Instruction & Service Manual
Contents
1. 23 7 4 CLEANING ANTI STATIC BAR IF SUPPLIED FOR YOUR APPLICATION 24 8 PREVENTATIVE MAINTENANCE 25 8 1 BASIGS sasa no 25 8 2 INTERMEDIATE oir erst obierit T bere tim e OU I 26 8 4 CONTROL BOX PETALI 27 8 5 ROLLERS AND BEARINGS ed kas Fe bob ia acd niaii 28 8 6 ADHESIVE ROLLS 29 8 7 SUDE SYSTEMS er a err 29 9 FAULT FINDING kazana wa daki pa Luo kaa ka Ra ka ana 30 10 MACHINE SPECIFICATIONS AND DIMENSIONS 31 11 AWGHS EXTERNAL DATA iuc ooa 32 12 XWCH3 EXPLODED DRAWINGS 33 13 ELECTRICAL SCHEMATIC DIAGRAM 34 14 PNEUMATIC SCHEMATIC 35 Pi56998r04 2 ER3836R13 20 05 2011 CE SAFETV WITH VOUR CLEANING HEAD At TEKNEK we want you to operate your Cleaning Head in conditions of maximum safety at all times Listed below are procedures that should be followed during set up and operation of the machine 1 When removing the equipment from the transport box ensure that lifting aids are available and in place as required refer to section 2 Removal of mo2. 1 x DOUBLE SIDED Pi55782 TWO MACHINE CONTROL 1 x 2 SINGLE SIDE Pi55783 MACHINE WITH COVERS ProFace PLC Pi55923 CONTROL BUTTONS AND INDICATORS SYMBOL DESCRIPTION AUTO MANUAL SWITCH AUTO IS USED TO OPERATE THE MACHINE FROM A LINE Wa SIGNAL VN MANUAL IS SELECTED WHEN THE OPERATOR NEEDS TO OPERATE THE MACHINE ROLLERS CLEANING ROLLER INDICATOR o ti THIS INDICATOR ONLY OPERATES WHEN THE RUBBER CLEANING ROLLER IS IN THE OPERATING POSITION ADHESIVE ROLLER BUTTON ILLUMINATED THIS BUTTON REMOVES REPLACES THE ADHESIVE ROLLER FROM THE RUBBER CLEANING ROLLER WHEN THE ADHESIVE ROLL IS ON THE BUTTON IS Pi56998r04 ER3836R13 20 05 2011 CONTROL BOX TYPES PART NUMBERS SINGLE SIDED Control Box Part Number EP55796 Layout Part Number Pi55781 DOUBLE SIDED Control Box Part Number EP55797 Layout Part Number Pi55782 TWO MACHINES IN ONE BOX Control Box Part Number EP55798 Layout Part Number Pi55783 Pi56998r04 ER3836R13 20 05 2011 PLC ProFace Control Control Box Part Number EP55922 Layout Part Number Pi55923 Pi56998r04 ER3836R13 20 05 2011 Machine Instruction ProFace LCD Screen XWCH Contact Cleaner www teknek com 2669 TEKNEK 6 MAINTENANCE 6 1 PURGING ADH
3. 7 4 JV 125 Mad Ge 9r Te 970 MI2 x 25 A fai OUT AIR 4mm 130 SLIDES 135 NO SLIDES ELECTRICAL CONNECTION This drawing is for a generic XWCH machine and shows the features required for installation The cover set if supplied should be assembled to the machine after the machine has been installed ensure that the components are installed in accordance with the instructions Pi56998r04 10 ER3836R13 20 05 2011 3 4 FITTING THE COVER SET IF SUPPLIED Information for Machine Builders and Installers The cover set if supplied should be assembled to the machine after the machine has been installed ensure that the components are installed in accordance with the instructions Assemble the parts of PL54489 to install the Cover Support Insert to each side and Switch Components to the pull out side DOOR SENSOR MOUNT 5 32 m em il Teknek equipment has not been designed tested nor approved to work in hazardous areas Should customers choose to install Teknek equipment in hazardous areas the customer must ensure that all necessary regulation and compliance issues are dealt with Teknek accepts no liabilitv for equipment used in hazardous environments Pi56998r04 ER3836R13 20 05 2011 4 MACHINE OPERATION Information for Machine Operators 1 It is important th
4. critical A check of the shaft pressure before each shift or before the machine is used after a period of idleness is strongly recommended AIRSHAFT SIZE MINIMUM PRESSURE OPERATING PRESSURE 3 INCH 76mm 21 PSI 1 5 BAR 29 PSI 2 BAR Slide Release Button Roller Clamp Screw Adhesive Airshaft O Cleaning Pa Roller Pi56998r04 18 ER3836R13 20 05 2011 6 3 REMOVING THE ADHESIVE ROLLS Information for Machine Operators The Adhesive Roll Airshaft is removed by un clamping the bearing retainers one each side to release the Airshaft Bearings from the Holders 2 Refer to Section 6 for correct removal and replacing of the adhesive roll and correct orientation of the adhesive roll to prevent unwinding of the adhesive during machine operation 3 Two operators should perform both the purging and fitting of the longer adhesive rolls 4 The Adhesive Roll Airshaft is replaced into the Holders by pushing it into the Holders and re attaching the Bearing Clamps or allowing the Adhesive Roll Clamp Blocks to capture the bearings 5 Information on machines fitted with twin Adhesive Rolls 6 The Airshaft for machines fitted with twin Adhesive rolls has two adhesive rolls placed on a common airshaft 7 When these are replaced they must be butted hard against each other and rotated to place the start of the wind at the same position on each roll befo
5. fitting of the longer Rubber Rollers if the machine is over 1200mm wide 4 The Rubber Roller is replaced into the Holders by pushing it into the Holders and re attaching the Bearing Clamps 5 Check that the bearing clamps have been securely fastened 6 Check that Rubber Cleaning Roller is free to rotate 7 If fitted on telescopic slides firmly replace the Rubber Roll Carriage into the machine and ensure that the lock is activated Pi56998r04 23 ER3836R13 20 05 2011 74 CLEANING ANTI STATIC BAR IF SUPPLIED FOR YOUR APPLICATION Information for Machine Operators WARNING THE LINE MUST BE STOPPED ALWAYS DISCONNECT THE CLEANING HEAD POWER SUPPLY S BEFORE PERFORMING ANY INTERNAL CLEANING OPERATION 1 On a daily basis any anti static bars supplied should be cleaned to remove any contamination from the needle points 2 TEKNEK recommend using a cleaning brush Teknek Part Number TK 5598 3 Failure to adhere to this instruction will diminish the performance of the anti static bar 4 Static bar checker Teknek Part Number Mi2393 can be used to monitor the effectiveness of the static bar Pi56998r04 24 ER3836R13 20 05 2011 8 1 TIMING BASICS ACTION REFER TO MANUAL 8 2 INTERMEDIATE CONTACT TECHNICAL SERVICES FOR THE GAS SPRING PART NUMBERS FOR YOUR MACHINE MACHINE TYPE AND SERIAL NUMBER ARE REQUIRED 8 3 ADVANCED DESCRIPTION QTY Linear Guideways Linear Slide Rail S
6. 836R13 20 05 2011 3 3 WIRING AND PNEUMATIC CONNECTION Information for Machine Builders 1 The KWCH product Control Box should be mounted near to the machine or in the designated area in the installation drawings There are two versions of the Control Box the standard unit with buttons and the PLC control unit with a touch screen 2 The control box is connected to the machine by an umbilical cable 3 Mains Electrical Power is supplied to the Control Box 4 Pneumatic Air supply Oil free and clean dry air set at a minimum of 5 bar is connected to the XWCH machine by a 6mm tube The air pressure is detected on the machine and a confirmation signal transmitted to the control box 5 The exhaust air from the machine is collected and delivered to a 4mm fitting at the other side of the machine This may be further piped away from the machine if required 6 Pneumatic and Electrical Connection Diagrams are attached 7 Finally assemble the Adhesive Roller s into the machine check the orientation of the adhesive wind see section 6 3 NOTE a line run signal may be required check your machine specification and a minimum air pressure supply is required as the machine is fitted with a pressure sensor that prevents the machine being operated if the pressure is too low Pi56998r04 9 ER3836R13 20 05 2011 ELECTRICAL CONNECTION IN AIR 6mm CONNECTION a 112 60 a CLEANING POINT p 60
7. E DOWN ORIENTATION HCH HORIZONTAL ORIDENTATION SLIDES BOTH CLEANING AND ADHESIVE ROLLERS FITTED WITH SLIDES 1SLIDE ADHESIVE FITTED WITH SLIDES NS NO SLIDES FITTED 12 SUB ASSEMBLIES TD54360 55515 PL54440 PL54441 PL54354 PL54377 PL54378 PL54379 PL54399 PL57359 SA57347 Pi56998r04 ER3836R13 20 05 2011 KWCH3 EKPLODED DRAWINGS SLIDE MODULE ASSEMBLY CONTROL CHASSIS ASSEMBLY SPRING ASSEMBLY 25 SPRING ASSEMBLY 100 ROLLER MOUNT ASSEMBLY 55 ACTUATOR ASSEMBLY 25 ACTUATOR ASSEMBLY 100 ACTUATOR ASSEMBLY AR ROLLER HOLDER SET INSTALLATION KIT BASIC INSTALLATION SUGGESTION 33 13 EW55786 EW55706 EW56518 Pi56998r04 ER3836R13 20 05 2011 ELECTRICAL SCHEMATIC DIAGRAM Electrical Schematic Diagram Electrical Schematic Diagram Electrical Schematic Diagram 34 14 PN57284 Pi56998r04 ER3836R13 20 05 2011 PNEUMATIC SCHEMATIC DIAGRAM Pneumatic Schematic 35 Pi56998r04 ER3836R13 20 05 2011 End of Document 36
8. ESIVE ROLLS Information for Machine Operators This operation should be carried out on a shift basis or more often if operating conditions dictate Teknek recommends that the line is STOPPED and the KWCH machine is OFF before any purging operations on the adhesive rolls if conditions allow the adhesive may be purged while the web is running through XWCH machines at speed below 50m min This is achieved by pressing the adhesive roll button on the control box and waiting until the Adhesive Roll has lifted clear from the cleaning roller and stopped rotating If the machine is fitted with adhesive roll slide out system unlock the slide by operating the knob on the catch of the Adhesive Carriage and pull out to the side Extreme care should be taken not to touch or contaminate the Cleaning Roller as this may still be rotating and cleaning To remove a layer from the adhesive roll lift the loose edge pull contaminated sheet clear This will expose a fresh layer of adhesive ensuring the optimum performance of the rubber cleaning roller Carefully tape back the loose edge of the adhesive onto the roll A check of the Operating Pressure in the Airshaft each time the adhesive is purged is recommended This can be done by trying to push the Adhesive Roll s along the Airshaft This simple check can lead to early detection of inflation problems with a shaft before it becomes critical If the pressure is too high then the adhesive may show co
9. ORIGINAL INSTRUCTIONS XWCH3 Instruction amp Service Manual WORLD LEADER IN CONTACT CLEANING Teknek Head Office Teknek Japan Ltd River Drive Big Van Onoecho Building Inchinnan Business Park 6 83 Onoe cho Nakaku Renfrewshire PA4 9RT Yokohama City Scotland UK Japan 231 0015 T 44 0 141 568 8100 T 81 0 45 640 0670 F 44 0 141 568 8101 F 81 0 45 640 0671 e teknek teknek com e japan teknek com www teknek com Pi56998r04 ER3836R13 20 05 2011 Teknek China Ltd Unit G02 G F Myloft 9 Hoi Wing Road Tuen Mun N T Hong Kong T 852 2468 3160 F 4852 2462 3036 e hk teknek com Teknek USA 8100 D Arrowridge Boulevard Charlotte NC 28273 USA T 1 704 499 9191 F 1 704 499 9190 e ussales teknek com SAFETY WITH YOUR CLEANING HEAD 3 SAFETY DATA i pi oke ko LI 4 ABRESIVE ROLLS SAFETY ISSUES sisti ciiin oti oun kib ra so on a ap EM EM 4 ROLL CONSTRUCTION pak kob 4 ANDLIN 8 STORAGE me p m 4 INTHE EVENT OF FIRE b 4 WASTE DISPOSAL m sicca velit SR a newlines IS 4 MACHINE SAFETY ISSUES nana kaama MABINA enari 4 OZONE EMISSION S kaprini ta gas kasek pa CER Dg n A 4 liz 4c 5nupdc 5 1 INT
10. RODUCTION ini ian koz ir Acor ixi exiens ka ek rnv 6 2 UNPACKING PROCEDURE kkrkkka kase ke aks kin kos eks krak anazaa 7 sivi kase pneu taa n n p etapa 8 3 1 PRE INSTALLATION 8 3 2 INSTALLATION and MACHINE SETUP essent nnne nnnm nnns 8 3 3 WIRING AND PNEUMATIC CONNECTION eene ann nanna nterna nnne nnn 9 3 4 FITTING THE COVER SET IE SUPPLIED erento sevi ero oranti trat p ipu toe esee 11 4 MACHINE OPERATION sp ski ka Rua ERR nha k k akite kas r k 12 5 CONTROL BOX LAYOUTS ierra kare ken nta kata guck ap aka pik 13 MAINTENANCE e 17 6 1 PURGING ADHESIVE ROELS eut RP CET ta ke uses deste xoa pax uou Sap iet on 17 6 2 REPLACING THE ADHESIVE 18 6 4 AIRSHAFT nanasi atentos aoa nawa rock tac koc tana kia ausa 21 7 CLEANING RUBBER ROLLERS iii isk kn kon ki riim mn ei kipa ak ci 22 7 1 NANOGLEEN ROLLERS 22 7 2 FILM PANEL ULTRACLEEN TYPE ROLLERS icccsccsicsssesscasssscitestscaresesscastessareseraraceticace 22 7 3 REMOVING AND REPLACING THE CLEANING ROLLERS
11. SUPPLY REQUIREMENTS Cleaning Head Control Box AIR IN AIR OUT Pi56998r04 ER3836R13 20 05 2011 Aluminium End Blocks and general machined paris Aluminium Alloy Tube Rubber Roller Covers if fitted Aluminium Extrusion with PETG panels Mounting frame ITEM 40 x 160 Extrusion profile Natural Anodised Aluminium For XWCH3 same as line speed or up to 350m min 85 264v AC 50 60 Hz 5 7 Bars Oil Free 6mm hose connection 4mm tube fitting for exhaust air 31 Se 11 XWCH3 EXTERNAL DATA ATION ON URAWING ok IE SUPPLIED IN THIS MANUAL SUPPLIED IN His MANUAL CONTACT TECHNICAL SERVICES FOR FURTHER INFORMATION Single Sided Machines VCH HCH REFERENCE MACHINE DRAWING XWCHS 25 SLIDES VCH Pi58265 XWCHS 100 SLIDES VCH Pi58266 XWCHS 25 SLIDES UCH Pi58265 XWCHS 100 SLIDES UCH Pi58266 XWCHS 25 1 SLIDE VCH Pi58265 XWCHS 100 1 SLIDE VCH Pi58266 XWCHS 25 1 SLIDE UCH Pi58265 XWCHS 100 1 SLIDE UCH Pi58266 XWCHS 25 NS VCH Pi58265 XWCH3 100 NS VCH Pi58266 XWCH3 25 NS UCH Pi58265 XWCHS 100 NS UCH Pi58266 Double Sided Machines XWCHS 25 25 SLIDES Pi58267 XWCHS 100 25 SLIDES Pi58268 XWCHS 100 100 SLIDES Pi58269 XWCHS 25 25 1SLIDE Pi58267 XWCHS 100 25 1SLIDE Pi58268 XWCHS 100 100 1SLIDE Pi58269 XWCHS 25 25 NS Pi58267 XWCHS 100 25 NS Pi58268 XWCHS 100 100 NS Pi58269 VCH VERTICAL ORIENTATION UCH UPSID
12. VE ROLLS SAFETY ISSUES ROLL CONSTRUCTION Adhesive Rolls are made of pressure sensitive adhesive on a paper or filmic base and are generally safe and present no hazard to health provided normal rules for goods industrial hygiene are observed The following advice is given to ensure storage and usage of these products HANDLING 8 STORAGE On receiving goods inspect packages for signs of damage Inform supplier of shortage or damage immediately Store material in clean dry area Material should be stored in original packaging until required Rolls stored on their side not in original packaging may pressure mark or produce a flat if stored for long periods Shelf life is two years when stored correctly in original packaging Storage temperature should not exceed 23 C 73 F and 50 relative humidity IN THE EVENT OF FIRE The adhesive rolls will burn in the event of contact with flame Fumes may be given off by the acrylic adhesive and silicone release coating itself Fires may be extinguished with water provided that live electrical equipment is not in the vicinity The advice of your Fire Officer should be sought having regard for the layout of your premises and the particular operation involved WASTE DISPOSAL Adhesive Roll off cut may be disposed of through normal trade re use outlets If disposed of in a legal tip in compliance with relevant laws or incinerated in a licensed site in compliance with relevant laws the following shoul
13. at any operators using the XWCH machine are give clear instructions on how the product operates and what it designed to do 2 Operate the Cleaning Head by inputting a controlling signal to the control box or pressing the START button 3 Check that the Cleaning Head rollers move to the IN ON operating position i e the cleaning roller contacts the material to be cleaned and the adhesive roll is contacting the rubber roller 4 If the web is moving the blue roller and adhesive roll should be turning together with the processing of the web or substrate 5 Operate the machine to the OUT OFF condition and check that the Rollers return to their OUT OFF position The blue roller and adhesive roll should now be out of contact with each other 6 Carry out this test until the operator is satisfied that the cleaning head operates correctly and that the cleaning roller contacts the substrate support or pressure roller along its full length 7 Ensure that the operator s is comfortable with the operation of the machine and does not require further training to ensure safe operation Pi56998r04 12 ER3836R13 20 05 2011 5 CONTROL BOX LAYOUTS Drawings for the control box types are located at the rear of the manual MACHINE TYPE CONTROL BOX DRAWING LAYOUT NUMBER SINGLE SIDED VERTICAL 1 x SINGLE SIDE Pi55781 SINGLE SIDED HORIZONTAL 1 x SINGLE SIDE Pi55781 SINGLE SIDED UPSIDE DOWN 1 x SINGLE SIDE Pi55781 DOUBLE SIDED
14. d be noted Acrylic adhesive coated products should only be incinerated if the incinerator can cope with corrosive flue gasses MACHINE SAFETY ISSUES OZONE EMISSIONS The high voltage static elimination equipment in Teknek Machinery has been thoroughly tested and complies with OSHA Standard The maximum Allowable Concentration MAC of ozone under this regulation is 0 1 parts per million The maximum output in the vicinity of Teknek static eliminating devices is 0 04 ppm IMPORTANT NOTICE Published information concerning products is based upon research that the Company believes to be reliable but such information does not constitute a warranty Because of the variety of possible uses for Teknek products and the continuing development of new uses the purchaser should carefully consider the fitness and performance of the product for each intended use and the purchaser assumes all risks in connection with such use Seller shall not be liable for damages in excess of the purchase price of the product or for incidental or consequential damages All specifications are subject to change without prior notice Pi56998r04 4 ER3836R13 20 05 2011 TEKNEK GUARANTEE Teknek Limited TEKNEK guarantees that in the event of the XWCH3 Cleaning Head becoming defective due to faulty materials or workmanship within 12 months from the date of purchase assuming a two shift operation cycle the company shall replace all defective parts free of charge s
15. d may damage the media being processed by the Cleaning Head The use of non TEKNEK adhesives or cleaning rollers shall immediately void the warranty Pi56998r04 ER3836R13 20 05 2011 1 INTRODUCTION The XWCH3 Cleaning Head has been developed for cleaning applications where economy of space and consistently heavy duty reliable performance are critical factors This exciting product further advances the cleaning process technology developed by TEKNEK and complements the existing range of Industrial Cleaning Heads The cleaning method consists of rotating rubber rollers specially formulated to TEKNEK specification which remove contamination from each side or a single side of the media without abrasion or the use of chemicals The contaminants are simultaneously transferred to adhesive rollers allowing the rubber rollers to continue the cleaning process In addition an optional anti static system neutralises any static charge that may be present on the cleaned media thus preventing further attraction of airborne contaminants The XWCHG retains all the proven design features of TEKNEK Cleaning Heads and introduces further innovations including Automatic separation of the Adhesive Rollers from the Rubber Rollers 112mm 4 4 diameter Rubber Cleaning Rollers A 3 76mm Adhesive Roll System for increased operating time between purges Excellent access to Adhesive Rollers by optional side pull out Excellent access to Cl
16. eaning Rollers by optional side pull out Large line speed range options up to 350 m min Full compliance with CE and EMC regulations Minimum downtime for routine and emergency maintenance Simple control system Robust construction Simple installation into existing production lines Static removal system The XWCH3 Cleaning Head can be produced in many variations Single Sided Double Sided With slides one slide no slides 100mm and 25mm separation Vertical VCH Upside down UCH and Horizontal HCH The above versions are all available in the following cleaning roller formats Panel Film ULTRACIeen NANOCIeen PONS The range is also provided with or without dust covers as per customer requirements TEKNEK equipment is continuously developed and therefore we reserve the right to modify or alter it without notification Pi56998r04 6 ER3836R13 20 05 2011 2 UNPACKING PROCEDURE Information for Machine Builders and Installers 2 The Cleaning Roller s and the Adhesive Roller s are not installed in the machine but packed separately They must be carefully removed and stored until required 3 The Control Box is also packed separately remove and store safely 4 Cover Set s may be installed these should be removed before lifting the machine from the crate so care is required not to damage them 5 The machine can be safely lifted by slinging onto the rear extrusion cross member or by
17. ent cleaners on the Nanocleen rollers If the surface of the roller s deteriorates or contamination is evident contact Technical Services for assistance 7 2 FILM PANEL ULTRACLEEN TYPE ROLLERS On a daily basis The rubber roller s should be vigorously wiped using Tekwipes Teknek Part No Mi6700 On a weekly basis If the surface of the roller s deteriorates or contamination is evident vigorously wipe down using Scotchbrite Pad Teknek Part number Mi5068 and Isopropyl alcohol together NOTE Always allow Isopropyl alcohol to evaporate from the Film Panel Ultracleen rollers before allowing the Adhesive roll to come into contact with the rubber roller s DO NOT USE ACETONE SCREEN WASH OR ANY SOLVENT BASED CLEANER ON ANY TEKNEK RUBBER ROLLER AS THIS WILL DAMAGE THE COMPONENT AND INVALIDATE WARRANTY ENSURE THAT NO CLEANING LIQUID FLUIDS IMPREGNATE THE ADHESIVE ROLLER SURFACES Pi56998r04 22 ER3836R13 20 05 2011 7 3 REMOVING AND REPLACING THE CLEANING ROLLERS WARNING THE LINE MUST BE STOPPED ALWAYS DISCONNECT THE CLEANING HEAD POWER SUPPLY S BEFORE PERFORMING ANY INTERNAL OPERATIONS 1 If fitted unlock the slide by pressing of the knob on the catch of the Rubber Roller Carriage and pull out to the side 2 The Rubber Cleaning Roller is removed by un clamping the bearing retainers to release the bearings from the holders Note that the screw is captive in the holder 3 Two operators should perform both the removal and re
18. eted Adhesive Roller if un sheeted material is being used ensure that extreme care is exercised when purging the Adhesive Roller using the knife and that the blade is retracted immediately after use 7 DO NOT place fingers into areas that could expose them to injury such as open doors or covers or into the contact area of the cleaning rollers and the adhesive rollers 8 NEVER tamper with or override switches which may be visible when doors or covers are open as this practice could result in severe personal injury 9 NEVER interfere with or adjust pneumatic components if fitted as this practice could result in severe personal injury Authorised Personnel should always carry out Servicing and repairs 10 Before opening the machine for service or repair the electrical and pneumatic supplies if applicable should ALWAYS be disconnected by Authorised Personnel 11 Finally if the specification of the Cleaning Head is changed or modified in any way by the user following delivery from TEKNEK then it becomes the user s responsibility to ensure that the appropriate Machinery Directives are complied with WARNING NOTICE TO INSTALLERS AND USERS TEKNEK Limited have designed the XWCHS series for installations that are within the safety protection of one of a customer s parent machine or production line and have as such fitted NO specific safety protection devices to the XWCHS series Pi56998r04 3 ER3836R13 20 05 2011 SAFETY DATA SHEET ADHESI
19. n be found in the Installation Drawings relevant to the version of the machine that has been ordered 3 2 INSTALLATION and MACHINE SETUP Information for Machine Builders 1 Install the cleaning head into the working location 2 Centralise the cleaning head into the working position 3 Ensure that the machine is in the OFF condition 4 Connect the machine to the pneumatic supply 5 Install the Blue Cleaning Roller s roller mount assemblies are fitted with M8 caphead screws 6 Using the Jacking and Adjusting Screws set and check that the full width of the blue roller is clear from the cleaning point by the design dimension and is parallel this dimension can be 25mm or 100mm depending on customer selection 7 Operate the machine to check that the Rubber Cleaning Roller moves to the correct operating position 8 Inthe unlikely event that the machine movement is to fast or slow the speed of the machine movements may be adjusted by the flow control valves on the pneumatic cylinders if required READ NOTE in Section 9 This must only be done by a qualified engineer 9 The fasteners mounting the cleaning head should now be fully tightened to stop any further movement of the machine It is good practice to mark the screws to confirm a red spot of paint varnish to indicate that they are fully tightened and checked Flow Controls on Actuators Pneumatic Distribution and Control Pi56998r04 8 ER3
20. ntaminated high spots above the grippers and if the pressure is too low the adhesive roll may move during operation If fitted firmly replace the Adhesive Carriage slide into the machine and ensure that the lock is activated Depress the adhesive roll switch mounted on the front of the control box to reapply the adhesive roll back on to the rubber cleaning roll NOTE IT CAN BE GOOD PRACTICE TO TAPE DOWN THE CUT EDGE Please take advice on this as it is a preventative action that may be used to prevent damage should an operator insert the Adhesive Roll the wrong way Pi56998r04 17 ER3836R13 20 05 2011 6 2 REPLACING THE ADHESIVE ROLLS Information for Machine Operators The Adhesive Roll is mounted on an Airshaft and this item MUST be deflated to allow the Adhesive Roll s to be removed Once the new Adhesive Roll s is in position the Airshaft MUST be re inflated to retain the Adhesive Roll WARNING The Airshaft must only be re inflated using the Air Gun System supplied by TEKNEK to the recommended pressure range see Table below If this pressure is exceeded the Airshaft may cause uneven patches to appear on the Adhesive Roll and reduce the cleaning efficiency of the machine More information on the Airshafts is found in Sections 6 4 and 8 5 of this Manual Check the Operating Pressure in the Airshaft each time the adhesive is purged This can lead to early detection of inflation problems with a shaft before it becomes
21. re the shaft is inflated to the recommended pressure 8 When purging this unit treat the two rolls as one and remove the same amount from each roll Pi56998r04 19 ER3836R13 20 05 201 1 WARNING Please note the direction of the wrap of the adhesive with respect to the direction of the processed material If the wrap is in the wrong direction the Adhesive WILL unwind on to the Rubber Cleaning Roller and this will lead to downtime as repairs will be required to the XWCH3 to recover the Rubber Cleaning Roller from the Adhesive Please note the direction of the wrap of the adhesive rolls Pi56998r04 20 ER3836R13 20 05 2011 6 4 AIRSHAFT INFORMATION Air Shafts for use in TEKNEK Clean Machines Internal Concentric Expansion Rubber Pad Metal Body Types Operating Instructions These Airshafts are designed specifically for holding rolls of Teknek Adhesive Material ONLY in the Teknek Clean Machine 1 Connect Air Hose Supply Box to a convenient dry air source Use only the specially designed Safety Inflation Tool to expand the Airshaft 2 In no case should the shaft be operated with less than the minimum pressure see table This shaft is designed to support the Core Adhesive Roll and be driven by the Adhesive Roll freely running on the bearings only in a Teknek Clean Machine AIRSHAFT SIZE MINIMUM PRESSURE OPERATING PRESSURE 3 INCH 76mm 21 PSI 1 5 BAR 29 PSI 2 BAR 3 Position the shaft in the Adhe
22. s pre fix reads ARBS e g ARBS1500 XWCH3 CLEANING ROLLER TYPE No ULTRACLEEN MACHINE VERSION Adhesive Width mm Adhesives PANEL FILM NANO AR Face mm 600 622 1 ARBS0600 ARNSOG600 622 750 762 1 0750 ARNS0750 762 1000 1000 1 ARBS1000 ARNS1000 1000 1100 1100 1 ARBS1100 ARNS1100 1100 1200 1200 1 ARBS1200 ARNS1200 1200 1300 1300 1 ARBS1300 ARNS1300 1300 1400 1400 1 ARBS1400 ARNS1400 1400 1500 1500 1 ARBS1500 ARNS1500 1500 1600 1600 2 ARBS0800 1x ARNS1600 1600 1700 1700 2 0850 1 ARNS1700 1700 1800 1820 2 ARBS0910 1x ARNS1820 1820 2000 2000 2 ARBS1000 1x ARNS2000 2000 2200 2200 2 ARBS1100 ARNS1100 2200 2400 2400 2 ARBS1200 NOT AVAILABLE 2440 2500 2500 2 ARBS 1400 4 1100 NOT AVAILABLE 2500 8 7 SLIDE SYSTEMS TELESCOPIC SLIDES SYSTEMS IF FITTED CLEANING WIDTH SLIDE TYPE 600 750 1000 1100 1200 1300 1400 1500 1600 1700 1800 2000 2200 SD54501 SD54502 SD54503 SD54504 SD54505 SD54506 SD54507 SD54508 SD54509 SD54510 SD54511 SD54512 SD54513 FURTHER LISTS OF RECOMMENDED SPARES A list consisting of major spare parts and complete sub assemblies It can be transmitted from the TEKNEK Technical Services on request Please always quote the machine type and serial number Pi56998r04 ER3836R13 20 05 2011 9 FAULT FINDING IMPORTANT NOTE Before adjusting anything on the machine or control system TEKNEK recommena
23. s that the user confirms that the machine s are indeed outside the Design Specification as delivered to your reguirements The speed of operation of the machine is pre set at the factory before delivery The contact pressures of the Cleaning and Adhesive Rollers are pre set at the factory before delivery Increasing the pressure of contact of the Cleaning Roller or the Adhesive Roller will impair machine performance and the life of the rollers Increased contact pressure will significantly reduce the cleaning efficiency POSSIBLE CAUSE i Head coming down too quickly or too slowly ii Head going up too quickly or too slowly iii Adhesive paper wraps around rubber roller iv Contamination not being picked up vi Head not correct distance clear of substrate when in OFF condition Pi56998r04 ER3836R13 20 05 2011 CORRECTIVE ACTION Check and adjust airflow control Check and adjust airflow control Adhesive roll incorrectly installed Remove check orientation and replace Consider taping edge of adhesive i Check cleaning roller is contacting web adjust if necessary ii Check cleanliness of rubber roller Clean with Tekwipes iii Ensure adhesive roll is purging cleaning roller Remove outer layer of adhesive roll Adjust height setting of head as per installation 30 10 Machine Specifications and Dimensions GENERAL CONSTRUCTION FINISH ON SELECTED PARTS CAPACITY SPEED RANGE POWER
24. sive Roll Core Do not inflate while the shaft is spinning 4 Toinflate push the air inflation tool nozzle firmly into the valve receiver located inside the boss diameter at the end of the shaft This action will depress both the valve button and the tip of the inflation tool Hold the nozzle in place for approximately 10 seconds until the line pressure air gauge indicates a return of the desired pressure B 5 To deflate the shaft push in on quick release air valve allowing the air to escape through the hole in the centre of the button Remove the shaft from the roll core CAUTIONS e Do not deflate while the shaft is spinning e Do not use finger to release air from side valve Pi56998r04 21 ER3836R13 20 05 2011 7 CLEANING RUBBER ROLLERS Information for Machine Operators WARNING THE LINE MUST BE STOPPED ALWAYS DISCONNECT THE CLEANING HEAD POWER SUPPLY S BEFORE PERFORMING ANY INTERNAL CLEANING OPERATION The adhesive roll should be removed from the machine to facilitate access to the rubber roller for cleaning and prevent damage to the adhesive surface 7 1 NANOCLEEN ROLLERS Rollers should only be touched wearing clean white cotton gloves and should only be cleaned with special NANOWipe cloth and water see NANOCleen sheet at end of manual On a daily basis Wipe the roller s using the NANOWipe cloth dampened using clean water and wrung out until just damp NEVER use Tekwipes Isopropyl alcohol or other solv
25. st TEKNEK Cleaning Heads requires more than one person and care must be taken to avoid personal injury and damage to the machine during withdrawal from the transport box Ensure that the machine is installed safely and cannot topple over during use by mounting it on a stand or bolting it to the floor dependent on machine type 2 All Teknek Cleaning Heads which are electrically powered must be connected to earth Check also that the intended electrical supply complies with the designated machine specification The operating voltage is specified on the identification plate fitted adjacent to the power inlet socket 3 Before pressing the start button to operate the machine please read the entire contents of this manual to understand the workings of the machine Ensure that any new operators of the machine are given full instruction on use and an opportunity to read the manual before operating the equipment 4 If the Instruction and Service Manual is lost a new copy should be ordered from the manufacturer The address may be found on the Identification Plate on the machine 5 Safety considerations dictate that NO loose clothing should be worn adjacent to the machine when itisin operation All long hair must be tied back and preferably covered by a cap or a hair net Gloves if worn must fit the hands snugly as any surplus material at the fingertips constitutes a hazard when feeding workpiece during the cleaning cycle 6 Teknek machines use a she
26. tandard Linear Slide Rail Long Spring Plunger M5 St St Bearing Clamp 55 Roller Mount Assembly 55 Dependant on Slide Docking Pin Machine Type Slide Docking Bush Locking Pin Contact Technical Circlip External 018 Services Latch Button Latch Snib See Following Sheet See Following Sheet See Following Sheet 8 4 CONTROL BOX DETAILS PART No DESCRIPTION QTY Pi56998r04 ER3836R13 20 05 2011 Services Services Pi55783 Control Box XWCH3 2x SS Contact Technical Services 27 8 5 ROLLERS AND BEARINGS ALWAYS QUOTE THE MACHINE TYPE AND SERIAL NUMBER WHEN REQUESTING ASSISTANCE ADVICE OR SPARE PARTS FROM TEKNEK XWCH3 3112 RANGE BEARINGS Must be fitted using heat ADHESIVE ROLL BE9394 RUBBER ROLLER BE9394 CLEANING ROLLERS For applications that require a High Speed Roller the ref B is inserted after the SA e g SA11735 becomes SAB11735 ALL CLEANING WIDTHS 600 2500mm CONTACT TECHNICAL SERVICES ADHESIVE AIRSHAFTS CLEANING WIDTH 600 750 1000 1100 1200 1300 1400 1500 1600 1700 1800 2000 2200 2400 2500 PL54601 PL54602 PL54603 PL54604 PL54605 PL54606 PL54607 PL54608 PL54609 PL54610 PL54611 PL54612 PL54613 PL54614 PL54615 AIRSHAFT SIZE MINIMUM PRESSURE OPERATING PRESSURE 3 INCH 76mm 21 PSI 1 5 BAR 29 PSI 2 BAR Pi56998r04 28 ER3836R13 20 05 2011 8 6 ADHESIVE ROLLS 3 ADHESIVE ROLLS For Sheeted Adhesive roll
27. ubject to the following conditions i TEKNEK is satisfied that the Product has not been misused or used or operated in any way contrary to the instructions in the Manual provided TEKNEK is satisfied that repairs have not been carried out or have been attempted by persons not authorised by TEKNEK The product is made available for inspection by TEKNEK or its Authorised Distributor and TEKNEK is reasonably satisfied that the product is defective No replacement parts or adhesive rolls other than those recommended by TEKNEK are or have been used in or with the Product The following points should also be noted v vi vii viii This Guarantee is offered in addition to your statutory rights Component parts which require replacement due to normal wear and tear such as the Blue Rubber Rollers are excluded from this guarantee The Blue Rubber Cleaning Rollers carry a 6 month guarantee based on a 2 shift cycle excluding damage caused by use of unsuitable solvents or by knives or by other misuse and general wear This Guarantee is limited to the supply of replacement parts only i e any labour provided will be charged at the rate applicable at the time of any repair Teknek Limited is a Scottish company and this Guarantee is issued subject to Scots Law Please note that the use of spare parts or consumables other than TEKNEK recommended items may severely damage or significantly reduce the performance of your equipment an
28. using any of the M12 holes on the ends ensure that if slides are fitted that they are fully home and locked 6 Check that any slings do not damage the connectors on the ends of the frame 7 Remove the cleaning head from the transport box 8 Check unit for transit damage 9 Confirm that the Serial Number on the machine matches that shown on the cover of this Service and Instruction manual 10 In the case of damage or a discrepancy please notify the Authorised Distributor or TEKNEK Head Office immediately Pi56998r04 7 ER3836R13 The machine is shipped in a wooden crate 20 05 2011 3 XWCH3 INSTALLATION Information for Machine Builders and Machine Installers 3 1 PRE INSTALLATION IMPORTANT This machine is supplied un guarded customers must ensure that suitable guarding is provided to ensure the safety of all personnel from nips and trapping hazards before the machine is put into service 1 Place the cleaning head on a suitable workbench or work area 2 Thoroughly clean down the Cleaning Head with Isopropyl Alcohol in order to prevent the possibility of a transfer of contamination particles from the frame to cleaned materials exiting the cleaning head roller 3 Due to the speciality of the mounting frames manufactured for each specific cleaning head the following assumes that the framework installation location is ready to accommodate setting up of the machine to the substrate Details of the various mounting points ca
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