Operating instructions

Chill-Roll

RS
12/2007 CR-en-00

Operating instructions – Chill-Roll – RS 1

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2 Operating instructions – Chill-Roll – RS

 Manufacturer
MEGTEC Systems SAS
CE 2717 - 91027 Evry CEDEX

Telephone: 33 1 69 89 47 93
Fax: 33 1 64 97 74 14

MEGTEC retains all proprietary rights in and to the

information disclosed, which must not be
reproduced, copied, or used in whole or in part for
purposes other than those for which it is provided,
without written authorisation from MEGTEC.
12/2007 CR-en-00

Operating instructions – Chill-Roll – RS 3

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4 Operating instructions – Chill-Roll – RS

 1 Foreword........................................................................................................................................ 7

2 Technical characteristics ............................................................................................................. 9

2.1 Versions ................................................................................................................................................ 9
2.2 General description ............................................................................................................................. 10
2.3 Operating characteristics .................................................................................................................... 11
2.4 Dimensions and weight ....................................................................................................................... 13
2.5 Electricity............................................................................................................................................. 16
2.6 Compressed air................................................................................................................................... 16
2.7 Water................................................................................................................................................... 16

3 Operating instructions................................................................................................................ 17
3.1 Operating safety notice ....................................................................................................................... 17
3.1.1 General safety : ....................................................................................................................... 17
3.1.2 Protection and safety equipment ............................................................................................. 17
3.2 Starting up the chill-roll........................................................................................................................ 18
3.2.1 Preparation .............................................................................................................................. 18
3.3 Control panel....................................................................................................................................... 18
3.3.1 Emergency stop....................................................................................................................... 18
3.3.2 Service switch.......................................................................................................................... 18
3.3.3 Control panel 1, switch cabinet................................................................................................ 19

4 Installation - Connection ............................................................................................................ 21

4.1 Handling .............................................................................................................................................. 21
4.2 Cleaning .............................................................................................................................................. 21
4.3 Compressed air connection ................................................................................................................ 21
4.4 Electrical system connection............................................................................................................... 21
4.5 Water circuit connection...................................................................................................................... 22
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Operating instructions – Chill-Roll – RS 5

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6 Operating instructions – Chill-Roll – RS

 1 Foreword

1 Foreword
Introduction
This manual describes the proper installation,
operation and maintenance procedure for a chill-roll.

MEGTEC retains all rights of ownership in the

information supplied, which shall not be reproduced,
copied, or used in whole or in part for purposes
other than those for which it is furnished without
written authorization from MEGTEC.

The chill-roll is constructed for maximum operator

safety when operated under standard conditions for
the purpose intended when recommended
instructions are followed. All personnel involved with
the operation of the machine should be familiar with
its operation.
Proper operation of the machine provides better
safety for the operator and all workers in the work
area of the chill-roll.

The paster must be maintained according to the

instructions of this manual.

NOTE
Only use spare parts recommended by MEGTEC.

MEGTEC reserves the right to make modifications

without prior notice.
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Operating instructions – Chill-Roll – RS 7

 1 Foreword

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8 Operating instructions – Chill-Roll – RS

 2 Technical characteristics

2 Technical characteristics

2.1 Versions
This chill-roll has been built according to following
configuration:

Equipment Standard Technical

version

General configuration
1 web 1.1

Web width
1020 mm (40")

Structure
Non load bearing frames 3.1

Number of cylinders
5 cylinders A5

Motorization
MPP motorization NP

Web guide
E&L web guide 5.3

Webbing-up
No webbing-up system 6.1

Arrangement
Normal 9.1

3 manuals in standard languages (D, F, GB, E, I)

Delivery
Installation
Starting up and basic training (for users)
MEGTEC SA specific training

Basic feature
Version without charge
Version at extra charge
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Operating instructions – Chill-Roll – RS 9


1 2
5 The chill-roll also ensures the web tension after the
8 4
9 The chill-roll comprises following sub-assemblies :
1 linked together with cross-beams [3].
3 3
10
3 3
Fig. 1 General description
10
2 Technical characteristics
2.2 General description
Located after the dryer, it cools the web down to a
temperature near the surrounding temperature.
last printing unit.
The control of the differential between chill-roll
cylinder speed and press speed guarantees a stable
web tension.
The setpoint variation enables to adapt the web
tension to actual needs of production.
For an optimum web speed control, the last chill
cylinder is fitted with a nipping roller.
• a structure made up with two frames [1] and [2]
• cylinders mechanically linked with the motor [4]
and water supplied by a circuit [5].
• a pneumatic nipping roller [6] on the last chill
cylinder is controlled - manually or automatically
- from a local control panel [7].
• a three-phase AC motor « BAUMÛLLER » [4]
with fan and resolver [8].
• a web-guide [9] with local [10] and remote
control panels (according to the version).
NOTE
The chill-rolls can be delivered in different
configurations according to customer's needs.
The choice of certain versions can modify the
composition of the described sub-assemblies.
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Operating instructions – Chill-Roll – RS
 2 Technical characteristics

2.3 Operating characteristics

RS4

Max. web width 2040 mm 80"

Max. speed 570 m/min 1870 fpm

Max. paper weight 60 g/m² at 570 m/min

80 g/m² at 510 m/min

100 g/m² at 460 m/min

120 g/m² at 400 m/min

135 g/m² at 380 m/min

Ratio between chill cylinders and motor 3

4 cylinders - diameter : 410 mm 16.14"

Max. emergency stop deceleration rate 150 m/min/s 492 fpm/s

Max. operating temperature 45°C 113°F

RS5

Max. web width 2040 mm 80"

Max. speed 690 m/min 2260 fpm

Max. paper weight 60 g/m² at 690 m/min

80 g/m² at 610 m/min

100 g/m² at 530 m/min

120 g/m² at 470 m/min

135 g/m² at 420 m/min

Ratio between chill cylinders and motor 80/28

5 cylinders - diameter : 410 mm 16.14"

Max. emergency stop deceleration rate 150 m/min/s 492 fpm/s

Max. operating temperature 45°C 113°F

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Operating instructions – Chill-Roll – RS 11

 2 Technical characteristics

RS6

Max. web width 2040 mm 80"

Max. speed 810 m/min 2657 fpm

Max. paper weight 60 g/m² at 810 m/min

80 g/m² at 720 m/min

100 g/m² at 660 m/min

120 g/m² at 560 m/min

135 g/m² at 510 m/min

Ratio between chill cylinders and motor 80/28

6 cylinders - diameter : 410 mm 16.14"

Max. emergency stop deceleration rate 150 m/min/s 492 fpm/s

Max. operating temperature 45°C 113°F

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12 Operating instructions – Chill-Roll – RS

 2 Technical characteristics

2.4 Dimensions and weight

1/2 (A) + 390 1/2 (A) + 830 RS4
(C) Weight :

(B)
Web width Weight without frames
(A)
1020 4000 daN

1370 4500 daN

1530 4700 daN

(X) frame according to press web height

Dimensions :
2100

Web width

A B C

1020 1080 1280

1370 1430 1630

1530 1590 1790

1/2 (A) + 540

770
1050
(X)

1490

Fig. 2 Dimensions and weight RS4

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Operating instructions – Chill-Roll – RS 13

 2 Technical characteristics

1/2 (A) + 377 1/2 (A) + 831 RS5

(C)
Weight :

(B) Web width Weight without frames

(A)
1020 5300 daN

1370 5700 daN

1530 5900 daN

1700 6000 daN

2040 6200 daN

(X) frame according to press web height

1971

Dimensions :

Web width

A B C

1020 1080 1280

1370 1430 1630

1790
1530 1590 1790
780
1700 1760 1960

2040 2100 2300

1800
1300
(X)

Fig. 3 Dimensions and weight RS5

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14 Operating instructions – Chill-Roll – RS

 2 Technical characteristics

1/2 (A) + 377 1/2 (A) + 831 RS6

(C)
Weight :

(B) Web width Weight without frames

(A)
1020 5500 daN

1370 5900 daN

1530 6100 daN

1700 6300 daN

2040 6600 daN

(X) frame according to press web height

1971
Dimensions :

Web width

A B C

1020 1080 1280

1370 1430 1630

1790
1530 1590 1790
780
1700 1760 1960

2040 2100 2300

1800
1300
(X)

Fig. 4 Dimensions and weight RS6

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Operating instructions – Chill-Roll – RS 15

 2 Technical characteristics

2.5 Electricity
See MAN webbing-up

2.6 Compressed air

Supply pressure 6 to 10 bar

(87 à 145 psi)

Connection diameter 1/4" Gaz

Instant discharge 5Nm3/h - 3scfm

(nipping roller)

Average consumption negligible

2.7 Water
See specific piping drawing for this chill-roll, section
“Installation - Connection”.

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16 Operating instructions – Chill-Roll – RS

 3 Operating instructions

3 Operating instructions

3.1 Operating safety notice

Before operating the chill-roll, all personnel involved
must know the safety regulations as well as the
operating instructions. MEGTEC shall not be
responsible for damages due to an operation which
is not in accordance with the safety and operation
regulations described into this manual.
1 2
3.1.1 General safety :
The operator is to be safety-conscious while running
the machine. Loose clothing, long hair and jewelry
should be avoided during operation.
When handling hazardous materials (solvents etc.),
be sure all current safety rules are complied with.
Only qualified personnel should be engaged in chill-
roll operation and maintenance.

3.1.2 Protection and safety equipment

The chill-roll is equipped with safety guards situated
at places which could generate danger for the user.
The distance between chill cylinders is 4.7" (120
mm) to meet European Safety Standards.
These devices, necessary to ensure a total safety,
are detailed below :

[1] Paster identification plate.

[2] Protection screens.
[3] Protection guards.

3 NOTE
The chill-rolls can be delivered in different
configurations according to customer's needs.
The choice of certain versions can modify the
composition of the described sub-assemblies.
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Fig. 5 Protection and safety equipment

Operating instructions – Chill-Roll – RS 17

 3 Operating intructions

3.2 Starting up the chill-roll

3.2.1 Preparation
• Open water supply.
• Open compressed air supply (6 bar on 1PG).

3.3 Control panel

3.3.1 Emergency stop

• In the event of an emergency, press the
“Emergency stop” button.
The machine will shut down and the main switch
will be disconnected.
• Resolve the problem.
• To start the machine again, unlock the
Fig. 6 Emergency stop “Emergency stop” button and switch the
machine on.

3.3.2 Service switch

Interrupts the operating power to an individual unit.
Allows the restricted operation of the machine.
This switch must å ç í be used as an operating
function while the machine is running.

WARNING
The unit is not currentless!

All the specifically indicated installations in the

control cabinet are still under tension, in particular:
• Parts of the control system
Fig. 7 Service switch • Machine lighting
• Service power point(s) in the control cabinet
• Customer power point(s)

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18 Operating instructions – Chill-Roll – RS

 3 Operating intructions

3.3.3 Control panel 1, switch cabinet

[1] Production stop
Used to trigger a rapid register-true shutdown of
1 the machine assembly.
The red warning light [2] indicates:
2 – Continuous light: the machine assembly can
produce.
3
– Flashing light: an operating command has
been activated. The sound of the horn
4 indicates the start of the hold-off interval
during which an operating command can be
run without another warning. When the
machine starts, the display changes to a
continuous light.

5 The yellow warning light [3] indicates:

– Flashing light: a button has been pressed at
this control section. The operation of the
6 machine assembly has been stopped.
Pressing the production stop button triggers the
7 simultaneous display of a continuous red light
and a flashing yellow light.
[4] Press roll On/Off
In the case of “Press roll On” the button
illuminates.
[5] Crawl
Move forward, at crawl speed, until the
“Production stop” button is pressed or the safety
functions activated.
The command is only effective if the “Crawl” and
“Advance” buttons are pressed at the same time.
[6] Advance
Move forward in inching mode, at inching speed,
Fig. 8 Control panel 1 while the button is pressed.
[7] Set-up
“Set-up one” prepares the chill roll for set-up
work.
– Continuous light: the chill roll is ready for
production in the machine assembly.
– Flashing light: set-up activated.
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Operating instructions – Chill-Roll – RS 19

 3 Operating intructions

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20 Operating instructions – Chill-Roll – RS

 4 Installation - Connection

4 Installation - Connection

F 4.1 Handling
All precautions have been taken to prevent
corrosion.

The handling and slinging procedure is shown on

Fig. 9.

To define [F], Note the chill-roll weight mentioned on

45° page 13, page 14, page 15 “Technical
characteristics” according to the configuration and
add 1500 daN for the frames.

4.2 Cleaning
The machined parts of the paster are covered with
protective grease, which should be removed with a
clean rag.

4.3 Compressed air connection

The chill-roll must be supplied with filtered, dried
and unlubricated air. We recommend :
• a filter for solid particles larger than 0.025
micron,
• a drying by refrigeration for a dew point under
pressure below 37°F (3°C),
F • the use of a coalescing oil removal filter
(minimum oil removal efficiency: 99.999%).
It is recommended that the main air supply pipe be
a minimum of 2 inches in diameter with a downward
slope of 1 inch in 10 feet.
The chill-roll air supply should be connected to the
Compressed Air Filter (FAC) with a 1/4" Gaz female
threaded union.

The customer's compressed air system must insure

a pressure between 87 and 145 psi (6 and 10 bar)
at any time, at point of filter connection (see
compressed air specifications in Section “Technical
characteristics”).

4.4 Electrical system connection

The characteristics, colors and size of the incoming
cables must comply with the local codes at
installation site regarding the power specified in
Section “Technical characteristics”.
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Fig. 9 Handling

Operating instructions – Chill-Roll – RS 21

 4 Installation - Connection

4.5 Water circuit connection

The water circuit must be connected according to
the specific drawing of each chill-roll.

The inlet and return ports must be located above the

cylinder axis so that unions remain continuously
under pressure even in case of supply cut-off.
This precaution insures the permanent joint packing
lubrication.
We recommend to fit each outlet port with a
thermometer for temperature checking.

Connection according to drawing in Section

“Drawings & Diagrams”:
– M100910Y for RS4
– M103240Y for RS5
– M102693Y for RS6

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22 Operating instructions – Chill-Roll – RS

 Maintenance instructions

Chill-Roll

RS
12/2007 CR-en-00

Maintenance instructions – Chill-Roll – RS 1

 12/2007 CR-en-00

2 Maintenance instructions – Chill-Roll – RS

 Manufacturer
MEGTEC Systems SAS
CE 2717 - 91027 Evry CEDEX

Telephone: 33 1 69 89 47 93
Fax: 33 1 64 97 74 14

MEGTEC retains all proprietary rights in and to the

information disclosed, which must not be
reproduced, copied, or used in whole or in part for
purposes other than those for which it is provided,
without written authorisation from MEGTEC.
12/2007 CR-en-00

Maintenance instructions – Chill-Roll – RS 3

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4 Maintenance instructions – Chill-Roll – RS

 1 Foreword........................................................................................................................................ 7
1.1 Introduction ........................................................................................................................................... 7

2 Maintenance .................................................................................................................................. 9
2.1 Cleaning the cylinders........................................................................................................................... 9
2.2 Chill cylinder water supply................................................................................................................... 10
2.2.1 Coupling of rotating unions...................................................................................................... 10
2.2.2 Cylinder general feeding.......................................................................................................... 10
2.3 Maintenance of subassemblies ........................................................................................................... 10

3 Checks and adjustments............................................................................................................ 11

3.1 Mechanical and pneumatic checks ..................................................................................................... 11
3.1.1 Belt tension.............................................................................................................................. 11
3.1.2 Nipping roller ........................................................................................................................... 11
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Maintenance instructions – Chill-Roll – RS 5

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6 Maintenance instructions – Chill-Roll – RS

 1 Foreword

1 Foreword

1.1 Introduction
This manual describes the proper installation,
operation and maintenance procedure for a chill-roll.

MEGTEC retains all rights of ownership in the

information supplied, which shall not be reproduced,
copied, or used in whole or in part for purposes
other than those for which it is furnished without
written authorization from MEGTEC.

The chill-roll is constructed for maximum operator

safety when operated under standard conditions for
the purpose intended when recommended
instructions are followed. All personnel involved with
the operation of the machine should be familiar with
its operation.
Proper operation of the machine provides better
safety for the operator and all workers in the work
area of the chill-roll.

The paster must be maintained according to the

instructions of this manual.

NOTE
Only use spare parts recommended by MEGTEC.

MEGTEC reserves the right to make modifications

without prior notice.
12/2007 CR-en-00

Maintenance instructions – Chill-Roll – RS 7

 1 Foreword

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8 Maintenance instructions – Chill-Roll – RS

 2 Maintenance

2 Maintenance

2.1 Cleaning the cylinders

The cylinder scaling operation must be preferably
done at the end of the week because scale
removing needs a long time. If scaling has never be
done, you will need at least four hours for the first
cleaning operation.

This operation must be done as follows :

• Disconnect the water supply circuit from the
chill-roll and clean the cylinders.
• Disconnect each cylinder by dismounting flexible
pipes and rotating unions.
• Fill up each cylinder maximum on third with a
water solution mixed with 5% of hydrochloric
acid.
• Do not close the cylinder ends: imperatively
insure gases ducting towards the atmosphere.
• Get the cylinders turned at low speed (about 50
m/min press speed) for four hours.

WARNING
Gases escape to the open air and could be
injurious. Imperatively ventilate the premises.

• Drain the cylinders through the dia. 1/2" «Gaz»

port (between the frames) and check the result.
If necessary proceed the same operation again.
• When the result is acceptable, rinse with water in
order to stop chemical effects.
• Reconnect the flexible pipes on the rotating
unions and join the chill-roll to the water supply
network.
When the hard grade of water is important, this
operation must be done as soon as lack of chill-roll
effectiveness appears. It must be considered as a
normal maintenance operation. To replace the
hydrochloric acid, consult a local boiler
manufacturer for a suitable solution as used in water
boilers.

NOTE
The above mentioned times and values vary
according to the type of scaling substance used.
Refer to manufacturer recommendations.
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Maintenance instructions – Chill-Roll – RS 9

 2 Maintenance

2.2 Chill cylinder water supply

2.2.1 Coupling of rotating unions

Rotating unions do not require any external
additional part intended to prevent the casing from
rotating.

The slight offset and buckling motions that may

occur due to fitting operations should never involve
any stressing correction action. It is indispensable
that coupling of union to rigid piping should be
carried out by means of a flexible pipe.

Fitting of hose pipe to union has to be performed as

follows :
• With the casing body gripped in a vice, screw up
the fixed hose and adapter into the threading
provided on back part of union.
• Connect the union fitted with its hose to the
cylinder nozzle (putt Teflon tape for tightness).
• Connect the hose pipe to the rigid piping, using
the rotating end adapter.

2.2.2 Cylinder general feeding

The inlet and return ports must be located above the
cylinder axis so that unions remain continuously
under pressure even in case of supply cut-off. This
precaution insures the permanent joint packing
lubrication.
We recommend to fit each outlet port with a
thermometer for temperature checking.

2.3 Maintenance of subassemblies

See documentations in “Appendices”

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10 Maintenance instructions – Chill-Roll – RS

 3 Checks and adjustments

3 Checks and adjustments

3.1 Mechanical and pneumatic checks

3.1.1 Belt tension

Check the transmission belt tension is correct.

3.1.2 Nipping roller

See pneumatic diagram M 102909Y “Drawings &
Diagrams”
• The main compressed air supply is closed (valve
1VLV shut).
• The pressure gauge 1PG shows 0.
• Adjust the pressure regulator 1REG to minimum
pressure.
• Supply the chill-roll with compressed air (valve
1VLV open).
• Adjust the regulator 1REG to read 87 psi (6 bar)
on 1PG.
• The nipping roller moves to webbing-up position.
• Look for any possible leaks.
Check that the connections of plastic pipes are
not under strain.
• Set the fork joints and the nuts of the nipping air
cylinders 1CYL - 2CYL on the rod.
Rod in, the center distance [A] of the cylinders
axes should be 11.65” (296 mm) (see Fig. 1).
• Set 1SOL to position «1».
A
The nipping roller now comes in contact with the
cylinders. Check that the pressure is on all over
the roller.
• Set 1SOL to position «0».
The nipping roller returns to webbing-up
position.
• If, for a special job, the thrust of the nipping roller
is too high, decrease the pressure using
pressure reducer 1REG.

Fig. 1 Nipping roller

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Maintenance instructions – Chill-Roll – RS 11

 3 Checks and adjustments

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12 Maintenance instructions – Chill-Roll – RS

 Spare parts

Chill-Roll

RS
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Spare parts – Chill-Roll – RS 1

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2 Spare parts – Chill-Roll – RS

 Drawings & Diagrams

Chill-Roll

RS
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Drawings & Diagrams – Chill-Roll – RS 1

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2 Drawings & Diagrams – Chill-Roll – RS

 Appendices

Chill-Roll

RS
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Appendices – Chill-Roll – RS 1
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2 Appendices – Chill-Roll – RS