XQK/G Series

Electronic Cutter

User
Manual

Nantong Tongji Co., Ltd

www.tongji-china.com
 Use Manual - XQK/G Series Electronic Cutter

0. INTRODUCTION
0.1 SINCERE THANKS

Sincerely thanks for using our machine.

In order to use the machine at its best efficiency and protect the safety of the
machine operators, we suggest you read this machine user manual carefully,
because it will not only enable you to have a better understanding of the machine, but
also guide you to install, test, use and maintain the machine in the correct way, so that
the machine can give the best efficiency, and benefit your company most.
If you have any opinions and suggestions to this machine or you need our service,
please feel free to contact us.
Please communicate with us through following ways:

Nantong Tongji Co., Ltd

Add: No 19 Dasheng road, Gangzha District, Nantong Jiangsu, China
Phone: 0086-513-85059019, 0086-513-85059027; Fax: 0086-513-85656922
E-mail: sales@tongji-china.com

0.2 CUSTOMER AND MACHINE INFORMATION

Your information has been registered to our customer information system, as well
as the machine information. Whenever you need help, please provide us with the
following information:
Customer

Machine
Model Number:
Date of Manufacture:
Serial Number:
Power: V Hz Phase Wire

0.3 AIM OF THE USER’S MANUAL

This manual is provided to the customer together with the machine and is aimed
to provide the user with all the information required to:
Help the customer and operators understand the machine.
Inform the machine operator of all the safety precautions to be taken.
Handle the packed and unpacked machine safely.

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Install the machine correctly.

Inform the operator of the machine characteristics and how it works.
Operate the machine safely.
Perform the change-over procedures and maintenance properly and safely.
Know some common knowledge of trouble shooting.
Put the machine out of service safely and in compliance with current
regulations as regards the operators’ health and safety, as well as the
environmental protection.
The customer and the factory manager have the responsibility to carefully read
and understand the instructions contained in this manual as recommended by current
safety regulations. Besides, the machine operators and maintenance people should
also read and understand the parts of this manual dealing with the jobs they have to
perform, and get trained and qualified by the customer before they operate/maintain
this machine.
This manual assumes that current safety rules and sanitary regulations are
observed in the plant where the machine is to be installed. And reading and
understanding this manual will guarantee trouble-free operation and safe working
conditions.
The instructions, illustrations and technical documentation contained here are
the property of Nantong Universal Machinery Co., Ltd and can’t be reproduced or
transmitted in any form.
Furthermore, the customer should be certain that only copies of this manual that
have been updated by the supplier are given to the machine operators.

0.4 HOW TO USE THIS USER’S MANUAL

All pages in this manual are numbered and the page number is indicated at the
right below part of each page. When referring the manual, the user should first review
the TABLE OF CONTENTS to find the related chapter and its start page number, and
then the user can go the page and start to review the detailed information.
If the user can not find the satisfying information or find something wrong, please
communicate with the supplier for clarification before any actions that may cause
danger.

0.5 HOW TO KEEP THIS USER’S MANUAL

One electronic copy and one hard copy of the manual will be provided to the
customer with the machine. The manual should be kept with the utmost care and
accompany the machine wherever and whenever, even when the machine is sold.
The electronic copy of the manual should be kept in the customer computer or a
CD/DVD. The hard copy of the manual should be prevented from any damage or
contamination, such as fire, moisture, oil, etc, and the user should take care of it and
don’t touch it with dirty hands or put it in dirty environment.
Do not change anything of the manual.

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TABLE OF CONTENT
0. INTRODUCTION ............................................................................................................................................. 2

0.1 SINCERE THANKS .................................................................................................................................... 2

0.2 CUSTOMER AND MACHINE INFORMATION ....................................................................................... 2
0.3 AIM OF THE USER’S MANUAL............................................................................................................... 2
0.4 HOW TO USE THIS USER’S MANUAL ................................................................................................... 3
0.5 HOW TO KEEP THIS USER’S MANUAL ................................................................................................. 3

1. GENERAL INFORMATION ............................................................................................................................ 6

1.1 MACHINE IDENTIFICATION ................................................................................................................... 6

1.2 AFTER SALES SERVICE ........................................................................................................................... 6
1.3 SAFETY RULES ......................................................................................................................................... 7
1.4 MACHINE SAFETY MEASURES ............................................................................................................. 8
1.5 LABELS ON MACHINE............................................................................................................................. 9
1.6 WARNING OVER RESPONSIBILITY....................................................................................................... 9

2.TRANSPORTATION AND STORAGE ........................................................................................................ 10

2.1 MACHINE DISASSEMBLY BEFORE PACKING ................................................................................... 10

2.2 MACHINE DOWNLOADING .................................................................................................................. 10
2.3 MACHINE STORAGE .............................................................................................................................. 10
2.4 MACHINE UNPACKING ......................................................................................................................... 10
2.5 CHECKING AFTER UNPACKING .......................................................................................................... 11

3. TECHNICAL SPECIFICATION .................................................................................................................... 12

3.1 MACHINE FUNCTION ............................................................................................................................ 12

3.2 MODLE SELECTON ................................................................................................................................ 12
3.3 WORKING PRINCIPLE ............................................................................................................................ 13
3.4 PRODUCTS ............................................................................................................................................... 13
3.5 MACHINE CHARACTERISTICS ............................................................................................................ 13
3.6 TECHNICAL PARAMETERS ................................................................................................................... 13
3.7 MACHINE MAIN PARTS INTRODUCTION .......................................................................................... 13
3.8 SPECIAL CONFIGURATION ................................................................................................................... 18

4. INSTALLATION ............................................................................................................................................. 19

4.1 MECHANICAL INSTALLATION ............................................................................................................ 19

4.2 ELECTRICAL INSTALLATION............................................................................................................... 19
4.3 CHECKLIST AFTER INSTALLATION.................................................................................................... 19

5 CONTROL AND OPERATON....................................................................................................................... 20

5.1 POWER ON AND OFF.............................................................................................................................. 20

5.2 CONTROL BUTTONS .............................................................................................................................. 20
5.3 HMI DISPLAY ........................................................................................................................................... 21
5.4 LECTRICAL DRAWING .......................................................................................................................... 27

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6 ACHINE START UP ....................................................................................................................................... 28

6.1 CLEANING................................................................................................................................................ 28
6.2 PREPARATION ......................................................................................................................................... 28
6.3 POWER ON ............................................................................................................................................... 28
6.4 CUTTING SEETING ................................................................................................................................. 28
6.5 JOG RUN AND FUNCTION CHECK ...................................................................................................... 28
6.6 MOULD ASSEMBLE AND ADJUSTMENT............................................................................................ 29
6.7 DRY RUN .................................................................................................................................................. 29
6.8 PRODUCT RUN ........................................................................................................................................ 30
6.9 FIXED LENGTH SETTING ...................................................................................................................... 31
6.10 EMBOSSING SETTING ......................................................................................................................... 32

7 CHANGE-OVER AND TROUBLE SHOOTING ......................................................................................... 33

7.1 LINE CHANGE-OVER ............................................................................................................................. 33

7.2 TROUBLE SHOOTING ............................................................................................................................ 33
7.3 ISSUES AND SOLUTION ........................................................................................................................ 34
7.4 BIG ISSUE AND SOLUTION ................................................................................................................... 37
7.5 I/O LIST ..................................................................................................................................................... 38

8 MAINTENANCE .............................................................................................................................................. 39

8.1 SAFETY RULES DURING MAINTENANCE ......................................................................................... 39

8.2 MAINTENANCE TOOLS LIST ................................................................................................................ 39
8.3 CLEANING................................................................................................................................................ 41
8.4 CHECK ...................................................................................................................................................... 41
8.5 LUBRICATION ......................................................................................................................................... 42

9 ANNEX ............................................................................................................................................................. 43

9.1 NOISE LEVEL........................................................................................................................................... 43

9.2 OPERATING LIFE AND ABANDONMENT ANNOUNCEMENT ......................................................... 43
9.3 FREE TOOLS AND SPARE PARTS ......................................................................................................... 44
9.4 HOW TO ORDER SPARE PARTS ............................................................................................................ 44

10 OPERATION SOP ........................................................................................................................................ 45

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1. GENERAL INFORMATION
1.1 MACHINE IDENTIFICATION

There is one nameplate located on the machine, as per the indication below:
Machine name and model
Machine size
Machine weight
Power supply
Serial number and date of manufacture
Company name and address

1.2 AFTER SALES SERVICE

After the machine has passed the acceptance test in our company, it will be
transported to the customer’s specified place.
Our company will appoint technical support engineers to the customer’s factory
for machine test work. The test time will be negotiated and decided by the customer’s
needs.
The customer will be in charge of all of the fee of transportation, hotels, 3 meals
per day, as well as the technical support fee.
The machine guarantee period is 1 year. Within the guarantee period, it the
machine has any quality problem, our company will replace the broken parts with new
ones for free. If the machine has big problem and our engineers are needed for site
support, the customer will be in charge transportation, hotels, 3 meals per day,
without any technical support fee.
After the guarantee period, it the machine has any quality problem, our company
will replace the broken parts with new ones with only cost price. If the machine has
big problem and our engineers are needed for site support, the customer will be in
charge of all of the fee of transportation, hotels, 3 meals per day, as well as the
technical support fee.
Our company guarantees the machine for its life time. In case of failure, the
following details need to be supplied:
1) Failure details
2) Diagnostic report
3) How was the failure handled and results
4) Machine manufacture date and serial number
After sales service contact information:

Nantong Tongji Co., Ltd

Add: No 19 Dasheng road, Gangzha District, Nantong Jiangsu, China
Phone: 0086-513-85059019, 0086-513-85059027; Fax: 0086-513-85656922
E-mail: sales@tongji-china.com

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！
1.3 SAFETY RULES

When this machine is being used in the bar soap finishing line in the customer’s
workshop, machine operators must operate the machine in compliance with all of the
following safety rules and operation rules, and must fully understand and keep in
mind of all of the possible safety problems that may happen, as well as all of the
safety devices installed on the machine and the protective measures of the machine.
Do not attempt to operate until you have read thoroughly and understand
completely all instructions, rules, etc, which are contained in this manual. Failure to
comply can result in accidents involving fire, electric shock, or serious personal injury.
Keep owners manual and review frequently for continuous safe operation.
1) Know your machine
For your own safety, read the owner’s manual carefully. Learn its application and
limitations as well as specific potential hazards pertinent to this machine.
2) Keep work area clean
Disorder area and working table will cause accident.
3) Do not use in dangerous environment
Do not use power tools in damp or wet locations, or expose them to rain. Keeps
work area well illuminated.
4) Keep non-professional people away
All visitors should be kept at a safe distance from work area, and psycho and
non-operation people must NOT come near the machine.
5) Do not force the machine
It will do the job better and be safer at the rate for which it was designed.
6) Use the right tools
Do not force the machine or attachments to do a job for which they were not
designed.
7) Wear proper apparel
Avoid loose clothing, gloves ,neckties, rings, bracelets, or jewelry, which could be
caught in moving parts. Non-slip footwear is recommended. Wear protective covering
to contain long hair.
8) No alcohol
No one is allowed to enter the operation are after drinking alcohol, and no one is
allowed to drink alcohol in the working area.
9) Don’t maintain the machine in running states
The machine should be maintained such as lubrication, proper adjustment.
10) Before maintenance, accessory changing or assembling and reassembling
motor, be sure to cut off the power from the power resource
11) Keep the machine from irrelevant parts
Don’t place tools, mechanical parts or other non-operation relevant parts on the
machine or inside the machine.
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12) Use E-stop to stop emergent problem

Push the E-Stop immediately to stop the machine if some emergent problem
happens during the running,
13) Install and fix the protective board and safety cover
Do examine the machine carefully after the maintenance and repair work is done,
and make sure that the protective board and the safety cover are installed and fixed
firmly before starting the machine.
14) Follow operation manual when moving or lifting the machine
Go through in detail to refer to the instructions before any action is taken, and
move or lift the machine according to the operation manual.
15) Follow operation manual for lubrication work
Follow all of the lubrication rules and requirements and safety requirements when
filling oil in the machine. If not, it will cause injury to human body and also damage the
machine components.
16) Keep the control cabinets in safe and good environment
Find the most suitable position and do necessary to keep the cabinets from the
dusty, the electromagnetic radioactive, the vibration and the shocking environment.
17) Don’t change the safety system
Don’t close the safety swift or disable it.
Don’t change the machine safety system by any reason. It will be the user’s 100%
responsibility for any damage caused by the change of the machine safety system by
the user.
18) Use recommended accessories
Consult the owner’s manual for recommended accessories.
19) Never leave the machine running unattached

1.4 MACHINE SAFETY MEASURES

Several safety devices and guards are installed on the machine, including:
1 Fixed guards
The fixed guards are not equipped with safety switches, but they can only be
removed by using tools or keys. Only when the machine is OFF and locked, and by
the authorized professionals, can the guards be allowed removed for maintenance.
And as soon as the maintenance work is done, the guards must be fixed.
2 Emergency Stop button
The E-stop is used only for emergency to stop the machine immediately.
For the normal operations, use the Stop button.
3 Earth connection of machine and motor
Reliable earth connection can prevent electrical damage to operator and machine
in case of electricity leakage. The customer must do the earth connection according
to local regulations
4 Warning and Danger Label
Please follow the warning and danger labels on the machine. It will cause
damage even death if not strictly following the instructions. Please keep these labels
intact and clear to read for people, otherwise, change to new and same labels.
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5 Safety Door Switch

On the operation side, there is a door with a safety switch. When the machine is
running, and as soon as the operator opens the door, the machine will stop
immediately.

1.5 LABELS ON MACHINE

This table shows labels that are stuck on the machine.

Picture Description Qty Position
Electrical injury
may happen
1 Panel
when
approaching

1.6 WARNING OVER RESPONSIBILITY

Our Company will not be responsible for problems, damages and accidents due
to not following this manual, nor for problems resulting from modifications,
reconstruction or wrong installation of the machine.
Our Company will not be responsible for damages due to natural calamity, wrong
operation, lack of maintenance, short circuit caused by electrical failure.
Our Company will not be responsible for the use of packing materials and filling
products differing from soaps for which the machine has been designed. It is
specifically prohibited to use the machine for acid, corrosive or flammable
substances.
Our Company will not be responsible in case of parts replaced by parts not
supplied by us. To prevent accidents it is important the parts are replaced before the
end of their lifetime.

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2.TRANSPORTATION AND STORAGE

2.1 MACHINE DISASSEMBLY BEFORE PACKING

After customer test, the machine will be packed in wooden case.

2.2 MACHINE DOWNLOADING

The machine is particularly heavy. Please take care of handling the wood cases
properly. Packed machines transported on trucks or in containers are to be
unloaded by a fort lift truck, an overhead traveling crane or a crane.

Fort Lift Truck Overhead Traveling Crane Crane

Attention:
1. The lifting equipment hoisting capacity must be bigger than the cargo;
2. Pay attention to the cargo gravity center before hoisting

2.3 MACHINE STORAGE

If the machine is to be stored for a long period of time before use, open the crates
to verify the machine has not suffered from the transportation.
Keep the machine in a dry storage environment with the temperature between
-10°C and + 50°C, and the relative humidity between 10% and 80%. Keep the
machine in the horizontal position and do not load the machine with other machine on
top of it. Take all precautions necessary to prevent humidity to alter the components
of the machine. Grease or oil all parts subject to corrosion.

2.4 MACHINE UNPACKING

When the customer receives the cargo, please dismantle the wooden bottom per
below picture instruction:

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2
3

6
5 4

1: the lid, 2&4: the side walls, 3&5: the end walls, 6: the bottom
Attention: When dismantling all the nails on the lid, side walls and end walls of the
wooden case, operators should wear safety gloves in order to avoid any wounds or
abrasions caused by wood splinters.

2.5 CHECKING AFTER UNPACKING

When the machine has been unpacked, a check should be made by the customer
to see if there are some parts that have been damaged during the transportation or
some parts are missing/not delivered with the machine. In case of any parts damage
or parts missing, the customer should immediately take pictures and contact our
company.

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3. TECHNICAL SPECIFICATION
XQK/G series electronic cutter is a new model which our company has
developed especially for toilet soap and laundry soap production.
According to different line capacity and soap formula, we have several models of
different structure, worm size, worm material.

3.1 MACHINE FUNCTION

The soap billet from the plodder enters the machine through the conveyor, the
embossing and the cutter, then goes out as single soap bars.
As per different product for toilet soap and laundry soap, the machine has 2
functions:
1. For toilet soap: long soap billet;
2. For laundry soap: embossed soap bars;

Soap billet Soap bar

皂条

3.2 MODLE SELECTON

The machine capacity is the total number of the soap bars the machine can cut in
a minute.
STEP 1: Confirm which type of soap: toilet soap or laundry soap;
STEP 2: If toilet soap, select the model to below table:
Model Speed Line Capacity
XQK/G300 0-60 bars/min 500-4000 kg/hour
STEP3: If laundry soap, select the model to below table:
Model Speed Line Capacity
XQK/SG300 180 bars/min 500-2000 kg/hour
XQK/SSG300 180 + 180 bars/min 3000-5000 kg/hour
STEP4: if laundry soap, also need to confirm embossed sides:
Model Type Notes
XQK/SG300 2-side embossing Top and bottom
XQK/SG300 4-side embossing Top, bottom, front and back

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XQK/SSG300 2-side embossing Top and bottom

XQK/SSG300 4-side embossing Top, bottom, front and back

3.3 WORKING PRINCIPLE

The soap billet from the plodder goes through the top/bottom embossing,
front/back embossing, encoder, the cutter, and then goes out.
The top/bottom embossing are for laundry soap bars with LOGO;
The front/back embossing are for laundry soap bars with LOGO;
The encoder is to follow the soap bar movement to control the cutting position to
the set length.
The cutter is to cut through the soap billet to make soap bars.

3.4 PRODUCTS

Toilet soap and laundry soap.

3.5 MACHINE CHARACTERISTICS

The machine speed is fast to reach 180 bars/min. High precision within +-1g.
The machine can cut laundry soap bars or long toilet soap bars. For long toilet
soap bars, it can cut 2 bars at the same time to match with high speed dual-lane
stamper.
The machine is controlled by PLC, with HMI for easy operation and fault display.

3.6 TECHNICAL PARAMETERS

Parameter XQK/SG300 XQK/SSG300

Cutting Knife 1 2
Standard: top/bottom Standard: top/bottom
Embossing
Optional: front/back Optional: front/back
Cutting Speed(bars/min) 180 180+180
Cutting Lenght(mm) 50-1000 50-1000
Servo 2 2+2
Power(kW) Conveyor motor 0.18 0.18+0.18
Total 2.2 4.4
L 1400 1700
Dimension
W 960 1500
(mm)
H 1350 1350
Height of the soap billet(mm) 900-1150 900-1150
Weight(ton) 600 1200

3.7 MACHINE MAIN PARTS INTRODUCTION

The machine mainly consists of main frame, embossing unit, encoder unit, cam

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box, cutting unit, conveyor, side adjustment unit, control panel, etc.

1) Main Frame
It is welded part by carbon steel, solid and strong, low vibration during working.
The top cover is made of aluminum profile and transparent PC, easy to observe the
machine working status.
There are 4 feet, which can be height adjusted easily through the rotating. There
are wheels below the feet to make the machine easy to be pushed front and back
during maintenance.

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2) Embossing Unit
For laundry soap with LOGO, the unit is needed.
The height of the embossing roll can be adjusted for different size of soap. At the
end of the unit, there is an encoder to detect the soap bar movement and control the
cutting.
The soap embossing moulds are installed horizontally.

3) Encoder Unit
To follow the soap bar movement and control the cutting length and speed, there
is a roll which is on top of the soap bar to rotate with the soap forward movement.
The unit is tensioned by a spring to allow tight contact with the soap, and at the
end of the roll shaft, there is the encoder.

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4) Cam Box
This unit is the core of the machine. It’s driven by servo motor and gear box with
high precision and speed. It has 2 functions:
1) Cut the soap at the requested length;
2) Maintain the cutting section is vertical, so that the soap is vertical.
There are cams and rod units inside the box to control the knife movement.

5) Cutting Unit
The cutting unit is a link mechanism, driven by the cam box.
The knife is fixed as the end of the unit by screws.

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6) Conveyor
The conveyor is driven by a AC motor. To ensure the tightness of the belt, there
is a big nylon driving roll. The belt can be tightened by the screws at the end and at
the front.
The conveyor is controlled by VFD, and can be adjusted to actual speed need.

7) Control panel and operation box

There is an independent control panel and operation box for this machine.
For machine control, please refer to below chapters in the user manual.

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The image shown here is indicative only. The actual product may differ.

3.8 SPECIAL CONFIGURATION

1) Front and back embossing unit (optional with extra cost)

Some customer, they need 4 sides embossed for the laundry soap. In this case,
the machine needs to add the front and back embossing unit.
The front and back embossing unit is mechanically integrated with the top and
bottom embossing unit to guarantee the LOGO position.
The soap embossing moulds are installed horizontally.

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4. INSTALLATION
ATTENTION:
For the following installation work, only qualified professional engineers can do and must
follow tightly this installation instruction.
The machine must be installed and operated in the closed environment with the
temperature between -10°C and + 50°C, and the relative humidity between 10% and 80%.

4.1 MECHANICAL INSTALLATION

Step 1: Put the machine in position

Put the machine after the plooder, but keep a certain distance with the extrusion
head.
Step 2: Adjust the machine level and fix
Adjust the machine 4 feet to get the same height level with the plodder.
Fix the 4 feet.

4.2 ELECTRICAL INSTALLATION

According to our electrical drawings and documentation, the electrical installation

work must be done by qualified professional engineers. The work scope is as below:
1. Put the control panel in position to our drawings;
2. Wire the machine with the panel to our drawings;
3. Install the power supply from the workshop to the machine, and the wire earth
grounding;
4. Check all wires according to drawings.
5. Check all wire earth grounding.
ATTENTION: the electrical installation is of great importance and please take
care.
Modle Power(kW) Power Supply
XQK/SG300 2.2 3P+PE，2.5 mm2 wires
XQK/SSG300 4.4 3P+PE，2.5 mm2 wires

4.3 CHECKLIST AFTER INSTALLATION

1) Check if the machine and the panel are in position to the drawings;
2) Check if earth grounding is done for the machine and the panel.
3) Check all wires are installed to the drawings.
4) Check if there is oil inside the cam box;

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5 CONTROL AND OPERATON

5.1 POWER ON AND OFF

On side of the control panel, there is a main power switch. Switch it up for power ON
and switch it down for power OFF
Power ON Power OFF

5.2 CONTROL BUTTONS

Buttons Type Color Function

启动 Button Green Start the machine control power

Start

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停止 Button Red Stop the machine control power

Stop

电源 Light Green Show machine power status

Power

急停 Button Red Stop the machine immediately

E-Stop

5.3 HMI DISPLAY

At the operation side of the machine, there is a HMI.

The control screens of the HMI is as below

Button Function
中文 Chinese
English English
User Manage Enter User Manage, needs user name and pass word
Main Menu Enter Main Menu

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Button Function
Password 85059009
Current Class Standard machine only has 1 class
Parameter Internal Enter Parameter Internal
Main Menu Enter Main Menu

Button Function
Max Gain 100-300, normally 200-220
Set the speed below 190
Speed Limit
And the actual machine running speed will not exceed this
Current machine is 1:5, which is the servo motor gear box
Reduction Ratio transmission ratio I. If changed another gear box, this will
need to be changed
Embossing Encoder Initial setting is 3600 (if the customer changes to another
Resolution encoder, this will need to be changed)
Tachometering Initial setting is 5000 (if the customer changes to another
Encoder Resolution encoder, this will need to be changed)

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Tachmeter Wheel
250
Speed
Back Back to User Manage
Main Menu Enter Main Menu

Button Function
Date Press and set
Time Press and set
Week Press and set
Manual Operation Enter the Manual Operation
Fixed Length Cutting Enter the Fixed Length Cutting
Embossing Cutting Enter the Embossing Cutting
Parameter Enter the Parameter
Alarm Enter the Alarm

Button Function
Blade FWD The blade run forward
Blade REV The blade run backward

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Soap pick up conveyor run (no function for toilet soap

Conveyor 1
production)
Blade Home Blade returns to initial position
Simulation Run Dry run
Main Menu Enter Main Menu

Button Function
Reset The servo motor reset
Soap Bar Speed Display
Soap Bar Length Display
Blade Speed Display
Total Display
Zero Zero the turnover
SoapLength Setting Enter Soap Length Setting
Alarm Enter the Alarm
Start Start the machine
Main Menu Enter the Main Menu

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Button Function
SoapLength Setting Set the soap length
Back Back to Fixe Length Cutting
Acknowledge Confirm the setting
Main Menu Enter the Main Menu

Button Function
SoapBar Speed Display
Blade Speed Display
Total Display
Zero Zero the turnover
Parameter Embossing Enter the Parameter Embossing
Alarm Enter the Alarm
Start Start the machine
Main Menu Enter the Main Menu

Button Function
Offset Set the cutting positon

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Embossing Pieces Set the total soap pieces the mould runs a circle
Back Back to Fixe Length Cutting
Acknowledge Confirm the setting
Main Menu Enter the Main Menu

Button Function
This is an index to speed up the conveyor compared to the
soap bar extrusion speed.
Conveyor Gain
100-300, normally 200-200
The index is bigger, the conveyor is faster
This is an index to speed up the cutting compared to the
soap bar extrusion speed.
Blade Gain
100-300, normally 200-200
The index is bigger, the cutting is faster
Simulation Blade
Cutting speed in dry run
Speed
Simulation Conveyor
Conveyor speed in dry run
Speed
Back Enter the Main Menu
Main Menu Enter the Main Menu

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Button Function
Alarm Show current alarm message
Back Enter the Main Menu
Main Menu Enter the Main Menu

5.4 LECTRICAL DRAWING

The machine drawings are inside the machine control panel.

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6 ACHINE START UP
The biggest issue for the cutter is to cut the
belt and the cam box problems.
6.1 CLEANING

1) There is no foreign items or screws inside the machine.

2) There is no foreign items or screws inside the panel.

6.2 PREPARATION

1) Power is on and the voltage is stable.

2) Protective cover is full and installed, functional.
3) No non-relative people are around the machine;
4) The machine is power OFF.

6.3 POWER ON

1) Power on to the workshop.

2) Power on to the machine control panel.
3) Check if there is any abnormal noise.
4) Check if there is any static electricity or electricity leakage.

6.4 CUTTING SEETING

1) Set the cutting speed at 20 bars/min;

2) Set the cutting length at 100mm;

6.5 JOG RUN AND FUNCTION CHECK

Step Action Check

1 Press down ”Start” Machine is power on
2 Press down ”Stop” Machine is power off
Press down
“E-stop” while the
3 Then press down ”Start”, no movement
machine is in stop
status
Press down “Start”,
The machine stops immediately and if the “E-stop” is
4 then press down
not reset, then other buttons will not function.
“E-stop”
5 Power Power light is ON when Start, OFF when Stop
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6.6 MOULD ASSEMBLE AND ADJUSTMENT

A Assemble the moulds

B Adjust the mould postion
C and D Adjust the channel distance
E Adjust the encoder roll position
F Adjust the gear to align the LOGO of moulds

B
E
D
A C

F B

6.7 DRY RUN

Start the machine and dry run for 8 hours

Every 1 hour, check if there any abnormal noise or other problems
- Abnormal noise
- Motor temperature rises quickly (normally the temperature remains below
50 degrees)

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- Gear box temperature rises quickly (normally the temperature remains

below 50 degrees)
- Conveyor belt miss-placement
- Oil leakage, air leakage
- Machine vibration
Time Observation
1st hour
2nd hour
3rd hour
4th hour
5th hour
6th hour
7th hour
8th hour

6.8 PRODUCT RUN

1) Conditions for product run

Only after 8-hour dry run, can start the product run.
Can try dry run the machine several times to observe the machine functions and
the make the operator familiar with the machine
2) Speed Setting
For laundry soap, first set the speed at 100 bars/min, then speed up gradually.
For toilet soap, first set the speed at 20 bars/min, then speed up gradually.
3)Machine start sequence
a) Start the downstream conveyor and the stamper;
b) Start the stameper recycle conveyor;
c) Start the cutter;
4) Checklist
- The motor electricity current not exceeding the rated value
- The motor temperature is below 60℃
- The gear box temperature is below 60℃
- The screws are fixed, no vibration, not loose
- The machine not shaking
Attention:
 During dry run and product run, the operator needs to stands besides the
machine and can fast push the E-stop if emergency happens.
 Only qualified professional operator can operate the machine
 In the first 8 hours of product test, pay attention to abnormalities, such as
noise, vibration, temperature increase.
Laundry Soap Quality Check
Before formal production, need to check the soap quality.
Take every 1st soap of each 5 and write down below check results:
Soap Length Width Height Weight LOGO Cutting

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mm mm mm g Quality Section
verticality
1
2
3
4
5
6
7
8
9
10
Toilet Soap Quality Check
Before formal production, need to check the soap quality.
Take every 1st soap of each 2 and write down below check results:
Length Width Height Weight
Soap
mm mm mm g
1
2
3
4
5
6
7
8
9
10
Because for toilet soap, the bar is very long, so the precision is not high. Also, the
precision is related to the plodder extrusion speed stability.

6.9 FIXED LENGTH SETTING

1)Confirm the length;

2) HMI, Fixed Length setting, input the length, confirm;
3)Change to automatic mode “A”
4)Start
5)When the machine is cutting, check the soap length, can modify the length
precision by adjusting the Conveyor Gain and Blade Gain.

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6.10 EMBOSSING SETTING

1) Check the mould to see how many soap LOGO in the mould surface
2) Enter Embossing Cutting, Embossing Parameter, input the Embossing
Pieces, acknowledge/confirm;
3)Change to automatic mode “A”
4)Start
5)Adjust the Offset to make the LOGO in the middle of the soap (the value
can not be larger than the soap length, otherwise, it will cut the belt)
6)When the machine is cutting, check the soap length, can modify the length
precision by adjusting the Conveyor Gain and Blade Gain.

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7 CHANGE-OVER AND TROUBLE

SHOOTING
7.1 LINE CHANGE-OVER

Before changeover, the operator can move the cutter out, so that there will be
more space for the work. The changeover procedure is as below:
1) Stop the line
2) Cut off the electricity
3) Lock and tag
4) Clean
5) Check

7.2 TROUBLE SHOOTING

Following information are as reference to help customers to identify the problems

earlier and faster, and solve the problems more quickly in the right way.
Whenever any problem arises, it’s suggested that a thorough check of the
following list before taking any remedy actions which may prove to be unnecessary or
even cause machine damage.
No Part Failure and Solution
Failure: motor not start
Possible reasons and solutions:
1 Circuit breaker overload: close the break to see if any electricity leakage or
circuit shortage;
1 Motor
2 Contactor faulty: replace it
3 Servo faulty: check fault code and solution
4 Switch off: manual switch on
5 E-stop pressed: reset the E-stop
Failure: high temperature too high
Possible reasons and solutions:
2 Motor 1 motor bearing wore out or damaged: replacement
2 overload: check if the gear box is broken.
3 Motor fan damage: check if motor fan is running and if the fan is damaged
Failure: temperature too high
Possible reasons and solutions:
3 Gear box 1 Too much or too little oil: adjust the oil to the normal level
2 Gear box bearing wore out or damaged: replacement
3 Gear box gear wore our or damaged: replacement
Failure: oil leakage
4 Gear box
Possible reasons and solutions:

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1 sealing ring damaged: replacement

7.3 ISSUES AND SOLUTION

Below information is for customer reference in case of similar situation:

1)Soap weight precision not good
Check HMI of the setting of Conveyor Gain and Blade Gain.
For small soaps, the gain setting is very important

Meanwhile, check the extrusion speed of the plodder to see if the see is stable. If
the speed not stable, the weight is not precise.
2)The blade not vertical
Adjust the screws of the driving rods

3) Blade cuts the belt

Loosen the screws on the front and back side of the machine, then adjust the
screws on the left and right side of the cam box

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4) Knife pushes the soap

Check the original position
When the limit switch (A )is triggered, the knife should be on the top position (B)

5) LOGO off center

LOGO off center from top to bottom, need to adjust the molds position or the
cutter position.

6)LOGO off center

LOGO off center from left to right, HMI setting the Offset

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7)Embossing Encoder broke

For laundry soap production, if the embossing encoder broke, there will be length
issue.
If there is no spare parts available, temporarily, the customer can change to Fixed
Cutting mode.
When there is no original brand and type of the encoder, the customer find
another one, the setting must be changed on the HMI for the Embossing Encoder
Resolution.

8)Cutting Blade big clearance

Shake the blade with hand, and you can easily find the big clearance and the
blade is shaking easily. So if cutting laundry soap, there will be shape deformation
and weight precision issues.

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Open the cam box to see if anything has broken or if the rod has loosen its
screws.
Fix it or contact us for help if anything wrong.
9)Oil leakage of the cam box
After a long time of running, the sealing might wear out, so the oil leaks out.
Change new sealing.

10) Electronic board broke

If facing unsolved electrical problems, tried but still can not find the reason. Check
if below electronic board has broken.

7.4 BIG ISSUE AND SOLUTION

If facing below big issues, please contact us immediately.

1)Cam box breaks down, abnormal noise
Open the top cover of the cam box to check which part is broken, whether the
bearing or the rod.

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7.5 I/O LIST

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8 MAINTENANCE
The operation, maintenance, and repair of the machine can only be performed by
those who are qualified.
Do not wear rings, watches, chains, bracelets, etc. during maintenance.
Always wear individual protection devices (safety gloves, safety glasses and
safety shoes).
Do not use free flames, pointed elements or pins to clean the machine.
Do not smoke and drink during machine maintenance.
Do not do the machine maintenance after drinking alcohol.

Before any maintenance, the power and the

air must be cut off, lock and tag, and
prevent any other people near the machine
and prevent any miss-operation.
8.1 SAFETY RULES DURING MAINTENANCE

Warning
1) Turn OFF the machine.
2) Turn off and lock the power and air.
3) Working on the machine must be carried out by authorized professionals only.
Protective and Safety Devices
1) Do not override any protective and safety devices.
2) After having terminated maintenance work, close the guard doors and refit the
protective grates and covers.
During the Maintenance Process
1) Keep electrical and electronic components/assemblies dry.
2) Electrical lines, control cabinets, and plastic parts must not come into contact
with acid and caustic solutions.
3) Only when there are two professionals at the same time, can they start to solve
the electrical fault or error on site and take notes.
Welding and spark-producing work
1) Disconnect all electrical components before doing this type of work.
2) Protect the machine from any spark splashing and damage.
3) Protect the gear box oil from any fire.

8.2 MAINTENANCE TOOLS LIST

To carry our following maintenance work, following tools are needed and the

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customer should prepare them and always keep them available.

No. Picture Name Type Qty.

1 Trowel Small size 2 pieces

Double open end

2 SS 1 set
spanner

Inner hexagon
3 SS 1 set
spanner

4 Slotted screwdriver Magnet head 1 set

5 Phillips screwdriver Magnet head 1 set

6 Cotton, soft cloth Cotton, soft, dry Some

7 Air gun Small 1 piece

8 Digital multi-meter Safe and reliable 1 piece

9 Water bucket Plastic or metal 1 piece

10 Thermal gun Infrared, no touch 1 piece

Grease cup:
11 Grease gun M10x1 1 piece
(GB1152-89)
Note:
Too pictures above are just for demonstration, not real configuration or color. The

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customer should prepare these tools according to local market availability and
operators’ operation habits.

8.3 CLEANING

Pay attention to below things:

1) Cut off the power, lock and tag, so that the machine will not run accidentally;
2) Do not use any toxic and flammable cleaning liquid;
3) Only use non-toxic, odorless, and safety qualified cleaning detergent;
4) When use water to clear, air dry out the water after the cleaning;
5) When use the air gun, wear eye protection glass to prevent eye damage;
6) No liquid should be in contact with electricity;

8.4 CHECK

1) Every Shift (every 8 working hours)

A Check before run
1) Check if the oil height is within the requested range of the gear box;
2) Check if there is oil leakage
3) Check if the belt is at the center
B Check when the machine is running
1) Check if the knife cuts the belt
2) Check if the belt run off the center
3) Check every 4 hours if the temperature of the motor, the gear box is OK;
4) Check if there is abnormal noise from the cam box
5) Check the tightness of the belt
2) Every Week (every 40 working hours)
1) Change the oil inside the cam box after running the first 50 hours;
2) Check if the belt is broken;
3) Check if the knife screws are loose;
3) Every Month (every 200 working hours)
1) Check if need a new belt
2) Check if need a new knife
Check Points
Picture Check Points

If oil leakage from the cam box

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If the belt is tightened;

If the belt broken;

If the knife is fixed;

If the knife is broken;

If the sensor is fixed;

If the rotation block is fixed;

8.5 LUBRICATION

For a better preventative maintenance, the proper lubrication helps to keep

machine in good conditions. Regular lubrication need to apply the whole life of the
machine.
Before lubrication operation,
- Do not, by any means, mix mineral oils with synthetic oils.
- Do not, by any means, mix different types of saponified grease.
- Under extreme climatic conditions, it might be necessary to use grease with a
different viscosity (e.g., use thin-bodied oils at extremely low temperatures)
The machine should not be operated at its maximum speed during the 50
operating hours after it has been completed commissioning.
Do the lubrication work according to below table:
No. Position Picture Lubricant Cycle

N220 gear oil

1 Cam box 6 months
N320 gear oil

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9 ANNEX
9.1 NOISE LEVEL

When used under normal production conditions, the machine has a noise level of
85 dB. It’s essential to keep the machine in the following state to measure the noise
level:
All parts have the right setting
All lubrication points are lubricated
No over worn parts
No abnormal noise
No loud environmental noise
Measure method: When the machine is in full running mode, measure the noise
level at four sides with 1 meter distance from the machine and 1 meter high from the
ground.

1m

1m Machine 1m

1m

9.2 OPERATING LIFE AND ABANDONMENT ANNOUNCEMENT

The operating life of the machine is 15 years. After the operating life, the machine
should be abandoned and processed by relevant regulations and should not pollute
the environment.
The machine will be disassembly and the relevant parts will be processed by the
local laws and regulations.
1) Commercial parts
Recycle the commercial parts which are still in the operation life, like the motors,
transformers, bearings, pneumatic parts, etc.
2) Mechanical parts
Hand them to the junk dealing company for steel recycling.
3) Plastic
The plastic should be recycled, especially those polycarbonate protective door
plastic.
4) Oil and grease
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Put them into steel containers and hand them to the junk dealing company.
Do not pour the oil or grease into the sewers or on the ground to pollute the
environment.
5) Others
Hand them to the junk dealing company for suitable process.

9.3 FREE TOOLS AND SPARE PARTS

Model Part Spec/Drawing Number Qty Position

Wrench 1 Frame
XQK/SG Knife 1 Cutting
300 Bearing 1 Cam box
Key for the panel 1 Control panel
Wrench 1 Frame
XQK/SSG Knife 1 Cutting
300 Bearing 1 Cam box
Key for the panel 1 Control panel

9.4 HOW TO ORDER SPARE PARTS

When ordering spare parts, please provide follow information:

Spare Parts Ordering List

Customer information:
Machine name and model:
Machine serial number:
No. No. No. No. No.

Please first send Fax or e-mail to us and then make a call to confirm.

Nantong Tongji Co., Ltd

Add: No 19 Dasheng road, Gangzha District, Nantong Jiangsu, China
Phone: 0086-513-85059019, 0086-513-85059027; Fax: 0086-513-85656922
E-mail: sales@tongji-china.com

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10 OPERATION SOP

Cutter Operation SOP

Step 1: Start the machine
Side of the control panel, power on; (Picture 1)

Step 2: Check
If the blade at the highest position (original position), check if the limit switch is
ON; (Picture 2)
If the blade is vertical; (Picture 3)
If the belt at the center; (Picture 4)
In HMI, enter the “Manual Operation”, Blade FWD to see if cutting the belt;
(Picture 5)

2 3 4 5

Step 3: Start Sequence

Confirm the production is for fixe length or embossing, and then enter the HMI
screen to do the setting; (Picture 6)
Left, change to automatic mode “A”; (Picture 7)
Press Start; (Picture 8)

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6 7 8

Step 4: Close
HMI, change to manual mode “M”; (Picture 9)
Side of the control panel, power off; (Picture 10)

9 10

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Toilet Soap
and
Laundry Soap
Machine Supplier

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