Product Manual

PRODUCT MANUAL Clasimat Basic Vertical Carousel and Accessories

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Product Manual

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Clasimat Basic

Clasimat Basic

Vertical Carousel for trays

Vertical Carousel for rolls

Vertical Carousel for wire

Optimal for products of any size that are packaged in boxes, baskets or trays.

This is the ideal lift module for wholesalers needing to store fabric, carpet or linen.

Specially designed to store all types of spooled product.

Option of measuring and reeling up every cable pull.

Introduction to Clasimat Basic

Installation, Replacement and Use

4

General Information

19 – 20 Hooks and Product Pole Inspection

5

Safe Operation

21

Drive Chain

6

Warranty, Maintenance and Troubleshooting

22

Product Chain

7

Electrical Requirements

23 – 24 Product Hooks

8

Keypad Components

25

9

Keypad Operation

26 – 27 Roll Goods

28 – 30 Sling Goods

10 – 15 Keypad Programming

Maintenance and Inspection

Loading and Unloading

31 – 32 Tray Goods

16 Motor

33

17 – 18 Sprocket and Product Chain

34 – 38 Spool Goods

39

Tire Gondola

40

Safety Brace

41

Troubleshooting for Clasimat Basic

Guard Inspection

2

Garment Storage

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Product Manual

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Clasimat Basic

Vertical Carousel for clothing

Vertical Carousel for tires

Vertical Carousel for cylinders

Well-suited for stores who need to save time accessing a clothing item that need to be kept in perfect condition.

Suitable for small workshops that need to store several tire models.

Excellent for storing long cylinders of most kinds.

Cutter and Accessories 42 – 43 Cutter and Accessories 44

Cutter Components

45

Cutter Control System

46 – 47 Cutting System Operation 48

Blade Replacement

49

Carpet Roller, V-Dolly and Lift Cart

50

Troubleshooting for Cutter

51

Maintenance Check List

3

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Product Manual

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General Information

General Information The Clasimat Basic is a carousel that can be used for several different applications and adapt to many types of products (tires, film, garments, rolls, boxes...). The Clasimat Basic enhances productivity, increases security and storage density; all while having product delivered quickly and efficiently to the operator. Vertical carousels can save up to 70 percent of valuable floor space, minimize dependence on forklifts and ladders, and provide an ergonomic environment for employees.

Availability and Shipping Locations Interlake Mecalux frames and accessories are manufactured and distributed from our plants located at: 701 Interlake Drive Pontiac, IL 61764

1925 Corporate Way Sumter, SC 29150

1600 N. 25th Avenue Melrose Park, IL 60160

Las Rusias 2700 CP 87470 Matamoros

Blvd. Bellas Artes #9001 Tijuana, Baja California

ISO 9001:2000 certified ISO 9001:2000 certified Matamoros, Mexico 87310 and Tijuana, Mexico 22444.

Interlake Mecalux distribution centers include: 701 Interlake Drive Pontiac, IL 61764

1925 Corporate Way Sumter, SC 29150

1600 N. 25th Avenue Melrose Park, IL 60160

8607 Ave de la Fuenta San Diego, CA 92154

1520 Selene Dr. Carrollton, TX 75006

Painting to Protect The right coating can save products and the environment.

Storage warehouses are tough settings for storage components. Heat, cold, humidity and other environmental agents can result in corrosion and oxidation of storage materials. Constant movement of stock in and out of racks can also damage them.

To ensure long lasting protection of its products, Interlake Mecalux uses the most advanced methods of paint coating. The result is an attractive product that is resistant to harmful agents, and that will withstand normal wear and tear of warehouse operations.

Protecting the environment from the harmful effects of paint pollutants is also a concern for the company. The ISO (International Organization for Standardization), the world’s largest developer and publisher of International Standards, awarded Interlake Mecalux the ISO 14001 which provides a framework for a holistic, strategic approach to the organization’s environmental policy, plans and actions.

Interlake Mecalux uses cataphoresis, hydro soluble paint and powder coating to guarantee a high quality paint job in its products, which produce smaller amounts of volatile organic compounds (VOCs) than in other coating methods, ensuring a more ecological alternative to traditional painting methods.

UL Standards encompass UL’s extensive safety research, scientific expertise and uncompromising focus on quality. With over a century of experience and the development of more than 1,000 Standards, UL continues to break new ground in its mission to help create a safer, more sustainable world.

4 Clasimat Basic

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Product Manual Safe Operation

2012

Safe Operation Read This Manual Carefully *This owners manual contains important information on safety, operation, and maintenance.

Anyone who operates this storage system should carefully read and understand the contents of this manual before using this machine. * In any situation, please remember Safety First! * Only authorized, trained personnel should operate this system and it is highly recommended that all operators read this guide prior to using the system.

• The Product Manual should be read in its entirety prior to operating the system.

•

Lock Out the Machine - If any mechanical or electrical work is to be performed on the machine, the main disconnect switch should be turned off, and proper lock out tag out procedures should be followed. Accidental operation of the machine with a person present in the mechanical drive train could result in serious injury or death.

Proper lock out tag out procedures can significantly reduce the chances of this occurring

•

Electrical Hazard Present - NEVER open the control cabinet without turning off the main disconnect. Even then, 230 / 480 volts will remain active on the power line to the control panel. If you are not trained or certified to do electrical work, stay out of the panel, and call an electrician

•

Mechanical Pinch Points Present - NEVER operate the carousel while others are doing work around the carousel.

Always clear the immediate area of personnel before moving the carousel

Warranty, Maintenance and Troubleshooting Interlake Mecalux product quality speaks for itself and is backed up with a one year warranty on parts and labor. Our own experienced staff of Project Manager’s and Technician’s offer uncompromising aftermarket service. As the need arises we also employ outside contractors who are trained on our equipment and provide excellent supplemental support.

As with all equipment that relies on moving parts, preventative maintenance is a key factor to trouble free operation. For a nominal fee, Interlake Mecalux will perform preventative maintenance and create a PM schedule and record of service.

When the preventative maintenance program is purchased in the first year, Interlake Mecalux will extend the original warranty to a full 24 months from date of delivery.

The Interlake Mecalux Preventative Maintenance Program (IMPMP) is scheduled for a once or twice a year visit to the customer’s premises to inspect critical component necessary for the safe and uninterrupted operation of the machine.

The recommended interval for IMPMP is twice per year. If the optional once per year IMPMP is purchased only the original 12 month warranty remains effective.

EasyWMS software developed and created by the Mecalux Group are the brains that run the Clasimat. The six available levels of EasyWMS software also support and run other automated and advanced systems provided by the Mecalux Group. EasyWMS is a comprehensive software package but of course, our effort is for continues improvement. When new versions become available the customer will be notified of the upgrade.

Interlake Mecalux, is part of the Mecalux Group a Global provider of storage equipment and automated systems.

Our core competency is providing equipment, systems and services for material handling.

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Product Manual

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Electrical Information

Electrical Requirements General Electrical Information •

208 – 240 volt 60 Hz 6 amp 3 phase 1 ½ hp motor (absolute minimum 208 volt)

•

380 volt 50 Hz 4 amp 3 phase 1 ½ hp motor

•

460 – 480 volt 60 Hz 3 amp 3 phase 1 ½ hp motor (absolute minimum 414 volt)

* If more than one system is installed in your building, each should be wired on a separate 3 phase 20-amp circuit.

Be aware that regional power reductions, often referred to as “brown-outs” are becoming increasingly common in many parts of the world. These problems usually occur during the daylight hours in the warmer months and can cause sporadic or even continual running problems. If you are experiencing problems that are described as “low-voltage” in the troubleshooting section, a brownout could be the cause.

Diagnosis of this problem can be made by calling the electric company while the problem is occurring and inquiring if they are currently reducing power. If the problem is chronic, you may want to consider adding a line conditioner to your electrical system.

L3

Receptacle Power •

Make sure the receptacle has proper power

•

Verify that all three legs of power are present

L1-L2

L1-L3

L2-L3

WARNING: To the maximum extent permitted by applicable law, in no event shall the Mecalux Group or its suppliers be liable for any damages whatsoever (including without limitation, special, incidental, consequential, or indirect damages for personal injury, loss of business profits, business interruption, loss of business information, or any other pecuniary loss) arising out of the use of or inability to use this product as a result of an unauthorized personnel causing undue accident, abuse, or misapplication.

6 Clasimat Basic

L1

L2

N

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Product Manual

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Components

Components

1. Front Guard

2. Down Struts

3. Header

4. Exterior Panel

5. Drive Chain

6. Motor

7. Control Panel

8. Product Chain

12

9 5

3

6

9. Sprocket

10. Sprocket Cover

11. Lower Sprocket Cover

12. Safety Brace

13. Light current

(optional for added safety)

8 2

10 1

13 11

Usable Area for C1 or C2 Carousels

7

4

Machine Width

3’

4’

5’

6’

7’

8’

9’

10’

11’

12’

13’

14’

15’

16’

17’

18’

19’

20’

Additions based on 12’ machine (in.)

-108

-96

-84

-72

-60

-48

-36

-24

-12

0

12

24

42

48

60

72

84

96

Machine overall with (ft.)

5’

6’

7’

8’

9’

10’

11’

12’

13’

14’

15’

16’

17’

18’

19’

20’

21’

22’

Product usable width (in.)

41

53

65

77

89

101

113

125

137

149

161

185

191

197

209

221

233

245

7

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Product Manual

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Control System

Keypad Components Machine Access Code The control panel limits machine use for authorized personnel through a standard key pad code or an optional turn key. There are two types of control systems, as shown. The key pad allows for individualized access codes that can be programmed and monitored, while the turn key system allows for a single access key. Depending on your specific needs, you can have either on your Clasimat Basic.

The Control System There are two types of control systems, as shown. The keypad allows for individualized access codes, while the turn key system allows for a single access key.

Depending on your specific needs, you can have either on your Clasimat Basic.

1

1

2

2

The system can also be automated by connecting the Clasimat Basic to our EasyWMSÂŽ management software.

The Up and Down toggle switch (left) functions properly once the keypad has been activated. Turn the toggle switch to the right and run for 5 minutes.

Repeat for the left position.

3

3

The E-Stop functions properly when the machine is being operated, activate the E-stop.

The turn key (right) functions properly once the key is inserted into key hole. Turn according to the direction you wish the drive chain to move which automatically activates the machine, then use the green button for go and red for stop.

5 4 6

1. Serial and Model number

2. Reset Button 7

3. E-Stop

5

4. Keypad

5. Up/Down Toggle Switch

6. Up/Down Toggle Switch

7. Turn key

8 Clasimat Basic

* Enter 4 digit code, followed by (#) button to activate controls.

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Control System

Keypad Operation Machine Access Code

Programming Procedures

The major purpose of the CL-8 is to respond in various ways to the programmed access codes entered by authorized users and to protect against codes entered by authorized people.

An authorized code holder should observe the following precautions:

1. Do not let anyone watch you while you key-in

your code.

2. Enter your access code digits one by one

then press #.

3. Do not wait more than 5 seconds between

successive keystrokes or it will not activate

the machine.

4. If you find it necessary to send a silent alarm signal

without operating the machine, press * and #

simultaneously, so as to trigger the PANIC circuit.

5.

If you are forced to enter your code under duress, press the AMBUSH digit immediately after entering your code. This actives the PANIC output but will not arouse any suspicion, since the person who is threatening you is not supposed to be familiar with the length of the digital code. When an access code is entered correctly, the keypad will respond by tripping the auxiliary circuit. The green indicator will light up green as long as the internal relay remains energized.

Programming the keypad is, in simple terms, providing it with a set of instructions on how to react in various counting devises. The keypad must be programmes as soon as all installations and wiring have been completed. Later on, as changes take place, partial or full reprogramming may be carried out as many times as necessary.

The first step in “telling the keypad what to do” is to access the programming menu, which is accessible only by use of the current “master code”. The factory default master code is 1234 but after subsequent programming, this default code will automatically superseded by user code No. 01, which is the real master code.

Programming Tips

1. The programming menu is selected by keying

**4321**. The green LED will acknowledge (by flashing slowly) that the programming menu is now active.

2. While the programming menu is active, you can

select various programming functions by pressing a

number from 1 to 5 (table 1).

3.

Entering a function number while the green LED is flashing slowly causes the light to start flashing rapidly. The desired value should then be entered, followed by the “end-of-data” character #.

Table: 1. Programming Menu No. 1 2 3

4

6

Function Name

Value to enter

Description

Programming user codes

Any combination up to 8 digits

Each code entered is assigned to an authorized individual or to a group of people (programming chart - appendix A)

Timing the relay

01 to 98

Sets relay contact closure duration between 1 and 98 sec.

Latching the relay

99

Selects toggle mode (latching/unlatching)

Selecting AUX output mode

1 to 7

Each number entered selects a different AUXILIARY output operating mode (table 4)

Deleting all single user codes

user numbers, 02 to 56 [master code]

User code corresponding to the user number entered is deleted

Deleting all user codes

**# [master code]

All user codes are deleted in a single operation, except for master code 01

Ambush digit

0 to 9

The programmed digit will be valid until deleted or replaced

Delete ambush digit

*

The ambush digit is canceled

9

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Key Programming

Product Manual

2012

Control System

Table: 2. User Code Programming Steps Step

Enter

Description

1

1 [user no.] #

1 selects the user-code programming function which is always from 01-56

2

[user code] #

[user code] is from 1-8 digits from 0-9

3

[user code] #

[user code] repeats the previous step for verification

4

[trip code] #

1 to trip only the relay or 2 to trip only the AUX output or 3 to trip both

4.

Functions 2, 3 and 5 on the menu are single-stage programming operations. If the correct data is entered, followed by #, the green light lights up steadily for 2 seconds and then resumes flashing slowly (to return to menu).

5.

User code programming (Functioning No. 1 on the menu) is a 4-stage operation which calls for step by-step entry of several data groups are each terminated by pressing #, which serves here as a “separating character”. The last data group is also followed by keying #, which resumes its role as an “end-of-data” character.

8.

9. To quit programming altogether and return to

normal operation, press # while the green LED is

flashing slowly.

Figure 5. Programming Flow Chart Enter [**master code**]

LED flashes slowly

Table: 3. User Code Deleting Steps Step

Enter

Select Function No.

Description

4 [user no.] #

4 selects the user-code deleting function: **deletes all codes except for 01

LED flashes rapidly

or: 4 **#

4 selects the user-code deleting function: **deletes all codes except for 01

Enter Programming Data

1

2

To change your mind after having selected a function on the menu, press *; the green LED will flash slowly again, indicating that the same function or a different one may be selected.

[master code] is entered here to make sure [master code#] that the codes are being deleted by the senior user

6.

In multistage programming operations (functions 1 and 4 on the menu), when the group separating character # is pressed, the green LED will light steadily for 2 seconds to acknowledge but will then flash rapidly. Only when the “end of data” # is entered at the end of the last step – will the LED respond by lighting steadily for 2 seconds and then flashing slowly.

7.

When a programming error occurs, data is rejected, causing the green LED to go out for about three seconds and then to flash slowly. In such a case the entire programming sequence for the rejected function must repeated.

10 Clasimat Basic

LED flashes steadily for 2 sec. then resumes flashing

LED goes out for 3 sec. then flashes slowly again

Press # to quit

Preparing for Operation 1. Start programming by entering (** [master code]

**) then look for the green LED to start flashing.

2. Enter 4, **# [master code] #, to delete all user

codes, thereby ensuring that no user codes remain

in the memory as a result of factory test procedures.

This is a 2 stage process as follows:

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Product Manual Control System

- After entering the first [4] rapid flashing - After entering **# steady light for 2 sec. then rapid flashing again.

- After entering the master code [4321#] LED for 2 sec. then return to slow flashing.

3. Set the relay timer by entering 2. [TT #] where [TT] is the relay contact closer duration in seconds; enter 01 to 98 to obtain duration from 1 to 98 sec. or enter 99 to cause the relay to operate in the toggle (launch/unlaunch) mode.

4. Select the AUXILIARY output mode by entering 3, [M #] where [M] is expressed by a number selected from the mode column in Table 4 below.

5. If you do not intend to use an ambush digit, it is imperative that you enter 5 * # (the code which deletes the ambush digit), to ensure that no previously programmed digit remains in memory, choose one from 0 to 9 and program it by entering 5 [the desired ambush digit] #. *Having programmed an ambush digit, you must restrict user codes to seven digits or less and avoid choosing user codes ending with the same digit.

For example, if your ambush digit is 4 then avoid the user code ending with the number 4.

2012

6. Quit programming by pressing # while the LED is flashing slowly. The green light will then go out.

Testing the keypad After having prepared the keypad for operation and before programming the various user codes, the keypad should be tested. Since no user codes have yet been programmed, the factory-default master code is 4321 is the only code the CL-8 recognizes and should operate both the relay and the auxiliary output in accordance with the latest programming (stages 3-6 in previous paragraph).

1. Enter 4321# 2. Test the AMBUSH digit (if programmed) by entering 4321 [AMBUSH digit], this should send a one sec. pulse to the PANIC output.

3. Check if the REQUEST TO EXIT (remote) input operates the relay.

4. Press * and # together to verify that the PANIC output is activated.

Programming user codes

1

Pulsed for 1 sec. by every user code authorized to operate the auxiliary output.

After verifying proper keypad operation, the user codes can be programmed. Table 5 sets an example for assigning codes to individual users. Remember that user code no. 01will become the new master code as soon as it is programmed and should therefore be assigned to the person in charge of security.

2

Toggled (latch/unlatch) by every user code authorized to operate the auxiliary output.

*

3

Operated concurrently with the relay timer but stays enabled 5 sec. more after the relay is de-energized (operation time: TT+ 5 sec.). If the relay toggle mode has been selected (TT=99), the auxiliary output will be turned on for 5 seconds each time the relay is toggled.

1. Prepare a list of user codes you want to program and record them in your Programming Chart (see page 16)

4

Latches by user codes authorized to trip the auxiliary output, unlatches by pressing *

5

Turned on for ten sec. by pressing any key.

6

Oscillates at the rate of 1 Hz after 3 consecutive code errors.

This condition will persist for 10 min. and may be reset only by entering a valid user code (resetting is possible only after the first 30 seconds, during which the keypad will be locked out as a result of the 3 code errors).

7

Turned on by pressing 1 and 3 simultaneously. Remains on while either key is pressed.

Table: 4. Auxiliary Output Operating Modes Mode

Description

It is recommended that the master code be composed of 8 digits. If there is not an ambush digit, you may program user codes freely.

2. Invoke the programming menu by entering ** [master code] ** at this point we shall assume that the factory default of 4321 is still valid. When the programming menu is active, the green LED flashes slowly, approximately once every 2 sec.

3. Press 1 to select user code programming. The green LED begins to flash rapidly, indicating that the key pad is ready to receive data.

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Product Manual Control System

*Remember to prevent programming by an unauthorized user, you should change the default code [4321] right away. We recommend the code should contain 8 digits.

4. Enter user number 01 followed by #. The green LED will light steadily for 2 sec. and then return to rapid flashing.

5. Enter the code assigned to this user, followed by #.

The green LED lights steadily for 2 sec. and then return to rapid flashing.

6. Repeat the user code followed by #. The green LED will acknowledge as in step 5 above.

2012

Deleting user codes 1. Access the programming menu by entering ** [master code] **. With the programming menu active, the green LED will flash slowly.

2. Enter 4 to select the user code deleting function the green LED will respond by flashing rapidly flashing.

Indicating that the keypad is ready to receive data.

3. Enter the user number whose code you wish to delete or ** if you want to delete all users and finish off by entering #. The green LED will light steadily for 2 sec. and then resume flashing rapidly.

7. Now select which outputs will be tripped by the new master code: enter 1 to trip only the relay, 2 to trip only the auxiliary output and 3 to trip both. Than press #. This time the green LED lights steadily for 2 sec. then flashes SLOWLY, indicating that the new master code and its extent of control have been programmed successfully and that the keypad has returned to the programming menu. Now you can either program the following user code or quit programming by pressing # again.

*ATTENTION: the master code (01) cannot be deleted in this manner.

8. Continue to program all user codes as listed on your program chart. A blank form is provided on the next page.

Resetting user codes

Function

User No.

Separator

Separator

Trip Code

Enter

19/12

Cristina M.

1

01

#

54987652

#

3

#

19/12

Jesse W.

1

02

#

54987538

#

1

#

19/12

Adam S.

1

03

#

21549864

#

2

#

Date

User’s Name

1. Uncover the keypad’s case uncovering the circuit board.

2. Install the jumper across the two pins labeled JP2.

*Do not enter new data if the green LED responds by going out for 3 sec. after pressing [#] If the CL-8 detects an error, the green light turns off for 3 sec. and then turns to flashing slowly, thus indicating that the data has not been accepted. It would be necessary to repeat the entire programming sequence for the rejected user code. If you make an error while programming, press and you will be instantly returned to the programming menu. To quit programming, ensure that the green LED is flashing slowly, then press #, to restore to normal operation.

12 Clasimat Basic

5. If you intend to delete another user code, return to step 2 above. If you are through deleting, restore the keypad to regular operation by pressing # while the green LED is flashing slowly.

If you forgot or lost the user code 01 and it becomes necessary to reprogram the keypad, it is necessary to reset the master code to the factory default (4321) as follows:

Table: 5. User Code Programming Chart Example User code 1 to 8 digits Has to be repeated followed by a separator [#]

4. Enter the [master code] once more, followed by #. The green LED will light steadily for 2 sec. and then return to slow flashing.

3. Momentarily short circuit the pins labeled JP1 using a screwdriver or jump wire.

4. Wait 10 sec., remove the jumper from JP2 and immediately press 1234#. The green LED will light steadily for two sec. and then start flashing slowly, indicating that the programming menu is active. *ATTENTION: the master code has temporarily reverted to 4321. Remember, however, that all other data programmed previously remains intact!

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Product Manual Control System

5. Program a new master code (user code No. 01) immediately, and record it in a secret safe place. If you choose to quit programming at this stage, press # while the green LED is flashing slowly.

Programming changes The keypad can be partially or entirely reprogrammed after it has been placed in regular service; the procedures are similar to those for initial programming.

slowly. Enter 2: the LED flashes rapidly. Enter 08#: the LED lights for two sec. and then returns to flashing slowly. Press # again to return to normal operation.

Verify the timing by entering the master code or by pressing the request to exit switch.

2. Switch the relay to the toggle (latch/unlatch) mode.

1. Enter ** [master code] **. The green LED flashes slowly, indicating that the programming menu is active.

2. Select any function 1 to 5 on the menu (table 1).

3. Function number 1, programming user codes, entails completing four steps for each code as shown in table 2.

4. Having selected function No. 2 (timing or latching the relay), function No. 3 (auxiliary output mode) or function No. 5 (ambush digit), enter the desired value and press # as an “end of data” character. The green LED lights continuously for 2 sec. and then flashes slowly.

5. Function No. 4 entails completing two steps as shown in table 3.

As always, if you are having any problems with these instructions please call Interlake Mecalux at 708-344-9999 for assistance from one of our trained professionals.

Programming Examples

FORMAT: ** [master code] ** 2, 08 # # Enter ** [master code] ** and wait for the LED to flash

FORMAT: ** [master code] ** 4, 15 # # Enter ** [master code] ** and wait for the LED to flash slowly. Enter 4: the LED flashes rapidly. Enter 15# the LED lights for 2 sec. and returns to flashing slowly. Press # to return to normal operation. Verify the deletion by attempting to use the code: keypad should not respond.

5. Program the ambush digit to be 3.

FORMAT: ** [master code] ** 5, 3 # # Enter ** [master code] ** and wait for the LED to flash slowly. Enter 5: the LED flashes rapidly. Enter 3# the LED lights for 2 sec. and returns to flashing slowly. Press # to return to normal operation. Verify by entering the master code with the ambush digit at the end; the panic output should be triggered for one sec.

*

CAUTION! The ambush digit cannot be used with an eight digit user code. Use a different number at the end of master code then ambush #.

Examples:

FORMAT: ** [master code] ** 3, 2 # # Enter ** [master code] ** and wait for the LED to flash slowly. Enter 3: the LED flashes rapidly. Enter 2# the LED lights for 2 sec. and returns to flashing slowly.

Press # to return to normal operation. Enter the master code twice to verify that the output latches and then unlatches.

4. Delete user code 15.

The examples shown in this section all apply to reprogramming while the keypad functions normally. All references to “LED” means the green light.

1. Change the relay contact closure duration to eight sec.

FORMAT: ** [master code] ** 2, 99 # # Enter ** [master code] and wait for the LED to flash slowly. Enter 2: the LED flashes rapidly. Enter 99# the LED lights for 2 sec. then returns to flashing slowly.

Press # again to return to normal operations. Verify toggle operations by entering the master code twice or by pressing request to exit switch twice.

3. Change the auxiliary output to the toggle mode.

6. While the green LED is flashing slowly, select a new function or press # to restore normal operations. *

2012

13

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Product Manual

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Control System

Table: 1. Programming Menu No.

Function Name

1

Access to Programming Menu

Value to enter

Description

** [master code] **

• The green LED starts to flash slowly - the programming • Menu is active

2

Deleting all previous User Codes

[4] ** # [master code]

• After pressing [4] rapid flashing • ** deletes all user codes except for code No. 01 • After keying ** # steady light for 2 sec. then rapid flashing • After keying [master code] # steady light for 2 sec. then slowly flashing

3

Relay timing

[2] TT #

• After pressing [2] rapid flashing • [TT] = 01 to 98 sec. 99 selects the toggle mode, in which a user code will latch or unlatch the relay • After keying [TT] # steady light for 2 sec. then slowly flashing

4

Selecting AUX output operating mode

[3] [M] #

• After pressing [3] rapid flashing • [M] = a code specifying the operation mode of the AUX output (selected from Table 4 ) • After keying [M] # steady light for 2 sec. then slowly flashing

5

Defining an AMBUSH digit

[5] [A] #

• After pressing [5] rapid flashing • [A] = Ambush digit, 0 to 9 (see note below) • After keying [A] # steady light for 2sec. then slowly flashing

6

Deleting the AMBUSH digit

[5] * #

• After pressing [5] rapid flashing • * = Deletes the Ambush digit • After keying * # steady light for 2sec. then slowly flashing

7

Programming user codes (prepare a list, see next page)

[1] [NN] # [C] # [C] # [F] #

• After pressing [1] rapid flashing • [NN] = the serial number of the code user, 01 to 56 • After keying [NN] # steady light for 2 sec. then slowly flashing • [C] = the access code allocated to this user, 1 to 8 digits • After keying [C] # steady light for 2 sec. then slowly flashing • Repeat [C] # for verification; the LED responds as before • [F] = a code defining which outputs will be tripped by this user code • 1: Authorization to trip the relay • 2: Authorization to trip the AUX output only • 3: Authorization to trip both relay and the AUX output • After entering [F] steady light for 2 sec. and then slow flashing

8

Deleting individual user codes

[4] [NN] # [master code] #

• After pressing [4] rapid flashing • [NN] = the serial number of the code user, 02 to 56 • After keying [NN] # steady light for 2 sec. then slowly flashing • [master code] # steady light for 2 sec. then slowly flashing

• Quit programming by pressing # when the LED light flashes slowly. • While entering data, if the green LED responds by going out for 3 sec. instead of lighting for 2 sec. the data has not been accepted. Press [*] and repeat the entire stage from beginning. • An AMBUSH digit cannot be used with 8 digit user codes and should not be identical with the last digit in any code. • The PANIC output is tripped by pressing [*] and [#] simultaneously.

Table: 2. Auxiliary Output Operating Modes Mode

Description

1

Pulsed for 1 sec. by every user code authorized to operate the auxiliary output.

2

Toggled (latch/unlatch) by every user code authorized to operate the auxiliary output.

3

Latches by user codes authorized to trip the auxiliary output, unlatches by entry of any user code.

4

Latches by user authorized to trip the auxiliary output, unlatches by pressing *

5

Turned on for ten sec. by pressing any key

6

Oscillates at the rate of 1 Hz after 3 consecutive code errors. This condition will persist for 10 min. and may be reset only by entering a valid user code (resetting is possible only after the first 30 sec., during which the keypad will be locked out a result of the 3 code errors.)

7

Turned on by pressing 1 and 3 simultaneously. Remains on while either key is pressed.

14 Clasimat Basic

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User Code Programming Chart (advise to scan and keep copy in a safe place).

Date

User name

ProductManual_Clasimat.indd 15

New user code 1-8 digit

Separating character

Repeat user code for verification

Function

User #

Separating character

Separating character

Trip code

End of data character

1

01

#

#

#

#

1

02

#

#

#

#

1

03

#

#

#

#

1

04

#

#

#

#

1

05

#

#

#

#

1

06

#

#

#

#

1

07

#

#

#

#

1

08

#

#

#

#

1

09

#

#

#

#

1

10

#

#

#

#

1

11

#

#

#

#

1

12

#

#

#

#

1

13

#

#

#

#

1

14

#

#

#

#

1

15

#

#

#

#

1

16

#

#

#

#

1

17

#

#

#

#

1

18

#

#

#

#

1

19

#

#

#

#

1

20

#

#

#

#

1

21

#

#

#

#

1

22

#

#

#

#

1

23

#

#

#

#

1

24

#

#

#

#

1

25

#

#

#

#

1

26

#

#

#

#

1

27

#

#

#

#

1

28

#

#

#

#

1

29

#

#

#

#

1

30

#

#

#

#

1

31

#

#

#

#

1

32

#

#

#

#

1

33

#

#

#

#

1

34

#

#

#

#

1

35

#

#

#

#

1

36

#

#

#

#

1

37

#

#

#

#

1

38

#

#

#

#

1

39

#

#

#

#

1

40

#

#

#

#

1

41

#

#

#

#

1

42

#

#

#

#

1

43

#

#

#

#

1

44

#

#

#

#

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Product Manual

2012

Control System

Motor General Characteristics •

Motor bolts are torqued

•

Motor operates properly under load

•

Amp draw will be less then 5.5 AMPS even when there is a 20% out of balance present

•

Carousel stops within specs

The carousel can properly run with 20 percent out of balance, though Interlake Mecaulx does not recommend running the carousel in this out of balance state. The brake on the motor will stop the carousel within 3 inches.

Torque (4) bolts to 37ft. – lbs.

Maintenance and Inspection Brake Test Procedure:

A. Verify carousel has a balanced load.

B. Operate the carousel so it is running in the

down position.

C. Release button or toggle switch.

D. Measure the product drift from the point were the button/toggle

switch is released to the resting point of the product.

E. If the drift of the product exceeds 3 inches, the motor/brake unit

needs to be replaced.

16 Clasimat Basic

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Product Manual

2012

Control System

Sprockets and Product Chain Maintenance and Inspection Sprocket Seating

Sprocket and Product Chain Inspection

Confirm:

Confirm:

•

Product sprocket seated on shaft.

•

The snap rings are set properly.

•

Snap ring installed.

•

The cut washer and cotter pin are installed.

•

Cut (flat) washer installed.

•

No sprocket teeth are deformed, or bent.

•

Cotter pin installed.

•

Any debris in the drive ring and product sprocket are removed.

1

1. Chain

2. Cut (flat) washer.

3. Snap ring.

4. Hitch pin

Top View

4 3

2

Side View

17

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Product Manual

2012

Behind the Guard Inspection Inspect behind the guards then remove lower sprocket cover with a socket wrench Remove sprocket cover with a socket wrench then remove exterior panel (covers both sides of the machine) top to bottom with a socket wrench.

For further instructions contact an Interlake Mecalux representative at \708-344-9999. *WARNING: It is never permissible to store anything behind the Guard, for this is dangerous and could result in a broken machine.

1

18 Clasimat Basic

2

1. Lower sprocket cover

2. Sprocket cover

3. Exterior panel - covers both sides of

the machine - top to bottom

3

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Product Manual

2012

Hooks and Product Pole Product Chain Lubrication Points To ensure proper lubrication of all chains – lubricate between side plates and rollers indicated below #1 and #2. (30W SAE oil)

1

1. Side Plate

2. Rollers

2

Hook Inspection (right hook HOK0051, left hook HOK0052) •

Check pin for defects/cracks and bends

The spring should be in place. Keep the safety latch in the closed position. The safety latch should move freely and there should be no elongation and cracks at the throat of the hook.

•

Inspect hook for bends at the hook opening

1 2

5

1. Pin 2. Spring

3. Safety latch

4. Throat of the hook

5. Hook opening

3

4

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Product Manual

2012

Carrier Product Pole Inspection •

Inspect rivet ends for wear

•

Inspect pole for bends

Product pole should not be bent more then ½ inch in the middle. *Please refer to your custom referral drawing for product pole capacity charts.

2

1. Rivet

2. Carbon Steel Pole

1

Pole Inspection The hardware for the Combo Carpet/Vinyl Machines is to be installed by an authorized representative of Interlake Mecalux.

Determine if the pole has a deflection. If the pole has a deflection of more than 1/2” at the center, the pole needs to be replaced. This can be checked with a string from one end to the other while level.

Inspect rivet for wear or bends. Replace pole if either are present. *If pole remains deflected after all product has been taken off, do not use.

Call Interlake Mecalux for a replacement pole.

L/240=deflection

L

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Product Manual

2012

Drive Chain Drive Chain Adjustment We strongly recommend calling Interlake Mecalux to make such an adjustment. This is a difficult process and should be done by the professionals. Our trained staff is ready to assist you.

Call 708-344-9999 Excessive Drive chain tension can cause serious machine damage so run the carousel for 5 minutes forward and 5 minutes backward while observing drive chain movement. Stop machine between the most slack and the tightest spot.

Using a 15/16” box wrench tighten slack adjuster hex nut until chain has 1/2” to 1” deflection where noted.

•

Repeat steps 1 through 3 as necessary

3

4

2

1

1. Slack Adjuster

2. Hex Nut

3. Point of Deflection

4. Drive Ring on the

Product Sprocket

21

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Product Manual

2012

Product Chain Product Chain Adjustment *Excessive Drive Chain tension can cause serious machine damage!

We strongly recommend calling Interlake Mecalux to make such an adjustment. This is a difficult process and should be done by the professionals. Our trained staff is ready to assist you. Call 708-344-9999 •

Tension the product chain

•

Check Chain adjustment to make sure it is between 3/4” to 1-3/4”

To adjust chain loosen the 11-5/8 lock nuts to Lower Take up unit. Turn the 11-5/8 bolts to increase or decrease pressure on the chain making sure you tension both bolts evenly to desired tension then tighten lock nuts and install guard panels.

1

2

6’0”

1. Push Chain

2. Lower take up unit

3. 11-5/8” Bolts

22 Clasimat Basic

3

3

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Product Manual

2012

Installation and Replacement Product Hooks The product hook attaches to the product chain using a 9/16” bolt. One on each side of the chain that sits parallel with each other. The metal rod is the product pole that is easily placed onto the hooks with a spring latch. The bolt installs through chain from outside, with the nut toward the middle of the machine.

Installing Hooks: Insert Bolt– install Using 9/16” socket through the product chain from the outside of the machine to the inside.

Place hooks U0093002 and U0093004 over shoulder bolt

•

Slip flat washer U0090826 over bolt

•

Install nut U0090817 and tighten to 16–20 Ft/Lb

3

Carpet Vinyl Hook

•

1. 1/2” bolt U0099121

2. Place bolt here

3. Washer

4. Nut

Upright tube

1

4

2

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Product Manual

2012

If a Hook Breaks: Call Interlake Mecalux at 708-344-9999 for all replacement parts Replace hook by removing all product on product pole from any damaged hooks. Loosen bolt from product chain with 9/16� socket wrench then remove washer, hitch pin and nut. Follow instructions on previous page.

2

1. Washer

2. Hitch Pin

Wire Spool Hook

1

*The Rivet is Seated at the Bottom of the Hook. *The Safety Latch is Shown here in its Closed Position.

24 Clasimat Basic

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Product Manual

2012

Loading Correct weight balancing technique Used for all styles of Clasimat Basic Enter the access code to activate the machine and turn the selector in the UP direction. Continue until the product is safely lifted off of the loading dolly.

Move the loading dolly safely away from the machine.

Re-enter the access code to activate the machine and turn the selector to the UP direction. Load the second roll directly opposite the first roll.

Load each subsequent roll at the mid-point of each remaining open space, taking care to load each roll opposite the last roll loaded.

Important: When replacing empty rolls, keep in mind that you may have to rearrange the other rolls on the display to maintain proper balance. Keeping the display mix as evenly balanced as possible is one of the best ways to ensure the longevity and reliability of your system. If this method is followed, you should be able to avoid any balance problems during loading.

Observe that during the loading procedure the desired reference location does not drift more than 4� after releasing the up/down switch. If it does, you have most likely exceeded the out of balance capacity of the system. * Reload the system in an even pattern.

25

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Product Manual

2012

Loading and Unloading Procedure Loading Roll Goods Always remove any protective covering from the product roll prior to loading it, if applicable.

Slide product pole into carpet core while roll is on V-Shaped Loading Dolly.

Cycle V-Shaped Loading Dolly towards front of carousel.

Activate the machine by entering the access code (4321#) (Please refer to pages 10-16 for key pad operation and programming guide).

Rotate carousel until an open set of hooks are close to the location of the product pole.

1. V-Shaped Loading Dolly

2. Where the product pole attaches

3. Roll good security straps Side Profile

Latch one side of pole onto hook.

Latch opposite side of pole onto opposite hook.

Rotate carousel so that the roll lifts off V-Shaped Loading Dolly.

2

Run machine until first roll is on the opposite side of the loading area.

Load second roll in the same fashion as the first.

Cycle machine a quarter of the way around and load third roll (this will maintain carousel balance).

Rolled Good machines come with straps.

3

1

26 Clasimat Basic

Carpet or Vinyl Clasimat Basic

*CAUTION: Do not store anything under carousel

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Product Manual

2012

Roll Good Capacities Unloading Roll Goods

Cycle the pole meant to be unlatched to a comfortable height.

Unlatch one side of the pole and rest on V-Shaped Loading Dolly.

Unload opposite side of pole and rest on V-Shaped Loading Dolly. *As poles weigh between 20 and 50 lbs, the use of a dolly is not necessary in most cases with wire

Rolled Goods Capacity Grid Core Inside Diameter may not exceed Pole Outside Diameter by more than 1�.

If using the Brake Hook, Maximum Roll Diameter is 25�. *Please refer to your custom referral drawing for your specific rolled goods capacity charts.

Roll Outside Diameter

C1 Link Spacing

0 - 6.9"

3

6.9 - 9.9"

4

9.9 - 12.7"

5

12.7 - 15.5"

6

15.5 - 18.2"

7

18.2 - 20.8"

8

20.8 - 23.3"

9

23.3 - 25.7"

10

25.7 - 27.9"

11

27.9 - 29.9"

12

29.9 - 31.8"

13

31.8 - 33.5"

14

33.5 - 35.1"

15

35.1 - 36"

16

27

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Product Manual

2012

Loading and Unloading Procedure Loading Sling Goods Always remove any protective covering from the product roll prior to loading it, if applicable.

On a cart or V-Dolly cycle cylinder towards front of carousel.

Determine acceptable load cylinder height by running machine to a height determined by operator (this is usually 2 to 4 inches above the height of the product cylinder).

Slide slings towards carrier edge in order to slide over the ends of cylinder

1. V-Shaped Loading Dolly

2. Where the Sling Strap attaches Side Profile

Slide sling over product cylinder journal, repeat for opposite side.

Activate the machine by entering the access code (4321#) (Please refer to pages 10-16 for key pad operation and programming guide).

Run carousel so cylinder is lifted off cart and remove cart.

Rotate carousel so first carrier is on the opposite side of the machine.

Rotate carousel so first carrier is on the opposite side of the machine.

Cycle machine a quarter of the way around and load third cylinder (this will maintain carousel balance). *CAUTION: Do not store anything under carousel

2 1

28 Clasimat Basic

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Product Manual

2012

Sling Capacities and Types Sling Poles Sling Poles are perfect for sensitive goods like lithography printer rollers that need to be suspended so as not to damage the roller.

Sling Size varies with Product. For Print Cylinders, Journal Diameter, Roll Face Diameter, and the Diameter of any journal mounted bearings must be specified. *Please refer to your custom referral drawing for your specific sling goods capacity charts.

Maximum Gross Weight per Station

750 to 1500 lbs.

1 6

2

80” (8’ Wide Carousel) 152” (14’ Wide Carousel) 194” (17.6’ Wide Carousel)

Standard Size (width) Standard Color

Gloss Black

May be Used on

C1, C2 and 20k

4 5 3

1. Tee Bolt Connector

2. Slider Assembly

3. Locking Knob

4. Sling

4

5. Choker Pole

6. Slider Pole

29

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Product Manual

2012

Sling Poles Capacity Grid Capacities assume 1 cylinder per pole with sling point No more that 12” in from each end.

Carousel Size

Nominal Length

Pole Style

Outside Diameter

Wall Thickness

Net Capacity

6 foot

Slider

80"

3.5"

.1875"

1400 lbs.

12 foot

Slider

152"

3.5"

.1875"

1350 lbs.

1300 lbs.

15 foot

Slider

194"

3.5"

.1875"

6 foot

Choker

80-1/2"

3"

.120"

725 lbs.

12 foot

Choker

152-1/2"

3"

.120"

700 lbs.

15 foot

Choker

194-1/2"

3"

.120"

675 lbs.

*Please refer to your custom referral drawing for your specific sling goods capacity charts.

Sling Poles Usable Area =for C1 or C2 Carousels Machine Width

3’

4’

5’

6’

7’

8’

9’

10’

11’

Adder based on 12’ machine (in.)

-108

-96

-84

-72

-60

-48

-36

-24

-12

0

12

24

42

48

60

72

84

96

Machine overall with (ft.)

5’

6’

7’

8’

9’

10’

11’

12’

13’

14’

15’

16’

17’

18’

19’

20’

21’

22’

Product usable width (in.)

41

53

65

77

89

101

113

125

137

149

161

185

191

197

209

221

233

245

30 Clasimat Basic

12’

13’

14’

15’

16’

17’

18’

19’

20’

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Product Manual

2012

Loading and Unloading Procedure Tray Storage Always remove any protective covering from the product roll prior to loading it, if applicable.

Load first tray with product (trays are designed so that product fills 85% to 95% of the tray from front to back. This reduces the amount of tray tilt).

Activate the machine by entering the access code (4321#) (Please refer to pages 10-16 for key pad operation and programming guide).

Once first tray is loaded rotate tray so that the tray is at the opposite side of the machine.

1. Where the Tray attaches

2. Arm 3. Tray Side Profile

Load second tray in the same fashion as the first.

Cycle machine a quarter of the way around and load third tray and then three-quarters around to load the fourth tray (this will maintain carousel balance). *CAUTION: Do not store anything under carousel and do not load any item that

causes tray to tilt more than 5 degrees

3

Standard Tray

1 2

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Product Manual

2012

Tray Capacities and Types Standard Duty Tray Maximum Gross Weight for most common trays

•

Maximum Product depth = Tray Depth – 1/2”

•

Minimum Arm Length = Product Height x 75%

Standard Duty Trays for 12’ and 15’ wide carousels will have 3” high reinforcing tubes under the tray. For trays with reinforcing tubes, add 3” to the arm length.

Up to 650 lbs.

Net Tray Capacity

650 Lbs.

Standard Depths

12”, 16”, 18”, 20”, 24”

Standard Tray Usable Width

77” (8’ Wide Carousel) 149” (14’ Wide Carousel) 191” (17.6’ Wide Carousel)

May be Used On

C1, C2, 20k

*Please refer to your custom referral drawing for your specific tray goods capacity charts.

Two, Three, Tier and Heavy Duty Tray •

Maximum Product depth = Tray Depth – 1/2”

•

Minimum Arm Length = ((Product Height x 2) + 2-3/4”) x 75%

1

*Please refer to your custom referral drawing for your specific tray goods capacity charts.

2

Product Height

3

2 3/4 Product Height

Arm Length

Product Depth

Tray Depth

32 Clasimat Basic

1. Standard Duty Tray

2. Two Tier Tray

3. Three Tier Tray

4. Heavy Duty Tray

4

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Product Manual

2012

Loading and Unloading Procedure Garment Storage Always remove any protective covering from the product roll prior to loading it, if applicable.

Garment carriers are spaced on the carousel in two ways: 1) For shirts, which will accept a 20” deep x 32” height and 2) For pants 20” deep x 47” height (review labels on the carriers before loading).

To load, make sure the garment is on a hanger and hang it on the carrier’s pole.

Activate the machine by entering the access code (4321#) (Please refer to pages 10-16 for key pad operation and programming guide.)

Once the pole is filled, rotate carrier to opposite side and load the next carrier pole.

Repeat this in order to maintain balance of the machine. *CAUTION: Do not hang hangers on protective mesh and do not store anything under carousel

Garment Protector

33

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Product Manual

2012

Loading and Unloading Procedure Smaller Spooled Goods Always remove any protective covering from the product roll prior to loading it, if applicable.

Remove spool pole by unlatching the pole at each end, slide pole into core of spool.

Side Profile

Replace spool onto hooks making sure latches are engaged.

Ensure wire is secured and not loose (unraveling of spool may cause damage and injury).

Activate the machine by entering the access code (4321#) (See pages 9 – 14 for key pad operation and programming guide).

Load one carrier at a time and rotate carriers before loading to maintain proper machine balance.

Larger Spooled Goods Utilize the Spool Loading Dolly for larger spools.

Activate the machine by entering the access code (4321#). (See pages 9 – 14 for key pad operation and programming guide).

While spool is on the ground, place pole into core as mentioned in the first Spool section.

Wheel loading dolly into place, matching the dolly arms to the pole.

Rotate dolly handle down, maintaining force to keep the spool off the ground.

Wheel dolly and spool to hooks on the spool carrier.

Latch pole onto hooks as mentioned in the first Spool section.

Release your weight and remove dolly.

Load one carrier at a time and rotate carriers before loading to maintain proper machine balance. *CAUTION: Do not store anything under carousel

34 Clasimat Basic

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Counter Coiler Operation Purpose Assists in the measured safe and ergonomic removal of wire from parent spool.

Durable for cutting and measuring any wire size up to 8-gauge.

1

2

3

4

5

8

Step by Step Instruction Step 1: Pushing the Counter Coiler beam [a] into position in front of the desired spool, extend the Counter Coiler arm [b] outward away from the Clasimat. *NOTE: the Counter Coiler beam will not slide horizontally while its arm is extended out

Step 2: Check that the Coil Spires [c] are spread far apart before threading and coiling wire around it.

Step 3: With the beam in place, thread the wire through the Counter [e] while pushing the Stabilizing Lever [d] down and wedge the wire end into the Coil Wheel’s “Y” Brace [f].

Step 4: Manually crank the Coil Wheel [g] using the Rotating Handle [h].

Step 5: Once the desired length of wire has been coiled, snip it by pulling up on the Cutting Lever [i].

Step 6: Secure the coiled wire together using electrical tape, wire or string.

Step 7: Push in the Coil Wheel [g] to condense it to grab the now rolled up wire.

Step 8: Move the Counter Coil arm back to its inward position. *NOTE: Remember to roll stray wire back onto the parent spool before restoring it into the Clasimat

• Accuracy of +/- 1/2 of 1% • Capacity range 1/64” OD x up to 7/8” OD maximum (flexible material) • Steel plate construction with entrance and exit guides • Stainless steel and heat treated shafts and wear surfaces • Two machined steel metering wheels • Spring loaded constant tension floating idler arm • Mechanical counter that adds or subtracts; indicates 9,999’ 11” • Counter reset to zero with turn knob • 8 5/16” high by 7 1/4” wide, 5lbs.

35

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Product Manual

2012

Cutter Blade Replacement Wire Coiler Components

Call Interlake Mecalux at 708-344-9999 The specially designed 8” long blade can easily be replaced by pulling out the cotter pin and unhooking the handle that is attached. The blade can be replaced with a phone call to your Interlake Mecalux provider and we suggest you do so as soon as the blade starts to wear.

a. Counter Coiler Beam

Most blades last about a year, depending on how much you use it and what kind of wire or rope you cut into.

b. Counter Coiler Arm

c. Coil Spires

d. Stabilizing Lever

e. Counter

f. “Y” Brace

g. Coil Wheel

d

c e

g i

h f

a

d

g

e h

i b

36 Clasimat Basic

h

c

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Product Manual

2012

Spool Dispenser Purpose Transports wire larger the #6 to be loaded, cut or measured without the use of a forklift or dolly.

Spool Loading Dolly Step by Step Instruction Step 1: Roll dolly [a] directly in front of the wire spool.

(Note: Spool should be placed so that both round wheel portions are on the ground and the product pole is positioned through the center)

Step 2: Gently tipping the dolly forward, hook both ends of the product pole [b] onto both ends of the dolly hook arms [c].

Step 3: Position the loaded dolly in front of the open portion of the Clasimat.

(Note: toggle the open Clasimat wire carrier frame low enough that the dolly can feed the loaded spool onto the open hook arms)

Step 4: Guide the product pole with spool onto the Clasimat’s open hook arms [d]

d

b a

c

Spool

Spool Dispenser Loading Dolly

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Product Manual

2012

Spool Carrier

1. Left Product Hook

2. Left Hook

3. Wire Carrier Frame

4. Center Hook

5. Right Product Hook

6. Double Deep Right

7. 3/4 Product Pole

8. Double Deep Left

9. Product Pole Unloaded

10. Right Hook

11. Spool Loading Dolly

12. Loaded product pole rests

in notches

1

3

2 5

10 7 4

8

6

Maximum Gross Weight

200 lbs.

Maximum Travel Between Uprights

78”

Rotation of tray

90º

Maximum Diameter of Wire

1/64” to 7/8” or 1/2” gauge Wire/Rope

Power Requirements

None

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Product Manual

2012

Loading and Unloading Procedure Tire Gondola Always remove any protective covering from the product roll prior to loading it, if applicable.

Activate the machine by entering the access code (4321#).

(Please refer to pages 10-16 for key pad operation and programming guide) Determine acceptable loading height by running machine to a height determined by operator.

1. Tire Gondola

2. Where the product pole attaches Side Profile

Load tires onto the first gondola one at a time.

Use tire spike to keep tires from leaning by sliding spike into any one of the numerous spaces on the gondola.

Once loaded, rotate first gondola to the opposite side of the carousel.

Load the next gondola in the same fashion as the first.

Cycle machine a quarter of the way around and load third gondola.

(This will maintain carousel balance) *CAUTION: Do not store anything under carousel

1

•

Small Gondola 14-20” diameter tires

•

Medium Gondola 20-28” diameter tires

•

Large Gondolas 28-33” diameter tires

2

39

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2012

Safety Brace For all types of Clasimat Basic •

This can be added to the wire, tray or garment Clasimat Basic, for added security

•

Installed for the front, back or both; with mesh attached

•

Safety brace installs with 3/8-16 Bolt and 3/8 Flat Washer

•

Mesh attached with a Clip and Self Tapping Screw every 5 blocks

Back Front

1 2

2

1. Mesh

40 Clasimat Basic

2. Safety Brace

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Product Manual

2012

Troubleshooting for Clasimat For all service and replacement parts and to find out about our maintenance contract – Call Interlake Mecalux at 1-800-555-5555 PROBLEM

POSSIBLE CAUSES Chain is too tight

Call Service

Squealing noise while running

Dry hook journals

* Lube hook journals

Dry Product Chains

* Lube chain

Chain is too loose

Call Service

Chains are noisy

System runs slowly

System trips breaker(s) regularly

Motor hums but won’t move

SOLUTIONS

Chain is too tight

Call Service

Chain is dry

* Lube Chain w/30W SAE

Chain is out of alignment

Call Service

Low voltage

Check Voltage (208v Minimum)

Brakes dragging

Call Service

Open phase

Call Service

Short circuit

Call Service

Low voltage

Check voltage (208v min)

---

Call Service

Faulty component

(see information on Pg. 3 Regarding Electrical Requirements)

Open phase

Check electrical service

---

Check Voltage (208v min)

Low voltage

Call Service

Brake not releasing

Call Service Check controls Check Access Code

Motor won’t run or make any noise

No power to system

Check Store Breakers Press Reset button Check Voltage Supply

Stops running while in use

Control System Does not work

Running time elapsed

Re-enter access code

Loss of power

Check to see if circuit

---

Breakers are on

Estop depressed or not plugged in?

Press Reset button

Reset button not activated

Call Service

WARNING: To the maximum extent permitted by applicable law, in no event shall the Mecalux Group or its suppliers be liable for any damages whatsoever (including without limitation, special, incidental, consequential, or indirect damages for personal injury, loss of business profits, business interruption, loss of business information, or any other pecuniary loss) arising out of the use of or inability to use this product as a result of an unauthorized personnel causing undue accident, abuse, or misapplication.

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Product Manual

2012

Cutters and Accessories In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances. Do not modify the plug provided – if it will not fit the outlet, have the proper outlet installed by a qualified electrician. Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal.

Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded. Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool’s plug. Repair or replace damaged or worn cord immediately.

Make sure the tool is connected to an outlet having the same configuration as the plug. No adapter is available or should be used with this tool. If the tool must be reconnected for use on a different type of electric circuit, the re-connection should be made by qualified service personnel; and after re-connection, the tool should comply with all local codes and ordinances.

KEEP GUARDS IN PLACE and in working order.

REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on.

KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.

DON’T USE IN DANGEROUS ENVIRONMENT. Don’t use power tools in damp or wet locations, or expose them to rain.

Keep work area well lighted.

KEEP CHILDREN AWAY. All visitors should be kept safe distance from work area.

DON’T FORCE TOOL. It will do the job better and safer at the rate for which it was designed.

USE RIGHT TOOL. Don’t force tool or attachment to do a job for which it was not designed.

DO NOT USE EXTENSION CORD. Use of an extension cord can cause a drop in line voltage resulting in loss of power and overheating.

WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, Bracelets or other jewelry which may get caught in moving parts. Non slip footwear is recommended. Wear protective hair covering to contain long hair.

ALWAYS USE SAFETY GLASSES. Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.

SECURE WORK. Use clamps or a vise to hold work when practical. It’s safer than using your hand and it frees both hands to operate tool.

DON’T OVERREACH. Keep proper footing and balance at all times.

MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.

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2012

DISCONNECT TOOLS before servicing; when changing accessories, such as blades, bits, cutters, and the like.

REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in off position before plugging in.

USE RECOMMENDED ACCESSORIES. Consult the owner’s manual for recommended accessories. The use of improper accessories may cause risk of injury to persons.

NEVER STAND ON TOOL. Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted.

CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function – check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.

DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of the blade or cutter only.

NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don’t leave tool until it comes to a complete stop.

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Product Manual

2012

Cutter Components

1. Chain Guard

10. Plastic Wrap Holder

2. Slammer Bar

11. Counter

3. Pinch Roller

12. Coiled Product

4. Handle

11

13. Measurement displayed 1 5 1

8

5. Carpet Panel

14. Manual Wheel

6. Top Trays

15. Cut line

7. Swivel Casters

8. Safety Latch

2

5

2

7

6 2

8

2

4

2

3

3

2

3

9. Foot Cord 12

5

4

6 10

13

1

9

3

15

The Counter

7

Counter reset while product is lined up with the Cut Line then inspect the flip tray.

The hardware should be securely fastened and the decent pin should engage the tray when lifted into the receiving position.

14

The flip tray should then operate freely.

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Product Manual

2012

Machine Access Code The Control System The access code for your motorized cutting system is (4321#), (Please refer to pages 10-16 for key pad operation and programming guide) which will allow the machine to be activated for 2 minutes.

1 5

FOR

REV

CUT ROLL

1

2

2

6 2

8

2

4

3

3

LEFT RIGHT

5

7

2

3

1

1. E-Stop

2. Roll Forward and

Reverse Switch

3. Cutter Left Right Switch

4. Roll/Cut Selector Switch

5. Key Pad

2

3

1

2

3

4

5

6

7

8

9

*

0

#

4

5

Electrical Requirements •

240V, 60 Hz 2 amp 3 phase (2) 1/2 hp motor (absolute minimum 208 volts

If more than one system is installed in your building, each should be wired on a separate 3 phase 20-amp circuit.

•

Any voltage below 208 volts can result in motor failure

Be aware that regional power reductions, often referred to as “brown-outs” are becoming increasingly common in many parts of the country. These problems usually occur during the daylight hours in the warmer months and can cause sporadic or even continual running problems. If you are experiencing problems that are caused by low voltage a brown –out could be the cause. Calling the electric company while the problem is occurring and inquiring if they are currently reducing power can make diagnosis of this problem. If the problem is chronic, you may want to consider adding a line conditioner to your electrical system.

45

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Product Manual

2012

Cutting System Operation Step by Step Instruction Step 1: Select product to be dispensed from the carousel.

Step 2: Activate the rolled goods Clasimat Basic by entering the access code (4321#). (Please refer to pages 10-16 for key pad operation and programming guide) 3

Step 3: Remove the Velcro straps.

4

Step 4: Place cutting table in front of desired product and plug cutting table in. Move the rolled goods to approximately 36 inches above the cutting table while unrolling product.

5272

6 1283 2 4

3

1253

Step 5: With the pinch roll on the cutter in the down position and the slammer bar is in the up position, use the carousel to lower the unrolled portion of the product into the cutting table, while using the pinch roller to pull product onto the cutting table.

5

6

Step 6: Once desired product is on the cutting table, lower product until the top of the product is even with the leading edge of the cutting table.

Product needs to be squared in the center before rolling desired amount

- - -

Lift pinch roller Line product up with the cut line Lower pinch roller Reset the counter to zero

1. Rolled Goods 36�

above Cutting Table

2. Bottom of the Product

is even with the leading

edge of the Pincher Roller.

3.

Product fed into the Pinch Roller which grabs the product to feed it to the cutter.

4

2&3

1

4. Pinch Roller

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2012

Cutting System Operation Step by Step Instruction Step 7: To cut product, the selector switch on the control pane needs to be moved to the cut mode.

- The slammer bar must be in the down position.

- The right/left cut switch can be used to run the blade from make the cut.

7

Step 8: The final length of carpet can be reached by “tweaking� the cutter manually, using the manual wheel Step 9: Reset the trumeter counter to zero using lever Step 10: Stand in front of Cutter, push down the red foot cable to advance the product

7

Step 11: Roll up product as you unwind desired amount, making sure to watch the counter.

Step 12: Push the second handle forward to set Cutting Bar into place.

Step 13: Turn center toggle switch to the right to start the cutting process.

8

9

10

11

12

13

14

15

Step 14: After cutting, return to the front of the machine and either shrink wrap or tape product.

Step 15: After dispensing, pull both levers back before

moving on to the next product.

6

12 52 12

83

2

4

3

72 53

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Product Manual

2012

Blade Replacement Step by Step Instruction The tools needed are: • 5/32” Hex wrench • Quick grips (or equivalent) • Leather working gloves 1

2 shield

Step 1: Using the cutter controls, run the blade shuttle all the way to the left.

Step 2: Disconnect the machine from the power source.

Step 3: Expose the cutter blade by removing the access panel’s two thumb screws and lifting off the panel.

screws blade

3

4

5

6

Step 4: Lift the cutting bar into the up position and use a set of quick-grips (or equivalent) to hold the cutting blade shield up and out of the way as shown.

Step 5: Using a 5/32” Hex wrench, loosen both cap screws that hold on the blade.

Step 6: Remove only one of the two screws while leaving the other loose.

Step 7: Remove blade. To install a new blade, perform the reverse of this procedure.

7

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Product Manual

2012

Carpet Roller, V-Dolly and Lift Cart Accessories for Carpet and Vinyl Carpet Roller, V-Dolly and the Lift Cart are very important accessories for the Clasimat Basic for Rolled Goods.

1) Lift Cart - used to lift heavier rolled goods onto Clasimat Weight Capacity 600 lbs.

Standard Width 72” Standard Height 26-1/2” 2) Carpet Roller - used to roll rolled goods Weight Capacity 600 lbs.

Standard Width 72” Standard Height 26-1/2” 3) V-Dolly - used to move rolled goods Weight Capacity 800 lbs.

Standard Width 74” Standard Height 20”

1

2

3

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Product Manual

2012

Maintenance Check List See page 6 for details and warranty information.

WHAT TO CHECK

HOW OFTEN

Inspect hook

During every load

All product poles for bends, damage or wear

At every load

Lubricate drive chains using 30W SAE chain lube

Annually

Lubricate product chains using 30W SAE chain lube

Annually

All fasteners for tightness as needed

Annually

Operation of emergency-stop

Annually

WHAT TO CHECK

WHAT TO DO

Drive chain tension

Tighten to no more than 1” of slack

Product chain tension

Tighten to between 1”-2” of slack

Brake operation

Maximum 4” drift - call service

Motor sprocket

Call Service

All anchor bolts

Torque to 70 ft-lbs -5/8 anchors 120 ft-lbs -3/4 anchors

All mounted accessories

Torque to 35 ft-lbs

All hooks, latches, and springs

Replace any damaged parts immediately Check for hook replacement

All product poles

Replace any damaged parts immediately

Hook replacement

Recommended @ 1000 hours service – call service

Debris on upper sprocket assy

Inspect upper sprocket assy for plastic or debris

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2012

Troubleshooting for Cutter For all service and replacement parts call Interlake Mecalux at 708-344-9999

PROBLEM

Squealing noise while running

Drive Chains are noisy

POSSIBLE CAUSES

SOLUTIONS

Chain is too tight

Call Service

Dry hook journals

* Lube hook journals

Dry Product Chains

* Lube chain

Chain is too loose

Call Service

Chain is too tight

Call Service

Chain is dry

* Lube Chain w/30W SAE

Chain is out of alignment

Call Service

Product drifts more 4” after the button is released

System is out of balance

Balance System

Brake is out of adjustment

Call Service

Low voltage

Check Voltage (208v Minimum)

System runs slowly

Brakes dragging

Call Service

Open phase

Call Service

System out of balance

Re-balance load

Short circuit

Call Service

Low voltage

Check voltage (208v min)

---

Call Service

Faulty component

(see information on Pg. 3 Regarding Electrical Requirements)

System Alternates between Fast & Slow running or machines runs Erratically

System trips breaker(s) regularly

Motor hums but won’t move

Open phase

Check electrical service

---

Check Voltage (208v/414v min)

Low voltage

Call Service

Brake not releasing

Call Service Check controls Check Access Code

Motor won’t run or make any noise

No power to system

Check Store Breakers Press Reset button Check Voltage Supply

Stops running while in use

Control System Does not work

Running time elapsed

Re-enter access code

Loss of power

Check to see if circuit

---

Breakers are on

E-stop depressed

Press Reset button

Reset button not activated

Call Service

* Lubricate hooks and chain with 30W SAE

51

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e-mail:info@interlakemecalux.com | www.interlakemecalux.com | 1.877.632.2589

Sales Offices Chicago 1600 N. 25th Ave. Melrose Park, IL 60160 708-344-9999

Dallas 1520 Selene Drive Carrollton, TX 75006

San Diego 8607 Ave de la Fuente San Diego, CA 92154

Production Plants Chicago 1600 N. 25th Ave. Melrose Park, IL 60160

Matamoros Las Rusias 2700, Industrial del Norte CP 87470 Matamoros, Tamps, Mexico

Tijuana Blvd. Bellas Artes #9001 Ciudad Industrial Tijuana, Baja California, MX 22500

Pontiac 701 Interlake Drive Pontiac, IL 61764

Sumter 1925 Corporate Way Sumter, SC 29154

Offices Worldwide Argentina, Belgium, Brazil, Canada, Chile, Czech Republic, France, Germany, Italy, Mexico, Panama, Peru, Poland, Portugal, Spain, Turkey, United Kingdom, USA, Uruguay

The contents in this document refer exclusively to Interlake Mecalux products and are for informational and promotional purposes only. The information contained herein does not form the basis for warranty or guarantee.

Interlake Mecalux reserves the right to modify without prior notice the data, figures, products and finishes in the catalog.

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