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- Page 1 VERSATILE FEED ROLL FRV SERIES OPERATION AND INSTRUCTION MANUAL FRV1-36, FRV1-48, FRV1-56, FRV5-56 Part Number: CI0183670000EN Revision: 07.18.2019 Revision: B Insert name of product insert part number • 6/12/2018...
- Page 2 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. DCN No. ____________ © Copyright 2019 All rights reserved. Versatile Feed Roll 5”...
- Page 3 According to the contract terms and conditions of the Carrier, the freight claims are filed by the terms below. If the order is prepaid, ACS Group is responsible for the freight payment. ACS will file the claim with the truck line. We need pictures of the damaged freight and a copy of the delivery receipt marked Damaged Freight.
- Page 4 Please call 262-641-8600. Have the order number and item number available. Hold the items until you receive shipping instructions. Do not return any goods before receiving your RMA (Return Material Authorization) number from ACS. Returns Do not return any goods before receiving your RMA (Return Material Authorization) number and shipping instructions from ACS.
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Page 5: Table Of Contents
Table of Contents CHAPTER 1: SAFETY ..............7 How to Use This Manual ......................7 Safety Symbols Used in this Manual................. 7 General Safety Regulations ....................... 8 Responsibility ..........................8 Warnings and Precautions ...................... 11 CHAPTER 2: FUNCTIONAL DESCRIPTION ......13 Models Covered in This Manual .................... - Page 6 CHAPTER 6: TROUBLESHOOTING ........32 Introduction ..........................32 CHAPTER 7: APPENDIX ............34 Customer Satisfaction Warranty Program ................34 Technical Specifications......................37 Parts List and Drawings ......................43 Pneumatic Circuit Diagram ...................... 46 Spare Parts List ........................47 ASME Torque Specifications ....................47 Technical Assistance ........................
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Page 7: Chapter 1: Safety
Chapter 1: Safety How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your machine. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer. -
Page 8: General Safety Regulations
General Safety Regulations These regulations should be read, understood and periodically reviewed by all personnel involved in any way with this machine. Never operate or remove any machine components that are secured by mechanical fasteners unless the motor is electrically locked out and all moving parts are motionless. Do not circumvent the safety interlocks. - Page 9 Figure 1: Safety Tags and Warning Labels Hazard Alert Symbol Description/Explanation Preventative Maintenance High Voltage Hazard. The Every six months inspect all electrical electrical enclosure is supplied connections for secure attachment. with 3-phase electrical power. For further information see the Use caution when using or Maintenance Chapter in this manual.
- Page 10 Mandatory Symbol Description/Explanation Read operators Manual. This equipment must be operated and maintained by properly trained personnel. The information contained within this manual must be read and understood prior to operating this equipment. Lock Out. This equipment is operated with 3-phase electrical power.
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Page 11: Warnings And Precautions
Warnings and Precautions Our machines are designed to provide safe and reliable operation when installed and operated within design specifications, and follow national and local safety codes. To avoid possible personal injury or equipment damage when installing, operating, or maintaining this machine, use good judgment and follow these safe practices: ... - Page 12 ROTATION OF MOTORS: The correct rotating direction for the machine motor is clearly marked on the machine. Always check for proper rotation of motors. Incorrect rotation direction can cause severe damage. ELECTRICAL GROUNDING: All electrical equipment on the machine must be grounded in accordance to all local codes and Article 250 of the National Electric Code.
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Page 13: Chapter 2: Functional Description
5”, and 2) only the fixed roll has stripper assemblies. NOTE: This manual covers light maintenance only. No further maintenance should be performed without first contacting the ACS Service Department at the mailing address and phone number shown in this manual. -
Page 14: General Description
When calling the factory for service information and parts, please have the model and serial number of your machine on hand. If the feed roll has been purchased independently from the accompanying equipment, the serial number and nameplate will be located at the feed roll control box. - Page 15 1. Translating Roll 2. Fixed Roll 3. Maintenance Windows (covered by Cover Plates) The feed rolls are constructed from carbon steel DOM (Drawn over Mandrel) tubing with a medium knurled surface. This design provides a strong roll with good balance. Integral to each roll head is a replaceable end ring that is designed to be slightly larger than the knurled diameter of the roll so that, at the minimum gap, the knurled surfaces do not touch.
- Page 16 1. Delrin Stripper 2. Adjustable Stripper Assembly The strippers are used to ensure separation of sheet and roll at the exit side of the feed roll. Each roll has a set of adjustable stripper bars made from Delrin and mounted on a carbon steel mounting plate.
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Page 17: Foreseeable Misuse
The basic controls for the feed nip are an open/close valve and a filter/lubricator/regulator set mounted on the unit. See the Chapter 4: Operation for a discussion on air pressure settings. The drive system uses a number 60 duplex chain synchronously by a sprocket on a flange mounted gearbox. -
Page 18: Noise Considerations
Noise Considerations Maximum continuous Noise Levels for the Feed Roll (5” x 56”), was recorded as follows: - Sound Pressure (A LEQ) = 63.5 db(A), C Peak (C Pk) = 73.9 db(C). Subsequently, there is no requirement to wear hearing protection in the vicinity of the of feed roll machines. Versatile Feed Roll 5”... -
Page 19: Chapter 3: Installation
Inspect for damage during transit and notify the carrier immediately of any damage. • Check the packing list and notify ACS if there are any shortages. The machine weights for the Versatile Feed rolls are as follows: • FRV1-36: 975 lbs (442.3 kg) •... -
Page 20: Lifting Features
Lifting Features To facilitate lifting of the feed roll, each model has tapped holes for eyebolt lugs. These holes are M12 x 1.75, and are located in the corners of the top plate, indicated by the circles and arrows below. BEFORE LIFTING IS ATTEMPTED, ensure that all other bolts and features are properly tightened and mated. - Page 21 Refer to the wiring diagram in the customer information packet included with the feed roll and accompanying equipment. This diagram is part of the documentation shipped with the machine. Only the panel diagram will be appended in this manual. After power is connected, do not make any adjustments to the machine without performing the following operations: TURN POWER OFF and LOCK IT OUT per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag- out of Energy Sources).
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Page 22: Accessing The Rollers
Accessing the Rollers ROLLER ACCESS • If machine is running, press Stop button and wait for rollers to stop rotating. • Unscrew the six bolts that secure the cover plate. • Removal of the cover plate allows access to the translating roll as well as the stripper assembly. -
Page 23: Priming/Adjusting The Stripper Bars
Priming/Adjusting the Stripper Bars • DO NOT ADJUST STRIPPER BLADES IF THE FEED ROLL IS IN MOTION. ONLY ADJUST WHEN THE MACHINE IS IN THE OFF POSITION. The rolls should always be fully closed while adjustment is done. • To ensure maximum stripper capability, a malleable Delrin material is used. 1. -
Page 24: Initial Start-Up
Initial Start-up CHECK FOR MECHANICAL INTERFERENCES • TURN POWER OFF and LOCK IT OUT per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources). CHECK ROTATION OF MOTORS • With the cover plates in place and the drive set to FORWARD, jog the drive motor by pushing start and observing the rollers. -
Page 25: Chapter 4: Operation
Chapter 4: Operation Start-up PULSE-STARTING THE MOTOR • If the motor is turning in the proper direction, pulse-start the motor, regardless of desired speed. • Pulse-start the motor by providing full current (60Hz) to the motor through the VFD. Allow the motor to run and full speed before adjusting the VFD for the desired feed rate. -
Page 26: Adjusting The Gap Size
The rate the air cylinders open and close can be adjusted by the two (2) flow control valves attached to the cylinders. Control the speed the cylinder moves by adjusting the flow control valve on the exhausting side of the cylinder. To control the speed of the nip closing, adjust the control on the rod end (exhausting end) of the cylinder. -
Page 27: Shut-Down
Shut-down • To shut down, stop feeding the material into the feed roll, and allow the machine to run long enough to clear all material from the discharge chute and roller chamber. • Engage the stop on the electrical cabinet. This shuts off the drive motor. •... -
Page 28: Chapter 5: Maintenance
Chapter 5: Maintenance General Maintenance Notes Before ANY maintenance is attempted, ensure the following has been done: • TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag out of Energy Sources). • If it is not possible to lock out the power, have an electrician remove the fuses. •... -
Page 29: Replacing Stripper Bar
Replacing Stripper Bar • Because of the wear nature of the Delrin stripper bars, they will need to be replaced periodically. In order to do that, the feed roll must be accessed from the exit plate. 1. Remove the four (4) M10 bolts from the Delrin bar. 2. - Page 30 3. Remover feed nip top cover plate (This may require removal of the inlet chute). 4. Loosen the chain tensioner to slacken the chain and remove the roll's chain sprocket. Moveable Roll Sprocket Fixed Roll Sprocket Chain Tensioner Drive Put a wood board or stack of cardboard between the rolls and install a strap around both rolls to support them while the end plate is removed.
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Page 31: Preventative Maintenance Schedule
8. Support the roll that will remain in the nip with blocking under it and reposition the strap around the roll to be removed. 9. Slide the roll horizontally out of the nip until it clears the back wall and then lift it clear of the nip. -
Page 32: Chapter 6: Troubleshooting
Chapter 6: Troubleshooting Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components. All normal trouble-shooting must be accomplished with the power off, circuit breakers turned off, and with the machine tagged as out of service. - Page 33 Problem Possible Cause Possible Remedy Overfeeding Reduce feed rate Wrapping of material Strippers are worn down; either readjust or replace. Insufficient tension on chain drive, Check chain tension and adjust as Stalling slippage and burning required Installation fault, motor is running in Check the direction of the drive reverse direction sprocket and reset electrical...
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Page 34: Chapter 7: Appendix
Chapter 7: Appendix Customer Satisfaction Warranty Program The terms and conditions of the warranty set forth are for one (1) year from the original date of purchase by the original purchaser. The manufacturer warrants to the original purchaser the product and/or goods to which this disclaimer is attached, and manufactured by us, to be free from defects in material and workmanship under normal use and service. - Page 35 Refer to this manual for assistance in installing and maintaining a highly efficient machine. Questions regarding areas that are not covered in the manual should be referred to the service department at 262-641-3950. Versatile Feed Roll 5” Dia CI0183670000 • 07-18-2019...
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Page 37: Technical Specifications
Technical Specifications Versatile Feed Roll 5” Dia CI0183670000 • 07-18-2019... - Page 38 Versatile Feed Roll 5” Dia CI0183670000 • 07-18-2019...
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Page 43: Parts List And Drawings
Parts List and Drawings *NOTE THAT THE BELOW LIST WILL CHANGE PER EXACT PRODUCT; THIS LIST PERTAINS TO FRV5-56. Versatile Feed Roll 5” Dia CI0183670000 • 07-18-2019... - Page 44 (Sheet 1 of 2) Versatile Feed Roll 5” Dia CI0183670000 • 07-18-2019...
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Page 46: Pneumatic Circuit Diagram
Pneumatic Circuit Diagram Versatile Feed Roll 5” Dia CI0183670000 • 07-18-2019... -
Page 47: Spare Parts List
Spare Parts List FRVX-XX Recommended Spare Parts Model FRV1-XX FRV5-XX Part # ITEM Stripper Blade CI0183410000 Idler Bushing CI0183500000 Idler Sprocket CI0183510000 Tensioner CI0183520000 Gear Reducer CI0183530000 1.50” Bore Taper Bushing CI0183180000 1.25” Bore Taper Bushing CI0183190000 Roller Double Sprocket CI0183200000 When ordering spare parts, please have the model and serial number on hand. -
Page 48: Technical Assistance
Technical Assistance PARTS SUPPORT ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service. The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency.
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