sensor input (2) – Max Input ±20 mA
Individually programmable – 0 to 10 mA (preferred)
Digital port – Six Digital Inputs, active high
Low level: 0 to 0.9 V
High level: 3.6 to 24 V
– Four Outputs, open collector
55 mA at 1.6 V saturation
Maximum +30 VDC applied to output
+12 V available to port for input reference
Supply to accessories –
–
+12 V ±5%, 600 mA
-12 V ±5%, 80 mA
Maximum cable lengths
Power cable (18 AWG) – 15 m (50 ft) suggested. (Longer cables may be used if the voltage at the FIFE-500-XL is verified to be within the required 18-30 VDC input range). The suggested maximum length is 20 m (65 ft).
Sensors
Digital input/output port
RGPC-50/F
Operator interface
– 50 m (165 ft)
– 50 m (165 ft)
– 100 m (330 ft)
– 20 m (67 ft) www.maxcessintl.com FIFE-500-XL MI 1-917 1 C
7–1
Service requests and replacement parts
SERVICE
To request service or to get replacement parts, contact one of the following addresses:
Maxcess Oklahoma
222 West Memorial Rd.
Oklahoma City, OK, 73114, USA
Phone: 1.405.755.1600
Fax: 1.405.755.8425
Web: www.maxcessintl.com
Maxcess Europe
Max-Planck-Strasse 8
65779 Kelkheim
Deutschland
Telefon: +49.6195.7002.0
Fax: +49.6195.7002.933
Web: www.maxcess.eu
When ordering replacement parts, please indicate, where possible, part number, drawing number and model description.
If it is necessary to return the FIFE-500-XL for service, care must be taken to properly package the unit to prevent damage during shipment. If possible, use the original shpping containers.
NORTH, CENTRAL
AND SOUTH AMERICA
Tel +1.405.755.1600
Fax +1.405.755.8425 [email protected] www.maxcessintl.com
INDIA
Tel +91.22.27602633
Fax +91.22.27602634 [email protected] www.maxcess.in
EUROPE, MIDDLE EAST
AND AFRICA
Tel +49.6195.7002.0
Fax +49.6195.7002.933 [email protected] www.maxcess.eu
JAPAN
Tel +81.43.421.1622
Fax +81.43.421.2895 [email protected] www.maxcess.jp
CHINA
Tel +86.756.881.9398
Fax +86.756.881.9393 [email protected] www.maxcessintl.com.cn
KOREA, TAIWAN,
AND SE ASIA
Tel +65.9620.3883
Fax +65.6235.4818 [email protected]
© 2013 Maxcess
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