Content - erteka.lt technical manual rev 20070701.pdf · 2 Replace vacuum pump internal filters. 3 Replace desiccant nozzles. 4 Test all air connections for leaks. 5 Tighten all screws

DF50n Manual rev 20070701 P1/21

Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150

Desiccant filler DF50n Manual

Content Page

Normal operation 2

Preventive maintenance 4

Function description 5

Position adjustments 7

Fault finding and repair 7

Changing desiccant nozzle 8

Cleaning butyl nozzle 8

Changing drill bit 9

Changing the Blow filter 10

Wiring diagrams 11

Listing of PLC gates in 12

Listing of PLC gates out 13

DF PLC and sensors wiring diagram 14

DF 400V wiring diagram 14

DF butyl heater wiring diagram 15

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P1 P2 P3 P4

P5 P6 P7 P8 P9

Start up

1 Turn DF5nn on. (Release emergency switch) P7

2 Turn air on. (Turning switch on air inlet) P6

3 Adjust height position. (Handel up/down) P1

4 Set the 9-pole switch to 3. (Normal operation position) P8

5 Polish the butyl head with a polish containing silicon. P4

Putting a frame in to FD5nn

1 Put frame on position triangle. P5

2 Depress foot pedal.

3 The head will come down pushing the frame against the triangle. P5

3 Let the frame go.

Removing a frame from DF5nn

1 Grab the frame.

2 Depress the foot pedal.

3 Check and adjust butyl sealing.

Refilling of butyl.

1 Set the 0-9 switch to 9. P8

2 Depress foot pedal. (The butyl cylinder move back)

3 Put in a butyl slug. P2

4 Set the 9-pole switch to 8 P8

5 Depress the foot pedal (The butyl cylinder move forwards)

6 Set the 9-pole switch back to 3 P8




Set the butyl timer

1 Set the 0-9 switch to 6. P8

2 On the E100 panel push arrow down(7) P3

3 Push arrow Right (9)

4 Push Enter.

5 Keep NUM depressed while entering new value (1/10 sec)

6 Push Enter

For next head repeat 2 to 6.

7 Turn 0-9 switch back to 3

Alarms on operator panel P3

“Frame not full”

1 Depress foot pedal once. (Frame will move to load / unload position.)

2 Depress foot pedal again. (Frame will be released)

3 Check desiccant level in frame.

If frame is full:

1 Depress and release emergency switch (reset)

2 Start again normal input of frame.

3 Alarm “Frame not full” repeats.

4 Turn 9-pol switch from 3 to 2. (The frame will be sealed as normal) P8

Machine is dead

1 Check the electrical supply. (Depress and release emergency switch) P7

2 Check the pneumatically supply. (Turn air off and on) P6

Upper chamber is empty

1 Check desiccant level in supply drum.

Hydraulic pump off

Open cupboard and reset motor protection

Vacuum pump off

Open cupboard and reset motor protection.




Preventive maintenance

Daily

1 Check level of lubricating alcohol (drill bits)

2 Check level of lubricating oil (air motors)

3 Check level of hydraulic oil.

4 Check desiccant level in drum.

5 Check clamp cylinders connection to clamp bar.

If screwed out use screw fix blue or green, and tighten them.

6 Check desiccant nozzles for damage and butyl.

7 Check drill bit.

8 Use some silicon polish on butyl nozzle

Weekly

1 Clean main vacuum filter.

2 Check pressure on blow. If more than 2 bar change blow filter.

Yearly

1 Check vacuum pump lamellas

2 Replace vacuum pump internal filters.

3 Replace desiccant nozzles.

4 Test all air connections for leaks.

5 Tighten all screws.




Function description

S1 S2 S3 S4 P10 P11 P12

Sensors:

S1 Drill is out

S2 Lower chamber is not full

S3 Head is in Pickup position

S4 Upper chamber is full.

Pickup

1 Foot pedal depressed to start cycle

2 Head moves down with a reduced pressure to pickup position.

3 Position achieved is detected by S2

4 Transport clamp is activated.

5 Triangle is redrawn.

6 Pressure is returned to normal.

7 Pickup done

Drill

1 Frame is transported to drill position

2 Position clamp is activated.

3 Drill motor and transport forward is activated.

4 Drill is out is detected by S1.

5 Drill is kept out for some seconds.

6 Drill and transport is deactivated.

7 Drill is not out is detected by P1

8 Position clamp is deactivated.

9 Drill is done.




Desiccant filling

1 Frame is transported to desiccant filling position.

2 Position clamp is activated

3 A pressure between 1 and 2 bar is applied to the chambers.

4 Desiccant starts to flow in to the frame.

5 At intervals sensor S2 is checked.

5.1 No signal = Lower chamber is full

5.2 Signal = Lower chamber is not full

If lower chamber is not full the valve between upper and lower chamber will open.

Desiccant will flow from upper to lower chamber.

The time of flow is an expression of the volume.

This cycle will be repeated until no flow is detected.

6 Evaluation of filling

The total flow from upper to lower chamber will be compared to minimum volume

demanded with the position of the 0-9 switch.

6.1 Flow of desiccant from upper to lower chamber is < min demand.

6.1.1 Alarm is stated in the display.

6.1.2 Position clamp is deactivated.

6.1.3 Frame rests in desiccant filling position.

6.2 Flow of desiccant from upper to lower chamber is > min demand.

6.2.1 Position clamp is deactivated.

6.2.2 Degree of filling is displayed.

6.2.3 Desiccant filling done.

Closing of desiccant filling holes.

1 Frame is transported to butyl position.

2 Position clamp is activated.

3 Butyl cylinder moves forward. (Creating a pressure in the butyl)

4 Butyl is pushed in to the holes.

5 Butyl cylinder moved back (Taking of the pressure in the butyl)

6 Frame starts moving out of butyl position

7 Position clamp is deactivated.

Frame delivery

1 Frame is transported to frame delivery position.

2 Foot pedal is depressed.

3 Frame is released.

Head is reset and ready for a new cycle.

Filling of upper chamber.

1 Cycle is not active.

2 Sensor S4 is not detecting desiccant.

3 Vacuum and desiccant valve are opened.

4 Desiccant pump motor is started creating a push pull action. Pumping desiccant

from drum to upper chamber. This is a closed circuit and will not pollute the

desiccant with moister from new air.

5 When S4 detects desiccant chamber is full and action will be stopped.




Position adjustments Desiccant filling position

1 Depress emergency button.

2 Activate short transport cylinder and adjust P12 (M6 screw)

3 Put in an L frame, and adjust to maximal flow.

Butyl position


2 Activate long transport cylinder and adjust P10 (M8 grub screw)

Drill position

1 Make a frame interrupt at desiccant filling with foot pedal.

2 Adjust position of holes by washer or metal strips at P11

Fault finding and repair

Lower chamber is empty


2 Activate (blow and) the valve between upper and lower chamber.

2.1 If you do not get a flow from upper to lower chamber the desiccant outlet from the

upper chamber is probably blocked. Remove top of upper chamber (13mm nut).

Clean upper chamber and check the opening between upper and lower chamber.

2.2 If you do get a flow:

2.2.1 Check the optical cables.

2.2.2 Check the screw of the optical cable it should be only a nut with sticking

out of the block.

2.2.3 Adjust the sensitivity of the sensor (blue unit to the right of the PLC

Middle position)

2.2.4 Change the blow filter. (Inside the blow inlet of the sensor block between

the upper and lower chamber).

The butyl dose not close the opening in the frame

1 Hoes in frame and butyl nozzle dose not line up

1 Adjust butyl position.

1 Insufficient time

1 Set 9-pole switch to 6. Adjust butyl-filling time for left and right side.

2 Out of butyl

1 Go to refilling of butyl.

3 Hydraulic pressure not present.

1 Check if pump is active.

4 The butyl nozzle is blocked

1 Clean the butyl nozzle.

The DF4 delivers too much butyl.

1 Set 9-pole switch to 6. Adjust butyl-filling time for left end right side.

The flow of desiccant out of the lower chamber is slow

1 Increase blow pressure (max 2 bar)

2 The holes in the frame dose not line up with the desiccant nozzles.

Adjust frame desiccant position

3 Change filter.




P20 P21

P22 P23 P24 P25

Changing desiccant nozzle 1 Depress emergency button.

2 Turn off air.

3 Push in triangle.

4 Head slides to butyl position.

5 Remove nozzle cover

6 Remove grub screw P21

7 Push nozzle out with a screw driver.

8 Replace nozzle.

9 Check the position of the desiccant delivery slot

10 Test movement of head. Should barely touch nozzle.

Cleaning butyl nozzle 1 Depress emergency button.

2 Turn off air.

3 Let head rest on triangle.

4 Remove the 4 countersunk screws P22

5 Remove the 4 M8 screws P23

6 Remove the grub screw P24

7 Slide the head of the butyl nozzle P25

8 Remove the butyl nozzle and clean it.

9 On remounting check the position of the butyl delivery slots




P30 P31 P32

P33 P34 P35 P36

Changing drill bit 1 Remove grub screw P32

2 Disconnect air.

3 Push / drag drill unit out. If it is difficult to get out use a long screw driver and

knock carefully on P35 from the front.

4 Loosen P35, and change drill bit.

If you take out P36 see to that it clicks in on remounting

5 Push the drill unit in to the holder and line the grub screw to the positioning hole

in the air motor. This is to prevent the motor moving in the holder.

Aligning the drill unit.

If the hols have different distance from the edge of the butyl side the unit needs to be aligned.

1 Loosen P30, and the one on the other side.

2 The whole drill unit can now be turned around the centre screw.

3 Tighten all 3 screws after alignment.

Tightening the triangle

If the triangle is loos it can either be the cylinder to the braked or the triangle to the shaft.

To do this you have to take the complete drill unit off.

1 Remove the 4 M5 screws connecting it to the main body of the head.

2 Screw the triangle off.

3 Use green (strong) screw glue on the shaft and put it back.




P40 P41 P42

Changing the Blow filter 1 Remove tube from air fitting P40

2 Screw filter house P41 out of sensor block.

3 Knock filter P42 out of filter house.

4 Replace filter.

5 Use minimum force putting it together again.




Wiring diagrams U1 U2/U3

U4 U5 U6 U7 U8

U1 PLC

U2/3 Optical sensor left-head/right-head

U4 Main fuse

U5 24V DC power

U6 On/ Off relay.

U7 Vacuum pump relay.

U8 Hydraulic motor relay.




Listing of PLC gates in Signal to PLC

0 24VDC Left head upper chamber full

1 24VDC Left head lower chamber not full

2 24VDC Left head drill is out

3 24VDC Left head pickup position achieved

4 24VDC

5 24VDC

6 24VDC Left head foot pedal depressed

7 24VDC

10 24VDC

11 24VDC Vacuum pump on

12 24VDC Hydraulic pump on

13 24VDC Curve upper chamber full

14 24VDC Curve lower chamber not full

15 24VDC Curve foot pedal

16 24VDC

17 24VDC

20 24VDC 0-9 switch PL0




24 24VDC

25 24VDC

26 24VDC

27 24VDC

30 24VDC Right head upper chamber full

31 24VDC Right head lower chamber not full

32 24VDC Right head drill is out

33 24VDC Right head pickup position achieved

34 24VDC

35 24VDC

36 24VDC Right head foot pedal depressed

37 24VDC




Listing of PLC gates out Signal from PLC

0 24VDC Left head Triangle back

1 24VDC Left head Blow and vibrate on

2 24VDC Left head Vacuum valve open

3 24VDC Left head Desiccant valve open

4 24VDC Left head Valve between upper and lower chamber open

5 24VDC Left head Drill lubrication

6 24VDC Left head Position clamp on

7 24VDC Left head Transport clamp on

10 24VDC Left head Drill motor and transport on

11 24VDC Left head Blow swarf

12 24VDC Left head Short position cylinder on

13 24VDC Left head Long position cylinder on

14 24VDC Right head Short position cylinder on

15 24VDC Right head Long position cylinder on

16 24VDC Right head Triangle back

17 24VDC Right head Blow and vibrate on

20 24VDC Right head Vacuum valve open

21 24VDC Right head Desiccant valve open

22 24VDC Right head Valve between upper and lower chamber open

23 24VDC Right head Drill lubrication

24 24VDC Right head Position clamp on

25 24VDC Right head Transport clamp on

26 24VDC Right head Drill motor and transport on

27 24VDC Right head Blow swarf

30 240VAC Hydraulic bypass off

31 240VAC Right head Butyl cylinder forward

32 240VAC Right head Butyl cylinder reveres

33 240VAC Left head Butyl cylinder forward

34 240VAC Left head Butyl cylinder reverse

35 240VAC Hydraulic pump motor on

36 240VAC Vacuum pump motor on

37 240VAC Not in use




DF PLC and sensors wiring diagram

DF 400V wiring diagram




DF butyl heater wiring diagram




Operator manual DF50n Settings

0= Data com 1= Aim1 2= Aim2 3=Aim3 4= Aim4

5= Test head position 6= Desiccant safety factor 7= Butyl time adjustment

8= Test gates (+Foot pedal=Butyl forward) 9= Setup (+Foot pedal= Butyl reverse)

Position frame

Start/stop cycle




Refilling of butyl

=9

=

=8

=

=9

=




Maintenance:

Daly

Check lubrication level

Weekly

Clean large vacuum filter

Yearly

Replace

Small vacuum filter

Vacuum Blow Desiccant nozzle




Fault finding and repair

Frame not full

Position Desiccant nozzle/frame hole Blow pressure

0.5<P<1.8 bar

Butyl position/frame hole Drill position adjustment




Upper chamber not full

Sensor on when full Clean air filter

Clean vacuum filter Clean blow filter




Desiccant in filter

Replace vacuum filter Replace blow filter


Documents

Content - erteka.lt technical manual rev 20070701.pdf · 2 Replace vacuum pump internal filters. 3 Replace desiccant nozzles. 4 Test all air connections for leaks. 5 Tighten all screws