The Arizona Republic Newspaper hosted the 2000 Western Maintenance Conference in Phoenix. Attendance was up to 146 Technical personnel from 32 papers nationwide. As has been the case in the past, this conference provided valuable contact with other industry professionals, and provided many insights into how other papers are solving runnability and reliability issues. The following notes were taken during the various electrical/mechanical breakout sessions.

• 50% of the papers run 30# newsprint paper. Three sites have gone back to 30# from 27# due to runnability problems. San Bernardino is using green sleeves and feels that they improve control of the roll and therefore paster performance.

• Several things were pinpointed that could be the issue with start and stop web breaks; water, tension problems or impressions not coming off correctly. Also the E-stop sequence not set up correctly. Also discussed was air in the hydraulic lines causing impressions to come off cock-eyed.

• Use of the web sites "gossgraphics.com" and "westernmc.com" is being encouraged as an additional tool to solicit information and assistance in repairs and training.

• Cut-down to 50" was a popular topic. People with HO units seemed to have most problems. Open fountains were also a more difficult scenario.

• Arizona is using hydrogen peroxide to control biological growth in their Semlar system. They use a 10% solution and they put in 50ml., 5 days a week in each tank. The waster is tested every week or every other week. If the results come back high they give that tank an extra dose.

• Goss is recommending Mobil DTE 26, ISO 68 in place of Mobil DTE 24. For oil filtering, use 10 micron minimum.

• 451S is the most common fountain solution used.

• 40% of plants using chilled water to control biological growth, Santa Barbara is also using UV light. For plants using hydrogen peroxide, the benefits of using powder vs. liquid were discussed. Most sites agreed that liquid is better as it does not plug up filters.

• Philadelphia plugged the return lines on their spray bars and went to 50 psi, citing the gravity return line was not clean, and bacteria was growing in the line.

• Changing the off timing of the water dampeners, off sooner is better to prevent water breaks on stop.

• Check replacement Goss coils in spray bars for proper ohms between new and old, the new ones are damaging drink boards. Spraying Systems has a new type of nozzle that works well, orange in color.

• Some discussion on air getting into lines when hydraulics are shut off. This is a particular problem if there are leaks in the system. Impression eccentrics sticking could also make the on/off uneven.

• Ron Somaska will write a procedure on setting the hydraulic flow speeds for proper operation. A replacement cylinder is available from Parker, #TS-2000.

• Discussion on staggering impression-off time. Ron Somaska confirmed that this is recommended by Goss.

• Angle bar drive shafts leaking, some installed double lip seals and still leaked. Colorliners have extra bearings and more oil lines, which makes problem worse. No real fix at this time.

• Sticky blankets were discussed with no real reason known. May be a reaction to blanket wash. Ground-up plastic strap was found in Norpac recycled paper, blanket wash dissolved the plastic and then stuck to blankets.

• Some plant use NP32s on a and b levels and NP40s on c and d levels and run tension at 50% or a little lower. NP40s used without edge seals. Blanket changes average 750hrs, (Santa Barbara at 600hrs) or 3-4 months on stacks, 6 months on monos. The wall street Journal changes their blankets every 3 months. A straw poll indicated that most papers set impressions every time blankets are changed and run 1-2 days before set.

• Most sites are going to a no edge seal blankets on the towers. It seems to help with the gap problem. Here at the Times we have noticed by using them we have eliminated the gap problem. The decision of running different combination of blankets on the towers seems to be still out. Use whatever works best at your site. Some sites change blankets at 750 hours, Arizona changes them every three to four months on the towers and six on the mono units. Everyone changes out at .078.

• When asked if other shops were having problems with the C roller on the D level building up lint and ink, the answer was yes. Then when asked what they did about it and the answer was wash them, which is the same thing we have been doing.

• Some sites test-fire their severers every week. Santa Barbara has installed a test button to manually fire each knife.

• Different sites are trying different manufactures of belts on their RTP's. Seattle is currently testing a set of Habisat belts, they have been working there with no problems. Other plants are using different belts such as the Habasit #251, Nitta belt, blue in color from Colonial rubber and TF-33 a green/black belt. Santa Barbara runs leather side out, which causes cracks in middle of belt.

• Talked about the position of the Dancer, the LA Times installed a pointer to show it riding in the middle and Seattle installed an RV level to show how many degrees it is off. The RTP operator can inform the support staff how far off it is ten degrees high or low etc. These have both served to increase operator awareness of tension problems.

• Slip rings on the CT 50's need to run true. Santa Barbara tests slip rings every 30 days.

• For RTP belt pressure, most plants (all but Seattle) set at 20 psi for one belt and 60 psi for two belts.

• Transition tension, Santa Barbara has eliminated the auto slack function. Some talk about tension, if tension is up to 80% to 100% cut water back and then cut tension back to normal.

• RTP chuck spindle bolts breaking off, some doing upgrade with spiral pin and one other using stainless bolts, which they claim do not break (softer). RTP roll core piston pressure gauge, set 540 lbs. The hydraulic cylinder used, Parker Series 2H, Model 02.00CH2HCT24AC8.000, Serial HH183292

• New York Times and Arizona Republic have installed a device to adjust the nose in and out. The New York Times uses air pressure, it can be adjusted on the run. Arizona is mechanical and has to be adjusted at the start of the run. Air cylinder added to nose at NY Times, Jim Schmale, 1-718-281-7021

• Used nip rings at the Arizona Republic are being glass bead-blasted. They come out looking like new with significantly extended life. They dispose of the nips when they are .007-.008" undersized.

• Almost everyone is using one piece knives in their folders. There seems to be more wear on the folder area due to abrasive newsprint, caused by the mills adding ash to the pulp.

• Santa Barbara ground nips to 3/8" wide, only the area used. UMI supplies laminate or micarta nip rings, Philly installed on last set of small nips (left large set) above folding cylinder. Some change up to 9 week intervals.

• A-America sells tin coated slitters and hold up very well.

• IGS Folder knifes, $112.00 EA

• IGS sells split nip drive gears.

• Horizontal drive gearboxes, Goss has better fit on gear and shaft.

• Lubrication was a big question. Goss does not recommend a lubricant brand any more but gave ISO guidelines. It was urged to check new oils to see if standards are followed by all vendors.

• Tool-less lock ups were mentioned with some concern about the hinge pins in the new K&F and GOSS systems. Seattle Times’ new style was discussed with the matter left at "we are still testing but it looks promising"

• Some facilities are replacing their cylinders because they are pitted and rusted too bad (someone mentioned that Mountain States got a poor to bad review for work quality and service for these repairs).

• Blankets with wax on the edges (Rust-veto on other areas) was recommended for water and rust control.

• Many shops are going back to copper on the first ink drum for better pick up of ink. Ebonite on the other two.

• Check pre-load on cylinder bearings annually, (metro only).

• An .080" under cut on the nip barrels is improving the section pull by allowing the nip to pull instead of the surface of the barrel.

• Much of the folder discussion was around 50" cut down and what had to be done to the folding cylinder. (later incorporated in a hand out.)

• There was some discussion on paster patterns with a common agreement that the "Nose" of the pattern should not be less than 4". The use of pre made tabs was "worth the cost verses web breaks."

• Set the brush to just "touch" the web in the paster cycle. If it pushed too hard it would wear the brushes and if it was too far it would fire late.

• Some of the replacement parts that come for the load cylinder can be used in a different press and have a spring in them. When used in the METRO as a load cylinder the spring must be removed before installation.

• An upgraded part (Pin and seat) for the volume booster control is now made of Nylon. (The old part was Aluminum with Neoprene molded on it.)

• The valve on the pipe cylinder that controls the paster arm should point down when installed properly. There should be only a ball in the topside fitting with no spring.

• Bleed off rate with floating roller straight down should be 1 to 2 seconds but not more that 3 seconds and p.s.i. = 10-12# .

• A retrofit for Colorliner vsi encoders was found at the conference. Now that we have a source for parts we will begin rebuilding our vsi encoders. The price for one sensor is $120 versus $377 for a new encoder from Goss.

• New spray bar coils coming from Goss need to be checked. Need to check each coil for the correct ohm value.

• Some discussion on web detectors: Since Oxy Dry is no longer manufacturing web detector sensors. The suggestion to switch to Baldwin detectors was recommended. The Arizona paper has had good results with this detector.

• Some of the causes have been vsi encoder failure, 24-volt relay failure and poor quality relays from AB. Apparently AB is having the relays manufactured in China and the contacts when new have shown to have a high resistance. Some sites have switched to Idec relays as a replacement relay.

• Many sites suffering intermittent receiver errors. Some suggestions were to double check the console grounding and moving data cables away from the power cables. Replacing the PCB rack and pulling new cables to the effected units was also suggested

• Discussed Unit receiver errors: After CKT cards have been swapped most people thought it might be a shielding question or cabling. Denver Post said they learned to live with it. Making new ink presets for jobs for new press layouts to get rid of receiver errors will not work according to Goss. Many sites have grounded their 5 volt power supplies to reduce problems.

• Severer: problem occurs when the severer doesn’t fully retract after firing. Sometimes the rubber comes loose and inhibits the knife from fully retracting. Use special adhesive to hold the rubber in place.

• The Seattle Times is currently building a portable tester so spray bars can be tested in place. The Arizona Republic has been testing their spray bars in place by jumping out the enable signal and cycling each nozzle on/off via the unit panel.

• Several sites have problems with the laminated top peeling off the master work station console. The replacement is $10,000! Several sites have expressed concern over the high price and what the fix will be. Goss has no control over the price since the cover is sub contracted out. Some sites have started installing metal trim around the laminated top in an effort to keep it from peeling off.

• Discussed after market press controls, and there are as many opinions as there are systems. No conclusion reached.

• Discussed speed of chrome roller and desensitizing the roller.

• Some sites when running spec tension have been checking their Warner brake modules with a scope when having tension problems during transition.

• Checking the carriage brush for wear and tension. What is the acceptable brush length before replacing? Goss said you should get about 3-4 year of use before replacing the brush with a new nylon material. To determine a need to replace, look at the bottom of the brush for excessive wear and check the angle of the brush. Some sites check the brush pressure with a tension gauge. Look for about 65-ft lbs.

• Transition problems: Check CR 7, 8 and 9. Some sites are replacing these relays with Idec relays. Over time these relays are developing poor continuity upon contact closure.

• Momentary loss of the RTP drive-OK light: Check the relays in the drive cabinet. AB is recommending you change those relays, especially after suffering many years of power bumps

• Brake Pucks: In Philadelphia they do not clean their brake pucks. So far they have not had any problems because of that. In Minneapolis they remove their pucks and clean them in a solvent tank! They also have not had any problems with the brake pucks. The question was raised should we blow out the dust or remove pucks for cleaning or just leave them alone. No right answer as of yet.

• UPS Power to the RTPS: Several of the smaller papers are complaining of web loss and wraps when suffering power bumps. It was recommended that they install the Goss retrofit of UPS power to the Warner power supply. Contact Goss for this information.

• Knife Firing Early: Some sites running CT 50 reels complained of the knife firing early. The fix is replacing the worn dampener rubber on the knife-cocking cam. Replacement can be made from a cutting rubber and should be checked and replaced yearly.

• The Triple Trap: Problem is that the paster breaks 3 sec after leaving the reel room. Check the triple roller located just before entering the slitter near the top formers. Using a string, measure the length of the roller "S" length. It should be equal to the length of the paste pattern ( tape area). If the roller spacing is less than the required length (15" to 23") then this may be the problem area. You may want to shorten the pattern. Dan Vogel recommended this check.

• Varatio: Some sites report excessive backlash in the varatio gears. Check by rotating a full roll to top dead center. Stop the rotation and see if the spider arm moves backward.

• CPCT PBB: Check that we have a 50 millisecond delay before the expiring roll core brake comes on after the knife has fired. Dan Vogel Suggestion.

• Carriage to new roll Gap: Some sites have had problems with the point not picking up. Check that the gap is correct dimension, if ok check that the gap is even. Possible that carriage is out of tram or the roll position sensor is out of calibration. Discussed brush wear and most plants see about 3/32" wear per year. Bristles on brushes on reels should not be nylon they will melt.

• When doing the 50" cutdown the CT 50 reel need no adjustment but the sites with static belts will have to be adjusted.

• RTP drive ok light blinks during e-stop: This is normal when a rapid change in speed is due to a web break or e-stop.

• Numerous 24 volt loss faults: At the rtp drive you will see this fault when the power to the operator side was cycled off /on. It may be that the main control board is beginning to fail also.

• Discussed rubber bumpers on CT-50 reels. Made from cutting rubber. They wear out and should be checked. Some plants claim they received soft rubber bumpers from Goss.

• CT drive after power bump going into fault. Copley South of Chicago replaced all surge suppression (MOV) on control relays. Allan Bradley had recommended this to them.

• AC motor press drive- Since Seattle Times was the only press site running this type of drive at the conference it was a limited discussion. We explained that we are having some problems with our AC drives and Allen Bradley is currently looking into a fix.

• Fincor Drives: Some sites have been having problems with the press drive surging. Some are running a closed loop system and another was running an open loop system. They have tried mounting amp gauges on the drive panel doors to monitor for drive unbalance condition. They are also checking the trigger of the scr modules and the field voltage. Another suggestion was to drag the motors and isolate between the motor and drive train.

• Surging on metro liner Fincor drives: Discussed field weakening. Load balance of drives discussed. Orange Country register will have some Fincor drive parts available due to installing a new drive system.

• Drive Motor Selection: What is the proper number of motors to run versus dragging the motors. Each site seems to have their own rule of thumb when it came to drive motor selection.

• Drive Motor Cooling Air: Some sites are not running air to the motor for cooling. Some are running air that is not going through a dryer and the motors are developing mold problems on the windings.

• Main Drive Engage: Other sites are having numerous center 15 clutch problems You may want to check the linkage that moves the flag for the engage prox sensor. Is it pinned or bolted in? Also check the clutch solenoid, some sites have had problems with this component

New or recycled ideas from Goss:

• Cog belt delivery for the folder, it is to help delivery of papers to the Ferag. There are two test sites, NYT and Sacramento.

• Air bags on 160pg. folder, this is to help reduce marks from the last set of folding rollers.

• For RTP's they have an upgrade called Digital RTP Tension Panel. It costs about $20,000 per RTP. It is to help increase productivity, improve runnability, reduce maintenance, reduce down time, improve speed match, improve tension and improve diagnostics.

• APCS upgrade. Goss is able to come in and change everything over with only about 30 minutes of down time per press.

• New tucking blade shaft seal kit out, see SMB5065. A speedy sleeve and new seal were GOSS approved for repair of the tucking blade shaft in lieu of hard chroming.

• Press controls for pump page packs may be available by the end of the year.