Linear Commutated Meat Filler IMC-CMF100 INTERNATIONAL MACHINE CONCEPTS WELCOMES YOU TO YOUR NEW MACHINE

Transcription

1 Linear Commutated Meat Filler IMC-CMF100 INTERNATIONAL MACHINE CONCEPTS WELCOMES YOU TO YOUR NEW MACHINE Operation Manual: Date Version 1. Serial Number 1

2 CONTENTS Chapter 1 Machine Description 1.1 Uncrating Instructions 1.2 Installation 1.3 Electrical and Pneumatic connections 1.4 Chapter 2 Technical Parameters and Description 2.1 Chapter 3 Operation Instruction Filling volume adjustment Can Lifting system adjustments Filling Timing Adjustment Can in- feed scroll adjustment Chapter 4 Malfunctions (Faults) and their rectification Chapter 5 Table of possible faults 4.1 Cleaning Instructions 5.1 Maintenance Instructions 5.2 Chapter 6 List of main Mechanical Parts 6.1 List of main Electrical Parts 6.2 Placement of Sensors 6.3 Chapter 7 Electrical Diagrams 7.1 Chapter 8 Servo Driver Manual 8. Servo Drive Parameter setting list 8.2 Chapter 9 Spare parts list 9.1 2

3 Chapter Machine Description The IMC- CMF100 is an Automatic Linear rectangular can filling machine. This is a high quality efficient machine which Loads and Fills different types of containers. The functionality of the machine is such the cans are fed into the conveying system via an in- feed chain. The tins are then entered into a scroll wheel where they are separated and allowed to continue to the chain finger belt. These fingers are spaced so that enough separation time is allowed for the lifting and bottom up filling to take place. The filling machine will not fill if there is no can in position by virtue of a no can no fill sensor at the lifting station. The lifting station will lift into position every time but if there is no can it will not produce a fill cycle. The speed of the in- feed system is electronically controlled by an invertor driver to a three phase conveyor motor. The lifting, in- feed scroll and finger conveyor are all mechanically linked. The specific timing has been set by the factory, however each one of these can be individually set. The specific lifting height is also activated by a can system and the height of the lift can be set independently. The time for the lift and drop are not independent and therefore cannot be separated to create an independent up and down movement. The filling volumetric piston is controlled by a signal from the can in position sensor located at the in- feed conveyor lift station. If a signal is produced the servo motor will index one fill cycle and produce a fill volume control product deposit. The volumetric fill cylinder has an adjustment wheel to set the specific fill volume required for the fill of your specific canister. Note: Do not set the volume during a fill cycle. The filling head has a product cut off nozzle that is designed especially for your tin can size and as such the timing of the can to the lifting station is very important. The filling nozzle must go into the can completely so as not to damage the can seal area. The filling nozzle cut off is activated by a pneumatic cylinder that receives it signal from the filling machine. This specialized nozzle is to control the product tail. Further discussion of these functions will be available in Chapter 3 3

4 1.1 Un- crating Instructions During un- crating make sure that no physical damage to the outside of the crate has taken place. Carefully break open the exterior panels to reveal the machine and its working parts. The machine will be covered in a plastic protective cover. This is to be removed. Make sure that no parts have been damaged during transport, or fallen off the machine. The machine will arrive with certain parts dis- assembled. These need to be fitted to the machine to resemble the photos above the machine. The machine is fixed to the wooden palette by multiple metal brackets. Remove these brackets and discard or keep for future use. The doors and covers have been taped closed for safety reasons, these taped parts can now be opened. Surface rust can take place due to the excessive sea air during shipping. This will only be surface rust and a dry cloth should be used to remove this rust residue. The entire machine has been shipped with an oil coating on the surface to safeguard the machine from corrosion. This can now be removed with a very light detergent. The non- stainless steel parts should be re- oiled to prevent rusting taking place after cleaning. Do not leave the machine wet. The machine is top- heavy and as such, care should be taken when handling the machine and removing it from its wooden pallet. NOTE: DO NOT HANDLE THE MACHINE ON THE PRODUCT HOPPER. These parts are critically aligned and should they be bent out of position the machine may be damaged. v 1.2 Installation Only a qualified technician should perform the machine installation or a suitably trained person. Note: it is dangerous to work on a moving machine and the machine should be off and isolated before any form of work is performed. Machine should be placed in a well- ventilated room, free from dust and excessively corrosive materials. There should be at least 1,5m space around each side of the machine for convenient operation and maintenance. Prepare the power supply 380V 3 PHASE 50HZ. Three Phase and neutral, and connect to an appropriate earth wire. Pneumatic connections should take place as the designated connection. The air should not be less than 6Bar while the machine is operational. Air should be free of water and contaminants. The machine should be placed on level ground. After installing the machine, check if the machine is level by Level Instrument. If not, please adjust the four legs. 4

5 Check every part of the machine carefully for damage during shipping. Tighten any loose parts, screws and moving parts. All gearboxes should be checked for sufficient oil. Check all electrical connections for loose wires. Make a test of the machines electrical power and confirm the voltage and earth continuity. All safety connections relative to your own country should be adhered to. Before operating the machine, please lubricate: The Filler has a oil reservoir in the upper portion of the machine. Please check to see that no water has ingressesed into this area and that there are no foreign contaminants. Remove this Cover to check oil level Oil Reservoir must be half full and cover moving components Standard Type 30 Gearbox oil can be used in this area 5

6 1.4 Electrical and Pneumatic connections This machine requires a three phase connection and earth wire and a pneumatic air connection for a suitable compressed air supply. Electrical Connections Air connection v DISCLAIMER IMC will not be held responsible for incorrect installation and subsequent failure of the machine due to any installation procedure not being followed. Chapter Technical Parameters and Description Voltage Power Requirement Dimensions Maximum Can Size Maximum meat fill volume Maximum Can Fill Maximum Machine Speed Minimum Machine Speed Air Pressure Required Air Volume Required V at 50Hz + N + earth 5Kw 2381*2807*2470mm 74mm x 56mm x 89mm (Height) 100 kg s 350g 100 Cans/min 10 Cans/min 0.6 Mpa 10L/Min 6

7 Chapter Mechanical description and adjustments Filling volume adjustment The Filler can be adjusted for can filling volume. Adjust by loosening the lock not and turning the wheel either left or right according to the Note: Do not set the volume during a fill cycle. It is also possible to set a too full fill in the can and as such the filling will still be taking place while the can is in a downward motion Can Lifting system adjustments The Filling or Lifting system must be adjusted to the in- feed finger chain. The can must be lowered in sufficient time to allow the can to be completely lowered before the finger removes the can from the lifting area. Likewise the in- feed finger chain must be adjusted so that the can is in the perfect position in the lifting area for the lifting area to position the can under the filling nozzle. This will allow no damage to take place to the can during lifting and lowering of the cans. This timing can be adjusted in the following way. The filling head can be adjusted forwards and backwards by loosening the four holding bolts. Loosen and move filling head forwards and backwards to obtain obtain correct position for the can to the filling nozzle Note: Please make sure the sensor is in close proximity to the can. If not the filling cycle will not take place 7

8 Correct Presentation of Can therefore correct presentation of finger conveyor Sideways positioning can be achieved by adjusting these two holding plates Filling Timing Adjustment The timing of the filling cycle can not be manipulated from an operator point of view, however the timing can be incorrect if the sensors that have influence in the process are not correctly positioned. Note: The operation of the filling cycle needs to be carefully understood. In a normal operation cycle the filling cylinder will always come to a stop in the charged position, I.e. filled with product. An initiation of a fill will now depend on a can being lifted to activate the Can in Position (Filling Servo Motor Start) sensor The Filling Nozzle is operated from a Can in Position (Meat Filling Nozzle Open) Sensor It is extremely important that the sensors are not interchanged so as to not affect the timing of the system 8

9 Operation of Filling Cycle Description: The can will be presented to the lifting station situated under the filling nozzle. A no can no fill system is incorporated via two pneumatic cylinders that operate if a can is in position during the lifting cycle. The can lifts up via a cam system and once on the upward stroke the can will activate the first sensor, Can in Position (Meat Filling Nozzle Open) Sensor. This sensor will activate the pneumatic valves to allow the meat filling nozzle to open and after filling to shut. This nozzle opening is started before the actual meat pump sequence so as not to create a compression of the the high speed filling cycle. The can still in the upward motion now activates the Can in Position (Filling Servo Motor Start) sensor. This then starts the servo motor and produces a filling cycle. The cam is not adjustable for individual up and down speed control as it is fixed mechanically to the in- feed conveyor. However the lift profile is steeper than the drop profile creating a slower drop than lift scenario. This is to allow for all the meat to enter the can before that can face leaves the nozzle. Note: It is possible to start the pump cycle to early if the sensor is not situated right at the top of the lift stroke. This possibility must be avoided. Also NOT pushing the can to within approximately 10mm from the top of the nozzle (greater than 10mm) will cause the fill to create an air pocket under the meat and in such case the meat will overfill the can and possibly leave excess meat on top of the can after the fill cycle is complete. This is called a tail. This tail will create problems during seaming. Similarly if the can is pushed to high (less than 10mm) when a fill cycle is initiated the fill cycle will try to fill a can where no space is available and in such cases the meat will ooze out from the side of the filling nozzle. Also this practice must be avoided. The pump cycle will activate a sensor inside the servo cover Rotary valve open sensor this is a safety system to acknowledge that the rotary valve is indeed open before filling takes place. Note: If the start signal of the filling process is incorrectly set by virtue of the can not going high enough or stopping to low, or the Can in position sensor being incorrectly positioned, it will appear that the nozzle is opening too early or too late. This is NOT correct.. it is merely 9

10 a product of the incorrectness of the (A) can height position, (B) Can in position sensor being to low or too high. Set this position as a starting point to any correcting of can filling. Once a can fill has been initiated the process is controlled by the sensor location and not timers built into the software process. The filling will take place while the can is travelling in a downward direction, All filling must be complete before the can has left the nozzle. The speed control between can movement (up and down) and filling can not be adjusted independently. If a large tail occurs, this could be due to one of the reasons stated above in this section Can in- feed scroll adjustment It is possible to adjust the in- feed scroll relative to the in- feed conveyor fingers. This timing is critical so that the finger does not present itself before the can is in position. That means the scroll in- feed should be slightly ahead of the finger presenting itself. The adjustment takes place by adjusting the scroll (retard or forward) using this screw A. In- feed scroll Scroll Timing set Screw A Pick up Finger 10

11 Chapter 4 Malfunctions (Faults) and their rectification Fault Machines will not switch on Rectification Check power supply to machine Check main isolator is in a reset position Check emergency stop is not pushed (turned) Note: When the estop is released the filler will run to find its initial position and then stop Machine is on, but the machine will not run Have you pushed the Start push button Are any of the safety overloads in fault position reset after overload has been investigated See servo fault if in fault consult IMC technician for servo driver faults. (Consult separate servo drive manual) Check Production Speed is set above zero Is the volumetric adjustment handle pushed in and the sensor light not lit. Release the handle. 11

12 Machine is on and started but conveyor does not run. Check infeed conveyor overload switch. reset overload Check mechnicle linkage for broken drive faults or chain off or broken. Repair mechanicle breakage Machine running but not filling Check to see if the Can in position sensor is activating This can be seen by a small red led that operates when a can is in position Can in position sensor operates but machine still does not fill. The piston pushes forward but an erratic or no fill takes place. Check to see that there is no blockage in the meat hopper. Check that there is a fill cycle taking place from the servo drive this will necessitate the removal of the top cover of the machine to see that the servo motor does rotate one cycle during the correct time if the servo does rotate and still no filling cycle take place there could be a mechanical breakage in the connection between the servo motor and the piston push rod. There is a gearbox between these two points and should there be any fault this would require a replacement gearbox or linkage assembly The piston has O rings and these could be worn replace the O- rings. The nozzle does not open during a filling cycle Refer to section on Filling description: The nozzle is activated from a sensor on lifting Station Replace if faulty 12 check to see that the sensor operates during the fill cycle.

13 - Check to see if the pneumatic cylinder operates correctly The nozzle does not close after filling Check to see correct opeartion of pneumatic cylinders Filler does not draw in sufficient meat Check to see if the seals on the piston are in good condition replace seals if necessary Check to see if feed screw is in position and turning Machine runs to slowly Main rotary feeding valve is not in correct position Is their sufficient meat in the hopper Set machine speed up on speed controller panel Machine is in mechanical overload check all mechanical systems for tight or worn parts. Rest the valve to correct timing the timing should be when machine piston is in the 13

14 Meat filling leaves tail reversing position the valve should be open to the hopper and piston. When the machine is in a fill cycle the valve should be in a piston to filling pipe position. This can only be checked when the machine is empty and clean. See section for full explanation of rectification Chapter 5 Operation steps and Maintenance Instructions 5.1 Operation steps Note: Always clean the machine before operation and discard any foreign materials from the machine 1- Switch on machine, check that there is no damage to any mechanical parts 2- Run Empty cans through the machine, making sure all the machines timing is correct and that all the various machine sections operate. 3- Check the machine for visual damage and any stuck products in the conveyor. 4- Make sure the air is connected. 5- Load the hopper with meat and run through a few times to determine that the correct volume is obtained. 6- Run the machine up to speed using the speed increment button. placed correctly and over seal is correct. 8- Stop the machine using the stop/start button, and only on an emergency use the emergency stop button. If the Emergency stop button is used after releasing the button the filler will start and find its home position. The machine will not keep running after the home position is found. 5.2 Maintenance and Cleaning instructions Note: Do not maintain the machine while in operation 1- The machine is self lubricating and needs very little day to day maintenance. 2- The main volumetric piston requires its seals to be changed periodically. 3- Although most of the machine is Stainless Steel, surface rust can develop on non stainless steel parts, keep these parts oiled using a food grade non stick lubrication such as silicon spray. 14

15 4- Regular attention should be paid to the lubrication chamber, the oil will slowly be used up and so needs top up when required as the level drops. 5- Visual inspection of all pneumatic pipes for damage replace when necessary. Cleaning Procedure 1- The machine can be adequately cleaned by running hot water into the hopper. The machine should be jogged using the Clean button. All the product will be expelled in this manner. 2- Should a deeper clean be necessary the following steps need to be followed 3- Isolate the machine 4- Remove the main stirrer screw by turning it anti- clockwise 5- Unscrew the Main Unlocking bolt the volumetric valve connecting coupling must be de- coupled. Main Unlocking Bolt The Cylinder will be exposed at this point for cleaning Coupling Loosen with and Allen Key then pull back coupling 15

16 6- After this the plate can be opened on the hinges. This will expose the volumetric cylinder and the volumetric valve. These two area s can then be cleaned using hot water with a sterilizing solution that has been established as safe for your product. Note: Do not use a chlorine solution as this will damage the Stainless Steel. 7- The flexible pipe can also be removed by unscrewing both ends and then the pipe can be submerged in a cleaning solution. 8- The filling nozzle is made up of three pieces, it is recommended that this nozzle is not disassembled for routine cleaning but rather cleaned in position using hot water. This unit can also be cleaned by spraying a cleaning solution on and through it. 9- The main conveyor can be cleaned by spraying the conveyor with pressured hot water. It is recommended that after cleaning the entire conveyor is dried and lubricated due to its many parts requiring lubrication. Chapter List of main mechanical parts 16

17 6.2 List of Main Electrical Parts Item Description 1 Main Circuit Breaker 3 Phase 2 3 Phase switch for 3 Invertor driver for conveyor motor 4 Contactor for 5 Contactor for 6 PLC 7 In Line Filter 8 Volumetric motor servo driver 6.3 Placement of Sensors Nozzle Sensors I Filler Sensors ROTARY VALVE OPEN SENSOR FILLER HOME POSITION SENSOR VOLUMETRIC HANDLE ENGAGED SENSOR HOPPER MIXER DRIVE MOTOR PROJECT DESCRIPTION. Meatco Commutated Filler PROJECT NUMBER Meatco July 2017 DATE July 2017 DRAWING DESCRIPTION DESIGNER REVISION Meatco Filling System Sensor placement Michael Murphy Version 1 17

18 Chapter Electrical Diagrams I HOPPER MIXER DRIVE MOTOR PROJECT DESCRIPTION Commutated Meat Filler -Meatco PROJECT NUMBER Electrical Diagram 1 of 6 DATE May 2017 DRAWING DESCRIPTION DESIGNER REVISION Conveyor Motors 3 Phase Main Supply Michael Murphy Version 1 I SEE FULL INPUT/OUTPUT LISTING ON DIAGRAM 4 Filling Nozzle Activate Sensor Volumteric handle deactivation Sensor Can in Position Sensor Increase speed Decrease speed Stop/ Start E-Stop HOPPER MIXER DRIVE MOTOR PROJECT DESCRIPTION. Commutated Meat Filler -Meatco PROJECT NUMBER Electrical Diagram 2 of 6 DATE May 2017 DRAWING DESCRIPTION DESIGNER REVISION Sensors and Switches - Low Voltage Michael Murphy Version 1 18

19 PARAMETERS GROUP GROUP GROUP RS2A05AAAA0 I SANYO DENKI R2AA1835OMXHAO 2.7KW AC200V 11.0A HOPPER MIXER DRIVE MOTOR PROJECT DESCRIPTION PROJECT NUMBER DATE Commutateted Meat Filler - Meatco Electrical Diagram 3 of 6 May 2017 DRAWING DESCRIPTION 3 Phase Main Motor Circuit DESIGNER Michael Murphy REVISION Version v + Filling Rotary Valve open Sensor Filling Sevo Motor Start Sensor Volumetric handle Sensor Cleaning Button Increase speed Button Decrease speed Button Stop Start Button 41 0v - Servo Initialize Start --- A28 CN1 Conveyor Start --- DCM UF1 Conveyor Forward --- FWD UF1 Servo Filling Start --- A37 CN1 Start Relay Filling Servo Alarm --- A40 CN1 Can Conveyor Invertor Alarm --- RB1 UF1 Filling Nozzle Valve Open Conveyor can back up sensor Meat Filling Nozzle open Sensor E-Stop Start Point VFD/MD v v - PROJECT DESCRIPTION PROJECT NUMBER DATE. Commutateted Meat Filler - Meatco Electrical Diagram 4 of 6 May 2017 DRAWING DESCRIPTION PLC Inputs and Outputs DESIGNER Michael Murphy REVISION Version 1 19

20 Volumteric Servo Drive Volumteric Servo Motor Conveyor Invertor Drive PROJECT DESCRIPTION PROJECT NUMBER DATE Commutated Meat Filler - Meatco Electrical Diagram 5 of 6 May 2017 DRAWING DESCRIPTION DESIGNER REVISION Servo Motor and Driver - Volumteric Filler Michael Murphy Version 1 I HOPPER MIXER DRIVE MOTOR PROJECT DESCRIPTION Meat Filler Lifter - Meatco PROJECT NUMBER Electrical Diagram 1 of 1 DATE May 2017 DRAWING DESCRIPTION DESIGNER REVISION Main Power Circuit Michael Murphy Version 1 20

21 Chapter Spare parts list 1. Frame oil seal Dia.60*Dia.35* Frame oil seal Dia.40*Dia.65* O shape seal Dia.65* O shape seal Dia.170* O shape seal Dia.108* O shape Seal Dia.128* O shape Seal Dia.148* O shape Seal Dia.125* O shape Seal Dia.82.5* O shape Seal Dia.85* Bearing KR22PPX Bearing KR30PPX Valve Core GZH Piston GZH Spindle GZH Spindle GZH Sensor LT EI Sensor LT EI Magnetic Valve 4V21008B 1 21

22 Drawings of Food contact items Piston: Cylinder: Rotary Valve: Filling Valve: Filling Valve Actuator: Rotary Valve Block: 22