Egli Precision Engineering. F1 IMPULSE PACKAGING MACHINE User Manual

Transcription

1 Egli Precision Engineering F1 IMPULSE PACKAGING MACHINE User Manual

2 Table of Contents Introduction Safety Instructions Main Machine Components Machine Start Up Operation Panel Operation HMI Maintenance Basic Fault-finding Spare Parts [1]

3 Introduction Egli is a premium manufacturer of packaging and food processing machines. Egli has produced over 400 vertical form, fill and seal and baling machines to date, and more than 200 maize snack extrusion lines to customers all over SA and throughout Africa. Egli pride's its self on quality workmanship and reliable products. All spares are manufactured using the latest technology CNC machines. Strict quality standards and highly qualified technicians make sure our customers keep coming back. Our design and development department utilises Solidworks (state of the art 3D design software) to ensure new products are industry leaders. A continuous improvement design methodology is applied at all levels to achieve best results from all our current products. Recently, John Mitchell Former All Black rugby union player, captain and coach and also a quantity surveyor has joined the company as CEO and under his dynamic and experienced leadership Egli is expected to grow sustainably. It is our aim to become Africa s leading manufacturer in our industry. Congratulations on your purchase of an Egli machine! We trust you will enjoy many years of good service from it. Please study this manual closely to ensure you achieve the maximum performance and reliability from your machine. Please ensure all operators study the safety and operations sections thoroughly before use. Please feel free to contact our friendly staff on the details below. They will be happy to assist you with any spares requests or technical related queries you might have. [2]

4 Safety Instructions Machine instillation and start-up: Machine electricity supply is only to be installed and connected by a qualified electrician. Machine must be set up and commissioned by an Egli technician or an approved and qualified technician. Machine is to be set up on a level surface and in a clean and dry environment. Exposure to excessive dust and/or moisture should be avoided. Don't allow unqualified or untrained personnel to operate or maintain the machine at any time. Ensure this manual has been thoroughly studied before engaging with the machine. All doors must be closed and guards in place before machine is started. Machine and surrounding area should be inspected before use to ensure operation will commence safely. Before any doors or panels are opened or an maintenance work is carried out, ensure machine is switched off and correctly isolated. Safety points to remember: The sealing jaws are equipped with heating elements which reach high temperatures. Always be aware and do not touch these jaws while machine is on or for a time period after machine has switched off. The concealed blade on the front jaw is sharp and dangerous. Do not stand or sit on any part of the machine or any surrounding equipment. Do not operate the machine if any doors, panels or covers are missing or damaged. Do not at any time place your hands under the front doors of the machine to pull packaging material down while in operation. Rather stop the machine and correct. Always use the STOP option on the front of the machine to stop production. The emergency stop is only for use in emergency situations. Shutting the machine down in the correct sequence, prevents damaged product and spillage when starting up again. Never over-ride safety features. Safety features Red E-STOP button will shut the machine down in case of emergency. Red main isolator switch. Must be in off position with lock to ensure machine is safely isolated. Main pneumatic control valve. Will shut off pressure to machine in case of emergency. Door proximity sensor. Will not allow machine to start if front doors are open. [3]

5 Main Machine Components Main Machine Components 1 In-feed (not shown) 2 Forming Shoulder and Pipe 3 Draw-down and Vertical Seal 4 Controls 5 De-coiler (not shown) 6 Horizontal Seal 7 Exit conveyor (not shown) [4]

6 1. In-feed The gateway for product to enter the working area of the machine is through one of two in-feed systems: A) Volumetric doser B) Multihead weigher C) Auger doser A) B) C) Volumetric Doser This system uses specific size cups to achieve an accurate and consistent product volume. Unit is calibrated to achieve desired result by opening and closing the cup sizes. Multihead Weigher This system uses integrated load cells to weigh product. Each head has a catchment chute to apply correct weight of product as required. Auger Doser This system uses a purposemade screw to accurately meter set amounts of product. Usually used with powder type products. 2. Forming Shoulder and Pipe The function of the forming shoulder is to continuously direct the foil to the pipe. The shoulder then causes the foil to surround the pipe and creating a vertical cylindrical shape with an overlap. This shape is then ready to be sealed and receive the product. The pipe acts as a conduit for the product to flow from the in-feed system into the bag. The pipe is equipped with a hopper to receive the product. [5]

7 3. Draw-down and Vertical Seal The draw-down belt assembly runs against the vertical pipe and is used to pull the packaging film from the reel. The vertical sealing assembly applies heat to the over-lapped section of the film, at the vertical pipe, and creates a seal. 4. Control Panel The control panel houses all electrical, electronic and pneumatic components required to run the machine. This should remain securely closed at all times and should only be opened and worked on by qualified personnel. Outside the panel are the various buttons, dials, gauges and touch screen used for general operating of the machine. Operation of these will be discussed later in the manual. Also located on the panel are plug points, for the exit conveyor and any auxiliary equipment, and a regulator to manage air pressure coming into the machine and filter moisture from in-coming air. Please refer to the electrical and pneumatic schematic diagrams (found later in this manual) before any maintenance work is carried out on the machine. 5. De-coiler The de-coiler assembly is located at the rear of the machine frame. It consists of various rollers, a frame, de-coiler bar and braking system. Its function is to manage the unwinding of the roll of packaging film, to ensure an even and centralised feed to the shoulder. It does this through controlling the film tension and horizontal tracking. A photo-eye is added to the assembly to assist with graphic alignment and more accurate bag lengths. [6]

8 6. Horizontal Seal The rear and front horizontal jaws close on the bag. The jaws apply heat and simultaneously create the top seal for the filled bag and the bottom seal for the next bag to be filled. Located inside the front jaw is a blade that cuts off the filled and sealed package. 7. Exit Conveyor The exit conveyor will transport the completed bags. It is placed below the horizontal jaws and takes the packaged goods away from the machine to where they can be handled safely. [7]

9 Machine Start Up Prior to machine start up, a thorough examination of the machine and surrounding environment must be carried out. Things to look out for are: Film roll is centralised on shoulder, Film correctly tensioned, Condition on jaws and Teflon tape, Any misplaced objects on or around the machine, Loose covers/guards, Exposed wires, Damages or leaking pneumatic pipes, Excessive moisture build up in the air regulator, Any foreign objects/dirt in the in-feed hopper Should anything be out of place, contact your supervisor before proceeding with the start up. These checks should be performed daily. Install the packaging film roll as per the web diagram below. Check that the E-STOP is deactivated. Switch the main power switch on. Check that doors are closed and all safeties are in place. Wait for jaws to reach operating temperature. Push the START button. The machine will operate according to the following cycle: i. Vertical seal moves forward and makes a seal and then retracts to home position. ii. Film is drawn down after slight delay. iii. Horizontal jaws close, clamping the film after a slight delay. iv. The set heat is applied, sealing top of out-going bag and bottom of in-coming bag. v. Product is dropped into the bag. vi. Knife then cuts, separating bags and retracts to home position. vii. Horizontal jaws then open. viii. Sequence begins again. [8]

10 Operation Panel 1] HMI touch-screen panel 2] START button 8] STOP button 9] AMP meters 3] DOSER toggle switch 10] Volumetric adjustment 4] EMERGENCY STOP button 5] Belt pressure gauge 6] BELT PRESSURE regulator 11] Belt engage hand-lever 7] Main isolator switch 1] HMI touch-screen panel: Human machine interface (see next chapter). 2] START button: When pressed will run through machine cycle as laid out in previous chapter. 3] DOSER toggle switch: Activates in-feed system to allow product flow. Stops product flow when setting up packets. 4] EMERGENCY STOP button: (see safety features). 5] Belt pressure gauge: Shows pressure applied by the draw-down belt against the pipe. 6] BELT PRESURE regulator: Belt pressure adjustment. 7] Main isolator switch: (see safety features). 8] STOP button: Completes current cycle and then stops machine. 9] AMP meters: Displays current values in jaws. 10] Volumetric adjustment: Adjusts volumetric cup height (where applicable). 11] Belt engage hand-lever: Sets draw-down belts to OPEN or CLOSED. [9]

11 Operation HMI The FFS1 uses a DELTA HMI (Human-Machine-Interface) touch screen controller. This touch screen communicates with the PLC and enables interaction with the equipment. Production statistics can be viewed, machine functions monitored and various adjustments made. These adjustments are controlled by using various keys which out outlined below. Two levels of access allow changes at different levels. Operator access allows for operational changes to be made in the machine. Technician access requires a unique password and allows settings to be made and modified at a higher level on the machine. This password should only be issued to trained and qualified staff members. HMI screens: Current date and time. Product recipes saved settings for each different product to be run. Machine status Shows what mode the machine is currently in. Sealing temperature settings. Fault indicator. Current product in production. Production statistics. Current machine speed in BPM. Live bag count. Reset count to start at 0. Sets empty bag simulation and actual machine speed. Horizontal jaw delay setting. Draw down settings delay, length and speed. Test page to individually test each machine sub section. Production statistics. Sets passwords for each 8 levels of machine control access. In-feed settings delay, number of drops and strip run settings. Miscellaneous machine stopping settings. Cross seal jaw and knife settings. Seam seal settings delay and on time settings. Date coder delay settings. Bag kicker operation settings. Diagram explaining foil route through machine. Sets date and time as seen on main page. [10]

12 Maintenance The following maintenance procedures must be carried out timeously. This is in addition to a strict cleaning schedule and the visual checks as outlined in the Machine Start Up chapter. Adhering to the maintenance schedule will help ensure reliable operation and good service life from your Egli machine. NOTE: Be sure to refer to the chapter on Safety Instructions. Machine must be appropriately locked out before any maintenance work is carried out. NOTE: All bearings used are sealed units and wearing bushes are self-lubricating plastics no lubrication is required on the machine. Daily Maintenance Task Drain water trap Clean draw-down belts Notes This is located on the regulator at the rear side of the control panel. Unscrew the bottom nut until water and air spray out. Close the nut again when all the water has drained. Using a clean cloth, apply a small amount of methylated spirits (or equivalent solvent) to the belts and wipe clean. Ensure all dirt or excess material is removed to prevent belt slippage. Weekly Maintenance Task Clean sealing jaws Check knife Check Teflon tape Inspect wiring/piping Check wearing parts Notes Using a wire brush, clean off any build-up that may have occurred on any of the jaws. Be careful not be burnt on hot jaws while cleaning. Ensure the cavity on the jaw opposite the knife is clean and clear of any excess material. Check sharpness of knife by inspecting packets end quality. Should the knife be showing signs of wear alert a maintenance technician to have this replaced. Check the quality of the Teflon tape on the shoulder and pipe. Special attention should be given to the tape located on the sides of the pipe on which the draw-down belts run. Replace if necessary. Should any wire or pneumatic pipe be showing signs of wear and tear, call maintenance personnel to have this replaced before a leak or short occurs. Check all linear bearings, bushes and sleeves for wear. Gently apply pressure to the part perpendicular to the direction of travel and take note of any play. If play is excessive, notify maintenance personnel to replace. Special attention should be given to the horizontal jaw slide assembly and the vertical jaw pivot bushes as these are the hardest working parts. [11]

13 Basic Fault Finding When performing fault finding of any kind, always have this user manual at hand for reference purposes. Do not carry out maintenance or repairs beyond the basic steps mentioned in this manual. When in doubt contact maintenance personnel for assistance. Fault Probable Cause/s Action Machine will not start Main breaker tripped Door open Emergency stop engaged Air pressure too low Call electrician Close door/s Release emergency stop if all is clear Check compressor and regulator. Vertical seal Burnt seal Check temperature opening/rupturing Horizontal seal opening/rupturing Inconsistent bag length Product trapped in seals Not sufficient heat Burnt seal Not sufficient heat Knife blunt Seal bar alignment Foil roll loose on mandrel Draw down belt slipping Photo eye out of position Jaw timer too short Delay from multi-head too long Poor overlap set tracking Check temperature Check for broken wire Replace knife Maintenance staff to centralise sealer bar in jaw Tighten foil locking nuts Clean belts with solvent Replace belts if worn Re-teach photo eye Set jaw delay Re-set delay on multi-head For technical assistance or to arrange on-site training or maintenance from one of our technicians, please use the contact details below: Arnold Worthmann (Works Manager) Mobile: Mark Payne (Head of Electrical) Mobile: Johnathan Schmidt (Head of Automation) Mobile: Reece Morrison (Technician) Mobile: Marco Egli (Technical Support Assistant Manager) Mobile: [12]

14 Spare Parts The following critical spares, wearing parts and consumables are in stock and available on order. For additional spares on your Egli machine or assembly information, please request a complete parts list. Use contact details below to place your order: TEL: +27 (33) info@egli.co.za NOTE: For some spares (eg. Shoulder and pipe, volumetric cups and plates etc.) you will be required to supply information such as product type; bag size and bag material and size. [13]

15 Critical Spares / Wearing Parts Item Part Number Description Sub-assembly 1 FC-0003-E Volumetric scraper wear strip Volumetric 2 PR-0008-E FFS1 impulse jaw set (1x vertical seal, 1x horizontal front, 1x horizontal rear) 3 MA-0018-E Impulse wire terminal complete 4 TC-0014-E Insulating sleeve impulse wire terminal 5 ME-0008-P Spring compress 5x0.7x32 6 MC-0003-E Insulating plate seam seal FFS1 7 TC-0017-T Pin jaw mounting FFS1 seam seal 8 TC-0003-B Bush pivot FFS1 seam seal jaw 9 ME-0004-P Spring compress 8x1x35 10 TC-0008-B Spring retainer vertical jaw 11 PT-0001-B Draw-down belt 25 x 240L 12 TC-0006-A 20 tooth pulley draw-down 13 TC-0005-A Idler pulley draw-down 14 BR-0003-B Bearing RS 15 MC-0002-C Belt support draw-down 16 MA-0019-E Impulse double wire terminal complete 17 TC-0017-B Guide retainer horizontal jaw 18 TC-0013-E Insulator guide front jaw impulse 19 ME-0011-E Knife blade 290 Draw down and seam seal Horizontal seal Consumables Part Number PR-0002-E PR-0003-E PR-0004-E PR-0005-E PR-0006-E PR-0007-E PR-0008-E Description Teflon tape 30mm x 30m roll Teflon tape 60mm x 30m roll Teflon tape 90mm x 30m roll Fibre strip 1m Silicon strip 1m Impulse wire strip 0.25x3 1m Impulse wire strip 0.3x5 1m A full set of electrical drawings are supplied in the panel of your Egli machine, for your convenience. Should you require a second set or electronic copy, please contact our office and we would be happy to assist. [14]