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
4
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

Ortlinghaus-Werke GmbH Operating instructions TPI 780 EN
6
3.2. Condition on delivery
The scope of the deliverables is dened on the shipping documents.
Check whether the delivery is complete and correct. The packaging is in
accordance with the order.
3.3. Transport
Only use lifting gear with sufcient load capacity for transportation.
Observe the following instructions for transportation.
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.
Refer to the product drawing for the location of the transport threads and
the precise weight. Tighten the transport screws as prescribed.
Attention! Load the transport threads uniformly and only in a vertical
direction. Pay attention to the load bearing capacity of the lifting acces-
sories.
If the existing screws are used as an aid then steel cables must not be
used for transportation as the threads on the screws could be damaged.
If there is transportation damage then this must be reported immediately.
It is not permitted to commission or operate the equipment without having
carried out a professional check.

Ortlinghaus-Werke GmbH Operating instructions TPI 780 EN
7
4. Installation instructions
The supplier or operator is responsible for the installation of the product
described. Comply with the applicable regulations and requirements as
well as the instructions of this OI. Check the operational readiness before
installation. Use appropriate lifting gear for handling whilst the installation
work is being carried out.
Follow the instructions for installation.
Attention! Observe the hazard notes in chapter "8. Maintenance" and
"9. Repair, modication"! Observe the applicable environmental regula-
tions
It is necessary to carry out a check for compliance with the geometric
tolerances after installation. It may be necessary to correct misalignments
when adjusting the shaft(s) and other machine parts. Note that there may
be thermal expansion, shaft bending and mounts that are too soft.
Check tightening torques of all screws and correct if necessary.
4.1. Installation conditions
• Moving parts must be safeguarded by the customer against unintended
contact, without signicantly compromising the ventilation.
• The installation area and the product must be free of grease, dust or
other impurities.
• It must be ensured that no auxiliary substance such as oil or grease
contaminate the friction components during the installation or the subse-
quent operation. If clamping rings are used for shaft connection then no
oil must emerge from these after installation.
• There must be no damage present on the joints to the machine.
• Observe the t tolerances and the data on the product drawing. Other-
wise small cracks or gaps from angular or radial misalignment of the
shaft/machine are created.
• Ensure that there is adequate space available in the installation area.
• Observe the minimum clearance for the inow of cooling air and sufcient
clearance from external heat sources.
• Installation of a cover by the operator for the moving parts in order to
provide protection against crushing, catching, dust deposits and collision
with foreign bodies.
4.2. Fundamental installation variants
It is not possible to deal with special installation variants - custom-made for
machine construction - here. However, we would would like to show how
our products can be integrated with some examples.
4.3. Assembly
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
8
5. Commissioning
Prior to commissioning, the connection on the drive side and output side
must be checked for correct attachment. Furthermore, a functional test
must be carried out after maintenance or repair with a stationary system or
machine.
With hydraulic systems, the initial contamination must be ltered out before
rst use. The piston chamber should be bled via the connection provided
(if available) prior to commissioning.
Check for unusual noises, vibrations and oscillations. Monitor the oper-
ating temperature. If unusual heating should be detected in the rst hours
of operation, the commissioning is to be halted.
5.1. Hazard notes on commissioning
Hazard Cause Conse-
quences
Remedial actions, safety
information
Mechanical hazards:
Dynamic clutches/brakes:
Torque too high --> adjoining
parts are heavily loaded -->
Risk of breakages
Torque too low -->
Accelerated / braked parts do
not reach speed or standstill
in good time
Acceleration/
braking (kinetic
energy)
Running over,
sliding away,
crushing
Exclude personnel from remaining in the
hazardous area of the equipment, test in
integrated condition, slow increase of load,
adjust pressure system, check and observe
residual pressure, deactivate mechanical
emergency air venting before commis-
sioning
Pressure system: Reduction
of the effectiveness of the
clutch/brake due to back pres-
sure in the pressure lines
Acceleration/
braking (kinetic
energy)
Running over,
sliding away,
crushing
Monitor pressure in the pressure supply
lines
Activated mechanical emer-
gency venting: Braking effect
nullied!
Acceleration/
braking (kinetic
energy)
Running over,
sliding away,
crushing
Exclude personnel from remaining in the
hazardous area of the equipment, check
mechanical emergency air venting and
deactivate if necessary prior to commis-
sioning
Assembly: Inuencing of
the function through incor-
rect installation position and
locking of inner drive/shaft to
outer drive.
Encroachment of
a moving part on
a static part
Running over,
sliding away,
crushing
Check installation position in accordance
with drawing, secure inner drive in axial
direction, check for freedom of movement
and correct positioning of parts before
commissioning
Assembly/over-pressure:
Nullication of the effective-
ness of the clutch/brake due
to breakage of the fastening
screws or due to high pres-
sure or faulty assembly
resulting from incorrect
number of screws, property
class, tightening torque, for
example
Falling objects/
high pressure
Running over,
sliding away,
crushing
Observe data in the OI/drawing, screw tight-
ening torque, check number and property
class, secure screws against loosening,
observe and monitor max. permissible
pressure
Stability/structural
safety
Switching on the pressure
supply: Loosing of faulty pres-
sure connections, separation
of fastening screws
High pressure Penetration of
medium under
pressure,
Before commissioning, check pressure tight-
ness at low pressure, set pressure limiting
valve such that max. permissible value
cannot be exceeded (provide sufcient
safety margin!)

Ortlinghaus-Werke GmbH Operating instructions TPI 780 EN
9
Hazard Cause Conse-
quences
Remedial actions, safety
information
Assembly/pressure system:
Inuencing of the effective-
ness of the clutch/brake due
to incorrect axial and radial
installation position and
locking of inner drive/shaft to
outer the drive, insufcient
pressure at the piston
Machine move-
ment
Running over,
sliding away,
crushing
Check installation position in accordance
with drawing, secure inner drive in axial
direction, check for freedom of move-
ment and correct positioning of parts prior
to commissioning, observe and monitor
minimum necessary operating pressure/air
pressure and monitor piston end position if
necessary (e.g. by means of microswitch,
incorporation into machine control)
Reaching into moving or
rotating parts whilst the clutch/
brake is open, with switching
operation, high rotational
speed
Moving parts Crushing,
catching
Cover up openings to clutch/brake
Rotating parts
Thermal hazards:
Dynamic switching processes,
high speeds, oil level in the
clutch/brake too high (wet
running)
Objects or mate-
rials with high/low
temperature
Burning Operator instructions, clearance grill or
temperature sensor, observe oil ll quantity/
coolant oil ow, monitor speeds
Noise hazards:
Contact with parts under the
inuence of speed, incorrect
installation position (radial/
axial) and locking of inner
drive/shaft to outer drive,
operating pressure/air pres-
sure too low or missing, incor-
rectly aligned parts
Moving parts Discomfort, stress Check the fastening of the clutch/brake and
the inner drive, check installation position in
accordance with drawing, check for freedom
of movement of the clutch/brake, observe
and monitor minimum necessary operating
pressure/air pressure and monitor piston
end position if necessary
Dynamic clutch/brake proc-
esses
Friction surfaces Discomfort, stress None
Radial misalignment between
inner drive and outer drive
Out-of-balance
rotating parts
Discomfort, stress Check the fastening of the clutch/brake and
the inner drive, check installation position in
accordance with drawing, check for freedom
of movement of the clutch/brake
Oscillation hazards:
High rotational speeds Misalignment of
moving parts
Discomfort, stress Check the fastening of the clutch/brake and
the inner drive, check installation position in
accordance with drawing, check for freedom
of movement of the clutch/brake, comply
with speed limit and monitor if necessary
Material/substance hazards:
Leaks:
Operation with leaking clutch/
brake (wet running), with
assembly/disassembly of the
pressurised oil connections
Aerosol, uid,
vapour
Respiratory prob-
lems, allergisation
Clutch/brake leaking externally, apply liquid
sealant to all clutch/brake joints and the
connection parts, check leak-tightness prior
to commissioning or at appropriate intervals
during operation
Operation with non-sealed
clutch/brake (dry running)
Dust Allergisation None
Ergonomic hazards:
Straining, posture Fatigue, muscu-
loskeletal aggra-
vation
Note weight information, use transportation
devices, perform work in upright position

Ortlinghaus-Werke GmbH Operating instructions TPI 780 EN
10
Hazard Cause Conse-
quences
Remedial actions, safety
information
Hazards in connection with the operational environment of the machine
Under static and dynamic
loading of the clutch/brake:
Inuence on the function
and the torque through the
effects of corrosion and the
aging processes of organic
substances
Impurities, dust,
moisture
Running over,
crushing
At appropriate intervals:
Check load-bearing parts of the clutch/brake
for corrosion, oil change, check function, if
necessary house and protect clutch/brake
unit from corrosion, replace corroded or
damaged parts