NWP INSTRUCTION & SERVICE MANUAL - ttemsattemsa.mx/teknek/nwp/Pi51867r10NWPMANUAL(NEWERMACHINES… · 2012-05-17 · Teknek Head Office River Drive Inchinnan Business Park Renfrewshire,

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NWP INSTRUCTION & SERVICE

MANUAL

Original Instructions

WORLD LEADER IN CONTACT CLEANING Teknek Head Office River Drive Inchinnan Business Park Renfrewshire, PA4 9RT Scotland, UK T: +44 (0)141 568 8100 F: +44 (0)141 568 8101 www.teknek.com

Teknek Japan Ltd Big Van Onoecho Building, 6-83 Onoe-cho, Nakaku Yokohama City Japan 231-0015 T: +81 (0)45 640 0670 F: +81 (0)45 640 0671

Teknek China Ltd Unit G02, G/F., Myloft, 9 Hoi Wing Road, Tuen Mun, N.T., Hong Kong T: +852 2468 3160 F: +852 2462 3036

Teknek USA 8100 – D Arrowridge Boulevard Charlotte, NC 28273, USA T: +1 704 499 9191 F: +1 704 499 9190

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TABLE OF CONTENTS MACHINE SAFETY ................................................................................................................... 2

SAFETY WITH YOUR CLEANING HEAD / MACHINE ............................................................................................ 3

1 SAFETY DATA SHEET .................................................................................................. 4

1.1 ADHESIVE ROLLS ...................................................................................................................................... 4

1.2 HANDLING AND STORAGE ....................................................................................................................... 4

1.3 IN THE EVENT OF FIRE.............................................................................................................................. 4

1.4 WASTE DISPOSAL...................................................................................................................................... 4

2.1 EQUIPMENT – OPTION : Active Anti-Static ............................................................................................. 4

2.1.1 OZONE INFORMATION.................................................................................................................. 4

2 TEKNEK GUARANTEE.................................................................................................. 5

3 INTRODUCTION ............................................................................................................ 6

4 INSTALLATION.............................................................................................................. 7

4.1 UNPACKING ................................................................................................................................................ 7

4.2 INSTALLING ................................................................................................................................................ 7

4.2 INSTALLING ................................................................................................................................................ 8

4.3 MODE SELECTION .................................................................................................................................. 10

4.3.1 MACHINES WITHOUT REAR CONNECTION KIT ................................................................................... 10

4.3.2 MACHINES WITH REAR CONNECTION KIT ........................................................................................... 10

4.4 AUTOMATIC (PLC) MODE........................................................................................................................ 11

MACHINES WITHOUT REAR CONNECTION KIT ................................................................................................ 11

4.5 MANUAL MODE ........................................................................................................................................ 12

5 MACHINE OPERATION ............................................................................................... 13

5.1 START-UP OPERATION ........................................................................................................................... 13

6 ROUTINE OPERATION AND MAINTENANCE............................................................ 14

6.1 PURGING ADHESIVE ROLLS .................................................................................................................. 14

6.2 REPLACING THE ADHESIVE ROLLS...................................................................................................... 14

6.3 HANDLING AND CLEANING RUBBER ROLLERS.................................................................................. 16

6.3.1 NANOCLEEN ROLLERS.................................................................................................................. 16

6.3.2 FILM & ULTRACLEEN ROLLERS ................................................................................................ 16

6.4 CLEANING STATIC BARS........................................................................................................................ 16

6.5 REPLACING RUBBER ROLLERS............................................................................................................ 17

8 SPECIFICATION .......................................................................................................... 20

9 RECOMMENDED SPARES ......................................................................................... 21

9.1 PREVENTATIVE MAINTENANCE TOOLS ............................................................................................... 21

9.2 PREVENTATIVE MAINTENANCE PARTS................................................................................................ 21

9.3 LENGTH ORIENTATED SPARE PARTS .................................................................................................. 21

10 DIAGRAMS................................................................................................................... 22

MACHINE SAFETY

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SAFETY WITH YOUR CLEANING HEAD / MACHINE At TEKNEK we want you to operate your clean machine in conditions of maximum safety at all times. Listed below are procedures that should be followed during set up and operation of the machine.

• When removing the equipment from the transport box ensure that lifting aids are available and in place as required. Removal of most TEKNEK cleaning machines requires more than one person and care must be taken to avoid personal injury and damage to the machine during withdrawal from the transport box.

• Ensure that the machine is installed safely by securely mounting it to the frame of parent machine (dependent on machine type).

• All Teknek Narrow Web Clean Machines must be connected to earth (also known as ground).

• Check also that the intended electrical supply complies with the designated machine specification. The standard electrical supply is 24v DC line running signal.

• Before operating the machine, please read the contents of this manual.

• Ensure that new operators of the machine are given full instruction on use and read the manual before operating the equipment.

• NO loose clothing should be worn when the machine is in operation. All long hair must be tied back.

• DO NOT place hands into areas that could expose them to injury.

• NEVER tamper with or override switches that may be visible when doors or covers are open as this practice could result in personal injury.

• NEVER interfere with or adjust pneumatic components, as this practice could result in personal injury. Authorised Personnel should always carry out servicing and repairs.

• Before opening the machine for service or repair, the electrical and pneumatic supplies from the host machine should ALWAYS be disconnected by Authorised Personnel.

• If the specification of the NWP is changed or modified in any way by the user following delivery from TEKNEK then it becomes the user's responsibility to ensure that the appropriate Machinery Directives are complied with.

IMPORTANT NOTICE: Published information concerning products is based upon research that the Company believes to be reliable but such information does not constitute a warranty. Because of the variety of possible uses for Teknek products and the continuing development of new uses, the purchaser should carefully consider the fitness and performance of the product for each intended use and the purchaser assumes all risks in connection with such use. Seller shall not be liable for damages in excess of the purchase price of the product or for incidental or consequential damages. NOTE - Machine specifications may be subject to change without prior notice.

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1 SAFETY DATA SHEET

1.1 ADHESIVE ROLLS

TEKNEK Adhesive Rolls are made of pressure sensitive adhesive on a paper base and are safe and present no hazard to health provided normal rules for good industrial hygiene are observed. The following advice is given to ensure safe storage and usage of Adhesive Rolls.

1.2 HANDLING AND STORAGE i) On receiving goods, inspect packages for signs of damage. Inform supplier of shortage or damage

immediately. Store material in clean dry area. Material should be stored in original packaging until required. ii) Rolls stored on their side not in original packaging may pressure mark or produce a flat if stored for long

periods. iii) Shelf life is two years when stored correctly in original packaging.

1.3 IN THE EVENT OF FIRE i) The Adhesive rolls will burn in the event of contact flame. Fumes may be given off by the acrylic adhesive

and silicone release coating itself. Fires may be extinguished with water provided that live electrical equipment is not in vicinity. The advice of your Fire Officer should be sought, having regard for the layout of your premises and the particular operations involved.

1.4 WASTE DISPOSAL

i) Adhesive Roll off-cuts may be disposed of through normal trade re-use outlets. ii) If disposed of in a legal tip in compliance with relevant laws or incinerated in a licensed site in compliance

with relevant laws, the following should be noted:- Acrylic adhesive coated products should only be incinerated if the incinerator can cope with corrosive flue gases.

2.1 EQUIPMENT – OPTION : Active Anti-Static 2.1.1 OZONE INFORMATION

i) The high voltage static elimination equipment in Teknek Machinery has been thoroughly tested and

complies with the OSHA Standard. The Maximum Allowable Concentration (MAC) of ozone under this regulation is 0.1 parts per million. The maximum output in the vicinity of Teknek supplied static eliminating devices is 0.04 ppm.

ii) The A.C. bar is supplied with a power supply. The power supply is fully C.E. marked. This should be securely mounted to the host machine.

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2 TEKNEK GUARANTEE TEKNEK LTD ("TEKNEK") guarantees that in the event of the NWP becoming defective due to faulty materials or workmanship within 12 months from the date of purchase (assuming a two shift operation cycle), the company shall replace all defective parts free of charge subject to the following conditions:- i) TEKNEK is satisfied that the Product has not been misused or used or operated in any way contrary to the

instructions in the Manual provided. ii) TEKNEK is satisfied that repairs have not been carried out or have been attempted by persons not

authorised by TEKNEK. iii) The product is made available for inspection by TEKNEK or its Authorised Distributor and TEKNEK is

reasonably satisfied that the product is defective. iv) No replacement parts or adhesive rolls other than those recommended by TEKNEK are or have been used

in or with the Product. The following points should also be noted:- v) This Guarantee is offered in addition to your statutory rights. vi) Component parts, which require replacement due to normal wear and tear are excluded from this guarantee. vii) The blue rubber rollers are guaranteed for 6 months from date of purchase (assuming a two shift operation

cycle) viii) This Guarantee is limited to the supply of replacement parts only i.e. any labour provided will be charged at

the rate applicable at the time of any repair. ix) TEKNEK LTD is a Scottish company and this Guarantee is issued subject to Scots Law. Please note that the use of spare parts or consumables other than TEKNEK recommended items may severely damage or significantly reduce the performance of your equipment and may damage the web being processed by the Narrow Web Cleaner. NB - Due to the nature of some materials that are processed through the machine it may be necessary to review the replacement of the Rubber Rollers on a regular basis

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3 INTRODUCTION The NWP is a unique solution to the problem of dirt, static and other particulate contamination. The specially formulated roller removes contamination from the web without abrasion or the use of chemicals. The contamination is then transferred to the adhesive rolls leaving the rollers clean and ready to continue removing contaminant. Optional anti-static system neutralises any static charge, which is present on the media. The NWP is designed specifically for narrow web cleaning applications. The cleaning roll mechanism is mounted in a robust frame assembly that features a hinged upper hood unit to permit web thread-up. Upper and lower adhesive rolls are withdrawn from the cleaning head by means of slides and may be purged and replaced easily. It is recommended that the purging operation is done while the web is stationary. Removal and replacement of the blue cleaning rollers is a simple process using the quick release system. The standard NWP series is supplied with a 3 meter flying lead, for machine control/power supply. This arrangement allows the customer to integrate the machine with the parent machines’ line running signal. The air line pressure is fitted to 6mm barb fitting. Vertical webs can also be processed but the machine should be supplied and fitted with diverter roller(s) and the gas struts require to be changed (Contact Teknek for retrofit kits).

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4 INSTALLATION

4.1 UNPACKING

• Remove the machine from its packaging.

• Check for transit damage.

• Refer to the serial number on the machine when ordering spare parts

• Fill in and return the guarantee card Please notify TEKNEK immediately should there be any damage or discrepancy. IMPORTANT: Refer to installation information diagram Fig.1

Fig 1. Installation Diagram

NOTE 1: 430 & LARGER NWP MACHINES ARE FACTORY FITTED WITH 1x MA36711 REAR PLATE SUPPORT RIBS FOR TRANSPORT RIBS MUST BE REMOVED PRIOR TO INSTALLATION FOR REAR MOUNTED ORDERS.

NOTE 2: REAR PLATE SUPPORT RIBS MUST REMAIN ATTACHED FOR BASE MOUNTED ORDERS.

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4.2 INSTALLING

• Locate the machine as near as possible to the mounting area.

• Ensure that the area that is allocated for the unit is prepared for installation.

• Mount the machine so that on a double head the lower Rubber Roller is just in contact with the web and that the upper Rubber Roller is clear. On the single sided machine, the web should be contacting the idler roller in the base section of the machine.

• Securely fasten the unit to the installation area as instructed in Pi51142 or Pi511143 (see layout drawings section).

• Connect the unit as per the wiring and pneumatic diagrams located at the back of this manual.

• Thoroughly clean down the unit with Tekwipes.

• Undo the latch holding the cleaning heads together and lift up the top head.

• Remove the piece of paper between the blue rollers. (For shipping purpose).

• Clean down the blue rollers following the instructions in Section 6. Allow drying completely.

• Access the adhesive rolls and remove the outer cellophane wrapping. The Adhesive Rolls are mounted in spring-loaded holders (see section 6) *Please note the orientation of the adhesive roll is critical for correct operation. Refer to Fig 2. for correct orientation.

The NWP Cleaning Head is now ready to use.

Read Section 5 (Operation of Machine) before operating the machine.

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Fig 2. Correct Orientation of Adhesive Rolls

• It is important that the Adhesive Rollers are placed into the NWP machine in the proper orientation. This is to prevent the adhesive wrapping around the blue rubber rollers.

• The orientation of the machine and web direction is taken when standing at the front pull out doors.

Web Flow Direction Left to Right The top adhesive roll must be loaded so that the end with the red dot is loaded to the rear of the machine and the bottom adhesive roll must be loaded such that the end with the red dot is loaded to the front of the machine

Web Flow Direction Right to Left The top adhesive roll must be loaded so that the end with the red dot is loaded to the front of the machine and the bottom adhesive roll must be loaded such that the end with the red dot is loaded to the rear of the machine.

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4.3 MODE SELECTION 4.3.1 MACHINES WITHOUT REAR CONNECTION KIT The NWP can be operated in either automatic mode (plc) or manual mode. The operational mode can be selected by changing the wiring located under the top cover of the machine. To change from Manual to Auto remove the blue and red wires from their respective connectors and connect the Auto link. The wiring is shown in EW51845. The machine will be configured to customer specification before shipping.

View of connection – Standard Connection

4.3.2 MACHINES WITH REAR CONNECTION KIT

These machines cannot be easily changed in the field. The correct configuration should be specified at time of order.

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4.4 AUTOMATIC (PLC) MODE

MACHINES WITHOUT REAR CONNECTION KIT The machine is controlled by switching the 24V via the PLC output. Slide and head switches ensure safe operation by preventing switch on when the machine is open or slides out. MACHINES WITH REAR CONNECTION KIT The NWP is automatically controlled from an external source. Feed back from the slide and head switches are fed back to the plc which must ensure that the machine is safe to run. Run signals from the plc individually control the top and bottom adhesive. In this mode of operation the operator controls the NWP through the host machine. Run condition is shown by the indicator. (fig.3)

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4.5 MANUAL MODE

The NWP is set up to be manually controlled by an operator Operation is via the on/off button on the front of the machine (fig.3). The adhesive rolls will only engage if both the slide doors and the over center catch is closed. Both the top and bottom adhesives are activated from the push button. It is recommended that the adhesive rolls are switched off before opening the slide doors for purging.

Fig 3. Front view of machine

Teknek equipment has not been designed, tested, nor approved to work in hazardous areas. Should customers choose to install Teknek equipment in hazardous areas, the customer must ensure that all necessary regulation

and compliance issues are dealt with. Teknek accepts no liability for equipment used in hazardous environments.

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5 MACHINE OPERATION

5.1 START-UP OPERATION Start-up procedure for machine operation

• Place your web through the machine (this is done when the line is stationary) by undoing the over centre catch and opening the NWP machine fully.

• Close the machine and ensure that the over center catch has been securely fastened.

• Check that the Power and Air supplies are connected.

• In manual mode press on/off switch to put the machine in standby.

• In manual mode, press on/off switch. The adhesive rolls will come together. Press on/off switch again. The adhesive rolls will separate.

• In auto mode, the adhesive roll switch on and separation is controlled by the PLC.

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6 ROUTINE OPERATION AND MAINTENANCE

6.1 PURGING ADHESIVE ROLLS

• Strip a layer of adhesive from the adhesive rolls to reveal a clean layer of adhesive. This will ensure that the rubber cleaning rollers will be at their cleanest and most effective. The adhesive rolls can be accessed via the front pullout doors.

• Always strip both top and bottom rolls equally at the same time to ensure satisfactory operation.

• It is recommended that this is carried out once every 8 hours, or more frequently if the dust level is high.

6.2 REPLACING THE ADHESIVE ROLLS

Open drawer to access adhesive roll

Open fully as shown to access the adhesive roll.

The adhesive rolls are mounted into spring loaded holders.

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To change simply pull the empty core away from the machine to release the opposite end from its holder. The core can then be removed from the machine and replaced with a new adhesive roll. Pull adhesive roll away from the machine acting against the spring as shown:

This will give enough room to lift roll clear from the QHR mechanism.

Pull adhesive roll away from machine

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6.3 HANDLING AND CLEANING RUBBER ROLLERS 6.3.1 NANOCLEEN ROLLERS

Rollers should only be touched wearing clean white cotton gloves (Teknek Part No.Pi51577) and should only be cleaned with the special Nanocleen cloth.

On a daily basis Wipe the rollers using the Nanocleen cloth dampened using clean water and wrung out until just damp. NEVER use Tekwipes, Isopropyl alcohol or other solvent cleaners on the Nanocleen rollers. If the surface of the rollers deteriorates or the contamination becomes evident contact Technical Services for assistance.

6.3.2 FILM & ULTRACLEEN ROLLERS

The rubber roller should be vigorously wiped using Tekwipes, Teknek Part No. Mi6700.

The rubber rollers should be vigorously cleaned down with isopropyl alcohol and an abrasive pad (Teknek Part No. Mi5068) every 6 weeks. This will renew the cleaning surface and performance. Always allow isopropyl alcohol to evaporate before allowing the adhesive rolls to come into contact with the rubber rollers.

Do not use acetone, screen wash or any solvent based cleaner as this damages the special rubber and dissolves the adhesive.

Do not let the alcohol fall onto the adhesive rolls (it is best if the adhesives are pulled out from the machine during this operation). .

6.4 CLEANING STATIC BARS Once a week the active anti-static bars (if fitted) should be cleaned with a nylon bristle brush to remove contamination from the needle points. (Teknek Part number TK5598) See fig 4.

Fig 4 . Anti-Static Bar Cleaning

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6.5 REPLACING RUBBER ROLLERS

Open the machine by releasing the clasp at the front. The Rubber Roller retainers need to be removed to access the Rubber Roller. These are located at each end of the rubber roller,

Remove 2 cap head screws using the correct size Allen Key.

Remove rubber roller retaining bars

Rubber Roller Retainer

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Rubber roller retaining bar removed

Lift Rubber Roller clear from Roller Blocks. Replace Rubber Roller and refit the retaining bars at each end of the Rubber Roller.

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7 FAULT FINDING

Fault Possible Cause Action Required Machine does not operate No power electrical or pneumatic Ensure a 24v supply / line run signal is

present as well as 5-6 bar compressed air

Anti-static bar not operating (if active antistatic is fitted)

No power to anti-static transformer Ensure that the anti static transformer is supplied with correct voltage

Adhesive paper wraps around blue rollers

Wrongly installed adhesive rolls Check section in manual on adhesive orientation.

Blue rollers covered with contaminants

Adhesive rolls saturated with contaminants

Check and purge adhesive rolls

Machine does not operate as expected.

Machine maybe set up for the wrong mode of operation

Check jumper connections on connection board

Adhesive rolls do not engage with blue rollers

Air supply to the cylinders is incorrect

Check air supply. Adjust adhesive pressure regulators. Individual pressures can be set for top and bottom adhesive

Adhesive rolls empty Replace adhesive rolls Machine not cleaning surfaces satisfactorily Blue rollers covered with

contaminants Check and clean blue rollers. See Section 6.3

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8 SPECIFICATION

8.1 Machine Dimensions Refer to Pi52535 or Pi52536 and Weights

8.2 Machine Type In-line Narrow Web Platform (NWP) Cleaner.

8.3 Machine Construction Stainless Steel covers and fasteners. Anodised Aluminium frame.

8.4 Finish Brushed Stainless Steel and Anodised Aluminium

8.5 Capacity Capacity Accommodates materials up to 3.2mm (0.126") thick.

8.6 Speed As per Installed Web Speed (250m/min max)

8.7 Air Supply

5 - 7 bar dry and oil free.

8.8 Power 24v DC

8.9 Web Direction Models available to suit either Left to Right or Right to Left web flow relative to machine.

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9 RECOMMENDED SPARES

9.1 PREVENTATIVE MAINTENANCE TOOLS

Part No. Description Mi6700 Tekwipes Mi5068 Scotchbrite Pads Mi4609SP Anti-Static Cleaning Brush Mi2393 Anti-Static Checker

9.2 PREVENTATIVE MAINTENANCE PARTS

Part No. Description HA51621 Pneumatic Seal NW08 QRH

HA32582 O-Ring (Adh. Roll Core Holder)

SA52747 Solenoid Valve

HA32561 Latch

HA32562 Latch Keeper

9.3 LENGTH ORIENTATED SPARE PARTS

Description NWP 254 NWP 345 NWP 430 NWP 520 NWP 570 NWP 622 NWP 762

Rubber Roller - Film SA46915SP SA46917SP SA46919SP SA46921SP SA46923SP SA46925SP SA47637SP

Rubber Roller – Ultracleen SA43531SP SA43532SP SA43533SP SA43534SP SA43535SP SA43536SP SA43537SP

Rubber Roller - Panel Contact Technical Services SA46927SP

Rubber Roller – Nanocleen SA52372SP SA52371SP SA52373SP NA NA NA NA

Adhesive Roll (Sheeted) ARBS0254 ARBS0345 ARBS0430 ARBS0520 ARBS0570 ARBS0600 ARBS0750

Adhesive Roll (Filmic) ARNS0254 ARNS0345 ARNS0430 ARNS0520 ARNS0570 ARNS0622 ARNS0762

Anti-Static Bars (Active) AB37783 AB37784 AB37785 AB37786 AB39614 AB37787 AB37788

Gas Strut (Top Hood) Contact Technical Services

Loom Latch Switch EW51201

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10 DIAGRAMS 10.1 Electrical Schematic Diagram 10.2 Pneumatic Schematic Diagrams 10.3 Connection Diagram 10.4 Assembly Drawings 10.5 Layout Drawings