Montronics provides a retrofit kit that eliminates all the antiquated servo components and replaces them with modern proven technology. The current antiquated FIMA Servo drive system that has over 9 components will be replaced with an API Turbo® Stepping system that contains only four components, thus upgrading and simplifying. Since the API Turbo® stepping system has no maintenance and calibration requirements, this will add up to increased production with no additional reoccurring costs. 

KIT DESCRIPTION

This kit comes complete with all the replacement components mounted onto three panels that secures to already existing screw mounts. All old cables, connections, old wiring, switches, and sensors are replaced so nothing is left to chance. One panel replaces the entire top control panel, that has two switches, one indicator, 16 keypad, and a 80 character LCD display. The second panel replaces the old CPU/Regulator board card rack, and all other associated components. And the third panel replaces all the analog drive, and the power control components.

All sensors and switches are replaced by Banner® self contained sensor components, which will add greater reliability and durability, especially with the replacement of the End of Form switch.

All fuses and power management components are replaced with two new fuses, a four bank Circuit Breaker panel, Corcom® Line Filter, and AC power switch.

This equates to fast and simple installation, usually the first time requiring no more than four hours, before returning the cutter system back to production. 

OPERATIONAL FUNCTIONS

Even the control and operation of the system has been simplified. While maintaining a similar operation to the old system, to keep with operator familiarity thus reducing the learning curve, we take it two steps further. 

The operational buttons have been reduced to two, which provides all the functions the old buttons provided plus more. The operator can now simply load the form anywhere onto the Tractor Pins, Auto-phase the form up to the blade, start operation, suspend operation, clear operation, suspend slitter operation, with only two buttons, which means faster setup times. 

The other advantage of the new control of the system is the keyboard and LCD display. The operator can now adjust speed, fine adjust, select form size, change operational modes, formats, and adjust sequential shutdowns with a few key strokes. 

Features include:

A highly informative and interactive LCD display screen, that assists the operator in set-up and operation of the system. The display indicates push button actions, set-up stages, job set-up settings, cycling stages, End of Form sensor status, and error status. All this adds up to fast easy set-up and performance which will equate to raw performance and substantial gain in production.

An extended form travel range that allows the customer to run documents up to 28" in length. 

Auto-phasing feature, that allows the operator to go past the traditional Home position & specific pin placement Phasing processes. By simply placing the form anywhere on the pins, depressing the Start button once, and automatically the form will be sensed and moved into proper position ready for material cycling. 

A high speed perforation Knock Out feature, that will allow you to remove by double cutting out up to 4" of material. Thus producing a cleaner product while reducing added material, from your web processes.

A precision fine position incremental adjustment feature, that replaces the cumbersome manual knob adjustment, allows the operator the ease and accuracy of fine Forward and Backward adjustment.

An automated Slitter motor shutdown feature, that greatly extends Slitter blade life, especially if used in conjunction with the DC Motor upgrade kit. By automatically shutting down the Slitter motor if the system is not cycling, and starting back up when cycling resumes. This feature also shuts downs the Slitter motor in case of an material jam or transport error, which anyone knows causes a major reduction in blade life. If this feature is used in conjunction with the Slitter DC motor upgrade kit, which incorporates a KB® PWM DC drive, the start and stop time is less than 200 milliseconds. This means that system speed performance will not be affected by the shut down or start up feature, but you'll see the blade life greatly extended.

A production Lock Out Feature, that simply links the new production monitoring systems to the Cutter System. The installation of a Solid State relay provides all the isolation control required to lockout the system until proper production set-up has been completed. The LCD display provide the operator with a message (PRODUCTION LOCKOUT) indicating the reason why operation can't proceed, so no confusion can occur.

INTERFACE CONTROL

As standard, the system comes with a Bell + Howell L-Board interface, so retrofitting the system maintains all current operations. Also standard is the "Stand Alone" mode with Batch count capability. This feature allows the cutter system to feed a specified number of sets between a set pause, which can also be held until a trigger pulse is received.

DISCOUNTED BASIC PRICING

The current cost for the basic upgrade kit is offered to you at this substantial reduced price of $6,900.00 per unit from the normal list price of $7,900.00. Even though this reduced cost does not include installation, which is normally a 600.00 charge plus shipping (approx. $500.00 round trip from coast to coast), Montronics will reduce the installation cost to half price. But please don't feel these are your only options, this retrofit kit has been designed for easy installation by most maintenance personnel. We provide detailed cutter preparation and installation documentation, that we feel should make the conversion time less than six hours.

ULTIMATE CONCLUSION

In conclusion the cost for this upgrade is insignificant in comparison to the costs in parts, labor, and down time that can and will occur in the future. In further consideration, compare these prices with the prices of new cutter systems that range from $26,000.00 to $32,000.00. When you stop to consider this, you will receive a like new cutter for a little more than a 1/8th of the cost of a new cutter. With performance guaranteed to exceed current performance standards of the current FIMA 90 and other like competitors.

Additional options that can be purchased and upgraded at any time:

OPERATIONAL 

Additional features can be added at a very low cost that can provide functions that can't be found on any of the cutter systems out there. Thus providing you a more modular system for your specific operation.

MECHANICAL

Bearing Replacement Kit: All existing bushings contained within the Tractor pin feed housings and the Slitter housings that require daily oiling and maintenance, will be replaced by high quality self contained needle bearings, that require no maintenance. Thus eliminating loss of production and costly repairs due to over or under oiling. The benefits are far and beyond what most people fully understand. The Tractor Pin belts will last much longer, a recorded 6 times longer, since oil will no longer be soaking them. The Slitter drive belt will last longer do to less drag, and will never incur damage do to a frozen Bushing. The Slitter belts have been known to never have been replaced after this upgrade. Less clean up and no maintenance will guarantee more performance and more production, which means more profit.  Basic Cost = $500.00 (with Core replacement)

DC Slitter motor kit: This kit replaces the limited and antiquated AC drive motor with a variable speed KB® PWM DC Drive motor (1/4 Hp) and controller. This upgrade will pay for itself time and time again by extending Slitter blade life and power consumption. The operator will be able to select the proper Slitter blade speed for the speed of the paper travel, and this proper alignment insure the Slitter blades do not have to work any harder than they have to. In addition the Slitter Shutdown/Start Up feature will be enhance to perform to it's optimum, making the response almost instantaneous. The KB® PWM DC drive will provide low power consumption and stall protection, insuring a life span equal to the chassis.  Basic Cost = $800.00 (without Installation)

Cut Motor Upgrade kit: The cumbersome FIMA Clutch/Brake system that is comprised of multiple components, will be replaced by another single API Turbo® Stepping system that has far superior performance, that requires no maintenance or calibration. The added reliability, performance, and life span that is achieved, rounds out this system and takes it to where no other Cutter system has gone before.                            

Basic Cost = $1,300.00 (without Installation)

SYSTEM

You have several choices for adding a read system. The system can be upgraded to perform reading operations in OMR, BCR, or 2D, that would be used to collate documents either offline or within a system.

You can even take it one step further by adding AIM control. This will allow the cutter system to cut, collate before or after folding, then hold in a collector until transfer to the base is requested. You can even dictate how you want to request the transfer of the collated documents, thus allowing an extremely flexible control. The overall result being, making a document processing system for offline or online operation for a fraction of the cost of all other systems.

Retrofit Specifics:

1. Manufacturer:  Montronics, in conjunction with; Applied Motion, Penta, Banner, BEI, and Delta.

         (3) Mounting panel assembly, (1) Prep and Install documentation, (1) Schematic and diagram package

2. Warranty:

    A. 90 days on all replacement components, and 1 Year on CPEA2C Intelligent controller.

3. Delivery:

    A. 1-4 weeks from of a signed order, an initial deposit, and the core FIMA 90 cutter to be retrofitted if      

installation is to be performed by Montronics. Duration dependent upon inventory, workload, and the number of upgrades to be performed within a certain period.

4. Installation:

    A. Montronics will generally factory install any additional upgrades during the installation of the basic package at no additional cost. But customer imposed time constraints can result in an added cost. The customer will be made aware of any additional costs at the time of purchase, or if the Customer requests a change after the order was placed.