4471 Walden Avenue Lancaster, New York

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1 United Silicone Customer Care Kit US Tax Stamping Equipment 1

2 Table of Contents 1. Customer Le er 2. United Silicone Contacts 3. Maintenance Plans 4. Installa on Checklist 5. Installa on Guide 2

3 Dear United Silicone Customer, Congratula ons on your recent investment in tax stamping equipment from United Silicone. We are pleased to present the enclosed Customer Care Kit to you. In this package you ll find a complete contacts page, a United Silicone Service plan overview, and an installa on guide to assist you with the prepara on of your stamping facility. You will also receive an opera onal manual that will be shipped along with your machine. From our sales representa ves and customer service agents to our technical field engineers across the country, United Silicone is commi ed to providing you with superior products and services. A comprehensive quality assurance program has been successfully completed on your new equipment, including several thousand dry cycles in test mode. Our New York loca on carries a full range of parts and glue for all of our tax stamping machine lines. Customer Service personnel are available from 8:30AM 5:00PM EST Monday through Friday to process your orders. Once again, thank you for your purchase. United Silicone welcomes the opportunity to serve you and your company in the years to come. If you have ques ons regarding your new equipment, please feel free to contact any one of sales representa ves found on page two of this guide. Tom Le zia Business Unit Manager 3

4 Contacts For US Tax Stamping Equipment Sales Call (800) x1 Tom Le zia Director of Sales & Service Phone: (630) Fax: (630) tle Lee Humphries Technical Sales Specialist Southeast Phone: (919) Fax: (630) Robert Bacosa Technical Sales Specialist West Coast Phone: (209) Fax: (630) James Sutherland Technical Sales Specialist Central Phone: (716) Fax: (630) Mark Lindley Southwestern Sales Engineer Phone: (630) Fax: (630) Sco Messinger Technical Sales Specialist Northeast Phone: (630) Fax: (630) For US Tax Stamping Equipment Service Call (800) x2 Lance Herion Dispatch Service Manager Phone: (800) Fax: (800) Brian Jablonski Dispatch Service Technician Phone: (800) Fax: (800) For US Tax Stamping Equipment Part and Glue Orders Call (716) x135 Sheryl Alexander Contract Spare Parts Support Phone: (716) x135 Fax: (716)

5 United Silicone Preventa ve Maintenance (PM) visits are designed to preserve and enhance equipment reliability by monitoring and replacing worn components before they actually fail. The intent is to save you future service costs by inspec ng and maintaining your equipment, not simply by applying fixes. PM visits take me and commitment, but the benefits are cleaner, longer running equipment with reduced down me. During every PM visit our service team will make maintenance recommenda ons and provide you with a complete opera on report. We will record equipment deteriora on so you know to replace or repair worn parts before they cause system failure and cost you more in service. When considering the comparable costs of a PM program to standard billable service, one should compare not only the costs but the long term benefits and savings associated with a complete preventa ve maintenance program. Without preventa ve maintenance, for example, costs for lost produc on me from unscheduled equipment down me may be incurred. Also, rou ne preventa ve maintenance visits will result in savings due to an increase of effec ve system service life. Equipment Maintenance Training Programs are taught by our highly skilled service staff either on site or at our manufacturing facility depending on the availability of equipment. Our staff will thoroughly educate your maintenance team on all facets of electrical and mechanical components of the equipment you use now or will use in the future. Maintenance training programs are a great way to save money and me when it comes to servicing your facility s stamping opera on. United Silicone Remote Diagnos cs save you on service costs by remotely inspec ng equipment before and a er part failure. Remote diagnos cs can reduce equipment down me if problems are found and repaired quickly through camera and phone interac on. In most cases, with a qualified on site maintenance person or capable operator, remote technicians can eliminate the need for a service technician visit altogether. In extreme cases, visits may s ll be required a er final diagnosis. If in fact we are required to make a visit a er the call, our technicians will be prepared with the correct parts before we step foot in your facility. Pay Per Call Emergency calls are charged at a flat rate dependent on your proximity to the closest available technician. Prices are based on one (1) visit for one (1) stamping line with a maximum of eight onsite hours. Parts are not included in the pay per call emergency plan. Pricing is subject to change based upon availability of technician. Limited Free Phone Support is always available for fast responses to small issues. Wherever possible, our goal is get you up and running with minimal down me. 5

6 PREPARING FOR YOUR UNITED SILICONE TAX STAMPING EQUIPMENT INSTALLATION Please review this document for informa on regarding the installa on requirements for your United Silicone brand tax stamping equipment that will soon be arriving at your facility. Please complete, sign, date, and return this sheet to United Silicone Service. Once the form is received with all requirements met, a dispatcher will contact you to set up an installa on date. Installa ons will not be scheduled un l this form is returned to Service. Note: If the service technician is unable to perform the installa on due to inadequate site prepara on, you will be charged our standard hourly labor rate and travel costs in addi on to the quoted installa on charge. 6

7 Machine Pre Installa on Customer Checklist Site Prepara on 1. Is there adequate space to move the machine from the loading dock to the installa on site? 2. Does the installa on site have the required minimum Service Access Space around the machine? 3. Will the machine be integrated with exis ng/new conveyors? If so, a. Does the conveyor height match the in feed/discharge height of the machine? b. Is there a means of controlling the in feed back pressure of product presented to the machine? Electric Service 4. Has a dedicated line(s) with safety switch(es) been run to the installa on site? 5. Has the proper connector/receptacle(s) for hook up to the machine been installed? 6. Verify service: a. Voltage b. Phase c. Amperage Pneuma c Service 7. Has a dedicated compressed air line with shut off valve been run to the installa on site? 8. Verify service: a. Line Pressure (PSI) b. Flow (CFM) c. Supply Line Diameter Start up Items 9. Is there tobacco product available for start up & tes ng (50 half cases with stamps recommended)? 10. Have the personnel responsible for opera on and service been iden fied and will they be available for training immediately following installa on? Shi Hours: Op mal Days and me for Install (weekend are subject to addi onal charges) Company: Customer: United Silicone Tax Stamping Machine Pre Installa on Customer Checklist Fax this page only to (800) A en on: Dispatch or e mail to taxstampsupport@unitedsilicone.com 7

8 Tax Stamping Equipment and Your Facility The key to a smooth installa on and start up of any new equipment is to complete the necessary site work and installa on planning prior to the arrival of the equipment. Some key items to consider are: Loca on: An installa on site that provides sufficient service access (in addi on to any OSHA requirements) is necessary to be able to adequately maintain any piece of equipment. United Silicone requires that a minimum Service Access Clearance of 18 inches be maintained around all equipment and 36 inches in front of control panel/enclosure and machine access doors. Any in feed or discharge conveyors that are to be integrated with the Meyercord brand tax stamping equipment should be prepared and in place prior to the installa on date. Conveyor height and excessive product back pressure problems will cause installa on delays and machine malfunc ons. Contact United Silicone Service for addi onal assistance if required. United Silicone recommends that the customer DOES NOT uncrate the machine or any of its components un l they are near the installa on loca on. Sufficient space to transport the machine from the truck to its installa on site and space to uncrate is also required. Electrical: A dedicated circuit that matches the voltage and amperage requirements of the equipment, along with a safety switch of the same capacity outside the equipment must be provided. Some voltages may be well outside of their stated levels. Please have your actual levels properly checked. If you require a buck boost converter, United Silicone Service technicians can supply one at an addi onal cost. Consult your local electrical codes for proper cable size and ra ngs. An overhead drop above the machine s main electrical enclosure is the best method of supplying electrical power to your machine. This will minimize safety issues (i.e. tripping hazards or cord damage) while assuring maximum access to the machine. For machines that are not hard wired into the electrical panel, a female receptacle matching the male plug on the machine will need to be provided. See Appendix A: NEMA Receptacles Cau on: Incorrect voltage will cause severe damage to the equipment. For the protec on of the operator, the equipment must be electrically grounded. Pneuma c: For most tax stamping equipment, a sufficient source of clean, dry compressed air is required for proper machine opera on. It is recommended that a minimum 1/2 inch ID rigid copper line with shut off valve outside of the machine be plumbed from the compressed air source. See Appendix B: Supplying Compressed Air for Your Tax Stamping Equipment for help on determining the pneuma c quality & quan ty requirements for your facility. 8

9 The chart below is provided to assist you to ensure that the electrical and pneuma c u lity hook ups are available at the me of machine installa on: Machine Description Electrical Service Requirement Electrical Connection Compressed Air Requirement Pneumatic Fitting VL-10 Stamp Machine 220VAC 30 A, Single Phase PLUG, NEMA L6-30P /8 NPT Female VL-10 Tandem Stamp Machine 220VAC 30 A, Single Phase PLUG, NEMA L6-30P /8 NPT Female SSM Stamp Machine 220VAC 30A, Single Phase PLUG, NEMA L6-30P /8 NPT Female SSM Tandem Stamp Machine 220VAC 30A, Single Phase PLUG, NEMA L6-30P /8 NPT Female SSMP - Pressure Sensitive Stamp Machine 220VAC 30A, Single Phase PLUG, NEMA L6-30P /8 NPT Female M120 Stamp Machine with Cold Glue 30A 60Hz PLUG, NEMA L /4 NPT Female M120 Stamp Machine with Hot Glue 20A 60Hz PLUG, 3-Straight Blade (NEMA 5-15) /4 NPT Female M120 Tandem Stamp Machine with Cold Glue 240VAC, 60Hz, Single Phase, 30A, 4-wire Electrical Screw Terminals in Our Control Box /4 NPT Female (I at Closer and each Stamper) M120 Tandem Stamp Machine with Hot Glue M120 Triple Stamp Machine with Cold Glue M120 Triple Stamp Machine with Hot Glue Case Packer CC-612 Case Cutter 240VAC, 60Hz, Single Phase, 30A, 4-wire PLUS 240VAC, 60Hz, Single Phase, 20A 240VAC, 60Hz, Single Phase, 40A, 4-wire 240VAC, 60Hz, Single Phase, 40A, 4-wire PLUS 240VAC, 60Hz, Single Phase, 20A 120 VAC / 15 A, Single Phase 220VAC 30A, Single Phase Electrical Screw Terminals in Our Control Box and at Adhesive Supply Unit Electrical Screw Terminals in Our Control Box Electrical Screw Terminals in Our Control Box and at Adhesive Supply Unit PLUG, 3-Straight Blade (NEMA 5-15) PLUG, NEMA L6-30P 3 1/4 NPT Female (I at Closer and each Stamper) 4 1/4 NPT Female (I at Closer and each Stamper) 4 1/4 NPT Female (I at Closer and each Stamper) /8 NPT Female /8 NPT Female 9

10 Appendix A: NEMA Receptacles 10

11 Appendix B: Supplying Compressed Air for your Tax Stamping Equipment In addi on to electricity, most of United Silicone tax stamping equipment requires a source of compressed air. The quality and quan ty of the compressed air supply will affect the reliability of the equipment, the frequency and cost of service calls and down me, as well as, the ini al and on going energy costs of the compressed air equipment you select. If you are not purchasing your air system directly from United Silicone, please review the following considera ons when reviewing your air requirements 1) How Much Compressed Air Capacity Do I Need? The values listed in Air and Electrical Requirements above indicate the volume of compressed air at 90 psi, which is necessary to be available on a full me and con nual basis while each piece of equipment is opera ng. When calcula ng the total air requirement for all of your Meyercord brand tax stamping equipment, the first step is to add together these requirements for each piece of stamping equipment you intend to operate simultaneously. A worksheet has been provided below. Next add in any equipment which you expect you are likely to add within the next 3 5 years. Most air delivery systems have significant leaks and losses within them. Even a small leak at a fi ng can result in a large loss of compressed air. For new, high quality piping systems which have a total line length less than 25 feet, of large diameter, solid copper lines with few bends and connec ons, we recommend that you add at least 20% margin on top of your computed total air requirements. If your lines are old, longer, threaded pipe and or contain mul ple quick disconnect or other type fi ngs, you should add at least 30 40% margin on top of your calculated total air requirements. For example, if you have a VL 10 stamp line with a United Silicone Case Packer, no plans to add addi onal equipment and an air run of threaded pipe 50 from your compressor to stamping equipment, you should select a compressor which can supply at least 1.30 x ( ) = 11.7 CFM of compressed air at 90 psi. If you are planning to use a reciproca ng air compressor, it is typical prac ce to size the output of the compressor to be 1.5 to 2.0 mes larger than the amount of air you expect to consume on an ongoing basis. In this way, the compressor will not need to run con nuously. Following the example of the VL 10 Stamp Machine with a United Silicone Case Packer, you would need to specify 17 to 23 CFM of compressed air at 90 psi to allow your compressor to run at a reduced duty cycle. Reciproca ng compressor manufacturers o en recommend that running on a reduced duty cycle will extend the life of your reciproca ng compressor. (Scroll style compressors, on the other hand, are more commonly run 100% of the me and as a result, it is not necessary to include this extra factor when selec ng a scroll compressor. S ll, specifying a larger compressor always allows for future compressed air capability.) When selec ng an air compressor, it is important to note that the volume of air it can provide, usually stated in SCFM or CFM depends upon what pressure you are supplying the air at. For the purposes of selec ng a compressor system to drive your tax stamping equipment, you need only be concerned with how much air the compressor can supply at 90 psi. If a compressor is specified for an air output at a higher pressure, for example, psi, you can es mate the amount of air this compressor will deliver at 90 psi by mul plying as follows: 19 scfm x (135 psi / 90 psi) = 28 scfm. 11

12 2) Can I use a shared source ( shop air ) of compressed air for the Stamping Equipment? While some customer facili es already have an available source of compressed air, typically known as shop air, United Silicone strongly recommends against using these sources of compressed air for opera ng our stamping equipment. Typically shop air is shared among mul ple uses within a facility and the available volume of compressed air varies from moment to moment and day to day. Each me the available air volume on these shared systems drops below the levels required by our equipment, the stamping equipment will begin to perform irregularly. In addi on, shop air is typically intended for low performance machines such as air operated hand tools. The air used to operate these lower performance machines typically has much higher levels of air line contamina on (from grit, water and oil) than can be well tolerated within the precision machinery of the tax stamping equipment. The use of contaminated shop air can lead to costly and lengthy stamping equipment damages and down me. United Silicone recommends dedicated, clean, dry air for use with our equipment. 3) What about moisture, dirt and oil in the compressed air system? The quality of the air supplied to your stamping equipment is important. The three most common contaminants in compressed air supplies are water, grit and oil. Water is the most common contaminant. Water typically enters the system as incoming air is compressed. Air can hold less and less humidity as it is compressed. The humidity which is squeezed out of the air as it is compressed condenses within the compressor, tank and air lines. This is par cularly common if the rela ve humidity of the incoming air is high such as in facili es near lakes, rivers and oceans. In addi on, cold air holds less humidity than warm air. Air leaving a compressor is typically warm o en on the order of 150 F or more. If this air is rapidly cooled, for example, if the air line leaves the compressor and then travels through a cold warehouse or passes between two buildings, moisture can condense out and collect inside the air lines. Compressed air delivery systems need to be designed to remove excess moisture from the air and air lines. This is typically accomplished with a piece of equipment known as a Dryer. Two types desiccant dryers and refrigerated dryers are commonly used. Most air compressors have built in air filters designed to remove dirt and grit from incoming air. Standard industrial grade air compressor filters typically remove all par cles greater than 1 micron in diameter and are sufficient for use with all tax stamping equipment. Some compressed air systems are designed to add lubricant to the compressed air to reduce the wear and improve the performance of certain types of machinery. Other air delivery systems contain air/oil separators to remove oil from the compressed air. All tax stamping equipment is designed to operate on clean (no par cles or oil); dry (no water) air. All United Silicone tax stamping equipment comes standard with their own, integral coalescing filter bowls which are designed to remove oil, water and dirt which may have passed through the primary systems in the compressed air delivery system, but these systems are intended only to remove occasional contaminants and do NOT eliminate the need for properly filtered and dried air delivery systems. 12

13 4) What compressor and related equipment do I need? Most compressed air systems include each of the following components: Compressor & Storage Tank The primary choices among compressor types are piston/reciproca ng vs. rotary/screw. Among the piston compressors you will select between single and dual head compressors and lubricated vs. oil less. Screw compressors are generally more expensive but significantly quieter, usually less than 70 dba at a distance of 3 feet from the compressor (a level of sound typical on a busy downtown street) while reciproca ng compressors are o en above 80 dba (a level of sound similar to that near a typical residen al gasoline powered lawn mower.) The level of sound output is an important considera on and should not be overlooked. Since it is desirable to have the compressor located near the stamping equipment it should be noted that it is difficult to converse and some mes distrac ng to work in the par cularly noisy environment surrounding a reciproca ng compressor. Ideally the compressor can be moved around a corner, behind a wall, or one floor above or below the area where operators will be working but keep in mind that it is also important to try to have the compressor, delivery lines and stamping equipment all at nearly the same temperature as described elsewhere in this document. Screw compressors have fewer wearing components and generally require a simpler maintenance schedule. Screw compressors also deliver cleaner air with no oil in the air. This generally extends the life of the stamping equipment by reducing buildup inside of cylinders and air valves. If a reciproca ng compressor is used it is important to select a high quality oil coalescing filter to try to remove as much oil as possible from the compressed air stream. The number of heads (1 or 2) on a piston compressor relates to the total amount of air output. Generally dual head compressors will handle larger CFM requirements (typically 30+ CFM at 90 psi). As men oned earlier, rotary compressors are usually designed to run a 100% duty cycle while most reciproca ng compressors are usually used on a 50% 66% duty cycle. As such, it is usually necessary to specify a larger capacity reciproca ng compressor in order to provide the same output as a rotary compressor. A storage tank is designed to allow the compressor to not have to run full me to supply all of the necessary air flow. Typically a tank is sized to be 2 4 gallons per CFM output from the compressor (example, a 20 CFM compressor typically has a gallon tank). In many cases, water will condense inside por ons of the compressed air circuit including the compressed air tank. These tanks are designed with drains so that the water can be removed regularly (typically daily). Keep in mind that a significant amount of water can be removed, so it is important to have a drain or other means to remove the collected water from your facility. A er cooler The a er cooler is used to bring the temperature of the compressed air to sufficiently low temperatures so that it can be properly dried by either a desiccant dryer or refrigerated dryer. In some systems, the a er cooler and dryer are integrated into a single system. Most a er coolers are similar to automobile radiators consis ng of a heat exchanger and a fan which forces room air past the heat exchanger to cool the compressed air. Dryer Under typical warehouse opera ng condi ons, a dryer is needed which has a throughput (SCFM) equal to or greater than the total an cipated compressed air requirement. Drying capacity is specified in units of Dew Point. A typical refrigerated dryer supplies air with a maximum dew point of around 37F meaning that the air exi ng the dryer would not be expected to condense out moisture if it were kept above a temperature of 37F. When selec ng a dryer for a facility where the ambient temperatures are expected to fall below the dew point of the dryer, please consult directly with United Silicone Service or a compressor dryer manufacture to discuss the 13

14 specific details of the installa on. Special Desiccant Dryers are available that can produce very low dew points if needed. Regardless of which type of dryer you use, note that depending upon the condi ons of opera on, significant quan es of water may be removed by the dryer. It is usually necessary to have a floor drain or other provision near the dryer to allow easy removal of the condensed water from your facility. Delivery Piping Delivery piping is o en overlooked in the system design and problems with too small line diameters and too long piping runs can cause significant opera onal difficul es. Common problems to avoid include: Use large diameter piping. All piping should be a minimum of ½ dia for 0 30 CFM and ¾ dia for CFM. Above 60 CFM, consult Meyercord Service or a compressor equipment manufacturer for a custom piping plan be designed. Use short piping runs between the compressor and the equipment. Maintain all piping runs of ½ tubing to less than 40 feet and ¾ tubing to less than 75 feet. The maximum distance from the compressor to all pieces of equipment should be less than 75 feet. Avoid serial placement of equipment along a single piping run instead use a central manifold with individual branches to each piece of equipment. (Otherwise the last piece of equipment on the piping run may become starved as equipment upstream consumes the air before it reaches the last piece.) The temperature of air surrounding the compressed air delivery system is very important. The simplest arrangement is when the compressor, all delivery piping and the stamping equipment all remain at nearly the same temperature. If you are planning to locate the compressor in a different room, or in an outdoor shed, or if the delivery piping will pass through walls between areas of different temperature (for example, if the compressor is in one building and the delivery piping goes outside and then into the next building before reaching the stamping equipment) United Silicone recommends that you work with a qualified local compressor company to address the specifics of your installa on in a custom piping plan. 5) Can I purchase my compressed air equipment through United Silicone? Will Service repair my compressed air equipment? United Silicone can provide you with an air solu on system that includes quality manufactured parts that are recommended above. Purchasing your air system through United Silicone ensures proper installa on, service and warranty to maximize the poten al of your tax stamping equipment. Please contact United Silicone or your service technician for more details and pricing. 6) What about compliance with local laws/codes? United Silicone is used in many different jurisdic ons and regulatory environments. While we endeavor to provide safe and reliable equipment and installa on recommenda ons which represent generally accepted industry prac ce, the end user is ul mately responsible for selec ng, installing and plumbing the compressed air system in such a manner so as to meet all local ordinances and applicable safety and plumbing codes. United Silicone recommend that each customer work with a locally licensed contractor and/or plumber to ensure that the completed final system is in full compliance. United Silicone takes no responsibility in this regard and makes no representa on that the recommenda ons in this document and those of our field service technicians and other employees are necessarily in complete compliance with our customers site specific regulatory and/or safety requirements. 14

15 5.0 HP Air Compressors Engineered for 100% con nuous duty. Hardened steel crank sha with precision bearings. Splash lubrica on. Ideal for commercial or contractor use. All season select synthe c lubricant eliminates valve carboning Technical Specifica ons Electric Single Stage Air Compressor Motor Running Power 5.0 HP Free Air Maximum Pressure 16.1 CFM Free Air 90 psi 18.0 CFM Maximum Pressure 135 PSI Phase Single Voltage Ra ng 230 Volts Current Ra ng 21.5 Amps Tank Capacity 60 Gallons Tank Type Ver cal Height 71 Inches, Length 20 Inches Width 30 Inches NPT Outlet (F) 1/2 Inch 60 Hz Refrigerated Compressed Air Dryer Handles high inlet air temperatures. Eliminates troublesome water. Removes unwanted par cles to the micron level. Saves energy and prevents pipe swea ng. Highly efficient heat exchangers and fan switch minimize energy usage. HFC refrigera on system requires no lead adjustments. Includes fault light, automa c condensate drain, ambient air filter, and inlet strainer. Technical Specifica ons Refrigerated Compressed Air Dryer Air 50 Degrees Fahrenheit Dew Point Pressure at CFM Air 50 Degrees Fahrenheit Dew Point Pressure at CFM Power Ra ng 5/8 HP, Female NPT Inlet/Outlet 1/2 Inches Maximum Air Compressor 175 PSI 5 HP Maximum Compressor 125 PSI 5 HP 60 hz 115 Volts Height 28 Inches Depth 13 Inches Width 10 Inches Combina on A er cooler/separator/ Filter 15

16 Step 1: Complete the table below: TAX STAMPING EQUIPMENT AIR REQUIREMENT WORKSHEET Equipment Column A Compressed Air at 90 psi Column B Number of machines at your facility, include extra equipment you may add over 5 years Column C Mul ply each row in Column A by the quan ty in Column B VL 10 Stamp Machine 4.0 VL 10 Tandem Stamp Machine 5.0 SSM Stamp Machine 7.5 SSM Tandem Stamp Machine 8.5 SSMP Stamp Machine 5.5 Meyercord Case Packer 5.0 CC 612 Case Cu er 12.0 Step 2: Total all of the values in Column C = CFM at 90 PSI Step 3: Review Key Ques on #1 from this document and use this informa on to select an appropriate margin percentage based upon your specific site, piping type and length. The minimum recommended margin is 20%, but you may need a larger factor depending upon your facility. Enter your percentage on the line below. Write the value as a decimal number, for example, if your margin is 20%, write 0.20 on the line below. Margin = Step 4: If you are going to use a reciproca ng compressor enter 1.75 on the line below. If you are going to use a rotary compressor enter the value 1.00 on the line below. Compressor Factor = Step 5: Mul ply the values you wrote in steps 2, 3 and 4 together and write your answer on the line below. This is the minimum number of CFM your compressor will need to supply at 90 psi. (Step 2 Total) x (Margin) x (Compressor Factor) = 90 psi Step 6: Select an a er cooler, dryer and air line hose and air circuit layout which can accommodate a minimum CFM from Step 5. 16