IMCE-250 EXTRUSION LINE MACHINE INTERNATIONAL MACHINE CONCEPTS WELCOMES YOU TO YOUR NEW MACHINE Operation Manual: Date 2017
CONTENTS Chapter 1 Machine Description 1.1 Uncrating Instructions 1.2 Installation 1.3 Electrical and Sensor connections 1.4 Chapter 2 Technical Parameters and Description 2.1 Chapter 3 Operating Instruction Starting the machine for the first time 3.0 Computer screens and description 3.1 Mechanical description and adjustments 3.3 Chapter 4 Malfunctions (Faults) and their rectification Table of possible faults 4.1 Chapter 5 Maintenance instructions Chapter 6 Mechanical Drawing 6.1 Electrical Panel Layout 6.2 Sensors Drawing 6.3 Chapter 7
Electrical diagrams 7.1 Chapter 8 Manufacturers manuals 8.1 Servo drivers 8.1.1 Chapter 9 Spare parts list 9.1
Chapter 1 1.1 Machine Description This machine or production line is manufactured from many components and the final operation of the machine is to achieve either a bar shaped extruded product or a ball. For either of these two final products to be realized correct product has to be inserted into the first part of the line. The line is made up of the following essential sub machines. 1. The extrusion system 2. The extrusion nozzle 3. The take off /away conveyor system (no longer in system) 4. The cutter/blade system 5. The take away conveyor 6. The ball forming system 7. The take away conveyor The raw material is to be entered into the extrusion line via the hopper on top of the extrusion unit, care must be taken to ensure that the product does not clog up the extrusion transfer wheels, should this happen, the raw material is either to sticky or to tough and smaller quantities should be thrown into the extrusion to allow for easier extrusion. Should the extrusion line extrusion transfer wheels get clogged up, then the unit will need to be cleaned either by dismantling the unit and cleaning or removing the material and running some hot water through the extrusion system to alleviate the blockage. It must be understood that the extrusion system has two drive systems, The product extrusion transfer wheels and the screw extruder. Both these units can be adjusted for speed individually. The appropriate speed of these two items as well as the relative speed can only be determined when the line is running with appropriate product. This will take time and experience to determine as there is no correct setting. NOTE: Air temperature, relative humidity and fluidity of the product will determine the final extrusion settings.
Extrusion Transfer Wheels Extrusion Screws (Two) Note: See mechanical drawing of the system for removal and cleaning/dismantling Extrusion heads will determine the final shape of the product. If the product is pushed out of the extrusion head and the product is not consistent, i.e. It contains bubbles or space between the product. Change the speed settings of the extruder to alleviate these issues. The final product shape will be determined by the extruder nozzle. Extrusion Nozzle The extruded product will exit the nozzle and take on the same form as the nozzle internal. For bars the nozzle will be 4 sided and for the ball former the nozzle will be round. The final weight of the product will be determined by a combination of features. Bulk density of product Extruded area. Extruded cut length The take off conveyor speeds can be set so as to match the extruded product speed. Too fast and the product will be pulled apart and too slow and the product will be compressed causing a snake effect on the conveyor belt. The rope effect of the extruded product can now be passed under the cutter and the product can be cut accordingly. Correct length of the cut product can be achieved by changing the cutting frequency of the blade. This cut product length will determine the final bar length. For balls the product length must be determined so as to not jam the ball former and the ball weight will be determined from this length. The ball formed rope will be approximately equal in all dimensions prior to the ball former. Should a smaller ball be required, the following parts require changing. Extrusion nozzle Ball former plates- Male and Female
Ball former plates Note: Cut product of the incorrect size will not go through the ball former and will cause a blockage. The final exit conveyor can be set so as to provide the operator with a reasonable packaging experience. v Correct setting up of the machine is essential for correct operation and specific attention should be paid to the following areas. The person who operates this packaging machine must know the contents of this manual in detail. The operator and at least two mechanical and electrical staff will need to be trained on the machine after commissioning to ensure that daily maintenance of the machine. NOTE: All these areas will be covered in a later chapter (Chapter 3) 1.1.1 Machine Safety Guides The following safety guides pertaining to this machine must be observed in order to prevent accidents with this machine: The installation of all safety devices, such as protective doors, must be closed to enable the machine to operate. Note these parts cannot be dismantled. The machine operators must check the machine for any foreign objects that could cause damage to the machine prior to switching on and operation. Once the machine is running, no hands are to be placed or inserted near the sealing area as well as any of the running parts. 1.1.2 Safety with the Operational Parts The power supply must be switched off when the machine is being cleaned or repaired. If the machine is equipped with a hopper, do not insert hands or fingers into the filling device during operation.
Please report any damaged safety equipment on the machine as soon as damage is noted. The entire power source must be cut off during non-production. v Please note: Mechanical and bodily harm will be caused if the following parts are tampered with during production: The area at the cam transmission mechanism. In case of emergency, press the red EMERGENCY STOP button on the machine. The machine will stop running immediately. After troubleshooting, the button can be reset. 1.1.3 The Safety Devices 1.1.3.1 Emergency Shutdown Button In case of emergency, press the red EMERGENCY STOP button on the machine. The machine will stop running immediately. After troubleshooting, the button can be reset. Reset the Emergency Shutdown Button after activation by releasing with a quarter turn. 1.1.3.2 Safety Covers Check The state of the safety protection cover must be inspected before restarting the machine. 1.1.4 Structural Principles Structural Composition This machine is made up the following parts the electronic control system, the frame and stainless steel cover, the hopper, the extruder, the extruded dough conveyor, the cutter and the ball-making mechanism. Electrical Composition The electrical part of the machine consists of a PLC programmed by a computer programmer; a frequency converter runs this system. This is a highly integrated, well-controlled and reliable operation. The application of the touch screen technology allows for a more reliable, convenient and interactive interfacing for the operator. The Photo-electric Sensors, Encoders, proximity switches and various other switches are made up of high quality advanced sensor components, this allows for precise performance of the mechanical and electrical components.
Main Machine Components 1 Hopper 6 Extruder Nozzle 2 Stainless-Steel Machine Casing 7 Shute to Ball-Making Machine 3 Cutter 8 Ball-Making Machine 4 Conveyor Belt 9 Conveyor Belt from Ball-Maker 5 Servo Motor
1.2 Un-crating Instructions The machine is generally transported in wooden crates. During uncrating make sure that no physical damage to the outside of the crate has taken place. Carefully break open the exterior panels to reveal the machine and its working parts. The machine will be covered in a plastic protective cover. This is to be removed. Make sure that no parts have been damaged during transport, or fallen off the machine. The machine will get to you with certain parts dis-assembled. These need to be fitted to the machine to resemble the photos above of the machine. The machine is affixed to the wooden pallet by four metal brackets. Remove these brackets and discard or keep for future use. The doors and covers have been taped closed for safety reasons; these taped parts can now be opened. Surface rust can take place due to the excessive sea air during shipping. This will only be surface rust and a dry cloth should be used to remove this rust residue. The entire machine was shipped with an oil coating on the machine to safeguard the machine from corrosion. This can now be removed with a very light detergent. The non stainless steel parts should be re-oiled to prevent rusting taking place after cleaning. Do not leave the machine wet. The machine is top heavy and as such care should be taken when handling the machine and removing it from its wooden pallet. Handling After unpacking, a forklift can be used to maneuver the machine into position; the length of the fork must be long enough to reach under the width of the machine. See figure below. The center of gravity of the machine is about 1500mm from the right hand side (the electrical box side) frontal view of machine. NOTE: Do not handle the machine on the upper surface of the machine. This area has safety covers that might break. Under these covers are the upper movement systems. These parts are critically aligned and should they be bent out of position the bags may run off and the machine will not function.
1.3 Installation v only a qualified technician should perform the machine installation or a suitably trained person. Note: It is dangerous to work on a moving machine and the machine should be off and isolated before any form of work is performed Machine should be placed in a well- ventilated room free from dust and excessive corrosion type materials There should be at least 1.5 meters space around each side of the machine for convenient operation and maintenance. Power Requirements; three Phase, 380V, 50Hz, five-wire power supply, and to connect to an appropriate earth wire. Machine should be placed on flat ground. After installing machine, check if the machine is level by level instrument, if not, please adjust by the eight legs Check every part of the machine carefully for damage during shipping. Tighten any loose parts, screws and moving parts. All gearboxes should be checked for sufficient oil Check all electrical connections for loose wires. Make a test of the machines electrical power supply and confirm the voltage and earth continuity. All safety connections relative to your own country should be adhered too. TEST Voltage: Phase to Phase 380v AC Voltage: Phase to Neutral 220v AC Phase to Earth - >5000m Ohms Earth continuity <1 Ohm Compressed air supply >6 Bar during running conditions Before operating the machine, please lubricate the following parts: linear bearings and its bearing holes located in the rack system (Cover), cams located on horizontal main shaft. Although the machine has been designed to be virtually oil free. No two metal parts can run without some type of lubrication. The upper moving parts should be lubricated with silicon spray periodically to reduce wear.
1.3.1 Operation Panel Introduction Introduction to the Switches on the Operation Control Box 1 2 3 4 5 6 EXTRUDER SCREW EXTRUDER ROLLER L1 QF KM TYPE AND NAME 7 OF THE MACHINE L 24V TOUCH SCREEN PANEL L N KA6 0V INDICATOR LIGHT SHOWING POWER TO MACHINE N KM UPPER PRESS KA6 MOTOR 0.75 PLC 5 - Cutting Blade 6 - Ball-Rounding Machine 7 - Second Conveyor EMERGENCY STOP BUTTON Control Panel Emergency Stop Emergency stop of the entire machine Control Panel Light - The machine is powered on. To Stop the machine: Use the touch screen Stop Button. 1.3.3 The Motor v Emergency Stop Button This will stop the machine from running immediately, this stop should only be used in an emergency condition. Make sure the rotations of the motors are correct. The motors will have the wiring wrapped around the outside of each motor. These will need to be unwound and all electrics will need to be connected properly, see Chapter..for installation instructions.
1.3.4 Description of the machine The machine is used for the food industry, its function as a whole is for dough extrusion, cutting and rolling into balls, ball size is as per customers request. The machine has electronic and sensor controls. The dough needs to be placed into the hopper and the machine will cut and roll the dough after extrusion. 1.4 Electrical and Sensor Connections Chapter 2 2.1 Technical Parameters and Description Voltage Power Supply Cutting Time per Piece Machine Power Machine Size 380V 50Hz. Total power is 3KW 2-10 Seconds 3KW 4500mm x 1000mm x 1200mm * The actual working environment shall be based on the characteristics of the materials. Speeds can be compromised by material and powder characteristics.
Chapter 3 Operating Instructions Main Parts of the machine The frame is made up of Stainless-Steel and 70 X 50mm square tube. The frame is equipped with adjustable feet as well as wheels for easy moving and positioning. The frame is clad with Stainless steel. The machine is made up of the following parts: The Frame The Stainless Steel Machine Casing
The Extruder The extruder is equipped with a ripple roller, when the dough is placed into the hopper, the ripple roller will rotate and press the dough into the rotating screw which will extrude the dough onto the conveyor in a bar shape. The size of the bar will depend on the size of the nozzle attached. Dough Conveyor The bar of dough will be fed towards the cutter via the conveyor belt. The cutter is controller by the servomotor. The size of the dough cutting can be controlled by via touch screen.
The Blade Ball-making Mechanism The cut dough will be conveyed to the Ball-making machine. The rounded dough will then be dropped onto the conveyor. The Control Panel L N 1 2 3 4 5 6 EXTRUDER SCREW EXTRUDER ROLLER L1 QF KM 24V TYPE AND NAME 7 OF THE MACHINE L TOUCH SCREEN PANEL KA6 0V INDICATOR LIGHT SHOWING POWER TO MACHINE N KM UPPER PRESS KA6 MOTOR 0.75 PLC 5 - Cutting Blade 6 - Ball-Rounding Machine 7 - Second Conveyor EMERGENCY STOP BUTTON
The Motors 3.0 Starting the machine for the first time It is always advisable to rotate the machine at very slow speed using the jog function to ensure that the parts as shown above operate correctly. Testing using the manual functions can be performed before automatic function is processed. Ensure that all the above installation is carried out and tested before starting the machine for the first time. Full knowledge of the touch screen system should be understood before starting the machine. v No mechanical obstruction should be noted and all lubrication should be carried out. v Electrical tests to determine correct voltage and phasing (direction) must be carried out v Pneumatic connection must be made and pressure should be correct. Proceed with caution:
3.4 Computer screens and description IMC Logo Screen Home Screen
Start- up Screen Push Button Auto Allows operator to Auto-start the machine Push Button Stop Allows operator to stop the auto start-up On/Off Screen Switch Button Home Menu swap (System Setup for Home Screen settings Screen Switch Button Parameters Menu swap (System Setup for Parameters Screen settings) Screen Switch Button Manual Menu swap (System Setup for Manual Screen settings Screen Switch Button Password Menu swap (System Setup for Password Screen settings)
Manual Screen Push Button Upper Roller Motor Allows operator to switch Upper Roller Motor On/Off Push Button Extruder Screw Allows operator to switch Extruder Screw Motor On/Off Push Button Cut and Convey Allows operator to switch Cut and Convey Motor On/Off Push Button Convey Before Rounding Allows operator to switch Convey Before Rounding Motor On/Off Push Button Rounding Motor Allows operator to switch Rounding Motor On/Off Push Button Convey After Rounding Allows operator to switch Convey After Rounding Motor On/Off Push Button Auto Allows operator to switch the Auto On/Off Push Button Stop Allows operator to switch the Stop Motor On/Off Screen Switch Button Alarm Menu swap (System Setup for Alarm Screen settings) Screen Switch Button Back Menu swap (System Setup for previous Screen settings)
Parameter Screen Display/Set Button Upper Roller Motor Set Extrusion Roller Motor Frequency Display/Set Button Extruder Screw Set Frequency for the Extruder Screw Display/Set Button Cut and Convey Set Cut and Convey Frequency Display/Set Button Convey Before Rounding Set Convey Before Rounding Frequency Display/Set Button Rounding Motor Set Rounding Motor Frequency Display/Set Button Convey After Rounding Set Convey After Rounding Frequency Display/Set Button Cut Knife Speed Set Cut Knife Speed Frequency Display/Set Button Cut Rotating Time Set Cut rotating time in seconds Display/Set Button Cut Knife Route Set Cut Knife Repetitions Screen Switch Button Back Menu Swap (Allows Operator to return to previous screen) Note: When changing parameters the system will ask you for a password the password is 123456
Alarm Screen Display/Set Button Inverter Alarm Alarm will sound if the Inverter Alarm is faulty Screen Switch Button Back Menu Swap (Allows Operator to return to previous screen)
3.3 Mechanical description and adjustments The Extrusion Drive Motor (2) drives the Extruder Screw (1); which pushes the product in the hopper through the Extruder Rollers and forces the product out through the Extruder Nozzle. The extruded product then is conveyed via the First Conveyor Belt (4); which is controlled by the First Conveyor Motor, to the Cutting Mechanism (5). The Cutting Blade cuts the extruded product into small chunks, the pieces are then conveyed to the Ball Making Machine (6), where each cut piece is rolled inside the Ball-making Machine into a rounded ball and dispensed onto the Second Conveyor Belt (7); which is controlled by the Second Conveyor Motor. The RV Speed Reducer drives the Extrusion Drive Motor and the Screw. The Motor Drives the Speed Reducer and the Speed Reducer Drives the Conveyor Axis via the Gear Wheel Conveyor to the Passive Axis. This then drives the power to the Ripple Roller and Screw Axis The Passive Roller Tension controls the Conveyor Length adjustment; the RV Speed Reducer drives the conveyor
Chapter 4 4.1 Malfunctions (Faults) and their rectification Fault Always check the alarm screen for fault s Rectification See Alarm Screens on the drives for faults and reset Machines will not switch on Machine is on, but the machine will not run Machine is on and main motor is running but extrusion rollers will not turn Product does not feed Check power supply to machine Check main isolator is in a reset position Check emergency stop is not pushed Have you pushed the start push button Main motor should be running, if not main motor could be faulty. Qualified personnel to check motor electrical and mechanical functionality Main motor is driven by electronic speed control system, check drive unit for fault, if in fault disconnect power from machine and wait 5 minutes and then switch on machine again. If problem persists, main drive unit may be damaged. Replace unit Check speed control knob is set to center position 5 during fault finding Check to see if the touch screen systems has been activated and are turned on Product hopper empty
Chapter 5 5.1 Maintenance instructions This machine has very few moving parts and as such requires very little maintenance. Proper daily cleaning of the working surfaces needs to be carried out so that no powder residue remains on the working surfaces. Note: Not all parts of the machine are stainless steel and as such leaving these surfaces wet will result in surface rust. Daily maintenance: A visual inspection of all moving parts is to be done to determine that no parts have been damaged or corroded. Before starting the machine, any dirt or product must be removed The cutting blade needs to be inspected for damage and contamination All bearings and speed reducers need to be checked for oil. Lubricant should be changed after 3 months after start up. Oil will need to be changed every 6 months thereafter. Check that all parts are secure and inline. Monthly maintenance Lubricate all bearings in the machine Check and top up the main gearbox oil Check all electrical connections for damage or loose wiring. Please pay attention to the machine while running if there are any sound you can distinguish as abnormal. Stop and investigate Turn off the power switch when checking and cleaning the machine. Never put your hands between any of the moving parts of the machine while it is running. Pay attention when doing mechanical adjustments as this can severely influence the functioning of the machine. Check all Pneumatic and Vacuum pipes for wear and replace if necessary.
Check all drive belts for wear and replace if necessary Check all cams are tight and in position Check index gearbox coupling chain for slackness and tighten Check all springs for damage and re-tension if necessary Check all rod ends for looseness or wear and replace if necessary
Chapter 6 6.1 Main Mechanical Equipment Drawing (Extruder) 1 Nozzle 8 Liner 2 Nozzle Connector 9 Copper Plate Bearing 3 Extrusion Roller 10 Cover Board 4 Extrusion Axis 11 Screw 5 Hopper 12 Screw Convey Axis 6 Oil Seal Ring 35 x 43 x 10 13 Extrusion Slot 7 Oil Seal Ring 48 x 40 x 10 14 Cover
Main Mechanical internal parts (Gear Box) Drawing 1 Bearing 6 Extrusion Passive Axis 2 Base 7 Extrusion Gearbox 3 Extrusion Convey Axis 8 Straight Box 4 Extrusion Cover 9 RV50-60-0,55KW 5 Extrusion Puff Cover 10 Extrusion Gear
Main Mechanical internal parts (Screw Conveyor) Drawing 1 Rotate Bearing 6004 7 Screw Cover 2 Rotate bearing 6005 8 Screw Cover 3 Screw Main Drive Shaft 9 Screw Cover 4 Screw Passive Axis 10 RV40 5 RV40 Base 11 Gear Wheel 6 Screw Convey
6.2 Electrical Panel Layout 1 Invertor Drives Extrusion Roller Invertor Extrusion Screw Invertor Extruder conveyor Invertor Ball former Invertor Ball former conveyor 2 Plc Interface relays Servo Drive (Blade) 3 4 Power Supply 5 PLC 6 Main Power Contactor 7 Circuit breaker Main Supply
6.3 Sensors Drawing 1 Blade Zero Position Sensor 24v Dc Inductive Sensor
Chapter 7 7.1 Electrical Diagrams QF KM L N JT KA6 FWD FWD FWD FWD FWD KA1 KA2 KA3 KA4 KA5 COM U V W COM U V W COM U V W COM U V W COM U V W KM KA6 PLC CUTTING SOLENOID VALVE 3V UPPER PRESS MOTOR 3V SCREW MOTOR 3V FIRST CONVEYOR MOTOR 3V 3V BALL ROUNDING MOTOR SECOND CONVEYOR MOTOR PROJECT DESCRIPTION PROJECT NUMBER DATE IMCE-250 Extrusion Machine DRAWING NO.1 OF December 2017 DRAWING DESCRIPTION DESIGNER REVISION Electrical Drawing 1 MICHAEL MURPHY P- P+ 24 D- D+24 UVW 3V BLADE SERVO MOTOR Y0 Y1 24V L1
L1 QF KM L 24V N JT KA6 0V HMI 0X FWD FWD FWD FWD FWD KA1 KA2 KA3 KA4 KA5 N COM U V W COM U V W COM U V W COM U V W COM U V W KM KA6 PLC CUTTING SOLENOID VALVE 3V TOUCH SCREEN 3V SCREW MOTOR 3V BLADE - ORIGINAL POSITION FIRST CONVEYOR MOTOR 3V 3V BALL ROUNDING MOTOR SECOND CONVEYOR MOTOR PROJECT DESCRIPTION PROJECT NUMBER DATE IMCE-250 Extrusion Machine DRAWING NO.1 OF December 2017 DRAWING DESCRIPTION DESIGNER REVISION Electrical Drawing 2 MICHAEL MURPHY P- P+ 24 D- D+24 UVW BLADE SERVO MOTOR Y0 Y1 24V L1 PLC Electrical Diagram
L1 QF KM L 24V N JT KA6 HMI PLC XC3-24T-ELJ 0V HMI 0X FWD FWD FWD FWD FWD KA1 KA2 KA3 KA4 KA5 N GENERAL POWER SUPPLY CONTROL POWER SUPPLY KM UPPER PRESS KA6 MOTOR 0.75 PLC CUTTING SOLENOID VALVE COM SCREW MOTOR U V W 0.75 3V TOUCH SCREEN COM U V W FIRST CONVEYOR MOTOR 0.75 3V SCREW MOTOR COM BALL ROUNDING U V W MOTOR 0.75 3V FIRST CONVEYOR MOTOR SECOND COM CONVEYOR U V W MOTOR 0.75 3V BALL ROUNDING MOTOR CUTTING SOLENOID MOTOR 0.75 COM TOUCH U SCREEN V W POWER PROJECT DESCRIPTION PROJECT NUMBER DATE IMCE-250 Extrusion Machine DRAWING NO.1 OF December 2017 DRAWING DESCRIPTION DESIGNER REVISION Terminal Strip Drawing MICHAEL MURPHY P- P+ 24 D- D+24 CUTTER UVW ORIGINAL POSITION BLADE SERVO MOTOR Y0 Y1 24V L1
L1 QF KM L 24V N JT KA6 HMI PLC XC3-24T-ELJ 0V HMI 0X FWD FWD FWD FWD FWD KA1 KA2 KA3 KA4 KA5 N COM U V W COM U V W COM U V W COM U V W COM U V W KM KA6 PLC CUTTING SOLENOID VALVE 3V TOUCH SCREEN 3V SCREW MOTOR 3V FIRST CONVEYOR MOTOR 3V BALL ROUNDING MOTOR PROJECT DESCRIPTION PROJECT NUMBER DATE IMCE-250 Extrusion Machine DRAWING NO.1 OF December 2017 DRAWING DESCRIPTION DESIGNER REVISION Electrical Drawing 2 MICHAEL MURPHY P- P+ 24 D- D+24 UVW BLADE SERVO MOTOR Y0 Y1 24V L1
Chapter 8 Manufactures manuals 8.1.1 Servo Drivers 8.1.2 Invertor Drives EDS-A200 Series Single-phase Induction Motor Specialized Inverter n Features of EDS-A200 l Adapt to single-phase motor l 20%-50% efficiency saving l Pulse/analog input output channels; l 8 segments speed control; l Multiple running frequency/command specified channels; l Can realize copy for parameters by using long-distance keyboard; l Hi-performance isolating OC output, AC or DC load of 220V/0.5A Power range: 0.2kw~3.7kw 220V
Chapter 9 Spare Parts List Description Qty Unit Photo Recommended 1 Oil Seal Bearing 1 Pcs 35 x 43 x 10 2 Oil Seal Ring 1 Pcs 48 x 48 x 10 3 Extrusion Nozzle 1 Pcs 4 Ball-making Mechanism 1 Pcs 5 Conveyor Belt 1 Pcs
7 Blade Holders 1 Pcs 8 Conveyor Bearing 1 Set 9 Blade 1 Pcs 10 Conveyor Chute 1 Pcs 11 Extruder Rollers 1 Pcs
12 Motor 1 Pcs 13 Servo Motor 1 Set 15 Motor Gearbox 5 Pcs 16 Frequency Converter 6 Pcs 17 PLC 1 Pcs
18 Relay and Contactor 1 Pcs 19 Servo Drive 1 Pcs 20 Realys 1 Pcs