Filter welding unit - OEG AG

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elektronics and equipment production 

Operating Instructions 

Filter welding unit 

TRG 301-E 


TRG 301-E 

Edition: TRG 301-E / E Date: 11.01.97 gr



Table of contents 



TRG 301-E 

Chapter Page 

1. Application.............................................................................................................................. 03 

1.1. Use 

1.2. Safety notes 

2. Technical data..........................................................................................................................04 

2.1. Welding unit 

2.2. Electronic control unit 

2.3. Melt yarn storage 

3. Elements of the unit................................................................................................................07 




4. Setting into operation..............................................................................................................15 

4.1. Installation 

4.2. Setting into operation 

5. Safety notes..............................................................................................................................16 

6. Process description.................................................................................................................17 

6.1. Process data 

6.2. Sequence of operation 

7. Hints for use.............................................................................................................................20 

8. Maintenance and care.............................................................................................................20 

9. Accessories..............................................................................................................................20 

10. In case of failures.....................................................................................................................21 

11. After-sales service...................................................................................................................21 

Pameg AG, Staudnerbachstrasse 1, CH-9472 Grabs page 2 of 22



1. Application 

1.1. Use 



TRG 301-E 

The TRG 301-E filter welding unit is exclusively designed for longitudinal welding of cylindrical 

plastic filters. The filter fabric to be processed is made of polyester and nylon supplied by 

SEFAR AG, CH-9425 Thal, trade name NYTAL ®. 

The hot melt yarn is made of nylon and is produced by EMS-Chemie, CH-7013 Domat / Ems 

and available under the trade name GRYLON ® (Type K 110) and Polyester (Type SEFAR). 

The unit may only be used for producing and processing the products mentioned above. 

Only qualified and trained personnel are to operate the unit. Others only under supervision of 

qualified personnel. 

1.2. Safety notes 

Warning: In order to avoid electric shock do not expose the unit to rain and 

humidity. 

Caution: Take care of the mains cable 

Do not deform or damage the mains cable. If damaged or deformed this can 

cause electric shocks or breakdowns. 

Do not open the unit 

In order to avoid electric shock, unit cover may not be opened. In case of 

failures, please ask a qualified person. 

Do not insert objects 

Do not insert objects into the unit, especially metallic objects. Additionally, 

avoid seeping of fluids into the unit. Otherwise, electric shocks or breakdowns 

can be the result. 




2. Technical data 


2.1.1. Design 



TRG 301-E 

- The unit support and the console are a solid welded construction. The surfaces are coated 

light grey. 

- The strip heater supports and the guides are made from black glass fibre reinforced epoxy 

resin. Heat resistance is at max. 300° C. 

- The strip heater supports are made of a heat resistant fabric. Heat resistance is at max. 

200° C. 

- The swinging arm consists of a sectional steel with a light grey coated surface. 

- The swinging unit consists of a metallic axle carried on both sides and of a 4-fold secured 

gas pressure spring. For manufacturing these items high quality materials were used. 

2.1.2. Dimensions 

- Total length incl. melt yarn guide: 1600 mm 

- Width: 250 mm 

- Height: - with closed swinging arm 630 mm 

- with open swinging arm in parking position 1150 mm 

2.1.3. Weights 

- without accessories incl. connection cable 40 kg 

2.1.4. Connection values 

- oil-free compressed air from the reducing unit: max. 2 bar 

2.1.5. Heating capacity 

- pulse controlled heating capacity: max. 1000 W 

2.1.6. Usable width 

- usable working width for a correct welding: max. 800 mm 





2.2.1. Design 



TRG 301-E 

- The control unit is designed using the highest level of technology. A robust aluminium 

housing contains all operating elements which are clearly arranged. 

- The operating panel is coated with a high-quality LEXAN self-adhesive film. 


- Height of housing with extended feet: 250 mm 

- Width of housing: 450 mm 

- Depth of housing: 500 mm 

2.2.3. Weight 

- Total weight without connection cable: 18 kg 

2.2.4. Connection values 

2.2.5. Power 

- Supply voltage: 115 / 220 VAC // 50 / 60 Hz 

- Current consumption: max. 11 / 5,5 A 

- Power consumption under full load: max. 1100 W 





2.3.1. Design 



TRG 301-E 

- The melt yarn storage is made of a robust plastic box containing an insert for holding the 

bobbins. 12 yarn guide holes are in in the folding cover. 

When used the cover is secured with 2 spring catch locks. 


- Height: 600 mm 

- Width: 400 mm 

- Depth: 350 mm 

2.3.3. Weight 

- Magazine empty: 12 kg 

2.3.4. Storage capacity 

- No. of bobbins: max. 12 

2.3.5. Accessories 

- Two additional melt yarn guides are delivered by the manufacturer. They can be installed at 

the storage or at the working table in order to meet the customer’s requirements (see figure). 




3. Elements of the unit 


Fig. 1 

Key 

1 

5 

6 


2 

01 Unit support with console 

02 Swinging arm 

03 Upper heating system with integrated pressing power system 

04 Lower heating system with integrated temperature sensor 

05 Melt yarn guide 

06 Mounting holes for unit installation 


TRG 301-E 

Pameg AG, Staudnerbachstrasse 1, CH-9472 Grabs page 7 of 22 

3 

4



3.1. Welding unit, Details left 

Fig. 2 

Key 


01 Yarn clips 

02 Yarn guide 

03 Tensioning elements for strip heaters (covered) 


TRG 301-E 


2 

3 

1



3.1. Welding unit, Details right 

Fig. 3 

Key 


01 Yarn clips 

02 Yarn guide 

03 Tensioning elements for strip heaters (covered) 

04 Closing device for locking the swinging arm in operating position 


TRG 301-E 


3 

4 

2 

1




3.1. Welding unit, Detail of safety shut-down 

Fig. 4 

Key 

1 

01 Overtemperature forced safety shut-down 

02 Locking mechanism 

2 


TRG 301-E 





Fig. 5 

Key 


01 Gas pressure spring system of swinging arm 

02 Yarn clips 

03 Valve unit 

04 Pressure relief valve 

05 Pressure indication 

06 Compressed air connection 

6 


TRG 301-E 


4 

1 

5 

3 

2



3.2. Electronic control unit, Front view 

Bild 6 

Key 

2 

5 

1 

4 


01 Front panel with indicating and operating elements 

02 Timer indication 

03 Temperature indication 

04 Start / Stop key 

05 Timer preselector 

06 Temperature preselector 

07 Batch counter with Reset function 

08 Counter for total process cycles 


TRG 301-E 


6 

3 

7 

8



3.2. Electronic control unit, Rear cover 

Fig. 7 

Key 

1 


10 


TRG 301-E 

01 Hot air grid 

02 Combi element On Off / fuse / coupler socket 

03 Plug 1 / ST1 (red marking): front strip heater 

04 Plug 2 / ST2 (yellow marking): centre strip heater 

05 Plug 3 / ST3 (blue marking): rear strip heater 

06 Plug 4 / ST4 (7-pin): connection valve unit 

07 Plug 5 / ST5 (6-pin DIN): temperatur forced shut-down, 

sensor, swinging arm locking 

08 Plug 6 / ST6 (3-polig DIN): Option for foot switch 

09 Toggle switch H11/21/31: Switch off upper strip heaters 

10 Toggle switch H10/H11: Switch off front strip heaters 

11 Toggle switch H30/31: Switch off rear strip heaters 

12 Type plate 


9 

11 

8 

7 

6 

12 

5 

4 

3 

2




Fig. 8 

Key 

1 

01 Plastic box 

02 Folded cover 

03 Yarn guide holes 

04 Insert with bobbin holdings 

05 Spring catch lock 

4 



TRG 301-E 


2 

3 

5



4. Setting into operation 

4.1. Installation 

4.1.1. Welding unit 


1. Place unit on a sturdy base and fix it horizontally using 4 screws M10. 


TRG 301-E 

2. Measured from the upper edge of the base a free space of minimum 1200mm must be 

available for the movement of the swinging arm! 

3. Connect compressed air hose to the supply system. The pressure of compressed air is 

factory-set to max. 2bar. 

4. Unlock swinging arm and move it carefully into parking position (= open at limit stop; when not 

in use). 

4.1.2. Electronic control unit 

1. Place unit on a clean base and fold out feets. 

2. Connect cable to switched off unit. 

3. Connect unit to mains 115/230 VAC (50/60Hz) using supply cable (refer to type plate). 

4.1.3. Melt yarn storage 

1. Place melt yarn storage on console in a suitable position. 

2. Feed yarn threads clustered to the welding unit via the yarn guides. 

3. Attach yarn thread feeder on the yarn clips. 

4.2. Setting into operation 

1. All cables must be connected (excl. the optional foot switch). 

2. Switch on unit using the mains switch. 

3. Open welding bars and place into parking position. 

4. Check: ° timer indication must be on zero 

° temperature indication is between 20-25° C (room temperature) 

° if Start-/Stop key is activated no function may be started. 




5. Safety notes 



TRG 301-E 

01. The unit must only be used for its intended purpose and under the specified 

conditions (refer to chapter 1, Application). 

02. The control and the valve unit carry up 230 VAC. Pay attention to the general 

and local saftey regulations for live devices and to the saftey notes of chapter 

1.2. 

03. Pull mains plug before opening the control unit! 

04. Faulty cables or plugs must be replaced immediately by our after-sales service. 

05. The unit may only be used under normal room conditions. 

06. In case of heavy vibrations in the operating environment the welding unit should 

be installed vibration-free. 

07. During the welding process the bar locking must not be activated. The welding 

unit is under pressure! 

08. Do not touch the strip heaters during operation. Danger of burning! 

09. Under no circumstance, the folded swinging arm may be used as support or 

bearing surface. 

10. Avoid mechanical influences (by knifes, scissors etc.) to the working areas. 

11. The function of the gas pressure spring must be monitored and replaced by a 

authorized person, if required. 

12. If the cover of the strip heater (fabric band) is mechanically damaged a short 

circuit could be the result. The fabric must be replaced immediately. 

13. Only a undamaged fabric band enables a perfect working process. 

14. Use only suitable tools for professional adjusting of loosen fasteners. 




6. Process description 

6.1. Process data 

6.1.1. Timer 



TRG 301-E 

- The process can be interrupted at any time by activating the Start / Stop key. In case of 

restart the process starts: 

° with an actual temperature > 85° C at the Hold value 

° with an actual temperature � 85° C at set default value = process restart 

- The process cannot be started if 

6.1.2. Temperature control 

° the welding arm is not correctly locked 

° the temperature in the area of the front strip heater holder of the swinging 

arm is more than 60° C (safety feature overheating) 

- A temperature indication in the range of 0 to 200° C shows a correct function of the system. 

- The temperature is electronically limited to 200°C independently of the presettings. 

- At temperatures above 85° C (after the heating process) the swinging arm cannot be opened 

normally. The unit is under working pressure! 

- The temperature sensor for monitoring and controlling the control system is located in the 

centre of the working area. To obtain an accurate temperature measurement a contact 

pressure to the sensor is necessary in order to guarantee full heat transfer by the strip 

heater. Therfore, always weld above the temperature sensor (weld over) 




6.2. Sequence of operation 



TRG 301-E 

Step Procedure Check 

01 Feed filter fabric with inner side of welding seam and fix. - Fabric side 

02 Align filter fabric and tension until it lies flat. - Flat lying 

- Alignment 

03 Feed melt yarn in the desired number (max. no. of yarns 12 

per welding seam), tension and fix it. Correct yarn position in 

the direction of the welding seam, if necessary. 

04 Feed second filter fabric end (outside of welding seam). 

Position, tension and fix it. 

05 Turn swinging arm upwards from park position using the 

handle, place it into the locking position with slight pressure 

and engage (downwards). 

06 At the control unit preset timer and temperature within the 

allowed ranges using the preselector switches and/or check it. 

07 Start process by pressing Start / Stop key: 

° Valve activates compressed air supply and clamps filter 

fabric 

° Heating is started 

° Timer counts backwards to zero 

° Temperature indication increases to set value 

° If timer is on zero and temperature is � 85° C, the valve 

is switching to pressure release 

° Lamp of Start-/ Stop key extinguishes; welding process 

is finished 

- No. of yarns 

- Yarn tension 

- Yarn position 

- Flat lying 

- Alignment 

- Locking 

- Setting values 

within limit 

values 

- Indications 

- Valve control 

- Start / Stop 

indication lamp 






TRG 301-E 

Step Procedure Check 

08 Unlock swinging arm by activating the locking mechanism and 

turn into park position. 

09 Loosen welded filter and remove it carefully from the welding 

unit (take care of edges!) 

10 Clean cover of strip heater and working support 

11 Continue acc. to point 1 or switch off welding unit when 

working is finished: 

1. Swinging bar into parking position 

2. Switch off mains supply 

3. Disconnect compressed air supplly in case of longer work 

interruptions. 

- Lockings 

- Seam quality 

- Residues 




7. Hints for use 



TRG 301-E 

The filter welding unit is a customer-specific development. Experience has shown that wishes 

and ideas for process optimization are contributed by the user after start of production. After 

the introductory period, our know-how and experience is given in this chapter as a help for the 

user. 

8. Maintenance and care 

The TRG-301-E filter welding unit is designed for limited maintenance and care: 

- The yarn clips are factory-set. If required, a trained person should adjust them using 

suiable tools. 

- The strip heaters are pretensioned by springs in the tensioning elements. At rest 

these springs must be fully tensioned. If required, a trained person should adjust them 

using suiable tools. 

- The upper and lower fabric bands (cover of strip heaters) must be replaced frequently. 

- Remove upper clamping bars and lower support angles 

(Caution: - control switch swinging arm) 

- remove old fabric bands carefully 

- clean upper and lower support areas with alcohol 

- Install new fabric bands and tension 

- Install again upper clamping bars and lower support angles 

- Check position and tension of fabric bands and correct, if required 

- Welding unit in park position 

- The gas pressure spring is responsible for easy opening/closing of the welding unit. It 

is maintenance-free and needs no special care. After 50'000 double strokes the 

correct function cannot be guaranteed. So it is important to check the sum counter at 

the control unit (indication 25'000). Then replace it by a new factory-delivered gas 

pressure spring. This work should be done by a trained person using suitable tools. 

- The temperature sensor is located in the centre of the lower working surface below 

the centre strip heater and is perfectly set by the manufacturer. If the temperature 

sensor is faulty it must be replaced by a new one supplied by the manufacturer. For 

removing/installing the temperature sensor observe the following steps: 




9. Accessories 

Remove temperature sensor 



TRG 301-E 

- Loosen and remove both screws of the spacer at the lower supporting bar of the filter 

welding unit. 

- Pull spacer slowly upwards by slightly turning it by hand until the connector can be 

removed. 

(Caution: This work must be carried out very precisely and clean in order to avoid 

damage to the thin connection cables). 

- Remove temperature sensor from filter welding unit by drawing apart (not turning) the 

connector (consists of two parts). 

- Dispose faulty temperature sensor. 

Install temperature sensor 

- Insert a new temperature sensor into screw of spacer. 

- Join parts of connector (coding). 

- Push spacer together with temperture sensor and connector upwards (slowly turning 

by hand) through the hole in the lower support bar of the filter welding unit. Push it until 

the temperature sensor is positioned vertically in the hole of the supporting surface and 

until the spacer contacts the supporting bar of the filter welding unit. (Caution: This 

work must be carried out very precisely and clean in order to avoid damage to the thin 

connection cables) 

- Check the spring deflection of the temperature sensor: the sensor head must be 

slightly pressed to the centre strip heater from below. If the spring deflection can be 

guaranteed (can be obstructed by the thin connecting cables) pull again the spacer 

slightly upwards, turn it slightly and re-insert again. 

- Attach spacer to the supporting bar using the two screws. 

- Caution: At the lower side of the spacer is a plastic cover. Below this cover are two hex 

nuts for limiting the spring deflection of temperature sensor. They are factory-set and 

secured. When loosing these nuts the precise temperature measuring cannot be 

guaranteed. 

For ordering spare parts refer to spare parts list in the annex! 

The TRG-301-E filter welding unit is supplied ready for operation. Optionally, a spare parts set 

can be supplied with the unit. 




10. In case of failures 



TRG 301-E 

In case of failures, please check the following points before contacting our after-sales service. 

� no indication on the control unit: - check mains supply 

- check unit connections 

- check switch ON/OFF 

- check fuses (rear) 

� Timer cannot be started: - temperature between 20°C and 100° C 

- faulty sensor PT 100 

- bar not locked 

- supporting surface too hot (>85°C) 

- check all electrical connectors 

� Heating not switching on: - check toggle switch on rear of control unit 

- check desired scaling 

- check all electrical connectors 

� Irregular welding: - check plugs 1 to 5 

- correct setting values (Timer and temp. presel.) 

- no compressed air, check pressure indication 

11. After-sales service 

In case of failures, the steps mentioned above should be carried out before contacting our 

after-sales service department. The staff of PAMEG AG will try to analyse the error via phone, 

together with the customer, before initiating a maintenance action. 

If an error cannot be removed this way the unit can be sent back to the manufacturer where it 

will be checked and repaired, if necessary. A definitive repair deadline depends on the error 

analysis. 

After-sales service: PAMEG AG 

Staudnerbachstrasse 1 

CH - 9472 Grabs 

Phone: +41 (0) 81 750 30 05 

Fax: +41 (0) 81 750 30 09 

Note 

This operating instruction is not binding and can 

be changed or supplemented any time by 

PAMEG AG..

Filter welding unit - OEG AG

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