NovaTec Bessemer C Series Manual de usuario

Rotary Knife Cutter

Model: Bessemer C-Series:

C-2, C-3 & C-4

C Series IM 12 MAY 2015

C-Series IM 12 MAY 2014

Please record the following information,

which is specific to this piece of

equipment, in the space provided.

Our Parts/Service Department will need

these numbers to properly respond to

any of your requests.

Instruction Manual: C-Series IM 12 MAY 2015

Model #:___________________________

Serial #____________________________

DISCLAIMER: NOVATEC, Inc. shall not be liable for

errors contained in this Instruction Manual nor for

misinterpretation of information contained herein.

NOVATEC shall not, in any event, be held liable for any

special, indirect or consequential damages in

connection with performance or use of this information.

C-Series IM 1 MAY 2014

Table of Contents

1PURPOSE OF THIS MANUAL ............................................................................................................3

Explanation of Symbols...........................................................................................................................................3

2SAFETY PRECAUTIONS AND WARNINGS......................................................................................4

2.1 Safe Access to Guarded Blade Area ................................................................................................................4

3.0 GENERAL DESCRIPTION .................................................................................................................. 5

4.0 SPECIFICATIONS............................................................................................................................................6

4.1 Product Features........................................................................................................................................6

5.0 BLADE SPEED VS CUTS PER MINUTE.........................................................................................................7

6.0 OPERATING PRINCIPLES....................................................................................................................9

7.0 INSTALLATION......................................................................................................................................9

7.1 Mechanical Installation....................................................................................................................................10

7.1.1 The Blades ..........................................................................................................................................10

7.1.2 The Bushing ........................................................................................................................................11

7.2 Electrical Installation .......................................................................................................................................12

8.0 INDICATOR LIGHT DESIGNATIONS.................................................................................................. 14

9.0 PLC GENERAL OVERVIEW................................................................................................................ 15

9.1 Startup and Power Loss..................................................................................................................................15

10.0 SCREEN CONVENTIONS AND COMMON ELEMENT.....................................................................15

10.3 Screen Title...................................................................................................................................................16

10.4 Machine Status .............................................................................................................................................16

10.5 Standard Navigation Buttons ........................................................................................................................16

10.6 Cut Start/Stop Buttons ..................................................................................................................................16

11.0 SYSTEM STARTUP ...........................................................................................................................17

11.1 Initial Screen - ...............................................................................................................................................17

11.2 POWER UP Screen ......................................................................................................................................17

11.2.1 Verify Safety/Reset System...............................................................................................................17

11.2.2 Verify Safety/Press E-Stop................................................................................................................18

11.2.3 Reset System to Home Screen.........................................................................................................18

11.2.4 Homing Screen..................................................................................................................................18

12.0 MACHINE OPERATION.....................................................................................................................19

12.1 Quick Ops Screen Items...............................................................................................................................19

12.2 Cut Start/Stop Buttons ..................................................................................................................................20

12.3 Changing the CUT MODE ............................................................................................................................20

12.4 Recipe Select Screen....................................................................................................................................21

12.5 CURRENT RECIPE SCREEN............................................................................................................22

12.6 Setting Up Counters......................................................................................................................................23

12.7 Production Metrics ........................................................................................................................................23

12.8 QUICK OPS SCREEN VERSIONS ....................................................................................................24

C-Series IM 1 MAY 2014

13.0 SETUP SCREENS.............................................................................................................................. 26

13.2 LOGON .........................................................................................................................................................26

13.3 Home Screen................................................................................................................................................27

13.4 Recipe Functions ..........................................................................................................................................28

13.5 SETUP SCREEN 1.......................................................................................................................................29

13.6 SETUP Screen 2...........................................................................................................................................30

13.7 SETUP Screen 3...........................................................................................................................................32

13.8 Servo Setup Page.........................................................................................................................................34

13.9 Batch Counter Screens................................................................................................................................36

14.0 MAINTENANCE..................................................................................................................................37

At Startup ..............................................................................................................................................................37

Every bushing or blade change ............................................................................................................................37

Daily ......................................................................................................................................................................37

Every 3 Months .....................................................................................................................................................37

15.0 WARRANTY – NOVATEC, INC. - EFFECTIVE DATE 6-12-2012.....................................................38

C-Series IM 1 MAY 2014

1 PURPOSE OF THIS MANUAL

This manual describes the installation and operation of the NOVATEC Model C Rotary Knife Cutter.

Before installing this product, please read this guide and any additional guides associated with the

system’s auxiliary equipment.

Explanation of Symbols

This manual includes both general and task-specific safety precautions. These precautions

are highlighted in the manual by the following categories:

WARNING: This symbol identifies situations that are potentially

hazardous to personnel or equipment.

NOTE Highlights information provided in text or procedures. This

information may or may not be related to safety.

C-Series IM 1 MAY 2014

2 SAFETY PRECAUTIONS AND WARNINGS

These operating instructions must be read, understood, and implemented by all personnel

responsible for this system.

All mechanical and electrical work must be performed by qualified personnel only.

Always disconnect power before servicing.

Refer to the machine serial number nameplate and drawings supplied with this system for

actual power requirements.

Be sure to install the equipment with the proper electrical connections according to all national

and local regulations.

Electric power supply should be through a separate disconnect switch with properly sized

overload/fuse protection.

The customer is required to operate the equipment with all safety features in proper working

condition.

NOVATEC shall provide no further guarantee for function and safety in the event of

unauthorized modifications.

2.1 Safe Access to Guarded Blade Area

It is safe to access the guarded blade area when the power is on. NOVATEC Cutters use

a servo that has built in safety. It can execute a Safe Stop on E-Stop and has a Safe Torque

Off which is executed within 0.5 seconds of E-Stop. It also is monitoring itself for Safe

Standstill which is interlocked to the guard lock. With the addition of redundant safety relays,

motor contactor and guard interlock, the system can exceed SIL-3, PL-d safety requirements

for a Cat3 safety hazard.

NOTE: Additional guarding may be required where the product enters and exits the

bushing.

NOTE: The Safety Circuit Must Be Tested on 90 Hour Intervals

To meet the requirements for a Cat3 safety system, the safety circuit must be tested at regular

intervals to insure that it is functioning properly. When the system is first powered on, the

power must be engaged and then the E-Stop activated to ensure that it is functioning. After

90 hours of continuous operation a Warning Message will appear instructing the operator to

perform the safety verification test which involves pressing the E-Stop and the resetting the

circuit. Production can continue while the message is present but arrangements should be

made to perform the test as soon as possible.

Even though there is no power to the blade when the system is E-Stopped, there is still the

hazard of the sharp blade. Care should always be taken when working in this area.

Please contact Novatec if there are any questions or concerns.

C-Series IM 1 MAY 2014

3.0 GENERAL DESCRIPTION

The NOVATEC, C Series Rotary Knife Cutter offers high versatility to cut a wide range of profiles. It

is able to cut small profiles at high speeds and large profiles at lower speeds. Extrudate is fed into

the cutter from upstream, typically by a puller. Two cutter bushings, on either side of the knife, guide

the extrudate through the cutter. A rotary knife is mounted to a 12” diameter cutter head and driven

by a servo motor through a gear reducer. This knife cuts material that is supported between the

bushings. The knife is positioned at a home position until the cut motion begins. The knife then

rotates through a cutting lubricant/chip collection reservoir, through a felt blade wipe to clean the

blade, and then through the bushings again to make another cut. The cut extrudate continues to

move through the bushing where it is either collected or is conveyed further downstream by an

optional conveyor.

Two cutting modes are available: ON-DEMAND cutting mode and CONTINUOUS cutting mode.

Within these two major modes of operation, a wide range of parameters may be adjusted for

consistent, repeatable, and precise results.

•ON-DEMAND cutting mode allows 250 cuts per minute. The blade does not continuously

rotate, but instead starts and stops as needed.

•CONTINUOUS cutting mode allows up to 750 cuts per minute by continuously rotating the

cutter head at a speed sufficient to cut the desired length at the measured line speed.

C-Series IM 1 MAY 2014

52.37” Floor

C.L Control

36 “

”

58 5

39 9

37 7

4.0 SPECIFICATIONS

4.1 Product Features

•12” high torque cutter head

•Accepts rectangular bushings 19.75mm thick x 89.75mm wide x 150mm long

•Apex Dynamics 4:1 speed reducer

•Taper lock shaft bushing hardware

•2500 count quadrature cut length encoder with 12” circumference measuring wheel

•Knife thicknesses of .015, .020”, .025”, .030”, .040” available; Blades shaped and sharpened

to meet custom application requirements

•Safety interlocks provided for operator safety

•Removable cutting chamber cover with integral reservoir provides full access to cutting

chamber and cutting fluid reservoir

•Split clamp bushing arrangement provides easy bushing setup

•Indicator lights for machine status indication

•5-Year Warranty

C-Series IM 1 MAY 2014

5.0 BLADE SPEED VS CUTS PER MINUTE

The blade speed can be set anywhere from the Minimum On Demand Blade Speed to the

Maximum Blade Speed set on the System Setup page. Typically, the blade speed will be set

so that the product has the best possible cut. If the blade speed is set too low and the CPM

requirement is too high, the blade will not travel around in time to start the next cut and the

next cut will be ignored resulting in a part that is twice as long as intended. It is also possible

to set the On Demand Blade Speed and the Required CPM so high that eventually, it faults

the drive because there is too much power required for the move. Below are charts that show

the blade speed versus CPM for several cutters. It was determined by shop testing. Actual

results might be less due to lower supply power or higher ambient temperatures.

The tests were performed with 480VAC at 75F.

C-Series IM 1 MAY 2014

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