Maxcess TIDLAND D6X User manual

D6X Differential Air Shaft
Installation, Operation and Maintenance
Manual
EN
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TIDLAND WINDING SOLUTIONS

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TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS........................................................................................... 3
RECOMMENDED TOOLS................................................................................................................. 4
GENERAL SHAFT CARE .................................................................................................................. 5
MAINTENANCE SCHEDULE ............................................................................................................ 5
SHAFT CARE..................................................................................................................................... 5
POLYURETHANE BLADDERS ......................................................................................................... 5
FOAM SPRINGS................................................................................................................................ 5
PART IDENTIFICATION.................................................................................................................... 6
TENSION SEGMENT COMPONENTS........................................................................................... 6
CORE STOP TRAY COMPONENTS.............................................................................................. 6
PRESSURE CONTROL VALVE SYSTEM ........................................................................................ 7
HOW IT WORKS................................................................................................................................ 7
INSTALLATION.................................................................................................................................. 9
OPERATION ...................................................................................................................................... 9
TO REPLACE BLADDERS.............................................................................................................. 11
MAINTENANCE............................................................................................................................... 13
CORE STOP TRAY...................................................................................................................... 13
TROUBLESHOOTING..................................................................................................................... 15
SERVICE.......................................................................................................................................... 16

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Important Safety Instructions
When using this product, basic safety precautions should always be followed to reduce the
risk of personal injury. When using this product with any other equipment or machinery, all
safety requirements stipulated by that equipment or machinery manufacturer must be
followed. Compliance with local, state, and federal safety requirements is your responsibility.
Be familiar with the hazards and safety requirements in your work environment and always
work safely.
Read and understand all instructions and shaft design application limits before operation.
Never use this product for a purpose or in a machine it was not specifically designed for. See
Product Safety Data Sheet (PSDS) for more information.
1) Do not exceed the operation loads for this shaft as noted on its PSDS.
2) Follow all warnings and instructions marked on the product and on the PSDS.
3) Do not use fingers or other objects to deflate the shaft; Tidland recommends using the
Tidland Air Release Tool.
4) Inspect the shaft for wear and/or other safety and functional deficiencies before each
use.
5) Wear safety glasses or proper eye protection when operating the air system.
6) Do not remove or otherwise alter any setscrews or fastening devices prior to using this
product.
7) Do not operate this product if any setscrews or fastening devices are missing.
8) Do not lift shaft manually if it is beyond your capacity. Loads over 1/3 your body weight
may be prohibitive. Consult your company safety policy.
9) When lifting a shaft, use proper lifting techniques, keeping back straight and lifting with
the legs.
10)Do not carry or lift this product over wet or slippery surfaces.
11)Use appropriate mechanical lifting devices, such as a hoist or shaft puller, for heavier
shafts. When performing maintenance or repair procedures, do not pressurize the
shaft if journal setscrews are loose or missing.
12)When performing maintenance procedures, do not pressurize the shaft if the journal is
missing.
13)All replacement parts used on this product should be made to original Tidland
specifications. All maintenance and repair procedures performed on this product
should be done to Tidland specifications by qualified personnel.
If shafts with rubber air systems are stored longer than two weeks - store them
completely deflated, away from electric motors, away from direct sunlight or
florescent light, and in temperatures not exceeding 85ºF (29ºC).
When storing shafts with constant air pressure, the rubber air systems are subject
to distortion or cold flow.

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Recommended Tools
1) Clean, dry, non-lubricated air supply: 80-120 psi for proper operation.
2) Tidland Inflation Tool (Part No. 27L128052)
3) Tidland Air Release Tool (Part No. 27L111630)
4) Pincers for removing hose clamps, if installed.
5) Dow Corning Molykote® 55 O-ring grease
6) Low-strength thread locker (Loctite® 222 or equivalent)
7) Thread sealant (Loctite® 545 or equivalent)
For more accessories to help with your winding processes, visit www.maxcessintl.com.

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General Shaft Care
Maintenance Schedule
•During operation shifts, use compressed air to keep shaft free from dust anddebris.
•As needed, remove sticky residue. Use a soft cloth damp with a mild solvent, such as
rubbing alcohol.
Shaft Care
•Clean shaft with a soft cloth.
•Mild solvents may be used sparingly; make sure shaft slot and all parts are wiped
completely dry of solvents before beginning reassembly.
•Apply a lubricant if needed to aid assembly. Avoid grease, dry, or penetrating lubricants
Polyurethane Bladders
To help ensure leak free operation when replacing bladders:
•Measure the length carefully so that bladder will be secured under the element end
clamps.
•Always cut the bladders square across the end; bladders cut at an angle are at risk for
leaks.
•Ensure that the element end clamp screws are tightened to recommended torque
specifications. Use LOCTITE 242 on screw threads when reinstalling.
Foam Springs
•The foam material attached to the tension segment strip is fragile –use care when
handling the strip.
•A torn or broken strip can function, but such damage may result in the loss of tension
segments when the strip is outside of the tray.
•Tape can be used across top side of tension segments as temporary support during
disassembly or assembly.
•Strips with missing tension segments will prevent proper shaft operation. Do not use.

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Part Identification
TENSION SEGMENT COMPONENTS
CORE STOP TRAY COMPONENTS
SOC HD
Capscrew (2)
132582
Bladder
739338
Mushroom Head
Fitting 562024
Mushroom Barb Fitting
w/ O-ring
516618
End Clamp
270022857
Core Stop
Tray Assy
Journal Non-valve end
Journal Valve end
Core Stop Tray Assy.
(Wave Springs)
Empty core stop tray (PN):270042263
Wave springs (PN):270040399
Core Stop
270039080ASM
SOC HD
Capscrew (2)
132582
End Clamp
270022857
Quick Release Valve
(Midget)
270022857
Bladder
739338
Mushroom Head
Fitting 562024 and
Mushroom Barb
Fitting w/ O-ring
516618

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Pressure Control Valve System
Successful operation of the Tidland Differential Shaft series depends upon proper internal air
pressure
Variable pressure is required in order to control the air pressure on the tension segments as the
roll diameter increases. As the roll diameter grows, the required rate of pressure increase will
diminish due to the weight of the roll and friction between the roll and shaft. These parameters
will vary based on your application.
For low-tension winding applications, each of the Differential Shaft models can be equipped with
a pressure control system comprising two bleeder valves. Used with your applied air pressure,
these valves allow the operator to adjust and maintain internal air pressure where the required
internal pressure is very low and the pressure range is very small.
How it Works
As operating air pressure is applied to the shaft, the factory-set inlet valve causes a drop in
pressure as air enters the bladder. The exhaust bleeder valve controls the amount of that
pressure drop. The larger the exhaust opening, the greater the pressure drop, resulting in lower
internal bladder pressure. Reducing the exhaust opening increases the internal air pressure.
If you are unable to achieve optimal tension control by adjusting your applied air pressure, use
the exhaust bleeder valve to improve the resolution of your tension controller.
Before beginning the winding operation, please read and understand the
following.
NOTICE
CAUSES A PRESSURE DROP;
SHOULD NOT REQUIRE ADJUSTMENT
AFFECTS THE INTERNAL AIR PRESSURE;
CONTROL THE PRESSURE DROP BY
ADJUSTING THE OUTLET (EXHAUST
BLEEDER VALVE
AFFECTS THE INTERNAL AIR PRESSURE;
CONTROL THE PRESSURE DROP BY
ADJUSTING THE OUTLET (EXHAUST
BLEEDER VALVE

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As operating air pressure is applied to the shaft, the factory-set inlet valve causes a drop in
pressure as air enters the bladder. The exhaust bleeder valve controls the amount of that
pressure drop. The larger the exhaust opening, the greater the pressure drop, resulting in lower
internal bladder pressure. Reducing the exhaust opening increases the internal air pressure.
•Both valves are factory-set according to customer operating specifications: roll specs
(width, diameter and weight), and web tension (PLI).
•If you are unable to achieve optimal tension control by adjusting your applied air
pressure, use the exhaust bleeder valve to improve the resolution of your tension
controller. For the majority of applications, no adjustment is required for the exhaust
bleeder valve. For higher internal pressure, adjust to a smaller opening in the valve. For
lower internal pressure, adjust to a larger opening. Adjustments are made with a 1/8" hex
key.
•The restrictor valve at the inlet should not require adjustment.
•Do not operate shaft with missing valves.
•A muffler may be installed* on the exhaust bleeder valve outlet to reduce noise. A slight
hiss may be audible: this indicates that the Pressure Control Valve System is functioning,
allowing air to escape from the shaft as designed. The muffler must be removed (12 mm
socket) before attempting to adjust or remove the bleeder valve. (See Bleeder Valve
Maintenance, page 13.)
*Not available on all Differential shaft designs.
•The purpose of this graph is to
illustrate the characteristics of
bleeder valve function. The
tension values displayed are
arbitrary.
•Actual winding tension will differ by
variables such as bladder length,
shaft speed, roll specs (width,
diameter and weight), and core
material.
1) Stop winding operation and shaft rotation.
2) To adjust the internal air pressure, turn the valve in 1/8 turn increments using a 1/8"hex
drive wrench.
•To increase the pressure, turn the valve Clockwise.
•To decrease pressure, turn the valve Counterclockwise.
To clean or replace the valve, see pages 13 and 14.
DO NOT perform Adjustment while shaft is spinning
NOTICE
Exhaust Bleeder ValveFunction
VALVE CLOSED
1/8 TURN OPEN
1/4 TURN OPEN
APPLIED AIR PRESSURE - PSI
WEB TENSION - PLI

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Installation
1) Install shaft as required for your application.
2) Determine how many core stops are required. (2 per core in each tray)
3) Remove excess core stops or move them to the end of the tray. Ensure all core stop
screws are tight to prevent motion while machine is running.
4) Load cores.
Operation
CLAMP
CORE STOP
•Valve locations for the D6X shaft
vary according to customer
specifications.
•The shaft body may be stamped 1 or 2
at eachvalve location to aid with inflation
sequence.
CORE STOP
CORE STOP
TRAY
BLADDER RAISES
CORE STOP TRAY

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Step 1 –Set the Core Stops
Position core stops in each tray so that the core will have one stop on
either side of the core per tray.
Step 2 –Lock Sequence
Use SET SCREW (M4 X 0.7mm) to lock the core stop
in place axially. Torque SET SCREW to 1.5 Nm.
Shaft is ready for operation.
Step 3
Gradually inflate the tension segment bladder to achieve
required tension. Do not exceed 80 psi (5.5 bar). See
Pressure Control System (page 7)
To remove cores, deflate tension segment bladder to drop the core stop tray.
Core stops will remain locked in position in the core stop tray.
SET SCREW

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To Replace Bladders
•Bladder material supplied for replacement may be longer than the required finished
length. Do not cut to length until instructed.
•Use a small amount of LOCTITE 222 on the threads of all screws and tighten to torque
specifications noted in brackets.
Under Tension Segments
1. Remove all end clamps from the journal valve end slot.
(SOC HD CPSCR M5 x0.8x14mm)
2. Push –and pull gently –on each foam spring and
tension segment strip, to remove them from the slot one at a time. Tape may be used
across the top of segments as temporary support.
3. Remove themushroom head fittings from the bladder in the shaft slot.
4. Lift the bladder out of the slot and remove the mushroom barb fitting and O-ring from
the bladder.
5. Clean the shaft slot with rubbing alcohol and
dry thoroughly.
6. Cut square across one end of the new bladder
and install it in the slot, lined up near the edges
of the air fitting holes.
7. On the bladder, mark the location of the center
of the air fitting hole, as shown.
8. Using the Tidland Hole Punch Tool, punch a
hole in one wall only of the bladder. Use a small piece of plastic in the bladder to
prevent punching through both sides.
9. Fold the bladder ends as shown, reinstall the bladder in the shaft slot and seat the air
fitting in the hole.
10.Install the mushroom head fitting, then install the bladder end clamp with one socket
headed capscrew (M5 x0.8x14mm), securing the bladder underneath. [55-60 in·lbs /
6.2-6.8 Nm]
11.Apply a lubricant if needed to aid assembly. Avoid grease, dry, or penetrating
lubricants.
12.Reinstall the tension segment strips with the foam spring into the slot, taking care not
to tear the foam spring. Tape may be used across the top as temporary support. Push
together to eliminate any gap between strips.
13.Trim the bladder by cutting the free end square if the bladder material was longer than
the required finished length.
14.Fold the other end of the bladder as shown.
15.Install the other bladder end clamp with one socket headed capscrew (M5
x0.8x14mm), securing the bladder underneath. [55-60 in·lbs / 6.2-6.8 Nm]
•Note: Test the bladder for air leaks at 80 psi (5.5 bar). Spray soapy water onto bladder end
clamps and air fittings and watch for bubbles. When inflated, the bladder should raise the
tension segments.

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•Bladder material supplied for replacement may be longer than the required finished
length. Do not cut to length until instructed.
•Use a small amount of LOCTITE 222 on the threads of all screws and tighten to torque
specifications noted in brackets.
1) Remove both end clamps from the journal valve end alloy slot (SOC HD CPSCR M5
x0.8x14mm).
2) Slide core stop tray and wave springs out of the shaft.
3) Remove the mushroom head fittings from the
bladder in the shaft slot.
4) Lift the bladder out of the slot and remove the
mushroom barb fitting and O-ring from the
bladder.
5) Clean the shaft slot with rubbing alcohol and dry
thoroughly.
6) Cut square across one end of the new bladder and install it in the
slot, lined up near the edges of the air fitting holes, as shown above.
7) On the bladder, mark the location of the center of the air fitting.
8) Using the Tidland Hole Punch Tool, punch a hole in one wall only of
the bladder and insert the air fitting into the bladder. Use a small
piece of plastic in the bladder to prevent punching through both sides.
9) Insert the mushroom barb fitting into the bladder and install the O-ring.
10)Fold the bladder ends as shown, reinstall the bladder in the shaft slot and seat the air
fitting in the hole.
11)Install the bladder end clamp with one socket headed
capscrew (M5 x0.8x14mm ), securing the bladder
underneath. [55-60 in·lbs / 6.2-6.8 Nm]
WAVE SPRING
CORE STOP
TRAY
Clamp and
SOC CPSR

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12)Apply lubricant as needed. Avoid grease, dry or penetrating lubricants.
13)Slide the core stop tray with the wave spring into the slot.
14)Trim the bladder by cutting the free end square if the bladder material was longer than the
required finished length.
15)Fold the other end of the bladder as shown.
16)Install the bladder end clamp with one socket head capscrews, securing the bladder
underneath. [40 in·lbs / 4.5 Nm]
Note: Test the bladder for air leaks at 80 psi (5.5 bar). Spray soapy water onto bladder end
clamps and air fittings and watch for bubbles. When inflated, the bladder should raise the core
stop tray.
Maintenance
CORE STOP TRAY
To swap core stop trays without changing the bladder, follow these steps:
1) Remove one end clamp (SOC HD CPSCR M5x0.8x14mm).
2) Slide core stop tray and wave springs out of the shaft.
3) Apply lubricant as needed. Avoid grease, dry or penetrating lubricants.
4) Slide replacement core stop tray into the slot.
5) Slide the wave springs into the slot so they are between the core stop tray and the
underside of the T-slot
6) Fold the bladder as shown.
7) Install the bladder end clamp with one socket head capscrew, securing the bladder
underneath. [40 in-lbs. / 4.5 Nm]
Bleeder Valves
•If maintaining low tension during winding becomes difficult, the bleeder valve may require
adjustment or cleaning.
Note:
•The fine threads on the needle and the housing are easy to damage. Use care when
working with these components.
•Do not attempt to remove the bleeder valve housing from the shaft. If repair is necessary,
return the shaft to Maxcess (see Service at end of document).
•Location of valve varies due to custom shaft configurations.
Do not operate the shaft if:
•The valve is missing.
•The orifice is otherwise plugged.
Cleaning the Exhaust Bleeder Valve
1) Stop the winding operation and shaft rotation.
2) Locate the bleeder valve at the end or on the side of the shaft.
3) Using a 12 mm socket, carefully remove muffler*, if installed.

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4) Using a 1/8" hex drive, carefully back the needle valve all the way out of its housing
(counterclockwise).
5) Using compressed air, blow dust and debris out of the valve.
6) Carefully reinstall the needle valve in the housing.
7) Close the valve down until it just bottoms out in the housing, and then adjust as required
for your application.
8) Resume winding operation.
9) Adjust the bleeder valve incrementally to achieve required internal pressure.
Replacing the Exhaust Bleeder Valve
1) Stop the winding operation and shaft rotation.
2) Locate the bleeder valve at the end or on the side of the shaft.
3) Using a 12 mm socket, carefully remove muffler, if installed.
4) Using a 1/8" hex drive, carefully back the needle all the way out of its housing
(counterclockwise).
5) Carefully reinstall the needle valve in the housing.
6) Close the valve down until it just bottoms out in the housing, and then adjust as required
for your application.
7) Resume winding operation.
8) Adjust the bleeder valve incrementally to achieve required internal pressure.

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Troubleshooting
Problem
Possible Cause
Recommended Solution
Core stop tray does not lift
when air is applied.
Leak or obstruction
in air system.
Remove core stop tray from shaft.
Check bladder for holes, deformation or
debris around air fittings.
Air tubing not
connected under
core stop tray cover.
Remove cover from core stop tray and
reconnect the air tubing to the air
fittings. Check the tubing for holes or
obstructions.
Core stops move axially in
tray.
Fasteners are loose.
Hand tighten fasteners.
Different tension from
individual shafts
(Duplex Winder)
Leak or obstruction
in air system
Check all bladders for holes,
deformation or debris around air
fittings.
Exhaust Bleeder
Valve not adjusted
correctly.
Match tensions by adjusting
Pressure Control System in each Shaft.
Excessive core dust
Excessive tension
crushing core
Reduce winding speed: 5% overspeed
recommended Lower the range tension
pressure or adjust taper tension.
Check Bleeder Valve adjustment.
Core crushed by
web shrinkage (e.g.,
stretchable
materials)
Cut web and core from shaft, consider
using higher strength cores.
Core residue binding
core to shaft
Cut web and core from shaft. Use a rag
damp with small amount of mild
solvent, such as rubbing alcohol, to
clean the shaft.
Let shaft dry completely before
reloading cores.
Damaged tension
segments are not
retracting
Cut web and core from shaft; replace
tension segment strip.

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Service
If you have any questions about one of our products or need to speak with a Customer Service
representative, please use the contact information below.