Formax PowerMax 3000 User manual

PROVISUR TECHNOLOGIES • 9150 191st Street, Mokena, IL 60448 • Phone [phone] • Fax [phone] (98)
Europe: Schipholweg 315 • 1171 PL Badhoevedorp • The Netherlands • Phone [phone] • Fax No. [phone]
Web Site: www.Provisur.com
AM2C®BEEHIVE®CASHIN®FORMAX®multitecTM TSTTM WEILER®THE PROVISUR®FAMILY OF PROVEN BRANDS
SLICING SYSTEM
OPERATING MANUAL
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The purpose of this manual is to acquaint the owner of the
PowerMax3000TM Slicer with the basic information necessary to assemble,
operate, disassemble, clean and maintain the machine. The contents of
this book, when used with good judgment, should enable the operator and
mechanic to solve most normally occurring problems.
This manual deals with a typical machine. No attempt has been made to
describe every possible configuration that the machine may take or to
outline every procedure that may ever be performed. Each user may find it
necessary to develop ways of using the PowerMax3000TM Slicer to suit
unique circumstances or product.
The Formax Service, Engineering, and Training Departments are available
to help with any questions about suitability of any procedure.
IMPORTANT!
Read and understand the entire procedure before doing any repair or
setup operation.
CUSTOMER SERVICE - FORMAX, INC.
U.S.A. Main Office
9150 191st Street
Mokena, IL 60448-0330
Phone: [phone]
Fax: [phone]
e-mail: [e-mail]
TRAINING DEPARTMENT-U.S.A.
9150 191st Street
Mokena, IL 60448-0330
Phone: [phone]
Fax: [phone]
e-mail: [email protected]
AFTER HOURS SERVICE-U.S.A.
[phone]
EUROPE Main Office
Schipholweg 315
1171 PL Badhoevedorp
The Netherlands
Phone: [phone]
Fax: [phone]
e-mail: [e-mail]
TRAINING DEPARTMENT-EUROPE
Schipholweg 315
1171 PL Badhoevedorp
The Netherlands
Phone: [phone]
Fax: [phone]
e-mail: [e-mail]
AFTER HOURS SERVICE-EUROPE
+31-20-659.08.00
INTRODUCTION

PowerMax3000TM STANDARD FEATURES AND SPECIFICATIONS
PRODUCTION
•Touchscreen operator interface
•Computer controlled machine operation
•Backclamp Feed System
•1, 2, 3 or 4 loaves sliced together (depending on product size)
•Automatic or Manual loading options
•Variable slicing speed
•1500 RPM Knife speed
•3 second stopping time of Knife.
•Shingle, Stack, Bunch or Bulk slicing
ELECTRICAL AND SAFETY
•6000 lb (2722 Kg)
•7.2 kVA rating; 10.2 kVA with Knife heater
•200, 230, 380, 420, 460, 575 Volts, 50/60 Hz, 3 Phase
•Air Requirements: 6.9 bar, 140 L/M (100 PSI, 5 CFM)
•Lockout/Tagout Device
•24 Volt control system
•NEMA 4 standard Circuit Breaker
•Safety Guards with Interlocks
•“MASTER OFF” push buttons on both sides of machine
•Operating sound level: 80 dB (A Scale)
SANITATION
•“Cleanup Mode” allows the conveyors to run for cleanup
•Removable Infeed Conveyors
•Removable Jump Conveyor
•Removable Scale Grids
•Classifier Conveyor slides out, sections flip up for easy cleaning
•Removable Backclamps and Shear Bars
•Unibody cabinet design protects electrical panel doors from direct spray
•U.S.D.A. animal and plant health inspection service accepted
•Manufactured to C.E. Specifications
ENVIRONMENTAL OPERATING CONDITIONS
•+1°C to +25°C (+34°F to +77°F)
•Installation altitude up to 3000 m (9800 ft) above sea level
•Non condensing relative humidity of 20% to 80%
•The main frame enclosure and electrical cabinets must be bolted closed during cleaning operations
•Moisture condensation, water spray and the formation of ice inside electrical cabinets is not permissible
•This machine is not intended for use in explosive environments

PowerMax3000TM INSTALLATION DIMENSIONS

SECTION 1 SAFETY
Safety Information ...........................1-1
Safety Sign Locations .........................1-2
Safety Interlocks ............................1-4
Safety System Overview ........................1-5
Lockout/Tagout .............................1-6
SECTION 2 THEORY OF OPERATION
Introduction ...............................2-1
Clean-up Position ...........................2-1
Infeed Structure Lift ..........................2-1
Knife Cover ...............................2-1
Move to Ready Position ........................2-2
Loaf Lift Tray ..............................2-3
Safety Laser Scanner .........................2-3
Loaf Tray Lift Cylinders.........................2-4
Load Loaf Saddle Switch ........................2-4
Loaf Gate ................................2-5
Loaf Length Sensors ..........................2-5
Gripper Drives .............................2-6
Lower Infeed Conveyors ........................2-6
Grippers ................................2-7
Upper Infeed Hold Down Assembly ..................2-8
Shear Bar................................2-8
Knife ..................................2-9
Knife Motor ...............................2-9
Knife Retract Actuator .........................2-9
Slicing Conveyor ...........................2-10
Debris Conveyor ...........................2-11
Transfer Conveyor ..........................2-11
Transfer Alignment Actuator .....................2-11
Dynamic Scale Conveyors ......................2-12
Classifier Conveyors .........................2-13
SECTION 3 TOUCHSCREEN CONTROLS
Introduction ...............................3-1
“Home” Screen .............................3-2
“Run” Screen ..............................3-3
“Product Codes” Screen ........................3-4
TABLE OF CONTENTS
I
OPERATING SECTION

SECTION 3 TOUCHSCREEN CONTROLS (con't)
“Production Data” Screen .......................3-5
“Service Screen” ............................3-6
SECTION 4 TOOLING
Tooling Care ..............................4-1
Knife Care ...............................4-1
Shear Bar Care.............................4-2
Gripper Assembly Care ........................4-3
SECTION 5 ASSEMBLY
Classifier Conveyors ..........................5-1
Transfer Conveyor ...........................5-2
Dynamic Scale Conveyors .......................5-4
Debris Conveyor ............................5-6
Gripper Drive ..............................5-8
Grippers ................................5-10
Lower Infeed Conveyors .......................5-11
Shear Bar ...............................5-12
Loaf Lift Tray .............................5-13
Slicing Conveyor ...........................5-14
Knife..................................5-16
Side Doors ..............................5-17
Power“On”..............................5-18
SECTION 6 OPERATION
Introduction ...............................6-1
Assemble the Machine .........................6-1
Power“On”...............................6-2
Login ..................................6-2
Move To “Ready” Position .......................6-3
Select Product Code ..........................6-4
Cycle Start ...............................6-4
Load Product ..............................6-5
Start Feed ...............................6-6
Stopping the Machine .........................6-6
Remove Product ............................6-6
Machine Adjustments .........................6-7
Adjustments Screen..........................6-17
Production Data Screen........................6-35
Weight Data Screen..........................6-36
TABLE OF CONTENTS
II

SECTION 7 PRODUCT CODE PARAMETERS
Introduction ...............................7-1
Selecting a Product Code .......................7-1
Editing a Product Code.........................7-2
Creating a Product Code ........................7-4
Keyboard Buttons ...........................7-5
Copy an Existing Product Code ....................7-6
Rename an Existing Product Code...................7-7
Delete a Product Code .........................7-8
Programming Product Code Parameters................7-9
SECTION 8 DISASSEMBLY AND CLEANUP
Raise Classifier Conveyors.......................8-1
Move to “Clean” Position ........................8-1
Power “Off” ...............................8-2
Remove Side Doors ..........................8-2
Remove the Knife ...........................8-3
Cover TouchScreen ..........................8-4
Disassemble Slicing conveyor .....................8-4
Disassemble Debris Conveyor .....................8-5
Remove Shear Bar ...........................8-7
Remove the Infeed Conveyors .....................8-7
Remove Grippers............................8-9
Remove the Lower Infeed Conveyor Belts ...............8-9
Disassemble the Gripper Drive Assembly ..............8-10
Disassemble the Loaf Lift Tray ....................8-12
Disassemble the Classifier Conveyors ................8-13
Disassemble the Dynamic Scale Conveyors .............8-14
Disassemble the Transfer Conveyor .................8-16
Cleaning Instructions .........................8-20
TABLE OF CONTENTS
III

SECTION M1 LUBRICATION
Introduction ..............................M1-1
Procedures ..............................M1-2
Daily .................................M1-3
Weekly ................................M1-6
Monthly ................................M1-7
Monthly/2000 Hours.........................M1-10
SECTION M2 SERVICE SCREENS
Introduction ..............................M2-1
Monitor I/O ..............................M2-2
Chart Recorder ............................M2-6
Profibus Network ..........................M2-10
Scales ................................M2-11
Fault Log ..............................M2-14
Maintenance ............................M2-14
Machine Data ............................M2-15
Machine Options ..........................M2-15
Machine Tests ...........................M2-16
Programmer Options ........................M2-30
Administrator Options ........................M2-30
Schematics .............................M2-34
Illustrations .............................M2-34
SECTION M3 MOTION CONTROL / SERVO DRIVE SYSTEM
Introduction ..............................M3-1
Computer ...............................M3-1
Profibus Network ...........................M3-2
Modbus Network ...........................M3-2
Motion Control Module ........................M3-3
Active Line Module ..........................M3-4
Servo Drive Modules .........................M3-4
Servo Motor .............................M3-5
Resolver Feedback System .....................M3-5
Feedback Converters ........................M3-6
Servo Motor Cables .........................M3-7
48 VDC Linear Actuators .......................M3-8
48 VDC Rotary Actuators ......................M3-8
Rotary and Linear Actuator Cables..................M3-9
24 VDC Stepper Motors.......................M3-10
U3 Active Line Module: Electrical Overview ............M3-11
TABLE OF CONTENTS
V
MAINTENANCE SECTION

SECTION M3 MOTION CONTROL / SERVO DRIVE SYSTEM (con't.)
Motion Control Modules.......................M3-17
Servo Drive System .........................M3-31
Servo Drive Modules ........................M3-35
Servo Motors ............................M3-46
Resolver Feedback Converter Modules ..............M3-47
Motion Controller Replacement (U11) ...............M3-51
Active Line Module Replacement ..................M3-55
Servo Module Replacement ....................M3-59
Feedback Converter Replacement U0 ...............M3-63
Feedback Converter Replacement U13, 14, 15 ..........M3-65
SECTION M4 ELECTRICAL - ELECTRONIC
Introduction ..............................M4-1
Electrical Precautions ........................M4-1
Electrical/Electronic System Overview ................M4-4
Computer ...............................M4-4
Profibus................................M4-5
Components ............................M4-13
Electrical Overview (3-Phase AC Supply Voltage) .........M4-17
System Overview - A4 Safety Laser Scanner............M4-45
SECTION M5 PNEUMATICS
Introduction ..............................M5-1
Pneumatic Supply ..........................M5-1
Infeed Housing Manifold .......................M5-2
Mainframe Manifold .........................M5-3
Scale Manifold ............................M5-4
Pressure Switch ...........................M5-5
SECTION M6 DYNAMIC SCALE ASSEMBLY
Replace Scale Assembly .......................M6-2
Scale Calibration ...........................M6-5
Transfer Conveyor Repair ......................M6-9
Seal and Bearing Replacement ...................M6-9
TABLE OF CONTENTS
VI

SECTION SHS POWERMAXTM SERRATED KNIFE
HONING SYSTEM
Honing the Knife ..........................SHS-1
Maintenance and Lubrication ...................SHS-10
SECTION NSHS POWERMAXTM NON-SERRATED KNIFE
HONING SYSTEM
Honing the Knife .........................NSHS-1
Maintenance and Lubrication ..................NSHS-10
APPENDIX
International Symbols ......................Appendix
MSDS MATERIAL SAFETY DATA SHEETS
Dow Corning Molykote®G-4500 Synthetic Grease ........MSDS-3
Formax H1 Gear Oil .......................MSDS-11
G.C. Silicone Compound (Dielectric Grease) ..........MSDS-13
G.E. Silicone Rubber Sealant ..................MSDS-17
Loctite #243 Threadlocker....................MSDS-25
Semtol 70-30 Mineral Oil (White Oil) ..............MSDS-29
Synthetic Hydrocarbon Base Grease ..............MSDS-35
SCHEMATICS DRAWINGS
Electrical ...........................D-1-004554
Pneumatic Schematic .....................D-1-004555
TABLE OF CONTENTS
VII

031914 1-1
RECOGNIZE SAFETY INFORMATION
This is the Safety Alert Symbol. When you see this
symbol on your machine or in this manual, be alert to the
potential for personal injury or machine damage.
Follow recommended precautions and safe operating practices.
UNDERSTAND SIGNAL WORDS
DANGER!, WARNING!, and CAUTION! are signal words that are
used to alert the operator to potential hazards. The Safety Alert
Symbol is used with the signal word throughout this manual and on
safety signs.
ADANGER! Immediate hazard which will result in personal
injury or death!
AWARNING! Hazards or unsafe practices which could result in
personal injury or death!
ACAUTION! Hazards or unsafe practices which could result in
minor personal injury or product property damage!
SAFETY
INSTRUCTIONS General precautions and safety information.
IMPORTANT! Significant information pertaining to the subject
being explained!
FOLLOW SAFETY INSTRUCTIONS
•Carefully read all safety messages in this manual and on machine
safety signs.
•Keep all safety signs in good condition and replace any safety signs
that are damaged or missing.
•Keep your slicing machine in proper working condition.
•Do not make any unauthorized modifications to the machine.
•Do not disconnect or alter any safety devices.
•Inspect safety devices for proper function.
•Ensure safety switches are working and that controls are in working
order.
•Practice safe maintenance. Understand service procedures before
doing work. Never lubricate or service a machine while it is running.
Securely support any machine parts that must be raised for service
work.
SAFETY

1-2 031914
SAFETY SIGN LOCATIONS
MASTER OFF
These safety signs are
available in other languages.
Replacements can be
purchased from the following:
FORMAX, INC.-U.S.A.
Customer Service Dept.
9150 191st Street
Mokena IL 60448-0330
Phone: [phone]
FORMAX, INC.-EUROPE
Customer Service Department
Schipholweg 315
1171 PL Badhoevedorp
The Netherlands
Phone: [phone]
(B-26019)
(B-26018)
(B-24636)
(B-24631) (B-24631)

031914 1-3
(B-34324) (B-24631)
SAFETY SIGN LOCATIONS
LOCATED ON BOTH SIDES
OF MACHINE
(B-26018)
These safety signs are
available in other languages.
Replacements can be
purchased from the following:
FORMAX, INC.-U.S.A.
Customer Service Dept.
9150 191st Street
Mokena IL 60448-0330
Phone: [phone]
FORMAX, INC.-EUROPE
Customer Service Department
Schipholweg 315
1171 PL Badhoevedorp
The Netherlands
Phone: [phone]
MACHINE BACKSIDE
MASTER OFF
(B-26019)

1-4 031914
“A4”
#1 SIDE SCANNER
LASER CURTAIN
SB1
#1 SIDE
MASTER OFF
SQ1
#1 SIDE
ACCESS GUARD
SQ17
TOP DECEL
CONVEYOR GUARD
SAFETY INTERLOCK LOCATIONS
SQ8
INFEED STRUCTURE
INTERLOCK
SQ3
#2 SIDE
ACCESS GUARD
SB2
#2 SIDE
MASTER OFF
SQ4
SCALE CABINET
INTERLOCK

031914 1-5
SAFETY SYSTEM OVERVIEW
SAFETY ZONES FUNCTION BRANCH CONTACTOR
Main Guard Function Stops all motions KA1/KA2
Clean Function Allows clean motions only:
Structure
KA3/KA4
Safety Laser Scanner Inhibits Motions:
Product Lift Tray
KA7/KA8
KM2
CONTACTOR
KM3
CONTACTOR
KA1/KA2 KA3/KA4 KA5/KA6

ADANGER!
Follow your company’s
Lockout/Tagout procedures before
opening any guards or performing
electrical/mechanical/pneumatic
repairs.
This equipment contains
hazardous voltages and hazardous
moving mechanical parts. Loss of
life or severe personal injury can
result if instructions contained in
this manual are not followed. Only
qualified personnel should work
on this equipment, and only after
reading and understanding all
safety notices, installation,
operation and maintenance
procedures contained in the
manual for this machine.
Never override any safety device
on this machine!
1-6 031914
PNEUMATIC
LOCKOUT/TAGOUT
MACHINE BACKSIDE
LOCKOUT/TAGOUT DEVICE LOCATIONS
MAIN POWER
HANDLE WITH
LOCKOUT DEVICE