Conair SC-5 User Manual

Sure Cut Rotary Knife Cutter

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

SC-5 Servo Model

UGE059/1003

Installation

Operation

Maintenance

Troubleshooting

It is important to record the model and serial number(s) of your equipment and the date you received it in the User Guide. Our service department uses this information, along with the manual number, to provide help for the specific equipment you installed.

Keep this User Guide and all manuals, engineering prints and parts lists together for documentation of your equipment.

Date: Document Number: UGE059/1003

Serial number(s):

Model number(s):

Power Specifications:

Amps Volts Phase Cycle

DISCLAIMER: The Conair Group, Inc., shall not be liable for errors

contained in this User Guide or for incidental, consequential damages 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.

Record your equipment’s model and serial number(s) and the date you received it in the spaces provided.

THE CONAIR GR OUP, INC.

UGE059/1003 SC-5 SURE CUT Servo Knife Cutters

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1

Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2

How the Guide is Organized . . . . . . . . . . . . . . . . . . . . . . .1-2

Your Responsibilities as a User . . . . . . . . . . . . . . . . . . . . .1-2

ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3

How to Use the Lockout Device . . . . . . . . . . . . . . . . . . . .1-5

DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1

What is the SC-5 Sure Cut? . . . . . . . . . . . . . . . . . . . . . . . .2-2

Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

How the SC-5 Sure Cut Works . . . . . . . . . . . . . . . . . . . . . .2-5

SC-5 Sure Cut Features . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1

Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Positioning the SC-5 Sure Cut . . . . . . . . . . . . . . . . . . . . . .3-4

Connecting the Main Power Source . . . . . . . . . . . . . . . . . .3-6

Installing the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Installing the Cutter Blades . . . . . . . . . . . . . . . . . . . . . . . .3-8

Mounting the Cutter Bushings . . . . . . . . . . . . . . . . . . . .3-10

Checking Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Preparing for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1

The Cutter Control Feature . . . . . . . . . . . . . . . . . . . . . . . .4-2

Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Powering Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Preset to Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Time Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Cut Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Maintenance Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Encoder Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

Unit of Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Scale Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

Homing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Offset Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Power On Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

Checking Cut Quality . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

Starting the SC-5 Sure Cut . . . . . . . . . . . . . . . . . . . . . . . .4-29

Making Adjustments During Operation . . . . . . . . . . . . . .4-30

Stopping the SC-5 Sure Cut . . . . . . . . . . . . . . . . . . . . . . .4-31

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1

Maintenance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Preventative Maintenance Schedule . . . . . . . . . . . . . . . . . .5-4

Checking the Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

Inspecting Cutter Bushing Screws . . . . . . . . . . . . . . . . . . .5-7

Checking the Closure Latch . . . . . . . . . . . . . . . . . . . . . . . .5-7

Cleaning the Blade Tray . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Lubricating the Slide Rail System . . . . . . . . . . . . . . . . . . .5-8

Adjusting the Proximity Switches . . . . . . . . . . . . . . . . . . .5-9

Checking Electrical Connections . . . . . . . . . . . . . . . . . . .5-10

B-Loc Installation and Removal . . . . . . . . . . . . . . . . . . . .5-12

TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1

Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Identify the Cause of a Problem . . . . . . . . . . . . . . . . . . . . .6-3

Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

Product Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . .6-8

Replacing Safety and Proximity Switches . . . . . . . . . . . .6-12

Checking the Servo Amplifier . . . . . . . . . . . . . . . . . . . . .6-12

Adjusting the Proximity Switches . . . . . . . . . . . . . . . . . .6-14

Checking the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

Checking the Motor/Reducer Assembly . . . . . . . . . . . . . .6-17

Checking Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Service Information . . . . . . . . . . . . . . . . . . . . . .A-1

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Cutter Blade Selection and Use . . . . . . . . . . . . . . . . . . . . .B-1

Cutting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Calculating Blade Interruption . . . . . . . . . . . . . . . . . . . . . .B-4

Conair Cutter Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

All About Cutter Bushings . . . . . . . . . . . . . . . . . . . . . . . .C-1

Blade and Bushing Lubrication . . . . . . . . . . . . . . . . . . . . .D-1

Operator Display Overview . . . . . . . . . . . . . . . . . . . . . . . . E-1

ARTS/DIAGRAMS

This section has been provided for you to store spare parts lists and diagrams.

1-1

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

●●

Purpose of the User Guide . . . .1-2

●●

How the User Guide

is organized . . . . . . . . . . . . . . .1-2

●●

Your Responsibilities

as a User . . . . . . . . . . . . . . . .1-2

●●

ATTENTION: Read this so

no one gets hurt . . . . . . . . . . .1-3

●●

How to Use the

Lockout Device . . . . . . . . . . . .1-5

INTRODUCTION

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

1-2 INTRODUCTION

This User Guide describes the Conair SC-5 Sure Cut Servo Knife Cutter and explains step-by-step how to install, operate, maintain and repair this equipment.

Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet. You also should review manuals covering associated equipment in your system. This review won’t take long, and it could save you valuable installation and operating time later.

Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation.

Symbols within triangles warn of conditions that could be hazardous to users or could damage equipment. Read and take precautions before proceeding.

Numbers within shaded squares indicate tasks or steps to be performed by the user.

A diamond indicates the equipment’s response to an action performed by the user.

An open box marks items in a checklist. A shaded circle marks items in a list.

You must be familiar with all safety procedures concerning installation, operation and maintenance of this equipment. Responsible safety procedures include:

● Thorough review of this User Guide, paying particular

attention to hazard warnings, appendices and related diagrams.

● Thorough review of the equipment itself, with careful

attention to voltage sources, intended use and warning labels.

● Thorough review of instruction manuals for associated

equipment.

● Step-by-step adherence to instructions outlined in this

User Guide.

PURPOSE OF THE USER GUIDE

HOW THE USER GUIDE IS O

RGANIZED

◆ ❒

●

YOUR RESPONSIBILITY ASAUSER

WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.

This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of machine.

All wiring, disconnects, and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region. Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the machine serial plate.

INTRODUCTION 1-3

We design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide.

ATTENTION:

READ THIS SO NO

ONE GETS HURT

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

DANGER: Sharp blades!

Most injuries caused by knife blades occur when the cutter has been turned off. Handle blades with care at all times.

● Always lock out the cutter before opening the cutting chamber.

● Always wear cut-resistant gloves when the cutting chamber is open and when handling blades.

SC-5 cutters are equipped with several safety devices to ensure safe operation. Never remove or disable these devices to sustain production. Operating without these devices can cause severe injury.

● 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.(Do not attempt to change a blade or work in the cutting chamber with out locking out the power.

In order to protect the operator from possible harm from the rotating blade wheel, several safety features are built into this cutter. They include:

Two electric switches make a contact between the side and the clear polycarbonate sliding blade observation

windows such that the windows MUST BE CLOSED

in order to enable the blade wheel to spin.

●●

This prevents someone from opening the windows and having the blade wheel spin which can cause serious injury. Tampering with this safety feature will VOID ANY responsibility for safety.

A proximity switch is positioned on both the upstream and downstream side of the bushing holder. If there are no bushings in either side, the blade will not spin.

●●

This prevents someone from inserting their hands or

fingers in the cutting mechanism while the blade wheel

is spinning. Tampering with this feature will also

VOID ANY responsibility for safety.

A safety switch is positioned on the bushing holder flip up guard to prevent operation unless fully closed.

●●

This prevents someone from inserting their hands or

fingers in the cutting mechanism while the blade wheel

is spinning. Tampering with this feature will also

VOID ANY responsibility for safety.

A lockable main power disconnect is provided to pre-

vent the possibility of hazardous electrical shock while servicing the main electrical enclosure. (See How to use the Lockout Device, in Section 1)

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

1-4 INTRODUCTION

WARNING:Voltage Hazard

This equipment is powered by three-phase alternating current, as specified on the machine serial tag and data plate.

A properly-sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure. Improper grounding can result in severe personal injury and erratic machine operation.

Always disconnect and lockout power before opening the electrical enclosure or performing non-routine procedures such as maintenance and service.

ATTENTION:

READ THIS SO NO

ONE GETS HURT

CAUTION:It is always recommend

that the main power cord be disconnected and placed in clear view of the operator or service personnel while changing blades or servicing the cutter in any capacity.

HOW TO USE

THE

LOCKOUT

DEVICE

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

INTRODUCTION 1-5

WARNING: Electrical hazard

Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injur y from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity.

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. Do not stop the

cutter by turning off the disconnect. Always touch the off soft key on the interface first.

Isolate the equipment from electrical power.

Turn the rotary disconnect switch to OFF or O position.

Secure the device with an assigned lock or tag.

The equipment is now locked out.

CAUTION: Moving parts

Before removing lockout devices and returning switches to the ON position, make sure that all personnel are clear of the machine, tools have been removed and all safety guards are reinstalled.

2-1

●●

What is the SC-5 Sure Cut

Knife Cutter . . .............2-2

●●

Typical Applications . . . .......2-4

●●

How the SC-5Works ...........2-5

●●

SC-5 Features . ...............2-7

●●

Specifications . ...............2-7

●●

Optional Equipment . . . . .......2-8

DESCRIPTION

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

The Conair SC-5 Sure Cut Series rotary knife cutter has been designed to be “The most versatile cutter of the industry”.

With both capacity to cut small parts at high speeds or large tubes or profiles at low speeds this cutter can eliminate the need for moving cutters in and out of a line per application.

Today with custom profile houses potentially running 2-3 different profiles on one line in a given day, time is at a premium. Having to move different cutters in and out of line is no longer acceptable when time is money.

Mechanical Features

This series of servo rotary knife cutters use a 24 inch diameter flywheel optimizing surface speed and power. This is in fact the largest diameter wheel which could be used while still allowing it’s mounting under the bushing holder.

Flywheel

With a 24 inch diameter flywheel which is 1inch thick, many benefits become available.

Planetary Gear Reducer

A 10:1 in-line servo motor rated planetary gear reducer with 7 arc-minutes maximum backlash is mounted directly to a 3000 rpm brushless servomotor. A top flywheel speed of 300 rpm is realized. Even though the flywheel appears to be moving slowly, the actual surface speed at the blade at only 300 RPM’s is over 0.438 inch per millisecond. That’s twice the surface speed of a typical clutch brake cutter.

Instead of mounting the cutter head directly to the servo motor shaft, which is generally not designed for high radial load or axial load due to small shaft diameters, the 24 inch flywheel is mounted to the planetary gear reducer shaft which is designed for just this type of application. At the gear ratio and output speeds which this cutter was designed, radial load on the output shaft of the reducer is in excess of 1000 lbs where the servo motor shaft may only be 100 lbs or less. Potential wear on the servo motor shaft bearings is minimized.

The high speed\low torque power of the servo motor is efficiently converted into a low RPM\high surface speed\high torque power more suitable for cutting applications.

WHAT IS THE SC-5 SURE CUT?

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

2-2 DESCRIPTION

Continued

HAT IS THE

SC-5 S

URE

CUT?

CONTINUED

DESCRIPTION 2-3

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

The larger diameter flywheel used on the servo cutter offers the potential of higher surface speeds at dramatically lower blade rpm’s with high cutting torque. The typical grey area between on-demand cutting and flywheel cutting (150 cpm on-demand up to 300 cpm flywheel), typically seen in DC driven clutch\brake cutter is eliminated.

It should not be necessary to cut in on demand mode in excess of 150 cuts per minute which will greatly save on premature wear to the system. Not only does this cutter offer optimum blade surface speed throughout an extremely wide cuts per minute range, but extreme accuracy throughout.

The added benefit of the 24 inch diameter by one inch thick aluminum wheel is the stored inertia which adds power for cutting larger profiles and tubes. The size of the wheel actually adds horsepower to the system. Due to the use of 10:1 gear reduction, the servomotor is made extremely efficient and easily able to handle this weight with out detrimental effects.

Cutting from Below the Bushing Holder

The SC-5 Sure Cut Servo Cutter housing maximizes versatility and operational ease. Due to the size of the flywheel it was determined best to mount it directly below the bushing holder keeping the center of gravity low and offering the following benefits:

● Accessibility of the flywheel for ease of blade changes.

● Built in blade lubrication tray can be integral to the design

of the cutting chamber.

● An optional blade heating system can be added to give

optimum versatility to this cutter.

● With the bushing holder above the flywheel tremendous

cutting capacity is available without extreme blade length.

● Ease of discharge conveyor interface for part support and

automatic ejection systems is made simple with this layout.

● The optional slide system can enable the use of rigids and

flexibles.

To get the full benefit from the servo cutter Conair has provided several cutting modes, see Cutter Control, Section 4. The Conair SC-5 Sure Cut servo rotary knife cutter is a truly innovative cutter. Loaded with features and backed up by the most extensive service support system in the industry.

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

2-4 DESCRIPTION

TYPICAL APPLICATIONS

Extruded material that has been sized and cooled enters the cutter from the upstream side (See How the SC-5 Sure Cut Works, Section 2, step 1). Typically, a puller is placed just before the cutter; the puller pulls the extrudate through the sizing and/or cooling tanks and feeds it into the cutter.

The positional servo motor, is direct coupled to the cutter head, or an in-line planetary gear reducer that drives the cutter head. The planetary gear reducer arrangement increases cutting torque, improves servo motor efficiency, and offers improved bearing load ratings.

The cutting knife, attached to the cutter head, is driven by the servo motor (See How the SC-5 Sure Cut Works, Section 2, step 2). Two cutter bushings guide and support both the extrudate and the cutting knife. The cutter head is mounted directly to the in-line planetary gear reducer shaft using a BLoc coupling device, and may have as many as four optional blade positions. See Installation and Removal of B-Loc,

Section 5.

Two types of cutting modes are available. On-demand cutting modes (Timer, Encoder, Auto and Product) provide a single rotation cut cycle. However, in continuous cutting modes (Flywheel and Optional Follower) the cutting mechanism rotates continuously.

The knife guard includes a stainless steel lower tray, which can be used for blade lubrication. The upper knife guard includes a clear polycarbonate window. This allows you to watch the cutting blade during operation.

Cut pieces are collected or carried on to further processing by an optional conveyor (See How the SC-5 Sure Cut Works,

Section 2, step 3).

Continued on next page.

OW THE SC-5

URE CUT

WORKS

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

DESCRIPTION 2-5

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

2-6 DESCRIPTION

The cutter head holds the

blade(s) as they rotate and pass between the bushings, cutting the extrudate.

Extruded material enters the cutter from the upstream side.

Cut pieces are collected or

carried away on a conveyor.

HOW THE SC-5 S

URE CUT

WORKS

ONTINUED

The SC-5 Sure Cut Servo Cutter features:

SC-5 F

EATURES

DESCRIPTION 2-7

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

Swivel Casters

Parts discharge chute or optional discharge conveyor

Optional slide base assembly with position locking mechanism

Wide Range of Cutter Bushing Capacities

24-inch diameter flywheel with multiple blade mounting system

Polycarbonate blade observation window

Optional blade lubrication system

Heavy-duty leveling screws and pads

The standard control:

● Large easy-to-read display.

● Soft keys allows the opera-

tor to select different functions.

● Numeric keys permits data

entry for the operator.

● Fixed function keys contain

universal symbols and text.

MODELS SC-5 Performance characteristics

Extruder capacity in. {mm}

Tube diameters 2.25 - 5.25 {57 - 133}

Profile dimensions 2x4 - 2x10, 4x7 {51x102 - 51x254, 102x178} Blade drive motor Hp {kW} 4.6 {3.4} Feed direction right>left

Dimensions in. {mm}

A - Height 47 {1194} B - Height to centerline 40±2 {1016±50.8} C - Length 44 {1118} D - Width 52 {1321}

Voltage/phase/frequency 230 V/3/60 Hz 0r 460 V/3/60 Hz Cutter control Red Lion {CL01/FM4}

C D

● 24-inch flywheel

● Up to 150 cuts/minute on

demand with one blade

● Up to 300 cuts/minute with one

blade on Flywheel mode

● Blade speeds adjustable to

300 RPM

● Surface speeds to 0.438 inches

per millisecond

● Heavy-duty positional AC

brushless servo drive

● 10:1 planetar y gear head

reducer

● 3,000 pulse bi-directional

encoder

PECIFICATIONS

CONAIR SERVO CUTTER

Version 1.0

OPTIONAL EQUIPMENT

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

2-8 DESCRIPTION

Slide Base

This option is highly recommended for cutting flexible extrudates. While the cutter base is fixed and aligned with the puller, the cutter itself is mounted on a set of linear slides that allow as much as 12 inches of movement. The cutter can be moved away from the puller for startup, then moved close to the puller to enhance delivery to the cutter bushings.

Blade Wipe

The blade wipe system keeps the cutting blade clean by removing lubricant and particles from the blade. A felt pad sandwiched between two pieces of stainless steel and mounted next to the bushing wipes the knife before each cut.

Custom Bushing Holder Sizes Available:

Heavy Duty Blade Positions

●●

One blade position standard

●●

Optional 2 or 4 blade positions available

●●

Optional simitare blade available (see parts list for optional

blades.)

Round Profile

2.25 inch (standard) 2x4 inch

3.25 inch 2x6 inch

4.25 inch 2x8 inch

5.25 inch 2x10 inch 3x6 inch 4x7 inch

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

DESCRIPTION 2-9

TIP: Conair strongly recom-

mends the use of an isolation transformer.Ensuring clean and proper power can help avoid the need for costly service calls.

Discharge Conveyor

A discharge conveyor facilitates the removal of cut parts. Discharge conveyors are available in the following sizes:

● 6 inches wide by 6 feet long

● 6 inches wide by 10 feet long

● 6 inches wide by 16 feet long

Isolation Transformer

The isolation transformer protects sensitive electronics from incoming power, which helps prevent errors caused by electrical noise. It also protects equipment from electrical noise generated by the servo motor and associated amplifier. NOTE: An isolation transformer will not compensate for a ground that does not meet code requirements.

Left to Right Machine Operation

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.

OPTIONAL EQUIPMENT

3-1

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

●●

Unpacking the Boxes . . . . . . . . .3-2

●●

Preparing for Installation . . . . . .3-3

●●

Positioning the SC-5

Sure Cut . . . . . . . . . . . . . . . . .3-4

●●

Connecting the Main

Power Source . . . . . . . . . . . . .3-6

●●

Installing the Encoder . . . . . . . .3-7

●●

Installing the Cutter

Blades . . . . . . . . . . . . . . . . . . .3-8

●●

Mounting the Cutter

Bushings . . . . . . . . . . . . . . . .3-10

●●

Checking Repeatability . . . . . .3-12

●●

Preparing for Testing . . . . . . . .3-13

●●

Testing the Installation . . . . . . .3-13

INSTALLATION

The SC-5 Sure Cut Series Servo Knife Cutter comes fully assembled in a single crate.

UNPACKING THE BOXES

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

3-2 INSTALLATION

CAUTION: Lifting

To avoid personal injury or damage to the cutter, lift the cutter using a for klift or hoist with straps that have been positioned at the cutter's center of gravity.

Carefully uncrate the cutter and its components.

Remove all packing material

, protective paper, tape, and plastic. Compare contents to the shipping papers to ensure that you have all the parts.

Carefully inspect all components to make sure

no damage occurred during shipping. Check all wire terminal connections, bolts, and any other electrical connections, which may have come loose during shipping.

Record serial numbers and specifications in the

blanks provided on the back of the User Guide's title page. This information will be helpful if you ever need service or parts.

You are now ready to begin installation.

Complete the preparation steps in Preparing for Installation, Section 3.

You need these tools for installation:

❒ 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. Check the cutter’s seri-

al tag for the correct amps, voltage, phase and cycles. 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 servo cutter for maintenance and servicing. If the servo cutter has the optional slide base, be sure to check for clearance by extending the slide system in both directions.

PREPARING FOR INSTALLATION

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

INSTALLATION 3-3

WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.

This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of machine.

Move the servo cutter into position. Place the

servo cutter in position downstream of the belt puller.

Determine the best distance from the belt puller to

the SC-5 Sure Cut cutter.

● For flexible products, the cutter should be located

as close to the puller as possible to insure a minimum amount of space for the product between the point of exit of the puller and the inlet to the cutter bushing for most flexible products.

● For rigid products, allow some deflection space

between the puller and cutter. This will minimize product sag or excessive deflection during cutting which could affect the cut length accuracy.

As a general rule, place the cutter such that you feel no shock from the cut with your fingernail placed on the extrudate on the entrance of the puller. If you feel shock form the cut, simply allow more space between the cutter and puller.

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

3-4 INSTALLATION

OSITIONING

THE

SERVO

CUTTER

CAUTION: Lifting

To avoid personal injury or damage to the cutter, lift the cutter using a for klift or hoist with straps that have been positioned at the cutter's center of gravity.

NOTE: If the slide base option

was purchased, the cutting chamber can be slid back from the frame to allow ease of the string up procedure.

SC-5 Cutter

Continued

Align the cutter with the extrusion line.

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.

Adjust the cutter's floorlock/caster assembly

to the center height of the extrusion line using a 16- or 18-inch adjustable wrench. Once the correct height is reached, adjust the pad assembly to remove the weight from the casters for operation. This minimizes machine vibration during the cutting cycle.

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.

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

INSTALLATION 3-5

POSITIONING

THE

SERVO

CUTTER

CONTINUED

3-6 INSTALLATION

Open the servo cutter’s electrical enclosure.

Turn the disconnect dial on the door to the OFF or O position and open the door.

Insert the main power wire through the knockout

in the side of the enclosure. Secure the wire with a rubber compression fitting or strain relief.

Connect the power wires to the terminals indicated

on the wiring diagram that came with your machine.

IMPORTANT: Always refer to

the wiring diagrams that came with your servo cutter before making electrical connections.The diagrams show the minimum size main power cable required for your cutter, and the most accurate electrical component information.

CONNECTING

THE

MAIN

POWER SOURCE

WARNING: Electrical hazard

Before performing any work on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity.

WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.

This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of machine.

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

Check every terminal screw to make sure wires are

secure. Gently tug each wire. If a wire is loose, use a screwdriver to tighten the terminal.

Connect the ground wire to either grounding point

shown in the diagram.

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

INSTALLATION 3-7

Conair uses bi-directional encoders to ensure that only product that moves forward is counted. Installing the encoder consists of several parts:

● the encoder

● the measuring wheel

● the connecting cable

The encoder is fitted with a one foot circumference wheel which rides on either the upper belt of the belt puller or (for rigid profiles and pipe) on the extrudate itself upstream of the puller.

The encoder is supplied with an integral mounting bracket. How and where you attach the encoder to the puller depends on your particular puller and application.

● If the wheel rides on the puller belt, make sure that its lin-

ear alignment is the same as the belt. Place the wheel near the center of the belt to minimize bouncing. Try to avoid cracks and other belt features that may effect accuracy.

● Make sure the location allows you to keep the wheel

clean. Any small buildup on the wheel will effect its circumference and change the cut length.

After the encoder is installed, attach it to the cutter control using the supplied cable. The cable has been hard-wired to the control at the factory.

INSTALLING THE ENCODER

CAUTION: Handle with care.

The encoder is a delicate piece of equipment and must be handled gently.

Wheels

Connecting

Cable

Encoder

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

3-8 INSTALLATION

NSTALLING THE

CUTTER BLADES

DANGER: Sharp blades!

Most injuries caused by knife blades occur when the cutter has been turned off. Handle blades with care at all times.

● Always lock out power to the cutter before opening the cutting chamber.

● Always wear cut-resistant gloves when the cutting chamber is open and when handling blades.

● Always wait until the cutter head has completely stopped before opening the knife guard.

SC-5 Sure Cut cutters are equipped with several safety devices to ensure safe operation. Never remove or disable these devices to sustain production. Operating without these devices can cause severe injury.

Never attempt to change or work on Blades without first locking out power to the machine.

● 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 cutter head.

Installing the Cutter Blades

Shut off the main power disconnect and unplug the main power cord

when entering the cutter housing. There is a safety interlock on the cutter blade housing that will deactivate the servo amplifier and control system.

Remove the screws holding the blades,

remove the old blades and insert the new blades.

The blade, or blades as the case may be, will fit onto a roll pin or in a machined slot with a blade clamp to squeeze or tighten. Secure the blade.

For more information about choosing the appropriate blade for your material, see the Appendix B.

Continued

INSTALLATION 3-9

UGE059/1003 SC-5 SURE CUT Servo Knife Cutter

TIP: We recommend that you:

● Apply some protective cover on the portion of the blade you are handling, such as masking tape

to help prevent getting cut during installation and to leave it on until such time that you will start and check the cutting operation.

● Check the length that the blade extends out of

the cutter blade wheel. The blade needs to be

carefully checked to insure that the entire blade will pass completely through the product.

This is especially important with the very first insta-

llation and can be accomplished by rotating the wheel with the blade installed manually though the bushing and visually check to see that it will completely cover the entire bore of the bushing.

INSTALLING THE CUTTER BLADES

ONTINUED

CAUTION:Never attempt to change or work on

blades without first locking out power to the machine.

CAUTION: Use extreme caution as the blades will be very sharp.With the power off, the blade wheel can spin freely.

DANGER: Sharp blades!

Always wear cut-resistant gloves when the cutting chamber is open and when handling blades.Never open cutting chamber without locking out the cutter power and waiting until the cutter head stops spinning.

3-10

INSTALLATION

SC-5 SURE CUT Servo Knife Cutter UGE059/1003

MOUNTING THE CUTTER BUSHINGS

The Bushings

Generally, the bushing will be in two parts, an inlet and an outlet with the inlet bushing being tapered or otherwise contoured to assist in guiding the product into the cutter mechanism. It is extremely crucial to the success of the cutting process that bushing bores be exact and in perfect alignment with each half. They should be polished smoothed, burr free and generally several thousands oversized for optimum performance.

Installation of the bushing

Open the top hinged cover (yellow) to expose the top of the bushing holder.

Use the two set screws positioned on top of the bushing holder and turn them counterclock wise to loosen and remove the bushings.

Replace the desired bushings and tighten up the two set screws just enough to barely be

able to move the bushings. Rotate the blade wheel until the blade enters

the space between the two bushings.

Move the outlet bushing in until you can bare-

ly feel the blade scrape along the inside of the

bushing.

Move the inlet bushing inward until there is about 0.001 to 0.003 inch clearance between the blade and the outlet bushing.

Tighten the two screws in the housing to lock

in the bushings.

Rotate the blade wheel

by hand so that the blade passes through the space between the two bushings to insure that it will clear without hitting either bushing and passes through the space with little effort.

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