Razorgage Cyclone RazorOptimal User manual

Cyclone RazorOptimal User Manual
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CYCLONE
RAZOROPTIMAL
SAW SYSTEM

Cyclone RazorOptimal User Manual
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Table of Contents
General Safety Rules for Woodworking Machinery...............................................4
Safety Rules for Cut Off Saw ..................................................................................6
Arrival Inspection ...................................................................................................7
Installation .............................................................................................................8
Leveling.....................................................................................................9
Anchoring .................................................................................................9
Infeed/Outfeed Tables ............................................................................10
Electrical Power Connection....................................................................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 .........................................................31
Vertical Clamp Flow Controls ..................................................................32
Vertical Clamp Stroke Distance ...............................................................33

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Guide Rollers...........................................................................................33
Back Fence ..............................................................................................34
Squaring Back Fence 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

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General Safety Rules for Woodworking Machinery
WARNING
The operator must 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.
1. For your own safety, read the operation manual carefully. Know your machine. Learn its
applications and limitations, and any hazards specific to this machine. All personnel should be
trained in the operational procedures and received safety instruction before operating this
equipment. If you have not received proper training in the use of this machine, DO NOT
OPERATE THIS MACHINE, damage to the equipment or injury to the operator is possible.
2. This machine should not be operated without all of the guards in place and safety devices in
operation. Removal of any guards or disabling any of the safety devices may result in damage
to the equipment or injury to the operator. If any of the guards or safety devices are missing,
damaged or not working properly, DO NOT OPERATE THIS MACHINE, notify your supervisor
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 machine,
DO NOT OPERATE THIS MACHINE, damage to the equipment or injury to the operator is
possible.
5. In case of any equipment malfunction or jam the machine should be powered off and locked out
before clearing any materials from the operational areas of this machine. Once cleared the reset
procedures need to be followed when powering up the equipment. At no time should any of the
machine control systems including electrical, hydraulic or pneumatic circuits be manually
overridden.
6. Check machine for damaged parts. Before continued machine use any damaged guard or part
must be carefully checked for proper operation of its intended function. Check all moving parts
for proper alignment, check for binding of moving parts, breakage of parts, proper secure
mounting, and any other condition that may affect machine operation. Guards or other parts that
are damaged must be properly repaired or re-placed.
7. Machine must be properly grounded.

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8. Maintain and clean machine at recommend intervals. Intervals may need to be adjusted due to
work load or material type to keep machine in top condition. Follow instructions for lubrication,
setup, and changing accessories
9. Disconnect machine from power source before, changing accessories, or any servicing activity.
10. Avoid accidental starting. Make sure switch is in the off position before connecting to power.
11. Remove any tools or loose objects from work surface of machine. Make sure any tools used for
adjustment or maintenance are removed from machine before machine is restarted. Make a
habit of scanning for tools and scraps every time the machine is started.
12. Keep work area clean. Cluttered work areas and workbenches increase the likelihood of an
accident.
13. Do not use in dangerous environments. Do not use machine in damp or wet locations, or expose
them to rain. Keep work area well illuminated.
14. Keep children away. All visitors should 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 machine’s
suitability for a particular job.
18. Use only recommended accessories. Consult the operation manual for recommended
accessories.
19. Wear proper apparel. Avoid loose clothing, gloves, neckties, rings bracelets, or jewelry which
could be tangled in moving parts. Keep long hair contained to prevent entanglement. Non-slip
footwear is recommended.
20. Always wear safety glasses.
21. Secure the work piece.
22. Keep proper footing and balance at all times.
23. Do not use machine while under the influence of drugs, alcohol, or any medication.
24. Always wear a face mask or dust mask if operation creates excessive dust or chips. Always
operate machine in a well-ventilated area and provide proper dust removal.
25. Never leave machine running unattended. Turn power off. Do not leave machine until it comes
to a complete stop.

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Safety Rules for Cut-off Saw
WARNING
The operator must 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.
1. Read and understand the operation manual before operation.
2. Keep hands away from the cutting area.
3. Before making any adjustments disconnect all power sources including electrical and
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 not cut warped wood; work piece should lay flat on table without rocking.
7. Use infeed and outfeed supports when cutting long work pieces.
8. Set top clamp to minimum close height for material being processed.
9. Short trim scraps should only be removed by pushing them out with a scrap piece and NOT
with hands.

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Arrival Inspection
WARNING
The operator must 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.
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 operate saw without all components
present and in undamaged condition.

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Installation
WARNING
The operator must 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.
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 adjust feet to bring table into level position.

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Leveling
To ensure product moves freely through the saw system, it is important to level the saw. After the saw
has been located the saw can be leveled. Place the level on top of the saw adjacent to the back fence
to check for level side-to-side. To check level front to back place 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 system components aligned to each other. The saw has four mounting feet
located on the corners of the saw. Recommend using 3/8” x 12” anchor bolts.

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Infeed/Outfeed Tables
The Cyclone RazorOptimal comes with table attachment brackets for mounting the infeed and outfeed
tables. Use the diagram below to first bolt the table attachment bracket to the saw and then attach the
table. After attaching the tables to the saw make sure to level them. There are leveling adjustment bolts
on the table legs 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 10A supply. Check that your supply lines match the labeled voltage and the circuit
protection and wire gauge is adequate. Connect wires to the disconnect inside the electrical enclosure
as shown in pictures below.

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Electrical Interface Connections
The Cyclone Optimal system used a RazorGage automated positioner. To connect the RazorGage to
the Cyclone saw an interface cable, valve cable, crayon sensor cable, and board sensor cable will need
to be connected. The interface cable and valve bank cables are prewired from 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 terminals on the board. The
printer has a power cord that plugs into the power strip at the bottom on the tower and also an ethernet
cable that plugs into the crayon board.

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Air Supply Connection
The saw requires an 80 - 120 PSI compressed air supply connection. Connect air supply line to the
FRL located on the back side of the saw as shown below.
Pneumatic 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 two air lines if the
pusher operates backwards.

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Dust Collection
This saw requires dust collection to keep saw dust from collecting on the machine. Vacuum with the
minimum capacityof 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.

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Setup Procedure
Set the Home Offset (PUSHER TO SAW AT LOW LIMIT). Follow the steps below after starting the
software and homing the machine.
Touch in the MOVE TO POSITION box, enter the number 16, touch the MOVE ONLY radio button, and
press GO. Now take a board longer than 16” 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 POSITION and the
measured length of the part as the MEASURED PART LENGTH. Press CALIBRATE and then press
CLOSE You have now set the home offset.

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Calibration Screen
NOTE: The scale factor will be set at the factory and only needs to be modified if the parts get
incrementally smaller or larger than nominal as the pusher advances. Now that you have set the
Home Offset, the next step is to set the Scale Factor. Again, use the SAW STOP screen. Find the
longest, straightest piece of stock you can find and square one end. Measure the remaining length,
subtract an inch or two from it, and enter that length in the MOVE TO POSITION box. Highlight the
MOVE ONLY radio button and press GO. Now put the long piece of stock against the fence with the
squared end against the stop. 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 MAIN SCREEN press MORE, PARAMETERS,
ENCODER. Record the SCALE FACTOR along with the other information mentioned above. Go to the
jump drive that came with your machine or go to our website, www.razorgage.com/downloads and locate
the SCALE FACTOR CALCULATOR PROGRAM. Open the program and enter the information you
recorded and click CALCULATE. Enter the recommended scale factor in the ENCODER SCALE box on
the ENCODER screen of the PARAMETERS menu.
Encoder Parameters Scale Factor Calculator

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PUSHER TO SAW AT LOW LIMIT –This value is the home offset and is set through the machine
calibration process. Default is 0.5 inches
LOW LIMIT –This value is the lowest position that the RazorGage is capable of moving. It does
not need to be modified and cannot be selected from this screen.
HIGH LIMIT –This value is the highest position that the RazorGage is capable of moving. It
does not need to be modified and cannot be selected from this screen.
FIRST MOVE/CLAMP POSITION –The position from the end of the board to the saw at which
the infeed clamp will begin to activate. Default is 3 inches.
CLAMP SWITCH POSITION –When the pusher position 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 left-hand side of the screen. These parameters control the
speed, acceleration, and deceleration of the RazorGage. The MOVE TO RUN START SPEED is the
first move of the board run. It is an intentionally slower move to keep the board close to the back fence
until it is supported by the guide rollers and side clamps. RUN CURRENT is the percentage of current
applied to the motor which determines the effective torque of the RazorGage movement. Set the
parameters to the values shown below.
Motion Parameters

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Press the SAW button on the left-hand side of the screen and set the timer values as shown below. To
determine the kerf, measure a short board with square ends, saw it in two, put the two pieces together
and measure the overall length of the resulting two pieces. The difference between the original length of
the board and the length of the two boards together is the kerf.
Saw Parameters
SAW KERF –This value is the length of material the saw blade removes with each cut. If all
part lengths are off by the same amount from nominal dimension then the saw kerf may need to
be adjusted.
SAW CLAMP TIMER –This is the delay time after vertical clamp is activated before the saw
advance is activated. Because there is no sensor for the vertical clamp, this timer will need to be
set to 300ms at minimum. The vertical clamp needs to be fully engaging the part before saw is
advanced. If either the vertical clamp flow controls or stop position are adjusted this value may
need to be increased.
SAW TIMER –This is the delay time after saw advance is activated before the saw is
deactivated. The new saw versions have sensors to monitor saw position so this timer value
need to be set to 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 also found in the picture below. After a scan
the pusher arm should drop behind the stock material with the retaining plate on top of the board and the
main plate behind the end of the stock, shown in the diagram below. If you are noticing after scanning
that the main plate of the pusher arm (or flyswatter) is dropping down on top of the board or if the retaining
plate is not above the end of the stock material then there is likely a problem with either with the board
end sensor or the value entered in the PUSHER LENGTH parameter. If the flyswatter main plate is
dropping on top of the stock, increase PUSHER LENGTH. If it is going too far back and the flyswatter
stock retaining plate is dropping down behind the part then decrease the PUSHER LENGTH. When the
pusher or flyswatter drops down behind the stock, it should be positioned as shown in the diagram below.
There is a video that describes how to adjust the length sensor. Here is a link:
http://www.youtube.com/watch?v=3YqQzSEUVAw&list=UU7xgOZ6NMc1M3123BY-
UtgA&feature=share&index=2

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Scan Parameters
SCAN START POSITION (FROM LOW LIMIT) –This variable is the length of material the saw
blade removes with each cut. If all part lengths are off by the same amount from nominal
dimension then the saw kerf may need to be adjusted.
SCAN SPEED –The speed in inches/sec at which the RazorGage moves during scanning.
Default speed is 40 inches/sec.
PUSHER LENGTH –This is the length from the scan load side of the pusher to the process load
side of the pusher arm. See picture above. This value is used by the program to determine
where to drop the pusher after scanning. If the pusher is dropping on the end of the part increase
this value. Decrease this value if the pusher is dropping 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 can be setup for encoder pulses or inches. Default is inches.
AFTER SCAN IS DONE –This option changes the machine sequence after a scan. The first
option moves the RazorGage to the Run Start position then dropped the pusher arm. The
second (default) option is opposite. It drops the pusher arm and then move the RazorGage to
the Run Start position.
MINIMUM TRIM AT START –This variable is the minimum trim amount if the board has no
crayon marks. This value cannot be smaller than the scan end of board gap (approximately
0.250”). Default value is 0.750 inches.

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If you have the Raz-Array option, press the RAZ-ARRAY button on the left-hand side of the screen. The
description of the variables is below. Use APPLY CHANGES button to update changes to parameters.
SELECT THE FIELD… –Use the dropdown list to select field in the cutlist that contains the Raz-
Array bin numbers.
SWITCH THE ROW DIRECTION –Check this box to change row #1 from the top to the bottom.
SWITCH THE COLUMN DIRECTION –Check this box to change column #1 from the left to the
right.
SELECT HOW THE BINS ARE LAYED OUT –Horizontally layout is where the bins count up
horizontallyfirst 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 current bin and bin que.
Activates bin #1 and populates the que with sequential bins from 2 –maximum. Use the
SIMULATE NEXT BUTTON to set through testing bins.
Raz-Array Parameters
These settings should get your machine into good operating condition. Fine tuning some of these
parameters may be necessary to customize the machine’s operation to your needs.