Semi Auto Multiple Shrink Wrapping Machine

Transcription

1 Semi Auto Multiple Shrink Wrapping Machine

2 Customer: - Canadian Crystaline Water India Limited, 7,B Parivakkam Road, Leevathy Nagar. SeneerKupam Chennai service@canadianclear.com, clear.com Service :

3 EVATS/MSW/SA Page-01 CONTENTS Sl. No. Description Page 01 PREFACE TRANSPORATION SITE REQUIREMENT SAFTY PROCEDURES TECHNICAL DATAS TECHNICAL SPECFICATIONS MACHINE DESCRPTION MACHINE CONSTRUCTION UTLITIES 16

4 10 INSTALLATION ASSEMBLY & PRODUCTION 18 INSTRUCTION 12 PUTTING INTO OPERATION 20 Contents Page-02 Sl. No. Description Page 13 TROUBLE ELEMINATIONS MAIUNTENANCE INSTRUCTIONS ELECTRICAL SYSTEM RECOMMENDED SPARES 28 ***

5 EVATS/MSW/SA Page PREFACE First, we sincerely thank you very much for your selection of our EVATS series Semi Auto Multiple Shrink Wrapping Machine (MSW/SA). With its characteristics of smartness running and energy saving, we believe EVATS/MSW will greatly streamline your production process. We are producing various ranges in Shrink Wrapping Machines. By entrusting Canadian Clear to design, Engineering, Manufacture and supply of Automatic Bottling Machine you have become yet another happy client of the Canadian Clear Industrial group. Canadian Clear equipment is backed with the latest and hi-tech technology from all round the world to produce quality equipment to meet with International Standards. It is a must that the system be maintained and operated as per the details in the operational manual. Shivsu Canada Pure Fillers Pvt. Ltd is one of the members of the Shivsu Group of Companies. Shivsu incorporated the state of art technology in design engineering of the systems being manufactured. In order to that you will better understand to correctly operate and maintain our products. This manual provides you necessary information

6 on the Technical, Installation, Functioning, Maintenance and spares of our Multiple Shrink Wrapping Machine. We request you to read the whole manual prior to the first putting up into operation and to get your operating staff familiarized with the routine repair and maintenance work of the machine. This will help to achieve the efficiency offered by the machine. Preface Page-04 The Machine must be handled carefully during transportation, installation and use. This coupled with proper lubrication and maintenance will enable you to achieve the efficiency. Necessary training will be given to your operators when our technicians carry out the erection and at the time of handing over. Shrink Wrapping Machine overhauling & repair work must be done by well trained your specialties. However, should you need our support and service, please intimate planned service to us in due time. This manual has to be treated as confidential. The information given here cannot be copied, or improperly used for given to a third party without our confirmation. We are constantly working on further developments. Therefore, we reserve the right to change the design and technologies. Please understand that claims cannot be made based on the statements and pictures in this manual. ***

7 EVATS/MSW/SA Page TRANSPORTATION The Semi Auto Multiple Shrink Wrapping Machine, which is supplied by M/s. Shivsu Canada Pure Fillers Pvt. Ltd., is compact design. Some of auxiliaries used dismantled from the machine for transportation purpose. The transport dimensions specified in the machine connection diagram give the outer dimensions of the machine body. Please consider clear passages to prevent any damages to the machine. When moving the machine into the prepared place it is necessary to move the machine to the desired location only on movable rollers. Do not use any other suspension than the suspension bolts provided for this purpose. To avoid any accidents, lift and move only in the prescribed manner. Industrial safety codes and regulations must also to follow.

8 *** EVATS/MSW/SA Page SITE REQUIREMENT A. Site Selection Please choose an environment with low humidity, low air pollution and low temperature variation. Make sure there is sufficient space for installation and maintenance, otherwise there may be bumps or difficulty in work. Keep the environment around the machine clean and avoid direct sunshine and unstable voltage, which may make the product unstable and lead to cell damage. B. Civil Works. 1. Clean finished floor for the machine at the proposed site of erection of the plant. 2. Proper ventilation. C. Electrical Connection. Suitable electrical points should be provided for connecting the machine.

9 *** EVATS/MSW/SA Page SAFETY PROCEDURES A. General Information The Safety Summary describes the general requirement and condition for safe installation, operation and maintenance of the Machine. The operator shall read, understand and observe all the safety measures listed in this Manual. B. Machinery Safety - Before connecting the machine to the main, please make sure that the rated voltage of this machine is in compliance with local power system. - Please strictly follow the relevant national electronic manuals and standards of your country. - Emergency stop button of the machine is located on the control panel. Please make sure this button functions properly or not. - The grounding wire of the machine shall comply with relevant national standards.

10 C. Personnel Safety All potentially dangerous areas inside and around the machine are clearly marked with safety designs. Guarantee the safety installation, operation and maintenance personnel. Please strictly follow the requirements below:-. Do not put your hands into moving parts of the machine during production. Safety Procedures Page-08 Do not climb onto the machine when it is operation. The moving parts of the machine may cause vibration, thus danger of slipping off and falling down exist. Do not place sundries or other tools on surface of the machine, which may fall into the machine and cause failure or danger. When entering the machine for servicing, inspections, and cleaning, makes sure the machine is shut down and pressure in airlines is relieved. Strictly stick to the general directions of the labour safety regulation, when repairs are done on the filling machine (labour safety regulation - ASVO). The maintenance staff must cut off power supply and discharge the air source before entering the machine. Check the power leakage regularly. Disconnect immediately, if there is leakage.

11 The operator shall be familiarized with the safety warning signs and read the manual carefully. Contact our technical department if help is needed. The Figure-1 is defines the Safety signs with their corresponding potential consequence provide. *** EVATS//MSW/SA Page TECHNICAL DATAS A. General Information: - This Multiple Shrink Wrapping Machine consists of wrapping zone and Shrink Tunnel zone. B. Technical Parameters: Model. : EVATS/SA/MSW/ Serial No. : 03. Year of Manufacture. : 04. Type of Design. : Shivsu 05. Type of machine. : Straight Tunnel type. 06. Capacity. : 3 1 Liter Bottles

12 12 Nos. per Pack 07. Feeding & Unloading : By Manual. 08. Film cutting & wrapping : By Pneumatic cylinders. 09. Heating : By Heater Rods 09. Conveyor Movement : By Geared Motor. *** EVATS /MSW/SA Page TECHNICAL SPECFICATIONS 01. System consists : Wrapping & Shrink Tunnel units 02. Thickness of Film : Microns 03. Product to be packed : Any Filled Bottles-Pet up to 2 Liters 04. Feed. : By Manual on Tray 05. Type of Bottles. : Any Shape 06. Film cutting done by : Pumatic Cylinder 07. Wrapping done by : Pumatic Cylinder 08. Type of Movement : Linear 09. No. of Heater rods in Shrink Tunnel : Four at Right, Left & Bottom 10. Temperature required at

13 Shrink Tunnel : 250ºC 11. Length x Width x Height. : 2700 x 1200 x 2000 MM. 12. Electrical data : 3 - Phase 415 volts. 50 HZ Voltage Control 24 V AC, 50 HZ Total Power : 27 HP 14. App. Weight. : 1.0 Ton *** EVATS /MSW/SA Page MACHINE DESCRIPTION Please refer the enclosed drawings along with this:- 1. G.A. of Wrapping and Shrink Tunnel Machine - GA/MSW/SA/01 2. Film Threading Diagram - D/MSW/SA/02 3. G.A. of Sealing Jaw Assembly - GA/MSW/SA/03 4. G.A. of Packing Stages - GA/MSW/SA/04 Wrapping Zone Structure: Structure made by MS square tube and Angles. The L type structure is provided with clamps, sliding arrangements and slots to fix the rollers, Sensors and cylinders. Loading

14 Filled bottles are feed manually for wrapping at front side of the unit. Quantity of bottles per pack will be selected based on the bottle size. Film Carrier: There are two film roll carrier one at the top another at the bottom. The rollers are fitted with the bearings for smooth rolling. The guide rollers are given centralize of the film roll. Machine Description Page-12 Film Unwinding System: The film from the carrier passes through rubber roller. This roller pulls the film from the film roll. There rollers are rotated by the unidirectional sprocket which is rotated by a pneumatic cylinder connected to chain. The Optical sensor controls the feed of film sheet. Sealing Jaw Unit: This unit consists of one fixed bottom jaw and the moving top jaw. When the switches are pushed simultaneously, the pneumatic cylinder moves down the jaw. The sealing blade is made of brass and cutting edge is Teflon coated. The blade gets heated by heater rod. The spring loaded guards are provided to press the film properly while sealing and cutting. The spring action will enable the sealed film to separate properly. The temperature of the jaw is maintained by the controller. The timer is control the movement of the blade.

15 Pusher & Holding Unit: Pusher in front of the machine is operated by pneumatic cylinder, is to load the product for sealing. At rear side holding cylinder is fitted to hold the product at top sealing.. Shrink Tunnel Zone From wrapping unit the product is pushed by means of same Pneumatic cylinder to the shrink tunnel SS Mesh type chain conveyor. The products used seat on the SS Mesh and move slowly inside of the chamber for shrinking. The heat generated by electrically through heater rods. Machine Description Page-13 Require temperature is set in the temperature controller and the auto to cut off if temperature is exceeded. The blower used suck the excess the hot air and help to maintain the temperature. After shrinking that products move towards the unloading zone. In outside of the chamber the products get cooled by means of cooling fan. Variable Frequency drive is provided to control and set the required speed. Structure Structure made by MS squarer tube, Angles and Plates. The Straight type structure is provided with the slots and supports to fix the drive & driven rollers with chain and heating chamber. Hot Air Chamber The chamber is fabricated from CRCA Sheet in box module. The walls are stuffed with glass wool for heat insulation. The finned heaters are fixed at

16 the bottom and the ceramic open type heaters are provided at both side walls. The blower is fixed on the top lid. The design of the chamber is such that the hot air is circulated inside the chamber properly. All the heater rods are connected with Temperature controller. The temperature and the flow of air inside the chamber is controlled & maintained such a way to shrink the film properly. Cooling Zone A high velocity cooling fan with tilting facility is provided at the outlet to cool the product which comes out of the hot air chamber. Final shrinkage is taken place during the cooling process. Machine Description Page-14 Conveyor Assembly The heavy duty SS mesh type chain enables the product to travel inside of the hot air chamber and cooling zone. The conveyor chain runs over the special type sprockets on the drive & idler shafts. The drive shaft is fitted with bearings. The idler shaft is fitted with take up bearing to adjust the tension of chain. Conveyor is connected with heavy duty gearbox. Speed of the conveyor is can be varied by VFD provided in control panel. Control Panels The self contained control panel for Wrapping and Shrink tunnel is provided at left side of the machine. The Panels consists of the controls for Main drive, Blower, Cooling fan, Timer and Temperature controller with emergency switch & VFD. Unloading: - The packs used lift manually at unloading point after cooling.

17 Features 01. SS Mesh type chain conveyor is provided for long life and to withstand the heat. 02. Special type heavy duty rollers are provided to move the mesh without any noise, jerk and vibration. 03. The Rubber rollers are provided to pull the sheet with grip and avoid movement at left & right sides. 04. The Optical sensors are provided near Rubber rollers, to control and get require length of film sheet for wrapping. *** EVATS/MSW/SA Page MACHINE CONSTRUCTION A. Constructions. The Wrapping & Shrink Tunnel units are constructed with MS materials. The Heavy duty Sprockets are in MS and the Chain mesh is in SS. The Rubberized rollers are in MS. The Take up, UCFL & UCFT Bearings are used at all Drive and Driven shafts. Geared motor is connected with mesh. The Machine base is mounted on leg pads for the fine adjustment. B. Material Specifications. The Base Section - 40 x 40 x 6 thick L Angle 32 x 32 x 2.5 T Box Pipe Bottom Tray at wrapping - 2 mm thick SS Heating Chamber at shrink tunnel mm thick CRCA. Shafts - MS Doors & Covers - CRCA

18 C. Bought out items: Geared motor - Bonfiglioli /Orbito Pneumatic Cylinders & Fittings - Janatics Electrical Components - Siemens/Telemecanique Bearings - SKF/NTN Heater Rods - Shivsu Temperature Controller - Selctron Timer - Selctron VFD - Telemecanique. *** EVATS/MSW/SA Page UTILITIES A. Power: Wrapping 230 V, Single Phase, AC Power : 1 HP. Shrink Tunnel. 415V, 3 Phase, AC, 50 Hz. Main drive : 1.0 HP. Heater rods : 24 HP. Blower : 0.5 HP. Cooling Fan : 0.25 HP Total Power : HP.

19 B. Air. : 06 Kg/ cm 2 *** EVATS/MSW/SA Page INSTALLLATION The machine is to be carried by 2T Crane/Fork lifter. Make sure the staffs are sufficiently experienced. Weight of the machine is 1.0 T. But considering the size of the machine, need 2T Capacity to balance the machine during lifting. The machine is to be lifted with the help of heavy-duty belt if it is crane. The machine does not need a special foundation. - Pay attention while lifting machine. - The machine has to position properly finished floor. - The levelness of the machine shall be calibrated with leveling instruments after it is positioned. - Clear the stains on the machine inside after the machine is leveled. - The machines should be grounded. - Check all other related dismantled components are reached at the spot and any damage during Transportation or Unloading. - Connect all dismantled Components if any.

20 - Fix all Doors and Covers. - Check all nuts & bolts for tightness or missing. - Check the Airline size and location. - Check the Power line size and location. - Check whether the power voltage is stable. - Check the control panel box for any loose terminals. - Check whether the emergency switch functions properly. - Check the grounding wire and wire connections. For Trial - Check weather required film roles are available for trial. - Check weather filled bottles are available for trial. *** EVATS/MSW/SA Page ASSEMBLY & PRODUCTION INSTRUCTIONS Aligning Position the wrapping unit first and connect the shrink tunnel unit as per drawing. The machine is to be placed on the floor, leveling to be done. For leveling use Level Indicator and checked at all four corner points. Power Connection Control panel is provided at side of the machine. Customer has to provide the lead main control panel. The cables cross sections have to be selected accordingly to the machine connection diagram and are dependent upon the length of the cable lead to the control panel. The motor is to be checked for proper direction of rotation during the test run at the manufacturing firm. In case of incorrect direction or rotation reverses the lead to the control cabinet.

21 Main drives mesh Chain Conveyor. : Chains to move forward. The installation has to comply with our regulations and should be carried out by an electrician prior to putting the machine into operation, check the electrical safety devices and interlocking. Also ensure that proper earthing has been provided. Wrapping Unit Adjust the height of the wrapping unit, so that the products slide smoothly to the shrink tunnel from wrapping unit. Keep film roll on the top & bottom film carriers properly. Slide the ends of film through drive & idler roller and bring the end to the sealing jaw. Set the temperature at 250 degree C. Wait till the sealing jaw temperature reaches the set temperature. The temperature may vary according to the thickness & quality of film. Assembly & Production Instruction Page-19 Start up of Machine Before start up, above said points should be finished. - Put the main Switch ON in wrapping - - ON the conveyor Main drive at required Speed in Shrink tunnel. - ON the heaters at required Temperature in Shrink tunnel. - - On the Blower Fan in Shrink tunnel. Operations During operation of Machine, operator is required, who must do the following works: - Watch the bottles proper position manual loading on tray - Watch the signal lamps in control panel. - Watch the Bottles falling during pushing to shrink tunnel unit. - Up and Down smooth movement of Cylinders.

22 - Air pressure at all Cylinders. Closure of Work - Stop the feeding of Bottles. - The machine should run with available Bottles. - After unloading of all Packs, Switch OFF the heaters and drive. - Close the air valves. *** EVATS/MSW/SA Page PUTTING INTO OPERATION Machine is ready for operation after taking care of the points mentioned in Chapters 10 & 11. To prevent damage to the individual assemblies when putting the machine into operation, it is necessary to strictly observe the instructions. The trained person should operate the machine. Refer all the drawings along with this. Wrapping Unit 1. After initial settings, take a seal by jointing the films (one from the top and other from the bottom). If sealing is not good adjust the settings accordingly. 2. Load the product on the platform in front of the pusher plate. 3. Press the push button. This will push the product to the sealing position. The film forms a neat wrap over the product.

23 4. Now press the ON buttons at the same time with hands. This will pushes the sealing jaw downwards; the product is sealed and cut off the extra material. 5. If the sealing cutting is not proper, adjust the temperature setting accordingly till get good sealing & cutting. 6. After sealing, load the next product in front of the pushing plate. When this is pushed the sealed product carried into shrink tunnel. Shrink Tunnel Unit 1. Check the tensioning of conveyor chain. 2. After initial settings, put the main switch, blower switch, conveyor switch and heater switch ON. Putting into Operation Page Set the required temperature. According to the thickness and quality of the film the shrinking temperature will be changed. The exact setting temperature can be attained by trial and error only. 4. The product wrapped & sealed in the shrink film should kept on the conveyor. 5. Switch on the cooling fan. 6. Study the product after shrinking, if not shrink properly, reduce the conveyor speed. If there is over shrinking increase the speed of the conveyor. 7. The temperature also can be adjusted to get proper shrinking. 8. Whenever the temperature is reset, the temperature controller will take few minutes to reach that temperature. After reaching the set temperature it will fluctuate up & down and will take few more

24 minutes to settle down. During this period it is not advisable not to take production. 9. According to the ambient or room temperature where the machine is installed the required temperature also will vary. 10.Once the temperature and conveyor is set, start the continuous production. Keep 8 to 10 gap between each pack for proper shrinkage. *** EVATS//MSW/SA Page TROUBLE ELEMINATIONS F - Failure C - Cause S - Solution 1 F - If Pumatic cylinders are not function. C - Check the Air connection & Hose. S - Correct the Air connection, Pressure and replace defective hose. 2 F - If Pumatic cylinders are not functioning properly, after attending the corrections in Point-1. C - Check the compact Solenoid valves. S - Replace or Reset the Solenoid valves. 3 F - Shrinking is not proper.

25 C - Check the temperature & main drive speed. S Set the required temperature to suit site condition and tune require speed in VFD. 4 F - Shrinking is not proper after attending the corrections in Point-3 C - Check Heater rods. S - Replace defective Heater rods. 5 F - Film sheet is not feeding properly. C - Check the Optical sensors & Rod location. S - Replace the defective sensor or reset the location rod. Trouble Eliminations Page-23 6 F - Control supply is on but power contactors are not picking up. C - Check MCB & O/L Relay, Circuit switches & Break Circuit. S - Reset if O/L Relay is operated 7 F - Packs are at hot condition at unloading point. C - Check the Cooling Fan. S - Switch on the Cooling Fan or Rectify/ Replace the Fan if defective. 8 F - Control supply is not available. C - Check control supply & MCB s are all on. Check control contactor is working. S - Press the control supply and check the coil.

26 *** EVATS/MSW/SA Page MAINTENANCE INSTRUCTIONS Work Force - A Person with two to three years experience in service and assembly line should operate this machine. He should be able to ensure correct and strict maintenance of the various systems involved in the machine. - Labor for loading the bottles in feeding zone & unloading the finished products. - One Assistant to check the quality of packing. Safety Device Sensors are attached to the machine to protect the operators and avoid the machine wastage. Check the safety devices for functional reliability weekly. In doing so, lubricate the lift cylinder rods for smooth movements.

27 If a safety device failed, do not start the machine for operation again before the failure has been eliminated. The whole electrical system of the machine has to be checked partly by an electrician. Wrapping - Apply light grease to all the chains. - Regulator may be maintained 6Kg/Cm²pressure. - If there is any film deposit over the sealing blade apply silicon spray when the blade is hot and clean with soft cloth. Don t use any sharp tools or knife to clean the blade, which will damage the Teflon coating of the heater blade. - If the Teflon tape on the sealing rubber pad is damaged, replace it. Note: When the machine is OFF the sealing jaw will slide slowly down and sit over the silicon rubber pad. Maintenance Instructions Page-25 With the heat and weight of the jaw a groove may be formed on the silicon rubber. To prevent this, small plywood place or a felt piece may be kept on the silicon rubber pad so that the jaw will rest over that Shrink Tunnel - Clean the conveyor if there is any polythene residues stuck on it. - Apply silicon grease on the conveyor chain. - Apply grease on the bearings & sprockets shafts. - Regulator may be maintained 6 Kg/Cm² pressure. FRL Connect the pressure line from the compressor to the FRL unit at the filter end. Set the pressure of the compressor point between 8 Kg/Cm² - 10

28 Kg/Cm². Now set the regulator at 6Kg/Cm². Before connecting the air line fill the lubricator with necessary oil. Machine Units Specified operation instructions, which have to be strictly observed, are attached to our documents for the following machine units. Geared motor, VFD and Temperature controllers Lubrication of the Machine All bearing points will be lubricated by manually. For Geared motor - See Manual. Note: When disassembling the bearings, do not abrade with emery the brown lead coat on the pin. The given periods should be maintained to obtain a reliable function and long service life of the machine. *** EVATS/MSW/SA Page ELECTRICAL SYSTEM This machine control panels for Wrapping and Shrink Tunnel is mounted independently at left side adjacent to the machine. The control supply is from 415V AC to 440 V AC 50HZ 3 phase. The machine is provided, which allows the operator for the following functions: Wrapping - Control ON / OFF - Heater ON / OFF

29 - Film Feeder ON / OFF - Pusher ON / OFF - Start & pusher - Emergency Stop Tunnel - Control ON / OFF - Heater ON / OFF - Drive ON / OFF - Blower ON / OFF - Cooling Fan ON / OFF Electrical System Page-27 Details of Control Panel The Control Panel is designed to operate main drive. All main MCB, Conductors, OL Relay fixed in the machine panel. Incoming Power Supply - 3 Phase 415 v AC 50 Hz Control Voltage - 230V AC between R and Neutral Main Drive for Shrink Tunnel: The Main Drive control by manually. VFD control the main drive to set the require speed.

30 Contents Drawings - Control Panel for Wrapping (MSW/SA/EC/W/001). - Control Panel for Shrink Tunnel (MSW/SA/EC/ST/002). *** EVATS/MSW/SA Page RECOMMENDED SPARES (Ref. Drawing: GA/MSW/SA/01) The purpose of this heading to facilitate the ordering of spare parts. To quickly identify the spare parts required, please note following instructions. - Consult the table of contents and find out the number of sub assembly. - Take the sheet showing a sectional view of the particular sub and the assembly associated components.

31 - Consult the associated spare parts lists and the item number, part number and description from the list. Note: 1. We will be grateful for any information on the experience you have gain in the frequency of wear. 2. Please refer this spare parts list along with drawings. Recommended Spares Page-29 Sl. No. Part No. Description.. Qty 01 Blade Rubber Roller Heater Rods Guide Roller -Small Guide Roller -Small 01

32 ***