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DF50n Manual rev 20070701 P1/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Desiccant filler DF50n Manual
Content Page
Normal operation 2
Preventive maintenance 4
Function description 5
Position adjustments 7
Fault finding and repair 7
Changing desiccant nozzle 8
Cleaning butyl nozzle 8
Changing drill bit 9
Changing the Blow filter 10
Wiring diagrams 11
Listing of PLC gates in 12
Listing of PLC gates out 13
DF PLC and sensors wiring diagram 14
DF 400V wiring diagram 14
DF butyl heater wiring diagram 15
DF50n Manual rev 20070701 P2/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
P1 P2 P3 P4
P5 P6 P7 P8 P9
Start up
1 Turn DF5nn on. (Release emergency switch) P7
2 Turn air on. (Turning switch on air inlet) P6
3 Adjust height position. (Handel up/down) P1
4 Set the 9-pole switch to 3. (Normal operation position) P8
5 Polish the butyl head with a polish containing silicon. P4
Putting a frame in to FD5nn
1 Put frame on position triangle. P5
2 Depress foot pedal.
3 The head will come down pushing the frame against the triangle. P5
3 Let the frame go.
Removing a frame from DF5nn
1 Grab the frame.
2 Depress the foot pedal.
3 Check and adjust butyl sealing.
Refilling of butyl.
1 Set the 0-9 switch to 9. P8
2 Depress foot pedal. (The butyl cylinder move back)
3 Put in a butyl slug. P2
4 Set the 9-pole switch to 8 P8
5 Depress the foot pedal (The butyl cylinder move forwards)
6 Set the 9-pole switch back to 3 P8
DF50n Manual rev 20070701 P3/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Set the butyl timer
1 Set the 0-9 switch to 6. P8
2 On the E100 panel push arrow down(7) P3
3 Push arrow Right (9)
4 Push Enter.
5 Keep NUM depressed while entering new value (1/10 sec)
6 Push Enter
For next head repeat 2 to 6.
7 Turn 0-9 switch back to 3
Alarms on operator panel P3
“Frame not full”
1 Depress foot pedal once. (Frame will move to load / unload position.)
2 Depress foot pedal again. (Frame will be released)
3 Check desiccant level in frame.
If frame is full:
1 Depress and release emergency switch (reset)
2 Start again normal input of frame.
3 Alarm “Frame not full” repeats.
4 Turn 9-pol switch from 3 to 2. (The frame will be sealed as normal) P8
Machine is dead
1 Check the electrical supply. (Depress and release emergency switch) P7
2 Check the pneumatically supply. (Turn air off and on) P6
Upper chamber is empty
1 Check desiccant level in supply drum.
Hydraulic pump off
Open cupboard and reset motor protection
Vacuum pump off
Open cupboard and reset motor protection.
DF50n Manual rev 20070701 P4/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Preventive maintenance
Daily
1 Check level of lubricating alcohol (drill bits)
2 Check level of lubricating oil (air motors)
3 Check level of hydraulic oil.
4 Check desiccant level in drum.
5 Check clamp cylinders connection to clamp bar.
If screwed out use screw fix blue or green, and tighten them.
6 Check desiccant nozzles for damage and butyl.
7 Check drill bit.
8 Use some silicon polish on butyl nozzle
Weekly
1 Clean main vacuum filter.
2 Check pressure on blow. If more than 2 bar change blow filter.
Yearly
1 Check vacuum pump lamellas
2 Replace vacuum pump internal filters.
3 Replace desiccant nozzles.
4 Test all air connections for leaks.
5 Tighten all screws.
DF50n Manual rev 20070701 P5/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Function description
S1 S2 S3 S4 P10 P11 P12
Sensors:
S1 Drill is out
S2 Lower chamber is not full
S3 Head is in Pickup position
S4 Upper chamber is full.
Pickup
1 Foot pedal depressed to start cycle
2 Head moves down with a reduced pressure to pickup position.
3 Position achieved is detected by S2
4 Transport clamp is activated.
5 Triangle is redrawn.
6 Pressure is returned to normal.
7 Pickup done
Drill
1 Frame is transported to drill position
2 Position clamp is activated.
3 Drill motor and transport forward is activated.
4 Drill is out is detected by S1.
5 Drill is kept out for some seconds.
6 Drill and transport is deactivated.
7 Drill is not out is detected by P1
8 Position clamp is deactivated.
9 Drill is done.
DF50n Manual rev 20070701 P6/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Desiccant filling
1 Frame is transported to desiccant filling position.
2 Position clamp is activated
3 A pressure between 1 and 2 bar is applied to the chambers.
4 Desiccant starts to flow in to the frame.
5 At intervals sensor S2 is checked.
5.1 No signal = Lower chamber is full
5.2 Signal = Lower chamber is not full
If lower chamber is not full the valve between upper and lower chamber will open.
Desiccant will flow from upper to lower chamber.
The time of flow is an expression of the volume.
This cycle will be repeated until no flow is detected.
6 Evaluation of filling
The total flow from upper to lower chamber will be compared to minimum volume
demanded with the position of the 0-9 switch.
6.1 Flow of desiccant from upper to lower chamber is < min demand.
6.1.1 Alarm is stated in the display.
6.1.2 Position clamp is deactivated.
6.1.3 Frame rests in desiccant filling position.
6.2 Flow of desiccant from upper to lower chamber is > min demand.
6.2.1 Position clamp is deactivated.
6.2.2 Degree of filling is displayed.
6.2.3 Desiccant filling done.
Closing of desiccant filling holes.
1 Frame is transported to butyl position.
2 Position clamp is activated.
3 Butyl cylinder moves forward. (Creating a pressure in the butyl)
4 Butyl is pushed in to the holes.
5 Butyl cylinder moved back (Taking of the pressure in the butyl)
6 Frame starts moving out of butyl position
7 Position clamp is deactivated.
Frame delivery
1 Frame is transported to frame delivery position.
2 Foot pedal is depressed.
3 Frame is released.
Head is reset and ready for a new cycle.
Filling of upper chamber.
1 Cycle is not active.
2 Sensor S4 is not detecting desiccant.
3 Vacuum and desiccant valve are opened.
4 Desiccant pump motor is started creating a push pull action. Pumping desiccant
from drum to upper chamber. This is a closed circuit and will not pollute the
desiccant with moister from new air.
5 When S4 detects desiccant chamber is full and action will be stopped.
DF50n Manual rev 20070701 P7/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Position adjustments Desiccant filling position
1 Depress emergency button.
2 Activate short transport cylinder and adjust P12 (M6 screw)
3 Put in an L frame, and adjust to maximal flow.
Butyl position
1 Depress emergency button.
2 Activate long transport cylinder and adjust P10 (M8 grub screw)
Drill position
1 Make a frame interrupt at desiccant filling with foot pedal.
2 Adjust position of holes by washer or metal strips at P11
Fault finding and repair
Lower chamber is empty
1 Depress emergency button.
2 Activate (blow and) the valve between upper and lower chamber.
2.1 If you do not get a flow from upper to lower chamber the desiccant outlet from the
upper chamber is probably blocked. Remove top of upper chamber (13mm nut).
Clean upper chamber and check the opening between upper and lower chamber.
2.2 If you do get a flow:
2.2.1 Check the optical cables.
2.2.2 Check the screw of the optical cable it should be only a nut with sticking
out of the block.
2.2.3 Adjust the sensitivity of the sensor (blue unit to the right of the PLC
Middle position)
2.2.4 Change the blow filter. (Inside the blow inlet of the sensor block between
the upper and lower chamber).
The butyl dose not close the opening in the frame
1 Hoes in frame and butyl nozzle dose not line up
1 Adjust butyl position.
1 Insufficient time
1 Set 9-pole switch to 6. Adjust butyl-filling time for left and right side.
2 Out of butyl
1 Go to refilling of butyl.
3 Hydraulic pressure not present.
1 Check if pump is active.
4 The butyl nozzle is blocked
1 Clean the butyl nozzle.
The DF4 delivers too much butyl.
1 Set 9-pole switch to 6. Adjust butyl-filling time for left end right side.
The flow of desiccant out of the lower chamber is slow
1 Increase blow pressure (max 2 bar)
2 The holes in the frame dose not line up with the desiccant nozzles.
Adjust frame desiccant position
3 Change filter.
DF50n Manual rev 20070701 P8/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
P20 P21
P22 P23 P24 P25
Changing desiccant nozzle 1 Depress emergency button.
2 Turn off air.
3 Push in triangle.
4 Head slides to butyl position.
5 Remove nozzle cover
6 Remove grub screw P21
7 Push nozzle out with a screw driver.
8 Replace nozzle.
9 Check the position of the desiccant delivery slot
10 Test movement of head. Should barely touch nozzle.
Cleaning butyl nozzle 1 Depress emergency button.
2 Turn off air.
3 Let head rest on triangle.
4 Remove the 4 countersunk screws P22
5 Remove the 4 M8 screws P23
6 Remove the grub screw P24
7 Slide the head of the butyl nozzle P25
8 Remove the butyl nozzle and clean it.
9 On remounting check the position of the butyl delivery slots
DF50n Manual rev 20070701 P9/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
P30 P31 P32
P33 P34 P35 P36
Changing drill bit 1 Remove grub screw P32
2 Disconnect air.
3 Push / drag drill unit out. If it is difficult to get out use a long screw driver and
knock carefully on P35 from the front.
4 Loosen P35, and change drill bit.
If you take out P36 see to that it clicks in on remounting
5 Push the drill unit in to the holder and line the grub screw to the positioning hole
in the air motor. This is to prevent the motor moving in the holder.
Aligning the drill unit.
If the hols have different distance from the edge of the butyl side the unit needs to be aligned.
1 Loosen P30, and the one on the other side.
2 The whole drill unit can now be turned around the centre screw.
3 Tighten all 3 screws after alignment.
Tightening the triangle
If the triangle is loos it can either be the cylinder to the braked or the triangle to the shaft.
To do this you have to take the complete drill unit off.
1 Remove the 4 M5 screws connecting it to the main body of the head.
2 Screw the triangle off.
3 Use green (strong) screw glue on the shaft and put it back.
DF50n Manual rev 20070701 P10/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
P40 P41 P42
Changing the Blow filter 1 Remove tube from air fitting P40
2 Screw filter house P41 out of sensor block.
3 Knock filter P42 out of filter house.
4 Replace filter.
5 Use minimum force putting it together again.
DF50n Manual rev 20070701 P11/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Wiring diagrams U1 U2/U3
U4 U5 U6 U7 U8
U1 PLC
U2/3 Optical sensor left-head/right-head
U4 Main fuse
U5 24V DC power
U6 On/ Off relay.
U7 Vacuum pump relay.
U8 Hydraulic motor relay.
DF50n Manual rev 20070701 P12/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Listing of PLC gates in Signal to PLC
0 24VDC Left head upper chamber full
1 24VDC Left head lower chamber not full
2 24VDC Left head drill is out
3 24VDC Left head pickup position achieved
4 24VDC
5 24VDC
6 24VDC Left head foot pedal depressed
7 24VDC
10 24VDC
11 24VDC Vacuum pump on
12 24VDC Hydraulic pump on
13 24VDC Curve upper chamber full
14 24VDC Curve lower chamber not full
15 24VDC Curve foot pedal
16 24VDC
17 24VDC
20 24VDC 0-9 switch PL0
21 24VDC 0-9 switch PL1
22 24VDC 0-9 switch PL2
23 24VDC 0-9 switch PL3
24 24VDC
25 24VDC
26 24VDC
27 24VDC
30 24VDC Right head upper chamber full
31 24VDC Right head lower chamber not full
32 24VDC Right head drill is out
33 24VDC Right head pickup position achieved
34 24VDC
35 24VDC
36 24VDC Right head foot pedal depressed
37 24VDC
DF50n Manual rev 20070701 P13/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Listing of PLC gates out Signal from PLC
0 24VDC Left head Triangle back
1 24VDC Left head Blow and vibrate on
2 24VDC Left head Vacuum valve open
3 24VDC Left head Desiccant valve open
4 24VDC Left head Valve between upper and lower chamber open
5 24VDC Left head Drill lubrication
6 24VDC Left head Position clamp on
7 24VDC Left head Transport clamp on
10 24VDC Left head Drill motor and transport on
11 24VDC Left head Blow swarf
12 24VDC Left head Short position cylinder on
13 24VDC Left head Long position cylinder on
14 24VDC Right head Short position cylinder on
15 24VDC Right head Long position cylinder on
16 24VDC Right head Triangle back
17 24VDC Right head Blow and vibrate on
20 24VDC Right head Vacuum valve open
21 24VDC Right head Desiccant valve open
22 24VDC Right head Valve between upper and lower chamber open
23 24VDC Right head Drill lubrication
24 24VDC Right head Position clamp on
25 24VDC Right head Transport clamp on
26 24VDC Right head Drill motor and transport on
27 24VDC Right head Blow swarf
30 240VAC Hydraulic bypass off
31 240VAC Right head Butyl cylinder forward
32 240VAC Right head Butyl cylinder reveres
33 240VAC Left head Butyl cylinder forward
34 240VAC Left head Butyl cylinder reverse
35 240VAC Hydraulic pump motor on
36 240VAC Vacuum pump motor on
37 240VAC Not in use
DF50n Manual rev 20070701 P14/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
DF PLC and sensors wiring diagram
DF 400V wiring diagram
DF50n Manual rev 20070701 P15/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
DF butyl heater wiring diagram
DF50n Manual rev 20070701 P16/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Operator manual DF50n Settings
0= Data com 1= Aim1 2= Aim2 3=Aim3 4= Aim4
5= Test head position 6= Desiccant safety factor 7= Butyl time adjustment
8= Test gates (+Foot pedal=Butyl forward) 9= Setup (+Foot pedal= Butyl reverse)
Position frame
Start/stop cycle
DF50n Manual rev 20070701 P17/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Refilling of butyl
=9
=
=8
=
=9
=
DF50n Manual rev 20070701 P18/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Maintenance:
Daly
Check lubrication level
Weekly
Clean large vacuum filter
Yearly
Replace
Small vacuum filter
Vacuum Blow Desiccant nozzle
DF50n Manual rev 20070701 P19/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Fault finding and repair
Frame not full
Position Desiccant nozzle/frame hole Blow pressure
0.5<P<1.8 bar
Butyl position/frame hole Drill position adjustment
DF50n Manual rev 20070701 P20/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Upper chamber not full
Sensor on when full Clean air filter
Clean vacuum filter Clean blow filter
DF50n Manual rev 20070701 P21/21
Rjukan Metall Svadde 3660 Rjukan Norway www.rjukan.com Tele +47 35080150
Desiccant in filter
Replace vacuum filter Replace blow filter