Paprima JET-X 2000 Operating And Maintenance Manual

Water jet tail cutting system

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Operating and Maintenance Manual for

JET-X 2000

Water Jet Tail Cutting System

: 615

ROJECT

UMBER

Paprima Industries 75

Guthrie

Dorval, Quebec H9P 2P1

Canada

Tel:514 422-9555

Fax:514 422-9777

E-Mail:

sales@paprima.ca

615

Paprima Industries

Table of Contents

Summary of Contents for Paprima JET-X 2000

Page 1 Operating and Maintenance Manual for JET-X 2000 Water Jet Tail Cutting System : 615 ROJECT UMBER Paprima Industries 75 Guthrie Dorval, Quebec H9P 2P1 Canada Tel:514 422-9555 Fax:514 422-9777 E-Mail: sales@paprima.ca Paprima Industries...
Page 2: Table Of Contents
JET-X 2000 Manual Table of Contents Safety Precautions ........................1 Confidentiality ..........................2 Accident Procedures ........................3 Simplified System Description ..................... 4 Operating the Tail Cutter ......................6 The Zero Energy State (ZES) ....................11 Recommended Routine Inspection ................... 12 The Tail Cutting Beam ......................
Page 3: Safety Precautions
The software program supplied by Paprima is designed to technically introduce a reasonable number of safety interlocks as a means of avoiding accidental injury. The Purchaser’s mill expressly agrees not to alter the software program without the written consent of Paprima Industries Inc. PAPRIMA INDUSTRIES ASSUMES NO RESPONSIBILITY FOR INJURIES TO OPERATING PERSONNEL RESULTING FROM UNAUTHORIZED ALTERATIONS OF THE PAPRIMA SOFTWARE.
Page 4: Confidentiality
Paprima Industries Inc and submitted to the purchaser under confidentiality. It may not be reproduced, transmitted, divulged or used otherwise in whole, or in part without the written permission of Paprima Industries Inc. Paprima Industries...
Page 5: Accident Procedures
JET-X 2000 Manual Accident Procedures In the event that a person is injured through contact with the water jet, the resulting injury may appear insignificant and give little indication as to the extent of the injury beneath the skin and deeper tissues.
Page 6: Simplified System Description
JET-X 2000 Manual Simplified System Description The P & I Diagram The P & I diagram provides the reader with an overview of the complete JET-X water jet tail cutting system. Each major component is discussed on the following pages in more detail. (Refer to drawings at the end of this manual.)
Page 7 JET-X 2000 Manual The Tail Cutter Arm Assembly The tail cutter arm assembly is equipped with two high-pressure diamond nozzles. Each nozzle has a small aperture, typically 0.1 - 0.125 mm. The nozzle assembly can be adjusted in different ways. Each nozzle is held in place with a set screw.
Page 8: Operating The Tail Cutter
JET-X 2000 Manual Operating the Tail Cutter The operating tasks can be performed automatically through illuminated push buttons on the operator control panel. Each tail cutter can locate a number of pre-determined points across the sheet width with a high degree of repeatable precision. For this reason, the end-of-travel stop point will not be overrun, which positively avoids jamming of the drive.
Page 9 JET-X 2000 Manual Push Buttons – POSITION This section contains the following push buttons: TAIL 1, TAIL 2, TAIL 3, and ENLARGE / PARK. The light of the push button is flashing when the tail cutter is travelling into position and it turns on solid when the tail cutter is in position.
Page 10 JET-X 2000 Manual With the selector switch in the MAINTENANCE mode, the CUT ON/OFF push button serves to turn the jet on, while the jet nozzle is in the PARK position. This feature allows for testing of the jet nozzles after servicing, or for routine checks, when paper is running on the machine. In the MAINT mode, the hydraulic power unit, the intensifiers and the high-pressure solenoid valve before the tail-cutting beam will come on and off every time the on/off command is given.
Page 11 JET-X 2000 Manual Controls on the Drive Side On the drive side and tending side one finds a local disconnect switch for the tail cutter motor, and a small junction box. The local disconnect switch Typical arrangement of motor breaker The switch has two positions: ON and OFF.
Page 12 JET-X 2000 Manual The Junction Box Illuminated light (white) - PARK The white ENLARGE/PARK light should be on, indicating that the jet carriages are in the PARK position. Spring loaded switch – CUT ON / OFF When the spring-loaded switch is set to ON and released, the jet will come on. When the spring- loaded switch is set to OFF and released, the jet will shut off.
Page 13: The Zero Energy State (Zes)
JET-X 2000 Manual The Zero Energy State (ZES) Before initiating any maintenance work, it is of crucial importance that all components of the high-pressure water system are de-energized to Zero Energy State (ZES). Electrical power 1) Open, lock, and tag breakers to PLC/DCS cabinet feed...
Page 14: Recommended Routine Inspection
Paprima is designed to technically introduce a reasonable number of safety interlocks as a means of avoiding accidental injury.
Page 15 JET-X 2000 Manual The diamond nozzles can achieve a long lifetime under continuous operation. On discontinuous service as for tail cutters, it may be necessary to replace a nozzle prematurely due to plugging. For details on how to change the nozzle, refer to the section “Monthly Service”.
Page 16 JET-X 2000 Manual WARNING! It is mandatory to open the downstream valve leading to the nozzle to release pressure to the environment and to close the upstream valve leading to the pneumatic high-pressure valve. Before replacing the nozzle, you must achieve a Zero Energy State. However, to speed up the procedure, it is possible to fully close the hand valve on the pressure side and to OPEN and lockout the valve leading to the nozzle.
Page 17   Check high-pressure hose for leaks.  Check the oil level of the drive motor gear case. If replacement is required, Paprima  recommends MOBILGEAR 636 or equivalent with a viscosity of 150 VG 220.  Check chain and chain tension on the tail cutter beam. The chain should be tensioned by ...
Page 18: The Tail Cutting Beam
JET-X 2000 Manual The Tail Cutting Beam Removal of the Inner Sub-Assembly With the carriage located in the PARK position, it is possible to remove the complete inner sub-assembly from the tending side as follows: (Refer to installation drawing at the end of this manual.) ...
Page 19 (17 mm) with a torque wrench to 30 Nm. After torqueing, verify that the carriage moves smoothly - readjust if required. The two faces of the carriage contain four spring-loaded wiper pads. Paprima recommends that these pads are lubricated with non-stick Molybdenum spray by Target Company (Product # 1210016).
Page 20 The high-pressure hose is made of a polymer core, reinforced by several layers of special steel wire mesh. To give this material an improved life- cycle, Paprima sleeves the hose with an outer mantle of corrugated Teflon necessitating special cooling jacket couplings for connecting the cooling air to the outer mantle.
Page 21 JET-X 2000 Manual High pressure hose and cooling sleeve disassembled Carefully pull out the high pressure hose from its Teflon sleeve. Drive assembly with distribution of cooling air Paprima Industries...
Page 22 JET-X 2000 Manual Re-insert the new high pressure hose into the Teflon sleeve from the side of the high pressure water entry. Push the hose slowly through the Teflon sleeve until the tip of the hose reaches the curvature of the power track (about (1/2 the length of the hose). With the hand crank, move the carriage about 2 to 3 feet inside beam.
Page 23 JET-X 2000 Manual When replacing the power chain, we recommend first to removing the unit that carries the power track and the hose connections. Loosen the (4) hex-bolts and slide assembly to the side. This provides access to the chain lock on the carriage. The new chain can be linked to the old chain by means of the lock and be drawn over the whole width of the tail cutter beam.
Page 24 JET-X 2000 Manual The Cutting Head Cutting on the dryer cylinder (where installed) On modern high speed paper machines it has become necessary to thread the sheet through the dry end, even without an open sheet traction. Therefore, no mechanical tail cutters can be used. The tail is cut by the waterjet on the dry end.
Page 25: Troubleshooting The Tail Cutter
JET-X 2000 Manual Cutting in the open sheet run (where installed) The nozzle head (patent pending) keeps the paper sheet close to the nozzle. With the jet on, the instrument pressurized air flows to an air amplifier which functions according to the Venturi principle.
Page 26 JET-X 2000 Manual General This section provides information necessary to identify, isolate and correct problems occurring during operation of the tail cutter. Troubleshooting Tips The following are several tips that have proved beneficial in isolating system malfunctions. Be aware that live electrical circuits are present in the control console whenever the master disconnect is ON, regardless of the EMERGENCY STOP button position.
Page 27: Motion Problems
JET-X 2000 Manual Motion Problems Tail cutter does not respond to any pushbutton input from the operator panel Probable Cause Corrective Action Comments Press Reset button E-Stop switch is not released Release stop switch Set the disconnect switch to “ON”...
Page 28 JET-X 2000 Manual Tail cutter carriage attempts to move beyond the mechanical limits of travel of the beam. Check while the VFD The proximity switch is activating Check the equipment to ensure that as the carriage moves across all components are properly is running.
Page 29: Recommended Torques
JET-X 2000 Manual Recommended Torques Lb•ft COMPONENT HP FITTINGS H.P. Nut 1/4” H.P. Nut 3/8” H.P. Nut 9/16” H.P. Jet nozzle nut Paprima Industries...
Page 30: The Electrical Components
JET-X 2000 Manual The Electrical Components The motion of the tail utter is controlled by an electrical control system. This system is made up of these main components:   Encoder   Proximity switch   Variable Frequency Drive (VFD, Customer supply) ...
Page 31 JET-X 2000 Manual Distributed Control System (DCS) OR Programmable Logic Controller (PLC) The DCS OR PLC is the master controller of the system. It is used to control the motion, set the alarms, and convert the signal from the encoder into a position that can be used for control calculations.
Page 32: The Motion Control Section
The actual input addresses are converted to virtual contacts that are used throughout the Paprima program. At this point, the program will execute the tail cutter loop. The output addresses are also converted from virtual contacts in the Paprima program to the actual output coils that will activate devices in the field.
Page 33: Setting Position Parameters
JET-X 2000 Manual Setting Position Parameters The tailcutter power unit must be on. Ensure that the carriage of the tailcutter is in the PARK position. When in the PARK position, the white light on the operator console must be on.
Page 34 There is a limit on the range that can be set in the values sent to the analog card. The motor will not run with a frequency below 5 Hz. Paprima recommends NOT TO CHANGE the speed since the corresponding deceleration window has to be changed to match the new speed.
Page 35: Alarm Messages
JET-X 2000 Manual Alarm Messages The alarm bits set from the Pump program and Motion program will display the following messages on the alarm display unit. No alarm conditions Message: PAPRIMA INDUSTRIES ALARM CONDITIONS WHICH DISABLE THE SYSTEM The following alarms indicate a permanent problem until resolved. These are hard-wire alarms.
Page 36 JET-X 2000 Manual Message: NOT READING PARK POSITION VERIFY BEAM RESET SWITCH & RESET ON OPC Reason: Verify the Beam Reset Switch (BRS). Verify if the chain inducer clip has come loose from the chain. Refer to troubleshooting section for more details.
Page 37: Motion Program Flowchart
JET-X 2000 Manual Motion Program Flowchart START SET NUMBER OF TAIL POSITIONS INPUT SIGNAL LOW COOLING AIR DISPLAY WARNING PRESSURE ENCODER SIGNAL CONVERSION EMERGENCY STOP DISPLAY ALARM SET OPTIMUM SPEED SET STOP WINDOWS LIMIT ALARM STOP/RESET MOTION CONTROL SET STATUS BIT...
Page 38 JET-X 2000 Manual VFD Parameter Settings Allen Bradley Power Flex 70 File Group PAR. DESCRIPTION PAPRIMA Internal SETTING value Motor Control Motor Data Motor NP Volts 4600 Motor NP FLA Motor NP Hertz Motor NP RPM 1740 1740 Motor NP Power...
Page 39 JET-X 2000 Manual Statistics Author: Lou B. Approved: Reference Material: 588_JET-X 2000_English.doc Date: 2012.10.19 Revised: ----- Paprima Industries...