IMCL-2000P LIQUID PACKAGING MACHINE WITH DATE CODER

Transcription

1 IMCL-2000P LIQUID PACKAGING MACHINE WITH DATE CODER OPERATING MANUAL 1

2 CONTENTS Chapter 1: Machine Description (3) Chapter 2: Technical Parameters (5) Chapter 3: Operating Instruction (6) Chapter 4: Maintenance Instruction (16) Chapter 5: Malfunctions and their rectification (18) Chapter 6: List of main parts (28) Chapter 7: Electrical schematic diagram (30) Chapter 8: How to set photocell (32) Chapter 9: Piston (33) Chapter 10: Equipment list (37) Chapter 11: Spare parts list (43) Chapter 12: Dimension list (50) Chapter 13: Date coder adjustments (51) Chapter 14: Date coder manual (52) Attachments: Drive motor brake unit module appendix (66) 2

3 Chapter 1: Machine Description The IMCL-2000P Liquid Packaging Machine is an all stainless steel packing machine, researched and developed by IMC for the international market. It has the functionality of being able to fill, form and seal packets into the sachet format. The well designed and ergonomically appearance makes this machine ideal for your needs. Various kinds of air-free liquid, especially for bag package of mineral water, soy sauce, vinegar, fruit juice and other beverages or iced beverage, bean milk, milk, bean curd and liquid chemical products can be packed. This instruction manual explains all work necessary for instruction, operation, and regular maintenance and malfunction rectification associated with automatic packer. 1.1 Functions 1) Ultraviolet sterilization 2) Bag-forming 3) Thermal vertical sealing 4) Date printing (option on certain models) 5) Linear bag feeding 6) Volumetric filling 7) Thermal transverse sealing 8) Bag-cutting 9) Automatic counting 3

4 1.2 Warnings All moving parts are strictly prohibited from touching during running, especially in the process of thermal transverse sealing area, or it could lead to personal injury. The sterilization lamp must be turned off before replacement of film. DANGER! UV LIGHT EXPOSURE CAN LEAD TO BLINDNESS SWITCH OFF SANITISER SWITCH BEFORE OPENING THIS DOOR The machine body must be connected to the ground safety. 4

5 Chapter2: Technical parameters 2.1 Production capacity: 1500 bags/hour 2.2 Packing volume: ml/bag (steeples adjustment) 2.3 Precision of filing: % 2.4 Width of film: 320mm, 240mm with date coder 2.5 Power: Motor 1.1kw 2.6 Vertical sealing: 0.5kw, Transverse sealing: 0.5kw 2.7 Ultraviolet sterilize lamp: 15w 2.8 Voltage: 220v 50hz 2.9 Weight of machine: 500kg 3.0 Oversize (LXWXH): 1050 X 920 X 1950mm We reserve the right to make structural and electronic alterations in the course of further technical development 5

6 Chapter 3: Operating instructions 3.1 Install the machine in a dry and well ventilated place with sufficient lighting. The four wheels of the machine body should be firm. If necessary, fix the machine with four embedded bolts. 3.2 Fill the product container (not supplied) with clean water (or 75 C alcohol). Make sure that the inlet pipe is kept away from the transverse sealing block. Start the machine and run for 5 to 10 minutes to rinse the pipe so as to meets the foodstuff sanitary standards. 3.3 Load packing material. Step 1: Unlock the paper holding axis and brake. Lever Lift up spring, pull lever forward, move bracket backwards. 6

7 Step 2: Lift up paper holding axis, loosen the paper travelling wheels, load packing material. Paper holding axis Paper travelling wheels Step 3: Lock the paper holding axis. Step 4: Make sure the packing material is entering the driving roller straight. If the packing material is not at an even distance it will pull your packing material roll out of position. Adjust the paper travelling wheels to correct the position of the packing material. Adjust the rollers for even tension on the film in the following areas. 7

8 3.4 Feed the packing material through the forma A. Put the film through two guide pipes and buckle it to the former. Keep the film symmetrical on both right and left sides. Follow the steps below on how to load the packing paper. B. To release the packing paper you will need to activate the sensor by lifting the bar. Sensor Bar C. Make sure the copper block for thermal vertical sealing is in the open position. 8

9 D. Make sure that the film feeding into the forma is not caught or too tight this will result in not being able to feed the film through the forma by hand. E. Open lock by pulling it out and turning clockwise. Closed Open F. Open forma sides. G. Feed the packing paper between the forma sections. 9

10 H. Join packing paper together, film holding wheels. Make sure that the packing paper right side overlaps the left side. Close the film holding wheels. Paper guide wheels I. Close the folding plate of forma. Make sure that the right side of the packing material overlaps the left side of the forma. Close the right side of the folding plate on the forma. Left Right J. Keep the packing material symmetrical on both right and left sides. 10

11 3.5 The roster sensor setup must always be activated only when the film is running. The sensor tells the packet to feed must first operate and then when the packet is running down then only must the sensor for the printer to print be operated. Printer Sensor Paper run, feed Copper blocks open 3.6 Adjust thermal vertical sealing temperature to the range between 120 C and 150 C and thermal transverse sealing temperature between 200 C and 250 C. The adjustment of temperature is subject to the quality and thickness of film at that time. Then carefully adjust for fine-tuning. Do not start production of filling until preheated for 20 minutes, thereafter the machine can go on working and it is not necessary to preheat except for power off. Temperature is not allowed up to 260 C; otherwise hot sealing block will be damaged. To adjust the temperature put in the desired number. 3.7 Adjust the position of bag-feeding connection rod on variable crank so as to obtain the desired length of bag. Shorten the length by turning clockwise and lengthen by turning counter clockwise. Switch off main power supply before adjusting. Turn the setting knob after unscrewing clamp nut of sliding block. Upon the accomplishment of adjustment, tighten clamp nut before restarting. 11

12 Variable cam Clamp nut Allen key Loosen the clamp nut with an Allen key. 3.8 Adjust position of volumetric pump lever on variable crane to obtain the desired filling quantity. Reduce the quantity by turning inward and increase by turning outward. The method is same as clause 3.6. The piston ring of machine is an adjustable component. 12

13 3.9 During regular production the output product is counted automatically through counter. Stop the machine when running out of packing material. When you replace the film turn the value of pump to recycle state to stop feeding the liquid. Do not feed the liquid until new bag is formed Filter your filling liquid in advance for any solid matters. After the machine has been used for a period of time, inspect the transverse and vertical sealing non-adhesive Teflon* cloth, if it is worn unscrew the Teflon* clamp pipe and adjust the Teflon position with a section of new Teflon and then tighten the Teflon* clamp pips. (Adjust before worn completely). Note if not carried out the bags will stick to the sealing jaws 13

14 3.11 The highest position of liquid in the filling tank (barrel) should not exceed 0.5 meters above the pump so as to ensure the precision of quantity Regularly check the vertical and transverse sealing blocks. Clean away the dirt stuck on the surface of copper blocks, which may severely affect the hot sealing result. Do not clean the blocks with metal tools or scrapers or with sand paper, otherwise the working surface will be damaged and cannot be used again. After the cooling of blocks, wipe the surface with cloth or wooden tool dipped with organic solvent to remove the foreign matters. 14

15 3.13 If you find the bag is not sealing, are the ends joined together or leaking. If leaking perhaps the temperature can be increased for this material. Do not touch them with your hand or a tool while the machine is running. Stop the machine immediately. Restart after troubleshooting Action routines and coupling sizes are set to optimal state before delivery. For maintenance, skilled technician are required. Record the original coupling sizes before dismantling. 15

16 Chapter 4: Maintenance instruction 4.1 After use wash away residual liquid in the pipe with water, otherwise the residual liquid will be degenerative and affect the quality of next production. Remove plastic pipe for transfusion and clean it with a brush, keep it clean and dry. 4.2 Regularly grease the moving parts of the machine with sufficient 30# machine oil or lithium based grease, otherwise the operation will be out of order and that will severely affect service life of machine. Grease transmission agent once per day. Grease the pump transmission bar once per shift. 16

17 4.3 Regularly check the machine and clean away any foreign matter on the surface of transverse copper block. It is not allowed to have encrustation on the surface, otherwise thermal conductivity will be reduced, the temperature of copper will rise, and thermal transverse sealing and thermal cutting bag will be out of order. 4.4 Please pay attention to any abnormal sound when the machine is running, if there are any, immediately stop the machine and rectify the problem. 4.5 Single sheet plastic film for the machine should be 80 micrometers thick. The tension strength, even thickness and lubricating property of film should be guaranteed. The weight of each roll of plastic should be controlled under 18kg (320mm) or 14kg (240mm). Transverse hot sealing temperature should be under 260. Poor thermal sealing or high failure rate of bag caused by employing single sheet plastic film is not recommended by the manufacturer, and is not within extent of liability borne by the manufacturer. Recommended film construction for the IMCL-2000P Ice Lolly Machine is LDPE 80 micrometers thick. Film width minimal size is 100mm and maximum size is 245mm. 17

18 Chapter 5: Malfunctions and their rectification 5.1 The machine does not turn on. 1. An electrician is required to check power supply for loss of phase or under-voltage. 2. Check main power supply is turned on. 3. Check that all electrical components are in order. 5.2 The moving part of the machine makes an abnormal sound. 1. Lack of lubricant on relative running surfaces. 2. The screws are loose and that results in the change of position of parts. Check and fasten parts regularly. 3. The moving parts severely worn. 5.3 Insufficient liquid in the sachet. 1. The screw on connecting rod is loose. 2. There are some foreign particles in the liquid inlet/outlet one-way valves. 3. There is air in liquid inlet pipe or the sealing is bad. 4. The liquid level in material barrel is too high. Inlet Outlet 18

19 5.4 The bag length is not fixed, sometimes it is longer. 1. Bag-feeding tension screw is loose; the rubber pad is worn or has oil and dirt on it. Clean with household detergent. 2. Film brake link does not swing forward and backward normally. 3. Plastic coiling tape is overweight. 19

20 5.5 The temperature of the vertical and transverse sealing elements does not rise or is not stable. 1. Check the temperature controller is in order. 2. Check if the temperature sensor is damaged or is loose. 3. Check if the heating tube is damaged. 4. Check if the power supply is out of phase, the connector plug is loose. 20

21 5.6 The sealing surface is not good, the failure rate of bag is high, and the date is not printed distinctly. 1. Change non-adhesive cloths or adjust non-adhesive cloth position. 2. Check the rubber pad is flat or worn. Change if it is worn. 3. Too much filling. A small amount of air in chamber should remain. 5.7 While operating the machine you feel you are getting shock. 1. The power supply wire is connected wrong or is not connected properly. 2. The whole machine should be connected to the ground properly. 3. The wire of the sealing copper block should have good connection to the ground. 4. The wire of the sealing copper block should have good insulating property to ambient surrounding. 5. Do not spray liquid to power supply connector plug or any electrical appliance. 21

22 5.8 The transverse sealing and bag cutting are out of order, the bags are not cutting off and are connecting with each other, and the bearing strength is insufficient after the thermal sealing. 1. Clean away foreign matters stuck on transverse sealing copper block immediately. 2. Check if the Teflon cloth on the thermal barrier on the copper block is loose. 3. Check the rubber pad is flat or worn. Change if it is worn. 4. Plastic film should be 80 micro meters thick. 5. Adjust the pressure of transverse sealing copper block. 22

23 6. Check if the blade on transverse sealing copper block is scarred. 5.9 The pump leaks. 1. The clearance of piston ring is enlarged. 2. Methods of resolution: unscrew the screw on the piston loop bar of pump, screw down slightly and clockwise, example: turn inward (do not screw down too tight; otherwise piston ring will be damaged) 23

24 6.0 The packing paper does not feed down through the bag feeding unit. 1. Switch on the power for the machine 2. Turn on the run switch. 3. Make sure the stop film switch is in an off position. 4. If the film does not move adjust the pressure of the bag feeding unit. 24

25 6.1 In case of finding leakage on piston rod after using for a period. Unscrew fixing screw and turn loop bar of piston rod clockwise (e.g. turn inward) to make the piston expand so that the leakage can be removed. (Remember that the adjusting volume should be tiny, otherwise the piston ring will be damaged). Tighten clamp nut upon the accomplishment of adjustment to avoid loosening and changing position. Refer to how to assemble a piston step

26 6.2. The plastic sticks on the Teflon cloth in the horizontal sealing area. 1. The temperature is too high or too low on the temperature controller When you run LDPE 80 micron film the temperature should be set on the horizontal temperature controller at 170 C, the temperature on the vertical temperature controller at 130 C. 2. Clean any plastic that is melted on the Teflon cloth with a clean wet cloth. 3. If your Teflon cloth is damaged. Replace with new. 26

27 6.3. If your sachet is leaking in the horizontal sealing area. 1. Check that the copper bock on the horizontal sealing area is aligned when they join together. 2. Check the pressure on the horizontal sealing area. Turn off the heating element and stick a piece of paper between the sealing areas; you should not be able to remove the paper when the jaws are closed. To adjust the pressure of the sealing area you will need to loosen the bolts and move the horizontal copper block towards the machine and tighten up the bolts. After you have made any adjustments on the pressure on the horizontal sealing area you will need to check that the copper bock on the horizontal sealing area is aligned. 27

28 Chapter 6: List of the main parts 1 Central plate of former 2 Base plate of former 3 Folding plate of forma 4 Copper block for thermal vertical sealing 5 Central filling tube 6 Bag feeding unit 7 Thermal transverse sealing 8 Bunker 9 Control instrument panel 10 Water delivery tube 11 Bag feeding motor 12 Up check valve 13 Three way direction change valve 14 Low check valve 28

29 15 Damping swing rod 16 Photocell sensor 17 Material feeding motor 18 Switchboard of electrical appliance 19 Hot cutting switch 20 Reducer 21 Motor 22 Connection rod of quantitative pump 23 Loop bar of piston rod of quantitative pump 24 Quantitative pump 25 Coiling material swing plate 26 Bag position regulating stand 27 Germicidal lamp 28 Material check roll 29 Vertical sealing cam 30 Bag feeding start and stop sensor 31 Transverse sealing cam 32 Crank of quantitative pump 29

30 Chapter 7: Electrical schematic diagram 30

31 Film drive motor relay 2 PLC 3 AC Contactor main motor 4 Film drive motor controller 5 Vertical temperature element relay 6 Horizontal temperature element relay 7 Circuit breaker main 31

32 Chapter 8: How to set the film photocell sensor Adjust the length from the registration eye to the film, the brighter the circle the better. Moving the film until the registration eye light aims to the eye mark on the film. If the registration eye is too sensitive all not sensitive enough, adjustment should be made on the unit. To adjust the registration eye sensitivity unit turn the sensitivity adjustment to point B, just the indication from off to light. 32

33 Chapter 9: Piston 9.1 Assembled piston 9.2 Disassembled piston 33

34 9.3 Piston Spares 1 Main volumetric cylinder barrel 2 Seal holding rod 3 Main body piston 4 Cylinder barbell rear plate 5 Cylinder barrel front plate and outlet 6 Non return valve 7 Seal fixing plate 8 PTFE seal ring front 9 Rubber seal 10 PTFE seal ring rear 34

35 9.4 How to assemble the piston. Step 1: Look at the two parts with rings part 10 and part 8, they are different, one is flat on top and the other is tapered. Push the non tapered one onto part 3 from the nuts side. Step 2: Follow the white one with the brown one with the brown ones hollow side facing away from the first white ring look at 9.2 if you are battling. Now follow the brown ring with the tapered white ring so that the taper fits into the back of the brown ring. Step 3: Push part 7 up to the back of the plastic ring. You will need to make sure the nuts are off part 3. You will need to grease around the outside of the rings during assembly and when fitted together all around the outside with food grade grease. Step 4: Take part 4 and push it over part three with the large flange pointing towards the white rings and the small side towards the nuts. Step 5: Take part 2 and push it through part 4 and screw in onto part 3 till it touches part 7. This will hold the seals tight together. Step 6: Turn with your hands part 2 till the seals are quite tight together; take note that part 9 will expand as the part 8 forces it open. The white ring that has the taper forces its way into the brown ring and so the brown ring opens up. So if you make part 2 too tight it will do the same. 35

36 Step 7: Pick up part 1 and you will see that it has a small 6mm hole on the one side; this hole will be the bottom touching part 4, when you push it down over the piston and seals. Refer to drawing 9.3. Step 8: Look at part 5; underneath can you see the white ring this white ring is the seal, part 1 must fit into this part perfect for the cylinder not to leak. Step 9: The whole cylinder stays together using the rods see 9.1; extra thread at the bottom the top has the dome nuts. You need to tighten each screw a little bit one by one and then keep going around until the entire cylinder is tight. If it s not even then it will leak. Step 10: Now take the large nut and screw it onto part 3 till it touches part 2. You will see part 2 is the part that moves in and out of part 4 when the machine is running. This part must be greased every day. Step 11: The small 6mm hole of part 1 must be touching part 4. If the ice lolly liquid is leaking from this hole it means that part 2 must be turned tighter some more and the nuts locked up again. This will expand the brown seal. Step 12: When you put the piston on the machine the part 6 must drop into part 5 from the top. 36

37 Chapter 10: Equipment list Nos. Part Name Photo Usage Model 1 Brass block (Vertical seal) Seal PE bag vertically 190mm 2 Brass block (horizontal seal) Seal PE bag horizontally 200mm 3 Vertical silicon rubber Gasket for sealing 190mm 4 Transverse silicon rubber (white) Gasket for sealing 204mm 5 Transverse Teflon rubber (black) Gasket for sealing 204mm 6 Transverse Teflon bar (white) Hold cutter 204mm 37

38 7 Teflon cloth (per square meter) For sealing 1 meter width 8 Teflon adhesive tape (10m/roll) Stick on forma for sealingt transfer 10 meter roll 9 Temperature sensor Temperature of heater to meter 2 meter lengh 10 Digital Temperature controller Control sealing temperature 11 Transverse Heating tube (300W) Give heat for sealing 300w 12 Vertical Heating tube (500W) Give heat for sealing 500w 13 Sealing rubber for pump (3pcs/set) Seal the pump 38

39 14 O-ring of printer Belt of printer 15 Pump (250 or 300ml) Pump the liquid for filling 250ml 16 Motor (1HP) Give all turning parts power 750w, YL Reducer box Slow down the speed of motor 1/40 18 Film pulling motor Pull film down 60w 19 Film feeding motor Feed film 25w 20 AC Contactor CJX

40 21 Circuit breaker Power protection DZ Proximity switch Give the signal of film running TL-05MY1 23 Photocell sensor Check eyemark of film to control cutting position DC10~30v KT6W- 2N Counter Count packing number TH11J 25 UV Sterilizer tube (15Watts) Sterilize PE film with UV 15w 26 Run/Stop switch To start or stop machine 27 Power switch Control of main power 40

41 28 Heater/Sterilizer switch Switch of heater 29 Spring (3pcs/set) 30 Upper cam Control vertical sealing 31 Down cam Control horizontal sealing 32 Pulley (for motor) Connect with motor 33 Pulley (for reducer box) Connect with motor Φ78 34 Organic glass cover Transfer the speed of motor A940Li970LD 41

42 35 Forma To Form the bag 475mm width 36 Rubber wheel for film pulling Transfer the speed of motor A940Li970LD 37 Motor belt To pull the film Φ85*55 42

43 Chapter 11: Spare Parts List 11.1 Critical spare parts list Note: We highly recommend that you keep the following spares on hand. Nos. Part Name Photo Recommend Quantity 1 Forma 1 PC 2 Temperature sensor 2 PCS 3 Transverse Heating tube (300W) 2 PCS 4 Vertical Heating tube (500W) 2 PCS 5 Teflon cloth (per square meter) 1PC 43

44 11.2 Recommended Spare Parts List Nos. Part Name Photo Recommend Quantity 1 Digital Temperature controller 1PC 2 Sealing rubber for pump (3pcs/set) 4PCS 3 O-ring of printer 4PCS 4 UV Sterilizer tube (15Watts) 1PC 5 Ink Rollers 10PCS 12 x sets (0-9) 6 Digits 8 x blanks 4 x (/) 44

45 11.3 Wearing parts List Nos. Part Name Photo Recommend Quantity 1 Vertical silicon rubber 2PCS 2 Transverse silicon rubber (white) 2PCS 3 Transverse Teflon rubber (black) 2PCS 4 Transverse Teflon bar (white) 2PCS 45

46 11.4 Spare parts Nos. Part Name Photo Recommend Quantity 1 Copper block (Vertical seal) 1PC 2 Copper block (horizontal seal) 1PC 3 Pump (250 or 300ml) 1PC 4 Motor (1HP) 1PC 5 Reducer box 1PC 6 Film pulling motor 1PC 46

47 7 Film feeding motor 1PC 8 AC Contactor 1PC 9 Circuit breaker 1PC 10 Proximity switch 1PC 11 Photocell sensor 1PC 12 Counter 1PC 13 Run/Stop switch 1PC 47

48 14 Power switch 1PC 15 Heater/Sterilizer switch 1PC 16 Spring (3pcs/set) 1PC 17 Upper cam 1PC 18 Down cam 1PC 19 Pulley (for motor) 1PC 20 Pulley (for reducer box) 1PC 48

49 21 Organic glass cover 1PC 22 Rubber wheel for film pulling 1PC 23 Motor belt 1PC 24 Film holding pole (with rubber and spring) 1PC 25 Single-way valve & seal 1PC 26 Piston & seal (pump) 1PC 49

50 Chapter 12: Dimension list Nos. Part Name Photo Diameter 1 Copper block (Vertical seal) L240mm W15mm 2 Copper block (horizontal seal) L202mm W50mm 3 Transverse Heating tube (300W) L170mm Diameter 15mm 220V 300W 4 Vertical Heating tube (500W) L240mm Diameter 15mm 220V 500W 50

51 Chapter 13: Date coder adjustments 13.1 Adjust printing position of date coder A) Increase or decrease the setting on the position of the date coder by pressing (+) or (-) key. B) The roster sensor setup must always be activated only when the film is running. The sensor tells the packet to feed must first operate and then when the packet is running down then only must the sensor for the printer to print be operated. 51

52 Chapter 14: Date coder manual 52

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