Carpet Shearing Machine

Sara Tex Co.

Contents
1-GENERAL INFORMATION ........................................................................................................ 4
1-1 INTRODUCTION ..................................................................................................................... 4
1-2 AIM AND CONTENTS .............................................................................................................. 4
1-3 ADDRESSEES ....................................................................................................................... 4
1-4 PRESERVATION..................................................................................................................... 5
1-5 INSTALLATION LOCATION PROPERTIES ...................................................................................... 5
2- SAFETY .................................................................................................................................. 6
2-1 APPLICATIONS ...................................................................................................................... 6
2-2 REMARKABLE NOTES FOR USER .............................................................................................. 6
2-3 CONSIDERATIONS ................................................................................................................. 6
2-4 SAFETY OBSERVATIONS ......................................................................................................... 7
2-5 MACHINE PLATE ................................................................................................................... 7
2-6 DANGEROUS AREAS............................................................................................................... 8
2-7 SAFETY DEVICES .................................................................................................................. 9
2-8 CONTROL AND NAVIGATION .................................................................................................... 9
2-9 ELECTRICAL PROTECTIONS................................................................................................... 10
2-10 COLOR ............................................................................................................................ 10
2-11 SUCTION UNITS ................................................................................................................. 11
2-12 LIGHTING ......................................................................................................................... 11
2 -13 RESIDUAL RISKS ............................................................................................................... 11
2-14 W ASTE DISPOSALS........................................................................................................... 12
3- HANDLING, DIMENSIONS AND WEIGHTS ............................................................................ 13
4- INSTALLATION AND ASSEMBLY.......................................................................................... 15
4-1 INSTALLATION ..................................................................................................................... 15
4-2 TECHNCAL DATA................................................................................................................. 15
4-3 ELECTRICITY ..................................................................................................................... 16
4-4 AIR COMPRESSOR............................................................................................................... 16
4-5 ROTATING DIRECTION CONTROL............................................................................................ 17
5- TECHNICAL DESCRIPTIONS OF THE MACHINE ................................................................... 18
5-1 TECHNICAL AND OUTPUT DATA.............................................................................................. 20
5-2 CARPET PATH .................................................................................................................... 20
6- DESCRIPTION OF MACHINE COMPONENTS ........................................................................ 21
6-1 INLET GUIDE ROLLER........................................................................................................... 21
6-2 METAL DETECTOR ............................................................................................................... 21
6-3 BRUSHING ROLLER (OPTIONAL) ............................................................................................. 21
6-4 SAFETY W INDOW ................................................................................................................ 22
6-5 TENSION ............................................................................................................................ 22
6-6 SHEARING UNIT BED ........................................................................................................... 22
6-7 INTERNAL BRUSHING ROLLER ............................................................................................... 22
6-8 SHEARING UNIT .................................................................................................................. 23
6-9 AUTOMATIC LUBRICATION ..................................................................................................... 23
6-10 HORIZONTAL TRAVERSING MECHANISM OF CYLINDER ............................................................. 24
6-11 MOTION MECHANISM ......................................................................................................... 24
6-12 OUTLET DRAG ROLLER ...................................................................................................... 25

Sara Tex Co.

6-13 FOLDING UNIT ................................................................................................................... 25

7- MAINTENANCE AND LUBRICATION ..................................................................................... 26
7-1 GENERAL MAINTENANCE ...................................................................................................... 26
7-1-1 Machine Cleaning ...................................................................................................... 26
7-2 SHEARING CYLINDER AND APPURTENANCES............................................................................ 27
7-3 CONSUMABLE PARTS ........................................................................................................... 29

Sara Tex Co.

This manual is an integral part of the machine and must be accompany with it
wherever it is used.
-The user must keep it integral and in good condition.
-The whole information in this handbook including texts and illustrations, is for
explaining and describing the shearing machine, and the manufacturer reserves the
right to make any changes and innovations necessary to improve the quality and
specifications of the products.
This manual is valid for the following machine models:

SHEARING MACHINE
CPS III

3400

CPS IV

4400

CPS IVD

4400

Sara Tex Co.

1-GENERAL INFORMATION
1-1 Introduction
The SARATEX shearing machine is the result of a long term experience in the case
of textile finishing machinery production (for carpet, mouquette and fabric).
Recent electronic science findings have been used to control this machine which
makes it very easy to handle. It is, however, necessary to comply with all the
instructions present in this users manual in order to obtain a constant and high
quality performance of the operator.

1-2 Aim and Contents

The aim of this instructions book or user manual is to offer the operator all the
information that are necessary to use the machine properly and to manage it in the
most autonomous and safe way as possible.
It includes all the information concerning technical specification, functioning, usage
and maintenance.
Before carrying out any operation on the machine, operators and qualified
technicians have to carefully read the instructions contained in this manual.
For any doubt concerning the interpretation of these instructions, contact the
manufacturer to obtain the necessary explanations. (You can also contact with the
support service through: www.saratex.com).

1-3 Addressees
This instructions book is addressed not also to the operators of the machine;
But also these have to perform the operations reserved to maintenance men or
qualified technicians.
The manufacturer has not to be held liable for damages arising out of the inability of
complying with this warning.

Sara Tex Co.

1-4 Preservation
The instructions Book has to be kept near the machine in a proper container and,
above all, sheltered from liquids and from any other substances that may
compromise its readability.

1-5 Installation Location Properties

The machine must be located in a room where adequate working conditions can be
ensured for the operators safety. The machine does not require special
environmental conditions and has to be installed in an industrial building that is well
lighted with a solid and leveled floor as described later on. It has to be lighted as
foreseen by the legislation in force in the country where the machine is to be
installed and has to always grant
grant a good visibility in all of the machines sides,
side and
emergency push buttons to prevent from dangerous accidents creation.
creation
Concerning computerizes and electronically usage environmental temperatures must
be between 0-40C otherwise conditioning systems are required which must have
been requested by the client in the time of ordering. Humidity must range between
%10~ %80.
In the case of any disregards to above mentioned conditions, and its confirmation by
the technician, any given services or spare parts
parts replacement would be out of
guarantee. (Fig.1)

Fig.1
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Sara Tex Co.

2- SAFETY

2-1 Applications
The machine is devised and manufactured for shearing different types of carpet and
mouquette.

2-2 Remarkable Notes for User

The machine has not to be used:
- For other uses, different from the foreseen ones in 2-1 part.
-in an explosive or aggressive environment or when there are high concentration of
dust or other oil substances suspended in the air.
- In a fire risk environment.
- With electromagnetic inter blocks or earth disconnection excluded.
- While processing materials which are not suitable for the machine. We would like
to mention that the guarantee conditions will not be valid if the end-user does not pay
attention to the marginal notes.

2-3 Considerations
We wish to remind the operator that he/she has to carefully read all the information
carried in this manual, especially as far as the necessary precautionary measures to
ensure safety that are reported in this chapter accordingly
Furthermore, it is indispensable that the operator complies with the warning remarks
listed below:

- The user has to be trained to use machines driving and stop devices,
As well as being aware of their functioning.

- The user operations on the machine, is only limited to his/her responsibilities.

- The installation location of the machine has to be arranged in such a way, to
ensure proper and safe working conditions for operators

- Use the machine only in normal psychophysical and physical conditions

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Sara Tex Co.

- Use personal safety clothes correspondent to the hind of operation and in

accordance with local available standards.
- Do not remove or elude the machine security devices; otherwise the machine will
lose it conformity to safety condition and the manufacturer is not responsible for the
un-expected accidents which may occur accordingly.
- The user will have to take care of keeping the machine always efficient since all the
damages arising out of the inability of complying with these recommendations and of
the lack of care, are to be charged to user himself. So the user, have to keep the
machine and the working area always clean and in order;
- Using genuine spare parts only, the machine performances and reliability will be
ensured.
The guarantee will be invalid in the case of using the machine without paying
attention to specially the general remarks above.

2-4 Safety Observations

The machine is devised and manufactured with the aim of eliminating all the risks
connected to its use.
It is supplied together with instructions manual, electrical diagrams, pneumatic
diagrams and all that is required to properly use and avoiding any risks for those use
the machine.
All accessible assemblies, if not differently required by technical needs, have
properly rounded and/or rounded off edges. All assemblies have dyed coverage

2-5 Machine Plate

Manufacturers logo and the machine inclusion could be found on this plate. (Fig. 2)

Sara Tex Co.

Fig.2
- Manufacturers name and address
- Machines name
- Serial number
- Year of manufacturing
The plate on the machine must not be pulled out and destructed for any reason. Out
of guarantee procedures will apply if the plate is destructed.

2-6 Dangerous areas

- Working areas, adjustment and electronic controlling devices are mostly located
near the operator intended position, for easy monitoring. So any neglect from the
operator would be riskful for both the operator and the machine.
- The dangerous areas of the machine include the areas where the moving
components are placed and their nearby areas. (Fig. 3)

Sara Tex Co.

Fig.3
2-7 Safety Devices
In order to avoiding from moving components being touched with hand or fingers, the
machine has been equipped with safety devices. These safety devices include both
fixed and moving parts. Moving parts stoppage is under control with the operator in
necessaries.
The guard switches are fixed and can stop the machine during
ing loading or unloading
the carpet or shearing process. Before the doors have been completely closed, the
machine wouldnt be able to work and stops by sudden door openings. The machine
m
will be out of guarantee in case of the guard switches are removed or damaged.

2-8 Control and Navigation

All the electric drivers can be easily available with any predicted languages
anguages via the
touchable monitor. (Fig. 4)

Sara Tex Co.

Fig.4
Control buttons on main panel:

- Starting up
- Normal stop
- Emergency stop
- Carpet speed control
- Pile height cutting control
- The stop emergency push-buttons are also placed on each four sides of the
machine.

2-9 Electrical Protections

The machine is equipped with a direct grounding of all the electric components and
of the metal frame. If the grounding connection mentioned above is not done, the
guarantee service cannot be under consideration for any reason.

2-10 Color
Metal parts have been covered by antistatic colors.

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Sara Tex Co.

2-11 Suction units

The machine is equipped with suction hoods to gather the pile produced in the
shearing process and by the beaters.
The capacity and prevalence of the suction system will be explained subsequently.
(Fig.5)

Fig.5
2-12 Lighting
Lighting is obtained in two ways:
- To ensure a good vision in main working areas, some lamps have been installed,
which are supplied with the machines power and usable when the machine is
running.
- In the case of any needs for mechanical- electronic repairs or electrical parts tests,
essential lightning inside the cabins have been foreseen.

2 -13 Residual risks

While performing the periodic maintenance the operators may run some residual
risks:
- Probability of entangling with the roller which is dangerous.

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Sara Tex Co.

- Shearing cylinder spiral blades and the ledger blade are extremely sharp, so they
can cause to injuries. (Fig.6)

Fig.6

In order to avoiding such accidents, all staff members must use close fitting working
clothes and thick firm working gloves.

- The rolling cylinder area presents a residual risk of hand trapping.

It is recommended to avoid touching all rotating cylinders and rollers.
All above mentioned risks occurrence returns to the user, and the manufacturer will
not take responsibility for the matter.

2-14 Waste disposals

While working, waste or refuse matters are produced that have to be collected,
recycled or eliminated in compliance with the laws in force in the country where the
machine has been installed.

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Sara Tex Co.

3- Handling, dimensions and weights

Loading and unloading from the truck can be done with the cranes and metallic
cables. (Never use lift truck). (Fig.7)

Fig.7
In (Fig, 8) you can see how to carry the machine, It is recommended to charge only
the trained personnel to carry out the sling and to give them the maneuvering
instructions
Since the handling of bulky units not allowed complete visibility to the workers; it is
advisable to be supported by auxiliary persons.
Proceed slowly in order to avoid dangerous oscillation.
It is forbidden to pass or stop under overhung loads. You can use special heavy duty
industrial skates in order to move the machine under the roofed areas.

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Sara Tex Co.

Fig.8
Machine Width

CPS III 3400`

5360 mm

3790 mm

CPS IV 4400`

6460 mm

4890 mm

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Sara Tex Co.

4- INSTALLATION AND ASSEMBLY

4-1 Installation
The floor on which the machine is to be located, must be level with a maximum
difference in height of 5 mm between the points of support, and it must be able to
support the weight marked on the table.
The field must be flattened in length and width. We advise to install some steel
plates under the frame holders of the machine. To avoid the vibration in higher
machine speeds the flooring leveled flooring is so important. Otherwise all problems
which may occur will be in the responsibility of the end-user and will not serviced
according to guaranty procedures.

4-2 Technical data

CARPET SHEARING

CPS III

CPS IV

CPS IVD

TABLE

3400 mm

4400 mm

4400 mm

BASIC MACHINE POWER

14.5 Kw

26 Kw

41.5 Kw

POWER CONSUMPTION

11 Kw

20 Kw

32 Kw

VOLTAGE

380 V

380 V

380 V

FREQUENCY

50 Hz

50 Hz

50 Hz

AIR PRESSURE

6 BAR

6 BAR

6 BAR

NUMBER OF SPIRAL BLADES

18 PCS

24 PCS

224 PCS

1 PCS

1 PCS

2 PCS

22 Kw

28 Kw

44 Kw

NUMBER OF SHEARING
CYLINDERS
SUCTION UNIT POWER

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Sara Tex Co.

4-3 Electricity
The electrical equipment is pre-set for 380 VAC - 50/60 Hz.
With different voltage it is necessary to use an auto-transformer which can be
supplied by SARATEX.
Control panel should be installed in suitable and available place, near the machine.
Connect the inlet electricity cable to the main switch, considering the safety
regulations. Before the main supply connection the voltage must be considered
according to the table. The power supply and the electric supply cables must have all
standard features otherwise the machine would be out of guarantee.

4-4 Air Compressor

Connect the machine to the outlet with a G pipe in 6 bar pressure.
At the inlet of the pneumatic system a safety pressure switch is located which does
not allow the machine to start-up if the air pressure is lower than 4 bar. (Fig. 9)
The air connection must be absolutely as mentioned above. Otherwise any problem
will be in the responsibility of the end-user and will not be serviced according to
guarantee procedures.

Fig.9

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Sara Tex Co.

4-5 Rotating Direction Control

All the main moving components of the machine (spiral blades, brush roller and drag
cylinders) have separate motors activated by inverters and therefore they have the
ability of rotating in different directions.
In case of any change (driver motors), when the power supply is connected it is
necessary to check the rotating direction.

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Sara Tex Co.

5- TECHNICAL DESCRIPTIONS OF THE MACHINE

Teflon brush roller can be optionally mounted at the front of the machine which
enables you to work shear your acrylic and polypropylene carpets with more
efficiency.
The distance between the brush roller and the carpet can be controlled with %0.01
mm. accuracy.
All moving parts are operated by independent motor drives making it easy and Quick
to load and unload the carpet.
The foreseen horizontal motion of the shearing cylinder, removes or minimizes the
shearing marks on carpet surface. (Fig.10)

Fig.10

The motion of the shearing cylinder in such manner (horizontal traversing motion)
makes an even smooth shearing process through all surface of the carpet.
The speed and the rotating direction of the Teflon brush roller are under control by
operator. The machine stops during the process will may cause cross markings on

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Sara Tex Co.

the carpet surface (do to shearing cylinder stop- motion action or remaining oil
stains). Backward movement of the carpet after each stop ensures preventing from
these effects.
Operating parameters such as shearing height, shearing cylinder speed, the amount
of Teflon brush roller contact with carpet surface, rotation speed of the rollers, the
tension amount between the brake cylinder and bottom drag cylinder are all
controllable by operating the touch screen control panel.
Protection sensors and the metal detector make maximum safety during the process.
Carpet entrance through drag rollers, is under control; which provides an even drag
with high accuracy.
All pre-stored settings can be readout from the history to run the correct process with
the same adjustments. (Fig.11)

Fig.11
Warning:
The text, data and illustrations in this manual are given as a simple guideline and
the manufacturer reserve the right to make any changes or necessary innovations in
order to improve the quality and efficiency of the product.

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Sara Tex Co.

5-1 Technical and Output Data

- working widths:

H 3400/4400 mm

- Carpet speed:

0/0 ~ 25 m/min. continuously variable

- Compressed air consumption: 6 bar feeding Consumption 10 nl/m.

- Noise level:

85 dB/A

5-2 Carpet Path

The Figure no. 12 shows the correct path of the carpet through the shearing
machine.

Fig.12
Attention:
Do not steer the carpet using your hands when the shearing cylinder is rotating since
it may involve risks of trapping for the operator.

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Sara Tex Co.

6- DESCRIPTION OF MACHINE COMPONENTS

6-1 Inlet Guide Roller
The inlet guide roller designed to drag the carpet to the shearing machine with an
adequate tension and keep it center.

6-2 Metal detector

The metal detector is placed at the machine inlet; this device will stop the machine
automatically in the case of any metal object detection to prevent from damaging the
shearing unit.

6-3 Brushing Roller (optional)

This roller with Teflon covering is designed to clean the disposal of shearing process
and changing its rotating direction is possible. The speed and rotating direction are
independently under control by inverter drivers. (Fig.13)

Fig.13

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Sara Tex Co.

6-4 Safety Window

In order to protecting the operator from being injured with sharp spiral blades, a
safety transparent window located in front of shearing cylinder. Opening the safety
window will stop the machine automatically. A pneumatic system has been designed
to produce the opening and closing motion of window. This motion is controllable via
the touchable monitor. (Fig.14)

Fig.14

6-5 Tension
Speed difference between the inlet drag cylinder and outlet one makes the suitable
tension. Changing the tension is available through the inverter drivers.

6-6 Shearing Unit Bed

The shearing unit bed is designed to feed the carpet to the shearing unit and is
adjustable from 6 points. The bed profile can be supplied with various types
depending on working requirements.

6-7 Internal Brushing Roller

The brushing Teflon cover roller makes the piles oriented in the same direction,
especially for non acrylic carpets.

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Sara Tex Co.

6-8 Shearing Unit

This unit is the main part of the shearing machine. The shearing unit consists from a
complete shearing cylinder (a cylinder with spiral blades mounted on its surface),
and one ledger blade, working together enable the shearing process. The cylinder
rotational speed for 3400 mm machine type varies from 0- 1000 rpm and 0- 600 rpm
for the 4400 mm type, controllable via inverter drivers. With shearing cylinder and the
ledger blade adjustments different shearing qualities is achievable. The contact
pressure between the shearing cylinder and the ledger blade can regulated in both
sides, by a computerized system up to 0.01 mm accuracy for the first time in the
world. Independent pneumatic control allows the shearing cylinder to be separated
from the ledger blade, thus allowing the ledger blade to be checked, aligned and
cleaned. (fig.15)

Fig.15
The shearing cylinder is completely enclosed by a hood with a hinge front, enabling
not only the sheared pile to be sucked in, but also the felt to be housed to lubricate
the shearing cylinder.

6-9 Automatic lubrication

Distributes oil on the felt of the shearing cylinder full automatically. The frequency of
the lubrication and the duration can be programmed by operators.
The oil pump distributes the lubrication synchronized on the felt, under required
pressure. (Fig.16)

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Sara Tex Co.

Fig.16

6-10 Horizontal Traversing Mechanism of Cylinder

In order to access to better shearing result, a traversing motion has been engaged
for the shearing cylinder. During the shearing process, horizontal traversing motion
mechanism in couple with rotating motion of the cylinder, across the ledger blade,
provides a very high level quality.
quality (fig.17)

Fig.17
6-11 Motion Mechanism
sm
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Sara Tex Co.

The shearing height is the distance between the bed and the ledger blade and can
be adjusted by operator from the touchable control panel.
The amount of height can be set between 2-25 mm.

6-12 Outlet Drag Roller

This roller has been located at the machines delivery part and controllable via
inverter drivers to put out different speeds. The speed amount is observable on the
panel.

6-13 Folding Unit

This part is designed to carrying the finished carpet more easily on trolleys.
According to shearing process speed, the speed of the folding unit changes, using
the inverter drives. (fig.18)

Fig.18

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Sara Tex Co.

7- MAINTENANCE AND LUBRICATION

7-1 General Maintenance
The main power switch must be turned off before beginning any maintenance and
cleaning operation.
Thanks to shearing machines design and structure, there is no need for any special
maintenance. Only periodical lubricating and usual controls are recommended.
7-1-1 Machine Cleaning
For periodical cleaning of dust, lint and possible carpet waste, mechanical parts,
electronic components and the electrical cabinet, it is recommended to use suction
hoods after using the air jet guns. (fig.19)
In the case of using air jet guns, please remind to complying with all precautionary
and safety instruments, such as such as safety glasses and masks.

Fig.19

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Sara Tex Co.

7-2 Shearing Cylinder and Appurtenances

The lubrication oil should be selected, according to following tables. In the absence
of any mentioned oils, use the most similar ones. Felt lubricating which covers the
cylinder surface; have to be done continuously and uniformly.
Attention: Low density lubricants may be sucked by suction hood very easily and
cause to high temperature for cylinder. The lubricant specifications for machine:

- Various automatic lubricants, S.A.E no 10 - 40 S.E.A for felt lubricating.

- Lubrication with normal brushes every 8 hours lubricant grade of S.A.E 40.
- Using incombustible grease in bearing housing of shearing cylinder and its weekly
control. (fig.20)

Fig.20

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Sara Tex Co.

- Greasing the Automatic Gearboxes (fig.21)

Fig.21

- All gearbox motors, synthetic oil checking. (fig.22)

Fig.22

- Low rpm bearing housing grease checking each 3 months

- Horizontal motion gearbox synthetic oil checking every month with grade no.80

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Sara Tex Co.

7-3 Consumable Parts

1- Shearing cylinder and spiral blades
2- Ledger blade
3- Drag cylinders rubber
4- Brushing fillets
5- Automatic lubrication felt
6- Automatic lubrication pipes
and pneumatic jacks.

The above mention parts wear out according to various carpets as well as working
condition, which may differ one to another.
Depending working condition, the end-user may change those parts according to his
experience. In case, if the end-user does not satisfy with the job getting from the
machine, please feel free to contact with the service department of SARATEX for
further assistance.

FELT LUBRICATOR
KLUBER TEX M 32 N
MOBIL ETNA OIL 2

AUTOMATIC
LUBRICATION

ESSO MILLCOT K 1 50
OIL
TOTAL AMPELIS 29
SHELL VEXILLA OIL F
100
AGIP ASP 100

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Sara Tex Co.

COMPRESSED AIR CONTROLER

AGIP F1 OSO35
EVERY 250 WORKING
HOURS

OIL

KLUBER AIRPRESS 32
ESSO SPINESSO 22

MOBIL MOBIL DATE

DRIVING BELT

EVERY 250
WORKING
HOURS

30

Check tension and

wear

V BELT
TYPE A

Sara Tex Co.

WORM GEARS
MINERAL OIL
AFTER THE FIRST 400
WORKING HOURS
THEN EVERY 3000
WORKING HOURS

KLUBER OIL GEM 15-220

ESSO SPARTAN EP 220
SHELL TIVELA SC 320

SYNTHETIC OIL
AGIP-BELASIA S 220
KLUBER SYNTHESO D 220 EP

SUPPORT WITH BEARING

AGIP F1-GR MU EP
EVERY 2000
WORKING HOURS

NORMAL
GREASE

KLUBER-STABURAGS B 15 A

SHELL ALVANIA GREASE EP

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Sara Tex Co.

CAM GEARS

KLUBER OIL GEM 15-220

EVERY 1000
WORKING HOURS

MINERAL
OIL

ESSO SPARTAN EP 220

SHELL TIVELA SC 320

POSITIONER GEARS

KLUBER SYNTHESO D 220 EP

EVERY 500
WORKING
HOURS

SYNTHETIC
GREASE

SHELL TIVELA SC 320

IP TELESIA COMPOUND B

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Sara Tex Co.

NOTES:

Sara Tex Co.

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NOTES:

Sara Tex Co.

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