Ortlinghaus TENSIOBAR TPI 780 EN User manual

Ortlinghaus-Werke GmbH
Postfach 50 14 40
42907 Wermelskirchen
Kenkhauser Str. 125
42929 Wermelskirchen
Germany
Tel. [phone]
Fax [phone]
Email [email protected]
Website www.ortlinghaus.com
Version: 01.2010
Operating Instructions
Technical product information
TPI 780 EN
TENSIOBAR
Pneumatic line tension feedback control
system for unwinding devices
with pneumatic actuated tension brakes
- operating console
0087-454-00-007 series
Contents
1. Safety instructions 2
2. Technical data 4
3. Transport, packaging 5
4. Installation instructions 7
5. Commissioning 8
6. Operation 11
7. Troubleshooting 13
8. Maintenance 14
9. Servicing and repair, modication 16
10. Spare parts 19
11. Storage, de-commissioning 20
12. Disposal 22
13. Annex 23

Ortlinghaus-Werke GmbH Operating instructions TPI 780 EN
2
1. Safety instructions
These operating instructions, hereafter referred to as OI, contain impor-
tant information, required in order that our product be operated safely and
properly in machines and systems. Technical product information (TPI) is
a constituent part of this OI.
In addition to this OI please also refer to the technical descriptions, product
drawing and the application-specic technical data, e.g. design calcula-
tions. If this should not be contained within the scope of documenta-
tion then please request this immediately from Ortlinghaus. Without the
product drawing this OI is incomplete.
Always consider the operating instructions for the other components in
the system or machine. In addition, observe the legal stipulations of the
national and European legislation as well as the regulations pertaining to
accident prevention and environmental protection. We accept no liability
for damage caused as a result of disregarding this OI. Subject to change.
Please ensure that you have the currently valid version.
Pass this OI on to your customers! If necessary, you can download our OI
or TPI via the internet from the "Service" directory at www.ortlinghaus.com.
You are also free to make copies of this example. Always keep the OI near
to the machine or system in order to ensure direct accessibility.
We reserve the right to make technical changes to this OI as part of tech-
nical further development. Please ensure that you have the most recent
version of the information.
1.1. Who are the operating instructions aimed at?
This OI is aimed at qualied personnel that
➞are familiar with the installation, commissioning and operation of the
product.
➞are qualied due to having read and understood the instructions, or
through training or instruction.
They are intended for
➞installation personnel from the machine/system manufacturers.
➞machine operator's tters.
1.2. What can be found in the operating instructions?
This OI with the product drawing contains all the necessary information
related to the product named on the cover page for the proper utilisation
throughout the various life phases.
Note the residual dangers and safety information provided for the life
phases.

Ortlinghaus-Werke GmbH Operating instructions TPI 780 EN
3
1.3. Use of these instructions
➞Read through this OI completely before working with the product.
➞The instructions in the OI must be complied with.
➞Consider the product drawing as well as any design calculations.
➞This OI is part of the product and should be kept accessible for all
users.
➞If the product is passed on to a third party then pass this OI on as well.
1.4. Notes on the symbols used in the text
Our products are produced in accordance with our knowledge of latest
engineering practice at the time of design and are operationally safe
and are subject to constant product enhancement. Nonetheless there
is a danger to personnel and property if the following instructions are
not complied with. For hazard-free installation, function and operation
the most important passages in the following pages are highlighted with
symbols.
This symbol means:
There is a risk of serious injury with the activity described or whilst in
operation.
This symbol means:
There is a risk of injury and damage to the machine with the activity
described or whilst in operation.
This symbol means:
There is an electrical hazard, for example through electric shock, and a risk
of serious injury with the activity described.
This symbol informs you that you must take particular note of this
passage.
This symbol provides important explosion protection information.
Non-compliance with safety notices results in a loss of any claim to
damage replacement.
1.5. Personnel qualications and training
Work on our products may only be carried out by professionals who
possess appropriate qualication or professional training pertaining to the
tasks to be carried out, and who know and understand the content of this
OI.
Professional personnel must know and observe the applicable safety
standards. They must use appropriate safety equipment. Furthermore,
professional personnel must be able to detect possible hazards that could
arise in the course of carrying out their work.
The range of responsibility, competence, qualication and monitoring of
professional personnel is the responsibility of the operator. If personnel do
not possess the requisite qualications and knowledge then they must be
trained and instructed accordingly.

Ortlinghaus-Werke GmbH Operating instructions TPI 780 EN
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2. Technical data
2.1. Intended Use
Please refer to the advice and information for this and the following chap-
ters of the technical product information (TPI) or instructions: "Installation
and maintenance" in point "13. Annex" in the respective chapter.
2.2. Appropriate use
Our products are intended exclusively for use in accordance with the tech-
nical data stipulated per the design shown on the product drawing
(0 . . . - . . . - . . - . . . . . .)
The order-specic design which was performed by Ortlinghaus may only
be used for the intended application.
The technical data specied by the customer is a component of the
intended use. Insofar as a specication sheet which has been approved by
both sides is present, it is also essential. The customer is responsible for
the correctness of its data.
Our product is intended to be integrated into a system or machine or to be
assembled with other components to form a system or machine. For this
reason, the product should only be brought into circulation once the system
or machine into which the product is to be integrated has completely
fullled the applicable EU machinery directive.
The adherence to the present technical product information and observ-
ance of the residual dangers are also part of the appropriate use. During
the various applications (life phases) in which damage to the machine or
hazards to personnel can arise, the operator must ensure that appropriate
safety measures are applied. Observe the applicable national regulations
pertaining to accident prevention and environmental protection
2.3. Improper use
Any alternative or additional use other than as described in chapter "2.1.
Intended Use" and "2.2. Appropriate Use" is considered to be improper
use. Ortlinghaus is not liable for the damages resulting thereof.
If the safety instructions and residual hazards are not observed then this is
also considered improper use.
Unauthorised modications and alterations to the product are not permitted
for safety reasons and result in the loss of any entitlement against Ortling-
haus.
2.4. Functional description
Please refer to the advice and information for this and the following chap-
ters of the technical product information (TPI) or instructions: "Installation
and maintenance" in point "13. Annex" in the respective chapter.

Ortlinghaus-Werke GmbH Operating instructions TPI 780 EN
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2.5. The Ortlinghaus numbering system
Example: 0 111 - 222 - 33 - 444 555
0 = Code digit for products
Code digit for series
Code digit for design characteristics
Built dimensions
Sequence no.
Further design characteristics
3. Transport, packaging
The delivery is to be checked for transport damage and any apparent
deciencies upon receipt. In the event of damage, inform Ortlinghaus
accordingly. Only products that are in technically awless condition are to
be installed or commissioned.
Read the OI before commencing further work.
3.1. Hazard notes on transport, packaging
Hazard Cause Conse-
quences
Remedial actions, safety
information
Mechanical hazards:
Loose parts can move around
during transportation
Encroachment of
a moving part on
a static part
Injury, crushing,
abrading,
catching,
running over
Secure loose parts against moving and do
not reach into assemblies during transporta-
tion
Falling objects Note the attitude of the packaging (note
TOP direction!), wear safety footwear
Transportation, handling,
moving
Falling objects Use of secure lifting gear with sufcient load
capacity
Open the packaging, lift
with the use of inadequately
dimensioned lifting acces-
sories
Gravity (stored
energy)
Note the attitude of the packaging (note
TOP direction!), use appropriately dimen-
sioned lifting accessories, wear safety
footwear
Greased or oiled parts can
slide away during transpor-
tation
Slippery surfaces Secure parts, set down on stable and non-
slip base, wear safety footwear and gloves
When removing from pack-
aging, transportation without
packaging
Sharp edges,
pointed parts
Secure parts for transportation, check for
damage and sharp edges before removing
parts, wear safety gloves/footwear
If stored at the perimeter No stability/struc-
tural safety
Secure parts against rolling or tipping during
transportation
Ergonomic hazards:
Straining,
posture
Fatigue, muscu-
loskeletal aggra-
vation
Note weight information, use transportation
devices, perform work in upright position
Material/substance hazards:
Fluids seeping out during
transportation
Fluid Poisoning, re,
allergisation
Take protective measures when dealing
with leakages
Sliding Remove uid