Band-it IT8000 3/8" Tie-Lok® User Manual User Manual
Below you will find brief information for IT8000. The IT8000 3/8” Tie-Lok® Data Tool is designed to install 3/8" Tie-Lok® ties with repeatability and control. It provides data to ensure the quality of the finished assembly and is adjustable for individual applications. The tool uses pneumatic cylinders and an electric motor powered with an AC connection and can be programmed by the user to accommodate specific applications utilizing the HMI (Human-Machine Interface).
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User Manual
IT8000
User Manual
IT8000
3/8” Tie -Lok® Data Tool
Original document
(Not a translation)
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
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Document #P80080 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2022
All rights reserved
All rights reserved
User Manual IT8000
3/8” Tie -Lok® Data Tool
TABLE OF CONTENTS
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
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User Manual IT8000
3/8” Tie -Lok® Data Tool
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
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Document #P80080 Rev. B
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BAND-IT-IDEX, Inc. 2022
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User Manual IT8000
3/8” Tie -Lok® Data Tool
SAFETY GUIDELINES AND WARRANTY
SAFETY INSTRUCTIONS
Read this manual to help you understand the intent and operation of this tool prior to installing BAND-IT Tie-Lok
® ties. o This product manual contains detailed instructions for setting up the tool and safely
installing ties. o Always wear safety glasses and appropriate gloves when operating this tool. o Keep hands away from tool head and clamp while operating. o Care should be taken to ensure fingers are not in the way of the clamp being applied. o Maintain the tool by following the scheduled preventative maintenance interval provided in this document. o Never use this product for anything other than its original intended purpose.
IMPORTANT: o The object clamped and the 3/8 " Tie-Lok® tie must be compatible with each other and the environment in which the final product will be used. o Always disconnect from air and electrical power sources before performing maintenance.
The IT8000 tool is designed for use with BAND-IT 3/8 " Tie-Lok® ties only. Accordingly, BAND – IT – IDEX, Inc. makes no representations with respect to the compatibility of these tools when used with non-BAND-IT or any other incompatible clamps.
WARRANTY
For warranty information go online at: https://www.band-it-idex.com/en/terms-conditions
Save these instructions for future use.
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User Manual IT8000
3/8” Tie -Lok® Data Tool
This equipment has been tested by BAND-IT-IDEX and meets the requirement of stability during use, storage conditions, transportation, assembly, dismantling when out of service, testing or foreseeable breakdowns providing that the proper safety precautions are observed.
DANGER — Misuse of this equipment may result in serious injury to personnel.
• Only use the equipment for its intended purpose, as described in this manual
• Do not attempt to operate the equipment with covers removed
• Refer to the installation section before installing machine
• Do not operate machine with wet hands
Please read this entire manual before unpacking, setting up or operating this equipment. Pay attention to all danger and caution statements. Failure to do so could result in serious injury to the operator or other personnel, or damage to the equipment.
SAFETY SIGNS
High Voltage – Risk of electric shock
Pinch Point – Refer to accompanying documents
Caution – Refer to accompanying documents
It is the task of the employer to warn his or her staff of risks, to train them on prevention of accidents, and to provide necessary safety equipment and devices for the operator’s safety.
Before starting to work with the machine, the operator should check the features of the machine and learn all details of the machine’s operation. The machine should only be operated by staf f members who have read and understand the contents of this manual.
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User Manual IT8000
3/8” Tie -Lok® Data Tool
GUARDING AND INTERLOCKS
Safeguards:
• Main Tool Housing: Covers primary mechanical body and actuators to prevent pinching during operation
• Head cover: Covers the mechanical head piece of the tool to prevent pinching during cutoff process
• Circuit breaker: Housed inside main enclosure.
• Power cord: Main method of removing power to unit. Unplug from wall or main enclosure.
Interlocking functions and features:
• The tool is not intended to operate without guards in place. The tool does not have any interlock functions or features that prevent operation if the guards are missing or enclosures are open. It is the responsibility of the user to provide safety interlocks if required.
E-Stop
Securing machine for safe maintenance:
• The tool must have all power and compressed air sources removed before service.
• All guards must be replaced, and enclosures closed before power and air sources are reconnected to the unit.
• Before preventive maintenance, disconnect device from wall. The appliance plug is the disconnect device.
• The Device comes with an emergency stop (E-Stop button)
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Figure 1
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PRODUCT SAFETY LOCATIONS
Figure 2
Figure 3
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IT8000
3/8” Tie -Lok® Data Tool
Warning:
Do not place fingers, hands, or any body parts under the cutting head while tool is running
Warning:
Do not place fingers, hands, or any body parts near the outlet of the tail eject while tool is running
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User Manual IT8000
3/8” Tie -Lok® Data Tool
OVERVIEW
• The IT8000 is designed to install 3/8" Tie-Lok® ties with repeatability and control. The machine is adjustable for individual applications and provides data to ensure the quality of the finished assembly
• The IT8000 is powered by pneumatic cylinders and an electric motor powered with an AC connection.
Data is transferred from tool to controller (Siemens PLC) and can be extracted utilizing USB or ethernet
• The mechanical drive portion of the tool tensions, dimples, and cuts a clamp to form a durable and strong fastened joint between two objects
• The electronic control of the tool uses feedback from the mechanical portion to accurately control the tension process of the tool and activate the punch and cut
• The tool can be programmed by the user to accommodate specific applications utilizing the HMI
(Human-Machine Interface)
• The tool can provide a data output to allow for verification of the integrity of the finished assembly
QUICK START OVERVIEW
1.
Connect data and motor cable to tool (Page 15)
2.
3.
4.
5.
6.
Note: Ensure controller power and air are off before connecting to the tool (Page 16)
Connect data cable to controller (Page 16)
Connect air harness to tool (Page 15) and controller (Page 17, Fig. 20)
Connect HMI (touchscreen) to controller (page 16)
Connect external regulator to controller (page 16)
Connect air hose to external controller regulator (page 17)
7.
8.
Customer supplied: connect with either 3/8 ” OD push-to-connect fitting or ¼” NPT thread
Plug in controller (110V US standard outlet)
Power on tool, ensure door latch is set to “On” and flip power switch on outlet module (Page 16)
Note: If the controller is not getting power, ensure the internal circuit breaker is flipped on
9.
HMI will boot up main program screen
10.
Enter tool serial number, located by the three mounting holes (Page 19)
11.
Tool settings are factory set to recommended settings for .019” band thickness (punch pressure)
1.
Ensure all settings are correct for application (page 31) and input settings as necessary
1.
Set punch pressure (Page 17)
2.
Set tension torque (Page 31)
8.
3.
Set error passcode preference (Page 38)
Message banner at top of screen should read "Tool Ready" and the tool is ready to use (if trigger is unresponsive press the "Reset Error" button on the HMI)
Note: The controller needs approximately 30 seconds to boot up before the trigger is responsive
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User Manual IT8000
3/8” Tie -Lok® Data Tool
ENVIRONMENT
TRANSPORTATION, STORAGE, HANDLING
Table 1
Transportation
Storage
Handling
Avoid shocks and vibration
Immediately check units for transport damage and inform your transport company, if necessary
If possible, ship in original packaging
Store unit in a clean, dry place with air temperature between -25°C and +55°C (-13°F to
131°F)
Use techniques appropriate for lifting and moving heavy objects.
Normal operating conditions are defined as:
For Indoor Use ONLY
Temperature range from 5°C to 40°C (41°F to 95°F).
Max relative humidity 80% for temperatures up to 31°C (88°F), decreasing linearly to 50% at 40°C (104°F).
Conforms to Applicable RATED POLLUTION DEGREE 1.
Correct illumination for safety of operator (ISO 8995-89).
Avoid using the tool near equipment with strong EMI / RFI emission.
Avoid using the tool near equipment susceptible to EMI / RFI interference.
This tool has been tested for:
Altitude: Sea level to 5690 ft (1730 m)
Atmospheric pressure: 14.7 lbs/in 2 (1 Kg/cm 2 ) to 12 lbs/in 2 (0.85 Kg/cm 2 )
Tool size:
Tool only: 12 ” L x 6.5
” W x 8 ” H ( 305 x 165 x 203 mm)
Controller box: 20 ” x 20 ” x 10” ( 508 x 508 x 254 mm)
Tool weight: 10 lbs (4.5 kg)
Controller weight: 63 lbs (28.6 kg)
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User Manual IT8000
3/8” Tie -Lok® Data Tool
TOOL SETUP
OPERATING REQUIREMENTS
Table 2
Clamp Type
Operation Air Requirements
Power requirements
Human-Machine Interface (HMI)
Emergency Stop
BANDIT 3/8” Tie -Lok® Tie Series
80 PSI (552 kPa) Clean dry compressed air
Air Flow Rate: 0.25 CFM (7.1 L/min.)
Do not exceed pressure listed on regulator assembly
110-230 Volts 50-60 Hz Grounded AC 4 A Max
Programmable Color Touchscreen
Application of emergency stop button will stop electric motor and open all valves, removing air pressure from pneumatic cylinders.
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PART DESCRIPTIONS AND LOCATIONS
Cutter Arm Cut-off
Cylinder
Cut-off Cylinder Mount
Plate (Serial Number
Located here)
IT8000
3/8” Tie -Lok® Data Tool
Cut
Straight
Link
Cut
Link
Tangency and Buckle
Sensors
Tool Head
Knife
Figure 4
Drive shaft
Frame
Trigger
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Trigger Link
Tension Wheel
Punch
Cylinder
Punch
Holder
Punch
Backing
Wheel
Lower Band
Guide
Upper
Band
Guide
Figure 5
Trigger
Cylinder
11
Pinch Arm
Clamp
Cylinder
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PART DESCRIPTIONS CONT.
Pneumatics
Cover
Right
Cover
Handle
Cover
IT8000
3/8” Tie -Lok® Data Tool
Head
Cover
Left Side
Cover
Figure 6
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INSTALLATION TOOL DIMENSIONS
Figure 7
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Figure 8
13
IT8000
3/8” Tie -Lok® Data Tool
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CONTROLLER ENCLOSURE DIMENSIONS
The controller box is designed to be mounted with (4) 9/16” holes on the back mounting plate.
Figure 9
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IT8000
3/8” Tie -Lok® Data Tool
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User Manual IT8000
3/8” Tie -Lok® Data Tool
CONNECTING THE TOOL TO CONTROLLER
This tool requires both electricity and compressed air to operate. Provisions must be made to deliver both to the tool in a safe manner. The tool can be plugged in a standard 110V outlet.
Connect the data cable to the main tool housing. Ensure that the key is aligned before attempting to screw down the connection (Fig. 10). Each electrical connector has a unique interface, do not attempt to force a plug into a connector if the receptable does not match or the key is misaligned.
Connect the motor cable to the motor. Align the two arrows on cable and connector and then rotate a quarter turn (fig. 11).
The tool includes an air harness with six ¼” (6.35mm) outside diameter tubes pre -assembled to quick-connect ends. Attach one end to the controller and the other end to the tool connection point, taking care to align keys before insertion. Once inserted, twist coupling until it is tight on the connector.
Only plug in the power cable to the controller after all the other connections have been completed. The power entry module includes the ON/OFF switch. The power cable provided with the tool is standard grounded plug compatible with North America outlets.
Data Cable Key
Data Cable
Motor Cable
Figure 11
Figure 10
Motor Key
Air Harness
Figure 12
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3/8” Tie -Lok® Data Tool
CONNECTING THE HMI AND REGULATOR TO CONTROLLER
The connection to the HMI (Human-Machine Interface) (Fig 14) is hardwired, so the green HMI cable only needs to be connected to the controller. To connect the HMI cable to the controller, align the red dots and press the connector in (fig. 13) On the side of the HMI is a USB port that can be used to transfer tool data. The system regulator has two connections that must be connected (Fig.17). Each electrical connector has a unique interface, do not attempt to force a plug into a connector if the receptable does not match or the key is misaligned.
The controller has inputs for a Pass/Fail “cutoff signal” and remote actuation to operate the tool hands free.
These do not need to be connected to run the tool in normal operation.
The controller has multiple switches. The I/0 power switch above the plug and the door latch function the same, cutting all power and air to the controller. The E-stop on the top of the box removes air from the tool and power to the motor. The HMI will remain on.
Figure 13
Figure 14 - HMI
Regulator
Connections
HMI Key
E-Stop
Door Latch
Power Switch
Pneumatics
Valve Bank
Cable
Connections
Bank
Figure 15
HMI Cable
Connector
Cut-off Signal &
Ethernet Port
Remote Trigger Data Cable
Figure 16
Figure 17
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3/8” Tie -Lok® Data Tool
AIR SYSTEM SETUP AND PRESSURE SETTINGS
Table 3 - Recommended Pressure Settings:
Tie Thickness
(in)
Punch Pressure
(psi)
System Pressure
(psi)
0.019
0.024
65 ± 2
80 ± 2
80 ± 5
80 ± 5
C aution: Pressures above the specified settings may cause premature clamp failure and/or tool wear.
Use the external regulators to adjust the air pressure on the tool. The system pressure regulator is in-line with the Input Air line (Fig 16). It has two connectors that much be attached to power and read the regulator. The punch pressure regulator is in-line with Punch Extend line (Fig. 19). The punch must be extended to read the pressure.
The punch pressure reading is shown on the manual screen. (pg. 33). The regulators are adjusted independently. Note that the HMI pressure limits may need to be updated as well (pg. 36), but the pressure cannot be adjusted in the HMI. The regulator has a 3/8” OD push -to connect fitting on it. If a different style of fitting is preferred to connect to the input regulator, the fitting can be removed and replaced with a different
¼” NPT fitting.
The controller and tool harness air-line valve numbering is shown below.
Valve Position Actuator
Tool Air Harness
1
Punch Extend
2
3
Cut Extend
Trigger Extend
4
Clamp Extend
5
6
Punch Retract
Cut Retract
Figure 18
Table 4
Controller Pneumatics Valve
Bank
Exhaust
1 2 4
Unused
Input
Air
6 5 3
Exhaust
Figure 19
Figure 20
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AIR FLOW TIMING
The following chart shows the cylinder actuation for one complete tie install.
IT8000
3/8” Tie -Lok® Data Tool
Event description
Timing / duration
Clamp cylinder Extend
Tool ready for next tie
At rest
Engage gripper
Tension clamp / engage punch cylinder
Actuate trigger to dimple
Retract punch
Reset trigger
Cut-off Eject
Entire duration of tensioning tie and ejecting scrap
Entire duration of
Immediately after tightening tie sensors are activated
60 ms
(Punch
Extend
Duration)
Immediately 150 ms (Cut after punch retract
Retract
Delay)
Auto Eject
Only*
(0.5 s)
Punch cylinder
Extend
Retract
Trigger cylinder Extend
Extend
Cut-off cylinder
Pressurize
Retract
Figure 21
Exhaust
*Scrap Ejection: If the automatic ejection setting is ON (recommended), the tail scrap will be automatically released from the tension wheels after the cut operation to ease in pulling out scrap. Otherwise, the tool will wait for the next trigger press to eject scrap. Note: Regardless of the setting, the scrap will have to be pulled out by hand. See HMI settings to change the setting (pg. 35)
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3/8” Tie -Lok® Data Tool
SYNCING TOOL TO CONTROLLER
How to connect or replace an existing tool to the controller:
1.
Activate E-stop or turn controller off to disable air and power to motor.
2.
Disconnect data and motor cable to current tool (only required if a tool is connected).
3.
Disconnect pneumatic tubing harness to current tool (if required)
.
4.
Connect data and motor cable to new tool.
5.
Connect pneumatic tubing harness to new tool
.
6.
Release E-stop or turn controller back on. Ensure Door Latch is in the
On
position.
7.
Go to settings screen (General tab)
1.
Select “Change Tool”
2.
Select the serial number
3.
Type in the new tool’s serial number
4.
Select “Enter”
8.
5.
Enter “Clamp Count” And “Tool Cycle Count”
6.
Select “Done”
Input tool settings (If changing application)
1.
Set system pressure and punch pressure (Refer to settings, page 31)
2.
Set tension torque (Refer to settings, page 31)
9.
3.
Set ejection preference
Message banner at top of screen should read " Tool Ready " and the tool is ready to use.
If an error is shown, press the error reset button.
Note: When powering on the controller, it takes approximately 30 seconds for the system to be functional. Air pressure and motor power will not be activated until after this point.
E-Stop
Door Latch
Power Switch
Figure 22
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User Manual IT8000
3/8” Tie -Lok® Data Tool
OPERATION
TIE INSTALLATION PROCEDURE
1.
Lace the tie snug around the assembly and locate the buckle in the target location.
The tie should be at least 3 inches longer than the assembly circumference.
2.
Band should be applied to a uniform solid surface allowing the buckle adequate support during the tie installation operation. (pg. 21)
3.
Insert the tail of the clamp into the tool at a 30° angle from the buckle. The tail needs to be inserted a minimum of 2.5
” into the tool.
4.
To reduce the risk of jamming, do not activate the tool until the tie is inserted 2”.
5.
Ensure proper tool orientation (see below).
6.
Begin tensioning by pushing and holding down the trigger or by using the remote trigger system. If the trigger is released, the tool will stop tensioning and open the gripper.
7.
The tool will continue to run until it reaches the desired tension. At this point the tool will
30°
Figure 23 hold tension but not fire the punch until the tool is moved tangent to the work surface.
8.
Once the tangency and buckle sensors have been activated the tool will complete the punch and cut cycle.
9.
Data will be logged onto the controller (and can be downloaded to an external
Note: A blinking red LED signifies an error during install. device). The clamp count is updated.
10.
After the cycle is complete, remove the scrap tail. The tool is now ready for the
Check the error message on the HMI and verify the clamp next tie. was installed correctly.
TOOL OPERATION
The starting tool orientation should be rotated back to allow for the front corner of the buckle to hit first. Go straight into the buckle with the tool in this orientation.
Continue to install the band until it reaches full tension in the orientation shown. Once the LED is solid yellow , rotate the tool to be tangent to the work piece and buckle.
Once the tangency sensors are activated the LED will turn green and the tool will punch & cut the band.
Figure 24
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Figure 25
20
Figure 26
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User Manual IT8000
3/8” Tie -Lok® Data Tool
TIE INSPECTION
The IT8000 forms a locking dimple into the Tie-Lok®
Tie with the punch and cuts the remaining tail.
When installing a Tie-Lok® tie, a visual check is recommended to verify the presence of a locking dimple after the tie has been applied.
Locking Dimple
Figure 27
CLAMP PLACEMENT
Buckle location is critical to clamp performance. Use the following guidelines as a reference.
• Do not install clamps at an angle (Fig. 28)
• Buckle locations cannot be over air gaps (Fig. 30)
• Avoid sharp corners, add largest radius possible on square corners (Fig. 29)
• Tie-Lok® can be installed on flat surfaces
• Do not install clamps on tapered surfaces or on tube bends (Fig.29)
• Tie-Lok® advised min installed diameter is 1”
• The buckle area of the shield must be free of voids and wrinkles ss
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Figure 29
21
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Figure 30
Figure 28
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User Manual IT8000
3/8” Tie -Lok® Data Tool
MOUNTING AND FIXTURING
At a minimum BAND-IT recommends that the tool be connected to a tool balancer or connected to an ergonomic lift assistance arm.
Tool Balancer
•
The tool needs to be located directly above the clamp location if using a balancer as shown below
(Figures 32 & 33).
•
The balancer must support the weight of approximately 10 lb.
•
The tool comes with a hanger loop to mount to a balancer.
•
For more complex installations there are three mounting holes on the side. See page 25 for more information about controlling the tool in roll and yaw.
•
Note that the center of gravity is behind the hanger bracket. For best performance, the pivot point should be located on the CG, not directly on the hanger bracket. (Fig 31)
Figure 32 Figure 33
[57.4]
Figure 31
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User Manual IT8000
3/8” Tie -Lok® Data Tool
Tool Balancer Cont.
If multiple ties are installed with the same tool, a slide rail or swing arm is required to move between the ties.
Always allow the tool to hang directly above the installation. Pulling the tool at an angle will cause increased strain on the operator. Figures 35-36 are an example of a weight balancer that can rotate in all 3 axis. Depending on the application, the harness can either be routed up the balancer or at ground level. For technical drawings or further information about this design, contact your account manager.
Figure 35
Figure 34
23
Figure 36
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3/8” Tie -Lok® Data Tool
Recommended Setup: For the most ergonimic design, we recommend moutning the tool on an articulating arm or fixture.
Articulating Arms
•
Three 10-32 mounting holes are provided to attach the IT8000 to an articulating arm.
•
The arm must be able to support approximately 10 lb. in addition to any brackets installed to the tool.
•
See page 25 for more information about controlling the tool in roll and yaw.
•
See Figures 39 & 40 for two examples of articulating arms.
Hanger
Loop
Figure 37
Mounting
Holes
Figure 38
Figure 39
Figure 40
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TOOL ROTATION
The tool may have to rotate in all three axes of rotation depending on the application (Fig. 42).
Pitch is required for all setups, as this rotation is required to ensure the buckle is installed tangent to the work piece. A minimum of 30° of rotation is required for the tool to operate, but 120° is recommended. The tool should be allowed to rotate both forwards and backwards from the tangent point the buckle is expected to be placed. See Figure 41 for the minimum rotation away from the buckle.
Yaw is typically required if the tool is installing more than one clamp, especially if the tool is on a swing arm or articulating arm. 180° of rotation is recommended, 90° in each direction from straight on.
Figure 41
Roll is required on applications that have clamp(s) at different angles. Depending on the application, 90° of rotation is recommended.
Yaw
Roll
Figure 42
25
Pitch
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CENTER OF GRAVITY
The center of gravity (CG) is shown below in relation to the hanger loop and mounting holes. The closer the rotational point is to the CG, the easier the rotation will be.
If roll is required for the application, centering the rotation around the roll axis is the top priority. Followed by pitch and then yaw.
CG Icon
[4.1] [55.9]
Figure 44
[57.4]
[47.2]
Figure 43
Figure 45
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MOUNTING EXAMPLES
Figures 46-49 are an example of an articulating arm and mounting bracket that can rotate in all 3 axis. For technical drawings or further information about this design, contact your account manager.
Pitch Axis
Yaw Axis
Figure 47
Roll Axis
Figure 46
Figure 48 Figure 49
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For applications where roll is not required, a bracket with Pitch and Yaw control can be used (Figure 51).
Note that the center of gravity is behind the hanger bracket. For best performance, the pivot point should be located on the CG, not directly on the hanger bracket.
Yaw Axis
Pitch Axis
Figure 51
[57.4]
Figure 50
HARNESS ROUTING
It is recommended to run the pneumatic/electrical harness down the length of the articulating arm. This will keep the harness out of the way and protect it from being damaged. Ensure that there is enough slack in the harness to not bind as you maneuver the tool.
Note: the harness will stick approximately 2 ” ( 51 mm) behind the tool if the harness is routed as shown below.
Figure 52
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TOOL CLEARANCE REQUIREMENTS
Minimum Clearance Requirements
A.
Channel Height (max)
B.
Head Width (min)
C.
Centerline distance to flange (min)
D.
Tool Width
0.25” [6.4mm]
0.8
5” [ 21.6mm]
1.00” [25.4mm]
5.50” [139.7mm]
D
Figure 53
A
B
Figure 54
C
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SENSOR ACTIVATION
Note: the tangency sensor is only activated on metallic objects.
If installing on plastic or rubber, the sensor will need to be disabled.
To ensure proper sensor activation, the channel area where the buckle is placed must be void of dimples and folds.
If using a foil shield, it is recommended to have a 1”x1” (25mmx25mm) coined or stamped section without wrinkles where the buckle will be placed. Note the location of the tangency sensor that is activated by sensing the installation surface.
To verify the sensors are activating properly, the Manual screen on the HMI has two indicators that light up when the buckle and proximity sensors are activated.
If the sensors are activated improperly without metal near the sensors, first clean the sensors to ensure there are no metal shavings interfering with the sensor. Then verify the sensor location. They should be depressed .005.010” into the tool head.
If the sensors are still malfunctioning, verify the electrical connections.
Buckle
Sensor
Figure 55
REMOTE ACTUATION
The IT8000 can be remote actuated with a foot pedal or palm buttons via the remote trigger 4 pin connection on the side of the box. If using the Mencom yellow cable supplied with the controller, the brown to white pin connection needs to be closed to activate the tool. The external trigger setting also needs to be “On” in Settings.
Contact BAND-IT IDEX for recommendations on remote triggers.
CUT-OFF SIGNAL
The IT8000 can send a “cut off” signal similar to the IT6000. Instead of being triggered by the pressure difference inside the tool, the controller will send the signal when a clamp has been installed and did not fail any verification checks. A use case of this would be to count the number of clamps installed on an assembly. The connector is located next to the remote actuation on the controller. If using the Mencom yellow cable, measure the signal across the white and blue wires. Contact BAND-IT IDEX for recommendations on how to setup the cutoff signal.
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FACTORY PROGRAM SETTINGS
See page 35-38 for additional information about these settings
Table 5
Tab Setting
General Target Torque
Setpoints Min Supply Pressure
Max Supply Pressure
Torque Tolerance
Min Punch Duration
Max Punch Duration
Min Punch Pressure
Max Punch Pressure
Timing
Speed
Line Up Tool Timeout
Position Sensors Debounce
Cut Off Delay
Punch Extend Duration
Auto Eject Duration
Cut Retract Delay
Max Tension Speed
Value
10 s
0.01 s
0.05 s
0.10 s
0.5 s
0.20 s
50%
40%*
75 PSI
85 PSI
0.10 in-lbf
0.5 ms
5.0 ms
63 PSI
67 PSI
*Recommended target torque is 40% for optimal component life and performance. For additional clamping performance, target torque can be set to a maximum of 50%.
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SOFTWARE AND ELECTRONICS
HMI OVERVIEW
Home Screen
Status Banner Tool Ready : Shows status of tool and error codes if applicable
Clamp Count: Increments every install. Resettable in Settings , not tied to a specific tool.
Lifecycle Count: Increments every install, a controller count, not resettable.
System Pressure: Pressure reading off input regulator, controls the non-punch cylinders
Punch Pressure: Pressure reading inside tool, controls only the punch cylinder
Motor Torque: Instantaneous motor torque
Punch Max Duration: Max duration for the punch velocity sensor before giving an error
Punch Duration: Actual punch duration of the previous cycle
Motor Torque Target: target final torque
Serial Number: Serial number of the tool, tied to the motor. Can only be changed when switching motors.
Tool cycle Count: Cycles on the current serial number, resettable when first connecting to a tool.
Error code Count: Count of errors, can be reset in Settings.
Log In / Log Out: Allows/Prohibits access to the Settings tab.
Reset Error: Resets any error on the top banner
Figure 56
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Manual Screen
Enter Manual Mode: Turns on Manual Mode. Allows individual cylinders and the motor to fire independantly for troubleshooting. This will prevent the tool from operating when the trigger is pulled. Manual Mode needs to be selected for the functions on this screen to work.
Note: Manual mode will stay activated if you leave the “Manual” screen. The tool will not install a clamp in this state. An LED on the F1 button will blink to alert you that the tool is still in manual mode.
Pull Band: Rotates the motor to pull the tie into the tool. The motor runs at the speed indicated next to Torque
Move.
Release: Rotates the motor to push the tie out of the tool. The motor runs at the speed indicated next to Torque
Move.
Torque Move: Rotates the motor to pull the tie into the tool until the torque indicated in the changeable field is reached.
Cylinder Extend/Retract: Fires each cylinder independently, either extending or retracting.
System/Punch Pressure: Shows the current system and punch pressure
Contact Switches/Trigger Indicators: The round indicators will light up blue when the contact switch sensors or trigger are activated respctively.
Figure 57
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Graph Screen
The graph screen shows several inputs over the course of a tie install. Velocity and Torque are the motor readings. Pressure is the punch pressure inside the tool. It also has two vertical lines where the Punch and Cut happen. All data shown on the graph screen is stored in the PLC. When switching to the graph screen the HMI will auto populate with the most recent cycle. When on the graph screen “ Refresh ” must be pressed. Graph populating takes around 1 minutes. There is a green status bar below the “Reset Error” button that shows graphing progress.
Punch Time History
Punch time history can be seen under the graph tab, by clicking on TABLE. The table shows the punch time for the last 30 clamps. It automatically updates with the latest clamp at the top. To return to the graph screen, press the “graph” button.
Figure 58
Figure 59
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Settings Screen – General
Target Torque: Percent of max torque the tool tensions the band with, 40% is recommended.
Lot Number: Adds a lot number to the data stored
Change Tool: Used when changing to a new tool, see pg. 19 for a detailed overview.
Choose File: Selects the data file you want to upload. File format is “TOOLSERIAL# MM_DD_YYYY” .csv
Multiple cycles are store to each data file, typically a full days’ worth of installs.
Copy Log to USB: transfers the selected file to USB flash drive if installed. If a duplicate file name is already on a
USB stick, the current file will be over written with the latest version.
Enable Contact Switch: double tap On/Off switch to enable or disable the tangency and buckle sensors.
Eject Mode:
Auto: Activates the motor for a preset time after the cut to eject the tail
Manual: does not run the motor after cut.
Units: Changes between Metric and English units
External Trigger: The tool will respond to the trigger when off, or the remote trigger connected to the controller when on.
Reset Cycle Count. Resets the Clamp Count on the top of the screen
Exit runtime: closes the IT8000 program and goes to the home windows screen.
To update date and time on the HMI: Exit Runtime -> Settings -> Date/Time -> Restart Runtime
Figure 60
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Settings Screen – Error
Error bypass – Automatically resets errors without hitting Reset Error
Enable Error Codes Passcode – Requires a passcode to clear an error
Error Codes to Require Passcode – Number of errors in a row before the passcode is needed.
Settings Screen – Setpoints
Min/Max Supply Pressure – Prevents tool from operating outside the settable supply pressure range
Min/Max Punch Pressure – Prevents tool from operating outside the settable punch pressure range
Min/Max Punch Duration – Settable range of punch duration. Tool will give error outside of range.
Torque Tolerance – Tool will give error if cycle torque is outside of target torque.
Cycle Warning Count – PM count to notify when the tool needs to be regreased
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Figure 61
Figure 62
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Settings Screen – Timing
Line up tool timeout – Time before error between when tension is reached and when the proximity sensors are activated.
Position Sensors Debounce – How long the proximity sensors need to be in position before the tool completes the cycle.
Cut off delay – Delay between punch and cut
Punch Extend Duration – Time the punch cylinder is extended.
Auto Eject Duration – Time the tool runs after cut (if automatic ejection is enabled)
Cut Retract Delay – Time the cut cylinder is extended.
Settings Screen – Speeds
Max Tension Speed – Speed of tool during installation
Slow speed – For standard operation, slow speed is not used.
Eject Speed – Speed of ejection (if automatic ejection is enabled)
Manual Jog Speed – Speed of motor jog in manual mode.
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Figure 63
Figure 64
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Settings Screen – Passwords
Error Acknowledgement Password: Requires a password to Reset Error (Optional)
Settings Administrator Password: Password required to access the SETTINGS tab.
Password screen will pop up if Log In is attempted on the HOME screen.
Auto logout is available for both passwords and the time limit before the logout happens is adjustable.
HMI Physical Buttons
Figure 65
The HMI Screen has physical buttons to the sides of the touch screen. Figure 66 shows the settings for those buttons.
Figure 66
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MAINTENANCE
MAINTENANCE SCHEDULE
The IT8000 tool requires periodic maintenance to prevent malfunction or damage. Refer to the table below for recommended maintenance intervals of critical tool components. Intervals may vary depending on the operating environment.
Table 6
Components Recommended
Service
Backing Wheel Grease pin
Inspect and replace if worn
Tension Wheel Clean with wire brush
(included w/ tool)
McMaster PN:7092T18
Punch
Inspect and replace if worn
Inspect and replace if worn
Knife Grease
McMaster PN: 1208K22
Inspect and replace if worn
Head Assembly Inspect and replace if worn
Recommended Interval
Every 20,000 clamps
100,000 clamps
Every 20,000 clamps
50,000 clamps
100,000 clamps
Every 20,000 clamps
50,000 clamps
100,000 clamps
Page Ref.
40
45
41
45
44
40
42
43
To maximize performance and extend tool life:
• Do not use degreaser on any part of the tool.
• Do not spray any lubricant or cleaner into the pneumatic system.
• Do not remove factory-applied lubrication from inside tool unless performing a thorough maintenance procedure and then replacing with clean lubricant immediately.
• Follow preventative maintenance and parts replacement instructions at appropriate service intervals.
• For maintenance beyond what is described in this manual, contact BAND-IT.
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LUBRICATION
Lubricate knife and pin with Bel-Ray Molylube extreme pressure grease .
•
Lubricate backing wheel pin through the grease port on side of tool. L8503 or similar needle type grease fitting is required.
•
Lubricating the knife requires partially sliding it out, see page 42 for instructions. To increase time between grease, it is recommended to grease the involute linkage as well.
Involute Linkage
Figure 68
Important:
Pneumatics Cover
Prior to any maintenance or disassembly, be sure to disconnect all power sources to the tool and discharge pressurized air from the air system.
Knife
Figure 69
Grease Port Figure 67
Side Cover
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TENSION WHEEL CLEANING
1.
Remove the clevis pin (1) holding the pinch arms (2) and allow it to swing down. Be careful to ensure the backing wheel and pin do not slide out with the pinch arms removed.
2.
Enter manual mode to drive the tension wheel for a few revolutions with the wire brush (1/4 ” brush width) (3) pressed firmly up into the rotating wheel.
3.
During reassembly, re-center the tension wheel between the pinch arms and the band guide lined up on the pinch arms to allow for proper re-assembly.
1
2
3
Figure 70
Important:
Prior to any maintenance or disassembly, be sure to disconnect all power sources to the tool and discharge pressurized air from the air system.
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KNIFE REPLACEMENT
Remove the Head Cover (1). Pinch the front of cover and rotate down to remove. Remove the E-Clips (2) on the non-motor side only. Push the 2 pins (3) down far enough to allow the linkage (4) to swing out. Remove the knife (5).
Apply a film of grease to the new knife and pins and reassemble, using new E-clips if needed.
Replacement Knife Kit Part Number: H80935
1
Note: The cutter knife has only one cutting edge. This edge must be properly oriented as shown when installing.
Cutting
Edge
Figure 71
3
Important:
Prior to any maintenance or disassembly, be sure to disconnect all power sources to the tool and discharge pressurized air from the air system.
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4
Figure 72
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HEAD REPLACEMENT
Remove the Head Cover (1). Remove the E-Clips 2x (2) on the motor side only. Pull the pins 2x (3) out of the head. Swing the Linkages (4) down to access the head bolts. Remove the bolts (7/64 ” hex key) 4x (5). Disconnect the sensor cable and remove the head (6).
Apply a film of grease on the pins and knife and reassemble. Ensure that the upper pin goes through the trigger assembly linkage (7) (Fig. 74). Apply Blue Loctite to screws. Only pull-on gray cable jacket when connecting head sensor.
The pneumatics cover or side cover may need to be removed to reconnect the head sensors or to insert the pins.
Replacement Head Kit Part Number: H80945 or H80940 (No Sensors)
2
3
6
7 4
5
Figure 73
1
Important:
Prior to any maintenance or disassembly, be sure to disconnect all power sources to the tool and discharge pressurized air from the air system.
Figure 74
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Figure 75
User Manual IT8000
3/8” Tie -Lok® Data Tool
PUNCH REPLACEMENT
Remove the head as shown on page 43. Extend the cylinder by pulling on the punch (1) until the punch holder is visible. Punch the spring pin (3/32” Dia) (2) out.
Reassemble. Always using a new spring pin (2) when replacing the punch.
Replacement Punch Kit Part Number: H80925
2
1
Important:
Prior to any maintenance or disassembly, be sure to disconnect all power sources to the tool and discharge pressurized air from the air system.
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TENSION AND BACKING WHEEL REPLACEMENT
Remove the Side Cover (1). Remove the screws (9/64 hex key) 8x (2). Remove the clevis pin (3) and drop the pinch arms.
Remove M4 screws (3mm key) 3x (4). Remove Motor assembly (5). The gripper wheel can now be pulled out of the tool (6).
To remove the backing wheel, push the pin out (7) and remove the wheel (8).
Reassemble, applying blue Loctite to M4 screws.
1
Replacement Tension Kit Part Number: H80915
3
2
Figure 76
Important:
Prior to any maintenance or disassembly, be sure to disconnect all power sources to the tool and discharge pressurized air from the air system.
5
6
8
Figure 77
4
7
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TROUBLESHOOTING
TROUBLESHOOTING GUIDE – Table 7
Observed Problem Possible Cause Solution
Backing Wheel is touching Tension Wheel.
Verify the return cycle of the clamp cylinder is unimpeded and clamp cylinder is fully retracted.
Clamp tail does not insert into tool.
Clean tension and backing wheels with wire brush.
Excess material from previous operation did not fully eject.
Verify the tension wheel rotates enough to remove scrap tail by hand.
Tension wheel does not rotate while tensioning.
Loose motor shaft collar.
Tension Wheel slipping.
Ensure set screw between motor and gearbox is tight. Check for foreign object present or other obstructions.
Inspect clamp tail for evidence of slipping. Clean
Tension and Backing Wheels with wire brush. If slipping persists, replace Tension and/or Backing
Wheel.
Loss of air pressure to Clamp cylinder (<80 Verify that air source and fittings are pressurized,
PSI). unobstructed, and not leaking.
Pre-set tension is not reached.
Drive-train failure. Contact BAND-IT.
Clamp tail pinched off at tension wheel due to high pinch force on backing wheel.
Verify air pressure to Clamp Cylinder does not exceed 80 PSI.
Tension setting too high for clamp/application.
Ensure tension setting (motor torque) is correct for clamp type and application.
Backing wheel pin un-lubricated. Lubricate.
Failure to cut clamp tail.
Loss of air pressure to cut-off cylinder
(<70 PSI).
Verify that incoming air pressure meets minimum requirements. Check for leaks or obstructions.
Excessively worn or damaged knife or tool
Replace knife or head. head.
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Observed Problem Possible Cause Solution
Cut-off link jam.
Cut-off Cylinder arm not connected properly.
Failure to cut clamp tail (cont.)
Knife and pins un-lubricated.
Loose head mounting screws.
De-energize system for safety. Contact BAND-IT.
Verify Cut-off Cylinder arm is connected properly, with pins fully inserted.
Lubricate.
Tighten all mounting screws.
Cut-off cylinder actuation timing is less than recommended.
Punch pressure too low.
Clamp buckle located above void or opening.
Object being clamped is hand-held.
Actuate cutoff cylinder for at least recommended timing.
Check pressure setting. Check air tubing and fittings for obstructions.
Be sure to locate buckle on fully supported surface.
Small light-weight objects clamped must be properly held in place in a fixture.
Locking dimple too shallow.
Object being clamped is soft with thick wall.
Adjust the Punch pressure higher and verify dimple depth. Be sure that object clamped is held in place and locked down in fixture. Adjust tension and hold force settings if necessary.
Actuate punch cylinder for at least recommended timing.
Punch cylinder actuation timing is less than recommended.
Trigger mechanism did not fire properly.
Verify that air source and fittings are pressurized, unobstructed, and not leaking. Verify that the trigger cylinder can extend and retract without obstruction. Grease the trigger clevis pin.
Locking dimple too deep.
Punch cylinder pressure too high. Adjust to a lower pressure.
Head sensors not activating
Sensor Damaged
Place metallic object against sensor and verify the sensor activates on the HMI screen.
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Observed Problem
No power to tool or sub-components
Possible Cause Solution
Unplugged power cord
/ connectors.
Check power cord. Check all connections between components. Be sure to match connector styles, number of pins on individual connections and observe keyed orientation of the connectors. All threaded sleeves on connectors must be fully assembled and secured.
Power entry plug switch or door latch turned Off
Check switch status.
Internal Circuit
Breaker(s) tripped to
Off position.
Check to make sure all Circuit Breakers are in the On position (located inside the Electrical
Control box).
Tool does not activate when the trigger is pulled.
E-stop is pressed down Check switch status
Manual mode is activated
Tool will not install a clamp in manual mode, turn off to go to normal operation
External trigger is on. Turn off external trigger.
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
48
Document #P80080 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2022
All rights reserved
All rights reserved
User Manual IT8000
3/8” Tie -Lok® Data Tool
ERROR CODES
Types of Error Messages:
Warning Messages: These message types are displayed to assist operators with understanding tool behavior and typically resolve themselves. These can be set to persist if the cycle is ended by the operator before they resolve, depending on the “Enable Error Bypass” setting.
They do not count toward Failed clamp counts. All warning type errors will begin with a “3”.
Error Messages: These do not stop the sequence and the tool can complete an installation when these occur, but they may mean that the tool has not installed the band to the right specifications. Error messages will persist when the “Enable Error Bypass” setting is not checked. These message types will increment the “Error Codes” counter. All error messages begin with a “2”.
Critical Alarms: When these errors occur, the tool cannot continue to operate normally, the tool will not complete the installation and the tool will enter the faulted state. Critical alarms will always be displayed independent of the “Enable Error Bypass” setting and require the user to address the issue or reset the error before the tool can continue operation. The first digit of critical alarms begins with a “ 1 ” .
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
49
Document #P80080 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2022
All rights reserved
All rights reserved
User Manual IT8000
3/8” Tie -Lok® Data Tool
Table 8 – Error Code Summary Table:
Number
135
144
Description
Band Slipping
Detected
Tool Line Up
Timeout
Details
This error occurs when large changes in motor velocity are detected, and the number of detections exceeds the amount of allowable slipping events defined on the HMI.
When this error is triggered, the tool will fault, the LED will blink red, and the sequence will end.
Possible Cause: See “ Pre-set tension is not reached ” troubleshooting section.
This error occurs when the time limit set by the “Line Up Tool Timeout” setting on the
HMI is exceeded before the contact switches are triggered. When this error is triggered, the tool will fault, the LED will blink red, and the sequence will end.
Possible Cause: Buckle/proximity sensors are not functioning correctly.
155
212
213
224
311
312
313
BAND-IT-IDEX, Inc.
A Unit of IDEX Corporation
4799 Dahlia Street
Denver, CO 80216-3070 USA
P: 1-800-525-0758
General
Servo Fault
Detected
Parameters
Not Passed –
Punch
Duration Out of Range
This error occurs when the servo and/or the drive are in a faulted state. When this error is triggered, the tool will fault, the LED will blink red, and the sequence will end.
Possible Cause: Obstruction in drivetrain.
This error will occur after a completed cycle if the measured "Punch Duration" is outside of the allowed range set on the HMI.
Possible Cause: Obstruction in punch assembly, damaged punch cylinder.
Parameters
Not Passed –
Torque Out of Tolerance
This error will occur after a completed cycle if the measured motor torque is outside of the allowed range set on the HMI for the set monitoring period. The torque is monitored from the point where it reaches the torque tolerance band and through tightening until after the punch operation.
Possible Cause: Tolerance settings too tight, worn motor/gearbox.
Parameters
Not Passed –
Contact
Switch Lost
Contact
Supply
Pressure Out of Range
This error will occur after a completed cycle if the contact switches lose contact during the monitoring period. The contact switches are monitored from the time they are first lined up to just after the punch.
Possible Cause: Operator movement during installation process
This message will display when the trigger is pressed, and the supply pressure is outside of the range defined on the HMI.
Possible Cause: Regulator set incorrectly
Punch
Pressure Out of Range
This message will display on the HMI while waiting for the punch pressure measurement to reach the set pressure range. If the punch pressure is achieved, the message will clear, and the tool will continue the sequence normally.
Possible Cause: Regulator set incorrectly
Torque Out of Tolerance
Before Cut
This message will display if the tool has completed the punch operation and motor torque has left the set torque tolerance before the tool completes the band cutting operation. The message will persist until the tool adjusts tension back to within tolerance, at which point it will automatically clear.
Possible Cause: See “ Pre-set tension is not reached ” troubleshooting section.
50
Document #P80080 Rev. B
© Copyright
BAND-IT-IDEX, Inc. 2022
All rights reserved
All rights reserved
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Key features
Installs 3/8" Tie-Lok® ties
Adjustable tension control
Data logging for quality verification
HMI programmable for custom applications
Pneumatic operation with electric motor
Automatic cut-off function
Frequently asked questions
The IT8000 tool is designed for use with BAND-IT 3/8 " Tie-Lok® ties only.
The tool requires 80 PSI (552 kPa) of clean, dry compressed air with an air flow rate of 0.25 CFM (7.1 L/min.).
The tool requires 110-230 Volts 50-60 Hz Grounded AC with a 4 A Max.
Always disconnect from air and electrical power sources before performing maintenance.