Baader IS-033 Guide
IS-033
___________________________________________________________________________
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Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
2 Page 2
Preface
This manual is dedicated to the personnel responsible for the operation, maintenance and
service of a Baader IS-033 Heading Machine.
Carefully read the instructions and safety precautions given in this manual. Do not attempt to
operate maintain or service this machine until you have thoroughly read and understood the
information contained in this manual.
It is the responsibility of the owner to ensure training is given to all personnel involved on the
operation of these machines.
Baader Ísland ehf. Will not assume any liability for damages due to the non-observance of
this manual, inadequately trained personnel, improper handling of the machine nor its
application in fields other than those specified in this manual.
In case of arbitrary modifications by removing or mounting parts or any modification of the
machine without our written approval, our conformity declaration (EC directive) will become
invalid.
Use only Baader genuine spare parts.
It is imperative to comply with the legal safety regulations for food processing machinery which
are in force in your country.
This manual is the intellectual property of Baader Ísland ehf and may not be copied,
reproduced nor made available to third parties without our prior written approval.
Warning To clearly show details of this machine, covers, guards, barriers or doors may
have been removed or shown in an open position. All such safety components must be
replaced prior to the machine being used. Failure to observe this instruction may result in
serious personal injury or death.
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
3 Page 3
Table of Contents
Preface......................................................................................................................................2
Table of Contents.....................................................................................................................3
Pictograms used in this manual.............................................................................................4
Safety instruction.....................................................................................................................6
Safety sensors .........................................................................................................................7
General .....................................................................................................................................8
Technical Data: ........................................................................................................................9
Machine Set-up ......................................................................................................................10
Dimensions.............................................................................................................................10
Power Connection .................................................................................................................11
Water Connection..................................................................................................................13
Initial Start-up Procedure......................................................................................................15
Cleaning..................................................................................................................................16
Main cleaning.........................................................................................................................17
Preservation...........................................................................................................................18
Adjustment of the cycle control proximity switch ..............................................................19
Adjustment of the locking arm stop.....................................................................................21
Adjustment of cycle start position .......................................................................................22
Cam alignment position ........................................................................................................23
Adjustment of the knife-drive support bracket ...................................................................25
Adjustment of the transport fork setting distance..............................................................27
Replacement of the transport fork cam roller .....................................................................28
Adjustment of the Transport Fork........................................................................................29
Adjustment of the in-feed plate ............................................................................................30
Adjustment of the back plate maximum travel stop screw................................................32
Adjustment of the angular position of the back plate. .......................................................33
Adjustment of the back plate minimum travel stop screw.................................................34
Adjustment of back-plate travel position.............................................................................35
Adjustment of the trigger......................................................................................................36
Tension of the knife drive belt ..............................................................................................37
Knifes......................................................................................................................................38
Grease Lubrication................................................................................................................41
Lubricant change of the gear motors...................................................................................42
Country related list of cleaning Agents and Disinfectants.................................................43
Henkel Sales Partners ...........................................................................................................44
Lubrication and Preservative Recommendation.................................................................46
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
4 Page 4
Pictograms used in this manual
Important Note
Caution In case of non compliance, damage of the
machine and or property cannot be ruled out.
Particular attention required:–
Danger of personal injury.
Danger
Unprotected electrical systems.
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
5 Page 5
SAFETY PRECAUTIONS
IMPORTANT FOR THE MACHINE OPERATORS!
Non-specified use, as well as improper operation of the machine can result in serious bodily
injuries and severe material damages. It is essential that operators observe the following
safety instructions.
Read the operating instructions prior to starting up the machine.
Unauthorised personnel must not operate maintain or service the machine.
Wear close fitting work clothing, especially around arms.
Do not wear any finger rings.
Do not reach into running machine.
Do not place loose articles on the machine.
Do not run the machine unattended.
In case of failure of the functional sequence, prior to cleaning, maintenance and
lubrication, switch off the machine. Put the machine switch to 0position and secure it.
Only qualified personnel should maintain or service the machine, strictly observing
these operating instructions.
The safety devices installed by the manufacturer must not be bypassed, modified or
removed!
Spraying in electrical enclosures and controls gears is prohibited; explosion hazard.
Never operate maintain or service this machine if affected by alcohol or other
substances that may impair alertness or judgement.
Use safety protective equipment.
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
6 Page 6
Safety instruction
Prior to starting up the machine:
Ensure all machine covers are fitted.
Verify the proper functioning of all safety devices.
During operation, the machine should stop ...
... when setting the main switch (1) of the heading machine to position 0.
... when pressing the 0-button (2) (red light).
... when actuating the safety lever (3) in front off the in feeding section.
… when opening the guard by the kniwe area
… when removing the head chute
1
2
3
IS-033
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_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
7 Page 7
Safety sensors
Machines built from May 2012 have magnetic safety sensors as standard.
The sensors comprise two parts, (1) a magnet and (2) a
sensor, which need to be aligned for correct working. Please
refer to photograph A.
Failure of the magnetic safety sensors can be the result of:
Opening and closing the guard too quickly;
Opening and closing the guard only a short distance;
Closing the guard with a slamming action;
To rectify this situation the following steps should be taken.
Open the guard fully and close it in a controlled
manner;
Turn off the power supply for 10 seconds and then
restore power;
Machines built after November 2014. Depress the
top most button on the control unit for 3 seconds.
Please refer to the photograph B.
1
2
A
B
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
8 Page 8
General
The machine is designed to remove the head of whitefish with throat cut.
It is recommended to wash the fish prior to beheading.
Note:
Live fish and fish in the state of rigor mortis cannot be processed.
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
9 Page 9
Technical Data:
Fish Species
: Whitefish
Process Condition
: Throat cut
Size range
: 1 to 13 kg
Throughput rate
: Up to 30 fish per minute
Power Consumption
: 2.2 kW
Water supply
- Consumption
- Pressure
- Connection
: approx 10 litre per minute
: 1 to 5 bar (15 to 75 psi)
: 3/8" (hose ID 10mm)
Dimensions
- Length
- Width
- Height
: 1673mm (65.9")
: 930mm (36.6")
: 1777mm (70")
Weight
: 310kg
Operator requirements
: 1 person
Noise measurement (evaluation
according to DIN 45635)
Workplace level (LpAeq)
: 82dB(A) –Wear Ear Protection.
The machine is configured for the above mentioned size range and throughput rate. However
the proportions and the quality of the fish (season, fishing ground, degree of freshness etc.)
have an influence on the figures indicated, these may vary in practice. Live fish and fish in the
state of rigor mortis cannot be processed.
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
10 Page 10
Machine Set-up
The machine shall be readily accessible
from all sides for ease of operation and
maintenance.
Place the machine on the base plates
(fig.1 item 1), using the adjusting
spindles (fig.1 item 2) level and adjust
the working height of the machine.
When complete lock the adjusting
spindles using the lock nut
(fig.1 item 3).
1
2
3
Fig 1
IS-033
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_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
11 Page 11
Dimensions
875
1098
550
1777
600
110
930
1637
350
Machine Applications and Features:
The fish is placed belly to operator head first into the machine. The fish head is held
and the entire fish is transported to the knife section where a high-yield head cut is
performed. The main body of the fish, with collarbone attached, discharges to the front
of the machine. The head is transported via a chute to the rear.
Thanks to its construction, the operator has a clear view of the working area.
Adjustments e.g. for adaptations or service operation, including knife replacement are
easily performed.
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
12 Page 12
Power Connection
The machine is supplied with approximately 5m of
Ölflex 191 5 G 2.5 cable terminating in a type 416P6 plug which is
IP44 splash-proof and conforms to IEC 60 309-2.
To comply with the legal safety regulations, the machine has to be connected to the mains
electrical supply in accordance with the circuit diagram taking into account the regulations of
the local electrical authorities and the rules EN 60204 and VDE 0100.
Seal the cable bushes and screw so they are watertight.
An electrician must read and understand the electrical drawings supplied
with the machine before connecting to the electrical supply. After
connecting the machine the electrician should test correct function of the
electrical equipment and ensure the machine is correctly grounded. It is
important to verify the correct rotation of the electrical motors. Ensure
that all exposed electrical equipment is properly covered. Seal the cable
bushes and tighten to make watertight. The doors of the cabinet must be
closed after the completion of the electrical connection.
Always lock the main electrical switch in the OFF position prior to performing any maintenance
or service work.
Do Not bypass or wire around any safety equipment.
Removal of any cover or guard is prohibited.
Improper operation or insufficient maintenance can result in serious personal injury and severe
material damages.
Employees who are responsible for safe working practices have to ensure that :-
- any maintenance or service work is only completed by qualified personnel.
- operating instructions and information required for procedures completed by operators
to be available at all times. Operators must strictly observe the contents of this
information
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
13 Page 13
Water Connection
The water connection (fig.2 item1) is
configured for 3/8" hose (ID 10mm).
The hose should be led from the top
down to the machine and secured to
the hose tail by means of a hose clip.
Water pressure should be a between
1 to 5 bar (15 to 75 psi)
1
Fig 2
IS-033
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Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
14 Page 14
Warning
Ensure the machine is isolated from the electrical supply before attempting to rotate the
machine by hand. Failure to observe this instruction may result in serious personal injury or
death.
Use a suitable tool to manually rotate the machine (fig.3 item 1)
Start-reset button (fig.3 item 2).
Note:
Pressing the start-reset button for more than 1 second when released the machine will run for
1 complete cycle.
Stop button (fig.3 item 3)
Safety lever Emergency Stop (fig.3 item 4)
1
2
3
Fig 3
4
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
15 Page 15
Initial Start-up Procedure
Prior to starting the machine, remove the preservative from all areas in contact with the
product.
Wash the machine from bottom to top using a low pressure wash (max 30 bar) with drinking
water heated to 60°C.
After cleaning, run the machine briefly; grease to remove any cleaning fluid that may have
penetrated the bearings.
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
16 Page 16
Cleaning
Clean the complete machine at regular intervals (8 operating hours).
When using low-pressure cleaning devices, do not direct the jet into bearings.
Rest periods
Set the main switch unto position 0.
Remove product remainders and wash the machine from all sides with a powerful water jet.
Pre cleaning
Start and clean the machine observing the appropriate safety distance from the moving
machine parts:
with low pressure, max 30 bar.
with 60°C drinking water.
from bottom to top.
Keep the safety distance.
Make sure that clothing, hoses, cleaning devices do not get caught by
the moving components of the machine; danger of serious bodily
injuries and damage to the machine.
Do not run the machine unattended.
After pre cleaning, stop the machine, set the main switch to position 0and secure it.
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
17 Page 17
Main cleaning
The main electrical switch shall be at the 0position and lock it.
Observe the safety instructions at the beginning of this manual.
Wear protective clothing during cleaning and sanitation operations.
Observe the specific national regulations for the cleaning agents and
disinfectants used.
Operation
Cleaning Agent
Device / Method
Remarks
Main Cleaning
2 –5% P3-topax 17 *
Foam with low-
pressure foaming
device
From bottom to top
reaction time 15
minutes
For removing calcareous deposits, use 1 time
per week cleaning foam 2 –5% P3-topax 56
instead of P3-topax 17
From bottom to top
reaction time 15
minutes
Drinking water at
60°C
Rinse with low
pressure, max 30 bar
Carefully from top to
bottom
Check
Visual
Sanitation
1% P3-topax 91
Low-pressure
spraying, max 30 bar
From top to bottom,
reaction time about
10 –15 minutes since
contingent upon germ
spectrum; refer to
product data sheet
Rinsing
Drinking water max
20°C
Low pressure,
max. 30 bar
Rinse again carefully
* To avoid white deposits, P3-topax 17 should not be foamed on hot surfaces.
The cleaning agents P3-topax 17 and P3-topax 56 recommended the avoidance of
painted areas of the machine due to aggressive cleaning properties of the products..
After cleaning run the machine briefly and grease to remove any cleaning fluid that may have
penetrated the bearings.
Correctly dispose of cleaning agents that are ecologically harmful.
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
18 Page 18
Preservation
Prior to the machine not being used for long periods. Protect the machine using
food approved preservatives.
Recommended preservatives:
Preservation spray MBF 370 –ref. no. 51.10.0201.(400 ml can)
Preservation liquid MBF 360 –ref. no. 51.10.0200 (5 l container)
These preservatives meet the requirements according to USDA-H1
Before resuming production, remove the preservative from all areas in contact with the
product:
with low pressure, max 30 bar.
with 60°C drinking water.
from bottom to top.
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
19 Page 19
Back-plate In-feed plate Transport-fork
Trigger Fish-chute Head-chute Knife
IS-033
___________________________________________________________________________
_______________________________________________________________________________________
Baader Ísland ehf, Hafnarbraut 25, Kopavogur, Iceland Tel: +354 520 6900 Fax: +354 520 6911
20 Page 20
Adjustment of the cycle control proximity switch
Prior to working on the machine switch the main electrical switch to the 0
position and lock it. Failure to comply may result in serious personal injury or
death.
It is important to verify that the proximity switch is correctly located in the holder (fig.4 item 2)
prior to adjustment.
Loosen the gland nut (fig.4 item 3).
Push the cable sheath towards the
holder, whilst maintaining pressure
re-tighten the gland nut.
Loosen the 2 hexagon nuts
(fig.4 item 1).
Rotate the machine manually as
described on page 13, so that the
switch-fane is at its closest position to
the proximity switch holder (fig.4 item 2).
Adjust the distance between the switch-
fane and the proximity switch (fig.4 item
2) to 1mm.
Re-tighten the 2 hexagon nuts (fig.4 item 1).
1
2
Fig 4
3
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