CN860 Manual Operation Single Knife Slitter

Transcription

1 Shanghai Hensley Enterprise Co., Ltd 上海海世利实业有限公司 CN860 Manual Operation Single Knife Slitter Operation, Maintenance & Spare Parts Manual Co. Name: Machine Serial No.: S/N Please ensure all employees operating this machine have read this Manual with attention drawn to all cautionary and important notes prior to operating machine

2 IMPORTANT NOTE SINGLE KNIFE SLITTING The principle on which this type of slitting is based, depends on the knife being able to displace the roll width being slit. Materials which are too dense or have been wound too tightly may be unsuitable to slit by this method. In this case either the roll must be rewound to a lesser tension or the material cut on a machine known as a slit/rewinder. Knife parameters are crucial in successful Single Knife Slitting (Refer Knife Selection Section 9.1 in Manual) As widths being slit increase so must the secondary or back bevel on the knife in order to balance the forces and achieve a straight cut. Failure to pay attention to choosing a knife with the correct bevel will result in the knife chipping or in an extreme case shatter.

3 IMPORTANT NOTICE CONSULT YOUR ELECTRICIAN REGARDING YOUR POWER SUPPLY WE RECOMMEND YOUR ELECTRICIAN HARD WIRES MACHINE. IF A RESIDUAL CURRENT DEVICE (RCD) IS FITTED TO YOUR SINGLE PHASE POWER OUTLET IT WILL CAUSE INVERTOR (VSD) TO OVERLOAD WHEN USING STANDARD LEAD & PLUG. TO AVOID UNNECESSARY PROBLEMS OCCURRING, PLEASE ENSURE YOU TAKE THE FOLLOWING STEPS BEFORE COMMISSIONING AND SETTING UP YOUR MACHINE. 1. Read your manual BEFORE trying to operate machine. 2. Unpack the machine, lay out the components and check for transport damage. 3. Check contents against your Packing Slip. 4. Report any damage or missing components. 5. Assemble the machine in accordance with instructions in the Manual. CHECK ALL BOLTS FOR TIGHTNESS. 6. Follow the instructions in the Manual to... Level the machine. Connect electrical power. 8. Ensure that you understand the principles and functions of the machine BEFORE you attempt to operate the machine.

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6 1 1 SPECIFICATION Javelin CN860 Manual Single Knife Slitter DESCRIPTION POWER REQUIREMENTS: CN860 Single Phase 240 Volts (with Invertor fitted) MACHINE DIMENSIONS: LENGTH: 2500 mm (98 ) DEPTH: 1100 mm (43 ) HEIGHT: 1650 mm (65 ) WEIGHT: 450 Kg (990lbs)-(fully Optioned) CAPACITY LOG ROLL: OUTSIDE DIAMETER: CORE INSIDE DIAMETER: WIDTH: 1630 mm (64 ) 305 mm ( 12 ) 76.2 mm ( 3 ) 51 mm ( 2 ) (OPTIONAL) 25.4 mm ( 1 ) (OPTIONAL) MOTOR: CHUCK: KNIFE: CHUCK/MANDREL DRIVE: Connected to: INVERTOR (V S DRIVE): KNIFE DRIVE: OUTSIDE DIAMETER: BORE: THICKNESS: 1.5kw (2HP), AC, 6 pole motor 1.5kw (2HP)/Single Phase ( converts power to 3 Phase (SP IN 3PH OUT) Free rotating knife with Knife Brake 3 pin chuck 330 mm ( 13 ) 25.4 mm ( 1 ) 3mm (1/8 ) INDEXING UNIT: ROTATING MANDRELS: EXPANDING SECTION WITH INTERNAL JAWS: ROTATING MANDRELS Rack & Pinion System with carriage position lock. Electronic Digital Read Out Screen) (OPTIONAL). (if fitted displays width to be cut) Accepts 1630 (64 ) wide rolls on 76.2 mm ( 3 ) I/D cores To accept 76mm (3 ) I/D cores To accept 25.4mm (1 ) I/D cores (OPTIONAL) To accept 51mm (2 ) I/D cores (OPTIONAL)

7 2 2. INSTALLATION 2.1 SHIPPING AND UNPACKING Use forklift with at least 500Kg (1000lbs) capacity and move the machine to the area of final location. Remove packing case and carefully remove shrink film protective covering. Unload accessories and lay them down on the floor for ease of identification during reassembly. Check machine and accessories and report any damages/omissions immediately. 2.2 SPACE REQUIREMENTS In addition to machine floor plan, room should be provided around the machine to allow for Ease of service Loading of material onto mandrel For stacking of raw & finished materials See Fig. 2.2 for suggested layout. A relatively flat & solid floor with at least 200 Kg/m 2 (366lbs/yd 2 ) load capacity is required. 4800mm (15 4 ) Machine Floor Plan Loading Area for Mandrel 600mm (2 ) Operator Working Area 2800mm (9 2 ) 2010mm (6 2 ) Fig. 2.2 CN860 footprint SAFETY MEASURES: Non slip surface around machine Hazard tape around designated area Good safe housekeeping around machine.

8 3 2.3 ASSEMBLING & LEVELLING MACHINE 1. With a forklift, remove machine from floor of packing case. 2. Lower the machine on to rubber strips supplied (to prevent vibration). RUBBER STRIPS: Place under machine base front and back Used to minimise vibration. 2.4 CONNECTING TO ELECTRICAL SUPPLY IMPORTANT NOTE: machine. Only use a qualified industrial Electrician to connect power to Refer to machine specifications/schematics for electricity supply machine wired to. NOTE: CONSULT YOUR ELECTRICIAN REGARDING YOUR POWER SUPPLY WE RECOMMEND YOUR ELECTRICIAN HARD WIRES MACHINE. IF A RESIDUAL CURRENT DEVICE (RCD) IS FITTED TO YOUR SINGLE PHASE POWER OUTLET IT WILL CAUSE INVERTOR (VSD) TO OVERLOAD WHEN USING STANDARD LEAD & PLUG. 2.5 CONNECTING TO PNEUMATIC SUPPLY (if Venturi Spray System fitted) 1. At least 224 litres per minute (8 cfm) compressor at kpa (80 ~ 90 psi) line pressure is required. 2. Fitting to suit customer s compressed air line is required (see Fig 2.5) Note: To ensure trouble free performance, air supply to machine MUST BE clean, dry and free of oil. Pneumatic connection is located on Right Hand side (chuck end) of machine. Connection only fitted when Venturi Spray System option included. Note: Connection is ¼ Gas thread Fig. 2.5

9 4 2.6 SET UP MACHINE IN PREPARATION FOR SLITTING 1. Connect machine to a power point (See section 2.4 Connect to Electric supply). 2. Connect compressed air line to machine (if Venturi Spray fitted). 3. Fit mandrel and lock it in position and raise RH mandrel support. 4. Select appropriate knife (refer to the operator reference sheets or knife selection guide (Section 4.6)) and fit on to spindle taking note of the following: Clean the locating surfaces of knife spindle, backing plates, and knife. Slide first (inner) backing plate, knife then second backing plate (outer) onto the spindle. Ensure knife and BOTH backing plates are located on the dowel pins on either side of spindle. (see Fig 2.6.1) Do up the cap screw until finger tight and then tighten spindle cap screw with the spanner and hex key supplied. NOTE: The knife is engraved and must be positioned on the spindle with TOP uppermost and the two lines pointing to the mandrel. 6. Set knife forward stop: Bring knife edge gently against mandrel using hand lever. Adjust knife forward stop (black knob see photo) (see Fig 2.6.2) until knife is about 2mm off mandrel. 7. The machine is now ready for use. 8. Test lubricant system (if fitted). Fill water bottle and add a good quality car wash-n-wax solution. Dilute 1:50. NOTE : 1) Setting the knife too far forward will prematurely damage the mandrel sleeve. 2) Setting the knife too far back will prevent it cutting through the core. Knives should be engraved for easy identification for: Correct location on knife spindle Bevel type Sharp or Rounded edge NOTE: Knife in picture is double bevel single bevel knives knife must be placed on spindle with main/primary bevel facing AWAY from chuck to enable displacement of material during slitting process Backing plates should be marked for position either side of knife to ensure knife runs true Fig Ensure knife and BOTH backing plates are located on the dowel pins on either side of spindle before tightening. Fig Knife Fwd Stop WARNING: Failure to set fwd stop correctly can result in damage to the knife

10 5 3. MACHINE FUNCTIONS 3.1 CHUCK SPINDLE DRIVE The mandrel is driven by a 1.5 kw (2HP) 6 pole motor and fitted with 1.5kw (2HP) Single Phase inverter (VSD). 3.2 CHUCK SPINDLE The main spindle is located within the face plate or chuck and drives the mandrel. It is mounted in a sealed bearing and bolted to the mainframe. 3.3 ROTATING MANDREL with EXPANSION SECTION (76mm/3 ) The mandrel (with expansion section to grip I/D of 76mm (3 ) cores rotates with the chuck spindle. It is held in place in the chuck spindle by two opposing screws. It can be removed from the machine by sliding it out after loosening the 2 lock screws which lock into dimples in the mandrel. The mandrel is fitted with PE sleeves to protect the knife edge from the steel mandrel. Log roll is gripped by turning the T handle anti-clockwise (CAUTION: ensure handle is removed before starting machine) to expand the internal jaws. (see Fig 3.3) T Handle NOTE: Excessive force tightening exp jaws with T Handle may cause damage to jaws Chuck PE sleeve Mandrel Locating Screws Metal Carriage stop bracket Ensure this bracket is not removed as this can cause damage to machine Expanding Section of Mandrel Fig 3.3 Rotating Expanding Mandrel WARNING: DO NOT LEAVE MANDREL UNSUPPORTED IF A HEAVY LOG ROLL IS LOADED AS DAMAGE TO THE MANDREL MAY OCCUR

11 6 3.4 ROTATING MANDREL for 25.4mm (1 ) I/D CORES (OPTIONAL) The mandrel rotates with the chuck spindle and is fitted with a PE sleeve along the full slitting length to protect the knife edge. A special chuck plate is fitted with pin holders that will reach down to the 25.4mm/1 core together with an adjustable mandrel support bracket (movable) to prevent mandrel from flexing FITTING THE 25.4/1 MANDREL 1. Expand 76mm/3 internal jaws out to their full extent (A) so that pin (B) will slide under the jaws. 2. Align dimples in mandrel (C) with cap screws located behind chuck (D) 3. Slide mandrel through chuck until pin contacts chuck body. 4. Raise mandrel support arm and fit nylon adapter (E). 5. Tighten cap screws evenly ensuring cap screw are located into dimples in mandrel. 6. Adjust forward knife stop to suit mandrel. 7. Fit metal carriage stop on front slide rails at chuck end of machine (F) to prevent damage from knife coming into contact with rotating chuck. D B C A E Ensure additional RED bracket (F) fitted and not removed when using 25.4mm (1 ) mandrel as this will cause damage to machine F

12 FITTING THE CHUCK PLATE (for 1 /25.4mm Mandrel) 1. Move knife carriage to R/Hand end of machine 2. Retract internal chuck Jaws (A) to their full extent 3. Slide chuck plate over mandrel to chuck CAUTION: Ensure plastic edge protector is fitted over knife edge during this process 4 Hold chuck over internal jaws squarely (F) 5 Expand jaws to grip inside of chuck and tighten firmly 6 Rotate chuck by hand to ensure it is running true (G) F G FITTING MANDREL SUPPORT BRACKET (for 1 /25.4mm Mandrel) 1. Hook the support bracket pins (A) into the slot (B) in the rear carriage rail. 2. Lower the front of the support brackets onto the front rail and nip up knob (C) 3. Set the support bracket as close as practical to the end of the log roll. 4. After several cuts are made the slit rolls can be moved away and the support bracket moved close to the end of the log roll again. Movable Mandrel Support Bracket A C B WARNING: DO NOT LEAVE MANDREL UNSUPPORTED IF A HEAVY LOG ROLL IS LOADED AS DAMAGE TO THE MANDREL MAY OCCUR

13 8 3.5 ROTATING MANDREL TO ACCEPT 51MM (2 ) I/D CORES (OPTIONAL) The mandrel rotates with the chuck spindle and is fitted with a PE sleeve along the full slitting length to protect the knife edge. Chuck jaws grip OD of extended PE sleeve (See Fig 3.5.1) FITTING THE 51mm/2 MANDREL The mandrel is held in place in the chuck spindle by two opposing screws (same as the 76mm/3 mandrel). It can be removed (installed) from the machine by sliding it in/out after loosening the 2 lock screws which lock into dimples in the mandrel. (See Fig 3.5.1) Chuck 51mm Mandrel covered with PE Sleeve Mandrel Locating Screws Chuck Jaws Fig mm / 2 Rotating Mandrel

14 9 3.6 CHUCK (3 PIN) The chuck is a slotted face plate mounted on the front of the main spindle. It is fitted with a set of 3 push-in type pin holders for external gripping. When fitted with the rotating mandrel, it is supplied with a set of pin holders capable of gripping a range of log roll diameters from 76.2 to 305 mm (3 12 ). 3.7 KNIVES All knives should be engraved with the word TOP for correct location on knife spindle. Knife is always mounted on the spindle with engraved marking to the top and with main/primary bevel facing AWAY from chuck and supported by a backing plate** on each side and held in place by a cap screw. When properly set, runout must not exceed ±0.1 mm (0.004 )(4 thou). Refer Section 5.4 **Backing plate should also be engraved with TOP for correct positioning and also OUT to indicate which plate is place on the outside of knife. Caution: Always use cut resistant gloves when handling knife 3.8 KNIFE SHARPENING Refer Section 4.5 for bevel requirements to achieve good slitting results (See Fig 3.7) 3.9 KNIFE SPINDLE The knife spindle in conjunction with backing plates holds the knife firmly to keep it within an acceptable runout both radially and axially. (See Fig 3.8) Knives should have 8 main (primary) bevel plus a. small 11 bevel to strengthen outer edge of knife Add back bevel to reverse side of knife to suit width to be cut NOTE: Main bevel should always face away from chuck Fig 3.7 Knife small 11 bevel to strengthen outer edge of knife Inner Backing Plate Spindle NOTE: Protective strip (available from Javelin) placed over exposed knife edge during maintenance or when machine not in use. Fig 3.8

15 KNIFE BRAKE A knife brake is fitted to the spindle (see Fig. 3.10). The knob behind the knife pedestal should be tightened just enough to slow down the knife rotation as it cuts through the material. This will help if there is a problem with double cutting or when slitting narrow widths. Varying the amount of braking can be useful when slitting all types of products When slitting hot stamp foils the knife spindle brake should be tightened so that the knife is stationary until it contacts the core. The knife must rotate when it contacts the core, so that a new section of knife edge is exposed, thus preventing a dull spot forming on cutting edge. Knife Brake Adjusting Knob Fig KNIFE LUBRICATION The knife lubrication is used to keep heat down which results from friction between the knife and the material being slit, and to prevent adhesive build up on knife and slit roll. Spray Nozzle Hand Lever STANDARD LUBRICATION Foam Pads fitted either side of knife which can be saturated with lubricant from p0ump action bottle VENTURI SYSTEM (OPTIONAL) The system is fitted using a vacuum generator (Spray Nozzle). Compressed air flowing through the vacuum generator draws water into the air stream to form a mist. The unit is located on top of the knife guard. Two plastic containers are located at rear of machine. One holds lubricant while the other collects residual overspray As a lubricant, add approximately 30ml of lubricant Plastic Containers to 2 litres of water to the water container. We recommend the use of Javelin lubricant to minimise rust. Fig 3.11 Note: The spray only operates when the knife is moved forward, off the rear stop If problems arise see Section 6.1 for trouble shooting KNIFE PEDESTAL The knife pedestal is mounted on the carriage plate. The indexing hand wheel (refer Fig 3.13) is used to move the knife along the bed of the machine. The hand lever (refer Fig 3.11) is used to move the knife towards the mandrel.

16 INDEXING Indexing is achieved by traversing the knife carriage and reading off the indexing counter (when fitted). The knife pedestal traverses by hand wheel and rack and pinion. When the knife is moved forward off the reset switch, the counter resets to zero for the next index. (Ref fig ) An electronic counter (Optional) provides a digital display for the width of cut. Carriage Lock Indexing (traversing) Handwheel Rack Fig 3.13 Indexing Mechanism DIGITAL COUNTER (WIDTH DISPLAY) (when fitted) The Digital Counter is connected to a rotary encoder and is graduated in.2mm (.008 ) increments: Electronic digital counter displays width to be slit Rotary Encoder Fig Index counter reset (to zero) switch WARNING: DO NOT LEAVE TOOLS ON TRAY UNDER PEDESTAL AS DAMAGE TO ENCODER MAY RESULT

17 12 4. MACHINEOPERATION 4.1 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 this machine, everyone connected with its operation should be made fully aware of the High Voltages, High Speed Motion and Sharp, Rotating Automatically Actuated 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 a flexible plastic cover 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 ALLoperators & maintenance personnel have read and understood this manual before operating or carrying out maintenance on this machine. Ensure only qualified electricians work on the electrical components of the machine. Operators must not open the electrical cabinet, motor drive cabinet or operator panel. In the case of an electrical malfunction qualified electrical personnel/contractor should be called.

18 PRINCIPLES OF SINGLE KNIFE SLITTING Slitting by the single knife method is basically the ability of a circular knife to displace the slit roll as it enters the log. Single knife slitting is not a precise science. number of factors including: Slitting results are affected by a 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 Materials which are too dense or have been wound too tightly may be unsuitable to slit by this method. In this case either the roll must be rewound to a lesser tension or the material cut on a machine known as a slit/rewinder. Knife parameters are crucial in successful Single Knife Slitting (Refer Knife Selection Section 4.6) As widths bering slit increase so must the secondary or back bevel on the knife in order to balance the forces and achieve a straight cut. CAUTION: Failure to pay attention to choosing a knife with the correct bevel can result in the knife chipping or in an extreme case shatter. CAUTION ~ always use cut resistant gloves when handling knives ~

19 PRINCIPLE OF OPERATION - SLITTING The JAVELIN series CN860 is a Manually Operated Single Knife, lathe type slitting machine for cutting log rolls of Fibreglass, rubber, adhesive tape, stamping foils & textiles. The CN860 will accept a log roll up to 305 mm ( 12 ) x 1630 mm (64 ) & core diameter of 76.2 mm ( 3 ) is standard. Other mandrels from 1 diameter are available on request. The log roll is slid onto a PE sleeve covered steel mandrel from the right hand end of the machine and secured internally by expanding jaws and externally by a 3 pin chuck. The width of cut is checked by using the optional Digital Width Counter, or by manually measuring with a tape measure. When the machine is turned ON, the chuck spindle will rotate the log roll. By pulling the hand lever forward manually, the knife will move forward making its first cut through to the core on which the material is wound. Upon completion of the cut, the hand lever is pushed all the way back until the knife clears the diameter of the log ready for indexing to the left for the next cut. Also refer to Sections 4.2 Slitting tolerances/4.3 Principles of single knife slitting 4.4 SETTING UP AND OPERATION PROCEDURE to ON to shift brake calliper towardsregulator 8 & PRESSURE GAUGE 9 can also be NOTE: Layout of Control Panel may vary according to options fitted. adjusted but will only be functional during actual rewinding. Mandrel Drive START BUTTON Emergency Stop Mandrel Drive STOP BUTTON Mandrel Speed Knob Mandrel Rotation Fwd Rev Main Isolator Power Switch on side of Control Box IMPORTANT SAFETY NOTE: Use STOP BUTTON to end mandrel rotation. Fig. 4.5 Control Panel

20 15 1. Check mandrel speed set to zero 2. Check emergency stop released 3. Press reset button 4. Load log roll onto mandrel and slide up to face of the chuck 5. Raise mandrel support arm 6. Secure log roll by inserting the T handle into the chuck and turning anti clockwise to expand internal jaws (Do Not overtighten). When required push chuck pins into OD of material and tighten screws on back of chuck plate. 7. Ensure the end of the log roll is pushed up against the chuck face to prevent any deflection during slitting. 8. Using the hand wheel traverse the knife carriage to the right hand end of log roll and to where the first cut is to be made. 9. Press mandrel start button. 10. Turn mandrel speed dial to required RPM 11. Adjust brake to suit product to be slit. 12. Turn Venturi spray system to lubricate knife (if fitted) 13. Using hand wheel index knife to position where first cut is to be made while checking display digital width counter (if fitted) for accuracy. 14. Engage carriage lock (Ensure surface dry and clear or clamp may move during slitting resulting in a width error) 15. Pull hand lever forward with even pressure to make the cut until the knife cuts through the material and the core. The spray (if fitted) should operate as the knife comes forward. NOTE: If log roll rotation becomes uneven, stop cutting action briefly and then recommence with even pulling action on handle with arm straight and standing back from machine a little more. (see Fig 4.5 below) 16. When the cut is completed, push the hand lever all the way back until the OD of the log roll is cleared and the digital counter (if fitted) is reset to zero. 17. Using the hand wheel move the knife to the next slitting position and repeat from No 14. Fig 4.5 Photo 1 Correct position - shows the correct arm position with the operator back a little from the machine when pulling the cutting lever. Action should be an even action until the cut is complete. X Photo 2 Incorrect position shows the operator standing too close and pulling the lever with a bent arm action. This will result in the knife developing vibration particularly with larger diameter log rolls..

21 KNIFE SELECTION ~ always use cut resistant gloves when handling knives ~ KNIFE BEVELS When slitting narrow widths only a primary bevel is required but with wider widths a back bevel is needed to balance the forces on either side of the knife so that it will cut straight through the roll without deflecting CAUTION: Knife may be damaged or shatter if insufficient back bevel on knife when slitting wide widths. Trying to slit a roll to a wide width from a tightly wound log roll, using a knife with insufficient back bevel, risks chipping or shattering the knife. Diagram No Slitting range Up to 22 mm (7/8 ) 25.4 mm (1 ) - 38 mm (1½ ) 40 mm (1 5/8 ) - 96mm (4 ) Over 100mm (4 ) Any width (very hard materials) Dense materials that will not displace Knife requirements No Back Bevel 0.5 mm (1/64 ) Back Bevel 1.5 mm (1/16 ) Back Bevel Equal Bevel both sides of knife Tightly wound denser rolls will require test slitting to determine the best knife bevel & edge for product Additional angle on primary bevel 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. **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 or spacer roll) Diagram 1: Knife with no back 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 equal bevel both sides Diagram 5: Knife with reinforced edge (No. 2 angle) (refer to manual for details) No. 1 angle No. 2 angle 1-2mm (1/16-3/32 ) NOTE: A rounded edge is preferred for most adhesive tapes. Some exceptions would be, for example, foam sealant & paper tapes which require a sharp edge. Too sharp an edge can result in edge breaking down (chipping). Edge should be slightly rounded with Shielded oil stone to prevent this occurring. NOTE: It is imperative records be kept for specific materials so the operator knows which knife to choose each time a particular product is to be slit. Ref: Operator Reference Sheets in the Manual.

22 KNIFE STORAGE The knife is the most important item on your machine. Knives should be kept in a purpose built cabinet and knife edge protected with protective strip. ~ always use approved protective gloves when handling knives~ Operators should read the guidelines for knife selection, preparation and maintenance carefully. 4.7 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 4.8) hold the stone flat against knife edge and slowly rotate the knife with the other gloved hand. This will have the effect of dulling the sharp edge. Polish knife edge with Scotch Bright IMPORTANT NOTE If knife is slightly chipped you will need to return to supplier for repair.. Fig 4.8

23 OPERATOR REFERENCE SHEETS CN860 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: Width To Be Cut : Density Of Material : Tolerance Required : Weight of Log Roll : Knife : Diameter Thickness No. of Backing Plates Back Bevel : Size Knife Braking : Knife Edge : Sprays : Chuck Grip : Support Plate To Prevent 1st Roll From Collapsing : On Rounded Off Internal Off Sharp On External Yes No

24 19 5. PREVENTATIVE MAINTENANCE 5.1 GENERAL Apart from daily cleaning & rust prevention control, the CN860 machine needs very little maintenance attention. Keeping the machine clean & dry at the end of each shift is essential for preventing rust and corrosion which leads eventually to expensive parts replacement (refer to Section 5.2). Note: Always remove knife and backing plates at end of each day and keep clean and free from grit. Wipe with light oil or spray with kerosene & oil mixture Indexing gear & rack teeth should be cleaned DAILY with brush and/or air gun. CAUTION: Wear Safety glasses if using air gun as grit may fly and cause injury to eye/s. 5.2 LUBRICATION & MAINTENANCE CHART PART METHOD NO. OF PLACES LUBRICANT DAILY NOTE: Take care to keep area clean and dry where carriage lock clamp contacts body of machine otherwise clamp will not hold and errors in indexing will occur Carriage Rails & Wipe with oil impregnated rag 2 Light machine oil or Traversing Rack spray with kero/oil mixture Polycarbonate Cover Wipe over with soft cloth soaked in 1 Mild detergent mixed mild detergent and water or windex. with water Do not use other type of cleaner or WINDEX (hydrocarbons) otherwise window cleaner. polycarbonate will crack Safety Cover Check daily and report immediately if Interlock Safety not working Switches SIX MONTHS Machine Level Level Spirit Level Mandrel/Chuck Check for straightness & running freely See Manual Mandrel Sleeves Check for worn/uneven surface Visual Knife Spindle Run Out Dial Indicator Knives & Backing Plate Run Out Dial Indicator Knife Brake Check holding knife when full engaged Knife free when released Carriage Lock Check lock clamps securely. Adjust if necessary Traversing Rack Smear by hand full length Multi purpose grease Teeth (See Fig ) of rack Chuck/Mandrel Drive Check belt tension Belt Knife Pivot Bearings Grease Gun 2 Multi purpose grease Bearing in Mandrel Grease Gun 1 Multi purpose grease Support Arm Foam Pads Replace when worn and will no longer absorb lubricant Venturi Lubrication System (if fitted) Clear lubricant container and remove any sediment. Recommend Javelin lubricant to prevent rust build up on knife and prevent build-up of sediment in spray nozzle

25 MANDREL SLEEVE REPLACEMENT mm (3 ) ROTATING MANDREL Loosen cap screws on retain collar at load end of machine and slide old sleeves off and slide new ones on and replace retaining collar and tighten cap screws. This collar prevents the sleeves from separating. The sleeves may appear to be a loose fit but when the retaining collar is pushed against sleeve at load end of machine and grubscrews are tightened the sleeves will not move. Ensure that there is no clearance between collar and sleeve. NOTE: As standard sleeves are 100mm short, to enable retaining collar to be fitted a 100mm piece of sleeve is at the load end of the machine. While these 100mm sleeves are available they are not supplied with standard sleeve unless requested, we therefore suggest the original 100mm be retained if in reasonable condition. NOTE: Machine ex China will not have 100mm sleeve Ensure when reordering for first time to ask for the additional 100mm sleeve.

26 SLITTING TOLERANCES a. CHECKING FOR BACKING PLATE RUNOUT: Backing plates that have been dropped onto a hard surface may be out of specification and will need to be replaced. i) Run a smooth flat file across the face of the backing plate and washer to ensure 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 (See Note). iv) Runout should not be more than.08mm (.003 ). If runout exceeds tolerance, mark backing plate in 2 positions and one position on spindle with marking pen. v) Rotate backing plate to position 2 and re check if runout is excessive. 1 4 NOTE: Check backing plate on inside by fitting large backing plate/small backing plate and nut, then placing dial vernier on edge of backing plate as shown in picture. backing plate 2 spindle NOTE: Backing plates may differ in appearance principle is the same. 3 2 DIAL INDICATOR b. CHECKING FOR KNIFE RUNOUT Place dial indicator on knife face (1 at top-picture A) and rotate knife to 2 (Picture B). A run out of not more than.08mm (.003 ) is permissible. A B

27 22 6. TROUBLE SHOOTING- MACHINE PROBLEMS 6.1 VENTURI SPRAY SYSTEM (WHEN FITTED) PROBLEM/EFFECT Spray not working. REMEDIES Check air supply Valve turned off Check Flow control open Move pedestal off rear stop Check:. Water pick-up tube is pushed into bottle Water bottle is full Flow valve adjustment Loose fitting or split tubes Air pressure of flow rate too high forcing water back into bottle (N.B. spray starts when knife is brought forward) Air but not water. Felt Pads worn & not contacting Knife Replace Pads 6.2 ROTATING MANDRELS PROBLEM/EFFECT Mandrel vibration (See Note Section 4.3 item 16) CAUSE Core loose fit on mandrel I/D oversized. REMEDIES Use correct core size. Log roll out of round. Slow mandrel speed. Using 25.4mm (1 ) mandrel Mandrel sleeves become worn too quickly Mandrel becomes worn Strands protruding from PE mandrel sleeve. Move 25.4mm/1 mandrel support bracket closer to knife Mandrel secured in place by Tighten screws. 2 cap screws behind chuck which lock into counter sunk holes in mandrel. Knife penetrating mandrel Check mechanical knife stop set sleeve too deep as per Manual with knife edge at least 2mm from OD of sleeve Knife cutting too deep into Adjust knife depth. Smooth mandrel sleeve. surface of sleeve with angle grinder 6.3 KNIFE BRAKE PROBLEM/EFFECT Brake does not hold knife CAUSE Brake Pads worn REMEDIES Replace

28 DIGITAL INDEX COUNTER (WHEN FITTED) PROBLEM/EFFECT Reads inaccurately CAUSE Scale factor error REMEDIES Re-enter scale factor Loose Wire Encoder wheel not contacting rail Check wiring Spring broken or stretched Obstruction prevents wheel turning Fit new Encoder (Encoder cannot be repaired) Encoder failure 6.5 MANDREL SUPPORT ARM PROBLEM/EFFECT Mandrel vibrates Sideways movement between mandrel support arm and mandrel support bearings. Knife not slitting through core and/or knife cutting too far into mandrel sleeve at one end of machine. CAUSE Bearings loose between mandrel support arm and mounting bracket. REMEDIES Tighten bearing housings and or grub screws in bearings onto support arm pivot shaft Mandrel support not aligned parallel to knife carriage. Raise mandrel support. Traverse carriage to extreme left. Adjust forward knife stop so that the knife just touches mandrel. Traverse knife to the extreme right and move knife forward to mandrel. Loosen grub screws locking mandrel support arm to pivot bearings and move arm sideways so that knife touches the mandrel sleeve fractionally harder than at other end of machine (0.1mm or ). Lock grub screws and recheck.

29 KNIFE (OUT OF TOLERANCE) PROBLEM/EFFECT Poor quality slit rolls CAUSE Knife spindle, backing plates and knives must be clean of all grit when putting knife and backing plates onto spindle and located in same position each time. Knives and backing plates should be marked for this purpose. Failure to do this will cause knife run out. Knife sharpened incorrectly altering the bevel angle. REMEDIES Mount dial indicator on knife and look for excessive run out. (Refer Section 5.5 of Manual) CAUSE Two cap screws behind chuck become loose REMEDIES Push mandrel firmly back into place (tap with rubber hammer) line up counter sunk holes in mandrel spindle (journal) with cap screw behind chuck tighten cap screws. Return knife to Javelin for bevel to be reground. 6.7 MANDREL PROBLEM/EFFECT Mandrel becomes loose 6.8 EXPANSION JAWS PROBLEM/EFFECT Expansion jaws will not expand evenly CAUSE Weld on expansion jaws breaks REMEDIES Remove mandrel to access jaws re weld or replace jaws 6.9 KNIFE CUTTING HANDLE PROBLEM/EFFECT Handle comes loose CAUSE Caps screws come loose REMEDIES Remove knife then look for three phillip head counter sunk screws inside aluminium guard. Remove screws and the knife guard should then come off. Tighten up the two cap screws that secure the handle (5mm Allen Key required) Reassemble as before.

30 25 7. TROUBLE SHOOTING- SLITTING PROBLEMS 7.1 SELF WOUND ADHESIVE TAPE PROBLEM/EFFECT Double cutting causes tape to tear when being unwound CAUSE Knife running out of tolerance. Worn mandrel sleeve. Replace sleeve. Set knife stop correctly to avoid premature sleeve damage. Speed of knife entry too fast Slow down knife forward speed. Core diameter too loose on mandrel Slit roll telescopes after slitting Self wound foil tapes, copper, aluminium, lead, tear when being unwound after slitting Adhesive smearing on sides of rolls. Tape sticks together and cannot be separated. Soft adhesive coated tapes such as Teflon film are left with steep ridges on either side of the slit roll. Knife edge shatters Concave or convex rolls. Tape visually poor and not suitable for resale. REMEDIES Replace Knife. Tight and loose section in log due to uneven adhesive coating Knife edge roll over causing tape to tear when unwound. Specify correct inside diameter to core manufacturer. Slit log separating tight and loose sections and rewind to acceptable tension Interline foil before slitting. Knife edge unsuitable Sometimes very sharp knife can cause this problem. Round off knife edge Insufficient lubrication Check and adjust sprays No back bevel on knife Grind back bevel on knife to minimise problem. Knife too sharp Round edge of knife to strengthen. Knife hits steel mandrel Adjust knife forward stop. Core is hard or thick Reduce knife forward speed when cutting through core Refer Section 4.6 Knife bevel unsuitable

31 INTERLINED & NON ADHESIVE COATED MATERIALS EG VINYL USED IN SIGN INDUSTRY PROBLEM/EFFECT Inside of roll moves towards end of log Difficulty pulling knife through log roll Log roll stops rotating before cut is completed Knife pushes vinyl/film aside and will not cut through core CAUSE Layers of vinyl or other substrate not bonded together as with self wound adhesive products. Film wound too tight. Check back bevel on knife suitable for width being cut Non adhesive Paper/Film/Foil slipping on the core Knife edge very blunt REMEDIES Glue end of roll with Hot Melt Glue Log roll should be pushed against chuck face or spacer roll. Rewind to lesser tension. Use knife with larger back bevel. Use strong adhesive tape to anchor the leading edge of paper/film/foil to core. Reverse the direction of rotating mandrel as this has effect of tightening the roll. Resharpen knife 7.3 FABRICS/FIBREGLASS/FOAMS (WITHOUT PRESSURE SEHSITIVE ADHESIVE) PROBLEM/EFFECT Poor quality slit rolls CAUSE Knife is dull Log roll loosely wound Mandrel speed too slow Width of slit roll varies from outside to inside of roll As product is not bonded together centre layers move as knife penetrates roll. REMEDIES Sharpen knife more frequently Rewind to tighter tension. Wrap log roll with stretch film. Increase mandrel RPM as much as possible. Bond end of roll (at chuck end) with Hot Melt Glue Use roll support at r/hand end of roll 7.4 HOT STAMP FOIL NOTE: Log tension for narrow slit rolls up to 48mm should be tighter Log tension for wider rolls 72mm plus should be less tight PROBLEM/EFFECT Edge of knife shatters CAUSE Foil wound too tight Insufficient knife brake friction Knife too sharp REMEDIES Rewind to softer tension Tighten brake so knife turns only when cutting through core. Slightly round cutting edge of knife Width of slit roll varies As product is not bonded Bond end of roll (at chuck end) from outside to inside together centre layers move with Hot Melt Glue of roll as knife penetrates roll. Log roll should be pushed against chuck face or spacer roll. NOTE 1: When slitting large diameters of Hot Stamp Foil on a 25.4mm I/D core the mandrel speed must be reduced. The knife brake must also be used to lock the knife at all times when slitting stamping foils. Knife should rotate only near the core. NOTE 2: Lubricant should not be used when slitting stamping foils.

32 SLITTING TECHNIQUES 8.1 DENSE MATERIALS (i.e. rubber, some fabrics and foam tapes) : 1. Use a strong adhesive tape to anchor the leading edge of your rubber/fabric/foams to the core onto which the product is to be rolled. 2. Roll up product as tightly as possible and use adhesive tape to hold outer edge in place. 3. Wrap finished (log) roll tightly with stretch film. 4. This will help prevent slit rolls falling apart. 5. For heavy materials reduce mandrel speed to avoid vibration 6. For softer materials increased mandrel speed. 7. The leading edge of rubber on outside of wrap of log roll should run in the opposite direction to mandrel/chuck rotation. 8. Adjust knife brake so that knife begins to rotate only as it enters the log roll. 8.2 FILM PROTECTION TAPE 1. Use knife with equal bevel on both sides for cut widths wider than 50mm. 2. Use small amount of knife brake 3. Keep mandrel speed between 1/3rd to half speed. 8.3 SLITTING INTERLINED MATERIALS Any interlined material especially large diameters need to be glued with a hot melt glue at the chuck end only, to prevent the centre of the log roll slipping away whilst it is being cut. Note: When slitting copper, lead or aluminium foil whether or not coated with a pressure sensitive adhesive, an interlining paper is essential to achieve quality slit rolls.

33 28 9. MACHINE SPARE PARTS 9.1 SPARE PARTS SUMMARY Prices on Application ITEM JAVELIN PART NO: DESCRIPTION Knife Drive Assembly Backing Plate for Knife Lock Cap Screw Knife Drive Chain Chuck Assembly Chuck Pins & Grub Screws (Set of 3) Chuck Pin Holders, complete (Set of 3) Chuck Drive Belt Mandrels Mandrel Sleeves (Ø 76mm (White) **Refer Note Section 5.4 of manual Mandrel Sleeves (Ø 51mm (White) Mandrel Sleeves (Ø 25.4mm (White) Gas Strut 400 Newton Spray (Venturi) System Spray nozzle Spray system complete ACCESSORIES SUMMARY ITEM JAVELIN PART NO: DESCRIPTION Mandrel - Rotating* 1600mm (63 )x25.4mm (1 ) 1600mm (63 )x51mm (2 ) Mandrels - Rotating (Expanding)* 1600mm (63 )x76mm (3 ) Roll Support Discs 3 I/D x 12 O/D Used to support slit rolls of narrow width interlined tapes to prevent them unravelling during the slitting process. Circular Knives (See Note 1) 330mm (13") OD x 3mm (1/8") x 1"ID Note 1: All knives are ground with a primary bevel of 8 - if secondary or back bevel is required an extra charge is made. Knife Lubricant for Spray System (500ml) Safety Cut resistant gloves Shielded Oil Stone 7 8.

34 29 Table of Contents 1 SPECIFICATION JAVELIN CN860 MANUAL SINGLE KNIFE SLITTER INSTALLATION SHIPPING AND UNPACKING SPACE REQUIREMENTS ASSEMBLING & LEVELLING MACHINE CONNECTING TO ELECTRICAL SUPPLY CONNECTING TO PNEUMATIC SUPPLY (IF VENTURI SPRAY SYSTEM FITTED) SET UP MACHINE IN PREPARATION FOR SLITTING MACHINE FUNCTIONS CHUCK SPINDLE DRIVE CHUCK SPINDLE ROTATING MANDREL WITH EXPANSION SECTION (76MM/3 ) ROTATING MANDREL FOR 25.4MM (1 ) I/D CORES (OPTIONAL) FITTING THE 25.4/1 MANDREL FITTING THE CHUCK PLATE (for 1 /25.4mm Mandrel) FITTING MANDREL SUPPORT BRACKET (for 1 /25.4mm Mandrel) ROTATING MANDREL TO ACCEPT 51MM (2 ) I/D CORES (OPTIONAL) FITTING THE 51mm/2 MANDREL CHUCK (3 PIN) KNIVES KNIFE SHARPENING KNIFE SPINDLE KNIFE BRAKE KNIFE LUBRICATION STANDARD LUBRICATION VENTURI SYSTEM (OPTIONAL) KNIFE PEDESTAL INDEXING DIGITAL COUNTER (WIDTH DISPLAY) (when fitted) MACHINEOPERATION OPERATOR SAFETY PRINCIPLES OF SINGLE KNIFE SLITTING PRINCIPLE OF OPERATION - SLITTING SETTING UP AND OPERATION PROCEDURE KNIFE SELECTION KNIFE STORAGE ROUNDING KNIFE EDGE OPERATOR REFERENCE SHEETS PREVENTATIVE MAINTENANCE GENERAL LUBRICATION & MAINTENANCE CHART MANDREL SLEEVE REPLACEMENT mm (3 ) ROTATING MANDREL SLITTING TOLERANCES a. CHECKING FOR BACKING PLATE RUNOUT: b. CHECKING FOR KNIFE RUNOUT... 21

35 30 6. TROUBLE SHOOTING- MACHINE PROBLEMS VENTURI SPRAY SYSTEM (WHEN FITTED) ROTATING MANDRELS KNIFE BRAKE DIGITAL INDEX COUNTER (WHEN FITTED) MANDREL SUPPORT ARM KNIFE (OUT OF TOLERANCE) MANDREL KNIFE CUTTING HANDLE TROUBLE SHOOTING- SLITTING PROBLEMS SELF WOUND ADHESIVE TAPE INTERLINED & NON ADHESIVE COATED MATERIALS FABRICS/FIBREGLASS/FOAMS (WITHOUT PRESSURE SEHSITIVE ADHESIVE) HOT STAMP FOIL SLITTING TECHNIQUES DENSE MATERIALS (I.E. RUBBER, SOME FABRICS AND FOAM TAPES) FILM PROTECTION TAPE SLITTING INTERLINED MATERIALS MACHINE SPARE PARTS SPARE PARTS SUMMARY ACCESSORIES SUMMARY... 28