Rotary Knife Cutter
© NOVATEC, INC 2015 All Rights Reserved
C Series IM 12 MAY 2015
Model: Bessemer C-Series:
C-2, C-3 & C-4
C-Series IM 12 MAY 2014
Please record the following information,
which is specific to this piece of
Instruction Manual: C-Series IM 12 MAY 2015
DISCLAIMER: NOVATEC, Inc. shall not be liable for
errors contained in this Instruction Manual nor for
misinterpretation of information contained herein.
special, indirect or consequential damages in
equipment, in the space provided.
Our Parts/Service Department will need
these numbers to properly respond to
any of your requests.
Model #:___________________________
Serial #____________________________
NOVATEC shall not, in any event, be held liable for any
connection with performance or use of this information.
© 2015 NOVATEC Inc. All Rights Reserved
Document: C-Series IM 12 MAY 2014
C-Series IM 1 MAY 2014
Table of Contents
PURPOSE OF THIS MANUAL ............................................................................................................ 3
1
Explanation of Symbols ........................................................................................................................................... 3
2 SAFETY PRECAUTIONS AND WARNINGS ...................................................................................... 4
2.1 Safe Access to Guarded Blade Area ................................................................................................................ 4
3.0 GENERAL DESCRIPTION .................................................................................................................. 5
4.0 SPECIFICATIONS ............................................................................................................................................ 6
4.1 Product Features ........................................................................................................................................ 6
5.0 BLADE SPEED VS CU TS PER MINUTE ......................................................................................................... 7
6.0 OPERATING PRINCIPLES .................................................................................................................... 9
7.0 INSTALLATION ...................................................................................................................................... 9
7.1 Mechanical Installation .................................................................................................................................... 10
7.1.1 The Blades .......................................................................................................................................... 10
7.1.2 The Bushing ........................................................................................................................................ 11
7.2 Electrical Installation ....................................................................................................................................... 12
8.0 INDICATOR LIGHT DESIGNATIONS .................................................................................................. 14
9.0 PLC GENERAL OVERVIEW ................................................................................................................ 15
9.1 Startup and Power Loss .................................................................................................................................. 15
10.0 SCREEN CONVENTIONS AND COMMON ELEMENT ..................................................................... 15
10.3 Screen Title ................................................................................................................................................... 16
10.4 Machine Status ............................................................................................................................................. 16
10.5 Standard Navigation Buttons ........................................................................................................................ 16
10.6 Cut Start/Stop Buttons .................................................................................................................................. 16
11.0 SYSTEM STARTUP ........................................................................................................................... 17
11.1 Initial Screen - ............................................................................................................................................... 17
11.2 POWER UP Screen ...................................................................................................................................... 17
11.2.1 Verify Safety/Reset S ystem ............................................................................................................... 17
11.2.2 Verify Safety/Press E-Stop ................................................................................................................ 18
11.2.3 Reset System to Home Screen ......................................................................................................... 18
11.2.4 Homing Screen .................................................................................................................................. 18
12.0 MACHINE OPERATION ..................................................................................................................... 19
12.1 Quick Ops Screen Items ............................................................................................................................... 19
12.2 Cut Start/Stop Buttons .................................................................................................................................. 20
12.3 Changing the CUT MODE ............................................................................................................................ 20
12.4 Recipe Select Screen.................................................................................................................................... 21
12.5 CURRENT RECIPE SCREEN ............................................................................................................ 22
12.6 Setting Up Counters ...................................................................................................................................... 23
12.7 Production Metrics ........................................................................................................................................ 23
12.8 QUICK OPS SCREEN VERSIONS .................................................................................................... 24
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13.0 SETUP SCREENS .............................................................................................................................. 26
13.2 LOGON ......................................................................................................................................................... 26
13.3 Home Screen ................................................................................................................................................ 27
13.4 Recipe Functions .......................................................................................................................................... 28
13.5 SETUP SCREEN 1 ....................................................................................................................................... 29
13.6 SETUP Screen 2 ........................................................................................................................................... 30
13.7 SETUP Screen 3 ........................................................................................................................................... 32
13.8 Servo Setup Page ......................................................................................................................................... 34
13.9 Batch Counter Screens ................................................................................................................................ 36
14.0 MAINTENANCE .................................................................................................................................. 37
At Startup .............................................................................................................................................................. 37
Every bushing or blade change ............................................................................................................................ 37
Daily ...................................................................................................................................................................... 37
Every 3 Months ..................................................................................................................................................... 37
15.0 WARRANTY – NOVATEC, INC. - EFFECTIVE DATE 6-12-2012 ..................................................... 38
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WARNING: This symbol identifies situations that are potentially
1 PURPOSE OF THIS MANUAL
This manual describes the installation and operation of the NOVATEC Model C Rotary Knife Cutter.
Before installing this product, please read this guide and any additional guides associated with the
system’s auxiliary equipment.
Explanation of Symbols
This manual includes both general and task-specific safety precautions. These precautions
are highlighted in the manual by the following categories:
hazardous to personnel or equipment.
NOTE
Highlights information provided in text or procedures. This
information may or may not be related to safety.
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2 SAFETY PRECAUTIONS AND WARNINGS
These operating instructions must be read, understood, and implemented by all personnel
responsible for this system.
All mechanical and electrical work must be performed by qualified personnel only.
Always disconnect power before servicing.
Refer to the machine serial number nameplate and drawings supplied with this system for
actual power requirements.
Be sure to install the equipment with the proper electrical connections according to all national
and local regulations.
Electric power supply should be through a separate disconnect switch with properly sized
overload/fuse protection.
The customer is required to operate the equipment with all safety features in proper working
condition.
NOVATEC shall provide no further guarantee for function and safety in the event of
unauthorized modifications.
2.1 Safe Access to Guarded Blade Area
It is safe to access the guarded blade area when the power is on. NOVATEC Cutters use
a servo that has built in safety. It can execute a Safe Stop on E-Stop and has a Safe Torque
Off which is executed within 0.5 seconds of E-Stop. It also is monitoring itself for Safe
Standstill which is interlocked to the guard lock. W ith the addition of redundant safety relays,
motor contactor and guard interlock, the system can exceed SIL-3, PL-d saf ety requ irement s
for a Cat3 safety hazard.
NOTE: Additional guarding may be required where the product enters and exits the
bushing.
NOTE: The Safety Circuit Must Be Tested on 90 Hour Intervals
To meet t he r equirem ent s fo r a C at 3 safety sys t em , t h e safety cir c u it m u st b e te s t e d at r egular
intervals to insure that it is functioning properly. When the system is first powered on, the
power must be engaged and then the E-Stop activated to ensure that it is funct ioning. After
90 hours of continuous operation a Warning Message will appear instructing the operator to
perform the safety verification test which involves pressing the E-Stop and the resetting the
circuit. Production can continue while the message is present but arrangements should be
made to perform the test as soon as possible.
Even though there is no power to the blade when the system is E-Stopped, there is still the
hazard of the sharp blade. Care should always be taken when working in this area.
Please contact Novatec if there are any questions or concerns.
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3.0 GENERAL DESCRIPTION
The NOVATEC, C Series Rotary Knife Cutter offers high versatility to cut a wide range of profiles. It
is able to cut small profiles at high speeds and large profiles at lower speeds. Extrudate is fed into
the cutter from upstream, typically by a puller. Two cutter bushings, on either side of the knife, guide
the extrudate through the cutter. A rotary knife is mounted to a 12” diameter cutter head and driven
by a servo motor through a gear reducer. This knife cuts material that is supported between the
bushings. The knife is positioned at a home position until the cut motion begins. The knife then
rotates through a cutting lubricant/chip collection reservoir, through a felt blade wipe to clean the
blade, and then through the bushings again to make another cut. The cut extrudate continues to
move through the bushing where it is either collected or is conveyed further downstream by an
optional conveyor.
Two cutting modes are available: ON-DEMAND cutting mode and CONTINUOUS cutting mode.
Within these two major modes of operation, a wide range of parameters may be adjusted for
consistent, repeatable, and precise results.
• ON-DEMAND cutting mode allows 250 cuts per minute. The blade does not continuously
rotate, but instead starts and stops as needed.
• CONTINUOUS cutting mode allows up to 750 cuts per minute by continuously rotating the
cutter head at a speed sufficient to cut the desired length at the measured line speed.
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52.37” Floor
36 “
28
58 5
39 9
4.0 SPECIFICATIONS
to
C.L Control
4.1 Product Features
• 12” high torque cutter head
• Accepts rectangular bushings 19.75mm thick x 89.75mm wide x 150mm long
• Apex Dynamics 4:1 speed reducer
• Taper lock shaft bushing hardware
• 2500 count quadrature cut length encoder with 12” circumference measuring wheel
• Knife thicknesses of .015, .020”, .025”, .030”, .040” available; Blades shaped and sharpened
to meet custom application requirements
• Safety interlocks provided for operator safety
• Removable cutting chamber cover with integral reservoir provides full access to cutting
chamber and cutting fluid reservoir
• Split clamp bushing arrangement provides easy bushing setup
• Indicator lights for machine status indication
• 5-Year Warranty
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5.0 BLADE SPEED VS CUTS PER MINUTE
The blade speed can be set anywhere from the Minimum On Demand Blade Speed to the
Maximum Blade Speed set on the System Setup page. Typically, the blade speed will be set
so that the product has the best possible cut. If the blade speed is set too low and the CPM
requirement is too high, the blade will not travel around in time to start the next cut and the
next cut will be ignored resulting in a part that is twice as long as intended. It is also possible
to set the On Demand Blade Speed and the Required CPM so high that eventually, it faults
the drive because there is too much power required for the move. Below are charts that show
the blade speed versus CPM for several cutters. It was determined by shop testing. Actual
results might be less due to lower supply power or higher ambient temperatures.
The tests were performed with 480VAC at 75F.
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CAUTION: A ll machines must be grounded to prevent "shocks" from
6.0 OPERATING PRINCIPLES
The NOVATEC Model C rotary knife cutter model C is used to cut lengths of plastic extrudate. In
either the ON DEMAND or CONTINUOUS MODE.
ON DEMAND MODE: Plastic extrudate is fed through two inline bushings, which guide the plastic
through the cutter. The instant of cutting can be determined by a sensor, length of time or an
Encoder. Once the signal is sent to the PLC, the PLC processes the request and initiates the cut. A
servomotor rapidly accelerates the cutter head with attached blade(s) to rotate either 180° or 360°,
slicing through the extrudate. The cutter head then returns to its home position and waits for another
cut signal from the PLC.
CONTINUOUS MODE: Plastic extrudate is fed through two inline bushings, which guide the plastic
throug h th e cutter. T he instant of cutting can be determined by a length of time or an Encoder. Once
the signal is sent to the PLC, the PLC processes the request and initiates the cut. A servomotor
continuously rotates the cutter head with attached blade(s), slicing through the extrudate. The cutter
head rotates continuously at a speed sufficient to cut the desired length at the measured line speed.
7.0 INSTALLATION
1. Carefully unpack the cutter and any other components delivered with it. Check all
packaging for loose parts, documentation, and other included items. Carefully inspect the
cutter. Ensure that no wires, bolts, screws, terminals, or other connections have come
loose during shipping. Check to ensure that all moving parts are not obstructed by debris
or excess packing material.
2. You may require the following tools to complete the installation:
a. 16” or 18” adjustable wrench
b. Feeler gauges
3. All national and local electrical, building, and safety codes need to be followed. Proper
grounding of all equipment is important. Check the electrical wiring schematic for wiring
numbers and details. The following paragraphs describe installation of typical system
components. Some of them are optional and may not be required for your system.
static electricity that is generated by some materials as they are moved.
This is an extremely important step.
All electronics are susceptible (to varying degrees) to electrostatic damage
and, although as much protection as possible has been designed into the
system; this cannot completely eliminate upsets due to electrostatic voltage
being accidentally introduced into the electronic circuitry.
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Determine the position of the cutter. This should be done with consideration to the location of
the adjacent puller and to the nature of the extrudate. For flexible and semi-flexible extrudate,
locate the cutter closer to the puller to minimize extrudate buckling during a cut. For rigid
extrudate, allow more space between cutter and puller to improve cut finish quality and
consistency.
7.1 Mechanical Installation
Once the general position has been determined, carefully align the cutter with the extrusion
line. It is easiest to adjust the position on the floor before adjusting to the proper height.
Ensure that all downstream equipment is properly aligned (pullers, tanks, etc.). To adju st the
centerline height of the cutter, adjust each foot pad at the corners of the base of the cutter with
a 16 or 18 inch adjustable wrench. Ensure that the cutter is level.
7.1.1 The Blades
When installing the cutter blades, great care should be taken to avoid being cut. Use cutresistant gloves to avoid injury. Wait until the knife assembly fully stops before opening the
inspection door.
Ensure the cutter has stopped rotating; rotate the key switch clockwise (to 2 o’clock) and wait
5 seconds for the door to unlock; open the bushing guard (yellow cover).
Rotate the cutter head to a point where the hole in the
Cutter head, lines up with a hole in the cutter enclosure.
Insert an Allen wrench through the two holes to hold the
cutter head in place.
This avoids the possibility that the cutter head will move while
loosening/tightening bolts.
Remove the bolts holding the counter-balance or the old
blade(s), remove counter balance or the old blade(s), and
fasten new blade(s) in the same way the old blade was
attached.
Check that the new blade fully extends through the bushing so that the entire product is cut.
Tighten the knife-securing hardware to 140 inch-pounds of torque.
Always check the blade(s) to bushing clearance after
installing a new blade(s) by rotating the cutter head
manually and inspecting the gap between each of the
bushings and the blade(s).
Ensure that the blade(s) moves freely through the
bushings and that the bushings are properly
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NOTE: Counter-balance weight, opposite the
blade is used.
NOTE: Counter-balance should be
removed on end where blade is installed.
NOTE: When a single blade is installed, it
secured before re-powering the machine.
must be installed on same end of cutter
head as the HOME SENSOR is installed.
blade, must remain bolted in place if only one
7.1.2 The Bushing
Ensure the cutter has stopped rotating; rotate the key switch clockwise to “UNLOCK”
(2 o’clock) and waiting 15 seconds for the door to unlock before opening the bushing guard
(yellow cover). Loosen the rectangular bushing by loosening the12mm socket head set screw
located on the top of each cylindrical bushing holder. Test the location of the bushings for
accuracy by retightening the bushing holder socket head set screw and manually rotating the
cutter head to ensure that the blade passes through the two bushings. When satisfied with
the fit, fully retighten the bushing holder, inspect the blade clearance an additional time and
make sure the cutter head can rotate a full revolution while clearing the bushings. During
initial set up, the cylindrical bushing holders should be adjusted relative to one another by
loosening the socket head cap screws on the front of the machine that clamp the bushing
holders in place. This adjustment ensures the rectangular bushing holders are rotationally
aligned about the axis of the cylinder.
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WARNING: Do not install communication cable where it will
communications and/or possibly causing damage.
7.2 Electrical Installation
Always disconnect and lock out the main power supply before wiring power and control cables
between the NC rotary knife cutter controller and the external devices. Refer to the wiring
diagram and general arrangement drawings supplied with this system before making electrical
connections.
Use shielded cable for communications wiring.
Keep communication cables and control wiring as far as possible from high voltage
equipment. If you must run cable across power lines, run the cable at right angles to the
line.
Ensure the equipment grounding is properly connected. Shielded cable should be
grounded at one end only and is typically grounded in the main I/O enclosure.
come into contact with any buildup of electrical charge!
It may be tempting to run the wire next to the material conveying
lines, but a substantial buildup of electrical charge can and will occur,
especially with certain types of plastic resins and, if the conveying
lines are not grounded, they can arc to the cable disrupting
Open the cutter’s electrical enclosure and insert the main power through a knockout in the
wall of the enclosure. Connect the power wire as indicated on the included wiring diagram.
Check that all terminal screws are secure. Close electrical enclosure.
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KNIFE GUARD
LOCK/UNLOCK
EMERGENCY STOP
RESET
ALARM LIGHT
Before testing the machine, confirm that the placement and wiring of the cutter conform to all
applicable national and local regulations. When ready, turn on the main disconnect. Make
sure that the E-Stop button is in the out position. Press the reset button.
EMERGENCY STOP
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8.0 INDICATOR LIGHT DESIGNATIONS
The indicator light on top of the operator panel is used for machine alarm and status conditions.
Following is the meaning of those designations.
• Red – Cutter is Faulted
There is a fault condition that has stopped the machine
or powers down the safety circuit.
• Solid Orange – Warning is Present
There is a condition that requires operator attention.
The machine will continue to run.
• Flashing Orange – Blade is Homing
The safety circuit has been powered on and the blade servo is homing.
• Flashing Green – Cutter is Ready
The system is ready to start but is not running. Press the Run Product or Run Scrap button to
start machine.
• Solid Green – Cutter is Running Production
The system is cutting production parts.
• Flashing Green/Orange – Cutter is Running Scrap
The system is cutting Scrap parts.
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9.0 PLC GENERAL OVERVIEW
The NOVATEC, C Series cutters use a Siemens PLC controller to control a servomotor
actuated knife which can be signaled to cut, based on a number of input sensors.
Siemens Operator Interface and Programmable Logic Controller
The Siemens Human Machine Interface (HMI) is a touch-screen viewing and data entry
device, located on the face of the control panel. The screens are graphical in nature and
display information in text and/or by symbol change. The HMI communicates with the internal
Siemens Programmable Logic Controller (PLC) using standard Ethernet protocols.
9.1 Startup and Power Loss
When power is first applied to the Cutter following a power loss, the Cutter will return to the
Quick Ops screen and must be re-initialized. Recipes saved on the device will retain their
settings, and the machine will be in the last state it was in before powered down.
10.0 SCREEN CONVENTIONS AND COMMON ELEMENTS
10.1 Button Borders
Any item which has an operation will appear raised by the use of
shadowing around it to form a border. If the border is grey, then
the current user logged on does not have access to activate the
operation. If the operator presses a button with a grey border a
popup screen will appear prompting them to enter a user name and password. When a button
is pressed, the shadowing on the border will change to indicate to the operator that the system
recognized the button being pressed. Any button or field that has a grey background cannot
be activated. Items will appear on grey backgrounds if they are to report information only or
they are unavailable in the current mode of operation.
10.2 Logon
These two buttons will appear in the top right corner of
every screen. The right button will display "Logon" to
indicate that no one is logged on or it will display the user level of the current person logged
on. Pressing this button will bring up a popup to allow the operator to enter a user name and
password. The button on the left is used to log out and secure the system. It is possible to
change the default user in the machine setup.
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To
To
To QUICK OPS
To
10.3 Screen Title
A Title will appear in the top center or every screen.
10.4 Machine Status
In the top right hand of every screen will be the current
running status of the machine.
10.5 Standard Navigation Buttons
These 4 buttons appear on the bottom of every screen for quick navigation to other screens.
Previous Page
Home Screen
Screen
Alarms Page
10.6 Cut Start/Stop Buttons
CUT PRODUCT - Press this button to start the cutting of good product using the mode and
setting from the recipe. If the count is enabled, it will count each part as the blade crosses
into it.
STOP - Press this to stop the cutter with the blade at home position
(even in continuous mode).
CUT SCRAP - Press this button to shift to the scrap settings and stop counting.
NOTE: The cutter will quickly and automatically switch between any modes including between
continuous and on-demand cutting. The Cut Scrap button may be hidden in the system setup.
TEST CUT - Press this button to activate a single on-demand test cut. The test cut can be executed
while the system is running on-demand product. It will not be counted and the following cut will be cut
at the proper length/time. If the cut is done very close to when the set on-demand cut needs to
execute, it may interrupt that cut. The method for executing a Test Cut can be set in two ways in the
system setup. It can be set so that a popup menu shows up to confirm the test cut or it can be set so
that the button must be held for 1/2 second before the test cut is executed. This is to prevent
inadvertent test cuts.
NOTE: A Test Cut cannot be executed while the unit is running in continuous mode.
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11.0 SYSTEM STARTUP
When powering up the machine, a series of operations must take place to insure that the safety
system is functioning properly. It only needs to be done once on power up.
11.1 Initial Screen -
While the system is booting up the
screen will first be blue with a few icons
and then this initial screen will appear for
about 3 seconds.
If it is not replaced by the screen below
after 15 seconds, there is a problem with
the equipment and it should be looked at
by maintenance.
11.2 POWER UP Screen
This screen instructs the operator in the procedure to verify that the safety system is
functioning properly. The operator must first satisfy all of the conditions of the safety circuit.
The first 4 lines of the screen prompt instruct the operator on the procedure.
11.2.1 Verify Safety/Reset System Screen
his screen appears and instructs the
T
operator in the procedure to verify that
the safety system is functioning properly.
The operator must first satisfy all of the
conditions of the safety circuit.
The first 4 lines of the screen prompt
instruct the operator on the procedure.
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11.2.2 Verify Safety/Press E-Stop Screen
If the operator performed the correct
functions above, the light will blink
orange and this screen appears. The
prompt in the upper left corner instructs
the operator to "PRESS E-STOP".
This tests that the equipment will
respond properly if the E-Stop is pressed
when there is a true emergency.
11.2.3 Reset System to Home Screen
The prompt in the top left corner now
instructs the operator to Reset the
System again by twisting the Red
Emergency Stop button clockwise...AND
pressing the Black RESET button again.
11.2.4 Homing Screen
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Homing - The prompt in the top left
corner now indicates that the system is
Homing. The light will blink orange
again.
When complete, the screen will
change to the Quick Ops screen and
the light will blink green.
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Cut Mode
Parameter
Units
Encoder
Set Length
in/mm
End
Sensor
Delay Time
sec
Time
Cycle Time
sec
1
12.0 MACHINE OPERATION
The factory pre-sets allow the cutter to start production using the encoder input.
If you want to use the encoder input,
simply enter a length in the SET
LENGTH box. A numeric screen
will pop-up. Enter the cut length and
press to return to the Quick Ops
screen. Enter the RPM’s in the same
manner, based on your experience.
The cutter will run in ON DEMAND or
CONTINUOUS MODE based on your
entries.
12.1 Quick Ops Screen Items
Cut Parameter - Used to enter the value to control when the cutter
activates. It is dependent on the cut mode set on the recipe screen. It will
always show the product cut values when the system is stopped.
Blade Speed - Enter the optimum blade speed for the cut when
running in On Demand mode. In Continuous Mode, this is greyed out
and shows the currently running blade speed that is determined by
the calculation of Set Length and Line Speed.
Measured Length - This is the length of the cut measured by the
encoder signal. If an encoder is not used, this field will always be
zero. It can be set up to always read the last cut length or hold the
last cut length for a specified time before showing the accumulated
cut le ngth.
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2
2
12.2 Cut Start/Stop Buttons
CUT PRODUCT - Press this button to start the cutting of good product using the mode and setting
from the recipe. If the count is enabled, it will count each part as the blade crosses into it.
STOP - Press this to stop the cutter with the blade at home position (even in continuous mode).
CUT SCRAP - Press this button to shift to the scrap settings and stop counting. The cutter will
quickly and automatically switch between any modes including between continuous and on-demand
cutting. The Cut Scrap button may be hidden in the system setup.
TEST CUT - Press this button to activate a single on-demand test cut. The test cut can be executed
while the system is running on-demand product. It will not be counted and the following cut will be cut
at the proper length/time. If the cut is done very close to when the set on-demand cut needs to
execute, it may interrupt that cut. A text cut cannot be executed while the unit is running in
continuous. The method for executing a text cut can be set in two ways in the system setup. It can
be set so that a popup menu shows up to confirm the test cut or it can be set so that the button must
be held for 1/2 second before the test cut is executed. This is to prevent inadvertent test cuts.
12.3 Changing the CUT MODE
You can change to END SENSOR MODE or TIME MODE by logging in as LEVEL 1.
Press LOGON button.
A small pop-up screen
will appear
Then press the ******** button
below level1.
An alpha/numeric screen will
appear.
Enter 1111 then touch
toreturn to the Quick Ops
Screen.
User name and Password factory defaults:
level1 : 1111 (Operator)
level2 : 2222 (Production Supervisor)
level3 : 3333 (Maintenance)
setup : 4444 (Factory Presets – Setup Group)
Press the SELECT RECIPE button.
The Recipe Select screen (below) will appear.
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12.4 Recipe Select Screen
Use the Up/Down arrows to navigate to the recipe that you wish to run.
NOTE: To select Recipe 1 you must first press the down button and then the up button.
Select the recipe with the arrow key which points to the left. Alternatively you can press the
"Load Default Values" button to load the Manual recipe.
This will return you to the Quick Ops screen and the loaded recipe number will appear on the QuickOps screen.
NOTE: Recipe “Save As” Screen
The Recipe Save As screen is the same as the Recipe Select except that the Load Default
Values is replaced by the check box. Select the recipe that you want to save as and press
the check box.
Now that a recipe number is entered you can press the EDIT RECIPE icon on the Quick Ops
screen and the CURRENT RECIPE screen will appear.
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3
12.5 Current Recipe Screen
Note: Similar recipe settings are available for both product and scrap.
Encoder – Press this button to change the mode to cut based on the cut lengt h. The length is
typically measured by an encoder but can be set up with other methods.
Cut Length – Set the part length that will activate the cut cycle when in Encoder Mode.
End Sensor – Press the button to change to a cut that is activated by a sensor input. The sensor
typically is supplied by the customer.
Delay Time – Set the time in seconds after the end sensor activates to activate the cut cycle. This
can be used to trim the length very precisely instead of trying to mechanically move the sensor very
small distances.
Time – Press the button to change to a cut that is activated by a repeating internal timer that is
accurate to 1 millisecond.
Cycle Time – Set the time from the start of one cut cycle to the start of the next cut cycle.
Level 2 or above personnel can use the SAVE button to save the recipe.
If there is a change to the running recipe from what is currently saved, it will appear blue and pressing
it will open the following popup screen where the operator can save the recipe under the current
number by pressing "Yes" or save it as a different recipe number by pressing "Save As". T o cancel
the recipe save, the operator can press "No".
Press to return to the Quick Ops screen.
The operator can choose test cut or cut scrap until the product is
satisfactory and then cut product to commence with production as explained on page 17.
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12.6 Setting Up Counters COUNTERS
(Located on the Quick Ops Screen under the EDIT RECIPE icon.)
These fields show and control the current batch count. The fields
displayed will depend on whether box count is enabled or disabled. The
count values may be changed at any time by pressing on the numeric
field. For the Box Count and Box Fill fields, a popup will ask you to enter
the numeric value or cancel it. The button in the top right corner will
appear with the pause symbol if the count is running or it will appear with
the green arrow when it is stopped. The button on the bottom right is to
remove one part from the count. This can be convenient when the
operator finds a bad part and removes it from a box and is especially
useful in high speed lines where editing the part count while running is
nearly impossible.
Batch Counter Setup Access
This button, located under the Test Cut button, is used to open a screen which
contains all of the batch count features. (See Batch Count Screen) Can also be
accessed through the HOME screen.
12.7 Production Metrics
(This box is on the Quick Ops screen below COUNTERS)
This displays some extra information about the process.
The cut rate is based on the time between the last 2 cuts
and is rounded off to a whole number. The line speed is
what is being perceived by the system. It can be set up to
come from many sources including the encoder. The Part
Temp is only available with the added option and displays the temperature of the part as it enters the
cutter.
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12.8 Quick Ops Screen Versions
This is the default screen on startup and
can also be accessed with the Quick Ops
button on the bottom of every screen. It
is a quick overview of the current running
operation and has only buttons and
information relevant to the current mode.
This is the screen view without the
operator being logged in. It will change
look based on operating conditions and
user setup selections.
This is the view when the user is logged
on as level1 authority but there is an
alarm that has caused the system to shut
down. If the alarm horn is enabled, the
red Silence Alarm button appears in the
middle of the screen. notice that the Cut
buttons are grey because they are no
longer functional. The alarm button also
changed colors to indicate a problem.
This is the view with everything
operational and the operator logged on.
Also the box count was disabled so now
only the piece count is visible.
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This view shows the system cutting
product. The red Stop button has
dimmed and the green Cut Product
button has lit up. The status box in the
top left hand corner has changed to
indicate the current mode.
The st art count button was pressed
and the counters are now incrementing
with each cut.
In this view the Cut Scrap button was
pressed and it is cutting scrap in timed
cycle mode which is indicated in the
status box and by the lighted cut scrap
button. The field beneath the status box
now shows Cycle Time in seconds
instead of Set Length in inches. This is
the parameter that controls when the cut
cycle is activated and is dependent on
the operation mode. When stopped, it
always shows the mode that is set for
cutting product. The modes can be
changed on the recipe screen.
This view shows the machine running
continuous mode which is a special
encoder mode of operation. This mode is
automatically activated when the cut
length and line speed causes too little
time between cuts for the system to run
in On Demand mode. Notice that the
blade speed is greyed out. The system
automatically adjusts it to maintain the
set length based on the line speed. Test
cut is not available when running in
continuous.
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13.0 SETUP SCREENS
13.1 Accessing the SETUP screens
SETUP screens are accessed through
the HOME screen. Many entries on
the SETUP screens require a Level 3
password.
Press t o access HOME screen.
Then follow the instructions below to
LOGON.
13.2 LOGON
Press in upper RH corner of HOME screen and the following screen will appear.
Then press the ******** button next
to level2.
An alpha/numeric screen will
appear.
NOTE: If the proper level of
password protection has
not been entered prior to attempting
changes,
the alpha/numeric password entry
keypad will appear, prompting the
user to input the proper user name
and password before changes can
be made.
User name and Password factory defaults:
level1 : 1111 (Operator)
level2 : 2222 (Production Supervisor)
level3 : 3333 (Maintenance)
setup : 4444 (Factory Presets – Setup Group)
Enter 3333 then touch to return to the HOME Screen.
NOTE: Access levels should be assigned to specific levels of personnel to avoid unwanted
changes being made to sensitive settings.
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1 1 2 3 2 3 6 6 4 4 5 5 7
7
13.3 Home Screen
Quick Ops Button Opens the Quick Ops screen. Same function as pressing the Quick Ops button at
the bottom of the screen.
Recipe Select - Opens the
recipe select screen. Same
function as on the Quick Ops
screen. (Pages 18,19 and 25)
System Setup - Opens the
system setup screen to access
extended functions for different
machine operations and
configurations. Requires Level
3 password for access.
Batch Counters - Opens the
batch counter screen. Has the
same function as on the Quick
Ops page. (See 13.9 page 33)
Cutter Picture - Shows the picture and model number for this cutter. If the picture is blank, there
was a problem with the servo and PLC communicating. Try cycling power. Contact maintenance if
the problem persists.
Installed Software Version - This is important to note when contacting NOVATEC service.
Time & Date – If time and date are not correct they should be corrected so ALARMS will have the
correct time and date stamp. (See 13.5 page 26)
NOTE:
If either time or date need to be corrected, press to access SETUP PAGE 1.
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13.4 Recipe Functions
Recipe Number - The gray field on top shows the currently
active recipe number.
Recipe Name - The blue field underneath shows the currently
active recipe name associated to the number. By default, the
recipe name is Recipe followed by the number. It can be set by
a level 2 operator on the recipe management page.
Select Recipe - Pressing this button opens a screen for the operator to choose a preconfigured
recipe. When the machine is powered up, it will recall the recipe and all changed settings that were
present when it was powered down. This makes recovery from power outages as simple as possible.
(See Recipe Select Screen)
Edit Running Recipe - The next button, which looks like a piece of paper and pencil, is the Edit
Running Recipe button. Pressing this button opens the screens to change all of the settings of the
currently running recipe. The cut parameter, on-demand blade speed and count setup values on this
page are part of the recipe. They are made available on this page for quick access. There are some
items in the recipe that can be changed by the level 1 operator and others require a level 2 operator
but all items are visible to both. (See Current Recipe Screen)
Save Recipe - The next button that looks like a floppy disc is used to save the recipe. It is visible to
level 2 and higher operators. If the recipe hasn't changed, it will appear grey and will not function. If
there is a change to the running recipe from what is currently saved, it
will appear blue and pressing it will open the following popup screen
where the operator can save the recipe under the current number by
pressing "Yes" or save it as a different recipe number by pressing
"Save As". To cancel the recipe save, they can press "No".
Special Manual/Default Recipe - There is a special recipe that is used when the operator wants to
manually enter in recipe values without accidentally overwriting an existing recipe. They can recall
this "Default" recipe when they go to the recipe select screen. The recipe number will show as 0 and
the title will be "Manual". This recipe cannot be saved over so it remains constant. It is set to have
good known starting values for setting up a new product. (See Recipe Select Screen)
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1
1
2 2 3
3
13.5 SETUP SCREEN 1
To change Time and/or
Date: Press the appropriate
Button and enter the date as:
xx/xx/xxxx or the time as
xx:xx:xx (24 hour clock).
Press to return to the
SETUP 1 screen.
Press to access User Configuration to change the usernames, passwords and auto-
logoff times . See 13.3 on page 23. You can assign specific personnel or personnel levels for each of
the access levels.
All items on this page are accessible to be changes by a level 2 or higher user. The arrow to go
to the second setup page will only appear for level 3 and higher users.
SYSTEM OPTIONS
Enable/Disable Scrap Mode – Press this button to Enable Scrap Mode.
Imperial/Metric Units – Press this button to toggle the display units
between English and Metric.
AT END OF BOX
Count Triggers - Triggers change in machine operation when part count
reaches end of box and production. Is the same function as on the Counter
Screen.
PRODUCTION OUTPUTS 1 - There are two dry contact outputs supplied in
the control panel. Q0.0 corresponds to Production Output 2 and Q0.1
corresponds to Production Output 1. They can be configured to trigger on
many events including Part Cut, Box Change, Production Done, Running,
Run Product, Run Scrap, Stopped or Faulted. The signal can be delayed
and held for a user settable amount of time. They are not high speed
response signals. There is a typical lag of about 30 ms with an error of +/-10 ms. If a higher speed,
more precise output is required, option NC8016 shown on schematics is required. Sales must be
contacted to ensure the proper form of the output device.
LENGTH DISPLAY HOLD TIME - This value determines how long the
display will show the last cut length before showing the accumulated length
of the next part. Set it to zero to always show only the last cut length. It is
recommended to be set to at least 500ms. Parts that are cut faster than 500ms may be difficult to
see no matter the setting.
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END SENSOR MASK
It is commonly required to mask the end sensor signal after activation to
prevent subsequent activations. Set the timer value to prevent a second
activation until the time set has expired. Never set the value higher than
the time between cuts or cuts will be missed. The mask can be can also
be configured to reset on either the positive or negative going production
signals or by a customer provided signal to input 1.0 on the PLC.
13.6 SETUP Screen 2
This screen is used to set some of the more advanced features of the equipment. All of the
items on the left column require a setup authorization. Everything else can be accessed by
level 3 authorization.
ENABLE TEMPERATURE SENSOR – This field enables the temperature
display on the Quick Ops Screen. This is an optional item that must be
purchased separately or the end user must install their own device.
BUSHING SENSOR INSTALLED – Press this to enable bushing sensors if they
are installed. Sensors are not installed on systems that have permanently
installed bushings.
TEST CUT CONFIRM REQUIRED - This button toggles the requirement for the
popup window to confirm a test cut. To avoid accidental activation, the test cut
button will require it be held for 1/2 second.
WEB SERVER ENABLED/DISABLED - Toggles the availability of the screens to be accessed from
another HMI or web browser. If it is enabled without the required license installed, an annoying
message will appear every few minutes.
STARTUP LOGON
All machines ship with the user login set to none as default which means the
operator must log in to start the machine. The system can be set so that it is
always level 1, level 2 or level 3 when it starts or is logged off. Be careful when setting it to higher
levels because it may give unintended access to features which operators don't understand.
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ENCODER SETTINGS
Encoder Counts/Rev – The number of quadrature pulses per revolution
of the encoder. (If it is 2,500 ppr quadrature then the value is 10,000)
Wheel Circumference – Distance for one revolution of the encoder,
typically the circumference around wheel connected to encoder. If the encoder is measuring
slightly off, change this value to correct.
ON DEMAND LENGTH REFERENCE – Choose the measuring method
that the system will use to activate the cut sequence when using encoder
mode.
None – The length is calculated based on the Estimated Line Speed
entered by the operator in the recipe. This is useful for setup or when the
customer wishes to enter the puller speed manually.
Encoder – The encoder input pulses are used to determine the length.
ProfiNet – An Ethernet connection between a Novatec supplied puller and the cutter is required.
The puller transmits its actual speed every 1/10 seconds and the cutter uses this to calculate the
accumulated length. It calculates the point between the 1/10 second data by assuming the last
received speed to get very accurate cuts.
CONTINUOUS SPEED REFERENCE – This has the same options as the length reference but is
used to determine the speed reference when running in continuous. It is possible to use different
modes for each depending on how stable a signal is. The signals should be nearly identical or
unpredictable switching might occur when changing between On Demand and Continuous modes.
AUDIBLE ALARM TYPE
This is used to configure the horn sounds. Different sounds can be set for
Fault, Warning, and when the Count gets to set values. the choices are
None, Slow Beep, Short Beep, Fast Beep, and Continuous. Each beep
duration and cycle time can be customized so that operators can distinguish
between machines audibly.
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13.7 SETUP Screen 3
All items on this page require setup authorization except for Exit HMI and background color.
PROCESS LIMITS – Determine the blade speed limits and the points at
which the cutter will switch between On Demand and Continuous Mode.
Max Cut Rate Demand – This determines the minimum time between on
Demand cuts. It also determines when the system should switch to
continuous mode.
• Min Blade Speed Demand – Sets the minimum speed that can be
entered as the On Demand blade speed on the recipe screen.
Min Blade Speed Cont – Sets the minimum permissible RPM of the
blade in continuous mode. Typically this is set to a value which can still give a good cut to the
product.
Max On Demand Blade Speed – This sets the maximum blade speed for On Demand cutting . Th is
will be limited by the max motor speed and is typically set by NOVATEC so that the drive does not
fault when accelerating and decelerating and the overall system can handle the forces of the blade
motion.
Note: It is possible to make settings where there are line speeds that cannot be handled by Max
On Demand CPM or Minimum Continuous Mode blade speed.
The Max continuous speed is the max speed of the motor and the gear box. It is possible to run
the continuous speed so fast that when it stops or transitions to On Demand Mode, the drive
faults.
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VELOCITY ADJUSTMENTS - Adjusts the velocity so that the received
velocity creates parts of the correct cut length.
Offset – Adds the value in the offset to the value read.
Scale – Multiplies the value in the scale to the value read.
SPEED MATCHING CALC – Sets the characteristics for how the cutter
responds to the speed signal when running continuous mode.
Gain - Determines how fast the cutter will respond to changes in line
speed. Setting it to .99 will make it react immediately but can cause
oscillation. A typical setting it between 0.5 and 0.8.
Measurement Window – This will determine what values outside the range of the set line speed will
be ignored as noise. Three consecutive readings outside the window will cause the cutter to stop.
Setting it to 100% effectively overrides it.
Screen BACKGROUND Color - Select the Red, Green and Blue content using the
sliders or the numeric entry fields. The area around the check box will show the
new background color. When the color is ok, press the checkbox to change the
background colors of all the screens. Black(0,0,0) is the default background color.
Care should be taken to not use very bright colors or colors that match other fields
because they will bleach out some items.
RESET SYSTEM TO FACTORY DEFAULTS
Pressing this button will set all of the setup values to the defaults for the
type of machine detected. A drop down box will appear to accept or
cancel. This should only be pressed if the setup values were altered such that the machine
cannot run properly.
SERVO SETUP – This button is for maintenance and experienced operators only.
Pressing this opens the detailed setup information for the blade servo. This button will
be greyed out if the system is running.
EXIT HMI
This button is for maintenance persons only. It will stop the operator interface program
and return the unit to the Windows CE operating system. All control of the machine is
lost until the program is restarted or power is cycled. The emergency stop will still be
functional.
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13.8 Servo Setup Page
This page is for maintenance and experienced operators only.
CAUTION: Great care should be used when accessing this page. Incorrect values
could make the equipment unusable.
Validate Safety – This button is only used when commissioning the servo system
or if a component is replaced. The procedure checks the components of the
system against the safety program written and ensures that they are compatible. Because
components and software can be upgraded at later dates, the test must be performed even if the
component being changed is the same type. The validation components are the servo motor,
encoder, power module, control unit, program and CF card. The safety license is stored on the CF
card. If it is missing, an alarm warning will be displayed but the system is still operational.
Motor Direction – The motor direction is set when the machine is first
commissioned based on the hardware used. It is dependent on the machine
being fed from the left side or right side.
Home Offset - When the machine is first powered up, it homes to a sensor and then
moves an offset and sets this as the final home position. This is so that a machine
with 2 blades will not stop with one of the blades in the cut area and to maximize the
cut energy. It can set for the blade being used. To perform the home offset, enter a
new offset in degrees and cycle power to the machine. This will be the new zero or home position.
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Blade Position – This shows the current position of the blade in degrees relative to the home offset
position. To set either of the positions to the
right, move the blade to the desired position
and press the arrow to save the position. A
confirmation will appear in the numeric field
and you must accept or cancel.
Reverse Home Direction – This position sets the position of the blade where it will go backwards or
forwards to home. If the position is lower than this value it goes backwards to home, otherwise it
goes forward to home. When homing on power up, the blade always homes in the forward direction.
If there is product in the path of the blade, it will obstruct the blade or it will be cut. If 2 blades are
installed and the system is stopped improperly with the Emergency Stop, the blades will stop
immediately where they are. When the system is powered up, there is a 50% chance that the blades
will need to move through the product to get home and therefore the product will need to be removed
to allow the blade to move to home.
Blade at Cut Position – This sets the position of the blade where it counts the product. It is usually
set when it is completely through the product.
USE DYNAMIC TUNING
Dynamic tuning is used to change tuning parameters when
running between on-line and continuous.
On Demand operation requires an extremely fast response with large acceleration torques being
used.
Continuous mode prefers a slower response to maintain the set speed in a tighter tolerance.
The values shown in the window can be adjusted to account for changing loads and aging of the
equipment. Be very careful changing any of these. Improper settings could cause the servo to
become unstable, loose torque or continuously fault. Dynamic tuning can be turned on and off with
the button. The servo will use the parameters that were running when it was turned off.
SERVO MOTOR DATA– These settings are for reference only. The
values are read by the drive and depend on the equipment installed.
Gear Ratio - Shows the gear box attached.
Rated Servo Speed - Rated speed of the motor at rated torque at 400V.
It can be affected by the ambient temperature and supply voltage.
Max Servo Speed – This is the maximum possible speed that the motor
can obtain though torque will be reduced from the nameplate rating.
Motor Temp – The temperature of the motor. Most motors can handle
temperatures up to 140C. Frequent heating and cooling of the motor can
cause premature damage.
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13.9 Batch Counter Screens
(Accessed through Home Screen)
Counter Screen with Box Count Disabled Count er Screen with Box Count Enabled
Most of the fields are duplicates of what is on the Quick Ops screen. The following explains the extra
buttons.
Count Reset - Press and hold to reset the counters.
Warnings and Alarms - Signals can be set to activate a warning
message or sound a siren when production reaches a certain point.
The system calculates the time remaining at the current production
rate and determines if the alarm should activate. Set the time in
minutes and tenths of minutes and the event to activate the alarm
which can be Never, End Of Box, End of Production, or Both. The
Warning Alarm will active a warning message the same way as any other. The Alarm Siren activates
the horn only which can be silenced on the Quick Ops Screen. The siren must be configured in the
system set up to activate.
At End of Box: - (Requires box count to be enabled). Used to determine
the action of the cutter when the part count has reached the end of box.
At End of Production: – Used to determine the action of cutter when the
part count has reached the total pieces setting.
Continue – The cutter keeps cutting the same product and
counter keeps incrementing
Cut Scrap – If scrap mode is Enabled, the cutter will execute the scrap
recipe and the counter will not increment.
Stop – The cut ter will stop.
Enable/Disable Box Count - Press this button to change the counting mode. Box count
is enabled if the button is bright.
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WARNING: Before beginning repair work, disconnect all power sources and
WARNING: Auxiliary equipment may contain moving parts that may cut, crush, or
hands or limbs in equipment during operation.
14.0 MAINTENANCE
It is recommended that maintenance and inspection be performed on a scheduled basis. Maintenance
requirements may vary widely for each installation and specific operating conditions. It is suggested that a
complete inspection be performed with necessary maintenance at the end of the first month, the first three
months, and the first six months. These inspections will indicate how often future maintenance will be
necessary.
All electrical, mechanical repairs and tests are to be performed by qualified personnel only.
Disconnect electric power from control box before opening panel for maintenance.
Depressurize pneumatic system before performing maintenance or repairs on pressure containing
components. Check all pressure gauges to ensure that depressurization has occurred.
Cutter enclosure may be hot. Components inside the enclosure will be hotter than the air inside,
especially the servomotor and resistor.
Do not disable or bypass equipment safety features.
Refer to system component manuals for additional information.
secure against inadvertent reconnection.
otherwise injure personnel when safety/access covers are removed. Do not place
At Startup
Verify all guards are in place and able to be fully closed.
Ensure blades are attached securely.
Record equipment Serial Numbers and the NC Controller program revision level.
Every bushing or blade change
Verify free motion of blade(s) past bushings and that bushing gap is properly set
Daily
Clean bushings and lubricant tray.
Every 3 Months
Check all electrical connections to make sure that they have not become loose, especially those
connections at contactors, like motor starters.
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15.0 WARRANTY – NOVATEC, INC. - EFFECTIVE DATE 6-12-2012
NOVATEC, INC. OFFERS COMPREHENSIVE PRODUCT WARRANTIES ON ALL OF OUR PLASTICS
AUXILIARY EQUIPMENT. WE WARRANT EACH NOVATEC MANUFACTURED PRODUCT TO BE FREE
FROM DEFECTS IN MATERIALS AND WORKMANSHIP, UNDER NORMAL USE AND SERVICE FOR THE
PERIODS LISTED UNDER “WARRANTY PERIODS” . THE OBLIGATION OF NOVATEC, UNDER THIS
WARRANTY, IS LIMITED TO REPAIRING OR FURNISHING, WITHOUT CHARGE, A SIMILAR PART TO
REPLACE ANY PART WHICH FAILS UNDER NORMAL USE DUE TO A MATERIAL OR WORKMANSHIP
DEFECT, WITHIN ITS RESPECTIVE WARRANTY PERIOD. IT IS THE PURCHASER’S RESPONSIBILITY TO
PROVIDE NOVATEC WITH IMMEDIATE WRITTEN NOTICE OF ANY SUCH SUSPECTED DEFECT.
WARRANTED REPLACEMENT PARTS ARE BILLED AND SHIPPED FREIGHT PRE-PAID. THE
PURCHASER MUST RETURN THE SUSPECT DEFECTIVE PART, FREIGHT PREPAID AND WITH
IDENTIFYING DOCUMENTATION TO RECEIVE FULL CREDIT FOR THE PART RETURNED. NOVATEC
SHALL NOT BE HELD LIABLE FOR DAMAGES OR DELAY CAUSED BY DEF ECTS. NO ALLOWANCE WILL
BE MADE FOR REPAIRS OR ALTERATIONS WITHOUT THE WRITTEN CONSENT OR APPROVAL OF
NOVATEC.
The provisions in equipment specifications are descriptive, unless expressly stated as warranties. The liability of
NOVATEC to the purchaser, except as to title, arising out of the supplying of the said equipment, or its use,
whether based upon warranty, contract or negligence, shall not in any case exceed the cost of correcting
defects in the equipment as herein provided. All such liability shall terminate upon the expiration of said
warranty periods. NOVATEC shall not in any event be held liable for any special, indirect or consequential
damages. Commodities not manufactured by NOVATEC are warranted and guaranteed to NOVATEC by the
original manufacturer and then only to the extent that NOVATEC is able to enforce such warranty or guaranty.
NOVATEC, Inc. has not authorized anyone to make any warranty or representation other than the warranty
contained here. Non-payment of invoice beyond 90 days will invalidate the warranty. A renewed warranty can
be purchased directly from NOVATEC.
Please note that we always strive to satisfy our customers in whatever manner is deemed most expedient to
overcome any issues in connection with our equipment.
Warranty Period :
Note: All warranty periods commence with the shipment of the equipment to the customer.
NPS Bessemer Series Pullers = 5 Years
C Bessemer Series Cutters = 5 Years
NC Bessemer Series Cutters = 5 Years
Custom Built Equipment = 1 Year
Exclusions:
Routine maintenanc e/replacement parts ar e excluded from the warranty. These include, but are not limited to:
belts, knives, hoses, g askets, m otors, intern al solenoi ds, fus es and m otor brushes. Us e with abrasi ve mater ials
will void the warranty of any standard product. Wear resistant options may be available to extend usable service
life with abrasive materials. NOVATEC reserves the right to limit the warranty if the customer installs
replacement parts that do not meet the specifications of the original parts supplied by NOVATEC.
This warranty shall not apply to equipme nt:
1. Repaired or altered without written appr ov al of NOVATEC unless such repair or alteration was, in our
judgment, not responsible for the failure
2. Which has been subject to misuse, negligence, accident or incorrect wiring by others
3. Warranty is void if proc essing rates exceed manufacturer-recommended levels or if dam age is caused by
ineffective power isolation and/or power spikes/sags or incorrect installation.
NOTE: All conditions and content of this warranty are subject to changes without notice.
NOVATEC, Inc.
222 E. Thomas Ave.
Baltimore, MD 21225
www.novatec.com
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