www.conairgroup.com USER GUIDE UGE064-0907 Medline Combination Puller/Cutter CMSC Model Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.
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Ta b l e o f C o n t e n t s 1-1 I n t r o d u c t i o n Purpose of the user guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ATTENTION: Read this so no one gets hurt . . . . . . . . . . . . . . . . . . . 1-3 How to use the lockout device . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the belt gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 For puller model 1-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 For puller model 3-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Checking repeatability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Repeatability test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Preparing for testing . . . . . . . . . . . . . . . . .
Configuring the blow off settings (optional) . . . . . . . . . . . . . . . . . . 4-21 Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Blow amount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Blow activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring the set up 1 folder . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Modes page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Selecting modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 Mode page descriptions - Puller modes . . . . . . . . . . . . . . . . . . . . 4-47 Mode page descriptions - Cutter modes . . . . . . . . . . . . . . . . . . . . 4-50 Scroll page descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quality page description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86 Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86 Input polarity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88 When bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89 Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90 Take away/Blow off. . . . . . . . . . . . . . . . .
Zoom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-118 Profile/Bubble/Taper modes - Analog page description . . . . . . . . 4-119 Profile/Bubble/Taper modes - Digital output page description . . . 4-124 Setting output length and duration . . . . . . . . . . . . . . . . . . 4-125 Profile/Bubble/Taper modes - Graph all page description . . . . . . 4-128 Profile/Bubble/Taper modes - Gauge control page description. . . 4-129 Cutter operator control features . . . . . . . . .
Home offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-154 Offset example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-156 Power on time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-157 Cutter power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-158 Puller operation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 M a i n t e n a n c e Maintenance features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Warnings and cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Preventative maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Inspecting cutter blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Inspecting blade hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1 Tr o u b l e s h o o t i n g Before beginning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Identify the cause of a problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Puller operation problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Cutter operation problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E Appendix Choosing belt materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Conair belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 F Appendix Using the digital belt gap sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 Adjusting the pneumatic upper belt actuator . . . . . . . . . . . . . . . . . .
SECTION 1 Purpose of the user guide . . . . . . . . . . . . . . 1-2 How the guide is organized . . . . . . . . . . . . . 1-2 Yo u r r e s p o n s i b i l i t i e s a s a u s e r . . . . . . . . . . . 1 - 2 AT T E N T I O N : Read this so no one gets hurt . . . . . . . . 1-3 How to use the lockout device . . . . . . . . . . .
Purpose of the User Guide This User Guide describes the Conair Medline Combination Puller/Cutter and explains step-by-step how to install, operate, maintain and repair this equipment. Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet. You also should review manuals covering associated equipment in your system.
AT T E N T I O N : Read this so no one gets hurt WA R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n o r servicing may result in equipment damage or p e r s o n a l i n j u r y. This equipment should be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation and potential hazards of this type of machine.
AT T E N T I O N : Read this so no one gets hurt (continued) We design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide. WA R N I N G : P i n c h h a z a r d Never remove or disable safety devices to sustain production. Operating without these devices could lead to hazardous conditions that can cause severe injury.
How to Use the Lockout Device CAUTION: Before performing maintenance or repairs on this product, you should disconnect and lockout electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity. Lockout is the preferred method of isolating machines or equipment from energy sources. Your Conair product is equipped with the lockout device pictured below.
1-6 l Introduction
SECTION 2 What is the Medical Combination Puller/Cutter? . . . . . . . . . . . . . . . . . . .2-2 Ty p i c a l a p p l i c a t i o n s . . . . . . . . . . . . . . . . . . 2 - 2 Limitations . . . . . . . . . . . . . . . . . . . . . . . . 2-3 How the Combination Puller/Cutter works . . . 2-4 Specifications: Medline Combination Puller/Cutter . . . . . . . . . . . . . . . . . . . 2-7 Puller optional equipment . . . . . . . . . . . . . . 2-9 Cutter optional equipment. . . . . . . . . . . . . .
What is the Medical Combination Puller/Cutter? The Conair Medline Combination Puller/Cutter pulls small extruded tubing through sizing and/or cooling tanks and cuts the product to lengths. Since the puller and cutter are mounted on the same chassis, alignment problems are minimized. The puller portion's dual servo drive system offers extremely accurate speed control. Different puller belt materials optimize performance with different types of extruded materials, or applications.
Limitations • The unit is limited by the traction length (the length over which the extrudate is in contact with the puller belts), which is fixed for particular models. • The outer surface of the puller belt material will affect performance. Softer (low durometer) materials provide good “grab”, but will wear more quickly, and may tear if the belt jams. Harder (high durometer) materials last longer, but may not grab the extrudate properly.
How the Combination Puller/Cutter Wo r k s First, the extruded material that has been sized and cooled enters the combination puller/cutter from the upstream side. The extrudate passes through and is positioned by guide rollers. Then, the two opposing belts move the extrudate through the puller. These belts have grooves that fit teeth on the puller’s sheaves (sprockets), preventing side-toside movement. Belt coverings are available in a variety of materials for specific applications.
How the Combination Puller/Cutter Wo r k s ( c o n t i n u e d ) Clear knife guard Digital belt gap read-out (Optional) Belt adjustment Servo cutter motor Cutter head with blade(s) Emergency Stop Material inlet through cutter bushings Belt guard (with clear walk-through design) Guide rollers Particulate collection tray Optional mister for bushing and tube lubrication Puller belts (FDA) PD series Optional stainless steel stand (shown). White painted carbon steel is standard.
How the Combination Puller/Cutter Wo r k s ( c o n t i n u e d ) PD series selftracking FDA sheaves (sprockets) Precision idler rolls Puller belt 50 Duro white (FDA) natural rubber or white (FDA) closed face sponge Emergency Stop Grease fittings (4) Dual servo puller motors with precision planetary gearheads Product guide roll Digital belt gap (Optional) CPC-1-12 puller model shown 2-6 l Description
Specifications: Medline Combination Puller/Cutter MODELS Performance characteristics Extrudate capacity in. {mm} dia. Blade drive motor (3000 rpm) CSC cutter Hp {kW} Electrical requirements Full Load Amps Drive type(Puller) 230V/3 phase/60Hz 460V/3 phase/60Hz Cutter Control 2.46 {1.83} (2) 0.43 {0.32} A 71.0 {1803.4} 42.0 {1067} 40.0 {1016} 27.0 {685.8} 1.0 {25.4} 12.0 {304.8} 2.0 {50.8} 715 {324} 800 {363} D Dual Servo with precision planetary gearhead (2) 0.
Specifications: Medline Combination P u l l e r / C u t t e r (continued) MODELS Performance characteristics Extrudate capacity in. {mm} dia. Blade drive motor (3000 rpm) CSC cutter Hp {kW} Puller drive motor Hp {kW} Optional Servo drive motor Hp {kW} Dimensions in. {mm} A - Height B - Height to centerline, ±2 {±50.8} C - Width D - Depth Belt width ±3/8 {±9.
Puller Optional Equipment • Digital belt gap sensor and readout - (Optional) Allows the operator to set a zero point, then measure belt gap (in thousandths of an inch) relative to this setpoint. • Remote belt speed control - (Optional) Allows the puller speed to be controlled by an external source. (Remote Digital Potentiometer) the time of purchase to optimize puller performance in a particular speed range.
Cutter Optional Equipment (continued) • Follower cutting Mode - Follower Mode allows the operator to program the desired cut length and the number of blades. The controller then automatically follows the puller and adjusts the speed of the flywheel to maintain cut length accuracy. This is known as an electronic gear lock system. The cut length accuracy is maintained even if the puller changes speed.
SECTION 3 Installation Unpacking the boxes . . . . . . . . . . . . . . . . . 3-2 Preparing for installation . . . . . . . . . . . . . . 3-3 Po s i t i o n i n g t h e C o m b i n a t i o n P u l l e r / C u t t e r . . . 3 - 4 Installing the cutter blades . . . . . . . . . . . . 3-7 Mounting the cutter bushings . . . . . . . . . . . 3-8 Adjusting belt tension . . . . . . . . . . . . . . . 3-10 Fo r p u l l e r m o d e l 1 - 1 2 . . . . . . . . . . . . . 3 - 1 0 Fo r p u l l e r m o d e l 3 - 2 0 . . . . .
Unpacking the Boxes The Conair Medline Combination Puller/Cutter comes fully assembled in a single crate. CA U T I O N : L i f t i n g To avoid personal injury or damage to the puller/cutter, lift the puller/ cutter using a forklift or hoist with straps that have been positioned at the puller/cutter’s center of gravity. To uncrate the Medline Combination Puller/Cutter: 1 Carefully uncrate the puller/cutter and its components. 2 Remove all packing material, protective paper, tape, and plastic.
Preparing for Installation 1 You will need these tools for installation: r wire strain relief r 16 or 18 inch adjustable wrench r set of Allen wrenches r set of Feeler gauges r 1/2 inch open or box end wrench r flashlight. 2 Plan the location. Make sure the area where the Medline Combination Puller/Cutter is installed has the following: r Clearance for safe operation and maintenance. Make sure there is enough clearance around the servo cutter for maintenance and servicing.
Po s i t i o n i n g t h e M e d l i n e Combination Puller/Cutter 1 Move the Medline Combination Puller/Cutter into position. Place the puller/cutter in position downstream of the last sizing or cooling tank. CA U T I O N : L i f t i n g To avoid personal injury or damage to the cutter, lift the cutter using a forklift or hoist with straps that have been positioned at the combo’s center of gravity. 2 Align the puller/cutter with the extrusion line.
Po s i t i o n i n g t h e M e d l i n e Combination Puller/Cutter (continued) 3 Measure the centerline height of the extrudate as it exits the extrusion die. Adjust all equipment on the extrusion line (sizing tank, cooling tanks, puller/cutter) to this height. 4 Adjust the puller/cutter's floor lock/caster assembly to the center height of the extrusion line using a 16 or 18-inch adjustable wrench. Remove the weight from the casters by locking down the floor locks.
C o n n e c t i n g t h e M a i n Po w e r S o u r c e WA R N I N G : E l e c t r i c a l h a z a r d Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity.
Installing the Cutter Blades DA N G E R : S h a r p B l a d e s ! Most injuries caused by knife blades occur when the cutter has been turned off. Handle blades with care at all times. • • • Always wear cut-resistant gloves when the cutting chamber is open and when handling blades. Always lock out power to the cutter before opening the cutting chamber. Always wait until the cutter head has completely stopped before opening the knife guard.
Mounting the Cutter Bushings DANGER: Sharp blades Always wear cut-resistant gloves when the cutting chamber is open and when handling blades. Never open cutting chamber without locking out the cutter power and waiting until the cutter head stops spinning. 1 Rotate the cutter head until the blade is positioned in the gap between where the bushings are located. 2 Slide the downstream bushing into position, positioning it up to and barely touching the blade (using a feeler gauge).
Mounting the Cutter Bushings (continued) 4 Slide the upstream bushing into position, positioning it up to and barely touching the blade (using a feeler gauge). NOTE: the blade should not be deflected. 5 Tighten the bushing retaining system against the flat side of the bushing to hold the bushing in position. 6 Rotate the cutter head by hand to make sure the bushings did not move, and that the blade still passes through the gap between the bushings.
A d j u s t i n g B e l t Te n s i o n For Puller Model CPC 1-12 1 Turn the main power disconnect to the off position. 2 Remove the upper and lower polycarbonate belt guards: • Remove the screws attaching guards to unit (five each: front). • Remove guards. Screw (10) 3 Check belt tension. Use a tension-measuring tool. Belts should be just tight enough to prevent slipping, and the gap between the upper and lower belts should be even across the width of the belt.
A d j u s t i n g B e l t Te n s i o n For Puller Model CPC 1-12 (continued) 5 Fine tune tension: • Lower the belts to a gap of about 1/8 inch (3 mm). See Installation Section entitled, Setting the Belt Gap. • From the upstream end of the belts, look down the length of the belts at the gap between the belts. If the gap is not even, adjust the tension until the gap is even and measures 1/8 inch. The shape of the gap should not be concave (over-tightened) or convex (too loose).
A d j u s t i n g B e l t Te n s i o n For Puller Model CPC 3-20 (continued) 4 Adjust belt tension, if necessary. Adjust tension by turning the threaded tension rods. Keep tension on front and back edges, top and bottom belts as even as possible. Threaded tension rods 5 Fine-tune the tension: • Lower the belts to a gap of about 1/8 in. (3 mm). See Installation Section entitled, Setting the Belt Gap. • Check the appearance of the belt gap. From the upstream end, look down the length of the belts.
Setting the Belt Gap For Puller Model CPC 1-12 The upper and lower belt boom assemblies are controlled by a common threaded rod. Turn the hand wheel to move the belts up and down. The belt gap should be set to the dimensions of the extruded product, being careful not to make the gap so small that the pressure causes distortion in the product. 1 Turn the hand wheel until the gap between the belts reaches the desired distance.
Checking Repeatability IMPORTANT: See Operation Section entitled, Tuning the Cutter, if using Red Lion HMI and Control Techniques/ Emerson Servo Drives Before any Conair Medline Combination Puller/Cutters are shipped, they are tested for cut time repeatability to be sure they are within performance specifications. The repeatability test checks the performance of the rotary knife cutter to return to the home park position after a complete cut.
R e p e a t a b i l i t y Te s t R e s u l t s Results in Flywheel Mode The display shows DevCC a full revolution of the cutter head. The reading is in milliseconds, to the third decimal place, i.e. 0.010 is 0.01 milliseconds (or 10 microseconds). If the reading exceeds 0.200 there is a problem with the cutter drive. If this occurs the error is too large and there is a problem in the cutter drive that must be corrected.
P r e p a r i n g f o r Te s t i n g 1 Make sure all components are installed according to assembly drawings. Make sure that all bolts have been checked for tightness. 2 Check to ensure that the combination puller/cutter is firmly locked into position with the anchoring screws. 3 Check that all wiring conforms to electrical codes, and all wiring covers are in place. DANGER: Pinch Hazard! Never remove or disable safety devices to sustain production.
Te s t i n g t h e I n s t a l l a t i o n Tw o - L i n e H M I I n t e r fa c e O p e r a t i o n 1 Plug in the main power cord and turn on the main disconnect. The display should fully illuminate and start up. Power on lights will illuminate. 2 Check that the “Emergency Stop” buttons are in the out, extended position.
Te s t i n g t h e I n s t a l l a t i o n (continued) To u c h s c r e e n H M I I n t e r fa c e O p e r a t i o n 1 Plug in the main power cord and turn on the main disconnect. The display should fully illuminate and start up. Power on lights will illuminate. 2 Check that the “Emergency Stop” buttons are in the out, extended position.
SECTION Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . 4-6 . 4-7 . 4-8 . 4-8 . 4-9 . 4-9 4-11 4-11 4-12 4-12 4-13 4-14 4-14 4-15 4-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 4-2 l Operation (continued) Changing the password . . . . . . . . . . . . Using the events page . . . . . . . . . . . . Using the faults page . . . . . . . . . . . . . Using the IO page. . . . . . . . . . . . . . . . Diagnostics character . . . . . . . . . Debounce . . . . . . . . . . . . . . . . . . Configuring the set up 1 folder . . . . . . Modes page . . . . . . . . . . . . . . . . Selecting modes . . . . . . . . . . . . . Mode page descriptions - Puller modes .
Operation (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93 4-94 4-95 4-96 4-97 4-98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100 4-101 4-102 4-102 4-104 4-104 4-105 4-106 4-107 . . . . 4-108 4-109 4-112 4-113 4-114 4-115 4-118 . . . . . 4-119 . . . . . 4-124 . . . . . 4-125 . . . . . 4-128 . . . . . . . . . . . . . . . . .
Operation (continued) Functions areas . . . . . . . . . . . . . . . . . Test . . . . . . . . . . . . . . . . . . . . . . . . Cut mode . . . . . . . . . . . . . . . . . . . . . Minimum measurement . . . . . . . . . . . . Maintenance area . . . . . . . . . . . . . . . Encoder area . . . . . . . . . . . . . . . . . . . Encoder direction. . . . . . . . . . . . . . . . Unit of measure . . . . . . . . . . . . . . . . . Scale distance . . . . . . . . . . . . . . . . . . Scales counts . . . . . . . . . . . . . .
Conair Medline Combination P u l l e r / C u t t e r - To u c h Pa n e l The Conair Medline Combination Puller/Cutter uses a common Red Lion G310 color touchscreen operator interface. Touchscreens provide a user-friendly interface to the puller/cutter. Information can be shown while maintaining an easy-toread and easy-to-use environment. On the left-hand side of the panel are seven general-purpose buttons and a “Menu” button, these are not used in this application.
U s i n g t h e M a i n Pa g e The Main Page appearance is affected by the modes that have been selected for the Medline Combination Puller/Cutter. In the Main Page example, the puller is set to Master Mode and the cutter is set to Encoder Mode. The chosen mode appears at the bottom of each control section.
U s i n g t h e M a i n Pa g e (continued) U s i n g F o l d e r Ta b s A series of folder tabs appear at the top of every page. Each folder contains a page containing further parameters, selections or more folders. Tabs act as a simplified menu to move between pages. The last tab pressed opens the folder to show the page(s) contained inside. Highlighted tabs appear darker in shade compared to unselected tabs. In the example below, the “Main” tab has been selected. Sample of a single-tiered tab page.
Using the Puller Control For right-to-left configurations the cutter control is shown on the left with the puller control on the right, as in the example. Images of the controls may be switched at the factory for left-to-right combinations. A message appears above each control to show if the drive is running or stopped. "Running" is shown as white text on a green background and "Stopped" is shown as white text on a red background.
Using the Puller Control Setting the Puller Speed (continued) Scroll Method The (+) and (-) buttons can be used to add or subtract the value shown in the Scroll Size window to the current speed setting. Scroll Size is a user preference value. Four presets are available but only one may be selected at any given time. In the example, the chosen Scroll Size is set to ±0.10 FPM. To enter a new puller speed: 1 Press either the (+) or (-) scroll button to increase or decrease the set speed.
Using the Puller Control Setting the Puller Speed 0 NOTE: In this example, cut length is being altered. (continued) A title appears at the top of the pop-up keyboard to confirm which preset is being modified. See Operation Section entitled, Using the Cutter Control, Setting the Cut Length. The explanation given in that section applies to changing any preset. The procedure to change any measurement using the Keyboard method is • If the pop-up is accessed by mistake press “Exit” to remove it.
Using the Puller Control (continued) Using Footage The middle section of the puller control displays footage. Footage can be reset at the beginning of a production run and can be used to record the amount of material produced. To reset the footage counter: 1 Press the “Reset” button to “zero” the counter. Remote Scroll amount is a user preference. See Operation Section entitled, Scroll Page Description. The “On/Off” button is used to enable or disable the remote.
Using the Puller Control (continued) Switched (Local/Remote) Modes This section will have additional buttons and indicators for Switched or Trim Modes. Extra mode related items appear at the right. Switched modes include a Local/Remote “Select” button and indicators. The state of Local or Remote is provided as an output at the puller drive (Module Output 3). Remote = On, Local = Off. A n a l o g Tr i m M o d e s Analog Trim modes will have a Trim “On/Off” button and indicator.
Storing the Belt Gap The belt gap dimension can be stored here. The value should be read from the belt gap gauge and entered at this window. When returning to a product that was previously produced the user can recall the recipe value by viewing the saved file and then setting the belt gap to match. See Operation Section entitled, Using Files Pages, File Pages. 1 View the belt gap measurement from the digital readout located on the Medline Combination Puller/Cutter’s cabinet.
Using the Cutter Control Length The cutter portion has multiple sections. These are grouped into categories. • Total Counter • Cut Length • Batch Counter • Blade Speed • Batch Settings • Blow Settings Sample - Encoder Mode 4-14 l Operation Sample - Flywheel Mode Features differ between the various modes. For example, the length in Encoder Mode can be set by the operator whereas Flywheel Mode (blade spins continuously) can only show length as a captured value.
Using the Cutter Control Length (continued) Timer and Product Modes display a time value instead of a length. Time is measured in seconds to three decimal places. Sample - Time Mode Length can be changed using the (+) and (-) buttons that are just below the length readout or it may be keyed in using the pop-up keyboard. The time is shown in seconds.
Using the Cutter Control Setting the Cut Length (continued) Keyboard Method To change length using the keyboard method, press the Length window. A pop-up keyboard will appear. The new length can then be keyed in. All numeric presets are altered using this method. An example of how to change the length is provided to help describe the key sequence. In this example, Length is 2.750" and will be changed to 6.000". 1 Press the length window. A numeric pop-up keyboard appears.
Using the Cutter Control Setting the Cut Length Keyboard Method ( c o n t i n u e d ) 2 For 6.000" key in the new length as shown. 4 The new length is now in the Cut Length window. Operation l 4-17 4 Operation 3 Then press “Enter”. (The pop-up keyboard is removed).
Using the Cutter Control Using Encoder Sequence, Cuff and P r o f i l e / B u b b l e / Ta p e r M o d e s Encoder Sequence, Cuff and Profile/Bubble/Taper Modes have many length presets. There are too many to be able to show on the Main Page. The length section on the Main Page for these modes is replaced by a button that is used to go to a secondary page that contains the extra presets. Sample of the Main Page with Profile/Bubble/Taper Mode selected.
Setting the Blade Speed Sample - Flywheel Mode showing Blades preset (for multiple blades) NOTE: Blade Speed adjustment is an option, on some cutters Blade Speed will be fixed. To adjust the blade speed: 1 Press the Blade Speed window. A numeric pop-up keyboard appears. 2 Key in the new blade speed. 3 Then press “Enter”. The pop-up keyboard is removed. 4 The new blade speed is now in the Blade Speed window. Operation l 4-19 4 Operation Blade Speed shows the RPM of the blade.
Using Multiple Blades Multiple blades may be entered and fitted for Flywheel and Follower modes only. An additional preset will appear in Blade Speed section for entering the amount of blades. Also, a circular or balanced arm style blade holder will be fitted for the extra positions. Blade Speed will then appear as Cuts per Minute (CPM) instead of RPM. CPM = Blade Speed x Number of Blades. Blade options for Follower and Flywheel Modes.
Using 180 Degree Cutting (Optional) An option is available for use with the Encoder Mode where 2 blades may be fitted to the blade arm. The cut then makes 180-degree on-demand indexes (half a revolution). 180 and 360-degree buttons are provided when this option has been added. Configuring the Blow Off Settings (Optional) A dedicated output is available for use with a Blow Off/Take Off Conveyor.
Configuring the Blow Off Settings (Optional) (continued) Ti m e Time is the on-time duration for the air valve(s) of the Take Off/Blow Off Conveyor. The time needed to eject the product should be kept short to avoid exhausting accumulated air. The status of the air valve(s) will show in the Blow/Quality section. An indicator light that is next the the word “Blow” will illuminate when the valve(s) is on. To set the Time amount of the Take Off/Blow Off Conveyor’s air valve(s): 1 Press the Time window.
Configuring the Blow Off Settings (continued) (Optional) Blow Amount Blow Amount is available to blow one or many pieces off the Take Off/Blow Off Conveyor at once. For example, if the Blow Amount is set to 5 the Blow Off valve(s) on the conveyor will blow once after 5 pieces have been cut. To change the Blow Amount setting: 1 Press the Blow Amount window. A numeric pop-up keyboard appears. 3 Then press “Enter”. The pop-up keyboard is removed.
Configuring the Blow Off Settings (continued) (Optional) Style IMPORTANT: The options “Blow always when Good” and “Blow always when Bad” can expend a lot of air. Their settings should be kept low or not used when possible. Pressing the “Style” button will toggle through three different Blow Settings. Blow Amount as shown in the example above is one of the options. Other options are "Blow always when Good", or "Blow always when Bad”.
Configuring the Blow Off Settings (continued) (Optional) Scrap/Sort The “Scrap/Sort” toggle button provides the option to force product to be scrapped (even if it is good) or be sorted into good and bad by using the Quality Sort feature. See Operation Section entitled, Quality Page Description. U s i n g t h e To t a l a n d B a t c h C o u n t e r To t a l C o u n t e r To activate the Total Counter: 1 Press the “On/Off” button to toggle the Total Counter feature on and off.
U s i n g t h e To t a l a n d B a t c h C o u n t e r (Optional) (continued) Batch Counter The Batch Counter is a 6-digit readout display and is used with the Batch Settings section that is located directly beneath the Total Counter. When used with the Quality Sort feature only good pieces will be counted. To activate the Batch Counter: 1 Press the “On/Off” button to toggle the Batch Counter feature on and off. When the Batch Counter is on, an indicator light will illuminate.
Configuring the Batch Settings (Optional) Set (continued) To enter a Set amount: 1 Press the Set window. A numeric pop-up keyboard appears. 2 Key in the new set amount. 3 Then press “Enter”. The pop-up keyboard is removed. Wa r n The Warn preset is set to a value less than the Batch setpoint. This level activates an operator warning that signifies a batch is near to completion. A yellow Warn light is shown on the touch panel when the count is between Warn and Set values.
Configuring the Batch Settings (continued) (Optional) Pulse/Latch The “Pulse/Latch” button option offers the choice of making the output pulse or latch on (stay on). The Latch option turns on the output, which will stay on until the “Reset” button is pressed. The Pulse option will only pulse the output, which will not require the “Reset” button to be pressed. In the Latch Mode there is an extra light that is shown on the touch panel to show the state of the Batch Complete output.
A c c e s s i n g S e c u r e d Pa g e s a n d Presets Some pages and presets require a user name and password for access. Only when the user has successfully signed in will the protected page be displayed or a changed in the preset be finalized. In the following example the operator has pressed a tab requiring the user to sign in (logon). A message appears - Secure Access Control - Must Authenticate to Access Page. To access the password protected screens: maintenance personnel.
A c c e s s i n g S e c u r e d Pa g e s a n d P r e s e t s (continued) 2 A second keyboard appears for password entry. Enter in the user password 0 0 “PASSWORD” followed by the “Enter” key. NOTE: The password is a user preference, see Operation Section entitled, Changing the Password to create a new password. NOTE: The password characters do not appear as they are typed. An asterisk character appears for each key press.
U s i n g F i l e Pa g e s The File Page screen has three sections. One section is used for creating, saving and reopening files. Another section is for Ethernet. The remaining section is for password creation and alteration. To access the File Pages: The filing system has a similar feel to any PC based software. Files may be created and recalled. The 8,3 DOS style of word naming is used (8 character filename with a 3 character extension). Extensions are fixed to .CSV (comma separated file).
U s i n g F i l e Pa g e s Opening a File Files are listed in alphabetical order. The "A-Z" and "Z-A" buttons provide options to show files in alphabetical order or reversed alphabetical order. To open a file: 1 Press the “Open” button that is located on the main File Page. 2 Once on the Open File Page, press directly on the file name or select the file by using the “Up” or “Down” buttons.
U s i n g F i l e Pa g e s (continued) Deleting a File A file may be deleted by using the arrow buttons and then pressing the “Delete” button. A red warning appears detailing which file is about to be deleted with options to keep or discard the file To delete a file: 1 Press the “Open” button that is located on the main File Page. buttons.
U s i n g F i l e Pa g e s (continued) Saving a File A file can be saved using the “Save” or “Save As...” buttons. The “Save” button should be used when making changes to a file that is currently open. To update a current file using the “Save” button: 1 Press the “File” tab after changes have been made to the current running program. 2 Press the “Save” button to update the current file. The “Save As...” button is used when a new filename is required. An area is provided to enter the filename.
U s i n g F i l e Pa g e s Saving a File (continued) 4 Press the “Enter” button to lock in the new file name. The pop-up keyboard will be removed and the main File Page will be displayed. Operation l 4-35 4 Operation 3 Enter in a new file name in the pop-up keyboard.
U s i n g F i l e Pa g e s (continued) File Contents 0 NOTE: The “<” and “>” buttons The contents of any saved file can be viewed using the File Contents feature. From the File Page, you can select to view the contents of any file. are used only to scroll sideways if there are multiple columns. To view the contents of a file: 1 Press the File tab, if not currently at the File Page. 2 Press the “View File Contents” button. A File Contents Page will be displayed.
Configuring the Network Settings The Medline Combination Puller/Cutter’s touch panel has Ethernet capabilities. For the Ethernet to function correctly the control must be set to conform to the current network. The control must be rebooted for new settings to take effect. This can be achieved by cycling the power on the control or by pressing the “Update” button. To setup or update the Network Settings: 1 Press the setting to be configured or updated.
C h a n g i n g t h e Pa s s w o r d This feature is provided to change a password. The user can access and change their own password only. Factory personnel have the option to rewrite any user password. To change a user password: 1 Press the File tab if not currently at the File Page. 2 Press the “Next” or “Previous” buttons located by the Password Alteration window to select the username’s password to be changed.
U s i n g t h e E v e n t s Pa g e To access the Event Page: The Events Page is used to record changes in activity. Cutter and puller events are being recorded in the example. A variety of different events are recorded and time stamped. • “Previous” and “Next” buttons become active after the list expands to allow movement through the list. • The “Clear” button can be used to erase the list. 0 NOTE: The panel has the ability to record events to the compact flash memory card.
U s i n g t h e Fa u l t s Pa g e 0 To access the Faults Page: NOTE: Diagnostics characters on the drives may be viewed through the door window of the lower electrical cabinet. The IO Page also shows diagnostic characters. 0 NOTE: The panel has the 1 Press the Faults tab. If a fault occurs the screen will flash and an alarm will sound from the touchscreen. Some faults clear automatically, others need maintenance attention.
U s i n g t h e I O Pa g e To access the IO Page: 1 Press the IO tab. IO refers to digital inputs and outputs at the drive and at the FM-4 program module that is clipped on to the front of the drive. Inputs that are active are shown with green lights. Outputs that are active are shown with red lights. The IO number is shown to the left of each indicator. Inputs and outputs that have program assignments are labeled accordingly at the right of each indicator. NOTICE: The drive has 4 inputs and 3 outputs.
U s i n g t h e I O Pa g e (continued) Diagnostics Character Drives include a diagnostics character on the front of every drive. A copy of the character is shown on this page. In this example, all drives show a 'P' which means programs are running. To view a diagnostics character: 1 Press any diagnostics character on the touchscreen to show a basic and detailed pop-up description for that code. Descriptions shown on the pop-up match those found in the Control Techniques manual.
U s i n g t h e I O Pa g e Debounce (continued) The cutter portion has two inputs with adjustable filters. These are End Sense (used by Product mode) and Good/Bad. Debounce filters are measured in seconds to three decimal places. When relay or switch contacts are used these should be filtered between 0.005 and 0.100 seconds. When the signal input is from a transistor or solid-state driver set the debounce amount to zero. 1 Press the End Sense or Good/Bad Debounce window.
Configuring the Set Up 1 Folder M o d e s Pa g e 0 NOTE: Modes Page sample for a combination puller/cutter equipped with all options displayed. IMPORTANT: Only personnel with maintenance rights can access this page. To access the Modes Page: 1 Press the Set Up 1 tab. 2 The Modes sub-tab is defaulted to appear first when the main tab “Set Up 1” is pressed. The cutter and puller have up to eight modes available each. Unavailable modes are grayed out.
Configuring the Set Up 1 Folder M o d e s Pa g e (continued) Control sample with fewer modes Warning messages shown on Modes Page Operation l 4-45 4 Operation Modes may be changed only when the machine is stopped. All options are grayed out while the machine is running. In addition, a red warning message for each control is shown to explain "Cannot change modes when running".
Configuring the Set Up 1 Folder Selecting Modes To select a mode for either the cutter or puller: 1 Press the appropriate mode for either the cutter or puller. 2 The selected mode will appear at the bottom of each section. 3 Press the Main tab when finished selecting modes. See Operation Section entitled, Mode Page Descriptors - Puller/Cutter Modes 0 NOTE: Profile/Bubble/Taper Modes will need to be set for both the puller and cutter sections.
M o d e Pa g e D e s c r i p t i o n s - P u l l e r Modes Master Mode When the puller is in Master Mode it directly controls the speed of the extrusion line. In this instance the puller is the Master. Sensors may be included in the extrusion process to monitor the product and auto-correct the speed as in an automated diameter size process. Auto-corrections are made to the same preset that the operator uses. The operator can enter in a new value at the Main Page to control speed.
M o d e Pa g e D e s c r i p t i o n s - P u l l e r M o d e s (continued) Switchable Modes Two of the modes listed are known as switchable modes. These have dual possibilities using a mixture of the modes already discussed. The puller can be started in one mode and then switched to another. A selector switch appears on the Main Page in the puller section whenever Master/Analog Remote or Master/Follower Remote modes are selected. In addition, indicator lights show which of the two modes are selected.
M o d e Pa g e D e s c r i p t i o n s - P u l l e r M o d e s (continued) P r o f i l e / B u b b l e / Ta p e r M o d e This is a special mode that is used to sequence through a set of velocity changes in order to make a product with varying diameters. It is similar to Master Mode except it has many setpoints (Master Mode has one setpoint). This mode is used with the Matching Mode on the cutter. In this mode, the operator sets velocities and distances. Two distances are provided for every velocity.
M o d e Pa g e D e s c r i p t i o n s - C u t t e r Modes Ti m e M o d e Time Mode is used to set a time interval between cuts. For example, a setting of 1.000 will ensure that one cut is made per second. Time can be adjusted using thousandths of a second increments. Encoder Mode Encoder Mode is used to set product length using distance obtained from an encoder. In the Combination Puller/Cutter an encoder is built into the puller motor. This encoder is used to provide length information to the cutter.
M o d e Pa g e D e s c r i p t i o n s - C u t t e r M o d e s (continued) Follower Mode Follower Mode is similar to Flywheel Mode where the blade spins continuously. However, in this mode the operator sets a length and the blade spins at the RPM needed to make that length. The cutter calculates a gear ratio based on length and puller speed. It then remains at that gear ratio. This mode is also known as Gear Lock. The line speed should remain stable within ±5%.
M o d e Pa g e D e s c r i p t i o n s - C u t t e r M o d e s (continued) P r o f i l e / B u b b l e / Ta p e r M o d e This mode is used with the Matching Mode on the puller. Cut distances are measured using the encoder but are synchronized to the profile sequence. Each time the puller starts a profile sequence it outputs a sync signal to the cutter and PLC's. The cutter uses the sync signal to load cut lengths into a queue. No cuts are made at this time.
S c r o l l Pa g e D e s c r i p t i o n s C u t t e r S c r o l l s - Pa n e l The Scroll Page is used to change these scroll increment setpoints for both the puller and cutter sections. To access the Scroll Page: 1 Press the Set Up 1 tab. 2 Press the Scroll sub-tab. Scroll amounts are the user preferred values. (continued) Operation l 4-53 4 Operation Two scroll increments are available to adjust the cut length.
S c r o l l Pa g e D e s c r i p t i o n s C u t t e r S c r o l l s Pa n e l (continued) Two setpoints on the Cutter Scrolls Panel are used to adjust the cutter control. One setpoint is for course trimming, the other is for fine trimming. To change the Cutter Scroll Size increments: 1 Press the first Cutter Scroll window. A numeric pop-up keyboard appears. 2 Key in the new scroll increment. 3 Then press “Enter”. The pop-up keyboard is removed.
S c r o l l Pa g e D e s c r i p t i o n s (continued) P u l l e r S c r o l l s - Pa n e l The values in this list can be set in any order. It is recommended that they be placed in a descending order for line set up where the operator can begin with coarse settings and then end with fine. To change the Culler Scroll Size increments: 1 Press the first Puller Scrolls window. A numeric pop-up keyboard appears. 2 Key in the new scroll increment. 3 Then press “Enter”. The pop-up keyboard is removed.
S c r o l l Pa g e D e s c r i p t i o n s (continued) Puller Scrolls - Remote Contacts Two settings are available for remote contacts (laser gauge or switches that are located at the extruder) that are used to increase or decrease the puller speed. One is used for Speed Modes such as Master Mode. A contact closure or switch will add or subtract this increment to the speed setpoint on the Main Page. To change the Speed Modes scroll increment: 1 Press the Speed Modes FPM window.
S c r o l l Pa g e D e s c r i p t i o n s Puller Scrolls - Remote Contacts (continued) To change the Ratio Modes scroll increment: 1 Press the Ratio Modes window. A numeric pop-up keyboard appears. 2 Key in the new scroll increment. Lower product line speeds will require a smaller increment change, higher product line speeds will require a larger increment change. 3 Then press “Enter”. The pop-up keyboard is removed.
S c r o l l Pa g e D e s c r i p t i o n s (continued) P u l l e r S c r o l l s - R e m o t e D i g i t a l Po t Two settings are available for remote digital pot. One is used for Speed Modes such as Master. A click clockwise or counterclockwise made by rotating the digital potentiometer will add or subtract this increment to the speed setpoint on the Main Page. To change the Speed Modes scroll increment: 1 Press the Speed Modes FPM window. A numeric pop-up keyboard appears.
S c r o l l Pa g e D e s c r i p t i o n s P u l l e r S c r o l l s - R e m o t e D i g i t a l Po t (continued) To change the Ratio Modes scroll increment: 1 Press the Ratio Modes window. A numeric pop-up keyboard appears. 2 Key in the new scroll increment. Lower product line speeds will require a smaller increment change, higher product line speeds will require a larger increment change. Also, this number is dependent on the number of rotations of the remote digital potentiometer’s rotary dial.
E n c o d e r s Pa g e D e s c r i p t i o n The Encoders Page is for factory personnel only. Information contained in this page will not be mentioned in this Operator Instruction Manual. R a m p s Pa g e D e s c r i p t i o n To access the Ramps Page: 1 Press the Set Up 1 tab. 2 Press the Ramps sub-tab. Cutter Four choices of ramp styles are available. S-Curves provide less wear on the mechanics of the cutter by use of smoothing at the beginning and end of the ramp.
R a m p s Pa g e D e s c r i p t i o n Cutter (continued) 0 NOTE: All values can be changed by pressing individual windows and using the keyboard method to alter the value. See Setting the Cutter Length, Keyboard Method. • Linear - rate of change is constant throughout the speed change • 1/4 S-Curve - linear portion is 1.143 x average acceleration • 5/8 S-Curve - linear portion is 1.
R a m p s Pa g e D e s c r i p t i o n (continued) Puller Four choices of ramp styles are available. S-Curves provide less wear on the mechanics of the puller by use of smoothing at the beginning and end of the ramp. The middle of the profile is linear but uses a steeper gradient to compensate for the smooth ends.
R a m p s Pa g e D e s c r i p t i o n Puller (continued) To change the Puller Ramp type: 1 Press either the Linear, 1/4 S-Curve, 5/8 S-Curve or S-Curve radio button. A dot will appear in the radio button of the selected curve type. • Acceleration and Deceleration preset is the average rate of change that will be used for speed changes. For example, a puller set to 100 FPM will accelerate from zero in one second with a 100.0 FPM/S ramp.
S c a l e Pa g e D e s c r i p t i o n The Scale page is available to set all scale values. The Scale Page is used to calibrate all aspects of both the puller and the cutter to the match actual machine output. To access the Scales Page: 1 Press the Set Up 1 tab. 2 Press the Scale sub-tab.
S c a l e Pa g e D e s c r i p t i o n (continued) Cutter - Encoder Input To change the Encoder Input distance: 1 Press the Cutter section’s Encoder Input distance window. A numeric popup keyboard appears. 2 Key in the new distance. This is the length scaling of the material passing through the cutter bushing. 3 Then press “Enter”. The pop-up keyboard is removed.
S c a l e Pa g e D e s c r i p t i o n (continued) Puller - Encoder Input Puller Encoder Input is used to scale the encoder input of the lower belt for a Follower application. Two presets are used. In the example, the amount of counts per motor revolution are used. The scaling shown in this example matches a similar style of puller. The motors on the pullers have 2,048 pulses per motor revolution on both A and B channels.
S c a l e Pa g e D e s c r i p t i o n Puller - Encoder Input (continued) The puller motor rotates using counts received at the encoder input. In the example shown, the motor will rotate once for every 8,192 counts. 1 Press the Puller section’s Encoder Input Count window. A numeric popup keyboard appears. 2 Key in the new count amount. This is the number of counts within the revolution amount made by the puller motor. 3 Then press “Enter”. The pop-up keyboard is removed.
S c a l e Pa g e D e s c r i p t i o n (continued) Puller - Encoder Output A 2,048-pulse quadrature encoder is built into both puller servomotors. The drives have the motor encoder as an output on a 44-pin 'D' connector. Scaling is provided to set the amount of pulses that are outputted per motor revolution. Any integer number between 1 and 2,048 may be set.
S c a l e Pa g e D e s c r i p t i o n (continued) Puller - Belt Scale The puller Belt Scale section is used to define the distance the belt moves after the motor has rotated a set number of revolutions. In this example, using a 16:1 gearbox will move the belt 6.672 inches every 10 revolutions of the puller’s motor. To correct Belt Scale Length, divide the set length by the actual length of the product to find the error ratio.
S c a l e Pa g e D e s c r i p t i o n (continued) M a x i m u m S p e e d a n d Vo l t s Maximum Speed and Volts settings are used to set the maximum speed of the puller. The puller can be limited to any speed up to the absolute maximum speed shown in the FPM Max window. It is not possible to set a speed higher than Set FPM Max. A separate maximum is available for the Profile/Bubble/Taper Mode, maximum FPM for this mode is typically less than for other modes.
S c a l e Pa g e D e s c r i p t i o n M a x i m u m S p e e d a n d Vo l t s (continued) To set maximum puller speed: numeric pop-up keyboard appears. 2 Key in the new maximum speed. This is the new FPM the puller will be limited to when producing product. 3 Then press “Enter”. The pop-up keyboard is removed. To set maximum Profile/Bubble/Taper Mode puller speed: 1 Press the Puller section’s Maximum Speed and Velocity, Profile Mode window. A numeric pop-up keyboard appears.
S c a l e Pa g e D e s c r i p t i o n M a x i m u m S p e e d a n d Vo l t s (continued) An analog output is available that can be used to remotely monitor the puller speed. In the example 250 FPM will generate 10 volts DC. To set the voltage output: 1 Press the Puller section’s Maximum Speed and Velocity, Volts Out window. A numeric pop-up keyboard appears. 2 Key in the new Volts Out amount.
S c a l e Pa g e D e s c r i p t i o n (continued) Analog Input To set set the Maximum and Minimum Volts setting: 1 Press the Puller section’s Analog Input, Maximum or Minimum window. A numeric pop-up keyboard appears. 2 Key in the new voltage. The voltage can not be set above 10 volts for the Maximum Volts setting. 3 Then press “Enter”. The pop-up keyboard is removed. In Analog mode it is typical to have the speed range controlled by zero to 10 volts.
S c a l e Pa g e D e s c r i p t i o n (continued) Tr i m M o d e s - A u t h o r i t y In Trim Modes, it is typical to set Maximum voltage to 10 volts and Minimum Voltage to 5 volts. 5 volts would then be the middle point of the scale where no speed correction would be necessary. With this scaling 10 volts would provide the maximum speed increase and 0 volts would provide the maximum speed decrease, 5 volts would have no effect.
S c a l e Pa g e D e s c r i p t i o n (continued) R e m o t e D i g i t a l Po t e n t i o m e t e r Calibrations can be made by using the Learn feature. For calibration, it is necessary to “learn” the time for one click clockwise and one click counterclockwise. The “Learn” button automatically places the results in the proper box. • Center - is the average time between rotating the potentiometer’s rotary dial clockwise one click (+1) and counterclockwise (-1) one click.
S c a l e Pa g e D e s c r i p t i o n (continued) Scale Units Scale Units changes the measurements identifiers and speed/distance ratios for all pages. The setting DOES NOT switch measurements from English to Metric. Scaling measurements will need to be converted when switching between English and Metric. To set Scale Units: 1 Press the Cutter section’s Scale Units, “Select” toggle button. This will change all measurements from English to Metric or Metric to English.
A n g l e s Pa g e D e s c r i p t i o n To access the Angles Page: 1 Press the Set Up 1 tab. Positional servomotors will require a reference point. This position is known as Home or Zero. On a cutter the Home reference must occur at one point within the 360-degree turn of the blade arm. • Reducer - If the motor has a gear reducer, a proximity sensor is used to detect a target (usually a bolt) that is mounted on the blade arm. • No Reducer - The internal zero marker that is built into the motor is used.
A n g l e s Pa g e D e s c r i p t i o n (continued) Pa r k A n g l e Park Angle is the place to park the blade. It is typical to park the blade 60 to 180 degrees before the cut angle. Acceleration can be checked on the Ramps Page using the Calculations at the bottom of the page to ensure blade can reach speed in the angle provided. See Operation Section entitled, Ramps Page Description, Calculations. To change the Park Angle: 1 Press the Park Angle Degree window. A numeric pop-up keyboard appears.
A n g l e s Pa g e D e s c r i p t i o n (continued) Cut Angle Cut Angle is the position where the blade is in the cutter bushing. The center of the bushing or blade just entering the bushing can be used. To change the Cut Angle: 1 Press the Cut Angle Degree window. A numeric pop-up keyboard appears. 2 Key in the new Cut Angle. Ensure that the distance from the Park Angle to the Cut Angle allows the cutter blade to reach its required speed before it enters the material to be cut.
S e t U p 2 Pa g e D e s c r i p t i o n The Set Up 2 folder contains the following five pages. • Puller Tune • Puller (Factory) • Cutter Tune • Cutter (Factory) • Quality To access the Puller Tune Page: 1 Press the Set Up 2 tab. 2 Press the Puller Tune sub-tab.
S e t U p 2 Pa g e D e s c r i p t i o n (continued) Tu n i n g t h e B e l t D r i v e Both the puller and cutter drives have a set of presets with similar functions. A description for any parameter in this section applies to all drives. Please refer to Control Techniques documentation for additional information and setting descriptions. Effects of Tuning 0 NOTE: All values can be changed by pressing individual windows and using the keyboard method to alter the value.
S e t U p 2 Pa g e D e s c r i p t i o n (continued) Tu n i n g t h e B e l t D r i v e Upper Belt - Additional Controls The control for the upper belt includes additional controls that are there to help balance the load between the two belts. Since motors, gear boxes and belts are similar it is expected that gear ratio should always be 1.000:1. However, there are always mechanical differences.
S e t U p 2 Pa g e D e s c r i p t i o n Tu n i n g t h e B e l t D r i v e (continued) Effects of Tuning Load Sharing Load Sharing: • Level - Once both drives exceed the Threshold the Level of difference is checked next. If the difference is great enough the Top Belt must either increase or decrease ratio. • Time - Updates to the belt drive will occur at this time interval. • Step - This setting controls the change that will be made to the Gear Ratio.
S e t U p 2 Pa g e D e s c r i p t i o n (continued) Tu n i n g t h e C u t t e r The right-hand side of the Cutter Tune page is used to test repeatability. The tester is permanently enabled. “Test Reset” may be pressed at any time to begin a fresh test. For example, after changing any tune value the test may be reset to begin a fresh test. Repeatability is shown in length and time formats. Length is the most important.
S e t U p 2 Pa g e D e s c r i p t i o n Tu n i n g t h e C u t t e r (continued) • Captured Difference - shows the length that the drive captures each time the blade enters the cutter bushing. It should match the set length very closely. However, this test cannot factor in slippage or shrinkage of the product. Operation l 4-85 4 Operation • Max-Min Repeatability - This value is the difference between the maximum and minimum values that were captured by Captured Differences.
Q u a l i t y Pa g e D e s c r i p t i o n Offsets Quality is used with a product measurement control. A laser or ultrasonic gauge is mounted upstream of the cutter and used to monitor the product. This may check size, wall thickness and defects. While product is Good it sets an output to a state that means good. The output will change to Bad for out of tolerance product. To access the Quality Page: 1 Press the Set Up 2 tab. 2 Press the Quality sub-tab.
Q u a l i t y Pa g e D e s c r i p t i o n Offsets (continued) To adjust the “Distance to Good” and Distance to Bad” length: 1 Press the Distance to Good or Distance to Bad window. A numeric pop-up keyboard appears. 2 Key in the new length amount. Ensure that the “Distance to Good” length is set higher than the “Distance to Bad” length. 3 Press “Enter”. The pop-up keyboard is removed. • QC Enable - Should be checked when Quality Control is in use.
Q u a l i t y Pa g e D e s c r i p t i o n (continued) I n p u t Po l a r i t y Radio buttons are available to choose the meaning of the quality input. Options are “On Means Good” and “On Means Bad”. To change the meaning of the quality input: 1 Press either ”On Means Good” or On Means Bad”. A dot will appear in the radio button of the selected quality input type. 0 NOTE: The Debounce value can be changed by pressing its individual windows and using the keyboard method to alter the value.
Q u a l i t y Pa g e D e s c r i p t i o n (continued) When Bad To adjust the Scrap Length: 1 Press the Scrap Length window. A numeric pop-up keyboard appears. 2 Key in the new length amount. Ensure that the Scrap Length is set at least twice as long as lengths that are good. 3 Press “Enter”. The pop-up keyboard is removed. • Use this Length - The “Use this Length” check box should be checked when the entered scrap length is required.
Q u a l i t y Pa g e D e s c r i p t i o n 0 (continued) NOTE: The Deferred Sample Length can be changed by pressing its individual windows and using the keyboard method to alter the value. See Operation Section entitled Setting the Cutter Length Scroll and Keyboard Methods. Counters Good and Bad counters are provided. The Good counter will only count product that has been labeled good at the cutter and the Bad counter will only count product that has been labeled bad at the cutter.
Fa c t o r y Pa g e s D e s c r i p t i o n The Puller and Cutter sub-tabs located within the Set Up 2 folder are for factory personnel only. Information contained on these pages will not be mentioned in this manual.
A b o u t Pa g e D e s c r i p t i o n Press the “About” tab to show contact details for The Conair Group. The About page appears as a pop-up in the center of the screen. A software version number will appear here whenever changes or upgrades are made. Press the “Exit” button to remove this pop-up.
E n c o d e r S e q u e n c e Pa g e Description Encoder Sequence mode is a variation of Encoder mode that has up to four lengths. See Operation Section entitled, Modes Page Description. The four lengths and a Sequence Amount window are shown the main Encoder Sequence Page. In this example, Sequence Amount is set to 2 which means Lengths 1 and 2 will be produced alternatively. Lengths 3 and 4 in this example will not be produced.
E n c o d e r S e q u e n c e Pa g e Description (continued) Setting Sequence Lengths To activate and change cut lengths: 1 Press the Sequence Amount window. A pop-up keyboard appears, enter the amount of sequence cuts needed (1-4). 2 Press “Enter”. The pop-up keyboard is removed. All length windows can be altered, but will only be used if they are selected with the Sequence Amount. 3 Press the Cuts length window of the cuts to be used. A pop-up keyboard appears. 4 Press “Enter”.
C u f f Pa g e D e s c r i p t i o n To access the Cuff Mode Sub-Page: 1 Press the Set Up 1 tab and then press the Modes sub-tab. 2 Select Cuff Mode for the cutter section. “Cuff Settings” will be displayed at the bottom of the cutter section when selected properly. 3 Press the Main Page tab. 4 A “Cuff Settings” button will now be displayed in the cutter portion’s length window. 5 Press the “Cuff Settings” button to access the Cuff Mode Main Sub-Page.
C u f f Pa g e D e s c r i p t i o n (continued) Tr i g g e r S e t t i n g s Trigger settings are used to define the Cuff shape. A length at a sustained level must be met in order for the section to be considered a Cuff. Choices for cuff detection are “Look for Sensor Off” or “Look for Sensor On”. To change the Look for Sensor input sensor detection logic: 1 Press the “Look for Sensor On/Off” button to toggle the sensor’s input logic.
C u f f Pa g e D e s c r i p t i o n (continued) Gate Off Distance Gate Off Distance is used to disable the sensor for the length set once a cuff has been detected. The length set should be less than the actual distance between cuff sections, this is so the Trigger Distance setting sensor will be active to detect the next cuff. Set lengths of 80 to 90% of the length between cuffs should be used. 1 Press the Gate Off Distance window. A pop-up keyboard appears. 2 Press “Enter”.
C u f f Pa g e D e s c r i p t i o n (continued) Cuts Up to three cuts may be made from one Cuff. Cut 1 cannot be disabled. Cuts 2 and 3 are optional and are generally used for cutting out scrap sections. An option is also included to count or not count the cut that is made by cuts 2 and 3. To change and activate cuff cut lengths: 1 Press the Cuts 1, 2 or 3. A pop-up keyboard appears, enter the new cut length distance. Each cut length is relative to the beginning of a cuff edge. 2 Press “Enter”.
C u f f Pa g e D e s c r i p t i o n Cuts (continued) Example Timing Waveforms Operation l 4-99 4 Operation Cuff / Corrugation Sample passing through a Cutter bushing
P r o f i l e / B u b b l e / Ta p e r M o d e P r o f i l e Pa g e D e s c r i p t i o n Profile/Bubble/Taper is a special mode that uses a velocity profile to create a product with a varying diameters. See Operation Section entitled, Modes Page Description. A “Profile Settings” button replaces the Length preset that appears on the Main Page when this mode is selected. To access the Profile/Bubble/Taper Main Sub-Page: 1 Press the Set Up 1 tab and then press the Modes sub tab.
P r o f i l e / B u b b l e / Ta p e r M o d e P r o f i l e Pa g e D e s c r i p t i o n ( c o n t i n u e d ) Puller The puller section has similar options that are on the Main Page. See Operation Section entitled, Main Page Description, for Footage Counter, Remote Scroll and Belt Gap descriptions. Velocity (FPM) To change the Body On/Off setting: 1 Press the “Body On/Off “button found at the bottom-right of the Profile Page, to toggle the setting on and off.
P r o f i l e / B u b b l e / Ta p e r M o d e P r o f i l e Pa g e D e s c r i p t i o n Puller Velocity (FPM) ( c o n t i n u e d ) If the “Body On/Off” button is set to “On”, the velocity section (FPM) becomes locked out. The value shown for speed is the actual speed only, which can not be altered. The scroll buttons will disappear and a (Read only) message appears. Sequence (Total Length) This defines the entire length of the Profile/Bubble/Taper product including any portions that are to be scrapped.
P r o f i l e / B u b b l e / Ta p e r M o d e P r o f i l e Pa g e D e s c r i p t i o n Puller (continued) To change the Distance to Bubble length: 1 Press the Distance to Bubble window. A pop-up keyboard appears 2 Key in the new Distance to Bubble Length and press “Enter”. The pop-up keyboard is removed.
P r o f i l e / B u b b l e / Ta p e r M o d e P r o f i l e Pa g e D e s c r i p t i o n ( c o n t i n u e d ) Cutter Location Offset Location Offset is available to adjust and set the physical distance between extruder die and the cutter blade of the Medline Combination Puller/Cutter. This preset is needed to ensure that all cuts are synchronized with the profiles, bubbles, tapers within the product. To set the Location Offset: 1 Measure the distance from the extruder die and the cutter blade.
P r o f i l e / B u b b l e / Ta p e r M o d e P r o f i l e Pa g e D e s c r i p t i o n Cutter (continued) To set Additional Cut lengths: 1 Press the Additional Cuts 1 and/or 2 window. A pop-up keyboard appears. 2 Enter the new additional cut length(s). Ensuring that the cut length(s) are within the Sequence (Total) Length. 3 Press “Enter”. The pop-up keyboard is removed. 4 The new distance is now displayed in either the Additional Cuts 1 or 2 window.
P r o f i l e / B u b b l e / Ta p e r M o d e P r o f i l e Pa g e D e s c r i p t i o n Cutter (continued) Body Off Cut This length is used to cut the product while the “Body On/Off” toggle button is set to “Off”. This value will be ignored when the “Body On/Off” button is set to “On”. The Body Off Cut length is a user preference. To activate and change the Body Off Cut length: 1 Press the Body Off Cut window. A pop-up keyboard appears. 2 Enter the distance, in inches, for the cut length.
P r o f i l e / B u b b l e / Ta p e r M o d e P r o f i l e Pa g e D e s c r i p t i o n Cutter (continued) To activate changes made to this page: 1 View the Graph Page once all changes are made, to ensure proper operation. See Graph All Page to view all length and velocity relations. 2 Press the “Off Line” button, if currently Off Line, this will then select On Line. All values will then download and the new changes will be activated.
P r o f i l e / B u b b l e / Ta p e r M o d e Ve l o c i t y Pa g e D e s c r i p t i o n The velocity page has a scrollable list of presets for setting profile. Up and down buttons are used to scroll through the list. There are three values required for every index section. These are marked Ramp, Level and Velocity. To access the Profile/Bubble/Taper Velocity Sub-Page: 1 Press the Set Up 1 tab and then press the Modes sub-tab. 2 Select Profile/Bubble/Taper Mode for both the cutter and puller sections.
P r o f i l e / B u b b l e / Ta p e r M o d e Ve l o c i t y Pa g e D e s c r i p t i o n Index Every index has two ramps (a front edge ramp and a back edge ramp). The back edge ramp is also the front edge ramp for the index that follows, i.e. indexes 1 and 2 share a ramp (the transition between the two velocities). See the illustration below for a graphical representation of an index.
P r o f i l e / B u b b l e / Ta p e r M o d e Ve l o c i t y Pa g e D e s c r i p t i o n Index (continued) Velocity View Profile View A graph is available on the Velocity Page which shows a velocity waveform that is to scale or a profile simulation. The graph can be toggled from velocity to profile by pressing the “Velocity View/Profile View” button. The graphs include the cut positions as vertical lines going through the product.
P r o f i l e / B u b b l e / Ta p e r M o d e Ve l o c i t y Pa g e D e s c r i p t i o n Index (continued) • Sequence (Total Length) - This is a copy of the same preset that is on the Profile Page. • Ramp Length - This is the length used for the speed transition (velocity change) for a set index. • Level Length - This is the length that will be maintained at the set velocity for this index. • Velocity - This is the target velocity for the index to be achieved at the end of the front edge ramp.
P r o f i l e / B u b b l e / Ta p e r M o d e Ve l o c i t y Pa g e D e s c r i p t i o n ( c o n t i n u e d ) R a m p Ty p e 0 NOTE: Rounding of edges occurs naturally in the product due to elasticity. Ramp types can be changed while the machine is running to test ramp effect on types of extruded material. Four types of ramps are available, a S-Curve type may be used to provide rounding of the extruded at the ramp ends. This may help to reduce the amount of points needed to create a product.
P r o f i l e / B u b b l e / Ta p e r M o d e Ve l o c i t y Pa g e D e s c r i p t i o n ( c o n t i n u e d ) Key To access the Index pop-up guide: 1 Press the “Key” button. 2 Press the “Exit” button, once finished viewing the Key. Operation l 4-113 4 Operation The “Key” button can be used to show a simplified diagram showing the aspects of an index.
P r o f i l e / B u b b l e / Ta p e r M o d e Ve l o c i t y Pa g e D e s c r i p t i o n ( c o n t i n u e d ) Drive Data The drive receives the information that the operator enters into the Combination Puller/Cutter, but in a different format. A pop-up is shown after pressing the “Check Drive Data” button from the Velocity Page. The button, when pressed, shows a list of values that are downloaded into the drive. This list is primarily for diagnostic purposes, which the operator can ignore.
P r o f i l e / B u b b l e / Ta p e r M o d e Ve l o c i t y Pa g e D e s c r i p t i o n ( c o n t i n u e d ) Ratio Calculator To access the Ratio Calculator: 1 Press the “Ratio Calculator” button. 2 Press the “Return To Previous Page” button once all calculations have been made. (continued) Operation l 4-115 4 Operation The Velocity Page includes a Ratio Calculator. This is used to help the operator determine what the body speed needs to be in relation to the Tip Speed.
P r o f i l e / B u b b l e / Ta p e r M o d e Ve l o c i t y Pa g e D e s c r i p t i o n Ratio Calculator (continued) The extruder emits a constant volume of material, so the ratio of speeds to make a product will be the inverse ratio of the wall area. The Ratio Calculator assists in the calculating the area ratio of round solid or single lumen products. Enter the OD (outside diameter) or the ID for each section.
P r o f i l e / B u b b l e / Ta p e r M o d e Ve l o c i t y Pa g e D e s c r i p t i o n Ratio Calculator (continued) 1 From the Velocity Page, press the “Auto Fill” button. This will take the Belly Speed that was calculated with the Ratio Calculator and insert it into the Velocity (Body) window found inside the table on the Velocity Page. If using more than one Index: 1 Calculate the second Index using the Ratio Calculator.
P r o f i l e / B u b b l e / Ta p e r M o d e Ve l o c i t y Pa g e D e s c r i p t i o n ( c o n t i n u e d ) Zoom All graphs have a Length Zoom. Press any point on the graph to zoom in, press the graph again to zoom out. If the point pressed is before that start of a bubble, the zoomed image fills from the zero point or start of the sequence on the left to the distance of the pressed position.
P r o f i l e / B u b b l e / Ta p e r M o d e A n a l o g O u t p u t s Pa g e D e s c r i p t i o n To access the Profile/Bubble/Taper Analog Output Sub-Page: 1 Press the Set Up 1 tab and then press the Modes sub tab. 2 Select Profile/Bubble/Taper Mode for both the cutter and puller sections. “Profile” will be displayed at the bottom of each section when properly selected. 3 Press the Main tab. 4 A “Profile Settings” button will now be displayed in the cutter portion’s length window.
P r o f i l e / B u b b l e / Ta p e r M o d e A n a l o g O u t p u t s Pa g e D e s c r i p t i o n (continued) Analog Outputs are an optional feature used with Profile/Bubble/Taper Mode. In some cases bubbles are created using digital air valves that can be switched on and off. When Analog Outputs are provided, a PLC (Programmable Logic Controller) will be included for every two channels of analog. Options are none or 2, 4, 6 or 8 channels of analog.
P r o f i l e / B u b b l e / Ta p e r M o d e A n a l o g O u t p u t s Pa g e D e s c r i p t i o n (continued) To select a analog channel (keyboard method): 1 Press the Analog Select number. A pop-up keyboard appears. 2 Enter the number of the analog channel to be viewed. 3 Press “Enter”. The pop-up keyboard is removed and the analog channel selected will be displayed along with its output presets (up to 32).
P r o f i l e / B u b b l e / Ta p e r M o d e A n a l o g O u t p u t s Pa g e D e s c r i p t i o n (continued) Each Analog Output has 32 setpoint pairs (x,y values). In this example using four x,y pairs, 2.362” and 1.0% are used for the setpoint of position 1. This means that the air will be at 1% after 2.362”. If the air is making a transition from one level to another over a length, the points in between the two setpoints are calculated.
P r o f i l e / B u b b l e / Ta p e r M o d e A n a l o g O u t p u t s Pa g e D e s c r i p t i o n (continued) • Bar Graphs - These reflect the state of the analog outputs. The bar will rise and fall while the puller is running. • Copy % to Next - Two buttons have this feature. They may be used to copy the percent value in the box above to the next box below. Operation l 4-123 4 Operation • Clear List - Copies the Percent Value on the top line to all the percents in the output list.
P r o f i l e / B u b b l e / Ta p e r M o d e D i g i t a l O u t p u t s Pa g e D e s c r i p t i o n Digital Outputs are available in groups of four; 4, 8, 12 and 16 digital outputs are possible. A PLC (Programmable Logic Controller) or PLC's provide the digital outputs. Four digital outputs are shown in this example. A digital output can be on or off. These are typically used to operate pneumatic valves. The digital graph is shown under the profile graph.
P r o f i l e / B u b b l e / Ta p e r M o d e D i g i t a l O u t p u t s Pa g e D e s c r i p t i o n (continued) On At Each Digital Output has an “On At” point. This is the distance from the beginning of the sequence to when the output turns on. In the sample Output 1 will turn on 1.0" from the start of the sequence. In this example, the length is the distance air pressure will turn on and the duration is length the air will remain on.
P r o f i l e / B u b b l e / Ta p e r M o d e D i g i t a l O u t p u t s Pa g e D e s c r i p t i o n Setting Output Length and Duration (continued) Duration Each Digital Output has a duration. Duration is how long the output remains on. Distance or time can be used. In the sample output 1 has a duration of 2.0" which means the air will turn on at 1.0” and stay on for 2.0”. It will then turn off at 3.0” from the start of the sequence.
P r o f i l e / B u b b l e / Ta p e r M o d e D i g i t a l O u t p u t s Pa g e D e s c r i p t i o n Setting Output Length and Duration (continued) 1 Press the Type window. The display will toggle between length (“) or time (sec). • Enable On/Off - The “Enable On/Off” toggle button is used to enable or disable a particular Digital Output. When it is disabled the output is forced to “Off”. If the puller is stopped all outputs are disabled.
P r o f i l e / B u b b l e / Ta p e r M o d e G r a p h A l l Pa g e D e s c r i p t i o n All graphs appear together on this page to help show the relationship (positions) for Profile, Cuts, Velocity, Analog and Digital outputs. Numeric data is not shown. Zoom is available when working with the graph. See Operation Section, entitle Velocity Page Description. To access the Profile/Bubble/Taper Graph All Sub-Page: 1 Press the Set Up 1 tab and then press the Modes sub tab.
P r o f i l e / B u b b l e / Ta p e r M o d e G a u g e C o n t r o l Pa g e D e s c r i p t i o n To access the Profile/Bubble/Taper Gauge Control Sub-Page: 1 Press the Set Up 1 tab and then press the Modes sub tab. 2 Select Profile/Bubble/Taper Mode for both the cutter and puller sections. “Profile” will be displayed at the bottom of each section when properly selected. 3 Press the Main tab. 4 A “Profile Settings” button will now be displayed in the cutter portion’s length window.
C u t t e r O p e r a t o r C o n t r o l Fe a t u r e s The Operator Control provides an intuitive user-friendly method to interface with the Conair Servo Cutter. Information is viewed and entered at the Operator Control and is communicated to the servo positional amplifier via the RS-232 serial communication link. The Operator Control is a flat membrane panel consisting of 22-keys and a large 2 line x 20 back lit LCD screen. Soft Keys-allows the operator to select different functions.
Cutter Operator Control Instructions Main Screen MAIN SCREEN There are two types of main screens, length or time measurement and cuts per minute measurement. The type displayed varies depending on the current cut mode setting. See the mode operator display overviews. 1 ENC 00000.000 in. Parts Off Length The Main Screen has seven features. The top line displays the active preset (only with multi preset option), cut mode, active measurement and the unit of measure.
Cutter Control Instructions Menu function key is used to access the Menu Area This area can only be accessed from the main display screen for each mode. See the Menu Area section for more information. Parts Select Area Screen Under the current mode on the left side of the bottom line of the display is a soft key labeled Parts. Pressing this key accesses the Parts Select Screen. SELECT PARTS AREA Total Exit Batch This screen provides access to the parts Total/softkey1 or Batch/softkey3 areas.
C o n t r o l I n s t r u c t i o n s : To t a l S c r e e n (continued) Exit Softkey2 Under the counter, in the center is a soft key labeled Exit. Pressing this key will return the display to the Parts Select screen. Reset Softkey3 Under the counter, on the right is a soft key labeled Reset. Pressing this key will zero the counter. EXIT or PREV, fixed function keys return the display to the Parts Select screen.
Cutter Control Instructions: Batch Screen BATCH SCREEN By pressing softkey3 located under the word Batch on the Parts Select Screen, a six-decade Batch counter is available. Additional information on how to access this screen can be found in the operator display overview in Appendix G of this manual. BATCH 000,000 pcs. Change Off Reset This is typically used to count the pieces required to fill a carton, with the product being cut. The batch counter counts up to the batch preset and resets to zero.
Cutter Control Instructions: Batch S c r e e n (continued) Batch Select Area Screen Under the batch counter, on the left is a soft key labeled Change. Pressing this key displays the Select Batch Area screen. Additional information on how to access this screen can be found in the operator display overview in Appendix G of this manual. SELECT BATCH AREA Preset Exit Alarm This screen provides access to the batch Preset/softkey1 or batch Alarm/softkey3 areas.
Cutter Control Instructions: Batch S c r e e n (continued) Numeric keys Key in the batch required and press enter. If you require a batch of 50 parts you must key in 50 and then press enter. Enter or Delete? If the keyed in number is correct press the enter key for it to be accepted and return to the Main screen. If it is wrong press the delete key and the previous preset will reappear.
Cutter Control Instructions: Length Screen LENGTH SCREEN By pressing the soft key located under the word Length on the Encoder, Follower or Auto Mode Main Screen, the preset for the Length counter is available. Additional information on how to access this screen can be found in the operator display overview in Appendix G of this manual. LENGTH#1 0000.000 in. Exit #Prst Raise will increase the preset by 0.010 inch. The key can be pressed once for each 0.
Cutter Control Instructions: Preset to Run Screen PRESETS TO RUN SCREEN By pressing the soft key located under the word #Prst on any Length Screen, the value for the number of presets to run is available. Additional information on how to access this screen can be found on the multiple preset example in the operator display overview in Appendix G of this manual. RUN 4 PRESETS Exit The number shown is the current number of presets to run value, i.e. how many measurement presets and batches to run.
C u t t e r C o n t r o l I n s t r u c t i o n s : Ti m e Screen TIME SCREEN By pressing the soft key located under the word Time on the Main Timer Mode Screen, the preset for the timer is available. Additional information on how to access this screen can be found in the operator display overview in Appendix G of this manual. TIME 00000.00 0 sec Exit The number shown is the current time preset value, i.e. the time interval to cut the product. A cursor will appear in the least significant digit.
Cutter Control Instructions: Hold-Off Screen HOLD-OFF TIME SCREEN By pressing the soft key located under the word Time on the Main End Sense Mode Screen, the preset for the hold-off timer is available. Additional information on how to access this screen can be found in the operator display overview in Appendix G of this manual. Holdoff 00000.500 sec Exit The number shown is the current hold-off time preset, i.e. the time interval to ignore the photo eye and avoid false cuts.
Cutter Control Instructions: Blade Speed Screen BLADE SPEED SCREEN By pressing the soft key located under the word Blade or Speed depending on the current mode, the preset for that modes blade speed is available. Additional information on how to access this screen can be found in the operator display overview in Appendix G of this manual. SPEED 0750.0 rpm Exit The number shown is the active modes current blade speed preset, i.e. the speed the blade will pass through the part.
Cutter Control Instructions: Blade Count Screen BLADE COUNT SCREEN By pressing the soft key located under the word Blade or Count depending on the current mode, the preset for the blade count is available. Additional information on how to access this screen can be found in the operator display overview in Appendix G of this manual. RUN 1 BLADES Exit The number shown is the current blade count preset, i.e. the number of blades mounted to the cutter head. A cursor will appear in the least significant digit.
Cutter Control Instructions: Functions Areas FUNCTION AREAS Additional information on how to access and navigate these screens can be found in the operator display overview section of this manual. SELECT FUNCTION > Blade Test Mode Menu fixed function key is used to access the Function Areas from any main mode screen. There are two Function Area screens. The user can toggle between the two screens with the Next and Prev fixed function keys. Next or Prev, Pressing Next selects the second Function Area.
C u t t e r C o n t r o l I n s t r u c t i o n s : Te s t TEST SOFTKEY Pressing soft key two located under the word Test on the first Function area screen, selects the repeatability tester. Off DevCP 000.000 mS > Exit Reset The DevCP repeatability tester displays total deviation time in milliseconds. This time is from a cut being requested until the blade reaches the part. The smallest measured value is subtracted from the largest measured value and the resulting deviation is displayed on the screen.
C u t t e r C o n t r o l I n s t r u c t i o n s : Te s t (continued) Next, Pressing Next selects the DevCC test if available. If the arrow on the top right hand side of the screen is visible the current mode also supports the DevCC test. 0 NOTE: The test available DevCP, DevCC or both is dependent on the active cut mode. The DevCC repeatability tester also displays total deviation time in milliseconds. This time is from a cut being requested until the next cut request.
Cutter Control Instructions: Cut Mode Mode Softkey By pressing the soft key located under the word Mode, the different Cut Modes are available. There are two Cut Mode screens. The first screen provides choices for the standard modes available on all cutters. SELECT CUT MODE > Encdr Sense FlyWhl The second screen displays choices for optional cut modes. The user can toggle between the two screens with the Next and Prev fixed function keys.
Cutter Control Instructions: Minimum Measurement Min Softkey By pressing the soft key located under the word Min on the second Function Area Screen, the Minimum allowable measurement value is displayed. The active mode and the CURRENT MIN TIME IS 00000.150 sec. cuts per minute limit for the model of cutter determines the actual value displayed. The screen will be displayed for 15 seconds or until any key is pressed, then return to the second Function Area screen.
Cutter Control Instructions: Encoder Area Menus are a convenient way to access and monitor parameters that do not need to be altered often, i.e. home position, encoder direction, scale or unit of measure. In addition, preventive maintenance parameters can be monitored for trouble- shooting and scheduling purposes. Factory Softkey This area is password protected for factory use only.
Cutter Control Instructions: Encoder A r e a (continued) Encdr Softkey By pressing the soft key located under the word Encdr on the Maint. Area Screen, there are three sub-menus, Drctn, U/M, and Scale accessible. Additional information on how to access this screen can be found in the Maintenance Area of the operator display overview section of this manual. SELECT ENCODER AREA Drctn U/M Scale Exit or Prev, Pressing Exit or Prev will return the display to the Maint. Area screen.
Cutter Control Instructions: E n c o d e r D i r e c t i o n (continued) If a negative symbol is shown to the left of the count value on the main mode screen the encoder signal is reversed, i.e. rotating in the wrong direction. The Cutter will not function while the encoder is going negative. The direction function corrects this by changing what the servo drive interprets as a positive direction, CW or CCW rotation.
Cutter Control Instructions: Unit of M e a s u r e (continued) Scale Softkey By pressing the soft key located under the word Scale on the Encoder Area Screen, there are two sub-menus, Dist., and Counts accessible. Additional information on how to access this screen can be found in the Maintenance Area of the operator display overview in Appendix G of this manual. SELECT SCALE AREA Dist. Exit Counts Exit or Prev, Pressing Exit or Prev will return the display to the Encoder Area screen.
Cutter Control Instructions: Scale Distance DISTANCE SOFTKEY By pressing the soft key located under the word Dist. on the Scale Value Screen, the scaled distance is available. This value must be set after a U/M change. Additional information on how to access this screen can be found in the Maintenance Area of the operator display overview in Appendix G of this manual. ENTERDISTANCE DISTANCEPER PER ENTER COUNTS COUNTS12.00 12.0000 in. in. The number shown is the current distance value, i.e.
Cutter Control Instructions: Scale Counts COUNTS SOFTKEY By pressing the soft key located under the word Counts on the Scale Value Screen, the scaled counts are available. Additional information on how to access this screen can be found in the Maintenance Area of the operator display overview in Appendix G of this manual. 12.000 in. EQUALS 12000 COUNTS The number shown is the current count value, i.e. the pulses per revolution of the encoder.
Cutter Control Instructions: Homing HOMING A defined Home location is required for all servo-positioning applications. After initial power up, emergency stop or guard opened, home position must be found. All motion is relative to this home position. The home cycle occurs once after power is applied to the servo drive in response to the Start push button being pressed. The cutter head rotates towards the home sensor at the programmed on-demand blade speed.
Cutter Control Instructions: Home Offset (continued) Exit or Prev, If no change is required press Exit or Prev to return to the Maintenance Area screen. Raise will increase the value by 1.0. The key can be pressed once for each 1.0 increment required or held down to scroll up. Releasing the key will freeze the value at the last value. Lower will decrease the value by 1.0. The key can be pressed once for each 1.0 decrement required or held down to scroll down.
Cutter Control Instructions: Offset Example Home Offset Example With the Cut Enable on/off turned off and the cutter started, entering a new value at the Home Offset screen will initiate a home routine using the new value. The graphic example above demonstrates the resulting home position with a 15 degree offset. The acceptable range for this value is 00.0 to +45.0 degrees. Making an entry outside of this range generates the following error message on the operator display. HOME OFFSET RANGE IS 00.
C u t t e r C o n t r o l I n s t r u c t i o n s : Po w e r O n Ti m e TIME SOFTKEY Pressing the soft key located under the word Time on the P/M area screen, selects the Power-On time screen. POWER ON 00000.0 Hrs Exit The Power-On time screen displays the total time in hours that the machine has had the power switched on. This information could be used for scheduling preventive maintenance. The displayed time can not be reset.
C u t t e r Po w e r i n g U p Power Up Sequence At power up a series of system screens briefly appear. The software is Red Lion's Edict-97. This screen or similar shows first. Edict-97 Runtime Ver. 5.05.134 Next, the Communications message appears **STARTING COMMS** If there are any problems with communications, this screen will remain on longer than a couple of seconds. If there are no communication problems the Conair Combination Puller/Cutter program will begin to run.
Puller Operation Control 1 Apply power to the machine. Place the disconnect in the “ON” position. 2 Open the gap between the puller belts to the desired gap for the product to be 3 pulled. Depress the green “START” button to start the drive. 0 NOTE: If the puller does not start, make sure the “Emergency Stop” button is pulled out in the extended position.
P u l l e r O p e r a t o r C o n t r o l Fe a t u r e s The Operator Control provides an intuitive user-friendly method to interface with the Conair Servo Puller. Information is viewed and entered at the Operator Control and is communicated to the servo positional amplifier via the RS-232 serial communication link. The Operator Control is a flat membrane panel consisting of 22-keys and a large 2 line x 20 back lit LCD screen. Soft Keys-allows the operator to select different functions.
Puller Operator Control Instructions: Main Screen MAIN SCREEN When the puller is first powered up, the following screen will appear after 5 seconds. The type displayed varies depending on the current puller setting. SPEED Sm. 485.0 FPM Change Ftg. Scroll Increment Softkey Puller speed adjustment can be done by programming the Scroll Increment preset. Scroll increments can be set for course or fine adjustments.
Puller Operator Control Instructions: Programming Scroll Increments The Scroll Increment Screen provides programmable preset scroll increments for puller speed. Increments are set for course (Lg), fine (Sm) and remote (Rm) scroll adjustments. Enter Inc/Dec Values Lg 10.0 Sm 1.0 Rm 5.0 To adjust scroll increments: 1 Press the “Menu” button. 2 Key in the new Course (Lg.) increment preset using the numeric keypad.
Puller Operator Control Instructions: Using Scroll Increments Lg (Course) and Sm (Fine) puller scroll increments are used to adjust the puller’s speed (FPM). Each preset is programmed to increase or decease the puller’s speed by a user specified amount. Rm (Remote) can only be used with the optional Puller Speed Remote. See Operation Section entitled, Puller Operator Control Instructions, Puller Speed Remote. SPEED 500.0 Lg. Change FPM Ftg.
Puller Operator Control Instructions: Operator Entered Speed Change Puller speed can be entered manually by using the Operator Entered Speed Change Softkey/Softkey 2 and entering the new puller speed with the controller’s numeric keypad. SPEED 500.0 Lg. Change FPM Ftg. To enter a new puller speed: 1 Press the Operator Entered Speed Change Softkey/Softkey 2. Enter Spd. 500.0 FPM Max Is 610.0 Return 2 Use the control keypad to enter the new puller speed.
Puller Operator Control Instructions: Footage Counter The Footage Counter provides a digital readout of the total footage of material that has passed through the puller. The counter can be reset at any time, suppling a current readout of total footage. SPEED 500.0 Lg. Change FPM Ftg. To view or reset the footage counter: 1 Press the Footage Counter Softkey/Softkey 3. 2 Press the softkey directly under “Rst.” to reset the Footage Counter.
Puller Operator Control Instructions: Diagnostics Screen There are three servo puller control system diagnostics screen. Refer to the Servo Drive and Amplifier manuals which came with your belt puller to service your system. The servo amplifier will have a window with letters or numbers to represent operational conditions. 003 COMMS FAILURE ACCEPT ALL To acknowledge and clear a fault: 1 Correct the fault.
Puller Operator Control Instructions: P u l l e r S p e e d R e m o t e (Optional) The optional Puller Speed Remote is used upstream on an extrusion line to correct puller speed. The increment of change used is set at the Scroll Increment Screen. See Operation Section entitled, Puller Operator Control Instructions: Programming Scroll Increments. 1 Press the “Up” or “Down arrow buttons located on the right side of the controller to adjust the puller’s speed.
Before Starting Combination Unit Before you start daily operation of the Combination Puller/Cutter, you need to perform preventative maintenance. Necessary maintenance is described in the Maintenance section of this Users Guide. WA R N I N G : Be sure that power to the puller/cutter is OFF when doing any maintenance on the puller/cutter. Follow all safety rules when performing any maintenance on this equipment.
Start-Up Preparations for Puller If you have not already done so, perform daily maintenance check, power up the puller/cutter, select the cutting mode and blade speed and make a test cut to check cut quality. Use the slide system to move the cutter as far from the puller as possible: 1 Loosen the turnbuckle below the puller/cutter by turning 1-2 turns clockwise. 2 Slide the cutter as far downstream as it will go. 3 Tighten the turnbuckle by turning it counterclockwise.
Start-Up Preparations for Puller (continued) DA N G E R : M o v i n g Pa r t s H a z a r d Take all necessary precautions when working around moving parts to prevent body parts and clothing from being pulled into the machine. Always disconnect and lock out the main power source before performing maintenance on the puller. Never remove or disable safety devices to sustain production. Operating without these devices could lead to hazardous conditions that can cause severe injury.
Po w e r i n g U p t h e C u t t e r 1 Plug in the power cord to restore power after any required maintenance. 2 Turn on the main power. The cutter control will start up. The amber power on light illuminates. (Two line HMI only) 0 NOTE: You can watch the servo motor amplifier's status screen during start up through the window on the back of the electrical enclosure. This display gives information that may be useful if you have a problem. See the Troubleshooting section of this manual.
Starting the Puller DA N G E R : M o v i n g Pa r t s H a z a r d Take all necessary precautions when working around moving parts to prevent body parts and clothing from being pulled into the machine. Always disconnect and lock out the main power source before performing maintenance on the puller. Never remove or disable safety devices to sustain production. Operating without these devices could lead to hazardous conditions that can cause severe injury.
Stopping the Puller WA R N I N G : S a f e S t o p p i n g Do not use any part of the rotary disconnect to stop the belt puller. Use the recommended procedure to assure a safe stopping. 1 Remove extrudate from the puller. 2 Press the “Puller Stop” button. 3 Turn rotary disconnect to OFF. Shutting Down the Puller To shut down the puller, perform the stopping procedure listed above. No additional steps are necessary if the puller is shut down for short period of time.
0 0 NOTE: See Operation Section entitled, Scale Page Description for steps to change cutter and puller modes if using Red Lion HMI and Control Techniques/ Emerson Servo Drives. NOTE: See Operation Section entitled, Scale Page Description for steps to change cutter and puller modes if using Red Lion HMI and Control Techniques/ Emerson Servo Drives.
Setting the Cut Mode Tw o - L i n e H M I I n t e r fa c e O p e r a t i o n 1 Be sure that the Cut On/Off button is OFF. 2 Press the Select button to activate the cutting mode you want. A mode is active 0 NOTE: See Operation Section entitled, Modes Page Description for steps to change cutter and puller modes if using Red Lion HMI and Control Techniques/ Emerson Servo Drives. when the LED next to it is lit. Each time you press Select the control activates the next available mode.
0 NOTE: See Operation Section entitled, Modes Page Description for steps to change cutter and puller modes if using Red Lion HMI and Control Techniques/ Emerson Servo Drives. Making Adjustments During Operation for the Cutter There are several adjustments you can make during normal cutting.
Stopping Only the Cutter You can shut down just the cutter portion of the combination puller/cutter if you need to change or adjust cutter blades: 1 Press Cut On/Off Softkey to Off to stop cutting. 0 NOTE: Press the “Cutter Off” button if using Red Lion HMI and Control Techniques/ Emerson Servo Drives 2 Press Stop Cutter button to disable the servo motor. 3 Turn Cutter Power On/Off switch to Off. Power is no longer supplied to the cutter portion of the combination puller/cutter.
Stopping the Combination Puller/Cutter WA R N I N G : N e v e r u s e a n y p a r t o f t h e g u a r d circuit or the rotary disconnect to stop the c o m b i n a t i o n p u l l e r / c u t t e r. This can cause damage to the equipment and injury to personnel. Use the recommended procedure to assure safe stopping. To safely stop the Combination Puller/ Cutter: 1 Press Cut On/Off Softkey to Off to stop cutting (Softkey text changes to off).
SECTION Maintenance 5 Maintenance features. . . . . . . . . . . . . . . . . 5-2 Wa r n i n g s a n d c a u t i o n s . . . . . . . . . . . . . . . . 5 - 2 Preventative maintenance schedule . . . . . . . 5-4 Inspecting cutter blades . . . . . . . . . . . . . . . 5-6 Inspecting blade hardware . . . . . . . . . . . . . 5-6 Inspecting cutter bushing retaining system . . 5-7 C h e c k i n g t h e cl o s u r e l a t c h . . . . . . . . . . . . . 5 - 7 Checking floor locks . . . . . . . . . . . . . . . . .
M a i n t e n a n c e Fe a t u r e s The Servo Cutter CSC combo model needs regular, scheduled maintenance for peak performance.
Wa r n i n g s a n d C a u t i o n s (continued) DA N G E R : P i n c h H a z a r d Never remove or disable safety devices to sustain production. Operating without these devices could lead to hazardous conditions that can cause severe injury. Take all necessary precautions when working around moving parts to prevent body parts and clothing from being pulled into the machine.
Preventative Maintenance Schedule • Daily r Checking puller belts for wear If a belt shows sign of cracks, tears, or other damage, replace it. See Maintenance Section entitled, Replacing Belts r Checking puller belt tension Check the belt tension. See Maintenance Section entitled, Testing Belt Tension. r Checking belt gap Check the belt gap. See Maintenance Section entitled, Checking the Belt Gap. r Inspecting cutter blade(s) Clean, sharpen or replace as needed.
Preventative Maintenance Schedule • (continued) Monthly r Checking hardware on the knife guard Inspect the hardware on the knife guard (fasteners on hinge and the clear blade guard window). Tighten as needed. r Checking bushing holder proximity switches Inspect the proximity switch set screws. Adjust as needed. See Maintenance Section entitled, Adjusting the Cutter Proximity Switches. r Cleaning the clear blade guard window Clean using glass cleaner or plain water.
Inspecting Cutter Blades Blades become dull over time depending on the material being cut, cut rate, blade speed, and blade material and thickness. Check blades regularly for sharpness as well as scratches, nicks, burrs, and material buildup. Clean, or replace as needed. See Installation Section entitled, Installing Cutter Blades. DA N G E R : S h a r p B l a d e s ! Most injuries caused by knife blades occur when the cutter has been turned off. Handle blades with care at all times.
Inspecting Bushing Retaining System Check the bush retaining system that secures the cutter bushings. If bushings move during cutting, cutting blades, and possibly the drive chain, could be damaged. Bushing Retaining System Checking the Closure Latch Check the latch and adjust it so the knife guard closes completely. This prevents false triggering of the safety switch. Latch It is best to remove the weight from the casters for optimum stability during cutting cycles.
C l e a n i n g Pa r t i c u l a t e Tr a p The Particulate Trap is built into the cutter assembly. Depending on cut rate and type of material and lubrication, the area will need to be cleaned on a regular basis. Open the knife guard and, using a shop vac or other similar equipment, remove all liquid and solids from the cutting chamber and around the bushings. Particulate Trap Lubricating the Linear Rail Check the shafts on the linear rail system.
Checking Grease Locations For Puller Model 1-12 Lubricate all shafts and grease fittings as needed. 0 Grease Fitting NOTE: Use regular grease for all locations except thread rods, vertical shafts, and vertical shaft drive boxes. For thread rods use FDA silicone or grease. Lubricating Shaft and Fittings For Puller Model 3-20 You should check the shafts and grease fittings weekly, and lubricate as needed Lubricate thread rods and vertical shafts with Never-Seize or an equivalent lubricant.
Adjusting the Cutter Proximity Switches Follow all warnings and cautions listed at the beginning of the Maintenance section of this User Guide. 1 Be sure the main power is disconnected and the cutter is locked out. 2 Loosen the bushing retaining system that holds the cutter bushings. Bushing Retaining System 3 Remove the cutter bushings. 4 Check the depth of the proximity switch face for each bushing. It should be recessed no more than 0.010 inches, but should not interfere with the bushings themselves.
Checking Electrical Connections WA R N I N G : E l e c t r i c a l H a z a r d Before performing any work on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup. A lockable device has been provided to isolate this product from potentially hazardous electricity. WA R N I N G : I m p r o p e r I n s t a l l a t i o n , o p e r a t i o n , o r servicing may result in equipment damage or p e r s o n a l i n j u r y.
Checking Electrical Connections (continued) 3 Open the electrical enclosure. 4 Inspect all wires and connections. Look for loose wires, burned contacts, and signs of over-heated wires. Have a qualified electrician make any necessary repairs or replacements. 5 Close the electrical enclosure door. 6 Inspect the exterior power cords. Cords should not be crimped, exposed, or rubbing against the frame.
Te s t i n g B e l t Te n s i o n 1 Turn the main power disconnect to the off position. 2 Remove the upper and lower belt guards: • Remove the five (5) screws that attach the guard at the front. • Disconnect the safety cable (upper guard). • Lift off and remove guard. Screw enough, and the gap between the upper and lower belts should be even across the width of the belt. 0 NOTE: It is important to have the proper belt tension.
Te s t i n g B e l t Te n s i o n (continued) 4 Adjust belt tension, if necessary. Adjust tension by turning the threaded tension rod. Threaded Tension Rod 5 Fine tune tension: 5-14 l Maintenance • Lower the belts to a gap of about 1/8" (3 mm). See Installation Section entitled, Adjusting Belt Gap. • From the upstream end of the belts, look down the length of the belts at the gap between the belts. If the gap is not even, adjust the tension until the gap is even and measures 1/8”.
Checking the Belt Gap For Puller Model 1-12 The upper and lower belt boom assemblies are controlled by a common threaded rod. Turn the hand wheel to move the belts up and down. Hand Wheel For Puller Model 3-20 The belt gap should be set to the dimensions of the extruded product, being careful not to make the gap so small that the pressure causes distortion in the product. 1 Turn the hand wheel until the gap between the belts reaches the desired distance.
Replacing the Belts For Puller Model 1-12 To replace puller belts: 1 Turn the rotary disconnect to the OFF position. 2 Remove the upper and lower belt guards. 3 Release belt tension by loosening the threaded rods. Keep tension on front and back edges as even as possible by turning each rod 5-10 revolutions, then switching to the other side. Continue until the belt is loose enough to slide off the puller. Threaded Tension Rod 4 Remove the belt from the puller.
Replacing the Belts (continued) For Puller Model 3-20 WA R N I N G : M o v i n g Pa r t s Improper servicing may result in equipment d a m a g e o r p e r s o n a l i n j u r y. Before removing lockout devices and returning switches to the ON position, make sure that all personnel are clear of the machine, tools have been removed and all safety guards are reinstalled.
Replacing the Belts For Puller Model 3-20 (continued) 4 Remove the belt from the puller. Check the rollers and pulleys for buildup, especially inside grooves. Clean if necessary. 5 Reverse the process to install the new belt. Make sure ribs inside the belt fit properly into grooves. Keep tension on front and back sides of the belt as even as possible while tightening the belt tension. Turn each rod 5 to 10 revolutions, then switch to the other side. 6 Adjust belt tension and belt gap.
C h e c k i n g To rq u e WA R N I N G : N o L u b r i c a n t s ! Do NOT use lubricants on the Trantorque coupling device. WA R N I N G : S h a r p B l a d e s ! Always wear cut-resistant gloves when the cutting chamber is open and when handling blades. Never open cutting chamber without locking out the cutter power and waiting until the cutter head has stopped completely. Handle blades with care at all times.. The Trantorque coupling device connects the servo motor to the cutter head.
5-20 l Maintenance
SECTION 6 Tr o u b l e s h o o t i n g Before beginning . . . . . . . . . . . . . . . . . . . 6-2 A few words of caution . . . . . . . . . . . . . . . . 6-2 Identifying the cause of a problem . . . . . . . . 6-4 Puller operation problems . . . . . . . . . . . . . . 6-5 Cutter operation problems . . . . . . . . . . . . . . 6-6 Product quality problems . . . . . . . . . . . . . . 6-10 Replacing safety and proximity switches . . . 6-15 Checking the servo amplifier . . . . . . . . . . .
Before Beginning You can avoid most problems by following the recommended installation, operation and maintenance procedures outlined in this User Guide. If you have a problem, this section will help you determine the cause and tell you how to fix it. Before you begin troubleshooting: o Find any wiring, parts, and assembly diagrams that were shipped with your equipment. These are the best reference for correcting a problem.
A Fe w Wo r d s o f C a u t i o n (continued) DA N G E R : S h a r p B l a d e s ! Most injuries caused by knife blades occur when the cutter has been turned off. Handle blades with care at all times. • • • Always wear cut-resistant gloves when the cutting chamber is open and when handling blades. Always lock out power to the cutter before opening the cutting chamber. Always wait until the cutter head has stopped completely before opening the knife guard.
Identifying the Cause of a Problem The Troubleshooting section covers problems directly related to the operation and maintenance of the Combination Puller/Cutter. This section does not provide solutions to problems that originate with other equipment. Additional troubleshooting help can be found in manuals supplied with the other equipment.
Puller Operation Problems Symptom Possible cause Solution The puller ‘creaks’ while running. The belt is too tight. Check the belt tension; loosen if necessary. The bearings are failing. Replace the bearings. The “Emergency Stop” button is pushed in. Pull out the “Emergency Stop” button. (Make sure it clicks into position.) The puller does not start.
Cutter Operational Problems Symptom Possible Cause Solution Servo drive is without power. The “Emergency Stop” button is pushed in. Pull out the “Emergency Stop” button. Master safety relay not energized Check that the bushings are in place. Make sure that the blade guard is closed. Master Safety relay (ISC) has failed. Replace relay. Pressing Start Cutter has no effect. The light does not light. Pressing the Manual cut button does not produce a cut when in an on-demand mode.
Cutter Operational Problems (continued) Symptom Possible Cause Solution After pressing Start Cutter, the cutter head rotates and stops in wrong position. The Blade Home proximity switch failed or the connection to it is loose. Check connections and replace switch if needed. Master safety relay does not energize. Guard circuit is open. Check that the bushings are in place. Make sure that the blade guard is closed. Loose connection to guard circuit. Tighten connection.
Cutter Operational Problems (continued) Symptom Possible Cause Solution In encoder or timer modes, the display shows the count which resets, but a cut does not occur at the point of reset. There is a problem with the servo amplifier. See Checking the Servo Amplifier. There is a loose connection. Check wiring for loose connections. Blade speed does not change when new speed is entered into the control. There is a communication failure between the control and drive.
Cutter Operational Problems (continued) Symptom Possible Cause Solution Blade speed does not change when new speed is entered into the control. There is a communication failure between the control and drive. Check wiring for loose connections and tighten. Cutter Mode selection does not change cut mode. There is a communication failure between the control and drive. Check wiring for loose connections and tighten. The park (home) position is drifting, i.e.
Product Quality Problems Symptom Possible Cause Solution Annular rings present on the extrudate. The belt puller is too close to the cutter. If the extrudate is interrupted (stopped during processing), annular rings can develop, especially on a thin-walled product. Slightly increase the distance between the puller and the cutter, and test the product until the distance is correct. Burrs at cut site. The bushings do not provide enough support during cutting.
Product Quality Problems (continued) Solution Hairs or strings. Blade speed is too low. Increase the blade speed or decrease the blade cut path area (blade width). The blade is too thick. Excessive blade thickness can cause frictional heat. Use a thinner blade. The blade is wrong for the application. Change angle of the blade attack or the blade style to decrease the cut path area. Material is building up on the blade and wiping off on the cut site. Use blade lubrication (water, etc.
Product Quality Problems (continued) Symptom Possible Cause Solution Cracks at cut site. The extrudate is too cold. If the extrudate is too cold, it can fracture or whiten during cutting. Raise the extrudate's temperature. The blade speed is too high. High blade speeds can cause too much impact. Lower the blade speed. The bushings are not providing enough support during cutting. Change the bushing design to make them more supportive. The cutting blade is too sharp.
Product Quality Problems (continued) Solution Cut is not square. The extrudate is too cold. Low blade speeds can cause excessive blade interruption. Increase blade speed or decrease the blade cut path area. The blade speed is too high. Check that blade is 90 degrees relative to the bushing holder. The bushings are not providing enough support during cutting. If the cutter bushings are not properly gapped, the blade may be free to move with the extrudate. Check and adjust if necessary.
Product Quality Problems (continued) Symptom Possible Cause Solution Length of cut is incorrect. Repeatability is wrong. Test for repeatability. See Troubleshooting Section entitled, Testing Repeatability. Also see Operation Section entitled, Tuning the Cutter if using Red Lion Servo controls for Repeatability Testing. Encoder, input device problem. Check encoder, input device and clean. Run repeatability test, See Checking the Encoder, Troubleshooting Section. There is a problem with the puller.
Replacing Safety and Proximity Switches Three safety switches are included in CSC cutter sections: a keyed safety switch on the knife guard, and a proximity switch on each cutter bushing. A failure in any of these switches prevents the puller/cutter from running. • Safety Switch If you suspect a problem with the keyed safety switch on the knife guard, check for loose or damaged wires. Replace the switch if wires appear to be undamaged.
Checking the Servo Amplifier The servo amplifier is equipped with a digital readout that can be seen through the viewing window on the electrical enclosure. This display shows amplifier status and error messages. Refer to the supplier's documentation included with this User Guide. 0 NOTE: Make sure you look for servo amplifier messages before you shut off the power, because fault message will be lost. Checking the Motor Assembly 1 Open the knife guard.
Checking the Encoder When the encoder is working properly, the measurement displayed will count up to the preset and reset to zero. 1 Check all connections. 2 Check the encoder cable for damage. If necessary, replace. 3 Check the connector that attaches the cable to the encoder. Internal wiring may be shorted out if this connector is not handled properly. 4 Check the encoder itself. There should be no play in the shaft. 5 If all else fails, contact Conair Customer Service. See Appendix A.
0 NOTE: See Operation Section entitled, Set Up 2 Page Description, Tuning the Cutter if using Red Lion HMI and Control Techniques/Emerson Servo Drives Te s t i n g R e p e a t a b i l i t y Before any Conair puller/cutters are shipped, they are tested for cut time repeatability to be sure they are within performance specifications. The repeatability test checks the performance of the rotary knife cutter to return the home park position after a complete cut.
R e s u l t s o f R e p e a t a b i l i t y Te s t i n g Results in Flywheel mode The display shows DevCC a full revolution of the cutter head. The reading is in milliseconds, to the third decimal place, i.e. 0.010 is 0.01 milliseconds (or 10 microseconds). If the reading exceeds 0.200 there is a problem with the cutter drive. If this occurs the error is too large and there is a problem in the cutter drive that must be corrected.
Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Department for a Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have nominal fee. We ’ r e H e r e t o H e l p installing and operating your equipment.
Equipment Guarantee Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination.
Cutter Blade Selection and Use Cutter blade characteristics such as material, design, and thickness can have a large effect on cut quality. Blade materials • Blue tempered spring steel is most commonly used because of its cost and availability over a wide range of thicknesses (0.010-0.062 inch). It is a very tough material with an HRC value of approximately 48-51 and fair wear characteristics.
C u t t e r B l a d e S e l e c t i o n a n d U s e ( continued) Blade Design • Straight-edge knives have a straight cutting surface. A chopping action (which has cutting forces parallel to the cut) is typically obtained with straight-edge blades. Because the blade is mounted on a rotary arm, some slicing action (which has additional force vectors at various angles to the cutting edge) is obtained, but generally not through the entire cutting action.
C u t t e r B l a d e S e l e c t i o n a n d U s e ( continued) Blade Thickness Because material is displaced rather than removed in rotary knife cutting, think of the blade as a wedge. The thicker the blade, the greater the displacement. This displacement can cause fracture in rigid profiles and tubing, which is often observed as a whitening on all or a portion of the cut. You can reduce this fracturing by reducing the thickness of the blade.
Calculating Blade Interruption Blade interruption is the length of time which the blade interrupts the extrudate during the cutting process. Knowing blade interruption allows you to optimize blade speed and design for specific applications. You can calculate blade interruption for your application if you know: • the cutting blade width • blade speed (cutter rpm) • extrudate cross section.
( continued) 1.1 87 ” Calculating Blade Interruption 2.2 5” Straight blade Curved blade To calculate interruption time: (0.937 in. + 0.250 in.) X 60,000msec/rev = 3.2 msec 31.4 in. 718 rpm Knowing the interruption time and the line speed, you can calculate the amount of production deflection that must be accommodated during cutting. To calculate the amount of extrudate deflection between the cutter and puller, multiply line speed by interruption time: Blade Interruption time, msec 3.
Conair Cutter Blades Contact Conair Parts for blade recommendations. Replacement blades are available from Conair.
All About Cutter Bushings Rotary knife cutter bushings are probably the most ignored aspect of cutting. Yet, they are probably the most important ingredient to obtaining clean, square, accurate cuts with minimal jamming and broken blades.
All about Cutter Bushings ( continued) • If you are cutting a square or rectangular profile, whether rigid or flexible, a round bushing bore will not offer proper support and will often lead to an "S" shaped cut. A flat bottomed bushing will offer excellent support and enhance the shearing action of the blade. • In the case of flexible extrudates, allow 0.010-0.050 inch clearance depending on durometer and surface; the softer durometers and tacky surfaces require the most clearance.
All about Cutter Bushings ( continued) C u t t e r b u s h i n g s h e a r s u r fa c e q u a l i t y Similar to a dull pair of scissors, if the cutter bushing shear surface is not sharp the tube or profile is not supported to the side of the blade and the cut will not be clean. In some cases, the entrance of the downstream cutter bushing is slightly radiused to minimize jamming. While this practice helps accommodate bushing bores that are not quite aligned, it has a negative effect on cut quality.
All About Cutter Bushings ( continued) Cutter bushing length CA U T I O N : B l a d e h a z a r d In order to comply with OSHA regulations, the distance from the sidewall of the cutter to the blade (through the bushing) must be long enough to prevent fingers from reaching the blades. On flexible extrudates, it is important to minimize the length of the cutter bushings.
All About Cutter Bushings ( continued) Adjusting the cutter bushing gap If the bushing gap is too big, material is dragged down between the bushings creating a burr, especially with flexibles. This may lead to jamming within the bushings where the upstream side of the cut extrudate actually hits against the downstream bushing surface. This is especially apparent with flexibles with non-concentric walls where a slight bow is present.
Blade and Bushing Lubrication Blade and bushing lubrication can nearly always improve the quality of cutting. Description of the cutting process Unlike sawing, a rotary knife cutter displaces material rather than removing it. When the knife blade first contacts the extrudate, it pushes it against the opposite side of the cutter bushings. If there is too much clearance the extrudate may crack or distort before cutting even begins.
Blade and Bushing Lubrication Friction and heat during cutting ( continued) If the blade has a rough surface where the extrudate rubs against it, material will accumulate on the blade in a cheese grater fashion. This scratched material will also be passed from the blade to the next cut and be seen as hairs or flakes. Some of the more flexible materials, such as silicones, soft urethanes and flexible PVCs, also exhibit drag against the blade during the cutting cycle.
Blade and Bushing Lubrication ( continued) Common cutting lubricants Commonly used general purpose lubricants include: • Tap water • Dish washing liquid (Joy, etc) • Glycol (anti-freeze, coolant) • Water-soluble silicone cutting oils • Diesel fuel • Mold release • Mineral oil Medical grade lubricants: • Distilled water • Isopropanol (isopropyl alcohol) • Mixtures of isopropanol and water Lubrication systems The most basic blade lubrication system for rotary knife cutters is using a stainless steel tray f
Choosing Belt Materials When considering puller performance, an important concern is the type of puller belt. To select the proper belt material, you must consider the extrudate's tendency to deform under pressure. For example, thin wall profiles and tubing are prone to deformation, so you need lower pressures and longer traction lengths to deliver the required pulling force without deformation and slippage. Various belt materials are available: natural rubber, neoprene, urethane, and dual material.
Using the Digital Belt Gap Sensor The digital belt gap sensor uses a linear scale attached to both belts to measure the relative distance between the belts. The relative distance is shown in thousandths of an inch (.001). The sensor has five buttons: • (On/Off) - Turns the device on and off. • (Mode) - Press to choose the readout in decimals, fractions, or millimeters. • (+) - Press to move up one engineering unit. • (0) - Press to zero the reading.
Adjusting the Pneumatic Upper Belt Actuator You can adjust the opening and closing speed of the air cylinder assembly that operates the upper belt boom assembly by adjusting (lifting and turning) the air regulator handle.
Appendix l F-2