TTR-50/8 Tissue Tack and Reel System

Transcription

1 TTR-50/8 Tissue Tack and Reel System Manual Number: MM099 Publication Date: 2/2013

2 2013 All Rights Reserved. This manual is furnished with the TTR-50/8 Tissue Tack and Reel System and may only be used or copied in accordance with the terms of purchase. No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Valco Cincinnati, Inc. The information in this manual is furnished for educational purposes only, is subject to change without notice, and should not be construed as a commitment by This manual was written and designed at, 411 Circle Freeway Drive, Cincinnati, Ohio Part Number: MM099 Printed in the USA Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati, Ohio TEL: (513) FAX: (513) Valco Cincinnati Limited Hortonwood 32 Telford, TF1 7YN, England TEL: (+44) FAX: (+44) Valco GmbH Storkower Str. 6 D Gallun,Germany TEL: (+49) FAX: (+49)

3 Declaration of Conformity (According to EN 45014) Manufacturer: Authorized Representatives in Europe: declares that the product: Product Name: complies with the following Council Directives: Safety of Machinery: Low Voltage Equipment: EMC: and conforms to the following standards: Safety: Risk: EMC Emissions: EMC Immunity: Place and Date: Signature: Valco Melton A division of Valco Cincinnati, Incorporated 411 Circle Freeway Drive Cincinnati, OH USA Valco Cincinnati, Ltd. Unit 7-8 Hortonwood 32 Telford TF1 7YN England TTR-50/8 TT&R System 2006/42/EC 2006/95/EC 2004/108/EC EN :2006 EN EN :2007 EN :2007 EN EN :2005 EN EN EN EN EN EN Cincinnati, Ohio USA CE Mark first fixed 2006 David H. Swedes, Director of Engineering & Manufacturing Melton S.L.U Pol. Industrial Agustinos calle G, n Orcoye Navarra, Spain This Declaration of Conformity has been generated electronically and is legally binding without signature

4 TABLE OF CONTENTS Section 1 - Introduction System Description System Components System Layout Section 2 - Safety Information Trained Personnel Safety Symbols Intended Use of the Equipment Installing Operating Maintenance and Repair Hot Adhesive Safety Section 3 - Wiring Guidelines Routing Low-Voltage Leads Connecting the Electrical Power Section 4 - Basic Features Front Panel Features Control Panel Features Side Panel Features Back Panel Features Section 5 - Installation System Layout Connecting the Power Connecting the Glue Hoses to the Unit Connecting the Glue Hoses to the Manifold Connecting the Conduits to the Unit Connecting the Cables to the Junction Box TTR-50 Pump Packing Installation TOC-1

5 Contents MM099 TTR-50/8 TT&R System Section 6 - Operation System Operation Accessing the Main Menu Recommended Parameters Touchscreen Operation Accessing the Fault Menu Using the System Setup Menu Programming the Control Using the Glue Pressure Menu Using the Valve Setup Menu Screens Using the Temperature Control Menu Screens Using the Option Setup Menu Screen Using the Inactivity Timer Setup Menu Screen The Configuration Menu Screen Typical Reel Turn-up Sequence Re-threading Section 7 - Maintenance Guidelines Cleaning the Filter Cleaning the Exterior of the Unit Automatically Maintaining Tank Fill Levels Cleaning Valves/Nozzles Changing the Pump Valve Maintenance/Disassembly Tightening Pump Packing (monthly) Flushing Hoses, Manifold and Glue Valves (twice/year) Draining and Cleaning the Tank (twice/year) Checking Fluid Connections Changing Out Pressure Relief Plungers (779xx884) Section 8 - Troubleshooting Fault Message List If a valve fails to spray properly If the unit fails to build pressure Section 9 - Specifications Section 10 - Warranty General Warranty Information Cold Glue Equipment and Electronic Controls Hot-Melt Units, Hoses, Valves, Guns, and Related Equipment TOC-2

6 MM099 TTR-50/8 TT&R System Contents Section 11 - Service Section 12 - Parts List How to Order Parts TTR-50 Hot-Melt Unit (DLM3123) Washdown Valve (769xx997) Valve Rebuild Kit (703xx208) Standard Nozzle Washdown Valve (766xx582) Auto Refill Kit (561xx154) Other Kits Manifold/J-Box Assembly (DLM3122) Valve Manifold Assembly (DLM3120) Overall Assembly (DLM 3121) Extension Cable, Heated Hose (029xx279) DC Cable Assembly (029xx155) Valve Driver Cable Assembly (029xx153) AC Cable Assembly (029xx154) Appendix A - Wiring Diagrams... A-1 Appendix B - Maintenance Schedules... B-1 TOC-3

7 SECTION 1 - INTRODUCTION System Description System Components The TTR-50 is a medium-volume heating unit designed for use in roll-tissue gluing applications, including roll tissue core pickup and tissue tack and reel. The TTR-50 can be equipped with anywhere from (8) to (24) valves. The system heats and pumps adhesive, using a positive-displacement, electric, motor-driven gear pump. Components of the TTR-50 Tissue Tack and Reel System include: Individually controlled temperature zones Heated tank (reservoir) Air filter/regulator, glue filter, and glue pressure gauge Closed-loop pressure control Glue valves Fluid-supply manifold Flushing system (optional) Auto-Fill System System Layout Figure 1-1. System Layout 1-1

8 SECTION 2 - SAFETY INFORMATION The safety related information contained in this section (and throughout the manual) applies to the various tasks performed with many different adhesive units and all hot-melt units. Where appropriate, safety specific warnings are included within the body of the manual. These instructions must be adhered to at all times. Failure to follow the safety instructions provided could result in damage to the unit or injury to the equipment operator. The following practices are recommended with regard to basic safety: Read the Safety Information section thoroughly before installing and operating the hot-melt unit. Ensure that this information is accessible to any and all persons operating, maintaining, and repairing the unit. Follow all warnings contained in the text related to tasks performed with or on the hot-melt unit. Always wear protective clothing and equipment (e.g., safety eyewear and gloves) when operating or maintaining the unit. Ensure that all local, county, state, and national codes, regulations, rules, and laws related to safety and safe operating conditions are met and followed. Trained Personnel One of the most important ways to ensure safe operations is having qualified, well-trained individuals. It is incumbent on the company operating the equipment to ensure that installation, operations and maintenance personnel meet the necessary training requirements. Trained personnel thoroughly understand the installation, operation, maintenance, and repair of equipment. They must also be physically capable of performing required tasks. Necessary training includes related safety education and complete instruction in the proper installation, operation, maintenance, and repair of equipment. Safety Symbols The following safety symbols are used throughout the manual to warn against possible dangers. Failure to observe and follow the warnings provided could result in damage to the unit or injury to the equipment operator. Warning! Failure to observe could result in personal injury, death, or damage to equipment. 2-1

9 Section 2 - Safety Information MM099 TTR-50/8 TT&R System Important Safety Symbols - Continued Warning! Danger of electrical shock. Failure to observe could result in personal injury, death, or damage to equipment. Warning! Disconnect equipment from line voltage. Caution! Failure to comply could result in damage to the equipment. Warning! Risk of burns exists. Wear heat-protective clothing at all times. Warning! Risk of burns exists. Wear protective safety goggles at all times. Warning! Risk of burns exists. Wear heat-protective gloves at all times. Caution! Hot surface. Failure to observe could result in burns. 2-2

10 MM099 TTR-50/8 TT&R System Section 2 - Safety Information Intended Use of the Equipment The equipment and/or system is designed and intended to be used in a manner described in this manual. Uses are considered unintended if governing regulations are not followed or if the equipment and/or system is used in a manner other than that described. Warning! Use of this equipment in a manner other than described in this manual could result in personal injury, death, or damage to equipment. Read all instructions, warnings, tags, and labels before operating the equipment. is not responsible for personal injury or equipment damage resulting from unintended use of the equipment. Some actions that qualify as unintended use include the following examples: Failure to observe and follow safety rules and instructions. Unauthorized modification of the equipment and/or system. Failure to follow installation, operation, maintenance, or repair instructions. Use of unqualified personnel to install, operate, maintain, or repair the equipment. Failure to follow safety rules and regulations outlined by material safety data sheets, government authorities, or safety councils. Use of unapproved or incompatible materials or supplementary equipment. Warning! Failing to follow safety instructions and procedures can result in personal injury, death, or damage to equipment. Installing With regard to installation and electrical safety, the following procedures apply: Hot-melt equipment is to be installed and connections (electrical, pneumatic, gas, and hydraulic) are to be made ONLY by qualified personnel. 2-3

11 Section 2 - Safety Information MM099 TTR-50/8 TT&R System Installing - Continued Components and accessories are to be installed in accordance with the instructions provided and applicable codes. All equipment must be properly grounded and fused in accordance with rated current consumption (refer to the equipment identification plate). Inspect external cables for wear or damage on a regular basis. Cables must never be squeezed or pinched. To avoid unnecessary contact, do not locate cables and hoses in high traffic areas. Do not use hoses to pull the equipment. Operating Gauge and insulation for power supply must be adequate to handle rated current consumption. Warning! Failing to follow safety instructions and procedures can result in personal injury, death, or damage to equipment. The equipment should only be operated by qualified personnel in compliance with the instructions detailed in this manual. Check the equipment on a daily basis. Immediately replace any damaged or worn parts. Do not alter or modify the equipment. Do not allow the equipment to be operated by impaired individuals or personnel who are unable to operate the equipment for physical reasons. Before starting the unit, check all protection and warning devices to ensure that they are completely functional. If these devices are not functioning properly, do not operate the unit. If safety equipment must be removed in order to install, maintain, or repair the unit, it should be restored immediately after the work is completed. In the event of unit malfunction, switch the unit off immediately and have it inspected and repaired by qualified personnel. Always wear recommended protective eyewear, gloves, and clothing when operating the equipment. 2-4

12 MM099 TTR-50/8 TT&R System Section 2 - Safety Information Maintenance and Repair Only qualified personnel should perform the maintenance and repair procedures detailed in this manual. Protective clothing and equipment should be worn at all times when performing these tasks. Warning! The unit may still be energized even after the circuit breaker or main power switch is off. The following steps should be completed prior to maintaining and/or repairing equipment: Disconnect, lock out, and mark the external power supply. Test to make sure the external power supply has been disconnected. Try operating the unit. If the unit does not impart energy, you can proceed with the equipment maintenance or repair. If the equipment energizes, repeat the disconnect procedure and test the equipment again. Read and follow the maintenance/repair instructions included in this manual, including instructions for relieving pressure in the unit. Only use Valco parts and use insulated tools to remove or install system components. Never use an open flame to clean the unit or any unit components. Refer to the material manufacturer s Material Safety Data Sheet (MSDS) before working on any material. Ensure that the MSDS and other material information is stored near the equipment and accessible. Hot Adhesive Safety Contact with hot adhesive or hot areas of the equipment may produce a severe burn to the skin. Always refer to the material manufacturer s Material Safety Data Sheet (MSDS) before working with any hot melt material. Warning! Risk of burns exists. Wear heat-protective clothing, safety goggles, and heat-protective gloves at all times when working with hot melt materials. 2-5

13 Section 2 - Safety Information MM099 TTR-50/8 TT&R System Hot Adhesive Safety - Continued If hot adhesive comes in contact with the skin, do the following: 1. Immediately immerse the contacted area in clean, cold water. It is recommended that a source of clean, cold water be provided near the hot-melt work area. 2. Do not attempt to remove hot melt material from the skin. 3. Cover the affected area with a clean, wet compress and seek medical attention immediately. In addition, make sure that the work area is adequately ventilated. Be sure that recommended processing temperatures are not exceeded. If recommended temperatures are exceeded, personnel are in danger of exposure to decomposing material. When unit operation and cleaning are completed, dispose of the equipment and materials used according to local regulations. 2-6

14 SECTION 3 - WIRING GUIDELINES Routing Low- Voltage Leads Warning! Failure to observe could result in personal injury, death, or damage to equipment. When routing low-voltage leads, follow these guidelines: Do not route low-voltage leads in the same conduit as wires carrying a high-current load. Do not route low-voltage leads adjacent to, or across wires carrying a high-current load. If low-voltage leads must cross or run parallel to wires carrying high current, keep the leads at least 6" (152 mm) from high-current wires. Do not splice or solder leads. Trim leads to the required length. Leads should be only as long as necessary for installation. All wiring should be in conduits or wireways. Connecting the Electrical Power Warning! Electrical connections should be made only by experienced service personnel! Failure to observe could result in personal injury, death, or damage to equipment. When connecting the supply of electrical power, follow these guidelines: Connect the control to a clean supply of electrical power. Use a dedicated circuit if possible. If a dedicated circuit is not available, do not connect the control to a circuit that supplies high-amperage equipment use another circuit such as a lighting circuit. Otherwise, equipment may not function properly. 3-1

15 SECTION 4 - BASIC FEATURES Front Panel Features Control Panel Main Power Disconnect Figure 4-1. TTR-50 Front Panel Features Description of Front Panel Features Feature Name Control panel Main power disconnect switch Function The control panel contains the Power ON indicator light, Control ON/Control OFF switches, and the touchscreen display. This switch connects the power to the system when handle is placed in the ON position. 4-1

16 Section 4 - Basic Features MM099 TTR-50/8 TT&R System Control Panel Features Figure 4-2. TTR-50 Control Panel Description of Control Panel Features Feature Name Power ON Indicator Light (white) Control ON Button (black) Control OFF Button (red) Control ON Indicator Light (green) Touchscreen Display Function Illuminates when the main disconnect is turned on and the unit is connected to an electrical power source. Used to apply heat to the system and activate the control. Deactivates the control. Indicates that the control has been activated. Provides system status information and a method for selecting control options. 4-2

17 MM099 TTR-50/8 TT&R System Section 4 - Basic Features Side Panel Features Hose Connection Glue Pressure Gauge Figure 4-3. TTR-50 Side-Panel Features 4-3

18 Section 4 - Basic Features MM099 TTR-50/8 TT&R System Back Panel Features Glue Reservoir (Glue Tank) Valve Driver Panel Figure 4-4. TTR-50 Back Panel Features 4-4

19 SECTION 5 - INSTALLATION System Layout Figure 5-1. System Layout Connecting the Power Warning: Electrical connections and adjustments should be made only by an experienced electrician. Failure to observe could result in personal injury, death, or damage to equipment. Warning: Properly route all electrical wires to avoid danger to personnel and damage to moving parts of machine. Failure to observe could result in personal injury, death, or damage to equipment. Warning: Disconnect all power before opening the control. Only qualified personnel should open and service the control. Failure to observe could result in personal injury, death, or damage to equipment. 5-1

20 Section 5 - Installation MM099 TTR-50/8 TT&R System Connecting the Power - Continued The TTR-50 is compatible with 380/400/416/480 voltage (3-phase, 50/60 Hz, 40A). For the proper wiring connections for your voltage, see the wiring schematics provided with your system. These diagrams also illustrate how to change your voltage selection. (Valco recommends that you label your supply voltage.) Incoming 3-phase power must be connected so that the glue-pump motor turns in a clockwise direction when viewing the TTR-50 unit from the back. To connect the main power supply, follow these steps: 1. Locate desired position for power entry on electrical enclosure. 2. Drill holes for customer-supplied power cable. 3. Connect the power-cable securely to the main-disconnect terminals inside the unit. 4. Connect ground wire to ground block on electrical enclosure. Connecting the Glue Hoses to the Unit Warning: Never disconnect the glue hoses from a running TTR- 50 hot-melt unit. Hot melt is under high pressure. Turn off the power then remove the hose. Failure to observe could result in personal injury or death. Caution: Do not operate the TTR-50 hot-melt unit with the fluid outlet ports open to the air. Failure to observe could result in personal injury or damage to equipment. Caution: When routing and installing heated hoses, avoid creating sharp corners and edges. Do not bend hoses less than 18 inch (460 mm) radius. Do not step on the hoses. Group heated hoses in such a way that they do not contact one another. Avoid the use of unnecessarily long hoses where the hose is looped or curled on the floor. Failure to observe could result in damage to hoses. To connect the glue hoses to the TTR-50 unit, follow these steps: 1. Connect either end of the glue hose to the glue-hose fluid connection (hose #1 - direct connection, hose #2 - extension cable). 5-2

21 MM099 TTR-50/8 TT&R System Section 5 - Installation Connecting the Glue Hoses to the Unit - Continued 2. Insert the plugs into the proper receptacles. Plugs and receptacles are labeled. 3. Insert the Y-connector through the cord grip on the front electrical enclosure conduit plate. Connecting the Glue Hoses to the Manifold To connect the glue hose to the manifold, follow these steps: 1. Connect the end of the glue hose to the fluid connection on the manifold. 2. Tighten the fitting. Connecting the Conduits to the Unit The TTR-50 system is shipped with three or four interconnect cables: One or two valve-driver cables One AC control cable One DC control cable 5-3

22 Section 5 - Installation MM099 TTR-50/8 TT&R System Connecting the Cables to the Junction Box Connections are located on the bottom of the 6 X 6 enclosure. Valve Cable Connection AC Cable Connection DC Cable Connection Top view looking down inside of the 6 X 6 enclosure. Figure 5-2. Connecting Cables to the Junction Box 5-4

23 MM099 TTR-50/8 TT&R System Section 5 - Installation TTR-50 Pump Packing Installation 1. Remove the pump from the TTR-50 unit and place it shaft-up on a clean working surface. 2. Remove the three packing retainer plate hex head cap screws. 3. Remove the packing retainer plate. 4. Remove the six socket head cap screws from the pump body. 5. Separate the top pump plate from the pump assembly; working from the inside surface of this plate, use a socket or dowel to push out the bottom packing washer, packing material and top packing washer. 6. Reinstall the top pump plate making sure that the mating plate surfaces are completely free of debris; insert the bottom packing washer in the packing cavity to ensure that the top plate is centered with the pump shaft; use a straight-edge to ensure that all pump plates are aligned; torque the six screws to 10 ft.-lb using a cross-bolt pattern. 7. Wrap 1/8 diameter packing rope (P/N 561xx082, included in seal kit 561xx100) clockwise around the pump shaft to completely fill the packing cavity; cut off the excess packing material. 8. Reinstall the top packing washer. 9. Reinstall the packing retainer plate. 10. Reinstall the three packing retainer screws and snug them equally; ensure that the top packing washer enters the packing cavity. 11. Reinstall the pump on the TTR-50 unit 12. While operating the pump at 2,000 psi, gradually tighten the three packing retaining screws in equal increments until shaft leakage stops. 5-5

24 Section 5 - Installation MM099 TTR-50/8 TT&R System TTR-50 Pump Packing Installation - Continued Packing Retainer Plate Top Packing Washer Packing Bottom Packing Washer Pump Top Plate Packing Cavity Figure 5-3. TTR-50 Pump Packing Installation 5-6

25 SECTION 6 - OPERATION System Operation To begin system operation, follow these steps (see Figure 6-1.): 1. Turn the main disconnect on to apply power to the TTR-50 unit. 2. The Power ON indicator light will illuminate (light up), indicating power to the system. 3. After approximately one minute, the touchscreen panel will start operation and indicate system status. 4. If the red light on the Control OFF push button is on, pull the Control OFF push button out. 5. Press the Control ON push button to enable the pump and heaters. 6. The green Control ON Indicator light will illuminate. Power ON Indicator Light Control ON Indicator Light Control Disable Button Control Enable Button Figure 6-1. The TTR-50 Control Panel 6-1

26 Section 6 - Operation MM099 TTR-50/8 TT&R System Recommended Parameters The following parameters are recommended for the TTR-50: Warning: Follow adhesive manufacturer s recommended temperature specification. Excessive temperatures can char adhesive, damage equipment, and cause injury. Pressure: 2400 psi Tank, pump, supply hose temperature: 175 F (79 C) Valves, valve manifold temperature: 185 F (85 C) Valve trigger time: 200 ms Fan sprays generally become wider with increased pressure and temperature. Touchscreen Operation Fan patterns may degrade if valves are fixed for more than 400 ms. Accessing the Main Menu When the TTR-50 control is powered on, the following Main Menu screen displays (depending on your system, the screen may look slightly different): System status message Displays current glue pressure Displays current reservoir temperature 16 Displays pump status Press to enable/disable the pump Press to display the system setup menu Press to display the last six system faults Press to clear all system faults Figure 6-2. Main Menu Screen 6-2

27 MM099 TTR-50/8 TT&R System Section 6 - Operation Accessing the Fault Menu From the Main Menu screen, press the Fault Menu button. The Fault Menu screen displays, showing the last six system faults. Use this screen to view the fault information or clear the fault log. Press to clear the log of system faults Press to return to the main menu screen Figure 6-3. Fault Menu Screen 6-3

28 Section 6 - Operation MM099 TTR-50/8 TT&R System Programming the Control From the main menu screen, press the Setup Menu button. The System Setup Menu screen displays. Using the System Setup Menu Displays current pump status (enabled/disabled) Moves boom position to home Displays current system glue pressure Displays current boom position Press to test fire one system valve Press to turn manual pump testing off Press to activate manual pump testing Moves boom position to fire Press to test fire all valves in the system Press to display the glue pressure menu screen Press to display the first of four valve setup menu screens Press to display the option setup menu screen Press to display the first of four temperature menu screens Press to return to the main menu screen Figure 6-4. System Setup Menu Screen 6-4

29 MM099 TTR-50/8 TT&R System Section 6 - Operation Using the Glue Pressure Menu From the System Setup Menu screen, press the Glue Setup Menu button. The Glue Pressure menu screen is used to set the running pressure of the system during a turn-up. Press this button to increase the glue pressure setpoint Press this button to increase the firing delay Press this button to decrease the glue pressure setpoint Press this button to decrease the firing delay Maximum pressure 2400 psi Minimum pressure 1700 psi 2400 psi is the normal running pressure. Displays the firing delay in seconds (0.01 to 1.0 seconds) Press this button to return to the system setup menu screen Press this button to return to the main menu screen Figure 6-5. Glue Setup Menu Screen 6-5

30 Section 6 - Operation MM099 TTR-50/8 TT&R System Using the Valve Setup Menu Screens From the System Setup Menu screen, press the Valve Setup Menu button. The first of 4 Valve Setup Menu screens displays. Screens 1 and 2 are used to turn the individual valves on and off. Press to enable/ disable valves individually Press to display the second valve setup menu screen Press to display the third valve setup menu screen Press to display the fourth valve setup menu screen Press this button to return to the system setup menu screen Press this button to return to the main menu screen Figure 6-6. Valve Setup Menu Screen 1 6-6

31 MM099 TTR-50/8 TT&R System Section 6 - Operation Valve Setup Menu Screens - Continued Valve Setup Menu screen 2 works similar to screen 1. Press to enable/ disable valves individually Press to display the first valve setup menu screen Press to display the third valve setup menu screen Press to display the fourth valve setup menu screen Press this button to return to the system setup menu screen Press this button to return to the main menu screen Figure 6-7. Valve Setup Menu Screen 2 6-7

32 Section 6 - Operation MM099 TTR-50/8 TT&R System Valve Setup Menu Screens - Continued Valve Setup Menu screen 3 is used to set the firing mode for the valves. Displays the valve number Displays the firing mode Press this button to increase the valve number In unison mode, all active valves fire at the same time for the valve open duration. Press this button to decrease the valve number In sequential mode, valves fire sequentially in pairs for the valve open duration, starting at the center of the sheet and progressing outward. The sequence begins when commanded by the trigger signal (supplied by the parent machine). Press this button to display the first valve setup menu screen Press this button to display the second valve setup menu screen Press this button to return to the system setup menu screen Press this button to return to the main menu screen Press this button to display the fourth valve setup menu screen Figure 6-8. Valve Setup Menu Screen 3 6-8

33 MM099 TTR-50/8 TT&R System Section 6 - Operation Valve Setup Menu Screens - Continued Valve Setup Menu screen 4 is used to set the open duration and the open delay for the valves. Displays the open duration in milliseconds Displays the sequential open delay in milliseconds Press this button to increase the open duration (milliseconds) of the active valve(s). Press this button to increase the sequential open delay (milliseconds). Press this button to decrease the open duration (milliseconds) of the active valve(s). Press this button to decrease the sequential open delay (milliseconds). Press this button to display the first valve setup menu screen Press this button to display the second valve setup menu screen Press this button to return to the system setup menu screen Press this button to return to the main menu screen Press this button to display the third valve setup menu screen Figure 6-9. Valve Setup Menu Screen 4 6-9

34 Section 6 - Operation MM099 TTR-50/8 TT&R System Using the Temperature Control Menu Screens From the System Setup Menu screen, press the Temp Setup button. The first of 4 temperature setup menu screens displays. Screen 1 is used to set the temperatures for the tank and the pump. Displays the chosen setpoint temperature for the tank Displays the chosen setpoint temperature for the pump Press to increase setpoint temperature for the tank Press to increase setpoint temperature for the pump Press to decrease setpoint temperature for the tank Displays the actual temperature of the tank Press to decrease setpoint temperature for the pump Displays the actual temperature of the pump Press to display the hose temperature menu screen Press to display the manifold temperature menu screen Press to display the valve temperature menu screen Press this button to return to the system setup menu screen Press this button to return to the main menu screen Figure Temperature Setup Menu Screen

35 MM099 TTR-50/8 TT&R System Section 6 - Operation Using the Temperature Control Menu Screens - Continued Screen 2 is used to set the temperatures for hose 1 and hose 2. Displays the chosen setpoint temperature for hose 1 Displays the chosen setpoint temperature for hose 2 Press to increase setpoint temperature for hose 1 Press to increase setpoint temperature for hose 2 Press to decrease setpoint temperature for hose 1 Displays the actual temperature of hose 1 Press to decrease setpoint temperature for hose 2 Displays the actual temperature of hose 2 Press to display the tank/pump temperature menu screen Press to display the manifold temperature menu screen Press to display the valve temperature menu screen Press this button to return to the system setup menu screen Press this button to return to the main menu screen Figure Temperature Setup Menu Screen

36 Section 6 - Operation MM099 TTR-50/8 TT&R System Using the Temperature Control Menu Screens - Continued Screen 3 is used to set the temperatures for manifold 1 and manifold 2. Displays the chosen setpoint temperature for manifold 1 Displays the chosen setpoint temperature for manifold 2 Press to increase setpoint temperature for manifold 1 Press to increase setpoint temperature for manifold 2 Press to decrease setpoint temperature for manifold 1 Displays the actual temperature of manifold 1 Press to decrease setpoint temperature for manifold 2 Displays the actual temperature of manifold 2 Press to display the tank/pump temperature menu screen Press to display the hose temperature menu screen Press to display the valve temperature menu screen Press this button to return to the system setup menu screen Press this button to return to the main menu screen Figure Temperature Setup Menu Screen

37 MM099 TTR-50/8 TT&R System Section 6 - Operation Using the Temperature Control Menu Screens - Continued Screen 4 is used to set valve temperatures. Each valve setpoint temperature can be independently adjusted. When Master is selected, incremental changes affect all valves, and the Actual readout displays and average of all valves. For example, if the master setpoint is increased 10 degrees, then each valve setpoint will be increased 10 degrees from its original setting. Displays the chosen setpoint temperature for the selected valve Displays the selected valve (Master = all valves) Press to increase setpoint temperature for the selected valve Press to increase valve number Press to decrease setpoint temperature for the selected valve Press to decrease valve number Displays the actual temperature of the selected valve Press to display the tank/pump temperature menu screen Press to display the hose temperature menu screen Press to display the manifold temperature menu screen Press this button to return to the system setup menu screen Press this button to return to the main menu screen Figure Temperature Setup Menu Screen

38 Section 6 - Operation MM099 TTR-50/8 TT&R System Using the Option Setup Menu Screen From the System Setup Menu, press the Option Setup Menu button. The Option Setup Menu screen displays. Press this button to display the configuration menu screen Press this button to go to the timer menu screen Press this button to return to the system setup menu screen Press this button to return to the main menu screen Figure Option Setup Menu Screen 6-14

39 MM099 TTR-50/8 TT&R System Section 6 - Operation Using the Inactivity Timer Setup Menu Screen When the Option Menu screen displays, press the Timer Menu button. The Inactivity Timer Menu screen displays. Use this screen to adjust the length of time the system can be inactive before it automatically shuts off the pump and heaters. This prevents degradation of the adhesive. The length of time can be anywhere from 2 hours to 24 hours. You can also use this screen to shut the timer off. Displays the desired time off set point hours Displays the actual time the machine has been on (in hours) Press to increase setpoint for inactivity time Press to turn inactivity timer ON Press to decrease setpoint for inactivity time Press to turn inactivity timer OFF Press this button to return to the system setup menu screen Press this button to return to the main menu screen Figure Inactivity Timer Menu Screen 6-15

40 Section 6 - Operation MM099 TTR-50/8 TT&R System The Configuration Menu Screen The Configuration Menu screen should only be used by qualified Valco technologists. Please do not access this menu! Access to this menu by unqualified persons can cause loss of valuable settings and production time. 6-16

41 MM099 TTR-50/8 TT&R System Section 6 - Operation Typical Reel Turn-up Sequence The Valco Cincinnati Tissue Tack and Reel turn up system for tissue machines requires PLC control to fully automate the reel section and turn up sequence. The PLC program should control the reel section and turn up logic completely independent of the spool loading system and other areas of the machine. The automation of the reel turn-up sequence starts when the new spool (also called the mandrel or core) is detected in the primary arm. In order to start the automated sequence, the secondary arms (currently holding the almost completed roll of tissue) will be in the pressing condition (pressing up against the reel at the 3:00 position) and the primary arms will be in the upright (12:00) position.. There should be approximately a ½ to 1 gap between the spool and the reel. When all these condition are met, a ready indication should be sent to the PLC that the reel turn-up sequence can begin. The PLC now waits for a signal from a proximity switch located on the rail, which detects the roll diameter of the completed roll. Turn-up sequence: As soon as the roll reaches the completed roll diameter proximity switch, the turn-up sequence begins. Generally a horn or warning light alerts the operators that the turn-up sequence has begun. This is where the logic for the Valco system takes place. The spool accelerator (a tire or belt) will be activated to synchronize the speed of the incoming spool with the reel drum. This generally occurs 2 minutes before the new spool begins to move to the turn up position. The Valco pump should be activated at this point to begin pressurizing the system; full pressure generally takes seconds. When spool synchronization is achieved, the primary arm will be activated to begin moving to the reel turn up position. The air shower should be activated between the time the spool begins to move and before it reaches the turn-up position to begin creating positive pressure under the web psi is normally sufficient (the air shower should be mounted at or near the doctor blade, which is at approximately the 8:00 position). New spool Direction of tissue travel Reel drum Synchronization position Reel turn up position Reel position 6-17

42 Section 6 - Operation MM099 TTR-50/8 TT&R System Typical Reel Turn-up Sequence - Continued Approximately 2 seconds before reaching the reel turn up position the saws (or water slitters) should be deactivated. Edge trimmers or slitters can be left on. Because the center of rotation of the primary arm is slightly off of the center of rotation of the reel drum, the new spool will get closer to the reel as the primary arms come down. Contact must be uniform across the reel and should occur at approximately the 10:30 position. It is better to have a slightly higher spool speed than reel speed at contact to reduce the possibility of tearing the sheet. Nip pressure must be even from tending to drive side. Less nip relief will add pressure against the reel. Nip cylinders must be in good shape with no play in the pistons; this could create uneven contact across the reel. As soon as the spool is in the reel turn up position the secondary arm will be activated to eject the completed roll. Air pressure now building under the web will create a billow (loop) in the slackening tissue web. This can be aided by applying a brake to the secondary roll as it kicks out. When the loop is in the proper position (very approximately the height of the spool), the Valco valves will fire to tack the paper onto the new core. Length of time may vary, but generally ms is sufficient. After the transfer, the saws (slitters) are reactivated and the Valco pump should be turned off to depressurize the system. The primary arms will go to the reel position only when the proximity switch located on the rail detects the completed roll. The secondary arm will take over the primary arms when the primary arm is on the reel position and the secondary arms are in pressing mode. 6-18

43 MM099 TTR-50/8 TT&R System Section 6 - Operation Re-threading The re-threading sequence is set to run off of the number one valve (the first valve on the tending side of the machine) on the system. If the customer s web break sensor detects a break, a signal should be sent from the customer s PLC to immediately start pressurizing the Valco system. Because only one valve is fired, the system can be ready to fire in as little as seconds. The re-thread valve is fired from a manual push button on the operator control panel. As soon as the tail catches, the Valco system should be depressurized as with the full turn-up sequence. 6-19

44 SECTION 7 - MAINTENANCE Guidelines This section contains maintenance procedures for the PCM-50 Tissue Tack and Reel System. Your hot-melt system will run longer and more efficiently if you follow a preventative maintenance program. Valco recommends the following general maintenance: Keep the tank as full of adhesive as possible. This reduces the forming of dried adhesive on the interior side walls of the tank. Keep the tank lid closed. (Any contamination in the tank will increase the chance of poor performance. Dust, dirt, and dried adhesive are the major causes of clogged nozzles.) When clogging due to dried adhesive or dirt becomes frequent, completely drain, purge, and clean the system. Refer to Flushing the Hoses, Manifold, and Glue Valves and Draining and Cleaning the Tank (Reservoir) in this section. To protect against contaminants fouling the control valves, periodically inspect all air line filters and regulators. Check piping for any leaks. Regularly inspect all heated hose connections for adhesive leaks. Regularly inspect all fittings. Tighten fittings if needed. See Appendix B Maintenance Procedures for suggested maintenance intervals. 7-1

45 Section 7 - Maintenance MM099 TTR-50/8 TT&R System Cleaning the Exterior of the Unit To clean the exterior of the PCM-50 unit, follow these steps: Caution! Never hose or steam-clean the unit. If the surrounding area is cleaned in this manner, protect the unit by covering it with plastic or other waterproof material. Failure to comply could result in damage to the equipment. 1. Turn off the main power. 2. Using a damp cloth, clean the cabinet with a mild soap-andwater solution. Cleaning the Filter In order to keep the PCM-50 system operating properly, it is necessary to regularly check and clean the filter (Figure 7-1). Warning: Always use insulated gloves and proper eye protection when working around hot adhesive and equipment. Failure to observe could result in personal injury, death, or damage to equipment. To clean the filter, follow these steps: 1. Turn off the main power. 2. Make sure there is no adhesive pressure in the system. 3. Remove the cap/filter assembly. 4. Flush the cap/filter assembly with water. 5. Using a brush, clean the cap/filter assembly. 6. Replace the cap/filter assembly. 7. Turn on the main power. Due to the direction of adhesive flow (inside of the screen to the outside of the screen), impurities and sediment will be collected on the inside of the filter screen. 7-2

46 MM099 TTR-50/8 TT&R System Section 7 - Maintenance Cleaning the Filter - Continued Filter Screen Filter Cap Figure 7-1. Filter Automatically Maintaining Tank Fill Levels Caution! Keep the tank lid closed to prevent dust ingress. Failure to do so will cause damage to the pump. The PCM-50 Tissue Tack and Reel System provides an Automatic Fill system to prevent the adhesive in the tank from falling below a desired level. Inspect the transfer pump periodically to make sure it is functioning correctly. If needed, use the air motor repair kit (560xx013) and the pump repair kit (560xx697) to rebuild the pump. When glue consumption causes the tank level to fall below the upper level probe, a signal is sent to the control indicating that the tank should be refilled. The control activates the refill pump (typically an air-operated pump) until the upper level probe signal is no longer active. When glue consumption causes the tank level to fall below the lower level probe, another signal is sent to the control indicating that the tank is nearly empty. At this point, the control sends an alarm to the operator. The alarm could indicate that the adhesive supply drum is empty or that there is a failure in the refill pumping operation. 7-3

47 Section 7 - Maintenance MM099 TTR-50/8 TT&R System Cleaning Valves/ Nozzles 1. Place manifold in nozzle maintenance position and move the ball valve to shut off gun pressure. 2. With a wet cloth, wipe excess adhesive and paper dust from the nozzles to prevent buildup and char from forming on the nozzle spraying surface. Caution! Do not spray directly with high pressure water. 3. Remove nozzles, if necessary. Use stamped wrench to hold seat adapter (703xx112) to valve body while removing nozzle retainer nut (703xx123). Changing the Pump 1. Thread in pump shut-off valve completely (clockwise) 2. Remove the pump drive shaft. 3. Remove the four socket head cap screws (798xx173) that mount the pump to the manifold. 4. Remove the pump. 5. Inspect the brass pump gasket for wear at the inlet/outlet ports. If eroded, it should be replaced (703xx208). 6. Replace the check valve (704xx761) and the O-ring (746xx060). 7. Mount the new pump. 8. Tighten the socket head cap screws. 9. Replace the pump drive shaft. 10. Thread the shut-off valve counterclockwise until it is fully open. Valve Maintenance/ Caution! If seat adapter has been loosened, the O-ring (745xx066) must be replaced. Also, activate valve while removing seat and/or seat adapter. Disassembly 1. Remove items 1, 5, and seat adapter from existing valve (see Figure 7-2). 2. Remove items 2 and 3 from pressure tube (do not remove retainer nut). 3. Clean seat adapter and remove old O-ring. 7-4

48 4. Insert new O-ring (item 4) into seat adapter. MM099 TTR-50/8 TT&R System Section 7 - Maintenance Valve Maintenance/Disassembly - Continued 4. Insert new O-ring (item 4) into seat adapter. 5. Insert new spring into new plunger and slide into pressure tube. 6. Attach seat adapter and torque to in-lbs. 7. If possible, activate valve coil while pushing plunger into pressure tube until it clicks into place. Activating coil relieves pressure on plunger when attaching the seat so that it does not get scored by the plunger. 8. While keeping coil activated, attach new seat (item 1) and torque to in-lbs Valve Housing Seat Adapter Pressure Tube Figure 7-2. Valve Disassembly Retainer Nut Tightening Pump Packing (monthly) 1. Inspect pump for shaft seal leakage. 2. With an open-end wrench, turn each of the three hex head cap screws on the pump seal retainer 1/4 turn clockwise in sequence. 3. Observe the leakage while the pump is running. 4. Repeat if necessary. Caution! Overtightening packing will damage pump and reduce packing life. 7-5

49 Section 7 - Maintenance MM099 TTR-50/8 TT&R System Flushing Hoses, Manifold and Glue Valves (twice/year) The TTR-50 unit is equipped with a flushing system that allows you to flush water through the hoses, manifold, and glue valves. To flush the system, follow these steps: 1. Disconnect the air supply from the supply pump. 2. Push the Control OFF button on the control panel. 3. Remove Hose from the TTR unit. 4. Attach the flushing kit (799XX606) to the end of the hose that was removed. 5. Connect a water hose to the flushing system. For best cleaning, a warm to hot water supply should be used. 6. Open the inlet ball valve on the water supply. 7. Push the Control ON button on the control panel. 8. Disable the glue pump on the main screen. 9. Open the flush valve on the end of the glue application manifold (this allows the water to flush the hoses and manifold). 10. Allow the water to run from the manifold flush valve until the water is clear. 11. After flushing, close the flush valve that was opened in Step 8 above. 12. Remove the nozzles from each valve. 7-6

50 MM099 TTR-50/8 TT&R System Section 7 - Maintenance Flushing Hoses, Manifold and Glue Valves (2X year) - Continued 13. Push the purge button located above each valve (this allows the water to flush the applicator valves). 14. After purging hoses, manifold, and valves, close the water inlet ball valve (see Step 5). 15. Push the Control OFF button on the control panel. 16. Disconnect the water supply from the flushing system. 17. Remove the flushing kit from the TTR Reconnect the hose to the TTR Push the Control ON button on the control panel. 19. Enable the glue pump on the main screen. 20. Open the flush valve on the end of the glue application manifold. 21. Turn the pump on manually from the HMI. (This allows the new adhesive to remove the water from the system). 22. After flushing out the water, close the flush valve that was opened in Step 20 above. 23. Push the purge button located above each valve (this allows the adhesive to flush the water out of the applicator valves). 24. Turn the pump off manually from the HMI. 25. Replace the nozzles from each valve. 7-7

51 Section 7 - Maintenance MM099 TTR-50/8 TT&R System Draining and Cleaning the Tank (twice/year) Warning! Do not pump water through the gear pump. Pumping water through gear pump will irreparably damage the pump. To drain and clean the tank, follow these steps: 1. Turn off the main power. 2. Position a container beneath the drain valve for the tank. Drain valve 3. Remove the drain valve by turning it completely counterclockwise. 4. Drain tank from reservoir into container. Customer may replace drain valve with drain fitting and hose to reduce mess. 5. Remove tank screen. 6. Clean tank screen with water. 7. Flush tank with water to remove any built up dust, char and/or old adhesive. 8. Wipe down inside of tank with a lint fee cloth until clean. 9. Remove any water that may still be in the tank (water will harm the pump). 10. Replace the drain valve. 11. Refill the tank with new adhesive (check the expiration date of the adhesive) 12. Turn on main power. 7-8

52 MM099 TTR-50/8 TT&R System Section 7 - Maintenance Checking Fluid Connections Periodically check all fluid connections for leakage, including the following: Hot-melt unit (pump gasket) Hose connections Gun/manifold connections Nozzles/seat/seat adapter 7-9

53 Section 7 - Maintenance MM099 TTR-50/8 TT&R System Changing Out Pressure Relief Plungers (779xx884) To change out pressure relief plungers (779xx884), do the following: 1. Make sure there is no adhesive pressure in the system. 2. Press the control OFF button on the control panel. 3. Disconnect power to the unit. 4. Remove items 1 (781xx479), 2 (781xx480), 3 (745xx007), 4 (745xx912), 5 (779xx872), and 6 (779xx884) as shown in Figure Figure 7-6. Change Out Pressure Relief Plungers 5. Always replace items 3 (745xx007), 4 (745xx912), and 5 (779xx872) when replacing the plunger assembly [Item 6, (779xx884)]. 6. Reassemble the unit and connect the main power. 7. Press the control ON button on the control panel. 8. Adjust the air pressure until the desired pressure is met (approximately psi). The pressure reading on the pressure gauge should be close to the set pressure on the screen. 7-10