Baader IS-028 Guide

Maintenance, spare parts and user’s handbook
IS-028/028s
Hafnarbraut 25
200 Kopavogur
Iceland
Tel: [phone]
Fax: [phone]
[email protected]
www.baader.is

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
2
PREFACE
The manual presents the machine and its proper usage for users. It contains
important information about its installation as well as safe, reliable and efficient
usage. It is intended for:
- Machine operators who usually operate and clean the machine daily
- Technicians responsible for the installation, preparation for production and
maintenance of the machine.
Read the manual and precaution instructions carefully. Do not operate the machine
before reading the manual and before the manual instructions are understood.
The manual must be always readily available where the machine is used. It must be
supplemented by the operator with additions and current directives of the respective
country concerning accident prevention and emission control.
This manual is part of the machine.
The manual must be included when the machine is purchased!
The manual must neither be copied nor accessible to a third party or misused without
our written consent!
The company Baader Ísland Ltd. is not responsible for any damage due to the failure
to comply with the manual, inadequate training of the personnel, unusual usage of
the machine as well as its usage for a different purpose than the one specified in this
manual!
Observe the current safety and legal procedures concerning machines in food
industry.
It is the responsibility of the machine’s owner that all the personnel operating the
machine receive training in the machine usage.
When dismounting, supplementing machine parts or making changes to the machine
on your own initiative without our consent, our declaration of accordance (EB-
Directive/CE) will expire.
Use only spare parts from BAADER!
Caution! In order to show better the machine’s functionality the protective parts have
been opened and removed. All protective parts must be in place when operating.
Otherwise it can lead to serious damage to health or death.

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
3
CONTENTS
PREFACE ..................................................................................................................................... 2
CONTENTS .................................................................................................................................. 3
WARNING ................................................................................................................................... 5
CAUTION SIGNS .......................................................................................................................... 6
SAFETY MEASURES ..................................................................................................................... 7
SAFETY INSTRUCTIONS............................................................................................................... 8
PROTECTIVE PARTS..................................................................................................................... 9
PROTECTIVE PARTS SENSORS................................................................................................... 12
SAFETY MARKING ON THE MACHINE....................................................................................... 13
GENERAL INFORMATION ON THE MACHINE ........................................................................... 14
DESCRIPTION OF EFFICIENCY ................................................................................................... 14
TECHNICAL INFORMATION IS-028............................................................................................ 15
TECHNICAL INFORMATION IS-028S.......................................................................................... 16
DIMENSIONS DRAWING IS-28 .................................................................................................. 17
WORK AREA IS-28..................................................................................................................... 18
DIMENSIONS DRAWING IS-28S ................................................................................................ 19
WORK AREA IS-28S................................................................................................................... 20
KNIVES ...................................................................................................................................... 21
WORK CONDITIONS.................................................................................................................. 22
ELECTRICAL CONNECTION........................................................................................................ 23
WATER CONNECTION............................................................................................................... 24
COMPRESSED AIR CONNECTION.............................................................................................. 25
TRANSPORTATION.................................................................................................................... 26
Information on transportation ............................................................................................. 26
Preparation for transportation............................................................................................. 26
Transportation by ship.......................................................................................................... 26
Transportation by airplane ................................................................................................... 27

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
4
Moving the machine............................................................................................................. 28
Certified transport equipment ............................................................................................. 28
Moving the machine with a forklift ...................................................................................... 28
Moving the machine with a trolley....................................................................................... 28
INSTALLATION OF THE MACHINE............................................................................................. 29
BEFORE STARTUP ..................................................................................................................... 30
STARTUP ................................................................................................................................... 31
THE MACHINE TAKEN OUT OF SERVICE ................................................................................... 32
THE MACHINE READY FOR STORAGE ....................................................................................... 32
STARTING THE MACHINE ......................................................................................................... 33
FEEDING THE MACHINE ........................................................................................................... 33
UPPER AND LOWER FIN FISHER ............................................................................................... 34
PLATES ...................................................................................................................................... 34
SPIKE PRESS .............................................................................................................................. 35
OTHER CONTROLLERS .............................................................................................................. 35
DE-HEADING............................................................................................................................. 36
OPTIONAL EQUIPMENT............................................................................................................ 36
ROTARY KNIVES INSTALLED...................................................................................................... 37
UPPER ROTARY KNIFE IS-28/28S .............................................................................................. 38
LOWER DE-HEADING KNIFE IS-28............................................................................................. 40
LOWER DE-HEADING KNIFE IS-28S........................................................................................... 41
ADJUSTMENTS OF THE MACHINE ............................................................................................ 43
Gap between knives ............................................................................................................. 43
Adjusting backplates............................................................................................................. 44
Adjusting plates .................................................................................................................... 45
Movement of the knife part ................................................................................................. 46
Adjustment of eye spikes ..................................................................................................... 47
Adjustment of head bar........................................................................................................ 47
CONTROL PANEL....................................................................................................................... 48
Switch box............................................................................................................................. 48
Air board ............................................................................................................................... 50
Water board.......................................................................................................................... 50

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
5
The Main Switch ................................................................................................................... 51
MAINTENANCE ......................................................................................................................... 52
Inspection and maintenance plan ........................................................................................ 53
Lubrication............................................................................................................................ 54
Lubrication areas .................................................................................................................. 55
CLEANING ................................................................................................................................. 56
Cleaning at work breaks and pre-cleaning before the main cleaning.................................. 58
Main cleaning ....................................................................................................................... 59
Detergents and disinfectants (from Henkel) ........................................................................ 61
Lubricants and protection substances.................................................................................. 63
Grease and oils mixed together............................................................................................ 64
Miscibility types grease and oils ........................................................................................... 65
WARNING
In the manual of BAADER machines you can find chapters on particular dangers or
special conditions. They are identified by words of warning and caution signs in
accordance with the Machinery Directive
(2006/42/EB) and Norm IEC 82079-1 as well as Norm ANSI Z-535.2 and Z-535.3.
Words of warning are always structured in the following manner:
WARNING
Danger!
Description of consequences if applicable
--Preventing the danger

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
6
CAUTION SIGNS
Instruction
Caution, Warning, if the instructions
are not observed, it can cause a
personal injury or machine failure
Danger, high risk of serious injury
Risk of high voltage

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
7
SAFETY MEASURES
The machine operators, repair technicians or cleaning personnel must read,
understand and observe the manual when performing all the necessary actions.
Safety instructions
-Misusage and wrong operation of the machine can cause serious health
and physical damage.
-It is forbidden to short-circuit, change or remove safety equipment from the
manufacturer.
-Security marking on the machine must be always noticeable and legible.
Faulty or worn-out safety marking must be immediately replaced.
-Read the manual before operating the machine.
-It is forbidden for untrained personnel to deploy and operate the machine.
-Wear tight body workwear, especially covering the arms.
-Tie long hair together and cover it.
-Do not wear watches, rings, bracelets, etc.
-Do not interfere with the machine while it is running.
-Do to place any objects on the machine.
-Do not step on or use conveyor belts for storage of heavy objects.
-Bacterial infections in cut injuries can cause complications (e.g. blood
poisoning). It is impossible to eliminate these consequences even if the
machines are thoroughly cleaned and disinfected! Therefore observe the
following:
oClean the machine thoroughly and disinfect it before the installation,
the end of operation, maintenance and repair.
oWear protective gloves while working on machine parts or tools with
sharp edges.
oNever run a check on the bit of the cutting edge on the skin.
oSeek medical assistance immediately in case of cut injuries!
-It is forbidden to spray any substance into the electrical switch box and the
switching device; fire and explosion risk!
-Do not let the machine run unattended.
-Turn the machine off, put the main switch in 0-position and lock it:
oin case of disruptions in the processing flow
obefore cleaning
obefore the installation and end of operation
obefore maintenance and repair work
obefore lubrication
obefore leaving the machine area
-Maintenance and repair work may only be performed when the machine is
at rest. Make sure it is impossible to turn the machine on and an
appropriate warning sign is in place.
-To make sure it is impossible to turn the machine on, the main switch must
be padlocked.

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
8
SAFETY INSTRUCTIONS
Before activating the machine:
Check if all protective parts are in place
Check if all the safety equipment works
The running machine must be stopped...
… when the EMERGENCY stop is
pressed (fig. 1, pos. 1)
… when the stop button is activated (fig.
1, pos. 2)
… when the EMERGENCY-bar switch is
activated (fig. 1, pos. 3)
… when a protective part is put up or put
in the open position (fig. 1 and 2, blue
protective parts)
2
1
2
3
1

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
9
PROTECTIVE PARTS
All flip-up protective parts of the machine are kept closed with a pump. No locks need
to be opened manually or with tools.
To open the machine it is enough to grasp the handle and pull it. The pump also
keeps the protective parts in the open position. It is good to hold the cover when
opening and closing.
Protective parts closed
Flip-up protective parts are specified
in fig. 5 and 6 in green. (IS-028s
shown)
5
6

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
10
Protective parts open
Flip-up protective parts are
specified in fig. 7 and 8 in green.
(IS-028s shown)
7
8

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
11
COVER AND SAFETY LIGHTS ON CONTROLLER BOX
On the control box there are 6 lights that indicate which safety sensor is activated if
the safety circuit is not complete.
3
1
2
4
6
5
3
2
1
6
5
4

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
12
PROTECTIVE PARTS SENSORS
There are 6 protective parts
sensors in the machine (fig. 9
and 10 in yellow). Under various
conditions they can be
connected incorrectly
-If a protective part is
opened very little and
closed.
-If a protective part
bounces when being
closed.
-If a protective part is opened and
closed very quickly.
There are two ways of correcting the
connection.
-Open the protective part
in question and close it
again slowly.
-Hold the button on the
white light on the control
panel for 3 sec. and reset
all protective parts
sensors.
Sensors must be set in such a
way so that the longer sides
face each other (fig. 11)!
9
10
11

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
13
SAFETY MARKING ON THE MACHINE
It is forbidden to spray into the machine
-Explosion risk!
-Order number of stickers: 37601110
-Sticker on the switch box (fig. 5, pos. 1)
Warning of dangerous voltage!
-Order number of sticker: 37601104
-Sticker on the switch box (fig. 5, pos. 2)
Warning of stinging injury
Warning of cut injury
Warning of bruise injury
Warning of bruise injury
-Order number of sticker: 37601129
Use suitable protective gloves

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
14
GENERAL INFORMATION ON THE MACHINE
Figure 12
1 - Tray 5 –Production area
2 –Electricity, air and water control 6 –Heads out
3 –Control panel 7 –Headless fish out
4 –Feed-in area
DESCRIPTION OF EFFICIENCY
IS-28 and IS-28s remove heads along with the collar bone of whitefish
Bear in mind that the machine is not designed for living and frozen
fish or fish in rigor mortis.
2
1
4
5
6
7
3
12

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
15
TECHNICAL INFORMATION IS-028
Species of fish
:Whitefish
Condition of fish
:Gutted fish
Size range
:4 –13kg
Output of the machine (1)
:fish per min.
Power requirements of the
machine
:2,5 kW
Water requirements of the
machine
- Usage
- Pressure
- Connection
- Type
:12,5 l/min at 2 bars 20 l/min at 5 bars
:2 to 5 bars
:1/2" Hose nozzle
:Drinking water
Air
Pressure
:4-8 bars
Volume
Dimensions
- Length
- Breadth
- Height
:3150 mm
:1700 mm
:2130 mm
Weight
:850 kg
Operation
:1 person
Noise limits
:82dB(A) –Wear Ear Protection.
1) The machine is made for the above-mentioned size and output ranges.
Nevertheless, due to the influence of the fish ratio and quality (depending on the time
of year, fishing ground, freshness, etc.) on the above-mentioned ranges, they can, in
fact, vary. It is not possible to process fish in rigor mortis or frozen fish.
2) The usage is restricted to clean water! Dirty water causes blockages.
3) Noise measurement (estimated pursuant to DIN EN ISO 11201)

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
16
TECHNICAL INFORMATION IS-028S
Species of fish
:Whitefish
Condition of fish
:Gutted fish
Size range
:1 –8kg
Output of the machine (1)
:fish per min.
Power requirements of the
machine
:2,5 kW
Water requirements of the
machine
- Usage
- Pressure
- Connection
- Type
:12,5 l/min at 2 bars 20 l/min at 5 bars
:2 to 5 bars
:1/2" Hose nozzle
:Drinking water
Air
-Pressure
:4-8 bars
-Volume
Dimensions
- Length
- Breadth
- Height
:2300 mm
:1370 mm
:2104 mm
Weight
:800 kg
Operation
:1 person
Noise limits
:82dB(A) –Wear Ear Protection.
1) The machine is made for the above-mentioned size output ranges. Nevertheless,
due to the influence of the fish ratio and quality (depending on the time of year,
fishing ground, freshness, etc.) on the above-mentioned ranges, they can, in fact,
vary. It is not possible to process fish in rigor mortis or frozen fish.
2) The usage is restricted to clean water! Dirty water causes blockages.
3) Noise measurement (estimated pursuant to DIN EN ISO 11201)

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
17
DIMENSIONS DRAWING IS-28

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
18
WORK AREA IS-28
The machine must be accessible on both sides for maintenance and adjustment.
Space for the operator must be secured next to the tray on the side of the machine
where the knives are and the platform must be on the right side of the machine to
enable easy replacement of knives.

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
19
DIMENSIONS DRAWING IS-28S

IS-28/28s
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: [phone] Fax: [phone]
[email protected] / www.baader.is
20
WORK AREA IS-28S
The machine must be accessible on both sides for maintenance and adjustment.
Space for the operator must be secured next to the tub on the side of the machine
where the knives are and the platform must be on the right side of the machine to
enable easy replacement of knives.