INSTRUCTION MANUAL
FOR
FORDS PACKAGING SYSTEMS
18 HEAD ROTARY INDUCTION SEALER
SERIAL NUMBER
21510
1 95150217_01 Copyright Fords Packaging Systems Ltd 1998. All rights reserved.
Fords Packaging Systems Ltd. Ronald Close Woburn Road Industrial Estate Kempston Bedford MK42 7SH
Tel: +44 (0)1234 846600 Fax +44 (0)1234 853040 e-mail: [email protected] website: www.fords-packsys.co.uk
Every effort has been made to ensure that the information given in this manual is correct at the time of printing. However, the product described in this manual is subject to continuous development and improvement. Fords Packaging Systems Ltd accepts no responsibility for any loss, damage or injury arising from the use of any information given in this manual.
SPECIFICATION
MACHINE TYPE Rotary Induction Sealer
YEAR OF PRODUCTION 2012
MACHINE SERIAL NUMBER 21510
MAXIMUM SPEED 160 containers per minute
ELECTRICAL SUPPLY 480V, 3ph, 60hz
PNEUMATIC SUPPLY 7 bar
2 95150217_01 SECTION 1
SUPPLIER INFORMATION
3 95150217_01 SECTION 1 SUPPLIER INFORMATION
1.1 INTRODUCTION
This manual relates specifically to Fords Packaging Systems Ltd. Rotary Induction Sealer.
1.2 ABOUT THIS MANUAL
This manual contains information required for correct installation and commissioning of the Rotary Induction Sealer, together with operating and maintenance instructions.
All procedures detailed in this manual should only be performed by suitably trained and qualified personnel.
This manual should be read prior to attempting to install, operate or maintain the unit.
Fords Packaging Systems Ltd. will not be liable for any injury or damage resulting from a failure to follow the procedures and instructions detailed in this manual.
1.3 ADDITIONAL DOCUMENTATION
In addition to the basic manual, the documentation package supplied with all new machines includes the following:
Overall layout drawing showing basic machine sizes and space requirements for installation.
Parts lists, including assembly diagrams and recommended spares.
Electrical circuits diagrams.
Pneumatic circuits diagrams.
Third party component information.
These additional documents are all machine specific. They will be bound as appendices to this manual, or in additional binders as required.
4 95150217_01 SECTION 1 SUPPLIER INFORMATION
1.4 WARRANTY
Fords Packaging Systems Ltd. warrants all equipment against defects in workmanship and materials for a period of 12 months from the date of shipment, or 2,000 hours of operation, whichever occurs earlier.
The warranty is limited to free replacement and shipping of any faulty part, or sub-assembly which has failed due to poor quality or manufacturing errors. All claims must be supported by evidence that the failure has occurred within the warranty period.
All warranty claims must specify the unit/type number and the serial number. These details are printed on the unit identification plate, as fixed to each unit.
The warranty will be void if any modification is carried out on the unit without prior written approval from Fords Packaging Systems Ltd. For warranty purposes the following conditions must be satisfied:
Only genuine Fords Packaging Systems Ltd. approved spare parts, lubricants and materials must be used.
All scheduled maintenance operations detailed in this manual must be carried-out at the specified intervals by suitably trained and qualified personnel. The machine must not be operated outside the design parameters specified in this manual.
Failure to satisfy any of these conditions will automatically void the warranty.
5 95150217_01
SECTION 2
SAFETY
6 95150217_01 SECTION 2 SAFETY
2.1 STANDARDS FOR SAFETY
CE-marked machines, along with those supplied with a Certificate of Incorporation, have been designed and manufactured to comply with the essential health and safety requirements of the European Union Directives as stated on the relevant documentation supplied with the manual.
Machines that do not require be CE-marking are built to a similar level of safety unless alternative regulations or equipment levels are specified.
2.2 RESPONSIBILITY FOR SAFETY
Every care has been taken in the design and manufacture of the equipment to ensure that it meets all the safety requirements mentioned in Section 2.1. However, any individual operating or working on any machinery is primarily responsible for:
Personal safety, safety of other personnel, and the machinery.
Correct utilisation of the machinery in accordance with the procedures in this manual.
The contents of this manual include suggested best working practices and procedures. These are issued for guidance only, they do not take precedence over the above stated individual responsibilities or any local safety regulations that may exist.
2.3 MISUSE OF EQUIPMENT
The Rotary Induction Sealer is intended to be used for sealing caps on to plastic containers. It is not suitable for purposes other than those specified in this manual. Any use of the equipment other than for its intended use, or operation of the equipment contrary to the relevant procedures, could cause injury to the operator, or damage to the equipment. The unit must never be operated outside the design parameters specified in this manual.
2.4 MANUAL SAFETY CONVENTION
The following conventions are used in this manual to alert the reader to areas of potential hazard and to provide additional information regarding particular subjects.
A WARNING is given in this document to identify a hazard which could lead to personal injury. Usually an instruction will be given, together with a brief explanation and the possible result of ignoring the instruction.
A CAUTION identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution. Usually an instruction will be given, together with a brief explanation and the possible result of ignoring the instruction.
A NOTE is used to highlight additional information which may be helpful to you but where there are no special safety implications.
7 95150217_01 SECTION 2 SAFETY
2.5 MACHINE END-OF-LIFE
2.5.1 Procedure for disposal/scrapping
When this product has reached the end if its useful life, a number of possible options are available:
Contact the original manufacturer to determine if there is a possibility of buy-back. Sell on as a complete unit through a professional scrap metal trader. Dismantle and dispose of individual parts for scrap.
Whichever route is chosen, in order to maintain a safe environment, methods for moving the machine must be those described in the original Operation Manual. For the purposes of disposal, the machine construction can be considered as follows:
Metals used are mainly Stainless Steel and may be recycled through conventional channels. Plastic materials are non-hazardous, and are principally Nylatron GSM (Gearwheels) and Clear Acrylic (Guard Doors). No hazardous chemicals were used in the construction, although appropriate measures should be taken with regard to lubricants contained within the machine. Electrical & electronic devices should be recycled / disposed of against prevailing Policy & Law at time of disposal.
Note: Certain PCB’s may contain Lithium-Ion batteries.
Order of dismantling is not important, although components should not be removed in an order that causes the machine to be unstable.
8 95150217_01 SECTION 2 SAFETY
2.6 SAFETY LABELS
The following labels are fixed at strategic points around the unit so as to provide instruction, or to warn of potential hazards which may exist. All personnel should be familiar with the labels, the potential hazard to which they refer and the advice given in this manual, BEFORE using the machine.
Mandatory instruction: Refer to the manual.
White symbol on a blue circular background. This label is used whenever any of the other warning labels are fixed. It is used to instruct personnel to refer to this manual for information regarding the warning labels used and the potential hazard to which they refer.
WARNING: FAILURE TO UNDERSTAND THE MEANING OF WARNING LABELS AND THE POTENTIAL HAZARD TO WHICH THEY REFER, ALONG WITH FAILURE TO FOLLOW THE ADVICE GIVEN, MAY LEAD TO SERIOUS INJURY.
Warning: High Pressure Air
Black symbol on a yellow background
No maintenance work (involving removal of access panels) should be carried-out without first isolating the mains air supply to the unit. A "DO NOT OPERATE" sign should be placed over the mains isolator to prevent it inadvertently being switched on.
Work on pneumatic equipment must only be carried-out by suitably trained and qualified personnel.
Warning: Moving Machinery Black symbol on a yellow background
No maintenance work (involving removal of access panels) should be carried-out without first switching off the machine, isolating all power supplies and isolating the mains air supply to the unit. The unit main electrical isolator switch should be operated to the off (0) position. A "DO NOT OPERATE" sign should be placed over the operator control panel to prevent the machine inadvertently being switched on. The pneumatic isolator switch must be moved to the closed position and a "DO NOT OPERATE" sign should be placed over the isolator to prevent it inadvertently being switched on.
9 95150217_01 SECTION 2 SAFETY
2.6 SAFETY LABELS (Cont...)
Warning: Lethal Voltage.
Black symbol on a yellow background.
Used to warn of an electrical hazard that is considered potentially dangerous. It is attached to all guard panels and fixed covers behind which electrical hazards may be present.
Work on electrical equipment should only be carried out by suitably trained and qualified personnel.
WARNING NO WORK SHOULD BE CARRIED OUT ON ELECTRICAL EQUIPMENT WITHOUT FIRST SWITCHING OFF AND ISOLATING ALL POWER AND CONTROL SUPPLIES. CONSULT THE KRONES MANUAL FOR THE SITING POSITION OF THE MAINS ISOLATOR. THE ISOLATOR SHOULD THEN BE FIXED IN THE OFF POSITION BY USE OF A SUITABLE LOCKING DEVICE, I.E. PADLOCK, AND LABELLED WITH A `DANGER - DO NOT OPERATE' SIGN SO AS TO PREVENT ACCIDENTAL RE-CONNECTION OF POWER BEFORE ALL WORK IS COMPLETED.
Warning: Non Ionising Radiation
Black symbol on a yellow background.
Used to warn of a potential hazard arising from the emission of high frequency, electro-magnetic energy. It is attached to all guard panels and fixed covers behind which this energy may represent a potential hazard.
WARNING The high frequency, electro-magnetic energy emitted from the Induction Sealing equipment will cause the heating of any metallic object that enters the electro-magnetic field. Whilst working in the area of the electro-magnetic field it is essential that the electrical supply to the Induction Sealer Generator is isolated and that all metallic rings, watches, jewellery etc. are removed. Failure to do so may result in serious burn injuries.
See section 2.8.2 and 2.8.5 for locations of the electrical and pneumatic isolators.
10 95150217_01 SECTION 2 SAFETY
2.7 GENERAL SAFETY
The following list of general safety precautions must be followed by all personnel responsible for operating or maintaining the machine:
1. Guards and interlocked protective devices provided by the equipment manufacturer must not be bypassed, disconnected or removed. The machine must only be operated with all access panels and interlocked safety guards properly fitted. 2. Never override or change the settings of any safety switches or devices so as to reduce the level of safety originally provided. 3. Check daily that any interlocked safety guards and emergency stop buttons are operating correctly.
2.8 OPERATIONAL SAFETY
1. Operator, service and maintenance personnel should carefully read this manual, understand and fully comply with any machine mounted warnings labels and instruction plates. Do not paint-over, alter, or deface these labels and plates, or remove them from the machine. All labels and plates which become unreadable must be replaced. 2. Only qualified personnel who have read this manual and have been instructed in the safe use of the machine should be entrusted to operate it. 3. All personnel should know where any emergency stop buttons and safety devices are located in case of an emergency. 4. Operators must be instructed on the correct way to stop the machine. Any interlocked safety guards and emergency stop switches should only be used to stop the machine in an emergency. 5. Never attempt to perform any maintenance or cleaning whilst the machine is in motion. 6. Store all tools and cleaning cloths on a workbench, not on the machine. 7. Keep the area around the machine clear of obstacles (such as packing cases etc.) to maintain easy access. 8. Be sure the machine is in good operating condition at all times. In the event of the machine producing any unusual noises, smoke or signs of excessive heat etc., switch off the machine and report the incident to your supervisor. 9. Never leave the machine running unattended for long periods.
11 95150217_01 SECTION 2 SAFETY
2.9 SAFETY DEVICES
Note: The Rotary Sealer safety circuit is linked into and controlled by the PLF Filler. Activating any safety device attached to the Rotary Sealer will E-stop the PLF Filler, and vice versa.
2.9.1 Emergency Stop Switches
There are four emergency stop switches fitted on the Sealer, as follows:-
Front Left Guard Structure - Location 1
Front Right Guard Structure - Location 2
Rear Right Guard Structure - Location 3
Rear Left Guard Structure - Location 4
If any of the emergency stop buttons are pressed, the Sealer will come to an immediate halt. Refer to the HMI manual for Reset and Re-start operations.
12 95150217_01 SECTION 2 SAFETY
2.9 SAFETY DEVICES (Cont...)
2.9.2 Interlocked Safety Guards
There are sixteen Interlocked Safety Guards fitted on the Sealer, each with a lockable safety switch, positioned as follows:-
Sealer Front Left Guard Door - Location 5 Sealer Front Right Guard Door - Location 6 Sealer Rear Left Guard Door - Location 7 Sealer Rear Right Guard Door - Location 8 Sealer Left Side Guard Door - Location 9 Sealer Right Side Guard Door - Location 10 Sealer Infeed Front Left Guard Door - Location 11 Sealer Infeed Front Right Guard Door - Location 12 Sealer Infeed Rear Left Guard Door - Location 13 Sealer Infeed Rear Right Guard Door - Location 14
These doors are electronically locked in their closed position and cannot be opened whilst the machine is running. Once the machine has been bought to rest, the locks are released and the doors can be opened.
Whilst open, the machine cannot be started.
13 95150217_01 SECTION 2 SAFETY
2.9 SAFETY DEVICES (Cont...)
2.9.3 Fixed Guards and Covers
The fixed covers around the base of the Sealer should only be opened by trained personnel, whilst the Sealer is at rest and electrically isolated via the Main Electrical Isolator Switch (see section 2.9.4). These covers MUST be replaced before restarting the machine.
2.9.4 Main Electrical Isolator Switch
This is located on the right hand side of the Main Electrical Control Cabinet, positioned on the first floor mezzanine level.
The unit should be locked in the ‘off’ position, using a suitable locking device (padlock), to prevent accidental supply of electrical current whilst work is being carried out on the machine.
14 95150217_01 SECTION 2 SAFETY
2.9 SAFETY DEVICES (Cont...)
2.9.5 Local Sealing Turret Electrical Isolators
These are located on each of the Turret Power Control Cabinets at locations 15 - 19.
The unit should be locked in the ‘off’ position, using a suitable locking device (padlock), to prevent accidental supply of electrical current whilst work is being carried out on the Sealing Turret.
WARNING - THE ROTARY SEALER DRIVETRAIN, INFEED FEEDSCREWS AND PRESS DRIVE SYSTEMS ARE ALL DRIVEN BY THE PLF FILLER, AND AS SUCH DO NOT HAVE LOCAL MOTOR ISOLATORS FITTED.
15 95150217_01 SECTION 2 SAFETY
2.9 SAFETY DEVICES (Cont...)
2.9.6 Pneumatic isolators, Regulators and pressure switches.
There are 2 pneumatic supply / isolation points fitted to the sealer:
2.9.6.1 Mains Air Supply Shut-off Valve
This unit supplies air to the Sealer Turret Seal Head Control pneumatic circuit. It is located at floor level on the Sealer, adjacent to the Air Supply Drop.
2.9.6.2 Sealing Turret Seal Head Supply Shut-off Valve
This unit supplies air to the Sealer Turret Seal Head Control pneumatic circuit. It is located at high level on I/O Plate at location 20.
These units should be locked in the ‘off’ position, using a suitable locking device (padlock), to prevent accidental supply of pneumatic air whilst work is being carried out on the Sealing Turret.
Note: Turning off the Mains Air Supply Shut-Off Valve will cut feed to the Sealing Turret Seal Head Supply.
See section 9.2.6.3, for a general description of the Air Supply Shut-off valve operation.
16 95150217_01 SECTION 2 SAFETY
2.9 SAFETY DEVICES (Cont...)
2.9.6 Pneumatic isolators, Regulators and pressure switches (Cont...).
2.9.6.3 Pneumatic Supply Shut-off Valve – General Description
Each Shut-off Valve unit consists of:
A. Manual Pneumatic Isolator Turn the actuator 90° clockwise to remove air pressure and 90° anti-clockwise to apply the air pressure. B. Pressure Regulator Turn the actuator clockwise to increase the set air pressure and anti-clockwise to lower the set air pressure. C. Pressure Lock-off There is a pull-out section located at the top of the Regulator which allows the unit be locked in the ‘off’ position, using a suitable locking device (padlock), to prevent accidental supply of pneumatic air whilst work is being carried out. D. Filter The lower section of the Regulator body contains a filter unit. Ensure that the air pressure is switched off using the Pneumatic Isolator before removing the Filter Unit. Turn the housing clockwise to remove the filter Unit and anti-clockwise to re- install the Filter Unit. PNEUMATIC PRESSURE SWITCH IF THE AIR SUPPLY PRESSURE TO THE SEALER FALLS BELOW A FACTORY SET PRESSURE, THE SEALER WILL COME TO AN IMMEDIATE HALT.
C B A
D E
17 95150217_01 SECTION 2 SAFETY
2.9 SAFETY DEVICES (Cont...)
2.9.7 Torque Limiters
The Sealer Drive Train, Container Handling Parts and the Feedscrews are driven from a lay shaft connected to the PLF Filler. This Shaft is fixed to a Transfer Gearbox in the Sealer Base. The control of this shaft is by the PLF Filler, however a Mechanical Torque Limiter is fitted to the outfeed shaft of the gearbox, protecting the Filler Drive Train / PLF Drive Shaft. In addition to the Main Drive Torque Limiter, the Infeed and Exit Starwheel Drive Assemblies, and the Feedscrew Drive Assemblies are fitted with Mechanical Torque Limiters, located in the Base area of the Sealer. Should the torque in any mechanism rise above the factory set limit, the torque limiter is activated, which disconnects the drive to the relevant Starwheel / Feedscrew. Activation of any Torque Limiter is detected by a safety sensor and the Filler / Sealer will stop immediately in an E-stop condition.
If a Torque Limiter is tripped, the cause of the jam should be investigated and the cause removed, prior to resetting. The Torque Limiters can only be reset by manually turning the Area that has become unseated.
As all of the Torque limiters are single point, they will always reset in the correct position.
18 95150217_01 SECTION 3
PRODUCT DESCRIPTION
19 95150217_01 SECTION 3 PRODUCT DESCRIPTION
3.1 INTRODUCTION
The Rotary Induction Sealer is designed to heat seal pre-filled containers.
The machine can cap and seal a maximum of 168 bottles per minute.
3.2 TECHNICAL SPECIFICATION
Machine Output (nominal) 160 Bottles Per Minute Machine Output (maximum) 168 Bottles Per Minute Seal Downforce * 500N Seal Time (approximate) * 2.2 seconds (variable) Electrical Supply 480V, 3Ph Grounded 60Hz Control Voltage 24 Vdc Pneumatic Supply (nominal) 6 bar (90 psi) Low Pressure Cut-out (operate) <3.5 bar (51 psi) Low Pressure Cut-out (reset) >4 bar (58 psi) Noise Output <75 dBA
Note: that values marked * are potentially variable between containers, and as such final operating parameters should be defined during testing, commissioning and validation trials at the customer site. The final figures for each container should be recorded by the customer for future reference.
20 95150217_01 SECTION 3 PRODUCT DESCRIPTION
3.3 SEALER WORKING PRINCIPLE
The containers are fed along a conveyor, separated by a feedscrew, where a second infeed screw 'A' aligns the containers for cap applying and for transferring into the sealing turret.
The containers pass under the cap applier 'B' which places the foil caps onto the containers as they travel through the screws.
The infeed screws feed the containers to the infeed starwheel 'C', which transfers the containers onto the pedestal of the rotating turret 'D', which is fitted with pneumatically actuated sealing heads.
As the turret rotates, the appropriate heat sealing head descends onto the container (if a cap has been not been applied the head will not descend). The seal time is determined by the software program and is independent of machine speed. The correct combination of heat and pressure is applied to seal the coating on the foil cap to the container, producing a hermetic and tamper evident seal.
The heat sealing head ascends so that the containers are ready to be taken out of the turret by the exit starwheel 'E'. The exit starwheel places the now sealed containers onto the exit section of the conveyor, which transports the containers away from the machine 'F'.
21 95150217_01 SECTION 3 PRODUCT DESCRIPTION
3.3 SEALER WORKING PRINCIPLE ( Cont...)
3.3.1 Consecutive Missing Applied Caps
If caps become stuck in the lower part of the chute or the cap applier, it is possible that uncapped containers will pass through the machine and on down the production line.
A sensor is positioned on the infeed plough to detect containers as they pass under the "no cap/no seal" sensor. If a pre-set number of consecutive uncapped containers (typically 4) are detected, then the fault signal will be issued, the machine will be automatically stopped. The blue RESET lamp on the Operator Cabinet will be illuminated and a message will be displayed on the Operator Cabinet display panel. Refer to the Electrical Control section of this manual for Reset and Re-start operations.
3.3.2 The Sealing Cycle
The Rotary Sealer employs an induction sealing process to seal foil caps to the containers. The sealing parameters for each sealing process are pressure, heat and time. The pressure is applied by a pneumatic cylinder, the heat is generated by an induction generator and the time is controlled by the PLC.
The total seal cycle consists of the seal head down time, the induction generator ON time and the cure time. The relative timing relationship is shown below in the timing diagram. The seal time and the cure time are set at the HMI. The seal head down time is fixed within the control programme and is not available to the operator.
22 95150217_01 SECTION 3 PRODUCT DESCRIPTION
3.3 SEALER WORKING PRINCIPLE (Cont...)
3.3.3 Induction Generator Power Level Control
The power developed by the induction generators can be set to a fixed level, or it can be controlled automatically by the power reduction programme.
With the power reduction programme switched OFF, the power level generated is set to the minimum power setting. No changes to this level will take place while the Sealer is running.
With the power reduction programme switched ON, the power level generated is set automatically. When first selected, the power level is set to the minimum power level setting. If the Sealer remains stationary or there are no containers passing through the Sealer, then the power level will gradually increase to the maximum power setting. As containers pass through the Sealer, the power level is gradually reduced, in steps, to the minimum power level.
Note The decreasing step values and the increasing step values can be set independently. They do not need to be equal. The decreasing step values are applied at the end of each sealing cycle. The increasing step values are applied on a time basis. The power level of each sealing station is set independent to each other.
23 95150217_01
SECTION 4
TRANSPORTATION, HANDLING & STORAGE
24 95150217_01 SECTION 4 TRANSPORTATION, HANDLING & STORAGE
4.1 DELIVERY AND STORAGE
To ensure consistent quality and maximum reliability, each Sealer is tested and inspected before leaving the factory. If the machine is to be put into storage, prior to installation, the following precautions should be observed:
The machine should be stored in an area where there is minimal activity to limit the risk of accidental physical damage. The machine should be stored in its original packing case (if supplied), under cover and protected from dust, frost and rain.
4.2 INSPECTION
The machine will be despatched from Fords in wooden transport crates. The crates must always be handled carefully, observing the lifting points, gross weight, orientation and centre of gravity markings.
Once the machine has been delivered, inspect the crates to ensure that no damage has occurred during transit. Any visible damage must be reported to Fords prior to installation:
If the pneumatic and electrical services have been pre-installed, they should be checked to ensure that they are suitable. If the environmental or installation conditions are unsatisfactory, Fords Packaging Systems should be contacted for further advice.
4.3 MOVING THE TRANSPORT CRATES
WARNING: HEAVY LOAD. THE INDIVIDUAL TRANSPORT CRATES MAY WEIGH IN EXCESS OF 8,000 KG. TO PREVENT INJURY OR DAMAGE TO THE UNIT, ALWAYS USE APPROVED LIFTING EQUIPMENT. THE MACHINE MUST ALWAYS BE HANDLED WITH CARE. OBSERVE ALL MARKINGS ON THE CRATES, PARTICULARLY REGARDING WEIGHT DISTRIBUTION AND LIFTING POINTS. THEY CAN BE MOVED USING A FORK-LIFT TRUCK.
4.4 LOCATION REQUIREMENTS
The main elements of the sealer are supplied in a number of separate transport crates, and as such will require re-assembly on site. Ensure there is adequate space to manoeuvre the individual sub-assemblies into their required positions before unpacking.
4.5 UNPACKING AND SITEING THE SEALING SYSTEM
The Sealer is the largest of the individual items, however its final position is set by the Infeed tunnel that forms the joint between the Filler and the Sealer.
25 95150217_01 SECTION 4 TRANSPORTATION, HANDLING & STORAGE
4.5 UNPACKING AND SITEING THE SEALING SYSTEM (Cont...)
4.5.1 Unpacking / Siteing The Infeed Area
The infeed area supports the lower end of the cap chute and the cap applier.
To remove the infeed tunnel from its transport crate and position it accurately, the following sequence should be observed: 1. Position the transport crate enclosing the Infeed area as close to the final position as possible, then remove the lid of the crate and remove any loose items. 2. Remove the lid of the crate and remove any loose items that can be easily reached. 3. Remove the front panel, ensuring that any braces secured to the panel are loosened first and again remove any loose items that are easily reached. 4. Repeat this process until all of the side panels and braces are removed. Ensure there are no more loose items on the sealer base or the base of the crate. 5. Using suitable lifting equipment, raise the Infeed area off of the base of the crate and move it to its final site position. Once the Infeed Area is positioned correctly, it can be levelled by adjusting the 4 feet. 6. Once levelled, the Infeed area should be bolted to the Outfeed Tunnel of the Filler.
4.5.2 Unpacking / Siteing The Sealer
Note: The bulk of the Sealer Base weight is towards the back of the sub-assembly, and as such the rear of the crate.
To remove the Sealer Base from its transport crate and position it accurately, the following sequence should be observed: 1. Position the transport crate enclosing the Sealer Base as close to the final position as possible, with the rear of the crate easily accessible. 2. Remove the lid of the crate and remove any loose items that can be easily reached. 3. Remove the front panel, ensuring that any braces secured to the panel are loosened first and again remove any loose items that are easily reached. 4. Repeat this process until all of the side panels and braces are removed. Ensure there are no more loose items on the sealer base or the base of the crate. 5. Using suitable lifting equipment, raise the sealer base off of the base of the crate and move it to its final site position. Once the Sealer Base is positioned correctly, it can be levelled by adjusting the 11 feet. 6. Once levelled, the Sealer should be bolted to the Infeed Tunnel. 7. The conveyor can now be fastened to the Infeed area and the Sealer Base.
WARNING: IT IS CRUCIAL THAT ANY LIFTING BEAMS / ATTACHMENTS ARE REMOVED AND THE BOLTS REPLACED BEFORE THE MACHINE IS STARTED.
4.6 FINAL RE-FIT OF SEALER BASE
After the Infeed and Seal are sited, the rest of the containers should be unpacked carefully, and all loose items fitted prior to starting the machine.
26 95150217_01
SECTION 5
INSTALLATION
27 95150217_01 SECTION 5 - INSTALLATION 5.1 LOCATION REQUIREMENTS
To achieve optimum performance and trouble-free service, it is essential that the proposed installation site meets with the location and space requirements for the unit being installed.
It is important to ensure that a minimum service access space is maintained for cleaning and maintenance purposes.
5.2 FOUNDATIONS
The sealer must be installed on a floor or platform which has been designed with a floor loading capacity capable of supporting the machine's weight. If the maximum floor loading weight is not exceeded, special foundations are not required.
When the unit has been installed, the feet should be adjusted to ensure that it is level, with the weight evenly distributed over all the feet.
5.3 ELECTRICAL CONNECTION
WARNING: ELECTRICAL CONNECTIONS MUST BE CARRIED OUT IN ACCORDANCE WITH LOCAL ELECTRICITY REGULATIONS BY QUALIFIED PERSONNEL. THE UNIT MUST NEVER BE OPERATED ON A VOLTAGE OR FREQUENCY OTHER THAN THAT FOR WHICH IT WAS MANUFACTURED.
The unit is designed for 3-phase operation. Each unit is supplied complete with all the internal wiring installed and configured in accordance with the voltage and frequency specified on the identification plate.
For mains power connection details refer to the electrical wiring diagram section of this manual. The unit must be adequately earthed and equipped with a fused isolator to enable the mains power supply to the unit be isolated for inspection and servicing.
The power supply cables and mains fuses must be of the correct size and rating in accordance with the maximum current specified on the unit identification plate.
WARNING: AFTER CONNECTING THE MAINS SUPPLY CABLES DO NOT SWITCH ON THE POWER TO THE MACHINE. SOME INTERNAL COMPONENTS ARE LIVE AS SOON AS THE POWER IS APPLIED, AND INITIAL SWITCH-ON MUST ONLY BE DONE BY FORDS AUTHORISED PERSONNEL.
28 95150217_01 SECTION 5 - INSTALLATION 5.4 PNEUMATIC SUPPLY
Compressed air represents a source of considerable potential energy and, as with electricity, precautions must be taken to prevent accidents.
WARNING: THE UNIT MUST NEVER BE OPERATED USING AN AIR PRESSURE HIGHER THAT THE MAXIMUM DESIGN PRESSURE. THE MAXIMUM UPSTREAM PRESSURE MUST NOT EXCEED 10 BAR (155 PSI). COMPRESSED AIR MUST NEVER BE ALLOWED TO IMPINGE UPON THE BODY. PIPES AND VALVES MUST NOT BE BLOCKED BY HAND.
Ensure that the pressure isolation valve is in the "closed" position. A "DO NOT OPERATE" sign should be placed over the isolator to prevent it inadvertently being switched on. Connect the mains air supply to the unit regulators. Switch on the mains air supply and adjust the unit regulator to 7 Bar (102 psi). Switch off the mains air supply.
WARNING: AFTER CONNECTING THE MAINS AIR SUPPLY AND ADJUSTING THE UNIT REGULATOR, DO NOT OPEN THE PRESSURE ISOLATION VALVE. SOME ACTUATORS WILL CHARGE AS SOON AS THE PRESSURE IS APPLIED. INITIAL SWITCH-ON MUST ONLY BE CARRIED-OUT BY FORDS AUTHORISED PERSONNEL.
29 95150217_01
SECTION 6
OPERATING INSTRUCTIONS
30 95150217_01 SECTION 6 - OPERATING INSTRUCTIONS
6.1. INTRODUCTION
This section of the manual describes the operation and control features of the Rotary Induction Sealer. Direct control of the Sealer is performed via the HMI touch screen, provided by PLF International. Please refer to the provided operator manual for further information.
6.2. SAFETY
The machine was designed with safety in mind, and includes safety features to help prevent injury and damage.
6.2.1 Emergency Shutdown
Before attempting to use the machine you must know how to shut it down in an emergency. There are four emergency stop switches fitted on the unit, as outlined in section 2.9.1 of this manual. If any of the emergency stop buttons are pressed, the unit will come to an immediate halt
Refer to the Electrical Control section of this manual for Reset and Re-start operations.
CAUTION: THE EMERGENCY STOP BUTTONS SHOULD ONLY BE USED IN THE CASE OF AN EMERGENCY. THE EMERGENCY STOP PROCEDURE CAUSES STRESS TO THE MACHINE DRIVE COMPONENTS AND MUST NEVER BE USED FOR ROUTINE STOPPING OF THE MACHINE.
6.3 PREPARING TO START
Before starting the sealer at the beginning of a shift, carry-out the following checks:
1. If any components have been removed for cleaning they must be reassembled prior to powering-up the sealer. 2. Switch on the air supply at all Pneumatic Shut-off Valves, as outlined in Section 2.9.6 of this manual. 3. Check turret height setting. This should be set in accordance with the recorded counter reading on the height adjustment shaft. 4. Switch on the main electrical supply, as outlined in Section 2.9.4 of this manual. 5. Check the HMI display for error messages and take corrective action as indicated. Refer to the HMI manual (supplied PLF International) for additional information.
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6.4 SHUTDOWN PROCEDURE
1. Stop the supply of containers to the sealer. 2. Allow machine to seal and discharge all remaining containers. 3. Press the Stop button on the HMI unit to stop the Sealer. 4. Switch off the mains isolator.
The sealer can now be cleaned to local operator’s standards.
6.5 OPERATOR CONTROL STATION
The operator control area is located in the Infeed Tunnel area and contains the HMI touch screen that is used to control all electrical functions of the Sealer. Its operation is outlined in a separate manual, provided by PLF International.
WARNING BEFORE ATTEMPTING TO USE THE MACHINE YOU MUST READ AND FOLLOW ALL THE SAFETY INFORMATION IN SECTION 2. PARTICULAR ATTENTION MUST BE PAID TO WARNINGS AND CAUTIONS. IF THERE ARE ANY WARNINGS OR CAUTIONS WHICH YOU DO NOT UNDERSTAND, CONTACT YOUR SUPERVISOR TO ARRANGE PROPER TRAINING ON THE USE OF THE MACHINE.
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SECTION 7
SIZE CHANGE
33 95150217_01 SECTION 7 SIZE CHANGE
7.1 SEALING HEAD HEIGHT ADJUSTMENT
The Sealing Turret can be height adjusted to allow for future, differing container heights and to adjust the sealing top load applied to the container. Adjustment is made by loosening the central column locknut ‘A’ and then turning the hand wheel 'B' located at the rear of the machine, as per the sketch below.
Turning the hand wheel clockwise will raise the Sealing Turret and turning the hand wheel anti-clockwise will lower the Sealing Turret.
WARNING ADJUSTMENT SHOULD ONLY BE MADE WHILST THE MACHINE IS STATIONARY AND THE LOCKNUT IS LOOSENED. BEFORE RESTARTING THE MACHINE, THE LOCKNUT MUST BE RETIGHTENED
To increase the top load during sealing, lower the Turret height slightly such that the Seal Head Springs compress further during the seal process. To decrease the top load during sealing, raise the Turret height slightly such that the springs are compressed less.
A counter is mounted behind the adjustment hand wheel to record Turret height settings for future reference and repeatable re-setting.
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SECTION 7 SIZE CHANGE
7.2 CONTAINER HANDLING COMPONENTS
7.2.1 Feedscrew Removal
The twin Feedscrew system is mounted within the Infeed Tunnel / Sealer Mainframe and consists of two removable Feedscrews.
Each Feedscrew is removed by releasing a single pull knob (a supplied assistance tool is recommended to aid the movement of the knob). The removal sequence is as follows:-
While holding Feedscrew ‘A’, move pull knob ‘B’ to the right using the Feedscrew Release Tool ‘C’ and then lift the Feedscrew vertically, allowing it to pivot on the infeed end support until it is clear of the right hand support shaft and drive pin. Release the pull knob and then remove the Feedscrew by pulling it to the right at an angle.
WARNING THE FEEDSCREW SECTIONS ARE HEAVY! CARE MUST BE TAKEN TO AVOID TRAPPING FINGERS BETWEEN THE RELEASED FEEDSCREW AND THE CONVEYOR SECTION.
To re-fit each Feedscrew, section, firstly align the infeed end of the Feedscrew with the relevant drive dog ‘D’ at the infeed end, then pull the knob to the right, lower the Feedscrew into position and align with the support shaft and drive pin (you may need to rotate the screw to gain the correct alignment) then release the pull knob.
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SECTION 7 SIZE CHANGE
7.2 CONTAINER HANDLING COMPONENTS (CONTINUED)
7.2.2 Infeed and Exit Starwheels
The Infeed Starwheel ‘D’ and Exit Starwheel ‘E’ are each retained by a quarter-turn lock ‘F’.
Each Starwheel assembly includes a location pin to ensure that the Starwheel can only be positioned in its correct orientation.
7.2.3 Turret Starwheel Segments
The Turret Starwheel is made up of three segments ‘G’, each retained by two quarter- turn locks ‘H’.
7.2.4 Outer Guide
The Outer Guide is made up of three segments ‘I’, each retained by two quarter turn locks ‘J’.
7.2.5 Centre Guide
The 2-part Centre Guide ‘K’ is retained by three quarter-turn locks ‘L’.
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SECTION 8
REGULAR MAINTENANCE
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SECTION 8 REGULAR MAINTENANCE
8.1 SEALER MAINTENANCE
WARNING BEFORE ATTEMPTING ANY MAINTENANCE TASK ON THE SEALER, ENSURE THAT THE MACHINE HAS BEEN STOPPED AND THAT THE ELECTRICAL AND PNEUMATIC SUPPLIES HAVE BEEN ISOLATED AS OUTLINED IN SECTIONS 29.4 AND 2.9.6 OF THIS MANUAL.
8.1.1 Guard Panels
The Sealer is provided with guards and covers for the dual purpose of protection from dirt/dust etc, and for protecting the operator from the moving parts. All fixed panels are secured by a number of hexagon head screws
WARNING MAKE SURE ALL GUARDS AND COVERS ARE IN PLACE BEFORE RUNNING THE SEALER.
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SECTION 8 REGULAR MAINTENANCE
8.1 SEALER MAINTENANCE (Cont...)
8.1.2 Sealer Lubrication Schedule
COMPONENTS LUBRICATION INTERVAL Lower Turret Bearings Interflon Food Grease Monthly METHOD
The Lower Turret Bearing Housing has one Grease Nipple 'A' fitted. Using a suitable Grease Gun, pump an amount of Grease into the Nipple.
Wipe away any excess grease that bleeds from around the seals under the bottle slide plate 'B'.
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SECTION 8 REGULAR MAINTENANCE
8.1 SEALER MAINTENANCE (Cont...)
8.1.2 Sealer Lubrication Schedule (Cont...)
COMPONENTS LUBRICATION INTERVAL Upper Turret Bearing Interflon Food Grease Monthly Housing METHOD
The Upper Turret Bearing Housing has a Grease Nipple 'C' fitted. Using a suitable Grease Gun, pump an amount of Grease into each Nipple.
Wipe away any excess grease that bleeds from around the seals under the wear strip retainer 'D'.
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SECTION 8 REGULAR MAINTENANCE
8.1 SEALER MAINTENANCE (Cont..)
8.1.2 Sealer Lubrication Schedule (Cont..)
COMPONENTS LUBRICATION INTERVAL Height Adjustment Shaft Interflon Food Grease Monthly Bearing Housing METHOD
The Height Adjustment Shaft Bearing Housing has a Grease Nipple 'E' fitted. Using a suitable Grease Gun, pump an amount of Grease into the Nipple.
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SECTION 8 REGULAR MAINTENANCE
8.1 SEALER MAINTENANCE (Cont...)
8.1.2 Sealer Lubrication Schedule (Cont...)
COMPONENTS LUBRICATION INTERVAL Sealer Base Drive train Rocol Foodlube Multipaste Monthly Spray (or similar) METHOD
Remove Sealer Base outer Guard Panels.
Using an Aerosol Spray, apply Grease to the teeth of the gears that make up the Sealer drive train.
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SECTION 8 REGULAR MAINTENANCE
8.1 SEALER MAINTENANCE (Cont...)
8.1.3 Seal Head Ascent Velocity Adjustment
Each cylinder's velocity is set to optimum during initial factory set-up. However, the ascent velocity may be adjusted independently by means of a screw 'F' in the flow control valve 'G' mounted in the upper cylinder port.
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SECTION 8 REGULAR MAINTENANCE
8.1 SEALER MAINTENANCE (Cont...)
8.1.4 Replacing a Seal Head Assembly
1. Ensure that the head to be replaced is over the bottle slide plate. With the power off, as outlined in section 2.9.4 of this manual, the turret can be manually turned to position the head as required. 2. Disconnect the plug at the disconnect point, and the pneumatic pipes from the cylinder fittings 'G' and ‘H’, noting which pipe went to which fitting. 3. Support the head then remove the 2 M12 bolts from position 'I'. 4. Remove the seal head and place on a clean flat surface. 5. Place an empty container in the starwheel below the now vacant seal head position. 6. Fit the new seal head into position, re-installing the 2 M12 bolts and tighten the bolts so that the head is held flat but can move slightly for positional adjustment. DO NOT nip the bolts tight as the head needs to be correctly aligned to the container. 7. Take hold of the head in positions 'J' and then carefully pull the head down vertically so that the mask 'K' engages smoothly over the container neck without the container being misplaced. If the engagement is not clean move the head assembly at the segment plate 'L' and re-try the alignment until smooth engagement is attained. 8. Nip tight the bolts and check the alignment. If smooth engagement is still not achieved, slacken the bolts and repeat step 7. 9. Reconnect the pneumatic pipes to the correct fittings, then reconnect the plug at the disconnect point.
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SECTION 8 REGULAR MAINTENANCE
8.1 SEALER MAINTENANCE (Cont...)
8.1.5 Replacing a Seal Head Cylinder
1. Remove the head as noted in Section 8.1.4 items 1 to 4 2. Remove the alignment rods 'M' and their associated springs, then slacken the glands 'N', and carefully draw the pipes and cable towards the head as far through the gland as possible (the cable plug will prevent the cable from being drawn through the gland). 3. Screw out the piston rod 'P' from the seal head support plate 'L'. 4. Remove the seal head complete from the cylinder nose, taking care to not to lose the shim 'Q'. 5. Note the orientation of the cylinder 'R' on the segment plate 'L’, remove the 4 bolts 'S' then remove the cylinder from the segment plate. 6. Remove the 2 air fittings 'G' and ‘H’ from the air cylinder, re-apply sealing tape to the threads of the fittings and secure to the new air cylinder in their correct orientation.
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SECTION 8 REGULAR MAINTENANCE
8.1 SEALER MAINTENANCE (Cont...)
8.1.5 Replacing a Seal Head Cylinder (Cont...)
7. Fit the new cylinder to the segment plate, ensuring the cylinder is in the same position as before then tighten the air cylinder nose nut. 8. Fit the seal head to the cylinder by screwing the piston rod into the seal head support plate, ensuring that the shim has been re-fitted. 9. Refit the alignment rods, then draw the pipes and cables back through the glands, leaving enough slack to permit the 50mm travel of the cylinder without putting the pipes and cable under tension, and tighten the glands. 10. Refit the seal head assembly to the turret then carry out the alignment routine as outlined in section 8.1.4 steps 7 and 8.
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SECTION 8 REGULAR MAINTENANCE
8.1 SEALER MAINTENANCE (Cont...)
8.1.6 Replacing a Seal Face Rubber
1. Remove the Seal Head as described in section 8.1.4 items 1 to 4. 2. Carefully unscrew the 4 nylon screws (C) that fasten the outer mask (A) to the seal head body (B). 3. Carefully unscrew the 3 nylon screws (F) that fasten the inner mask (E) to the seal head body (B). 4. Remove both the inner and outer mask and then remove the old seal face rubber (D) from the seal head body (B). 5. Fit a new seal head rubber (D) around the inner mask (E), ensuring that the seal face rubber is lying completely flat. 6. Re-fit the inner mask (E) by replacing the nylon screws (F,) ensuring that the seal face rubber (D) remains totally flat when the inner mask is clamped down - take care to not over-tighten the screws into the seal head. 7. Re-fit the outer mask (A) by replacing the nylon screws (C,) ensuring that the seal face rubber (D) remains totally flat when the outer mask is clamped down - take care to not over-tighten the screws into the seal head.
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