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Troubleshooting
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Summary of Contents for Conair CTS 5
- Page 1 Traveling Saw CTS Models 5, 7 and 9 Installation Operation Maintenance Troubleshooting Instant Access Parts and Service (800) 458-1960 (814) 437-6861 www.conairnet.com The Conair Group, Inc. One Conair Drive Pittsburgh, PA 15202 Phone: (412) 312-6000 Fax: (412)-312-6227 UGE058/0803...
- Page 2 Volts Phase Cycle DISCLAIMER: The Conair Group, Inc., shall not be liable for errors contained in this User Guide or for incidental, consequential dam- ages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.
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Page 3: Table Of Contents
PERATION The Saw Control ....... .4-2 Machine Frame and Support System ....4-4 Blade Height Adjustment . - Page 4 Servo Instructions .......B-1 IAGRAMS This section has been provided for you to store spare parts lists and diagrams. CTS Saw ...5-1 UGE058/0803...
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Page 5: Introduction
...1-3 How to Use the Lockout Device ... .1-5 UGE058/0803 NTRODUCTION ....1-2 CTS Saw... -
Page 6: Purpose Of The User Guide
UIDE IS RGANIZED ESPONSIBILITY NTRODUCTION This User Guide describes the Conair CTS Saw and explains step-by-step how to install, operate, maintain and repair this equipment. Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety infor- mation in the instruction packet. -
Page 7: Attention: Read This So No One Gets Hurt
User Guide. DANGER: Sharp blades! Most injuries caused by knife blades occur when the saw has been turned off. Handle blades with care at all times. Always wear cut-resistant gloves when the blade guard is open and when handling blades. - Page 8 Improper grounding can result in severe personal injury and erratic machine operation. Always disconnect and lockout power before opening the electrical enclosure or performing non-routine procedures such as maintenance. CTS Saw UGE058/0803...
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Page 9: 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. To use the lockout device: Stop or turn off the equipment. -
Page 11: Description
How the CTS Saw Works ..2-3 CTS Saw Features ...2-5 Specifications ....2-6 Optional Equipment . -
Page 12: What Is The Cts Saw
CTS S YPICAL PPLICATIONS ESCRIPTION The Conair CTS Saw is an on- or off-line sawing device capa- ble of both on-demand and continuous cutting. Conair CTS Saws 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... -
Page 13: How The Cts Saw Works
The Conair CTS saws are designed for the inline cutting of profiles, pipe and tubing of a wide variety of sizes. Located as part of the extrusion line downstream of the extruder, the CTS performs five sequential functions in the cut operation as follows: 1. - Page 14 Cut pieces are col- lected on a dump table or carried away on a conveyor ESCRIPTION The CTS Saw models have these features: CTS Saw Extruded material enters the saw from the upstream side. (right-to-left operation)
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Page 15: Cts Saw Features
Hinged table guards for easy access to the clamps CTS Saw CTS S EATURES Self-contained table to reduce machine footprint and enhance safety with no moving parts extending past the base Access doors on both ends of the saw for easy maintenance. ESCRIPTION... -
Page 16: Specifications
‡ If the optional chip collection system is ordered, add 50 lbs. {22.7 kg} to to the installed and shipping weights. § The optional chip collection system adds 6 A on 230V models; 3 A on 460V models. UGE058/0803 TRAVELING CUT-OFF SAW CTS-5, CTS-7 AND CTS-9 CTS-5... -
Page 17: Optional Equipment
(highly recommended for proper operation) Left to right machine operation This options changes the machine direction from the standard right to left extrusion flow. Finer tooth blade for thin material and materials that are easy to fracture. UGE058/0803 PTIONAL QUIPMENT CTS Saw ESCRIPTION... -
Page 19: Installation
Unpacking the Boxes ..3-2 Preparing for Installation ..3-3 Positioning the CTS Saw ..3-4 Connecting the Main Power Source ... . .3-6 Installing the Encoder . -
Page 20: Unpacking The Boxes
NPACKING THE OXES NSTALLATION The CTS Saw comes fully assembled in a single crate. CAUTION: Lifting To avoid personal injury or damage to the saw lift the saw using a forklift or hoist with straps that have been positioned at the saw's center of gravity. -
Page 21: Preparing For Installation
All wiring should be completed by qualified personnel and should comply with your region’s electrical codes. Clearance for safe operation and maintenance. Make sure there is enough clearance around the saw for maintenance and servicing. WARNING: Improper installation, oper- ation, or servicing may result in equipment damage or personal injury. -
Page 22: Positioning The Cts Saw
CAUTION: Lifting To avoid personal injury or damage to the saw, lift the saw using a forklift or hoist with straps that have been positioned at the saw's center of gravity. Determine the best distance the CTS Saw. - Page 23 Use a plumb line or laser to check for a straight line from the extrusion die through each line component to the saw center line of the table. Adjust as necessary. UGE058/0803 OSITION THE CONTINUED...
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Page 24: Connecting The Main Power Source
ONNECTING OWER OURCE IMPORTANT: Always refer to the wiring diagrams that came with your saw before making electrical connec- tions. The diagrams show the minimum size main power cable required for your saw, and the most accurate electri- cal component information. -
Page 25: Installing The Encoder
CAUTION: Handle with care. The encoder is a delicate piece of equipment and must be handled gently. Conair uses bi-directional encoders to ensure that only product that moves forward is counted. Installing the encoder consists of sever- al parts: the encoder... -
Page 26: Installing The Saw Blades
Remove the hex nut. The blade is held on with a hex nut tightened on the motor arbor shaft. Based on either right to left or left to right saw operation, the hex nut will be either a left hand or right hand thread. -
Page 27: Preparing For Testing
Make a sample cut. motor and press the manual cut button. The saw should make one sample cut. If the saw is not working properly at any time, turn it off immediately and refer to the Troubleshooting section of this User Guide. -
Page 29: Operation
The Saw Control ... . .4-2 Machine Frame and Support System ....4-4 Blade Height Adjustment . -
Page 30: The Saw Control
IMPORTANT: Before applying power, ensure that the SAW BLADE UP and TABLE FORWARD valves are closed (fully clockwise), and that the saw blade is not installed on the cut-off saw. Connect the electrical line cord to a source of power com- patible with the nameplate on the saw cut-off saw. - Page 31 TABLE START micro-switch. Adjust the clamp pressure regulator to grasp the pro- file firmly. NOTE: Both the clamp pads and pressure can be adjusted so that the profile is not crushed. UGE058/0803 ONTROL EATURES CONTINUED CTS Saw PERATION...
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Page 32: Machine Frame And Support System
The saw blades are mounted to and driven by a 3500 RPM arbor motor. This motor is mounted on a pivot assembly, which guides and secures the saw blade through the cutting process. -
Page 33: Upper Clamp Adjustment
Make sure the power is grounded through the power cable to the plant electrical ground. The operator control panels are located on the front of the saw frame. The pneumatic control panel is located to the left of the operator controls platform. -
Page 34: Pneumatic Cylinder Operation
Incoming pressure should be set at approximately 65 PSI. Maximum pressure is 70 PSI. IMPORTANT: This unit should always be supplied with clean dry air. Incoming pressure should be set at approximately 65 PSI. Maximum pressure is 70 PSI. CTS Saw Manual UGE058/0803... -
Page 35: Electrical Operation
The operation of the saw consists of an automatic sequence of events. To start the saw the main power must be on and the appro- priate air supply to the machine. With the power on, the control panel will have the power on light illuminated. -
Page 36: Machine Lubrication
They should be visually inspected for wear and replaced as necessary. - Saw Track Rollers- The steel cam rollers that the saw motor carriages travel on, will after time, begin to wear from the constant contact with the saw tracks. They should be visually inspected for wear and replaced as necessary. - Page 37 Remove the hex nut. The blade is held on with a hex nut tightened on the motor arbor shaft. Based on either right to left or left to right saw operation, the hex nut will be either a left hand or right hand thread.
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Page 38: Chip Collection Shrouds And Blower Connection
Conair’s optional vacuum system. WARNING: If you did not purchase a Conair dust collec- tion system you must connect a customer supplied dust collector. Failure to do so may result in a fire hazard! -
Page 39: Maintenance
Schedule ....5-4 Checking the Blades ..5-6 Checking Electrical Connections ....5-7 UGE058/0803 AINTENANCE CTS Saw... -
Page 40: Maintenance Features
Use this maintenance schedule as a guide. You may need to shorten the time of the maintenance schedule, depending on how often you use the saw, and the types of material flowing through it. Follow all precautions and warnings when working on the equipment. - Page 41 DANGER: Sharp blades! Most injuries caused by saw blades occur when the saw has been turned off. Handle blades with care at all times. Always wear cut-resistant gloves when the blade guard is open and when handling blades.
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Page 42: Maintenance Overview
Inspecting saw alignment Proper saw alignment is critical for optimum perfor- mance. Use a plumb line or laser to check for a straight line from the extrusion die to the saw bush- ings. Check floor locks It is always recommended that the weight be removed from the casters for optimum stability during cutting cycles. - Page 43 Quarterly Blow or vacuum, dust and chips from the inside the saw. Remove all dust and chips from inside all control cabinets. Remove any excess oil from the pneumatic enclosure. Verify that all electrical terminals are tight.
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Page 44: Checking The Blades
(see Installing Saw Blades). DANGER: Sharp blades! Most injuries caused by knife blades occur when the saw has been turned off. Handle blades with care at all times. Always wear cut-resistant gloves when the blade guard is open and when handling blades. -
Page 45: Checking Electrical Connections
Turn the main power disconnect to the off position before opening the electrical enclosure on the back of the saw or the back of the control. This is a safety device to prevent you from opening the doors if the power is still on. - Page 46 CTS Saw . Look for loose Cords should...
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Page 47: Uge058/0803 Cts Saw
Cause of a Problem ..6-3 Electrical Problems ..6-4 Product Quality Problems ..6-5 Checking the Servo Amplifiers .6-7 Checking the Encoder ..6-8 UGE058/0803 CTS Saw... -
Page 48: Before Beginning
Check that you have manual for other equipment connected in the system. Troubleshooting may require investigating other equipment attached to, or connected with the saw. WARNING: Improper installation, oper- ation, or servicing may result in equipment damage or personal injury. -
Page 49: Identifying The Cause Of A Problem
Operating without these devices can cause severe injury. The Troubleshooting section covers problems directly related to the operation and maintenance of the saw. This section does not provide solutions to problems that originate with other equipment. Additional troubleshooting help can be found in manuals supplied with the other equipment. -
Page 50: Electrical Problems
LECTRICAL ROBLEMS Symptom Saw will not start Saw blade runs backwards ROUBLESHOOTING 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. -
Page 51: Product Quality Problems
RODUCT UALITY ROBLEMS Solution Re-align the product guides. Insure that the rear guide is square with the saw blade and tighten. Adjust the front guide accordingly allowing enough clearance for smooth product passage. Adjust speed control for blade feed into part (slower) Investigate blade choice for the application. - Page 52 Check encode or input device Check puller for drive consis- tencies or any belt to product slippage. Check cut length counter Check rubber saw clamps for wear and replace as necessary Clean roller ways Check and clean rodless cylin- Check table actuation solenoid...
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Page 53: Checking The Servo Amplifier
This display shows amplifier status and error mes- sages. Refer to the supplier's documentation included with this User Guide. NOTE: Make sure you look for servo amplifier messages before you shut off the power. UGE058/0803 HECKING THE ERVO MPLIFIER CTS Saw ROUBLESHOOTING... -
Page 54: Checking The Encoder
WARNING: Delicate equipment The encoder is a delicate piece of equipment. Any rough handling can damage fragile parts. If all else fails, contact Conair Customer Service. See Appendix page A-1. CTS Saw If neces- There should be no play... -
Page 55: Before You
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. -
Page 56: Appendix
(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 deter- mined by us to be defective after examination. - Page 57 Operator Control Instructions The Operator Control provides an intuitive user-friendly method to interface with the Conair Servo Traveling Saw. Information is viewed and entered at the Operator Control and is communicated to the servo positional amplifier via the RS-232 serial communication link.
- Page 58 Conair Servo Traveling Saw Operator Control Instructions Numeric keys These are the black keys containing numbers 0 to 9. Numbers permit data entry of parameters. See Raise and Lower for value trim. Fixed Function Keys (at Bottom) Underneath the numeric keys are fixed function keys. They contain universal symbols and text.
- Page 59 Conair Servo Traveling Saw Operator Control Instructions Contents Page 4 ...Power up Sequence Page 5 ...Main Screen – Length Counter ...Count On/Off Page 6 ...Total ...Total Reset ...Total On/Off Page 7 ...Length Preset ...Total Reset Page 8 ...Homing Page 9 ...Home Already...
- Page 60 If there are any problems with communications, this screen will remain on longer than a couple of seconds. If there are no communication problems the Conair Servo Traveling Saw program will begin to run. The following C O N A I R S E R V O S A W V e r s i o n 1 .
- Page 61 If a negative symbol is shown to the left of the count value, the encoder signal is reversed, i.e. rotating in the wrong direction. The Saw will not function while the encoder is going negative. It is possible to correct this by using the Direction function on the Maintenance Area page found in the Menu area.
- Page 62 Conair Servo Traveling Saw Operator Control Instructions Total Softkey By pressing the soft key located under the word Total on the Main Screen, a six-decade total counter is available. T O T A L 0 0 0 , 0 0 0 p c s .
- Page 63 Conair Servo Traveling Saw Operator Control Instructions Length Softkey By pressing the soft key located under the word Length on the Main Screen, the preset for the Length counter is available. L E N G T H 0 0 0 0 . 0 0 0 i n .
- Page 64 There are two kinds of home sequence, home seek and home already. Home Seek If the saw table has been stopped away from the home location and the power to the machine switched off, upon reapplying power, the first motion will be a home seek.
- Page 65 After this, motion is similar to the previous description. After a successful home has been completed, if the saw is stopped and the power to the machine is left on, the table position is still known. When the saw is restarted, the table will return at the cut cycle, table return speed.
- Page 66 Conair Servo Traveling Saw Operator Control Instructions MENU AREA S E L E C T M E N U M a i n t . Menu function key is used to access the various Menu areas. There are two menus Maint. and Factory, with access via password to various sub-menus.
- Page 67 Conair Servo Traveling Saw Operator Control Instructions Maint. Area There are three sub-menus, Dirctn, P/M, and Table accessible in the maintenance area. S E L E C T M A I N T . A R E A D i r c t n...
- Page 68 Conair Servo Traveling Saw Operator Control Instructions P / M S o f t k e y Pressing the soft key located under the word P/M on the Maint. area screen. Selects the P/M area screen. Two preventive maintenance sub-menus, Time and Cycles can be displayed.
- Page 69 Conair Servo Traveling Saw Operator Control Instructions Cycles Softkey Pressing the soft key located under the word Cycles on the M A C H . C Y C L E S 0 0 0 0 0 0 0 0 E x i t P/M area screen, selects the machine cycles screen.
- Page 70 Conair Servo Traveling Saw Operator Control Instructions R e t u r n S o f t k e y Pressing the soft key located under the word Return on the E N T E R T A B L E R E T U R N S P E E D 1 2 0 0 .
- Page 71 Conair Servo Traveling Saw Operator Control Instructions A d v a n c e S o f t k e y Pressing the soft key located under the word Advance on the Table area screen. Selects the Table Advance Speed screen.
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Page 72: Error Message
C O U L D N ’ T C O M P L E T E C U T I N S A F E D I S T A N C E The saw will continue to attempt making cuts, but parts will not be added to the total. - Page 73 Product: Saw CTS-5 REV #: 023525L020/0703 Instruction Manual: Assembly / Part Number (s) Reference Part Number Number General 26682401 191-668-1105 Blades Opt. 2667760103 Table Assembly, Pneumatic / Servo 26678001 29031102 26676701 26677901 29037407 26677301 29031102 29120631 2990151001 29901930 * Indicates recommended spare parts | > Indicates revisions change | Italicized indicates typographical...
- Page 74 Reference Part Number Number Servo Opt. / Table Travel 20974117 29051011 29908007 2905320340850 29053632 2905320400850 29053631 2905320640850 29053633 2905338800850 29053322000850 26671748 26671810 26676901 26667660101 315-165-1012 315-167-3007 315-163-2017 315-167-2129 315-167-3013 266-766-02 315-170-1001 26635304 1545-30096 71301811 17302403 * Indicates recommended spare parts | > error TO ORDER PARTS CALL TOLL FREE (800) 458-1960 Product:CTS-5...
- Page 75 Reference Part Number Number Electrical Control, 3hp 230/460v (7140360201) 27500675 27501514 20973414 27500202 27500923 27500109 20801476 20801459 26671601 26671602 1605-30000 1608-30000 26666702 230 Volt 27501510 20604012 1646-30192 * Indicates recommended spare parts | > error TO ORDER PARTS CALL TOLL FREE (800) 458-1960 Product: CTS-5 REV #: 023525L020/0703 Instruction Manual:...
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