D490 User Manual: Tidland
Contents
1. D490S Damage to plastic cartridge Excessive overspeed RPMs Reduce overspeed page 6 2 Shaft leaking air Bladder not secure under end Ensure that bladder is pinched under clamps the ridge of the end clamp Ensure that M8 end clamp screws are tightened to 17 Nm 12 5 ft lbs Bladder leak Remove and inspect bladder Replace if necessary Bladder does not inflate properly Air supply not connected Ensure good connection to air supply Air fitting in bladder is plugged Remove air fitting Blow air through it to remove debris Cartridges do not expand fully cores do not lock Cartridges installed in the wrong direction Check shaft rotation direction and ensure cartridges are installed correctly Cartridge races are worn and chrome balls are loose Replace cartridge Dust or contamination build up in cartridges Remove cartridges from shaft and manually actuate them while blowing dust and debris from moving parts Replace cartridge if it will not actuate Irregular friction Dust or contamination build up in cartridges Remove the cartridges and clean contaminants from parts Clean and lubricate the shaft See page 7 4 Worn or damaged friction element Remove cartridges and inspect the friction element replace if worn Missing or worn Teflon washers ball type cartridges only Remove cartridges and inspect for missing washers Replace wash2. 2 80 psi Ambient operating temperature 50 C 122 F Core 1 3 shafts 3 000 3 040 6 shafts 6 000 6 060 8 shafts 7 998 8 060 10 shafts 9 998 10 060 12 shafts 11 998 12 060 Core material Ball type cartridge Fiber or plastic cores Spring type cartridge Fiber cores only See page 4 1 for all core specifications www maxcessintl com Tidland D490 MI 746508 1G 10 1 SERVICE Service requests and replacement parts Please have your shaft serial number available when you call Maxcess 2305 SE 8th Avenue Camas WA 98607 1 360 834 2345 1 800 426 1000 www maxcessintl com Tidland D490 MI 746508 1G NORTH CENTRAL EUROPE MIDDLE EAST CHINA AND AFRICA AND SOUTH AMERICA Tel 49 6195 7002 0 Tel 86 756 881 9398 Tel 1 360 834 2345 Fax 1 360 834 5865 Fax 49 6195 7002 933 Fax 86 756 881 9393 sales maxcessintl com sales maxcess eu info maxcessintl com cn www maxcessintl com www maxcess eu www maxcessintl com cn KOREA TAIWAN WEBEX 3 D INDIA JAPAN AND SE ASIA asia maxcessintl com Tel 91 22 27602633 Tel 81 43 421 1622 Fax 91 22 27602634 Fax 81 43 421 2895 www maxcess asia india maxcessintl com japan maxcessintl com www maxcess in www maxcess jp 2013 2015 Maxcess
3. OC ORI M 7 2 deese ne c pe e Ee RO CORR RO Fa CE COUR AU DO COR CU FER Fei C CR die tds 7 2 Replacing the air system elements 7 3 Using bulk bladder material 7 3 Preparing the bladder nenne nenne nnnnnenenne nennen 7 3 Installing the elements 7 4 Cartridges i hae ER PER FO UN GE OR I 7 6 www maxcessintl com Tidland D490 MI 746508 1G CONTENTS TROUBLESHOOTING 8 1 SPECIFICATIONS 9 1 SERVICE AND PARTS 10 1 www maxcessintl com Tidland D490 MI 746508 1G 1 1 About these operating instructions INTRODUCTION 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 on our website or by calling the number 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 D490 These instructions are important for the machine manu
4. page 3 1 o Lubricate the shaft and friction element with Ballistol oil as described on page 7 4 www maxcessintl com Tidland D490 MI 746508 1G 7 6 MAINTENANCE Cartridges Spring type A Do not use solvents 1 Remove the cartridges from the shaft 2 Remove springs from the cartridges in the axial direction to prevent damage to the springs 3 Use compressed air to remove dust and debris from cartridge parts 4 Clean cartridge body with a mild solution of soap and water o Replacement springs are available by special order Call Maxcess for assistance with part numbers Ball type 1 During operation keep cartridges free of dust and debris 2 If dust build up on the cartridges prevents acutation remove the cartridges from the shaft for cleaning 3 Remove cartridges from shaft actuate while blowing dust and debris from moving parts 4 Clean the cartridge body with a light application of non petroleum based solvent Note Excessive solvent can cause accumulation of dust and debris Dry the cartridge body throroughly before loading cores 5 Make sure the shaft body is clean free of dust and debris and properly lubricated See page 7 4 6 Discard and replace the cartridge if it will not actuate www maxcessintl com Tidland D490 MI 746508 1G 8 1 Problem D490B Bladder is melting TROUBLESHOOTING Possible Cause Excessive overspeed RPMs Solution Reduce overspeed page 6 2
5. relative speed between shaft and cartridges D490B To prevent damage to bladder do not exceed limits illustrated in chart below Pressure Overspeed Limits Maintaining Safe Temperature for Plastic Components 70 Ambient 310 290 270 MEL 25 Overheating or seizing will occur 230 4 210 OVERSPEED rpm 190 170 150 130 Recommended operation 110 oo z T je 5 10 15 20 25 30 35 40 45 PRESSURE psi www maxcessintl com Tidland D490 MI 746508 1G 7 1 Maintenance schedule Recommended MAINTENANCE Daily Keep shaft clean and dry Use compressed air to remove dust and debris buildup Every 30 days Remove the cores Use compressed air to blow out dust and ensure that cartridges turn freely on the shaft If cartridges are sticking disassemble and clean the shaft Use a mild solution of soap and water to remove residue from shaft Inspect cartridges for wear and debris buildup See page 7 6 for cleaning instructions Inspect friction strip for wear Replace visibly worn material See page 7 3 Inspect shaft body for wear There should be no signs of galling if scoring or serious wear is detected call Maxcess Customer Service for assistance Before reinstalling cartridges make sure shaft is clean and free of dust and debris and properly l
6. MI 746508 1G 5 3 INSTALLATION Installing the shaft continued REWIND applications cartridge orientation 1 Cartridge load direction 2 Shaft rotation is CLOCKWISE Q 3 Ball type cartridge Retainer ring should be visible as shown facing away from the load direction 4 Spring type cartridge End of spring points in direction of shaft rotation 1 Cartridge load direction 2 Shaft rotation is COUNTER CLOCKWISE A 3 Ball type cartridge Flange should be visible as shown retainer ring faces load direction gt 4 Spring type cartridge End of spring points in direction of shaft rotation www maxcessintl com Tidland D490 MI 746508 1G 5 4 INSTALLATION Installing the shaft continued UNWIND applications cartridge orientation 1 Cartridge load direction 2 Shaft rotation is COUNTER CLOCKWISE A 3 Ball type cartridge Retainer ring should be visible as shown facing away from the load direction 4 Spring type cartridge End of spring points in opposite direction of shaft rotation 1 Cartridge load direction 2 Shaft rotation is CLOCKWISE 3 Ball type cartridge Flange should be visible as shown retainer ring faces load direction 9 4 Spring type cartridge End of spring points in opposite direction of shaft rotation www maxcessintl com Tid
7. P MAXCESS Tidland D490 Differential Shaft User Manual MI 746508 1G CONTENTS INTRODUCTION 1 1 About these operating instructions ccccceececsscecceseeceeeecseeeeceueesseeeeseeeesseeeeseneess 1 1 Prod ct Overview an ae Gul vea fe Aci Gala enh Site 1 2 Model number Key uan sitters sense ach ee 1 2 Available models ces ee 1 2 SAFETY INFORMATION 2 1 Symbols used coe eet tee veto ne teen en tow ar eo Ga Red 2 2 Proper VD 2 3 Decomimissionilg sette te reete Per peer eiae tee Feet dete Dee a ees 2 4 ASSEMBLY DIAGRAM AND PARTS LIST 3 1 Shaft c MpoNentS darn een 3 1 CORE SPECIFICATIONS 4 1 General Core Quality an er teet EE E 4 1 Core Dimensions c ee EX REX EN e VER n 4 1 Table 1 Minimum core widths nnns 4 1 INSTALLATION 5 2 Installing the shaft seien an a In xx Exe teed 5 2 Cartridge orientation dent n ee AGE RN Y YR dero lan 5 3 REWIND applications 5 3 UNWIND applications iii 5 4 OPERATION 6 1 Air pressure etc le 6 1 Iristalling the cores diee ehe ae AA ee 6 1 WINING ses noe cen ie Cee Se ee item ite 6 2 Overspeed uno Phe dvi Pie radar deitate uei A 6 2 MAINTENANCE 7 1 Maintenance schedule 7 1 Recommended tools and supplies nennen 7 1 Removing cores from the shaft 7 2 Reinstallinmg cores aii nag a
8. allation The larger design shafts are heavy Appropriate equipment is to be used and the safety rules of the company must be observed A Operation WARNING Danger of entanglement or pinching during operation Keep hands and loose clothing away from rotating shaft A 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 bladders without the leaves installed Decommissioning The shaft must be disposed of in accordance with all the applicable national state and local regulations www maxcessintl com Tidland D490 MI 746508 1G 3 1 ASSEMBLY DIAGRAM AND PARTS LIST Shaft components QO Recommended spare parts a r as required Item Description Qty Pert No dus N America Europe 1 Set screw M6 X 8 mm 3 shaft 6 520013 M194412 Set screw M10 x 16 mm all other shaft sizes 6 525577 M194430 ii 2 Spacer 2 custom custom 3 Cartridge item 3a Spring type a r Note 1 5 Note 1 5 item 3b Ball type a r Note 1 Note 1 3 shaft a r 702106 M372898 4 Washer Note 2 6 shaft a r 758835 M386840 5 Shaft body custom custom 6 Bladder material Note 3 4 a r 739338 M193425 i 7 Air fitting 3 739339 M250318 8 Pro
9. ers if missing or worn Insufficient lubrication on shaft body See page 7 4 www maxcessintl com Tidland D490 MI 746508 1 G 8 2 Problem Cartridges do not collapse fully cores do not unlock TROUBLESHOOTING Possible Cause Dust or contamination build up in cartridges Solution Remove cartridges from shaft and manually actuate them while blowing dust and debris from moving parts Replace cartridge if it will not actuate Cores slipping on cartridges Cores are too big See core size tolerance requirements If cores are within specifications contact Maxcess Excessive rattling in shaft Cartridge races are worn and chrome balls are loose Replace cartridge Chrome balls are falling out of the cartridge Cartridge races are worn Replace cartridge Excessive shaft vibration Shaft imbalance Contact Maxcess Balls or cartridge races are stuck parts don t move Dust or contamination build up in cartridges Remove cartridges from shaft and manually actuate them while blowing dust and debris from moving parts Replace cartridge if it will not actuate www maxcessintl com Tidland D490 MI 746508 1 G 9 1 SPECIFICATIONS Specifications specifications A WARNING Do not use the devices outside of their rated Refer to your Product Safety Data Sheet PSDS for your custom shaft specifications Operating air pressure 0 14 5 5 bar
10. eter D490S 12 0 inch D490S FIBER ONLY shaft diam FIBER ONLY DUPLEX SIMPLEX eter DUPLEX SIMPLEX 768654 768653 M380981 M386539 50 mm 1 969 in 50 mm 1 969 in 102 mm 4 016 in 102 mm 4 016 in Requires special alignment of cores on cartridges Call Maxcess for assistance 52mm 2 047 in 52mm 2 047 in www maxcessintl com Tidland D490 MI 746508 1 G 5 2 Installing the shaft General N AN Cartridge Types INSTALLATION 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 Important The cartridges are directional and are factory installed relative to customer shaft rotation direction Determine shaft rotation clockwise or counterclockwise If the shaft is reinstalled on another machine and rotation direction changes the cartridges must be removed reversed and reinstalled See instructions for your application Rewind page 5 3 Unwind page 5 4 Cartridges installed incorrectly will not grip the cores Ball type cartridges must have a washer installed on each side of all cartridges Ball type cartridge Spring type cartridge See illustrations on the following pages to ensure correct installation for your application www maxcessintl com Tidland D490
11. facturer 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 www maxcessintl com Tidland D490 MI 746508 1G 1 2 Theory of operation Model number key Available models INTRODUCTION The D490 Differential shaft uses cartridges that are designed to spin on the shaft even after web tension causes them to grip and lock the core Slippage is between the shaft body and cartridges not the core so dust is not generated by core wear Independent cartridges allow for winding multiple cores of different roll widths and roll diameters at the same tension Shaft series shaft type cartridge type Shaft series D Differential Shaft type 490 air shaft Cartridge type B ball S spring D490B D490S www maxcessintl com Tidland D490 MI 746508 1G SAFETY INSTRUCTIONS Safety When using this Tidland product always follow basic safety r precautions to reduce the risk of personal injury Your company s information safety instructions and procedures should always be followed When usi
12. land D490 MI 746508 1G 6 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 entanglement or pinching during operation Keep hands and loose clothing away from rotating shaft Pee Air pressure Shaft operation requires 0 14 5 5 bar 2 80 psi Installing the cores 1 Install shaft as required for your machine application Connect supply air to rotary union typical Inflate the shaft to lock the inner race of the cartridges to the shaft 3 1 bar 45 psi max 4 Install the cores 5 Adjust core positions and attach the web To ease installation of cores twist the core as you slide it on For rewind operation twist core in the direction of shaft rotation For unwind operation twist core in opposite direction of shaft rotation www maxcessintl com Tidland D490 MI 746508 1G 6 2 Inflating the shaft and winding Overspeed OPERATION The Tidland D490 differential shaft is designed for rewind applications If you would like to use a D490 for an unwind operation please contact Maxcess Customer Service Begin the winding operation at 0 14 0 3 bar 2 5 psi for low tension winding During winding observe the tension controller readout and adjust the applied air pressure as needed D490S To prevent damage to plastic cartridges do not exceed 30 RPM
13. lications require proper lubrication to maintain a smooth interface between the shaft body and the cartridges Apply Ballistol oil liberally to the friction element and the shaft body and then wipe off the excess Use enough lubrication to prevent galling of the shaft body but not so much that it is thrown from the shaft during start up Installing the elements 1 Install the bladder with air fitting sealed or unsealed in the slot making sure that the air fitting is seated in the hole 2 Fold the bladder ends as shown and install the element end clamps and fasteners 3 Tighten to 17 Nm 12 5 ft lbs Install the protection strip and the friction element in the slot on top of the bladder 5 Lubricate the shaft and friction element with Ballistol oil as described above Bladder with double fold is folded on top 12 4 L_ 29mm 0 5 1 2 1 17 1 Air fitting 4 Flat head cap screw 2 Bladder 5 Protection strip 3 Element end clamp 6 Friction element Single fold bladder illustrated on next page www maxcessintl com Tidland D490 MI 746508 1G 7 5 MAINTENANCE Installing the elements continued Bladder with single fold is folded under 12mm 7 A 23mm 0 5 0 9 1 Air fitting 4 Flat head cap screw 2 Bladder 5 Protection strip 3 Element end clamp 6 Friction element Component part numbers are on
14. ng 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
15. or material damage The signal word NOTICE refers to the possibility of damage to equipment 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 www maxcessintl com Tidland D490 MI 746508 1G 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 D490 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 www maxcessintl com Tidland D490 MI 746508 1G SAFETY INSTRUCTIONS Basic safety information continued A Installation and commissioning WARNING Danger of falling down or muscle or skeletal injury during inst
16. r Use a shim for better accuracy Torque set screws to 7 Nm 5 2 ft lbs www maxcessintl com Tidland D490 MI 746508 1G 7 3 Replacing the air system elements Using bulk materials Preparing the bladder bulk material MAINTENANCE Tidland D490 shafts are assembled with sealed bladders If you need to replace the bladder call Maxcess Customer Service for assistance Please have your shaft serial number available You may also order bulk material for bladders friction elements and protection strips Use the following formulas to determine the correct material lengths for your shaft Friction element slot length 74 mm 2 91 Protection strip slot length 74 mm 2 91 If you use bulk bladder material instead of the sealed bladder assembly Bladder length slot length 1 Cut the bladder to length Make sure ends are square 2 Using dimensions illustrated below locate and punch hole for air fitting Punch only through one wall of bladder 3 Insert the air fitting into the bladder 21 8 mm 0 86 XX X 1 mm X XX 0 04 9 9 mm 0 39 Ld 4 0 mm 0 16 E un Punch through one wall only www maxcessintl com Tidland D490 MI 746508 1G 7 4 MAINTENANCE Installing the elements Loctite 243 Use on all threads during reassembly Follow manufacturer s instructions for best results Ballistol oil High load app
17. tection strip material Note 4 a r 739340 M245285 E 9 Friction element material Kevlar a r 775909 M394448 Note 4 Corsid110 a r 754029 M338602 10 End clamp 6 757450 M390458 11 Flat head cap screw M8 x 16 mm zinc plated 6 132937 M127969 12 Rotary union optional 1 126231 M186624 Note 1 Cartridge part numbers are dependent upon cartridge width see chart in page 4 1 Note 2 For use with ball type cartridge only use one washer on each side of all cartridges Note 3 To order the sealed bladder assembly for your shaft call Maxcess Please have your shaft serial number available Note 4 When using bulk material cut to length using formulas in page 7 3 Note 5 Replacement springs are available by special order Call Maxcess for assistance with part numbers www maxcessintl com Tidland D490 MI 746508 1 G 4 1 CORE SPECIFICATIONS Core specifications General core quality Surface condition of the internal diameter should be smooth for easy installation Inner edges of cores should be clean and without burrs Core dimensions 1 Core inner diameter I D range must be between 3 shafts 3 000 3 040 6 shafts 6 000 6 060 8 shafts 7 998 8 060 10 shafts 9 998 10 060 12 shafts 11 998 12 060 a If core 1 0 5 are smaller they will be very difficult to load onto shaft If larger they will not lock properly b Long cores large slit widths and cores with I D defects for example ovality curva
18. ture etc will be more difficult to load if they are at the low end of allowable range 2 See Table 1 page 4 1 for minimum core widths 3 Core width run out on a single core should be no greater than 0 020 4 Core wall thickness tolerance on a single core should be no greater than 0 010 Variance in the core wall thickness will contribute to increased vibration and reduced roll quality www maxcessintl com Tidland D490 MI 746508 1G 5 1 INSTALLATION Table 1 Minimum core widths CARTRIDGE TYPE CORE MATERIAL APPLICATION TYPE 3 0 inch shaft diameter DUPLEX PART NO N AMERICA 754817 PART NO EUROPE M373598 CARTRIDGE WIDTH 24 mm 0 95 in STANDARD MINIMUM CORE WIDTH ABSOLUTE MINIMUM CORE WIDTH FIBER ONLY DUPLEX SIMPLEX DUPLEX SIMPLEX 754520 754900 M375974 M357351 9 mm 0 35 in 20 mm 0 79 in 42 mm 0 65 in FIBER ONLY DUPLEX SIMPLEX 755041 M347869 10 mm 0 39 in 22 mm 87 in FIBER ONLY DUPLEX SIMPLEX 754521 M375975 6mm 0 24 14 mm 55 in 6 0 inch shaft diameter ANY DUPLEX 757448 M377935 24 mm 0 95 in FIBER ONLY DUPLEX SIMPLEX 8 0 inch shaft diameter D490S FIBER ONLY DUPLEX SIMPLEX 757449 768655 M377934 M386538 25mm 0 98 in 50 mm 1 969 in 102 mm 4 016 in 52 mm 2 047 in 10 0 inch shaft diam
19. ubricated See page 7 4 tools and supplies Hex drive wrenches 3 and 5 mm Loctite 243 or equivalent medium strength threadlocker Mild non petroleum based solvent Ballistol oil Hole punch for bladder air fitting Tidland Part No 760668 Hole locator guide purple Tidland Part No 760792 www maxcessintl com Tidland D490 MI 746508 1G 7 2 MAINTENANCE Removing cartridges from the shaft Before deflating the shaft remove the cores 1 Remove the spacer from the shaft 3 mm hex drive 2 Install on the shaft an empty core that is long enough to cover all of the cartridges Mark the direction of rotation on the core 3 Manually rotate the shaft to lock the core onto the cartridges Deflate the shaft completely 5 Slide the core off of the shaft with the cartridges secured inside To ease removal of cores twist the core as you slide it off For rewind operation twist core in the direction of shaft rotation For unwind operation twist core in opposite direction of shaft rotation Reinstalling cartridges Spacer gap If reinstalling the cartridges loaded inside an empty core note the rotation direction marked on the core If reversing rotation direction turn the core 180 end to end Confirm cartridge orientation for your application Rewind page 5 3 Unwind page 5 4 When reinstalling the spacer at the end of the shaft you must leave a 030 gap between the last washer and the space
20. 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 www maxcessintl com Tidland D490 MI 746508 1 G 2 2 Information about safety instructions Symbols used AN N 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 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
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