Rotary clipper school

1. Rotary clipper school

14 December, 2006
Raute Controller, 24 GPM Servo Proportional Valves
www.raute.com

2. COURSE CONTENT

N O M E
1
COURSE CONTENT
Section
1
2
3
4
5
6
Topic
SAFETY
DESCRIPTION
CLIPPER THEORY
OPERATION
MAINTENANCE
TROUBLESHOOTING
Tags
CONTROLLER
O
Durand (old)
N
Raute (New)
AREA
M
Mechanic
E
Electric
LEVEL
2
Version 1.0 - June 2006
1
General
2
Advanced
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2

3. Section 1 SAFETY

Section 1 - SAFETY
N O M E
1
Section 1
SAFETY
GENERAL
References:
Plant safety procedures
Clipper Manual - Section 1
SPECIFIC
Critical points:
Hydraulic Power Unit (Knife & Rolls)
Conveyors and hold-downs
Non critical points:
Controller cabinet power
3
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2

4. Section 1 SAFETY

Section 1 - SAFETY
M E
1
Section 1
SAFETY
IMPORTANT:
The safety procedures described in the following pages are
intended only to highlight some specific points regarding the
Rotary Clipper and are not meant to replace nor substitute, in any
case nor to any extent, any other safety procedures applicable,
whether issued by the mill or by any other local, federal or
otherwise relevant authority.
In case of conflict or contradiction between the recommendations
contained in this document and those emanating from these
authorities, the latter will take precedence.
4
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5. GENERAL PROCEDURES

Section 1 - SAFETY - GENERAL PROCEDURES
M E
1
GENERAL PROCEDURES
MAIN POINTS
5
1.
DO NOT OPERATE NOR SERVICE ANY MACHINERY UNTIL
YOU GET THE APROPRIATE TRAINING TO DO SO.
2.
ALWAYS USE SAFETY GEAR: HIGH VISIBILITY VEST,
HARD HAT, SAFETY GLASSES, EAR PLUGS AND STEEL
TOE SHOES.
3.
LOCATE AND KNOW HOW TO USE THE EMERGENCY
STOP BUTTONS.
4.
LOCK-OUT ALL SYSTEMS AS REQUIRED, BEFORE
SERVICING ANY MACHINERY OR ENTERING ANY
HAZARDOUS AREAS.
5.
REFER AND COMPLY WITH PLANT SPECIFIC SAFETY
PROCEDURES.
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6. SPECIFIC PROCEDURES

Section 1 - SAFETY - SPECIFIC PROCEDURES
M E
1
SPECIFIC PROCEDURES
MAIN POINTS
1.
SHUT OFF AND LOCK-OUT HYDRAULIC PUMP
2.
CLOSE SHUT-OFF VALVE AT THE HYDRAULIC TANK
3.
TURN OFF CONSOLE POWER
4.
TURN OFF ELECTRONIC CONTROLLER POWER
5.
LOCK-OUT INFEED CONVEYOR
6.
LOCK-OUT HOLDOWN BELTS
7.
LOCK-OUT OUTFEED CONVEYOR
8.
DISCHARGE ACCUMULATORS
ALL SYSTEMS MUST BE AT ZERO ENERGY STATE
6
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7. HYDRAULICS LOCK-OUT

Section 1 - SAFETY - LOCK-OUT
M E
1
HYDRAULICS LOCK-OUT
SHUT-OFF VALVE
CLOSED AND
LOCKED OUT
ONLY WITH NEW
RAUTE CONTROLLER
MAIN SWITCH
LOCKED OUT
7
DISCHARGE VALVE
CLOSED AND
LOCKED OUT
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8. MECHANICAL LOCK-OUT

Section 1 - SAFETY - LOCK-OUT
M E
1
MECHANICAL LOCK-OUT
MAIN SWITCH
OFF AND
LOCKED OUT
IN-FEED
LOCKED-OUT
OUT-FEED
LOCKED-OUT
HOLD DOWN AIR
VALVE CLOSED
HOLD DOWN
LOCKED-OUT
8
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9. Section 2 DESCRIPTION

Section 2 - DESCRIPTION
N O M E
1
Section 2
DESCRIPTION
CLIPPER FRAME
Knife Subsystem
Anvil rolls
HYDRAULIC UNIT
General view
Controls
General views
CONTROLLER
Basic wiring
CONTROL LOGIC
9
Hardwired logic
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2

10. CLIPPER VERSIONS

Section 2 - DESCRIPTION - CLIPPER VERSIONS
M E
1
CLIPPER VERSIONS
Rotary Clipper
Clipper Frame
Hydraulic Power Unit
Controller
Durand
Knife subsystem
Raute
Knife Drive
15 GPM valves
Others
24 GPM valves
Blade
Anvil rolls subsystem
Drive
Rolls
10
Hydraulic drive
Electric drive
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VFD Cabinet
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11. CLIPPER FRAME

Section 2 - DESCRIPTION - CLIPPER FRAME
M E
1
CLIPPER FRAME
Servo Valve
Lift Cylinder
Encoder
Top roll
position adjust
Knife Motor
Knife
position adjust
11
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12. UPGRADED KNIFE DRIVE (24GPM)

SECTION 2 - DESCRIPTION - CLIPPER FRAME - KNIFE DRIVE ASSEMBLY
N
M E
1
UPGRADED KNIFE DRIVE (24GPM)
Manifold
Knife Motor
24 GPM
Servo Valve
Return line
12 bit
Encoder
Relief port
12
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13. KNIFE LINKAGE

SECTION 2 - DESCRIPTION - CLIPPER FRAME - KNIFE DRIVE SHAFT
M
KNIFE LINKAGE
COUPLING
RADIAL
BEARINGS
KNIFE TENSION
CYLINDER
ENCODER
HYD. MOTOR
TENSION CYL
PRESSURE INLETS
THRUST
BEARING
13
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14. KNIFE DRIVE ASSEMBLY

SECTION 2 - DESCRIPTION - CLIPPER FRAME - KNIFE DRIVE SHAFT
M
KNIFE DRIVE ASSEMBLY
RADIAL
BEARINGS
MOTOR
COUPLING
SPINDLE
BUSHING
MOTOR
SHAFT
SPINDLE
SAFT
THRUST
BEARING
14
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15. KNIFE COUPLINGS ASSEMBLY

SECTION 2 - DESCRIPTION - CLIPPER FRAME - KNIFE DRIVE SHAFT
M
KNIFE COUPLINGS ASSEMBLY
GREASE POINT
TOGGLE PIN
KNIFE PINS
TOGGLES
KNIFE
SPINDLE
KNIFE CLAMPS
TOGGLE PIN
15
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GREASE POINT
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16. KNIFE BLADE

SECTION 2 - DESCRIPTION - CLIPPER FRAME - KNIFE BLADE
M
KNIFE BLADE
~40°
120”
3.75”
Minimum knife width is 3.25”
KNIFE ORIENTATION
VENEER FLOW
16
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17. KNIFE ENCODER ASSEMBLY

SECTION 2 - DESCRIPTION - CLIPPER FRAME - 8 BIT ENCODER
M E
KNIFE ENCODER ASSEMBLY
ENCODER MOUNTING
BLOCK
12 BIT
ENCODER
TINY MITE
COUPLING
CLAMP RING
17
THERMAL
INSULATION RING
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18. ANVIL ROLLS - IDLE SIDE VIEW

SECTION 2 - DESCRIPTION - CLIPPER FRAME - ANVIL ROLLS - TOP DRIVE VIEW
O M E
1
ANVIL ROLLS - IDLE SIDE VIEW
TOP-ROLL
BEARING
TOP ROLL
KNIFE
BOTTOM
ROLL
IN-FEED
DRIVECHAIN
18
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19. TOP ROLL ELECTRIC DRIVE

SECTION 2 - DESCRIPTION - CLIPPER FRAME - ANVIL ROLLS - TOP DRIVE VIEW
N M E
1
TOP ROLL ELECTRIC DRIVE
ELECTRIC
GEARMOTOR
ADJUSTING
BOLT
TOP ROLL
19
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20. BOTTOM ROLL ELECTRIC DRIVE

SECTION 2 - DESCRIPTION - CLIPPER FRAME - ANVIL ROLLS - BOTTOM DRIVE VIEW
N M E
1
BOTTOM ROLL ELECTRIC DRIVE
BOTTOM ROLL
ELECTRIC
GEARMOTOR
ADJUSTING
BOLTS
20
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21. TOP ROLL OFFSET

SECTION 2 - DESCRIPTION - CLIPPER FRAME - ANVIL ROLLS - TOP ROLL OFFSET
N M E
1
TOP ROLL OFFSET
CONTACT
POINTS
ROLL PRESSURE SETUP MUST BE DONE DIFFERENTLY!
21
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22. HPU GENERAL VIEW

SECTION 2 - DESCRIPTION - HYDRAULIC POWER UNIT - FLOW CONTROLS LOCATION
N O H M E
1
HPU GENERAL VIEW
Knife tension
pressure valve
Head UP-DOWN
valve
H6
H6
Main flow control
for rolls
Accumulators
H6
Oil cooling fan
22
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23. FLOW CONTROLS DETAIL

SECTION 2 - DESCRIPTION - HYDRAULIC POWER UNIT - FLOW CONTROL DETAIL
N O H M E
1
FLOW CONTROLS DETAIL
Knife tension
pressure valve
Roll Drives main
flow valve *
Head Up/Down
pressure valve
Roll Drives main
flow control *
* Not used with electric roll drives
23
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24. RAUTE CONTROLLER - 1

SECTION 2 - DESCRIPTION - CONTROLLER - CABINET
N
E
1
RAUTE CONTROLLER - 1
STATUS LAMPS
15” TOUCH SCREEN
COMPUTER
24
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25. RAUTE CONTROLLER - 2

SECTION 2 - DESCRIPTION - CONTROLLER - CABINET
N
E
1
RAUTE CONTROLLER - 2
NETWORK
CABLE
CLIPPER
COMPUTER
15” TOUCH SCREEN
COMPUTER
25
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26. RAUTE CONTROLLER - 3

SECTION 2 - DESCRIPTION - CONTROLLER - CABINET
N
E
1
RAUTE CONTROLLER - 3
SERVO VALVES
POWER SUPPLY
CLIPPER
COMPUTER
ATX COMPUTER
POWER SUPPLY
ROLL TACHOMETERS
INPUT BOARD
24 DC FUSES
AC INPUT AND FUSE
ANALOG OUTPUT
AND WATCH DOG
OUTPUT BOARD
DC/DC POWER UNITS
KNIFE ENCODERS
INPUT BOARD
SCANNER & PLC
I/O BOARD
SERVO VALVES &
ROLL VFD
26
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27. ROLLS VFD CABINET

SECTION 2 - DESCRIPTION - CONTROLLER - CABINET
N
E
1
ROLLS VFD CABINET
Control Signals
MAIN AC SWITCH
AC FUSES
BOTTOM ROLL VFD
TOP ROLL VFD
27
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28. CONTROLLER - I/O WIRING

SECTION 2 - DESCRIPTION - CONTROLLER - SIGNAL LEVELS
E
CONTROLLER - I/O WIRING
5 VDC
READY
Scanner
LHS
FIRE (CUT)
BLADE CONTACT
ENCODERS
RHS
RAUTE
ENABLE
Controller
RESET (HOME)
Console
LHS
VERTICAL
SERVO
VALVES
RHS
or PLC
0..10 VDC*
12 VDC
28
120 VAC
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29. ROLL SPEED CONTROL SIGNALS

SECTION 2 - DESCRIPTION - CONTROLLER - SIGNAL LEVELS
N
E
ROLL SPEED CONTROL SIGNALS
0..10 VDC
Raute
Clipper
Controller
ROLL
ENCODERS
5 VDC
TOP ROLL SPEED
BOTTOM ROLL SPEED
120 VAC
RUN COMMAND
Console
or PLC
DRIVE READY
ROLL
SPEED
VFD
CABINET
M
BOTTOM
M
DRIVE AT SPEED
GEAR
MOTORS
DRY CONTACT
29
TOP
1
2
V
D
C
400 VAC
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30. CONTROL LOGIC - PAGE 1 - AC

SECTION 2 - DESCRIPTION - CONTROL LOGIC - HARDWIRED - PAGE 1 -AC
E
CONTROL LOGIC - PAGE 1 - AC
KNIFE TENSION SW
30
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31. CONTROL LOGIC - PAGE 2 - AC

SECTION 2 - DESCRIPTION - CONTROL LOGIC - HARDWIRED - PAGE 2 - AC
E
CONTROL LOGIC - PAGE 2 - AC
31
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32. CONTROL LOGIC - PAGE 3 - DC

SECTION 2 - DESCRIPTION - CONTROL LOGIC - HARDWIRED - PAGE 3 - DC
E
CONTROL LOGIC - PAGE 3 - DC
32
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33. SECTION 3 CLIPPER THEORY

SECTION 3 - CLIPPER THEORY
N O M E
1
SECTION 3
CLIPPER THEORY
CLIPPER GOALS
• Exact clip point
•Parallel clips
• Match knife/roll speeds
• Minimize response time
• Straight clips (no bias)
OPERATION
• Knife positions
• Clip steps
• Clip cycle
• Clip zone
• Knife/roll speed mismatch effects
33
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34. KNIFE POSITIONS

SECTION 3 - CLIPPER THEORY - KNIFE POSITIONS
M E
1
KNIFE POSITIONS
BLADE ANGLE
HOME POSITION
CLIP POSITION B
285° (202)
TOP
ROLL
HOME POSITION A
0 ° (0)
15°
VENEER
FLOW
195°
KNIFE
15°
BLADE
ROTATION
HOME POSITION B
180° (127)
CLIP
POSITION A
105° (74)
34
BOTTOM
ROLL
There are two home positions separated by
half turn of the blade
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35. CLIP STEPS

SECTION 3 - CLIPPER THEORY - CLIP STEPS
M E
1
CLIP STEPS
1 - HOME POSITION (A)
Knife begins to move
upon receiving a FIRE
signal from scanner
TOP
ROLL
2 - CLIP POSITION
Knife in vertical position. Veneer
is clipped between the blade and
the bottom roll
3 - HOME POSITION (B)
Knife stops after rotating
half turn (180 degrees)
ROLL
ROTATION
TOP
ROLL
TOP
ROLL
KNIFE
KNIFE
ROTATION
CLIP
VENEER
BOTTOM
ROLL
0°
BOTTOM
ROLL
105°
ROLL
ROTATION
BOTTOM
ROLL
180°
VENEER FLOW
35
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36. CLIP CYCLE

SECTION 3 - CLIPPER THEORY - CLIP CYCLE
M E
1
CLIP CYCLE
TYPICAL CLIP
HOME POSITION B
180°
KNIFE POSITION
CLIP POINT
105°
FIRE SIGNAL
HOME POSITION A
0°
V1
V3
V2
VALVE
DRIVE
100%
V4
V5
0%
T1
0 ms
T2
13 ms
T3
40 ms
T4
54 ms
T5
70 ms
TIME
36
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37. CLIP ZONE

SECTION 3 - CLIPPER THEORY - CLIP ZONE
M E
1
CLIP ZONE
CLIP QUALITY IMPROVES WITH KNIFE SPEED
VERTICAL SPEED (VS) = R x W x cos (α)
BLADE CUTS EASIER THROUGH VENEER AS THE VS INCREASES
VS IS ALWAYS ZERO AT CLIPPING POINT
BLADE
FIRST CONTACT POINT
α
VENEER
BOTTOM ROLL
37
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38. KNIFE/ROLL SPEED MISMATCH

SECTION 3 - CLIPPER THEORY - KNIFE/ROLL SPEED MISMATCH
M E
1
KNIFE/ROLL SPEED MISMATCH
ROLL < KNIFE
LESS WEAR
ROLL > KNIFE
MORE WEAR
KNIFE CUTS THROUGH
KNIFE BANGS THE ROLL
38
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39. TYPICAL CLIP RESPONSE

SECTION 3 - CLIPPER THEORY - TYPICAL CLIP RESPONSE
E
TYPICAL CLIP RESPONSE
180°
105°
FIRE
KNIFE POSITION
500 FPM
0°
VALVE
DRIVE
100%
V1
V3
V2
V4
V5
0%
T1
0 ms
T2
13 ms
T3
40 ms
T4
54 ms
T5
70 ms
TIME
39
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40. SECOND CLIP CATCH-UP

SECTION 3 - CLIPPER THEORY - SECOND CLIP CATCH-UP
E
SECOND CLIP CATCH-UP
360°
Second
Clip
285°
Catch-Up
180°
First Clip
105°
KN
IF
E
PO
SI
TI
ON
0°
DRIV
E
100%
VALV
E
0%
V3
V1
V3
V6
V2
V2
V5
V4
T1
T2
T3 T6
T4
T3
T4
T5
FIRE
SIGN
AL
0
40
TIME
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41. TIME RESPONSE ADJUSTMENT

SECTION 3 - CLIPPER THEORY - TIME RESPONSE ADJUSTMENT
E
TIME RESPONSE ADJUSTMENT
180°
ON TARGET
105°
TOO LATE
TOO SOON
T1 T1 T1
HI OK LOW
GH
KN
IF
E
PO
SI
TI
ON
0°
V3
V1
100%
V2
V4
VALVE
DRIVE
T1
T2
TIME
FIR
E
D_LTIME1 = LEFT
D_RTIME1 = RIGHT
41
V5
0%
T3
T4
T5
PARAMETER: C_TIMTRK
FALSE=MANUAL MODE
TRUE=AUTO TRACK MODE
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42. SPEED RESPONSE ADJUSTMENT

SECTION 3 - CLIPPER THEORY - SPEED RESPONSE ADJUSTMENT
E
SPEED RESPONSE ADJUSTMENT
180°
105°
ON TARGET
TOO SLOW
KN
IF
E
PO
SI
TI
ON
TOO FAST
0°
V1
100%
V5
V4
0%
T1
T2
T3
T4
T5
TIME
VALV
E
DRIV
E
FIR
E
D_LVALV2 = LEFT
D_RVLAV2 = RIGHT
42
V3
V2
PARAMETER: C_SPDTRK
FALSE=MANUAL MODE
TRUE=AUTO TRACK MODE
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43. LANDING POSITION ADJUSTMENT

SECTION 3 - CLIPPER THEORY - LANDING POSITION ADJUSTMENT
E
LANDING POSITION ADJUSTMENT
HIGH
180°
OK
LOW
105°
KN
IF
E
PO
SI
TI
ON
0°
V1
100%
V3
V2
T1
T3
T2
TIME
VALVE
DRIVE
FI
RE
PARAMETER: C_LANTRK
FALSE=MANUAL MODE
TRUE=AUTO TRACK MODE
43
V5
V4
0%
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T4
T5
D_LTIME4 = LEFT
D_RTIME4 = RIGHT
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44. SECOND CLIP ADJUSTMENT

SECTION 3 - CLIPPER THEORY - SECOND CLIP ADJUSTMENT
E
SECOND CLIP ADJUSTMENT
360°
Second Clip
TOO BIG
285°
180°
TOO SMALL
First Clip
105°
0°
V3
V1
100%
V6
V2
V2
V5
V4
0%
KNI
FE
POS
ITI
ON
DRIVE
VALVE
T1
T2
T3 T6
0
T3
T4
T4
T5
TIME
FIRE
SIGNA
L
D_LVALV6 = LEFT
D_RVALV6 = RIGHT
44
V3
PARAMETER: C_2NDTRK
FALSE=MANUAL MODE
TRUE=AUTO TRACK MODE
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45. SPEED FACTOR

SECTION 3 - CLIPPER THEORY - SPEED FACTOR
E
SPEED FACTOR
180°
TOO BIG
105°
TOO SMALL
KNI
FE
POS
ITI
ON
0°
V3
V1
100%
V2
V4
0%
VALV
E
DRIV
E
T2
TIME
T3
T4
T5
FIRE
T1
V5
V2 = Vtarget / Speed Factor(DEFAULT)
V2 = Vtarget / Speed Factor (AUTO TRACK)
45
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D_LSPFAC = LEFT
D_RSPFAC = RIGHT
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46. ACCELERATION FACTOR

SECTION 3 - CLIPPER THEORY - ACCELERATION FACTOR
E
ACCELERATION FACTOR
180°
105°
TOO SMALL
KNI
FE
POS
ITI
ON
TOO BIG
0°
V1
100%
V3
V2
V4
0%
T1
T2…
TIME
T3
VALV
E
DRIV
E
FIR
E
T2-T1 = Vtarget / Accel Factor(DEFAULT)
(T2 –T1)= Vtarget / Accel Factor(AUTO TRACK)
46
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T4
V5
T5
D_LSPFAC = LEFT
D_RSPFAC = RIGHT
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47. KNIFE/ROLL SPEED MEASURE

SECTION 3 - CLIPPER THEORY - KNIFE/ROLL SPEED MEASURE
E
KNIFE/ROLL SPEED MEASURE
KNIFE SPEED
LOW
ZONE AFTER
CONTACT
ROLL SPEED
115°
ZONE BEFORE
CONTACT
KNIFE SPEED
E2
105°
KNIFE SPEED
HIGH
T2
E1
KNI
FE
POS
ITI
ON
95°
T1
Speed Before = E1/T1 . Knife Diam .
Speed After = E2/T2 . Knife Diam .
47
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48. NORMAL/SOFT LANDING

SECTION 3 - CLIPPER THEORY - NORMAL/SOFT LANDING
E
NORMAL/SOFT LANDING
NORMAL
180°
C_SOFLAN
NORMALFALSE
SOFTTRUE
SOFT
KNI
FE
POS
ITI
ON
0°
100%
FIRE
105°
V1
V3
V2
V4
0%
VALVE
OPENI
NG
T1
0 ms
T2
13 ms
T3
40 ms
T5
T4
54 ms 62 ms
V5
V5
T5
72 ms
TIME
48
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49. RESPONSE VERSUS KNIFE SPEED

SECTION 3 - CLIPPER THEORY - RESPONSE VERSUS KNIFESPEED
E
RESPONSE VERSUS KNIFE SPEED
Clip position (105°)
SPEED
~ 500 FPM
Max SPEED
~ 1200 FPM
Min TIME
~ 32 ms
49
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TIME
~ 40 ms
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50. SECTION 4 OPERATION

SECTION 4 - OPERATION
N O M E
1
SECTION 4
OPERATION
CLIPPER
CONSOLE
CONTROLLER
50
Operator’s PB and SW console
Raute controller cabinet
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2

51. CLIPPER CONSOLE LAYOUT

SECTION 4 - OPERATION - CONSOLE LAYOUT
M E
1
CLIPPER CONSOLE LAYOUT
4
1
2
5
INDICATOR
LAMPS *
3
6
*LAMPS BLINKING INDICATE FAULT
51
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52. STARTUP SEQUENCE

SECTION 4 - OPERATION - STARTUP SEQUENCE
M E
1
STARTUP SEQUENCE
1 - CLIPPER POWER ON
2 - HEAD DOWN
3 - HYDRAULIC PUMP ON
4 - KNIFE TENSION AUTO
5 - ROLLS ON
52
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53. STOP TO CLEAR SEQUENCE

SECTION 4 - OPERATION - STARTUP SEQUENCE
M E
1
STOP TO CLEAR SEQUENCE
2 - HEAD UP
1 - ROLLS OFF
DO NO ENTER THE CLIPPER AREA!!
53
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54. FULL STOP SEQUENCE

SECTION 4 - OPERATION - STARTUP SEQUENCE
M E
1
FULL STOP SEQUENCE
3 - CLIPPER POWER OFF
2 - HYDRAULIC PUMP OFF
1 - ROLLS OFF
54
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55. HMI - MAIN SCREEN

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI - MAIN SCREEN
TITLE
PANEL
PROGRAM
INFO
KNIFE
PANEL
CONTEXT
INFO
ROLLS
PANEL
CLIPPER
PANEL
COMMAND
PANEL
MENU
PANEL
55
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56. HMI MAIN SCREEN - KNIFE PANEL

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI MAIN SCREEN - KNIFE PANEL
VALVE OPENINGS AND NULL VALUES
CALCULATED
KNIFE WIDTH
LEFT SPINDLE
POSITION
KNIFE/ROLL
SPEED SET POINT
KNIFE/ROLL SPEED
TRACKING MODE
KNIFE RESPONSE
AVERAGE TIME
ACTUAL KNIFE
SPEED GAUGE
RIGHT SPNDLE
POSTION
VALVE AUTO-NULL
STATUS
SPINDLES STATUS
LEFT SIDE
56
RIGHT SIDE
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57. MAIN SCREEN - KNIFE STATUS

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
MAIN SCREEN - KNIFE STATUS
NORMAL CONDITION
DRIVE STATUS
TUNE STATUS
ENCODER
SPEED
MOTOR
TIME
VALVE NULL
LANDING
TIME OUT
SECOND CLIP
WARNING CONDITION
57
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58. HMI MAIN SCREEN - ROLLS PANEL

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI MAIN SCREEN - ROLLS PANEL
NORMAL CONDITION
ROLL WEAR STATUS
DRIVE STATUS
ROLL SPEEDS
DRIVE MODE
SET POINT
ROLL DIAMETERS
(CALCULATED)
ACTUAL SPEED
WARNING CONDITION
58
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59. HMI MAIN SCREEN - INFO PANEL

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI MAIN SCREEN - INFO PANEL
INFO WINDOW
NETWORK LINK
STATUS
59
LAST NETWORK
MESSAGE
LAST CLIPPER
MESSAGE
Version 1.0 - June 2006
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60. HMI MAIN SCREEN - BUTTONS

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI MAIN SCREEN - BUTTONS
COMMAND BUTTONS
CLIPPER
READY/ NON READY
MANUAL
FIRE
OK/CLEAR ALARM
DIAGNOSTICS
ACTIVE
MENU BUTTONS
60
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61. HMI - KNIFE SETUP SCREEN

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI - KNIFE SETUP SCREEN
ACTUAL VALUES
CLIP
PARAMETERS
AUX.
CTRLS.
TUNE CONTROLS
COMMANDBUTTONS
61
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62. HMI - ROLLS SETUP SCREEN

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI - ROLLS SETUP SCREEN
TOP
ROLL
BOTTOM
ROLL
BUTTONS
BACK TO PREVIOUS SCREEN
62
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63. HMI - TOP ROLL SETUP PANEL

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI - TOP ROLL SETUP PANEL
LOOP VALUES
PHYSICAL PARAMETERS
OUTPUT SIGNAL
ROLL TACHOMETER PARAMETERS
63
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64. HMI - GRAPHICS SCREEN

SECTION 2 - DESCRIPTION - CONTROLLER SCREENS
N
E
1
HMI - GRAPHICS SCREEN
HOME
POSITION B
POSITION AXIS
(DEGREES)
CLIP
RESULTS
SPEED ZONES
after
CLIP POINTS
HOME
POSITION A
before
TIME AXIS (MS)
HOME
POSITION B
64
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65. HMI - DIAGNOSTICS SCREEN

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI - DIAGNOSTICS SCREEN
TEST
SELECTOR
VALVE
NULL
MOVE TO
POSITION
BUTTONS
65
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66. HMI - DIAGNOSTICS SCREEN

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI - DIAGNOSTICS SCREEN
SIDESELECTORS
ENCODER
POSITIONS
ENCODER
STATUS BITS
MOTOR TEST
SPEED RESULT
ADJUST
BUTTONS
MOTOR TEST PARAMETERS
66
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67. HMI - DATA TABLE SCREEN

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI - DATA TABLE SCREEN
ANALOG
VALUES
BOOLEAN
VALUES
ANALOG
NAVIGATION
BOOLEAN
NAVIGATION
SYSTEM
LOG
COMM
MESSAGES
MENU NAVIGATION
67
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68. HMI - MIS SCREEN

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI - MIS SCREEN
68
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69. HMI - MOISTURE SCREEN

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI - MOISTURE SCREEN
69
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70. HMI - MOISTURE SETUP SCREEN

SECTION 2 - DESCRIPTION - CONTROLLER - SCREENS
N
E
1
HMI - MOISTURE SETUP SCREEN
70
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71. SECTION 5 MAINTENANCE

SECTION 5 - MAINTENANCE
N O M E
1
SECTION 5
MAINTENANCE
QUICK CHECKS
HYDRAULIC SETUP
Adjusting the hydraulic pressures
ROLL ALIGNMENT
Vertical alignment
Horizontal alignment
ROLL SPEED SETUP
Match roll speed to knife speed
KNIFE HANDLING
Removal/Installation
Setup
ENCODERS SETUP
71
Roll wear
Servo, Spindles RPM
Filters
Shafts and bearings
General procedure
Only one spindle removed
Encoder replacement
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72. ROLL WEAR & MISALIGNMENT

SECTION 5 - MAINTENANCE - QUICK CHECKS - ROLL WEAR
M
ROLL WEAR & MISALIGNMENT
CLIPPER MUST BE LOCKED OUT FOR THIS PROCEDURE!
1/2
6”
1/2
6”
MEASURE CIRCUMFERENCE AT THREE POINTS
ROLL
LEFT
CENTER
RIGHT
34.6”
34.25”
34.4”
AVERAGE OF LEFT/RIGHT = (34.6” + 34.4)/2 = 34.5”
ROLL WEAR (L,R - CENTER) = 34.5” - 34.25 = 0.25”
ROLL VERT. MISSALIGNMENT (L-R) = 34.6” - 34.4 = 0.2”
EXAMPLE VALUES !
72
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73. OIL FILTERS, CLASSIC CLIPPER

SECTION 5 - MAINTENANCE - QUICK CHECKS - FILTERS
O M
1
OIL FILTERS, CLASSIC CLIPPER
REPLACE FILTERS
EVERY 3 MONTHS
LOW PRESSURE FILTER
HIGH PRESSURE FILTERS
(ONE PER SPINDLE) *
* Not present in upgraded clipper
73
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74. SPINDLES TOGGLES

SECTION 5 - MAINTENANCE - QUICK CHECKS - SPINDLES SAFT AND BEARINGS
M
SPINDLES TOGGLES
WEARING POINTS
KNIFE
SPINDLE
74
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75. SPINDLES BUSHINGS

SECTION 5 - MAINTENANCE - QUICK CHECKS - SPINDLES SAFT AND BEARINGS
M
SPINDLES BUSHINGS
RADIAL
BEARINGS
COUPLING
SPINDLE
SAFT
THRUST
BEARING
75
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76. HYDRAULICS SETUP - 1

SECTION 5 - MAINTENANCE - QUICK CHECKS - HYDRAULICS SETUP 1
H
2
HYDRAULICS SETUP - 1
Roll speed fine
adjustment
Servo
valve
Safety valve
Cross
port
relief
• Main pressure to
servo valve and
knife
• Always close when
changing or
working on any
part of the knife
assembly
• Valve is shown in
the OPEN position
• It may be located
as shown or on the
hydraulic reservoir
High-pressure filter 3 micron *
* Not present in upgraded clipper
76
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77. HYDRAULICS SETUP - 2

SECTION 5 - MAINTENANCE - QUICK CHECKS - HYDRAULICS SETUP 2
M
HYDRAULICS SETUP - 2
H1
Pressure gauge
H6
H2
Main relief valve
Pump compensator
Adjust to 1750-1800 PSI
reading on H1
Hydraulic pump
77
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78. HYDRAULICS SETUP - 3

SECTION 5 - MAINTENANCE - QUICK CHECKS - HYDRAULICS SETUP 3
M
HYDRAULICS SETUP - 3
Knife tension
pressure valve
Adjust to 550-600 PSI
Main flow control for rolls
Adjust for required roll speed
H6
H6
Accumulators
H6
Head UP/Down
pressure valve
Adjust to 900-1000 PSI
Cooling fan
78
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79. ROLL ALIGNMENT PROCEDURE

SECTION 5 - MAINTENANCE - ROLL ALIGNMENT PROCEDURE
M
ROLL ALIGNMENT PROCEDURE
ROLL ALIGNMENT TOOL SET *
TAIL END T-BAR
SLEEVE
DRIVE END T-BAR
* NOTE: There is a different set of T-bars for the clipper with top offset roll
79
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80. ROLL ALIGNMENT - GOALS

SECTION 5 - MAINTENANCE - ROLL ALIGNMENT GOALS
M
ROLL ALIGNMENT - GOALS
Adjust
TOP
Adjust
Adjust
BOTTOM
Adjust
80
VERTICAL
ALIGNMENT
HORIZONTAL
ALIGNMENT
Rolls and spindle axis
must be aligned
Rolls must be parallel
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81. ROLL ALIGNMENT - SETUP

SECTION 5 - MAINTENANCE - ROLL ALIGNMENT PROCEDURE - VERTICAL
M
ROLL ALIGNMENT - SETUP
1 - Head UP
HEAD UP
2 - Raise rolls
& knife
3 - Head DOWN
Roll UP
(10-15 turns)
HEAD DOWN
Knife UP
(10-15 turns)
HYDRAULICS ON!
81
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82. VERTICAL ROLL ALIGNMENT - 1

SECTION 5 - MAINTENANCE - ROLL ALIGNMENT PROCEDURE - VERTICAL
M
VERTICAL ROLL ALIGNMENT - 1
4 - Set T-bar & Level
~Horizontal*
Visible gaps
No gaps
(<0.002”)
* USE ONLY MACHINIST GRADE LEVEL
82
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83. VERTICAL ROLL ALIGNMENT - 2

SECTION 5 - MAINTENANCE - ROLL ALIGNMENT PROCEDURE - VERTICAL
M
VERTICAL ROLL ALIGNMENT - 2
5 - Adjust rolls
Make Horizontal
Adjust
Gap
No gaps
(<0.002”)
Gap
Adjust
83
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84. HORIZONTAL ROLL ALIGNMENT - 1

SECTION 5 - MAINTENANCE - ROLL ALIGNMENT PROCEDURE - HORIZONTAL
M
HORIZONTAL ROLL ALIGNMENT - 1
6 - Lower Knife
Keep Horizontal
No gaps
(<0.002”)
HYDRAULICS ON!
84
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85. HORIZONTAL ROLL ALIGNMENT - 2

SECTION 5 - MAINTENANCE - ROLL ALIGNMENT PROCEDURE - HORIZONTAL
M
HORIZONTAL ROLL ALIGNMENT - 2
7 - Lower Top Roll
No gap at least
in one side
Keep Horizontal
HYDRAULICS ON!
85
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86. HORIZONTAL ROLL ALIGNMENT - 3

SECTION 5 - MAINTENANCE - ROLL ALIGNMENT PROCEDURE - HORIZONTAL
M
HORIZONTAL ROLL ALIGNMENT - 3
8 - Adjust Top roll
T-Bar
No gaps in T-Bar
<0.002”
T-Bar
HYDRAULICS ON!
86
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87. ROLL SPEED SETUP - GOALS

SECTION 5 - MAINTENANCE - ROLL SPEED SETUP
O M
ROLL SPEED SETUP - GOALS
ROLL SPEEDS MUST BE EQUAL
TO KNIFE SPEED
TYPICAL KNIFE SPEED
VALUES
430 TO 480 FPM
87
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88. ROLL SPEED SETUP - 1

SECTION 5 - MAINTENANCE - ROLL SPEED SETUP
O M
ROLL SPEED SETUP - 1
FROM PUMP
COARSE FLOW
(IN HPU)
BOTTOM
MOTOR
BOTTOM BYPASS
TOP
MOTOR
TOP BYPASS
HYDRAULIC
UNIT
CLIPPER
FRAME
RETURN TO TANK
88
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89. ROLL SPEED SETUP - 2

SECTION 5 - MAINTENANCE - ROLL SPEED SETUP
O M
ROLL SPEED SETUP - 2
FROM PUMP
EXAMPLE VALUES !
ADJUST SPEED OF
SLOWEST ROLL
SLOWEST ROLL
(480 FPM)
BOTTOM
MOTOR
FULLY CLOSED
FASTEST ROLL
(500 FPM)
TOP
MOTOR
FULLY CLOSED
RETURN TO TANK
89
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90. ROLL SPEED SETUP - 3

SECTION 5 - MAINTENANCE - ROLL SPEED SETUP
O M
ROLL SPEED SETUP - 3
FROM PUMP
SLOWEST ROLL
(480 FPM)
BOTTOM
MOTOR
FASTEST ROLL
(500 --> 480 FPM)
TOP
MOTOR
EXAMPLE VALUES !
FULLY CLOSED
FINE TUNE SPEED OF
FASTEST ROLL
RETURN TO TANK
90
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91. ROLL SPEED SETUP - 4

SECTION 5 - MAINTENANCE - ROLL SPEED SETUP
O M
ROLL SPEED SETUP - 4
LINE FROM TOP
HYD. MOTOR
LINE TO TOP HYD.
MOTOR
CASE DRAIN
RELIEF VALVE
HYD. MOTOR
CASE DRAIN
BOTTOM ROLL
NEEDLE VALVE
CASE DRAIN
RETURN LINE
TOP ROLL
NEEDLE VALVE
PRESS. LINE FROM
PUMP
LINE TO BOTTOM
HYD. MOTOR
91
RETURE LINE TO
TANK
LINE FROM BOTTOM
HYD. MOTOR
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92. ROLL SPEED SETUP - 5

SECTION 5 - MAINTENANCE - ROLL SPEED SETUP
N
M
ROLL SPEED SETUP - 5
92
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93. KNIFE HANDLING SETUP

SECTION 5 - MAINTENANCE - KNIFE SETUP
M
2
KNIFE HANDLING SETUP
1 - Head UP
and Secure
2 - Hydraulics OFF
3 - Shut-off valve OFF
ONLY WITH NEW
RAUTE CONTROLLER
DISCHARGE VALVE CLOSED
AND LOCKED OUT
93
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94. KNIFE REMOVAL

SECTION 5 - MAINTENANCE - KNIFE REMOVAL
M
KNIFE REMOVAL
REMOVE THESE
NUTS FIRST
KNIFE CLAMP
KNIFE
SPINDLE
94
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95. KNIFE INSTALLATION - 1

SECTION 5 - MAINTENANCE - KNIFE INSTALLATION - 1
M
KNIFE INSTALLATION - 1
INSTALL KNIFE CLAMP
OUTSIDE THE CLIPPER
MATCH MARKS ALIGNED
IN BOTH SPINDLES
KNIFE
KNIFE ORIENTATION
SPINDLE
FLOW
95
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96. KNIFE INSTALLATION - 2

SECTION 5 - MAINTENANCE - KNIFE INSTALLATION - 2
M
2
KNIFE INSTALLATION - 2
1 - Head UP
2 - Raise top roll
and knife
1
Roll UP
(10-15 turns)
3 - Knife Tension ON
4 - Lower Head
5 - Check toggles
4
3
Knife UP
(10-15 turns)
3
5
2
HYDRAULICS ON!
96
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97. KNIFE SETUP

SECTION 5 - MAINTENANCE - KNIFE SETUP
M
KNIFE SETUP
2 - LOWER THE TOP ROLL
2
2
1
1 - LOWER THE KNIFE
1
HYDRAULICS ON!
97
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98. KNIFE ENCODER

SECTION 5 - MAINTENANCE - ENCODER ASSEMBLY
M E
KNIFE ENCODER
MOUNTING DETAIL
98
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2

99. TINY-MITE COUPLING

SECTION 5 - MAINTENANCE - KNIFE ENCODER COUPLINGS
M E
TINY-MITE COUPLING
COUPLING
DISC
3/8” CLAMP
558-9502
1/4” CLAMP
558-9500
558-9501
558-9503
3/8”
COUPLING
99
1/4”
COUPLING
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100. ENCODER COUPLING ASSEMBLY

SECTION 5 - MAINTENANCE - KNIFE ENCODER COUPLINGS
M E
ENCODER COUPLING ASSEMBLY
ENCODER
SHAFT (3/8”)
COUPLING
DISC
3/8”
COUPLING
100
MOTOR
SHAFT (1/4”)
1/4”
COUPLING
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101. LUBRICATION

SECTION 5 - MAINTENANCE - LUBRICATION
M
2
LUBRICATION
L4
L4
4
L1
L2
L3
USE ONLY GREASE TELLUS _________ OR EQUIVALENT!
101
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102. Section 6 TROUBLESHOOTING

SECTION 5 - TROUBLESHOOTING
N O M E
1
Section 6
TROUBLESHOOTING
GENERAL
Normal failures
Threshold failures
QUICK GUIDE
Symptom
Cause
Solution
CONTROLLER BASED
Diagnostics tests
Graphics
102
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103. GENERAL

SECTION 5 - TROUBLESHOOTING - GENERAL
M E
GENERAL
NORMAL FAILURES
• Originated by a single element (e.g.: broken spindle)
• Easy to diagnose
• Direct fixing by repair/substitution of parts
THRESHOLD FAILURES
• Multiple origins (e.g: Bias clip)
• Effects only seen after a certain “threshold” is passed
• Difficult to diagnose
• Multiple actions required to fix the problem
103
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104. QUICK GUIDE - EXAMPLE

SECTION 5 - TROUBLESHOOTING - QUICK GUIDE - EXAMPLE
M E
QUICK GUIDE - EXAMPLE
Response time
SYMPTOM
PROBABLE CAUSE
ACTION
Response time above 42 ms on
both sides
Low hydraulic pressure
Adhust pump to 1800 psi
of higher
Low clipping speed
Adjust rolls and knife
speed to 450 fpm or
higher
Local accumulator discharged
Recharge or replace
accumulator
Thrust bearing with excessive
drag
replace bearing
Faulty servo-valve
Replace servo-valve
Faulty motor
replace motor
Mechanical failure in the
slowest spindle (motor,
bearing, coupling)
repair
Faulty servo-valve
Replace servo-valve
Response time above 42 ms only
on one side
Response time difference between
sides greater than 2 ms
104
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105. THRESHOLD ISSUES - EXAMPLE

SECTION 5 - TROUBLESHOOTING - THRESHOLD ISSUES - EXAMPLE
M E
THRESHOLD ISSUES - EXAMPLE
BIAS CLIP
• Symptoms: Veneer sheets are not perfect rectangles but
parallelograms.
• Possible causes
A. Spindles with different response times (1 ms ~ 0.1 in @ 500 FPM)
B. Outer in-feed belts with different speeds in both sides. Worn belt is a
typical cause.
C. Hold down belts with different gap in each side. Incorrect hold down
alignment.
105
Solution: Multiple actions may be required.
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106. Section 6 DIAGNOSTICS - ENCODER

SECTION 5 - TROUBLESHOOTING - DIAGNOSTICS - ENCODER
N
M E
Section 6
DIAGNOSTICS - ENCODER
2
1
4
3
106
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107. Section 6 DIAGNOSTICS - MOTORS

SECTION 5 - TROUBLESHOOTING - DIAGNOSTICS - MOTORS
N
M E
Section 6
DIAGNOSTICS - MOTORS
2
1
6
3
4
5
107
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108. GRAPHIC OF A NORMAL CLIP

SECTION 6 - TROUBLESHOOTING - GRAPHICS - NORMAL CLIP
N
M E
GRAPHIC OF A NORMAL CLIP
CLIP
RESULTS
CLIP POINT
HOME
POSITION A
HOME
POSITION B
108
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109. LEFT ENCODER FAILURE

SECTION 6 - TROUBLESHOOTING - GRAPHICS
N
M E
LEFT ENCODER FAILURE
TRACE DIP
109
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110. LEFT ENCODER BACKLASH

SECTION 6 - TROUBLESHOOTING - GRAPHICS
N
M E
LEFT ENCODER BACKLASH
FLAT LINE
DETAIL
110
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111. RIGHT MOTOR LAGGING

SECTION 6 - TROUBLESHOOTING - GRAPHICS
N
M E
RIGHT MOTOR LAGGING
CLIP STILL OK
HOME
POSITION A
MOVEMENT DELAYED
111
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112. RIGHT COUPLING PROBLEM

SECTION 6 - TROUBLESHOOTING - GRAPHICS
N
M E
RIGHT COUPLING PROBLEM
ENCODER MOVING
BACKWARDS
SUDDEN
START
112
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113. Section 7 APPENDIX

SECTION 7 - APENDIX
Section 7
APPENDIX
113
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114. PARTS

SECTION 7 - APENDIX
PARTS
QUALITY RAUTE PARTS
114
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115. PARTS & SERVICE

SECTION 7 - APENDIX
PARTS & SERVICE
PARTS & SERVICE PHONE NUMBERS
115
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