CALA031664.00.en Preliminary

Cartulinas CMPC S.A.
Planta Maule
BM19 (M450VALZ) Valmet Technologies / J Isomaa
2015-11-04
MACHINE OPERATING INSTRUCTIONS

1 OPTICALENDER METAL BELT CALENDERING..................................................................1
2 GENERAL PREPARATIONS...................................................................................................3
2.1 Control voltage.................................................................................................3
2.2 Grease lubrication............................................................................................4
2.3 Pneumatic system...........................................................................................4
2.4 Cleaning of rolls...............................................................................................4
2.5 Doctors............................................................................................................4
2.6 Web break monitoring......................................................................................5
2.7 Belt edge control and monitoring.....................................................................6
2.8 Safety gates.....................................................................................................7
3 PREPARATION FOR CRAWLING...........................................................................................9
3.1 Hot oil systems, local controls..........................................................................9
3.2 SymCDS roll hydraulics.................................................................................11
3.3 Belt hydraulics...............................................................................................14
3.4 Circulation lubrication (Belt guide and Thermo rolls)......................................15
3.5 Circulation lubrication (paper guide rolls).......................................................16
3.6 Oil joints cooling and lubrication (Belt guide rolls)..........................................17
3.7 Belt Service position......................................................................................19
3.8 Belt tightening from service mode to minimun tension...................................20
3.9 Belt run tension (belt centarlizing process)....................................................21
3.10 Summary.....................................................................................................25
OptiCalender Metal Belt

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4 Operating Instructions
Cartulinas CMPC S.A. Planta Maule

BM19 (M450VALZ) Valmet Technologies / J Isomaa
2015-11-04
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4 PREPARATIONS FOR RUNNING ........................................................................................27

4.1 Running permission ......................................................................................27
4.2 Hot oil systems, operating station .................................................................30
4.3 Doctors .....................................................................................................32
4.4 Electric drive (local control, drives) ................................................................33
4.5 Preparations for tail threading .......................................................................34
5 CALENDERING
.....................................................................................................37
5.1 Tail Threading Sequence ..............................................................................37

5.2 Hot oil system (operating station) ..................................................................39
5.3 Nip controls ...................................................................................................39
5.4 Other controls................................................................................................41
5.5 Operator role .................................................................................................42
5.6 Summary .....................................................................................................43
6 END OF CALENDERING .....................................................................................................45
6.1 End of calendering ........................................................................................45
6.2 Web break ....................................................................................................46
6.3 Emergency stop ............................................................................................48
6.4 Roll change ...................................................................................................49
7 SHUTDOWN .....................................................................................................53
7.1 Preparation for shutdown ..............................................................................53
7.2 Before any maintenance disconnect and lock-out the energy supplies.........54

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Valmet Technologies / J Isomaa
1 OPTICALENDER METAL BELT CALENDERING

Meaning of this document is to clarify the main tasks of the operator
when preparing and using OptiCalender Metal Belt for calendering.
Detailed instructions can be found from the Calender Operating and
Machine Manuals delivered by Valmet Technologies.
This document is divided to seven main categories:
General preparations
2 Preparations for crawling
3 Preparations for running
4 Calendering
5 End of calendering
6 Preparations for shutdown
NOTE! Some of figures presented in this document are from similar

projects, NOT specifically from M450VALZ Calender.
PICTURE 1 OptiCalender Metal Belt

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2
GENERAL PREPARATIONS
2.1 Control voltage

Check that the calender control system supply voltages are on
(messageon the operating station). If not, turn the voltage on from the
control switches located inside the Siemens S7 main I/O cabinet (local
control, electric room).
Check that the Sensodec- condition monitoring system supply voltage ison
(displays on the operating station).
Check that the power of the power supplies located in the field boxes
areon (message on the operating station). If not, turn the power on from
the control switches or circuit breakers located in the cabinets.
Check that the electric drive control voltage is on and that the start prevention switches can be switched run position (local control).
PICTURE 2 Control voltage monitoring display

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2.2 Grease lubrication

Check that there is sufficient grease on the belt guide roll guideways and in
other lubrication points.
2.3 Pneumatic system

Make sure the instrumentation air and mill air lines are pressurized and
shut-off valves are open (local instruments).
2.4 Cleaning of rolls

Check before starting calendering that the all rolls (especially the belt) are
clean. Clean the rolls and belt according to separate instructions, if
needed.
Warning! Do not allow liquid to contact hot roll, roll damage
may occurs. Roll may crack, shooting hot fluid and roll
fragments. Burns, serious injuries or death may result.
Caution! Do not use sharp objects to clean belt or thermo roll.
2.5 Doctors
Check that the doctor blades are clean and in good operating condition.
Set the doctors to operating position
-
If necessary, you can set the doctors on load

whencalender roll are rotating (the blade in contact with
the roll)
Remember to close doctors and cleaning devices

always before starting tail threading
When calender is rotating and the doctor blades are in load,

oscillationstarts automatically.

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2.6 Web break monitoring

Check that the lenses of the photocells are clean and that there are
nopaper pieces or other objects in the measurement range. Check
that all the photocells are selected to use.
PICTURE 3 Web monitoring operating display

Check that safety hand valves are open
web cutting device blow cutting device (air doctors)

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2.7 Belt edge control and monitoring

Check that the lenses of the photocells are clean and that there are no
paper pieces or other objects in the measurement range.
PICTURE 4 Metal belt edge control and monitoring operating display
2.8 Safety
gates
Check that all safety gates are closed and
acknowledged.

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Caution! If gate is open or not acknowledged, starting of

Calender rolls is prevented.
Caution! Safety gates have opening permission, when
Calender rolls are in zero speed.

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3 PREPARATION FOR CRAWLING
3.1 Hot oil systems, local controls

Detailed information and instructions about the hot oil systems (bottomroll
and belt) can be found from the hot oil systems operating instruction
manual.
Check that the hot oil systems control voltage is on (message on the operating station). Control voltage can be put on by pushing the "control
voltage" pushbutton.
Check the possible alarms and if there is no danger, acknowledge themby
pressing "unlocking" and "emergency stop reset" push buttons.
Check that the oil level at the hot oil system unit is high enough. Oil levelis
correct when the expansion tank oil level does not alarm. If necessary,
pump in oil with filling pump until oil level low alarm has been acquitted for
about 5-10 minutes.
Check that the hand valves of the desired circuit are open.
-
hand valves on both sides of the pump going to

thethermo roll and metal belt
hand valves at the machine level in the oil ingoing

andoutgoing lines to thermos roll and metal belt.
Check that cooling water lines hand valves are open and that there
iscooling water available.
Start the primary circuit pumps. If the pump wont start and the "oil
levellow" alarm cannot be acknowledged ("unlocking" pushbutton), pump
more oil from the storage tank.
Check hot oil system visually for leaks.
Caution! Do not attempt to heat or cool if these prerequisites
are not met.
Control heating on.
If the oil is cold, the oil flow alarm is on and it cannot be
acknowledged.Perform a cold start as follows:

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press the cold start button and keep it

downacknowledge the alarms
control heating on
release the cold start button when the oil flow

lowsignal light goes off.
PICTURE 5 Heating Cooling system operating display, metal belt.
Warning! Beware hot oil when disconnecting the oil

coupling.
Caution! Do not touch the hot oil system piping, pipes can be
very hot!

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Caution! Heating must not be on during oil filling/draining.

Caution! The hot oil system should be operated only by
appropriately trained personnel.
Note: Only the first heating of the hot oil system or heating after oil
change (filling) are carried out according to separate hot oil system
operating instructions. Existing water in the oil must be boiled out
from the system.
3.2 SymCDS roll hydraulics

Check that all suction valves for the pumps are open.
PICTURE 6 Suction valve.

Start the filter/cooling pumps.

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Shower
pipe pump
Main pumps
Suction valves
Heating
Filtering / cooling
pump
PICTURE 7 Sym hydraulics operating display, typical.

Check that oil heating has been selected on to Auto mode. The
resistorswill switch on automatically, if required.
Set the oil temperature setpoint to 65 C (65-75 C) Start the filtering and
cooling pump.
Start two main pumps (M1) and (M2) of the three main pumps when theoil
temperature is above 35C.
The third main pump (M3) is a spare pump and can be selected instead
ofsome other main pump.
Check that all necessary hand valves are open.
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3.3 Belt hydraulics

Check that all suction valves for the pumps are open. Start the
filter/cooling pump.
Start one (M1) of two main pumps. The pump M2 is normally a sparepump
and stays stopped.
Heating
PICTURE 8
Suction valves
Belt loading hydraulics operating display.

Check that all necessary valves are open
When pump is running, check that the supply line pressures are
sufficient(loading cylinders appr. 160 bar.

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3.4 Circulation lubrication (Belt guide and Thermo rolls)

Check that oil heating has been selected onto Auto mode. The resistorswill
switch on automatically, if required.
PICTURE 9
Bearing lubrication operating display (Guide & Thermo rolls).

Check that there is cooling water available and that all valves are open.
Check that the main valves are open. Check that all suction valves for
thepumps are open.
Start one of the pumps of the circulation lubrication unit when the oil temperature in the tank is above 35oC. The other pump is a spare pump.

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The set temperature of oil flowing to the rolls is 40-50C and normal pressure is appr. 5 bar.
Check that the lubrication flow to the bearings (Bearing lubrication operating display) is sufficient. After a long shutdown, it can take several hours
for the oil to heat to get sufficient flow.
Thermo roll
16 l/min
Guide rolls
11 l/min
3.5 Circulation lubrication (paper guide rolls)

Existing system for paper guide rolls only
Check that oil heating has been selected to Auto mode.
Theresistors will switch on automatically, if required.
Check that there is cooling water available and that allvalves
are open.
Check that the main valves are open. Check that all
suctionvalves for the pumps are open.
Start one of the pumps of the circulation lubrication unitwhen
the oil temperature in the tank is above 35oC. The other pump
is a spare pump.
The set temperature of oil flowing to the rolls is 40-50C
andnormal pressure is appr. 5 bar.
Check that the lubrication flow to the bearings (Bearing lubrication operating display) is sufficient. After a long
shutdown, it can take several hours for the oil to heat to get
sufficient flow.
Paper guide rolls 0,25 l/min
3.6 Oil joints cooling and lubrication (Belt guide rolls)

There is a separate new similar unit for Belt guide rolls. Thermo roll hasan
own existing oil joint lubrication unit
Check that the lubrication unit oil level is sufficient (visually from the
unit)and necessary manual valves are open.
Check that there are cooling water available and necessary hand
valvesare open.
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Existing Unit
PICTURE 10
Oil rotary joint cooling operating display.

Start the lubrication/cooling pump.
Check that the flow is sufficient.

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PICTURE 11

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Rotary joint manual flow meter.

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3.7 Belt Service position

BELT IS ON SERVICE POSITION, when belt guide roll control
cylinders position measurement indicates minimum value 0-5
mm
Acknowledge belt fault (operator display, picture

When belt fault is acknowledged, belt is controlled
fromfault to service mode, if service mode permission
basic conditions are fulfilled (interlocking ok):
PICTURE 12
Belt service mode interlocking, Help display.
3.8 Belt tightening from service mode to minimun tension

Before is possible start the Calender drives, belt must reach the
minimumtension
BELT IS ON MINIMUM TENSION, when belt guide roll control
cylinders pressure measurements show right pressure
level.
Belt is possible to switch (control desk) to minimum tension, when

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All fluid systems are ready and pumps running Safety gates
are acknowledged
And the other minimum tension basic conditions are fulfilled
(interlocking ok)
PICTURE 13
Belt minimum tension requirements.
3.9 Belt run tension (belt centarlizing process)
BELT IS ON RUNNING TENSION, when belt guide roll control

cylinders pressure ramps are ready and the pressure values
on TS and DS corresponds to running tension
When the minimum tension of the belt is reached and
drivetightening speed permission is on, is possible switch belt to
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tightening speed Select tightening speed 45 m/min from

drive control pane Drives start to tightening speed.
Belt centralizing and tightening to running tension takes
placeautomatically, belt positioning begins.
After belt has been centralized and belt control has been stable3
minutes, tightening ramp to running tension begins automatically.
During tightening ramp pilot light in control box is blinking
andafter ramp is done light is lit.
After right running tension level is achieved, rolls will go
automatically to crawling mode (15 m/min), if the interlocks for
crawling mode are OK.
PICTURE 14
Sym CDS roll tightening speed permission

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PICTURE 15

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Thermo roll tightening speed permission.

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PICTURE 16
SymCDS roll crawling permission.
PICTURE 17
Thermo and belt guide roll crawling permission.

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3.10 Summary
Stack rolls can be controlled to crawling (drives panel, local control)

as soon as items listed in section "preparations to crawl" are fullfilled.
Local control panel, typical.
If prerequisites listed before are not met, OptiCalender Metal Belt will
not start crawling. Help displays will give information of which
prerequisite is missing.

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4
PREPARATIONS FOR RUNNING
4.1 Running permission

Start the calender according to instructions provided in "Preparing
calender crawling".
Calender operation can start as soon as the calender startup has
been finalized according to instructions.
The rolls must be rotated at crawl speed before accelerating up to
run speed to avoid endangering the calender operation because of
vibration of the rolls. The control system calculates the rotation time
needed.
It is recommended to rotate the rolls in roll storage before installing
on the machine.
During operation, the control system automatically monitors the
operation of the calender and calender-related equipment. In case of
failure, an alarm is generated.
Monitor the calender actively during operation to achieve the
required paper quality.
Running permission is obtained when following prerequisites are
fulfilled:

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PICTURE 18
Sym roll running permission, Help display
PICTURE 19
Thermo & Belt Guide roll running permission, Help display
If prerequisites listed above are not met, Calender will not start
running. Help displays will give information of which prerequisite is
missing.
Other tasks listed in this section are preparations for calendering.

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4.2 Hot oil systems, operating station

Heating can be started as soon as the rolls are crawling (drives panel, local control.
Set the oil temperature target value for thermos roll and belt. System
willautomatically start heating, if the set temperature is higher than the
actual (measured) temperature. If set temperature is lower than actual
temperature, system will start cooling automatically. Control is based on
the average of the inflowing and return oil temperature.
Note! Heating of the rolls is possible only when the rolls are
rotating. Keep the Calender rolls rotating during the entire
heating/cooling stage. Observe the operation of the equipment
and possible alarms.
PICTURE 20
Thermo roll Hot oil unit, operating display.

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The control system monitors and controls the inflowing oil temperature so
that it will not, on average, change more than 1-2 C/min. The heating
stage may take several hours, depending on desired running temperature.

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4.3 Doctors
There are two doctors (Thermo roll doctor, Belt doctor) for metal belt calender and two cleaning devices (SymCDS roll and Belt Inner cleaning
device)
The operation of doctors and cleaning devices are controlled from
controldesk.
The cleaning devices are controlled on automatically, when rolls arestarted
(tightening speed, crawling or running).
Doctors and cleaning devices are automatically controlled off, when
rollshave reached zero speed.
When the rolls are running at calendering speed, control the doctors
towork position and blades to the roll (local control).
PICTURE 21

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Doctor status information display.

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The doctors are controlled on when switched doctors ON from stack control
panel.
When the doctor blade has been controlled to the roll, oscillating willswitch
on automatically when the roll is rotating.
Doctors should be controlled on to the roll just before beginningthe tail
threading.
In the web break situation doctors should be controlled off fromthe roll, if
the break is long. The reason for this is that if the nips are open, no
doctoring is needed.
Note! The rolls must be rotating before doctor can be put to
oscillating.
4.4 Electric drive (local control, drives)

Check the speed setting of the calender rolls. Check the tension
control set values and selections. Compare the speed difference
setting of the drives to previous group. Check the speed difference
settings of the guide and spreader rolls.

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4.5 Preparations for tail threading
PICTURE 22
OptiLoad main operating display.

Check that the threading area is free of obstacles and the rolls are clean.
Check that the safety gates are closed and acknowledged. Acknowledgement ensures that there are no people in the area and gives operating
permission to the tail threading devices.
Check that the calender rolls are running at run speed. If not, start
thecalender rolls including the spreader and guide rolls.

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Check the tension set points before and after the calender (drive panel,
local control).
Check that the doctors are on and oscillating (local control) Check that
the QCS scanner is in home position (local control).
Check that the tail threading ropes are in the tail threading position (automatic and local control).
Check the speed setting of the tail threading ropes and control the ropesto
run speed (local control).
Check the speed setting of threading belts and control the FoilForces
torunning speed (local control).
Check that the reel is ready for run. Check that pulper is ready and Auto
state.
Control the tail cutters to tail threading position (TS, local
control).Control the tail cutters on and check the web width (local
control).

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PICTURE 23

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Tail threading local control panel.

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5 CALENDERING
5.1 Tail Threading Sequence

Control the tail threading on when all preparations have been done, "Tail
threading ready" pilot lamp is lit and the web moisture is suitable (local
control). Start the treading sequence.
Phase 1 (From dryer to Calender)MC (mechanical tail cutting device)

turns to tail threading position MC system cuts the tail and guides it to
the rope nip
Ropes (3 pcs) guide the tail to basement before calender
Phase 2 (trough the nip)MC turns to tail threading position
FoilForce #1 is fixed and installed before nip MC system cuts the

tail and guides it to the FoilForce #1
Tail is guided between belt and thermo roll into the nip and then to
Calender pulper
Phase 3 (via next rope loop to reel)MC turns to tail threading position
MC system cuts the tail and guides it to the rope nip Side blows
start for the short moment guiding tail away from ropes. Ropes (3 pcs)
guide the lead of the tail to the the reel.
Follow the tail threading visually and adjust FoilForce/rope speed if needed.
Observe the web as it goes through the Calender during tail threading.
Ifrequired, interrupt tail threading, remove possible paper pieces from the
tail threading devices and stack area. Control tail threading on again.
When the tail is at the reel, control loose web band to DS (local
control).Stop widening when band is extended to one meter wide
(automatic).
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Tighten the web band to approximately right level (local control, drives)
byspeeding up the reel. Reel is on speed control. Control the web to full
width (local control).
Allow the web to stretch to its full width on the reel then adjust the
reelspeed, if required, to straighten the web. When reel tension is 60%
from (from drives) the set target value, reel goes automatically to tension
control.
Stop foil force belts when the web is in the reel full width. Control the tail
threading ropes to crawl (local control).
Check that the tail threading ropes are in the calendering position (automatic and local control).
Caution! Rope break may occur, keep hands clear of rope and
pulleys.
Caution! Do not thread the tail manually.
Caution! Watch out for rope nips and belt conveyor.
5.2 Hot oil system (operating station)

Check the temperature and operation of the roll circuits.
Note that temperature changes are slow during run.
Caution! Beware of the hot surfaces.
5.3 Nip controls

Check the web traveling through the nip. However, adjust spreader
rollsonly if absolutely necessary.
Check the nip load set value. (5-70 kN/m)
Check that all photocells are selected on, that the web break detection
isactive and that photocells see the web. The web break detection is
automatically turned on when the web is full width
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There are three pairs of photocells at calender area (one pair before
nipone pair before, one pair after nip and one pair before the reel)
Web tension information before the calender is found from the main operating display or Web monitoring operating display.
Control Nip close, relieving state (local control).
-
Top SymCD roll zone pressures ramp up to

calculatedvalues as the nip closes.
The calenders bottom roll drive (thermos roll) goes

automatically into tension control and the top roll goes
to torque control when the nip is closed.
Control Nip loading state (local control)

Nip loading can be selected off, if required, by controlling nip close or nip
open (local control).
Nip loading
Nip close
Nip open
PICTURE 24
Local control panel, typical.

Check again the web travel through the stack.
Once the nips are closed and the situation is stable, control loading
on(local control).

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The status of the nip is shown on the operating station and on the
localcontrol box. When the status changes, the signal light of the
corresponding status will flash (local control).
5.4 Other controls

Following controls can be started once the web is on, nips closed
andloading and situation is stable.
Check that the QCS measuring frame is scanning.
Check that caliper control (cross direction) is selected and in
automaticmode.
The caliper control measurement signal is received from the
measuringframe. The multi-zone SymCD rolls function as actuators.
Check that Sensodec condition monitoring system is monitoring the
niprolls and there are no alarms.
Caution! Follow continously the belt surface condition. Take
action if needed.
During run, the control system automatically monitors the operation of
thecalender and that of the most important calender-related equipment. In
case of failure, an alarm is generated and if necessary quick-opening
happens.
To protect the belt, web break detection is the most important.
Quick-opening can be controlled also from the control box in case needed.
5.5 Operator role

The operator must, actively monitor calender operation.
Operator must keep the rolls and belt clean and make sure that the required quality is achieved.
Operator must immediately react to any malfunctions or faults he detectsor
which are indicated to him by the control system.

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If there is any indication of possible damage to the roll or belt cover

(dirtyrolls, overheating, web break, vibrations etc.), the operator must cut
the web, open the nip as quickly as possible by pressing the quick
opening button (local control, black mushroom push-button) and stop
calender.
If the belt is cracked it must be fixed or changed to new one immediately.
Warning! It is not allowed to use calender with cracked rolls or
belt.
The operation and condition of the hot oil system, roll and calender hydraulics, and other calender-related equipment must also be monitored on
a regular basis.
5.6 Summary
Stack rolls can be controlled to running (drives panel, local control)
as soon as items listed in section "preparations for running" are
fullfilled. In short
Calender is crawling hot oil unit pumps running

circulation lubrication pump running rotary joint
cooling / lubrication pump running roll change is not
selected rolls have been rotated at least hour after
shutdown roll diameters are correct belt is run
tension belt cover is on place safety gates are
closed and acknowledged belt cleaning devices are
loading
belt doctors can be open but should be closed before tail threading
Below is a short calendering checklist based on sections 3.1 3.7
and 4.1 4.5. It is assumed that calender roll are rotating at running
speed
set thermo roll oil temperatures to desired level set the

nip load to desired level select caliper control depending on

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calendered paper grade control doctros on before

beginning tail threading do tail threading
close the stack by pressing "nip close" pushbutton

control loading on by pressing "nip loading" pushbutton
start QCS scanner
check that Sensodec condition monitoring system is monitoring and
there are no alarms
follow continuously belt and belt roll cleanliness calender

operation must be actively monitored and corrections made if needed

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6
END OF CALENDERING
6.1
End of calendering
Control the nip to open (local control). The nip will open when loading
hasramped to the minimum load.
Set the thermo roll oil temperature set value to 50- 80C. The hot oil
system will then start to cool the thermo rolls.
as long as thermo roll or belt oil temperature is higher than 80C, stack
rolls are not allowed to be stopped.
The stack rolls can be stopped when the thermo roll and belt oil temperature is below 60C.

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6.2 Web break

Web break information is received from the photocells The web can
also be cut by the web cutting device (local control).
If a web break is detected:the web cutting device will cut the web
ahead of the calender
PICTURE 25
Web cutting device.
Caution! Beware of the striking blade.
the nip will open in quick opening mode (without minimum load control)
the Sym CD-roll pressures are quick released nip drives switch to
speed control
the thermo roll temperature set value will be kept constant, i.e. the rolls
will not be cooled.
After a web break the rolls are rotating with nips open.
If there are any paper wrapper around the rolls, the rolls mustbe
cleaned immediately. If paper cant be removed with pressurized air
can the rolls be stopped momentarily and paper removed while rolls
are not rotating.

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Caution! The stack rolls must be started again as soon as

possible after web break has been cleared.

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6.3 Emergency stop

In an emergency stop situation (one of the emergency stop buttons
hasbeen pressed):
if nip is open the cutting knife will not cut the web the electric
drives are braking with full force
all movements will stop, sequences will be reset, and new controls will
be prevented
the nip will open in fail safe mode
thermo roll and belt heating system circulation pumps are stopped
When the emergency stop information has disappeared:
acknowledge the alarms (operating station)
acknowledge the e-stop of heating cooling systems (local control) and
start the circulation pumps
start the calender rolls to crawl (local control)
Note! Because of the threat of thermo roll overheating, the rolls
must be controlled to crawling (or run) as soon as possible.
6.4 Roll change

Set the thermo roll oil temperature set value to 50C if thermo roll change.
When the temperature set value has been reached, stop the stack rolls
and all other rolls near working area.
When the rolls have stopped, turn the protective switches of the motors
tothe disabled position and lock them (local control).
Stop the pumps of the roll you want to change (operating station)if a
SymCD roll is changed, the all pumps of that roll hydraulics unit except
cooling/filtering pump
if a thermo roll is changed, the circulation pump (or spare pump) of the
circuit concerned, bearing lubrication/cooling circulation pumps and rotary
joint cooling unit pump. Close the circulation lubrication lines and the oil
coupling lubrication/cooling lines.

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PICTURE 26

BM19 (M450VALZ)
2015-11-04
43
Loading hydraulic pressure accumulator.
Note! Before any maintenance close (HV2) at loading hydraulics

unit and open smaller black color hand valves (DV1) at the
accumulator unit to release loading hydraulics system
pressure.
Stop all the pumps of the calender hydraulic unit, except

cooling/filteringpump. Make sure that loading hydraulics pump hand valve
(HV2) is closed and locked and accumulator unit hand valves (DV1 are
opened.
Turn the protective switches of motors to the disabled position and
lockthem.
Mecanical roll change can start. Change the roll according to a
separateinstruction in maintenance manuals
Select "roll change" from the operating station. Enter the new diameter of
the roll to the electric drives (operating panel).
Turn the protective switches back to their normal positions.
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After maintenance close the accumulator hand valves DV1 and open
theloading hydraulics hand valve (HV2).
Start the pumps (see pages earlier) of the changed roll and open thelines.
Control the rolls to crawl. Clean the rolls.
Note! If the roll change mode is on, the calender can't be

switched to normal run.

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BM19 (M450VALZ)
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7
SHUTDOWN
7.1
Preparation for shutdown
Open the calender nips normally.
Set the temperature set value of the hot oil systems roll circuits to
50C(operating station). Rolls are still running.
Stop the calender rolls about half an hour later when the temperature ofthe
thermo roll and belt has decreased to the required value (local control).
Stop the heating circuit pumps (local control). Stop the rotary joint
lubrication and cooling pump (operating station).
Stop the SymCD roll hydraulics pumps. Check that the heating
selectionsremain on (operating station).
Stop the pump of the circulation lubrication unit (operating station). Stop
the loading hydraulics pumps (operating station).
7.2 Before any maintenance disconnect and lock-out the energy

supplies
Turn the protective switches of motors and drives to the disabled
positionand lock them.
In case of a short shutdown (<12 h) it is advisable to leave the
heating/cooling circulation of the hydraulic units and the oil lubrication
on, in order to avoid an excessive drop of the oil temperature in the
machinery. If there are no protective switches installed for motor
and drives, safety state must be secured with another way, for
example removing fuses from MCC and Drive control cabinets
according to mill lock-out safety procedure.

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Pressure supply of the pneumatic system of the Calender can be

discon-nected from the switching point of the mill system main line
located at the automation module.
Closing the main line prevents the supply of compressed airto all
pneumatics equipment of the calender except web break knife.
Stroke of the web break knife can be prevented separatelyby
disconnecting its supply from a separate shut-off valve.
Before electrical maintenance, turn off the field power supply
(equipmentcabinet, power supply switches) to the serviced or at the
point that feeds the serviced object
- To switch off the supply voltage of the calender control
system turn the switch located in I/O- and Field
cabinets to position 0. Each cabinet contains a
separate main switch and a 120V supply to the UPS
and field devices. Voltage distribution of the Calender
control system and field supplies is separated so that
there are two main switches for each cabinet.
o

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The main switch of control system suppliesthe

power for control system devices (CPU,
I/O-rack, network devices)
The main switch of field equipment
suppliesthe power to field devices (solenoid
valves,
proportional valves)

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Cartulinas CMPC S.A.

MACHINE OPERATING INSTRUCTIONS

OptiCalender Metal Belt

Cartulinas CMPC S.A. Planta Maule

4 PREPARATIONS FOR RUNNING ........................................................................................27

5.1 Tail Threading Sequence ..............................................................................37

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1 OPTICALENDER METAL BELT CALENDERING

NOTE! Some of figures presented in this document are from similar

PICTURE 1 OptiCalender Metal Belt

OptiCalender Metal Belt

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OptiCalender Metal Belt

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2.1 Control voltage

PICTURE 2 Control voltage monitoring display

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2.2 Grease lubrication

2.3 Pneumatic system

2.4 Cleaning of rolls

If necessary, you can set the doctors on load

Remember to close doctors and cleaning devices

When calender is rotating and the doctor blades are in load,

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2.6 Web break monitoring

PICTURE 3 Web monitoring operating display

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2.7 Belt edge control and monitoring

PICTURE 4 Metal belt edge control and monitoring operating display

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Caution! If gate is open or not acknowledged, starting of

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3 PREPARATION FOR CRAWLING

3.1 Hot oil systems, local controls

hand valves on both sides of the pump going to

hand valves at the machine level in the oil ingoing

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press the cold start button and keep it

release the cold start button when the oil flow

PICTURE 5 Heating Cooling system operating display, metal belt.

Warning! Beware hot oil when disconnecting the oil

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Caution! Heating must not be on during oil filling/draining.