ryeco marking system

RYECO, Inc. Rev: 02 104--S 0-0 3131-3g ToC

RYECO MARKING SYSTEM TABLE OF CONTENTS: SECTION 1 PRODUCT SHEETS

- Descriptions and Standard Features - Options - Sales Order

SECTION 2 INSTALLATION Section 2.0 Marking System Installation Overview

Drawings: - Mill Interface Requirements - Marking System Overview - Power Wiring Table - Operator Station - Inspection System Wiring Table - Operator Station- Marking Station Control Box Wiring Table - Ink Station-Marking Station Control Box Wiring Table

Section 2.1 Operator Station Installation

Drawings: - Operator Station Dimensional Drawing

Section 2.2 Edge Marking Station Installation

Drawings: - Marking Station Dimensional Drawing - Post Drawing– Standard Actuator (Optional) - Bracket Drawing – Standard Actuator (Optional)

Section 2.3 Ink Station Installation Drawings: - Ink Station Dimensional Drawing - Ink Station Bolt Hole Pattern Drawing

Section 2.4 Installation Check List

SECTION 3 SYSTEM OPERATIONS, SOFTWARE AND MAINTENANCE Section 3.0 Marking System Operation Overview

Section 3.1 Marker Operator Station

Drawings: - Operator Station Internal Wiring

Section 3.2 Marker Station

Section 3.21 - Marker Actuator Station Drawings: - Actuator Station Dimensional Drawing - Actuator Station Internal Wiring Section 3.22 - 3100 Extension Tube Drawings: - Extension Tube Dimensional Drawing - Extension Tube Internal Wiring - Extension Tube Internal Tubing Section 3.23 - Edge Marking Module (EMM) Drawings: - Edge Marking Module Dimensional Drawing - Edge Marking Module Internal Wiring (if applicable) - Edge Marking Module Internal Tubing Section 3.24 – Edge Tracking Module (ETM) Drawings: - Edge Tracking Module, Dimensional Drawing - Edge Tracking Module, Internal Wiring - Edge Tracking Module, Internal Tubing Section 3.25 – Optional Modules (when applicable) Edge Crack Detection or Edge Mark Sensing Other Modules Drawings: - Module, Dimensional - Module, Internal Wiring - Module, Internal Tubing

Section 3.3 Ink Station

Drawings: - Ink Station, Dimensional (See 2.3 Ink Station Installation) - Ink Station, Internal Wiring - Ink Station, Tubing Overview

Section 3.4 Marker Software - General - I/O description - Functions and parameters - How to use the PLC Display Panel - How to use Operator Station Display Panel

SECTION 4 COMPONENT LAYOUTS, PARTS LIST AND MATERIAL

SAFETY DATA SHEETS - Subassembly Component Layouts - Subassembly Parts List - Dye Material Safety Data Sheets (MSDS) - CE Declaration of Conformity - UL 508A Standard Policy Statement

SECTION 5 TROUBLESHOOTING AND GLOSSARY - Troubleshooting - Maintenance Tasks and Schedule - Marker Test Station Operator Manual - Optional - Glossary

The manual is for use in installing, operating and maintaining Ryeco Marking System. Please read each section carefully to ensure proper installation, operation and maintenance of the system.

RYECO, Inc. Rev: 01 S 1-0 3111-3g.doc

SECTION 1.0 Product Sheet:

• Descriptions and standard features • Options

Sales Order:

• RYECO order number • Customer purchase order number • RYECO model number with options • Subassembly numbers, quantities and descriptions • Dye type • Spare parts

Defect and Code Edge Marking System with Tracking Models 3113-3g, 3133-3g & 3163-3g

Defect & code marking

Edge Marking System

System Design Features

High speed electrical spray head with adjustable dye flow for code marks

Short 5 millisecond code marks possible (2” at 2000f/m, 50 mm at 625 M/M)

Marks footage codes on one surface and six color defects on the other surface of the web

Marks can be offset to allow only defect marks to be visible from end of reel and code marks can be read by sensors or cameras

Improved and operator adjustable water flush and cleaning routines

Length or time based defect marking for more accurate unwind control

Maintenance display panel with expanded diagnostic software and alarm outputs

Reduced dye usage via shorter code mark capabilities

Automatic edge tracking and automatic sheet break retraction

Two surface marking

Remote pressurized dye tanks

Quick disconnects for all connections and no exposed or unprotected tubing

Overspray and mist evacuation system

Food grade water-based dyes

System Description

RYECO’s third generation of Marking Systems include our new Deluxe Defect and Code Marker. The system is designed to provide both Defect Marks and Code Marks on opposite surfaces of the same web.

Applications

Code marking is used to place short encoded footage marks along the web for Automatic Un-wind Control. Code marks are on the top while defect marks are on the bottom. A defect and code marker is generally interfaced to a web inspection system or to the mills quality control scanner. De-fects and off-spec paper are marked for removal during the unwind process. The code marks are read by automatic unwind control systems allowing for accu-rate stopping on footage regard-less of slabbing or reel slippage. The defect mark acts as a backup stopping system and aids the op-erator in more precise defect lo-cating.

Flexibility RYECO offers three models of our Defect and Code Marker. The features and options offered are listed on the back of this document.

RYECO’S Edge Marking Sys-tems include features designed to reduce maintenance and improve reliability. Heavy duty hardware with complete modularity and quick disconnects ensure years of continuous use.

RYECO Incorporated has been providing services and manufacturing specialty Paper

Industry Products since 1989. We have over 1500 installations worldwide and a

reputation for excellent customer service and top quality products. We offer Edge

Crack Detection, Edge Marking and Unwind Control, Sheet Break Detection and Lane

Marking Systems.

Defect Marks

Defect and Code Markers

Models 3113-3g , 3133-3g & 3163-3g Defect and Code Marking

Default Features: Defect Marking Features:

Automatic edge tracking (12” travel) One defect marking colors- water-based dye (Model 3113-g)

Defect mark bottom and code mark top Three defect marking colors- water-based dye (Model 3133-3g)

Automatic expanded water flush Six defect marking colors- water-based dye (Model 3163-3g)

Over spray and mist evacuation No dye mix on color changeover

One 5-gallon pressurized dye tank (Model 3113-3g) Code Marking Features:

Two 5-gallon pressurized dye tanks (Model 3133-3g) Five millisecond mark length (2”@2000f/m, 50mm at 625 M/M)

Three 2-gallon pressurized dye tanks (Model 3163-3g) Fully adjustable dye flow metering

Independent sprayer positioning Clean on/off marking

Length or time based marking Electric sprayer with needle cut-off

Expanded diagnostics/maintenance panel One color code mark (water-based dye)

810 Pickens Drive EXT Marietta, GA 30062 Phone: 770.423.0934 Fax: 770.424.2554 www.ryeco.com

Model 3133-3g Three-Color Defect and Code Marking System

Sales OrderCustomer No.:

Order No.:

Bill To: Ship To:

Date Ship Via F.O.B. Terms

Purchase Order No. Cust. Req Date Sales Person Our Order Number04/22/10 FrtClt-Ocn-Schnkr Origin Net 30

SG2-E-24561 06/25/10 Honeywell Oy - OEM 100569

Honeywell PTE LTD-C/O Simpang Honeywell Building

Simpang Bedok Post OfficePO Box 181, Singapore91480,Singapore, Singapore

17 Changi Business ParkCentral 1Singapore, 486073 Singapore

HWSS100569

RYECO Incorporated810 Pickens Drive Ext.Marietta, GA 30062

Quantity Item Number Description Unit Price AmountReq Shipped B.O.Serial Number

05/18/10

Ryeco Rel Date

Victor.Siaw@honeywell.com

FaxPhoneEmail

LI_DISCDiscount

1 Ryeco Marking System Model3133-3G TE/NF/BS/NE/MTfor TPJI Machine 5

Consist of the followingcomponents:

1 20 063 315 EXT TUBE 3133/NFAcct Code:8

1 20 123 100 ACT STA 3131-33-3gAcct Code:8

1 20 363 315 EMM 3133-3g/TE/NF/BS/NEAcct Code:8

1 12307 THREADED ORIFICE.010Acct Code:8

1 20 873 010 Nozzle Assy/NE .010Acct Code:8

1 20 400 001 ETM-1100Acct Code:8

1 20 563 316 INK STA 3133-3g/NF/MTAcct Code:8

1 20 663 100 OP STA 3131-63-3gAcct Code:8

2 10993 Operator ManualW/ CDAcct Code:8

1 Software: 3133_NF2

4 12450 DYE BLUE CONCENTRATE GALNon-Haz. Acct Code:11

5 12460 DYE RED CONCENTRATE GALNon-Haz. Acct Code:11

Thank You For Your Business!

Sales OrderCustomer No.:

Order No.:

Bill To: Ship To:

Date Ship Via F.O.B. Terms

Purchase Order No. Cust. Req Date Sales Person Our Order Number04/22/10 FrtClt-Ocn-Schnkr Origin Net 30

SG2-E-24561 06/25/10 Honeywell Oy - OEM 100569

Honeywell PTE LTD-C/O Simpang Honeywell Building

Simpang Bedok Post OfficePO Box 181, Singapore91480,Singapore, Singapore

17 Changi Business ParkCentral 1Singapore, 486073 Singapore

HWSS100569

RYECO Incorporated810 Pickens Drive Ext.Marietta, GA 30062

Quantity Item Number Description Unit Price AmountReq Shipped B.O.Serial Number

05/18/10

Ryeco Rel Date

Victor.Siaw@honeywell.com

FaxPhoneEmail

LI_DISCDiscount

1 13023 Shipping Crate (Large)OSD 48" x 48" x 31"ISD45 5/8"x48"x31" ActCd:11

Order subtotal

Order total

Orders are shipping via Ocean.Requested ship date no later than 6/25Notify Honeywell Prior to ship.BAX is Schenker USA

Ship Wt Total 357.25

Thank You For Your Business!

RYECO, Inc. Rev: 1.0 S 2-0 31003g Install .doc

SECTION 2.0 Edge Marking System Installation Overview Overview:

• This Section provides the documentation and drawing required to install your system

• An Edge Marking System consists of three subsystems/subassemblies: o Operators Station o Edge Marking Station o Ink Station

Interfacing requirements:

• AC Power 110 or 220 VAC, Single Phase to the Operator Station (OP) o Refer to the 110 (220)-OP wiring table for detailed information on

cable and Belden Equivalents • Operator Station to existing web inspection system (WIS)

o Refer to the OP-WIS wiring table for detailed information on cable and Belden Equivalents

• Ryeco system inputs: the mill is to use Ryeco provided 24VDC for input voltage. Ryeco system outputs are 24VDC transistor outputs (PNP). Use Ryeco provided 0VDC as the circuit 0VDC. To interface with Ryeco’s Operator Station, each I/O must be isolated with an isolation relay in order to prevent damage to Ryeco’s PLC. Use an opto-isolator or solid state high speed relay (Finder part# 38.81.0.024.9024 or equivalent) for high speed connections

Listed below are the inputs/outputs that the RYECO system will need in order to generate marks and track the web: • 24VDC will be supplied from Ryeco to the WIS • 0VDC will be supplied from Ryeco to the WIS • Mark 1 (2, 3, etc.) will be a signal from the WIS to the Ryeco Operator Station to make a

defect mark (24VDC pulse via the isolation relay) • Remote On will be a signal from the WIS that sends the marking head assembly on

sheet to acquire the sheet edge, track it, and prepare it to make defect marks when the actuator station is in auto mode. This signal must remain high for the marker to stay on sheet. When a sheet break occurs, the unit will retract off sheet. This signal must be recycled in order to move the marking head assembly back to the sheet edge.

• Reel Change will be a signal from the WIS that will retract the marking head assembly off sheet. It will then complete a solvent (water) flush and dye re-prime routine. The marking head assembly will re-acquire the sheet edge automatically when the flush and re-prime routine is complete.

• On Sheet Out is an output signal that the Ryeco system will send when the marker is “On Sheet”. The signal is isolated just like the others, except it will remain high while the system is on sheet, then will drop low if that condition is no longer true (off the sheet)

• Diagnostic Error will remain high until an error condition occurs then will transition from high to low. Error conditions (from Ryeco) are: Low air pressure, low level dye (optional), forward / reverse disagree bit

• ENCODER (TACH) input is only used then the mark length is controlled by the web speed

RYECO, Inc. Rev: 1.0 S 2-0 31003g Install .doc

• Actuator Control Box or the Edge Marking Station to the Operator Station wiring interface

o Refer to the OP-CB wiring table for detailed information on cable and Belden Equivalents

o Run in a conduit, chase or cable tray

• Ink Station to the Actuator Control Box / Edge Marking Station wiring interface (Wiring provided with your Ryeco System in the Ink Station Tube Jacket)

o Refer to the IS-CB wiring table for details on terminations

RYECO, Inc. Rev 01 107--S 1-1 31XX-3g System Interface

MILL INTERFACE REQUIREMENTS

Customer

5/17/10

Customer Power wiring 110-OP-3

ACTUATOR STATIONOperation Section 3.21

EXTENSION TUBE Operation Section 3.22

Customer Signal wiring OP-CB-30

EDGE MARKING STATIONInstall Section 2.2 Operation Section 3.2

OPInOp

EDGE MARKING MODULE, (EMM) Operation Section 3.23

OPTIONS: EDGE CRACK DETECTOR, (ECD)OR EDGE MARK SENSOR (EMS) Operation Section 3.25

EDGE TRACKING MODULE,(ETM) Operation Section 3.24

MILL EQUIPMENT DCS, WIS, PLC etc.

Signal wiring OP-WIS-16

Customer Instrument Airand Water

ERATOR STATION stall Section 2.1 eration Section 3.1

INK STATION Install Section 2.3 Operation Section 3.3

Tube jacket (with multi-cable IS-CB-10) provided by Ryeco

ECD OPTION Customer Instrument Air

Cables

c. All rights re

Tubing

Note: - Items in supplied - Labeling appear th drawings

served.

Customer drain when applicable

shaded boxes are to beby the mill. for cables are as they roughout the text and in this manual.

RYECO, Inc. Rev: 02 113--S 2-1 Op Sta 40DTP

SECTION 2.1 Operator Station Installation

Overview:

• Contains all of the electronic controls to interface with the Edge Marking Station • Mounted close to the Edge Marking Station installation location

o Mount on a sturdy post or to a wall/frame with uni-strut bars o For the bolt hole pattern see the drawing on the next page. o Power required for the Edge Marking system is 110 or 220 VAC switch

selectable (single phase) with a load requirement of 3.2 or 1.6 amps respectively

Drawings: Op Station 40DTP, Dimensional

RYECO, Inc. Rev: 02 115--S 2-2 Marking Station

SECTION 2.2 Edge Marking Station Installation

OVERVIEW: • The Edge Marking subsystem consists of the actuator, actuator control box,

extension tube, and edge tracking and marking modules ( and options) • In most installations the actuator station can be mounted parallel to the floor

on a stable mounting structure near the sheet edge. In very dusty or wet conditions a “Hanging Installation” is recommended.

• In systems with a jaw the extension tube can be rotated up to 45 degrees in the tube clamps

• non-jawed systems allow 90 degree rotation to align with the sheet edge • Actuator travel allows flexibility to deal with web wander and deckle change • Standard actuator travel is 12 inches (300 mm) • Optional actuator travel lengths of 24 inches (600mm) and 36 inches

(900mm) are available • Standard extension tube subassembly length is 30 inches (762mm) • Optional extension tube subassembly lengths from 30 inches (762mm) to 76

inches (1930.4mm) are available • Optional extension tube configurations consist of gooseneck, forward

gooseneck, and offsets. Customizations are available for specific locations. • Optional Mounting Posts and Brackets are available

Mill supplied mounting structure:

• Standard mounting distance from the web edge to the centerline of the post or angle bracket is 16 – 26 inches (406mm – 660mm)

• A mounting bracket example for a “hanging installation” or a ‘top mount installation” is shown later in this section of the manual.

• A “top mount post” can be a 4 inch diameter (102mm) pipe with a 6 inch x 10 inch (152.4mm x 254mm) platform welded on the top.

• For the height from the mounting platform to the height of the paper surface see the drawings in this section. Allow small adjustments in the mechanism

• The bolt hole pattern in the platform for the actuator mounting feet is 4 inches (101.6mm) in machine direction by 8 inches (203.2mm) in cross direction.

Mill plumbing requirements (only for systems with dye evacuation):

• A drain hose is supplied that connects to the vacuum generator at the back of the Edge Marking Station to mill sewer or waste dye collection system

• The drain will need to be fixed to the structure that mounts the Edge Marking Station and plumbed from the exit side with rigid tubing to the mill sewer

• The fitting is a ½ inch female NPT • The drain line must be vented for proper operation

Air for the Edge Crack Detection if this option is included:

• Systems with the Optional Edge Crack Detection require a ¼ inches (6 mm) O.D. air line connected to the bottom of the actuator control box.

RYECO, Inc. Rev: 06 119--S 2-3 Ink Sta 2T-5G-1A-4L

SECTION 2.3 Ink Station Installation

Overview: • The station contains pressurized dye tanks, air regulators, water regulator, an

activation solenoid for vacuum pump (if applicable) and a low air pressure sensor

• It supplies the required dye(s), atomization air, ETM purge air, and air to the vacuum generator (if applicable) of the Edge Marking Station

• Must be installed within 20 feet (6.1 meters) of the Edge Marking Station. (Pre-fabricated tubing and wiring -- 20 feet (6.1 meters)).

• Mount the ink station so that the bottom of the dye tanks and tube jacket are no lower or higher than 5 feet (1.5 meters) above or below the Edge Marking Station -- height of the web to be marked -- to ensure adequate delivery of dye to the sprayer(s).

• NOTE: Contact Ryeco if these specifications need to be exceeded. Mill supplied mounting structure:

• Mount on a post with a platform welded on top, or to a wall/frame with uni-strut bars

• See the drawing for the bolt hole pattern (later in this section) Air and water supply requirements:

(refer to the system overview drawing preceding this page for specifications) • Instrument air line

o Rigid air line needs to be connected to the correct side of the ink station. o Filter incoming air, non-filtered instrument air will cause plugging. o Verify pressure

• Water line (for systems utilizing water based dyes only) o Potable water is recommended. o The mill water line needs to be connected to the correct side of the ink station o Filter incoming water, non-filtered water will cause plugging. o Verify pressure

Notes:

• For non water based dyes a thinner will be provided in one of

the dye tanks in replacement of the water line. • For non-water based dyes the number of colors available

may be reduced. Drawings:

o Ink Station, Dimensional o Ink Station, Bolt Hole Pattern

RYECO, Inc. Rev: 02 3133/63-3g Checklist S 2.4 SECTION 2.4 Installation Check List Overview:

• To ensure systems function as intended they should be commissioned by a trained RYECO Technician or a trained RYECO Representative

• Some customers have experience with RYECO Systems and feel comfortable installing and

commissioning the systems.

• The installation checklist is provided for your assistance.

• The checklist should be followed and any changes to setting for your specific application should be documented and saved for future reference.

Installation Checklist for RYECO 3133-3g and 3163-3g 1. Edge Marking Station:

A. Ensure proper height and stability of actuator station mounting bracket/post. Web material must be centered in the jaws of the ETM and EMM modules.

B. Verify proper drain connection from extension tube. (Mill side drain line should be

properly vented.) C. For edge crack detection option: Verify ETM/ECD airline is properly connected to

actuator station and is regulated and filtered according to the requirements in the system manual.

D. Set the Actuator Station into Manual Mode.

2. Ink Station:

A. Verify the 3/8” air line and ¼” water line are properly connected, regulated and filtered according to the requirements in the system manual

B. Verify ETM air pressure is approximately 20 – 30 psig. C. Ensure mounting height from extension tube. (Extension tube should not be mounted

higher or lower than 5 feet above ink station)

D. Fill Dye tanks with appropriate dye color.

3. Operator Station:

RYECO, Inc. Rev: 02 3133/63-3g Checklist S 2.4

A. Ensure Power supply is set for the correct input voltage (110 or 220 VAC Single Phase)

B. Ensure customer supplied signals are isolated from the Ryeco system using relays or opto-isolators

4. System Pre-Test:

A. Verify Wiring Terminations: Operator Station (OP) – Control Box (CB), 110-OP, and Operator Station (OP) – Web Inspection System (WIS) Wiring Tables

B. Verify wiring terminations: Operator Station (OP) – Control Box (CB) and Ink Station (IS)

– Control Box (CB) Wiring Tables 5. System Testing:

A. Turn Power on to the Ryeco system B. Prime all colors and solvent by pressing the manual dye buttons

C. Ensure over spray evacuation is working and drain line is securely connected

D. Adjust ETM amplifiers for lightest grade material and test tracking functions with sample

E. Verify all inputs signals from the WIS are functional:

Mark 1 (If applicable) Mark 2 (If applicable) Mark 3 (If applicable) Mark 4 (If applicable) Mark 5 (If applicable) Mark 6 (If applicable) (High Speed) Mark 1 (If applicable) Remote On Reel Change

Note: System will not go on sheet in auto mode if there is no Remote On signal or if a break condition exists and the Remote On signal has not been cycle.

F. Ensure Actuator Station is in Manual Mode and apply the ‘Remote On’ signal to the Ryeco system

G. Place the actuator station in Auto Mode and the marking head assembly will move on sheet

after a short pause to ensure all colors are primed

H. Verify proper tracking and ensure the actuator carrier is a minimum of 3” from FWD Limit and 3” from REV Limit while on sheet and tracking

I. Record initial system setting below:

Initial System Settings:

Software Version

Air In From Mill

Water In From Mill

Internal Water Pressure (Flowing)

Air Atomizing Pressure

Dye Pressure

ETM Purge Pressure

ECD Purge Pressure

Ink Length

Fade Length

Defect Mark Width

High Speed Mark Pin Adjustment (NC Spray Gun Version Only)

High Speed Mark Width

J. Make several test marks and adjust system parameters as needed. Record all final system

settings below:

Final System Settings: Software Version

Air In From Mill

Water In From Mill

Internal Water Pressure (Flowing)

Air Atomizing Pressure

Dye Pressure

ETM Purge Pressure

ECD Purge Pressure

Ink Length

Fade Length

Defect Mark Width

High Speed Mark Pin Adjustment (NC Spray Gun Version Only)

High Speed Mark Width

7. Custom System Features/Options: (Note: List all custom options and check below)

NOTES:

RYECO, Inc. Rev: 05 S 3-0 3100-3g Operation .doc

SECTION 3.0 Edge Marking System Operation Overview

Overview: • Inputs from the Mill and/or Web Inspection System (WIS) control the operation of

the system • Detailed information on the operation and maintenance of subsystems or

subassemblies is provided in the following sections

ALL INTERFACE SIGNALS SHOULD BE TERMINATED USING ISOLATION RELAYS TO AVOID DAMAGE TO THE PROGRAMMABLE LOGIC CONTROLLER. USE AN OPTO-ISOLATOR OR SOLID STATE HIGH SPEED RELAY FOR HIGH SPEED CONNECTIONS. (FINDER PART #38.81.0.024.9024 OR EQUIVALENT)

Inputs from WIS:

• Remote On signal (constant signal high) will send the marking head assembly on sheet.

• Reel Change signal is a (one-shot high) signal at the beginning of reel change (turn up) that indicates the start of a new roll

• Tachometer Pulses are used when the marks and/or space between marks are controlled in units of length (inches, feet, centimeters or meters). Typically this is used in certain types of high speed marking.

• (High Speed) Mark 1 – Marking Systems with one high speed marker • Defect Mark 1 -- one color Defect Marking System • Defect Mark1, 3 and 4 – three color Marking Systems • Defect Mark 1, 2, 3, 4, 5 and 6 – six color Marking Systems

Outputs to WIS and / or customer PLC:

• On Sheet Out signal indicates that the Marker is on sheet and ready to receive marking signals.

• Diagnostic Error (normally high = no errors) outputs when system has low air pressure, a dye tank level is low or when the Edge Tracking module inputs a forward and reverse disagree bit to the PLC

• Mark Error (optional) signal indicates if a mark has not been detected. Requires a Mark Verification module

Once the Edge Marking System is installed and commissioned:

• Ensure that air and water are supplied to the system continuously (water is only used as solvent on waterbased dye systems)

• Monitor dye level in tanks and fill as needed • Detailed preventive maintenance tasks and schedules are provided in Section 5.

Cautions:

• Never wash down the Operator Station • Never wash down the Actuator Station (doing so can cause the lead

screw to rust and seize) • Loss of air may cause a loss of tracking due to dirty optics • Loss of filtered water may cause plugging at the sprayer nozzles

RYECO, Inc., Rev: 04 S 3-1 Op Sta 40DTP.doc

Section 3.1 Operator Station

Figure 1 - Operator Station

Specifications Supply Voltage 110-120 VAC 3.2A 60 Hz 220-240 VAC 1.6A 60 Hz Input/Output Voltage 24 VDC 6.5A Operating Temperature 32°F - 122°F (0°C - 50°C) Operating Humidity 85%RH Size 14” X 16” X 6.25” (355.6mm X 406.4mm X 158.75mm) Bolt Pattern 12” X 16.75” (305mm X 425mm) Construction Painted NEMA 12 (IP52)

Function

• Performs tracking, marking and diagnostic functions for the system using ladder based control software.

• Contains a visible display unit o F1 – F4 Function keys allow the operator to manually control the color marking or

solvent flush. o Allows the operator to change I/O parameters o Displays preset parameters o Displays diagnostics information

• Contains circuit breaker and power supply for the system • Contains interfacing terminals for connecting to Web Inspection System • Contains interfacing terminals and motor control card for connecting to the edge marking

station • Provides actuator motor speed control via motor control card.

Refer to Section 3.4 for a more complete description of the inputs, outputs, software routines, and F1 – F4 function keys.

Operational Variables The speed of the Actuator Table travel can be adjusted at the motor control card inside the door panel of the Operator Station. Motor Control Card Adjustment Procedure (refer to Figure 2): 1. Dip Switch Setting

Position 1 = Off (left) Position 3 = On (right) Position 2 = Off (left) Position 4 = Off (left)

2. Velocity Pot 1.1 Turn the Velocity Pot clockwise 25 full turns. 1.2 Turn the Velocity Pot counter clockwise 5 full turns

3. Pot 1 (Preset by the Mfg – Do not adjust) 4. Pot 2 (Speed Control)

4.1 Turn Pot 2 counter clockwise 10 full turns. 4.2 Turn Pot 2 clockwise 3 full turns.

5. Pot 3 (Lurch Speed) 5.1 Turn Pot 3 counter clockwise 10 full turns. 5.2 Turn Pot 3 clockwise 3 full turns

6. Pot 4 (Preset by the Mfg – Do not adjust) 7. Testing

4.1 Put the system into the ON SHEET mode. 4.2 Observe the Time it takes for the Actuator carrier to travel the full 12” stroke. (The time for the actuator to travel the full 12” stroke should be between 4-5 seconds). 4.3 Adjust Pot 2 as necessary to obtain the desired speed of 4-5 seconds.

*Note: If the actuator oscillates when you hold a sample paper steady in the ETM jaw, turn Pots 2 and/or 3 counter-clockwise in ¼ turn increments until oscillation ceases.

Figure 2 – Motor Control Card

Velocity Pot.

Pot. 1 Pot. 2 Speed Pot. 3 Lurch Pot. 4

Dip Switches Right=ON Left=OFF

Maintenance

CAUTION!

• Do not use solvents or cleaning fluids inside the

Operator Station. • Do not spray or wash down the interior or exterior of the

Operator Station. • Drop the input to (REMOTE ON) to retract the edge

marking system from the sheet edge before turning off the power to the Operator Station.

Function Check • Observe the LED on the Power Supply. LED will indicate green for power on,

red for over-current condition. If LED indicates fault condition, cycle the 4 Amp Main Power Feed Breaker to reset.

• Check that the red power indicator LED on the mini-controller is on. • Observe display on the door of the Operator Station. Display should be

illuminated green with no error indication. • Check to make sure all breakers are closed. The breakers service the following

components: o 4 Amp Single-Pole: Main Power Feed o 4 Amp Pop-Up Single Pole: Motor Control Card o 3 Amp Pop-Up Single Pole: Operator Station Terminal Strip o 2 Amp Pop-Up Single Pole: Mini-Controller

• Individual components can be isolated by opening the corresponding breaker • Observe the LED on the Motor Control Card. LED will indicate green for power

on, red for over-current condition. If LED indicates fault condition, cycle the 4 Amp Motor Control Card Breaker to reset.

• Check diagnostics on display unit. • Observe the activity of the Operator Station microprocessor Inputs and Outputs.

The following conditions should be present: o When the REMOTE ON Input from the Web Inspection System is Active

High and the actuator is in the Auto mode: The actuator will drive forward until the Edge Tracking Module finds

the sheet edge. If no sheet is present, the actuator will continue forward until the

forward limit is reached and then retract to reverse limit. The REMOTE ON Input must be re-cycled (low to high) before the

actuator will drive forward to find the sheet edge again. o Once the Edge Tracking Module has found the sheet edge, the ON SHT

Output should be active high o When the REMOTE ON Input from the Web Inspection System is not

Active High, the actuator should retract all the way to reverse limit. The REV LIMIT and FWD SENSE inputs should show active high

Periodic Maintenance Periodically clean display unit as required.

RYECO, Inc. Rev: 02 126--S 3-2 Marking Sta Operation

SECTION 3.2 Marking Station (Tracking Station) Operation Overview: • The Station performs the edge tracking and various other functions based on the

requirements such as: o Marking o Crack Detection o Mark Verification o Air Shower o Web Guide o Custom Functions

• The station consists of the following subassemblies: o Actuator and Actuator Control Box Subassemblies o Extension Tube Subassemblies o Edge Tracking Module o Additional modules based on functionality requirements:

- Edge Marking Module - Mark Verification Module - Edge Crack Detector Module - Air Showers - Web Guide - Custom Modules

• Detailed information for each of the subassemblies is provided in its appropriate

section

RYECO, Inc., Rev: 03 S 3-21 Act Sta 12P-2SWT-LIM.doc

SECTION 3.21 Actuator Station

Overview:

What is its’ function?

• To move the marking head assembly forward and backward perpendicular to web direction using manually controlled switches on the Actuator Station door panel or automatic outputs from the Operator Station PLC.

• Contains limit switches that protects the actuator motor and carrier group from running into the mechanical stop.

• Buttons on the actuator control box allow the operator to initiate marking function by pressing the specified color button for a desired time of marking.

What does it look like?

• A black anodized aluminum electric linear actuator with a control box mounted on the back – See Figure 1

• Actuator consists of a sealed screw/carriage mechanism driven by a 24 VDC motor

• A twelve conductor molded cable exit the control box to interface the marking head assembly

Figure 1 - Marker Actuator Station Components

Note: In certain applications (dusty and/or wet) an inverted mount option is

preferred.

Operation:

What are the operational variables?

• Switches on the actuator control box allow the carrier to be operated manually or in automatic mode

• The speed of the actuator table travel can be adjusted on the motor control card in the Operator Station. (Refer to Section 3.1 - Operator Station)

• The manual mark push buttons on the bottom row allow the operator to mark colors individually (or in combination) as long as the button(s) are pressed – See Figure 2

Figure 2 - Marker Actuator Station Control Box

(Shown with two Color buttons, may vary by system)

How can I check its’ operation?

• The function of the Actuator can be checked by putting the system into manual mode with the switches on the control box.

• Turning the AUTO/MAN switch to MANual allows the actuator carriage to move forward or reverse by holding the FWD/REV switch in the desired position.

• Manual marks can be made by pressing the specified mark button for the duration of the mark desired.

• When more than one DYE button is pressed simultaneously, the mark created is a mixture of the colors.

• When the system is in AUTOmatic mode and the “REMOTE ON” signal is received by the Operator Station (Refer to Section 3.1 Operator Station), the marking head assembly should move forward, acquire the sheet edge and follow the web wander automatically.

Warning!

• Never wash down the “band seal” of the Actuator directly • Do not immerse the Actuator

Maintenance:

How do I check its’ function?

• Turn the AUTO/MAN switch on the Control Box to MANual. • Actuate the carriage forward or reverse by holding the FWD/REV switch in the

desired position. • Make manual marks by depressing the dye button, or combination of dye

buttons, desired for the length of the mark required. • When the system is in AUTOmatic mode and the “REMOTE ON” signal is

received by the Operator Station, the marking head assembly should move forward, acquire the sheet edge, and then follow the web wander automatically.

Warning!

Do not move the actuator carrier past reverse limit in manual mode. This will keep the marking head assembly from reacquiring the sheet edge once the “REMOTE ON” signal is recycled

All marking functions can be activated by putting a jumper between the +24 VDC on position 1 of term X-1 and the corresponding position for the signal as specified in the Actuator Station Wiring Drawing FWD LIM Activates the Forward Limit of the actuator (creates a sheet

break routine in the microprocessor) ATOM AIR SOL 1 or 2 Activates the atomization air solenoid in the extension tube

SOLVENT SOL 1 or 2 Activates the solvent solenoids in the ink station DYE SOL 1,2, or 3 Activates the appropriate dye solenoid in the extension tube VAC SOL Activates the vacuum solenoid in the ink station (when applicable)

MAN DYE 1, 2, or 3 Activates the appropriate manual mark sequence SPRAY GUN 1 or 2 Activates the Spray Gun Solenoid in the extension tube

(activates the jeweled nozzle and pin in the Edge Marking Module for NF/NC versions)

What periodic maintenance is needed?

• There is no periodic maintenance needed on this module • Components that may need replacing are the motor brushes (part # 10953), the

limit switches (part #11919 and #11920), the motor (part #10952), the wiper band (part #10954)

What setup changes and adjustments can I make? • The forward and reverse limit switch positions can be changed along the side of

the actuator to facilitate the needs of the limit functions of the overall system. • The standard position of the limit switches will stop the movement of the carriage

at approximately ½” from the forward and reverse mechanical stops. • The actuator carrier group should always activate the electrical limit switch before

reaching the mechanical stops when in Automatic mode • The speed of the actuator carrier group travel can be adjusted at the motor

control card located on the door of the Operator Station. (Refer to Section 3.1 - Operator Station)

Caution!

• The limit switches do not stop the motor when in Manual

mode • If the actuator carrier group is positioned past the reverse limit

switch in manual mode and then switched to automatic mode, the actuator will not respond to the “REMOTE ON” signal

• Manually position the actuator carrier group between the limit switches to ensure satisfactory operation

How do I replace the subassembly?

• Powering down the system and un-terminating the cable connections • The assembly can then be removed by releasing the four 5/16” bolts from the

actuator mounting feet • The limit switches are replaced by disconnecting the quick disconnects between

the limit switch and the Control Box. • Remove the single clamp screw. • Take the clamp off and pull the switch out. • Position the switch in the track and fasten clamp down with screw and reconnect. • Terminate with correct polarity (brown wire on position 1, +24 VDC).

Specifications: Operating Temperature: 190°F (88°C) Operating Humidity: 99% RH Travel\Stroke: 12” (standard) (305 mm) Speed: 0-4.5 inches per sec Construction: Black Anodized Aluminum Size: 29.0” Length X 6.0” Width X 9.6” Height (737 mm x 152 mm x 244 mm) Drawings: Actuator Station, Dimensional drawing Actuator Station, Internal Wiring drawing

RYECO, Inc., Rev: 02 130--S 3-22 Ext Tube

SECTION 3.22 3100 Extension Tube

Figure 1 - 3100 Extension Tube and Mounting Assembly Note: In certain applications inverted installation is preferred.

Specifications Rotation 0 to 45 degrees Operating Temperature 32°F - 190°F (0°C - 88°C) Operating Humidity 99% RH Size (standard) 31.5” long x 4.75” wide x 4.125” high

(800mm x 120mm x 104.8 mm) Custom: Custom lengths 24 to 70 inches (609.6 – 1778 mm)

Custom shapes (goose-necks, other) 24 to 70 inches (609.6 – 1778 mm) Construction 316L Stainless Steel Internal voltage: 24 VDC

Function

• The 3100 Extension Tube houses the electrical cables, solenoids and tubing required to operate various modules.

• The Transition Box mounted on the end has slotted holes in the top and bottom to allow for alignment of various modules.

• The Tube Clamps allow the Extension Tube to be rotated to match any sheet angle and the Extension Tube may also be moved forward or backward in relationship to the mounting plate.

RYECO, Inc., Rev: 02 130--S 3-22 Ext Tube

Operational variables

• The position of the 3100 Extension Tube in the tube clamps can be moved backwards or forwards by loosening the clamps

• The extension tube can be rotated to match any sheet angle from the horizontal up to 45 degrees (Contact Ryeco for applications more than 45 degrees)

• The ideal position allows for about 3 inches (76.2mm) of forward travel prior to reaching FWD LIM on the actuator when on sheet

• Changing the alignment and rotation of the 3100 Extension Tube in the tube clamps allows the edge modules to match the sheet edge alignment requirements

• For systems without edge tracking: Adjust the position of the Extension Tube in the tube clamps to mark further into the sheet or further off-sheet

Scribing reference marks on the Extension Tube and Edge Modules will facilitate quick and accurate re-positioning after removing the units for maintenance.

Maintenance

Function Check A general Extension Tube functional check is done with all system components connected.

Warning!

• Do not use solvents or cleaning fluids inside the extension tube

due to the presence of electrical cables and tubing • Never spray cleaning fluids or water directly into the transition

box • Do not immerse the extension tube • Dry thoroughly before applying power if it becomes wet • Never operate the system without air pressure

RYECO, Inc., Rev: 02 130--S 3-22 Ext Tube Maintenance and Trouble-shooting

• The user can check the continuity of the five-pin yellow cable in the system as well as the signals to the solenoids. The pin layout of the cable is included in the drawings.

• The flow of dye and air through the extension tube can be checked by creating mark inputs to the system with the Edge Modules disconnected and removed.

• The Edge Modules (ETM, EMM etc.) can be removed from the transition box as follows:

o Mark the positions of the Edge Modules in the Transition Box before removing

o Disconnect the vacuum generator, 10 tube connection and interface cable o Remove the screws that hold the Edge Modules in place o Release the three 6-32 end cap screws at the back of the extension tube o Push the end cap of the extension tube forward into the extension tube

while pulling gently on the Edge Modules • This will expose the Edge Modules service connections at the back of each

Module • Once each Edge Module is disconnected the inner parts of the extension tube

can be pulled out through the back end of the extension tube (not through the transition box)

The solenoids in the extension tube can be activated if the power is on. Place a jumper between +24 VDC (position 1 on the terminal barrier strip) and terminal of the corresponding solenoid on the same terminal barrier strip. To determine the solenoids and terminals in the delivered system see enclosed extension tube wiring drawing. Periodic maintenance

• The technician may need to flush the dye supply lines if they have become contaminated (Refer to Section 3.1 - Ink Station)

• The air, dye and solvent solenoids need to replaced as needed when they have been determined as faulty

Warning!

• Always make sure the clamps are latched • Watch for the clamps hitting machine frames, equipment or in

the path of a moving scanner system

RYECO, Inc., Rev: 03 134--S 3-23 EMM 2010

Section 3.23 Edge Marking Module™ (EMM) Operation

Model 3112-3g Model 3132-3g/DS Models 3113-3g, 3131-3g

& 3161-3g

Figure 1. Various Edge Marking Modules

Specifications: Operating Temperature 190° F (88°C) Operating Humidity 99% RH Size 7.0” x 4.0” x 2.5” (178mm x 102mm x 64) Maximum angle from horizontal 45 degrees Construction 316L Stainless Steel Voltage level (when applicable) 24 VDC Standard EMM configurations are:

o 3111-3g is a single sided defect marker. It makes single color marks on the top surface of the web.

o 3131-3g is a three color defect marker. It makes defect marks on the top and bottom surfaces of the web.

o 3112-3g is a high speed (code) marker. It marks single color codes on the top (or bottom) surface of the web.

o 3113-3g is a defect and high speed (code) marker combination. It makes single color defect marks on the top or bottom or the web and single color code mark on the opposite surface of the web.

o 3133-3g is a defect and high speed (code) marker. It makes up to three colors of defect marks on the bottom and single color code mark on the top surface of the web.

o 3161-3g is a six-color defect marker. It makes defect marks on the top and bottom surfaces of the web.

o 3163-3g is a six color defect marker and one color high speed (code) marker. It makes defect marks on the bottom and code marks on the top surface of the web.

NOTE: User specific top and bottom sprayer configurations are available on request.

Function

• A Edge Marking Module™ typically applies a defect mark to the edge of a moving web and/or a high speed (code) mark further on sheet. Marks are usually atomized, although there are applications that benefit from an unatomized mark.

• A Defect gun is designed to efficiently mix and change colors. • The dye lines contain check valves to prevent individual dye seepage into the other

colors. • A high speed (code) gun is capable of high frequency marks and is designed to

precisely start and stop marks at designated intervals. Code guns can be used for defect marking in some applications.

• The 1/2” push fitting at the back of the module allows for the use of a vacuum system to remove over spray from the marker.

Installation

• The module is fastened inside of a transition box via a pair of 1/4-20 stainless steel screws.

Caution:

• Make sure that the Edge Marking Module is placed upright in the

transition box. Placing the EMM upside down will cause an excessive amount of dye to spill out of the module. Refer to Figure 1.

• The upright orientation of the marker is distinguishable by the top side containing the 1/4-20 screw mounting holes and the bottom side containing the 1/2” drain fitting at the back of the module

• There is a single quick disconnect connector on the back of the marker that groups the air, solvent and dye supply tubes together and a separate ½” push in fitting for the vacuum line.

Operational variables • The user can change the position of the EMM™, in the transition box, relative to the

tracking module to mark further into the sheet or nearer to the edge • This procedure also changes the width of the mark in cross machine direction. The

optimal position puts 90% of the mark on the sheet and 10% off. • The operator can change the position of the sprayers inside of the EMM, relative to the

each other to make code mark further into the sheet or nearer to the edge. The maximum offset is .29 inches (7,5 mm).

• The air atomization pressure to the EMM™ can be adjusted

• The dye tank pressure can be adjusted. This is commonly done from the Ink Station regulator to decrease droplet size (higher pressure) or increase droplet size (lower pressure) of the atomized dye on the sheet. (Refer to Section 3.3 -- Ink Station)

Figure 3 - EMM Adjustment

Tuning of operational variables

• To make the mark more visible from the end of the reel, the alignment on the sheet can be changed to mark closer to the edge.

• To make the mark narrower or wider, the distance of the spray nozzle from the web can be adjusted. To adjust the spray width, remove the Edge Marker Module Outer Cap, then loosen the sprayer mounting plate and slide the spray forward or backward. Moving the spray gun closer to the web will decrease the mark width..

• The air atomization can be changed to atomize more of the dye and slightly decrease drying time or atomize less dye with larger droplets, creating a coarser mark

• The recommended air pressure is 30 - 40 psi (2.0 –2.8 bar) for optimum atomization of the dye. Unatomized markers may require different air pressures.

• The dye tank pressure to the EMM™ can be adjusted between 1 and 5 psi (.07 – .34 bar) to increase the flow of dye. The /NF high speed (code) gun requires 5-7 psi (.34-.48) of dye pressure.

Maintenance

Functional Check

• Create spray marks on the sheet edge by using F1-F3 (F4) function keys on the Operator Station Display Panel or using the Actuator Station dye buttons (Not available in all models).

• Most systems are interfaced to a reel change mark input to create a mark at turn up.

• The user needs to make sure that clean air and water are supplied to the Ink Station at

all times, and check to see that there is an ample supply of dye in the tanks. (Refer to Section 3.3 --Ink Station)

Warning!

• Water is recommended as the cleaning agent for water based dyes • Solvent based dyes require dye specific solvents. Use the appropriate solvent for each dye. • Use only RYECO dyes and solvents. The use of alternate dyes and solvents void the Ryeco Warranty.

• The user can also create mark inputs to the Edge Marking System to simulate and verify the automatic spraying functions.

• Check a recent mark on the web o Make sure there is a mark on both top and bottom of the sheet (depending on

your model). o The ideal edge mark is achieved when the module is positioned to mark ninety

percent (90%) of the defect mark on the web and 10% off the edge of the web. This maximizes the visibility of marks from the end of the roll.

• Look inside the module jaw with a flashlight to see the internal waste dye collection tank; or rotate the head assembly when the system is off sheet, to check if any liquid runs out of the jaw. There should be a clear passage to the drain fitting and there should not be excessive debris inside of the inner tank.

Periodic maintenance

• Clean the Marker module periodically in place: o Manually retract the marking head assembly. o Push F4 function button on keypad display. The system will spray water

(solvent) and vacuum will be on. Repeat this procedure three or four times. • Change out the marker with a RYECO “Hot-Swap” and clean the removed marker

module by spraying warm water or ambient temperature solvent inside the jaw opening and allowing the liquid to drain. Repeat this procedure until the unit is clean.

• When removing the marking unit, cover the fittings on the back of the module to prevent paper or particles getting into the fittings.

• If required clean spray gun tip with Q-tip and warm water or solvent.

RYECO, Inc., Rev: 03 134--S 3-23 EMM 2010 Subassembly replacement

• Remove the ¼ - 20 stainless steel screws from the top of the transition box that hold the EMM and other modules in place – All modules in the transition box must be loose.

• Release the end cap at the back of the extension tube by removing the (3) 6-32 screws.

• Push the end cap of the extension tube forward into the extension tube while gently pulling the EMM out of the transition box.

• Now the EMM service connections are exposed at the back of the EMM. • The tubes can be removed from the fitting by pressing in on the release ring and

pulling out the tube connector. • When replacing the module, make sure that the EMM is installed upright and oriented

correctly. The ¼-20 screws are on the top of the transition box and the EMM is located downstream relative to the other modules.

RYECO, Inc., Rev: 04 138--S 3-24 ETM

SECTION 3.24 Edge Tracking Module (ETM-1000™)

Figure 1 - ETM Module

Specifications Operating Temperature: up to150°F (65°C) Operating Humidity: up to 85% RH Response time: 0.5mS Sensor Type: Infra-RED Signal Output: PNP open collector 100mA Size: 7.0”X4.0”X1.0” (178mm X 102mm X 25mm) Construction: 316L Stainless Steel

Function

• The Edge Tracking Module (ETM) is used to recognize the edge of the web and follow web wander. The tracking module generates two active high signals (100 mA open collector), FWD SENS and REV SENS, which are used to position the marking head assembly of the RYECO System.

• The ETM uses an air purge design that keeps the internal components cool and the optical windows free of debris.

Operational adjustments

Figure 2 - ETM Module Alignment Examples

• The position of the Edge Tracking Module, with respect to other modules in the transition box, can be changed, as per Figure 2 - ETM Module Alignment Examples

• Changing the alignment of the Edge Tracking Module™ in the transition box allows the other module(s) to function at different locations in cross direction on the sheet edge.

Maintenance

Function Check • The user needs to make sure that the required amount of instrument air is

supplied to the system at all times. • The user should feel air escaping from the optical windows inside the jaw

surface. • Simulate the paper edge and check that the system follows the edge movement.

o AUTO/MAN switch at the actuator station in the AUTO mode and the REMOTE ON input signal is applied

o Insert a piece of paper in the jaw and move the paper back and forth to simulate paper wander. The system will follow the paper edge

• An alternative method, for systems interfaced to a RYECO Actuator Station, would be to put the system into manual tracking mode at the Actuator Station (Refer to Section 3.21 -- Actuator Station)

o Turn the AUTO/MAN switch on the back of the Actuator Station to MANual

o Move the marking head assembly off sheet by turning the FWD/REV switch to the REVerse position (Do move past the reverse limit switch)

o Put the system back into AUTOmatic and the marking head assembly should move out and acquire the sheet edge

Warning!

• Do not use solvents or cleaning fluids inside of the module due to

electronic components, plastics and bonding agents within this unit

• Solvents may fog the optics and reduce the sensitivity • Never spray cleaning fluids or water directly into the optical

windows of the module • Do not immerse the module • Dry thoroughly before applying power if the module interior

becomes wet • Never operate the ETM-1000™ sensor without air pressure

How do I replace the subassembly

• The Edge Tracking Module™ is replaced by removing the two 1/4-20 S/S screws from the top and bottom of the transition box

• Slide the module out. If the module will not slide out of the transition box refer to Maintenance and Troubleshooting section of the extension tube. (Section 3.22)

• Remove the air and electrical connections. The air supply tube can be removed from the fitting by pressing in on the red ring and releasing the tubing.

Checking Signals

• The module produces outputs that can be checked in the following manner. With 24 Vdc applied to the five pin molded cable (24 Vdc at position 1, 0 Vdc at position 2), the technician can check the signals with a digital meter and a sample sheet of paper to simulate the web.

• The FWD SENS signal is on pin 3 and the REV SENS Signal is on pin 4. (The signals are active high 100 mA open collector).

• The technician can also check the condition of the LED output indicators on the forward and reverse amplifiers located inside the ETM housing.

• The green LED signals that 150% of the light for the signal is being received (stability) and the red LED signals that the amplifier is outputting (output high).

• For modules interfaced to a RYECO Operator Station, the outputs can be seen on the input side of the mini-controller LEDs (FWD SENS/REV SENS). With the system in off-sheet mode, you can insert a piece of paper all the way in the jaws and observe the mini-controller LEDs reversing condition.

The ETM-1000™ Edge Tracking Module Off-line Check and Adjustments

Figure 3 - ETM-1000 Amplifier Settings ETM Off-Line Check

• After moving the Actuator Station off sheet, mark the current ETM module

position in the transition box before removing the module from the transition box. • Remove the ETM-1000™ module from the transition box via two 1/4 x 20 SS

screws. (one on top and one on the bottom of the transition box) • Remove the lid held by the five 6-32 screws • Rest the module on a stable surface while still connected to the 5-pin yellow

cable. • The ETM-1000™ module contains two amplifiers, forward and reverse (see figure

3) • The FORWARD amplifier should be in "MODE" [1] • The REVERSE amplifier should be in "MODE" [E] • Both photo-amplifier Alarms (ALM.) should be OFF and the (TIMER) should be in

full counter-clockwise position • With power on and no paper in the jaw, both amplifiers should show a green LED

ON. This is the stability LED indicating that the light received is at 150% • If the green LED is not on for either amplifier, it must be adjusted with sens

potentiometer. • When there is no paper in the jaw the forward [1] amplifier red LED should be ON

(indicating an output) and the reverse amplifier red LED should be OFF • Placing the lightest sample of paper entirely in the jaws of the sensor will cause

both green LEDs to go OFF and the red LEDs should reverse conditions (The Reverse red LED should be ON and the Forward red LED should be OFF)

• Both red LED's will be OFF when paper is placed at the halfway point of the aperture indicating perfect alignment on the sheet edge.

RYECO, Inc., Rev: 04 138--S 3-24 ETM Amplifier Adjustment Procedure

• To adjust the amplifiers, pull the amplifier off of the din rail and pop off cover with a small screwdriver

• Turning the SENSitivity trimmer clockwise makes the sensor less sensitive, counter-clockwise, more sensitive

• Without paper in the jaws, turn the trimmer counter-clockwise until the green LED goes OFF

• Then turn the trimmer slowly clockwise until the green LED comes ON and continue one half turn clockwise

• Insert a lightweight sample of paper in the jaw to cover the front pair of apertures, the red LED should go OFF

• Move the sample of paper completely in the jaw covering both pairs of apertures, the red "REVerse" LED will come ON

Periodic maintenance

• Periodically wipe debris from the surfaces in the module jaw • If the module has been operated without air for a period of time, the module

interior and optics may need cleaning or replacing • If oil or drying agents (desiccant) have been introduced into the air system, the

module interior and optics may need cleaning or replacing

RYECO, Inc., Rev: 03 S 3-3 Ink Sta.doc

SECTION 3.3 Ink Station

Overview:

What is its’ function? • Serves as the initial routing point for vacuum air (if applicable), water, and service

air to the Marking System • Standard configurations include:

Model Tanks Capacity Colors 3111-3g One Five Gallons One 3112-3g One Five Gallons One 3113-3g One Five Gallons One

3131-3g & 3231-3g Two Five Gallons Three 3132-3g Two Five Gallons Three 3133-3g Two Five Gallons Three 3161-3g Three Two Gallons Six 3163-3g Three Two Gallons Six

What does it look like? • Made with 316L stainless steel for strength and resistance to corrosive agents • Overall Ink Station Dimensions for the different system configurations are shown:

Model Width Height Depth 3111-3g 12.8 in (324mm) 15.3 in (387mm) 14.1 in (357mm) 3112-3g 12.8 in (324mm) 15.3 in (387mm) 14.1 in (357mm) 3113-3g 12.8 in (324mm) 15.3 in (387mm) 14.1 in (357mm)

3131-3g & 3231-3g 19 in (482.6 mm) 15 in (381.0 mm) 14 in (355.6 mm) 3132-3g 19 in (482.6 mm) 15 in (381.0 mm) 14 in (355.6 mm) 3133-3g 19 in (482.6 mm) 15 in (381.0 mm) 14 in (355.6 mm) 3161-3g 19 in (482.20mm) 14.95 in

(379.73mm) 14.19 in

(36.31mm) 3163-3g 19 in (482.20mm) 14.95 in

(379.73mm) 14.19 in

(36.31mm)

• Standard ink stations hold replaceable polypropylene tanks • Tanks with level sensors are optional • There is a tubing shroud exiting the right hand side of the enclosure that houses

1/4” (6 mm) and 3/8” (10 mm) tubing. o The 1/4” (6 mm) tubes supply the air, water and dye to the ten-tube

connector at the end of the shroud. o The 3/8” (10 mm) tube supplies air for the vacuum generator located at

the end of the shroud. • The tubing shroud is typically configured at the factory for 20 feet (6.1 meters)

Specifications: Operating Temperature 32° F - 190° F (0° C - 88° C) Operating Humidity 99% RH • The enclosure houses:

o The air atomization, solvent and dye pressure regulators o The atomization and vacuum air supply solenoids

• It has mounting holes on the back and bottom for flexibility in mounting locations.

Figure 1 –Ink Station

(Shown with three 2-Gallon Tanks) Operation:

What are the operational variables? • The operator can change the air atomization pressure from the regulator located

on the front panel of the Ink Station • The operator can change the dye tank pressure from the regulator located on the

front panel of the Ink Station (except in 3111-3g systems) • The operator can change the ETM purge pressure from the regulator located

inside the Ink Station chassis • The operator can change the solvent pressure from the regulator located inside

the Ink Station chassis • Dye can be added to the reservoirs

Why would I change the operational variables? • The air atomization to the Edge Marking Module can be changed to:

o Atomize more or less of the dye o Change the intensity of the mark o Effect the drying time of the dye o Typically set between 32 and 40 psi (2.2 and 2.8 bar) o Non-jawed marker applications 5 – 10 psi (.34 -.69 bar) (If applicable)

• The dye tank pressure can be changed to: o Allow more or less of the dye flow to change the intensity of the mark o Set between 1 and 5 psi (.07 and .34 bar) for defect guns o Set Between 3 to 8 psi (.2 to .6 bar) for /NF type code guns

How can I check its’ operation? • Check the marking functions by pressing the manual dye buttons located on the

Operator Station keypad or on the door of the Actuator Station • Clean air and solvent should be supplied to the Ink Station at all times. A low air

pressure sensor is located in the ink station that will provide an output signal if the customer supplied air pressure drops below a minimum of 60 psi (4.14 bar).

• Check that there is an un-contaminated and un-diluted supply of dye in the reservoirs

Warning!

• Always tighten the lids on the reservoirs after filling. Use only

full strength RYECO approved dye • Do not dilute (adding water dilutes the preservative which inhibits

biological formations) • Do not mix the dye colors in the dye tanks

Maintenance:

How do I check its’ function?

• Check to see that the dye reservoirs are pressurized by turning off the air supply, slowly removing the dye reservoir lid, and observing the de-compression of the tanks

• Fill dye reservoirs with RYECO dye only • Ensure all lids are tightened properly to maintain the reservoir pressurization • Check that the Ink Station has an adequate supply of un-contaminated and un-

diluted dye • The flow of dye and solvent can be checked at the quick disconnect ten tube

connector: o Compress the appropriate shutoff valve on the female ten tube connector.

A steady trickle of fluid should be delivered to that position according to the Ink Station tubing drawing

o Solvent flow can be checked by pressing the F4 button on the Operator Station keypad while the appropriate shutoff valve is compressed. (except 3111-3g systems)

• Ensure that a minimum of clean air 60 (6.2 bar) and water 10 psig (.7 bar) are supplied to the Ink Station

• Check the inline vacuum generator for overspray evacuation during a mark sequence

• Vacuum top to bottom bias (with optional bottom vacuum unit installed) can be adjusted via inline adjustment valves in system 3231-3g. (#12434 valves are factory preset for optimum performance)

• Check the output/drain of the vacuum generator for any obstructions and ensure the drain line is vented

What periodic maintenance is needed? • Clean the reservoirs thoroughly if they become contaminated, diluted or the

wrong dye has been introduced • If there has been contamination clean the reservoirs and fill with solvent. Tighten

the lid and allow it to pressurize, then compress the corresponding valve at the ten tube connector until clear solvent is flowing

• Then reconnect the ten-tube connector to the extension tube. Remove the EMM and repeat procedure by pushing the mark activation buttons at the Operator Station or Actuator Station

• Empty and dry the reservoirs thoroughly and fill with RYECO dye. It is recommended to do this procedure approximately every 6 months or if the reservoirs have been contaminated

What setup changes and adjustments can I make? • The air atomization pressure can be adjusted by turning the knob on the front

panel of the ink station • The dye reservoir pressure can be adjusted by turning the knob on the top of the

front panel of the ink station • The current atomization and dye reservoir pressure will be displayed on the

gauge located on the front panel of the ink station • Use caution when adjusting the dye reservoir regulator. If the pressure is set too

high it may damage the dye reservoir • The solvent supply pressure can be adjusted by changing the settings of the

preset regulators located within the Ink Station

How can I quickly troubleshoot the subassembly? • The flow of dye and solvent can be checked at the quick disconnect ten tube

connector: o Compress the appropriate shutoff valve on the female ten tube connector.

A steady trickle of fluid should be delivered to that position according to the Ink Station tubing drawing

o Solvent flow can be checked by pressing the F4 button on the Operator Station keypad while the appropriate shutoff valve is compressed. (except 3111-3g systems)

How do I replace the subassembly? • To replace the dye reservoirs:

o Shut off the air supply to the Ink Station o Release the pressure in the reservoir by slowly unscrewing the lid o Remove the pressurization air and fluid compression fittings o Lift the tank out of the Ink Station o Tanks do not need to be empty to remove o Insert new tank and reconnect lines

Drawings Ink Station, Wiring Ink Station, Tubing

RYECO, Inc., Rev: 01 S 3-4 Software 3133_NF (R01).doc

SECTION 3.4 SOFTWARE FUNCTIONS FOR HIGH SPEED

MARKING WITH DEFECT MARKING TABLE OF CONTENTS: 3.4.1 GENERAL

- MARKING SYSTEM MOVEMENTS AND CLEANING FUNCTIONS - HIGH SPEED MARKING - DEFECT MARKING - DEFECT MARK SEQUENCE

3.4.2 INPUT/OUTPUT DESCRIPTIONS AND RELATED FUNCTIONS

- INPUT NUMBERS AND DESCRIPTIONS - OUTPUT NUMBERS AND DESCRIPTIONS

3.4.3 SYSTEM FUNCTIONS AND SYSTEM PARAMETERS - FIRST SCAN - ACTUATOR MOTOR TIME OUT SAFETY FUNCTIONS - SHEET EDGE MOVEMENT SENSITIVITY FILTERING - CYCLICAL OFF SHEET FLUSH FUNCTION - OFF SHEET FLUSH - SYSTEM RE-PRIME - REEL CHANGE WATER PURGE AND MARKING - SHEET BREAK - FWD/REV DISAGREE - DIAGNOSTICS ERROR - DEFECT MARKING - ATOMIZATION OFF DELAY

3.4.4 CABINET FRONT PANEL DISPLAY PARAMETERS AND MESSAGES 3.4.5 ACCESSING TIMERS AND DATA MEMORY 3.4.6 FRONT PANEL DISPLAY UNIT FUNCTIONS

3.4.1 GENERAL MARKING SYSTEM MOVEMENTS AND CLEANING FUNCTIONS

• For automatic operation of the marking system, the Actuator Station Auto/Man switch must be in AUTO position.

• All automatic marking and tracking functions are disabled when the Actuator Station Auto/Man switch is in the MAN position.

• The marking head assembly will prime all colors and leave reverse limit to acquire the sheet edge when the REMOTE ON (input) signal transitions from low to high.

• The marking head assembly will remain on sheet while the REMOTE ON (input) signal is being received.

• The marking head assembly will retract to reverse limit and complete a sheet break flush routine when the REMOTE ON (input) signal transitions from high to low.

• The marking head assembly will retract to reverse limit and remain there when the programmable logic controller (PLC) receives the forward sensor (FWD SENS) and reverse sensor (REV SENS) input signals at the same time.

• When the REEL CHANGE (input) signal is received, the marking head assembly will retract from the sheet edge and perform a solvent flush routine followed by a re-prime of all dye colors. The marking head assembly will then re-acquire the sheet edge and continue all marking and tracking functions.

• During extended outages, the Ryeco system can perform an off sheet solvent flush routine for a predetermined amount of time. This function can be activated using the PLC located in the Operator Station.

HIGH SPEED MARKING

A high speed spray gun is located at the front of the EMM jaw. This will allow the high speed spray gun to mark further onto the web material leaving a space between the mark and the edge of the web. The area between the mark and the edge of the web is known as ‘White Capping’.

High Speed marks are short marks that vary depending on the type of spray gun used.

High Speed marks are controlled by the Web Inspection System by providing a “high signal” to the High Speed Mark input.

The High Speed marker can be used:

- To mark distance (feet or meters) on the reel.

- To mark defects (Not applicable with the NF spray gun version)

High Speed marks are made using an electrically activated, specially designed, high speed spray gun.

Cameras or sensors are used to read High Speed marks usually before slitting at the winder to assist in locating defects.

DEFECT MARKING

Defect marks can vary in length depending on customer requirements. Since the mark needs to be visible from the edge of the roll, the standard length is usually between 3-10 seconds. The defect spray nozzle orientation is also located deeper in the jaw of the Edge Marking Module (EMM) to ensure that only the edge of the sheet is marked.

DEFECT MARK SEQUENCE

The sequence of a defect mark starts with a 1 second 24VDC pulse signal from the Web Inspection System (WIS). Once this signal is received the Ryeco system will activate and spray the appropriate dye color (based upon customer request), atomized air (used to control the amount of dye and solvent droplets), and vacuum generator (used to remove any excess dye and solvent droplets during the mark sequence).

After the initial defect mark, the Ryeco system will perform a fade length routine. This routine will spray solvent (used to dilute the dye and keep the sprayer tip from plugging with dried dye), atomized air (used to control the amount of dye and solvent droplets), and vacuum generator (used to remove any excess dye and solvent droplets during the mark sequence). View diagram below. Defect Mark Sequence Diagram Mark Input __~_____________________________________________________ Dye Length ___~~~~~~~~~~__________________________________________ Fade Length ______________~~~~~~~~~~_______________________________ Atomization Air ___~~~~~~~~~~~~~~~~~~~~~_______________________________ Vacuum Air ___~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~____________

Device Value range Label Function Preset

DM 0008 0-65535 (0.1 Second) Defect Length

The value in this Data Memory determines the

length of the defect mark. 10.0 Seconds

DM 0009 0-65535 (0.1 Second) Fade Length

The value in this Data Memory determines the length of the fade length.

3.0 Seconds

3.4.2 INPUT/OUTPUT DESCRIPTIONS AND RELATED FUNCTIONS INPUT NUMBERS AND DESCRIPTIONS

A complete list of Inputs with a description of each function is listed in the following table.

Note: Some inputs may not apply to this installation. INPUT NUMBERS DESCRIPTIONS

(HS) MARK 1 [000] This input is used for all high speed marking other than defects. ----- [001] Not used in this application.

MANUAL MODE [002] Disables all automatic marking functions when high. ----- [003] Not used in this application.

TACH IN [004] Allows the customer to control the length of the defect mark while matching machine speed.

TACH IN [005] Allows the customer to control the length of the defect mark while matching machine speed.

FWD SENS [006] Moves the marking head assembly forward to acquire the sheet edge when in automatic mode and receiving a remote on signal.

REV SENS [007] Moves the marking head assembly away from the sheet edge when in automatic mode and receiving a remote on signal.

FWD LIM [008] Stops the marking head assembly from moving into the mechanical stop and damaging the actuator motor. Also, when this input is high, it sets the internal sheet break condition in the mini controller.

REV LIM [009] Stops the marking head assembly from moving into the mechanical stop and damaging the actuator motor. This input also sets the sheet break solvent flush condition in the mini controller.

REMOTE ON [010]

Sends the marking head assembly out to acquire the sheet edge and prepare to make high speed or defect marks when the actuator station is in auto mode. This signal must remain high for the marker to stay on sheet. When a sheet break occurs, this signal must be recycled in order to move the marking head assembly back to the sheet edge.

MARK 1 [011] Input signal from WIS that will spray the appropriate color located in the Dye 1 ink tank of the ink station.

MARK 4 [014] Input signal from WIS that will spray the appropriate color located in the Dye 1 and Dye 3 ink tanks of the ink station.

REEL CHANGE [101] The marking head assembly will retract from the sheet edge, complete a solvent flush routine, re-prime all dye colors, and then re-acquire the sheet edge.

MAN DYE 1 [102] Will spray Dye 1 as long as the button is pressed on the actuator station or operator station.

CRACK/MARK SENS [105]

This input is high whenever a crack is detected in the web material or whenever the system Is utilizing mark verification to read marks.

LOW LEVEL DYE [106] Indicates that there are low levels of dye in the dye reservoirs. It also activates “Diagnostic Error” output signal.

LOW AIR PRESS. [107] Indicates that the air supplied to the system has dropped below the minimum operating range of 60 psi (4.14 bar) minimum. The “Diagnostic Error” output signal is activated.

OUTPUT NUMBERS AND DESCRIPTIONS

A complete list of Outputs with a description of each function is listed in the following tables.

Note: Some inputs may not apply to this installation. OUTPUT NUMBERS DESCRIPTIONS

SPRAY GUN 1 [500] Controls all high speed marking nozzles.

INTERNAL PULSE [501] Protects the high speed nozzle from an excessive mark input by resetting the length of the input after 2 milliseconds.

ATOM AIR SOL 1 [502] Activates the High Speed Marker atomizing solenoid. ATOM AIR SOL 2 [503] Activates the Defect Marker atomizing solenoid.

(HS) DYE SOL [504] Activates the High Speed Dye solenoid. DYE SOL 1 [505] Activates the Defect Marker Dye 1 solenoid. DYE SOL 2 [506] Activates the Defect Marker Dye 2 solenoid.

DYE SOL 3 [507] Activates the Defect Marker Dye 3 solenoid. SOLVENT SOL 1 [508] Activates the High Speed solvent solenoid. SOLVENT SOL 2 [509] Activates the Defect solvent solenoid.

VAC SOL [510] Activates the Vacuum solenoid during all marking and flush routines.

MTR FWD [511] Will cause the actuator to move forward when in auto mode. MTR REV [512] Will cause the actuator to move backward when in auto mode.

ON SHEET OUT [513] Signal will remain high while the system is on sheet.

DIAGNOSTIC ERROR [514]

Will remain high until an error condition occurs. Error conditions are: low air pressure, low dye tank levels and a forward / reverse disagree bit.

MARK ERROR [515] Signal is used in the Mark Verification option when a mark is not detected within a specified time frame. This signal will go from high to low when an error occurs.

3.4.3 SYSTEM FUNCTIONS AND SYSTEM PARAMETERS FIRST SCAN When the power is turned on to the Operator Station, the actuator will retract to reverse limit. Note: The Actuator Station should be in manual mode when system power is turned on. ACTUATOR MOTOR TIME OUT SAFETY FUNCTIONS The motor forward and motor reverse timeout timers protect the actuator motor from damage in case the forward or reverse limit switch fails. NOTE: These timers should be adjusted based on the length of the actuator. For a 12-inch actuator the recommended time in 8 seconds: for a 24-inch actuator the value is 10 seconds. Device Value range Label Function Preset

T/C 000 0-65535 .1 Sec Timer

MTR FWD Timeout

A safety timer to protect the actuator motor from damage in

case the forward limit switch fails.

10.0 Seconds

T/C 001 0-65535 .1 Sec Timer

MTR REV Timeout

A safety timer to protect the actuator motor from damage in

case the reverse limit switch fails.

10.0 Seconds

SHEET EDGE MOVEMENT SENSITIVITY FILTERING Poor, continuously uneven sheet edge can cause the Edge Tracking Module (ETM) to continuously output positioning signals. This can lead to excessive actuator positioning movement or constant marking head assembly oscillation on the paper edge. Filtering the Forward Sensor and Reverse Sensor signals with short leading edge timers eliminates the unnecessary motor control signals and prevents excessive movement and oscillation. Note: The filter timers must be short so that they do not affect the system capability to track the sheet edge. For example: 10 ms equals 6” (15 cm) at 3000ft/min (1000 m/min).

T/C 034 0-65535 .001 Sec

FWD SENS Filter

Minimum accepted Forward Sensor signal (Recommend 10

ms) 10 milliseconds

T/C 035 0-65535 .001 Sec

REV SENS Filter

Minimum accepted Reverse Sensor signal (Recommend 10

ms) 10 milliseconds

CYCLICAL OFF SHEET FLUSH FUNCTION During extended outages, an off sheet cleaning cycle can be selected to activate at designated time intervals. This function will keep the spray nozzles clean and free of obstructions. When this function is active, the cycle interval can be defined through the Operator Station front panel display. The water flushing functions are described in the OFF SHEET FLUSH section.

DM 0030 0-65535 Water Flush Activation

Value of 1 or higher activates and 0 deactivates

0=Off 1=On

T/C 006 0-65535 .1 Sec Timer

Water Flush Cycle

Water flush will commence at set time interval.

(3600.0 sec =1 hr)

3600.0 seconds

SYSTEM RE-PRIME When a new or recycled REMOTE ON input signal is received, the system will prime all colors before moving to acquire the sheet edge.

T/C 007 0-65535 .1 Sec Timer Re-Prime Primes all colors when the remote

on signal is received.

REEL CHANGE WATER PURGE AND MARKING When the reel change signal is received, the marking head assembly will retract from the sheet edge, complete a solvent flush routine, re-prime all dye colors, and then re-acquire the sheet edge.

T/C 008 0-65535 .1 Sec Timer

R/C MTR REV

Motor reverses for set time at reel change. 10

T/C 009 0-65535 .1 Sec Timer

R/C Solvent Flush

Performs solvent flush for set time on reel change. 30

T/C 012 0-65535 .1 Sec Timer

R/C Re-prime

Re-primes all colors for set time on reel change. 30

SHEET BREAK In the event of a sheet break, the system attempts to acquire the sheet edge. When the forward limit (FWD LIM) has been reached and the signal is active for 1 second, the Ryeco system interprets this as a sheet break and retracts to the reverse limit (REV LIM). Once the reverse limit (REV LIM) is reached, the marking system will perform an off sheet flush cycle.

Note: To reacquire the sheet edge and resume defect marking, the REMOTE ON signal must be recycled. FWD/REV DISAGREE When both the FWD SENS and the REV SENS signals from the Edge Tracking Module are active at the same time, the marking system interprets this as an error in the tracking module. The actuator is retracted to reverse limit and will remain at reverse limit until the error has been corrected. An error message will appear on the Operator Station front panel display screen and the Diagnostic Error output will transition from low to high. DIAGNOSTIC ERROR When one of the 3 error signals are activated (Low Level Dye, Low Air Pressure, FWD/REV Disagree bit), the Diagnostic Error output will transition from low to high and an error message will be written to the Operator Station front panel display screen. If 2 or more errors occur simultaneously, the screen will read ‘Multiple Errors’. DEFECT MARKING Defect length defines the time the system will mark a defect when a one-shot signal is applied to a Mark 1, 2, 3, 4, 5, or 6 Input. If the value is zero, the length of the signal given by the customer control system will determine the length of the defect mark.

ATOMIZATION OFF DELAY Atomization off delay is provided to prevent sprayer spotting due to non-atomized dye on the sheet at the end of a defect mark. This timer should be increased until spotting is no longer present. 3.4.4 CABINET FRONT PANEL DISPLAY PARAMETERS AND MESSAGES THE FRONT PANEL DISPLAY PARAMETERS MUST BE CHECKED AND ENTERED BEFORE THE USE OF THE MARKING SYSTEM. The following displays with parameters are shown on the four-line front panel display:

SW. Version: XXXX Pulse Width: 8 On Prime: 3

“OFF SHEET FLUSH ON” FADE LENGTH 5 DEF LENG 2

Reference Only 3.4.5 ACCESSING TIMERS AND DATA MEMORY

The following are step-by-step instructions for accessing the devices from the Face Plate of the KV-40 DTP Mini-Controller: Note: Press the ⇔ key then the until the screen shows the device DM in the top left corner.

1. Select the device type with the key (Timers and counters = TC, Data Memory = DM). 2. Select the device number with the / keys. 3. Hold the key for 3 seconds until the set value appears at the bottom of the screen (the

digit on the far left will flash.

4. Select the digit to be changed using the key (the digit to be changed will flash until the

next digit is selected).

5. Change the selected digit using the / keys.

6. Hold the key for 3 seconds to enter the new set value into the selected device number. 3.4.6 FRONT PANEL DISPLAY UNIT FUNCTIONS The FRONT PANEL DISPLAY provides access to some system functions and manual operations. The table below shows the function for each key on the Display.

Setting Operation Key Function Allows the selection of increment (decrement) quantity.

/ Allows the Increases/decreases current value with selected increment/decrement quantity.

Moves to numeric value change status when pressed and held for 3 seconds

F 1 F 2 F 3 F 4

To make a Parameter Change complete the following steps:

• Press the / Keys to move between pages. • Press and hold the Key for 3 seconds until the first parameter line on

the page begins to flash. • Press the / Keys to highlight the parameter to be changed. • Press the Key to highlight the digit to be changed. • Press the / Keys to increase/decrease the parameter value. • Press and hold the Key for 3 seconds. • Repeat as needed for each parameter.

NOTES:

RYECO, Inc., REV00 146--S 4-0 Title Page

4.0 Component Layouts, Parts List, and Material Safety Data Sheets (MSDS)

4.1 Component Layouts

4.2 Parts List

4.3 Material Safety Data Sheets (MSDS)

Extension Tube 3133-3g/NF Sub Assembly # 20 063 315

11172 18108(2) 18110(3)

10080 11844

10552 10553

10580 11826(2)

11190 11210

(refer to parts list for descriptions)

11762 11729

Actuator Station 12” Sub Assembly # 20 109 003

And 24” Sub Assembly # 20 109 005

11920(2) 10951(2) 11919(2) 10956

10950 (12”) 10955 (24”) 11867

Actuator Station 3131-33-3g Sub Assembly # 20 123 100

& # 20 123 110 20 163 100

OR 20 163 110 (METRIC) Actuator Control Box

20 109 003 Actuator Replacement

See following pages (refer to parts list for descriptions)

Actuator Control Box 3131-3g, 3133-3g, 3113-3g Sub Assembly # 20 163 100

#20 163 112 & 20 163 110 (METRIC)

11991 11993 (X 2)

11990 11993

11852 (15)

11989 11992 11993 11994

11645(2)

10065 10020

(Configuration may vary, refer to parts list for descriptions)

EMM 3133-3g/NF/NE Sub Assembly # 20 363 315

10110(1) FOR SOLVENT

LINE ONLY

11190 11210

11912 12340

20 873 101 W / 20 873 010

20 393 010 W / 12308

19109(5) FILTERS 19110 (INSERTS)

ETM 100 MODULE Sub Assembly # 20 400 001

10520 (2) 10530 (2) 10052 10720

10350 (COVER) NOT SHOWN

INK STATION 3133/NF Sub Assembly # 20 563 315

and #20 563 316

10860 13028 11030 11861 (2)

10912 (2)

10861 11818

11081 18109 11748 10900 11797

11170 11200

13045 WATER FILTER

(NOT SHOWN), w/13058 CAR-

TRIDGE

12356 PRES-SURE

OPERATOR STATION 3131-63-3g Sub Assembly # 20 663 100

11856 11857 11858

11102 11704 11694 11842 11251(2) 11016

11852 (22)

RYECO Incorporated #100569-HWSS-TPJI-3133-3g/TE/NF/BS/NE/MT-MPM5

Parts List

S/A Number: 20 063 315 EXT TUBE 3133/NF

Part Number Description U/M Quantity 10031 Cable Pigtail 12-Pin each 1

10080 CABLE 5 PIN,FEMALE,MOLDED 6' each 1

10552 EXT TUBE 3.5 3100 each 1

10553 TRANSITION BOX - 3100 each 1

10580 CLAMP LATCH each 2

10620 END CAP 3.5 7100 each 1

10630 MOUNTING PLATE 2.5 & 3.5 each 1

10650 SOLENOID MOUNTING BRACKET each 1

10730 FTG 1/8 BARB "T" PLASTIC each 2

10751 FTG 10-32M X 1/8 BARB SS each 6

10763 FTG 1/4NPTMX1/8NPTF REDUCER each 1

10780 FTG 1/8NPTF ELBOW BRASS each 1

10800 FTG 1/8NPTM X 1/8BARB BRASS each 2

10849 FTG 1/4 NPTM X 1/2 PUSH NKL each 1

11042 DIODE, ZENER each 1

11049 DIODES - SOLENOIDS each 1

11172 CONNECTOR TEN TUBE FEMALE each 1

11190 CONNECTOR TEN TUBE MALE each 1

11210 WALL MT TEN TUBE CONNECTOR each 1

11280 TUBING 1/4 OD POLYURETHANE ft. 9

11281 TUBING 1/4 OD POLYETHYLENE ft. 18

11311 TUBING 1/2 OD POLYETHYLENE ft 3

11729 FTG 1/2CMPX3/8NPTF SS BH each 1

11762 FTG 3/8 NPTM SS QD each 1

11826 TUBE CLAMPS 3.5-3g each 2

11827 TUBE CLMP HNGE PLATE-3g each 4

11828 TUBE CLAMP HINGE PIN-3g each 4

11844 CABLE 3 PIN F MOLDED 6' each 1

11935 FTG 1/8 PLASTIC PLUG each 2

11942 BARRIER STRIP 12 EURO each 1

12102 VORTEX TUBE, AIR 8 CFM each 1

12316 FTG CPLR 1/4 NPTF SS each 1

13054 FTG 1/2"OD PUSH "Y" each 1

18037 FLOW RESTRICTR .010 each 1

18039 FLOW RESTRICTOR .04, 1/8 BRB each 1

18108 SOLENOID-LM-AIR each 2

18110 SOLENOID-LM-DYE each 3

18112 SOLENOID PLUGS-LM each 2

18148 FTG 10-32MX1/8 ELB SWIVEL each 4

S/A Number: 20 109 003 ACT REPL 3131-63

Part Number Description U/M Quantity 10950 LINEAR ACTUATOR TOLO "12" each 1

10951 MOUNTING FEET TOLO

ACTUATOR each 2

10956 ACTUATOR MOTOR COVER each 1

10992 PLUG KNOCKOUT 1.5 DIA PLTD each 1

11867 WIRE-ACT MOTOR ft 3

11919 LIMIT SWITCH-FEMALE EACH 2

11920 LIMIT SWITCH-MALE EACH 2

S/A Number: 20 123 100 ACT STA 3131-33-3g

Part Number Description U/M Quantity

20 109 003 ACT REPL 3131-63 each 1

20 163 100 ACT CNTRL BOX 3131-33-3g each 1

S/A Number: 20 163 100 ACT CNTRL BOX 3131-33-3g

Part Number Description U/M Quantity 10020 Connector .750 HUB Elbow each 1

10065 CABLE 12 PIN F MOLDED 3' each 1

10086 CABLE 10 STRAND WIRE feet 1

10280 DINRAIL ft. 1

10450 BACK PLATE 8 x 6 each 1

10864 GROUND LUGS (7 POSITION) each 1

11645 TERM BLK - END BRACKET each 2

11665 3/4 NUT FOR CONN 10020 each 1

11689 ENCL ACT BX-RA each 1

11815 CORD GRIP, PG-16, BH each 1

11816 CORD GRIP, PG-21,BH each 1

11852 TERM BLOCK STACKABLE each 15

11853 TERM BLK END PLATE-LF each 1

11873 FIXED BRIDGE 2 POS each 2

11982 LEGEND "AUTO/MAN" METAL each 1

11983 LEGEND "FWD/REV" METAL each 1

11986 LEGEND "DYE 1" METAL each 1

11988 LEGEND "DYE 3" METAL each 1

11989 SWITCH 2 POS, GE each 1

11990 SWITCH 3 POS RTN TO CTR,GE each 1

11991 SWITCH 1 POS MOMENT BLACK,G each 2

11992 SWITCH BLK N/C, GE each 2

11993 SWITCH BLK N/O,GE each 5

11994 SWITCH FLANGE 5 POS,GE each 1

12002 PLUG KNOCKOUT 1/2 B/NYL each 1

12003 PLUG KNOCKOUT 7/8 B/NYL each 1

19074 SWITCH BLK N/O STKBL, GE each 1

S/A Number: 20 363 315 EMM 3133-3g/TE/NF/BS/NE

Part Number Description U/M Quantity 10110 CHECK VALVE 1/16 each 1

10731 FTG 1/8 BRB "Y ", NYLON each 1

10750 FTG 10-32M X 1/8 BARB BRASS each 2

10806 FTG 3/8 NPTM X 1/2 PUSH NKL each 1

10835 FTG 1/16 BRB " Y ", SS each 1

11174 TEN TUBE M-INSERT 1/16 ID each 5

11190 CONNECTOR TEN TUBE MALE each 1

11210 WALL MT TEN TUBE CONNECTOR each 1

11272 TUBING 3/16 OD POLYETHYLENE ft 4

11280 TUBING 1/4 OD POLYURETHANE ft. 1.5

11829 HOUSING EMM-3g each 1

11830 COVER,HOUSING EMM-3g each 1

11833 BRACKET EMM 10 TUBE-3g each 1

11835 SPRAYER MT PLATE-3g each 2

11845 CABLE PIGTAIL 3 PIN each 1

11894 INNER TANK EMM-3g_1.32 each 1

11903 SPRAYER MOUNTING SHIMS each 1

11912 OUTER CAP EMM-3g_30 deg_S each 2

11931 Cable Assy /NC Coil/NF Valve each 1

11935 FTG 1/8 PLASTIC PLUG each 2

12338 Insulator, EMM, NF each 1

12340 Insulator, Outer Cap, NF each 1

13033 FTG 1/16" ELBOW BARB PP each 1

19109 FILTER, 1/16" BRB, Nylon each 5

19110 Filter, Replacement 1/16" Br each 0

20 393 010 SPRAY GUN/NF-3g each 1

20 873 101 Spray Gun/NE, 3T each 1

S/A Number: 20 393 010 SPRAY GUN/NF-3g

Part Number Description U/M Quantity 11934 O-RING ESPRAYER ADJ SCREW each 1

12301 GUN VALVE, NF each 1

13049 COLLET, NF GUN each 1

13050 NOZZLE BODY NF GUN each 1

13051 RETAINER NF GUN each 1

13057 NOZZLE CAP-3g NF GUN each 1

S/A Number: 20 400 001 ETM-1100

Part Number Description U/M Quantity 10052 Cable Pigtail 5 Pin M SS each 1

10341 TERMINAL BLK 5 POS FOR ECD each 1

10350 LID ETM/ECD each 1

10490 HOUSING ETM each 1

10520 PHOTO EMITTER & RCVR ETM set 2

10530 AMP PHOTO ETM each 2

10720 FTG 1/4" OD Pushx 10-32M NKL each 1

10811 FTG 10-32F BULKHEAD (NICKEL) each 1

S/A Number: 20 563 316 INK STA 3133-3g/NF/MT

Part Number Description U/M Quantity 10086 CABLE 10 STRAND WIRE feet 25

10603 HOSE CLAMP 5/8 DIA. SS each 1

10605 HOSE CLAMP 3/4 each 1

10679 FILTER SCREEN 1/4ID SS each 2

10690 FTG 1/4 CMP X 1/4 CMP BH SS each 2

10720 FTG 1/4" OD Pushx 10-32M NKL each 2

10730 FTG 1/8 BARB "T" PLASTIC each 4

10731 FTG 1/8 BRB "Y ", NYLON each 1

10741 FTG 6MM BLKHEAD UNION SS each 1

10742 FTG 10MM BLKHEAD UNION SS each 1

10750 FTG 10-32M X 1/8 BARB BRASS each 4

10759 FTG 1/4X1/4X1/8 BRB "T" each 1

10763 FTG 1/4NPTMX1/8NPTF REDUCER each 2

10780 FTG 1/8NPTF ELBOW BRASS each 1

10792 FTG 1/8NPTM X 10-32F "T" each 1

10799 FTG 1/8NPTM X 1/4 BARB ELBOW each 3

10800 FTG 1/8NPTM X 1/8BARB BRASS each 4

10802 FTG 1/8NPTM X 1/8BRB SS each 4

10811 FTG 10-32F BULKHEAD (NICKEL) each 2

10860 GAUGE - AIR 60 psi each 1

10861 GAUGE-AIR/WATER 15 psi each 1

10900 FRONT PLATE INK ST 3 TANK each 1

10912 INK TANK 5 GAL, (20L) each 2

10913 Clamp 1/4 Screen SS each 2

11030 REGULATOR-AIR 0-150 PSI each 1

11081 SOLENOID VALVE SPOOL 24VDC each 1

11170 CONN. TEN TUBE FEMALE S/OFF each 1

11173 TEN TUBE F- INSERT 1/8 BRB each 1

11180 TUBE JACKET 1.375 ft. 20

11200 TUBE SHROUD each 1

11281 TUBING 1/4 OD POLYETHYLENE ft. 125

11290 Tube .250 x .180, 316SS ft. 2

11315 TUBING 6MM OD POLYURETHANE each 2

11316 TUBING 10MM OD POLYURETHANE each 0.5

11547 FTG MUFFLER 1/8 NPT each 1

11593 INK STAT. TUBE FLANGE each 1

11730 AIR VACUUM each 1

11734 TUBING 5/8 ID PVC REINFORCED Ft 7

11748 REG-AIR PRECISION each 1

11763 FTG 3/8 NPTF SS QD each 1

11792 HOSE CLAMP 1.5" DIA. SS each 1

11797 CHASSIS INK ST 10 GAL each 1

11818 REGULATOR-WATER each 1

11860 BARRIER STRIP 10 POSITION each 1

11861 SOLENOID 2WY-N/C-24VDC-7W each 2

12098 Ftg 3/8" NPTM "T" PUSH each 1

12341 VALVE, SHUT-OFF 1/4 X 3/8 each 1

12356 Valve, Relief,1/4"Push Union Ea 1

13028 LOW AIR PRESSURE SWITCH each 1

13045 FILTER, POREX, 40 MICRON each 1

13058 FILTER, REPLACEMENT each 0

18039 FLOW RESTRICTOR .04, 1/8 BRB each 1

18052 FTG 1/8NPTMX1/8 BARB ELB BRA each 3

18109 REG/GAUGE-ETM AIR each 1

20 590 004 FLOW RESTRICTORS SPARES each 2

S/A Number: 20 663 100 OP STA 3131-63-3g

Part Number Description U/M Quantity 10086 CABLE 10 STRAND WIRE feet 3

10280 DINRAIL ft. 1.5

10864 GROUND LUGS (7 POSITION) each 1

10980 Wire Duct Slotted, 1" x 2" ft 1

11016 POWER SUPPLY 24VDC 6.5 each 1

11102 CB SOLID STATE CONTR CARD each 1

11251 TERM. BLK RELAY- 24VDC-SPDT each 2

11645 TERM BLK - END BRACKET each 2

11694 CB Single Pole 24 VDC 4 AMP each 1

11697 BACK PLATE 16 X 14" each 1

11704 KEYPAD KVD 20 each 1

11816 CORD GRIP, PG-21,BH each 1

11842 MIN CONTROLLER-KV-40 DTP each 1

11843 ENCL 3g 16X14X6 W/ DISP each 1

11852 TERM BLOCK STACKABLE each 22

11853 TERM BLK END PLATE-LF each 1

11854 CB BASE each 3

11856 CB TOP 24 VDC 2 AMP each 1

11872 TERM BLK NON STACKABLE each 1

11873 FIXED BRIDGE 2 POS each 2

S/A Number: 20 873 101 Spray Gun/NE, 3T

Part Number Description U/M Quantity 12298 O RING .062 .250 X .375 each 1

18177 NOZZLE CAP NE GUN each 1

18180 NOZZLE BODY NE GUN 3T each 1

18199 NOZZLE TUBING,NE/NF each 3

810 PICKENS DRIVE EXT. * Marietta * GEORGIA * 30062 * PHONE: 800.227.9326 * 770.423.0934

MATERIAL SAFETY DATA SHEET

1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY/UNDERTAKING Product Name: : 10250 (3147) Blue Color

Pack Code: : Item #10250

Size: : 1 gallon or 55 gallon drum

2. COMPOSITION/INFORMATION ON INGREDIENTS

Substance/preparation: Preparation

Common Name CAS No.

Liquid Color Mixture N/A

Formula: Trade Secret per 29 CFR 191.1200 (i)(1) & Appendix D; All materials used are FDA approved.

Also can be used for Paperboard coating in accordance with 21 CFR 176.

Information on Hazardous Ingredients N/A

3. HAZARDS IDENTIFICTION No physical/chemical, environmental or human health hazards have been reported or known.

4. FIRST-AID MEASURES

Effects and symptoms

Inhalation : May be irritating to nose, throat, and respiratory tract.

Ingestion : May be irritating to mouth, throat and stomach.

Skin contact : May be mildly irritating to skin and discolor due to pigment

Eye contact : May be mildly irritating to eyes

First-aid measures

Inhalation : No specific first aid measures are required.

Ingestion : No specific first aid measures are required.

Skin contact : Immediately was off with plenty of water. If irritation develops, get medical attention.

Eye Contact : Immediately was out with water. If irritation develops, get medical attention.

5. FIRE-FIGHTING MEASURES Extinguishing media : Dry chemical, water spray, foam, carbon dioxide.

Special fire-fighting procedures : None known.

Unusual fire/explosion hazards : None known.

6. ACCIDENTAL RELEASE MEASURES Personal precautions : Put on appropriate personal protective equipment (see Section 8).

Environmental precautions : In the event of major spillage: Use appropriate containment to avoid environmental

And cleanup methods contamination. Take up with inert absorbing material. Place in suitable clean, dry

containers for disposal by approved methods. Use a water rinse for final cleanup.

7. HANDLING AND STORAGE Handling : Avoid contact with skin and eyes.

Storage : Store in a dry, cool and well-ventilated area. Keep out of the reach of children. For

Professional use only.

8. EXPOSURE CONTROLS/PERSONAL PROTECTION When handling product as supplied :

Engineering controls : No special ventilation requirements. General room ventilation is adequate.

Occupational Exposure Limits

: No occupational exposure limits have been established-United Kingdom.

Personal protective equipment

Respiratory system : No specific personal protection equipment is required.

Skin and body : If major exposure is possible, wear suitable protective clothing.

Hands : Rubber gloves recommended for prolonged or repeated skin contact.

Eyes : Safety glasses recommended.

Information should be confirmed by workplace assessment.

9. PHYSICAL AND CHEMICAL PROPERTIES

Physical state : Liquid

Color : Blue

Odor : Characteristic

Solubility : Easily soluble in cold water

pH : 3.5 – 8.0

Specific Gravity : 1.05-1.012

Flash point : Not established

10. STABILITY AND REACTIVITY

Local effects

Skin irritation : See section 4.

Eye irritation : See section 4.

Sensitization : None known.

Chronic toxicity : None known.

Specific effects

Carcinogenicity : None known.

Mutagenicity : None known.

Reproduction toxicity : None known.

12. ECOLOGICAL INFORMATION

No environmental hazards have been reported or known.

13. DISPOSAL CONSIDERATIONS

Methods of disposal : Disposal according to local regulations.

14. TRANSPORT INFORMATION

DOT Shipping Class- 50

DOT Hazard Class -Not Hazardous

15 REGULATORY INFORMATION

U.S. Toxic Substances Control Act

All components of this product are either listed on the U.S. Toxic Substances Control Act (TSCA) inventory of chemicals or are

otherwise compliant with TSCA regulations.

US.CERCLA-SARA (Superfund Amendments and Reauthorization Act of 1986 :

SARA-Title III Section 312 Hazard Category (40 CFR 311/312):

Not Hazardous

SARA Section 313:

This product does not contain any chemicals which are subject to the reporting requirements of the Act and title

40n of the Code of Federal Regulations, Part 372.

National regulations

United Kingdom: No additional national regulations are known to the supplier.

EU Regulations

EU Classifications : Classified as non-hazardous according to current legislation.

(67/548/EEC-88/379/EEC)

EINECS Status : All components are included in the EINECS inventories.

Other information : Not applicable.

16. OTHER INFORMATION

Coloring : Preservatives

HISTORY

Date of printing : 24 March, 2010

Date of previous issue : 22 January, 2010

Reason : Updated to customer specified format

The information provided in this Safety Data Sheet is Correct to the Best of our knowledge at the date of issue and covers applications when

used as directed. The information given is designed only as a guide for safe handling, use, processing, storage, transportation, disposal and

release and is not to be considered as a warranty or quality specification. The information relates only to the specific material designated and

may not be valid for such material used in combination with any other material or in any process, unless specified in the text.

MATERIAL SAFETY DATA SHEET Ryeco, Inc. Ryeco Part # 10260 810-B Pickens Industrial Dr. Marietta, GA 30062 Phone: 770-423-0934

1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY/UNDERTAKING Product Name : Bright Red COLOR Pack Code : Ryeco Part # 10260 Size : per gallon or 55 gallon drum Supplier : Ryeco, Inc. 810 B Pickens Industrial Drive Marietta, Georgia 30062 Phone: 770.423.0934 Fax: 770.424.2554

2. COMPOSITION/INFORMATION ON INGREDIENTS Substance/preparation: Preparation Information on Hazardous Ingredients*

Common Name CAS No. Bakers Preferred Airbrush Red #40 25956-17-6 Food Grade Color Blue #1 0003844-45-9 Yellow#5 1934-21-0

3. HAZARDS IDENTIFICTIONNo physical/chemical, environmental or human health hazards have been reported or known.

HMIS Hazard Ratings: Health – 0, Flammability – 0, Chemical Reactivity – 0, Personal Protection – B NFPA Hazard Ratings: Health – 0, Flammability – 0, Chemical Reactivity – 0

NOTE: HMIS and NFPA rating involve data and interpretations that may vary form company to company. There are intended only for rapid, general identification of the magnitude of the specific hazard. To deal adequately with the safe handling of this material, all the information contained in this MSDS must be considered.

4. FIRST-AID MEASURES Effects and symptoms Inhalation : May be irritating to nose, throat, and respiratory tract. Ingestion : May be irritating to mouth, throat and stomach. Skin contact : May be mildly irritating to skin and discolor due to pigment Eye contact : May be mildly irritating to eyes First-aid measures Inhalation : No specific first aid measures are required. Ingestion : No specific first aid measures are required. Skin contact : Immediately wash off with plenty of water. If irritation develops, get medical attention.

Eye Contact : Immediately wash out with water. If irritation develops, get medical attention.

5. FIRE-FIGHTING MEASURESExtinguishing media : Dry chemical, water spray, foam, carbon dioxide. Special fire-fighting procedures : None known. Unusual fire/explosion hazards : None known.

6. ACCIDENTAL RELEASE MEASURESPersonal precautions : Put on appropriate personal protective equipment (see Section 8). Environmental precautions : In the event of major spillage: Use appropriate containment to avoid environmental And cleanup methods contamination. Take up with inert absorbing material. Place in suitable clean, dry containers for disposal by approved methods. Use a water rinse for final cleanup. 7. HANDLING AND STORAGE Handling : Avoid contact with skin and eyes. Storage : Store in a dry, cool and well-ventilated area. Keep out of the reach of children. For Professional use only 8. EXPOSURE CONTROLS/PERSONAL PROTECTION When handling product as supplied :

MATERIAL SAFETY DATA SHEET Ryeco, Inc. Ryeco Part # 10260 810-B Pickens Industrial Dr. Marietta, GA 30062 Phone: 770-423-0934

Engineering controls : No special ventilation requirements. General room ventilation is adequate. Occupational Exposure Limits

: No occupational exposure limits have been established-United Kingdom. Personal protective equipment Respiratory system : No specific personal protection equipment is required. Skin and body : If major exposure is possible, wear suitable protective clothing. Hands : Rubber gloves recommended for prolonged or repeated skin contact. Eyes : Safety glasses recommended. Information should be confirmed by workplace assessment.

9. PHYSICAL AND CHEMICAL PROPERTIES Physical state : Liquid Colour : All different Odour : Characteristic Solubility : Easily soluble in cold water pH : 3.5 – 8.0 Specific Gravity : 1.05-1.012 Flash point : Not established

10. STABILITY AND REACTIVITY Local effects Skin irritation : See section 4. Eye irritation : See section 4. Sensitization : None known. Chronic toxicity : None known. Specific effects Carcinogenicity : None known. Mutagenicity : None known. Reproduction toxicity : None known. 12. ECOLOGICAL INFORMATION No environmental hazards have been reported or known.

13. DISPOSAL CONSIDERATIONS Methods of disposal : Disposal according to local regulations.

14. TRANSPORT INFORMATION DOT Shipping Class- 70 DOT Hazard Class -Not Hazardous 15 REGULATORY INFORMATION National regulations United Kingdom: No additional national regulations are known to the supplier. EU Regulations EU Classifications : Classified as non-hazardous according to current legislation. (67/548/EEC-88/379/EEC) EINECS Status : All components are included in the EINECS inventories. Other information : Not applicable. 16. OTHER INFOMATION Coloring : Preservatives HISTORY Date of printing : 10 January, 2008 Date of previous issue : ----------------- The information provided in this Safety Data Sheet is Correct to the Best of our knowledge at the date of issue and covers applications when used as directed.

NOTES:

CE Markers.doc

Declaration of Conformity

Manufacturer Name: RYECO Incorporated Manufacturer Address: 810-B Pickens Industrial Drive Ext. Marietta, Georgia 30062 U.S.A. Product Name: RYECO Marking and Reading Systems Model Numbers: All RYECO -3g and -3c model numbers Declares, that the entire product line conforms to the following standards: Safety: EN 60204, EN 292, and EN 60950 Low Voltage: EN 60051 Electromagnetic Compatibility: EN 50081-2 and EN 50082-2 Supplementary Information:

“The product complies with the requirements of the Low Voltage Directive 73/23/EEC, the Machinery Directive 89/392/EEC and the Electromagnetic Compatibility 89/336/EEC.”

Office of Engineering Manager Ryeco Incorporated Marietta, Georgia USA February 12, 2004

UL 508A Markers.doc

Industrial Control Panels

UL-508A Manufacturer Name: RYECO Incorporated Manufacturer Address: 810-B Pickens Industrial Drive Ext. Marietta, Georgia 30062 U.S.A. Product Name: RYECO Marking and Reading Systems Model Numbers: All RYECO -3g and -3c model numbers Declares, that the entire product line conforms to the guidelines provided in the Standard for Industrial Control Panels-UL 508A. Office of Engineering Manager Ryeco Incorporated Marietta, Georgia U.S.A. February 12, 2004

RYECO, Inc. Rev. 03 159--S 5-0 & 5-1Title Page & TS

Section 5.0 Troubleshooting, Maintenance Task, Test Station (if applicable) and Glossary

5.1 Troubleshooting

5.2 Maintenance Tasks and Schedule

5.3 Marker Test Station Operator Manual (Optional with Hot Swap)

5.4 Glossary

SECTION 5.1 TROUBLESHOOTING Refer to the appropriate referenced Subassembly Manual Section for more specific instructions on how to implement the Remedy. NO MARK:

Probable Cause Remedy Subassembly NotesOut of Dye Check Liquid Tank level

and refill as necessary.

Ink Station

Dye Strainer Clogged Clean screen on dye inlet line located on the bottom of the Dye Tank with water and/or solvent.

Ink Station

Dye Pressure < 1 psig (.07 bar)

Adjust Dye Tank air pressure higher. Do not exceed 5 psig (0.34 bar) For /NF Systems do not exceed 8 psig (.55 bar)

Ink Station

Sprayer Tip Clogged Wipe away any debris from the sprayer tip using a toothbrush and water or solvent.

Edge Marking Module

Sprayer Tip Clogged On /NF and /NE Spray Guns

Remove spray tip and reverse-flush orifice.

Edge Marking Module

Dye Lines Plugged Check flow of dye through tubes while manually spraying. For /NF and /NE Systems also check dye and water in-line filters.

Extension Tube

Dye Solenoid Failure Observe the activation of the Dye Solenoid while manually spraying.

Extension Tube

Improper or Loose Electrical Connections

Check all electrical connections against the electrical drawing.

MARK INTENSITY TOO LOW: Probable Cause Remedy Subassembly NotesAtomization Pressure too high

Lower Atomization Air Pressure

Ink Station

Edge Marking Module positioned too far on sheet or too far off sheet.

Adjust the Edge Marking Module in the transition box so that the spray catches the edge of the web to produce the desired mark width.

Edge Marking Module

Sprayer Tip Clogged Wipe away any debris from the sprayer tip using a toothbrush and solvent.

Edge Marking Module

Sprayer Tip Clogged On /NF and /NE Spray Guns

Remove spray tip and reverse-flush orifice.

Edge Marking Module

Electrical marker only Flow control screw Set too Tight

Open the metering screw in 0.1 turn increments

Code Marking Module

Dye tank pressure to low

Adjust the dye tank pressure higher. Do not exceed 5 psig (.34 bar) For /NF Systems do not exceed 8 psig (.55 bar)

Ink Station

MARK INTENSITY TOO HIGH OR DRIPPING: Probable Cause Remedy Subassembly NotesAtomization Pressure too low

Raise Atomization Air Pressure.

Ink Station

Vacuum (if applicable) not functioning properly.

Increase air pressure to vacuum generator and ensure vacuum discharge path is not blocked.

Ink Station

Dye tank pressure too high

Adjust the dye tank pressure lower

Ink Station

Marking modules with jaw only. Edge Marking Module installed upside down.

Ensure that the Edge Marking Module is installed with the vacuum port on the bottom of the module.

Edge Marking Modules with jaw

Electrical marker only Flow control screw set too open

Tighten the metering screw in 0.1 turn increments

Code Marking Modules only

MARK TOO SHORT: Probable Cause Remedy Subassembly NotesInk Len time too short. Increase Ink Len timer.

Operator Station

MARK TOO LONG: Probable Cause Remedy Subassembly NotesInk Len time too long. Decrease Ink Len timer.

Operator Station

MARK FADING FROM START TO END: Probable Cause Remedy Subassembly NotesPinched tube in the tube jacket.

Straighten or replace pinched tube.

Ink Station

SYSTEM NOT TRACKING THE EDGE PROPERLY: Probable Cause Remedy Subassembly NotesActuator mode selection switch in Manual.

Place the Actuator Mode Selection Switch to Auto.

Actuator Station

Only units with adjustable AMPS Photo-Amp Sensitivity not set to recognize current paper grade.

Adjust photo-Amp Sensitivity to recognize the lightest grade of paper.

Edge Tracking Module

Photo-eyes dirty or covered by debris.

Remove any debris covering the photo-eyes and/or clean the photo-eye lenses.

Edge Tracking Module.

System goes into Sheet Break prior to reaching paper’s edge.

Adjust the Extension Tube further towards the sheet in the tube clamps.

Extension Tube

FWD Sensor input high but actuator will not move toward sheet edge.

Recycle the Remote On Signal. Check for Manual mode. Make sure actuator carriage is not behind Rev Limit Switch.

Operator Station/ Actuator Station

Actuator carriage trapped behind Reverse Limit Switch.

Move the Reverse Limit Switch closer to the reverse bumper so that the carriage activates the switch when fully retracted.

Actuator Station

Actuator does not reach forward or reverse limits.

Motor Forward and Motor Reverse Timer are not set properly. Refer to Software Section 3.4.

Actuator Station

EDGE MARK SENSOR (IF INCLUDED) NOT READING PROPERLY: Probable Cause Remedy Subassembly NotesEdge Mark Sensor Module not set properly.

Refer to Manual Section 2.4 to set the sensor.

Edge Mark Sensor

Edge Mark Sensor lens dirty.

Clean lens with mild soap and water.

Edge Mark Sensor

Edge Mark Sensor not positioned correctly on the web.

Refer to Manual Section 2.4 to position the sensor.

Edge Mark Sensor or Edge Tracking Module

DIAGNOSTIC ERROR (Display Screen): Error Message Remedy Subassembly NotesETM ERROR

Both Fwd and Rev Sensors on steady. Remove any debris covering the photo-eyes and/or clean the photo-eye lenses. Adjust Photo Amp Sensitivity if adjustable AMPS.

Edge Tracking Module

LOW DYE LEVEL Refill dye tanks as needed.

Ink Station

LOW AIR PRESSURE

Mill Supply air has dropped below recommended pressure (70 psig)

Ink Station

RYECO, Inc., Rev: 00 160--S 5-11 Sample Defect Marks

Sample Defect Marks for Status Indication. Good Defect Marks on various grades at different machine speeds 1) 2) Red mark on LWC, 110gsm Blue mark on newsprint, 45gsm Machine Speed 620 meters per minute Machine Speed 1400 meters per minute 3) Blue mark on LWC, 110gsm Machine Speed 350 meters per minute Poor Defect Marks on various grades at different mac 4)

Red mark on Magazine Paper, 120gsm and machine spee Note that there is a splatter mark of a color that is diffthat the overspray dye is being blown onto the sheet wout the drain line or correcting a vacuum pump issue.

Note: All “Good” marks show very small inkdroplets evenly spread over the entire area ofthe mark. Your system may mark either topor bottom or both. Ideal mark position is 90%on 10% off. It is important that Ryeco dyesand inks are used to ensure that these resultsare achieved.

hine speeds, with indication of problem area

d 850 meters per minute.

erent from the base mark. This is an indication ithout atomization. This is rectified by cleaning

RYECO, Inc., Rev: 00 160--S 5-11 Sample Defect Marks Poor Marks on various grades at different machine speeds, with indication of problem area 5) Blue mark on LWC, 80gsm and machine speed 750 meters per minute. Note that the ink density is not consistent and spattered across a wider band, this is indicative of bad atomization. This is rectified by cleaning the nozzle and ensuring the air pressure is at the correct setting. 6) Blue mark on LWC, 95gsm and machine speed 650 meters per minute. Note that the ink density is poor and the mark is only partially hitting the web, this is indicative of bad atomization and misalignment. This is rectified by cleaning the nozzle, ensuring the air pressure is at the correct setting and setting up the mark position as described in the manual to ensure that the head is correctly aligned when paper is present. 7)

Black mark on LWC, 85gsm and machine speed 580 meters per minute. Note that the ink density is heavy but streaked due to no atomization, this is indicative of low to no atomization air pressure to the spray unit. This is rectified by ensuring the air pressure is at the correct setting and has unrestricted flow.

RYECO, Inc., Rev: 00 S 5-11 Sample Code Marks NF gun.doc

Sample Code Marks

Acceptable (readable) code marks on various grades of substrate and at different machine speeds can be achieved with the correct combination of hardware and software settings. (see sample below)

Sheet Edge

Typical /NF Gun code mark @ 3750 feet per minute.

Poor quality code marks. (see samples below)

Sheet Edge

Interrupted Mark

Probable Causes: Excessive water in the dye supply line, air or debris in the orifice nozzle Remedy: Perform a 20 second manual water flush followed by a 60 second manual dye prime. If problem persists remove Edge Marking Module (EMM) and reverse flush the orifice nozzle.

Sheet Edge

Extended Mark

(Web Inspection System identifies mark in excess of 2.0” long) Probable Cause: Excessive air in the orifice nozzle Remedy: Perform a 20 second manual water flush followed by a 60 second manual dye prime. If problem persists remove Edge Marking Module (EMM) and reverse flush the orifice nozzle.

Sheet Edge

Smeared Mark

Probable Cause: Failure of dye to dry prior to reaching the next contact roll. Remedy: Consider a faster drying dye or use a drying accelerator device. Call RYECO Inc. for assistance.

S 5-2 New Maintenance Task.doc REV 00 SECTION 5.2 -- EDGE MARKING SYSTEMS PREVENTATIVE MAINTENANCE Preventative Maintenance Routines

A. Weekly Maintenance Routine B. Monthly Maintenance Routine C. Semi-Annual Maintenance Routine D. Annual Maintenance Routine

A. Weekly Maintenance Routine

1. Ensure the Ink Station dye tanks are filled with uncontaminated Ryeco dye. 2. Visually inspect and clear any obstructions (i.e. paper dust buildup or paper stock) from the Edge Marking

Module.(EMM) 3. Visually inspect mark quality and width.

B. Monthly Maintenance Routine This schedule depends on environmental conditions and operational frequency of the marking system and should be adjusted accordingly. Monthly maintenance is usually performed during a routine machine outage when the system can be offline for a short period of time. Extension Tube:

1. Flush all dye lines with filtered warm solvent. Utilize the Ryeco Marker Test Station if available. 2. Flush the vacuum drain line with filtered warm solvent. The drain line should be free of obstructions. 3. Flush all dye lines with filtered air to remove all solvent droplets from the Extension Tube. Utilize the Ryeco

Marker Test Station if available. Edge Marking Module (EMM):

1. Clean the EMM by flushing all dye lines and spray nozzle with filtered warm solvent. (water) Utilize the Ryeco Marker Test Station if available.

2. Thoroughly clean the EMM by soaking in warm solvent. (water) Rinse all components, ensuring that the spray gun tip is free from debris and obstructions.

3. Flush all dye lines, spray nozzle, check valves and “Y” fittings with filtered warm solvent. (water) 4. Flush all dye lines with filtered air to remove all solvent droplets from the EMM. 5. Inspect and replace inline filters (Ryeco Part #19109) as needed. Replace filter element with Ryeco Part #19110.

Ink Station:

1. Inspect and replace inline filter (Ryeco Part #13045) as needed. Replace filter element with Ryeco Part #13058. Actuator: Inspect for smooth operation. Wipe rail clean as needed.

S 5-2 New Maintenance Task.doc REV 00 C. Semi-Annual Maintenance Routine Semi-annual maintenance is usually performed during a routine machine outage when the system will be offline for an extended period of time. Cleaning and Purging the Ink Station:

1. Remove the lids of each dye tank. Once the lids are removed, disconnect the air supply line for each tank. Then disconnect the dye supply tubing from each tank.

2. Empty all dye out of the tanks and clean them out with filtered warm solvent. 3. Re-fill each tank with filtered warm solvent and reinstall. 4. Re-connect the dye supply tubing first, then the air supply tubing to each tank. 5. Tighten the lids and allow the tanks to build up pressure 6. Ensure the dye tank pressure is set properly for your installation.

Standard Settings: [1-5 psig (0.07 – 0.34 bar)] 7. Once the tanks are pressurized, locate ink station ten tube connector with shutoffs. Press in each shutoff to allow

flow of solvent through each dye line. Completely flush each dye line with solvent. 8. After all dye lines are flushed with solvent. Repeat step 1 of this procedure and dry out each tank.

Note: Do not leave any solvent residue inside the dye tanks. 9. Refill each tank with the desired color of Ryeco dye.

Caution: Use only Ryeco specified dyes. (system and its components are configured specifically for these formulations)

10. Complete steps 4-7 in order to properly prime the ink station with dye. 11. Re-connect the ten tube connector of the ink station to the marking head assembly and manually prime all dye

colors.

RYECO, Inc., Rev: 01 S 5-3 Marker Test Station.doc

Section 5.3 Marker Test Station (Optional)

Overview:

What is its’ function?

• The Marker Test Station is furnished when the Hot Swap Package (See Figure 1) is purchased

• It can be used to test the operation of the extension tube, Edge Marking Module, and Edge Tracking Module in a test area away from the paper machine.

• It can be used to flush tubing, solenoids, and sprayers in a test area away from the paper machine.

Figure 1 - Hot Swap Package

What does it look like?

• The Marker Test Station includes a control box with buttons to activate dye and water solenoids. It also includes a tank with tubing and a ten-tube connector for connecting to the extension tube. See Figure 2.

Figure 2 - Marker Test Station (Deluxe model shown)

RYECO, Inc., Rev: 01 S 5-3 Marker Test Station.doc

How do I use the Mark Test Station to flush or test the tubing, solenoids, and sprayers?

Extension Tube Connection: • Connect power to the control box 110 VAC Single Phase or 220 VAC. Make sure

the power supply is set accordingly. • Connect an air line with 30 psig. • Fill Tank with warm water. • Connect ten-tube connector to the extension tube. • Connect the 12/10 pin yellow cable to the extension tube. • Open the appropriate dye line valves (refer to Extension Tube Tubing drawing). • Depress desired mark button for approximately 60 seconds. • Repeat until clear liquid flows from all dye lines. • Open air valve and depress desired mark button to ensure that the spray is fully

atomized and repeat as needed. • The Edge Tracking Module with jaw can be checked by removing the cover and

observing the Green and Red LED’s on the amplifiers as paper is passed through the jaw.

• The Edge Tracking Module without a jaw can be checked by removing the cover and observing the orange LED’s at the end of the amplifiers as paper is passed under the sensor windows. The displays will show low values 0-200 (800) when the paper passes under the sensor. When no paper is “seen” the reading is 999.

Edge Marking Module Connection: • Connect the ten-tube connector to the Edge Marking Module (EMM). • Connect the 3 Pin Yellow Cable to the EMM if equipped. • Open the appropriate Dye Line and Air Line valves (refer to EMM Tubing drawing). • Liquid will flow through the defect sprayer when the dye lines are opened. Depress

the SOL DYE C 1 button to activate the code sprayer if equipped. • Repeat as needed. • Close all valves when complete and disconnect Ten-Tube and 3 Pin Cable.

Drawings: Marker Test Station, Wiring Marker Test Station, Tubing

RYECO, Inc., Rev: 1 S 5-4 Glossary.doc

SECTION 5.4 -- Glossary of Terms AUX - Auxiliary Output from the RYECO Microprocessor CB – Actuator Control Box CCW - Counter Clockwise CD - Cross direction = direction perpendicular to travel of paper CFM - Cubic Feet Per Minute rating of pneumatic flow CW – Clockwise D. On – Dark On Signal that activates on dark conditions ECD - Edge Crack Detection Module (ECD-4000) EMM - Edge Marking Module (EMM-2000) EMS - Edge Mark Sensor ET - Extension Tube ETM - Edge Tracking Module (ETM-1000) FOLD - processed Fold over signal output from the RYECO Microprocessor FWD LIM - Forward Limit signal produced by the forward limit switch on the actuator station FWD SENS - Forward Sense signal produced by the forward ETM-1000 Amplifier GPH - Gallons per hour I.D. - Inside Diameter INTF - Interface signal output that is trailing edge activated IS - Ink Station L. On - Light On signal that activates on light condition LED - Light Emitting Diode MARK - Mark Signal output based on a crack defect being detected MD - Machine Direction = Direction of paper travel MM - Millimeter MTR FWD - Motor Forward signal to actuate the actuator table Forward MTR REV - Motor Reverse signal to actuate the actuator table into reverse NPT - National Pipe Thread (NPTM = Male NPTF = Female) O.D. - Outside Diameter OFF-DLY. - Off Delay Timer ON-DLY. - On Delay Timer OP – Operator Station PI – Pressure indicator PLC - Programmable Logic Controller PSI - Pounds per square inch value of fluid or pneumatic supply REEL CHG - Reel Change signal to the RYECO Microprocessor to indicate a turn-up REV LIM - Reverse Limit signal produced by the reverse limit switch on the actuator station REV SENS - Reverse Sense signal produced by the reverse ETM-1000 Amplifier SB - Sheet Break AIR SOL - Signal output to activate the air atomization solenoid DYE SOL 3 - signal output to activate the blue solenoid DYE SOL 1 - signal output to activate the red solenoid SOLVENT SOL - signal output to activate the water solenoid DYE SOL 2 - Signal output to activate the yellow solenoid SSC - Solid State Controller Card used to process motor control functions STB - Stability output of amplifier S – Solenoid Valve VAC - Volts Alternating Current VAC PMP - signal output to activate the Vacuum Pump Air Supply solenoid VDC - Volts Direct Current WIS – Web Inspection System

RYECO “Slash Code” Options Code Description

C One Color RB Remote actuator box 2C Two Color RD Redundant Display 24 24 inch actuator travel RC Ryeco Code 3C Three Color RS Remote Solenoids 36 36 inch actuator travel S1 Stainless Steel 1 gallon dye tank AA Airless Atomization S2 Stainless Steel 2 gallon dye tank B1 SBD 9000 S5 Stainless Steel 5 gallon dye tank B2 SBD 9000 EXT SC Single (Shared) Cabinet B3 SBD 9003 SL Stainless Steel Lead Screw B4 SOF 9006 SS Stainless Steel operator station B5 SOF 9006 PLUS TH Tach, High Speed BE Bottom encode top defect TL Tach, Low Speed BR B&R PLC TE Top Encode BS Bottom surface marking TS Top surface marking CG Cable Gland TT Thin or Clear web tracking CU Custom modification UV Ultra Violet Dye DD Dual Directional ECD module VB Vacuum Module below the web DE Dual EMM modules VD Video Jet Dual Mount DJ Deep Jaw Modules (Horizontal) VN Vacuum Non Jawed Module DP Dual point ECD module VJ Video Jet mounting bracket DS Dual surface marking VT Vertical Actuator EN Extended Nozzle WA Wireless Mark Activation FC Flow Control WC Waste Collector FF Fume Filter WJ Wide jawed modules G3 Gooseneck 3100 tube G5 Gooseneck 5100 tube HH High Heat applications IM Inverted Mount L3 Custom length 3100 tube L5 Custom length 5100 tube

L## Number of Lanes LS Low level warning for dye tanks MR Mark Reader MT Metric Fittings MV Mark verification sensor NB Pneumatic Pinout Nozzle NC E-Gun Electric Pinout Nozzle ND Delrin Body Nozzle NE Jewel Orifice Nozzle NF Embedded Jewel Orifice Nozzle NM No Ryeco mount provided NP Solvent based ink station NT No Extension Tube OM Offset Module

PB Profibus (Digital Communication System)

ryeco marking system

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