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Conair Sure Cut Rotary Knife Cutter SC-5 User Manual

Sure cut rotary knife cutter
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Sure Cut Rotary Knife Cutter
SC-5 Servo Model
The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: (412) 312-6000
Fax: (412)-312-6227
UGE059/1003

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Summary of Contents for Conair Sure Cut Rotary Knife Cutter SC-5

  • Page 1 Sure Cut Rotary Knife Cutter SC-5 Servo Model Installation Operation Maintenance Troubleshooting The Conair Group, Inc. Instant Access One Conair Drive Parts and Service Pittsburgh, PA 15202 (800) 458-1960 Phone: (412) 312-6000 (814) 437-6861 Fax: (412)-312-6227 www.conairnet.com UGE059/1003...
  • 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.

  • Page 3: Table Of Contents

    ....1-1 NTRODUCTION ABLE OF Purpose of the User Guide ......1-2 ONTENTS How the Guide is Organized .
  • Page 4 Calculating Blade Interruption ..... .B-4 Conair Cutter Blades ......B-6 All About Cutter Bushings .

  • Page 5: Introduction

    NTRODUCTION 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 .

  • Page 6: Purpose Of The User Guide

    This User Guide describes the Conair SC-5 Sure Cut Servo URPOSE OF Knife Cutter and explains step-by-step how to install, operate, maintain and repair this equipment. Before installing this product, please take a few moments to UIDE 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

    We design equipment with the user’s safety in mind. You can ATTENTION: avoid the potential hazards identified on this machine by fol- lowing the procedures outlined below and elsewhere in the EAD THIS SO NO User Guide. ONE GETS HURT DANGER: Sharp blades! Most injuries caused by knife blades occur when the cutter has been turned off.

  • Page 8: How To Use The Lockout Device

    WARNING: Voltage Hazard ATTENTION: This equipment is powered by three-phase alternating current, as specified on the machine EAD THIS SO NO serial tag and data plate. ONE GETS HURT A properly-sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electri- cal enclosure.

  • 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: Uge059/1003 Sc-5 Sure Cut Servo Knife Cutter

    ESCRIPTION What is the SC-5 Sure Cut Knife Cutter ....2-2 Typical Applications ..2-4 How the SC-5Works ... 2-5 SC-5 Features .

  • Page 12: Escription

    The Conair SC-5 Sure Cut Series rotary knife cutter has been HAT IS THE designed to be “The most versatile cutter of the industry”. SC-5 S 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.
  • Page 13 The larger diameter flywheel used on the servo cutter offers HAT IS THE the potential of higher surface speeds at dramatically lower SC-5 S 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 dri- ven clutch\brake cutter is eliminated.

  • Page 14: Typical Applications

    The optional slide system can enable the use of rigids and flexibles. To get the full benefit from the servo cutter Conair has provid- ed several cutting modes, see Cutter Control, Section 4. The Conair SC-5 Sure Cut servo rotary knife cutter is a truly inno- vative cutter.

  • Page 15: Sure Cut Features

    Extruded material that has been sized and cooled enters the SC-5 OW 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.
  • Page 16 SC-5 OW THE ORKS ONTINUED Cut pieces are collected or carried away on a conveyor. Extruded material enters the cutter from the upstream side. The cutter head holds the blade(s) as they rotate and pass between the bushings, cutting the extrudate.

  • Page 17: Specifications

    The SC-5 Sure Cut Servo Cutter features: SC-5 EATURES Parts discharge chute or Wide Range of Cutter optional discharge conveyor Bushing Capacities 24-inch diameter fly- wheel with multiple blade mounting system Polycarbonate blade observation window Optional blade lubrication system The standard control: Large easy-to-read display.

  • Page 18: Optional Equipment

    Slide Base PTIONAL This option is highly recommended for cutting flexible extru- dates. While the cutter base is fixed and aligned with the QUIPMENT 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.
  • Page 19 This option changes the machine direction from the standard right to left extrusion flow. Special Paint Type or Color This option covers any change from the standard Conair paint. Your Conair sales representative can analyze your needs and recommend the options that are right for your system.

  • Page 21: Installation

    INSTALLATION Unpacking the Boxes ..3-2 Preparing for Installation ..3-3 Positioning the SC-5 Sure Cut ....3-4 Connecting the Main Power Source .

  • Page 22: Unpacking The Boxes

    The SC-5 Sure Cut Series Servo Knife Cutter comes fully NPACKING THE assembled in a single crate. OXES CAUTION: Lifting To avoid personal injury or damage to the cut- ter, lift the cutter using a forklift or hoist with straps that have been positioned at the cutter's center of gravity.

  • Page 23: Preparing For Installation

    REPARING FOR You need these tools for installation: NSTALLATION 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 Plan the location. Make sure the area where the servo cutter is installed has the following: A grounded power source.
  • Page 24 OSITIONING Move the servo cutter into position. Place the servo cutter in position downstream of the belt puller. ERVO CAUTION: Lifting UTTER To avoid personal injury or damage to the cut- ter, lift the cutter using a forklift or hoist with straps that have been positioned at the cutter's center of gravity.

  • Page 25: Positioning The

    OSITIONING Align the cutter with the extrusion line. ERVO UTTER CONTINUED 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.

  • Page 26: Connecting The Main Power Source

    WARNING: Electrical hazard ONNECTING Before performing any work on this product, dis- connect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provid- OWER OURCE ed to isolate this product from potentially haz- ardous electricity.

  • Page 27: Installing The Encoder

    NSTALLING THE The encoder is a delicate piece of equipment and must be handled gently. NCODER 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 28: Installing The Cutter Blades

    DANGER: Sharp blades! NSTALLING THE Most injuries caused by knife blades occur when the cutter has been turned off. Handle UTTER blades with care at all times. Always lock out power to the cutter before LADES opening the cutting chamber. Always wear cut-resistant gloves when the cutting chamber is open and when handling blades.
  • Page 29 TIP: We recommend that you: NSTALLING THE Apply some protective cover on the portion of UTTER the blade you are handling, such as masking tape to help prevent getting cut during installation and to LADES leave it on until such time that you will start and check the cutting operation.

  • Page 30: Mounting The Cutter Bushings

    DANGER: Sharp blades! OUNTING THE Always wear cut-resistant gloves when the cut- ting chamber is open and when handling UTTER blades. Never open cutting chamber without locking out the cutter power and waiting until USHINGS 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 con-...
  • Page 31 Checking the Alignment of bushing to blade HECKING THE LIGNMENT OF Once you are sure that the blade will easily clear the bush- ings as it goes through the space you should then make USHINGS some test cuts to insure quality. Close the safety cover.

  • Page 32: Checking Repeatability

    Before any Conair SC-5’s are shipped, they are tested for cut HECKING time repeatability to be sure they are within performance spec- ifications. The repeatability test checks the performance of the EPEATABILITY rotary knife cutter to return to the home park position after a complete cut.

  • Page 33: Preparing For Testing

    Make sure all components are installed according REPARING FOR to assembly drawings. Make sure that all bolts on the cut- ter have been tightened. ESTING Check that cutter is firmly locked into position with the anchoring screws. Check that all wiring conforms to electrical codes , and all wiring covers are in place.

  • Page 35: Operation

    PERATION The Cutter Control ...4-2 Before Starting ....4-3 Powering Up ....4-3 Main Screen .
  • Page 36 The Operator Control provides an intuitive user-friendly PERATOR method to interface with the Conair Servo Cutter. Information is viewed and entered at the Operator Control and is commu- ONTROL nicated to the servo positional amplifier via the RS-232 serial communication link.

  • Page 37: Before Starting

    Before you start daily operation of the servo cutter, you need EFORE to perform preventative maintenance. Necessary maintenance is described in the Maintenance section of this Users Guide, TARTING see preventative maintenance, Section 5. WARNING: Be sure that power to the SC-5 cutter is OFF when doing any maintenance on the servo cutter.

  • Page 38: Powering Up

    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 SC-5 Cutter program will begin to run. The following message or similar shows for 5-seconds.

  • Page 39: Main Screen

    MAIN SCREEN PERATOR There are two types of main screens, length or time measure- ment and cuts per minute measurement. The type displayed ONTROL varies depending on the current cut mode setting. See the mode operator display overviews. NSTRUCTIONS CREEN The Main Screen has seven features.
  • Page 40 Menu function key is used to access the Menu Area. ONTROL This area can only be accessed from the main display screen for each mode. See the Menu Area section for more NSTRUCTIONS 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.

  • Page 41: Total Screen

    Reset Softkey3 ONTROL Under the counter, on the right is a soft key labeled Reset. NSTRUCTIONS Pressing this key will zero the counter. EXIT or PREV, fixed function keys return the display to the OTAL CREEN Parts Select screen. CONTINUED BATCH SCREEN ONTROL By pressing softkey3 located under the word Batch on the...
  • Page 42 Batch Select Area Screen ONTROL Under the batch counter, on the left is a soft key labeled Change. Pressing this key displays the Select Batch Area NSTRUCTIONS screen. Additional information on how to access this screen can be found in the operator display overview in Appendix E ATCH of this manual.

  • Page 43: Batch Screen

    Numeric keys ONTROL 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. NSTRUCTIONS Enter or Delete? ATCH If the keyed in number is correct press the enter key for it to be accepted and return to the Main screen.

  • Page 44: Preset To Run

    ONTROL Exit or Prev, if no change is required press Exit or Prev to return to the Main screen. NSTRUCTIONS Raise will increase the preset by 0.010 inch. The key can be ENGTH pressed once for each 0.010 inches increment required or held down to scroll up.

  • Page 45: Preset To Run

    Exit or Prev, If no change is required press Exit or Prev to ONTROL return to the previous Length Screen. NSTRUCTIONS Raise will increase the number by 1. The key can be pressed once for each increment of 1 required or held down to scroll RESET TO up.
  • Page 46 Raise will increase the preset by 0.010 second. The key can ONTROL be pressed once for each 0.010 second increment required or held down to scroll up. Releasing the key will freeze the pre- NSTRUCTIONS set at the last value then press enter. CREEN Lower will decrease the preset by 0.010 second.
  • Page 47 Raise will increase the preset by 0.010 second. The key can ONTROL be pressed once for each 0.010 second increment required or held down to scroll up. Releasing the key will freeze the pre- NSTRUCTIONS set at the last value then press enter. Lower will decrease the preset by 0.010 second.

  • Page 48: Blade Speed

    Raise will increase the preset by 1.0. The key can be pressed ONTROL once for each 1.0 increment required or held down to scroll NSTRUCTIONS up. Releasing the key will freeze the preset at the last value then press enter. LADE PEED Lower will decrease the preset by 1.0.

  • Page 49: Function Areas

    Raise will increase the preset by 1. The key can be pressed ONTROL once for each 1 increment required or held down to scroll up. Releasing the key will freeze the preset at the last value then NSTRUCTIONS press enter. LADE OUNT Lower will decrease the preset by 1.
  • Page 50 Next or Prev, Pressing Next selects the second Function Area. ONTROL Pressing Prev returns the display to the first Function Area screen. Pressing Prev from the first Function Area screen NSTRUCTIONS returns the display to the active main mode screen. UNCTION Menus are a convenient way to access and monitor parameters that do not need to be altered often, i.e.
  • Page 51 Next, Pressing Next selects the DevCC test if available. If the ONTROL arrow on the top right hand side of the screen is visible the current mode also supports the DevCC test. NSTRUCTIONS NOTE: The test available DevCP, DevCC or both is dependent on the active cut mode.

  • Page 52: Cut Mode

    Mode Softkey ONTROL By pressing the soft key located under the word Mode, the dif- ferent Cut Modes are available. There are two Cut Mode NSTRUCTIONS screens. The first screen provides choices for the standard- modes available on all cutters. SELECT CUT MODE >...
  • Page 53 Min Softkey ONTROL By pressing the soft key located under the word Min on the second Function Area Screen, the Minimum allowable mea- NSTRUCTIONS surement value is displayed. The active mode and the INIMUM EASUREMENT cuts per minute limit for the model of cutter determines the actual value displayed.

  • Page 54: Maintenance Area

    ONTROL Menus are a convenient way to access and monitor parameters that do not need to be altered often, i.e. home position, NSTRUCTIONS encoder direction, scale or unit of measure. In addition, pre- ventive maintenance parameters can be monitored for trouble- NCODER shooting and scheduling purposes.
  • Page 55 Encdr Softkey ONTROL By pressing the soft key located under the word Encdr on the Maint. Area Screen, there are three sub-menus, Drctn, U/M, NSTRUCTIONS and Scale accessible. Additional information on how NCODER ONTINUED to access this screen can be found in the Maintenance Area of the operator display overview section of this manual.

  • Page 56: Unit Of Measure

    If a negative symbol is shown to the left of the count value on ONTROL the main mode screen the encoder signal is reversed, i.e. rotat- NSTRUCTIONS ing in the wrong direction. The Cutter will not function while the encoder is going negative. The Direction function corrects NCODER IRECTION this by changing what the servo drive interprets as a positive...

  • Page 57: Scale Distance

    DISTANCE SOFTKEY ONTROL By pressing the soft key located under the word Dist. on the NSTRUCTIONS Scale Value Screen, the scaled distance is available. This value must be set after a U/M change. Additional information on CALE how to access this screen can be found in the Maintenance Area of the operator display overview in Appendix E of this ISTANCE manual.
  • Page 58 ONTROL COUNTS SOFTKEY By pressing the soft key located under the word Counts on the NSTRUCTIONS Scale Value Screen, the scaled counts are available. Additional information on how to access this screen can be found in the CALE OUNTS Maintenance Area of the operator display overview in Appendix E of this manual.

  • Page 59: Homing

    HOMING ONTROL A defined Home location is required for all servo-positioning applications. After initial power up, emergency stop or guard NSTRUCTIONS opened, home position must be found. All motion is relative to this home position. The Home cycle occurs once after power OMING is applied to the servo drive in response to the Start push but- ton being pressed.

  • Page 60: Offset Example

    ONTROL 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 NSTRUCTIONS 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 FFSET once for each 1.0 decrement required or held down to scroll down.
  • Page 61 ONTROL PREVENTIVE MAINTENANCE SOFTKEY Pressing the soft key located under the word P/M on the NSTRUCTIONS Maint. area screen. Selects the P/M area screen. Three pre- ventive maintenance sub-menus for monitoring Inputs, Time REVENTIVE and Cycles are displayed. MAINTENANCE 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.

  • Page 62: Power On Time

    ONTROL TIME SOFTKEY Pressing the soft key located under the word Time on the NSTRUCTIONS P/M area screen, selects the Power-On time screen. OWER The Power-On time screen displays the total time in hours that the machine has had the power switched on. This infor- mation could be used for scheduling preventive maintenance.

  • Page 63: Checking Cut Quality

    HECKING Press the manual cut button and observe the movement of the cutter blade. The cutter head makes a UALITY single rotation and the blade moves through the cutter bushings without interference. Insert a piece of extrudate through the cut- ter bushings.

  • Page 64: Making Adjustments During Operation

    AKING There are several adjustments you can make during normal cutting. These adjustments include: DJUSTMENTS In Timer mode, adjust the time between cuts URING In Encoder and Follower modes, adjust the length PERATION In Product mode, adjust the hold-off time In Flywheel mode, adjust blade speed Adjust blade speed in all modes except Follower...
  • Page 65 WARNING: Never stop the servo cut- TOPPING THE ter by opening the knife guard. SC-5 C This can cause damage to the equipment and UTTER injury to personnel. Use this procedure to safely stop the servo cutter: Press Cut On/Off soft key to stop cutting (soft key text changes to off).

  • Page 67: Maintenance

    AINTENANCE Maintenance Features ..5-2 Warnings and Cautions ..5-2 Maintenance Overview ..5-4 Preventative Maintenance Schedule ....5-4 Checking the Blades .

  • Page 68: Maintenance Features

    The Servo Cutter SC-5 Sure Cut models needs regular, sched- AINTENANCE uled maintenance for peak performance. Among the features that require maintenance are: EATURES 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...
  • Page 69 WARNING: Voltage Hazard ARNINGS AND This equipment is powered by alternating cur- rent, as specified on the machine serial tag and AUTIONS data plate. Do not operate the equipment at power levels other than what is specified on the ONTINUED machine serial tag and data plate.

  • Page 70: Maintenance Overview

    This section describes the daily, weekly, monthly and semi- AINTENANCE annual maintenance schedules that should be performed when changing materials or lines, or when changing equipment, as VERVIEW well as the maintenance procedures to follow. Cutting either flexible or rigid materials generates tremendous shock and vibration to the entire unit.
  • Page 71 Weekly REVENTATIVE Cleaning the blade lubrication tray (if the cutter this option). See Cleaning the Blade Tray, AINTENANCE Section 5. Lubricating shafts on optional slide rail system CHEDULE See Cleaning the Blade Tray, Section 5. ONTINUED Monthly Checking hardware on the knife guard Inspect the hardware on the knife guard (fasteners on hinge and the clear blade guard window).

  • Page 72: Checking The Blades

    Blades become dull over time depending on the material being HECKING cut, cut rate, blade speed, and blade material and thickness. Check blades regularly for sharpness as well as scratches, LADES nicks, burrs, and material buildup. Clean, sharpen or replace as needed (see Installing Cutter Blades, Section 3).

  • Page 73: Inspecting Cutter Bushing Screws

    Check the set screws that secure the cutter bushings. If bush- NSPECTING ings move during cutting, cutting blades and possibly the drive chain could be damaged. UTTER USHING CREWS Cutter bushing screws Check the hand knob and tighten it so the knife guard closes HECKING THE completely.

  • Page 74: 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. LEANING THE Depending on cut rate and type of material and lubrication, the area will need to be cleaned on a regular basis and the LADE lubricant replaced.

  • Page 75: Adjusting The Proximity Switches

    Follow all warnings and cautions listed at the beginning of the DJUSTING THE Maintenance section of this User Guide. ROXIMITY Be sure the main power is disconnected and the cutter is locked out. WITCHES Loosen the set screws that hold the cutter bushings. Remove the cutter bushings.

  • Page 76: Checking Electrical Connections

    WARNING: Electrical hazard HECKING Before performing any work on this product, disconnect and lock out electrical power LECTRICAL sources to prevent injury from unexpected ener- gization or start-up. A lockable device has been ONNECTIONS provided to isolate this product from potentially hazardous electricity.
  • Page 77 HECKING Open the electrical enclosure. LECTRICAL Inspect all wires and connections . Look for loose wires, burned contacts, and signs of over-heated wires. ONNECTIONS Have a qualified electrician make any necessary repairs or replacements. ONTINUED Close the electrical enclosure door. Inspect the exterior power cords.
  • Page 78 NOTE: In installations subjected to extreme corrosion, the slits in clamp INSTALLATION AND REMOVAL INSTRUCTIONS FOR collars Item 1 and Item 2, as well as in center collars, should be B-LOC™ LOCKING ASSEMBLY SERIES B112 sealed with a suitable caulking compound or equivalent. Likewise, push-off threads should also be protected from corrosion.

  • Page 79: Troubleshooting

    ROUBLESHOOTING Before Beginning ... .6-2 A Few Words of Caution ..6-2 Identifying the Cause of a Problem ..6-3 Electrical Problems .

  • Page 80: Before Beginning

    You can avoid most problems by following the recommended EFORE installation, operation and maintenance procedures outlined in this User Guide. If you have a problem, this section will help EGINNING you determine the cause and tell you how to fix it. Find any wiring, parts, and assembly diagrams that were shipped with your equipment.

  • Page 81: Identifying The Cause Of A Problem

    DANGER: Sharp blades! ORDS Most injuries caused by knife blades occur when the cutter has been turned off. Handle AUTION blades with care at all times. ONTINUED Always wear cut-resistant gloves when the cutting chamber is open and when handling blades.

  • Page 82: Electrical Problems

    Look in this section when you have problems such as lights on LECTRICAL the control that are working improperly, buttons that do not execute the function properly, and when information input is ROBLEMS not executed properly. Symptom Possible cause Solution The green start The E-stop button is Pull out the E-stop button.
  • Page 83 LECTRICAL ROBLEMS ONTINUED Possible cause Solution Symptom The Blade home proximi- Check connections and replace After pressing ty switch failed or the switch if needed. Start Cutter, the connection to it is loose. cutter head rotates slowly but does not stop.
  • Page 84 Fault on Amplifier prevent- ing cut cycle. Blade is stuck in extrudate/ bushings. Look at the drive and record the fault code and call the Conair service department. There is a problem with See Adjusting the Proximity the home proximity Switches, Section 5.
  • Page 85 LECTRICAL ROBLEMS ONTINUED Possible cause Solution Symptom There is a communication Check for wiring for loose Blade speed does failure between the con- connections and tighten. not change when new trol and drive. speed is entered into the control. Cutter mode selec- There is a communication Check for wiring for loose tion does not change...

  • Page 86: Product Quality Problems

    Look in this section when the final product does not meet RODUCT standards: has strings, burrs, cracks, or is misshaped. UALITY ROBLEMS Symptom Solution Possible cause Hairs or strings. Increase the blade speed or Blade speed is too low. decrease the blade cut path area (blade width) Excessive blade thickness can The blade is too thick.
  • Page 87 RODUCT UALITY ROBLEMS ONTINUED Symptom Possible cause Solution The bushings are not pro- Change bushing design to Burrs at cut site. viding enough support make them more supportive. during cutting. The bushing gap is too The bushing gap should be no wide.
  • Page 88 RODUCT UALITY ROBLEMS ONTINUED Symptom Possible cause Solution Cracks at cut The extrudate is too cold. If the extrudate is too cold, it site. can fracture or whiten during cutting. Raise the extrudate's temperature. The blade speed is too High blade speeds can cause high.
  • Page 89 RODUCT UALITY ROBLEMS ONTINUED Symptom Possible cause Solution Cut is not square. The blade speed is too Low blade speeds can cause low. 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.

  • Page 90: Replacing Safety And Proximity Switches

    Three safety switches are included in SC-5 Sure Cut cutters: a EPLACING keyed safety switch on the knife guard, and a proximity switch on each cutter bushing. A failure in any of these switches will AFETY AND prevent the cutter from running. ROXIMITY Safety Switch WITCHES...

  • Page 91: Adjusting The Proximity Switches

    The home position proximity switch should be 0.010 inch DJUSTING THE from the 5/16 inch thread rod on the cutter head for proper operation. ROXIMITY Open the flywheel clear guard window. WITCHES Locate the 5/16 inch thread rod on the cutter head.

  • Page 92: 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 A. Continued 6-14 SC-5 SURE CUT Servo Knife Cutter...
  • Page 93 Encoder Mounting and General Information HECKING THE The provided encoder is a precision instrument which outputs NCODER 3000 bi-directional quadrature pulses per revolution of the shaft. ONTINUED 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.

  • Page 94: Checking The Motor/Reducer Assembly

    HECKING THE Open the flywheel clear guard window. OTOR REDUCER Remove the cutter head by loosening the Trantorque assembly. Refer to the manufacturer's guide included with SSEMBLY this User Guide for information about the Trantorque assembly. Locate the four bolts holding the motor/reducer assembly to the cutter.
  • Page 95 Less than 0.1 millisecond Note: 1-millisecond at 60 feet per minute is equal to .012 inches. The repeatability mode is built into the Conair cutter controls and allows you to perform similar tests, without any external test equipment. It is recommended that you check repeatability on a regular basis.

  • Page 97: Appendix

    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 98: Warranty Information

    Returns must be prepaid. Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made.

  • Page 99: Cutter Blade Selection And Use

    Cutter blade characteristics such as material, design, and UTTER LADE thickness can have a large effect on cut quality. ELECTION 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).
  • Page 100 Blade Design UTTER LADE Straight-edge knives have a straight cutting surface. A chop- ELECTION ping 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.
  • Page 101 Blade thickness UTTER LADE Because material is displaced rather than removed in rotary ELECTION 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.

  • Page 102: Calculating Blade Interruption

    Calculating Blade Interruption UTTER LADE Blade interruption is the length of time which the blade ELECTION 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)
  • Page 103 UTTER LADE ELECTION 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 cal- culate the amount of production deflection that must be accommodated during cutting.

  • Page 104: Conair Cutter Blades

    Part Blade Bushing Blade Blade ONAIR UTTER Type Size Thickness Material x Length {inches} LADES {inches} 0235-30496 Straight , 4x10 0.025x9.5 Spring Steel 3515-30496-1 Straight , 2x4, 2x6 0.025x6.48 Spring Steel 3515-30496-2 Straight , 2x8, 2x10, 0.025x8.33 Spring Steel 2x12, 4x7 3515-30488 Curved , 4x7, 3x6...

  • Page 105: All About Cutter Bushings

    Rotary knife cutter bushings are probably the most ignored BOUT aspect of cutting. Yet, they are probably the most important ingredient to obtaining clean, square, accurate cuts with mini- UTTER mal jamming and broken blades. USHINGS This appendix contains information about several aspects of cutter bushings: bore characteristics bushing length...
  • Page 106 Supportive bushings become more important if heat is BOUT used to minimize whitening (fracturing). UTTER If you are cutting a square or rectangular profile, whether rigid or flexible, a round bushing bore will not offer USHINGS 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.
  • Page 107 Cutter bushing shear surface quality BOUT Similar to a dull pair of scissors, if the cutter bushing shear UTTER 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, USHINGS the entrance of the downstream cutter bushing is slightly radiused to minimize jamming.
  • Page 108 Cutter bushing length BOUT CAUTION: Blade hazard UTTER In order to comply with OSHA regulations, the distance from the sidewall of the cutter to the USHINGS blade (through the bushing) must be long enough to prevent fingers from reaching the blade.
  • Page 109 Adjusting the cutter bushing gap BOUT If the bushing gap is too big, material is dragged down UTTER between the bushings creating a burr, especially with flexibles. This may lead to jamming within the bushings where the USHINGS upstream side of the cut extrudate actually hits against the downstream bushing surface.

  • Page 110: Blade And Bushing Lubrication

    Blade and bushing lubrication can nearly always improve the LADE AND quality of cutting. USHING Description of the cutting process UBRICATION 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.
  • Page 111 Common cutting lubricants LADE AND Commonly used general purpose lubricants include: USHING Tap water Dish washing liquid (Joy, etc) UBRICATION Glycol (anti-freeze, coolant) Water-soluble silicone cutting oils Diesel fuel Mold release Mineral oil Medical grade lubricants: Distilled water Isopropanol (isopropyl alcohol) Mixtures of isopropanol and water Lubrication systems The most basic blade lubrication system for rotary knife cut-...
  • Page 112 If the blade has a rough surface where the extrudate rubs LADE AND against it, material will accumulate on the blade in a cheese grater fashion. This scratched material will also be passed USHING from the blade to the next cut and be seen as hairs or flakes. UBRICATION Some of the more flexible materials, such as silicones, soft urethanes and flexible PVCs, also exhibit drag against the...
  • Page 113 ENCODER MODE OPERATOR DISPLAY OVERVIEW ENC 00000.000 in. Parts Length SELECT PARTS AREA LENGTH 00000.000 in. Total Exit Batch Exit TOTAL 0,000,000 pcs. BATCH 000,000 pcs. Exit Reset Change Reset SELECT BATCH AREA Preset Exit Alarm PRESET 000,000 pcs. ALARM 000,000 pcs. Exit Exit...
  • Page 114 END SENSE MODE OPERATOR DISPLAY OVERVIEW SNS 00000.000 sec. Parts Time SELECT PARTS AREA Holdoff 00000.000 sec. Total Exit Batch Exit TOTAL 0,000,000 pcs. BATCH 000,000 pcs. Exit Reset Change Reset SELECT BATCH AREA Preset Exit Alarm PRESET 000,000 pcs. ALARM 000,000 pcs.
  • Page 115 FLYWHEEL MODE OPERATOR DISPLAY OVERVIEW FLY 00000.000 cpm Parts Blade SELECT PARTS AREA SELECT BLADE AREA Total Exit Batch Speed Exit Count SPEED 0000.0 rpm TOTAL 0,000,000 pcs. RUN 1 BLADES BATCH 000,000 pcs. Exit Exit Reset Exit Change Reset SELECT BATCH AREA Preset Exit...
  • Page 116 TIMER MODE OPERATOR DISPLAY OVERVIEW TMR 00000.000 sec Parts Time SELECT PARTS AREA TIME 00000.000 sec Total Exit Batch Exit TOTAL 0,000,000 pcs. BATCH 000,000 pcs. Exit Reset Change Reset SELECT BATCH AREA Preset Exit Alarm PRESET 000,000 pcs. ALARM 000,000 pcs. Exit Exit...
  • Page 117 FOLLOWER MODE OPERATOR DISPLAY OVERVIEW FOL 00000.000 cpm Parts Length SELECT PARTS AREA LENGTH 00000.000 in. Total Exit Batch Exit TOTAL 0,000,000 pcs. BATCH 000,000 pcs. Exit Reset Change Reset SELECT BATCH AREA Preset Exit Alarm PRESET 000,000 pcs. ALARM 000,000 pcs. Exit Exit...
  • Page 118 AUTO DEMAND MODE OPERATOR DISPLAY OVERVIEW ATO 00000.000 in. Parts Length SELECT PARTS AREA LENGTH 00000.000 in. Total Exit Batch Exit TOTAL 0,000,000 pcs. BATCH 000,000 pcs. Exit Reset Change Reset SELECT BATCH AREA Preset Exit Alarm PRESET 000,000 pcs. ALARM 000,000 pcs.
  • Page 119 MULTIBLE PRESETS ENCODER MODE (EXAMPLE) OPERATOR DISPLAY OVERVIEW 1 ENC 00000.000 in. Parts Length SELECT PARTS AREA SELECT LENGTH PRESET SELECT LENGTH PRESET Total Exit Batch Length3 Length4 Prev Length1 Length2 Next TOTAL 0,000,000 pcs. BATCH#1 000,000 pcs. LENGTH#1 00000.000 in. Exit Reset Change...

  • Page 120: Operator Display Overview

    FUNCTION AREA 1 FUNCTION AREA 2 OPERATOR DISPLAY OVERVIEW OPERATOR DISPLAY OVERVIEW (accessed by pressing the menu button) SELECT FUNCTION > < SELECT FUNCTION Blade Test Mode Parts MEASURMENT DEPENDENT ON MODE DEPENDENT ON MODE SEE MODE SEE MODE OVERVIEWS OVERVIEWS CURRENT MIN LENGTH The Current Settings...
  • Page 121 MAINTAINENCE AREA DISPLAY OVERVIEW (Accessed by pressing the menu button from Menu Area #1 and entering the correct password) SELECT MAINT. AREA Encdr Home Select Encoder Area OFFSET +15.0 Deg SELECT P/M AREA Drctn Scale Inputs Time Cycles Exit COUNT DIRECTION IS SELECT SCALE VALUE I1=Off I2=Off I3=Off MACH.

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