1、 TOPRA GD 1224/1228 Dwell Unit 1Dwell Unit Operation Introduction1 OverviewThis part is mainly to introduce the dwell unit functions and integrants. Dwell unit introduction：The bottom vacuum suction makes the paperboard transfer more precise and stable; The paperboard is dried enough before it comes
2、 into the next unit. Dust from slotter or die-cutter unit can be prevented from coming into printer unit. Also it offers space for adding other drying devices. The dwell unit is mainly composed of the followings: side frames, steel support, vacuum chamber assemblies, lifter assembly, hot air system,
3、 pneumatic assemblies, oil tank and oil returning circuit, lubricating system, driving gear, motor, electric cabinet and electrical control components. The dwell unit itself is a complete and independent unit. Main functions for vacuum chamber assemblies and fan assembly: motors are installed on the
4、 support of electric cabinet by the brackets. The motors connected with fans. As they run, the fans will run as well and then generate the suction power. The air was sucked downwards through the gap formed between long square hole of the guide plate and feeding wheels. The printed paperboards are su
5、cked tightly to the wheels for enough air speed and air flow，at the same time the paperboards are transferred downstream by the feeding wheels. Lifter main function: the running motor activates the lifter moving up and down, through that it can control the rise and down of vacuum chamber, so it cont
6、rols the feeding height finally. Hot air system main function：The printed paperboards are dried timely through the fan installed on the bracket. So the patterns on the printed paperboards will not be destroyed while passing the following units. Infrared drying system main function: the printed paper
7、board dried as it through the infrared system. So the patterns on the printed paperboards will not be destroyed while passing the following units. The driving gears are hardened, ground and HRC 55. The upper oil tank is made from aluminum plate and the lower oil tank is made from casting aluminum al
8、loy .The oil-returning-device is used to connect each unit lower oil tank when the units are locked， so the lubricant in each unit can be kept in the same level. The oil gauge can be used to watch the lubricant height in the lower oil tank .TOPRA GD 1224/1228 Dwell Unit 22 Lubricating System Introdu
9、ctionLower oil tank and oil circulating device Lubricating system main function：The filtrated lubricant is extracted out of the oil tank through oil pump，and the driving gear is lubricated through divider and small copper pipe. We can know if the lubricating system works properly through oil watchin
10、g system.Oil observing windowTOPRA GD 1224/1228 Dwell Unit 33 Mechanical parts position and description1 Electric cabinet 2 Fan assembly3 Hot air fan 4 Air chamber5 vacuum chamber 6 Infrared drying system7 Lifter assembly 8 Oil tank assembly9 Gear assembly 10 Electric control box assembly11 Digital
11、displayPart 11 is usually fixed on the last unit. TOPRA GD 1224/1228 Dwell Unit 41. air duct 2.control panel 3. oil observerTOPRA GD 1224/1228 Dwell Unit 54 Function IntroductionWe are going to introduce control panel function, including all buttons.4-1 Control Panel IntroductionControl panel4-2 Con
12、trol Panel Button Function Introduction 4-2-1 Emergency Stop Button Only used in emergency situation. Press this button, all machine action and automatic control stop. Turn the button clockwise, and the machine can be started again.TOPRA GD 1224/1228 Dwell Unit 64-2-2 Power supply indicatorTurn on t
13、he main switch，and the indicator is on Turn off the main switch，and the indicator is off 4-2-3 Unit interlock （1） （2） This is a 2 position switch. Used to control interlock close and opening When the button is turned to “I”, the interlock is opened. Opening and close for units can be processed. (sho
14、wn as pic 1) When the button is turned to “O”, the interlock is closed. Opening and close for units can not be processed. (shown as pic 2)Note: The switch is not allowed to use when the machine is in running, and the switch must be turned to theposition like picture (2)TOPRA GD 1224/1228 Dwell Unit
15、74-2-4 Unit movement（1） （2）Unit moving control button This is composed of 3 button switches to control the units moving direction. It is specially designed to avoid being injured while working. To make units move left，push right button with right hand and left button left hand, shown as picture one.
16、Note: It is invalid to push just one button. To make units move right， push right button with right hand and left button left hand, shown as picture one.Note: It is invalid to push just one button. When the units are closed，first you must turn unit interlock button left，shown as picture 1.You can no
17、t control unit movement until open interlock. When close units you must turn interlock button to right after the units meet，shown as picture (2)and the units will be closed. No matter the units move to right or left, the annunciator above the machine will flash and buzz to assure security. 4-2-5 She
18、et feeding height controlTOPRA GD 1224/1228 Dwell Unit 8 The top button is a indicator with lamp. Only the lamp is on, it can adjust the sheet feeding height. The bottom two buttons are used to rise or reduce the height. It cant be effective at below condition (lamp is off, no action press “-” or “+
19、”). At the below condition, the vacuum chamber moves downwards and the sheet feeding height will be lower. (lamp is on, and press “-” button). At the below condition, the vacuum chamber moves upwards and the sheet feeding height will be higher. (lamp is on, and press “+” button).Note: The sheet feed
20、ing height has been adjusted well prior to out of plant. So it usually neednt adjust and the lamp is off.TOPRA GD 1224/1228 Dwell Unit 95 Unit OperationThe section introduces mainly dwell unit adjustment and operation as well as some notes. Before operating the dwell unit, please be familiar with th
21、e following information. And also learn the electrical operation and the control panel.1. Linear rail 2. Vacuum chamber 3. Spiral lifer Vacuum chamber adjustmentAs above picture show, there are 4 sets linear rails at the beam of vacuum chamber (two sets at each side).Thy are fixed on the side frames
22、. The motor activates the lifter to have the vacuum chamber move up and down along the linear rail. Through that, it can adjust the sheet feeding height. Prior to shipping out of plant, the height has been adjusted well, so it neednt adjust once again. Two sets air cylinders control two fan doors on
23、e by one, because different sheet size needs different suction air width, which is adjusted through the open/close of fan door.TOPRA GD 1224/1228 Dwell Unit 10 Driving Belt Tension AdjustmentThe structure of synchronous tension belt is shown in the right. When the tension is not enough, it must be a
24、djusted as the following steps:1) Open the window cover plate of the paperboard outlet.2) Loosen the two set screws used to fix eccentric gear.3) Turn the hexagon head at the back of the eccentric gear until the belt is tensioned.4) Tighten the two set screws.TOPRA GD 1224/1228 Dwell Unit 116 Machin
25、e Cleaning and LubricatingAfter being used for a period of time, the machine should be regularly maintained6-1 Cleaning It is forbidden to apply acidic or alkaline substances (thinner, and rubber liquid) to clean the machine with paint; it is forbidden to clean the machine with hard steel brush, so
26、as to protect the original color and luster of the paint The appearance of the machine should be cleaned at each work shift, so as to ensure the operation surface clean. A large-scale cleaning shall be carried out for the entire machine each month, such as each roll of the machine, dust and contamin
27、ated oil on the axes, so as to ensure the clean of the appearance of the machine.6-2 Lubricating6-2-1 Dwell Unit Gear Box Lubricating： The forbidden luboil is applied in the gear box. The applied luboil should be #30 in the southern areas, and certain amount of lower number oil in the cold areas. Th
28、e luboil should be changed totally and the oil tank shouldbe cleaned completely after three months from the first date of machine operation. The filter should be cleaned at the same time. See the right picture. Lift the cover and take it down. This design is special for filter cleaning. The filtered
29、 lubricating oil inside the gear box is pumped to the distributing pipe. And then the lubricating oil will flow down onto the gear for lubricating. Lubricating oil amount should be between the upper and lower red lines, to be more exact, 15kg or so. When the machine runs and you can see the oil flow
30、ing through the oil observation window. It means that the lubricating system is running well.Gear box lubricant system diagramTOPRA GD 1224/1228 Dwell Unit 12Oil observing windowlower oil tank/ oil returning device/ oil gaugeGear box lubricant system diagram1 filter 2 purple copper pipe 3 gear pump
31、4 purple copper pipe5 distributor 6 oil dropping pipe 7 circulating pipeTOPRA GD 1224/1228 Dwell Unit 13Note: 1 The reducer should be maintained according to the manufacturer manual introduction. 2 The machine should be checked completely after one month running and change the consumable parts which
32、 are worn(for example, belt and air pipe)7 TroubleshootingTrouble Probable Cause Corrective ActionFeeding rolls are not parallelAdjusting the parallelismImproper feedingDriving synchronous belt too loosenTighten the beltPoor drying result Ventilator is out of work Check the circuit and ventilator8 C
33、onsumable parts list S.N Part Number Description Qty. Unit price Remark1 6334.02000.050Arc synchronous belt19 Dwell Unit Touch Screen InstructionTOPRA GD 1224/1228 Dwell Unit 149-1 OverviewThe standard dwell unit just has one set, but it can equipped with the amount according to the customers requir
34、ements. Its CPU226 as DP sub-station connected with whole PROFIBUS network. Its control panel adopts SIEMENS TP177A 6” touch screen, which connected with the S7-200PLC of printer unit by MPI. The dwell unit has two drying method: one is drying by infrared ray heater, the other is by hot air heater.9
35、-2 Control Panel Introduction1) Touch screenDwell unit equipped with Siemens TP177A 6touch screen, connected with S7-200 PLC by MPI method. It can collect data and machine running station in real time; it can set the data partly and adjust automatically; it also can do parameters calibration and but
36、ton function test. Its easy to operate and a good auxiliary monitor equipment for the computer main control panel (MP277 10”). If any malfunction of the main control panel, the operation can be completed by the touch screen.2) Anvil caliper button Press this button to enter into below screen, and th
37、e button indicator will be on. This screen is also the machine on screen.The screen for hot air heater:TOPRA GD 1224/1228 Dwell Unit 15The screen for infrared ray heater:It can adjust the anvil caliper through pressing button 4 “+” or button 3 “-”. If its related motor has no TOPRA GD 1224/1228 Dwel
38、l Unit 16function and its value doesnt change, please press button “Alarm” and button “logic inspect” to check the reason.Press “logic inspect” to enter into below screen:Check the conditions that will not have the anvil motor running.Prior to the start of the infrared ray heater, first it need set
39、the control method (one is by hand, the other is auto) for the temperature adjustment. Press “temperature adjust with infrared to enter into below screen:Press “hand” to enter into below screen:TOPRA GD 1224/1228 Dwell Unit 17Key in the No. from min. 0 to max. 100 in each box, which are used for the
40、 three heaters control. Then press “heater control” button on the main touch screen” to enter into “desiccate control” screen. At last, press “heater on” to enable the infrared heater. If you want stop the heater enable, just need press “heater off” buttonPress button to return “control” screen.Pres
41、s “auto” button, and then press “heater control” button on the main touch screen to enter into “desiccate control” screen. The following is press “heater on” button to enable the infrared ray heater, which will dry the ink as the set temperature. Press “heater off” button to stop it.9-3 Others funct
42、ion introductionTOPRA GD 1224/1228 Dwell Unit 18Press button on the machine on screen, it will enter into “function” screen:Press “modify” button to enter into below “calibration” screen:Adjust the vacuum chamber to the same level with the line on the side frame, and then enter into the “calibration
43、” screen. Input “0” to the anvil box and the press “enter”, the actual value will shown to be “0”. TOPRA GD 1224/1228 Dwell Unit 19That means the anvil zero point calibration completed.Press button, the screen language will be changed into English; press button, the screen language will be changed i
44、nto Chinese.Press button, it will enter into “Note” screen:During pushbutton test, it must set this unit PLC at “stop” condition in case of any accident or damage to machine. That means this unit CPU226 mode switch should be dial from “run” to “stop”, then the TOPRA GD 1224/1228 Dwell Unit 20pushbut
45、ton can be tested. After this, the screen will enter into below pic.:During pushbutton test, as press any button or turn any knob on the control panel, the corresponding one on the screen will be blacken. That means the connection between PLC and button/knob is good. This is usually used new machine
46、 debugging or machine troubleshooting, through that can check the connection status easily and quickly.Press “lamp test”, it can test whether the lamp on the control panel is connected well or not, and has any damage to it. If all lamps are normal, press this button, they will be on. If need downloa
47、d the screens of the touch screen, press “transfer mode” on this screen.Press “valve test” and then key in the correct user name (df) and password (37728). At the end, press “enter” to get the below “valve test” screen.TOPRA GD 1224/1228 Dwell Unit 21Press this button, the related valve will be acti
48、vated. For example, press “V503”, the Q0.6 of this unit PLC should has output, and the unit locked valve will be activated.3) Decrease “-” button4) Increase “+” button5) Unit lock button:As the knob turn to “I”, the valve has no power supply, and the air cylinder will be closed and the lock the next unit. As turn to “0”, it get the power supply, and then the air cylinder open and disconnecting with the next unit.7) Unit left movement button8) Unit right movement button9) Unit moving enable buttonThe unit can move left only when push 7 and 9 button at the same time.The
