Operating Manual · 6 Correct Use of a CyClean System Meech CyClean web cleaning systems should...
Transcript of Operating Manual · 6 Correct Use of a CyClean System Meech CyClean web cleaning systems should...
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Operating Manual
CyClean™Non-Contact Web Cleaning
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CONTENTS
CYCLEAN SYSTEM OVERVIEW 5
Model and Function 5
Double Sided Cleaning 6
Correct Use of a CyClean System 6
How CyClean Works 6
UNPACKING THE SYSTEM 6
SUGGESTED ORDER OF INSTALLATION 7
SYSTEM INSTALLATION - MECHANICAL/ELECTRICAL 7
Positioning of the System 7
Required Space and Mounting Holes 7
Web Direction and Tension 8
Head Orientation/Opening Options 8
Standard Web Gap and Adjustment 9
Connecting the Active Ionisation Equipment 10
Connecting the Remote On/Off Signal from the Line 12
SYSTEM INSTALLATION - PNEUMATIC 13
Compressed Air Requirement 13
Compressed Air Connections 13
Setting the Required Air Pressure 14
Adjustment of Head Opening & Closing Speed/Force 14
Compressed Air Circuit 15
SYSTEM INSTALLATION – VACUUM SYSTEM 15
SYSTEM INSTALLATION – DUCTING 15
OPERATING THE SYSTEM 16
Before Use 16
System Setup 16
MAINTENANCE AND INSPECTION 17
Inspection 17 Maintenance – Ionisation Equipment 18
Fault Finding – Ionisation Equipment 18
Maintenance – Vacuum System 18
SPARE PARTS 19
TROUBLESHOOTING 20
DRAWING PACK 21
Ducting 21 CyClean Head – Manual Opening 24
CyClean Head – Pneumatic Opening 29
Pneumatic Control Box Wiring Diagram 41
Declaration of Conformity 42
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CyClean™ System Overview
Models and Function
The Meech CyClean has been designed in response to increased demand for a compact, high performance, non-contact web cleaning system.
Through the application of advanced computational fluid dynamics, Meech has optimised the cleaning efficiency of CyClean to remove and extract contamination as small as 0.5 micron.
The Meech CyClean provides the following user advantages:
� Excellent contamination removal – removing particles as small as 0.5 micron.
� Non-contact cleaning – suitable for a wide range of substrates.
� Compact design - easier to install in cramped areas.
� Continuous cleaning – no need to stop the web.
� Static control – we will be contamination and static free on exit.
Double Sided CleaningCyClean is available as a double sided web cleaning system; single sided variants are not available.
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Correct Use of a CyClean SystemMeech CyClean web cleaning systems should only be used in installations for which they are designed.
If the CyClean is used in any other way than instructed in this manual, it will be considered as improper use.
How CyClean WorksThe excellent cleaning performance of CyClean is achieved from the combination of the following processes.
� The web passes through a cloud of ionisation on entry to the CyClean head, which neutralises any static charges.
� The web is then subject to a force of turbulent air created by the blowing and vacuum airflows within the head unit.
� High frequency micro-movements of the web are created by the turbulent air.
� The combination of the high frequency micro-movements and turbulent air shatters the web boundary air layer, releasing the contamination into the vacuum airflows.
� As the web exits the CyClean head, it passes through a second cloud of ionisation to prevent re-contamination of the web.
Unpacking the System
CAUTION
Observe correct manual handling procedures when removing the system from the packaging. It is likely that the system will exceed the recommended manual handling limit.
The CyClean will be delivered in a heavy duty wooden packing crate.
On receipt of the system, check the packaging for signs of shipping damage. If found, any damage should immediately be reported to the shipping company, the supplier of the system and Meech directly.
Inside the packing crate check the system for signs of damage. If found, any damage should immediately be reported to the supplier of the system and Meech directly.
Before installation of the system, it is recommended that you clean it to remove any potential packing contamination.
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Suggested Order of Installation
For ease of installation, it is recommended that the system components be installed in the following order:
1. Position and mount the head unit (the web must enter the head unit so that it reaches the aerodynamic flap before the blowing air slot).
2. Position and mount the Air Handling Unit (in free air to avoid overheating and considering the available ducting lengths).
3. Position and mount the control box (note the distance to the head and AHU and check the required cable lengths are available).
4. Make all the electrical connections.
5. Make all compressed air connections (if required).
6. Connect all ducting.
System Installation - Mechanical/Electrical
IMPORTANT
When installing the CyClean system, it should be positioned so that the web passes straight through the system.
IMPORTANT
Installation of the CyClean system should only be completed by those with suitable qualifications.
Positioning of the System The CyClean system should be installed in the position that was recommended by your Meech contact. The exact installation location will vary depending on the machine and application requirements.
In general, the CyClean system should be installed as close to the critical process as possible to minimise the potential of re-contaminating the web via airborne contamination.
Required Space and Mounting HolesPlease view the drawing section at the end of this manual for GA drawings and mounting hole positions.
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Web Direction and Tension
The CyClean must be mounted with the web passing through the unit so that it reaches the aerodynamic flap before the blowing air slot.
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1
2
2
3
3
4
4
A A
B B
C C
D D
Web
Direction
Web
Direction
IMPORTANT
The web must be kept under tension whilst the unit is running.
Head Orientation/Opening Options The CyClean head can be installed in any orientation without jeopardising cleaning performance. The CyClean head will be supplied to open/close with one of the two following options.
ManualThis opening method is standard for systems suitable for a maximum web width of up to 600mm.
This option should only be used for heads that are installed on a horizontal web. The top half of the head opens upwards by manual operation.
1
1
2
2
3
3
4
4
A A
B B
C C
D D
Manual
Opening
PneumaticThis opening method is standard for systems suitable for a web width range of 601mm to 2,000mm. Systems for narrower web widths can be upgraded to pneumatic opening. This option can be installed so that the head unit opens at any angle. The moving half of the head unit can be controlled locally or remotely to allow full line integration.
1
1
2
2
3
3
4
4
A A
B B
C C
D D
Fixed Half
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Standard Web Gap and Adjustment The web gap is the total distance between the two halves of the CyClean head that the web passes through.
Manual OpeningThe web gap is fixed at 8mm and is not adjustable.
Pneumatic OpeningThe web gap is 8mm as standard. It can easily be adjusted by changing the cones and cups located in each corner of the head unit.
The cone and cup range available and the web gap created by each is shown in the following table.
Black + Black = 8mm
Black
Blue
m
m
m
+
+
Blue
Blue
= 9mm
= 10mm
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Connecting the Active Ionisation Equipment The CyClean system is supplied with the following active ionisation equipment:
� Qty 4 x Meech Model A914 Ionising Bars that are installed in the CyClean head unit.
� Qty 1 x Meech Model A905 Ionising Power Supply for systems to suit web widths up to 1,000mm, or, qty 2 for systems to suit web widths of 1,001mm or greater.
Connecting the Active Ionisation Equipment Before making any connections ensure the unit is disconnected from the mains.
The Meech Model A905 ionising power supply has 4 ionising appliance connection ports (2 on each side). Remove the lid of the 905 by unscrewing the three retaining screws, select the required number of ports, one per ionising bar, and remove the necessary grommets from the ports.
Connect the ionising bars by removing the lock washer and nut from the swivel connector of the appliance.
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Push the connector through a port in the power supply adjacent to the high voltage terminal.
Then refit both the lock washer and nut to the ionising bar. Ensure that the nut is fully tightened.
Connect the cable eyelet of the ionising bar to the high voltage stud of the 905 using the screw provided. Ensure that the nut of the ionising bar connector is fully tightened.
2mtr mains lead and IEC plug are supplied for connection to the 905. Insert the IEC plug into the IEC socket of the 905 ensuring the illuminated ON/OFF rocker switch is in the OFF position.
Connect the free end of the mains cable to the mains supply.
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IMPORTANT
For safety reasons this equipment must be grounded / earthed either via the mains plug or by direct connection to ground / earth.
Switch on the ionising system via the illuminated ON / OFF rocker switch of the 905.
In normal operation the ON / OFF switch will be illuminated red and the High Voltage indicator will be illuminated green.
Connecting the Remote On/Off Signal From the Line The following applies if your system has pneumatic opening and closing.
Connect a normally open (NO) signal from the line in the CyClean control box as shown in the image below and consult the wiring diagram in this manual.
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System Installation - Pneumatic
The following applies if your system has pneumatic opening and closing.
IMPORTANT
Installation of the CyClean system should only be completed by those with suitable qualifications.
Compressed Air RequirementThe CyClean system requires a compressed air supply to open and close the head unit.
The compressed air supply should meet the following specification:
� 3-7 bar (43-100psi)
� Clean and dry compressed air
Compressed Air Connections - Control BoxThe main incoming compressed air supply should be connected to the 4mm compressed air push fit fitting on the CyClean control box labelled Air In 1.
The compressed air hoses (blue and black) should be connected from the CyClean unit to the 4mm compressed air push fittings labelled Port 2 and Port 3. The blue hose connects to port 2, the black hose connects to Port 3.
Compressed Air Connections - CylindersThe system is supplied with a pneumatic hose loom for connection of the cylinders and a 5mtr length of pneumatic hose for connection of the loom to the control box.
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Setting the Required Air PressureThere is a pressure relief regulator valve inside the CyClean control box. Adjusting this valve will change the air pressure that will be fed to the cylinders mounted as part of the CyClean head.
This valve will have been set at Meech before your system was supplied.
CAUTION
If you need to adjust the pressure relief valve, make sure that it is not adjusted to provide maximum pressure. If too high a pressure is used, it may result in damage to your system.
Adjustment of Head Opening and Closing Speed/ForceThe speed/force at which the CyClean head opens and closes can be independently adjusted. This will be adjusted by Meech before your system is supplied so that:
� Open = medium to fast operation
� Close = slow speed
The speed can be adjusted using the valves on each of the cylinders.
IMPORTANT
When making any adjustment it is very important that all 4 cylinders are adjusted at the same time to the same setting. If this does not happen it can damage your system.
CAUTION
It is recommended that the closing speed/force of the head is minimal, as this is a pinch point that could cause injury.
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Compressed Air CircuitPlease view the drawing section at the end of this manual for a circuit diagram.
System Installation – Vacuum System Systems for up to a web width of 1,400mm are supplied as standard with an Air Handling Unit (AHU).
Systems for a web width of 1,401mm or greater are supplied with an AHU and Secondary AHU.
Consult the AHU manual for full installation and operation instructions.
System Installation – Ducting Meech offers 3 standard ducting kits that are detailed below. Each kit allows the CyClean head to be 5mtrs from the AHU.
There is a drawing of each kit in the drawings section at the end of this manual.
� Manual Opening
� Pneumatic Opening up to 600mm web width
� Pneumatic Opening greater than 601mm web width
When installing ducting, it is important to make sure that the length of ducting for the blowing and vacuum airflows is equal in length and that the same diameters are used.
Ducting should be cut to length to keep duct runs as short as possible.
Any bends in the ducting should be smooth and tight bends should be avoided. Once installed, check to make sure all duct connections are tight and that the duct is not damaged in any way.
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Operating the System
Before UseBefore using the CyClean system it is important that you have read and fully understand this manual.
IMPORTANT
Testing of the system is recommended before it is used for full production.
System SetupThe airflows of the CyClean non-contact web cleaning system should be adjusted to achieve optimum cleaning results.
The best cleaning results will be achieved, when the system is set to have a positive airflow into the CyClean head, on both the web entry and exit sides (minimising the risk of any recontamination).
The positive airflow into either side of the CyClean head is adjusted by bleeding off a volume of the blowing (positive) airflow to create an airflow bias in favour of vacuum. Consult the AHU manual for full instructions of how to balance the airflows.
The CyClean is now ready to use.
It is recommended that you monitor the system when it is first tested. If any problems are highlighted, please stop using the CyClean system and contact Meech International or your local distributor.
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1
2
2
3
3
4
4
A A
B B
C C
D D
Positive Airflow in
Positive Airflow in
Positive Airflow in
Positive Airflow in
Web
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Maintenance and Inspection
IMPORTANT
Always make safe the electrical and compressed air supplies before undertaking any maintenance work on the CyClean system.
IMPORTANT
Maintenance should only be completed on the CyClean system by those with suitable qualifications.
InspectionThe system will perform without serious deterioration, giving many years of service, providing the following visual inspection is made weekly.
Head UnitCheck for any external damage and the alignment of the head unit. Wipe over to remove any contamination present. Inspect that the cables from the ionising bars to the ionising power supplies and that those from the servo drives to the head unit are secure, free from damage and that they do not have any tight bends in them.
Vacuum SystemListen for any sounds that are not ‘normal’ i.e, grinding or scraping.
FiltrationCheck that the filter warning lights on the AHU are not lit when running. Check for any external damage to the filter media, i.e. rips. Check to make sure the filter bag is not blocked.
DuctingVisually inspect the ductwork look for any lose sections or holes. Check to make sure the ducting is not blocked.
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Maintenance – Ionisation Equipment
IMPORTANT
Always make safe the electrical and compressed air supplies before undertaking any maintenance work on the CyClean system.
IMPORTANT
Maintenance should only be completed on the CyClean system by those with suitable qualifications.
Ionisers require periodic cleaning. During normal operation, dirt will build-up on the emitter pins and upon the body of the ioniser. This will cause a reduction in performance.
Typically, weekly cleaning is sufficient. However, equipment used in some heavy contamination areas, such as gravure printing or where plastic fumes are present, may require daily cleaning. Equally, in a Class 100 area, cleaning may only be required on a monthly basis.
Advanced systems with performance monitoring, e.g 977cm and 904cm, will alert the operator to the need to clean the equipment before performance drops to an unacceptable level.
Before cleaning, ensure that the equipment is switched off.
Emitter pins can be cleaned very effectively with a brush. A dry toothbrush is ideal.
Ionising bars will need periodic wiping to clean grey deposits from the surface of the bar. A cloth moistened with a small amount of IPA or methylated spirits is recommended.
Should you have any additional questions regarding the maintenance of Meech equipment please contact Meech International directly or your local Meech distributor.
Fault Finding – Ionisation EquipmentFault finding guides for the Meech Model A905 ionising power supply and A914 AC ionising bars can be downloaded directly from the Meech website at www.meech.com
For further fault finding guidance please contact Meech International directly or your local Meech distributor.
Maintenance – Vacuum System
Consult the AHU manual for full installation and operation instructions
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Spare Parts
It is recommended that only Meech spare parts are used in your CyClean system. The use of non Meech parts may invalidate your warranty.
For details of spare parts, please contact Meech or your nearest Meech distributor.
Please quote the serial number of your CyClean system when ordering spare parts.
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Troubleshooting
Problem Cause Solution
No blolwing or vacuum pressure. Loose duct connection. Check all ducting connections are secure and that there is no damage.
Duct layout. Check the ducting layout to ensure there are no tight bends.
AHU fault. Check power is connected to AHU and that line interlocks are good (if used). Consult AHU manual for full operating instructions.
Removable panel of ducting manifold is not connected fully
Visually check the duct manifold and feel for air flow. Re-fit removable panel.
No ionisation. Various. See the Meech fault finding guide for the Meech Model A905 ionising power supply and A914 AC ionising bars, which can be downloaded directly from the Meech website at www.meech.com
If the problem being experienced is not listed above, or the remedy is unclear please contact Meech International directly or your local Meech distributor.
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Technical Drawings Ducting Configuration - Manual Opening
1 1
2 2
3 3
4 4
AA
BB
CC
DD
6x 1
.66m
tr L
eng
th
Ø40
mm
Fle
xib
le D
ucting
2x 3
.33m
tr L
en
gth
Ø1
50m
m F
lexib
le D
ucting
Ma
nual O
pen
ing
CyC
lean
He
ad
Un
it
CyC
lean D
uct M
anifold
Sin
gle
End fee
d
Air H
andling U
nit
Positiv
e P
ressure
Air
flow
Va
cuum
Airflow
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Ducting Configuration - Pneumatic Opening Single End Feed1 1
2 2
3 3
4 4
AA
BB
CC
DD
6x 1
.66m
tr L
eng
th
Ø40
mm
Fle
xib
le D
ucting
2x 3
.33m
tr L
en
gth
Ø1
50m
m F
lexib
le D
ucting
CyC
lean D
uct M
anifold
Sin
gle
End fee
d
Air H
andling U
nit
Positiv
e P
ressure
Air
flow
Va
cuum
Airflow
Pn
eum
atic O
penin
g
CyC
lean H
ead U
nit
Sin
gle
End
Fe
ed
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Ducting Configuration - Pneumatic Opening Double End Feed1 1
2 2
3 3
4 4
AA
BB
CC
DD
12
x 1
.66
mtr
Le
ng
th
Ø4
0m
m F
lexib
le D
uctin
g
2x 3
.33
mtr
Le
ng
th
Ø1
50
mm
Fle
xib
le D
uctin
g
CyC
lea
n D
uct
Ma
nifo
ld
Do
ub
le E
nd
fe
ed
Air H
an
dlin
g U
nit
Pn
eu
ma
tic O
pe
nin
g
CyC
lea
n H
ea
d U
nit
Do
ub
le E
nd
Fe
ed
Po
sitiv
e P
ressu
re A
irflo
w
Va
cu
um
Air
flo
w
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MA
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RIA
L:
DIM
EN
SIO
NS
MM
[IN
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]
DO
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T S
CA
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TIT
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:
DR
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No
:
25
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:
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:
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:
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[IN
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:
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L:
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:
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No
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L:
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:
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L:
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[IN
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:
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L:
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[IN
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No
:
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L:
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EN
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MM
[IN
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:
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L:
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EN
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[IN
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MM
[IN
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41
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Meech Static Eliminators Ltd Registered in England No. 1525004 VAT No. GB236 1298 65
Offices in: • UK • USA • Belgium • Hungary • China
Meech International
2 Network Point
Range Road, Witney
OX29 0YN, UK
Tel: +44 (0) 1993 706700
Fax: +44 (0) 1993 776977
email: [email protected]
web:www.meech.com
Declaration of Conformity
Equipment
CyClean™ Non Contact Web Cleaning System
Applicable Harmonised standards
LVD. EN 61010-1:2010
EMCD. EN 61000-6-4:2001
EN 61000-6-2:1999
EN 292-1
EN 292-2
EN 294
EN 50081-2
EN 61024-1
EN 60204-1
EN 954
EN 62061
EN 418
EC Council Directives Low Voltage Directive
2006/95/EC (Technical File)
Electromagnetic Compatibility Directive
2004/108/EC (Technical File)
Machinery Directive 89/392 as amended by the EC Directives 91/368 and
93/44 and 93/68.
On behalf of the above named company, I declare that, on the date the equipment
accompanied by this declaration is placed on the market, the equipment conforms with all
technical and regulatory requirements of the above listed directives.
………………….
Ian Walker, Engineering Manager.
EN 61000-3-2:2006/A2:2009EN 61000-3-3:2008EN 61000-6-1:2007EN 61000-6-3:2007/A1:2011EN 60950-1:2006/A12:2012EN 60335-1:2012EN50581:2012
44www.meech.comwww.meech.com
www.meech.com© Meech Static Eliminators Ltd 2012 www.meech.com
Meech International 2 Network PointRange Road, WitneyOX29 0YN, UK
Tel: +44 (0)1993 706700Fax: +44 (0)1993 776977email: [email protected]
Meech CE2151 FótSzéchenyi út. 46Hungary
Tel: +36 27535075Fax: +36 27535076email: [email protected]
Meech Static Eliminators USA Inc 2915 Newpark DriveNorton, OH 44203USA
Tel: +1 330 564 2000 / 1 800 232 4210Fax: +1 330 564 2005email: [email protected]
Meech Static Eliminators (Shanghai) Co. Ltd 7G, 7F, LP Tower #25 Xiangfeng Road 201103 Shanghai China
Tel: +86 400 820 0102 Fax: +86 21 6405 7736email: [email protected]
Meech Elektrostatik SAKaiserbaracke 66B-4780 St.VithBelgium
Tel: +32 8086 2983Fax: +32 8086 2821email: [email protected]
Meech ShavotechShavo House, Survey No.21A / 10 B, Plot No.394 South Main Road, Koregaon Park, PUNE 411 001 India
Tel: 020-26069641/ 26069642, Fax: No.020-26069644 e-mail: [email protected]