Tidland G590 Lug Shaft

Transcription

1 TIDLAND WINDING SOLUTIONS Tidland G590 Lug Shaft Operation and Maintenance EN 3" Shaft Diameter MI C

2

3 CONTENTS INTRODUCTION 1-1 About these operating instructions Product overview Model number key Available models SAFETY INFORMATION 2-1 Symbols used Proper use Decommissioning ASSEMBLY DIAGRAM AND PARTS LIST 3-1 Shaft components Parts list INSTALLATION 4-1 Installing the shaft OPERATION 5-1 Air pressure Inflating the shaft MAINTENANCE 6-1 Maintenance schedule Recommended tools and supplies Valves Removing the rubber tube assembly Replacing the air system elements Rubber tube assembly parts Installing a complete rubber tube assembly Building the rubber tube assembly Torque requirements TROUBLESHOOTING 7-1 SPECIFICATIONS 8-1 SERVICE AND PARTS 9-1

4 1-1 INTRODUCTION About these operating instructions All of the information herein is the exclusive proprietary property of Maxcess International, and is disclosed with the understanding that it will be retained in confidence and will neither be duplicated nor copied in whole or in part nor be used for any purpose other than for which disclosed. Copyright 2012, all rights reserved. Periodically there will be updates to this manual. The latest version is available at or by calling your regional office listed on the back page of this publication. These instructions are designed to help put the external element winding shafts into service and provide important notes for the proper use of the shaft. These instructions are valid for following shaft series: Series G590 These instructions are important for the machine manufacturer, end user, machine operator and maintenance personnel. Read and understand these instructions before installing and operating the shaft. The instructions must be read and used by all persons who have the responsibility of installing and maintaining these shafts. These instructions must be retained and incorporated in the technical documentation for the machine or partly completed machinery into which the shaft is installed. These are the original instructions, written in English.

5 1-2 INTRODUCTION Theory of operation The Tidland G590 air shaft is a medium to wide web width core shaft, made of aluminum or steel, with expanding lugs for high torque transfer to the core. The lugs are actuated by an internal air bladder to grip the core and are positively retracted with springs to enable easy, consistent roll or core loading and removal. Air is delivered to the shaft through a valve located in the end or on the side of the shaft body, or through a rotary union. Model number key Shaft series shaft type mounting type Shaft series Shaft type Mounting type G Global 590 = Lug shaft None = drop-in C = cantilevered Available models G590 G590C

6 2-1 SAFETY INSTRUCTIONS Safety information When using this Tidland product, always follow basic safety precautions to reduce the risk of personal injury. Your company's safety instructions and procedures should always be followed. When using this product with any other equipment or machinery, all safety requirements stipulated by that equipment or machinery manufacturer must be followed. Compliance with local, state, and federal safety requirements is your responsibility. No part of these or the following instructions should be construed as conflicting with or nullifying the instructions from other sources. Be familiar with the hazards and safety requirements in your work environment and always work safely. Read and understand all instructions and shaft design application limits before operation. Never use this product for a purpose or in a machine that it was not specifically designed for. See Product Safety Data Sheet (PSDS). Do not exceed the operation loads for this shaft as noted on its PSDS, Product Safety Data Sheet. Follow all warnings and instructions marked on the product and on the PSDS. Do not use fingers or other objects to deflate the shaft; use only the Tidland deflation tool. Inspect the shaft for wear and/or other safety and functional deficiencies daily, before each use. Wear safety glasses or proper eye protection when inflating or deflating or otherwise operating the air system. Do not remove or otherwise alter any setscrews or fastening devices prior to using this product. Do not operate this product if any setscrews or fastening devices are missing. Do not lift shaft manually if it is beyond your capacity. Loads over 1/3 your body weight may be prohibitive. Consult your company safety policy. When lifting a shaft, use proper lifting techniques, keeping back straight and lifting with the legs. (continued)

7 2-2 SAFETY INSTRUCTIONS Do not carry or lift this product over wet or slippery surfaces. Use appropriate mechanical lifting devices, such as a hoist or shaft puller, for heavier shafts. When performing maintenance or repair procedures, do not pressurize the shaft if journal setscrews are loose or missing. When performing maintenance procedures, do not pressurize the shaft if the journal is missing. All replacement parts used on this product should be made to original Tidland specifications. All maintenance and repair procedures performed on this product should be done to Tidland specifications by qualified personnel. Information about safety instructions The safety instructions and symbols described in this section are used in these operating instructions. They are used to avoid possible dangers for users and to prevent equipment damage. SIGNAL WORD Source of danger and its results Avoiding dangers The signal word DANGER refers to the danger of death or serious bodily injuries. The signal word WARNING refers to the danger of moderate to severe bodily injuries. The signal word CAUTION refers to the danger of slight to moderate bodily injuries or material damage. The signal word NOTICE refers to the possibility of damage to equipment. Symbols used The following safety identification symbols are used in these operating instructions. WARNING/CAUTION General danger or important note Reference to general hazards that may result in bodily injuries or damage to device or material.

8 2-3 SAFETY INSTRUCTIONS Basic safety information To ensure safe and problem-free installation of the winding shaft, the shaft must be properly transported and stored, professionally installed and placed in operation. Proper operation and maintenance will ensure a long service life of the shaft. Only persons who are acquainted with the installation, commissioning, operation and maintenance of the system and who possess the necessary qualifications for their activities may work on the shaft Proper use The Tidland G590 shaft is intended for the purpose of clamping cores or rolls to be used for winding or unwinding web materials (paper, cardboard, plastic film, non-wovens, textiles, and metal foils). Improper use Operation outside the technical specifications Any other use than the proper use shall be deemed inappropriate.

9 2-4 SAFETY INSTRUCTIONS Basic safety information (continued) Installation and commissioning WARNING Danger of falling down or muscle or skeletal injury during installation The larger design shafts are heavy. Appropriate equipment is to be used and the safety rules of the company must be observed. Operation WARNING Danger of entanglement or pinching during operation Keep hands and loose clothing away from rotating shaft. Maintenance and repair WARNING - Danger of entanglement or pinching Maintenance and repair tasks on the shaft must be performed only when the machine has been stopped and has been secured from being turned on again. WARNING Danger of bodily injury or damage to hearing. Do not inflate rubber tube outside of the shaft. Decommissioning The shaft must be disposed of in accordance with all the applicable national, state and local regulations.

10 3-1 ASSEMBLY DIAGRAM AND PARTS LIST Shaft components Shaft and journals Internal parts Rubber tube assembly

11 3-2 ASSEMBLY DIAGRAM AND PARTS LIST Parts list Tidland G590 Lug Shaft configurations vary; replacement parts are dependent upon number of lugs, length of rubber tube assembly, valve location(s) and body material. Parts are listed for reference. To order parts, call Tidland Customer Service. Please have your shaft serial number available. Item Description Shaft and Journals * 1 Valve, large (side or end location) * 2 Valve gasket, large (Note 1) * 3 Valve, small (end location only) 3a Valve gasket, small (Note 2) 4 Journal 5 Shaft body 6 Set screw, M10 Internal parts * 7 Lug (without stubs) * 8 Lug (with stubs) 9 Separator * 10 Poron springs (2 per lug) 11 Rubber tube assembly Rubber tube assembly * 12 Rubber tube material 13 Tube fitting 14 Tube fitting cap 15 Jam nut 16 O-ring connector 17 O-rings (2) 18 Gasket (sealing ring) * Recommended spare parts Note 1: Note 2: Large valve gasket must be ordered separately if replacing the large valve. Small valve is supplied with a gasket. The gasket is also available separately.

12 4-1 INSTALLATION Installing the shaft Upon receipt Before placing in service, visually inspect shaft for any damage due to shipping or mishandling. Track each shaft by recording its serial number and the date it was placed in service. See Maintenance Schedule (Section 6-1) for shaft inspection guidelines. General WARNING Danger of falling down or muscle or skeletal injury during installation The longer shafts are heavy. Appropriate equipment is to be used and the safety rules of the company must be observed. When using chucks on this shaft, always locate chucks as shown. Improper placement of chucks will reduce life cycle of the shaft. Questions about installation, application or load calculations? Call Tidland Customer Service.

13 5-1 OPERATION Operation Use only clean, dry, non-lubricated air. WARNING Danger of entanglement or pinching during operation Keep hands and loose clothing away from rotating shaft. WARNING Danger of high-speed projectile injury Do not inflate rubber tube assembly outside of the shaft. Tube fittings could disengage from assembly and become dangerous projectiles. Air pressure Shaft operation requires bar [ psi]. Inflating the shaft Use the Tidland Inflation Tool. Push the air nozzle firmly into the valve receiver, depressing both the valve button and the tip of the inflation tool. Do not exceed 8.3 bar [120 psi]. Deflating the shaft WARNING Danger of high pressure injection injury Do not use finger to deflate the shaft. Using the Tidland air release tool, push in the quick release air valve allowing the air to escape through the hole in the center of the button.

14 6-1 MAINTENANCE Maintenance schedule If any of these problems are found, remove the shaft from service and call Tidland Customer Service. These guidelines do not in any way extend or modify the Tidland Product Warranty. Specific shaft life is determined by actual operating conditions. These inspection intervals may be adjusted. General Keep shaft clean and dry. Between every roll change, use compressed air to remove dust and debris buildup. Note: When not in use, always store the shaft fully deflated to prevent cold flowing of the air bladder. Before each use Check for damage or excessive wear (see inspection section). Check for missing or loose fasteners. Inflate and deflate the shaft without a core installed and verify that each lug is expanding and retracting correctly. After one year Body Inspect lug slots for excessive wear. Inspect for squaring at the corners of the lug slots where cracks can develop. Dry polish with an abrasive pad around the ends of the suspect slots to expose any possible cracks. (continued)

15 6-1 MAINTENANCE Maintenance schedule (continued) Composite body Inspect the integrity of the outer fiberglass skin; if delamination is present or cracks* are visible, remove the shaft from service. * greater than 1.5 mm [.0625"] deep and 13 mm [.500"] long Journals Check for reductions in transitional radii between journal diameter steps. If wear is observed, check for cracks. Use magnetic-particle or dye-penetrant, or an equivalent procedure, to detect surface cracks. Measure diameters at those locations where journal, or body, rides on bearings. Measure diameter at those locations where the edges of mounted rolls ride on the shaft body, watching for diameter reduction of 0.015" (0.4 mm) or more. Recommended tools and supplies Hex drive wrenches: 5 mm Socket wrench: 19 mm [3/4 in.] Tidland inflation tools (contact Customer Service for options) Tidland air release tool (Tidland ) Tidland valve removal tool (for use with the small valve only): Part No. (North America) (wrench) (tool bit only)** Part No. (Europe) M (wrench) M (tool bit only)** Dow Corning Molykote 55 o-ring grease Loctite 243 (or equivalent medium-strength threadlocker) ** This part is a tool bit for use with a torque wrench. (Recommended)

16 6-2 MAINTENANCE Valves Valve may be located at end or side of shaft, or at both ends for dual air systems. Valve(s) must be removed before removing the valve journal. Small valves: Use the recommended Tidland valve removal tool. Large valves: Use socket wrench 19 mm [3/4"]. Reinstalling a valve Replace gasket when reinstalling a valve. Apply a thread sealant (according to the manufacturer's directions) to threads of the valve (unless the sealant is preapplied). NOTE: Valves with pre-applied thread sealant are good for multiple uses. Always inspect the valve threads for sufficient sealant; do not reuse more than six times. Screw the valve into the shaft; see Section 6-6 for torque requirements for each valve size. Removing the rubber tube assembly Remove the journal 1. Inflate the shaft to raise the lugs. 2. Insert retainer clips in each lug and deflate the shaft. 3. Remove the valve. 4. Match-mark the body and journal; remove the journal. 5. Pull the rubber tube assembly from the shaft. end view - retainer clips

17 6-3 MAINTENANCE Replacing the air system elements WARNING Danger of high-speed projectile injury Do not inflate rubber tube assembly outside of the shaft. Tube fittings could disengage from assembly and become dangerous projectiles. To prevent damage to the shaft and lugs, use a round clamping fixture to secure shaft during maintenance. Rubber tube assembly parts Some assemblies include a tube stiffener: tubes 11/16" and under include a wooden dowel inside the tube to aid in loading the assembly into the shaft. All fittings can be reused with new rubber tube material. If parts are rusted or worn, Tidland recommends replacing the entire rubber tube assembly. Valve-end fittings are bored through for air passage; non-valve fittings are solid Valve journal 2 O-ring connector 3 Jam nut 4 End cap 5 Tube fitting 6 Tube stiffener 7 Rubber tube

18 6-4 MAINTENANCE Reinstalling a complete rubber tube assembly 1. Apply o-ring grease to the connector o-rings. 2. Push the valve end tube fitting into the journal until firmly seated Insert the non-valve end of the rubber tube assembly into the shaft until fitting is fully seated in the socket. (Shaft not shown.) Apply o-ring grease to valve journal fit area; align match marks and reinstall the valve journal. 5. Apply Loctite 243 to the journal set screws; reinstall and tighten according to chart in Section Reinstall the valve; Section Valve journal 2 O-ring connector and o-rings 3 Rubber tube assembly (valve end) 4 Journal fit area 5 Rubber tube assembly (non-valve end) 6 Socket 7 Non-valve journal Note: If replacing o-ring connector (item 2), see torque requirements in Section 6-6.

19 6-5 MAINTENANCE Building the rubber tube assembly Cut rubber tube square at each end Install the end cap (1) on the rubber tube and mark its position on the tube (2). Remove the end cap Insert the tube fitting (3) deep inside the rubber tube Fit the end cap (4) over the tube. 5. Squeeze the tube (5) to force the tube fitting back toward the end. 6. Apply Loctite 243 to the tube fitting threads and install the nut (6). Do not tighten. 7. Secure the shaft in a round clamping fixture. 2 mm [1/16"] 8. Tighten the nut to draw the tube fitting out until fully seated in the end cap. 9. Tighten the nut to torque specified in Section The end cap must be within 2 mm of the mark on the rubber tube. Tube fitting threads should be perpendicular to the rubber tube. If crooked, loosen the nut and repeat the procedure. 11. Repeat the procedure for the non-valve end. Reinstalling the rubber tube assembly; Section 6-4.

20 6-6 MAINTENANCE Torque requirements Set screw torque Size Steel Body Aluminum Body M Nm [22-24 ft lbs] Nm [7-8 ft lbs] Tube fitting assembly torque Tube O.D. 1-3/8 inch Nm [38-40 ft lbs] 1-5/8 inch Nm [43-45 ft lbs] O-ring connector Item 2 (Section 6-4) 11 Nm [97 in lbs] Valve Valve size Small (end location) Large (end or side location) 5 Nm [44 in lbs] 17 Nm [150 in lbs]

21 7-1 TROUBLESHOOTING Problem Possible Cause Recommended Solution Shaft will not inflate or hold air Lugs fall through slots Leaking rubber tube assembly Valve leaking O-ring connector loose No tube stiffener Rubber tube lies flat when not inflated. Disassemble shaft and replace rubber tube assembly. Remove valve and inspect for thread sealant applied to threads.* Add thread sealant and reinstall. Tighten according to specifications in Section 6-6. Replace valve if necessary. Disassemble shaft and reinstall o-ring connector using Loctite 243 on the threads. Call Tidland for recommendation. Cores slipping Low air pressure Operate shaft at 80 psi minimum (5.5 bar) for optimal performance. Journals wear prematurely Excessive shaft vibration Air leak High loads or speeds Shaft imbalance See "shaft will not inflate or hold air" at the top of this list. Check PSDS specifications for your shaft application. Verify that journals are hardened. Inspect shaft for missing components or fasteners. * Valves with pre-applied thread sealant (from manufacturer) can be re-used up to six times.

22 8-1 SPECIFICATIONS Specifications WARNING Do not use the devices outside of their rated specifications. Refer to your Product Safety Data Sheet (PSDS) for your custom shaft specifications. Operating air pressure bar [ psi] Ambient operating temperature 38º C [100º F] Core diameter 76.2 ±.76 mm [3.00" ±.03"] Core types Fiber or plastic

23 9-1 SERVICE Service requests and replacement parts To request service or to get replacement parts, contact Tidland or one of the locations listed on the back page of this publication. Maxcess 2305 SE 8 th Avenue Camas WA Please have your shaft serial number available when you call.

24 NORTH, CENTRAL AND SOUTH AMERICA Tel Fax INDIA Tel Fax EUROPE, MIDDLE EAST AND AFRICA Tel Fax JAPAN Tel Fax CHINA Tel Fax KOREA, TAIWAN, AND SE ASIA Tel Fax Maxcess