Page 1 Combination Puller/Cutter CSC 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 UGE048/1103...
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
Cutter Control Instructions Test ....4-14 Cutter Control Instructions Cut Mode ....4-16 UGE048/1103 CSC Combination Puller/Cutter...
Page 4 Replacing Belts ....... .5-18 Checking Torque .......5-20 CSC Combination Puller/Cutter UGE048/1103...
Page 5 Choosing Belt Materials ......E-1 Conair Belts ........E-1 Puller Control Settings .
Page 7: Introduction
ATTENTION: Read this so no one gets hurt ...1-3 How to Use the Lockout Device ... .1-6 UGE048/1103 CSC Combination Puller/Cutter...
Page 8: Purpose Of The User Guide
This User Guide describes the Conair Combination Puller/ URPOSE OF Cutter and explains step-by-step how to install, operate, main- tain 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 9 Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate. UGE048/1103 CSC Combination Puller/Cutter NTRODUCTION...
Page 10: Attention: Read This So No One Gets Hurt
If a finger or piece of clothing is caught on the upper belt and drawn in, the guard flips up and immedi- ately shuts off the power to the entire combi- nation puller/cutter. NTRODUCTION CSC Combination Puller/Cutter UGE048/1103...
Page 11 When the knife guard is opened, the knife guard switch stops the cutter. Two proximity safety switches prevent cutter operation unless the cutter bushings are in place. The Stop button on the cutter control acti- vates a circuit that stops the knife. NTRODUCTION UGE048/1103 CSC Combination Puller/Cutter...
Page 12: 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 13: Description
Cutter Features ... .2-6 Specifications ....2-7 Optional Equipment ..2-8 UGE048/1103 CSC Combination Puller/Cutter...
Page 14: What Is The Combination Puller/Cutter
Different puller belt materials opti- mize performance with different types of extruded materials. The cutter portion utilizes a position-controlled servo motor. CSC units achieve park position repeatability less than 0.1 millisecond. Combination Puller/Cutter are available in several sizes:...
Page 15: Typical Applications
(see Specifications, Section 2). (The illustrations in this User Guide represent the standard right-to left configuration.) CSC cutters are limited to a specific range of product sizes based on each unit's cutting capacity. CSC cutters can operate over a range of speeds (depending on which options are included.) See Specifications, Section 2.
Page 16: How The Combination Puller/Cutter Works
Trantorque coupling device, and may have as many as one optional blade position. Cut pieces are collected or carried on to further processing by an optional conveyor (step 4). Continued ESCRIPTION CSC Combination Puller/Cutter UGE048/1103...
Page 17 ULLER UTTER bushings, cutting the extrudate. ORKS CONTINUED Extruded material enters from the upstream side. Cut pieces are collected Belts pull the extrudate through or carried away on a the puller to the cutter. conveyor. UGE048/1103 CSC Combination Puller/Cutter ESCRIPTION...
Page 18: Combination Puller/Cutter Features
Eye-level Controls Clear knife guard Belt adjustment Cutter head with blade(s) Servo motor E-Stop button Belt guard Material inlet through cutter bushings Guide rollers Belt guard Blade lubrication tray Puller belts Swivel casters and lockdown screws ESCRIPTION CSC Combination Puller/Cutter UGE048/1103...
Page 19 460V/1 phase/60Hz {3 phase} 11.0 14.0 10.5 16.8 16.2 Cutter Control Red Lion Red Lion Red Lion Red Lion Red Lion Servo Cutter Control* Red Lion* Red Lion* Red Lion* Red Lion* Red Lion* * Optional UGE048/1299 CSC Combination Puller/Cutter ESCRIPTION...
Page 20: Specifications
15-15 15-15 16.2 15-15 15-15 16.2 15-15 15-15 16.2 Cutter Control Red Lion Red Lion Red Lion Red Lion Red Lion Servo Puller Control* Red Lion* Red Lion* Red Lion* Red Lion* Red Lion* *Optional ESCRIPTION UGE048/1299 CSC Combination Puller/Cutter...
Page 21 The pad wipes and lubricates the knife before each cut. Continued CSC Combination Puller/Cutter UGE048/1103 ESCRIPTION...
Page 22: Optional Equipment
Cutting torque upgrades Several options can be used to increase the cutting torque: CSC 3 cutters can be upgraded from a 2.46 HP (MGE-455) to a 3.75 HP (MGE-490) servo motor. (The larger servo motor is standard on SCE-4, 5 cutters.) The standard aluminum cutter-head can be replaced with a heavier stainless steel one.
Page 23 Left to Right Machine Operation This option changes the machine direction from the standard right to left extrusion flow. Your Conair sales representative can analyze your needs and recommend the options that are right for your system. NOTE: Conair strongly recommends using an isolation transformer.
Page 25: Installation
Setting the Belt Gap ..3-12 Checking Repeatability ..3-14 Repeatability Test Results ..3-15 Preparing for Testing ..3-16 Testing the Installation ..3-17 UGE048/1103 CSC Combination Puller/Cutter...
Page 26: Unpacking The Boxes
The Conair Combination Puller/Cutter comes fully assembled NPACKING THE 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 27: Preparing For Installation
Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate. UGE048/1103 CSC Combination Puller/Cutter NSTALLATION...
Page 28: Positioning The Combination Puller/Cutter
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 combo's center of gravity. Combination Puller/Cutter Align the puller/cutter with the extrusion line. Continued NSTALLATION CSC Combination Puller/Cutter UGE048/1103...
Page 29 Use a plumb line or laser to check for a straight line from the extrusion die through each line component to the cutter bushings. Adjust as necessary. Adjust the belt puller entrance guide rollers to insure consistent product guidance. UGE048/1103 CSC Combination Puller/Cutter NSTALLATION...
Page 30: Connecting The Main Power Source
Connect the diagrams show the minimum ground wire to the size main power cable grounding point required for your cutter, and shown in the wiring the most accurate electrical diagram shipped with component information. your unit. NSTALLATION CSC Combination Puller/Cutter UGE048/1103...
Page 31: Installing The Cutter Blades
Attach blade to cutter head with blade screw. For on-demand cutting, mount the blade at the “on-demand” position stamped on the cutter head. For more information about choosing the appropriate blade for your material, see the Appendix B. UGE048/1103 CSC Combination Puller/Cutter NSTALLATION...
Page 32: Mounting The Cutter Bushings
Tighten the set screw against the flat side of the for the bushings, see About bushing to hold the bushing in position. Cutter Bushings, in Appendix Location of set screws Continued NSTALLATION CSC Combination Puller/Cutter UGE048/1103...
Page 33 CONTINUED Rotate the cutter head by hand to make sure the bushings did not move, and the the blade still passes through the gap between the bushings. UGE048/1103 CSC Combination Puller/Cutter NSTALLATION...
Page 34: Adjusting Belt Tension
NOTE: Loose belts result in belt and product slippage; over-tightened belts result in distorted product and can lead to prema- ture bearing failure. Continued 3-10 NSTALLATION CSC Combination Puller/Cutter UGE048/1103...
Page 35 If the gap is not even, adjust the tension until the gap is even and measures 1/8 inch. The shape of the gap should not be concave (over-tightened) or con- vex (too loose). Check tension and re-adjust as necessary. 3-11 UGE048/1103 CSC Combination Puller/Cutter NSTALLATION...
Page 36: Setting The Belt Gap
You may have to rotate it slightly to engage the key- way with the key on the shaft. Place the hand wheel on the left threaded rod and turn to move the upper belt up and down: Continued 3-12 NSTALLATION CSC Combination Puller/Cutter UGE048/1103...
Page 37 Place the handwheel on the right threaded rod and turn to move the lower belt up and down. CONTINUED The optional Pneumatic Upper Belt Actuator can also be used to position the upper belt. (See Appendix E.) 3-13 UGE048/1103 CSC Combination Puller/Cutter NSTALLATION...
Page 38: Checking Repeatability
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 39: Repeatability Test Results
There should be very little difference in these readings. Compare the cut-to-cut (CC) reading to the CC reading in the other modes. Since the product mode is influenced by external signals, this reading will reflect the speed regulation of the puller. 3-15 UGE048/1103 CSC Combination Puller/Cutter NSTALLATION...
Page 40: Preparing For Testing
Operating without these devices could lead to hazardous conditions that can cause severe injury. Take all necessary precautions when working around moving parts to prevent body parts and clothing from being pulled into the machine. 3-16 NSTALLATION CSC Combination Puller/Cutter UGE048/1103...
Page 41: Testing The Installation
If necessary, press button to display off. Press Start Cutter button. The light in the button should light. On CSC cutters, the cutter head will make one revolution until it finds its home offset position. NOTE: If “Home Runtime Failed” message is dis- played.
Page 43: Operation
Stopping Only the Cutter ..4-37 Stopping the Puller/Cutter ..4-38 Shutting down the Combinations Unit ....4-38 UGE048/1103 CSC Combination Puller/Cutter...
Page 44: Cutter Control Features
The Operator Control provides an intuitive user-friendly UTTER method to interface with the Conair Servo Cutter. Information is viewed and entered at the Operator Control and is commu- PERATOR nicated to the servo positional amplifier via the RS-232 serial communication link.
Page 45 On is displayed will disable the cutter. Likewise pressing this key while Off is displayed enables the cutter. Pressing the stop button forces the cut enable off. Manual cuts can still be made while the cut enable is off. PERATION UGE048/1103 CSC Combination Puller/Cutter...
Page 46: Cutter Control Instructions
Likewise pressing this key while Off is displayed enables the counter. Exit Softkey2 Under the counter, in the center is a soft key labeled Exit. Pressing this key will return the display to the Parts Select Continued screen. CSC Combination Puller/Cutter UGE048/1103 PERATION...
Page 47 Under the counter, on the right is a soft key labeled Reset. Pressing this key will zero the batch counter. EXIT or PREV, fixed function keys return the display to the Parts Select screen. Continued UGE048/1103 CSC Combination Puller/Cutter PERATION...
Page 48: Cutter Control Instructions Batch Screen
Lower will decrease the preset by 1. The key can be pressed once for each decrement required or held down to scroll down. Releasing the key will freeze the preset at the last value. Continued CSC Combination Puller/Cutter UGE048/1103 PERATION...
Page 49 The user has a choice of ways to adjust this number. Pressing the #Prst/Softkey3 accesses the number of presets to run screen. This feature is only available with the multiple preset/batch option. Continued UGE048/1103 CSC Combination Puller/Cutter PERATION...
Page 50: Cutter Control Instructions Length Screen
#1 continuously. If a 2 is entered only preset/batch 1 and 2 are processed. A cursor will appear in the least significant digit. The user has a choice of ways to adjust this number. Continued CSC Combination Puller/Cutter UGE048/1103 PERATION...
Page 51 The user has a choice of ways to adjust this number. Exit or Prev, If no change is required press Exit or Prev to return to the Main Timer Mode Screen. Continued PERATION UGE048/1103 CSC Combination Puller/Cutter...
Page 52: Cutter Control Instructions Time Screen
The user has a choice of ways to adjust this number. Exit or Prev, If no change is required press Exit or Prev to return to the Main End Sense Mode Screen. Continued 4-10 CSC Combination Puller/Cutter UGE048/1103 PERATION...
Page 53 The user has a choice of ways to adjust this number. Exit or Prev, if no change is required press Exit or Prev to return to the Blade Select or Main Mode Screen. Continued 4-11 PERATION UGE048/1103 CSC Combination Puller/Cutter...
Page 54: Cutter Control Instructions Blade Speed
The user has a choice of ways to adjust this number. Exit or Prev, if no change is required press Exit or Prev to return to the Blade Select or Main Mode Screen. Continued 4-12 PERATION CSC Combination Puller/Cutter UGE048/1103...
Page 55 Menu fixed function key is used to access the Function Areas from any main mode screen. There are two Function Area screens. The user can toggle between the two screens with the Next and Prev fixed function keys. < SELECT FUNCTION Parts Continued 4-13 UGE048/1103 CSC Combination Puller/Cutter PERATION...
Page 56: Cutter Control Instructions Function Areas
Reset. Pressing this key will reset all test values and start a new test. Exit or Prev, Pressing Exit, Prev or the Softkey under the word Exit resets all values and disables testing then returns the display to the Function area screen. Continued 4-14 CSC Combination Puller/Cutter UGE048/1103 PERATION...
Page 57 DevCP test. NOTE: The test available DevCP, DevCC or both is dependent on the active cut mode. 4-15 UGE048/1103 CSC Combination Puller/Cutter PERATION...
Page 58: Cutter Control Instructions Cut Mode
Next or Prev, Pressing Next selects the second Cut Mode Area. Pressing Prev returns the display to the first Cut Mode Area. Pressing Prev from the first Cut Mode Area screen returns the display to the Function Area screen. 4-16 PERATION CSC Combination Puller/Cutter UGE048/1103...
Page 59 Maint. Factory NSTRUCTIONS AINTENANCE Menu function key is used from the first Function Area screen to access the Maintenance area. There are two menus Maint. and Factory, with access via password to various sub-menus. 4-17 UGE048/1103 CSC Combination Puller/Cutter PERATION...
Page 60: Cutter Control Instructions Encoder Area
There are three sub-menus, Encdr, Home, and P/M accessible in the maintenance area. SELECT MAINT. AREA Encdr Home Exit or Prev, Pressing Exit or Prev will return the display to the Menu Area screen. Continued 4-18 CSC Combination Puller/Cutter UGE048/1103 PERATION...
Page 61: Cutter Control Instructions Encoder Direction
THE CUTTER MUST BE STOPPED TO CHANGE! This message will be displayed for 3 seconds or until any key is pressed. Press stop on the operator panel then try again. Continued 4-19 PERATION UGE048/1103 CSC Combination Puller/Cutter...
Page 62 English units of measure). The prescale value is set at the factory for your equipment and typical unit of measurement. However, it may occasionally be necessary to adjust the prescale value. 4-20 CSC Combination Puller/Cutter UGE048/1103 PERATION...
Page 63 If the keyed in number is correct press the enter key for it to be accepted and return to the Scale Value screen. If it is wrong press the delete key and the previous value will reap- pear. 4-21 UGE048/1103 CSC Combination Puller/Cutter PERATION...
Page 64 If the keyed in number is correct press the enter key for it to be accepted and return to the scale value screen. If it is wrong press the delete key and the previous value will reappear. 4-22 CSC Combination Puller/Cutter UGE048/1103 PERATION...
Page 65 A cursor will appear in the least significant digit. The user has a choice of ways to adjust this number. Exit or Prev, If no change is required press Exit or Prev to return to the Maintenance Area screen. Continued 4-23 UGE048/1103 CSC Combination Puller/Cutter PERATION...
Page 66: Cutter Control Instructions Home Offset
Making an entry outside of this range generates the following error message on the operator display. HOME OFFSET RANGE IS 00.0 TO +45 Deg. After 5 seconds or if any key is pressed the display returns to the Home Offset 4-24 PERATION CSC Combination Puller/Cutter UGE048/1103...
Page 67 The displayed count can not be reset. Exit or Prev, Pressing Exit, Prev or the Softkey under the word Exit returns the display to the Select P/M area screen. 4-25 UGE048/1103 CSC Combination Puller/Cutter PERATION...
Page 68 If there are any problems with communications, this screen will remain on longer than a couple of seconds. If there are no communication problems the Conair Combination Puller/Cutter program will begin to run. The fol- lowing message or similar shows for 5-seconds.
Page 69: Puller Operation Control
A digital line rate indicator (optional) can be used to set the desired puller speed. Note: This display should be programmed in feet per minute, with one decimal point (tenths of feet per minute), unless otherwise specified. 4-27 PERATION UGE048/1103 CSC Combination Puller/Cutter...
Page 70: Stopping The Puller
E-Stop button Press to stop the combination Puller/Cutter in an emer- gency. Puller Start button Pressing this button energizes the puller portion. Puller Stop button Press this button to shut down the puller portion. 4-28 PERATION CSC Combination Puller/Cutter UGE048/1103...
Page 71: Unit
Operating without these devices could lead to hazardous conditions that can cause severe injury. Take all necessary precautions when working around moving parts to prevent body parts and clothing from being pulled into the machine. 4-29 UGE048/1103 CSC Combination Puller/Cutter PERATION...
Page 72: Powering Up
If necessary, press button to display off. Press Start Cutter button. The light in the button should light. On CSC Combination Puller/Cutter, the cutter head will make one revolution until it finds its home offset position. NOTE: If “Home Runtime Failed” message is dis- played.
Page 73: Setting The Cutting Mode
Adjustment arrows to enter the number of blades (1, 2, 4, or 8). Press the Set button to accept the value. Use the Set button and Adjustment arrows to set the cut length. 4-31 PERATION UGE048/1103 CSC Combination Puller/Cutter...
Page 74: Setting The Scale Factor
For flexible products, the cutter should be very close to the puller. For more rigid products, allow enough space between the cutter and puller to absorb any shock generated during cutting. 4-32 PERATION CSC Combination Puller/Cutter UGE048/1103...
Page 75 If unsure, please do not hesitate to call for service. Adjust the belt puller entrance guide rolls to insure consistent product guidance. Adjust the belt opening to allow consistent traction to the product without deformation. Continued 4-33 UGE048/1103 CSC Combination Puller/Cutter PERATION...
Page 76 If the puller does not start, make sure the E-stop button pulled out in the extended position. Rotate the speed reference potentiometer to adjust belt speed. Observe the digital line rate indicator to observe line speed. (optional) 4-34 PERATION CSC Combination Puller/Cutter UGE048/1103...
Page 77: Starting The Puller
If the puller does not start, make sure the E-stop button pulled out in the extended position. Rotate the speed reference potentiometer to adjust belt speed. Observe the digital line rate indicator to observe line speed. (optional) 4-35 PERATION UGE048/1103 CSC Combination Puller/Cutter...
Page 78: Making Adjustments During Operation For The Cutter
PERATION In Product mode, adjust the hold-off time OR THE UTTER 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 press- ing the manual cut button at any time during on-demand cutting.
Page 79 Turn Cutter Power On/Off switch to Off. Power is no longer supplied to the cutter portion of the combina- tion puller/cutter. The belt puller will continue running. Follow the procedures Installing Cutter Blades, Section 3. 4-37 PERATION CSC Combination Puller/Cutter UGE048/1103...
Page 80 If the unit is shut down for an extended period of ULLER UTTER time, puller belts can and do acquire 'set.' If this occurs, let the puller run for 20-30 minutes before use. This should remove any set from the belts. 4-38 PERATION UGE048/1103 CSC Combination Puller/Cutter...
Page 81: Maintenance
Checking the Belt Gap ..5-15 Replacing Belts ... .5-18 Checking Torque ...5-20 UGE048/1103 CSC Combination Puller/Cutter...
Page 82: Maintenance Features
The Servo Cutter CSC combo model needs regular, scheduled AINTENANCE maintenance for peak performance. Among the features that require maintenance are: EATURES Puller belts Cutter blades Blade mounting hardware Cutter bushings The knife guard hardware Floor locks Lubrication Optional slide rail system...
Page 83 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. Never remove or disable these devices to sustain pro- duction. Operating without these devices can cause severe injury.
Page 84: Preventative Maintenance Schedule
Lubrication Tray, Section 5. Lubricating shafts on slide rail system See Lubricating the Slide Rail, Section 5. Checking shafts and grease fittings Lubricate all shafts and grease fittings as needed. See Checking the Grease Locations, Section 5. Continued AINTENANCE CSC Combination Puller/Cutter UGE048/1103...
Page 85 Inspecting control panel lights Check to make sure no LEDs or lights are burned out on the control panel. Replace as needed. Checking motor brushes Inspect the motor bushes. Replace as needed. See Replacing Motor Brushes, Section 5. UGE048/1103 CSC Combination Puller/Cutter AINTENANCE...
Page 86: Inspecting Cutter Blades
LADE washer. Replace the holding pins if they appear worn. ARDWARE WARNING Do not operate the combination puller/cutter without washers and blade-securing bolt securely in place. AINTENANCE CSC Combination Puller/Cutter UGE048/1103...
Page 87: Inspecting Cutter Bushing Screws
This prevents false triggering of the safety switch. LOSURE ATCH It is best to remove the weight from the casters for optimum HECKING stability during cutting cycles. Check to see if the floor lock- LOOR OCKS ing mechanism is properly adjusted. UGE048/1103 CSC Combination Puller/Cutter AINTENANCE...
Page 88: Cleaning The Lubrication Tray
Check the shafts on the slide rail system. Even though these shafts are stainless steel, it is recommended that a light oil LIDE (WD-40 or similar) be applied to the shafts as needed. Wipe off any excess. AINTENANCE CSC Combination Puller/Cutter UGE048/1103...
Page 89: Checking Grease Locations
For thread rods and vertical shafts, use Never-Seize or equivalent. The vertical shaft drive boxes require a high-temperature grease. Use Mobilgrease 28 or equivalent. Lower bearing grease fitting UGE048/1103 CSC Combination Puller/Cutter AINTENANCE...
Page 90: Adjusting The Cutter Proximity Switches
See Mounting the Cutter Bushings, Section 3 and the Appendix C and D. Plug in the power cord and turn the main power dis- connect to the on position if all other maintenance is com- pleted. 5-10 AINTENANCE CSC Combination Puller/Cutter UGE048/1103...
Page 91: Checking Electrical Connections
This is a safety device to prevent you from opening the doors if the power is still on. Main power safety disconnect Continued 5-11 UGE048/1103 CSC Combination Puller/Cutter AINTENANCE...
Page 92 If the main power cord runs along the floor, make sure it is not positioned where it could rest in pooling water or could be run over and cut by wheels or casters. 5-12 AINTENANCE CSC Combination Puller/Cutter UGE048/1103...
Page 93 NOTE: It is important to have the proper belt ten- sion. Loose belts result in belt and product slippage; over-tightened belts result in distorted product and can lead to premature bearing failure. Continued 5-13 UGE048/1103 CSC Combination Puller/Cutter AINTENANCE...
Page 94: Testing Belt Tension
If the gap is not even, adjust the tension until the gap is even and measures 1/8”. The shape of the gap should not be concave (over-tightened) or convex (too loose). Check tension and readjust as necessary. 5-14 AINTENANCE CSC Combination Puller/Cutter UGE048/1103...
Page 95 You may have to rotate it slightly to engage the key- way with the key on the shaft. Place the hand wheel on the left threaded rod and turn to move the upper belt up and down. Continued 5-15 UGE048/1103 CSC Combination Puller/Cutter AINTENANCE...
Page 96: Checking The Belt Gap
ONTINUED The optional Pneumatic Upper Belt Actuator can also be used to position the upper belt. Refer to Appendix E for more infor- mation. 5-16 AINTENANCE CSC Combination Puller/Cutter UGE048/1103...
Page 97: Replacing Belts
Make sure ribs inside the belt fit properly into grooves, and keep tension on front and back sides as even as possi- ble by alternating between the two threaded rods. Adjust belt tension and belt gap. See Testing Belt Tension, Section 5. 5-17 UGE048/1103 CSC Combination Puller/Cutter AINTENANCE...
Page 98: Checking Torque
Use a torque wrench to make sure the nut is tight- ened to the proper installation torque (2000 in-lb or 225 N-m). Do not overtighten; it can cause damage to the unit. 5-18 AINTENANCE CSC Combination Puller/Cutter UGE048/1103...
Page 99: Troubleshooting
Checking the Encoder ..6-18 Testing Repeatability ..6-19 Results of Repeatability Testing ....6-20 UGE048/1103 CSC Combination Puller/Cutter...
Page 100: Before Beginning
Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injury from unexpect- ed energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity. ROUBLESHOOTING CSC Combination Puller/Cutter UGE048/1103...
Page 101 When the knife guard is opened, the knife guard switch stops the cutter. Two proximity-type safety switches prevent operation unless the cutter bushings are in place. The Stop button activates a circuit that stops the knife. UGE048/1103 CSC Combination Puller/Cutter ROUBLESHOOTING...
Page 102: Identifying The Cause Of A Problem
This section does not provide solutions to problems originating with other equipment on the extrusion line. Additional troubleshooting help can be found in the documen- tation manuals included with this User Guide. ROUBLESHOOTING CSC Combination Puller/Cutter UGE048/1103...
Page 103: Puller Operation Problems
‘creaks’ while run- section 5. ning. The bearings are failing. Replace the bearings. The E-stop button is Pull out the E-stop button. The puller does pushed in. (Make sure it clicks into posi- not start. tion.) ROUBLESHOOTING UGE048/1103 CSC Combination Puller/Cutter...
Page 104: Cutter Operation Problems
Manual cut button ning. does not produce a Check wiring between the cut when in an on- There is a loose connec- demand mode. push button and input three on tion. the servo drive and tighten connection. ROUBLESHOOTING CSC Combination Puller/Cutter UGE048/1103...
Page 105 Bussing proximity is bad replace switch E-stop button is pressed Pull out E-stop button Input from encoder Check encoder cable for conti- Measurement display does not failed. nuity. Connect any loose wires. change value. Encoder failed. Replace encoder. UGE048/1103 CSC Combination Puller/Cutter ROUBLESHOOTING...
Page 106 Section 6. i.e. the blade parks Micron reducer has further away from slipped. the original park site. The Trantorque coupling Refer to the Trantorque has slipped. instructions, Section 5. ROUBLESHOOTING CSC Combination Puller/Cutter UGE048/1103...
Page 107 Reducer Assembly, Section 6. i.e. the blade parks Micron reducer has further away from slipped. the original park position. The Trantorque coupling Refer to the Trantorque instruc- has slipped. tions, Section 5. UGE048/1103 CSC Combination Puller/Cutter ROUBLESHOOTING...
Page 108: Product Quality Problems
Adjust if necessary. The blade speed is too Increase blade speed or decrease the cut path area. low. The blade is too thick. Use a thinner blade or add heat to extrudate. 6-10 CSC Combination Puller/Cutter UGE048/1103 ROUBLESHOOTING...
Page 109 Change to a different blade cut path is causing a design. See Appendix B. ‘cheese grater’ effect. The extrudate is too cold. If the extrudate is too cold, it can fracture during cutting. Raise the extrudate's tempera- ture. 6-11 UGE048/1103 CSC Combination Puller/Cutter ROUBLESHOOTING...
Page 110 Slightly dull the blade. If using Nylon, it may be If nylon is cooled too quickly, cooling too quickly. its molecular structure may become unstable, leading to poor physical properties. Try more gradual cooling. 6-12 ROUBLESHOOTING CSC Combination Puller/Cutter UGE048/1103...
Page 111 There must be enough space For rigid products the between the puller and cutter puller is too close to the cutter. to allow for the extrudate to stop during cutting. 6-13 ROUBLESHOOTING UGE048/1103 CSC Combination Puller/Cutter...
Page 112 Length of cut is Section 6. incorrect. Encoder, input device Check encoder, input device and clean. Run repeatability problem. test, see Section 6. Run repeatability test. See There is a problem with the puller. Section 6. 6-14 ROUBLESHOOTING CSC Combination Puller/Cutter UGE048/1103...
Page 113: Restoring Default Memory Settings
The numeric keypad is enabled. If necessary, use the numeric keypad to enter a new value. CAUTION Press the Enter button within 10 seconds to accept the new number. Otherwise the para- meter reverts to the previous value. 6-15 ROUBLESHOOTING UGE048/1103 CSC Combination Puller/Cutter...
Page 114: Replacing Safety And Proximity Switches
Three safety switches are included in CSC cutter sections: a EPLACING keyed safety switch on the knife guard, and a proximity switch on each cutter bushing. A failure in any of these AFETY AND switches prevents the puller/cutter from running.
Page 115: Checking The Servo Amplifier
Handle blades with care at all times. If the proximity switch does not sense the cutter head after this adjustment, remove the switch and test it outside the cutter. Replace if necessary. 6-17 UGE048/1103 CSC Combination Puller/Cutter ROUBLESHOOTING...
Page 116: Checking The Encoder
Check the encoder itself. There should be no play in the shaft. If all else fails, contact Conair Customer Service. See Appendix A. WARNING: Delicate equipment The encoder is a delicate piece of equipment. Any rough handling can damage fragile parts.
Page 117: Testing Repeatability
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 118: Results Of Repeatability Testing
There should be very little difference in these readings. Compare the cut-to-cut (CC) reading to the CC reading in the other modes. Since the product mode is influenced by external signals, this reading will reflect the speed regulation of the puller. 6-20 ROUBLESHOOTING CSC Combination Puller/Cutter UGE048/1103...
Page 119 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 120: Appendix
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 121: 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 122 UTTER LADE Blade Design ELECTION Straight-edge knives have a straight cutting surface. A chop- 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 123 Blade thickness UTTER LADE ELECTION 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.
Page 124: Calculating Blade Interruption
Calculating Blade Interruption UTTER LADE Blade interruption ELECTION 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)
Page 125 UTTER LADE ELECTION To calculate interruption time: (0.937 in. + 0.250 in.) X 60,000msec/rev = 2.25msec 44.0 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 126: Conair Cutter Blades
Part Blade Bushing Blade Blade ONAIR UTTER Type Size Thickness Material LADES 3515-02285 Razor 2 inch* 0.015 in. Stainless Steel 3515-00975 Razor 2 inch* 0.025 in. Stainless Steel 3515-30088 Straight 2 inch 0.010 in. Stainless Steel 3515-30096 Straight 2 inch 0.015 in.
Page 127: 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 128 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 129 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 130 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 131 Adjusting the cutter bushing gap BOUT UTTER If the bushing gap is too big, material is dragged down between the bushings creating a burr, especially with flexibles. USHINGS This may lead to jamming within the bushings where the upstream side of the cut extrudate actually hits against the downstream bushing surface.
Page 132: 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 133 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 134 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 135 Various belt materials are available: natural rubber, neoprene, urethane, and dual material. Available belts are listed under Conair Belts in this Appendix. ONAIR ELTS Part Material...
Page 136: Choosing Belt Materials
ONAIR ELTS Part Material Durometer Covering Color Wear Traction Thickness Approved Model 426 Belt type: Poly V 655 L 20 3511-30016 Natural rubber 35-40 .39 in (10mm) tan, brown medium excellent 3511-30088 Natural rubber 50-55 .39 in (10mm) tan, green medium- excellent excellent...
Page 137 This table shows the settings for each control parameter set at ULLER the factory. The parameters are set either to the default setting, or to a setting specific to your requirements (Customer col- ONTROL umn). If you change any value, record it in this column. Keep these values up-to-date so you can easily restore your puller to ETTINGS normal operation if the memory is corrupted.
Page 138 Code Parameter Range Default Customer ULLER Max RPM (external 1-9999 reference input: secondary mode) ONTROL Max RPM (feedback: 1-9999 secondary mode) ETTINGS Max RPM (auxiliary 1-9999 input: secondary mode) Scaling Format Selection and Control Output format Primary scaling mode Secondary scaling mode Primary display mode Secondary display mode Tuning...
Page 139: Puller Control Settings
PID (Proportional, Integral, Differential) tuning is the process DVANCED of setting the control algorithm parameters (codes 65-69) to achieve optimum performance. While each puller is tuned ROCEDURE before shipment to optimize performance over the entire speed PID T range, customers may wish to tune the puller for their specific UNING operating conditions.
Page 140: Using The Digital Belt Gap Sensor
The digital belt gap sensor uses a linear scale attached to both SING THE belts to measure the relative distance between the belts. The relative distance is shown in thousandths of an inch (.001). IGITAL The sensor has five buttons: ENSOR On/Off - Turns the device on and off.
Page 141 You can adjust the opening and closing speed of the air cylin- DJUSTING THE der assembly that operates the upper belt boom assembly by adjusting (lifting and turning) the air regulator handle. NEUMATIC PPER CTUATOR Handle PPENDIX NEUMATIC PPER CTUATOR UGE048/1103...

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Conair CSC User Manual

Introduction

Description

Installation

Operation

Operation

Maintenance

Troubleshooting

Appendix

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