Frequently Asked Questions

Please review these frequently asked questions before seeking technical help. If your issue or question is not addressed here, please call us.

After the system is installed, it's time to connect it to the plant air supply. Note: a minimum of 60 psi is needed to seat the air filter auto drains. Check to ensure that all hoses are connected according to the instruction manual. Please note that a small amount of air will discharge from the Servo Controller and Air-Flow Sensor.

These videos may also prove helpful.

What should the actual operating air pressure be?
Typically, input air should be between 3 and 6 PSI. For the most economical operation (minimal air consumption) adjust the air pressure to the lowest pressure suitable for your application. Excessive air pressure could make the system unstable causing it to oscillate back and forth (hunt). Insufficient air pressure can result in sluggish operation and slow shifting speed.

How do I balance out the system so the guide moves at the same speed in both directions?
Remove the web completely from the sensor. Then move a business card (or similar) in and out of the sensor while simultaneously adjusting the knurled Bias Adjustment Knob on the Servo Controller until the shifting speed of the cylinder is approximately equal in both directions when the "card" is inserted and withdrawn from the sensor. NOTE: As a reference point, the distance between the inside of the Bias Knob and Servo Controller's housing should measure approximately 14mm.

What if the Air Cylinder (actuator) will not move in either direction or moves too slowly?

1. Air pressure is too low for system operation. Increase air pressure. Then move a business card (or similar) in and out of the sensor while simultaneously adjusting the Bias Adjustment Knob.
2. Remove the Servo Controller's side plate to make sure the Shuttle moves freely. If not, refer to Page 9-1 of the instruction manual.
3. Auto-Center three-way valve may be in Auto Center position (up). Depress push/pull valve.
   

What if the Air Cylinder (actuator) moves erratically in one or both directions?

1. Air pressure is too high. Decrease air pressure while simultaneously adjusting the Bias Adjustment Knob until system works smoothly.
2. Check to make sure that guiding assembly is not binding and moves freely.
3. Remove the Servo Controller's side plate to make sure the Shuttle moves freely. If not, refer to Page 9-1 of the instruction manual.
4. Possible restriction or cut in air line, inspect all air lines for obstructions, cuts, or loose connection at air line fittings.
5. Possible cylinder blow by. Remove the cylinder airlines from the servo, cover one of the cylinder air inlets with finger and try to compress piston. If no movement is experienced cylinder is okay.
   

What if the system oscillates back and forth (hunts)?

1. Air pressure is higher than necessary. Decrease air pressure while simultaneously adjusting the Bias Adjustment Knob.
2. The "gain" pressure (needle valve) is too high. Turn needle valve inward (clockwise) until oscillation stops. Then re-bias the system.
3. Air lines are too long. Shorten to maximum length of six feet each. Relocate Servo Controller if necessary.
4. Possible restriction in air line. Inspect for restrictions or sharp bends that may cause kinks.
5. Sensing head is mounted in wrong location. Relocate.
6. Sensing head mounting is too loose allowing movement of the sensor. Secure mounting.
   

Is scheduled maintenance required?
No maintenance is required ... scheduled or otherwise.

What is covered under the 10-year warranty?
Coast's unparalleled 10-year warranty is unconditional and covers all system components when the equipment is installed as recommended.

What type of machines can use an All-Air Guiding System?
Coast's unique All-Air System is ideally suited for printing presses, blown film extruders, bag machines, packaging machines (pharmaceutical/medical, food, etc.), coaters, laminators, inspection machines, form/fill/seal machines, and virtually any other web processing and converting machine.

Are any spare parts recommended?
No. Because the All-Air System's profoundly simple, friction-free design incorporates very few moving parts. This means the components are not subject to a considerable amount of wear and tear, so there's no need to stock expensive spare parts inventories.

How much air does the All-Air System use?
Remarkably, the All-Air System uses only approximately 1.5 CFM (42 l/m) at a typical operating pressure of 5 PSI. The cost to operate an All-Air System is only 2.5 cents per hour.

Is technical start-up assistance required?
Unlike electro-mechanical systems, the All-Air System requires only a single connection to plant air. Most installations normally take less than 30 minutes and no adjustments are necessary after installation and start-up.

How accurate is the All-Air System?
At Coast Controls, the guiding results are guaranteed to the customer’s complete satisfaction. Placing a numerical value on accuracy can be difficult to determine due to a variety of factors (i.e., system dead band, the condition of the material's edge, positioning of downstream idler rollers); however, the All-Air System has held tolerances of +/- 0.005/inch under optimal guiding conditions.