Rates: Installation and service rates are quoted separately per job. The base rate (call for quote) is multiplied by the number of (10 hour) days estimated for completion and expenses (lodging, transportation, meals, etc) are added plus 15%.
The estimated time for completion assumes timely electrical wiring installation by the customer or their contractor. Delays due to circumstances not controlled by the installer may incur additional charges for wait time.
Generally one service technician is provided and the customer provides a forklift with operator and a mechanical helper (usually a maintenance person).
Customers are strongly encouraged to obtain installation and training services with their system purchase. While the procedures for installing and operating are relatively simple for an experienced individual, the initial learning curve is immensely reduced with proper instruction. This results in less down time due to inadvertently clogged nozzles and transitions, less equipment damage from improper use, and quicker production targets for skilled operators.
Training: Equipment and System training is provided with each installed machine or system. Maintenance personnel and operators are shown how to use the equipment, troubleshoot and maintain the machinery for long-lasting performance.
Equipment Installation Procedures
The following procedures are based on installing a pre-wired Pillow System I with two nozzles. If your system is not pre-wired then your electrician can follow the control panel print attached to the equipment for installation and use the check-out procedures below to complete set-up.
SET-UP PROCEDURES
1) Place Opener in desired location.
- Level and bolt to the floor
- Bolt reserve chute to Opener (insure that the viewing window is facing the outlet side of the opener)
2) Place the feeder over the reserve chute. Observe the following notes:
- The front of the feeder must be lifted to insure that the lip on the front misses the reserve chute
- Install the electric eye on the reserve chute.
- Attach the extended apron to the rear of the feeder.
- Install and lace the apron.
- Tighten apron. (Note: apron must be tightened evenly from side to side.)
- Level the extended apron and the feeder, and then bolt to floor.
3) Bolt on the outlet transition to the opener (it may be shipped attached)
- Bolt shut-off valves to the outlet transition
- Position blowers and adjust height to level and match the shut-off valves.
- Bolt together and bolt to floor.
4) Position control panel between the blowers. Remove lower front motor cover on Opener. See System front view (pdf).
- Connect plug labeled "To Sol #1" to solenoid valve #1
- Connect plug labeled "To Sol #2" to solenoid valve #2. See feeder control setup (pdf).
- Connect blowers to corresponding wires
- Run conduit for opener motors and connect labeled wires.
- Run conduit labeled "Feeder" under opener on the floor, to the junction box on left side of Feeder, and connect labeled wires.
- Connect electric eye #1 (on opener) to junction box on feeder.
- Connect both feeder motors to the labeled wires.
- Connect filtered and regulated air (40-60 PSI) to the
following locations:
- Solenoid valve #1 & #2
- Extended apron clutch
- Connect foot switches to the proper location.
5) Test rotation of all motors. Use the diagram provided (pdf).
- If any motor turns the wrong direction swap any two of the three wires on the motor.
6) Check the operation of the electric eyes.
- Electric eye #1
- Turn on the feeder doffer
- Turn on the lift apron
- The lift apron should be moving
- Slide a dark (opaque) piece of paper in front of the eye.
- The lift apron should stop after a few (2-10) seconds.
- Once it stops, remove the paper.
- It should start moving within one second.
- Electric eye #2
- The extended apron should be moving.
- Slide a dark opaque piece of paper in front of the eye.
- The extended apron should stop after a few (1-2) seconds.
- Once it stops remove the paper.
- It should start moving within one second.
7) Shut-off valves and foot switches.
- Turn on all motors using the control panel
- Press foot switch #1
- Shut-off valve #1 should open
- You should feel a rush of air out of the nozzle.
- The feed rolls should start turning.
- Release the foot switch
- The shut-off valve should close slowly
- The feed rolls should stop spinning
- Press foot switch #2
- Shut-off valve #1 should open
- You should feel a rush of air out of the nozzle.
- The feed rolls should start turning.
- Release the foot switch
- The shut-off valve should close slowly
- The feed rolls should stop spinning
8) Test run with fiber.
- DO NOT START THIS STEP UNTIL SYSTEM HAS BEEN PROPERLY INSTALLED
- ROTATION OF ALL MOTORS CHECKED
- ALL MECHANICAL MOTIONS MOVE FREELY
- ELECTRIC EYES FUNCTION PROPERLY
- Turn on all motors with the control panel. (refer to the "General Operational Procedure" for instructions on starting motors)
- Place three (3) hands full of fiber on the extended apron.
- Watch for fiber to fall into the reserve chute.
- Hold a pillow tick half-way up the nozzle
- Press the foot switch until fiber fills the tick
- Repeat this process until fiber no longer flows.
- Alternate nozzles to insure proper operation. (Note: both nozzles may be operated together, but production per nozzle will decrease)