Sure Cut Rotary Knife Cutter SC-5 Servo Model Installation Operation Maintenance Troubleshooting Instant Access Parts and Service (800) 458-1960 (814) 437-6861 www.conairnet.com The Conair Group, Inc.
Record your equipment’s model and serial number(s) and the date you received it in the spaces provided. It is important to record the model and serial number(s) of your equipment and the date you received it in the User Guide. Our service department uses this information, along with the manual number, to provide help for the specific equipment you installed. Keep this User Guide and all manuals, engineering prints and parts lists together for documentation of your equipment.
INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1 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 . . . . . . . . . . . . . . . . . . . .1-5 TABLE OF CONTENTS DESCRIPTION . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1 Maintenance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Preventative Maintenance Schedule . . . . . . . . . . . . . . . . . .5-4 Checking the Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Inspecting Cutter Bushing Screws . . . . . . . . . . . . . . . . .
INTRODUCTION ● Purpose of the User Guide . . . .1-2 ● How the User 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 . . . . . . . . . . . .
PURPOSE OF THE USER GUIDE This User Guide describes the Conair SC-5 Sure Cut Servo Knife Cutter and explains step-by-step how to install, operate, maintain and repair this equipment. HOW THE USER GUIDE IS ORGANIZED Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation.
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. DANGER: Sharp blades! ATTENTION: READ THIS SO NO ONE GETS HURT Most injuries caused by knife blades occur when the cutter has been turned off. Handle blades with care at all times. ● Always lock out the cutter before opening the cutting chamber.
WARNING: Voltage Hazard ATTENTION: This equipment is powered by three-phase alternating current, as specified on the machine serial tag and data plate. READ THIS SO NO ONE GETS HURT A properly-sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure. Improper grounding can result in severe personal injury and erratic machine operation.
WARNING: Electrical hazard 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. HOW TO USE THE LOCKOUT DEVICE Lockout is the preferred method of isolating machines or equipment from energy sources. Your Conair product is equipped with the lockout device pictured below.
DESCRIPTION ● What is the SC-5 Sure Cut Knife Cutter . . . . . . . . . . . . . . . 2-2 ● Typical Applications . . . . . . . . . . 2-4 ● How the SC-5Works . . . . . . . . . . . 2-5 ● SC-5 Features . . . . . . . . . . . . . . . . 2-7 ● Specifications . . . . . . . . . . . . . . . . 2-7 ● Optional Equipment . . . . . . . . . . .
WHAT IS THE SC-5 SURE CUT? The Conair SC-5 Sure Cut Series rotary knife cutter has been designed to be “The most versatile cutter of the industry”. With both capacity to cut small parts at high speeds or large tubes or profiles at low speeds this cutter can eliminate the need for moving cutters in and out of a line per application. Today with custom profile houses potentially running 2-3 different profiles on one line in a given day, time is at a premium.
The larger diameter flywheel used on the servo cutter offers the potential of higher surface speeds at dramatically lower blade rpm’s with high cutting torque. The typical grey area between on-demand cutting and flywheel cutting (150 cpm on-demand up to 300 cpm flywheel), typically seen in DC driven clutch\brake cutter is eliminated. It should not be necessary to cut in on demand mode in excess of 150 cuts per minute which will greatly save on premature wear to the system.
TYPICAL APPLICATIONS Cutting from Below the Bushing Holder The SC-5 Sure Cut Servo Cutter housing maximizes versatility and operational ease. Due to the size of the flywheel it was determined best to mount it directly below the bushing holder keeping the center of gravity low and offering the following benefits: ● Accessibility of the flywheel for ease of blade changes. ● Built in blade lubrication tray can be integral to the design of the cutting chamber.
Extruded material that has been sized and cooled enters the cutter from the upstream side (See How the SC-5 Sure Cut Works, Section 2, step 1). Typically, a puller is placed just before the cutter; the puller pulls the extrudate through the sizing and/or cooling tanks and feeds it into the cutter. HOW THE SC-5 SURE CUT WORKS The positional servo motor, is direct coupled to the cutter head, or an in-line planetary gear reducer that drives the cutter head.
HOW THE SC-5 SURE CUT WORKS CONTINUED 3 Cut pieces are collected or carried away on a conveyor. 1 Extruded material enters the cutter from the upstream side. 2 2-6 DESCRIPTION SC-5 SURE CUT Servo Knife Cutter The cutter head holds the blade(s) as they rotate and pass between the bushings, cutting the extrudate.
The SC-5 Sure Cut Servo Cutter features: Parts discharge chute or optional discharge conveyor CONAIR SERVO CUTTER Version 1.0 SC-5 FEATURES Wide Range of Cutter Bushing Capacities 24-inch diameter flywheel with multiple blade mounting system Polycarbonate blade observation window Optional blade lubrication system The standard control: ● Large easy-to-read display. ● Soft keys allows the operator to select different functions. ● Numeric keys permits data entry for the operator.
OPTIONAL EQUIPMENT Slide Base This option is highly recommended for cutting flexible extrudates. While the cutter base is fixed and aligned with the puller, the cutter itself is mounted on a set of linear slides that allow as much as 12 inches of movement. The cutter can be moved away from the puller for startup, then moved close to the puller to enhance delivery to the cutter bushings. Blade Wipe The blade wipe system keeps the cutting blade clean by removing lubricant and particles from the blade.
Discharge Conveyor A discharge conveyor facilitates the removal of cut parts. Discharge conveyors are available in the following sizes: ● 6 inches wide by 6 feet long OPTIONAL EQUIPMENT ● 6 inches wide by 10 feet long ● 6 inches wide by 16 feet long Isolation Transformer The isolation transformer protects sensitive electronics from incoming power, which helps prevent errors caused by electrical noise. It also protects equipment from electrical noise generated by the servo motor and associated amplifier.
INSTALLATION ● Unpacking the Boxes . . . . . . . . .3-2 ● Preparing for Installation . . . . . .3-3 ● Positioning the SC-5 Sure Cut . . . . . . . . . . . . . . . . .3-4 ● Connecting the Main Power Source . . . . . . . . . . . . .3-6 ● Installing the Encoder . . . . . . . .3-7 ● Installing the Cutter Blades . . . . . . . . . . . . . . . . . . .3-8 ● Mounting the Cutter Bushings . . . . . . . . . . . . . . . .3-10 ● Checking Repeatability . . . . . .3-12 ● Preparing for Testing . . . . . . . .
UNPACKING THE BOXES The SC-5 Sure Cut Series Servo Knife Cutter comes fully assembled in a single crate. CAUTION: Lifting 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 cutter's center of gravity. 3-2 INSTALLATION 1 Carefully uncrate the cutter and its components.
1 You need these tools for installation: ❒ ❒ ❒ ❒ ❒ ❒ 2 wire strain relief 16- or 18-inch adjustable wrench set of Allen wrenches set of feeler gauges ½ inch open or box end wrench flashlight PREPARING FOR INSTALLATION Plan the location. Make sure the area where the servo cutter is installed has the following: ● A grounded power source. Check the cutter’s serial tag for the correct amps, voltage, phase and cycles.
POSITIONING THE SERVO CUTTER 1 Move the servo cutter into position. Place the servo cutter in position downstream of the belt puller. CAUTION: Lifting 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 cutter's center of gravity. SC-5 Cutter 2 NOTE: If the slide base option was purchased, the cutting chamber can be slid back from the frame to allow ease of the string up procedure.
3 Align the cutter with the extrusion line. POSITIONING THE SERVO CUTTER CONTINUED 4 Measure the centerline height of the extrudate as it exits the extrusion die. Adjust all equipment on the extrusion line (sizing tank, cooling tanks, belt puller, and cutter) to this height.
CONNECTING THE MAIN POWER SOURCE WARNING: Electrical hazard Before performing any work 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. WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.
CAUTION: Handle with care. The encoder is a delicate piece of equipment and must be handled gently. INSTALLING THE ENCODER Conair uses bi-directional encoders to ensure that only product that moves forward is counted.
DANGER: Sharp blades! INSTALLING THE CUTTER BLADES Most injuries caused by knife blades occur when the cutter has been turned off. Handle blades with care at all times. ● Always lock out power to the cutter before opening the cutting chamber. ● Always wear cut-resistant gloves when the cutting chamber is open and when handling blades. ● Always wait until the cutter head has completely stopped before opening the knife guard.
TIP: We recommend that you: ● Apply some protective cover on the portion of the blade you are handling, such as masking tape to help prevent getting cut during installation and to leave it on until such time that you will start and check the cutting operation. INSTALLING THE CUTTER BLADES CONTINUED ● Check the length that the blade extends out of the cutter blade wheel. The blade needs to be carefully checked to insure that the entire blade will pass completely through the product.
DANGER: Sharp blades! MOUNTING THE CUTTER BUSHINGS 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. The Bushings Generally, the bushing will be in two parts, an inlet and an outlet with the inlet bushing being tapered or otherwise contoured to assist in guiding the product into the cutter mechanism.
Checking the Alignment of bushing to blade Once you are sure that the blade will easily clear the bushings as it goes through the space you should then make some test cuts to insure quality. CHECKING THE ALIGNMENT OF THE BUSHINGS 1 Close the safety cover. 2 3 4 Turn on the Power (Rotary main disconnect). 5 Check the quality of the cuts. Adjust the bush- setting and adjusting the gap ing if necessary. for the bushings, see About Press the Green start button.
CHECKING REPEATABILITY Before any Conair SC-5’s 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. Acceptable repeatability times allowed for each cutter model prior to shipping are: Type of Cutter Repeatability Time AC Pneumatic Cutter DC Pneumatic Cutter Positional Servo Less than 1 millisecond Less than 1.
1 Make sure all components are installed according 2 Check that cutter is firmly locked into position 3 Check that all wiring conforms to electrical codes, and all wiring covers are in place. 1 Locate the main disconnect switch on the front of the control cabinet. Turn it on. You should see the to assembly drawings. Make sure that all bolts on the cutter have been tightened. FOR with the anchoring screws.
OPERATION ● The Cutter Control . . . . . . . . . . .4-2 ● Before Starting . . . . . . . . . . . . . .4-3 ● Powering Up . . . . . . . . . . . . . . . .4-3 ● Main Screen . . . . . . . . . . . . . . . .4-5 ● Total Screen . . . . . . . . . . . . . . . .4-6 ● Batch Screen . . . . . . . . . . . . . . .4-7 ● Length Screen . . . . . . . . . . . . . .4-9 ● Preset to Run . . . . . . . . . . . . . .4-10 ● Time Preset . . . . . . . . . . . . . . .4-11 ● Blade Speed . . . . . . . . . . . . . . .4-13 ● Function Areas . .
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. OPERATOR CONTROL FEATURES 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. CONAIR SERVO CUTTER Version 1.
Before you start daily operation of the servo cutter, you need to perform preventative maintenance. Necessary maintenance is described in the Maintenance section of this Users Guide, see preventative maintenance, Section 5. BEFORE STARTING WARNING: Be sure that power to the SC-5 cutter is OFF when doing any maintenance on the servo cutter. Follow all safety rules when performing any maintenance on this equipment.
POWERING UP Note: If “Home Runtime Failed” message is dis played. Check for malfunctions of misadjusted sensor. CONTINUED 6 Open the knife guard. The machine start push button should go out. If the cutter is not working properly at any time, turn it off immediately and refer to the Troubleshooting section of this User Guide. If you do not encounter any problems, proceed to the Operation section. Power Up Sequence At power up a series of system screens briefly appear.
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 OPERATOR CONTROL INSTRUCTIONS MAIN SCREEN 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.
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.
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. CONTROL INSTRUCTIONS TOTAL SCREEN CONTINUED 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 E of this manual.
CONTROL INSTRUCTIONS BATCH SCREEN 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 E of this manual. SELECT BATCH AREA Preset Exit Alarm This screen provides access to the batch Preset/softkey1 or batch Alarm/softkey3 areas.
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. Batch Pre-Alarm Preset Screen By pressing the soft key located under the word Alarm on the Batch Area Screen, the preset for the Batch pre-warn Alarm is available.
CONTROL INSTRUCTIONS LENGTH SCREEN Exit or Prev, if no change is required press Exit or Prev to return to the Main screen. CONTINUED Lower will decrease the preset by 0.010 inch. The key can be pressed once for each 0.010 inch decrement required or held down to scroll down. Releasing the key will freeze the preset at the last value then press enter. Raise will increase the preset by 0.010 inch. The key can be pressed once for each 0.010 inches increment required or held down to scroll up.
Exit or Prev, If no change is required press Exit or Prev to return to the previous Length Screen. Raise will increase the number by 1. The key can be pressed once for each increment of 1 required or held down to scroll up. Releasing the key will freeze the preset at the last value then press enter. Lower will decrease the preset by 1. The key can be pressed once for each decrement of 1 required or held down to scroll down. Releasing the key will freeze the preset at the last value then press enter.
CONTROL INSTRUCTIONS TIME SCREEN CONTINUED Raise will increase the preset by 0.010 second. The key can be pressed once for each 0.010 second increment required or held down to scroll up. Releasing the key will freeze the preset at the last value then press enter. Lower will decrease the preset by 0.010 second. The key can be pressed once for each 0.010 second decrement required or held down to scroll down. Releasing the key will freeze the preset at the last value then press enter.
Raise will increase the preset by 0.010 second. The key can be pressed once for each 0.010 second increment required or held down to scroll up. Releasing the key will freeze the preset at the last value then press enter. Lower will decrease the preset by 0.010 second. The key can be pressed once for each 0.010 seconds decrement required or held down to scroll down. Releasing the key will freeze the preset at the last value then press enter.
CONTROL INSTRUCTIONS BLADE SPEED SCREEN CONTINUED Raise will increase the preset 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 preset at the last value then press enter. Lower will decrease the preset by 1.0. The key can be pressed once for each 1.0 decrement required or held down to scroll down. Releasing the key will freeze the preset at the last value then press enter.
Raise will increase the preset by 1. The key can be pressed once for each 1 increment required or held down to scroll up. Releasing the key will freeze the preset at the last value then press enter. Lower will decrease the preset by 1. The key can be pressed once for each 1 decrement required or held down to scroll down. Releasing the key will freeze the preset at the last value then press enter.
CONTROL INSTRUCTIONS FUNCTION AREAS CONTINUED Next or Prev, Pressing Next selects the second Function Area. Pressing Prev returns the display to the first Function Area screen. Pressing Prev from the first Function Area screen returns the display to the active main mode screen. Menus are a convenient way to access and monitor parameters that do not need to be altered often, i.e. blade speed, blade count, cut mode, repeatability test, min. allowable measurement and cuts per minute.
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. 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.
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 standardmodes 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.
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. CONTROL INSTRUCTIONS MINIMUM MEASUREMENT 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.
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 troubleshooting and scheduling purposes. Factory Softkey This area is password protected for factory use only. Please do not attempt to get around the password protection as parameters beyond this point are used for calibration and setup.
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 SELECT ENCODER AREA Drctn U/M Scale CONTROL INSTRUCTIONS ENCODER AREA CONTINUED to access this screen can be found in the Maintenance Area of the operator display overview section of this manual. Exit or Prev, Pressing Exit or Prev will return the display to the Maint. Area screen.
CONTROL INSTRUCTIONS ENCODER DIRECTION CONTINUED CONTROL INSTRUCTIONS UNIT OF MEASURE 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.
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 E of this manual. CONTROL INSTRUCTIONS SCALE DISTANCE ENTERDISTANCE DISTANCEPER PER ENTER COUNTS COUNTS12.00 12.0000 in. in. The number shown is the current distance value, i.e.
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 E 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.
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.
CONTROL INSTRUCTIONS HOME OFFSET CONTINUED 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. Releasing the key will freeze the value at the last value. Numeric keys Key in the distance desired and press enter.
PREVENTIVE MAINTENANCE SOFTKEY Pressing the soft key located under the word P/M on the Maint. area screen. Selects the P/M area screen. Three preventive maintenance sub-menus for monitoring Inputs, Time and Cycles are displayed. CONTROL INSTRUCTIONS PREVENTIVE MAINTENANCE SELECT P/M AREA Inputs Time Cycles Additional information on how to access this screen can be found in the Maintenance Area of the operator display overview in Appendix E of this manual.
CONTROL INSTRUCTIONS POWER ON TIME 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.
1 Press the manual cut button and observe the movement of the cutter blade. The cutter head makes a single rotation and the blade moves through the cutter bushings without interference. 2 Insert a piece of extrudate through the cutter bushings. 3 Press the manual cut button. A single cut is made 4 Inspect the cut. If necessary, adjust the blade design CHECKING CUT QUALITY at the preset blade speed. (This works even if Cut On/Off is off.) or blade speed. See All About Cutter Blades, Appendix B.
MAKING ADJUSTMENTS DURING OPERATION There are several adjustments you can make during normal cutting. These adjustments include: ● In Timer mode, adjust the time between cuts ● In Encoder and Follower modes, adjust the length ● In Product mode, adjust the hold-off time ● In Flywheel mode, adjust blade speed ● Adjust blade speed in all modes except Follower ● Perform a manual cut and reset the length by pressing the manual cut button at any time during on-demand cutting.
WARNING: Never stop the servo cutter by opening the knife guard. This can cause damage to the equipment and injury to personnel. STOPPING THE SC-5 CUTTER Use this procedure to safely stop the servo cutter: 1 2 3 Press Cut On/Off soft key to stop cutting (soft key text changes to off). Press Stop Cutter button to disable the servo motor (start light is off). Turn the rotary disconnect to the off position. WARNING: Never turn off the rotary disconnect first.
MAINTENANCE ● Maintenance Features . . . . . . . .5-2 ● Warnings and Cautions . . . . . . .5-2 ● Maintenance Overview . . . . . . .5-4 ● Preventative Maintenance Schedule . . . . . . . . . . . . . . . . .5-4 ● Checking the Blades . . . . . . . . .5-6 ● Inspecting Cutter Bushing Screws . . . . . . . . . . .5-7 ● Checking the Closure Latch . . .5-7 ● Cleaning the Blade Tray . . . . . . .5-8 ● Lubricating the Slide Rail System . . . . . . . . . . . . . . .5-8 ● Adjusting the Proximity Switches . . . . . . . .
MAINTENANCE FEATURES The Servo Cutter SC-5 Sure Cut models needs regular, scheduled maintenance for peak performance. Among the features that require maintenance are: ● Cutter blades ● Blade mounting hardware ● Cutter bushings ● The knife guard hardware ● Cutter alignment ● Floor locks ● Lubrication tray ● Shafts of optional slide rail system ● Electrical cables ● Control panel lights WARNINGS CAUTIONS AND To maintain the best performance of the servo cutter, it must be cleaned and inspected regularly.
WARNING: Voltage Hazard This equipment is powered by alternating current, as specified on the machine serial tag and data plate. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate. WARNINGS CAUTIONS AND CONTINUED A properly-sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure.
MAINTENANCE OVERVIEW This section describes the daily, weekly, monthly and semiannual maintenance schedules that should be performed when changing materials or lines, or when changing equipment, as well as the maintenance procedures to follow. Cutting either flexible or rigid materials generates tremendous shock and vibration to the entire unit. Anything that can loosen, will over time.
● Weekly ❒ Cleaning the blade lubrication tray (if the cutter has this option). See Cleaning the Blade Tray, Section 5. ❒ Lubricating shafts on optional slide rail system See Cleaning the Blade Tray, Section 5. ● Monthly ❒ 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. ❒ Checking bushing holder proximity switches Inspect the sets screws which retain the bushing holder proximity switches for tightness.
CHECKING 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, sharpen or replace as needed (see Installing Cutter Blades, Section 3). DANGER: Sharp blades! Most injuries caused by knife blades occur when the cutter has been turned off. Handle blades with care at all times.
Check the set screws that secure the cutter bushings. If bushings move during cutting, cutting blades and possibly the drive chain could be damaged. Cutter bushing screws Check the hand knob and tighten it so the knife guard closes completely. This prevents false triggering of the safety switch.
CLEANING THE BLADE TRAY (OPTIONAL) This tray is built into the cutter assembly as a simple method of applying lubrication to your blade during cutting cycles. Depending on cut rate and type of material and lubrication, the area will need to be cleaned on a regular basis and the lubricant replaced. Open the clear guard windows and, using a shop vac or other similar equipment, remove all liquid and solids from the cutting chamber and around the bushings. Replace the lubricant.
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 2 Loosen the set screws that hold the cutter bushings. 3 Remove the cutter bushings. 4 Check the depth of the proximity switch face for each bushing. It should be recessed no more cutter is locked out. ADJUSTING THE PROXIMITY SWITCHES than 0.010 inches, but should not interfere with the bushings themselves.
CHECKING ELECTRICAL CONNECTIONS WARNING: Electrical hazard Before performing any work 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. WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.
3 4 5 6 Open the electrical enclosure. 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. CHECKING ELECTRICAL CONNECTIONS CONTINUED Close the electrical enclosure door. Inspect the exterior power cords. Cords should not be crimped, exposed, or rubbing against the frame.
INSTALLATION AND REMOVAL INSTRUCTIONS FOR B-LOC™ LOCKING ASSEMBLY SERIES B112 Thank you for purchasing a B-LOC™ Keyless Frictional Locking Device. B-LOC™ keyless connectors provide a high capacity, zero-backlash shaft/hub or coupling connection by means of a mechanical interference fit. Please follow these INSTALLATION AND REMOVAL INSTRUCTIONS carefully to ensure proper performance of this B-LOC™ unit.
TROUBLESHOOTING ● Before Beginning . . . . . . . . . . . .6-2 ● A Few Words of Caution . . . . . .6-2 ● Identifying the Cause of a Problem . . . . . . . . .6-3 ● Electrical Problems . . . . . . . . . .6-4 ● Product Quality Problems . . . . .6-8 Repair ● Replacing Safety and Proximity Switches . . ● Checking the Servo Amplifier . . . . . ● Adjusting the Proximity Switches . . ● Checking the Encoder . ● Checking the Motor/ Reducer Assembly . . . ● Checking Repeatability UGE059/1003 . . . . . .6-12 . . . . .
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. Find any wiring, parts, and assembly diagrams that were shipped with your equipment. These are the best reference for correcting a problem. The diagrams will note any custom features or options not covered in this User Guide.
DANGER: Sharp blades! 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.
ELECTRICAL PROBLEMS Look in this section when you have problems such as lights on the control that are working improperly, buttons that do not execute the function properly, and when information input is not executed properly. Symptom Possible cause Solution ◆ The green start The E-stop button is pushed in. Pull out the E-stop button. button does not illuminate when pressed Check to see if: ❒ The blade guard is closed. ❒ Master Control relay (MCR) has failed. Replace relay.
ELECTRICAL PROBLEMS CONTINUED Symptom Possible cause Solution ◆ After pressing The Blade home proximity switch failed or the connection to it is loose. Check connections and replace switch if needed. Guard circuit is open. Check to see if: Start Cutter, the cutter head rotates slowly but does not stop. ◆ Master safety relay does not energize ◆ While in Encoder mode, no count is displayed UGE059/1003 ❒ The blade guard is closed. ❒ Loose connection to guard circuit. Tighten connection.
ELECTRICAL PROBLEMS CONTINUED Symptom Possible cause Solution ◆ In encoder or There is a problem with the cutter control. Check for control output. There is a problem with the servo amplifier. See Checking the Servo Amplifier. There is a loose connection. Check wiring for loose connections. There is an anti-jam circuit signal. This error appears when the blade does not go through the cut cycle in the required time.
ELECTRICAL PROBLEMS CONTINUED Solution Symptom Possible cause ◆ Blade speed does There is a communication Check for wiring for loose connections and tighten. failure between the control and drive. not change when new speed is entered into the control. ◆ Cutter mode selection does not change cut mode. ◆ The park (home) position is drifting, i.e. the blade parks further away from the original park site.
PRODUCT QUALITY PROBLEMS Look in this section when the final product does not meet standards: has strings, burrs, cracks, or is misshaped. Symptom Possible cause 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.
PRODUCT QUALITY PROBLEMS CONTINUED Symptom Possible cause ◆ Burrs at cut site. The bushings are not pro- Change bushing design to viding enough support make them more supportive. during cutting. UGE059/1003 Solution The bushing gap is too wide. The bushing gap should be no more than .001-.003 inch larger than the blade. Check and adjust if necessary. The blade speed is too low. Low blade speeds can cause excessive blade interruption. Increase blade speed or decrease the blade cut path area.
PRODUCT QUALITY PROBLEMS CONTINUED Symptom Possible cause ◆ Cracks at cut The extrudate is too cold. If the extrudate is too cold, it can fracture or whiten during cutting. Raise the extrudate's temperature. site. The blade speed is too high. Solution High blade speeds can cause too much impact. Lower the blade speed. The bushings are not pro- Change the bushing design to viding enough support make them more supportive. during cutting. 6-10 TROUBLESHOOTING The cutting blade is too sharp.
PRODUCT QUALITY PROBLEMS CONTINUED Symptom ◆ Cut is not square. UGE059/1003 Possible cause Solution The blade speed is too low. Low blade speeds can cause excessive blade interruption. Increase blade speed or decrease the blade cut path area. The blade is misaligned. Check that blade is 90 degrees relative to the bushing holder. The cutter bushings are not properly gapped. If the cutter bushings are not properly gapped, the blade may be free to move with the extrudate.
REPLACING SAFETY AND PROXIMITY SWITCHES Three safety switches are included in SC-5 Sure Cut cutters: a keyed safety switch on the knife guard, and a proximity switch on each cutter bushing. A failure in any of these switches will prevent the 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.
The home position proximity switch should be 0.010 inch from the 5/16 inch thread rod on the cutter head for proper operation. 1 Open the flywheel clear guard window. 2 Locate the 5/16 inch thread rod on the cutter head. It should be 0.010 inch from the proximity switch ADJUSTING THE PROXIMITY SWITCHES sensor when it passes that location. If necessary, loosen the jam nuts, readjust the distance, and re-tighten the jam nuts.
CHECKING THE ENCODER When the encoder is working properly, the encoder LEDs on the control panel light or flicker as the encoder wheel moves and generates signals. If the LEDs do not light when the encoder wheel moves: 1 Check all connections. 2 Check the encoder cable for damage. If neces- 3 Check the connector that attaches the cable to the encoder. Internal wiring may be shorted out if this sary, replace. connector is not handled properly. 4 Check the encoder itself.
Encoder Mounting and General Information The provided encoder is a precision instrument which outputs 3000 bi-directional quadrature pulses per revolution of the shaft. CHECKING THE ENCODER CONTINUED Do not apply excessive axial or radial thrust on encoder shaft (rated for 30lbs. axial thrust). Do not press or dive gears or pinions on the encoder shaft. Encoders are an instrument containing an accurately positioned electronic system.
CHECKING THE MOTOR/REDUCER ASSEMBLY 6-16 TROUBLESHOOTING 1 Open the flywheel clear guard window. 2 Remove the cutter head by loosening the Trantorque 3 Locate the four bolts holding the motor/reducer 4 Refer to the Micron installation and maintenance information included with this User Guide to check and adjust the motor/reducer assembly. Refer to section 5, Installation and Removal Instructions for B-Loc. assembly.
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. Acceptable repeatability times allowed for each cutter model prior to shipping are: Type of Cutter Repeatability Time AC Pneumatic Cutter DC Pneumatic Cutter Positional Servo (FX) Less than 1 millisecond Less than 1.
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 installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use.
EQUIPMENT GUARANTEE PERFORMANCE WARRANTY 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 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.
CUTTER BLADE SELECTION AND USE 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.
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. (This effect can also be minimized by heating the profile or tube.
CUTTER BLADE SELECTION AND USE 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.
CUTTER BLADE SELECTION AND USE To calculate interruption time: (0.937 in. + 0.250 in.) X 60,000msec/rev = 1.13msec 87.9 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 X Line speed, X 12 = Deflection, time, msec fpm 60,000 in. 1.13msec X 60 fpm X 12 = .
CONAIR CUTTER BLADES B-6 APPENDIX Part No. Blade Type Bushing Size {inches} Blade Thickness x Length Blade Material {inches} 0235-30496 3515-30496-1 3515-30496-2 Straight Straight Straight 41/4, 51/4, 4x10 0.025x9.5 21/4, 2x4, 2x6 0.025x6.48 31/4, 2x8, 2x10, 0.025x8.33 2x12, 4x7 Spring Steel Spring Steel Spring Steel 3515-30488 Curved 31/4, 4x7, 3x6 Spring Steel CONAIR CUTTER BLADES 0.025x11.
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 Supportive bushings become more important if heat is used to minimize whitening (fracturing). ● 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 in.
Cutter bushing shear surface quality 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 Cutter bushing length CAUTION: Blade hazard 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 blade. On flexible extrudates, it is important to minimize the length of the cutter bushings. It is very difficult to push flexible extrudates through since it tends to compress as it is pushed, causing a marginal increase in the tube diameter.
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. ALL ABOUT CUTTER BUSHINGS ● Locate the downstream bushing such that it touches the blade without deflecting it.
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.
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 BLADE AND BUSHING LUBRICATION 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 filled with th
BLADE AND BUSHING LUBRICATION 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.
ENCODER MODE OPERATOR DISPLAY OVERVIEW ENC 00000.000 in. Parts Off Length OR OR SELECT PARTS AREA Total Exit Batch TOTAL 0,000,000 pcs. Off Exit Reset BATCH 000,000 pcs. Change Off Reset SELECT BATCH AREA Preset Exit Alarm OR PRESET 000,000 pcs. Exit LENGTH 00000.000 in. Exit OR ALARM 000,000 pcs.
END SENSE MODE OPERATOR DISPLAY OVERVIEW SNS 00000.000 sec. Parts Off Time OR OR SELECT PARTS AREA Total Exit Batch TOTAL 0,000,000 pcs. Off Exit Reset BATCH 000,000 pcs. Change Off Reset SELECT BATCH AREA Preset Exit Alarm OR PRESET 000,000 pcs. Exit Holdoff 00000.000 sec. Exit OR ALARM 000,000 pcs.
FLYWHEEL MODE OPERATOR DISPLAY OVERVIEW FLY 00000.000 cpm Parts Off Blade OR OR SELECT BLADE AREA Speed Exit Count SELECT PARTS AREA Total Exit Batch TOTAL 0,000,000 pcs. Off Exit Reset BATCH 000,000 pcs. Change Off Reset SPEED 0000.0 rpm Exit OR PRESET 000,000 pcs. Exit ALARM 000,000 pcs.
TIMER MODE OPERATOR DISPLAY OVERVIEW TMR 00000.000 sec Parts Off Time OR OR SELECT PARTS AREA Total Exit Batch TOTAL 0,000,000 pcs. Off Exit Reset BATCH 000,000 pcs. Change Off Reset SELECT BATCH AREA Preset Exit Alarm OR PRESET 000,000 pcs. Exit TIME 00000.000 sec Exit OR ALARM 000,000 pcs.
FOLLOWER MODE OPERATOR DISPLAY OVERVIEW FOL 00000.000 cpm Parts Off Length OR OR SELECT PARTS AREA Total Exit Batch TOTAL 0,000,000 pcs. Off Exit Reset BATCH 000,000 pcs. Change Off Reset SELECT BATCH AREA Preset Exit Alarm OR PRESET 000,000 pcs. Exit LENGTH 00000.000 in. Exit OR ALARM 000,000 pcs.
AUTO DEMAND MODE OPERATOR DISPLAY OVERVIEW ATO 00000.000 in. Parts Off Length OR OR SELECT PARTS AREA Total Exit Batch TOTAL 0,000,000 pcs. Off Exit Reset BATCH 000,000 pcs. Change Off Reset SELECT BATCH AREA Preset Exit Alarm OR PRESET 000,000 pcs. Exit LENGTH 00000.000 in. Exit OR ALARM 000,000 pcs.
MULTIBLE PRESETS ENCODER MODE (EXAMPLE) OPERATOR DISPLAY OVERVIEW 1 ENC 00000.000 in. Parts Off Length SELECT PARTS AREA Total Exit Batch OR OR TOTAL 0,000,000 pcs. Off Exit Reset BATCH#1 000,000 pcs. Change Off Reset SELECT BATCH AREA Preset Exit Alarm SELECT BATCH PRESET Batch1 Batch2 Next OR SELECT BATCH PRESET Batch3 Batch4 Prev PRESET#1 000,020 pcs. Exit OR SELECT LENGTH PRESET Length3 Length4 Prev SELECT LENGTH PRESET Length1 Length2 Next OR LENGTH#1 00000.000 in.
FUNCTION AREA 1 OPERATOR DISPLAY OVERVIEW FUNCTION AREA 2 OPERATOR DISPLAY OVERVIEW (accessed by pressing the menu button) SELECT FUNCTION > Blade Test Mode < SELECT FUNCTION Min Parts CPM MEASURMENT DEPENDENT ON MODE DEPENDENT ON MODE SEE MODE OVERVIEWS CURRENT MIN LENGTH IS 0000.000 in. SELECT CUT MODE > Encdr Sense FlyWhl OR WHICH TEST OR BOTH DEPENDENT ON MODE DevCP 000.000 mS > Off Exit Reset OR < DevCC 000.
MAINTAINENCE AREA DISPLAY OVERVIEW (Accessed by pressing the menu button from Menu Area #1 and entering the correct password) SELECT MAINT. AREA Encdr Home P/M OR Select Encoder Area Drctn U/M Scale COUNT DIRECTION IS INCORRECT Change OFFSET +15.0 Deg Exit SELECT SCALE VALUE Dist. Exit Counts SELECT P/M AREA Inputs Time Cycles I1=Off I2=Off I3=Off I4=On I5=On I6=Off OR MACH. CYCLES 00000000 Exit OR OR POWER ON 00000.0 Hrs. Exit SEL.UNIT OF MEASURE In. Exit mm. ENTER DISTANCE PER COUNTS 12.
