140/1 MOO 4 TAMBOL SAM-NGAM, DON TUM, NAKORN PATHOM 73150.
THAILAND
Tel. : 034 - 381 313 Fax. : 034 - 381 717
Web Site : http://www.kzcorp.com E-mail : [email protected]
INSTALLATION
OPERATING AND
MAINTENANCE
INSTRUCTIONS
FOR THE
ROTARY SCREENS
END RINGS GLUEING MACHINE
Order No.: ___________
Delivery Date:____________
Client:- -----------------
Address:- -----------------
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K+Z Agents:- -----------------
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-----------------
Tel:- +----------------
FaX:- +----------------
E-mail: -----------------
1
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SECTION INDEX
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1 FORWARD
2 EQUIPMENT DESCRIPTION
2.1 Item, Type, and Warrantee
3 INSTALLATION
3.1 Inspection
3.2 Installation
3.3 Installation Procedure
3.4 Commissioning
4 OPERATING INSTRUCTIONS
5 MAINTENANCE
5.1 Service Schedule
6 SUPPLEMENTARY DETAILS
2
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SECTION 1. FORWARD
____________________________________________________________
The information contained in this booklet, is intended for
the interest and use of the engineers responsible for the
running and maintenance of the following equipment.
This booklet should be studied before the unit is run for
the first time and thereafter be ready available for
reference.
In case of doubt, regarding the correct functioning or
adjustment of any parts of the equipment, or in the event of
any problems which cannot be remedied by reference to the
information contained in the booklet, K + Z Corp., Ltd.
should be consulted immediately.
In communicating with the Company, the Machine Serial/Order
Number should always be quoted.
K + Z CORPORATION LTD.,
140/1 MOO 4 TAMBOL SAM-NGAM,
DON TUM,
NAKORN PATHOM 73150.
THAILAND.
Tel: +66(0) 34 381 313
Fax: +66(0) 34 381 717
E-mail: [email protected]
Web Site: http://www.kzcorp.com
3
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SECTION 2. EQUIPMENT DESCRIPTION
____________________________________________________________
2.1. ITEM : ROTARY SCREENS – “END RING” GLUEING MACHINE
Suitable for up to 210 cm. Long Rotary Screens (180 cm.
Printing Width).
Comprising of:-
A rigidly Fabricated Steel support Framework, retaining
adjustable Base Frames withheld on a series of Linear
Bearings, running on precision ground Guide Tracks.
The 2 End Section adjustable Base Frames, having been
ready prepared for retaining “Self-Centering Chucks”
which have been suitably Machined for withholding the
Screen Aluminum “End Rings” in alignment, ready for
insertion into the Rotary Screens.
Said End Section Adjustable Base Frames, equipped with
Quick Release Clamping System to enable the Insertion
of the Aluminum End Rings, and to accommodate the
varying Rotary Screen Lengths.
The 2 Intermediate Middle Section adjustable Base
Frames having been ready prepared for retaining the
interchangeable Clamping Units for withholding the
Screens in position for when inserting said Aluminum
End Rings into the Rotary Screens.
The 2 End Section having been ready prepared for
retaining the Electrical Heating Elements with Ducting
arrangement for Drying the applied End Ring Adhesive,
End Ring Gluing Unit complete with the related Control
Panel retaining the applicable Switchgear, ready
prepared for 220/240 Volts, 50 Hz., Single Phase
Electric Supply.
4
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SECTION 3. INSTALLATION
____________________________________________________________
3.1. Inspection
On delivery,- all items should inspected - by the
Client, if damage has occurred (particularly during
transit), then K+Z Corp. Ltd., together with the
Transport and Insurance Companies should be immediately
notified, but in any event, not later than 3 DAYS
following delivery.
3.2. Installation
All necessary items should be thoroughly cleaned before
installation, and all sundry machine parts scraped
clean of protective coating then lightly oiled, also
ensure that all packing material is removed, together
with any other protective coverings.
3.3. Installation Procedure
The herein Machinery/Equipment is self contained, and
all the Machine functions are repeatedly tested before
leaving our Factory to ensure satisfactory Operation.
However, for Transportation purposes to avoid damages
the Heating Elements and the Screen Alignment Locators
are removed from the adjustable Base Frames.
Although the installation work is minimal, however for
Safety precaution, certain Checks and Actions should be
carried out before re-assembling the above said Parts:-
a) Place the Rotary Screen “End Ring” Gluing Unit in
the required position.
The Gluing Unit Frame, Must thereafter be leveled
and Bolted down with Anchor Bolts at the points
provided at the Base of the Machine Framework
before proceeding with Re-connection of the Parts
which have been removed for transportation purposes
b) Connection of Services:-
ELECTRICS
Connect the Rotary Screen “End Ring” Gluing Unit
Control Panel to a Terminated, 32 Amps., 220/240
Volts, 50 Hz., Single Phase Electric Supply, with
Earth.
C) Before starting the commissioning procedure, check
again that sections 3.1. through 3.3. have been
completed correctly.
When satisfied, the Machine can then be Tested for
the Insertion and Gluing of the End Rings into the
Rotary Screens.
5
___________________________________________________________________
SECTION 3. Cont. INSTALLATION
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CHECKING THE ALIGNMENT OF THE END-RING GLUING MACHINE
Please note that with continuous use, the End-Ring Gluing Machine
should always be periodically checked for Alignment, thus ensuring
that the Unit is prepared for use by the Operator.
By using a “Spirit Level”, Check
that the Complete Framework of
the End-Ring Gluing Machine is
perfectly Level.
Adjustable Screws are located at
the Base of the Unit Framework
to allow for any necessary
adjustment which may be required
to level the Framework (see
photos below).
6
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SECTION 3. Cont. INSTALLATION
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Checking the “Parallel” Alignment
of the Self-Centering Chucks.
By providing a “Plumb Bob”
together with a Can of Oil (to
prevent oscillation of the “Plumb
Line”), from the “Rear Side’ Of
the Unit (see Photos). Check that
both of the Self-Centering Chucks
are in perfect Alignment with each
other.
By placing the “Plumb Bob Line”
over the Self-Centering Chucks,
and by measuring the distance of
the “Plumb Line” to the Aluminum
Bearing Housings which support the
Self-Centering Chucks Base-Plates,
any discrepancies in the Parallel
Alignment of both Self-Centering
Chucks will be noted.
If Re-adjustment be required,
first Mark with a Pencil/Pen the
existing position of the Self-
Centering Chucks Support Block,
and slightly release the 4 Screws
retaining the Self-Centering
Chucks Supporting Block,
thereafter carefully move the
complete Supporting Block to the
necessary required Dimension to
achieve the “Parallel Alignment of
both Self-Centering Chucks.
7
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SECTION 3. Cont. INSTALLATION
___________________________________________________________________
Checking the “Squared” Alignment
of the Self-Centering Chucks.
Initiate procedure by Locking the
Self-Centering Chucks Bases in a
suitable position to enable the
accurate Measuring of the Distance
between the Self-Centering Chucks.
By providing a Suitable Measuring
Tape, carry-out the accurate
measurement of the Distance
between the 3 Jaws on the Self-
Centering Chucks (see Photos),
thereafter to ensure consistency,
follow the same procedure by
carrying out the Measurements on
the 4 Sides of the Self-Centering
Chucks.
If Re-adjustment be required,
first Mark with a Pencil/Pen the
existing position of the Self-
Centering Chucks Support Block,
and slightly release the 4 Screws
retaining the Self-Centering
Chucks Supporting Block,
thereafter carefully move the
complete Supporting Block to the
necessary required position to
achieve the Alignment of both
Self-Centering Chucks.
8
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SECTION 3. Cont. INSTALLATION
___________________________________________________________________
Checking the Alignment of the
Screens Clamping Units.
Place the appropriate Size
Aluminum End-Rings into the Self-
Centering Chucks.
Insert the Screen Clamping Units
into their “Retainer Units”, and
thereafter adjust the Screen
Clamping Units (See Photos) until
the Clamping Units will “Fit”
smoothly onto the Aluminum End-
Rings, thereafter locking the
Screen Clamping Units into the
designated Position.
Check that the Screen Clamping
Units will thereafter Slide easily
on/off the Aluminum End-Rings thus
ensuring that the Screens will be
Held in perfect Alignment with the
Aluminum End-Rings.
9
___________________________________________________________________
SECTION 3. Cont. INSTALLATION
___________________________________________________________________
3.4. Commissioning
Begin by ensuring that the appropriate Size Rotary
Screen Clamping/Supporting Units(Item 6)together with
the appropriate Size Heater Blower Housings (Item 4)
(suitable for the intended Rotary Screen Size) have
been connected to the related adjustable Base Frames
of the Machine (Item 12 and 13).
On assessing the Length of the Intended Rotary Screen
to be used, decide on the suitable location to Place
and Lock into Position the “Self Centering Chucks”
Support Frames (items 15), followed by selecting the
suitable Position to Place the Screen Clamping Units
(items 6) to retain the intended Rotary Screen whilst
the Gluing Operation is being carried out.
I) Place the Intended Rotary Screen on the Screen
Clamping Units (items 6), and Close the Clamps to
withhold the Screen into position.
II) Place the Aluminum “End Rings” into the “Self-
centering Chucks”, ensuring that the “End Rings”
Locators (Cut-outs) are correctly placed on the
Keyed Jaw of the “Self-centering Chucks”, and
safely lock the “End Rings” into position.
III) Slide the Self-centering Chucks Support Frames
(Item 15) to the Rotary Screen, and Check that the
Alignment of the End Rings with the Rotary Screen
is in the intended correct Position.
IV) If any miss-alignment is noted, then the Guide
Shafts (Item 5), and all the supporting Equipment
(Items 12, 13 and 15) must be thoroughly Checked,
to correct the Miss-aligned Section of the Unit.
V) When satisfied that all the appropriate related
Units on the Machine Base Framework have been
Checked and/or Adjusted for Perfect Alignment, the
End Ring Gluing Machine will then be ready for the
Gluing Application of the Aluminum “End Rings” to
the Rotary Screens.
10
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SECTION 4. OPERATING INSTRUCTIONS
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4.1 “END RING” GLUING PROCEDURE
I) At the initial learning stages, the Operator is
advised to first Test the Machine for alignment,
as described in the aforesaid COMMISSIONING
Procedure, by repeating the Sequences as are
stated above in Section 3.4, and ensuring that
the “Self-centering Chuck” with the Adjustable
Screw attachment (Item 8, applicable for the
Insertion of the Aluminum “End Rings”) has been
Unscrewed to allow at least 80 mm movement which
will be required for the Insertion of the 2
Aluminum “End Rings” into the Rotary Screen.
II) When assured that all the related applicable
Units are in Perfect Alignment for carrying out
the “End Ring” Gluing Procedure, thereafter if
and when necessary, carry out the Measuring,
Marking, and Cutting of the Rotary Screen to
the desired/appropriate Length applicable for
the position of relative Engraved Section of
the Rotary Screens.
III) Having now ensured and Cut the Rotary Screen to
the correct Length, initiate the “End Ring”
Gluing Operation by allowing the “Tapered
Section” of the Aluminum “End Rings” to be
properly Aligned and started to “Enter” into
the Rotary Screen(if necessary, to Insert the
End Ring into the Screen, use the Provided
Prizing Tool), thereafter Locking the “Self-
centering Chucks” Support Frames (Item 15) into
Position
IV) Check if the Screen Alignment Locators (Items
16) have been Set to Locate with the relative
“Pointers” on the Rotary Screens.
V) If the Screen Alignment Locators have not been
Set, then Gently Turn the Rotary Screen on the
“End Rings” to Locate with the appropriate
Markings between The Aluminum “End Rings” and
the Rotary Screen, thus preparing the Screen
Alignment Locators ready for the “End Ring”
Gluing Procedure of the next Rotary Screens.
11
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SECTION 4. Cont. OPERATING INSTRUCTIONS
___________________________________________________________________
VI) Apply the relevant Adhesive onto the Now
remaining Exposed Sections of the Aluminum “End
Rings”, followed by Gently Turning the “Screw”
of the “Self-centering Chuck” with the
Adjustable Screw attachment, thus Inserting the
Aluminum “End Rings” into the Rotary Screen,
ensuring that any excess Adhesive on the
external section of the Screen has been
removed, thus avoiding the excess Adhesive
dripping onto the “Meshed” section of the
Blower Housings.
VII) Place the Heater Blower (Item 4) in Position
for Drying the Adhesive, thereafter Select the
Set Point of the Blowers Temperature
(Blowers equipped with 7 Temperature Positions
20⁰ to 650⁰ Cent. - see attached Instructions),
thereafter “Set” the Timer on the Control Panel
to a Suitable Drying Period (say 15 Minutes),
followed by turning the Start Switch to the
“ON” Position.
On Completion, the Timer will automatically
Switch the Unit “Off”.
VIII)After ensuring that any excess Adhesive left on
the Screen has been “Sanded” down, release the
Rotary Screen from the “Self-centering Chucks”
and the Support Frames.
NOTE : On Completion of requirements, For Safety Purposes,
the “End Ring” Gluing Unit should be turned OFF at
the Electric Supply Terminal.
12
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SECTION 4. Cont. OPERATING INSTRUCTIONS
___________________________________________________________________
Checking the Alignment of
the
Heating Elements “Blower
Housings”
Insert the Screen Clamping Units
into their “Retainer Units”, and
thereafter adjust the Heating
Elements “Blower Housings” (See
Photos) until the Clearance around
the Aluminum End-Ring (or the
Screen) is Equal (eg.: 5 mm
Clearance), thereafter locking the
Screen Clamping Units into
Position.
Check that the Screen Clamping
Units will thereafter Slide easily
on the Screens thus maintaining
the said 5 mm. clearance.
Insert the Heating Element Units
into Position, connecting them
into the Provided Sockets,
thereafter Testing their Operating
Capability.
OPERATING TEMPERATURE
NUMBER MAXIMUM OC
1 60 OC
2 80 OC
3 120 OC
4 160 OC
5 200 OC
6 240 OC DANGEROUS
7 290 CO
8 350 OC
9 400 OC
13
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SECTION 4. Cont. OPERATING INSTRUCTIONS
___________________________________________________________________
Setting the Alignment
of the Screen “Engraved
Pointer”.
The End-Ring Gluing
Unit is provided with
Screens Alignment
Locators to ensure that
the End-Rings are
perfectly located to
the Screen Engraved Set
Points (See Photos).
To check the Exact
Position of the Screen
Engraved Set Points to
the Position of the
Screen Alignment
Locators, thus ensuring
the perfect Alignment.
It is recommended that when possible an already prepared Existing
Printing Screen be Used to Check the Screen Alignment compatibility
with the Printing Machine.
Any Adjustment which may be required to the Self-Centering Chucks
is carried out by Slightly altering the position of the Chuck
Locking Device Retaining Plate which is Bolted on the rear of the
Chucks.
14
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SECTION 4. Cont. OPERATING INSTRUCTIONS
___________________________________________________________________
Checking the Alignment of the
Screen “Engraved Pointer”.
Select a suitable Engraved
Screen having the Set Points
Engraved for Aligning
Consecutive Screens of the
Design to be Printed.
Place the Selected Screen onto
the Screen Clamping Units by
following the instructions as
detailed in Section 3.4 of the
End-Ring Gluing Unit Operating
and Maintenance Manual.
By carefully “Tapping” gently
the Supporting Blocks for the
Self-Centering Chucks, insert
the Aluminum End-Rings into
the Screen (if necessary using
the provided “Prising Tool” to
assist the Aluminum End-Ring
Insertion Operation – (See
Photo).
When the Aluminum End-Ring is
totally inserted into the
Screen, and the relative
Screen Alignment Locator
having been Set to the
Engraved Pointer, thereafter
to enable the Operator to
Check and Set the Opposite
Side Screens Alignment
Locator, temporarily use
Adhesive Tape to Hold the
Aluminum End-Rings in
Position, so as the Screen can
therefore be turned around and
inserted into the Opposite
Side Self-Centering Chuck for
Setting the Opposite Side
Screens Alignment Locator
15
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SECTION 5. MAINTENANCE
____________________________________________________________
5.1. Service Schedule
The operator, should conform to the schedule presented
in the following pages. The details contained are based
on an eight hour shift and coded as shown in the
following table:-
S Every Shift Change.
W Weekly.
M Monthly.
3M Three Monthly.
6M Six Monthly.
A Annually.
It should be appreciated however, that good maintenance
is very much a matter of experience, knowledge of
machines and general engineering practice.
The aim of this schedule, is to act as a guide for the
operator, who it is hoped, will treat in good faith the
suggestions we offer.
An important factor governing the successful working of
any machine, is the attention given, or the extent to
which the operator is prepared to go towards achieving
trouble free, therefore economical use of his
equipment.
Maintenance, means keeping a practiced eye over the
equipment, looking/watching/anticipating trouble before
it occurs.
CAUTION : The mixing of oils and grease of different
Manufacturers, is not to be recommended.
Should it become necessary to change, the
existing oil or grease must first be removed and
the machine parts cleaned.
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LOCATION ACTION COMMENT CODE
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16
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SECTION 6. SUPPLEMENTARY DETAILS
____________________________________________________________
Drg. No. ERG-01 END RING GLUEING MACHINE LAYOUT
ARRANGEMENT
Drg. No. ERG-E01 POWER AND CONTROL CIRCUIT
Drg. No. ERG-E02 TERMINAL BLOCK
Drg. No. ERG-E03 CONTROL PANEL
Drg. No. ERG-E04 MOUNTING BOARD
Drg. No. ERG-E05 ELECTRICAL EQUIPMENT LIST
