Maxcess Tidland D3 User manual

Tidland D3 Differential Air Shaft
Installation, Operation and Maintenance Manual
EN
For use with Tidland Serial Numbers 651931 and after
Includes Appendices for earlier shaft models
MI 638671 1 Q
TIDLAND WINDING SOLUTIONS

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Tidland D3 Differential Air Shaft
MI 638671 1 Q
Page 2
SAFETY INSTRUCTIONS
When using this Tidland product, basic safety precautions should always be followed to
reduce the risk of personal injury. Your company's safety instructions and procedures should
always be followed. 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.
No part of these or the following instructions should be construed as conflicting with or
nullifying the instructions from other sources. Be familiar with the hazards and safety
requirements in your work environment and always work safely.
1. Read and understand all instructions and shaft design application limits before operation.
2. Never use this product for a purpose or in a machine that it was not specifically designed for. See
Product Safety Data Sheet (PSDS).
3. Do not exceed the operation loads for this shaft as noted on its PSDS, Product Safety Data Sheet.
4. Follow all warnings and instructions marked on the product and on the PSDS.
5. Inspect the shaft for wear and/or other safety and functional deficiencies daily, before each use.
6. Wear safety glasses or proper eye protection when inflating or deflating or otherwise operating the
air system.
7. Do not remove or otherwise alter any setscrews or fastening devices prior to using this product.
8. Do not operate this product if any setscrews or fastening devices are missing.
9. 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.
10. When lifting a shaft, use proper lifting techniques, keeping back straight and lifting with the legs.
11. Do not carry or lift this product over wet or slippery surfaces.
12. Use appropriate mechanical lifting devices, such as a hoist or shaft puller, for heavier shafts.
13. When performing maintenance or repair procedures, do not pressurize the shaft if journal
setscrews are loose or missing.
14. When performing maintenance procedures, do not pressurize the shaft if the journal is missing.
15. All replacement parts used on this product should be made to original Tidland specifications.
16. All maintenance and repair procedures performed on this product should be done to Tidland
specifications by qualified personnel.

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Tidland D3 Differential Air Shaft
MI 638671 1 Q
Page 3
TABLE OF CONTENTS
Safety Instructions.................................................................................................................2
Tidland Customer Service......................................................................................................4
Recommended Tools.............................................................................................................4
Nomenclature and Part Numbers...........................................................................................5
Shaft..................................................................................................................................5
Tray Assembly...................................................................................................................6
Pressure Control Valve System .........................................................................................7
How it Works......................................................................................................................7
Operation...............................................................................................................................8
Bleeder Valves...................................................................................................................8
Muffler............................................................................................................................8
Adjusting the Exhaust Bleeder Valve .............................................................................8
Inflation Sequence.............................................................................................................9
To Begin Winding ............................................................................................................ 10
When Winding is Complete..............................................................................................10
Maintenance........................................................................................................................11
General Information.........................................................................................................11
Maintenance Schedule.................................................................................................11
Shaft Care....................................................................................................................11
Polyurethane Bladders.................................................................................................11
Poron®Springs ............................................................................................................11
Wear Bars....................................................................................................................11
Exhaust Bleeder Valve.....................................................................................................12
Cleaning.......................................................................................................................12
Replacing.....................................................................................................................12
Tension Segment Tray.....................................................................................................13
Remove Tension Segment Tray from Shaft .................................................................13
Disassemble Tension Segment Tray............................................................................ 14
Shaft and Tray Maintenance........................................................................................ 15
Install Bladders................................................................................................................ 16
Core-Locking Element (Lower Bladder) .......................................................................16
Tension Segment Element (Upper Bladder).................................................................17
Install Tension Segment Strip.......................................................................................... 18
Install Tray in the Shaft Slot.............................................................................................19
Replace Wear Bars.......................................................................................................... 19
Troubleshooting...................................................................................................................20
Appendix A..........................................................................................................................22
Appendix B..........................................................................................................................23

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Tidland D3 Differential Air Shaft
MI 638671 1 Q
Page 4
CAUTION
Wear eye protection when using tools or compressed air.
TIDLAND CUSTOMER SERVICE
800.426.1000 www.maxcessintl.com
360.834.2345
Visit the Tidland Repair and Return Center online to review our return policies
or to submit an electronic Return Material Authorization Request at
www.maxcessintl.com/returns.
RECOMMENDED TOOLS

Clean non-lubricated air supply: 0-40 psi (0.0-2.8 bar) for proper operation.
Tidland Inflation Tool (P/N 128052)
Tidland Air Release Tool and (P/N 111630)
Tidland Hole Punch Tool (P/N 560345)
Hex drive wrenches: 2.5mm, 7/64"
LOCTITE® 242 (blue)
Parker Super O-Lube O-ring Lubricant (make no substitutions)
Small pliers

For more accessories to help with your winding processes, visit www.maxcessintl.com
NOTICE
Maximum operating air pressure = 40 psi (2.8 bar)
Maximum overspeed = 10%; recommend 5%

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Tidland D3 Differential Air Shaft
MI 638671 1 Q
Page 5
SOC HD CAPSCREW (2 PLCS EACH TRAY)
616740
TENSION SEGMENT TRAY ASSEMBLY
SHAFT BODY
O-RINGS (3 PLCS EACH SLOT)
126193
Earlier shaft models
have only 2 o-rings.
REQUIRED:
ROTARY AIR SUPPLY
INFLATES UPPER BLADDER
TO RAISE TENSION SEGMENTS
VALVE (LOCATION MAY VARY)
INFLATES LOWER BLADDER
TO LOCK CORE STOP SEGMENTS
CALL FOR PART NUMBER
WEAR BAR
SEE NOTE BELOW
NOMENCLATURE AND PART NUMBERS
Air valve locations vary for the Tidland Equalizer Model D3 Differential Air Shaft. See page 9
for complete instructions on inflation sequence and valve operation.
Shaft
For shaft serial numbers before 660659, see page 11 for information about wear bars.
TRAY RETAINING ROD
(2 PLCS EACH TRAY)
653041
WEAR BAR
652361
FOR SERIAL NUMBERS
660659 AND AFTER
EXHAUST BLEEDER VALVE OUTLET
(END OR SIDE LOCATION)
REGULATES UPPER BLADDER
TO RAISE TENSION SEGMENTS
639967
MUFFLER
665891
SOC HD CPSCR
VARIES BY CONFIGURATION
CALL FOR PART NUMBER

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Tidland D3 Differential Air Shaft
MI 638671 1 Q
Page 6
ASSEMBLY DIAGRAM AND PART NUMBERS
Tray Assembly
See Appendix B for shaft serial numbers up to and including 651018.
Spacer (UHMW) part profile changed with serial number XXXXXX, but it does not affect assembly.
Rotary Air End
Non-Rotary Air End

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Tidland D3 Differential Air Shaft
MI 638671 1 Q
Page 7
OPERATION
Pressure Control Valve System
Successful operation of the Tidland Differential Shaft series depends upon proper internal air
pressure. 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, which is critical in low-tension
winding applications where the required internal pressure is very low and the pressure range
is very small.
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.
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.
For the D3 Differential Shaft, this Pressure Control Valve System affects only the
upper bladder that controls the tension segment height.
Note: The Pressure Control Valve System is installed in Tidland D3 shafts starting with serial
number 644698.
NOTICE
Before beginning the winding operation, please read and understand the
following.
CAUSES A PRESSURE DROP;
SHOULD NOT REQUIRE ADJUSTMENT
AFFECTS THE INTERNAL AIR PRESSURE; CONTROL
THE PRESSURE DROP BY ADJUSTING THE OUTLET
(EXHAUST BLEEDER VALVE, PAGE ERROR! BOOKMARK
NOT DEFINED.)

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Tidland D3 Differential Air Shaft
MI 638671 1 Q
Page 8
OPERATION
Bleeder Valves
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 12.)
*Not available on all Differential shaft designs.
Adjusting the Exhaust Bleeder Valve
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 the pressure, turn the valve
counterclockwise.
DO NOT adjust while shaft is spinning.
To clean or replace the valve, see page 12.
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.
Exhaust Bleeder Valve Function
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0
APPLIED AIR PRESSURE - PSI
WEB TENSION - PLI
1/8 TURN OPEN
VALVE CLOSED
1/4 TURN OPEN
CLOSE

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Tidland D3 Differential Air Shaft
MI 638671 1 Q
Page 9
OPERATION
Inflation Sequence
NOTICE
The core-locking feature may be disarmed if the
appropriate pressurization sequence is not followed.
Successful operation of the D3 differential shaft depends upon proper pressurization.
Tidland recommends the use of precision instrumentation to ensure that inflation specifications are
met.
Do not exceed maximum operating pressure as outlined in chart on page 10. Excessive pressure
may cause bladder to explode or premature wear of tension segments and wear bars.
Deflate the Bladders
The D3 shaft is equipped with two separate bladders.
The upper bladder, inflated through the rotary union
air supply, controls the pressure of the tension segments
against the cores.
The lower bladder, inflated through a side or end
valve, raises the core-locking bar that locks the
tension segments between the cores in a raised position.
1. Make sure both bladders are completely deflated.
2. Install cores on shaft.
At the Rotary Union Air Supply
3. Using clean, non-lubricated air, inflate the tension element
bladder with a constant air source at a pressure high enough
to raise the tension segments to their maximum height.
Recommended: 20-40 psi (1.4-2.8 bar)
At the Side Valve
4. Using clean, non-lubricated air, manually inflate the
lower core-locking bladder to raise the locking angle bar.
You may hear it "click" into place as it locks the tension
segments in their raised position.
Recommended: 40 psi (2.8 bar)
At the Rotary Union Air Supply
5. Deflate the upper bladder to 0 (zero) psi, which will lower
the tension segments under the cores.
The following conditions must be met or the shaft
will not work properly:
The tension segments between the cores must remain
raised at a height that prevents lateral movement of the
cores on the shaft.
The tension segments beneath the cores must be
fully retracted, and cores should turn by hand easily
on the shaft. If they do not, refer to Troubleshooting
on page 21.
TENSION
SEGMENT
UPPER
BLADDER
LOWER
BLADDER
CORE-LOCKING
BAR
TENSION
SEGMENT
TRAY
3.
4.
5.

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Tidland D3 Differential Air Shaft
MI 638671 1 Q
Page 10
OPERATION
To Begin Winding
Important! Low-tension winding requires very low pressure.
1. Begin winding between 0 –1 psi (0-0.1 bar).
Tidland recommends precision instrumentation to ensure proper air pressure.
2. Make sure that cores can slip on the shaft as the winding continues.
(If they do not, refer to Troubleshooting on page 21.)
3. Continue winding.
4. During winding, observe the tension controller readout and adjust the applied air pressure as
needed. Adjusting the exhaust bleeder valve may improve the effectiveness of the tension
controller. (See page 8.)
D3 Pressure/Overspeed Limits
(Maintaining Safe Temperature for Plastic Components 70° Ambient)
20
40
60
80
100
120
140
160
180
200
220
240
260
15 20 25 30 35 40 45 50
PRESSURE, psi
OVERSPEED, rpm
Overheating or seizing will occur
Recommended operation
When Winding is Complete
1. When the desired roll size is reached and winding has stopped, manually deflate the lower bladder
(side or end valve) using the Tidland air release tool. To ensure that all the air is exhausted from
the bladder, increase the air pressure in the tension segment bladder (rotary union valve) while
engaging the air release tool in the side/end valve. This forces the core-locking bar down and
squeezes the air out of the lower bladder.
2. Reduce tension segment pressure (rotary union valve) to zero psi.
3. Rolls are now ready to be repositioned or removed from shaft.