Kadant Blade Operating Manual
Kadant Blade Operating Manual
Kadant Blade Operating Manual
INSTALLATION
AND
OPERATION
MANUAL
Rev 1
1
INDEX
1) GENERAL
a) Features & Benefits
b) Description
c) Theory of Operation
2) INSTALLATION
a) Tools & Equipment requirements
b) Existing equipment requirements for retro-fit
c) Care and handling
d) Installation instructions.
i) Installing a complete new doctor system equipped with an ACCUFLAKE holder
ii) Retro-fitting a new holder to an existing doctor
3) OPERATION
a) Blade installation/removal
b) Blade material requirements
c) Loading and unloading the blade
d) Loading pressure requirements
4) MAINTENANCE
a) Alignment gauges and special tools
b) Quick maintenance chart
5) TROUBLE-SHOOTING
2
1) GENERAL
a) Features and Benefits
3
b) Description
i) Adjustability
This blade holder is equipped with micro-adjusting screws that allows the user to “Fit” the blade to the
roll surface by turning the screws and “Profiling” the blade holder.
Localized force of any sudden impact such as tail threading or a sheet break is spread over the entire
structure.
This unique option allows the user to quickly remove the blade holder from the doctor assembly. This
facilitates routine cleaning and maintenance as well as expediting emergency blade holder
replacements.
4
c) Theory of Operation
i) Proper operation of this system requires that the doctor back assembly is able to pivot freely. This
allows the blade tip to rotate towards the roll for loading and away from the roll for unloading. Shown
below is a doctor outfitted with air cylinders and an ACCUFLAKE blade holder in the loaded position.
ii) When the blade is loaded against the roll, the pressure on the blade increases. As the loading pressure
increases, the blade deflects under the load.
iii) When the doctor is placed in the unloaded position, the blade is lifted from the roll as shown below.
This allows for the removal and installation of blades.
5
2) INSTALLATION
i) Before attempting to install a new doctor with an ACCUFLAKE blade holder or retrofit an
existing doctor, read this entire manual.
ii) If your new holder is equipped with a removable holder adapter, make sure you also refer to Instruction
Sheet # 12 that was provided with the equipment.
iii) Check to see that you have all of the proper tools and equipment required to complete the task.
vii) Wrenches, come-a-longs and other tools required to complete the installation.
i) Any existing doctor back must have a corrosion-free mounting surface to insure the blade holder can
seat properly. A machined surface with a step for the holder to register against is required.
ii) The ACCUFLAKE blade holder can be retrofitted to almost any existing doctor back system.
Because the blade holder might have a different configuration than the one it is replacing, the blade
contact
point may NOT remain the same.
iii) In some cases, the change may be so slight that it will not effect the operation of the doctor.
(1) If the bearing brackets are slotted enough or the doctor can be shimmed up or lowered easily,
simple adjustments can be made to correct this condition
6
c) Care and Handling.
i) ACCUFLAKE blade holders are equipped with solid steel or stainless steel components. Like all blade
holders, they are designed to endure normal machine conditions. Blade holders in general are not
designed to withstand abusive handling or mistreatment. As a guideline, the following “Do’s and
Don’ts” apply to any blade holder.
DO DON’T
Take care when unpacking your new blade holder Don’t beat on the holder with a hammer or pry on
or doctor back. it to remove it from its packaging.
Don’t wrap a strap or chain directly around the
blade holder.
Don’t walk on, sit on, stand on or lean anything
Protect the blade holder from receiving pinpoint
on a blade holder.
pressure that could be applied by straps, etc. when
installing/removing a doctor back. If the blade holder is attached to the doctor back,
don’t rest the blade holder on anything allowing it
to support the weight of the doctor back once it is
removed from the shipping container.
Don’t insert a new blade or leave an old blade in
Leave the blade out of the holder until the doctor
the holder when installing or removing the holder
back is in place.
or doctor back.
ii) If your ACCUFLAKE blade holder is equipped with the removable adapter, it is advisable to remove
the holder from the doctor back when installing or removing the doctor from the machine. This will
allow you to wrap a strap (not a chain) directly around the doctor back giving greater control for
positioning. This is especially helpful when installing a doctor into a dryer section where direct
vertical access is not available for over-head cranes.
iii) Some doctors are equipped with a place for your straps that is located in close proximity to the center
of gravity and the operating position of the doctor back. If yours has them, use them.
d) Installation Instructions
i) Installing a complete new doctoring system equipped with an ACCUFLAKE blade holder.
(1) Read this entire manual and follow the instructions closely. Instruction sheet # 10 will help you
install the brackets, bearings, doctor back, loading and oscillation.
(2) Once the entire doctor system is in position, install a new doctor blade and proceed with the
alignment. Remember that alignment should be done in two stages.
7
(a) Pre-alignment
(i) With loading devices in the neutral or Zero-Energy state, set the doctor so the blade is at
the proper blade angle to the roll tangent and parallel to the axis of the roll.
If your doctor is equipped with air cylinder loading, it is advisable during this phase of
the alignment to disconnect the cylinders from the levers or arms on the doctor back.
(i) Once the blade angle and level has been established, connect and set the loading
mechanisms in accordance with their respective installation and setting instructions.
Pressurize the loading system to operating pressure and recheck the blade angle. It may be
necessary to reset the position of the doctor bearings at this time to correct any angle loss
due to blade deflection under load.
CAUTION
3
DO NOT exceed " Final Dimension
4
8
(ii) When the proper blade angle under normal loading pressure has been established, it is
necessary to profile the blade to the roll. The procedure below should be followed to
complete this process.
1. A feeler gauge is used in conjunction with the Allen Wrench on doctors that are
designed with an ACCUFLAKE style blade holder.
2. The feeler gauge is used to control the fit of the blade to the roll surface. This is called
profiling the blade.
3. It is important to make sure that there is only enough loading pressure being applied to
barely make blade contact. Profiling the blade must be done with little or no blade
deflection. It is recommended that you place the loading pressure to 0 PSI during this
procedure.
4. When installing a new holder, make sure that all micro-adjusting screws are backed out
and all mounting bolts are tight before starting the profiling process.
5. The doctor must be set and aligned prior to starting the profiling process and the doctor
must be loaded just enough to get the blade to touch the roll with little or no blade
deflection.
RECOMMENDED PROCEDURE
Identify tight fit areas. Try to back out the micro-adjusting screws where the blade fit is too tight.
Identify and note where loose fit areas are. A crayon works well to mark the blade holder. Do not mark on the roll
surface.
Taking care not to over adjust the screws, start in the middle of the widest loose area, turn the center set screw in as
needed, but not more than 1 turn.
Work your way from side to side, to the edges of the loose area turning the screws progressively less as shown in the
sketch below.
Always slide the feeler back over where you have been.
Repeat for the next widest loose area.
Recheck complete holder after each area of adjustment.
THESE TWO NEXT WITH 1/2 TURN
E
OS
LO
9
ii) Retrofitting a new ACCUFLAKE blade holder onto an existing doctor system without a removable
adapter. (NOTE: If your holder is fitted with a removable adapter system, refer to Instruction Sheet #
12 that was provided with the equipment.)
(1) If your particular retrofit requires a filler strip (usually provided by KADANT), it will be necessary
to install it between the machined surface of the doctor back and the ACCUFLAKE blade holder.
A standard filler strip is shown below.
(2) Carefully remove the existing blade holder assembly from the doctor system.
(3) Clean and inspect the machined mounting surface. It is imperative that this surface is flat, straight
and free of debris.
iii) Determine if you have tapped holes in the doctor back as shown above or clear holes. If you have
tapped holes, it is recommended that you clean and re-tap all of the holes prior to reuse.
iv) When assembling and mounting the holder to the doctor back, always start with the center hole.
v) Never tighten any mounting bolts until all mounting bolts have been started and you are sure that all of
the holes/slots are lined up correctly. Line up the holder so that it is bottomed out on the machined step
as shown here.
vi) A doctor back with a machined step is strongly recommended. If you are trying to retrofit this holder
to a doctor back that does not have a machined step use piano wire or other similar method to ensure
the holder is mounted straight on the doctor back.
Machined Step
(Not Required)
Machined
surface
10
vii) If you are mounting directly to your doctor back (no removable adapter supplied), torque all mounting
bolts to standard torque specifications.
viii) If you are mounting the holder to a removable adapter, follow the torque specifications that came with
the removable holder equipment.
ix) The installation of the ACCUFLAKE blade holder is now complete. Refer to Instruction Sheet # 10 and
other literature received with your system to complete the installation and alignment.
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3) OPERATION
i) ACCUFLAKE blade holders accept standard KF style blades. The holders are designed to accept the
blade from either end or for the blade to be inserted into the front of the holder. Holders that accept the
blade from the end are referred to as end removal holders. Holders that accept the blade from the front
are referred to as front removal holders.
ii) End removal blades can only be inserted from the end of the holder. Line up the rivets and clips as
shown below and slide the blade into the holder.
Clips face the top plate and TOP PLATE
rivets face the bottom plate CLIPS
iii) Front removal blades are inserted into the holder by first centering the rivets and clips on the machined
notches in the bottom plate of the holder. Guide the blade into the holder and slid it to the right or left
to secure the clips and rivets. This prevents the blade from falling out of the holder.
NOTCHES
12
b) Blade Material Requirements
ii) Consult with your KADANT applications engineer to determine the best blade material for your
specific needs.
iii) In general, synthetic materials are more desirable than metal materials.
iv) ACCUFLAKE blade holders are designed to accept a wide range of material thickness. Thicker blades
may be routed to fit in the blade cavity area as shown below.
v) If you use synthetic “end removal” blades that are ¼” thick, KADANT recommends that you purchase
these blades routed as shown above. This method of blade installation eliminates the clips and rivets
and simplifies the installation and removal.
i) Kadant recommends that all doctor blades be loaded before turning the rolls. This is especially
important on synthetic roll covers.
ii) Most blades do not fit perfectly tight inside of blade holders. If they did, you would not be able to
insert or remove blades from the holders.
iii) Because of this required gap, the blade can pivot slightly in the blade holder. If the blade is loaded
against a roll that is turning, the tip of the blade may dig into the roll and cause damage.
iv) On softer roll covers such as the types frequently used in the wet ends of machines, it is advisable to
wet down the rolls and wire or felt prior to loading the blade. Only then should the machine drive be
engaged.
v) Soft roll covers may also require lubrication showers to guard against roll damage from the blade.
vi) Your doctor may be equipped with manual, remote manual or automatic loading and unloading.
Follow the instructions for your specific control package to operate this function.
i) Each application is unique. KADANT recommends that you apply “OPTIMUM” pressure to your
doctor. OPTIMUM pressure is defined as “The least amount of pressure that does the job.”
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ii) How to establish “OPTIMUM” PRESSURE
(1) Since each application is unique, it is impossible to generate accurate standards for typical
doctoring positions. You are encouraged to consult with your KADANT applications engineer to
determine a starting point pressure for your application.
(2) Once you have established a “Starting Point”, it is recommended that you follow the procedure
below to discover the “Optimum” pressure.
(3) Observe the operation of the doctor for the life of the first blade. If the doctor has been performing
well, lower the air cylinder loading pressure by approximately 10% when the 2nd blade is installed.
(4) Observe the operation of the doctor for the life of the second blade. If the doctor has been
performing well, lower the loading pressure by about 1 psi (6-894 KPA-KN/M2) on the gauge
when the next blade is installed
(5) Continue to lower the loading pressure by 1-psi during each blade change until the doctor operates
at less than required performance. At this point, the previous loading pressure is established to be
the absolute minimum. Optimum pressure should be 1-psi (6-894 KPA-KN/M2) more than
absolute minimum. The following is an example:
PRESSURE PERFORMA
FUNCTION
NCE
PSI KPA-KN/M2 OK
1st Blade installed at start-up pressure 24 165 OK
2nd Blade installed at +/- 10% reduced pressure 22 152 OK
rd 2
3 Blade installed at 1-psi (6.984 KPA-KN/M ) 21 145 OK
reduced pressure
4th Blade installed at 1-psi (6.984 KPA-KN/M2) 20 138 OK
reduced pressure
5th Blade installed at 1-psi (6.984 KPA-KN/M2) 19 131 OK
reduced pressure
6th Blade installed at 1-psi (6.984 KPA-KN/M2) 18 124 Roll is
reduced pressure streaking
5th Blade is absolute minimum pressure 19 psi (131 KPA-
KN/M2 )
4th Blade is OPTIMUM PRESSURE 20 psi (138 KPA-
KN/M2)
(1) As a blade wears into the roll, the area of blade contact increases. Even though loading pressure
remains unchanged, actual blade pressure decreases due to this increase in contact as shown below:
14
(2) Increasing loading pressure with a worn blade will greatly reduce the efficiency of the doctor and
may allow the sheet to pass under the blade and wrap the roll due to the additional deflection of the
blade.
IMPORTANT NOTE: CHANGE THE BLADE RATHER THAN INCREASING THE LOAD.
IF A HIGHER BLADE LOAD IS NEEDED, REPLACE THE BLADE FIRST.
(3) Decreasing loading pressure when a worn blade is installed may actually improve the operation of
the doctor. This occurs because the area of contact between the blade and roll increases as the
blade wears. If loading pressure is decreased, the blade deflection decreases, lifting the back of the
worn area away from the blade. The result is pinpoint contact with higher pressure as shown
below:
15
4) MAINTENANCE
i) KADANT Solutions Division has a variety of specialized equipment available to help you install, set, align
and operate your doctor for optimal performance.
(a) ANGLESTAR
The ANGLESTAR is an accurate and easy-to-use electronic blade angle gauge. This tool is
used to measure blade angle and set the doctor level.
(b) TEMPLATES
Blade angle templates can be used in most cases to measure blade angle only. They are not as
accurate as the THERMOSTAR and do not measure level.
16
(c) CANNON LEVEL
The Cannon Level is used to check the level of the doctor. It is accurate, but not necessary if
you have the ANGLESTAR.
The clean-out tool is sized perfectly to fit into and clean any ACCUFLAKE blade holder
asshown below.
17
b) Quick Maintenance Chart
18
5) TROUBLE SHOOTING
TROUBLESHOOTING GUIDE FOR ACCUFLAKE DOCTOR SYSTEM
Check the obvious first to determine that parts are not worn out or loose. Have someone load and unload the
doctor while you observe the following parts for wear and tightness:
BEARINGS – BRACKETS – AIR CYLINDERS – JOURNALS - OSCILLATION - HOLDER
PROBLEM POSSIBLE CAUSE FIX
Air has been shut off or insufficient air Turn on air or increase pressure as
pressure to cylinders needed
Control panel malfunction Check and repair controls
Disconnect air lines at each cylinder to
Air cylinder lines have been swapped ensure air is present and connect
properly
Oscillation is restricting pivot action Check/adjust oscillation as needed
Doctor does not pivot Bearings restricting pivot Replace bearings
to the load or unload Unload doctor; reduce loading pressure
Sticking Air cylinders
position to 0 PSI. Load doctor and increase
pressure to cylinders until they start to
NOTE: New air cylinders require some
move. If cylinders do not move
“break in” time to reduce the “break-away
smoothly at lower pressure than used
pressure” required to start cylinders in
for “run” purposes, they might be
motion.
sticking. Replace cylinders.
Remove blade and make sure top plate
Air cylinders may be bottomed out is about 1/8” away from roll when
doctor is loaded
Check to insure nothing is hitting the
Interference with surrounding equipment
doctor back
All mechanical Consult with KADANT Solutions
Incorrect blade for application
functions of doctor Division representative
appear to be in good
Roll is worn or too porous Regrind surface to acceptable condition
working order, but
doctor still does not May require release agent added to
shed the sheet shower
properly or allows Sheet is not releasing from roll
crumbing/water to go Stock chemistry may have changed
behind the blade
Lube shower not adjusted for 200% Adjust, repair or clean shower as
coverage or nozzles are plugged needed
Felt is dirty allowing deposits to transfer to
Blade wear is roll Clean felt
scalloped Poor moisture profile entering press Investigate and correct profile
Blade holder is dirty Clean holder
Blade holder is damaged Repair/replace holder
Blade running dry on edges
Blade wear is heavy Add edge lube showers or order special
on ends Sheet properties add lubrication to roll in blades with edge relief slots
sheet run area
Blade wear is light on Sheet properties add abrasives to roll in
Install lube shower in sheet run area
ends sheet run area
Blade wearing more
on one end than the Doctor misaligned Realign and set doctor.
other
19
6) SPARE PARTS LIST
NO.
ITEM DESCRIPTION KEY NO.
REQ.*
20
NOTES
DATE INSTALLED:
BLADE ANGLE ON TENDING SIDE:
BLADE ANGLE ON DRIVE SIDE:
21
WEIGHT
1910 (Kg)
637.3 A DOCTOR LOAD CHART
BAR PSI PLI KN/M
0.00 0.0 0.37 0.06
0.34 5.0 1.45 0.25
0.69 10.0 2.54 0.44
ROLLER FACE 1500 1.03 15.0 3.62 0.63
BLADE LENGTH 1500
00
1.38 20.0 4.71 0.82
12
1.72 25.0 5.79 1.01
HOLDER LENGTH 1520 1.90 27.5 6.34 1.11
2.07 30.0 6.88 1.20
2.24 32.5 7.42 1.30
10°
70 2.41 35.0 7.96 1.39
295
19
8°
2.59 37.5 8.51 1.49
11
2.76 40.0 9.05 1.58
2.93 42.5 9.59 1.68
150
3.10 45.0 10.14 1.77
1420
3.28 47.5 10.68 1.87
1420
Kadant has been a global market leader in roll cleaning systems and technologies for more
than 80 years. During that time, our roll cleaning assemblies and diverse family of carbon
fiber, composite, and metal roll cleaning blades have earned a reputation for high precision,
efficiency, and reliability. Our field engineers are trained to identify roll cleaning problems
and provide cost-effective solutions that provide the user the opportunity to increase
efficiency and productivity.
Kadant UK Limited
Riverside Works
Woodhill Road
Bury, Lancashire England BL8 1BD
Tel: +44-61-764-9111
Fax: +44-61-797-1496
Kadant Lamort SA
39, rue de la Fontaine Ludot
BP 30046 51302 Vitry-le-Francois cedex
France
Tel: +33-(0)-3-26-74-80-85
Fax: +33-(0)-3-26-74-72-38