#J3000 Operator Manual Front Pg July 2016 - irp … · JAVELIN MACHINERY (AUSTRALIA) J3000 OPERATION MANUAL (Incl Troubleshooting Machine Problems) _____ 2

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: J3000 series(up to & incl S/N188)

AUTOMATIC SINGLE KNIFESLITTER

JULY 2016

OPERATION MANUALINCL. TROUBLESHOOTING

MACHINE PROBLEMS

JAVELIN MACHINERY (AUSTRALIA) J3000 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 viewed and understood

this 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

A KNIFE WITH EQUAL BEVEL ON BOTH SIDES MUSTALWAYS BE USED ON THIS MACHINE.

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

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 "ELECTRONIC WIDTH INDEXER".

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

Note: Serious damage to machine can occur if careful attention not given to thesepoints.

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

• Fill up the spray bottle with water and JAVELIN lubricant.• Turn power on at the main electrical cabinet.• Raise the POLYCARBONATE GUARD.• Fit the mandrel as required.• When using the rotating mandrel tighten the cap screws in the chuck spindle and

leave the non rotating mandrel lock knob loose. For the non rotating mandreltighten the non rotating mandrel lock knob and remove the cap screws from thechuck spindle.

• Raise the mandrel support arm.• Select knife size.• Check the knife and backing plate condition.• Fit knife, backing plate and washer on to the knife spindle.• Check for adequate clearance between the knife and grinding wheel.• Engage the knife lock and tighten the spindle nut. Note: Left hand thread. When

saw cutting large diameter rolls 2 x 101mm (4”) diameter washers must be used.As these washers do not have a knife lock locating hole the knife brake must beengaged to hold the saw blade stationary whilst the spindle nut is tightened orloosened.

• Retract the knife locking pin.• Adjust the KNIFE FORWARD STOP.


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6JULY 2016

SET UP & OPERATION PROCEDURE Cont’d

• Set the GRINDER DWELL TIMER if necessary.• Enter the number of CUTS PER GRIND into counter if required.• Slide on log roll.• Raise the mandrel support arm.• Secure log roll into chuck or expanding mandrel.• Set the ADJUSTABLE REAR STOP with the knife about 10mm (½”) past the

outside diameter of the log roll.• Traverse the knife just past the left hand end of the log roll.• Press the ‘START’ button and switch to ‘SEMI’ mode.

Note: The adjustable rear stop knob should be approx. in line with the proximityswitch below it.

• Adjust the Forward Approach and Cutting Speed controls.• Check SLITTING TIMER COUNTER (Forward Knife Speed).• Set KNIFE DWELL TIME.• Direct sprays onto knife bevel.• Enter the width required to be cut into the INDEXING COUNTER.• Set the RH CARRIAGE STOP.• Set the LH CARRIAGE STOP.• Enter the number of rolls to be cut into the ROLL COUNTER (Note: first cut is not

counted).• Lower the POLYCARBONITE GUARD.• Traverse knife to where first cut is to be made.• Set AUTO CARRIAGE RETURN if required.• Select the gear when using two speed gearbox. (Second gear only used for saw

cutting).• Turn the knife switch to ‘ON’, adjust the KNIFE RPM and set the grinder to ‘AUTO’ if

required, or turn the knife switch to ‘OFF’ and adjust the knife brake if necessary.• 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.• Check index for accuracy. Refer to Carriage Index Counter section in this manual.• Lower the POLYCARBONITE GUARD and press the “START” button.


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7JULY 2016

3. MACHINE FUNCTIONS

The JAVELIN series J3000 is an automatic single knife, lathe type slitting machine.

Log rolls of tape can have a maximum diameter of ∅410 mm (∅16") and minimumdiameter of ∅25.4 mm (∅1"), this is depending on the mandrel fitted. Maximum rollwidth 1600mm (63”).

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.

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.

PHASE ROTATION INCORRECT LAMP (see Fig. 3-1B)

Lamp will illuminate and the machine will not operate when 3 phase power has notbeen correctly installed.

MOTOR OVERLOAD LAMP (see Fig. 3-1B)

Lamp illuminates and machine will not operate when motor overloads.

POLYCARBONITE GUARD KEY SWITCH (see Fig. 5-2-1)

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 or plug isdisconnected from machine.

MANDREL SUPPORT ARM LAMP (see Fig. 3-1B)

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


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8JULY 2016

KNIFE REAR STOP LAMP(see Fig. 3-1B)

If the REAR KNIFE STOP has not been adjusted properly, the lamp will be illuminatedand the machine will not operate.

LEFT HAND OVERTRAVEL PROXIMITY SWITCH

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

RIGHT HAND OVERTRAVEL PROXIMITY SWITCH

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

For machines from and including serial no. 163.

Fig 3-1A Main Control panel

Fig 3-1B Side Control panel

Control Panel.(NOTE:) Control Panel Configuration may vary frommachine to machine Machines up to and including162 are fitted with pneumatically operated toggle

lever on side of control panel


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9JULY 2016

3.2 KNIFE PEDESTAL ASSEMBLY

Fig. 3.2 Knife Pedestal

3.2.1 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. (See Fig 7.1)

3.2.2 BACKING PLATE , WASHER & NUT

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.

See caution above in Section 3.2.1 re use of backing plates.

HINGED KNIFE GUARD

NUT

WASHER

BACKING PLATE

REMOVE COVER TOADJUST SPINDLEBEARINGS

KNIFE LOCK


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10JULY 2016

3.2.3 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 indicatior 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)

KNIFE EDGE

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


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11JULY 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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12JULY 2016

OPERATOR REFERENCE SHEET

Date: Ref:J3000 Knife & Machine Settings

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) :

Gearbox speed: 1 2

Knife Braking : On Off

Pressure (kpa)

Knife Edge : Rounded Sharp

Knife Distance To Outside

Diameter Of Roll :

Knife Dwell Time : No. seconds

Forward Knife (Cutting) Speed :

*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 time for the knifeagainst the rubber covered mandrel and also time taken to traverse between cuts. Extra allowance willhave to be made where the auto grind is engaged in order to accurately asses total time taken forloading & unloading & slitting one full log roll.)

Auto Grind : On: Off:

No. cuts between grinding:Grinder dwell time:

Carriage Speed : Low: High:(Check P1 when setting carriage speed for tolerance)

Sprays : On Off Low Med High

Chuck Grip : Internal External

Support Plate To Prevent 1st

Roll From Collapsing : Yes No


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13JULY 2016

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™

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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14JULY 2016

3.2.4 FITTING KNIVES TO KNIFE SPINDLE

As previously mentioned, any rust or burrs on the knife, knife spindle, backing plates,nut or washer will cause problems including significant variations in width from one slitroll to 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.

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.

3.2.5 KNIFE LOCK

One of your backing plates has had a locating hole drilled in it in order to accept thespring loaded knife lock pin.

CAUTION: After fitting the knife, care should be taken to retract this pin so thatdamage to the backing plate and knife motor is avoided.

Machines from Serial No. 165 are fitted with a proximity sensor to prevent knife motorrunning when lock pin is engaged.

3.2.6 KNIFE DRIVE CONTROL

KNIFE ‘ON ⇔ OFF’

This is a two position, selector switch which provides ‘ON ⇔ OFF ’ control of the knifemotor. (see Fig. 3-1A)

In the 'OFF' position, the knife will not operate unless the knife grinder selector is in'AUTO'.

In the 'ON' position, the knife will start up and run at the speed set by the knife speed(rpm) control potentiometer provided that the green 'START' lamp is on andPOLYCARBONITE GUARD is down.

KNIFE SPEED (RPM)

An invertor (Variable Speed Drive) is fitted to provide variable speed. A tachometer isalso provided to indicate the RPM speed at which the knife is running. (see Fig. 3-1A)


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15JULY 2016

GEAR BOXES

Two types of gear boxes can be fitted:

A single speed gear box provides the torque required at lower speeds for productssuch as foam tapes for example. (see Fig. 3.2.6a)

The two speed gear box is fitted where sawcutting is required. When the higher speedis selected for saw cutting this gearbox provides the necessary torque required toprevent the knife stalling while making the cut. (see Fig. 3-2-6b)

KNIFE BRAKE

This air regulator adjusts the pressure applied to the brake pads to restrict the freerotation of the knife blade. The degree of brake pressure applied can be seen on theknife brake pressure dial gauge above. The brake will not operate when the knife isdriven. (see Fig. 3-2-6c)

Fig. 3-2-6c Knife Brake

VACUUM EXTRACTOR NOZZLE

Fig. 3-2-6a Single Speed GearboxFig. 3-2-6b Two Speed Gearbox


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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).

Turn the longitudinal adjusting knob (see Fig. 3-3) so that there is approximately 25.4mm (1") between the cutting edge of the knife and the diamond dresser supportbracket (knife edge - approx. centre of grinding wheel). Then turn the lateral adjustingknob (right angle to knife) until grinding wheel contacts knife bevel evenly.

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 all theblack mark has been removed. This indicates the bevel is correctly ground and right tothe 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. Retighten 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 NOTEEnsure that the knife lock MUST be retracted and all safety covers are in position.Check there is adequate clearance between knife and grinding wheel 6 mm (¼”).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.

CAUTION: It is not recommended that knives be removed from the machine forresharpening. Knives sharpened by outside contractors or on othersharpening devices almost inevitably lead to knives running out of truewith 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

The COUNTER on the side of the electrical cabinet can be set to the number of rolls tobe slit between each grinding of the knife. Then the timer is set to the period requiredfor grinding. the KNIFE GRIND is switched to 'AUTO' (see Fig. 3-1A). The knife willnow sharpen automatically after a pre-determined number of cuts for a pre-determinedperiod without any assistance from the operator.

GRINDER DWELL TIMER (see Fig. 3-1A)

This timer is only used when both the mode switch and the knife/grinder switch are in'AUTO' The time delay set on this, controls the length of time spent grinding the knifeblade when the auto-grind cycle is in progress.

4HP AC MOTOR

GEARBOX

KNIFE BRAKE

KNIFE MOTOR

LONGITUDINALADJUSTINGKNOB

LATERALADJUSTING KNOB

SWIVEL PLATE NUT

GRINDING MOTOR

KNIFE GUARD

GRINDING WHEEL

GRINDING DRESSING

DEBURRING UNIT


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18JULY 2016

CUTS PER GRIND COUNTER (see Fig. 3-1A)

This counter only functions when both the slitting mode and knife/grind selectors are in'AUTO' Each time that a cut is completed with the mode selector in 'AUTO', thecuts/grind counter decreases its count by 1. When the count total is equal to zero thecounter indicates to the PLC that it is time to commence a grind cycle.

The preset entered in this counter determines the total number of cuts that will bemade before an automatic grind cycle is initiated. This preset can be adjusted bypressing the 'P1' button and then the appropriate digit keys (6, 5, 4, 3, 2, 1) until thedesired value is displayed, then the counter enter button 'E' must be depressed toenter this new number into the counter memory. Now push the counter reset button 'R'to show the new preset value. Note that if the counter reset button 'R' is operatedduring a normal 'AUTO' cycle then the remaining value will be reset to the full presetvalue.

3.3.2 DEBURRING UNIT

(See Fig. 3.3.3) 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.

3.3.3 GRINDING WHEEL DIAMOND DRESSER

The diamond dresser is used to renew the cutting surface on the grindstone. Turn theknife grinder switch to “Dress” position when performing this process. Depending onthe amount of use it will be necessary to replace the diamond tip occasionally.

Fig. 3.3.3 Deburring Unit and Grinding wheel diamond dresser

DIAMONDDRESSER

DEBURRER

GRINDINGWHEEL


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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 an air over oilpneumatic cylinder to provide for smooth operation.

Fig. 3.4 Knife carriage forward and retract movement

3.4.1 SETTING KNIFE STOP

FORWARD KNIFE STOP

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, the knife is held forward against the stop. Then by turning the knife stop knobin or out adjust the knife so it just penetrates the rubber mandrel sleeve by about 0.5mm to 0.75 mm (.02” - .04”). If you adjust it too deeply you will find the mandrel rubbercover will become badly worn very quickly. It is important to note that the mandrelsupport at the end of the machine is in its raised position at all times when adjustingthe knob. (see Fig. 3-4)

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 FORWARD STOP

Control Panel.(NOTE:) Control Panel Configuration may vary from

machine to machine Machines up to and including 162are fitted with pneumatically operated toggle lever on side

of control panel

RETRACT FORWARD

For machines from and including serial no. 163.


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20JULY 2016

KNIFE REAR STOP

Loosen the adjusting KNIFE REAR STOP knob,located at the left hand side of the carriage andmove the carriage to a position where the knife has10 mm clearance from the outside diameter from thelog roll. Adjust the rear stop knob so the greentraversing lights are illuminated. (START BUTTONmust be illuminated). Retighten knob. (see Fig. 3-4-1)

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 The machine will cut out if the rear stop and the forward stopsense together and an orange warning light will flash on the main electricalpanel warning the operator to adjust the rear stop.

3.4.2 KNIFE CARRIAGE FORWARD AND RETRACT CONTROL

The Knife Carriage Forward and Retract Control Buttons on the main operator controlpanel (see Fig. 3-4-2) are used to move forward or retract the knife when positioningknife to the mandrel sleeve or outside diameter of the log of material to be slit.

NOTE: Machines up to and including Serial No. 162 are fitted with pneumaticallyoperated toggle lever see Fig. 3.1A.

FORWARD SPEED CONTROL ‘ FAST ⇔ SLOW(Labelled “Forward Knife Speed” and located above main operator’s control panel)’ (see Fig. 3-1A)This flow valve determines the speed taken by the knife to cut through the material.

ANTI-CLOCKWISE ⇒ ‘ FAST ’ CLOCKWISE ⇒ ‘ SLOW ‘

SLOT FOR SLIDING REAR STOPKNOB TO REQUIRED POSITION

Fig. 3.4.1 Knife rear stop


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FORWARD KNIFE SPEED TIMER

The digital timer reads in tenths of a second, it is used in conjunction with the forwardor cutting speed control to determine the optimum slitting speed (time) recommendedin the JAVELIN "Operator Reference Sheets". It measures the time taken for theknife to advance from its back most position until the cut is completed. (see Fig. 3-4-2)

KNIFE DWELL TIMER

This timer determines the delay during which the knife remains fully advanced to allowthe knife to cut through the core. Time range 0-12 seconds. This is adjusted to delayrequired by turning knob clockwise to increase and anti-clockwise to decrease.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.(see Fig. 3-4-2)

Fig. 3-4-2 Control Panel .. Knife Control

FORWARDKNIFE SPEED

FAST SLOW

FORWARD

KNIFE SPEED

FORWARD KNIFE

SPEED TIMER

KNIFE DWELL

TIMER

FORWARD KNIFE

STOP

KNIFE REAR

STOP


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3.5 KNIFE CARRIAGE - TRAVERSING

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

3.5.4 SETTING CARRIAGE STOP

RIGHT HAND CARRIAGE STOP

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. (see Fig. 3.5.4a)

Fig. 3.5.4a Right-hand carriage stop

Note: If extended pin holders are fitted, the stop must be moved out to prevent theknife from hitting pin holders.

LEFT HAND CARRIAGE STOP

Move the adjustable LH CARRIAGE STOP or the mandrel support until knife stops inthe desired position. (see Fig. 3-5-4b)

Fig. 3.5.4b Left-hand carriage stop

RIGHT-HAND CARRIAGE STOP

LEFT-HAND CARRIAGE STOP


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3.5.2 KNIFE CARRIAGE TRAVERSING CONTROL

CARRIAGE TRAVERSE LEFT BUTTON

This blue, illuminated push button enables the carriage to travel left provided that themode switch is set to 'MANUAL', the knife is retracted or in the slitting position, thecarriage left and the carriage left overtravel switch are not activated. (see Fig. 3-1A)

The blue lamp indicates that the above conditions have been satisfied and that thecarriage is ready to move left when the push button is pressed.

If the push button is held in for longer than three seconds, the carriage will traverseleft automatically at high speed until either the left hand carriage stop is contacted orthe emergency stop is pressed.

CARRIAGE TRAVERSE RIGHT BUTTON

This blue, illuminated push button enables the carriage to travel right provided that themode switch is set to 'MANUAL', the knife is retracted or at the first cut position, thecarriage right and the carriage right overtravel switch are not activated. (see Fig. 3-1A)

The blue lamp indicates that the above conditions have been satisfied and that thecarriage is ready to move right when the push button is pressed.

If the push button is held in for longer than three seconds, the carriage will traverseright automatically at high speed until either the right hand carriage stop is contactedor the emergency stop is pressed.

CAUTION: Ensure knife is clear of log roll before traversing

CARRIAGE RETURN ‘ OFF ⇔ AUTO ‘

The two position carriage 'RETURN' selector determines whether an automaticcarriage return cycle is to be commanded. This mode selector must also be in ' AUTO'to enable this function to operate. (see Fig. 3-1A)

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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CARRIAGE SPEED ‘ LOW - HIGH - (IF FITTED)

The Knife carriage traverse motor has two speeds. This two position selectordetermines which speed the carriage will begin traversing. 'LOW' speed is normallyselected for greater accuracy, but if accuracy is not critical then 'HIGH' speed may beselected (approx 0.05 less accurate). ‘(see Fig. 3-2A)

Generally ‘HIGH‘ speed traversing is only used when cutting widths over 38.1 mm(1½").

Note: If high speed is selected then the carriage overrun distance 'P1' on theCARRIAGE INDEX COUNTER will have to be increased to account for thegreater stopping distance required when operating the 'AUTO' mode.


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3.6 INDEX COUNTER

The electronic INDEX COUNTER (see Figs. 3-6-1 & 3-6-2) is used in 'AUTO' modeand ‘MANUAL’ mode (it cannot be used in ‘SEMI’ mode) and controls the index rightdistance at the end of each cut. The input to the counter is a 360° pulses/rev encoderattached directly to the carriage traverse ballscrew.

The COUNTER has the ability to disable programming by connecting the PGM dis.Terminal to common and this link has to be removed before attempting to reprogramthe counter.

Carriage Index Counter

Fig. 3-6-1 Single Index Counter

Carriage Index Counter

Fig. 3-6-2 Dual Function Index Counter


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3.6.1 INDEX COUNTER…SINGLE FUNCTION (metric OR imperial):

P SettingsP1 Button for carriage over run distance and will remain a constant for all cut widths over 5mm

(1/5”/0.20”). For widths less than 5mm the ‘P1’ will have to be adjusted slightly. (see below‘Adjusting Tolerance’)

P2 Button displays the index distance and determines the width of each cut. The index distance can be changedby pressing this button and setting new width. (see below ‘To set WIDTH’)

6 – 1 These digits appear below the particular digit position required. Keep depressed until requireddigit displays, repeat on the appropriate buttons ‘6 – 1’ until the desired value is obtained.

E Enter button. Must be depressed to enter the new index distance.

R Preset button to show new index width

To set WIDTH:

1. Press2. Set width required by depressing appropriate ‘6 – 1’ digits

3. Set value by pressing then

NOTE: After depressing ‘E” a momentary flashing of the display indicates the newindex width has been correctly entered.

Your new value is now entered.

Note: Value capacity range: METRIC to 1 decimal placesIMPERIAL to 3 decimal places.

ADJUSTING TOLERANCE:

NOTE: ERROR VALUE .. IF NEGATIVE “ - ” SIGN DISPLAYED OTHERWISEVALUE IS “POSITIVE”.

e.g. if error value negative (ie - .12)

1. Press (Figure shown (usually ‘1.28’) is index error set at Javelin factory) .

NOTE: If ‘P1’ is pressed and a minus sign is still displayed at the left hand side of the counter, the ± displaybutton must be pressed to remove the minus sign before the ‘P1’ can be adjusted correctly

2. Adjust reading by “+.12” i.e. if reading 1.28 change to 1.40 by depressingappropriate ‘6-1’ buttons

Set value by pressing then .

e.g. if error value positive -.. if error .12 you will adjust above readingfrom 1.28 to 1.16

NOTE: PRESET WILL RETURN TO PREVIOUS FIGURE IF EACH DIGIT IS NOTRE-ENTERED IN SIX SECONDS.

REFER TO MANUFACTURER’S MANUAL SUPPLIED WITH MACHINE MANUAL FOR MORE DETAIL ON ABOVE

SETTINGS.

Note: Index errors of ± .1mm (.004”) or under are acceptable. Machine will nevershow a consistent .00 index error as the momentum of the carriage will always pushthe carriage to some degree beyond .00

P2

E R

P1

E R


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3.6.2 INDEX COUNTER … DUAL FUNCTION (metric AND imperial):

NOTE: PUT INTO IMPERIAL (inches) OR METRIC (mm) MODEFIRST AT SWITCH

To set WIDTH:

4. Press to scroll through to P Setting required. (See Below for P Settings)5. Move cursor (blinking digit requiring change) by pressing < or >.6. Adjust value by depressing ∧ or ∨.

7. Set value by pressing ENT then

Your new value is now entered.

Note: Value capacity range: METRIC to 2 decimal placesIMPERIAL to 3 decimal places.

ADJUSTING TOLERANCE:

NOTE: ERROR VALUE .. IF NEGATIVE “ - ” SIGN DISPLAYED OTHERWISEVALUE IS “POSITIVE”.

e.g. if error value negative (ie - .12)

3. Press to scroll through to P setting required .4. Move cursor (blinking digit requiring change) by pressing < or >.5. Adjust reading by “+.12” i.e. if reading 1.28 change to 1.40 by depressing ∧ or ∨.6. Set value by pressing then .

e.g. if error value positive -.. if error .12 you will adjust above readingfrom 1.28 to 1.16

NOTE: PRESET WILL RETURN TO PREVIOUS FIGURE IF EACH DIGIT IS NOTRE-ENTERED IN SIX SECONDS.

REFER TO MANUFACTURER’S MANUAL SUPPLIED WITH MACHINE MANUAL FOR MORE DETAIL ON ABOVESETTINGS.

P1P2P3P4

P Settings

= metric (mm) tolerance= metric (mm) width= imperial (inches) width= imperial (inches) tolerance

Note: Index errors of ± .09mm (.004”) orunder are acceptable. Machine willnever show a consistent .00 index erroras the momentum of the carriage willalways push the carriage to somedegree beyond .00

PRS

F2RST

PRS

ENT F2RST

PRS


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3.7 ROLL COUNTER

An electronic ROLL COUNTER (see Fig. 3-1A) which automatically counts thenumber of rolls slit ('AUTO' mode only). The counter decreases its count each time theknife begins to retract from the roll. On the counter value reaching zero, the machinewill then either stop or automatically return the carriage to the start position, dependingon which position the carriage 'RETURN' switch is in. The PRESET entered in thiscounter determines the total number of cuts that will be made after the mode selectoris switched to 'AUTO' position.

This PRESET (ie. the number of rolls to be cut) can be adjusted by:

1. Pressing button 'P1'2. Pressing the digit keys ‘1 - 6 ’ until the desired value is displayed.3. Pressing enter button 'E' into the counter memory.4. pressing reset button ‘R’ to display new value.

Note: If the reset button 'R' is operated during a normal auto cycle then theaccumulated value will be reset to the preset.The counter does not count the first cut, as this is usually an off-cut or trim.

Fig. 3-7 Roll counter

ROLL COUNTER


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3.8 CHUCKS

There are two optional chucks supplied by JAVELIN. One is a pneumatically operatedchuck and the other manually operated.

3.8.1 PNEUMATIC CHUCK – MK II

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

With 4 external pin holders and 2 internal pin holders the pneumatic MK II chuck (seeFig. 7-7) provides four setting ranges to achieve a gripping capacity from ∅25.4 mm(∅1”) to ∅406 mm (∅16”) log roll. It is independently mounted on chuck spindle.Gripping and releasing is made by pressing the air nozzle into the chuck air inlet. Airinlet labelled ‘GRIP’ and next to it the label ‘RELEASE’ for opening the chuck. The airnozzle is conveniently located next to the chuck.

GRIPPING RANGE SET-UP

The pin holders are mounted on sliding bars by a socket head screw. There are aseries of locating holes on each sliding bar in order to position the pin holders to themost suitable position to grip the core or material. Two sizes of pin holders areavailable.

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

Gripping force is adjusted thru a regulator mounted on motor cabinet. Gripping force ismeasured in terms of air pressure as shown on gauge mounted next to regulator.Suitable force can be achieved by actually gripping the material to be slit, thenadjusting the regulator to suit.

(J3000 models)

Fig. 3-8-1-2 Pneumatic Chuck MK II

GAS STRUT

EXPANDING MANDREL

AIR NOZZLE TOGRIP & RELEASECHUCK PINS

POLYCARBONITEGUARD STOP

SLIDING BAR

PIN HOLDERS

RH CARRIAGE STOP


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3.8.2 PNEUMATIC CHUCK MK I (‘J2000-600 Models only’ up to Serial 149)

With 4 external pin holders and 2 internal pin holders the MK I chuck provides tensetting ranges to achieve a gripping capacity from ∅25.4 mm (∅1”) to ∅406 mm(∅16”) log roll. Gripping and releasing is made by 2 pneumatic cylinders directlyoperating 2 internal pin holders and 2 pneumatic cylinders operating 4 external pinholders by rotary linkage system. 4 external pin holders locked from outwardsmovement due to centrifugal force by 2 cam locks operating on the rotary linkagesystem. Disengagement of the cam locks by external cylinder movement activating therelease ring.

PNEUMATIC COUPLING

• Engages to admit air pressure to internal and external pneumatic cylinders.• Disengages to release seals and allow chuck rotation.

PILOTED NON RETURN VALVES

• Allows pneumatic pressure to be maintained on internal and external cylinderswhen pneumatic coupling is disengaged.

• Allows internal and external pin holders to retract.

GRIPPING RANGE SET-UP

The pin holders are mounted on sliding bars by a socket head cap screw and can beadjusted to different positions to suit the diameter of the log roll. The procedure is asfollows:

• Operate release button to disengage pin holders to their full extent as detailedabove

• Lower POLYCARBONITE GUARD and then raise it to disengage pneumaticcoupling so that the chuck may be rotated

• With external pin holders retracted fully, undo the socket head cap screws from thesliding bar (accessible from behind chuck face plate)

• Withdraw sliding bar and install alternate sliding bar into the chuck face plate slot• Insert a socket head cap screw through linkage arm and into appropriate hole in

rear of sliding bar and tighten• Rotate chuck to next pin holder and repeat above procedure until all 4 pin holders

have been changed

GRIPPING FORCE ADJUSTMENT (see Fig. 3-2A)

Gripping force is adjusted thru a regulator mounted on machine front cover. 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.

CHUCK ‘OFF ⇔ ON’ (see Fig. 3-1A)

In order for the chuck/mandrel to rotate the chuck switch must be in the “ON” positionstart lamp on, Polycarbonite guard lowered and the mandrel support raised.


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3.8.3 MANUAL CHUCK

The main spindle locates and drives the mandrel. It also drives the chuck when fittedas an option. It is mounted in a sealed bearing and bolted to the mainplate.

The chuck (see Fig. 7-8) is a slotted face plate mounted on front of main spindle. It isfitted with a set of 4 push-in type pin holders for external gripping.

When fitted with rotating mandrel, it is supplied with a set of short pin holders capableof gripping a range of log roll diameter from 76.2 ∼ to 406 mm (3” ∼ 16 ”).

An additional set of long pin holders with gripping range from 25.4 ∼ 254 mm (1” ∼ 14”)is optional.

Fig. 3-8-2 Manual chuck

CHUCK PIN

CHUCK PIN HOLDER


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3.9 MANDREL SUPPORT ARM

The mandrel support arm (see Fig. 3.9) 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. 3-9 Mandrel Support Arm

MANDREL

SUPPORT LOCK

MANDREL SUPPORT

ARM LOCK


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3.10 MANDRELS

3.10.1 ∅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“GRIP ⇔ RELEASE’ switch to expand the jaws inside the mandrel.

The rotating mandrel (see Fig. 7-12) rotates with the chuck spindle. It is held in thechuck spindle by two opposing cap screws, it can be removed from the machine bysliding it out after loosening the two cap screws which lock into dimples in the mandreland removing the cap screw joining the coupling halves together.

CAUTION: Do not engage non-rotating mandrel lock when using rotating mandrel.(see Fig. 3-2A)

3.10.1.1 FITTING EXPANDING MANDREL TO MACHINE

The sequence is:

• Loosen the non-rotating mandrel lock.• Remove the M6 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.• Check that marks on the chuck and the mandrel align (if fitted).• Connect the air cylinder coupling by fitting the M6 bolt. The halves of the coupling

have marks for alignment (if fitted).• Check operation of the air cylinder and drive.

CAUTION: Tighten two screws in the chuck spindle to provide drive for the mandrel.Connect the mandrel coupling to the air cylinder.

4 expansion jaws arelocated below redmandrel sleeve sectionto grip I/D of 3”(76.2mm) core.

Fig. 3.10.1 3” Expanding Rotating Mandrel


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3.10.1.2 ∅76.2MM (∅3”) ROTATING TRIM MANDREL with expansion section

∅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.

3.10.2 ∅76.2 MM (∅3") ROTATING MANDREL WITH STATIONARYSHAFT (J2000-600 models only)

The ∅76.2 mm (∅3") mandrel will rotate with log roll around a stationary ∅38.1 mm(∅1½") mandrel.

The rotating mandrel consists of a steel tube fitted with a double set of needle rollersat each end and mounted on stationary shaft. A natural rubber mandrel sleeve is fittedover tube to protect the knife.

• The benefits are less vibration because inner shaft is stationary.• High load capacity needle roller bearings.• Easily replaced natural rubber sleeve.

Note: 1 mm (4thou) clearance is needed between the locking collar and ∅76 mm(∅3") mandrel.

3.10.3 NON-ROTATING MANDRELS FOR CORE SIZES UNDER 76.2MM (3”)

Non-rotating mandrel (see Fig. 7-11) has a fibre insert along its full length to protectthe blade during the slitting cycle. A location dimple is drilled in one end of the shaft,when installed in the machine it gives the correct register of the blade to fibre strip.The word 'TOP' is stamped into the shaft on the load end to help line up the dimplewith the mandrel lock.

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

CAUTION: Cap screws in chuck spindle must be left loose or removed and mandrellock tightened.

3.10.3.1 ∅25.4 MM (∅1") NON-ROTATING MANDREL


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

3.10.3.2 ∅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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3.11 SAFETY GUARD

3.11.1 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. 6-11)

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 of squeegees.Dry with soft cloth or moist cellulose sponge to prevent water spotting.Under NO circumstances should petroleum/gasoline based products be used,

3.11.2 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 or plug is disconnected frommachine.

Fig. 3-11-2 Rear Safety Guard Gate

PLUG

LIMIT SWITCH


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Fig. 3.11.2a Bracket securing rear cage right-hand rear machine above mandrelsupport air cylinder.

Fig. 3.11.2b Bracket securing rear cage left-hand rear machine above air service unit.


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3.12 SPRAY SYSTEM

The Spray System (see Fig. 3.12) is for lubricating and cooling the side of the knife toprevent adhesive build up. The sprays work on a Venturi System. The vacuumgenerator sucks air and water to form a mist.

Add approximately two and a half tablespoons of lubricant (Note: Low gradedetergents cause rust & can congeal and block tubes. Javelin has sourced agood quality lubricant which is 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 for controlling the amount of air, the other forcontrolling the amount of water.

Fig. 3.12 Venturi Spray System

Fig.12a Spray system containers

WATER CONTAINING 2½TABLESPOONS OF JAVELINLUBRICANT

WATER DRAININGFROM KNIFE GUARD


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3.13 MACHINE CONTROL PANEL

Fig. 3.13 Machine Control Panel

3.13.1 MODE ‘ SEMI ⇔ MANUAL ⇔ AUTO ‘

The three position selector switch provides ‘SEMI ⇔ MANUAL ⇔ AUTO’ (see Fig. 3-13) and automatic control of the system provided that the green ‘START’ lamp is on.

MANUAL ‘ MODE

The knife is easily moved in or out using the manually operated joystick. The mode isused to set up the machine.In the ' MANUAL' position, the carriage, knife and grinder can be operated as per therelevant controls 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.


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3.13.2 START BUTTON

This green, illuminated push button (see Fig. 3-13) 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.

3.13.3 EMERGENCY STOP

This switch is a red PUSH/PULL illuminated button (see Fig. 3-13) 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.


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6. TROUBLE SHOOTING

6.2 SLITTING TOLERANCESTo 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 significiantvariations in width from roll to roll although the index counter will still read correctly.Always check for any loose wires to the encoder or index counter. A clutch brakeproblem is usually indicated by erratic tolerances displayed on the P1. When checkingfor a problem with the unit always first check the correct voltage is going to the clutchbrake.

Remember that any burrs on the knife, backing plate, washer and even the locking nutare enough to prevent 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 dial vernier do not allow the jaws of the vernier toclose against 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.

a. CHECKING FOR KNIFE SPINDLE RUN OUT:

Place dial indicator on clamping face of knife spindle and rotate spindle 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.


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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 spindlewith marking pen.

1

2

3

4

backing plate

spindle

.

c. CHECKING FOR KNIFE RUNOUT

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

Check runout in each position. If a position is found which is within tolerancepermanently mark backing plate and spindle. Ensure that the marks are alignedwhenever the backing plate is being placed back on the spindle

NOTE: Checkbacking plate oninside by fittinglarge backingplate/smallbacking plateand nut, thenplacing dialvernier on edgeof backing plateas shown inpicture.

A B


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43JULY 2016

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 locate knife lock in knife backing plate to

prevent knife spindle from turning.• Remove cover from left-hand end of spindle.• 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 remove knife lock.

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.

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


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44JULY 2016

6.3 BALLSCREW DRIVE

6.3.1 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• Adjust 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, adjust taper bearings on ballscrew.

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 adjusting nuts. Loosen the two grub screws inthe alloy timing pulley. loosen outer nut and adjust inner locknut to lightly preload taperbearings. Tighten outer nut, a grub screw in pulley, check for end play in ballscrew,check ballscrew rotates smoothly.


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45JULY 2016

6.3.2 CLUTCH BRAKE UNIT

Machines manufactured after December 1993 are fitted with a Warner Electric clutchbrake unit which is “self adjusting”.

Machines manufactured up to December 1993 are fitted with a Lenze clutch brakewhich is adjusted as follows:

ADJUSTING THE AIRGAP - LENZE

Value in (P1) should be no greater than 2.2 mm, if so turn power off at main isolatorand adjust airgap in clutch brake. The four screws (1) in the output cover must beloosened until the underlying pressure springs are released (1-2 turns). They must notbe completely removed.

The small cover in the casing slot has to be removed. You will see a radial hole intowhich you can insert a cylindrical rod and can now rotate the cam ring, the cam ringhas to be rotated to its stop in the arrow direction. There after rotate the ring backapprox. 0.1 mm (0.004"). Retighten the airgap screws rotate clutch brake pulley toensure brake is not binding. If it is increase airgap fractionally. Turn power on andcheck (P1) for over run.

ENCODER PLUG

ENCODER BALLSCREW TIMINGPULLEY

GRUB SCREWS

LOCK NUTS

CLUTCH BRAKEFig. 6.3.2 Warner Electric clutch brake


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46JULY 2016

6.4 INDEX COUNTERPROBLEM/EFFECT CAUSE REMEDIES

Digits not changing onindex counter whentraversing.

Incorrect programming. Compare programming inindex counter withprogramming sheet. If incorrectturn off power, removeretaining screws in controlpanel and swing hinged paneldown carefully.Remove program disconnectlink and reposition controlpanel. Turn machine on andmake necessary changes,check counter is workingcorrectly.Turn off power replace disablelink and control panel screws.

Loose terminals. Turn off machine and checkterminal rails and wires areconnected on back of counter.

Faulty plug. Check plug on encoder, forbroken wires or wires shortingout.

Encoder faulty. Replace encoder, note whichend of the encoder is fitted intoballscrew. If incorrect indexcounter will count backwards.

Index counter faulty Replace

6.5 KNIFE GRINDING

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

• Loose knife spindlebearings

• Slightly raise or lowerknife RPM

• backing plate bent or nolonger concave

• Tighten knife spindlebearings

• loose grinding wheel ongrinder motor shaft

• replace backing plate

• tighten grinding wheel


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47JULY 2016

6.6 PNEUMATIC CHUCK

6.6.1 PNEUMATIC CHUCK MK II

(see Fig. 7-7)

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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48JULY 2016

6.6.2 PNEUMATIC CHUCK MK I

PROBLEM/EFFECT CAUSE REMEDIESPin holders fail to operate inany direction

• Pneumatic coupling (24)not engaged

• No air supply topneumatic couplingports (24A)

• Air leakage in system• Main air supply pressure

setting too low• External pin holder

pressure regulatorsetting too low

• Operate pneumaticcoupling

• Check air supply

• Rectify leaks• Check and adjust

compressor switched on• Check and adjust supply

pressure

External pin holders do notdisengage

• Push rod bracket loosecylinder barrel

• Push rod disengagedfrom either push rodbracket or cam lockrelease ring

• Both cams are not beingdisengaged

• Adjust and tight

• Refit push rod

• Check push rod brackets(30) adjusted correctlyadjust cam screws. *Low air pressure

Pneumatic coupling doesnot disengage

• No air supply topneumatic couplingclamping cylinders

• Supply pressure toclamping cylinder portstoo low

• Air leakage in system

• Check air supply

• Check and adjust thecompressor switched on

• Rectify leaksChuck will not rotate • Pneumatic coupling

engaged• Disengage pneumatic

coupling. * Low airpressure

Pins do not engage with φ1.25" mandrel with pinholders on lowestadjustment hole

• Long sliding barsinstalled

• Shoulder screws locatedin incorrect holes at rearof sliding bars

• Fit short sliding bars

• Fit shoulder screws tocorrect holes

Pins do not accommodatelargest roll φ 16" 406 mmwith dogs at highestadjustment hole

• Short sliding barsinstalled

• Shoulder screw locatedin incorrect holes at rearof sliding bars

• Fit long sliding bars

• Fit shoulder screws tocorrect holes

Pins do not engagesimultaneously

• Pin holders not installedin common hole position

• Shoulder screws notinstalled in common holepositions

• Fit pin holders tocommon hole position

• Fit shoulder screws incorrect holes positions

Cause: L.E.D. switch on coupling cylinder incorrectly position *(L.E.D. light must be off).


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49JULY 2016

6.7 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

6.8 MANDRELS

6.8.1 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

6.8.2 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..

6.9 POLYCARBONITE GUARD

Machine will not operate unless the key mounted on the POLYCARBONITE GUARD isfully engaged into the switch (see Fig. 6-8).

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. 6-8 Polycarbonite Guard Key Switch

SAFETYSWITCH

LEXANGUARD

GAS STRUT


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52JULY 2016

6.10 SPRAY SYSTEM

PROBLEM/EFFECT CAUSE REMEDIESSpray not working. • No air pressureor 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

• Filter missing or blockedin spray system waterbottle

• 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)

• Replace filterClean filter usingcompressed air.Clean water bottle

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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53JULY 2016

6.11 PNEUMATIC SYSTEM

PROBLEM/EFFECT CAUSE REMEDIESKnife jumps forward orknife cutting actionspongy

• Low oil level.• Air in system.• Loose Fittings/air or oil

line not sealing – checkfor air/oil leak (see notebelow).

• Check oil level.• Bleed system.• Tighten fitting.

Knife moves rapidly tomandrel

• Cutting speed flow valveopened too far.

• Low oil level• Air in system

• Turn flow valve clockwise toslow speed.

• Check oil level.• Bleed system.

Knife jumps forward whenslitting mode switch isturned from semi or autoposition to manualposition

• Solonoid valve 23opening bypass valve 17too quickly

• Fully close flow valve andthen adjust the valveapproximately 0.8 mm(1/32") on the circumferenceof the screw.

Knife and other aircontrolled functions slowor cease to operate.

• Low air pressure. • Check air pressure (700kpa).

Knife does not moveforward.

• Knob controlling forwardspeed of knife closed off.

• Faulty solenoid valve orelectrical fault.

• Turn anti-clockwise to open.

• Check.

REFER TO MAINTENANCE MANUAL FOR INFORMATION ON :1. CHECKING OIL LEVELS IN RESERVOIRS2. BLEEDING AIR FROM SYSTEM3. BLEEDING OIL FROM SYSTEM

NOTE: When replacing any section of tubing for air or oil take care that tubing is cutsquare otherwise there will not be a positive seal which will cause problems asdescribed above.


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54JULY 2016

6.12 ELECTRICAL SYSTEM

ELECTRICAL CONTROL SYSTEM

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. 6-8)• The mandrel support must be raised.• Safety cage door to be closed.

MOTOR OVERLOAD

The motors are protected by overload setting located in the main electrical cabinet, inthe following order:

Carriage Motor M1Grinder Motor M2Knife Motor M3Chuck Spindle Motor M4

PLC OPERATION

The programming function for this machine are contained on a Eeprom module insidethe PLC unit.

All electrical equipment is controlled from this point its operation can be checked byusing the LED display located on the front of the unit.

ROLL COUNTER

To check display is operating correctly press the two buttons on the left hand side ofthe counter together.Ensure the dip. switch settings are as shown below:

SW 1 2 3 4 5* UP position

* * * * * DOWN position

CUTS PER GRIND COUNTER

This counter is the same as the roll counter and all the functions are the same asabove.


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55JULY 2016

INDEX COUNTER

The input for this counter is 360 pulse/revolution encoder located on the end of theballscrew, this counter has two preset values, preset #2 ‘P2’ which is the indexingdistance and preset #1 ‘P1’ which is the stop signal to the clutch/brake unit. This stopsignal is a constant time to allow for the de-acceleration of the ballscrew.The counter has the ability to disable programming by connecting the "PGM.DIS"terminal to common and this link has to be removed before attempting to re-programthe counter.

Ensure that the dip. switch setting are as shown below:

SW 1 2 3 4 5* * UP position* * * * * DOWN position

ROLL COUNTER

The counter is set up for a timed output of 2.0 seconds as the counter reaches zero,and is automatically reset to the preset value after the timed output.

KNIFE DWELL TIMER

The Knife Dwell Timer is to ensure there is a timed stage at fully advanced knifeposition. After the timed stage is complete the carriage will retract via the retractsolenoid, called for the Knife Dwell Timer. The timer is to be set at 0-10 seconds.

AUTO GRIND TIMER

The Auto Grind Timer is to ensure that the operation of the Auto Grind Solenoid is onlyfor a pre-determined time. The timer is to be set at 0-1 minutes.

WIRING

All connections are to be checked for loose connections due to transport vibration.The supply cable for this machine is to be of a size to carry a load of 25 amp.The connection terminals are located towards the bottom left hand corner of the mainelectrical cabinet.

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 push buttons are alight. If

not alight, then retract knife until they are. The lamps indicate that all safetyconditions for traversing are intact.

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 brake disengages. If theclutch/brake is satisfactory then check that all motor connections are tight.


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56JULY 2016

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.• 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.

KNIFE FAILS TO OPERATE

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

• Check knife motor overload is intact (refer to overload section).• Green lamp is ON.• Safety hood is down and switch contact is closed.• Mandrel support is raised and indicating lamp is OFF.• In DC version, check that both the fuses on the speed controller are OK.• If invertor is used check power on lamp, and that no fault lamps are on.• If all these conditions are correct it will mean the knife motor contact will need to be

replaced.

KNIFE FAILS TO ADVANCE

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

INDEX COUNTER FAILS TO COUNT

• Check that the index counter is programmed correctly (refer to index countersection).

• Check connection to shaft encoder at ballscrew.• Check connection terminal at the rear of the counter.


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57JULY 2016

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 proximity switch has sensed carriage will not return.

CHUCK FAILS TO ROTATE

• Check that the hood is down.• 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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58JULY 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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59JULY 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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60JULY 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 .................................................................................................................................... 7

3.1 MAIN ISOLATOR SWITCH & SAFETY FEATURES....................................................................................... 73.2 KNIFE PEDESTAL ASSEMBLY ........................................................................................................................ 9

3.2.1 KNIFE SPINDLE .......................................................................................................................................... 93.2.2 BACKING PLATE , WASHER & NUT.......................................................................................................... 93.2.3 KNIFE SELECTION ................................................................................................................................... 10

KNIFE DIAMETER ..........................................................................................................................................................10KNIFE BEVELS................................................................................................................................................................10KNIFE EDGE ....................................................................................................................................................................10KNIFE SELECTION .........................................................................................................................................................11OPERATOR REFERENCE SHEET..................................................................................................................................12ROUNDING KNIFE EDGE ..............................................................................................................................................13

3.2.4 FITTING KNIVES TO KNIFE SPINDLE.................................................................................................... 143.2.5 KNIFE LOCK.............................................................................................................................................. 143.2.6 KNIFE DRIVE CONTROL.......................................................................................................................... 14

KNIFE ‘ON ⇔ OFF’ .........................................................................................................................................................14KNIFE SPEED (RPM).......................................................................................................................................................14GEAR BOXES...................................................................................................................................................................15KNIFE BRAKE .................................................................................................................................................................15

3.3 KNIFE SHARPENING....................................................................................................................................... 163.3.1 AUTO GRIND FUNCTION ........................................................................................................................ 173.3.2 DEBURRING UNIT .................................................................................................................................... 183.3.3 GRINDING WHEEL DIAMOND DRESSER............................................................................................... 18

3.4 KNIFE CARRIAGE - FORWARD AND RETRACT MOVEMENT ................................................................. 193.4.1 SETTING KNIFE STOP.............................................................................................................................. 19

FORWARD KNIFE STOP ................................................................................................................................................19KNIFE REAR STOP..........................................................................................................................................................20

3.4.2 KNIFE CARRIAGE FORWARD AND RETRACT CONTROL.................................................................... 20FORWARD SPEED CONTROL ‘ FAST ⇔ SLOW.........................................................................................................20FORWARD KNIFE SPEED TIMER.................................................................................................................................21KNIFE DWELL TIMER....................................................................................................................................................21

3.5 KNIFE CARRIAGE - TRAVERSING................................................................................................................ 223.5.4 SETTING CARRIAGE STOP ...................................................................................................................... 22

RIGHT HAND CARRIAGE STOP ...................................................................................................................................22LEFT HAND CARRIAGE STOP ......................................................................................................................................22

3.5.2 KNIFE CARRIAGE TRAVERSING CONTROL .......................................................................................... 23CARRIAGE TRAVERSE LEFT BUTTON.......................................................................................................................23CARRIAGE TRAVERSE RIGHT BUTTON ....................................................................................................................23CARRIAGE RETURN ‘ OFF ⇔ AUTO ‘.........................................................................................................................23CARRIAGE SPEED ‘ LOW - HIGH - (IF FITTED).......................................................................................................24

3.6 INDEX COUNTER ............................................................................................................................................ 253.6.1 INDEX COUNTER…SINGLE FUNCTION (metric OR imperial):............................................................. 263.6.2 INDEX COUNTER … DUAL FUNCTION (metric AND imperial): ........................................................... 27

3.7 ROLL COUNTER............................................................................................................................................... 283.8 CHUCKS ............................................................................................................................................................ 29

3.8.1 PNEUMATIC CHUCK – MK II .................................................................................................................. 293.8.2 PNEUMATIC CHUCK MK I ...................................................................................................................... 303.8.3 MANUAL CHUCK...................................................................................................................................... 31

3.9 MANDREL SUPPORT ARM............................................................................................................................. 32


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61JULY 2016

3.10 MANDRELS..................................................................................................................................................... 333.10.1 ∅76.2 MM (∅3”) ROTATING MANDREL with expansion section ......................................................... 33

3.10.1.1 FITTING EXPANDING MANDREL TO MACHINE ........................................................................................333.10.1.2 ∅76.2MM (∅3”) ROTATING TRIM MANDREL with expansion section ........................................................34

3.10.2 ∅76.2 MM (∅3") ROTATING MANDREL WITH STATIONARY SHAFT (J2000-600 models only)....... 343.10.3 NON-ROTATING MANDRELS FOR CORE SIZES UNDER 76.2MM (3”) ............................................. 34

3.10.3.1 ∅25.4 MM (∅1") NON-ROTATING MANDREL .............................................................................................343.10.3.2 ∅38 MM (∅1½") TO ∅51 MM (Ø2”) NON ROTATING MANDREL.............................................................35

3.11 SAFETY GUARD............................................................................................................................................. 363.11.1 POLYCARBONITE GUARD..................................................................................................................... 363.11.2 REAR SAFETY GUARD GATE................................................................................................................. 36

3.12 SPRAY SYSTEM ............................................................................................................................................. 383.13 MACHINE CONTROL PANEL....................................................................................................................... 39

3.13.1 MODE ‘ SEMI ⇔ MANUAL ⇔ AUTO ‘.................................................................................................. 393.13.2 START BUTTON....................................................................................................................................... 403.13.3 EMERGENCY STOP................................................................................................................................. 40

6. TROUBLE SHOOTING .................................................................................................................................... 41

6.2 SLITTING TOLERANCES................................................................................................................................ 41a. CHECKING FOR KNIFE SPINDLE RUN OUT: ............................................................................................ 41b. CHECKING FOR BACKING PLATE RUNOUT: ............................................................................................ 42c. CHECKING FOR KNIFE RUNOUT................................................................................................................ 42d. HOW TO TIGHTEN KNIFE SPINDLE BEARINGS:....................................................................................... 43e. PEDESTAL ALIGNMENT................................................................................................................................ 43f. ALIGN KNIFE PARALLEL TO CHUCK .......................................................................................................... 43

6.3 BALLSCREW DRIVE........................................................................................................................................ 446.3.1 BALLSCREW AND NUT............................................................................................................................. 446.3.2 CLUTCH BRAKE UNIT.............................................................................................................................. 45

6.4 INDEX COUNTER ............................................................................................................................................ 466.5 KNIFE GRINDING ............................................................................................................................................ 466.6 PNEUMATIC CHUCK....................................................................................................................................... 47

6.6.1 PNEUMATIC CHUCK MK II ..................................................................................................................... 476.6.2 PNEUMATIC CHUCK MK I ...................................................................................................................... 48

6.7 MANDREL SUPPORT ARM............................................................................................................................. 496.8 MANDRELS....................................................................................................................................................... 50

6.8.1 NON ROTATING MANDREL ..................................................................................................................... 506.8.2 ROTATING MANDREL .............................................................................................................................. 51

6.9 POLYCARBONITE GUARD............................................................................................................................. 516.10 SPRAY SYSTEM ............................................................................................................................................. 526.11 PNEUMATIC SYSTEM................................................................................................................................... 536.12 ELECTRICAL SYSTEM.................................................................................................................................. 54

ELECTRICAL CONTROL SYSTEM ...............................................................................................................................54MOTOR OVERLOAD.......................................................................................................................................................54PLC OPERATION.............................................................................................................................................................54ROLL COUNTER..............................................................................................................................................................54CUTS PER GRIND COUNTER ........................................................................................................................................54INDEX COUNTER............................................................................................................................................................55ROLL COUNTER..............................................................................................................................................................55KNIFE DWELL TIMER....................................................................................................................................................55AUTO GRIND TIMER......................................................................................................................................................55WIRING.............................................................................................................................................................................55KNIFE CARRIAGE FAILS TO TRAVERSE ...................................................................................................................55KNIFE FAILS TO OPERATE...........................................................................................................................................56KNIFE FAILS TO ADVANCE .........................................................................................................................................56KNIFE FAILS TO RETRACT...........................................................................................................................................56INDEX COUNTER FAILS TO COUNT...........................................................................................................................56GRINDER FAILS TO OPERATE .....................................................................................................................................57CARRIAGE FAILS TO AUTOMATICALLY RETURN LEFT WHEN RIGHT HAND STOP IS CONTACTED .........57CHUCK FAILS TO ROTATE ...........................................................................................................................................57

MANDREL SLEEVE REPLACEMENT ............................................................................................................. 58

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#J3000 Operator Manual Front Pg July 2016 - irp … · JAVELIN MACHINERY (AUSTRALIA) J3000 OPERATION MANUAL (Incl Troubleshooting Machine Problems) _____ 2