#j5000 j8000 tsfront page july 2016

Javelinthe leading edge in converting technology for the Paper Film and Foil industries

Javelin Machinery (Australia)A.C.N. 005 543 411 ABN 18 005 543 411

Email: [email protected]: www.javelinmachinery.com.au

HEAD OFFICEPO Box 805, Glen Waverley Vic 3150 Australia

Phone: +61 3 8786 3614

Model: J5000 – J8000 seriesAUTOMATIC SINGLE KNIFE

SLITTER

JULY 2016

OPERATION MANUALINCL. TROUBLESHOOTING

MACHINE PROBLEMS

JAVELIN MACHINERY (AUSTRALIA) J5000/J8000 OPERATION MANUAL(Incl. Troubleshooting Machine Problems)

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1JULY 2016

IMPORTANT NOTENOTE TO OPERATOR: SINGLE KNIFE SLITTING

The principle on which this type of slitting is based, depends onthe knife being able to displace the roll width being slit.

Materials which are too dense or have been wound too tightlymay be unsuitable to slit by this method.

In this case either the roll must be rewound to a lesser tension orthe material cut on a machine known as a slit/rewinder.

Knife parameters are crucial in successful Single Knife Slitting(Refer Knife Selection Section)

As widths being slit increase so must the secondary or backbevel on the knife in order to balance the forces and achieve astraight cut.

Failure to pay attention to choosing a knife with the correct bevelwill result in the knife chipping or in an extreme case shatter.

An Operation & Maintenance Manual was supplied with machine,ensure operators have read, understood and familiarizedthemselves with machine before operating

Javelin Machinery (Australia)


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2JULY 2016

OPERATOR SAFETY

PLEASE NOTE FOLLOWING BEFORE COMMENCING OPERATION:

Safety should be a constant concern of everyone around any type of machinery.While more than normal precautions were taken in the manufacture of thismachine, everyone connected with its operation should be made fully aware of theHigh Voltages, High Speed Motion and Sharp, Rotating AutomaticallyActuated Cutting Tools involved.

To prevent injury, the suggestions below should be followed:

1. KEEP CLEAR of cutting blade, rotating mandrel, chuck and material when the

machine is in motion.

2. ENSURE all GUARDS in position & safety systems operational before starting

the machine..

3. DO NOT place your hands between the knife and rolls when loading or

unloading. ENSURE knife is in its furthest back position.

4. KEEP the area around the machine CLEAN and DRY proof surface or mats.

Only the operator to work within area designated by hazard tape.

5. ENSURE main isolator is switched OFF before any maintenance is carried out.

6. USE suitable PROTECTIVE GLOVES when handling blades.

7. Ensure KNIFE IS REMOVED OR KNIFE EDGE COVERED with the flexible

plastic cover provided when servicing or cleaning and when machine not in use.

8. Request ASSISTANCE when CHANGING knives or LOADING heavy material

onto the mandrel.

9. Ensure operators & maintenance personnel have read and understood

Manual before operating or carrying out maintenance on this machine.

Ensure only qualified electricians work on the electrical components of themachine. Operators must not open the electrical cabinet, motor drive cabinetor operator panel. In the case of an electrical malfunction qualified electricalpersonnel/contractor should be called.


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3JULY 2016

OPERATOR ALERT

PLEASE NOTE FOLLOWING BEFORE COMMENCING OPERATION:

After fitting knife to machine … Disengage knife lock.

When changing to a smaller or largerdiameter knife or mandrel …

Re-adjust forward knife stopwhenever the knife or mandrel ischanged.

When changing to a larger diameter knife ordiameter of log roll increases …

Check rear stop so that knife isclear of roll

Before commencing to cut … When knife is clear of tape by10mm to 20mm (½” to ¾”),adjustable rear stop knob should beapproximately in line with proximityswitch below it and blue light is on.

When using the 3 or 4 pin chuck and whereextended pin holders are being used …

Check that there is clearancebetween the chuck racks or the pinholders and the knife spindle whenthe knife is in the forward position.REMOVE PIN HOLDERS WHEN NOT IN USE.

Before sharpening knife... Ensure there is 5mm (¼”) clearancebetween the grinding wheel and theknife before turning on the knifegrinder.

When using a knife with no back bevel … Do not attempt to slit wide widths ofdense material or damage tobacking plate and knife will result –refer to knife chart.

Driving the knife when slitting denseproducts such as high density foams.

If attempting to slit widths over ½”you will need to reduce knife RPMto avoid heat build up which canresult in damage to knife andbacking plate. ENSURE CHUCK IS IN

FWD MODE. If the sides of the slitrolls are sticky and the knife is hotyou may need to switch off knifedrive and allow knife to free rotate inorder to displace slit roll.


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4JULY 2016

1. PRINCIPLES OF SINGLE KNIFE SLITTING

Slitting by the single knife method is basically the ability of a circular knife todisplace the slit roll as it enters the log.

Single knife slitting is not a precise science. Slitting results are affected by anumber of factors including:

• the type of backing (i.e. Polyester/Cloth/Foam)• evenness of adhesive coating,• tension under which the log has been wound to• knife diameter• knife sharpness or dullness• air or room temperature

While Javelin can recommend settings for different products and widths, theoperator must be aware of the factors mentioned and make adjustmentsaccordingly.

ALWAYS USE HIGH CHROME HIGH CARBON STEEL KNIVES. CHROMECONTENT RETAINS THE KNIFE EDGE (DURABILITY) WHILE THE CARBONIS FOR HARDNESS.

ENSURE KNIVES RUN TRUE – CHECK WITH A DIALINDICATOR.

THE RULE IS TO USE THE SMALLEST DIAMETER KNIFE TOMINIMIZE RUNOUT AND GET BEST RESULTS

CAUTION~ always use cut resistant gloves when handling knives ~

ONLY PERSONNEL CERTIFIED TO SHARPEN AND BEVEL KNIVES SHOULDOPERATE KNIFE GRINDING FUNCTION


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5JULY 2016

2. MACHINE OPERATION

PRINCIPAL OF OPERATION

The log roll is slid on to the mandrel from the left hand end of the machine andsecured into a chuck with gripping pins and or gripped internally by means of anexpanding section of the mandrel.

The width of the cut is set by using the PanelView 600.

The cutting cycle starts from the left hand end of the log roll.

When the machine is turned on in the ‘AUTO’ cycle:

• The chuck will rotate the log roll• The knife moves forward and cuts the material automatically• Upon completion of the first cut, the knife will retract• The carriage will index right to the programmed width automatically

This cycle is repeated until the entire log roll is cut or the machine is stopped.

When the machine cuts the last roll on the log, it will automatically traverse (if switch isset to auto traverse) back to the load end of the machine ready to make the first cut ofthe next log roll.

2.1 SETTING UP AND OPERATION PROCEDURE

CAUTION: Serious damage to machine can occur if careful attention not given tothese points.

• Turn on compressed air. The correct operating pressure approximately 700kpa(100psi).

• Ensure machine is level. (Critical - See note 1 following)• Fill up the spray bottle with water and a ‘salt free’ detergent (approx. 2½

tablespoon) to reduce rust. (eg. Good quality truck wash (CT18), car wash or similarproduct).

• Turn power on at the main electrical cabinet.• Raise the POLYCARBONITE GUARD.• Fit the mandrel as required. See “Mandrels” in this handbook.• Raise the mandrel support arm.• Select knife size. See “Knife selection” in this handbook.• Check the knife and backing plate condition.• Fit backing plate, knife & washer on to spindle• Tighten the cap screws.


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6JULY 2016

CAUTION: When saw cutting large diameter rolls 2 x 101mm (4”) diameter washersmust be used.

• Check for adequate clearance between the knife and grinding wheel.• Adjust the KNIFE FORWARD STOP. (See note 2 following)• Lower mandrel support arm.

CAUTION: Retract knife away from mandrel ensuring sufficient room is left to slide thelog roll on without any danger of contact with the knife which can result inserious injury.

• Slide on log roll.• Raise the mandrel support arm.• Secure log roll using chuck or expanding mandrel.

CAUTION: When not using chuck pins to hold material, REMOVE pin holders asinjury can occur from contact with pins.

• Set the ADJUSTABLE REAR STOP with the knife about 10 mm (½”) past theoutside diameter of the log roll. (See note 3 following).

• Traverse the knife just past the left-hand end of the log roll.• Press the ‘START’ button and switch to ‘SEMI’ mode.• Adjust knife approach speed knob.• Set Knife Approach Time.• Set Knife Cutting Speed.• Check SLITTING TIME (Forward Knife Speed).• Set KNIFE DWELL TIME.• Direct sprays onto knife bevel and back towards centre of knife.• Enter the width required to be cut into the ‘ROLL WIDTH’.• Set the RH CARRIAGE STOP.• Set the LH CARRIAGE STOP to where you would like the knife to stop when it

automatically traverses back up the bed of the machine (i.e. to just after the salvageedge of the log rolls being slit)

• Enter the number of rolls to be cut into the ROLL COUNTER (Note: first cut is notcounted).

• Traverse knife to where first cut is to be made.• Lower the POLYCARBONITE GUARD.• Set AUTO CARRIAGE RETURN if required.• Turn Knife Switch to FWD or REV to drive knife if required (See note 4 following)• Set knife RPM (See note 5 following)• If Knife Drive not required turn knife switch ‘OFF’ (See note 6 following)


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7JULY 2016

‘Sharpen on Command’ :• Set Grinder to AUTO if required

(Before you set grinder to AUTO you must first ensure the grinding wheel is in the rightposition by sharpening the knife first as per Knife Sharpening section of this Handbook)

• Set the GRINDER DWELL TIMER if necessary.• Enter the number of CUTS PER GRIND into counter if required.

• Turn the chuck switch to FWD or REVERSE.• Adjust the CHUCK RPM.• Select the machine mode to ‘AUTO’ position and slitting will commence.• Lift the POLYCARBONITE GUARD and check the finished roll quality after slitting

one or two rolls. (See note 7 following)• Check index for accuracy.• Lower the POLYCARBONITE GUARD and press the ‘START’ button.

Hint: An ‘Operator Reference Sheet’ (refer back of Handbook) should be filled in eachtime a particular product has been successfully slit so that it is repeatable in thefuture. Failure to do this will only mean the same evaluation with the resultantloss of material/time will have to be gone through the next time that product hasto be slit.

Note 1: Position machine carriage in approximate centre of rails.Place an engineer's level across front and rear guide rails at the left-hand endof the machine and adjust the feet at left end of machine until level.Place engineer's level at right hand end and adjust the four adjustable feetuntil right hand end is level.(To enable the level to clear the ballscrew cover, small packing of equalthickness will need to be placed on each rail)Check for level lengthwise and adjust left hand end as required.Recheck level across the rails at left-hand end.

Ensure that all feet have approximately the same load on them.Note 2: Knife should be set so that it just fractionally (.5mm-.75mm/.02”-.04”)

penetrates the rubber mandrel sleeve. If the knife does not touch themandrel, use the joystick to move the knife forward as the Forward Knife Stopis simultaneously turned clockwise until the knife contacts the mandrel.Set the cutting speed to a medium speed, turn the machine on in ‘SEMI’mode and check the knife contact with the mandrel. Adjust if necessary.

Note 3: The adjustable rear stop knob should be in line with the proximity switchbelow it.

Note 4: Knife to be driven only if product requires it – (Refer Operator ReferenceSheet to determine if required).

Note 5: To adjust knife RPM:• Lower Polycarbonite guard (ensure chuck is ‘off’ and you are in ‘manual’

mode).• Press the ‘start’ button and adjust using the potentiometer.• When the required knife RPM is set, lift Polycarbonite guard to stop the

knife.Note 6: In some cases the knife brake may need to be used. Adjust brake pressure

by turning pressure regulator and reading pressure on gauge (Refer toOperator Reference Sheet to determine if brake required and if so, pressurefor product/width being slit.)

Note 7: When lifting the Polycarbonite guard to check the quality of the slit rolls, the


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8JULY 2016

guard should be lifted before the machine commences to travel to the nextindexed width, otherwise the roll counter will be out by one every time themachine is stopped.

Hint: To maximise longevity of mandrel sleeves ensure …• the knife is set so that it just fractionally penetrates the rubber sleeves• minimum vibration of mandrel by lowering the mandrel speed• the forward dwell timer is set to hold the knife on the mandrel long enough for

the roll to rotate and the knife to cut through the core.


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9JULY 2016

3. MACHINE FUNCTIONS

The JAVELIN series J5000 is an automatic single knife, lathe type slitting machine forcutting log rolls of tape.

3.1 MAIN ISOLATOR SWITCH & SAFETY FEATURES

This must be turned to the ‘OFF’ position before any electrical work is carried out. Togain access to the main control cabinet, the isolator switch must be turned ‘OFF’ andthe release catch pressed downwards to open the door. The same applies whenclosing the door.

Note: If main power has been turned off you must wait 30 seconds before turningthe machine on again. This is to allow the Variable Speed Drives to powerdown. If power is applied before they power down a fault situation will occurand the alarm will sound.

EMERGENCY STOP (see Fig. 3-1A)

This switch is a red PUSH/PULL illuminated button and over-rides all operation. Theswitch must be pulled outwards before the machine can be started.

START BUTTON (see Fig. 3-1A)

This green, illuminated push button is used to restart the system after it has beenstopped. The green lamp indicates that the system has been started.

POLYCARBONITE GUARD KEY SWITCH

As a safety feature, the machine will not operate when the POLYCARBONITE GUARDis lifted.

REAR SAFETY GUARD SWITCH

As a safety feature the machine will not operate when the gate is opened.

MANDREL SUPPORT ARM

As a safety feature, the machine will not operate when the air operated MandrelSupport is lowered.

LEFT HAND OVERTRAVEL LIMIT SWITCH

As a safety feature, the overtravel LIMIT switch will stop the machine should theadjustable LH CARRIAGE STOP fail.

RIGHT HAND OVERTRAVEL LIMIT SWITCHAs a safety feature, the overtravel limit switch will stop the machine should theadjustable RH CARRIAGE STOP fail.


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10JULY 2016

Fig. 3-1A Main Control Panel

Fig. 3-1B Side Control Panel

EXPANDINGMANDREL

MANDRELSUPPORT

NON-ROTATINGMANDREL LOCK

HOODADJUSTMENT

STARTBUTTON

EMERGENCYSTOP

DEBURRER

FORWARD KNIFE STOP

GRIPPING FORCEREGULATOR

KNIFE CARRIABEJOYSTICK

KNIFE CUTTINGSPEED

KNIFE APPROACHSPEED


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11JULY 2016

3.2 KNIFE PEDESTAL ASSEMBLY

3.2.1 KNIFE SELECTION

When purchasing knives you must ensure the angle of the bevel is ground to suit theJavelin grinder.

There are two grades of steel knives available. Alloy steel knives are less expensiveand suitable for slitting products where the knife is not regularly sharpened. Whenslitting more abrasive products such as some textiles or foam tapes where the knife issharpened regularly it is necessary to use *HCHC (Highchrome High Carbon Steel)knives for longevity and also to maintain a sharp knife edge.

KNIFE DIAMETER

The rule is to use the smallest diameter knife possible to minimise any run out. Usinga dial indicator check the knife for run out. It is preferable to be with .1mm (4thou).

KNIFE BEVELS

When slitting narrow widths only a primary bevel is required but with wider widths aback bevel is needed to balance the forces on either side of the knife so that it will cutstraight through the roll without deflecting. (also see knife selection table)


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12JULY 2016

KNIFE SELECTION

~ always use cut resistant gloves when handling knives ~

KNIFE BEVELS When slitting narrow widths only a primary bevel is requiredbut with wider widths a back bevel is needed to balance the forces on eitherside of the knife so that it will cut straight through the roll without deflecting(See note re bevels below)

CAUTION: Knife may be damaged or shatter if insufficient back bevel on knifewhen slitting wide widths. Trying to slit a roll to a wide width from a tightly woundlog roll, using a knife with insufficient back bevel, risks chipping or shattering the knife.

Diagram No. Slitting range Knife requirements

1 Up to 22 mm (7/8”) No Back Bevel

2 25.4 mm (1”) - 38 mm (1½”) 0.5 mm (1/64”) Back Bevel

3 40 mm (1 5/8”) - 96mm (4”) 1.5 mm (1/16”) Back Bevel

4 Over 100mm (4”) Equal Bevel both sides of knife

5 Any width (very hard materials) Tightly wound denser rolls will require test slitting to determinethe best knife bevel & edge for product Additional angle onprimary bevel

Dense materials that will not displace Must be rewound to a lesser tension

THE ABOVE DIMENSIONS ARE A GUIDE ONLY AND WILL VARY ACCORDING TO THE DENSITY OF THE MATERIAL TO BE SLIT.

Diagram 1:Knife with noback bevel

Diagram 2:Knife with 0.5mm(1/64”)back bevel

Diagram 3:Knife with 1.5mm(1/16”)back bevel

Diagram 4:Knife with equalbevel both sides

Diagram 5:Knife with reinforcededge (No. 2 angle)(refer to manual fordetails)

NOTE: A rounded edge is preferred for most adhesive tapes. Some exceptions wouldbe, for example, foam sealant & paper tapes which require a sharp edge. Toosharp an edge can result in edge breaking down (chipping). Edge should beslightly rounded with Shielded oil stone to prevent this occurring.

KNIFE DIAMETER The rule is to use the smallest diameter knife possible to minimise any run out. Using a dial indicator, check theknife for excessive run out.KNIFE BEVELS .The primary bevel on each knife has a long bevel at 8º with a smaller bevel at the outer edge of the knife at 11ºto strengthen knife edge. All Javelin grinders are factory set to 11º and care must be taken for this not to change. We recommendknives be either ground on your machine or returned to Javelin in order to maintain 11º bevel. Knives sent to contractors may result inbevel angle being changed with resultant slitting problems. To ensure knives are sharpened to the edge we suggest running a thinmark around the outer edge with a black pental pen. This mark will disappear once the knife has been sharpened to the edge.

NOTE: It is imperative records be kept for specific materials so the operator knows which knife to choose each time a particularproduct is to be slit. Ref: Operator Reference Sheets in the Manual.

No. 1 angle

No. 2 angle1 - 2mm (1/16” - 3/32”)

**With interlined materials it may be necessary to glue end of log roll to prevent centre of roll moving out,also if tightly wound a Diagram 3 bevel may be required. (Ensure log roll is pushed up against chuck face orspacer roll)


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13JULY 2016

OPERATOR REFERENCE SHEET

J5000 Knife & Machine Settings Date: Ref:

Customer Name:

Product Description :

Manufactured By :

Brand :

End Use/s :

Log Roll : Diameter: Width:

Length: Core size:

Material thickness:

Mandrel : Speed: Direction:

Width To Be Cut :

Density Of Material :

Tolerance Required :

Weight of Log Roll :

Knife : Diameter: Thickness:

No. of backing plates:

Main Bevel : Angle 1 Angle 2

Back Bevel : Size:

Saw Tooth Knife: TPI No. of washers:

(Note: As a general rule, prior to selection knife required, check notes on back page)

Knife : On Off

Knife Speed (rpm) : Direction:

Knife Braking : On Off

Pressure (kpa)

Knife Edge : Rounded Sharp

Knife Distance To Outside

Diameter Of Roll :

Knife Dwell Time : No. seconds

Knife Approach speed (pot setting) :

Knife Cutting speed (pot setting) :Knife approach time (seconds):

*Total cutting cycle per roll (sec):

Time cycle per log roll (min):

Est. No. of cut rolls (hr):

(*Total cutting time includes both forward & back movements of the knife plus dwell timefor the knife against the rubber covered mandrel and also time taken to traverse betweencuts. Extra allowance will have to be made where the auto grind is engaged in order toaccurately asses total time taken for loading & unloading & slitting one full log roll.)

Auto Grind : On: Off:

No. cuts between grinding:Grinder dwell time:

Sprays : On Off Low Med HighChuck Grip : Internal ExternalSupport Plate To Prevent 1stroll from collapsing : Yes No


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14JULY 2016

KNIFE EDGEA rounded edge is preferred for most adhesive tapes. Some exceptions would be, forexample, foam sealant tapes which require a sharp edge.

ROUNDING KNIFE EDGE

Operator MUST wear cut proof gloves when performing this function.

Turn off power at main isolating switch and using a Shielded Oil Stone (see Fig 3.3.1) holdthe stone flat against knife ege and slowly rotate the knife with the other gloved hand. Thiswill have the effect of dulling the sharp edge. Polish knife edge with Scotch Bright™

3.2.2 KNIFE SPINDLE

The knife spindle should be kept free of any grit and wiped over prior to fitting a knife.

The spindle is precision ground and supported by two tapered bearings with provisionfor adjustment.

3.2.3 BACKING PLATE , WASHER & CAP SCREWS

These items must be stored and kept clean in exactly the same manner as describedfor knives (above). Any grit or burrs must be removed or they will cause knife run outand resultant poor slitting results. Cap screw threads should be cleaned andlubricated regularly.

IMPORTANT NOTE

If knife is slightly chipped youwill need to retun it to JAVELINfor repair. The knife grinder onthis machine is not intended forheavy grinding.

Fig 3.3.1


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15JULY 2016

3.2.4 FITTING KNIVES TO KNIFE SPINDLE

As previously mentioned, any rust or burrs on the knife, knife spindle, backing platesor washer will cause problems including significant variations in width from one slit rollto the next.

Javelin knives have two parallel lines and the word “top” engraved on the face of theknife. The knife should be fitted so that the word “top” is uppermost in position and thetwo parallel lines face the mandrel. Providing the knife is always ground in thisposition as well as being located in this position when slitting, you will ensure axial andradial run out of the knife is minimal. This is the primary reason for having a knifegrinder mounted on the machine.

Fig. 3.2.4 Fitting the knife

Note: A rust inhibitor or light oil should be regularly wiped over the knife spindle,knife and backing plates to prevent any rust build up.


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16JULY 2016

3.3 KNIFE SHARPENING

The Knife Sharpening device (see Fig. 3-3) is provided on the machine so as toreduce the run out on the blade and assist in reducing any resultant slitting problemsas described in 3.2.4 (Fitting knives to the machine).

Use the joystick to move the grinder forward (longitudinal) until the proximity switchmounted on the grinder slide base has sensed on the cutting edge of the knife. Theknife edge is now approximately centred on the grinding wheel.

Ensure that there is approximately 3mm clearance between the grinding wheel and theknife.

Turn the knife grinder selector switch to the ON position. Grinder and knife motors willstart and grinder will move towards knife. Use joystick to move grinder in (laterally)until it contacts knife evenly. NOTE: Joystick will only move (inch) grinderapproximately 1mm (1/32”) at a time.

If unsure where the knife is being ground mark a small section of the knife bevel witha black marking pen and regrind for a minute. Stop the grinder and check if the blackmark has been removed from the knife edge. This indicates the bevel is correctlyground and right to the edge of the knife.

Where a number two bevel is needed to strengthen the knife edge (see knifeselection). Loosen the two hexagonal bolts in the slotted swivel plate and move theplate the full extent of the slots. Re-tighten the hex bolts.

When a back bevel is needed, the knife is turned 180° front to back and theappropriate amount of bevel is ground.

IMPORTANT NOTECheck there is adequate clearance between knife and grinding wheel 3 mm (1/8”).Switch knife motor and knife grinding motor on (carriage traversing buttons must beilluminated before motors will start).

Note: Only the number 1 angle is used on a knife with a back bevel.As the back bevel length increases the length of the primary bevel willdecrease.

IMPORTANT NOTEIt is not recommended that knives be removed from the machine for resharpening.Knives sharpened by outside contractors or on other sharpening devices almostinevitably lead to knives running out of true or not being ground to the correct anglewith resultant slitting problems.

NOTE: The primary bevel on each knife has a long bevel at 8º with a smaller bevelat the outer edge of the knife at 11º to strengthen knife edge. All Javelin grindersare factory set to 11º and care must be taken for this not to change. To ensureknives are sharpened to the edge we suggest running a thin mark around the outeredge with a black pental pen. This mark will disappear once the knife has beensharpened to the edge. After sharpening knives should be lightly rounded to prevenedge from breaking (Refer Section 3.2.3 – Rounding Knife Edge)


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17JULY 2016

Fig. 3-3 Knife Sharpening

3.3.1 AUTO GRIND FUNCTION

See F2 on PanelView screen.

GRINDER DWELL TIMER


CUTS PER GRIND COUNTER


3.3.2 DEBURRING UNIT

(See Fig. 3.3) When the knife has been ground true, turn the DEBURRER switch to‘ON’ position (see Fig. 3-1A) to very lightly back bevel the knife while the knife is stillgrinding, this will de-burr the knife and it is now ready for use.

DEBURRINGUNIT CONTROLKNOB

GRINDERMOTOR


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18JULY 2016

3.3.3 GRINDING WHEEL DIAMOND DRESSER

The diamond dresser is used to renew the cutting surface on the grinding wheel. Turnthe knife grinder switch to “Dress” position when performing this process.

Fig. 3.3.3 Deburring Unit and Grinding wheel diamond dresser

DIAMOND TIPPEDDRESSER

DEBURRINGSTONE


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19JULY 2016

3.4 KNIFE CARRIAGE - FORWARD AND RETRACTMOVEMENT

The advance and retract motion of the knife carriage is controlled by a Variable SpeedDrive, motor and ballscrew.

3.4.1 SETTING KNIFE STOP

FORWARD KNIFE STOP (see Fig. 3-1A)

Adjust the forward position of the knife to the mandrel using the ( FORWARD KNIFESTOP ) control knob, marked ‘OUT⇔IN’, by using the Forward/Retract Knife JoystickControl. Turn the knife stop knob in or out adjust the knife so it just penetrates therubber mandrel sleeve by about 0.5 mm to 0.75 mm (.02” - .04”). If you adjust it toodeeply you will find the mandrel rubber cover will become badly worn very quickly. It isimportant to note that the mandrel support at the end of the machine is in it's raisedposition at all times when adjusting the knob.

CAUTION:To prevent damage to the knife spindle, knife or mandrel:• ‘FORWARD KNIFE STOP’ knob must be adjusted whenever a knife is changed.• Mandrel support MUST be raised when setting knife to mandrel.

KNIFE REAR STOP (see Fig. 3-4)

Fig. 3.4 Knife rear stop

Loosen the adjusting KNIFE REAR STOP knob, located at the left hand side of thecarriage and move the carriage to a position where the knife has 10 mm clearancefrom the outside diameter from the log roll. Adjust the rear stop knob so the greentraversing lights are illuminated. (START BUTTON must be illuminated). Retightenknob.

KNIFE REAR STOP

PROXIMITY SWITCH


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20JULY 2016

CAUTION:If the knife is changed to a smaller or larger diameter or the log roll diameter isincreased or decreased the rear stop setting must be adjusted.Note: The KNIFE REAR STOP knob should be approximately in line with the proximity

switch below it.

3.4.2 KNIFE APPROACH SPEED POTENTIOMETER

(see Fig. 3.1A) Knife entry speed is set to a slower speed to enter the material. Oncethe set time for this speed has elapsed then the Knife Cutting Speed commences.

3.4.3 KNIFE CUTTING SPEED POTENTIOMETER

(see Fig. 3.1A) After the Knife Approach Speed set time has elapsed the machinethen enters the Knife Cutting Speed. This speed is set higher than the Approachspeed.

3.4.4 KNIFE APPROACH TIMER (see Fig. 3.1A)

Measures the time taken for the knife to advance from its back most position until itbegins its entry into the roll.

3.4.5 KNIFE DWELL TIMER (see Fig. 3-1A)

Enter on PanelView using F1 screen.


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21JULY 2016

3.5 KNIFE CARRIAGE – TRAVERSING (LEFT RIGHT)

The knife carriage traverses by means of a precision ballscrew. An encoder isattached to the drive end of the ballscrew.

3.5.1 SETTING CARRIAGE STOP

RIGHT HAND CARRIAGE STOP (see Fig. 3.5.1)

This ' RH HAND CARRIAGE STOP ' is set just past the position where the last cut isto be made. When the carriage contacts the stop, the carriage will automaticallytraverse back to the position of the left hand stop providing the auto return switch isturned on. Clearance between the chuck pins, pin holders and knife spindle should bechecked, and carriage stop moved out to provide clearance.

Fig. 3.5.1 Right-hand carriage stop

Note: If pin holders are fitted, the stop must be checked to prevent the knife or knifeguard from hitting pin holders.

RIGHT-HAND CARRIAGE STOP


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22JULY 2016

LEFT HAND CARRIAGE STOP (see Fig. 3-5-1a)

Move the adjustable LH CARRIAGE STOP or the mandrel support until knife stops inthe desired position.

Fig. 3.5.1a Left-hand carriage stop

3.5.2 KNIFE CARRIAGE JOYSTICK CONTROL (FORWARD, RETRACT,LEFT & RIGHT)

(See Fig. 3.1A). The joystick controls the left, right, in and out movement of the knifecarriage. To move the carriage, the mode switch must be in ‘MANUAL’. To traverseleft of right the green LEDs must be illuminated.The extent of carriage travel is set by adjustable stops left, right, front and rear.The carriage will only traverse left and right when it reaches the rear stop – this will beindicated by the green LEDs.If the joystick is held left or right for longer than three seconds it will continue until itreaches the carriage stop or the joystick is momentarily moved to the oppositedirection of travel.

CAUTION: Ensure knife is clear of log roll before traversing

LEFT-HAND CARRIAGE STOP


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3.5.3 CARRIAGE RETURN ‘ OFF ⇔ AUTO ‘

(see section 3.11.5) The two position carriage 'RETURN' selector determines whetheran automatic carriage return cycle is to be commanded. This mode selector must alsobe in ' AUTO' to enable this function to operate.

With the mode selector in the 'AUTO' position and the carriage return selector in the'OFF' position at the completion of the auto cycle (ie. the roll counter has counteddown to zero) or (if the carriage right limit switch is activated) the knife will retract andthe machine will halt all operations immediately. With the carriage return selector in'AUTO' and mode selector in 'AUTO' at the completion of the auto cycle (ie. the rollcounter has counted down to zero) or (if the carriage right limit is tripped) an automaticreturn will be initiated. The knife will retract to the second back position and thentraverse left at high speed until the adjustable left limit switch or the left overtravel limitswitch is reached. The machine will then halt all operations.


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3.6 PNEUMATIC CHUCK

The main spindle locates and drives the mandrel. It also drives the chuck. It ismounted in sealed bearings and bolted to the mainplate.

With 4 external pin holders the pneumatic MK II chuck has a gripping capacity from∅25.4 mm (∅1”) up to ∅710 mm (∅28”). It is independently mounted on chuckspindle. Gripping and releasing is made by pressing the air nozzle into the chuck airinlet. Air inlet labelled ‘GRIP’ and next to it the label ‘RELEASE’ for opening the chuck.The air nozzle is conveniently located next to the chuck.

GRIPPING RANGE SET-UP

The pin holders are mounted on sliding bars by a socket head screw. The sockethead screw is loosened and slid into the most suitable position to grip the core ormaterial.

GRIPPING FORCE ADJUSTMENT (see Fig. 3-1B)

Gripping force is adjusted through a regulator mounted on motor cabinet. Grippingforce is measured in terms of air pressure as shown on gauge mounted next toregulator. Suitable force can be achieved by actually gripping the material to be slit,then adjusting the regulator to suit.

Fig. 3-6-1-1 Pneumatic Chuck

CAUTION: When not using chuck pins to hold material, REMOVE pinholders as injury can occur from contact with pins.

GAS STRUT

PIN HOLDER

EXPANDINGMANDREL

SLIDING BAR

AIR NOZZLE TOGRIP & RELEASECHUCK PINS


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3.7 MANDREL SUPPORT ARM

The mandrel support arm (see Fig. 3.7) holds the mandrel and log roll in alignmentwith the chuck and also prevents run out of the mandrel with resultant faulty slit rolls.The mandrel support can be moved along the linear rails by releasing the mandrelsupport lock located below the linear rail.

MANDREL SUPPORT ARM LOCK

Under normal circumstances it is not necessary to engage the mandrel support armlock unless the mandrel is vibrating excessively due to an ‘out of round’ log roll.

CAUTION: If mandrel support arm lock is used it MUST be released before themandrel support arm is lowered to AVOID DAMAGE to the support armguides.

A manual or optional air operated mandrel support arm are available. The air operatedmandrel support arm helps reduce machine downtime during loading and unloading ofrolls.

Note: The machine will not operate with the air operated mandrel support lowered.

Fig. 3-7 Mandrel Support Arm

MANDREL

SUPPORT LOCK

MANDREL SUPPORT

ARM LOCK


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3.8 MANDRELS

3.8.1 ∅76.2 MM (∅3”) ROTATING MANDREL with expansion section

∅76.2 mm (∅3”) rotating expanding mandrel is fitted with a rubber sleeve to keepknife cutting edge off the metal part of the mandrel. Log roll is gripped by turning the‘RELEASE ⇔ GRIP’ switch to expand the jaws inside the mandrel.

The rotating mandrel rotates with the chuck spindle. It is held in the chuck spindle bytwo opposing cap screws, it can be removed from the machine by sliding it out afterloosening the two cap screws which lock into dimples in the mandrel and removing thecap screw joining the coupling halves together.

CAUTION: Do not engage non-rotating mandrel lock when using rotating mandrel.

3.8.1.1 FITTING EXPANDING MANDREL TO MACHINE

The sequence is:

• Loosen the non-rotating mandrel lock.• Remove the M5 bolt from the coupling.• Fit the mandrel to the machine.• Push home against the chuck face.• Align pop marks (if fitted) on left hand end of mandrel with pop marks on the

outside face of the chuck.• Tighten both drive screws in chuck spindle into dimples in mandrel - tighten the

screws progressively, alternating between each screw to ensure even pressurebetween screws. DO NOT tighten one screw fully and then the other.

• Connect the air cylinder coupling by fitting the cap screw.• Check operation of the air cylinder, expanding mandrel release grip and drive.

CAUTION: To avoid damage to mandrel ensure cap screws are located into dimplesbefore tightening.

Note: Check that there is no vibration in the mandrel when chuck is on. If there isany vibration loosen cap screws, rotate mandrel 180° and re-tighten as above.

3.8.1.2 ∅76.2 (∅3”) ROTATING TRIM MANDREL with expansion section

4 expansion jaws are located belowred mandrel sleeve section to grip I/Dof 3” (76.2mm) core.


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∅76.2 (∅3”) rotating trim mandrel is used to salvage ends of rolls or slit narrow widthrolls to useable width. The trim mandrel is a short length of normal rotating expandingmandrel to speed up the load and unload time of the roll.

3.8.2 NON-ROTATING MANDREL

Refers to mandrels that accept core sizes under 3” (76mm).

A mandrel adapter is fitted into the chuck spindle when using non-rotating mandrels.

Non-rotating mandrel has a fibre insert along its full length to protect the blade duringthe slitting cycle. A location dimple is drilled in one end of the shaft, when installed inthe machine it gives the correct register of the blade to fibre strip. The word 'TOP' isstamped into the shaft on the load end to help line up the dimple with the mandrellock.

The mandrel support should be moved up the bed of the machine as far as possibletowards the chuck to prevent the mandrel flexing and the possibility of some rolls notto be cut right through to the core.

The benefit of a non-rotating mandrel is that log rolls on cores of up to 51mm (2”) I/Dwill rotate with less vibration as there is less rotating mass, resulting in a better qualitycut.

Note: A bearing adaptor is also required to adapt the smaller diameter mandrels intothe chuck spindle.

Note: A fibre strip is not normally fitted to mandrel when slitting textiles unlessspecified.

CAUTION: Cap screws in chuck spindle must be removed and mandrel locktightened.

3.8.2.1 ∅25.4 MM (∅1") NON-ROTATING MANDREL

A ∅25.4 mm (∅1") nylon mandrel adaptor is supplied to adapt the ∅25.4 mm (∅1")mandrel to the support arm.

3.8.2.2 ∅38 MM (∅1½") TO ∅51 MM (Ø2”) NON ROTATING MANDREL

∅38 mm (∅1½") to ∅51 mm (∅2”) diameter mandrels are similar to the above but donot require adaptor block.


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3.9 SAFETY GUARD

3.9.1 POLYCARBONITE GUARD

The Polycarbonite guard fully encloses knife, mandrel and chuck area to protect theoperator from moving parts while the machine is operating.

When the Polycarbonite guard is in its raised position, the chuck will not run and themachine will not operate.

Machine will stop when cover is lifted. (see Fig.4.7)

Note: Machine will not operate if the Polycarbonite guard, when lowered, is not fullyengaged into the safety switch. (See Fig. 4.7)

Note: When cleaning the Polycarbonite guard use only warm soapy water or waterbased window cleaner and a soft cleaning cloth.DO NOT SCRUB or use brushes or squeegees.Dry with soft cloth or moist cellulose sponge to prevent water spotting.Under NO circumstances should petroleum/gasoline based products be usedas this will cause the polycarbonite to crack..

3.9.2 REAR SAFETY GUARD GATE

As a safety precaution the gate is fitted with a limit switch, which will shut the machinedown when the gate is opened.

NOTE: Machine will not operate if gate is opened.

Fig. 3-9-2 Rear Safety Guard Gate

LIMIT SWITCH


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3.10 SPRAY SYSTEM

The Spray System is for lubricating and cooling the side of the knife to preventadhesive build up. The sprays work on a Venturi System. The vacuum generatorcombines air and water to form a mist.

Fill water container with water and Lubricant Note: Low grade detergents cause rust &can congeal and block tubes. Javelin has sourced a good quality lubricant whichis now available in 1 Litre containers from Javelin

The sprays work only when the knife is moving forward in ‘SEMI’ or ‘AUTO’ mode.There are two flow valves. One valve controls both water and air supply.


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3.11 MACHINE CONTROL PANEL

Fig 3.11 Machine Control Panel

3.11.1 MODE ‘ SEMI ⇔ MANUAL ⇔ AUTO ‘

The three position selector switch provides ‘SEMI ⇔ MANUAL ⇔ AUTO’ (see Fig. 3-11) and automatic control of the system provided that the green ‘START’ lamp is on.

‘ MANUAL ‘ MODE

In the ' MANUAL' position, the carriage, knife and grinder can be operated as per therelevant switches whether the POLYCARBONITE GUARD is raised or the MandrelSupport Arm is lowered, providing the ‘START’ lamp and green LEDs are illuminated.

‘ SEMI ‘ MODE

In the ' SEMI ' position, the knife will advance, dwell and retract as in the fullyautomatic cycle but the carriage will not index to the next position and the chuck willnot operate if the POLYCARBONITE GUARD is raised. This mode is used to checkthe set up of the FORWARD KNIFE STOP, KNIFE REAR STOP, KNIFE DWELLTIME, KNIFE FORWARD SPEED and SPRAYS before proceeding to automaticoperation.‘ AUTO ‘ MODE

In the ' AUTO ' position the knife will automatically advance, dwell, retract and indexalong to the next cut position as set until the RH CARRIAGE STOP is reached. Oncecontacted, the carriage will automatically traverse back to the LH CARRIAGE STOPand be ready for slitting next log roll.

Note: ‘AUTO’ mode will only operate if the POLYCARBONITE GUARD is loweredand the Mandrel Support Arm is raised.

MODESELECTOR

STARTLAMP

KNIFECUTTINGSPEED

KNIFEAPPROACHSPEED

AUTOGRIND

KNIFEBRAKE

DEBURRER

KNIFEDRIVECONTROL

KNIFE CARRIAGECONTROL JOYSTICK

EMERGENCYSTOP


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3.11.2 START BUTTON

This green, illuminated push button (see Fig. 3-11) is used to restart the system after ithas been stopped. When the button flashes it indicates that the button needs to bepressed again to start the cycle. The green lamp on indicates that the cycle has beenstarted.

3.11.3 EMERGENCY STOP

This switch is a red PUSH/PULL illuminated button (see Fig. 3-11) and over-rides alloperation. The switch must be pulled outwards before the machine can be started.This button will illuminate if the phase rotation is incorrect.

3.11.4 PANELVIEW 600

The Allen Bradley PanelView 600 (see Fig. 3.11.4) is a combination Touch Screenand Keypad. The unit communicates with the PLC 1500 to provide automatedmachine control. The PanelView 600 is a multi-function device and the function keys (F1 to F10) have different functions depending on the screen or menu you are on.Not all keys perform a function. Numeric values are entered using the numeric keypadon the right.

The screen should be treated with the utmost care and should be cleaned with a waterbased glass cleaner.

Fig. 3-11-4 PanelView 600


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3.11.5 PANELVIEW 600 - MAIN OPERATOR PANEL

Fig. 3-11-5 PanelView 600 - Main Operator Panel

CARRIAGE RETURN

The Carriage Return function (see Fig. 3.11.5) determines whether an automaticcarriage return cycle is to occur. This mode selector must also be in ‘AUTO’ to enablethis function to operate. It is selected by touching the box on the screen.

With the mode selector in the 'AUTO' position and the carriage return 'OFF' at thecompletion of the auto cycle (ie. the roll counter has counted up to the entered numberof rolls) or (if the carriage right limit switch is activated) the knife will retract and themachine will halt all operations immediately. With the carriage return selected andmode selector in 'AUTO' at the completion of the auto cycle (ie. When the number ofrolls to be slit has been completed) or (if the carriage right limit is tripped) an automaticreturn will be initiated. The knife will retract to the second back position and thentraverse left until the adjustable left limit switch or the left overtravel limit switch isreached. The machine will then halt all operations.

SLIT SEQ NO.

This display (see Fig. 3.11.5) relates to multiple width function and shows in sequencefrom 1 to 6 the width currently being slit. The display “Recipe Enabled” will display inpink in the title bar when the function is active.


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ROLL WIDTH

To enter roll width (see Fig. 3.11.5) press F1 and then use the numeric keypad toenter the whole number value, then press enter. To enter the decimal value press F2and use the numeric keypad to enter the value, then press enter.To change the units between millimetres and inches go to screen Select Met/Imp.

CARRIAGE DISTANCE TRAVEL THIS CUT

(See Fig. 3.11.5). Displays the actual width the knife carriage has indexed for the rollcurrently being slit. The error/tolerance is displayed and indicates the ± value.

ROLL COUNTER

To enter the number of rolls of a specific width to be cut, press the F3 key and use thenumeric keypad to enter the value. The roll counter (see Fig. 3.11.5) will thenautomatically count the number of rolls slit (‘AUTO’ mode only). The counterincrements each time the knife begins to retract from the roll.

Once the entered value is reached the machine will then either stop or automaticallyreturn the carriage to the start position, depending on which mode the carriage returnis in.

Note: When lifting the Polycarbonite guard to check the quality of the slit rolls, theguard should be lifted before the machine commences to travel to the next indexedwidth, otherwise the roll counter will be over by one every time the machine isstopped.

KNIFE APPROACH TIME (SEC)

The Knife Approach time (see Fig. 3.11.5) sets the time in seconds that the knife is in“Knife Approach Speed” mode.

Press F4 and enter a value (in seconds) using the numeric keypad, then press enter.The knife approach speed potentiometer is set so that the knife enters the roll at aslower speed.

Once the seconds set for this speed have elapsed then the Knife Cutting Speedcommences. These two speeds are set using the two pots (potentiometers) on themachine control panel (see Fig 3.11).

KNIFE DWELL (sec)

This function (see Fig. 3.11.5) sets the time the knife remains fully advanced to allowthe knife to cut through the core. Press F5 and enter a value (seconds and tenths ofseconds) using the numeric keypad, then press enter.

Note: During ‘ AUTO ‘ and ‘ SEMI-AUTO ‘ MODE operations, the knife will advanceto its full forward position for a predetermined time before retracting from the Mandrel.


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KNIFE SPEED (RPM)

The knife speed (see Fig. 3.11.5) is controlled via a potentiometer that controls aninvertor (VSD.)fitted to provide variable speed. The PanelView 600 indicates the RPMspeed at which the knife is running.

CHUCK SPEED (RPM)

The chuck speed (see Fig. 3.11.5) is controlled via a potentiometer that controls aninvertor (VSD) fitted to provide variable speed. The PanelView 600 indicates theRPM speed at which the chuck is running.

3.11.6 PANELVIEW 600 – SELECT MET/IMP – ENGAGE AUTO GRIND

Fig. 3-11-6 PanelView 600 – Select Met/Imp – Engage Auto Grind

SELECT IMPERIAL/METRIC

See Fig. 3-11-6. Select metric (millimetres) or imperial (inches) by touchingcorresponding box on the screen.


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AUTO KNIFE GRINDING FREQUENCY

See Fig. 3-11-6. This display only functions when both the slitting mode andknife/grind selectors are in ‘AUTO’. Each time that a cut is completed with the modeselector in 'AUTO', the cuts/grind counter decreases its count by 1. When the counttotal is equal to zero the counter commences a grind cycle and rests.

Press F1 and use the numeric keypad to enter the value. This value determines thetotal number of cuts that will be made before an automatic grind cycle is initiated.

AUTO GRIND DWELL TIME

See Fig. 3-11-6. This function is only used when both the mode switch and theknife/grinder switch are in 'AUTO' The time delay set on this controls the length of timespent grinding the knife blade when the auto-grind cycle is in progress.

Press F2 and enter the value (seconds).

3.11.7 PANELVIEW 600 – PRODUCTION DATA

Fig. 3-11-7 PanelView 600 – Production Data


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TOTAL CYCLE TIME TO SLIT ON ROLL

See Fig. 3-11-7. This displays the total time in seconds to slit one roll from the timethe knife begins to advance until it retracts to its back position at the completion ofslitting the roll and traverses to the next cut. Used to determine the optimum slittingspeed (time) recommended in the Javelin Operator Reference Sheets.

Important – ensure that a knife with the correct bevel is used. For example do not usea knife with no back bevel to slit a very wide width.

In sequence, enter by pressing “Select Seq. 1” then enter the number of rolls by firsttouching the grey box on the screen under the word “Rolls”. Press the enter key.Then enter the number of slit rolls required by touching the blue display directly underthe word “Rolls” then press the enter key.

To enter the required width press the grey box under the word “Width” and then enterthe width in the blue display located directly underneath. Press the enter key.

Finally to enter the fraction or decimal figure after the decimal place press the grey boxlocated under “Dec. Point” and then the blue display directly below to enter thefraction. Press the enter key.

Repeat this process for each width required up to a maximum of six widths. When allrequired widths have been entered press the pink display “Enable Slit Seq.”

Press the F8 key to return to Main Operator Panel.TIME FOR KNIFE ADVANCE TO MANDREL

See Fig. 3-11-7. Displays the time taken to advance and slit the roll including the dwelltime on the mandrel.

TOTAL NUMBER OF ROLLS SLIT

See Fig. 3-11-7. Displays the total number of rolls slit for the life of the machine.

TOTAL RUN TIME

See Fig. 3-11-7. Displays the total number of hours the machine has been inoperation during its lifetime.

ROLLS SLIT SINCE LAST RESET

See Fig. 3-11-7. Number of rolls slit since the last reset. Can be reset each day/weekto determine production output. Reset by touching the box on the screen.


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3.11.8 PANELVIEW 600 – SELECT MULTIPLE ROLL WIDTH

Fig. 3.11.8 PanelView 600 – Select Multiple Roll Width

Fig. 3.11.8.1A PanelView 600 – Entering data in an Operator Reference Sheet


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Fig.3.11.8.1B PanelView 600 – Viewing an Operator Reference Sheet

The F4 screen (see Fig. 3.11.8) is used to enter up to six different widths to be slit forone log roll.Important – ensure that a knife with the correct bevel is used. For example do not usea knife with no back bevel to slit a very wide width.

In sequence, enter by pressing “Select Seq. 1” then enter the number of rolls by firsttouching the grey box on the screen under the word “Rolls”. Press the enter key.Then enter the number of slit rolls required by touching the blue display directly underthe word “Rolls” then press the enter key.

To enter the required width press the grey box under the word “Width” and then enterthe width in the blue display located directly underneath. Press the enter key.

Finally to enter the fraction or decimal figure after the decimal place press the grey boxlocated under “Dec. Point” and then the blue display directly below to enter thefraction. Press the enter key.

Repeat this process for each width required up to a maximum of six widths. When allrequired widths have been entered press the pink display “Enable Slit Seq.”

Press the F8 key to return to Main Operator Panel.


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3.11.9 PANELVIEW 600 – ALARM PANEL

Fig.3.11.9 PanelView 600 – Alarm Panel

3.11.10 KNIFE APPROACH SPEED POTENTIOMETER

See Fig 3.11. Knife entry speed is set to a slower speed to enter the material. Oncethe set time for this speed has elapsed then the Knife Cutting Speed commences.

3.11.11 KNIFE CUTTING SPEED POTENTIOMETER

See Fig 3.11. After the Knife Approach Speed set time has elapsed the machine thenenters the Knife Cutting Speed. This speed is set higher than the Approach speed.

3.11.12 KNIFE CARRIAGE JOYSTICK CONTROL (FORWARD,RETRACT, LEFT & RIGHT)

(See Fig. 3.11). The joystick controls the left, right, in and out movement of the knifecarriage. To move the carriage, the mode switch must be in ‘MANUAL’. To traverseleft of right the green LEDs must be illuminated.The extent of carriage travel is set by adjustable stops left, right, front and rear.The carriage will only traverse left and right when it reaches the rear stop – this will beindicated by the green LEDs.If the joystick is held left or right for longer than three seconds it will continue until itreaches the carriage stop or the joystick is momentarily moved to the oppositedirection of travel.


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3.11.13 KNIFE GRINDER

The grinder position is controlled by the joystick. The grinding assembly is fitted with aknife sensor to position the knife at the correct position for grinding.

‘AUTO’ GRINDThe counter (F2 screen) on the PanelView 600 can be set to the number of rolls to beslit between each grinding of the knife. Then the timer is set to the period required forgrinding. The knife grinder is switched to ‘AUTO’ (see Fig. 3.11). The knife will nowsharpen automatically after the set number of cuts for the set time without anyassistance from the operator.

‘DRESS’

The diamond dresser (see Fig. 3.11.13) is used to renew the cutting surface on thegrinding wheel. Turn the knife grinder switch to “Dress” position (see Fig. 3.11) whenperforming this process. Depending on the amount of use it will be necessary toreplace the diamond tip occasionally.

Fig. 3-11-13 Deburrer & Diamond Dresser

Grinding wheel

Diamond tipped dresser

Deburring stone


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3.11.14 KNIFE DRIVE CONTROL

KNIFE REV OFF FWD

(see Fig. 3-11) This is a three position, selector switch which provides forward, offand reverse control of the knife motor.

In the 'OFF' position, the knife will not operate unless the knife grinder selector is in‘ON’ or 'AUTO' postion.

In the forward or reverse position, the knife will start up and run at the speed set by theknife speed (rpm) control potentiometer provided that the green 'START' lamp is onand POLYCARBONITE GUARD is down.

3.11.15 CHUCK SPEED – FWD REV

See Fig). 3-11. This three position switch sets the REV OFF FWD rotation of thechuck. The potentiometer sets the speed of the chuck. The speed is displayed on theMain Operator Panel of the PanelView 600.

3.11.16 KNIFE BRAKE

See Fig. 3-11. This air regulator adjusts the pressure applied to the brake pads torestrict the free rotation of the knife blade. The degree of brake pressure applied canbe seen on the knife brake pressure dial gauge above. The brake will not operatewhen the knife is driven.

3.11.17 DEBURRER

When the knife has been ground true, turn the DEBURRER switch to ‘ON’ position(See Fig. 3-11 ) to very lightly back bevel the knife while the knife is still grinding, thiswill de-burr the knife and it is now ready for use.


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4 TROUBLE SHOOTING –

4.1 SLITTING TOLERANCES

To achieve tolerances within .1mm or ± 4 thou you need to check the following:

1. Use the smallest diameter knife possible … the bigger the knife diameter the morechance of run-out. Check our knife selection chart for a knife bevel to suit thewidth you wish to cut. As an example, you cannot hope to hold tolerances slittingnarrow widths with a knife with a back bevel.

2. Check the knife spindle, knife and backing plate for run-out using a dial indicator,as described below, where accuracy to .1mm (+/- 4 thou) is required.

3. With some products such as film tapes, you can use the knife brake so that theknife is locked and will not turn. By this method you eliminate any possibility ofknife run-out. However, you will need to stop slitting occasionally and rotate theknife so as to prevent a flat spot occurring on one section of the knife-edge.

Other factors that can affect tolerance are the index counter and encoder and in veryrare cases the clutch brake. An encoder problem is usually indicated by significantvariations in width from roll to roll although the PanelView 600 will still read correctly.Always check for any loose wires to the encoder or PLC.

A clutch brake problem is usually indicated by erratic tolerances displayed in thetolerance field in the PanelView 600. When checking for a problem with the unitalways first check the correct voltage is going to the clutch brake.

Remember that any burrs on the knife, backing plate and washer are enough toprevent tight tolerances being held.

Knives should always be fitted on the machine so that the engraved parallel lines facethe mandrel and the engraved word “top” is uppermost. The knife must always besharpened on the integrated knife sharpener mounted on the machine. Javelin knivesare bevelled at 11º and any alteration to that angle will cause problems. We stronglyadvise against sending knives out for sharpening. Even when you receive new knivesfrom Javelin they must be finally sharpened true on your machine.

Remember also that the mandrel must be aligned properly (see section 6.2 KnifePedestal alignment in this manual) and the fit of the rubber sleeve to the I/D of thecore of your material must be a close fit.

The material must be gripped firmly on the expanding mandrel and up against the faceof the chuck so there can be no sideways movement. If you are using a spacer rollbetween the chuck and material to be cut make sure it has straight edges and that it isapproximately the same diameter as the material to be cut.

When measuring slit rolls with a vernier do not allow the jaws of the vernier to closeagainst the cardboard or plastic core as this can give you a false reading.

If you follow the above points closely you will be able to slit tape to close tolerances.


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a. CHECKING FOR KNIFE SPINDLE RUN OUT:

Place dial indicator (see Fig 6.3) on clamping face of knife spindle and rotatespindle slowly, check for run out 0.03 - 0.05 mm (0.001" - 0.002") permissible.

To remove burrs or score marks from spindle face:i) run the spindle at medium speedii) hold a strip of emery cloth on a flat file and place it flat on the spindle face.

CARE MUST BE TAKEN NOT TO ROUND THE FACE OF THE SPINDLE.

b. CHECKING FOR BACKING PLATE RUNOUT:

The backing plate face should beconcave This can be checked byplacing a straight edge or steel ruleacross the face of the backingplate and checking if a gap of.1mm (.004”) exists.

Backing plates that have beendropped onto a hard surface maybe out of specification and willneed to be replaced.

i) Run a smooth flat file across the face of the backing plate and washer toensure there are no burrs.

ii) Check spindle face for burrs or grit.

iii) Fit backing plate and washer and check for runout with dial indicator.

iv) Runout should not be more than .08mm (.003”). If runout exceeds tolerance,mark backing plate in 4 positions and one position on spindle with marking pen.

1

2

3

4

backing plate

spindle

Check runout in each position. Ifa position is found which is withintolerance permanently markbacking plate and spindle.Ensure that the marks are alignedwhenever the backing plate isbeing placed back on the spindle.


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c. CHECKING FOR KNIFE RUNOUT

Place dial indicator on knife face and rotate knife. A runout of not more than.08mm (.003”) is permissible.

Fig 4.1c Checking for knife runout

d. HOW TO TIGHTEN KNIFE SPINDLE BEARINGS:

Tighten loose knife spindle bearings as follows:• Fit largest diameter knife.• Grasp knife on either side and try to move knife in, out, backwards and forwards.• If movement is detected in spindle apply knife brake to prevent knife spindle

from turning.• Remove cover from left-hand end of spindle and loosen grub screws in knife

spindle pulley.• Tighten nylon nut 1/6th of a turn to preload spindle bearings and check knife

again (see Point 3) for movement. Again tighten the nylon nut 1/6th of a turn andcontinue this process until there is no movement of the knife. This is exactly thesame process as tightening the front wheel bearings on a car. See followingnote.

• Replace cover and release knife brake.

Note: It is important not to tighten the nylon nut in one continuous turn of thespanner as this could put excessive load on the bearings and can cause damagewithin the pedestal.

e. PEDESTAL ALIGNMENT

If the knife has been jammed or forced at some time, the knife spindle could be bentor the pedestal could be out of square. The knife should be checked to see that it isparallel to the chuck face.


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f. ALIGN KNIFE PARALLEL TO CHUCK

• Remove the knife guard• Fit large diameter knife• Check the knife and spindle are running true• Remove mandrel• Adjust forward knife stop fully forward• Traverse knife close to chuck• Move knife forward• Measure distance between face of knife and chuck at the front and rear of the knife• Loosen pedestal retaining screws• Adjust as required to bring both faces parallel

4.2 KNIFE GRINDING

PROBLEM/EFFECT CAUSE REMEDIESKnife vibrates when beingground leaving scallopededge on knife. Usuallyoccurs with large diameterknives.

• Knife vibrating • Slightly raise or lowerknife RPM

• Loose knife spindlebearings

• Tighten knife spindlebearings

• backing plate bent or nolonger concave

• replace backing plate

• loose grinding wheel ongrinder motor shaft

• tighten grinding wheel


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46JULY 2016

4.3 BALLSCREW DRIVE

4.3.1 BALLSCREW AND NUT

Position and holds carriage accurately with no sideways play of carriage.

BALLSCREW NOISY OR VIBRATING

• Grease ballscrew nut• Check alignment of ballscrew nut mounting bracket• Check preload on ballscrew taper bearings

VARIATION IN WIDTH OR DOUBLE CUTTING

• Check preload on ballscrew taper bearings• Tighten ballscrew nut retaining bolts

TO CHECK FOR ENDPLAY IN BALLSCREW

Sideways freeplay in knife carriage. Traverse carriage to left hand end of machine,stand at end of the machine and grasp carriage, try to pull forward and backwards. Ifmovement is felt, determine if ballscrew is moving in bearing housing or ballscrew nutis loose on carriage or ballscrew.

If ballscrew nut retaining bolts are tight, ballscrew and nut are worn and generally needto be replaced.

ADJUSTMENT OF BALLSCREW END PLAY

Turn off the machine at main ON / OFF switch on the electrical cabinet, this dis-engaged electrical clutch / brake unit allowing the ballscrew to be rotated.

Remove rear cover to expose ballscrew bearing housing and adjusting nuts. Loosenthe two grub screws in the alloy timing pulley. loosen outer nut and adjust inner locknutto lightly preload taper bearings. Tighten outer nut, a grub screw in pulley, check forend play in ballscrew, check ballscrew rotates smoothly.


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47JULY 2016

4.3.2 CLUTCH BRAKE UNIT

Machines are fitted with a “self adjusting” clutch brake unit .

Machine is fitted with a Warner Electric clutch brake unit which is “self adjusting”.

Fig.4.3.2 Warner Electric clutch brake


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48JULY 2016

4.4 PNEUMATIC CHUCK

PROBLEM/EFFECT CAUSE REMEDIESPin holders not gripping orreleasing

• Low Air Pressure • Gripping pressure regulatormust be set to at least 2bar (30lbs/13.5kg)pressure.

One slide bar (pin holder)not moving.

• Low Air Pressure• Pin holder not fitted

correctly into slide bar.• No lubrication between

slide bar and wear strip.• Grit or rust between slide

bar and wear strip.

• As above.• Rectify

• See Lubrication Chart.

• Remove, clean andlubricate.

Pins disengaging frommaterial when machine isoperating.

• Air leading frompneumatic system

• Pressurise system andpaint all fitting in chuckpneumatic system withsoapy water and check forair bubble.


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49JULY 2016

4.5 MANDREL SUPPORT ARM

PROBLEM/EFFECT CAUSE REMEDIESMandrel vibrates. • Worn pivot bush/pivot

shaft in mandrel supportarm.

• Replace shaft bushes.

Sideways movementbetween mandrel supportarm and mandrel supportarm bracket.

• Mis-adjustment ofcollars

• Adjust locking collars onpivot shaft against mandrelsupport arm bracket.

Knife not slitting throughcore and/or knife cuttinginto mandrel at one end ofmachine.

• Mandrel support notaligned parallel to knifecarriage.

• Raise mandrel support.• Traverse carriage to

extreme right.• Adjust forward knife stop

so that the knife justtouches mandrel.

• Traverse knife to theextreme left and moveknife forward to mandrel.

• Loosen grub screwslocking mandrel supportarm to pivot shaft andmove arm sideways so thatknife touches the mandrelfractionally harder than atthe other end of machine(0.1 mm or 0.004").

• Lock grub screws and re-check.

Air operated mandrelsupport in-operative

• Lack of air • Check air supply.

Air operated mandrelsupport operates too slowor too fast at end ofstroke.

• Cushion flow valveincorrectly adjusted.

• Adjust flow valves locatedon either end of aircylinder, turn clockwise toslow down, anti-clockwiseto increase speed. Valvescontrol air exhausting fromcylinder.


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50JULY 2016

4.6 MANDRELS

4.6.1 NON ROTATING MANDREL

PROBLEM/EFFECT CAUSE REMEDIESMandrel vibrates • ∅25.4 mm (∅1")

adaptor not fitted tomandrel support.

• Core I/D diameteroversize.

• Log roll tear dropped orbowed.

• Incorrect cutting speed.

• Incorrect knife fitted.

• Mandrel flexing.

• Sprays not working

• Fit nylon adaptor block.

• Use correct size cores.

• Rewind log

• Check operator referencesheet.


• Move mandrel support upthe bed of the machinetowards the chuck as far aspossible.

• See Lubricant spray troubleshooting

Rolls sticking on mandrel • Worn or rough fibrestrip.

• Poor quality cores.

• Replace fibre strip.

Rolls sticking together • Lubrication of knifeineffective.

• Incorrect knife.

• Increase flow of lubricantand/or add extra detergentto water.


Chuck spindle becomingwarm

• Lack of lubricationbetween mandrel andchuck spindle.

• Grease mandrel throughchuck.

• Remove mandrel andlubricate.

Knife not cutting throughcore towards centre partof log

• Knife Dull or mandrelFlexing or bowed

• Not enough dwell time

• Sharpen Knife to ensure itslits through the corecleanly. A knife with a dulledge can tend to push thecore away rather than slitthrough as the mandrelflexes at its centre point

Check Mandrel for straightness• Increase knife dwell time

Move mandrel support upthe bed of the machine asfar as possible.Slow mandrel speed


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51JULY 2016

4.6.2 ROTATING MANDREL

PROBLEM/EFFECT CAUSE REMEDIESMandrel vibration. • Worn mandrel sleeve.

• Core ID oversize.• Log roll out of round.• Knife forward stop not

set correctly.• Mandrel flexing.

• Replace sleeve.• Use correct core size.• Slow mandrel speed.• Set knife close to mandrel.

• Move mandrel support upthe bed of the machinetowards the chuck asmuch as possible.

Mandrel overheats orgrinding noises omits frombearings.

• Insufficient clearancebetween mandrelretaining locking collarand mandrel.

• Bearings dry.• Bearings worn.

• Adjust to give 1 mmclearance.

• Grease bearings.• Replace bearings.

Strands protruding frommandrel.

• Knife cutting too deep. • Adjust forward knife stop..


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52JULY 2016

4.7 POLYCARBONITE GUARD

Machine will not operate unless the key mounted on the POLYCARBONITE GUARD isfully engaged into the switch (see Fig.4.7).

If key fails to fully engage into switch when safety hood is lowered, loosen the switchmounting screws and move the switch up until the key is fully engaged.

Fig. 4.7 Polycarbonite Guard Key Switch

GAS STRUT

SAFETYINTERLOCKSWITCH

KEY

POLYCARBONITEGUARD


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53JULY 2016

4.8 SPRAY SYSTEM

PROBLEM/EFFECT CAUSE REMEDIESSpray not working. • No air pressure or low

air pressure.• Knife must be moving

forward in a semi or automode.

• Flow valve (air control)closed off, open in an anti-clockwise direction.

Air but no water fromnozzle or intermittentspray.

• Water pick up tube notpushed into bottle.

• Water bottle empty.• Flow valve closed off.• Loose fitting or split

tubes.• Capillary tube blocked.

• Air pressure too highwill cause backpressure forcing waterout of system

• Push tube fully home.

• Fill bottle.• Open anti-clockwise.• Tighten fitting, check

tubing.• Remove tube from inlet

side of water supply flowvalve. Turn machine on.Block both spray nozzleswith your fingers. Airpressure will force anyobstruction out of thesystem. Replace watersupply tube and operateuntil spray works.

• Turn air pressure flow valveclockwise to reducepressure (air volume)

NOTE: Low grade detergents cause rust & can congeal and block tubes.Javelin has sourced a good quality lubricant which is now availablein 1 Litre containers from Javelin


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54JULY 2016

4.9 ELECTRICAL SYSTEM

ELECTRICAL CONTROL SYSTEM (see Fig. 2-4)

In order for the main system to be enabled:

• The main electrical panel isolate must be ON.• The motor overloads must be set (the motor overload indicator must be OFF.• The control panel emergency stop push button must be pulled out (red lamp must

be OFF.• The safety hood guard must be down with key switch engaged. (see Fig. 4.7)• The mandrel support must be raised.• Safety cage door to be closed.

PLC OPERATION

All electrical equipment is controlled from this point its operation can be checked byusing the LED display located on the front of the unit. The PanelView 600 has a faultscreen. A backup copy of the software is in an EPROM installed in the PLC. If theprogram is corrupted the program can be transferred into the PLC.

KNIFE CARRIAGE FAILS TO TRAVERSE

1. Check carriage motor overload is contacted (refer to motor section).2. In ‘MANUAL’ mode, check that the carriage left and right are alight. If not alight,

then retract knife until they are. The lamps indicate that conditions for traversingare met.

3. Carriage motor contactor operates but carriage fails to traverse. Check that theclutch/brake unit is operating correctly, if clutch/brake is OK then it should bepossible to turn the carriage ballscrew by hand when the power is turned off. If theclutch/brake is satisfactory then check that all motor connections are tight.

4. Carriage motor contact fails to operate, check the following:

• Green start lamp is ON.• PLC is in "RUN" mode.• Safety hood is down, and switch contact is closed.• Mandrel support is raised and indicating lamp is OFF.• Check machine has all three phases.• Carriage left and right over travel switches are OK.• Safety cage door closed and switch making contact.• Carriage left and right limit switches are OK.• Opposite direction auxiliary contact has been released.

If all these conditions are correct it will mean the carriage motor contactor will need tobe replaced.


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55JULY 2016

KNIFE FAILS TO OPERATE

If the knife fails to operate, check that the following conditions have been met:

• Check knife motor overload and fault screen (refer to overload section).• Green lamp is ON.• Safety hood is down and switch contact is closed.• Mandrel support is raised.

KNIFE FAILS TO ADVANCE

• Safety hood is down, and switch contact is closed.• Check that the knife advance limit switch is operating correctly.

KNIFE FAILS TO RETRACT

• Safety hood is down and switch contact is closed.• Check that the knife retract limit switch is operating correctly.

WIDTH COUNTER FAILS TO COUNT

• Check connection to shaft encoder at ballscrew.• Check connection terminal on PLC.

GRINDER FAILS TO OPERATE

• Knife must be allowed to start before grinder can operate.• Grinder dwell timer set to zero (refer to cut/grind section).• Carriage traverse lights must be illuminated.

CARRIAGE FAILS TO AUTOMATICALLY RETURN LEFT WHEN RIGHT HANDSTOP IS CONTACTED

• Check that the carriage RETURN selector is in AUTO.• Check that the retract limit switch is OK.• Check that the carriage left limit switch and carriage left proximity switch are

operating correctly.• If over travel LIMIT switch has sensed carriage will not return.

CHUCK FAILS TO ROTATE

• Check that the hood is down and fully engaged into safety switch.• Check that the mandrel support is raised.• The pneumatic chuck limit switch is closed.• Check operation of the hood contactor and chuck contactor.• If contactors are operating check condition of the motor.


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56JULY 2016

4.10 LIMIT & PROXIMITY POSITIONS/FUNCTIONS

Also refer to Fig. 7.1.5.

Fig. 6.10 Limit and proximity positions / functions

KNIFE TRAVEL BALLSCREW

SLOWDOWN PROXIMITYLEFT STOP

FRONT LIMIT

RIGHTSTOP


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57JULY 2016

MANDREL SLEEVE REPLACEMENT

400m (15¾”) width (Tan) Sleeve ReplacementRetaining Collar

The worn area is cut out using a strong sharp knife and the good sections pushed upthe mandrel. A retaining collar (see Figure 2) is secured to the mandrel by tighteningtwo grub screws. This collar prevents the sleeves from separating.

The sleeves may appear to be a loose fit but when the retaining collar is pushedagainst sleeve at load end of machine and grub screws are tightened the sleeves willnot move. Ensure that there is no clearance between collar and sleeve.

NOTE: To maximize longevity of mandrel sleeves ensure knife is set approximately 2 –3mm away from OD of sleeve. When operator pulls the cutting handle down the knifeshould then fractionally penetrate the sleeve.

Red Polyurethane 100mm (4”) Sleeve (Expansion Sleeve)

The 4” wide red polyurethane sleeve (see Figure 1) is a new accessory which fits onthe section of the mandrel where the expansion jaws are located. Because it is softeryou will find that it expands more evenly and therefore grips the I/D of the tape coremore securely. As there is a lot of wear on this part of the rubber sleeve it may alsoextend the life of the tan coloured rubber sleeve. You can easily replace just the redsection on its own:

Mandrel Sleeve (Tan)These sleeves cover steelmandrel. The sleeves are easyto slide on and remove enablingsmall sections of worn sleeve tobe easily replaced.

Red Polyurethane SleeveFits on the section of the mandrelwhere the expansion jaws arelocated. Because it is softer thejaws will expand more fully andtherefore grip the I/D of the tape

Retaining CollarCollar is secured to themandrel by tighteningtwo grub screws

Figure 2


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58JULY 2016

Replacement of Red Polyurethane Sleeve

• Remove the mandrel from the machine.

• Use plastic hammer and a wide bladed screwdriver or wedge to drive redsleeve towards the right hand end of the mandrel until internal jaws areexposed.

• Wrap adhesive tape around jaws.

• Remove red sleeve.

• Push on new sleeve to hold jaws in position.

• Remove tape and tap sleeve home to correct position.

IMPORTANT NOTE (RED SLEEVE):

Over an extended period the (red) expanding sleeve may develop a bulge andmake it difficult to slide log rolls over the red sleeve. To prevent this werecommend that you occasionally loosen the grub screw in the retaining collar(Fig. 2) and slide the sleeves down the mandrel as show in Fig. 1 to relieve thepressure on the expanding sleeve. Then just move the sleeves back intoposition and slide the retaining collar against the tan sleeve and tighten the grubscrew. Do not push the collar hard against the sleeve, as you will only causethe problem with the red sleeve to re-occur more quickly.

NON-ROTATING MANDREL - FIBRE STRIP REPLACEMENT

To replace fibre strip:

• Remove old fibre strip with sharp chisel or knife.

• Clean the ‘FLAT’ on the mandrel with solvent.

• Glue on new fibre strip with 2 pack - 24 hours araldite or similar high strengthadhesive.

• Hold in position with PVC - Vinyl tape until dry.

• Use emery paper or file to remove excess adhesive.


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59JULY 2016

TABLE OF CONTENTS

NOTE TO OPERATOR: SINGLE KNIFE SLITTING ........................................................................................ 1

OPERATOR SAFETY ............................................................................................................................................. 2

OPERATOR ALERT ............................................................................................................................................... 3

1. PRINCIPLES OF SINGLE KNIFE SLITTING ................................................................................................ 4

2. MACHINE OPERATION.................................................................................................................................... 5

2.1 SETTING UP AND OPERATION PROCEDURE............................................................................................... 5

3. MACHINE FUNCTIONS .................................................................................................................................... 9

3.1 MAIN ISOLATOR SWITCH & SAFETY FEATURES....................................................................................... 93.2 KNIFE PEDESTAL ASSEMBLY ...................................................................................................................... 11

3.2.1 KNIFE SELECTION ................................................................................................................................... 11KNIFE DIAMETER ..........................................................................................................................................................11KNIFE THICKNESS .......................................................................................................... Error! Bookmark not defined.KNIFE BEVELS................................................................................................................................................................11KNIFE SELECTION .........................................................................................................................................................12OPERATOR REFERENCE SHEET..................................................................................................................................13KNIFE EDGE ....................................................................................................................................................................14ROUNDING KNIFE EDGE ..............................................................................................................................................14

3.2.2 KNIFE SPINDLE ........................................................................................................................................ 143.2.3 BACKING PLATE , WASHER & CAP SCREWS ........................................................................................ 143.2.4 FITTING KNIVES TO KNIFE SPINDLE.................................................................................................... 15

3.3 KNIFE SHARPENING....................................................................................................................................... 163.3.1 AUTO GRIND FUNCTION ........................................................................................................................ 173.3.2 DEBURRING UNIT .................................................................................................................................... 173.3.3 GRINDING WHEEL DIAMOND DRESSER............................................................................................... 18

3.4 KNIFE CARRIAGE - FORWARD AND RETRACT MOVEMENT ................................................................. 193.4.1 SETTING KNIFE STOP.............................................................................................................................. 193.4.2 KNIFE APPROACH SPEED POTENTIOMETER...................................................................................... 203.4.3 KNIFE CUTTING SPEED POTENTIOMETER ......................................................................................... 20

3.5 KNIFE CARRIAGE – TRAVERSING (LEFT RIGHT) ..................................................................................... 213.5.1 SETTING CARRIAGE STOP ...................................................................................................................... 213.5.2 KNIFE CARRIAGE JOYSTICK CONTROL (FORWARD, RETRACT, LEFT & RIGHT)........................... 223.5.3 CARRIAGE RETURN ‘ OFF ⇔ AUTO ‘.................................................................................................... 23

3.6 PNEUMATIC CHUCK....................................................................................................................................... 243.7 MANDREL SUPPORT ARM............................................................................................................................. 253.8 MANDRELS....................................................................................................................................................... 26

3.8.1 ∅76.2 MM (∅3”) ROTATING MANDREL with expansion section ........................................................... 263.8.1.1 FITTING EXPANDING MANDREL TO MACHINE ..........................................................................................263.8.1.2 ∅76.2 (∅3”) ROTATING TRIM MANDREL with expansion section .................................................................26

3.8.2 NON-ROTATING MANDREL..................................................................................................................... 273.8.2.1 ∅25.4 MM (∅1") NON-ROTATING MANDREL ...............................................................................................273.8.2.2 ∅38 MM (∅1½") TO ∅51 MM (Ø2”) NON ROTATING MANDREL...............................................................27

3.9 SAFETY GUARD............................................................................................................................................... 283.9.1 POLYCARBONITE GUARD....................................................................................................................... 283.9.2 REAR SAFETY GUARD GATE................................................................................................................... 28

3.10 SPRAY SYSTEM ............................................................................................................................................. 293.11 MACHINE CONTROL PANEL....................................................................................................................... 30

3.11.1 MODE ‘ SEMI ⇔ MANUAL ⇔ AUTO ‘.................................................................................................. 30‘ MANUAL ‘ MODE.........................................................................................................................................................30‘ SEMI ‘ MODE.................................................................................................................................................................30‘ AUTO ‘ MODE ...............................................................................................................................................................30

3.11.2 START BUTTON....................................................................................................................................... 313.11.3 EMERGENCY STOP................................................................................................................................. 313.11.4 PANELVIEW 600...................................................................................................................................... 31


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60JULY 2016

3.11.5 PANELVIEW 600 - MAIN OPERATOR PANEL....................................................................................... 32CARRIAGE RETURN.......................................................................................................................................................32SLIT SEQ NO. ...................................................................................................................................................................32ROLL WIDTH ...................................................................................................................................................................33CARRIAGE DISTANCE TRAVEL THIS CUT................................................................................................................33ROLL COUNTER..............................................................................................................................................................33KNIFE APPROACH TIME (SEC) ....................................................................................................................................33KNIFE DWELL (sec) ........................................................................................................................................................33KNIFE SPEED (RPM).......................................................................................................................................................34CHUCK SPEED (RPM) ....................................................................................................................................................34

3.11.6 PANELVIEW 600 – SELECT MET/IMP – ENGAGE AUTO GRIND....................................................... 34SELECT IMPERIAL/METRIC .........................................................................................................................................34AUTO KNIFE GRINDING FREQUENCY.......................................................................................................................35AUTO GRIND DWELL TIME..........................................................................................................................................35

3.11.7 PANELVIEW 600 – PRODUCTION DATA.............................................................................................. 35TOTAL CYCLE TIME TO SLIT ON ROLL.....................................................................................................................36TIME FOR KNIFE ADVANCE TO MANDREL..............................................................................................................36TOTAL NUMBER OF ROLLS SLIT ................................................................................................................................36TOTAL RUN TIME...........................................................................................................................................................36ROLLS SLIT SINCE LAST RESET..................................................................................................................................36

3.11.8 PANELVIEW 600 – SELECT MULTIPLE ROLL WIDTH........................................................................ 373.11.9 PANELVIEW 600 – ALARM PANEL....................................................................................................... 393.11.10 KNIFE APPROACH SPEED POTENTIOMETER.................................................................................. 393.11.11 KNIFE CUTTING SPEED POTENTIOMETER ..................................................................................... 393.11.12 KNIFE CARRIAGE JOYSTICK CONTROL (FORWARD, RETRACT, LEFT & RIGHT)....................... 393.11.13 KNIFE GRINDER................................................................................................................................... 40

‘AUTO’ GRIND.................................................................................................................................................................40‘DRESS’ ............................................................................................................................................................................40

3.11.14 KNIFE DRIVE CONTROL...................................................................................................................... 413.11.15 CHUCK SPEED – FWD REV................................................................................................................. 413.11.16 KNIFE BRAKE........................................................................................................................................ 413.11.17 DEBURRER ............................................................................................................................................ 41

4 TROUBLE SHOOTING – .................................................................................................................................. 42

4.1 SLITTING TOLERANCES................................................................................................................................ 42a. CHECKING FOR KNIFE SPINDLE RUN OUT: ............................................................................................ 43b. CHECKING FOR BACKING PLATE RUNOUT: ............................................................................................ 43c. CHECKING FOR KNIFE RUNOUT................................................................................................................ 44d. HOW TO TIGHTEN KNIFE SPINDLE BEARINGS:....................................................................................... 44e. PEDESTAL ALIGNMENT................................................................................................................................ 44f. ALIGN KNIFE PARALLEL TO CHUCK .......................................................................................................... 45

4.2 KNIFE GRINDING ............................................................................................................................................ 454.3 BALLSCREW DRIVE........................................................................................................................................ 45

4.3.1 BALLSCREW AND NUT............................................................................................................................. 464.3.2 CLUTCH BRAKE UNIT.............................................................................................................................. 47

4.4 PNEUMATIC CHUCK....................................................................................................................................... 484.5 MANDREL SUPPORT ARM............................................................................................................................. 494.6 MANDRELS....................................................................................................................................................... 50

4.6.1 NON ROTATING MANDREL ..................................................................................................................... 504.6.2 ROTATING MANDREL .............................................................................................................................. 51

4.7 POLYCARBONITE GUARD............................................................................................................................. 524.8 SPRAY SYSTEM ............................................................................................................................................... 534.9 ELECTRICAL SYSTEM.................................................................................................................................... 54

PLC OPERATION.............................................................................................................................................................54KNIFE CARRIAGE FAILS TO TRAVERSE ...................................................................................................................54KNIFE FAILS TO OPERATE...........................................................................................................................................55KNIFE FAILS TO ADVANCE .........................................................................................................................................55KNIFE FAILS TO RETRACT...........................................................................................................................................55WIDTH COUNTER FAILS TO COUNT ..........................................................................................................................55GRINDER FAILS TO OPERATE .....................................................................................................................................55CHUCK FAILS TO ROTATE ...........................................................................................................................................55

4.10 LIMIT & PROXIMITY POSITIONS/FUNCTIONS ........................................................................................ 56

MANDREL SLEEVE REPLACEMENT ............................................................................................................. 57

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