Servo Knife Cutters CSC Models 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 CSC 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 wear cut-resistant gloves when the cutting chamber is open and when handling blades.
ATTENTION: READ THIS SO NO ONE GETS HURT WARNING: Voltage Hazard This equipment is powered by high voltage alternating current, as specified on the machine serial tag and data plate. 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 Servo Knife Cutter? . . . . . . . . . . . . . .2-2 ● Typical Applications . . . . . . . . . .2-3 ● How the Servo Cutter Works . . .2-4 ● Servo Cutter Features . . . . . . . .2-6 ● Specifications . . . . . . . . . . . . . .2-7 ● Optional Equipment . . . . . . . . . .
WHAT IS THE SERVO KNIFE CUTTER? 2-2 DESCRIPTION The Conair CSC Series Servo Knife Cutter is an on- or offline cutting device capable of both on-demand and continuous cutting modes. CSC cutters utilize a positional-controlled servo motor to achieve cut-to-part position repeatability within 0.1 millisecond.
Conair CSC Series Servo Knife Cutters can cut extrudable plastics and rubber both on- and off-line. Other extrudable materials-foods, ceramics, magnets, soaps, etc.-may also be cut depending on specific application requirements. TYPICAL APPLICATIONS CSC cutters are available with different cutting capacities (2, 3, 4, and 5 inches) to suit your specific needs. The servo motor size and cutter head material may also be optimized for specific applications.
HOW THE SERVO CUTTER WORKS Extruded material that has been sized and cooled enters the cutter from the upstream side (see How the Servo Cutter Works continued, 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. 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 SERVO CUTTER WORKS CONTINUED The cutter head holds 2 the blade(s) as they rotate and pass between the bushings, cutting the extrudate. Cut pieces are collected or 1 carried away on a conveyor. Extruded material enters the 3 cutter from the upstream side.
SERVO CUTTER FEATURES The CSC Servo Cutter models have these features: Eye-level Control Servo motor and in-line planetary gear reducer Hinged and interlocked stainless steel blade cover Cutter head with blade(s) as seen through clear viewing panel Stainless steel blade lubrication tray Material inlet through cutter bushings Swivel casters and lock down screws 2-6 DESCRIPTION CSC Servo Knife Cutters UGE047/1003
SPECIFICATIONS A B D C MODELS CSC2L Performance characteristics Extrudate capacity, in. {mm} dia. 1.25 {318} Blade drive motor, Hp {kW} 2.7{1.86} High torque motor* N/A Feed direction right->left Dimensions in. {mm} A - Height 63 {1600} B - Height to centerline 42 ± 2 40 {1016} C - Width 36 {914} D - Depth 24 {614} Weight lbs. {kg} Installed 600 {272} Shipping 700 {317} Total Amps for Volt/phase/Frequency 230V/1/60Hz 16.6A 208V/1/60Hz* 18.3A 460V/1/60Hz* 8.3A 575V/1/60Hz* 6.
OPTIONAL EQUIPMENT Cutting torque upgrades Several options can be used to increase the cutting torque: ● CSC-2 and 3 cutters can be upgraded from a 2.7 HP (MGE-455) to a 3.8 HP (MGE-490) servo motor. (The larger servo motor is standard on CSC-4 and 5 cutters.) ● The standard aluminum cutter-head can be replaced with a heavier stainless steel one. When this option is picked, the maximum number of cuts per minute decreases from 400 to 200. Inertia, and thus cutting torque, is increased significantly.
Blade Wipe The blade wipe system keeps the cutting blade clean by removing lubricant and particles from the blade. A felt pad sandwiched between two pieces of stainless steel and mounted in the stainless steel blade lubrication tray wipes the knife before each cut.
OPTIONAL EQUIPMENT Discharge Conveyor A discharge conveyor offers support before, during, and after cutting, and facilitates the removal of cut parts. Discharge conveyors are available in the following sizes: ● 6 inches wide by 6 feet long ● 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.
INSTALLATION ● Unpacking the Boxes . . . . . . . . .3-2 ● Preparing for Installation . . . . . .3-3 ● Positioning the Servo Cutter . . .3-4 ● Connecting the Main Power Source . . . . . . . . . . . . .3-6 ● Installing the Encoder . . . . . . . .3-7 ● Installing the Cutter Blades . . . . . . . . . . . . . . . . . . .3-8 ● Mounting the Cutter Bushings . . . . . . . . . . . . . . . . .3-9 ● Checking Repeatability . . . . . .3-10 ● Preparing for Testing . . . . . . . . .3-11 ● Testing the Installation . . . . .
UNPACKING THE BOXES The CSC 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. Cutter 2 Determine the best distance from the belt puller to the CSC cutter. ● For flexible products, the cutter should be as close as possible to the puller.
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. 5 Adjust the cutter's floorlock/caster assembly 6 Use a plumb line or laser to check for a straight line from the extrusion die through each line to the center height of the extrusion line using a 16- or 18-inch adjustable wrench.
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.
INSTALLING THE CUTTER BLADES 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 completely stopped before opening the knife guard. CSC cutters are equipped with several safety devices to ensure safe operation.
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 2 Slide the downstream bushing into position, in the gap between where the bushings go. positioning it up to and barely touching the blade (use feeler gauge). NOTE: the blade should not be deflected.
CHECKING REPEATABILITY 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 Less than 1 millisecond Less than 1.
1 Make sure all components are installed according 2 Check that the cutter is firmly locked into posi- 3 Check that all wiring conforms to electrical codes, and all wiring covers are in place. 1 Turn on the main disconnect. Plug in the main power cord and turn on the main disconnect. The display should fully illuminate and bootup. The amber power on light illuminates. 2 Check that the E-Stop button is in the out, extended position. NOTE: If the E-Stop button is to assembly drawings.
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. WARNING: Be sure that power to the servo 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. 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 inch 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 trouble shooting 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 CHECKING CUT QUALITY at the preset blade speed. (This works even if Cut On/Off is off.) 4 Inspect the cut. If necessary, adjust the blade design 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 (CSC only) ● 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 SERVO 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 CSC models need 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. 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.
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 (See Cleaning the Blade Tray, Section 5). ❒ Lubricating shafts on optional slide rail system (See Lubricating the Slide Rail System, 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. Adjust as needed.
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. Check the latch and adjust it so the knife guard closes completely. This prevents false triggering of the safety switch.
CLEANING THE BLADE TRAY 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 knife guard 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 cutter is locked out. 2 Loosen the set screws that hold the cutter bushings. 3 Remove the cutter bushings. 4 Check the depth of the proximity switch ADJUSTING THE PROXIMITY SWITCHES 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 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 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. 5 6 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.
CHECKING TORQUE The Trantorque coupling device connects the servo motor to the cutter head. It is important that it is tightened to the proper torque. WARNING: No lubricants! Use no lubricants on the Trantorque coupling device. 1 Carefully remove the cutter blade. 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 has stopped completely.
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 UGE047/1003 . . . . . .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. CSC cutters are equipped with several safety devices to ensure safe operation.
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 ◆ Servo drive is The E-stop button is pushed in. Pull out the E-stop button. Master safety relay not energized Check to see if: without power ❒ Bushings are in place. ❒ The blade guard is closed. ❒ Master Safety relay (ISC) has failed.
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 and stops in wrong position. ◆ Master safety relay does not energize. ❒ The bushings are in place ❒ The blade guard is closed. ❒ Loose connection to guard circuit. Tighten connection. ❒ Guard switch is bad. Replace switch.
ELECTRICAL PROBLEMS CONTINUED Symptom Possible cause Solution ◆ In encoder or There is a problem with the servo amplifier. See Checking the Servo Amplifier. There is a loose connection. Check wiring for loose connections. timer modes, the display shows the count which resets, but a cut does not occur at the point of reset. ◆ Blade speed does There is a communication Check for wiring for loose connections and tighten. not change when new speed is entered into the control.
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 ◆ Hairs or strings. Blade speed is too low. Solution 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 6-8 Symptom Possible cause Solution ◆ Burrs at cut site. The bushings are not providing enough support during cutting. Change bushing design to make them more supportive. The bushing gap is too wide. The bushing gap should be no more than .001-.003 inches 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. UGE047/1003 The cutting blade is too sharp.
PRODUCT QUALITY PROBLEMS CONTINUED 6-10 Symptom Possible cause Solution ◆ Cut is not square. 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. Check and adjust if necessary.
Three safety switches are included in CSC 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.
ADJUSTING THE PROXIMITY SWITCHES 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 knife guard. 2 Locate the 5/16 inch thread rod on the cutter head. It should be 0.010 inch from the proximity switch sensor when it passes that location. If necessary, loosen the jam nuts, readjust the distance, and re-tighten the jam nuts.
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 neces- 3 Check the connector that attaches the cable to the encoder. Internal wiring may be shorted out if this CHECKING THE ENCODER sary, replace. connector is not handled properly. 4 Check the encoder itself. There should be no play in the shaft. WARNING: Delicate equipment The encoder is a delicate piece of equipment.
CHECKING THE MOTOR/REDUCER ASSEMBLY 6-14 TROUBLESHOOTING 1 2 Open the knife guard. 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. Remove the cutter head by loosening the Trantorque assembly. Refer to the manufacturer's guide included with this User Guide for information about the Trantorque assembly. assembly to the cutter.
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 Less than 1 millisecond Less than 1.5 millisecond Less than 0.
RESULTS OF REPEATABILITY TESTING 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.
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. You can calculate blade interruption for your application if you know: ● the cutting blade width ● blade speed (cutter rpm) ● extrudate cross section.
CUTTER BLADE SELECTION AND USE To calculate interruption time: (0.937 in. + 0.250 in.) X 60,000msec/rev = 2.25msec 44 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. 2.25msec X 60 fpm X 0.0002 = 0.
CONAIR CUTTER BLADES Part No. Blade Type Bushing Size Blade Blade Thickness Material 3515-02285 3515-00975 Razor Razor 2 inch* 2 inch* 0.015 in. 0.025 in. Stainless Steel Stainless Steel 3515-30088 3515-30096 3515-30104 3515-30016 Straight Straight Straight Straight 2 2 2 2 inch inch inch inch 0.010 0.015 0.020 0.025 in. in. in. in.
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.
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. Tubing may develop two distinctive marks related to the compression of the tube.
BLADE AND BUSHING LUBRICATION 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.
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 CONTINUED 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 fill
