Razorgage Cyclone RazorOptimal, User Manual

Page 1: ...Cyclone RazorOptimal User Manual 1 P a g e Technical Services Inc CYCLONE RAZOROPTIMAL SAW SYSTEM ...

Page 2: ...onnection 10 Electrical Interface Connections 11 Air Supply Connection 12 Pneumatic Connections 12 Dust Collection 13 Setup Procedure 14 Saw Capacity 21 General Operation 22 Machine Adjustments 26 Lockout Tagout Points 27 Saw Feed Flow Controls 28 Saw Stroke Distance 29 Saw Blade Speed 30 Horizontal Clamps Pressure Regulator 30 Horizontal Clamps Flow Controls 31 Vertical Clamp Pressure Regulator 3...

Page 3: ... to Saw Blade 35 Pusher Lift Height 36 Maintenance 37 Lubrication 37 Saw Blade Access 38 Changing Out Saw Blade 38 Replacement Parts List 39 Troubleshooting 41 Electrical Schematics 41 Pneumatic Schematics 45 Troubleshooting Guide 46 VFD Faults 50 Troubleshooting Reference Pictures 51 Troubleshooting E Stop Faults 53 ...

Page 4: ...pervisor immediately 3 If the operator has any safety concerns or questions regarding the operation of this equipment DO NOT OPERATE THIS MACHINE the machine should be locked out and your supervisor notified immediately 4 All Lock Out Tag Out procedures must be followed before servicing or adjusting this equipment If you have not received proper training in the Lock Out Tag Out procedures for this...

Page 5: ...ould be kept at a safe distance from work area 15 Make workshop childproof with padlocks master switches or by removing starter keys 16 Do not force the machine It will function better and safer at its designed rate 17 Use the right tools Do not force the machine or attachments to do a job for which they were not designed Contact the manufacturer or distributor if there is any question about the m...

Page 6: ...pneumatic 4 Minimum air pressure is 50 psi DO NOT operate saw if minimum air pressure is not available Normal working pressure is 80psi 5 At the start of each work session turn on saw and cycle the saw and check for normal operation of top clamp and blade advance cylinders Turn off saw and as the motor slows and comes to a stop check for correct rotation direction compared to arrow indicator 6 Do ...

Page 7: ...al must be available to all operators The Cyclone Optimal ships with two items a pallet and a crate The saw will be secured to a pallet The RazorGage positioner tables legs and tower control cabinet will be in the crate Unpack the saw ensuring that all parts are present and free from damage If any parts are missing or damaged contact your local distributor immediately Do not assemble or attempt to...

Page 8: ...followed This manual must be available to all operators Install saw with enough free space to conveniently allow workpiece to be brought into saw If infeed and or outfeed tables are required allow room for such The floor should be a flat non slip surface The saw will be more stable if bolted to floor After locating the saw use leveling feet to adjust level of saw table Place level on saw table and...

Page 9: ...ce level on the saw blade opening Use the jack bolts on the mounting feet to make the adjustments to saw level It is important that once the saw is level to check that all four mounting feet are sharing the weight of the saw Otherwise the saw will be unstable Anchoring After saw is leveled it is recommended that the saw is bolted down to the floor This will improve stability and help keep the saw ...

Page 10: ...egs and also on the table attachment brackets shown below Electrical Power Connection WARNING The operator must remove from and lock out all power sources to saw before servicing or connecting power The saw has been factory wired to the requested voltage before shipment The saw power requirements are either 208 230 VAC 3φ 30Amps OR 480 VAC 3φ 20Amps The RazorGage tower requires a separate 120V 1φ ...

Page 11: ...om the factory and need only to be plugged back into to the saw The interface cable connects to the underside of the saw control cabinet and the valve bank cable to the DIN connector on the valve bank The crayon and board sensor cables will need to be wired to the crayon optimal circuit board in the RazorGage tower Follow the sensor type and color code of the cable conductors marked next to the te...

Page 12: ...tic Connections The Cyclone Upcut Saw has all the valves for the Cyclone RazorOptimal System The air lines for the pusher arm pop up will need to be connected to the valve bank The valve for the pusher is the first valve from the left The air lines plug into the fittings on the bottom side of the valve The pusher is normally down and pops up when the solenoid on the valve is activated Reverse the ...

Page 13: ...res dust collection to keep saw dust from collecting on the machine Vacuum with the minimum capacity of 1200 CFM is recommended There are two 4 dust collection on the saw One port is located at the back of the saw and the other is underneath the saw carriage accessible from the left side of the saw ...

Page 14: ... with a squared end and put the square end against the pusher face and seat it against the fence so it is in position to be cut Again type 16 in the MOVE TO POSITION box click MOVE SAW and press GO THE SAW WILL CYCLE Remove the part from between the PUSHER AND THE SAW and press the CALIBRATE BUTTON Saw Stop Screen Measure the part you just cut and In the CALIBRATE screen enter 16 as the LAST POSIT...

Page 15: ...top Enter the same value into the MOVE TO POSITION box highlight the MOVE SAW radio button and press GO The saw will cycle so make sure you re clear and that there are no tools or other obstructions in the way of the blade path Now measure that part Make a note of the length you entered the length of the actual part and the current HOME OFFSET you set in the previous step Press DONE and from the M...

Page 16: ...Cyclone RazorOptimal User Manual 16 P a g e Technical Services Inc ...

Page 17: ...tion less than or equal to this value then the outfeed clamp is used instead of the infeed clamp Default is 12 inches OUT BOARD CLAMP OFFSET Distance from the outfeed clamp to the saw blade Default is 4 inches MOTION ERROR UNLOAD DISTANCE Distance the RazorGage will backup on a motion error or stall to allow room for board removal if necessary Default is 4 inches Now press the MOTION button on the...

Page 18: ...0 SAW UNCLAMP TIMER This is the delay time after saw advance is deactivated before the vertical clamp is deactivated The new saw versions have sensors to monitor saw position so this timer value need to be set to 0 Now press the SCAN button on the left hand side of the screen and set the Scan Start Position and Scan Speed values as shown below Enter the value for the Parameter called PUSHER LENGTH...

Page 19: ...ropping behind the part where the stock retaining plate is not engaged Default length is 13 5 inches CRAYON MARK OFFSET This offset determines where the saw cuts in relation the crayon mark on the board Default is 0 inches SENSOR DIFFERENCE Distance from board sensor to crayon sensor Default is 1 inch BOARD SENSOR KERF The width of the end of board sensor detection area SCAN UNITS The scan units c...

Page 20: ...LECT HOW THE BINS ARE LAYED OUT Horizontally layout is where the bins count up horizontally first then increments vertically Vertically layout is where the bins count up vertically first then increments horizontally SIMULATE NEXT BUTTON Changes active bin to the next bin in the que CLEAR BIN AND BIN QUE Deactivates current bin and clears bin que CLEAR BIN BIN QUE AND LOAD FOR BIN TESTING Clears cu...

Page 21: ...the blade to maximize thickness capacity The fence is adjustable to accommodate the potential material sizes as shown in the chart above For best cut quality on thin stock the work piece should be toward the rear of the saw Adjust the position of the fence toward the rear of saw to optimize cut quality See adjustment section for directions on adjustment of fence and squaring fence to blade after a...

Page 22: ...Cyclone RazorOptimal User Manual 22 P a g e Technical Services Inc General Operation ...

Page 23: ...he cutlist opens the list of parts will typically be sorted by material type Types are determined by the species thickness and width of the wood The sorting criteria can be easily changed to match the requirements of the customer s application 4 Choose a type to run Use the navigation keys to change type Use the LIST TYPES button to see all remaining types 5 Place a piece of stock matching the mat...

Page 24: ...ll start cutting automatically This option will be used in normal operation Alternatively you can use the SCAN WAIT and follow instructions below a If you press SCAN WAIT a diagram will appear showing the defects the fluorescent crayon scanner picked up during the scan Defects show up in red bands and clear spans show up in the green bands This is a good idea to use when getting started to check t...

Page 25: ...minimize waste While the machine is processing the board you can begin defecting a new board When the previous board is finished the pusher will return to the scan start position automatically Using the MOVE TO SCAN START button won t be necessary every time Just place the defected board against the fence crowd it against the back of the pusher foot and choose either SCAN WAIT or SCAN GO ...

Page 26: ...st thoroughly read and understand this manual before operating the saw or starting any servicing All safety and warning instructions should be followed This manual must be available to all operators WARNING The operator must remove from and lock out all power sources to saw before servicing or connecting power ...

Page 27: ...ned during installation If it is necessary to make changes to these settings i e material size changes make sure you read and understand all instructions before attempting to make any setup changes to the machine If any assistance is needed contact your distributor or RazorGage When removing any machine guards or panels properly lock out tag out machine power sources See pictures above for electri...

Page 28: ...ore adjusting Adjust by turning the dial clockwise to close the flow which slows motion or turning counterclockwise to hastens motion Use precaution when making adjustments to saw feed rate Changes to saw blade feed rate can affect cut quality To test saw go to SAW STOP MODE from the MAIN SCREEN and move the pusher out to high limit to get it out of the way Now place a test piece of board under th...

Page 29: ...Cyclone RazorOptimal User Manual 29 P a g e Technical Services Inc Saw Stroke Distance ...

Page 30: ... s recommendation Horizontal Clamps Pressure Regulator The pressure of the horizontal clamps is adjustable to allow clamping of material of varying rigidity To adjust the horizontal clamps pressure locate the horizontal clamps pressure regulators located under the right side of the saw table Pull out on the adjustment knob to unlock it Turn clockwise to increase the pressure and counter clockwise ...

Page 31: ...re that the horizontal clamps are clamping before the saw enters the material Adjust flow controls to change advance and retract speed as needed Vertical Clamp Pressure Regulator The pressure of the vertical clamp is adjustable to allow clamping of material of varying rigidity To adjust the vertical clamp pressure locate the vertical clamp pressure regulator located under the right side of the saw...

Page 32: ...the flow which slows motion and turning counterclockwise will hastens motion To test vertical clamp go to SAW STOP MODE from the MAIN SCREEN and move the pusher out to high limit to get it out of the way Now place a test piece of board under the top clamp and against the fence Enter a value equal to the current position select MOVE SAW then press GO The pusher won t move because it s already in po...

Page 33: ...the stops The more stops engaged the shorter the vertical clamp stroke Guide Rollers The Cyclone RazorOptimal is equipped with guide rollers to support the material as it is being feed through the saw The guide rollers apply downward pressure to the material The rollers are slightly angled toward the back fence to keep the material close to the fence while being advanced If a printer is used the r...

Page 34: ...k fence to center the material on the saw blade The back fence is mounted with slotted holes For small adjustments just loosen the bolts and slid in the slotted hole and retighten For larger adjustments the is a grid pattern of threaded holes remove the bolts and remount in a different set of holes Always square the back fence to the saw blade after any adjustment to the back fence See the next se...

Page 35: ...Cyclone RazorOptimal User Manual 35 P a g e Technical Services Inc Squaring Back Fence to Saw Blade ...

Page 36: ...the pusher arm down adjust the pusher so there is a 1 16 gap between the stock material thickness and the retaining plate of the pusher arm To make the adjustment loosen the bolts with the adjustment handles Then lower the entire pusher arm assembly until proper gap has been achieved Tighten the adjustment bolts If this adjustment is set too low it may cause a gap from the main plate to the materi...

Page 37: ...s The operator must remove from and lock out all power sources to saw before servicing Lubrication There are several components on the Cyclone Optimal Saw that need to be lubricated regularly The linear bearing rails on the saw carriage vertical clamp and horizontal clamps need to be lubricated every 5000 machine cycles with lithium soap based grease Each of the linear bearing block have a grease ...

Page 38: ...serve the proper rotation and be sure blade matches the rotation arrow Use scrap wood to block blade while tightening or loosening blade retaining screw Blade retaining bolt has left hand threads the direction for tightening and loosening is opposite from normal bolts To loosen retaining bolt turn wrench in same direction as rotation of blade clockwise when looking at the blade Note the direction ...

Page 39: ...RIVE 480V RGX01366 SAFETY TIMER RELAY RGX02187 NO FAULT 2 POLE RELAY RGX01742 RED EXTENDED HEAD PUSHBUTTON RGX01743 GREEN ILLUMINATED PUSHBUTTON RGX01747 E STOP PUSHBUTTON RGX01749 RED FLUSH ILLUMINATED PUSHBUTTON RGX01748 PUSHBUTTON HOLDER NC CONTACT RGX01620 PUSHBUTTON HOLDER NO CONTACT RGX01415 LINE REACTOR 480V RGX01414 LINE REACTOR 208V RGX00009 M DRIVE STEPPER MOTOR RGX00577 CYLINDER POSITIO...

Page 40: ...X00674 SPRING ROLLER SUPPORT RGX00482 END OF BOARD SENSOR RGX01533 CRAYON SENSOR RGX00805 CRAYON DEFECTING BOARD ASSEMBLY RGX00155 DIRECTLOGIC 06 PLC A full list of field replaceable parts can be accessed at our web site https razorgage com product line replacement parts ...

Page 41: ...Cyclone RazorOptimal User Manual 41 P a g e Technical Services Inc Troubleshooting Electrical Schematics Page 1 of 4 ...

Page 42: ...Cyclone RazorOptimal User Manual 42 P a g e Technical Services Inc Electrical Schematics Page 2 of 4 ...

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Page 45: ...Cyclone RazorOptimal User Manual 45 P a g e Technical Services Inc Pneumatic Schematics ...

Page 46: ...ted tightly The connector needs to be wiggled while tightening otherwise it doesn t tighten up enough to make a good connection and intermittent problems occur If the Mdrive I O cable connection is good and the Do Action input X1 on the PLC isn t coming on when running the program then the Mdrive I O is bad and it will have to be replaced see Figure 4 If the indicator on the saw cycle valve is on ...

Page 47: ...if tripped Lock out Tag out the saw electrical panel Check to see which overload is tripped left OL relay is left drill On the side of the tripped OL check pocket drill belt pullies and gearbox for excessive friction If necessary grease pocket drill gearbox Reset overload relay by pressing the blue reset button on it Reset the machine If starter is energizing check the wiring from the starter cont...

Page 48: ... indicator is off with the saw up and the cable wiring check out then proximity switch has failed Replace the sensor 11 ERROR 0007 No Air Pressure detected Input X13 Air pressure supply shutoff on the FRL is off Pinched or damaged air line Wiring problem Failed air pressure switch Turn air pressure supply shutoff on the FRL to on position Check air line running from the FRL to the pressure switch ...

Page 49: ...Replace the sensor 15 ERROR 0011 Saw cannot be started unless ONE of the Scribe Sensors are on Scribe motion is obstructed Scribe height is set too high Low Air Pressure or air leak Scribe front or rear cylinder proximity switch is loose Cable or wiring problem Failed cylinder proximity switch Witch system air off check for obstructions in scribe motion It should move freely by hand Remove any woo...

Page 50: ... the SAW DONE MOVE TO NEXT on screen button Check MDrive I O cable is tight Check the saw retracted prox switch and adjust if necessary If adjustment is ok check the cable connection and wiring back to RazorGage tower enclosure Press OK to recover from the error The recovery from this error exits the runtime screen back to the setup screen Press OK to recover from the error The recovery from this ...

Page 51: ...Cyclone RazorOptimal User Manual 51 P a g e Technical Services Inc Troubleshooting Reference Pictures Figure 4 Figure 5 ...

Page 52: ...Cyclone RazorOptimal User Manual 52 P a g e Technical Services Inc Figure 6 Figure 7 Figure 8 ...

Page 53: ...Cyclone RazorOptimal User Manual 53 P a g e Technical Services Inc Troubleshooting E Stop Faults ...

Page 54: ... randomly displays E Stop screens even though all guard interlocks are closed air pressure is present and all E Stop switches are disengaged then it is possible that the software E Stop circuit is compromised The software E Stop circuit comprises two wires that go from the Master Control Relay to the DB 9 connector that is on the PC end of the PLC communication cable To troubleshoot this potential...

Page 55: ...ain wire is hooked up to DB9 chassis If you have more questions about RazorGage products visit our Downloads page and our You Tube channel Both are accessible from the RazorGage home page www razorgage com If you would like to discuss an application feel free to call us at 515 232 3188 ...