Kolbe Portiomat PM 150 User manual

OPERATING MANUAL
(GB)
KOLBE - Portiomat
Model PM 150
KOLBE GmbH – Nirotechnik-Maschinenbau
Gewerbestraße 5
D-89275 Elchingen
Telefon [phone] – 0
Telefax + 49 (0) 73 08 / 96 10 – 98
www.kolbe-maschinenbau.com
e-mail [email protected]
Machine No. ........................



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Table of Contens
1. Safety Instructions
2. List of Dangers (residual risks)
3. Technical Data
4. Delivery of the Machine
5. Installation of the Machine
6. Commissioning
7. Cleaning Instructions
8. Guarantee Claims and Deficiencies
9. Maintenance and Servicing
10. Troubleshooting
11. Declaration of Conformity to EEC
1. Safety Instructions
Before commissioning the machine, read the operating
manual and safety instructions carefully and observe
them at all times.
Also ensure that all other users are familiar with the
safety instructions.
•Anybody involved at the user’s plant with the installation,
dismantling, commissioning, operation and maintenance
(servicing, maintenance and repairs) of KOLBE butchery
machines must have read and understood the relevant
operating manual and in particular the safety instructions in
full. We recommend that the user obtains written
confirmation of this
•KOLBE butchery machines are built to the state of the art
and are safe to use. However, if these machines are used
incorrectly of for improper purposes by untrained personnel
they may represent a danger
• KOLBE butchery machines (band saws, mincers and
portioning units) are exclusively designed for processing
meat and fish. Any other usage shall be regarded as
improper. The manufacturer may not be held liable for any
damage resulting from this; this risk shall be borne solely
by the user.
• Proper usage also includes the observance of the
operating, maintenance and servicing instructions issued
by the manufacturer.
• KOLBE butchery machines (band saws, mincers and
portioning units) may only be operated, maintained and
serviced by authorised, trained and instructed personnel.
This personnel must have been given special training in
the possible dangers which may occur.
• Responsibility for the installation, dismantling,
maintenance, commissioning, servicing and operating
must be clearly defined and observed so that no unclear
competence can occur which may involve aspects of
safety.
• Before starting work get to know all the equipment and
control elements on the machine and their function. When
the machine is working you will not have time to do so and
it will then be too late!
• The shut down procedures described in the operating
manual for installation, dismantling, maintenance,
commissioning, servicing and operating work must be
observed at all times.
• No action is to be taken which may reduce the safety level
of the machine.
• The operator must ensure that unauthorised persons are
not allowed to use the machine.
• The operator ist obliged to report and changes to the
machine which may reduce its safety level to his superior
immediately.
• The user must undertake to operate the machine only if it
is in perfect condition.
• By issuing the appropriate instructions and completing the
necessary checks the user must ensure the cleanliness
and clarity of the work station around the machine.
• Unauthorised modifications or changes to the machine are
not allowed and will render the liability of the manufacturer
for any resulting damage null and void.
• Do not reach into the infeed and outfeed area of the
machine or into the tools when they are operating (e.g. belt
saw blade, mincer work, cross knives, and stroke knives).
• Do not complete adjustment work when the machine is
operating. Wait until the machine has reached a standstill.
• Electrical and mechanical safety equipment must not be
removed.
• Before looking for faults or completing maintenance and
repair work, disconnect the electrical supply and have this
work completed by an authorised specialist (if necessary
secure the machine using warning signs).
• Before restarting the machine after maintenance or repair
work, check whether all the guards have been refitted
correctly.
• The general safety and accident prevention regulations as
well as other generally acknowledged safety regulations
are to be observed.

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2. List of Dangers (residual risks)
Please note the following danger areas on the machine!
2.1 Mechanical Dangers
- Risk of injury on the cutting edges of the cross knife. Do
not reach into the rotating cross knife behind the
perforated disc at the outfeed (for example cuts to the
hands or fingers or severance of the fingers). Wear cut-
resistant gloves when removing the knife.
- Risk of squashing or severance of the fingers, hand or
lower arm on the infeed parts of the moving knife (on the
input and the output side). Do not grasp into the
machine when table is put in and cover is closed and
the two parts of moulded sleeve are open.
- Risk of squashing the fingers or hand or foot, when
connecting the machine.
- Risk of bodily injury through impacts or squashing
 when coupling the machine on the meat mincer
 when handling between safety cover, inspection
door (locking) and the machine housing
 when adjusting the reflected light probe by obtaining
access through the slit (housing, table)
 when installing or removing all removable parts by
slipping them out
2.2 Risk due to Instability
Risk of bodily injury through impacts or squashing when the
machine, in particular the mobile version, falls over.
2.3 Electrical Dangers
- contact with the Risk of injury by direct or indirect
electricity supply.
- Risk of injury from defective electrical components.
2.4 Risks from Noise
- Risk of hearing damage by noise emissions of over 85
d(BA).
- An idling noise level of 82 d(BA) pursuant to EN ISO
3746:1995 (constant K = 4dB) has been measured on
the portionmat PM 150.
These values are emission values and do not
necessarily also represent safe workplace values.
Although there is a correlation between emission and
immission noise levels it is not possible to derive from
them with any degree of reliability whether additional
precautionary action, according to EN ISO 11690-1/-2,
is necessary. Factors which influence the immission
levels which currently affect the workplace include the
type of working area, other sources of noise, for
example the number of machines and other
neighbouring procedures and other operating conditions
other than those which are normal.
The permission workplace values may also vary from country
to country. However, this information is intended to enable
the user to make a better assessment of the risk involved.
The operator must take appropriate personal sound
protection measures if the noise levels go above 85 d(BA),
which means that he should wear ear plugs or ear protection
equipment.
2.5 Danger to Health
- Damage to the health of persons due to low
environmental temperatures. Use heat insulating
clothing if the environmental temperature goes below
7 °C.
2.6 Danger to Health due to non-observance of Hygiene
Principles and Cleaning Instructions:
- Danger to the health of persons and unacceptable
changes in the food to be processed, for example
 Ruination of the food (food poisoning)
 Internal acid attacks for the consumer due to
residual quantities of cleaning and disinfecting
materials in the food.
 Internal injuries for the consumer due to the
presence of foreign bodies (e.g. parts of the
machine or solid objects from other sources).

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3. Technical Data
3.1 Manufacturer KOLBE GmbH
Gewerbestraße 5
D-89275 Elchingen
3.2 Designation Portiomat PM 150
stainless steel
3.3 Product number Model PM 150
3.4 Technical Data
Every KOLBE product undergoes a thorough acceptance
test before being despatched where all of the functions
and safety equipment is checked .
4. Delivery of the Machine
The portiomat PM 150 is delivered in carton packaging on a
one-way pallet and shrinked in foil. The accessories, like
steering rollers, patty paper, moulded sleeve resp. free-flow
hand-off slide, hollow screw as well as operating manual list
are placed in a carton separately. Please inform the delivery
company immediately or us if the contents of the delivery do
not match to the delivery note. The transport company
should be contacted immediately if any transport damage is
detected.
5. Installation of the Machine
5.1 Installation Instructions
Remove the portiomat PM 150, after de-assembling the four
fixing screws, out of its packing and install, using the
enclosed fixing screws, the four steering rollers (2) on the
machine feet.
The appliance must be adjusted in height according to the
output height of the meat mincer using the hexagonal screws
and the attached winding handle (48). In the following
please set the portiomat correctly aligned to the meat mincer
so that the minced meat portions can be cut and moved
away from the machine cleanly.
All components which can be installed or removed weigh
less that 7 kg. which means that it is not necessary to
arrange for any transporting device of the same height.
The PM 150 should be stored in a cooled or air-conditioned
room for hygiene reasons.
The machine must only be used in a room which is lit to an
intensity of at least 500 Lux.
5.2 To connect the machine
Compare the motor voltage (see rating plate) with the mains
voltage. The machine must be connected by an authorised
electrician (following any local regulations). Pursuant to EN
60204 the machine is to be connected either using a plug
device or a main switch is to be inserted in the fixed supply
lead.
- Connection cable 3 x 1,5 mm²
(3 phases black + protective conductor yellow/green +
neutral conductor blue )
Main dimensions L x W 615 x 1365 mm
H ~960 - 1160 mm
Chassis dimensions LxWxH 615x660x205 mm
Connection height 750 x 950 mm
(mid of perforated disc)
Portioning cross-section max. ca. 75 x 150 mm
Portioning length 80 - 300 mm
Portioning weight 200-1000 g
Stroke of the knife 80 mm
Measurement conveyor belt WxLxD 200x2435x1 mm
Speed of conveyor belt
Supply voltage, 3 ph 0,40 400 m/s V
Nominal current at 400 V 0,87 A
Motor capacity, IP 54
0,25 kW
Reflected light probe
Cross-section area of the electrical
conductor
Fusing (slow action)
weight net
weight gross
11 – 30
1,5
16
140
160
V
mm²
A
kg
kg

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6.Commissioning
Important:
Before commissioning the machine read this
operating manual carefully. Please also pay
attention to the pictures shown on page 10 to
16.
6.1 General
The Portiomat PM 150 is designed for the preparation of
ready-for-sale portions of minced meat products resting
upon paper mats in suitable flat containers and has its
own integrated conveyor belt for moving the product
away from the machine. It is particularly suitable for use
in the meat industry.
It is used by suppliers and supermarkets for the
processing of larger quantities of individual portions of
minced meat products. The temperature of the processed
meat is about 0 – 4 °C.
6.2 Coupling the unit to the mincer
It is absolutely essential that the mains supply to the
machine be disconnected before coupling or uncoupling
the two units (pull out the cable plug!).
Depending upon the nature of the portion of minced meat
– i.e. whether it is patty-, free-flow- or Cevapcici-form –
the appropriate processing unit on the mincer casing (5)
together with the cutting element are to be checked. In
other words, ensure that the cutting element and the
moulded sleeve (52) or the transfer unit (54) are mounted
both horizontally and parallel with one another and that
the sealing nut (50) or (53) is properly tightened. After
this, using the two operating handles (42 and 46) open
the protection plates (43 and 45) of the front inspection
door (28). Slide up the equipment and couple it to the
moulded sleeve (52) or the free-flow transfer unit (54) as
appropriate. If necessary, match the height levels by
means of the height-adjustment screw or the winding
handle (48).
6.3 Current-operated safety interlocks
The Portiomat PM 150 will only operate if the safety cover
(7), the inspection door (28) and the side-door (25) are
closed. The power supply is turned on and off by a rotary
switch (17). The activating magnets (8 and 27) and the
internally-located sensors of the safety cover (7) together
with the inspection door (28) or the side-door (25) provide
an interlocking safety function so that the current is cut off
if any of them are opened.
6.4 Procedure for changing rolls of paper
- Disconnect the main power supply (pull out the plug!)
- Open both strap clips (29)
- Open the inspection door
- Remove the star grip screw (31) and withdraw the
articulated crank axle (33) from the winding handle
eccentric (32)
- Open the spring lock on conveyor belt (34) and swivel out
the moving knife frame (24) complete with the roller then
between the moulded sleeve (52) or the free-flow transfer
unit (54) and the moving knife frame (24), see page 11.
6.5 Removing the moving knife
- Disconnect the main power supply (pull out the plug!)
- Open both strap clips (29)
- Open the inspection door
- Remove the star grip screw (31) and withdraw the
articulated crank axle (33) from the winding handle
eccentric (32)
- Open the spring lock of conveyor belt (34) and swivel
out the moving knife frame (24) complete with the
moving knife (35) ensuring that in so doing the moving
knife is held in position
- Finally withdraw the moving knife (35) in a downwards
direction
- Remove the moving knife frame (24) including the knife-
guidance frames (40 and 41) from the two hinges in an
upwards direction
- Replacement of the knife takes place in the reverse
order of sequence as described above
6.6 Adjustment of inclination the delivery conveyor belt
- Disconnect the main power supply (pull out the plug!)
- Open the safety cover (7)
- It is possible vary the angle of inclination of the paper roll
shaft (19) between roughly 0 and 10° by loosening the
butterfly-nut (49)
- After this, the angle of the discharge belt (9) is fixed in
position by re-tightening the butterfly nut (49)
6.7 Dismantling the conveyor belt
- Disconnect the main power supply (pull out the plug!)
- Open the safety cover (7)
- A tension-control flap device (15) is located beyond the
deflection roller (16) and this should be lifted upwards to
release the tension in the conveyor belt (14)
- Remove the conveyor belt (14) sideways
- Replacement of the conveyor belt takes place in the
reverse order of sequence as described
6.8 Setting-up the portion length (portion weight)
The portion length (or the portion weight) can be adjusted in
a stepless manner by a movable reflected light probe (11).
Any necessary alteration is effected by using the length scale
and the side-mounted star grip (12). Since the nature of the
portion and the consistency of the minced meat (e.g.
depending on whether it is mixed meat, seasoned meat, etc.)
have an influence upon the weight the relationship between
length and weight is only an approximate one.
The adjustment range varies between about 80 and 300 mm
.

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7. Cleaning Instructions
Important!
Disconnect the main power supply when completing
any cleaning work (remove the plug, turn the main
switch off).
Wear goggles. Wear cut-resistant gloves in the area
of the moving knife.
7.1 Cleaning as detailed on the Cleaning Schedule
7.2 Cleaning Instructions
- Switch off the machine, wait until it reaches a standstill
(remove the plug)
- Remove the paper roll (21) for cleaning
- Remove paper roll (21)
- Open safety cover (7) for cleaning
- De--climb, take off and thoroughly clean conveyor belt
(14)
- Take off moving knife (35) and moving knife frame (24)
together with the knife guidance frames (40 + 41) and
clean thoroughly
- Take off moulded sleeve (52) resp. free-flow transfer unit
(54) from the mincer casing (5) and clean thoroughly
- Thoroughly clean the inner and outer areas
- Refer also to the detailed cleaning instructions
- on page 8.
- High pressure cleaning of the patties on the PM 150 is
not allowed for safety reasons.
- There is the danger of destroying electrical and
mechanical components in the process!
Lifting equipment for lifting and transporting the machine
to the working height (the work table) may be necessary.
All KOLBE machines are suitable for cleaning with surge
and jet water; nevertheless it must be ensured that the
electric switch parts and the sealing collar on the lifting
rod of PM 150 are only exposed to the jet of water for a
short time.
8. Guarantee Claims and Deficiencies
8.1 According to the German law, we offer a guarantee of 24
months on our goods for single shift operation starting
from the date of delivery. This assumes, however, that
the customer complies with the requirements of
maintenance and servicing as shown on page 8. The
first service has to take place within 12 months by an
authorised workshop after date of delivery.
8.2 This guarantee covers the repair or replacement of all
products which become defective during the guarantee
period as a result of proven material or workmanship
deficiencies by ourselves as the factory or authorised
contractual workshops.
8.3 The guarantee does not include any parts which are
subject to natural wear, the consequences of excessive
loads, improper cleaning or treatment and the non-
observance of the operating manual.
8.4 If any work is completed on the goods by the client or
third parties without our consent, we refuse to accept
any liability.
8.5 The products we manufacture comply with the EC-
Machine Directives.

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Cleaning Schedule
KOLBE – Portiomat PM 150
Important! Read and observe the operating manual!
Processes Cleaning products Methods Equipment Instructions
Coarse cleaning,
removal of product
residue, if necessary
after removing the
small parts
manual,
mechanical Spatula, scraper Start immediately after the end of
production
Thorough cleaning,
alkaline
If necessary instead of
alkaline cleaning, acidic
cleaning
2-5 %, for example:
Henkel Hygiene –
•P3-topax 19
•P3-topax 66
Messrs. Goldschmidt –
• Somplex grease
dissolver
For aluminium parts, e.g.
Henkel Hygiene –
• 2-5% P3-topax 12
Messrs. Goldschmidt –
• Somplex F
Foam for manual;
dwell time approx.
15 minutes
Low pressure
foam unit,
brush, tank, hand
spray
Rinse Water Low pressure less Low pressure
than 30 bar unit
temperature 50-
60°C water hose
Check Optical cleanliness
Thorough cleaning, For example: Foam or manual; Low pressure If necessary, instead
acidic Henkel Hygiene - dwell time approx. foam unit, of alkaline cleaning.
•3-6 % P3-topax 56 15 minutes hand spray, Follow manufacturer’s
Messrs. Goldschmidt –
• Somplex acidic foam brush to remove lime deposits instructions; check critical points and
problem areas.
Rinse
Water Low pressure less than 30 bar
temperature 50-60ºC
Low pressure
unit, water hose
Check Optical cleanliness Follow manufacturer’s
instructions; check
critical points and
problem areas.
Disinfect As per product data sheet Spray, foam, Low pressure After completing all
0,5-2 %, for example: dwell time as per foam unit, the cleaning work in
Henkel Hygiene - product data sheet spray gun the room.
•P3-topax 99
•P3-topax 91
Messrs. Goldschmidt -
•TEGO 2000
•TEGO IMC
Final rinse Drinking water Low pressure, Low pressure
less than 30 bar unit, water hose
Dry
Care P3-care oil Spray Spray gun External surfaces
of the machine.
This cleaning schedule only applies for machines which are made predominantly of stainless steel. If other materials are
used, coordination with the relevant cleaning product manufacturer is required. The details given in the cleaning schedule
refer to single-shift operation, for multiple shift operation the cleaning intervals are to be adjusted accordingly.

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Cleaning Instructions
Portioner PM 150 - Machine zones which require special and careful cleaning
Cleaning zones Cleaning products Methods Equipment Instructions
Removable parts:
- Moving knife frame
- Moving knife conveyor belt see cleaning schedule manual,
mechanical brush, paintbrush Remove parts and clean them in a tank or dishwasher.
Machine columns:
- Outer area and inner area
-Moulded sleeve und transfer
unit
- Inspection- and side door
see cleaning schedule manual,
mechanical brush, paintbrush Clean thoroughly with the brush or paintbrush.
Remove parts and clean them
thoroughly
Inspection cover:
- Inspection cover see cleaning schedule manual,
mechanical brush, paintbrush Clean external areas of the safety cover thoroughly with the
brush or paintbrush.
Chassis:
- The outer area and steering
rollers
see cleaning schedule manual,
mechanical brush, paintbrush Clean external and internal surfaces thoroughly with the
brush or paintbrush.
9. Maintenance and Service
Important!
Disconnect the main power supply before
completing any maintenance and servicing work
(remove the plug, turn the main switch off).
- Follow safety instructions for maintenance and servicing
work
- Moving installation for transport of working height
(working table necessary)
- Faults which are caused by inadequate or improper
maintenance may cause high repair costs and long
down times of the machine. Regular maintenance is
therefore essential.
-
- The reliability and the service life of the machine depend
on many factors, including the machine being properly
maintained.
- The following table contains schedules inspection and
maintenance instructions for the normal use of the
machine.
- As a result of the wide variety of operating conditions we
cannot state in advance how often a wear check,
maintenance and servicing work will be required. An
appropriate servicing schedule is to be drawn up on the
basis of your operating conditions.
- Our specialists will be pleased to help you with further
advice.
9.1 Maintenance and Servicing List
Inspection Intervals Inspection Points and Maintenance Instructions
Every day - Check the level of wear on the moving knife (35)
- Check the level of wear on the conveyor belt (14), the tightening strap clips (29) and replace them if
necessary
- Check the function of both magnetic sensors or the actuating magnets (8 + 27)
- Check whether the magnetic sensor interrupts the current flow when the safety cover (7) is open
- Check whether the magnetic sensor interrupts the current flow when the side- resp. inspection door
(25 + 28) is opened
- Check connection to the meat mincer to avoid blocking of portioning
Perform full cleaning according to the cleaning plan
Every month - The moving knife (35) is a wear part and must be re-sharpened carefully at specific intervals depending
on the operating conditions
- Check the electrical power supply line and the plug with an earthing contact and replace if necessary
- Check the tightening strap clip (29) on inspection door and replace it if necessary
- Check the function of the reflection light probe (11)
- Check all removable parts for distortion and align them if necessary
Every year - The inspection cover on the side must be removed in order to perform maintenance work on the
electrics and mechanics
Check bearing of crank drive and replace it if necessary
Check belt drive and replace it if necessary
Check gear motor and make oil-change if necessary

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10. Troubleshooting
Faults Cause Remedy
The portioner cannot be switched on
The moving knife is blocked
The chopped meat portions are piling up
on one another
Conveyor belt is blocked
The moving knife is not cutting properly
Faulty switching is taking place
The upper side of the chopped meat
portions is patchy
- Mains plug not inserted
- Swich on button is not set
- Mains supply failure
- Main fuses tripped
- The reflection light probe is dirty
- The magnetic sensor is defect
- The belt drive is defect
- The reflection light probe, the power
supply unit or the switch contactor is
defect
- The crank drive is defect
- The digital control unit is defect
- Clamping up due to a mishappen
moving knife or knife guide or a lump of
bone
- Belt drive is blocked due to a clambing
moving knife
- The portiomat is not properly flanged to
the meat mincer
- The moulded sleeve resp. free-flow
hand-off slide is dirty
- The moulded halves are bound together
but with a gap between them
- The moving knife is not cutting through
the meat properly
- The moving knife is blocked
- The conveyor belt is blocked
- Power supply is interrupted
- Electric control is defect
- Belt drive defect
- The crank drive is effect
- Moving knife is adjusted
- Faulty impulse of reflection light probe
- The reflection light probe is dirty
- The belt drive is defect
- The electric control is defect
- Moving knife is blunt
- The light/dark system of the reflection
light probe is reacting to external light
sources
- The parallel position of the reflection light
probe relative to the table plate was dis-
turbed
- The moulded sleeve profile is blocked up
with fat
- Insert mains plug
- Switch on button
- Call an electrician
- Replace fuses (call an electrician)
- Thoroughly clean the aperture plate and
reflection light probe
- Call in customer service
- Call in customer service
- Call in customer service
- Call in customer service
- Call in customer service
- Disconnect mains plug immediately and
call in customer service
- Call in customer service
- Set the portiomat correctly aligned to the
meat mincer
- Thoroughly clean the aperture
- Set the patty as steeply as possible
- See below
- See above
- Remove blockade resp.
call in customer service
- Call an electrician
- Call in Customer Service
- Call in Customer Service
- Call in customer service
- Call in customer service
- Disconnect the portiomat and then start
new after cleaning
- Thoroughly clean the aperture
- Call in customer service
- Call in customer service
- Please regrind carefully resp. renew
- Ensure that there is even illumination of
the device
- Adjust the holder for the reflection light
probe
- Thoroughly clean the two halves of the
moulded sleeve