rectangular duct work closure system - production …

WHISPER-LOC® II RECTANGULAR DUCT WORK

CLOSURE SYSTEM

INSTALLATION, OPERATION & MAINTENANCE MANUAL

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© Copyright 2009 by Iowa Precision Industries All Rights Reserved

The information in this document has been reviewed and is believed to be completely accurate. However, no responsibility is assumed for inaccuracies. Furthermore, IOWA PRECISION INDUSTRIES reserves the right to make changes to any products herein, at any time, to improve reliability, function, or design. IOWA PRECISION INDUSTRIES does not assume any liabilities arising out of the application or any use of any product described herein, neither does it convey any license under its patent rights nor the rights of others.

TRADEMARK NOTICES Iowa Precision Industries is a registered trademark. All other brand and product names are trademarks or registered trademarks of their respective companies.

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WHISPER-LOC® II Duct Work Closure System

TABLE OF CONTENTS TABLE OF CONTENTS LOCKOUT GUIDE ASSEMBLY DRAWINGS (Back of Manual) ELECTRICAL SCHEMATICS (Back of Manual)

Section/Page 1. INTRODUCTION ......................................................................................................................1-1 2. INSTALLATION........................................................................................................................2-1

A. UNPACKING THE MACHINE ............................................................................................2-1 B. INSTALLING THE MACHINE.............................................................................................2-1

(1) Hydraulic Reservoir Gauges ........................................................................................2-1 (2) Horizontal Model ..........................................................................................................2-2 (3) Vertical Model ..............................................................................................................2-2

(a) Counterweight.............................................................................................. 2-2 (b) Back Supports ............................................................................................. 2-2

(4) Vertical Model Pit Installation.......................................................................................2-3 3. CONTROLS..............................................................................................................................3-1

A. HORIZONTAL WHISPER-LOC® II ....................................................................................3-1 (1) Standard Horizontal Whisper-loc®...............................................................................3-1 (2) Powered Horizontal Whisper-loc® II ............................................................................3-1

B. VERTICAL WHISPER-LOC®II...........................................................................................3-2 (1) Standard Vertical Whisper-loc® II................................................................................3-2 (2) Powered Vertical Whisper-loc® II ................................................................................3-3

4. SAFETY....................................................................................................................................4-1 A. SAFETY PRECAUTIONS BEFORE STARTING THE MACHINE .....................................4-1 B. SAFETY PRECAUTIONS WHEN OPERATING THE MACHINE ......................................4-1

5. OPERATION.............................................................................................................................5-1 A. PREPARING DUCT WORK FOR FORMING.....................................................................5-1

(1) Support Plate Adjustment ............................................................................................5-1 (a) Support Plate Adjustment Procedure........................................................... 5-1

(2) Slide and Stop Block Adjustments ...............................................................................5-2 (a) Nonpowered Whisper-loc® II ....................................................................... 5-2 (b) Powered Whisper-loc® II ............................................................................. 5-4

(3) TDC Flange Modifications............................................................................................5-5 B. FORMING THE SEAM .......................................................................................................5-6

6. MAINTENANCE .......................................................................................................................6-1 A. SERVICING ........................................................................................................................6-1

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(1) Lubricant Recommendations / Specifications ..............................................................6-1 (2) Lubrication, General Requirements .............................................................................6-1 (3) Cleaning.......................................................................................................................6-1 (4) Preventative Maintenance Inspections ........................................................................6-1 (5) Hydraulic Reservoir......................................................................................................6-2

(a) Drain And Replace The Hydraulic Fluid ....................................................... 6-2 (b) Hydraulic Fluid Filter..................................................................................... 6-2 (c) Hydraulic Fluid Contamination ..................................................................... 6-2 (d) Maintaining Good Filtration .......................................................................... 6-2

B. ADJUSTMENTS .................................................................................................................6-3 (1) Hydraulic Pressure Settings.........................................................................................6-3

(a) Non-Powered Whisper-loc® II...................................................................... 6-3 (b) Powered Whisper-loc® II.............................................................................. 6-3

(2) Adjusting the PLC Timers ............................................................................................6-4 (3) Adjusting The Slide-Block Cable Tension....................................................................6-5

(a) Pivot Bolt ...................................................................................................... 6-5 (b) Pulley Adjusting Bolt..................................................................................... 6-5

C. COMPONENT REPLACEMENT ........................................................................................6-6 (1) Cable Replacement .....................................................................................................6-6 (2) Supply / Tool Requirements.........................................................................................6-6 (3) Component locations ...................................................................................................6-6 (4) Cable REMOVAL Procedure .......................................................................................6-7 (5) Cable INSTALLATION Procedure ...............................................................................6-9

LIST OF TABLES Table 6-1. Recommended Lubrication Products ..................................................................6-1

LIST OF FIGURES Figure 1-1. Completed Pittsburgh Seam..............................................................................1-1 Figure 1-2. Vertical Whisper-loc® II ......................................................................................1-2 Figure 1-3. Horizontal Whisper-loc® II .................................................................................1-2 Figure 2-1. Self-Contained Hydraulic Unit............................................................................2-2 Figure 2-2. Back Support Angle Weldments ........................................................................2-3 Figure 2-3. Back Support Angle Weldment in Place ............................................................2-3 Figure 2-4. Vertical Whisper-loc® II Pit Construction (Inches Top, Metric Bottom)..............2-4 Figure 3-1. Standard Horizontal Whisper-loc® II Control Panel...........................................3-1 Figure 3-2. Powered Horizontal Whisper-loc® II Control Panel ...........................................3-1 Figure 3-3. Standard Vertical Whisper-loc® II Control Panel ...............................................3-2 Figure 3-4. Powered Vertical Whisper-loc® II Control Panel ...............................................3-3 Figure 5-1. Minimum “Lip” Requirement For a Good Closure ..............................................5-1

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Figure 5-2. Support Plate Adjustment ..................................................................................5-2 Figure 5-3. TDC Flange Modifications .................................................................................5-5 Figure 5-4. Positioning Ductwork .........................................................................................5-6 Figure 6-1. The Two PLC Controller Adjustable Timers.......................................................6-4 Figure 6-2. Machine Flow Diagram ......................................................................................6-5 Figure 6-3. Hydraulic Symbols Used on IPI Drawings .......................................................6-17

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LOCKOUT GUIDE The protection of life and limb through responsible actions and adequate safeguards are the responsibility of all individuals in a workplace environment, or any environment where action or miss-action could possibly endanger the safety and well being of others.

All maintenance, repair and adjustment procedures performed on this equipment shall comply with existing established Lockout requirements. At a minimum, these requirements must include the use of a keyed padlock or similar device utilized to physically and securely remove and isolate any power source from the equipment, preventing accidental reapplication while personnel may be in exposed circumstances, subject to possible injury or death.

These requirements must also include the tagging of the lockout device to notify all individuals working in the area, or anyone who could for whatever reason be in a position to possibly remove or otherwise defeat the purpose of the lockout device, as to its installation, why, and the individual responsible for its application.

Power sources include electrical, pneumatic, hydraulic, or any other hazardous energy source. This procedure shall be used to ensure that the machine is stopped and isolated from all potentially hazardous energy sources and that these energy sources are locked out before employees perform any servicing or maintenance when the unexpected energizing, start-up of the machine, or the release of stored energy could cause injury.

FOR THIS UNIT (where applicable)

• Hydraulic power sources are provided with a lockable valve to block hydraulic pressure from the system. Where applicable, this valve shall be placed in the off position and locked in place.

• Electrical power sources are provided either with a male plug for connection to the electrical source, or are hardwired to the source distribution panel. When a plug is provided, the plug shall be disconnected from the source power and secured within a covering and tagged appropriately. When hardwired to the source distribution panel, the panel shall have a manual disconnect which is lockable in the off position, or in the event of a circuit breaker, the panel will have a lockable door which will deny access to unauthorized personnel.

• Pneumatic power is applied to the machine through a quick disconnect fitting. This quick disconnect fitting shall be disconnected from the pneumatic power source and secured within a covering and tagged appropriately.

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WHISPER-LOC® II

1. INTRODUCTION

The Whisper-loc® II operation is hydraulic, using no pneumatics. The slide block assemblies, which are the main forming mechanisms, are powered by two hydraulic motors located on the back of the equipment. These two motors pull cables which are attached to the forming slide blocks. The blocks move across the lip on the ductwork to perform the closing function.

Figure 1-1. Completed Pittsburgh Seam

The Whisper-loc® II machine features a new Pittsburgh closure system. It is designed for closing 26 gauge (.45 mm) through 18 gauge (1.21 mm) rectangular duct work, including raw-to-raw, slip & drive and all transverse duct connectors. The Whisper-loc® II quickly and quietly closes duct work in a fraction of the time required by conventional duct closure methods and without the danger of high noise levels. The Whisper-loc® II is ruggedly constructed to withstand years of use. The compact unit requires a minimum of operating floor space. The process is microprocessor controlled, designed for ease of operation with a minimum of maintenance. The portability of the horizontal style unit allows the equipment to be taken from plant to job site where it can be operational within minutes. The Whisper-loc® II is conveniently powered by 220 volts AC which operates a self-contained hydraulic unit. On models equipped with the hydraulically powered slide stop block adjustment, duct sections down to 18 inches (457 mm) can be sealed. On units equipped with the manual slide stop block and end support adjustment, duct sections down to 36 inches (914 mm) can be sealed. On the horizontal type model Whisper-loc® II, four swivel casters on the frame allow it to be easily moved about the shop or out of the way when not in use. These units will also fit through any standard 36 inch (914 mm) wide doorway. On the vertical model, the legs must be firmly fastened to the floor using the holes in the base plate on each leg. The vertical model is not designed to be portable.

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Figure 1-2. Vertical Whisper-loc® II

Figure 1-3. Horizontal Whisper-loc® II

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INSTALLATION

2. INSTALLATION In selecting a location for the Whisper-loc® II, especially for the vertical model that is secured permanently to the floor or foundation, consider the following factors: • Working weight (including oil tank filled to capacity) in relation to the building floor

support. • Access to the selected location where the machine will be used. • Adequate area to allow working space around the machine (a minimum clearance of 36

inches (914 mm) is recommended). This space requirement allows room to service the unit and helps provide adequate ventilation.

Consideration should be given to the location and availability of the required power source. The machine should also be located away from any grinding machines, sanding machines, spray painting areas and other sources of contamination, if at all possible. Answers to questions regarding site preparation and any other technical assistance is available free of charge by telephone between 8 a.m. and 4:30 p.m. CST, Monday through Friday, by calling (319) 364-9181, ask for the Service Department.

A. UNPACKING THE MACHINE When the machine arrives, inspect it carefully before accepting the shipment. It is important to note any damage on the Bill of Lading or other shipping documents so that a claim can be filed with a carrier. Pay special attention to the control console, as it contains delicate electronic equipment. Check for physical damage to switches and the components inside. If anything looks damaged, notify both the carrier (to file a claim) and the Iowa Precision Service Department at the factory (to order replacement parts). It is important to notify the factory promptly so that new parts arrive as soon as possible as it may not be possible to run the machine without them. No special procedures are required in unpacking the machine. Remove any covering, strapping, or skids that may be present. Remove any wooden blocks used as spacers, if present. Lifting eyes on the horizontal style Whisper-loc® II side frames were purposely built into the machine so that it could be hoisted off the skid or truck with a forklift or overhead crane. Lifting eyes for the vertical style unit are located on the top for hoisting it off the skid and into place for bolting to the floor. We recommend using heavy duty nylon straps or cables attached through these eyes to lift the equipment.

B. INSTALLING THE MACHINE (1) Hydraulic Reservoir Gauges

To prevent damage, the two pressure gauges for the hydraulic unit were removed prior to shipping. When installing the Whisper-loc® II, these gauges must be reinstalled. Use Teflon tape on fitting threads.

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Figure 2-1. Self-Contained Hydraulic Unit

(2) Horizontal Model After inspection and unpacking, lift the horizontal model off the skid and attach the four caster wheels (shipped separately with the machine) to the bottom of the unit. The unit can be moved about freely on the four caster wheels. Remove the two duct support tubes from their storage position. Remove the pin from each of the support tube brackets on the front of the machine and slip the support tubes onto the brackets. Replace both pins. The hydraulic tank is shipped filled with TEXACO RANDO HD 46. When replacing hydraulic oil, use the same or equivalent oil. Once in position, make the necessary connection to the electrical supply. This circuit should be dedicated to the Whisper-loc® II unit only.

(3) Vertical Model The vertical model Whisper-loc® II is shipped in a horizontal position without the four legs mounted on the machine. Stand the unit upright using the lifting eyes as the lift points. Take care to not damaging the hydraulic cylinder mounted on the bottom of the unit. After lifting the unit, hold it above the floor far enough to install the legs on the four corners. The legs must be installed so that the hole in the toe of each leg is straight out from the corner (as far from the center of the machine as possible). Once the four legs have been properly installed, move the machine to its permanent location. The hoisting device should remain attached until the unit is leveled and secured to the floor using the holes provided in each leg base plate. (a) Counterweight

Once in place, the non-powered vertical unit has a cylinder counterweight that is secured to the frame of the machine for shipping purposes. This counterweight must be unfastened from the frame and free to move on a vertical axis. The counterweight is used when the upper stop block is adjusted up or down for size changes.

(b) Back Supports Included with the Whisper-loc® II are three back support angle weldments of different lengths. The length of the support to be used must correspond to the length of the duct being processed. The support installs on the end mount backstops located on the upper and lower (vertical units), or the right and left heads (horizontal

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units). Position the backstop support between the heads, and align them to allow beading clearance. Secure the back support in place with the set screws provided.

NOTE Before making a machine size change, remove the back support angle.

Figure 2-2. Back Support Angle Weldments

Figure 2-3. Back Support Angle Weldment in Place

(4) Vertical Model Pit Installation The vertical Whisper-loc® II can be pit mounted to place its deck surface level with the surrounding floor. This type installation reduces the duct piece lifting required by the

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operator, and can speed up the handling operations during heavy production. The vertical Whisper-loc® II is designed to be set within such a pit if desired. Pit construction and dimensions, in both inches and metric, is shown below.

Figure 2-4. Vertical Whisper-loc® II Pit Construction (Inches Top, Metric Bottom)

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CONTROLS

3. CONTROLS A. HORIZONTAL WHISPER-LOC® II

(1) Standard Horizontal Whisper-loc® The standard horizontal Whisper-loc® unit utilizes a manual slide stop block adjustment. The unit is controlled by three switches located on top of the electrical cabinet.

Figure 3-1. Standard Horizontal Whisper-loc® II Control Panel

• POWER ON/OFF - A red lens pull-push type switch that illuminates when pulled out, indicating that the control power is ON, the hydraulic system is ON, and the unit operational. When pushed in, this switch shuts down electrical and hydraulic power to the system.

• LEFT BLOCK LEFT/RIGHT - This switch jogs the left Slide Block either LEFT or RIGHT.

• RIGHT BLOCK LEFT/RIGHT - This switch jogs the right Slide Block either LEFT or RIGHT.

• Foot Pedal Switch - This cycle start switch is identical on all types of Whisper-loc® units. Once the duct is in place on the Whisper-loc® II, the operator activates the cycle start switch with the toe of his shoe, and the seam sealing sequence is initiated.

(2) Powered Horizontal Whisper-loc® II The powered horizontal Whisper-loc® II is equipped with a powered slide stop block adjustment for size changes. There are four switches on top of the electrical cabinet, the POWER, LEFT BLOCK, RIGHT BLOCK and CARRIAGE.

Figure 3-2. Powered Horizontal Whisper-loc® II Control Panel

• POWER ON/OFF - A red lens pull-push type switch that illuminates when pulled out, indicating that the control power is ON, the hydraulic system ON, and the unit operational. When pushed in, this switch shuts down electrical and hydraulic power to the system.

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• LEFT BLOCK LEFT/RIGHT - When the Carriage clamp switch is in the LOCKED position, this switch jogs the left slide block either left or right. When the Carriage clamp switch is in the RELEASE position, this switch relocates both the stop block and the slide block assembly to the left or right as a unit (see the Carriage Lock/Release description below).

• RIGHT BLOCK LEFT/RIGHT - This switch jogs the right slide block either left or right. • CARRIAGE LOCK/RELEASE - This switch works in conjunction with the Left Block

Left/Right jog switch to adjust duct size changes, or changes in the type of duct connectors that require a size adjustment on the Whisper-loc® II. When the switch is in the LOCKED position, the left slide stop block carriage is clamped in position. The left slide block switch will jog only the slide block left or right. When this switch is in the RELEASE position, the left slide stop block is unclamped from the slide and mechanically connected to the movable slide block. When the left slide block switch is activated, both the stop block and the slide block assembly move as one unit. Using this method, adjustments for a size change are made in the RELEASE mode.


B. VERTICAL WHISPER-LOC®II (1) Standard Vertical Whisper-loc® II

The standard vertical Whisper-loc® II unit is not equipped with the powered slide stop block adjustment for size changes. The unit is controlled by three switches located on top of the electrical cabinet.

Figure 3-3. Standard Vertical Whisper-loc® II Control Panel


• UPPER BLOCK UP/DOWN - This switch jogs the Upper Slide Block either UP or DOWN.

• LOWER BLOCK UP/DOWN - This switch jogs the Lower Slide Block either UP or DOWN.

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(2) Powered Vertical Whisper-loc® II The powered vertical Whisper-loc® II unit is equipped with a powered slide stop block adjustment.

Figure 3-4. Powered Vertical Whisper-loc® II Control Panel


• UPPER BLOCK UP/DOWN - When the Carriage clamp switch is in the LOCKED position, this switch jogs the upper slide block either up or down. When the Carriage clamp switch is in the RELEASE position, this switch relocates the stop block assembly up or down (see the Carriage Lock/Release description below).

• LOWER BLOCK UP/DOWN - This switch jogs the Lower Slide Block either UP or DOWN.

• CARRIAGE LOCK/RELEASE - This switch works in conjunction with the upper block up/down jog switch to adjust duct size changes, or changes in the type of duct connectors that require a size adjustment. When the switch is in the LOCKED position, the upper slide stop block carriage is clamped in position. The upper slide block switch will jog only the slide block up or down. When the Carriage switch is in the RELEASE position, the upper stop block is unclamped. The upper block switch will now move the stop block assembly up or down to reposition for different duct sizes.

• Foot Pedal Switch - This cycle start switch is identical on all types of Whisper-loc® II units. Once the duct is in place on the Whisper-loc® II, the operator activates the cycle start switch with the toe of his shoe, and the seam sealing sequence is initiated.

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SAFETY

4. SAFETY Before operating the machine, read this section. Study and follow the safety precautions listed. Know the hazards associated with the piece of equipment you are working with, and be aware of its limitations. The precautions listed cannot cover all possible situations. Therefore, consider the consequences of your actions before executing any procedure or operation.

A. SAFETY PRECAUTIONS BEFORE STARTING THE MACHINE • Protect yourself. Wear safety glasses and leather gloves when handling metal. Do not

wear loose clothing, neckties, or jewelry. If long sleeves must be worn, avoid cuffs and buttons.

• Keep your work area clean. Clean up any oil spills, remove all scrap, rags, tools or other loose items that could cause you to slip, trip or fall.

• Ensure that the hydraulic pressure is set the specified level before operating the machine. • Keep the machine properly maintained. • Be alert for loose, worn, or broken parts, or unusual noises or actions. Do not attempt to

operate a faulty machine • Keep this manual nearby so the operator can refer to it if necessary. • Be aware of the location of the POWER OFF push-pull switch and use it to stop the

machine in an emergency.

B. SAFETY PRECAUTIONS WHEN OPERATING THE MACHINE • Be alert when operating the machine. Only one person should control the machine. Never

allow anyone to operate the controls while you are working on the machine. • Keep your fingers and hands away from the internal workings of the machine when starting

or stopping the machine. • Do not try to process duct parts that are beyond the specified thickness designated for the

machine. Use good quality metal free from irregularities or defects. • Continually observe the closure function of the machine. If any unusual condition

develops, immediately stop the machine. • Do not work on any moving device without first powering down the machine and taking

every safety precaution. • When cleaning the machine, or any of its components, do not use toxic or flammable

substances. • Do not perform any cleaning while the machine is in operation. • Never override or disable any safety switch or safety interlock. • Do not use adjustable or worn wrenches. A slipping wrench can cause injury. Replace

worn nuts, bolts, screws, etc., being sure they are of an equivalent quality of those being replaced.

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OPERATION 5. OPERATION

A. PREPARING DUCT WORK FOR FORMING Ductwork should be of good quality material. The better the duct piece is prepared for closure on the Whisper-loc® II, the better the closure procedure will be. The minimum "lip" requirement for a good closure varies from 1/4 inch (6.35 mm) for lighter gauge to 5/16 inch (7.9 mm) for 18 gauge (1.21 mm).

Figure 5-1. Minimum “Lip” Requirement For a Good Closure

(1) Support Plate Adjustment To ensure a good quality closure on a duct piece, it is important that proper clearance be maintained between the duct piece and the closure forming rolls. The support plates on each end (top and bottom for vertical units) are adjustable so that when the duct rests up against the plate, the position of the duct seam in relation to the slide block assembly forming rolls is correct. If ductwork is of good quality, fitting together easily during pre-assembly, there should be no problem closing it on the Whisper-loc® II. Ductwork which is difficult to mate (i.e., extremely tight fitting) may result in an unsatisfactory closure. Heavily insulated material or ductwork which is difficult to assemble should be hammered over approximately 1-1/2 inches (38.1 mm)at each end plus an additional 1-1/2 inches (38.1 mm) in the center.

(a) Support Plate Adjustment Procedure The support plate is adjusted using its adjusting screws.

1. First jog the slide block assembly so that the slide block final forming roller is in line with the support plate.

2. Place a straight edge on the support plate so that it extends out over the final forming roller on the slide block assembly. The clearance between the straight edge and the roller is very important to the quality of the seam tab form. This clearance may vary with the gauge of the material being processed, however a good starting point .015 inches (0.381 mm). • For more clearance, unscrew the socket head cap screw and screw IN

the set screw. • For Less clearance, unscrew the set screw and screw IN the socket

headed cap screw, then tighten the set screw. The unit clearance is factory set for processing a 4 foot (121.92 cm) duct length. This setting is a starting point. Readjustment may be required to run 3, 5, or 6 foot

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(91.4, 152.4, or 182.8 cm) duct. After a little experience and testing, the operator can usually make the correct adjustments in a very short period of time.

Figure 5-2. Support Plate Adjustment

(2) Slide and Stop Block Adjustments The stop blocks are adjustable to accommodate various sizes and styles of ductwork. Included with the Whisper-loc® II are shim washers for use with the slide blocks' final forming roller. If the final form roller is leaving an indent line on the rolled "lip", the roller is not out far enough. Either the roller can be shimmed using the shim washers, or the problem "lip" must be decreased in size. Usually, when this type of indent occurs, the lip is greater than the specified 5/16 inch (7.93 mm).

(a) Nonpowered Whisper-loc® II On the standard nonpowered Whisper-loc® II, the stop blocks and end support assembly are manually adjusted.

1. Horizontal Model The stop block can be adjusted by loosening the stop block mounting bolt from the bottom side of the machine and sliding the block to the desired location. The stop block is the block that bolts into a long slot in the bottom slide surface of the machine. From the top you can see the gold spring sticking out toward the slide block. The left slide block should be jogged as far left as necessary for the straight wheel to pass the left edge of the duct work. Once in this location, move the left stop block over until it hits the slide block and then lock it down. • In the case of TDC flanges, the slide block cannot be further left than the

outside edge of the TDC flange guide. In this location the straight wheel will be approximately in the center of the TDC flange guide.

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• Once in this location, move the left stop block over until lit hits the slide block and then lock it down. Next, loosen the hex head bolts on the front slide block track and slide the left end support assembly into position relative to the new left stop block position. Lock the bolts down on the front slide block track (it is only necessary to lock down the bolts in the vicinity of the slide block end support assembly).

• The right slide block should be jogged as far right as necessary for the straight wheel to pass the right edge of the duct work. Once in this location, move the right stop block over until it hits the slide block and then lock it down.

• In the case of TDC flanges, the slide block cannot be further right than the outside edge of the TDC flange guide. In this location the straight wheel will be approximately in the center of the TDC flange guide. Once in this location, move the right stop block over until it hits the slide block and then lock it down.

2. Vertical Whisper-loc® II On the non-powered vertical style units, the stop blocks are mounted on the end support assemblies. When the top end support assembly is moved for a size change, the stop block is automatically moved with it. It is only necessary to loosen the hex head bolts on the slide block track toward the edge and slide the top end support assembly up or down to the new size location. Lock the bolts back down (it is only necessary to lock the bolts down in the vicinity of the end support assembly). On the standard vertical style unit, the stop block locations have to be adjusted when switching to duct with the TDC flange connector (Figure 5-3). Shipped with each machine is a set of stop blocks approximately 2 inches (5.08 cm) in length that are stamped "B" for bottom and "T" for top. They each have a pin inserted in one end for mounting purposes on the machine. When working with the TDC flange duct, these stop blocks must be inserted in the top and bottom end stop locations. To make the stop block modifications, you must first jog the slide blocks away from the existing stop block locations to have adequate room to work, then shut-off power for maximum operator safety. • The top stop is designed to be inserted into the existing stop with the pin

and locked in place with a set screw on the permanent top stop block. • The bottom stop is designed to be inserted in place of the existing bottom

stop by removing it and replacing it with the "B" stamped stop. To switch back, just replace the bottom stop with the original and remove the top inserted stop marked with a "T".

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(b) Powered Whisper-loc® II On the powered Whisper-loc® II, the stop block assembly is adjusted using hydraulic power.

1. Horizontal Model On the powered horizontal style Whisper-loc® II units equipped with the powered stop block adjustment, size changes are made by switch position changes. To adjust the stop blocks, switch the "Carriage Clamp Lock/Release" switch to the Release position and jog the left slide block assembly (mechanically connected with the stop block carriage) to the desired position for size change using the positioning scale. The carriage is set to position to match the size of the duct before the end connectors or flanges are put on the duct. Once in position, set the switch back to the Lock position. The end stop is automatically moved with the stop block carriage on the powered units but still has to be modified when running TDC flange type duct connectors. • TDC Flange Modifications: There are two end stops with pins shipped with

each machine. These must be inserted into the existing stop springs on each end when switching over to TDC flange type duct, and the end stops removed when switching back. Be sure to leave the end stop spring in place.

2. Vertical Model On the powered vertical style Whisper-loc® II units equipped with the powered stop block adjustment, size changes are made by switch position changes. To adjust the stop blocks, run the upper block down, then switch the "Carriage Clamp Lock/Release" switch to the Release position. Using the Upper Block switch, position the slide block just above the location desired. Let the slide block drift down until it reaches the exact position to match the size of the duct before the end connectors or flanges are put on it. Set the Carriage switch to the Lock position, then run the upper block up. The end stop is automatically moved with the stop block carriage on the powered units but still has to be modified when running TDC flange type duct connectors. • TDC Flange Modifications: There are two end stops with pins shipped with

each machine. These must be inserted into the existing stop springs on each end when switching over to TDC flange type duct and the end stops removed when switching back. Be sure to leave the end stop spring in place.

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(3) TDC Flange Modifications There are two TDC stops shipped with each machine. The lower TDC stop must be inserted into the existing stop springs and the upper TDC stop must be inserted over the Slip and Drive stop before forming ductwork with a TDC flange. To install the lower TDC stop, raise the lower forming head to allow access, then lift out the Slip and Drive stop, and insert the TDC stop in its place. To install the upper TDC stop, lower the upper forming head to allow access. Insert the TDC end stop over the Slip and Drive stop, and tighten the setscrew. Reverse the procedure when no longer working with TDC flanges. Be sure to leave the end stop spring in place.

TDC End Stops Remove lower S&D stop and replace with TDC stop

Upper S&D stop installed Insert the TDC End Stop Adapter over S&D stop and Retighten the Set Screw

Figure 5-3. TDC Flange Modifications

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B. FORMING THE SEAM Using both hands, and grasping the duct piece in the middle of the duct and away from the ends, the operator places the duct piece with the Pittsburgh seam into position. While holding the duct in position, the operator steps on the foot pedal switch to start the cycle.

Figure 5-4. Positioning Ductwork

The duct clamps pivot into the inside corners and lock the ductwork against two tool steel plates at a 90° angle to each other. The bottom plates (one at each end of the carriage assembly) are adjustable for the height of ductwork relative to the slide mechanisms (refer to the slide block adjustment section when making any adjustments). After the duct clamps are down and bottomed out, the first slide block (right side as you face the horizontal unit or the bottom of vertical units) will slide across to close the duct seam just past the center sensor switch. The slide block will then return home to the right side (or lower) home sensor switch. Next, the opposite side slide block (left side or upper) will slide across to close the seam past the center sensor switch. The programmed operation allows an additional amount of time in this action to ensure that the two-formed areas overlap each other. The left (upper) slide block then returns to the left side (upper) home position. The duct clamps then retract clear of the duct, and the cycle is completed. The completed duct can now be lifted out of the Whisper-loc® II.

NOTE Any time the stop blocks are readjusted, removed, or replaced, the slide blocks should be jogged back against the stops. At that point, the machine is ready and the slide blocks will go the entire

length of the ductwork.

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MAINTENANCE

6. MAINTENANCE A. SERVICING

(1) Lubricant Recommendations / Specifications To ensure that the system is kept in a correct operating condition, it must be inspected and maintained on a regular basis. Proper cleaning and/or replacement of the hydraulic fluid filter, the periodic lubrication of bearings, bushings, chains and other moving friction and wear generating points will prevent damage to or failure of the unit, and provide optimum performance. Table 1 lists the types of lubricants used to maintain the machine.

Table 6-1. Recommended Lubrication Products

Description Recommended Products

CHAIN OIL WAY LUBRICANT 220

MULTI-PURPOSE LUBE MARFAX MULTI-PURPOSE #2 (TEXACO) MULTI-PURPOSE #2 GREASE (AMACO) MOBILITH AW #2 (MOBIL)

HYDRAULIC OIL RANDO AW HYDR-46 HYDRAULIC OIL (TEXACO) AW-68 HYDRAULIC OIL (AMACO) DTE #26 MOBILE

(2) Lubrication, General Requirements The maintenance technician must become familiar with all the lubrication points located on the machine. Chain drives and those points where metal-to-metal contact of movable surfaces are located must be adequately lubricated. The actual lubrication requirements for the machine and for individual points will be determined by usage requirements. These requirements will be based on the machine setup, usage and equipment environment. During lubrication procedures, a preventative maintenance inspection should also be conducted. Check the machine visually for loose nuts, bolts, parts out of adjustment, etc. Correct all deficiencies while they are small, and before they become operational problems. Certain parts of the machine are left unpainted to aid in the movement of the slide assembly when changing dies, etc. Keep these areas clean and coated with a light grease.

(3) Cleaning Keep the right and left slide block assemblies clean and free of dirt and sealant buildup.

(4) Preventative Maintenance Inspections • Weekly, check sensor switch mounting for security. • Inspect cables for damage and proper operation.

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(5) Hydraulic Reservoir Drain the hydraulic fluid from the hydraulic reservoir after the first 6 months of operation and every 6 months thereafter. Replace it with TEXACO RANDO AW HYDR-46 hydraulic fluid or its equivalent. A capacity tag is located next to the fill port on the tank.

(a) Drain And Replace The Hydraulic Fluid 1. Remove the hex-head drain plug 2. Drain all hydraulic fluid into a suitable container 3. Replace the hex-head drain plug 4. Refill the hydraulic reservoir to the level of the #1 sight gauge 5. Properly dispose of the used hydraulic fluid

(b) Hydraulic Fluid Filter Replace the hydraulic filter element every 6 months or sooner as indicated by the indicator gauge on the filter housing (refer to IPI Drawing 404-0148-01-00).

1. Remove the filter element (item #21) from the filter housing (item #9) by turning in a counter-clockwise direction (viewed from the top of the filter).

2. Clean the filter housing where it contacts the filter gasket to ensure that it is free of old gasket material.

3. Coat the gasket of the new filter element with hydraulic fluid. 4. Install the new filter element by screwing it into the filter housing in a

clockwise direction (viewed from the top of the filter). For proper torque, tighten the element 3/4 turn after the gasket contacts the filter housing.

5. Operate machine and check for leaks.

(c) Hydraulic Fluid Contamination Contamination is the prime enemy of machines that incorporate hydraulic systems. Contaminants in a hydraulic system may be solids, liquids, or gasses. Solids (grit, dust, metal particles) pose the greatest problem since they are the most common and the most damaging. Contaminants may be external or generated. External contaminants may enter a system while it is disassembled (i.e., for repairs) or through improperly serviced breathers. Lint is a common problem, introduced during cleaning and maintenance. Generated contamination results from existing contamination breeding new contamination. For example, tiny grit may score off particles within the system, which in turn grind off more. Uncontrolled, contamination multiplies rapidly. The quality components used in IPI hydraulic systems will operate for years without trouble, if kept free of contamination. If not, a variety of ills can result. Dirty oil can cause a pump to wear quickly, valves to stick, or internal leakage, degrading machine accuracy and capacity.

(d) Maintaining Good Filtration Many of the dirt particles that are harmful to expensive machinery are too small to see, so just because hydraulic fluid or a component looks clean doesn’t necessarily mean that it is clean. Good filtration guidelines include:

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1. Drain and replace hydraulic oil and put in a new filter every six months. The filter should be changed more often if the indicator on the reservoir goes into the red.

2. Maintain a stock of filters for emergency use. If it is necessary to open the system for repair, replace the filter.

A complete change of fluid and filter is advised in the case of gross fluid contamination. Replace only with Texaco RANDO HD-46 (or equivalent), a heavy-duty oil with anti-wear additives, treated to avoid rust and oxidation.

B. ADJUSTMENTS (1) Hydraulic Pressure Settings

(a) Non-Powered Whisper-loc® II The non-powered type Whisper-loc® II does not have a fluid flow adjustment to modify the speed of the machine. The only hydraulic adjustment on non-powered units is the setting of the relief valve pressure to 1800 psi (126.5 kg/cm2). This system pressure was set at the factory and should not require modification. Before attempting to adjust this setting, first contact the IPI service department for additional instructions. The adjustment for the relief valve is located on the side, or bottom, of the manifold where the valve is mounted. The system hydraulic pressure gauge is located on the hydraulic tank. To set the pressure:

1. Loosen the relief valve adjustment locking nut. 2. Manually operate the clamp valve (by pushing in on the end of the valve).

This halts the dumping of system oil pressure. 3. While holding the valve ON, adjust the relief valve until the gauge reads 1800

psi (126.5 kg/cm2). 4. Release the clamp valve and re-tighten the adjustment lock nut on the relief

valve.

(b) Powered Whisper-loc® II The hydraulic relief valve pressure is factory set to 1800 psi (126.5 kg/cm2). This system pressure should not require modification. Before attempting to adjust this setting, first contact the IPI service department for additional instructions. The adjustment for the relief valve is located on the side, or bottom, of the manifold where the valve is mounted. The system hydraulic pressure gauge is located on the hydraulic tank. To set the pressure:

1. Loosen the relief valve adjustment locking nut. 2. Manually operate the clamp valve (by pushing in on the end of the valve).

This halts the dumping of system oil pressure. 3. While holding the valve ON, adjust the relief valve until the gauge reads 1800

psi (126.5 kg/cm2). 4. Release the clamp valve and re-tighten the adjustment lock nut on the relief

valve. The powered type Whisper-loc® II has two additional factory set speed adjustments. These adjustments control the left (upper) slide block speed (when making a size

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change) and the speed of the locking/unlocking mechanisms of the powered adjustable left (upper) side stop block assembly. Before attempting to adjust either of these two settings, first contact the IPI service department for instructions.

(2) Adjusting the PLC Timers There are two adjustable timer potentiometers located on the PLC controller. Turning the potentiometer clockwise increases the time, and turning the potentiometer counterclockwise decrease time. The PAST center timer is controlled by potentiometer "0". This controls how far past center the slide block will travel after being sensed by the center proximity switch.

Figure 6-1. The Two PLC Controller Adjustable Timers

NOTE There are two (2) different center proximity switches, one for 36" (91.44 cm) or less duct length, and

a second proximity switch for 36" (91.44 cm) or longer duct.

CAUTION DO NOT set the timer so that when 36" (91.44 cm) or less duct is run the left (upper) bearing block strikes the right (lower) bearing block. The OVER TRAVEL TIMER is used for both left

(upper) and right (lower) blocks.

The HOME TIMER is controlled by potentiometer "1." The HOME TIMER controls how far the bearing block will travel after being sensed. The home proximity switch is located ahead of the mechanical stop for the bearing block. The timer should be set so that the bearing block bottoms out on the mechanical stop each time it returns home. If this timer is set too long, no damage will occur to the machine, but the cycle time of the machine will increase. The home timer is used for both bearing blocks.

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Figure 6-2. Machine Flow Diagram

(3) Adjusting The Slide-Block Cable Tension Adjust the slide block cable tension as required. There are two methods of doing this adjustment, depending on the type machine being serviced.

(a) Pivot Bolt The cable is adjusted with a pivot bolt on some models. Loosen the bolt, remove one or more slotted washers on the inside of the frame, as required, and retighten the pivot bolt.

(b) Pulley Adjusting Bolt Loosen the jam nut. Loosen the nut on the pulley shaft bolt and adjust the cables for the proper tension. Lock the jam nut back down.

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C. COMPONENT REPLACEMENT (1) Cable Replacement

The major wear items on the Whisper-loc® II are the two slide block cables. When wear on the cables becomes apparent, such as graying or broken strands or other visual indications that the cables are nearing the end of their useful life, they must be replaced. Follow the listed procedure when cable replacement becomes necessary. To decrease cable maintenance requirements, always replace both cables at the same time.

NOTE All instructions assume that you are standing in the normal operating position; front means toward

you and back means away from you.

(2) Supply / Tool Requirements Quantity Description

2 23' 6" X 1/4" wire rope extra flex cables 2 Pair Vise-grip pliers

1 3/4" combination box-end, open end wrench 1 1/4" Allen wrench (recommend socket type for 3/8” drive ratchet with a 2”

extension) 1 5/32" Allen wrench, to fit forming block cable set screws (T-handle

recommended) 1 Magic marker, or other marking device 1 Cutting torch or other means of cutting the installed cable. If a cutting torch is

not available, use friction tape to secure cable strands, then cut using bolt cutters, hacksaw, etc

(3) Component locations The following illustrations will help the maintenance person or operator become familiar with the location of the components during cable removal and installation.

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A Adjustable Head E Upper Cable Drum B Upper Forming Block F Rear Access Slot C Lower Forming Block G Lower Cable Drum D Upper Cable Tension Pulley H Lower Cable Pulley

(4) Cable REMOVAL Procedure The following is the recommended removal procedure of worn or defective cables.

1. Remove both access panels.

2. Remove old cable ends from the Forming Blocks by moving each forming block over the frame access hole to allow access to the Allen head set screws, which secure the cable to the block.

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3. Position the Adjustable Head to the six foot or two meter position depending upon model.

4. Rotate the upper and lower cable drums with the upper and lower forming block control switches to position the cable drums with the cables protruding outward and the cable clamps inward.

5. Remove power and lockout.

6. With power removed, loosen the jam nut and nut on the Upper Cable Tension Pulley bolt to relieve cable tension, and in preparation for new cable installment. Lower the pulley completely, to allow maximum adjustment range.

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7. With the forming blocks loose, tension removed from cables, and power shut down loosen the cable clamp (A) on both cable drums.

8. Remove the worn cables from the backside of the whisper-loc®.

9. With the cables removed, the upper and

lower forming blocks should be checked for excessive movement and the Front Slide Block Track location should be checked.

10. First, check the 6 3/32” (6.218) dimension shown on drawing number 404-0144-01-00. Adjust as needed.

11. Next, trolley the forming blocks up and down the tracks and check for any excessive movement. If the forming block rocks or twists, using a dead blow hammer, tap the outside of the Back Slide Block Track until the forming blocks trolley smoothly without binding or excessive movement.

12. Tighten all slide block track fasteners as needed.

(5) Cable INSTALLATION Procedure The following is the recommended installation procedure for new cables.

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1. Routing New Cable For Bottom Forming Block. Run one end of the cable through the right hand hole (C) of the cable block, which is located on the backside of the upper forming block (B).

2. Feed the same end of the cable into the right

hand hole (C) of the cable block located on the backside of the lower forming block (B). PHOTO SHOWS BOTH CABLES INSTALLED, USE THE RIGHT HAND HOLE DURING THIS STEP.

3. Feed both ends of the cable through the right

hand pulley track (B) of the upper and lower cable pulleys towards the back of the unit. UPPER CABLE TENSION PULLEY SHOWN

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4. Before the cable can be wound onto the cable drums, pull the end of the cable from the upper cable pulley past the lower cable drum, approximately 18”-24”.

5. Run the end of the cable from the lower cable

pulley to the lower cable drum. Route the cable “behind” and over the drum. Keeping the cable tight on the drum, wrap the cable around the drum in a counter-clockwise direction five (5) wraps, wrapping from the inside edge of the drum toward the center.

6. At the backside of the drum, run the cable

end through the lower drum clamp hole, through the lower slot of the cable clamp, and out the opposite cable slot at the front of the drum. Pull the cable tight and use a pair of vise-grip pliers on the end of the cable where it leaves the drum to hold the cable tight. DO NOT TIGHTEN THE CABLE CLAMP YET

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7. Run the end of the cable from the upper cable pulley to the lower cable drum. Route the cable behind and under the drum. Keeping the cable tight on the drum, wrap the cable around the drum in a clockwise direction, wrapping from the center of the drum toward the outside edge.

8. Feed the end of the cable through the backside slot, through the upper slot of the cable clamp and out the front cable slot.

9. Using vise-grip pliers on both cable ends, pull

the cable tight and securely tighten the cable clamp.

10. Routing New Cable For Upper Forming Block. Run one end of the cable through the left hand hole (A) of the cable block, which is located on the backside of the upper forming block (B).

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11. Feed the same end of the cable into the left hand hole (A) of the cable block located on the backside of the lower forming block (B).

12. Feed both ends of the cable through the left

hand pulley track (A) of the upper and lower cable pulleys. UPPER CABLE TENSION PULLEY SHOWN

13. Before the cable can be wound onto the cable

drums, pull the end of the cable from the lower cable pulley past the upper cable drum, approximately 18”-24”.

14. Run the end of the cable from the upper cable pulley to the upper cable drum. Route the cable “behind” and under the drum. Keeping the cable tight on the drum, wrap the cable around the drum in a clockwise direction five (5) wraps, wrapping from the outside edge of the drum toward the center of the drum.

15. Feed the end of the cable through the backside slot, through the upper slot of the cable clamp and out the front cable slot. DO NOT TIGHTEN CABLE CLAMP YET!

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16. Run the cable from the lower cable pulley, behind the lower forming block cable so that the cables always walk "away" from each other.

17. Route the end of the cable from the lower cable pulley to the upper cable drum. Route the cable behind and over the drum. Keeping the cable tight on the drum, wrap the cable around the drum in a counter-clockwise direction, wrapping from the center of the drum toward the inside edge.

18. Feed the end of the cable through the

backside slot, through the lower slot of the cable clamp and out the front cable slot.

19. Using vise-grip pliers on both cable ends, pull the cable tight and securely tighten the cable clamp.

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20. Cut the excess cable ends off at both drums leaving approximately ¾” sticking out of the drum. Because of fraying cable ends, this is best done using a cutting torch. If a cutting torch is not available, wrap the cable from the drum out three inches tightly with four layers of heavy friction tape, then cut the cables using bolt cutters or hacksaw in the center of the taped area. Helpful Hint: Dress the ends of the cables after they are cut off, or the ends of the cables may not pass through the drum slots the next time the cables are replaced.

21. Adjust the tension for both cables using the upper cable tension pulley adjustment bolt, tightening down the nut until the cables are tight, and then using the jam nut to lock the nut in place.

22. Manually raise the upper forming block to its end stop, and using a marker, mark the cable (left cable) at the “bottom” of the block. NOTE: ENSURE THE SLIP AND DRIVE STOPS ARE INSTALLED IN THE UPPER AND LOWER FORMING BLOCKS, BEFORE MARKING THE CABLES.

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23. Manually lower the bottom forming block to its end stop, and using a marker, mark the cable (right cable) at the “top” of the block. NOTE: ENSURE THE SLIP AND DRIVE STOPS ARE INSTALLED IN THE UPPER AND LOWER FORMING BLOCKS, BEFORE MARKING THE CABLES.

24. Set the upper forming block. Power on the unit and run the upper block cable “down” so that the mark on the cable is ½” below the frame access opening and shut off power.

25. Align the bottom edge of the upper forming block with the mark on the cable, and then through the access hole, tighten the two Allen head set screws from the backside of the machine.

26. Set the lower forming block. Power on the unit and run the lower block cable “up” so that the mark on the cable is ½” above the frame access opening and shut off power.

27. Align the top edge of the lower forming block with the mark on the cable, then through the access hole, tighten the two Allen head set screws from the backside of the machine.

28. Install ALL guards, covers or safety devises that were removed during cable replacement.

29. The cables are now properly installed. Reposition the Adjustable Head as required, and resume operation.

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Figure 6-3. Hydraulic Symbols Used on IPI Drawings

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DRAWING LIST The below listed assembly drawings are included in this section of the manual for the Whisper-loc® II.

HORIZONTAL: DRAWING NUMBER DESCRIPTION 402-0420-01-00 HYDRAULIC SCHEMATIC WHISPER-LOC 403-0237-03-00 RIGHT SLIDE ASSY WHISPER-LOC 403-0237-04-00 LEFT SLIDE BLOCK ASSEMBLY 404-0130-02-00 FINAL ASSEMBLY 404-0135-01-00 RIGHT SIDE OR LOWER CABLE ARRANGEMENT 404-0136-01-00 LEFT SIDE CABLE ARRANGEMENT 404-0144-01-00 SLIDE BLOCK TRACK SET-UP 404-0148-01-00 HYD UNIT ASSY WHISPER-LOC (NON CE)

ELECTRICAL SCHEMATIC DESCRIPTION E95-272B-H (220 VAC, 1 Phase, 50/60 Hz) WHISPER-LOC® HORIZONTAL

rectangular duct work closure system - production …

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