DS1200P 6 XP R3 Operation Instructions

Transcription

1 DS1200P 6 XP R3 Operation Instructions

2 C o n t e n t s Contents Page 2 Declaration of Conformity Page 3 Setting up the Machine Page 4-6 Maintenance Procedure Page 6 Service Intervals Page 7 Cleaning Procedures Page 7 Replacing Components Page 8 9 Electrical Box Overview Page 10 Pneumatic Box Overview Page 11 Fault Finding Procedures Page 12 Relay Identification Page 13 DC Power Supplies Page 14 Safety Circuit Page 15 PLC Inputs Page 16 PLC Outputs Page 17 Pneumatic Drawings Page 18 Parts List Page 19 Page 2 of 19

3 We EC Declaration of Conformity In accordance with EN ISO :2004 Scobie & Junor (Estd 1919) Ltd of 1 Singer Road, Kelvin Industrial Estate, East Kilbride, Glasgow, G75 0XS in accordance with the following Directive(s): 2004/108/EC 2006/42/EC hereby declare that: Equipment Model number The Electromagnetic Compatibility Directive The Machinery Directive Automatic Double Press DS1200P 6 XP R3 Serial Number is in conformity with the applicable requirements of the following documents Ref. No. Title Edition/date BS EN ISO BS EN ISO BS EN 1088 Safety of machinery. Basic concepts, general principles for design. Basic terminology, methodology Safety of machinery. Basic concepts, general principles for design. Technical principles and specifications Safety of machinery. Interlocking devices associated with guards. Principles for design and selection BS EN ISO Safety of machinery. Emergency stop. Principles for design 2008 BS EN ISO BS EN REGULATION (EC) No 1935/2004 Safety of machinery. Safety distances to prevent hazard zones being reached by upper and lower limbs 2003+A1: A1: A2: Safety of machinery. Electrical equipment of machines. General requirements 2006+A1:2009 On materials and articles intended to come into contact with food 2004 I hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specifications and is in accordance with the requirements of the Directive(s) Signed by:... Name: Position: Gordon Wicklow Director Done at: East Kilbride On: 12 November 2010 Document ref. No. P 6 XPR 3 The technical documentation for the machinery is available from the manufacturer at the above address. Any modifications to the DS1200P 6 XP, which have not been approved by The Scobie & Junor Group, will invalidate this declaration. Page 3 of 19

4 Congratulations on the purchase of one of the range of SCOTNET Automation equipment. The instructions and advise in this handbook are designed to let you run and maintain the machine as efficiently and smoothly as possible. If you have any questions regarding any aspect of our machinery, please feel free to contact us at Setting Up Your Machine This machine is used in stuffing applications, where pressure is required before the product is pushed through the tube. Two tube styles are available, either standard netting tubes, or casing finger tubes. Although the machines always leave in a clean condition, washing is advised before taking any machine into a food production area. The DS1200P 6 XP can be washed with water (not a high pressure hose). For full cleaning instructions, see the Cleaning Procedures section on Page 6. The machine should be positioned on a level surface. When in place, lock the four braked castors to secure the machine. Alternatively, use the Adjustable feet, for a more permanent position. (if supplied) (A) Connecting the Machine The DS1200P 6 XP is powered by 230-volt AC mains electrical supply and compressed air. Compressed Air Connection: The machine comes with 3-4 metres of braided air hose. This is at the rear of the machine. Connect the compressed air supply to this. The machine should have the air pressure set at the regulator between minimum 8 BAR and 10 BAR maximum. At 80 PSI, the machine uses approximately 70 ft 3 or 2000 litres of compressed air per minute. It is essential that the air supply is clean and dry. Note components that fail due to water damage are not covered by the warranty. Electrical Connection: The machine comes with approximately 3 metres of cable, which can be shortened as required. The machine must be supplied with a single phase supply. (B) Only for Option Pack AWI, Machine with Automatic Water Injection If your machine has AWI, it also needs to be plumbed into a drinking water supply. The machine comes with a length of 10mm hose for you to connect to your supply. The water should be at mains pressure. As an option, if mains water is not available, you can use the external pressurised water bottle instead. Page 4 of 19

5 (C) Fitting the Chambers and Tubes Isolate the machine from both the compressed air and electrical supply. On this machine, the same size of chamber and tube must be used on each side. Before beginning, ensure you have 2 tubes, 2 chamber bottoms, 2 pistons, 4 rings and one chamber top that all match in size. This instruction assumes the machine is empty, i.e. has none of the above fitted. If tubes etc are fitted, follow this procedure in reverse to remove them. Slide the lid fully to one side. Insert a Chamber Top into the open chamber, and hold with your arm, through the hole in the front of the machine. Close the lid over the chamber top, and lift it up into place. Secure with the positioning clamps on sliding lid. NOTE; ensure cut out section of chamber top is pointing towards the rear of machine. Screw the Pistons onto cylinder rod ends and gently nudge nylon rings into position. NOTE; the tapered rings to the front, the non-tapered to the rear. Slide the Chambers onto Press Plates; ensure chamber sliders are properly positioned onto press plates. NOTE; not sitting on press plates, slotted on Fit both Tubes to the machine. Reconnect the electric and compressed air supplies. (D) Running the Machine The machine is fitted with an emergency stop at each side. Once pressed, these require a quarter turn to release them. Make sure both are in the safe, released position before trying to operate the machine. If any of the safety circuit is broken e.g. a tube out, emergency stop pressed, the red LED will be illuminated and the Alan Bradley Touched Screen Panel will inform you what the fault is. Once the machine is safe and ready to run the green LED will be illuminated. Sliding the lid from one chamber to the other operates the machine. Once closed, the lid will lock until the machine has completed its cycle. (E) Adjusting the Automatic Water Injection (Only for machines fitted with AWI) The amount of water injected into the chambers can only be adjusted by your SCOTnet Service engineer. On installation, he will set it up for you. If you need to adjust the water flow, please contact our Service Desk. Page 5 of 19

6 (F) Anti Jam Technology The machine is fitted with a system that detects if it has jammed, normally because a product is too large. If this occurs, the machine will count out 5 seconds. If the machine has jammed while pressing; the cylinders will retract allowing you to open the lid and remove blockage, if the machine has jammed during the stuffing cycle the press will retract first and then the pusher cylinder will return to it s home position. Important Note: Only use netting tubes & chambers designed for use with the DS1200P 6XP stuffing system. If in doubt, contact our Service Desk. Daily Checks: Maintenance Procedures 1. Check the auto drain filter regulator for water collection. Manually drain if required. (This should drain automatically from pipe exiting the enclosure. 2. Check the cylinder fixings are properly secured. 3. Check the operation of the safety circuit. First remove each tube in turn. Each time one is removed, the red LED will be illuminated and an audible dump of air should be heard, the machine should not function, the display panel should indicate which parts of the safety circuit has been broken. Do the same check with each chamber door and e stop button. 4. Lubricate the lid slides with a food safe lubricant. 5. Ensure area under tube sensor switch guard is clean. 6. Ensure product juice is not allowed to stand on cylinder end caps, this can cause corrosion and failure of neck seals. 7. Check the machine functions, by moving the lid from side to side. NB If in doubt about anything, contact our Service Desk. Weekly Checks: 1. Check air pressure setting is between minimum 8 Bar and 10 Bar maximum. 2. Check all nuts and bolts for security, tighten if required. 3. Lubricate press cylinder end caps with food safe grease to repel product juice. 4. Check cylinder press plates are tight, tighten if required. NB If in doubt about anything, contact our Service Desk. Page 6 of 19

7 Service Intervals After installing the machine, we recommend that it is inspected by the installation engineer after: One Week One Month As required after this. We do not recommend leaving any machine for more than 6 months between services. The daily and weekly checks above must be carried out between services. Failure to service the machine in accordance with our recommendations invalidates the warranty. Cleaning Procedures DO NOT CLEAN MACHINE WITH HIGH PRESSURE APPARATUS Before cleaning the machine, remove the tubes, chambers, pistons, nylon rings and chamber top from the machine. For instructions on this see section C on page 4, Fitting the Chambers and Tubes. To ease the cleaning process you can put all of the removable parts in a Dolav of hot water. The machine can now be cleaned with low pressure hoses and a hand brush Do not spray water onto the Allen Bradley Touch Screen Panel. Once cleaned, replace all of the parts. Page 7 of 19

8 Replacing Components on the DS1200P 6 XP Some components on the DS1200P 6 XP require setting up before fitting replacements to the machine. Below, each component in the machine is pictured, with additional comments on how to replace them where required. Tube in Position Inductive Proximity Detectors (IPD) To detect when each tube is in position, 2 inductive proximity detectors are used. On each chamber, there are two Normally Open IPD s. Page 8 of 19

9 Chamber Door sensors The door sensor can be accessed by removing the pusher cylinder from inside the machine. Once removed you can then remove the desired sensor and replace. Chamber Lid Sensors The lid sensors are easily accessible and quick to replace, remember and put food safe lubricant in the connector when changing to repel water. Page 9 of 19

10 Electrical Box Overview Page 10 of 19

11 Pneumatic Box Overview NB: Left and Right definitions are for when machine is viewed from the tube end. Blue Tubing = Supply Silver Tubing = Exhaust Black Tubing = To bottom of cylinder White Tubing = To top of cylinder Page 11 of 19

12 Fault Finding Procedures Machine Fails to Operate Check the air pressure at the regulator. It should be set between minimum 8 Bar and 10 Bar Maximum (see Setting Up the Machine section) Check both tubes are located correctly on the machine. Check both emergency stops are released and in the safe position. (Red LED and Allen Bradley Touch Panel will inform you of any breaks in the emergency stop circuit). Check that the filter regulator is free from water. Check Isolator is in the On position, and the electrical supply is connected. There are some fuses in the Electrical Box inside the machine. Check that these have not blown. (See electrical drawing to identify fuses) Check the relevant Omron relays light up when the various doors etc are opened and closed. (See relay information sheet) For all other faults, contact our Service Desk. Automatic Jam Detection The machine is fitted with Automatic Jam Detection. Therefore if a product is placed in the chamber, and the chamber lid slid over, the cycle is started as normal. If the machine does not complete its cycle in a pre set time, it will detect this, and return the piston to its start position, and unlock the chamber door, so it can be opened, and the jam removed. Lid Will Not Open If lid will not open, the machine has not completed its cycle (jammed). The machine will automatically count to 5 seconds in this case and will then reset automatically. If the bottom chamber is jammed in the up position check the plc to make sure you are not getting a false signal from the bottom cylinder sensor. (See electrical drawings for inputs / outputs) Emergency Stop Pressing: When either emergency stop is pressed, the machine will stop wherever it us in its cycle. When the emergency stop is reset, the machine will reset itself, and retract the piston to the start position. When this is complete, the machine will be ready to run again. If there are any other problems, please contact our SCOTnet Automation Service Desk on: +44 (0) for assistance. Page 12 of 19

13 SCOTNET DS1200P6-P6XP DOOR / LID / TUBE RELAY INFORMATION R1; LEFT HAND SIDE TUBE SENSOR LEFT R2; LEFT HAND SIDE TUBE SENSOR RIGHT R3; LEFT HAND SIDE DOOR SENSOR TOP R4; LEFT HAND SIDE DOOR SENSOR BOTTOM R5; RIGHT HAND SIDE TUBE SENSOR LEFT R6; RIGHT HAND SIDE TUBE SENSOR RIGHT R7; RIGHT HAND SIDE DOOR SENSOR TOP R8; RIGHT HAND SIDE DOOR SENSOR BOTTOM R9; LEFT HAND SIDE LID SENSOR LEFT R10; LEFT HAND SIDE LID SENSOR RIGHT R11; RIGHT HAND SIDE LID SENSOR LEFT R12; RIGHT HAND SIDE LID SENSOR RIGHT PEASE LOOK AT MACHINE FROM FRONT WHEN USING THIS GUIDE. Page 13 of 19

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19 Part Code Description Description 2 DS1200P6XPR3 SAS1679 M12 Single Pole Normally Open Sensor 8 SAST M Straight Lead for S SAS1417 M12 Magnet PTM12 6 SA9688 Quick Exhaust Valve SE-1/2-B 2 SA Compact cylinder, double acting ADVU P-A-R3 4 SA System Control Valve 5/2 CPE18-M1H-5L-1/4 1 SA Cylinder Control Valve 5/3 Center Exhausted CPE18-M1H-5/3E-1/4 5 SA Manifold Basic Block 2 Valve CPE18-PRSG-2 2 SA Manifold End Block CPE-18-PRS-EP 2 SA Manifold Blanking Plate CPE18-PRSB 2 SA Expansion Block CPE18-PRSE-2 2 SA6844 Manifold silencer U-1/2B 10 SA3571 Blanking plug B-1/2 6 SA3569 Blanking plug B-1/4 1 SA Push-in fitting QS-1/ SA Plug socket KNEB LED 11 SA Threaded/Push-in fitting QSL-1/ SA Threaded/Push-in fitting QSLL-1/ SA Threaded/Push-in fitting QSL-1/ SA Push-in L-connector QSL-10 3 SA Threaded/Push-in fitting QS-1/ SA Push-in tee piece QST-10 4 SA Threaded/Push-in fitting QSL-1/ SA Push-in elbow QSL-16 9 SA Threaded/Push-in fitting QS-1/ SA9973 Bulkhead fitting SCM-1/2 9 SA Filter Regulator with Integral Guage MS6-LFR-1/2-D6-ERV-AS-Z 1 SA Mounting Bracket for MS6 Filter Regulator MS6-WR 1 SA Nut For MS6 Filter Regulator MS6-WRS 1 SA DNC Cylinder for P6XP DNC PPV-A-R3 2 SA Plastic tubing 10mm Black PLN-10x1,5-SW 5 SA Plastic tubing 10mm Neutral PLN-10x1,5-NT 5 SA Plastic tubing 16mm PLN-16X2-NT 3 SADN1021 Power Supply, 24V DC 2.1A 1 SAMK5101 Cylinder Proximity switch, 8 SAE11486 Extension cable 2 pin, 3 core, 2m, with 3 pin socket 8 SAIFT203 Normally Open Inductive Proximity Switch 4 SAE10700 Cable with Plug for Inductive Proximity Switch 4 SAXPK XP Kit 1 SASEAL Seal 1 SACHTS Chamber Top & Collagen Location Springs 2 SAXPFEET XP Feet 4 SACASTOR Castors 6 SAHANDLE Guard handles 8 NL61010 Cam Locks 2 SAXPRODG XP Nylon Rod Guide 2 SA800E15YE112 E Stop Sticker 2 SaMISC Miscalanious Parts 1 SAAB1762L40BWA MLX VDC PLC 1 SAAB2711M3A18L1 Pannel View 1 SAAB2711CBLHM05 Cable for Pannel View 1 SAMRR9T Guardmaster Safety Relay 3 SAAB800FPMT44 E Stop Push Button 2 SAAB800FALP Latch for E Stop 2 SAAB800FX10 Normally Open Contact for E-Stop 2 SAAB800FX01 Normally Closed Contact For E-Stop 2 SAAB1492-W3 Terminal Blocks 13 SAAB1492-EB3 End Cap 1 SAAB1492WG4 Earth Terminal 4 SAAB1492EB3Y Earth Terminal End Cap 3 SAAB1492EWD3 2 Pole Terminal Block 15 SAAB1492EBD3 3 Pole Terminal Block End Cap 2 SAAB1492CJ510 Center Jumpers 2 SAAB1492WFB4 Fuse Carrier 8 SA ISOLATOR 1 SAG2RV-SL700 Omron Relay with LED 8 SA Amp Fuse 2 SA Milliamp Fuse 6 CM40007 Food Safe Lubricant 1 SAR23432 Roller Assembly for Sliding Cover 4 Per Machine 4