1H300-400 Splicer PDF

 

MAINTENANCE MANUAL 9525671

MODELS 1H 300 AND 400 DIGITAL SPLICERS

COPYRIGHT FEBRUARY 1998 MARQUIP, INC.

 

This manual is intended solely for the use of Marquip's customers. The document contains designs and constructions developed and engineered by Marquip, Inc., which are its property. property. All use or copying is subject to written authorization. All designs and constructions are confidential. Any unauthorized manufacture or use violates the rights of Marquip, Inc. Any use of this document constitutes your agreement to these provisions.

NOTE:  Some options listed in this manual may not be included with your machine. Only options mentioned in your purchase contract are included with  your Marquip Marquip equipment. Marquip, Inc. - Corporate Headquarters 1300 North Airport Road Phillips, Wisconsin 54555-0028 715/339-2191

ii

 

INTENDED USE STATEMENT The Marquip Splicer provides continuous paper feed into processing lines, while maintaining line speed and controlling web tension. Paper can be spliced in either as running rolls are about to expire or as order changes require roll changeovers. Any uses other than those stated above must be approved by Marquip. See Marquip Work Order for specific machine information.

 

iii

 

TABLE OF CONTENTS SAFETY - 9525673 Safety................................ Safety.................... ........................ ......................... ......................... ...................... .......... Safety Guidelines....... Guidelines................... ........................ ........................ ........................ .................. ...... Specific Specifi c Safety Instructions........... Instructions........................ ......................... ...................... .......... Paper Roll Handling................... Handling............................... ........................ .................... ........ Operating Operat ing Procedures............. Procedures......................... ......................... ....................... .......... Dancer Roll Movement Movement ............. .......................... ......................... .................... ........ Safety Trip Wires Wires ................. ............................. ........................ ........................ .............. .. Sound Information Information .................. .............................. ......................... ......................... ................ .... Safety Signs................. Signs............................. ........................ ........................ ........................ ................ .... Safety/informati Safety/i nformation on Sign Sign Location Location ......................... ..................................... ............ Safety Features Features ....................... ................................... ........................ ........................ ................ ....

S-1 S-2 S-3 S-3 S-4 S-4 S-5 S-5 S-6 S-7 S-10

OPERATION - 9525674 Operator Controls Operator Controls ........................ .................................... ........................ ........................ ............ Operatorr Control Operato Control Descripti Descriptions ons ....................... ................................... .................. ...... Main Operato Operatorr Console Console Descriptio Descriptions ns ....................... ......................... .. Operator Interface Display Touchscreen Main Screen ........................ .................................... ........................ ........................ ............ Operator Interface Display Touchscreen Configuration Configu ration Screen....................... Screen................................... ........................ ............ End Operator Operator Controls Controls ....................... ................................... ........................ ............ Turning Power Power On........................ On.................................... ........................ ........................ ............ Turning Control Power Power Off (IES).................... (IES)................................ .................. ...... Safety Lockout Lockout (ZES)..................... (ZES)................................. ........................ ...................... .......... Machine Component Component Locations Locations ........................ ................................... ............... .... Brake Control................... Control............................... ........................ ........................ ........................ ............ Threading Threadi ng Sequence ................. ............................. ........................ ........................ .............. .. Splice Preparation Preparation .................. .............................. ......................... ......................... ................ .... Preparing Prepar ing New New Roll.................................. Roll.............................................. .................. ...... Threading Thread ing New New Roll Into Head Head Assembly Assembly .................. ..................  Applying Splicing Tape ......................... .............. ....................... ..................... ......... Trimming Trimmin g Paper .................. ............................... ......................... ........................ .............. .. Indexing Indexin g Paper........................ Paper..................................... ......................... ...................... .......... Checking Checkin g Paper Preparatio Preparation.................. n.............................. .................... ........ Moving Prepared Prepared Head In ........................ .................................... .................. ...... Tightening Tighten ing Paper ................. ............................. ........................ ........................ .............. ..  Adjusting for Uniform Tension............. Tension. ........................ ....................... ...........  Automatic Index System Syst em (optional) ....................... ........... ....................... ........... Tailgrabber™ Tailgra bber™ Optical Optical Splice Splice ............ ........................ ........................ .................... ........ Corefinder™ Corefin der™ ......................... ..................................... ......................... ......................... .................. ......

O-1 O-1 O-1 O-5 O-7 O-10 O-13 O-14 O-15 O-16 O-17 O-18 O-20 O-20 O-22 O-23 O-24 O-26 O-28 O-29 O-29 O-30 O-31 O-32 O-33

 

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MAINTENANCE - 9525675 Preventive Maintenance Preventive Maintenance ....................... .................................. ....................... ................ .... Cleaning................. Cleani ng............................. ........................ ........................ ........................ ................ .... Lubrication Lubric ation ................. ............................. ........................ ........................ ........................ ............ Generall Checks Genera Checks ........................ ..................................... ......................... .................... ........ Clamp Bar Test Procedur Procedure e ........................ .................................... ...................... .......... Head Assembly Drive System ....................... ................................... .................. ...... Lead Screw Screw Replacemen Replacement.................... t................................ ...................... .......... Paralleling Parall eling Heads................. Heads............................. ........................ ........................ .............. .. Carrierr Block Bushing Replacement Carrie Replacement............ ........................ .............. .. Clamp Bar Bar Replacement............ Replacement........................ ........................ .................... ........ Clamp Bar Cap Cap Replaceme Replacement nt ........................ .................................... ............ Replacing Replaci ng Clamp Bar Cylinder Cylinder Seals................... Seals......................... ......  Anvil Pad Replacement ................ .... ........................ ........................ ................. ..... Knife Blade Replacement Replacement ........................ .................................... .................. ...... Replacing Replaci ng Knife Cylinder Cylinder Seals........ Seals.................... ........................ .............. .. Cable Cylinder Cylinder ....................... ................................... ........................ ........................ .................. ...... Setting Up Up Cable Cylinder Cylinder E/P E/P Transducer.... Transducer................ ............ Dancer System ........................ .................................... ........................ ........................ ................ ....

M-1 M-2 M-3 M-4 M-5 M-7 M-7 M-8 M-10 M-12 M-14 M-15 M-18 M-19 M-20 M-22 M-26 M-28

Dancer Roll Alignment Alignme nt ....................... ........... ........................ ........................ ............ Index System ....................... ........... ........................ ........................ ........................ .................... ........ Index Wheel Adjustment Adjustment............ ........................ ........................ .................... ........ Capstan Roll System ......................... ..................................... ........................ .................. ...... Tensioning Tension ing Capstan Capstan Belt...................... Belt.................................. ...................... .......... Replacing Replaci ng Capstan Capstan Roll Roll Bearings Bearings ...................... .............................. ........ Pneumatic Pneuma tic Adjustment Adjustments s ....................... ................................... ........................ ................ .... E/P Transducers Transducers for Roll Roll Stands .............. ........................... ....................... .......... Test Procedure Procedure .................. .............................. ........................ ........................ ................ .... Setup Procedure Procedure............ ........................ ........................ ........................ .................... ........ Determination Determi nation of Brake Brake Gain.............. Gain.......................... ........................ ............ Limit Switches................. Switches.............................. ......................... ........................ ........................ ............ Photoeyes...................... Photoe yes.................................. ........................ ........................ ........................ .............. .. Mercury Switches Switches (non-Marq (non-Marquip uip roll stands) stands) ................. ................... ..  Adjustment ........................ ............ ........................ ........................ ........................ ................. ..... Replacing Replaci ng a Broken Broken Mercury Mercury Switch Switch ........................ .......................... .. Dancer Encoder............... Encoder........................... ........................ ........................ ........................ ............ Chain-Driven Chain-D riven Dancer Dancer Encoder.................... Encoder............................... ..................... .......... Dancer Home Home Proximity Proximity Sensor Setup Setup Procedure Procedure .......... ..........  Automatic Index System Syst em (optional) ....................... ........... ....................... ........... Setup Procedure Procedure............ ........................ ........................ ........................ .................... ........ Mechanical Mechani cal System.................. System.............................. ........................ ...................... .......... Pneumatic Pneuma tic System System............. ......................... ........................ ........................ ................ .... Touchscreen Touchscr een Display ......................... ..................................... ........................ .................. ...... Setting Display Display Contrast Contrast .................. .............................. ........................ .............. .. Setting Time and Date ....................... ................................... ........................ ............ Controlling Control ling the Splicer Splicer Without Without a Touchscree Touchscreen.......... n..........

M-31 M-33 M-34 M-35 M-36 M-37 M-38 M-41 M-41 M-43 M-44 M-46 M-47 M-50 M-50 M-51 M-52 M-54 M-55 M-56 M-56 M-56 M-58 M-59 M-59 M-60 M-61

 

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Introduction to the Programma Introduction Programmable ble Logic Logic Controller Controller ......... MIU .................... ................................ ........................ ........................ ........................ .................... ........ Battery, Memory, and Reprogram Reprogramming.............. ming...................... ........ Inserting Inserti ng a Memory Cartridge Cartridge ................ ............................ .................... ........ Storing a Program Program in CPU CPU .................. ............................. ....................... ............ Modifying Modifyi ng V-Memory V-Memory Locations Locations in the PLC................ PLC................ MIM.................................. MIM...................... ........................ ........................ ........................ ........................ ............ Timer/Counter Timer/Co unter Reference Reference List................ List............................ ........................ .............. .. Troubleshooti Trouble shooting ng ....................... ................................... ........................ ........................ ................ ....

M-64 M-64 M-64 M-65 M-65 M-67 M-69 M-71 M-72

GLOSSARY Glossary.............. Glossar y.......................... ......................... ......................... ........................ ........................ ............ G-1 ASSISTANCE  Assistance ...................... .......... ........................ ........................ ........................ ........................ .............. A-1

 

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SAFETY To safely operate Marquip machinery, machinery, operators and maintenance personnel must undergo training by Marquip. It is the customer's responsibility to provide training to new individuals. If you need assistance training new individuals, please contact Marquip Field Service. This Marquip equipment operates with minimal operator intervention. However, maintenance personnel are required to be in the area of potentially dangerous mechanical and electrical devices. Use EXTREME CAUTION while operating or servicing the machines. False external inputs may cause the equipment to operate in an abnormal sequence. When servicing machines, shut off all pneumatic, hydraulic, steam, and electrical power and relieve pressure in pneumatic and hydraulic systems. Place the machine in a Zero Energy State (ZES) by following the Safety Lockout  procedure in the Operation Operation section. Obey all safety signs! The safety precautions given in this manual are for operation and maintenance  personnel's protection. protection. Observe all rules of of safety and good judgment judgment for your coworkers' and your own protection. Many safety agencies recommend the use of hearing protection when work place noise exceeds an 8-hour time weighted average sound level of 85 dB(A). Furthermore, the use of hearing protection is required when work place noise exposures exceed 90 dB(A) over an 8-hour work day. Marquip strongly recommends that all operating personnel use adequate hearing protection to  prevent possible PERMANENT PERMANENT HEARING LOSS. LOSS. SAFETY INFORMATION

SAFETY - 9525673

This manual is an integral part of the machine and has to be stored in the immediate proximity of the machine.

  S- 1

 

SAFETY GUIDELINES 1.

Always Always keep keep dis disconne connect ct handle handle on power power control control ca cabine binett and pneumatic, pneumatic, steam, and hydraulic power locked out while performing maintenance duties, except when maintenance must be performed with the equipment operating.

NOTE:  Use EXTREME CAUTION when pneumatic and hydraulic power are turned off because some lines still may hold pressure. Relieve complete system of pressure. 2.

Stay clear clear of of all chain chain,, gear, and cable cable dr drives ives u until ntil power power to to machine machine h has as  been locked out.

3.

After After mai mainte ntenan nance, ce, replac replacee safety safety guard guardss secu securel rely y.

4.

Do not lubric lubricate ate with with equip equipmen mentt runni running. ng.

5.

Before Before applyin applying g power, power, ccheck heck in and and around around machine machine fo forr ope operato rators rs and and maintenance personnel, tools, and debris.

6.

Do not not bypass bypass ssafety afety switches. switches. Immediatel Immediately y repair repair an any y nonfunc nonfunctiona tionall safety switches.

7.

Before servicing, servicing, check for h high igh volt voltage age on on and and around around elect electrical rical components. Separate power sources run into the electrical enclosures. Some components may hold an electrical charge after power is removed.

8.

To avoid avoid inju injury ry,, keep clear clear of ju juncti nctions ons be between tween machi machines. nes. Do not operate operate line unless any safeguards between machines are in place.

Immediately report any accident or near accident which occurs on any Marquip equipment to Marquip, so necessary action can be taken. See Assistance section for telephone number.

S- 2

9525673 - SAFETY

 

SPECIFIC SAFETY INSTRUCTIONS PAPER ROLL HANDLING Before lifting paper roll, ensure both Roll Stand chucks are engaged in core. sWA WARN RNIN ING! G!

Li Lift ftin ing g pape paperr ro roll ll with with on only ly on onee Roll Roll Stan Stand d chuc chuck k engaged could damage fasteners and cause paper roll to drop. Unrestrained paper roll could cause severe injury or death.

Limited clearance exists when paper roll passes below Splicer frame. sWA WARN RNIN ING! G!

Ke Keep ep bo body dy clea clearr of of p pin inch ch po poin ints ts betw betwee een np pap aper er roll roll an and d Splicer frame. Clear the area before passing paper roll below Splicer frame. Failure to do so could cause severe injury or death.

Keep clear of area around running rolls when not preparing a splice. If unusual Roll Stand vibrations occur during operation, gradually stop machine and contact Maintenance. sWARNING!

Failure of Roll Stand chucks or fasteners while machine is running could cause paper roll to drop. Unrestrained paper roll could cause severe injury or death.

Before disengaging Roll Stand chucks from paper roll core, ensure paper roll is resting on support. ARNIN ING G! sWARN

SAFETY - 9525673

Do no nott o ope pen n Rol Rolll Sta Stand nd arms arms un unle less ss pa pape perr rol rolll is is otherwise supported. Unrestrained paper roll could cause severe injury or death.

  S- 3

 

OPERATING PROCEDURES Limited clearance exists beneath Splicer. Keep body clear when retrieving cores or otherwise working beneath Splicer: • • • •

Pinch points points exist exist when Splicer Splicer head head moves in and and o out. ut. It could could crush someone. Pinch point point exists exists when dancer dancer roll roll passes passes capstan capstan or or idler idler rroll. oll. Nip poin pointt exists exists when paper paper rol rolll unwind unwindss into into proces processing sing line. line. Pin Pinch ch point point exis exists ts betwe between en dance dancerr rol rolll and Splice Splicerr frame. frame.

sDA DANG NGER ER!!

Keep Keep cl clea earr of Sp Spli lice cerr fram framee and and al alll movi moving ng pa part rtss al alon ong g their entire ranges of motion. Failure to keep clear while working beneath Splicer could cause severe injury or death.

DANCER ROLL MOVEMENT Pinch points exist between moving dancer rolls and other parts of Splicer. Dancer rolls move whenever air supply is lost or restored either manually or automatically.. Air is controlled manually through the air disconnect valve and automatically  primary disconnect. Air Air is controlled automatically automatically through the the Control Power  push-button and and Run/Thread  Run/Thread-Up -Up keyswitch.  keyswitch.

S- 4

sWARNING!

When air is turned on, dancer rolls move. Pinch points exist between moving dancer rolls and other parts of Splicer.. Clear the dancer roll path before performing Splicer Turning Power On procedure in Operation section. Failure to do so could cause severe injury or death.

sWA WARN RNIN ING! G!

Da Danc ncer er roll rollss mov movee app appro roxi xima mate tely ly 10 10-4 -40 0 ssec econ onds ds af afte terr air is turned off. Pinch points exist between moving dancer rolls and other parts of Splicer. Clear the dancer roll path before performing Safety Lockout procedure in Operation section, and keep clear for 1 minute thereafter,, to ensure that air has been bled. Failure to do thereafter so could cause severe injury or death.

9525673 - SAFETY

 

WARN RNIN ING! G! sWA

If ai airr sup suppl ply y is is los lostt a and nd then then re rest stor ored ed wi with thou outt ope opera rato torr intervention, dancer rolls move. Pinch points exist between moving dancer rolls and other parts of Splicer. If air supply is lost, perform Safety Lockout procedure in Operation section to prevent remote activation of Splicer when air supply is restored. Failure to do so could cause severe injury or death.

sWA WARN RNIN ING! G!

To p pre reve vent nt ac acci cide dent ntal al mo move veme ment nt of da danc ncer er ro roll lls, s, on only ly one Run/Thread-Up key should be available for each Splicer. Keep spare keys in a locked location away from the Splicer. Splicer. Do not use a key from another Splicer Spli cer in the Run/Thread-Up keyswitch. Accidental dancer roll movement could cause severe injury or death.

SAFETY TRIP WIRES Splicers over fixed Roll Stands require safety trip wires on both sides of Splicer frame. If a safety trip wire is tripped, Roll Stand arms under it will not rise. sWA WARN RNIN ING! G!

Pers Person onal al inju injury ry or ma mach chin inee d dam amag agee ccou ould ld resu result lt from from raising roll stand arms into Splicer frame. Pinch points exist between roll stand arms and Splicer frame.

SOUND INFORMATION The sound pressure resulting from Splicer operation was measured at the operator stations and found to be less than 90 dB(A) under the following conditions: 305 MPM (1000 FPM), 189 cm (74.5 in) wide paper. Sound levels can vary slightly for other applications.

SAFETY - 9525673

  S- 5

 

SAFETY SIGNS Signal words used on the four types of safety signs identify the levels of hazard seriousness. Signal words in decreasing level of hazard seriousness are:

S- 6

sDANGER!

RED - Immediate hazards wh which will result in severe personal injury or death, if not avoided.

sWARN ARNIN ING G!

ORAN ORANGE GE - Haz Hazar ardo dous us or un unsa safe fe pr prac acti tice cess w whi hich ch could   result in severe personal injury or death, if not avoided.

sCA CAUT UTIO ION! N!

YELL YELLOW OW - A ha haza zard rdou ouss sit situa uati tion on or un unsa safe fe prac practi tice ce which could  result in minor personal injury, product, or property damage, if not avoided.

SAFETY INFORMATION

BLUE - A procedure or information concerning practices in or around a machine that will aid in the safe operation of the machine.

9525673 - SAFETY

 

SAFETY/INFORMATION SIGN LOCATION The following safety/information signs are mounted on this Marquip equipment. The number to the left of each safety sign corresponds with that number in the following figure(s) indicating safety sign location. For signs 1 and 2, see Marquip customer print set for part number and electrical safety information.

1.

2.

3.

4.

SAFETY - 9525673

  S- 7

 

5.

6.

7.

8.

9.

10.

11.

12.

13.

S- 8

9525673 - SAFETY

 

 Figure 1. 1. Safety Sign Locations Locations

SAFETY - 9525673

  S- 9

 

SAFETY FEATURES The following safety features are located on this Marquip equipment. The number to the left of each feature corresponds with that number in the following figure(s) indicating safety feature location. 1.

Capstan Gu Guard

2.

Ca Carr rria iag ge Dri Drive ve Guard uard

3.

Safety Safety Trip Trip Wi Wires res (fi (fixed xed Roll Roll Stand Standss only) only)* *

4.  Run/Threa  Run/Thread-Up d-Up keyswitch  keyswitch 5.

Wire Mesh Guard

6.

Pn Pneu euma mati ticc Di Disc scon onne nect ct

7.

Pow Power Di Disc sco onnec nnectt

8.

Chain Chain G Guar uard d (Autom (Automati aticc Index Index Sy Syste stem m option option o only nly)) *See Specific Safety Instructions in Safety section.

S - 10

9525673 - SAFETY

 

 Figure 2. Safety Safety Feature Locations Locations

SAFETY - 9525673

  S-11

 

PREVENTIVE MAINTENANCE Preventive maintenance includes cleaning, lubricating, and performing routine checks. sDA DANG NGER ER!!

Pe Perf rfor orm mS Saf afet ety y Loc Lock kout out pr proc oced edur uree iin n Op Operat eratio ion n sec section tion before performing maintenance. Failure to do so could result in severe injury or death.

 Figure 1. 1. Typical Model Model I Cross Section Section 1

Capstan Drive Belt

6

Optical Splice Photoeyes

2

Dancer Track

7

Head Drive Chains

3

Lead Screws

8

Clamp Bar  

4

Bearings

9

Head Assemblies

5

Roll Stand Chucks

MAINTENANCE - 9525675

  M -1

 

OPERATOR CONTROLS The numbers pointing to the operator controls correspond to the numbers in the Operator Control Descriptions.

 Figure 1. Main Main Operator Console Console

OPERATOR CONTROL DESCRIPTIONS MAIN OPERATOR CONSOLE DESCRIPTIONS 1.

 

C ontr ontr ol P owe ower 

White Illuminated Mushroom Head Push/Pull Button Function:  This pull-on, push-off button enables all manual functions. The white  pilot light indicates indicates Control Power  is  is on.

sDA DANG NGER ER!!

OPERATION - 9525674

Conf Confir irm m tha thatt peo peopl plee a are re clea clearr o off Spl Splic icer er.. A Act ctiv ivat atio ion n of of the Run/Thread-Up keyswitch causes the dancer roll to move. Pinch points exist between the dancer roll and other parts of the Splicer Splicer..

  O- 1

 

2.

 

Run/Thread-Up

Two-Position Keyswitch Function: Turn key to thread-up. Dancer roll moves to Forwar to  Forward  d  position  position and Splicer controls are locked out.

Remove key during thread-up sequence. After paper has been threaded, insert key and turn key back to Run to  Run position.  position. Dancer roll returns to Home to  Home position.  position.

3.

 

Splice

Green Illuminated Push-Button Function: Button illuminates when Splicer is prepared to splice. Pressing  button when iitt is illuminated starts splice cycle: • If danc dancer er rroll oll is not not in in posi positio tion n tto o splice, button flashes while dancer roll moves toward Home toward Home position.  position. • If line line spe speed ed iiss ttoo oo fas fastt to splice splice,,  button will flash. flash.

O- 2

9525674 - OPERATION

 

4.

 

Ope Operat rator I nte nterfac rface Displa Displayy and Touchscr T ouchscre een

Computer Display and Touchscreen

Function:  The Operator Interface  Display Touchscree Touchscreen n displays the Splicer

status on the Main and Configuration screens. It also provides controls for the operator through the touchscreen. Main screen displays real-time readouts of running roll diameter ( Roll Diam), Diam), web speed (W (Web Speed  Spe ed ), ), the total amount of paper run through the Splicer ( Lineal Run), Run), and the amount of paper from the last roll run through the Splicer ( Last Run). Run). Main screen also displays  Roll Running, Optical Optical Splice-Enable, Splice-Enable,  Prewarn, and Optical Splice OPT-OK   indicator light. Configuration screen displays Core Splice Diameter, Prewarn Diameter Offset , and Web Tension values. values.

5.

 

L eft Ar row 

Gray Push-Button Function:  Not Applicable.

6.

 

R ight Ar row  row 

Gray Push-Button Function:  Press this button to switch  between Main screen and Configuration Configuration screen. When viewing Maintenance screens, press this button to return to Configuration screen.

OPERATION - 9525674

  O- 3

 

7.

 

Up Ar row 

Gray Push-Button Function:  Not Applicable.

8.

 

D own Ar row 

Gray Push-Button Function:  Not Applicable.

9.

 

R un

Green Indicator Light on Computer Panel Function:  Light indicates there is DC  power to the display. display.

10.

 

Alarm

Red Indicator Light on Computer Panel Function:  Indicator illuminates momentarily when Splicer power is turned on.

11.

 

Com

Green Indicator Light on Computer Panel Function:  Indicator is illuminated if display is working properly. Light blinks if there is a connection problem.

12.

 

F ault 

Red Indicator Light on Computer Panel Function:  Indicator illuminates momentarily when Splicer power is turned on. Light will remain on if the

 batteries display need to be replaced.in the display

O- 4

9525674 - OPERATION

 

OPERATOR INTERFACE DISPLAY TOUCHSCREEN TOUCHSCREEN MAIN SCREEN

 Figure 2. 2. Main Screen

1-2.

 

R un unning ning R oll

Soft Buttons on Touchscreen Function: At start-up, select which roll is to be run first. Press 1 for left side or 2 for right side. Button is highlighted to indicate running roll.

OPERATION - 9525674

  O- 5

 

3.

 

Opti Opti ca call Splice Spli ce-OP -OPT T OK 

Indicator on Touchscreen Function: Indicator is highlighted if conditions are correct for use of optical splice system.

4.

 

Opti Opti ca call Splice Spli ce-E -E nable nable

Soft Button on Touchscreen Function: Press this soft button to activate optical splice system. To deactivate, press soft button again.

5.

 

C hange Scr een

Soft Button on Touchscreen Function:  Press this button to switch  between Main screen and Configuration Configuration screen. When viewing Maintenance screens, press this button to return to Configuration screen.

6.

 

Prewarn

Soft Button on Touchscreen Function:  Press this button to send the dancer roll to the Home the Home position  position to ready the Splicer for a manual splice.

O- 6

9525674 - OPERATION

 

OPERATOR INTERFACE DISPLAY TOUCHSCREEN TOUCHSCREEN CONFIGURATION SCREEN

 Figure 3. 3. Configuration Configuration Screen

NOTE:  If bar graph is replaced by row of asterisks, the actual value is set over the specified limit.

1.

 

C ore Splice Spli ce D i ame ameter  ter 

Increase Soft Button, Decrease Soft Button, and Bar Graph Function:  When activated, a splice occurs when diameter of running roll is less than previously set diameter. Use minus [-] or left arrow [←] and plus [+]  or right arrow [→] soft buttons above  bar graph to set the core splice diameter. diameter. The minus or left arrow decreases the value, and the plus or right arrow increases the value. To disable, disable, set the core splice diameter to 51 mm (2 in).

The bar graph is a graphic representation of the Core Splice Diameter  value.  value. The  bar graph decreases or increases as the value decreases or increases.

OPERATION - 9525674

  O- 7

 

2.

 

P r ewar war n D i ame ameter ter Offset  Of fset 

Increase Soft Button, Decrease Soft Button, and Bar Graph Function:  Prewarn diameter offset (larger than core splice diameter) is point

at which Splicer will prepare to splice by sending dancer roll toward Home toward  Home.. Use minus [-] or left arrow [←] and plus [+]  or right arrow [→] soft buttons above  bar graph to set the prewarn diameter diameter offset. The minus (left arrow) decreases the value, and the plus (right arrow) increases the value. The bar graph is a graphic representation of the Prewarn the Prewarn Diameter Diameter Offset  Offset . The bar graph decreases or increases as the value decreases or increases.

NOTE:  During normal machine

operation, the Splicer positions the dancer forward of the splice position to take up excess slack caused by deceleration while running a large roll. To disable this feature and keep the Splicer ready for instantaneous instantaneous splice,  set the prewarn diameter diameter to 152.4 cm (60 in) or larger.

3.

 

Web Tensi nsion on

Increase Soft Button, Decrease Soft Button, and Bar Graph Function:  Use minus [-] or left arrow [←] and plus [+] or right arrow [→] soft  buttons above bar graph graph to set web tension. The minus (left arrow) decreases the value, and the plus (right arrow) increases the value.

The bar graph is a graphic representation of the Web Tension value. value. The bar graph decreases or increases as the value decreases or increases.

O- 8

9525674 - OPERATION

 

4.

 

Maintenance

Soft Button on Touchscreen Function:  Press this button to bring up Password screen. Enter password to gain access to Maintenance screens. Contact

Marquip Field Service for assistance in accessing Maintenance screens.

5.

 

C hange Scr een

Soft Button on Touchscreen Function:  Press this button to switch  between Main screen and Configuration Configuration screen. When viewing Maintenance screens, press this button to return to Configuration screen.

OPERATION - 9525674

  O- 9

 

END OPERATOR CONTROLS

 Figure 4. 4. End Operator Controls

1.

 

H ead I n

Black Push-Button Function: Press to move head assembly in to splice cycle position.

2.

 

H ead Out 

Black Push-Button Function:  Press to move head assembly out to splice preparation position.

O - 10

9525674 - OPERATION

 

3.

 

Splice

Green Illuminated Push-Button Function: Button illuminates when Splicer is prepared to splice. Pressing  button when iitt is illuminated starts splice

cycle: • If danc dancer er rroll oll is not not in in posi positio tion n tto o splice, button flashes while dancer roll moves toward Home toward Home position.  position. • If line line spe speed ed iiss ttoo oo fas fastt to splice splice,,  button will flash. flash.

4.

 

B r ake R elease/ lease/Set  Set 

White Illuminated Push-Button Function: Press to release paper roll

 brakes. Button illuminates illuminates when brakes are released. Press again to set brakes. Button goes dark.

5.

 

Clamp/Unclamp

White Illuminated Push-Button Function: Press to hold paper with clamp bar. Button illuminates when  paper is clamped. Paper can be clamped only with head assembly in the Out    position. Press again to to release paper from clamp bar. Button goes dark. Paper can be unclamped with head assembly in the In the  In or  or Out  position.  position.

6.

 

Automatic 

Black Push-Button Function: Press to activate automatic clamp bar cycle when manually indexing  paper to proper position position for splice. Clamp/Unclamp button Clamp/Unclamp  button must be illuminated, and head assembly must be in the Out  position.  position.

OPERATION - 9525674

  O-11

 

7.

 

T r ap apsho shoo oter ter ’s Tr i gge gg er 

Hand-Held Black and Red Push-Buttons (On On and  and Off ) Function: Use for portable, manual splice control. Press and hold down

On button to activate Trapshooter’s On button Trigger. Release On On button  button to start splice cycle. To deactivate Trapshooter’s Trigger: a. Contin Continue ue to to ho hold ld dow down n On On button.  button.  b. Press and hold down down Off  button.  button. c. Release On On button.  button. d. Rel elea ease se Off  button.  button.

O - 12

9525674 - OPERATION

 

TURNING POWER ON NOTE:  This procedure may be used when starting a machine after Turning Control Power Off or after a Safety Lockout. 1.

Walk Walk arou around nd the mac machin hinee to to v veri erify: fy: a. All All gua guard rdss aand nd safe safety ty si sign gnss are are in plac place. e.  b. No debris or tools are in inside side machine. c. Pe Peop ople le ar aree cle clear ar of m mac achi hine ne..

2.

Turn air on. a. Shout “Air on.”  b. Pause, look, and listen listen.. c. Turn Turn air air on by rota rotatin ting g the the air air disco disconne nnect ct valv valvee ha handl ndle. e.

NOTE:  Some machine motion may occur when turning on air. 3.

Turn Turn primary primary and and seconda secondary ry (if appli applicab cable) le) di disco sconne nnects cts On On.. a. Shout “Power on.”  b. Pause, look, and listen listen.. c. St Stan and d tto o one one side side an and d mov movee h han andl dlee tto o On On..

4.

Tur urn n al all E-S E-Sttops on.

5.

Turn any Control Power Lockout  keyswitches  keyswitches (if applicable), physically mounted on machine, to On On.. a. Shout “Power on.”  b. Pause, look, and listen listen.. c. Turn k keeyswitch tto o 1.

sDAN DANGE GER! R!

6.

OPERATION - 9525674

When When powe powerr is is tur turne ned do on, n, danc dancer er ro rolls lls mov movee to to H om ome e  position. Pinch points exist between dancer rolls and other parts of Splicer. Stay out of dancer rolls' path during Turning Power On procedure.

Turn Turn contr control ol powe powerr on at main main o oper perato atorr co conso nsole. le. a. Shout “Power on.”  b. Pause, look, and listen listen.. c. Turn Control Power  Lockout  Lockout keyswitch to 1 (if applicable). d. Pull Control Power  button  button On On.. e. Turn Automatic  Automatic on  on (if applicable).

  O - 13

 

TURNING CONTROL POWER OFF (IES) sDA DANG NGER ER!!

This This pr proc oced edu ure will will resu result lt in the ma mach chin inee be bein ing gp pla lace ced d in a stopped, but Intermediate Energy State (IES). The machine may be put in this state by the operator between periods of normal operation or when minor  jam clearing and cleaning is required. Do not enter the machine when it is in this state. Follow the Safety Lockout procedure in Operation section to obtain a Zero Energy State (ZES).

1.

Pe Perf rfor orm m a nor norma mall sto stop p by by pus pushi hing ng Stop Stop button  button or Control Power  button.  button. a. Wait Wait fo forr mac machi hine ne to come come to a ssto top. p.  b. Shout “Power off.” c. Pa Paus use, e, look ook, an and li list sten en.. d. Turn Control Power Lockout  keyswitch  keyswitch to 0 (if applicable). e.

Re Remo move ve key key (if (if appl applic icab able le). ). disconnect and air rem remain ain on. NOTE:  Primary disconnect

O - 14

9525674 - OPERATION

 

SAFETY LOCKOUT (ZES) Perform safety lockout before performing any maintenance. Follow the Safety Lockout procedure to obtain a Zero Energy State (ZES). sDA DANG NGER ER!!

1.

Lower Lower all lifts and other other devices devices to their lowest lowest possib possible le positi position on (if applicable).

sDAN DANGE GER! R!

OPERATION - 9525674

Fa Fail ilur uree to pe perf rfor orm m Sa Safe fetty Lock Lockou outt pr proc oced edur uree befor eforee performing maintenance may result in severe injury or death.

Supp Suppor ortt lift liftss and and othe otherr de devic vices es b by y th thei eirr lo lock cking ing pins pins or bottom stops. Do not rely on normal stopping mechanisms only. Failure to do so may result in severe injury or death.

2.

Push Control Power button Power button Off .

3.

Turn Control Power Lockout keyswitch to 0 (if applicable).

4.

Remo Remove ve ke key y (i (iff ap appl plic icab able le). ).

5.

Tu Turn rn pri prima mary ry dis disco conn nnec ectt Off .

6.

Lo Lock ck ou outt pri prima mary ry di disc scon onne nect ct..

7.

Turn air Off  at  at pneumatic lockout valve.

8.

Lo Lock ck out out pn pneu euma mati ticc val valve ve..

  O - 15

 

MACHINE COMPONENT LOCATIONS

 Figure 5. 5. Machine Component Locations

O - 16

1

Operator Side of Splicer

12

Center Idler Roll

2

Main Operator Console

13

Lead Screw

3

Safety Trip Wires

14

Dancer Roll Home Proximity Sensor  

4

Carriage Drive Motor

15

Dancer Encoder  

5

Splicing Head

16

Capstan Roll

6

End Operator Console

17

Dancer Roll Assembly (Home Position)

7

PLC Enclosure

18

Cable Cylinder  

8

Dancer Ro Roll A Asssembly ((F Forward Po Position)

19

E/ P A Asssembly

9

Limit Switch

20

Manual Brake Controls

10

Capstan Drive Motor

21

Power Enclosure

11

Driv Drivee S Sid idee o off Spl Splic icer  er 

9525674 - OPERATION

 

BRAKE CONTROL To operate Splicer under automatic brake control, push brake selector lever in (Item 1, Figure 6). To operate brakes manually, manually, pull brake selector lever out (Item 2, Figure 6). Adjust brake pressure with manual brake regulator (Item 3, Figure 6). Increase (or decrease) regulator setting to increase (or decrease) brake torque.

NOTE:  For most precise regulation, adjust regulator below desired setting, then  slowly increase increase to setpoint. setpoint.

 Figure 6. 6. Brake Control 

OPERATION - 9525674

1

Br Braake Se Sele lect ctor or Leve Leverr In

2

Br Brak akee Sel Seleector ctor Leve Leverr O Out ut

3

Manu Manual al Br Brak akee Re Reg gul ulaator  tor 

  O - 17

 

THREADING SEQUENCE

 Figure 7. 7. Threading Sequence Sequence 1

 Head Out   Po P osition

8

Lower Fixed Idler Roll

2

 Head In P In Po osition

9

6 in Lower Dancer Roll

3

Dancer Rolls lls in in Home  Home P  Po osition

10

Point Idler Roll

4

Dancer Rolls lls in Thread-Up Thread-Up P  Po osition

11

8 in Upper Dancer Roll

5

Center Idler Roll

12

Upper Fixed Idler Roll

6

Capstan Roll

13

6 in Upper Dancer Roll

7

8 iin nL Lo ower wer Dan Dance cerr Rol Rolll

NOTE: Thread medium position Splicers from top of paper roll only. 1.

Move Move head head asse assemb mbly ly to to Head  Head Out position Out position on side side to be threaded.

2.

Thread Thread approxim approximately ately 1.5 m (5 (5 ft) of of paper thro through ugh head head as assembl sembly y, and  press  Clamp/Unclam  press Clamp/Unclamp p button to hold paper.  paper.  Clamp/Unclamp Clamp/Unclamp button illuminates.

3.

Move Move head head ass assembl embly y to to Head In position. In position. in  Head In position. In position. NOTE:  Both head assemblies should now be in Head

O - 18

9525674 - OPERATION

 

4.

Press Clamp/Unclamp Clamp/Unclamp button  button to release clamp bar. Clamp/Unclamp bar.  Clamp/Unclamp    button goes dark.

sDANGER!

5.

Before ttu urning Run/Thread-Up key, confirm that people are clear of Splicer. Failure to do so can ca n result in severe injury or death. Turning Run/Thread-Up key causes dancer assembly to move. Pinch points exist between dancer assembly and other parts of Splicer.

Turn Run/Thread  Run/Thread-Up -Up keyswitch  keyswitch to Thread-Up Thread-Up position.  position. Dancer assembly assembly moves to Thread-Up Thread-Up position.  position. Remove key when dancer assembly is in Thread-Up position. Thread-Up  position. Keep key with you.

sWA WARNI RNING NG!!

Do not not thread thread Spl Splice icerr u unle nless: ss: (1) R  Run/ un/Thr Thr ead ad-U -Up p key is turned to Thread-Up position, (2) dancer assembly is in F or war d  position,  position, and (3) key has been removed from switch. Failure to do so could result in severe injury or death.

6.

Thread Thread pape paperr throu through gh d danc ancer er carri carriage age,, pas passin sing: g: a. Over Over center center idler idler roll roll ((Ite Item m 5, Figu Figure re 7) and under under ca capst pstan an roll roll (Item 6).  b. Through lower danc dancer er carriage. i. Ov Over er 8 in llowe owerr dance dancerr roll roll (Item (Item 7 7,, Figur Figuree 7) 7).. ii. Around Around lowe lowerr fixed fixed idler idler roll roll (Item (Item 8 8,, Figure Figure 7). iii. Arou Around nd 6 in in lower lower dancer dancer rol rolll (Item 9, Figure Figure 7). c. Unde Underr poin pointt iidl dler er rol rolll (Ite (Item m 10 10,, Fi Figu gure re 7). 7). d. Th Thro roug ugh h upp upper er da danc ncer er car carri riag age. e. i. Ov Over er 8 in upper upper danc dancer er rroll oll (Item (Item 11, 11, Figure Figure 7). ii. Arou Around nd upper upper fixed idle idlerr rol rolll (Item (Item 1 12, 2, Figure Figure 7). iii. Arou Around nd 6 in in upper upper dancer dancer rol rolll (Item 13, Figure Figure 7). 7).

OPERATION - 9525674

7.

Anchor Anchor paper paper to downs downstream tream machinery machinery,, remo remove ve slack, slack, and press press  Brake Release/Set  button  button to set brake. Brake brake.  Brake Release/Set  button  button goes dark.

8.

Insert k keey in in Run/Threa  Run/Thread-Up d-Up keyswitch  keyswitch and turn to Run to  Run position.  position. Dancer assembly moves to Home to Home position.  position.

  O - 19

 

SPLICE PREPARATION PREPARING NEW ROLL 1.

Trim Trim of offf any any outer outer layers layers that that ma may y be damage damaged. d.

2.

Trim out all edge tears and nicks nicks using using a moon-sh moon-shaped aped cut (Figures 8 and 9).

 Figure 8. 8. Cutting Out Edge Tears Tears and Nic Nicks ks from New Roll 

 Figure 9. Removing Edge Tears Tears and Nicks

O - 20

9525674 - OPERATION

 

3.

Cut a 60° 60° angle angle on leadin leading g edge edge of ne new w roll to help help thread thread paper paper th through rough head assembly (Figures 10 and 11).

 Figure 10. 10. Cutting Leading Edge Edge of New Roll 

 Figure 11. 11. A Lead 

OPERATION - 9525674

  O - 21

 

THREADING NEW ROLL INTO HEAD ASSEMBLY 1.

Press and hold Head Out  Out  push-button.  push-button. Head assembly automatically stops when fully extended and below index wheel (Figure 12).

 Figure 12. 12. Index Wheel Location 2.

Press the Clamp/Unclamp Clamp/Unclamp push-button  push-button to disengage paper clamp inside head.

NOTE:  The paper clamp can only be clamped when the head is fully extended. 3.

Thread Thread paper paper throug through h head head assembly assembly.. Paper Paper is insert inserted ed below below guide guide (Figure 13) and above lower idler roll from back side of head.

 Figure 13. 13. Paper Running Running Through  Head Assembly (Back View) View)

O - 22

9525674 - OPERATION

 

 WARNIN RNING! G! Do not reach into head head as assembly sembly during splice s WA preparation. Contact with blade or activation of clamp bar while hands are in head assembly could cause severe personal injury.

4.

Pull Pull pa paper per throug through h head head asse assembl mbly y and and pr press ess Brake  Brake Release push-button Release push-button to activate brakes.

5.

Position Position paper paper in head assemb assembly ly to al align ign paper paper wi with th paper paper rol roll. l. Pull Pull paper paper tight, and press Clamp/Unclamp Clamp/Unclamp push-button  push-button to secure paper (Figure 14).

 Figure 14. 14. Activating Clamp Bar after Pulling Paper Tight  Tight 

APPLYING SPLICING TAPE 1.

Cr Crea ease se pape paperr aalo long ng bar bar.

2.

Apply Appl adhesiv adhesive transfer transferedge tape tape of to paper along bar. crease (Figures (Figures 1 15 5 and 16). Alignytape withe bottom preparation

 Figure 15. 15. Applying Adhesive Adhesive Transfer Transfer Tape to to Paper 

OPERATION - 9525674

  O - 23

 

 Figure 16. 16. Paper Preparation Preparation Bar  1

Nip Roll

5

50 mm (2 in) Tape

2

Preparation Bar

6

40 mm (1.5 in) Tape

3

Paper

7

25 mm (1 in) Tape

4

Paper Crease

8

Flush Cut-Off  

TRIMMING PAPER 1.

Cut paper paper across across bottom bottom edge edge of of prep preparati aration on ba barr (Fi (Figures gures 16 and and 17) 17)..

 Figure 17. 17. Trimming Paper on Preparatio Preparation n Bar 

O - 24

9525674 - OPERATION

 

2.

Trim paper paper corners corners back to to form 45° an angles gles if if splicing splicing onto onto a roll o off paper paper of same width (Figure 18). Trim paper further in if width of new paper is wider than paper currently being run (Figure 19).

 Figure 18. 18. Trimming Corners Corners of Paper Paper During Preparation Preparation

 Figure 19. 19. Trimming Trimming Paper Wider Wider than Currently Currently Running Paper  Paper  3.

Remove Remove backing backing from aadhes dhesive ive transf transfer er tape. tape. Ensure Ensure adhes adhesive ive portio portion n of tape remains on new paper (Figure 20).

OPERATION - 9525674

  O - 25

 

 Figure 20. 20. Removing Adhesive Transfe Transferr Tape Ba Backing  cking  SUGGESTIONS

1.

To avoid avoid dust dust aaccumu ccumulatio lation n on adhes adhesive, ive, do do not prepare prepare a sp splice lice more more than 20 minutes in advance.

2.

Apply Apply masking masking tape tto o front front of paper paper prepar preparation ation bar so so any adhesive adhesive left left on bar can be removed easily.

INDEXING PAPER 1.

Reset inde indexing xing system system by gentl gently y rota rotating ting bott bottom om of nip nip rol rolll toward toward center center of Splicer until mechanical indexing system stops (Figure 21).

 Figure 21. 21. Resetting Indexing Indexing System

O - 26

9525674 - OPERATION

 

2.

Place Place left left hand hand on on p prep repare ared d pape paperr. Pr Press ess Automatic  Automatic push-button  push-button with right hand (Figure 22). Immediately place right hand on paper and wait until clamp bar is automatically released (2.0 seconds). This prevents paper from slipping during indexing process.

 Figure 22. 22. Actuating Automatic Automatic Push-Button Push-Button

3.

When clamp is released released,, press press paper paper against against roll. roll. R Roll oll paper paper fforwa orward rd until until mechanical indexing system stops (Figure 23). Hold paper in place until clamp is activated (4.0 seconds).

 Figure 23. Indexing Paper an and d Roll 

OPERATION - 9525674

  O - 27

 

CHECKING PAPER PREPARATION Pull web index checkers so they are extended (Figure 24). Prepared paper should  be within safe limit to to ensure reliable splices. splices.

 Figure 24. 24. Operation of Web Web Index Checkers 1

Web Index Checkers

3

Prepared Paper

2

Tape

4

Paper Prepared within Limit

s CA  CAUT UTIO ION! N!

O - 28

5

Incorrectly Indexed Limit

Ensu Ensure re th that at web web iind ndex ex che checker ckerss d do on not ot rema remain in extended. A missed splice will occur and head assemblies may be damaged.

9525674 - OPERATION

 

MOVING PREPARED HEAD IN Press and hold Head hold Head In push-button In push-button to move head assembly to splice position.

NOTE:  Paper roll brakes automatically release as head is moved. Head stops when head assembly is fully in or when Head In push-button is released.

TIGHTENING PAPER Remove extra slack and press Brake press  Brake Release/Set  push-button  push-button to engage brakes (Figure 25).

 Figure 25. 25. Tightening Tightening Paper and Setting Setting Brakes

OPERATION - 9525674

  O - 29

 

ADJUSTING FOR UNIFORM TENSION TENSION To achieve reliable splices, paper must have uniform tension across its width. When preparing an unevenly wound or damaged roll of paper, a loose edge may occur (Figure 26).

 Figure 26. Loose Edge aft after er Preparation Preparation

O - 30

1.

Note Note which which edg edgee is loos loosee and move move hea head d assem assembly bly to Head to Head Out  position.  position.

2.

With With he head ad asse assemb mbly ly in in Head  Head Out  position,  position, hold tight edge to nip roll and  press Automatic  press  Automatic push-button.  push-button.

3.

When clamp clamp release releasess paper, paper, pull up loose loose edge edge about about 3 mm (0.1 (0.125 25 in) in) and wait until head reclamps paper.

4.

Rechec Recheck k posit position ion of pape paperr with with pape paperr ga gauge uges. s.

5.

Move Move head head asse assemb mbly ly to to Head  Head In position. In position. Tighten paper as described  previously and set brake.

9525674 - OPERATION

 

AUTOMATIC INDEX SYSTEM (optional) After threading a new roll into the head assembly (see Threading New Roll Into Head Assembly procedure in Operation section), paper can be automatically indexed.

NOTE:  It is still possible to index the paper manually. See Indexing Paper  procedure in in Operation Operation section. 1.

After After p prep repari aring ng a splice splice,, press press and hold hold th thee Head In button In button to move the head assembly into the In the In position.  position.

NOTES:   •

The head head assem assembly bly stops stops when when it iiss fully fully in or or wh when en the the Head  Head In  push-button is released. released.

•

The Automatic Automatic Index System System automa automatical tically ly starts starts indexing indexing after the head assembly has moved into the In the  In position.  position.

•

Paper can't be automa automatical tically ly iindex ndexed ed a secon second d time. time. If If an additional additional index is needed before a splice occurs, perform a manual index.

2.

Press the Brake Release/Set  Release/Set  button  button to release the brakes, and manually adjust paper tension.

3.

Press the Brake Release/Set  Release/Set  button  button to reset the brakes.

4.

If ne nece cess ssar ary y, pr pres esss Automatic  Automatic push-button  push-button to remove baggy edge. slack is remo removed ved before pressing pressing Automatic , or tape may NOTE:  Ensure slack move out of indexed position.

OPERATION - 9525674

  O - 31

 

TAILGRABBERTM OPTICAL SPLICE  Optical splice uses photoeyes (Item 1, Figure 27) mounted within each roll stand to monitor the running paper.

NOTE:  Regardless of maximum machine splicing speed, maximum optical splice  speed is 200 MPM (650 (650 FPM).

 Figure 27. 27. Optical Splice Photoeyes Photoeyes 1

O - 32

Photoeyes

1.

Check Optical Splice - OPT OK indicator  to make sure it is highlighted continuously (no blinking). This indicator is highlighted if following conditions are true: a. Sp Spllic icer er is re read ady y tto o ssp pli lice ce..  b. Both photoeyes on ru running nning roll side are blocked blocked by paper. paper. c. Runn Runnin ing g Roll Roll Sta Stand nd arm armss ar aree belo below w 35 cm (14 (14 in) in)..

2.

Press Optical Splice - Enable button. Enable button.

9525674 - OPERATION

 

3.

When either either photoe photoeye ye detect detectss en end d of paper, paper, a ssplic plicee in initia itiates. tes.

NOTE:  Operators should be ready to press Splice button even though optical splice has been activated. Edge tears may cause paper breakouts and may not be detected by the photoeyes.

NOTE:  Splice should be supervised by operator to avoid paper tearouts.

COREFINDER™ When roll diameter splice is used, a splice automatically occurs when the diameter of the running roll becomes less than a preset diameter. diameter. Splicer must be ready to splice and paper speed must be greater than 0.6 MPM (1.96 FPM). 1.

Ensure Ensure running running roll iiss securely securely held held by roll sstand tand arms. (No (No slippi slipping, ng, especially with small diameter rolls.) Roll diameter indicator should not change erratically.

2.

Set roll Prewarn Diameter Diameter Offset  to   to desired diameter.

3.

Set Corefinder Diameter  to  to any value greater than 51 mm (2 in).

NOTE:  Even if the Roll Diameter value is less than the preset Corefinder Diameter  value,  value, a splice will not occur until the line speed is  greater than 0.6 0.6 MPM (1.96 FPM). FPM).

NOTE:  Splice should be supervised by operator to avoid paper tearouts. 4.

OPERATION - 9525674

T disable Corefinder , set the Corefinder Diameter  to  to 51 mm (2 in) oroless.

  O - 33

 

CLEANING DESCRIPTION

LOCATION

INSTRUCTION

INTERVAL

Roll Stand Chucks

Item 5, Figure 1

Remove dust and debris.

All Rolls

Figure 1

Use acetone to remove old splicing tape.

Daily

Optical Splice Photoeyes (optional)

Item 6, Figure 1

Clean lenses.

Daily

Head Assemblies

Item 9, Figure 1

Blow off dust with air hose.

Weekly

Head Drive Components

Figure 3

Clean lead screws, bearing blocks, and carriage blocks to remove grease and dust. NOTE:  After cleaning, perform lubrication. See schedule.

Weekly

Dancer Track

Item 2, Figure 1

Scrape and blow off with air hose.

Weekly

Clamp Bar

Item 8, Figure 1

Remove paper or tape build-up from rubber surfaces of anvil and clamp  bar.

6 months

After each roll

AUTOMATIC INDEX SYSTEM (OPTIONAL)

Automatic Index Assembly

Centered under head assemblies when they are in the In the In position.  position.

Blow dust off index assembly with compressed air.

Weekly

 Nip Wheels

On nip roll.

Remove any tape left on nip wheels from splice preparation.

Weekly

Table 1. Cleaning Schedule

M-2

9525675 - MAINTENANCE

 

LUBRICATION DESCRIPTION

Air Line

LOCATION

LUBRICANT

QUANTITY

INTERVAL

Drive Side

ISO 32 nondetergent oil

As required

Weekly

Item 3, Figure 1

Citgo Lithoplex 2 or equivalent. (1) Run heads in. (2) Perform Safety Lockout. (3) Apply grease along length of lead screw. (4) Turn power on. (5) Run head out. (6) Wipe off excess grease.

As required

Weekly after steam cleaning

As required

Monthly

3 pumps

Monthly

As required

Monthly

3 pumps

Monthly

Lubricator  Lead Screws

sDANGER!

Do not run heads or lead screws in or out while applying grease or wiping off excess grease. Pinch points exist between lead screw and carriage block. Body parts (including head) will be hit by moving machine parts. Head Drive Chains

Item 7, Figure 1

Brush on ISO 100 oil.

Bearings

Item 4, Figure 1 Each end of capstan roll

Citgo Lithoplex 2 or equivalent.

AUTOMATIC INDEX SYSTEM (OPTIONAL)

Chain

Drive assembly

Brush on ISO 100 oil.

Bearings

All

Citgo Lithoplex 2 or equivalent.

Table 2. Lubrication Schedule

MAINTENANCE - 9525675

  M -3

 

GENERAL CHECKS DESCRIPTION

Pneumatic

LOCATION

Pn Pneu euma mati ticc Pack Pack

Regulators

INSTRUCTION

INTERVAL

Chec Check k sett settin ings gs.. Se Seee Pn Pneu euma mati ticc Ad Adju just stme ment ntss in

Daily

Maintenance section.

Pneumatic Filter

Pneumatic Pack

Purge filter of oil and water.

Daily

Optical Splice Photoeyes (optional)

Item 6, Figure 1

Verify alignment.

Daily

Clamp Bar

Item 8, Figure 1

Check clamp bar effectiveness. See clamp bar  procedure.

Monthly

Inspect for damage and contamination. Replace if necessary. Caps Capsta tan nD Dri rive ve Belt Belt

Item Item 1, F Fig igur uree 1

Check tension.

Monthly

Anvil Anvil Pad Pad

Item Item 2, Figu Figure re 11

In Insp spec ectt an anvi vill pa pad d fo forr da dama mage ge an and d . See Anvil contamination. Replace if necessary necessary. Pad procedure in Maintenance section.

Monthly

He Head ad Asse Assemb mbli liees

Ite Item 9 9,, Fig Figur uree 1

Ch Chec eck k fo forr p par aral alle leli lissm. Ni Nip p ro roll llss of of h hea ead ds m mu ust  be parallel to idler roll.

6 months

AUTOMATIC INDEX SYSTEM (OPTIONAL)

Fasteners

All

Check all fasteners to ensure machine is secure. Tighten if loose.

As necessary.

NOTE:  Immediately after installation, and after running machine  forinstallation. 16 hours after

Automatic Index Run Timer 

Splic licer PLC

Verify ify th thaat paper is indexed pro rop perly rly. (S (Seee Checking Paper Preparation procedure in Operation section.) If paper is not indexing  properly, adjust run timer accordingly. accordingly.

Table 3. General Checks Schedule

When splice reliability decreases.

M4

9525675 MAINTENANCE

 

CLAMP BAR TEST PROCEDURE To determine clamp bar effectiveness, perform the following procedures. Record your findings on a chart similar to Figure 2. Submit data to Marquip Field Service for analysis. 1.

Mat Mater eria ialls nee needed ded: a. Sp Spri ring ng scal scalee 0-2 0-23 3 kg kg ((00-50 50 lb). lb).  b. c.

50 mm x 610 mm (2 in x 24 in in)) strip of 127 g/m2 (26 lb) liner paper. Clamp Clamp to to secur securee paper paper to spring spring scale. scale. Nylo Nylon n strap strappin ping g tape tape will will work.

2.

Set clamp clamp bar bar re regu gulat lator or R7 R7 to 552 kPa (80 psi). psi).

3.

With With po powe werr on, on, mo move ve he head ad to Out  position.   position.

4.

Press Clamp/Unclamp Clamp/Unclamp push-button.  push-button. Insert paper strip through head at center of clamp bar. Press Clamp/Unclamp Clamp/Unclamp push-button  push-button to actuate clamp bar.

5.

Attach Attach spring spring scale scale tto o paper paper strip strip and pull until until paper begin beginss to sl slip ip through clamp. Record the peak force on chart at 102 mm (4 in) intervals from center of bars.

 

MAINTENANCE 9525675

M5

 

 Figure 2. 2. Clamp Bar Profile Profile

M6

9525675 MAINTENANCE

 

HEAD ASSEMBLY DRIVE SYSTEM

8301  Figure 3. 3. Head Assembly Drive Drive System

LEAD SCREW REPLACEMENT  REMOVAL  REMOVA L 1.

Move Move head head asse assemb mbly ly to to Head   Head   In position. In position.

2.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

sWARN WARNING! ING!

Head assembly could fall if if not properly properly se secured. cured. Secure head assembly before removing lead screws. Failure to do so could result in severe injury or death.

3.

Secure Secure head head assem assembly bly to brid bridge ge with with chain. chain.

4.

Manually Manually turn lead screws screws to bottom bottom head head again against st b blocks locks..

5.

Re Remo move ve chai chain n gu guar ards ds..

6.

Remove Remove llock ocknut nutss from from sprock sprocket et end end of le lead ad screw screw..

 

MAINTENANCE - 9525675

M -7

 

7.

Loosen Loosen bolts bolts going going th throug rough h idler idler sprockets sprockets and into into th thee chain chain adjustme adjustment nt  blocks.

8.

Turn bolts bolts on top top of ad adjust justment ment block blockss counterc counterclock lockwise wise to decrease decrease chain tension.

9.

Remo Remove ve chai chains ns an and d sspr proc ocke kets ts..

10 10..

Remo Remove ve ou oute terr bea beari ring ng bl bloc ock. k.

11.

Remov Removee pin pin fro from m round round nuts nuts on insid insidee end end of lead screw screw..

12.

Mark Mark round round nut and lead lead scre screw w fo forr reloca relocatin ting g pi pin. n.

13 13..

Remo Remove ve ro roun und d rret etai aini ning ng nu nut. t.

14.

Unscre Unscrew w llead ead scr screw ew from from carr carrier ier block. block.

15. 15.

Re Remo move ve lea lead d scr screw ew..

 INSTALLATION   INSTALLA TION  1.

Instal Installl parts parts in revers reversee orde orderr of of re remov moval. al.

2.

Tighten Tighten ffirst irst nut on sprocke sprockett end of lead lead screw screw to to a to torque rque of 34 Nm (25 ft-lb) to remove any slack in lead screw. Back off first nut one quarter of a turn and then tighten second nut against first nut.

PARALLELING HEADS 1.

Use contro controls ls to move move head head ass assemb embly ly to Head  to Head  In position.  In position.

2.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

3.

Manually Manually move move head head asse assembly mbly,, using using lead screw on the the driv drivee side until until carrier blocks (Item 1, Figure 4) on the head assembly bottom onto lead screw bearing blocks (Item 2).

M-8

9525675 - MAINTENANCE

 

 Figure 4. Lead Lead Screw Adjustments Adjustments 1

Carrier Blocks

2

Lead Lead Sc Scre rew w Be Bearin aring gB Blo lock ckss

4.

Nip rolls rolls of of heads heads must must be para paralle llell to idle idlerr rol roll. l.

5.

Check that both carrier carrier blocks blocks ttouch ouch lead screw bearing bearing blocks. blocks. If not: not: a. Remo Remove ve cha chain in aand nd spro sprock cket et guar guards ds..  b. Loosen bolts that go through through idler spro sprockets ckets and into threaded chain adjustment blocks (Items 1 and 3 or 5 and 7, Figure 5). c. If space space betw between een car carrie rierr block block and bearin bearing g bl block ock is grea greater ter than than 3 mm (0.125 in), chain must be jumped jumped one or more teeth on drive drive screw sprocket to bring blocks closer together. d. A fine fine adjust adjustmen mentt can be be mad madee by turni turning ng bo bolts lts o on n top of of adjust adjustmen mentt  blocks. Adjust these these blocks in opposite opposite directions unt until il carrier  blocks bottom on bearing bearing blocks. Motions Motions 2, 4, 6, and 8 (Figure 5) show the relation of sprocket motion to roll movement. e. Adjust Adjust chai chain n tensio tension n by turni turning ng bo both th ad adjus justme tment nt bo bolts lts iin n same same direcdirection equally. f. Ver erif ify y tha thatt n nip ip ro roll llss are are par paral alle lel. l.

IMPORTANT:  To completely seal splice, nip rolls must be touching all the way across.

NOTE: On machines with rubber nip rolls, if nip rolls are not touching all the way across, rubber nip rolls are worn. Replace rubber nip rolls. On machines with  steel rolls, if if rolls are not not touching, touching, bearings are are worn. Replace bearings. bearings.

 

MAINTENANCE - 9525675

M -9

 

 Figure 5. Adjusting Adjusting Parallel Parallel Nip Rolls 6.

Visual isually ly che check ck head head asse assembly mbly to ensure ensure that that all four corner cornerss (carr (carriage iage  blocks and cam rolls) ride ride on steel rail. If not, adjus adjustt as follows: a. Clam Clamp p car carri rier er blo block ckss tto o hea head d car carri rier er ttra rack ck..  b. Lift front of head and place spacer under “cam-supported” corner corner of head. c. Using Using chai chain n hoist hoist,, pull pull d dow own n on unsup unsuppor ported ted cor corner ner of h head ead.. d. If head head is overover-str straig aighte htened ned,, move move spacer spacer to o othe therr cam. U Untw ntwist isting ing is accomplished the same way.

M-10

9525675 - MAINTENANCE

 

CARRIER BLOCK BUSHING REPLACEMENT  REMOVAL  REMOVA L 1.

Use contro controls ls to move head assembly assembly until until carrier carrier blocks blocks o on n head head are  positioned behind behind sideframe access covers. (Item 1, Figure Figure 6).

 Figure 6. 6. Side Plate Location Location 1

Access Cover  

2.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

3.

Remove covers.

4.

Remove Remove paper paper prep prepara aratio tion n bar bar from from machin machine. e.

5.

Secure Secure head head asse assembl mbly y with with chain chain hoist. hoist.

s WARNI  WARNING! NG! The h head ead assembly assembly ma may y fall if not pr properly operly secure secured d with

chain hoist. Failure to do so may result in severe injury.

 

MAINTENANCE - 9525675

M-11

 

6.

Re Remo move ve le lead ad scre screws ws..

7.

Remove Remove ssnap nap ring ring (Ite (Item m 1, Figure Figure 7) 7) from insi inside de of carri carrier er block block (Item (Item 2).

8.

While While pryi prying ng head head up, up, slip slip carr carrier ier block block off. off.

 Figure 7. 7. Location of Snap Snap Ring and Flathead Flathead Screw 1

Snap Ring

2

Carrier Block  

3

Flathead Screw

4

Bushing

 INSTALLATION   INSTALLA TION  Install parts in reverse order of removal.

CLAMP BAR REPLACEMENT  REMOVAL  REMOVA L 1.

Move oppos opposite ite he head ad assembl assembly y out until until iitt is 10-13 10-13 cm (4-5 iin) n) fro from m inne innerr  bearing block.

2.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

M-12

9525675 - MAINTENANCE

 

3.

Remove Remove self-loc self-locking king nuts and washer washerss from from clamp clamp bar cylinder cylinder rod eends nds (Figure 8).

NOTE:  Use spanner wrench holes (Item 1, Figure 8) to keep rod from  spinning when when removing nuts. nuts.

 Figure 8. 8. Clamp Bar Cylinder Location

4.

1

Spanner Wr Wrench H Ho oles les

2

Spanner Wrench

Push up on on cyl cylinder inder rods. rods. This This giv gives es clearan clearance ce to remov removee clamp clamp bar. bar. Remove clamp bar and spacers.

 INSTALLATION   INSTALLA TION  1.

Instal Installl parts parts in revers reversee orde orderr of of re remov moval. al.

2.

When tightenin tightening g nuts, nuts, tighten tighten then back off one one qu quarter arter of a turn. turn.

3.

Check clamp bar profil profile. e. Adding Adding or removin removing g spa spacers cers betwee between n clamp clamp ba barr and clamp bar cylinder may be necessary. necessary.

4.

The clamp clamp bar bar should should not not interfere interfere with with tthe he paper paper pat path h when when the bar bar is iin n its unclamped position.

 

MAINTENANCE - 9525675

M-13

 

CLAMP BAR CAP REPLACEMENT  REMOVAL  REMOVA L 1.

Remove Remove clamp clamp bar bar accordi according ng to to th thee Cla Clamp mp Bar Bar Replacem Replacement ent proced procedure ure iin n Maintenance section.

2.

Remove Remove button-h button-head ead screws screws (Item 2, Figure Figure 9 9)) and washers washers (Item (Item 8) from clamp bar cap (Item 1).

 Figure 9. 9. Clamp Bar Cap 1

Clamp Bar Cap

5

Clamp Bar  

2

Button-Head Screw

6

Rubber Coating

3

Retainer Plate

7

Hose Grommet

4

Flat Head Screw

8

Washer  

3.

Replace Replace hose hose grommet grommetss (Item (Item 7, Figure Figure 9) on each each end end of clamp bar with with the new grommets provided.

4.

Remove Remove retainer retainer plates plates (Item (Item 3, Figure Figure 9) by removi removing ng fl flat at head head scr screws ews (Item 4) and washers.

5.

Slide Slide clamp clamp b bar ar cap cap of offf of clam clamp p ba barr (Item (Item 5 5,, Figure Figure 9).

M-14

9525675 - MAINTENANCE

 

 INSTALLATION   INSTALLA TION  1.

Slide new clamp clamp bar cap cap over over cla clamp mp bar, bar, pushin pushing g cap fully fully do down wn on clamp bar. Ensure slots in new cap are aligned with all screw holes in clamp bar.

2.

Insert Insert,, but do do not tigh tighten ten,, button button-he -head ad screw screwss (It (Item em 2, Figur Figuree 9) and washers (Item 8).

3.

Install Install retaine retainerr plates plates (Item (Item 3, Figure Figure 9), 9), maki making ng sure sure they they overlap overlap cl clamp amp  bar cap edges on each end. Insert, Insert, but do not tighten, tighten, flat head screws.

4.

Ensure Ensure cap cap is fully down on clamp clamp bar and ttight ighten en all all scr screws. ews.

5.

Reinstall Reinstall clamp bar accord according ing to to Clamp Clamp Bar Replacemen Replacementt pro procedur ceduree in Maintenance section.

REPLACING CLAMP BAR CYLINDER SEALS  REMOVAL  REMOVA L 1.

Move Move head head asse assemb mbly ly to to Head  Head In position. In position.

2.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

3.

Remove Remove cclam lamp p bar (see (see Clamp Clamp Bar Repl Replace acemen mentt proced procedure ure iin n Maintenance section).

4.

Discon Disconnec nectt air air lines lines from from cclam lamp p ba barr cylin cylinder der..

5.

Remove Remove bolts bolts securi securing ng clamp clamp bar bar tto o anvil anvil..

6.

Re Remo move ve cyli cylind nder er..

 

MAINTENANCE - 9525675

M-15

 

 DISASSEMBLY   DISASSEMB LY  1.

Remove Remove socket socket h head ead capscr capscrews ews holdi holding ng cover cover (I (Item tem 1 1,, Figure Figure 10) 10) to cylinder body (Item 2).

 Figure 10. 10. Clamp Bar Cylinder Cylinder,, Exploded View View 1

Cover

4

Polypak Rings

2

Cylinder Body

5

O-Ring

3

Piston

2.

Re Remo move ve cyli cylind nder er co cove verr.

3.

Remove Remove p pist iston on (Item (Item 3, 3, Figure Figure 10 10)) from ccyli ylinde nderr body body.

4.

Remove Remove p poly olypak pak ring ringss (Item (Item 4, Figur Figuree 10) an and d O-ring O-ring (Ite (Item m 5).

 ASSEMBLY  1.

Instal Installl new pol polypa ypak k ring ring in in cylind cylinder er body body..

NOTE:  Grease rings before assembling cylinder. 2.

Install Install new new polypak polypak ring ring on on pis piston, ton, aand nd install install piston piston in cylinder cylinder b body ody..

3.

Install Install new new O-ring O-ring in cap. Instal Installl cap to to cylinder cylinder body body and and sec secure ure with with four socket head capscrews.

4.

Force Force air air into into each each por portt to to check check for leaks. leaks.

M-16

9525675 - MAINTENANCE

 

NOTE:  Be sure top and bottom ports are located in their proper positions for installation of cylinder.  INSTALLATION   INSTALLA TION  1.

Bolt Bolt cyli cylind nder er to an anvi vil. l.

2.

In Inssta tall ll ai airr lin lines es..

3.

Replac Replacee clamp clamp bar (See (See Clamp Clamp Bar Bar Replace Replacemen mentt proced procedure ure iin n Maintenance section).

4.

Perform Perform Turni Turning ng Power Power On Proce Procedure dure in Operation Operation section. section.

 

MAINTENANCE - 9525675

M-17

 

ANVIL PAD REPLACEMENT s WARN  WARNING ING!! Use extreme extreme care care when when worki working ng near sharp knife b blade. lade.

Tape all sharp edges to ensure safety. sa fety.

 REMOVAL  REMOVA L 1.

Move Move head head asse assemb mbly ly to to Head   Head  In  In position.

2.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

3.

Re Remo move ve lo lowe werr iidl dler er ro roll ll..

4.

Remove Remove buttonbutton-head head screws screws (Item (Item 1, Figur Figuree 11) that hold pad ((Item Item 2) to head.

5.

Clea Clean n anvi anvill of al alll seal sealan antt and and du dust st..

 Figure 11. Knife Anvil  1

Button H Heead S Sccrews

2

Anvil Pad

3

Se Seam am Be Betw twee een nP Pad ad an and d Anv Anvil il

M-18

9525675 - MAINTENANCE

 

 INSTALLATION   INSTALLA TION  1.

Manu Manual ally ly pu push sh kn knif ifee ang angle le to In to In position.  position.

2.

Adjust Adjust clea clearan rance ce betwe between en pad pad and blad bladee for le less ss than than 1.6 1.6 mm (0.062 (0.062 in). in).

3.

Tig igh hte ten n scr crew ews. s.

4.

Manu Manual ally ly pu pull ll kn knif ifee aang ngle le to Out  position.  position.

5.

Reseal Reseal anvil anvil pad to anvil anvil sectio section n using using a ssilic ilicone one sealan sealantt at seam seam between between  pad and anvil over over full length (Item 3, Figure Figure 11).

KNIFE BLADE REPLACEMENT  WARNING ING!! Use extreme extreme care care when when worki working ng near sharp knife b blade. lade. s WARN Tape all sharp edges before removal.

 REMOVAL  REMOVA L 1.

Move Move head head asse assemb mbly ly to to Head  Head Out  position.  position.

2.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

3.

Remove Remove cclam lamp p bar (see (see Clamp Clamp Bar Repl Replace acemen mentt proced procedure ure iin n Maintenance section).

4.

Pu Push sh kni knife fe ang angle le in in to ac acce cess ss b bla lade de..

5.

Remove Remove aall ll nuts nuts and and bolts bolts secur securing ing b blad ladee to kn knife ife angle angle..

6.

Remove bl blade.

 INSTALLATION   INSTALLA TION  Install parts in reverse order of removal.

 

MAINTENANCE - 9525675

M-19

 

REPLACING KNIFE CYLINDER SEALS  REMOVAL  REMOVA L

1.  bolts. Move head assembly assembly h halfwa alfway y out to expose expose knife cyli cylinder nder m mount ounting ing 2.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

3.

Discon Disconnec nectt air air li lines nes from from knife knife cylind cylinder er..

4.

Remove Remove b bolt oltss securi securing ng kn knife ife cylin cylinder der tto o head head side side plates plates..

5.

Remove Remove self-loc self-locking king nut ssecuri ecuring ng cylind cylinder er rod rod to knife knife angle stud. stud.

6.

Move knife angle angle out until until cylinder cylinder can b bee removed removed ffrom rom k knife nife aangle ngle stud.

7.

Remove ccy ylinder 

 DISASSEMBLY   DISASSEMB LY  1.

Remove Remove socket socket h head ead capscr capscrews ews holdi holding ng cover cover (I (Item tem 1 1,, Figure Figure 12) 12) to cylinder body (Item 2).

 Figure 12. 12. Knife Cylinder, Cylinder, Exploded View View 1

Cover

4

Polypak Rings

2

Cylinder Body

5

O-Ring

3

Piston

M-20

9525675 - MAINTENANCE

 

2.

Re Remo move ve cyli cylind nder er co cove verr.

3.

Remove Remove p pist iston on (Item (Item 3, 3, Figure Figure 12 12)) from ccyli ylinde nderr body body.

4.

Remove Remove p poly olypak pak ring ringss (Item (Item 4, Figur Figuree 12) an and d O-ring O-ring (Ite (Item m 5).

 ASSEMBLY  1.

Instal Installl new pol polypa ypak k ring ring in in cylind cylinder er body body..

NOTE:  Grease rings before assembling cylinder. 2.

Install Install new new polypak polypak ring ring on on pis piston, ton, aand nd install install piston piston in cylinder cylinder b body ody..

3.

Install Install new new O-ring O-ring in cap. Instal Installl cap to to cylinder cylinder body body and and sec secure ure with with four socket head capscrews.

4.

Force Force air air into into each each por portt to to check check for leaks. leaks.

NOTE:  Be sure top and bottom ports are located in their proper positions for installation of cylinder.  INSTALLATION   INSTALLA TION  1.

Move knife knife angle angle out until until knife knife cylin cylinder der rod can be installed installed on knife knife angle stud.

2.

Install Install self-loc self-locking king nut to knife angle angle sstud. tud. Tight Tighten en nut, nut, then b back ack off off one quarter of a turn.

3.

Install Install bolts bolts to secure secure knife knife cylinder cylinder to h head ead side plates. plates.

4.

Repl Replac acee nylo nylon n cyli cylind nder er shaf shaftt guid guide. e.

5.

Remo Remove ve kn knif ifee an angl glee sup suppo port rt..

6.

In Inssta tall ll ai airr lin lines es..

7.

Perform Perform Turni Turning ng Power Power On proce procedure dure in Operation Operation section. section.

 

MAINTENANCE - 9525675

M-21

 

CABLE CYLINDER

 Figure 13. 13. Cable Cylinder  1

Snap Ring

4

Cable

7

Cable Anchor  

2

Shaft

5

Head Assembly

8

Snap Ring

3

Pulley Wheels

6

Piston

9

Seals

 REMOVAL  REMOVA L 1.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

2.

Verify that all all pneumat pneumatic ic gauges gauges registe registerr 0 kPa ((0 0 psi psi). ). If an any y pneumatic pneumatic gauge registers greater than 0, adjust to 0 with regulator.

3.

Detach Detach cylind cylinder er cables cables from dancer dancer cab cable le adjus adjustment tment frames. frames. Det Detach ach spring side first! Remove locknuts using a 15/16 in ratcheting box wrench or open-end wrench.

4.

Disconnect Disconnect air lines from both sides of cable cable cyli cylinder nder..

5.

Remove Remove all wraps wraps securin securing g electrica electricall con conduit duit or air lines to cable cable cylinde cylinder. r.

M-22

9525675 - MAINTENANCE

 

6.

Remove Remove bolts bolts from from each each end end of cylin cylinder der that that mount mount cable cylinder cylinder to sideframes.

7.

Re Remo move ve cabl cablee cyl cylin inde derr.

 DISASSEMBLY  DISASSEMB LY AND ASSEMBLY  ASSEMBLY  1.

If cable cable cylind cylinder er is attached attached tto o sideframe sideframes, s, pe perform rform Step Stepss 1 th throug rough h4 under Removal of cable cylinder and Steps 2 through 10 below. below. If cylinder is removed, start with Step 5 below.

2.

Using Using sna snap p ring ring pliers, pliers, remove remove snap ring (Item 1, Figure Figure 13) an and d cen center ter shaft (Item 2) of pulley wheels (Item 3) on each end of cable cylinder. Remove pulley wheel.

3.

Pull Pull cab cables les ((Ite Item m 4, Figur Figuree 13) tthro hroug ugh h sid sidefr eframe ames. s.

4.

On end end of cylinder cylinder neares nearestt dan dancer cer home home po positi sition, on, fully fully eexten xtend d cable. cable.

5.

On same same end, end, remove remove head assembly assembly (Item (Item 5, 5, Figure Figure 13) and gently gently lower lower it to end of cable.

6.

Pull on cable cable until until end of of piston piston ((Item Item 6, 6, Figu Figure re 13) 13) is eexpos xposed. ed.

7.

Unscrew Unscrew tthread hreaded ed portio portion n of cable cable anc anchor hor (Item 7, Figure Figure 13).

NOTE:  If threads have been sealed with Loctite, very gently heat rod and unscrew it. 8.

Remove Remove snap snap rin ring g (Item (Item 8, Figure Figure 13) on ca cable ble seal seal in in head head assembly assembly (Item 5).

9.

Pull detach detached ed cable cable back through through hea head d ass assembly embly.. The ccable able and and one one seal will pop out of head assembly.

10.

Remove Remove expose exposed d se seals als (It (Item em 9, Figure Figure 1 13) 3) o on n pisto piston n (Item (Item 6).

NOTE:  Note which way cup is installed in piston. 11.

Inspect p paarts: a. Wash Wash par parts ts in in so solv lven entt that that is is not not flam flamma mabl ble. e.  b. Check cylinder parts for rus rust, t, distortion, or damage. c.

Chec Check k ccab able le and and aall ll seal sealss ffor or wear wear..

 

MAINTENANCE - 9525675

M-23

 

12.

Install Install seals seals on pist piston. on. If necessary necessary,, lightly lightly oil oil cup seal so so it fits fits over over  piston.

13.

Thread Thread cables cables throu through gh head head assembl assembly y (Item (Item 5, Figur Figuree 13). 13). Not Notee which which way cable seal sits in head and install seal.

NOTE:  Install cables so that longer cable is mounted on forward end of Splicer. 14.

Instal Installl snap snap ring ring to reta retain in cab cable le seal. seal.

15.

Coat threads threads of threaded threaded rod rod on end o off cabl cablee with with Loctite Loctite 242. Screw threaded rod into piston.

16.

Install Install head head assembly assembly (Item 5, 5, Figure Figure 13) to to cabl cablee cylinder cylinder tube, tube, then then to Splicer sideframes.

17.

On opposi opposite te end of cable cable cylinder cylinder,, pull cable until piston piston hits hits head assembly (Item 5, Figure 13).

18.

Repeat Repeat Steps Steps 6 throug through h 17 for other other cabl cable. e.

19.

Put cylind cylinder er cable cable through through hole hole in sideframe sideframe so so it hangs hangs down down on on inside inside of machine. Do not nick cables or sheaves.

20.

Install Install pulley pulley wheels wheels on each side of cable cable cylin cylinder der..

21.

Remount Remount cables cables to dancer dancer carriage; carriage; attach attach solid solid end first, first, then spring spring end.

22.

Turn tensi tensionin oning g nut (Item 2, Figure Figure 14) 14) unt until il spring spring (Item (Item 3 3)) is 5 57.15 7.15 mm to 58.74 mm (2.25 in to 2.31 in) long.

M-24

9525675 - MAINTENANCE

 

 Figure 14. 14. Setting Cable Tension Tension 1

Mounting Bracket

3

Spring

2

Tensioning Nut

4

Tensioning Rod

23.

Attach Attach air line line to cable cylinder cylinder.. Remove Remove all old old pipe pipe sealant. sealant. Reapply Reapply a minimum amount of pipe sealant starting with third thread and working  back.

24.

Set Run/Threa  Run/Thread-Up d-Up keyswitch  keyswitch to match dancer roll position.

25.

Perform Perform Turni Turning ng Power Power On proce procedure dure in Operation Operation section. section.

26.

Set regula regulator tor R1 R1 to 552 kPa (80 (80 psi) psi) an and d regulato regulatorr R2 to 138 138 kP kPaa (20 psi). Check for leaks with dancer cable cylinders in both Thread-Up Thread-Up and  and  Run position.  Run  position.

27.

Readju Readjust st regul regulato atorr R1 to normal normal rrunn unning ing ttens ension ion..

 

MAINTENANCE - 9525675

M-25

 

SETTING UP CABLE CYLINDER E/P TRANSDUCER NOTE:  E/P setup should be performed without paper threaded through the Splicer. sDANGER!

Dancer roll moves during E/P setup and could crush someone in its path. Make sure Splicer area is clear of personnel before performing this procedure.

1.

Perform Perform Turni Turning ng Power Power On proce procedure dure in Operation Operation section. section.

2.

Re Remo move ve th thee E/P E/P co cove verr.

sDANGER!

Before turning Run/Thread-Up key, confirm that people are clear of Splicer. Failure to do so could result in severe injury or death. Turning Turning R un/T un/T hre hr ead-U -Up p key causes dancer roll to move. Pinch points exist between dancer roll and other o ther parts of Splicer.

3.

Turn Run/Thread  Run/Thread-Up -Up keyswitch  keyswitch to Thread-Up Thread-Up position.  position. Remove key when dancer is in forward position. Keep key with you.

 Figure 15. 15. E/P Transducer  Transducer  1

Zero Potentio iom meter  ter 

2

Span Pot Potentio iom meter ter

3

Gauge

M-26

9525675 - MAINTENANCE

 

4.

Se Sett the the ze zero ro po pote tent ntio iome mete ter. r. a. Adjust Adjust the zero zero pote potenti ntiome ometer ter (Ite (Item m 1, Figur Figuree 15) u unti ntill the g gaug augee (Item 3) registers 138 kPa (20 psi).  b. Decrease pressure sligh slightly tly.. c.

Sl Slow owly ly inc incre reas asee pres pressu sure re to to 138 138 kP kPaa (20 (20 ps psi) i)..

5.

Turn Run/Thread  Run/Thread-Up -Up keyswitch  keyswitch to Run to  Run position.  position.

6.

Set web web tens tension ion to 84 84 kg (18 (185 5 lb lb)) on touc touchsc hscree reen. n.

7.

Se Sett the the span span po pote tent ntio iome mete terr. a. Adjust Adjust the span span pote potenti ntiome ometer ter (Ite (Item m 2, Figur Figuree 15) u unti ntill the g gaug augee (Item 3) registers 545 kPa (79 psi).  b. Decrease pressure sligh slightly tly.. c. Sl Slow owly ly inc incre reas asee pres pressu sure re to to 545 545 kP kPaa (79 (79 ps psi) i)..

8.

Repeat Repeat Step Stepss 3 and 4 tto o res reset et the the zer zero o potent potentiom iomete eterr.

9.

Verify setup. a. Set web web tensi tension on to to 20 kg kg (4 (44 4 lb). lb). Gauge Gauge should should regist register er 234 234 kP kPaa ± 21 kPa (34 psi ± 3 psi).  b. Set web tension to 5 50 0 kg (110 lb). Gaug Gaugee should register 3 379 79 kPa ± 21 kPa (55 psi ± 3 psi). c. Set web web tensi tension on to to 80 kg kg (1 (176 76 lb). lb). Gaug Gaugee should should regist register er 524 524 k kPa Pa ± 21 kPa (76 psi ± 3 psi).

10.

If verifica verification tion procedure proceduress in Step 9 do not not perf perform orm as as specifie specified, d, repeat procedure.

 

MAINTENANCE - 9525675

M-27

 

DANCER SYSTEM

 Figure 16. 16. Dancer System 1

Air Cylinder Plugs

8

Chain

2

Access Cover

9

Dancer Carriage

3

Air Cylinder Cables

10

Rack Gear  

4

Cable Mo Mounting Br Brackets

11

Dancer S Sccrapers

5

Support Plate

12

Spring Steel Wear Cover  

6

Dancer Carriage Guides

13

Spiral Pins

7

Chain Guide Bracket

14

Short Dancer Track  

DISASSEMBLY 1.

Move Move Spl Splic icer er hea head d asse assemb mbli lies es to to Head In position. In position.

2.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

M-28

9525675 - MAINTENANCE

 

3.

Verify that all all pneumat pneumatic ic gauges gauges registe registerr 0 kPa ((0 0 psi psi). ). If an any y pneumatic pneumatic gauge registers greater than 0, adjust to 0 with regulator.

4.

Di Dise seng ngag agee air air cyli cylind nder ers: s: a.  b. c.

Remo Remove ve ac acce cess ss co cove verr (It (Item em 2, Fi Figu gure re 16). 16). Disconnect air cylind cylinder er cables (Item 3, Figure 16) from dan dancer cer carriage (Item 9). Remove Remove cable cable mount mounting ing bra bracke ckets ts ((Ite Item m 4, Figu Figure re 16) 16) o on n dance dancerr sid sidee  plates.

NOTE:  Perform Step 5 on both sides of Splicer. 5.

Provid Providee cleara clearance nce to to acc access ess danc dancer er ca carri rriage age g guid uides: es: a. Remo Remove ve supp suppor ortt pla plate te (Ite (Item m 5, 5, Figu Figure re 16). 16).  b. Remove dancer carriage guides (It (Item em 6, Figure 16). Align gui guides des with gap between short dancer track and long dancer track to remove.

6.

Di Dise sen ngage age enco encod der er:: a. Remo Remove ve cha chain in gui guide de bra brack cket et ((It Item em 7 7,, Figu Figure re 16) 16)..  b. Remove chain (Item 8, Figure 16).

7.

Raise Raise dan dancer cer car carria riage ge (It (Item em 9, 9, Figur Figuree 16 16): ): a. Remove Remove rack rack gear gear (Ite (Item m 10, 10, Fi Figur guree 16 16)) from from eeach ach sid sidee of Spl Splice icer. r.  b. Lift and support dan dancer cer carriage above dancer track.

NOTE:  Perform Step 8 on both sides of Splicer. 8.

Acce Access ss dan dance cerr trac track k comp compon onen ents ts:: a.  b. c. d.

9.

Remo Remove ve spring dan dance cerr steel scra scrape pers rs ((It Item emer1 11, 1, Fig Figur ure e 16 16). ). Remove wear cov cover (Item 12, Figure 16). Remove Remove spiral spiral pins pins (Item (Item 13, 13, Fig Figure ure 16) 16),, the then n bolts bolts,, along along shor shortt dancer track (Item 14). Re Remo move ve shor shortt d dan ance cerr ttra rack ck..

Acce Access ss danc dancer er carr carria iage ge comp compon onen ents ts:: a. Lower Lower and and suppor supportt dan dancer cer carr carriag iagee bel below ow Sp Splic licer er frame. frame. To To lowe lower, r, tilt dancer carriage in cross-machine direction to clear lead screws and head tracks.  b. Remove dancer rolls, bearing bearings, s, and/or sideplates.

  M-29

MAINTENANCE - 9525675

 

REASSEMBLY 1.

Reasse Reassembl mblee and and re repos positi ition on danc dancer er ccarr arriag iage: e: a. Replac Replacee side sidepla plates tes,, b bear earing ings, s, and/or and/or dan dancer cer rolls. rolls.  b. c.

Raise dancer carriage into Spli Splicer cer frame. To raise, til tiltt dancer carriage in cross-machine direction to clear lead screws and head tracks. Lift Lift and and suppor supportt danc dancer er carria carriage ge abo above ve dan dancer cer tra track. ck.

NOTE:  Perform Step 2 on both sides of Splicer. 2.

Re Reas asse semb mble le dan dance cerr trac track: k: a. Replac Replacee short short dancer dancer trac track. k. R Repl eplace ace,, but do n not ot ttigh ighten ten,, bol bolts. ts.  b. Replace spiral pins alon along g short dancer track; then tighten bolts. c. Repl Replac acee spr sprin ing g ste steel el wear wear cove coverr. d. Re Repl plac acee da dancer ncer scra scrape pers rs.. e. Replac Replacee dancer dancer carr carriag iagee gui guides des.. Do no nott overti overtight ghten. en. Alig Align n guides guides f.

with gap between short dancer track and long dancer track. Replace ssu upport pl plate.

3.

Realig Realign n danc dancer er carria carriage ge on dancer dancer tra track: ck: a. Lowe Lowerr d dan ance cerr carr carria iage ge onto onto da danc ncer er trac track. k.  b. Replace rack gear on both sid sides es of Splicer. Splicer. c. Positi Position on danc dancer er rolls rolls para paralle llell to caps capstan tan rroll oll.. Use lloop ooped ed ta tape pe (I (Item tem 1, Figure 17) to check if dancer roll (Item 2) is parallel to capstan roll (Item 3). Perform Dancer Roll Alignment procedure in Maintenance section if necessary. necessary.

4.

Re Re-e -en ngag gage enc enco oder er:: a.  b.

Replace cchain hain.guide brack Replace bracket. et.

M-30

9525675 - MAINTENANCE

 

 Figure 17. 17. Checking Dancer Roll Alignment  Alignment  1

Looped Tape

2

Dancer Roll

3

Capstan Roll

5.

Re Re-e -eng ngag agee air air cy cyli lind nder er:: a. Replac Replacee cable cable mou mounti nting ng bra bracke ckets ts on dan dancer cer sid sidee plat plates. es.  b. Reconnect air cylinder cabl cables es to dancer carriage. c. Replace ac access cco over.

6.

Perform Perform Turni Turning ng Power Power On proce procedure dure in Operation Operation section. section.

  M-31

MAINTENANCE - 9525675

 

DANCER ROLL ALIGNMENT 1.

If dancer dancer roll roll is not parall parallel el to capstan capstan roll, roll, choose choose one side side of dancer dancer roll to be moved.

2.

Loosen Loosen all bolts bolts (Item (Item 1, Fi Figure gure 18) that that hold hold rac rack k gear gear (Item (Item 2) to frame. Adjust rack gear until dancer roll and capstan roll are parallel.

 Figure 18. 18. Shim Placement 

3.

1

Bolts

3

Dancer Wheel

2

Rack Gear

4

Shim

Align Align dancer dancer ro roll ll under under one one rack gear bolt. bolt. P Place lace 0.75 0.75 mm (0.030 (0.030 in) sshim him (Item 4, Figure 18) under each dancer wheel (Item 3) to hold proper clearance dimension between rack and dancer gear. Tighten bolt. Remove shim before running machine.

4.

Tighten Tighten ea each ch bol boltt with dancer dancer roll directly directly under under eeach ach bolt bolt and shim under under dancer wheel.

5.

Move dance dancerr roll roll from from one end of of its travel travel to the other other and check check for binding.

M-32

9525675 - MAINTENANCE

 

INDEX SYSTEM The index system consists of a wheel mechanism that allows the operator to index the prepared leading edge of the new web to centerline of the nip roll.

 Figure 19. 19. Index Wheel  1

Index Wheel

2

Shoulder Bolt

3

Adjustment B Bo ol t

  M-33

MAINTENANCE - 9525675

 

INDEX WHEEL ADJUSTMENT To determine if the index wheels are properly adjusted, follow these steps: 1.

Run Run both both head headss to Head Out  position.  position.

2.

Perform Perform Splice Splice Preparatio Preparation n proced procedure ure on one head (See Splic Splicee Preparation in Operation section).  NOTE: Do not use splicing splicing tape.

3.

Use contro controls ls to move move prep prepare ared dh head ead to Head to Head In position. In position.

4.

Using Using a le level vel (I (Item tem 1, 1, Figure Figure 20) 20) an and d scal scalee (Item (Item 2), determine determine distance distance from edge of paper (Item 3) to top of the nip roll. Paper edge should be 70 mm (2.75 in) from top of nip roll (Item 4).

 Figure 20. 20. Proper Indexed Paper Paper Edge Locatio Location n 1

Level

3

Paper  

2

Scale

4

Nip Roll

5.

If paper paper is less less than than 70 mm (2.75 (2.75 in) from from to top p of n nip ip rol roll, l, turn adjusting adjusting  bolt (Item 3, Figure 19) clockwise. clockwise. If more than 70 mm (2.75 in), turn adjusting bolt counterclockwise.

6.

Repeat Repeat until until 70 mm (2.7 (2.75 5 in) in) is obtain obtained. ed.

NOTE:  If index wheel shows excessive wear, rotate 180° to provide more accurate indexing.

M-34

9525675 - MAINTENANCE

 

CAPSTAN ROLL SYSTEM The capstan roll system (Figure 21) consists of the following components: capstan roll, drive motor, belt, sheaves, and bearings.

NOTE:  The capstan encoder should be preloaded against the capstan roll with no more than 227 N (51 lb) of force. It only needs to press against the roll hard enough so the measuring wheel doesn't slip.

 Figure 21. 21. Capstan Roll System System

  M-35

MAINTENANCE - 9525675

 

TENSIONING CAPSTAN BELT 1.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

2.

Lo Loos osen en mo moto torr mou mount ntin ing g bol bolts ts..

3.

Turn Turn capst capstan an moto motorr tensi tensioni oning ng bolt bolt until: until: a. 4 mm (0.15 (0.156 6 in) in) de defle flecti ction on wit with h 22.5 22.5 N (5 lb) of for force ce give given n2 250 50 mm (10 in) of free span is present or   b. 7 mm (0.281 in) deflection w with ith 22.5 N (5 lb) of force giv given en a free span of 450 mm (18 in) is present.

4.

Tighten Tighten m motor otor mounting mounting bolts. bolts. Torque Torque to 50 50 N-m (37 ft-lb). ft-lb).

 Figure 22. 22. Belt Adjustment  Adjustment  1

Drive Belt

2

Capstan Mo Mottor Pu Pulley ley

3

Capstan Roll Pulle lley

M-36

9525675 - MAINTENANCE

 

REPLACING CAPSTAN ROLL BEARINGS 1.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

2.

Suppor Supportt caps capstan tan rol rolll with with chain chain hoist. hoist.

3.

If capstan capstan roll roll is driven, driven, loosen loosen capsta capstan n drive drive mot motor or by loose loosening ning bolts bolts on sides of capstan drive motor bracket.

4.

Remov Removee belt belt by pu pulli lling ng it it off caps capstan tan roll roll pull pulley ey..

5.

Remove Remove ca capst pstan an roll roll pulley pulley by disa disasse ssembl mbling ing bush bushing ing..

6.

Remove Remove bolts bolts from from each bearing bearing housi housing ng (o (on n eac each h end of cap capstan stan roll). roll).

7.

Remo Remove ve old old bea beari ring ngss from from hou housi sing ng:: a. Use Use pr pry y bar bar to tur turn n bear bearin ing g side sidewa ways ys in in hous housin ing. g.  b. Pull bearing out of hou housing. sing.

8.

In Inst stal alll new new be bear arin ings gs in in hous housin ings gs..

9.

Install bolts.

10 10..

In Inst stal alll caps capsta tan n roll roll pul pulle ley y.

11.

Asse Assemble mble bushing bushing and install install onto onto capstan capstan ro roll ll p pulley ulley..

12.

Install belt.

13.

If capstan capstan roll roll is driven driven,, fasten fasten capstan capstan drive drive motor motor in p place lace b by y tighteni tightening ng  bolts on sides of capstan capstan motor bracket.

14.

Tighten Tighten b belt elt accordi according ng to Tensioni Tensioning ng Capstan Capstan Belt procedure procedure in Maintenance section.

  M-37

MAINTENANCE - 9525675

 

PNEUMATIC ADJUSTMENTS

 Figure 23. 23. Operator Side Pneumatics Pneumatics ITEM (FIGURE 23)

COMPONENT

1

R5

Manual dancer control

Adjust as needed

2

R6

Maximum brake pressure

552 kPa (80 psi)

3

R7

Manual brake control, left side

Adjust as needed

4

R8

Manual brake control, right side

Adjust as needed

5

PR 3

Piloted regulator   (volume booster)

 None

6

PR 4

Piloted regulator   (volume booster)

 None

7

QE5

Quick exhaust valve

None

8

QE8

Quick exhaust valve

None

9

PR 1

Piloted regulator   (volume booster)

 None

10

QE3

Quick exhaust valve

None

DESCRIPTION

NOMINAL SETTING

M-38

9525675 - MAINTENANCE

 

 Figure 24. 24. Drive Side Pneumatics Pneumatics ITEM (FIGURE 24)

COMPONENT

1

QE4

Cable cylinder quick exhaust valve

None

2

PR2

Piloted regulator   (volume booster)

 None

3

CK1

Check valve

None

4

R2

Dancer roll bias pressure

138 kPa (20 psi) exactly

5

R3

Secondary dancer roll bias pressure

241 kPa (35 psi) exactly

6

—

Dancer roll bias pressure valve

None

7

—

Clamp valve

None

8

—

Knife valve

None

9

—

Run/Thread-Up valve

None

10

R10

Capstan assist low-pressure regulator

103 kPa (15 psi)

11

R9

Capstan assist high-pressure regulator

345 kPa (50 psi)

12

—

Capstan assist valve

Adjust with R9 and R10

13

R4

Capstan clutch regulator

Adjust according to run conditions: 207 kPa (30 psi) for lightweight webs, 345 to 415 kPa (50 to 60 psi) for heavier webs.

14

—

Capstan clutch valve

Adjust with R4

DESCRIPTION

NOMINAL SETTING

  M-39

MAINTENANCE - 9525675

 

ITEM (FIGURE 24)

COMPONENT

15

—

Nip roll brake valve

None

16

—

Automatic index valve (optional)

None

17

—

Automatic index valve (optional)

None

18

L1

Lubricator—Lubricates pneumatic system

Maintain oil level. Adjust for 5 to 6 drops as dancer moves from forward to home position.

19

R1

System pressure

552 kPa (80 psi)

20

F2

Filter

None

21

—

Automatic filter drain valve

None

22

F1

Filter

None

23

—

Automatic filter drain valve

None

24

—

Zero Energy State (ZES) Valve

None

25

PV1

Pneumatic lockout valve

None

26

—

Clamp valve

None

27

—

Knife valve

None

28

QE2

Quick exhaust valve

None

29

FC1

Flow control valve

Time required for dancer roll to travel from forward position to home position: • 5 to 7 seconds for 1H 300 Splicers • 6 to 8 seconds for 1H400 Splicers

 —

R700

Automatic index regulator (not shown)

241 to 552 kPa (35 to 80 psi)

DESCRIPTION

NOMINAL SETTING

M-40

9525675 - MAINTENANCE

 

E/P TRANSDUCERS FOR ROLL STANDS The roll stand brake pressures are modulated by Electro-Pneumatic (E/P) transducers. Each Splicer has two brake E/P transducers (one for the left roll and one for the right roll).

TEST PROCEDURE 1.

Set regu regulat lator or R6 ((Ite Item m 3, Figur Figuree 25) tto o 552 kPa ((80 80 psi) psi)..

 Figure 25. 25. E/P Location—Fixed Roll Stands 1

Lef eftt Bra Brake ke E/P E/P T Tra rans nsdu duccer 

2

Ri Righ ghtt Bra Brake ke E/P E/P T Tra rans nsd duce ucer 

3

Regulator R6

  M-41

MAINTENANCE - 9525675

 

 Figure 26. 26. E/P Locations—Roll-Out Locations—Roll-Out Roll Stan Stands ds

sDANGER!

1

Left Left Br Braake E/P E/P T Tra rans nsdu duccer 

2

Ri Righ ghtt B Bra rake ke E/P E/P T Tra rans nsd duce ucer 

Before ttu urning Run/Thread-Up key, confirm that people are clear of Splicer. Failure to do so can ca n result in severe injury or death. Turning Run/Thread-Up key causes dancer assembly to move. Pinch points exist between dancer assembly and other parts of Splicer.

2.

Turn Run/Thread  Run/Thread-Up -Up keyswitch to Thread-Up Thread-Up position  position to move dancer assembly to forward position. As dancer assembly moves forward, output  pressure of E/P valve must must drop to 0 kPa (0 psi). If outpu outputt pressure does not drop to 0 kPa (0 psi), perform Setup Procedure to set zero and span  potentiometers or check check running roll.

3.

Turn Run/Thread  Run/Thread-Up -Up keyswitch  keyswitch to Run to  Run position  position to move dancer roll to home position. As dancer roll moves toward home position, output of E/P will fluctuate until the dancer reaches the home position.

4.

Repeat Repeat Steps Steps 2 and 3 ffor or the the opp opposi osite te rol roll. l.

M-42

9525675 - MAINTENANCE

 

SETUP PROCEDURE 1.

Perform Perform Turni Turning ng Power Power On proce procedure dure in Operation Operation section. section.

2.

Verify air supply supply to E/P E/P transduce transducers rs (regulat (regulator or R6) is at least least 552 552 kPa kPa (80 psi).

3.

Re Remo move ve th thee E/ E/P P cov cover ers. s.

4.

Remove Remove AC power power cables cables (Item (Item 4, Figure Figure 27) from brake brake releas releasee valves valves (mounted behind E/P transducers).

sCAUT CAUTION! ION!

AC power power cables cables and other other DIN DIN cconne onnecto ctors rs shoul should d be removed only by a qualified technician. Improper handling could result in damage to connectors and valves.

 Figure 27. 27. E/P Transducers Transducers 1

Zero Potentiometer

3

Gauge

2

Span Potentiometer

4

AC Power Cable

NOTE:  E/P setup should be performed on the nonrunning roll. 5.

Press Brake Set/Release push-button Set/Release push-button to release brakes.

  M-43

MAINTENANCE - 9525675

 

6.

Set the the zero potentio potentiometer meter (Item 1, Figure Figure 27) on on the left brake E/P transducer: a. Adjust Adjust the the zero zero poten potentio tiomet meter er to p prov rovide ide lligh ightt brake brake press pressure ure when when turning the roll stand chuck.  b.

Decrease pressure until tthe he roll stand chuck spins spins freely. freely.

7.

Change Change running running roll and repeat repeat Steps Steps 5 and 6 for the right right brake brake E/P E/P transducer.

8.

Press Brake Set/Release push-button Set/Release push-button to set brakes.

9.

Set the the span span pot potentio entiometer meter (Item 2, Figure Figure 27) o on n th thee left brake E/P transducer: a. Adjust Adjust the span span pote potenti ntiome ometer ter cloc clockwi kwise se so tthat hat the the ga gaug ugee (Item (Item 3, Figure 27) registers 552 kPa (80 psi) ±34 kPa (5 psi).  b. Turn potentiome potentiometer ter counterclockwise counterclockwise to decrease pressure sl slightly ightly.. c. Slowly Slowly inc increa rease se pres pressur suree to tthe he setp setpoin ointt attai attained ned in Step Step 9a. 9a.

10.

Change Change running running roll and repeat repeat Steps Steps 8 and 9 for the right right brake brake E/P E/P transducer.

11.

Repeat Steps 5 throug through h 7 to re readjus adjustt the the zero zero po potenti tentiomete ometers. rs.

12 12..

Re Rein inst stal alll E/P E/P cove covers rs..

13.

Reconn Reconnect ect AC AC power power cable cabless to brake brake rele release ase valv valves. es.

NOTE:  Ensure machine is in correct roll-running condition after adjustments are complete.

DETERMINATION OF BRAKE GAIN This procedure assumes that all brake E/P transducers have been properly adjusted. See E/P Transducers Setup procedure in Maintenance section. Brake Gain value must be determined while running a large paper roll (1300 mm to 1500 mm [50 in to 60 in] diameter). Paper speed should be above 120 MPM (400 FPM), and the dancer roll must be stable. Brake Gain should be determined for left and right roll stands. If dancer roll is not stable, check if indicated roll diameter is correct. If diameter indication is not correct, check sensors and encoder. If diameter indication is correct, increase Brake Gain until dancer roll stability is achieved.

M-44

9525675 - MAINTENANCE

 

Once dancer roll stability is achieved, perform the following steps: 1.

Verify erify R2 (Bia (Biass Pressu Pressure) re) is is at 140 140 kPa (20 (20 psi) psi)..

2.

Record “Web Tensi Tension” on” as indicated indicated by the the touchsc touchscreen reen d disp isplay lay.. Normal Normal range for this value is 57 to 102 kg (125 to 225 lb).

3.

Monitor Monitor voltag voltagee command command to to running running roll brake brakess (si (signal gnal may vary vary slightly). This signal will be 0-10 V DC. For left roll check wire number 20201 with respect to 20001. For right roll check 20200 with respect to 20001. Record the voltage command.

4.

Record Record indicated indicated roll roll diamet diameter er (for metric metric configur configured ed machines, machines, tthis his value value will have to be converted converted to inches: 25.4 mm = 1 in).

5.

Record Record rol rolll radiu radiuss (radi (radius us = d diam iamete eter/2 r/2). ).

Place each set of values into the following formula for Digital Splicers: BRAK BR AKE E GAI GAIN N =[ =[Ro Roll ll Ra Radi dius us (in) (in)]] [[We Web bT Teension ion ((lb lbss)] [Brake Voltage Command (Volts)]

×

0. 0.1 112

N-m N-m in-lb

Example: Roll Radius (in) = 25 in Web Tension (lb) = 150 lb Brake Voltage Voltage Command (V) = 4 V BRAKE GAIN = [25 in] [150 lb]   4V

×

0.112 N-m = 105 N-m in-lb V

If Brake Gain values greatlyadjustments, from left Roll check for differences in E/Pvary transducer airStand leaksto inright Roll Roll StandStand, brakes, excessive drag from Roll Stand bearings, or grease on brake pads. Calculate the average of the Brake Gain values and enter into V5014, then set V5077 to 1 for value to take effect (see Modifying V-Memory Locations in PLC in Maintenance section). Record this value in the current value column of the Timer/Counter Reference list in Maintenance section. Larger numbers will make the system more sluggish to respond to change (dancer roll will take longer to reach desired position), while smaller numbers will tend to cause more instability (dancer roll will oscillate).

  M-45

MAINTENANCE - 9525675

 

LIMIT SWITCHES GENERAL The Marquip Splicer uses two limit switches per head, limiting travel of the head. One switch (Head Out) stops the head directly under the index wheels, and another (Head In), stops the head before carrier blocks bottom onto lead screw  bearing blocks.  ADJUSTMENT  1.

Adjust Adjust Head Head Out Out switches switches to stop stop distan distance ce bet between ween the carrier carrier block block (Item 2, Figure 28) 28) and the the bearing block (Item 1) of 67 mm (2.625 in).

 Figure 28. 28. Head Out Limit Switches Switches

2.

1

Bearing Block

3

Limit Switch Arm

2

Carrier Block

4

Actuator  

Adjust Adjust Head Head In switches switches to to sto stop p heads heads 16 mm to 19 mm (0.62 (0.625 5 in to 0.75 in) from their bottomed bottomed position position (Figure 29). 29).

M-46

9525675 - MAINTENANCE

 

 Figure 29. 29. Head In Limit Switches 1

Bearing Block

3

Limit Switch Arm

2

Carrier Block

4

Actuator  

PHOTOEYES  DESCRIPTION  Two photoeyes are mounted within each roll stand to monitor the running web. Regardless of maximum machine splicing speed, maximum optical splice speed is 200 MPM (650 FPM). SETUP  1.

Set Light/ Light/Dark Dark Select Selector or sw switch itch to to light light positi position on (switch (switch is is located located insid insidee scanning head).

2.

Maximum Maximum height height operati operation on is determined determined by a me mercury rcury swit switch. ch.

NOTE:  Photoeye beam is infrared and invisible to the eye. Use a board 1 m square (3 ft square) to locate line of sight. Board should be moved along an angle set by normal paper path from chuck to head assembly.

  M-47

MAINTENANCE - 9525675

 

 ALIGNMENT  1.

Lower the roll roll stand stand arms until centerline centerline of chuck chuck iiss 356 mm (14 in) from floor (Figure 30 or 31).

 Figure 30. 30. Adjusting Vertical Vertical Line of Sight, Sight,  Langston JP Roll Stand 

 Figure 31. 31. Adjusting Vertical Vertical Line of Sight, Sight,  Langston 143 Roll Roll Stand  2.

Adjust Adjust mercury mercury switch switch (1 HGSW on right right Roll Roll Stand Stand arm or 2 HGS HGSW W on left stand) to close at this point.

M-48

9525675 - MAINTENANCE

 

3.

Set photoeye photoeye intens intensity ity.. Intensity Intensity shoul should d be as hi high gh as possib possible le without without  beam reflection off any surface surface behind chuck. a. Using Using the the 1 m (3 ft) squ square are of b boar oard, d, d dete etermi rmine ne aactu ctual al rrang ange. e.  b. Adjust range by turning potentiometer located under under access cover on top of photoeye. Counterclockwise adjustment shortens range.

4.

Aim photoe photoeye ye acco accordi rding ng to to Figure Figuress 30 o orr 31 and and 32. 32.

 Figure 32. 32. Adjusting Horizontal Horizontal Line of Sight, Sight, Typical  Typical  CHECKING FOR PROPER PHOTOEYE OPERATION 1.

Prepare Prepare Splicer Splicer for splice. splice. See Splice Splice Preparatio Preparation n pro procedur ceduree in Operation Operation section.

2.

Select Select side side of mac machin hinee to tes testt by pus pushin hing g the the Running Roll  soft-button.  soft-button.

3.

Cover Cover both both ph photo otoeye eyess on side side of of machin machinee select selected. ed.

4.

Lo Lowe werr the the roll roll stan stand d arm armss u unt ntil il Optical Splice-OPT OK  indicator  indicator illuminates for roll running.

5.

Le Leav avee o opt ptic ical al spl splic icee dis disab able led. d.

6.

Unco Uncove verr p pho hoto toey eyes es on onee at a time time..

7.

Optical Splice-OPT OK  indicator  indicator should go out when either photoeye is uncovered.

8.

Cover both phot photoeyes oeyes again. again. Ena Enable ble o optica pticall splice. splice. Splice Splice should should fire fire when either photoeye is uncovered.

  M-49

MAINTENANCE - 9525675

 

MERCURY SWITCHES (non-Marquip roll stands) Mercury switches are contained in junction boxes mounted to each roll stand arm on the drive side. Fixed roll stands have four mercury switches per junction box; roll-out roll stands have one mercury switch per junction box. Mercury switches control the range of motion of roll stand arms and enable the optical splice circuit. Before replacing a broken mercury switch, follow Safety Lockout procedures in the Operation section. s WA  WARN RNIN ING! G!

The The m mer ercu cury ry in tthe hese se sswi witc tche hess is a h haz azar ardo dous us ma mate teri rial al.. Refer to the Material Safety Data Sheet before handling mercury switches.

ADJUSTMENT 1.

Raise Raise or low lower er the the roll roll stand stand ar arm m to th thee desire desired d height height..

NOTE:  See customer print set for heights. 2.

Remove Remove cover cover of of mercu mercury ry swit switch ch encl enclos osure ure..

3.

Loosen Loosen adjust adjusting ing screw screw ((Item Item 1, Figure Figure 33) 33) and rotat rotatee mercury mercury switch switch to achieve opening or closing of contacts (Item 2). For example, when adjusting 1 HGSW, HGSW, mercury must just close contacts when chuck is 356 mm (14 in) from floor. At this point tighten screw to maintain angle of switch.

4.

Install co cover.

 Figure 33. 33. Mercury Switch Adjustment  1

Adjusting Sc Screw

2

Contacts

M-50

9525675 - MAINTENANCE

 

REPLACING A BROKEN MERCURY SWITCH sWA WARN RNIN ING! G!

Me Merc rcur ury y is to toxi xic. c. Br Brea eath thin ing g va vapo pors rs or ab abso sorb rbin ing g mercury through skin is harmful. Clean up broken mercury switch immediately.

1.

Follow Follow safe-han safe-handlin dling g guidelin guidelines es in the Materia Materiall Safety Safety Data Data Sheet Sheet to to remove any loose debris from the broken mercury switch.

2.

Shut off Control Power .

3.

Cut the the wires wires to to the broken broken mercury mercury swit switch ch and and remove remove the the remaini remaining ng components of the broken switch.

4.

Splice Splice in the the wire wiress of a new new me mercu rcury ry sswit witch. ch.

5.

Place Place the the new new mercur mercury y switc switch h in its its h hold olding ing clamp. clamp.

  M-51

MAINTENANCE - 9525675

 

DANCER ENCODER  REMOVAL  REMOVA L 1.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

2.

Discon Disconnec nectt wires wires to to encod encoder er (Item (Item 3, Fi Figur guree 34 34). ).

 Figure 34. 34. Removing and Installing Installing Encoder  1

Encoder Shaft

3

Encoder  

2

Torque Mounting Bracket

4

Setscrew

3.

Loosen Loosen setscr setscrew ew (I (Item tem 4, Figure Figure 34) on encod encoder er sh shaft aft (Item (Item 1).

4.

Remove Remove ttorq orque ue mo moun untin ting g bracke brackett (Item (Item 2, F Figu igure re 34). 34).

5.

Remove Remove encode encoderr from from torq torque ue m moun ountin ting g br brack acket. et.

M-52

9525675 - MAINTENANCE

 

 INSTALLATION   INSTALLA TION  1.

Mount Mount n new ew enco encoder der to to torqu torquee mo mount unting ing bra bracke cket. t.

2.

Repl Replac acee torq torque ue mou mount ntin ing g brac bracke ket. t.

3.

Tighte Tighten n setscr setscrew ew on encod encoder er shaft. shaft.

4.

Conn Connec ectt wire wiress to enco encode derr.

5.

Rest Restor oree el elec ectr tric ical al po powe werr.

  M-53

MAINTENANCE - 9525675

 

CHAIN-DRIVEN DANCER ENCODER  REMOVAL  REMOVA L 1.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

2.

Discon Disconnec nectt wires wires to to encod encoder er (Item (Item 6, Fi Figur guree 35 35). ).

 Figure 35. 35. Removing and Installing Installing Encoder  1

Sprocket

4

Shaft

2

Bearing

5

Torque Mounting Bracket

3

Mounting Bracket

6

Encoder  

3.

Loosen Loosen setscr setscrew ew o on n encoder encoder sprocket sprocket shaft (Item 4, Figure Figure 35).

4.

Remove Remove ttorq orque ue mo moun untin ting g bracke brackett (Item (Item 5, F Figu igure re 35) 35)

5.

Remove Remove encode encoderr from from torq torque ue m moun ountin ting g br brack acket. et.

M-54

9525675 - MAINTENANCE

 

 INSTALLATION   INSTALLA TION  1.

Mount Mount n new ew enco encoder der to to torqu torquee mo mount unting ing bra bracke cket. t.

2.

Repl Replac acee torq torque ue mou mount ntin ing g brac bracke ket. t.

3.

Tighte Tighten n se setsc tscrew rew on eenco ncoder der sprock sprocket et shaf shaftt

4.

Conn Connec ectt wire wiress to enco encode derr.

5.

Perform Perform Turni Turning ng Power Power On proce procedure dure in Operation Operation section. section.

DANCER HOME PROXIMITY SENSOR SETUP PROCEDURE 1.

Allow Allow dan dancer cer ass assemb embly ly to move move tto o tthe he Home  Home position.  position. If the Splicer is threaded with paper, this can be done by releasing the brake on the running roll side.

2.

Turn Turn air air of offf and and lock lock out out pneu pneumat matic ic v valv alve. e.

3.

Shut off Control Power .

4.

Verify d dancer ancer roll roll home home proximity proximity sensor sensor is is directly directly beneath beneath singl singlee (6 in) dancer roll. If not, loosen the locking nuts on the proximity sensor, and slide it directly beneath single dancer roll.

5.

Adjust Adjust the the distance distance between between the the proximit proximity y sensor sensor and and the dancer dancer roll roll to 225 mm (0.08-0.20 in).

6.

Tighten Tighten tthe he lo locknu cknuts ts and and verify verify tthe he se sett di distanc stancee was maintaine maintained. d.

7.

Verify proper proper operatio operation n by watchi watching ng the the ligh lightt on the the bottom bottom of the  proximity sensor with with power on. The light should be on when whenever ever the dancer roll is directly above the sensor and should turn off when the dancer roll is moved away from the sensor.

  M-55

MAINTENANCE - 9525675

 

AUTOMATIC INDEX SYSTEM (optional) SETUP PROCEDURE 1.

Perform Perform Turni Turning ng Power Power On proce procedure dure in Operation Operation section. section.

2.

Move Move head head asse assemb mbly ly to th thee Head In position. In position.

3.

Set regul regulator ator R700 pressure pressure to 241 241 to to 55 552 2 kP kPaa (35 to 80 80 psi). psi).

4.

Use a sprin spring g scale scale to set each each aadjus djustment tment block to 44 44.5 .5 to 66.75 66.75 N (10 to 15 lb). Begin with the motor-side adjustment block (second block from end) and work to the opposite side.

NOTE:  The block closest to motor is nonadjusta nonadjustable. ble. 5.

Repeat Repeat Step 4 at least least once once tto o ensure ensure accurat accuratee nip wheel adjustmen adjustment. t.

6.

To instal installl new softw software, are, perfor perform m Stor Storing ing a Program Program in C CPU PU procedu procedure re in Maintenance section.

MECHANICAL SYSTEM REPLACING THE MOTOR  1.

Remove Remove wires wires ffrom rom the mot motor or (Ite (Item m 4, Fig Figure ure 36). 36).

2.

Remove Remove the the fou fourr mot motor or mounti mounting ng setscr setscrews ews (Item 1, Figure Figure 36).

M-56

9525675 - MAINTENANCE

 

 Figure 36. 36. Replacing the Motor Motor and Chains 1

Motor Mounting Setscrews

3

Chain

2

Sprocket

4

Motor  

3.

Remove Remove the sprock sprocket et (Item (Item 2, Figure Figure 36) 36) fro from m the sshaft haft on on the motor motor,, and set the sprocket aside.

4.

Remove Remove the mot motor or from from the index index aasse ssembl mbly y.

5.

Instal Installl the the new motor motor on on the the index index assemb assembly ly..

6.

Instal Installl the the sproc sprocket ket on the new mot motor or..

7.

Replace, Replace, but but d do o not not ti tighte ghten, n, the the four four mo motor tor moun mounting ting setscrews setscrews..

8.

Rewire Rewire the motor motor accord according ing to to the electr electrical ical p prints rints provided provided iin n customer customer  print set.

9.

Tension Tension the the chain (Item 3, 3, Figure Figure 36) aaccord ccording ing tto o the Te Tensio nsionin ning g Chai Chain n  procedure in Maintenance Maintenance section.

TENSIONING CHAIN 1.

Loosen Loosen four four motor motor mounti mounting ng setsc setscrews rews (Item 1, Figure Figure 36).

2.

Slide the motor motor (manually) (manually) down gradu gradually ally unti untill the chain (Item 3, Figure 36) is tight.

  M-57

MAINTENANCE - 9525675

 

NOTE:  The chain must be tight for the Automatic Index System to work. 3.

Tighte Tighten n th thee four four motor motor mount mounting ing setscr setscrews ews..

REPLACING CHAIN 1.

Loosen Loosen the the fo four ur mo motor tor mounting mounting setsc setscrews rews (Item 1, Figure Figure 36).

2.

Lift motor motor (Item 4, 4, Figure Figure 36) to it itss highest highest p posit osition. ion. Tight Tighten en one one of th thee motor mounting setscrews until it is snug.

3.

Pull the master master link on the the chain chain (Item (Item 3, 3, Figure Figure 36) 36) until until the the chain chain separates. Remove the old chain.

4.

Wrap the the new chain chain around around the the sprocket sprockets, s, fol followi lowing ng th thee path of the old chain.

5.

Perform Perform Tensio Tensioning ning Chain Chain pr procedu ocedure re iin n Mainte Maintenance nance sect section. ion.

PNEUMATIC SYSTEM REPLACING A CYLINDER  1.

Ensure Ensure that that both both head head ass assemb emblie liess are are in the Out  position.  position.

2.

Perfor Perform m Safety Safety Locko Lockout ut proced procedure ure in O Oper perati ation on secti section on..

3.

Remove Remove piston piston end end mounti mounting ng bolt bolt from from operat operator or side side cy cylind linder er and and drive drive side cylinder.

4.

Allow Allow the autom automatic atic index index assem assembly bly to pivot pivot arou around nd sh shaft aft until until iitt hangs hangs upside down. The cylinder will swing down with the entire assembly.

5.

Remove Remove cylinde cylinderr by removing removing nylon nylon nu nutt co connect nnecting ing cylinder cylinder to to side frame.

6.

Re Remo move ve nylo nylon n tu tubi bing ng..

7.

Install Install new new cy cylind linder er by connectin connecting g cylinder cylinder to fr frame ame with with nylon nylon nut. Cylinder should be free to pivot.

8.

Rotate Rotate the entire entire automatic automatic index index assembly assembly back back to the origin original al positi position. on.

9.

Replac Replacee tthe he pis piston ton end mounti mounting ng bol bolts. ts.

M-58

9525675 - MAINTENANCE

 

TOUCHSCREEN DISPLAY

 Figure 37. 37. Touchscreen Touchscreen Display Display 1

 Enter  Button  Button

2

 Left Arrow Button Arrow Button

3

 Right Arrow Button Arrow Button

4

Up Arrow Button Arrow Button

5

 Down Arrow Button Arrow Button

SETTING DISPLAY CONTRAST 1.

Pres Presss and and hol old d tthe he Enter   Enter  button  button (Item 1, Figure 37) until a menu appears (approximately 3 seconds).

2.

Use the Right  and Left  and Left Arrow buttons Arrow buttons to move the cursor to the System menu option and press Enter  press Enter .

3.

On th thee Sys Syste tem m scr scree een, n, us usee the the Up and and Down  Down Arrow buttons Arrow buttons to position the cursor on the Display line.

4.

Press the Right Arrow Arrow button  button to increase display contrast and the  Left Arrow button Arrow button to decrease display contrast.

5.

Move Move th thee cur curssor to to Exit   Exit  and  and press Enter  press Enter  to  to return to the Splicer operator screen.

  M-59

MAINTENANCE - 9525675

 

SETTING TIME AND DATE 1.

Pres Presss and and hol old d tthe he Enter   Enter  button  button (Item 1, Figure 37) until a menu appears (approximately 3 seconds).

2.

Use the Right  and Left  and Left Arrow buttons Arrow buttons to move the cursor to the Time menu option and press Enter  press Enter .

3.

Press the Enter  button  button to move the cursor to the item you wish to set (Hour, Minute, Day, Month, or Year). Press the Up Up and  and Down  Down Arrow Arrow  buttons to adjust adjust each item.

4.

To exi exitt tthe he Time Time aand nd Date Date Set Set scre screen: en: a. If your your displa display y has has a Marq Marquip uip-la -label beled ed fface acepla plate, te, press press tthe he Right   Right  and  and  Left Arrow buttons Arrow buttons simultaneously.  b. If your display has a UniOp-labeled faceplate, remove remove and reconnect display power.

M-60

9525675 - MAINTENANCE

 

CONTROLLING THE SPLICER WITHOUT A TOUCHSCREEN If the touchscreen should ever require replacement, Splicer operation can be controlled with the Machine Interface Unit (MIU) until a new touchscreen is installed. Roll running, web tension, core splice diameter, and prewarn diameter offset values can be entered in hexadecimal format using the MIU.

NOTE:  Optical Splice option should not be used without a touchscreen. NUMBER

HEXADECIMAL EQUIVALENT

NUMBER

HEXADECIMAL EQUIVALENT

0

0

80

50

1

1

90

5A

2

2

100

64

3

3

110

6E

4

4

120

78

5

5

130

82

6

6

140

8C

7

7

150

96

8

8

160

A0

9

9

170

AA

10

A

180

B4

11

B

190

BE

12

C

200

C8

13

D

210

D2

14

E

250

FA

15

F

300

12C

20

14

350

15E

30

1E

400

190

40

28

450

1C2

50

32

500

1 F4

60

3C

550

226

70

46

600

258

Table 4. Hexadecimal Equivalents

  M-61

MAINTENANCE - 9525675

 

SETTING THE RUNNING ROLL Keys shown in bold are the blue keys on the MIU. Keys that are underlined are the dark green keys. 1.

Turn off electrical electrical power power.. Power Power LED LED should should be be off on CPU. CPU.

2.

Insert Insert MIU into 15-pin 15-pin connect connector or on CPU, aand nd turn turn on cont control rol power power.. MIU should light up and screen should be blank. Otherwise, clear screen  by pressing CLR once or or twice.

3.

Tu Turn rn keysw eyswiitc tch h tto o Term Term position.  position.

4.

To set the left left roll roll runnin running, g, press: press: C 6 0 0 WDST K(CON) 4 0 ↵ ENT

5.

To set th thee right right roll roll runn running ing,, press press:: C 6 0 0 WDST K(CON) 8 0 ↵ ENT

NOTE:  When viewing the Splicer from the drive side, left and right are reversed (the right running roll will be on the left side and vice-versa).

SETTING WEB TENSION 1.

To che check ck the cur curren rentt web web tens tensio ion, n, pres press: s: V 3 5 0 2 WDST

2.

To set set web web ten tensi sion on,, pre press ss:: K(CON)  X  X  ↵ ENT

NOTE:  X is the hexadecimal equivalent of the desired web tension (See Table 4). Press Shift + 0, 1, 2, 3, 4, or 5 to enter hexadecimal alpha characters.

M-62

9525675 - MAINTENANCE

 

SETTING PREWARN DIAMETER OFFSET 1.

To check check the the curre current nt prewa prewarn rn diame diameter ter offs offset, et, pres press: s: V 3 5 0 1 WDST

2.

To set pre prewar warn n diam diamete eterr o offs ffset, et, press: press: K(CON)  X  X  ↵ ENT

NOTE:  X is the hexadecimal equivalent of the desired prewarn diameter offset value (See Table 4). Press Shift + 0, 1, 2, 3, 4, or 5 to enter hexadecimal alpha characters.

SETTING CORE SPLICE DIAMETER  1.

To che check ck cor coree sspl plice ice di diame ameter ter,, p pres ress: s: V 3 5 0 0 WDST

2.

To set cor coree sspl plice ice di diame ameter ter,, pres press: s: K(CON)  X  X  ↵ ENT

NOTE:  X is the hexadecimal equivalent of the desired core splice diameter (See Table 4). Press Shift + 0, 1, 2, 3, 4, or 5 to enter hexadecimal alpha characters.

MAINTENANCE - 9525675

  M-63

 

INTRODUCTION TO THE PROGRAMMABLE LOGIC CONTROLLER Components of the PLC include the Central Processing Unit (CPU), input and output modules, and I/O rack.

MIU The handheld programmer for the PLC is called Machine Interface Unit (MIU). This device mounts on the front of the CPU and may be used to monitor inputs and outputs, modify timer values, or perform other programming and troubleshooting troubleshootin g functions.

NOTE:  Power should be removed from the PLC before the MIU is installed or removed.

BATTERY, MEMORY, AND REPROGRAMMING The program is maintained in RAM in CPU. A battery is used to retain this memory when PLC power is turned off. If the voltage in this battery becomes low, low, a BATT status LED illuminates on the CPU. This indication means that program memory will be lost if PLC power is removed before a new battery is installed. at least every five years, or when when BATT status LED NOTE:  Replace battery at indicates low battery voltage. If the program is lost, it may be reinstalled using the MIU and memory unit. Downloading procedure is outlined on following pages.

NOTE:  Whenever a program is reloaded into the PLC, reload the VRAM by  setting V1400 V1400 to 1, and re-enter any any customer-specific customer-specific timer values (see Timer/  Timer/  Counter Reference List in Maintenance Maintenance section). For procedures not outlined in this section, contact the Marquip Field Service Department.

M-64

9525675 - MAINTENANCE

 

INSERTING A MEMORY CARTRIDGE To insert a memory cartridge in the MIU, first remove the MIU from CPU. Open cover on left side of MIU and insert the memory cartridge as shown in Figure 38. Be sure that the memory cartridge is aligned the same as Figure 38 and firmly seated.

 Figure 38. 38. Inserting a Memory Memory Cartridge in the MIU 

STORING A PROGRAM IN CPU To transfer a program from memory Cartridge in MIU to CPU, use following  procedure:

1.

Tu Turn rn on PLC PLC key keysw swit itch ch be fr from om Run  Run to  to Stop Stop,, then to Term Term position.  position. Program LED MIU should on.

 Figure 39. Key Key Sequence and Display Display

  M-65

MAINTENANCE - 9525675

 

2.

Tu Turn rn ke keys yswi witc tch h fr from om Term Term to  to Run  Run position.  position. Run LED should be on.

3.

With new progr program am in CPU, CPU, as shipped shipped Timer Timer Preset Preset Values must be loaded into V-memory. To do this, go to V1400 and enter a value of 1 by typing V (blue key) and 1400, then WD ST. Then press KCON (blue key), 1, and [ENTER]. Next check the V-memory values by typing V (blue key) and 2002 then WD ST. Value displayed should correspond to the as shipped value indicated in timer/counter reference list in Maintenance section. By pressing [NEXT], all V-memory values indicated in the list may be verified.

4.

Load Splicer Splicer model model word into V-memor V-memory y. To do this, this, perform perform Modify Modifying ing V-Memory Locations in the PLC procedure in Maintenance section to reenter V5100 to V5107 and V5110 to V5117. Next check the V-memory values. Value Value displayed should correspond to the write-in value indicated in Table 5. V-MEMORY LOCATION

CURRENT VALUE (WRITEIN)

V-MEMORY LOCATION

V5100

V5110

V5101

V5111

V5102

V5112

V5103

V5113

V5104

V5114

V5105

V5115

V5106

V5116

V5107

V5117

CURRENT VALUE (WRITEIN)

Table 5. Splicer Splic er Model Word Word Values Values

NOTE:  For the Splicer model word, refer to Splicer Model Word print in customer print set or contact Marquip Field Service.

M-66

9525675 - MAINTENANCE

 

MODIFYING V-MEMORY LOCATIONS IN THE PLC Keys shown in bold (V) are the blue keys on the Machine Interface Unit (MIU). Keys which are underlined are the dark green keys. 1.

Turn off electrical electrical power power.. Power Power LED LED should should be be off on CPU. CPU.

2.

Insert Insert Machine Machine Interfac Interfacee Unit Unit (MIU (MIU)) into into 1515-pin pin connector connector on CPU, CPU, and and turn on control power. MIU should light up and screen should be blank. Otherwise, clear screen by pushing CLR once or twice.

3.

To check check timer preset preset value value located located in V V-memo -memory ry,, pre press: ss: V 2 0 0 1 WD ST

Timer and counter values are located in V-memory starting at location V2001. Each timer number corresponds with the V-memory location as follows: TMR1, TMRF1, or CNT1=V2001 TMR2, TMRF2, or CNT2=V2002 Contents of the memory location are shown below each label. 4.

To modify modify V-memo V-memory ry locatio location n on rright ight side of of screen, screen, tu turn rn keyswi keyswitch tch tto o TERM and type: K(CON) 3 0 0 0

↵ ENT

The value 3000 is now in V-memory location on the left of the display. 5.

To go to next next V-me V-memor mory y lloca ocatio tion np pres ress: s:  NXT or PREV The K(CON), desired number, and

↵ ENT

  M-67

MAINTENANCE - 9525675

 

6.

Time Timer’s r’s an and d coun counter ter’s ’s V-me V-memor mory y de defin finiti ition on a. Slow Timer   •

•

 b.

999.9 seconds. To en enter ter 60.7 60.7 secon seconds ds into into a V-memo V-memory ry locati location on corresp correspondi onding ng to a TMR enter: K(CON) 6 0 7 ↵ ENT TMRF (Fast timer)

•

TMR TMRF F time timers rs count count 0 0.01 .01 sseco econd nd in incre cremen ments ts with with a maximu maximum m value value of 99.99 seconds.

•

To en enter ter 0.21 0.21 secon seconds ds into into a V-memo V-memory ry locati location on corresp correspondi onding ng to a TMRF enter: K(CON) 2 1 ↵ ENT CNT (Counter)

c.

7.

TMR ccou ount nt by 0.1 0.1 secon second d increm increment entss and h have ave a maxi maximum mum v valu aluee of

•

Count Counters ers increm increment ent by o one ne u unit nit at a time with a max maximum imum of 9,999 9,999 counts.

•

To eenter nter 60 count countss into into a V-memory V-memory loca location tion correspon corresponding ding to a CNT enter: K(CON) 6 0 ↵ ENT

To exit exit,, press press C CLR LR twi twice ce an and d tu turn rn keys keyswi witch tch to Run to Run mode.  mode.

M-68

9525675 - MAINTENANCE

 

MIM The Marquip Intelligent Module (MIM) (Figure 40) is located in slot 1 of the PLC. It is connected to the MIM Interface Board (MIB) by the 50-conductor ribbon cable. The MIM module controls the brake pressure and cable cylinder air pressure.

LIGHT

 Figure 40. 40. MIM Module

COLOR

DESCRIPTION

A1

Green

Power Indicator  

A2

Green

Heart Beat Light

A3

Green

N/A

A4

Green

N/A

B1

Red

Dancer referenced when ON (Flashes before it is referenced)

B2

Red

New configuration (Should be lit solid or off solid; toggles  between states when V5014 is written to.)

B3

Red

Communication

B4

Red

Communication

C1

Green

Right Roll is running roll

C2

Green

Left Roll is running roll

C3

Green

N/A

C4

Green

N/A

D1

Red

N/A

D2

Red

N/A

D3

Red

N/A

D4

Red

If light comes on, repower machine, then contact Marquip

  M-69

MAINTENANCE - 9525675

 

 Figure 41. 41. MIM Interface Board Board (MIB) Outputs Outputs and Inputs ITEM

LABEL

SIGNAL DESCRIPTION

ITEM

LABEL

SIGNAL DESCRIPTION

1

Out 10

Right Brake Output

7

In 3

Right Roll Revolution Sensor  

2

Out 11

Left Brake Output

8

In 4

Left Roll Revolution Sensor  

3

Out 12

Cable Cylinder Pressure Output

9

In 5

Dancer Home Proximity Sensor  

4

In 0

Dancer Encoder Channel A

10

-

Right Brake Output

5

In 1

Dancer Encoder Channel B

11

-

Left Brake Output

6

In 2

Capstan Encoder Input

12

-

Cable Cylinder Output

M-70

9525675 - MAINTENANCE

 

TIMER/COUNTER REFERENCE LIST TIMER/ COUNTER NUMBER

V-MEMORY LOCATION FOR PRESET

STANDARD VALUE

T0

V2000

50

Automatic Drain Duration

T1

V2001

35

Decel Web During Splice (Model 1H 300)

70

Decel Web During Splice (Model 1H 400)

CURRENT VALUE (WRITE IN)

FUNCTIONAL DESCRIPTION

T2

V2002

21

Time Required for Nip Roll to Close

T3

V2003

30

Nip Duration

T4

V2004

2

Delay to Accelerate New Web

T5

V2005

500

Maximum Acceleration Duration

T6

V2006

100

Max Head Backout Duration

700

Max Head Backout Duration (Zero-Tail splice option only)

T7

V2007

150

Delay to Unclamp Left Clamp for Manual Index

T1 0

V2010

400

Delay to Reclamp Left Clamp for Manual Index

T11

V2011

150

Delay to Unclamp Right Clamp for Manual Index

T1 2

V2012

400

Delay to Reclamp Right Clamp for Manual Index

T1 3

V2013

50

Time Required to Move Index Assembly

T1 4

V2014

350

Left Automatic Index Time

T1 5

V2015

200

Left Slack Removal Time

T1 6

V2016

50

Time Required to Engage Clamp

T1 7 T2 0

V2017 V2020

350 200

Right Automatic Index Time Right Slack Removal Time

T3 1

V2031

15

Decel Web for Zero-Tail splice (Model 1H 300)

30

Decel Web for Zero-Tail splice (Model 1H 400)

20

Heads In Timer (Model 1H 300)

40

Heads In Timer (Model 1H 400)

T3 2

V2032

T4 0

V2040

14

Delay Between Head Position Steps

CT0

V2100

60

Delay Between Automatic Drain Cycles Counter (in minutes)

Table 6. Timer/Counter Reference List 

NOTE:  All timers/counters use a 0.01 second base with the exception of CT0

which uses a 1 minute base.   M-71

MAINTENANCE - 9525675

 

TROUBLESHOOTING PROBLEM

1. Dancer Dancer rroll oll w will ill not not return return to  Home position.  Home  position.

POSSIBLE CAUSE

a. Wro Wrong ng roll roll run runnin ning. g.  b. Bias pressure set at more than 138 kPa (20 psi). c. Brakes on m manual anual contro control. l. d. Too mu much ch dirt on on danc dancer er track. track. e. Dan Dancer cer roll roll mechan mechanism ism  bound up. f. Web ttens ension ion sset et too too low. low.

2. No brake.

3. No splice light.

a.  b. c. d.

Control Power  off.  off. Brakes disconnected. Chu Chucks cks sli slippi pping. ng. Brakes on ma manual nual control. control.

f. Inc Increa rease se w web eb ten tensio sion. n. a.  b. c. d.

Turn Control Power  on.  on. Reconnect brakes. Adjust Roll Stand chucks. chucks. Set Set bra brake kes. s.

e. Verif erify y E/P set setup. up.

a. Operator did not go through automatic clamp sequence.  b. Wrong roll running. c. Burned out sp splice lice li light ght bu bulb. lb. d. Both h head eadss not fully fully in.

a. Go through through automatic automatic cclamp lamp sequence.  b. Switch roll running. c. Replace Replace sp splice lice light bulb. d. Pu Pussh Head In button In button to send heads in. e. Set Set br brak akes es..

a. Bad edges on old or new roll.

 b. Is Problem 3 occurring? c. Too short short a lead lead.. d. Paper dusty-kept dusty-kept in position position too long. e. Paper has moved moved do down wn too far far.. (Automatic Index option only.)

5. Dancer Dancer hes hesitat itates, es, eit either her direction.

a. Switch Switch rroll oll ru runni nning. ng.  b. Set bias pressure to exactly 138 kPa (20 psi). c. Ensure manua manuall brake valve is in  Automatic position.  Automatic  position. d. Clean Clean da dance ncerr trac track. k. e. Paralle Parallell the da dance ncerr roll.

e. E/P tran transdu sducer cer..

e. Bra Brake ke not not set set.. 4. Missed splice or tear out.

SOLUTION

Mechanical bind-up (sideframe clearance, track too tight, out of square, dancer cables loose.)

a. Splice old roll before bad edges edges appear. See Preparing New Roll  procedure in Operation section.  b. See Problem 3. c. See Prep Prepari aring ng Ne New w Roll  procedure in Operation section. d. Do not prepare prepare ssplice plice mo more re than 20 minutes in advance. e. Adjust the ttimer imer value value so th thee index time is shorter. (See Timer/ Counter Reference List in Maintenance section.) Check track for dirt and clearance. Check for parallelism between dancer roll and upper level center idler roll. Verify proper tension in  both dancer roll cables.

M-72

9525675 - MAINTENANCE

 

PROBLEM

6. Danc Dancer er b bot otto toms ms o out ut in

POSSIBLE CAUSE

SOLUTION

Heads not backing out soon enough

Check heads, capstan roll, and

after splice. Clamp bar not unclamped. Paper roll brake not released. Wrong roll running. Line running too fast during splice. Capstan not starting.

clamp bar for mechanical or electrical failure. Check roll running selection. Check web speed.

7. Dancer roll oscillation.

Chucks slipping.

Change chucks.

8. Dancer Dancer rroll oll o osci scillat llation ion and and chucks not slipping.

a. Brake shoes worn or slipping, slipping, causing excessive time delays in response to brake control commands.  b. Roll revolution sensor failed.

a. Make brake brake ad adjustmen justmentt or repa repair. ir.

 Forward  position.  position.

9. Dancer Dancer roll rollss oscill oscillate ate;; not not caused by 7 or 8 above.

 b. Replace or adjust roll revolution sensor on roll stand chuck.

a. Encod Encoder er in incorrect correctly ly wired wired o orr defective.  b. Incorrect E/P setup. c. Low bra brake ke gain. gain.

 b. Setup E/P transducers. c. Inc Increa rease se bra brake ke ga gain. in.

10. Tension increases with small roll.

Brake drag. Automatic brake will not drop to 0 kPa (0 psi).

Adjust or repair brakes. Adjust or repair E/P.

11. Heads sluggish. sluggish. Splice Splice or web sever not made.

Restriction in air line. Mechanical  bind-up.

Check head for sufficient air  pressure, wear, mechanical bind-up. Oil cylinders, check air line lubricators.

12. Serrated Serrated or poor cut on expired roll.

Clamp bar or knife failure. Knife fired too soon or too short.

Check clamp bar and knife for insufficient air pressure, wear,

Restriction in air line.

mechanical bind-up.

Nip rolls not driving in. Paper  preparation is wrong. Heads out of square. Insufficient nipping force. Accumulation of paper dust. Delay to cut-off spent web.

Decrease time to drive in nip rolls. Check nip rolls for parallelism and not sealing full width of paper. Check nip roll for proper nip force and for interference between rolls. Check that web is not being run into  Ready-To-Splicee position too soon,  Ready-To-Splic allowing paper dust to accumulate on tape. It may be necessary to delay preparing for splice. Check trailing edge tail of spent web.

1 3. P Po oor nip seal.

a. Check/Repla Check/Replace ce danc dancer er enco encoder der..

  M-73

MAINTENANCE - 9525675

 

PROBLEM

POSSIBLE CAUSE

SOLUTION

14. Wrinkles Wrinkles in paper (usually noticeable at dancer rolls).

Web tension. Poor quality of paper. Roll alignment.

Web tension too high. Align and  polish all rolls. Roll stock may have water damage from improper storage.

15. Paper breaking breaking at or near Splicer.

Clamp bar, brakes, anvil bar, dancer rolls. Paper preparation. Capstan motor.

Check for defective brakes causing excessive web tension. Check anvil  bar for being out of alignment to machine or heads. Check that dancer rolls are not bound up or out of alignment; check splice  preparation for not being square to nip roll or that paper is not tensioned properly.

16. 16. Mi Misa sali lign gned ed paper aper at spl splic icee.

Cu Cutt ttin ing g gui guide de.. Cla Clamp mp bar bar. Pap Paper er  preparation.

Check cutting guide is in correct  position. Check paper preparation is correct during operator setup.

17. Prepar Prepared ed web web slac slack k on one one side side..

Roll Sta Stand. nd. Pape Paperr roll. roll. Pa Paper per  preparation.

Check Roll Stand arms are level and in correct alignment to Splicer. Check paper roll is not tapered. Check for operator error during  paper preparation.

18. Slack in web while while running or immediately after splice.

Paper roll over-traveling.

Check for insufficient braking force due to: 1. Low air pressure. 2. Excessively worn chucks. 3. Excessively worn brakes. 4. Bad paper roll core.

19. Excessive Excessive or low air pressure from transducer.

Transducer. F Fiilters cl clogged.

Check tth hat tr transducer is is n no ot ou out of of adjustment, malfunctioning, or has an improper air supply.

20. Brakes appear appear to be  piped backward.

Wrong roll ru running.

Check roll running indicator at main operator console.

21. Brakes Brakes too slow to respond after splice.

Mechanical bind-up or excessive wear. Leaking air lines.

Check brakes for dirt or corrosion. Brake pads or lining may be excessively worn and have too much travel. Check that air lines are not too big. Check for leaks  between E/P transducers and  brakes.

M-74

9525675 - MAINTENANCE

 

PROBLEM

POSSIBLE CAUSE

SOLUTION

22. No brake immediately immediately after splice or dancer oscillation.

Brake gain iin ncorrectly set.

Verify high gain command. Change malfunctioning potentiometer. Complete brake gain identification.

23. Excessive Excessive dance dancerr roll travel during splice.

Timer settings. Brakes. Clamp. Knife. Line speed. Capstan.

Check timer settings. See Problem 9. Check clamp bars for free movement. Check to see if knife has cut old web.

2 4. C Caapstan not starting.

Motor impaired. Clutch not engaging.

Check fuses, heaters, starter. Check control signals to start capstan. Check output control signal to start capstan.

25. Index Index assemb assembly ly doe doess n not ot move. move.

Pne Pneuma umatic tic set setting tingss may may be incorrect.

Check settings. If the setting is less than 241 to 276 kPa (35 to 40 psi), set it higher.

26. Slack removal process does not remove slack.

Pneumatic settings may be incorrect.

Check settings. If the setting is above 414 kPa (60 psi), set it lower.

2 7. F Faailed splices.

Paper has moved down too far.

Adjust the timer value so the index time is shorter. (See Timer/Counter Reference List in Maintenance section.)

28. Automatic Automatic index time is consistently short.

Automatic Index Run Timer setting may be incorrect.

Adjust the timer value until indexing is accurate. (See Timer/ Counter Reference List in Maintenance section.)

29. Index time is consistently consistently too long.

Automatic Index Run Timer setting may be incorrect.

Adjust the timer value until indexing is accurate. (See Timer/ Counter Reference List in Maintenance section.)

30. Paper slipping.

Loose chain.

Tighten chain. (See Tensioning Chain procedure in Maintenance section.)

  M-75

MAINTENANCE - 9525675

 

PROBLEM

POSSIBLE CAUSE

SOLUTION

31. Paper falls out of Splicer head or index assembly is pivoting around shaft slower than usual.

a. Index assembly assembly not not moving moving freely.  b. Cylinder valve did not actuate. Pressure settings are too low. l ow.

a. Find aand nd eliminate eliminate tthe he so source urce o off the binding.  b. Verify valve operation. Increase the pressure settings.

32 32.. Pa Pape perr not not tens tension ioned ed co corre rrect ctly ly..

In Indiv divid idua uall nip nip wh whee eels ls ou outt of of adjustment.

Adjust nip wheels by tightening nylon nut under each nip wheel. Adjust second nip wheel from Automatic Index drive side and work across support frame to end. Repeat adjustment at least once. The drive train wheel for each motor is not adjustable. NOTE:  Center nip wheels must be the first to contact the nip roll.

33. T o ou uchscreen does not illuminate.

24 V power supply.

Check 24 V power supply. Replace if faulty.

34. Roll diamete diameterr incorrect on touchscreen.

a. Hall ef effect fect se sensor nsor o on n roll stand. stand.  b. Capstan encoder.

a. Rep Replac lacee se senso nsor. r.  b. Replace encoder.

35. Web speed incorrect on touchscreen.

Capstan encoder.

Replace encoder.

36. Optical Splice-Optic Splice  Ready indicator is not highlighted.

a. Rol Rolll stand stand arms ttoo oo hi high. gh.  b. Incorrect mercury switch setup. Faulty switch.

a. Lo Lowe werr arm arms. s.  b. Perform Mercury Switch Adjustment procedure in Maintenance section. Replace switch. c. Dec Decrea rease se we web b spe speed. ed.

c. Web sp speed eed to too o high ffor or optical optical splice (above 200 MPM [650 FPM]).