KTM TROXLER TV 2000 User manual

Document:BA-TV2000-2003-07.doc
Screw capping machine TV 2000
KTM-TROXLER
Wine cellar machines – Stainless steel technology
In der Rohrmatt 8
77955 Ettenheim - Münchweier
Tel. [phone]
Fax. [phone]
e-mail : [e-mail]
Internet :www.ktm-troxler.de

Declaration of conformity
Contents
1. For your safety ...................................................................................... 3
Symbols used in these instructions .................................................................... 3
Warning signs on the screw capping machine ................................................... 3
During emergencies ........................................................................................... 3
Safe working environment.................................................................................. 3
Stability of the plant ............................................................................................ 3
Safety devices .................................................................................................... 4
Intended use....................................................................................................... 4
For the environment ........................................................................................... 4
Safe transportation ............................................................................................. 4
2. Overview of screw capping machine.................................................. 5
3. Operator controls on switching unit................................................... 6
4. Adjusting the TV 2000............................................................................ 7
Preparing the capping unit.................................................................................. 7
Sterilising the screw capping machine................................................................ 7
Adjusting the bottle cap feeder to the bottle height............................................. 8
Adjusting the bottle guide to the bottle diameter................................................. 8
Assembling the capping unit............................................................................... 9
Dismantling the screw cap separator prior to transportation............................. 10
5. Technical Data..................................................................................... 11
6. Maintenance and Care........................................................................ 12
After the work has been completed .................................................................. 12
7. Assistance in case of malfunctions .................................................. 13
Troubleshooting instructions............................................................................. 13
Fault table......................................................................................................... 13
8. Accessories ......................................................................................... 14
9. Appendix.............................................................................................. 14
Parameter change for Siemens LOGO!........Fehler! Textmarke nicht definiert.
Circuit diagram for electricians .....................Fehler! Textmarke nicht definiert.
EU declaration of conformity..................................................................... 15

Declaration of conformity
About these operating instructions
This document
• explains how to safely operate and adjust the machine
• indicates any hazards and explain how they can be avoided (safety
instructions)
• includes numerous tips on efficient working and using the machine to its
full potential
• shows what steps should be taken when a malfunction occurs.
Read through these operating instructions before using the machine for the
first time. Pay particular attention to the safety instructions. Store these
operating instructions in a safe location for future use.
We do not accept liability for damages resulting from improper operation.
The KTM-Team
1. For your safety
Symbols used in these instructions
Hazard
Indicates an immediate hazard. Non-observance may result in death or
serious injury.
Caution
Indicates a potentially dangerous situation. Non-observance may result in
minor injury or material damage.
Information/tip
Indicates important information or a tip on usage.
Warning signs on the screw capping machine
Dangerous electrical voltage. Only qualified electricians should work on the
machine and its components.
During emergencies
If an emergency situation arises, switch off the machine as follows>
• set the main circuit breaker to "OFF/0".
• disconnect the compressed air supply.
Safe working environment
Ensure there is adequate lighting when working on the screw capping
machine.
Stability of the plant
Ensure the stability of all plant components (e.g. connection of belt drives,
bottle transfer points...) used in conjunction with the machine. If necessary,
fit additional support feet.
!
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Declaration of conformity
Safety devices
Only work on the screw capping machine when the safety devices are fitted
and functioning correctly.
1. Guard on screw capping machine
Plexiglas guard over capping unit. The control system immediately shuts off
the screw capping machine when the guard is pulled up.
The screw capping machine cannot be switched on if the guard is up.
2. Panels fitted to machine frame
The machine frame panels serve to protect against accidental contact with
sharp-edged metallic parts and moving belt drive components during
operation. Only start up the screw capping machine when the panels are
fixed in position.
Intended use
This screw capping machine is used to seal off bottles with screw caps. The
bottles are fed in using a belt drive system, the caps are automatically picked
up. The screw head presses the cap onto the bottle. The screw head then
knurls the thread into the cap. After the bottle is sealed, it is transported
away by the belt drive.
For the environment
Dispose of the condensation from the pneumatic water separator in an
environmentally-friendly manner.
Safe transportation
The TV 2000 screw capping machine may be transported using a fork-lift
truck or overhead crane.
• Two lifting eyes are provided at the top of the TV 2000 (see main diagram
page 5, position 2). These may be used to attach a lifting rope using a
rope shackle or carabiner. The TV 2000 can then be transported using a
crane or on the lifting fork of a fork-lift truck.
• The TV2000 can be laid on its back (rear doors) if it is being transported
by HGV or trailer.
The screw cap container can be detached from the screw cap channel
during transportation, see chapter 4.

Declaration of conformity
2. Overview of screw capping machine
1
Screw cap container:
Storing and separating screw
caps.
2 Lifting eyes:
Suspending the machine for
transportation by crane.
3 Screw head adjustment:
Adjust screw head to the height
of the bottle.
4 Screw cap feeder adjustment:
Adjust the screw cap feed to
the height of the bottle.
5 Switching unit with controls:
Controlling and switching the
TV2000.
6 Guard:
Protects against rotating screw
head.
7 Bottle belt:
Feeds bottles in/out for
capping.
8 Bottle guide:
Adjust to bottle diameter.
9 Compressed air supply:
Connect compressed air and
adjust pressure.
10Adjustable feet:
Used to set the machine upright
on an uneven floor.

Declaration of conformity
3. Operator controls on switching unit
Information/tip
The plexiglas guard is a safety device with an integrated
EMERGENCY-OFF function.
The capping unit can only be switched on when the guard is closed.
Connecting the screw
capping machine
• Establish the compressed air connection and open the
compressed air feed.
• Plug in the cable and set the main circuit breaker to "ON/I".
Adjusting the screw
capping machine
• Adjust the screw head and cap feed mechanism.
Switch the capping unit
on/off
• Close the guard.
• Press the "screw head" button, the screw head turns.
The green indicator lamp in the "screw head" button is lit. Press
again to switch off the screw head.
Switch the belt drive on/off
• Press the "belt drive" button, the belt starts to move.
The green indicator lamp in the "belt drive" button is lit. Press
again to switch off the belt drive.
Note
• Check the pressure drop during capping.
The pressure at the pressure gauge should not drop by more than 0.1 bar
during capping. If the pressure drop is higher, use pressure lines with an
inner diameter of at least 10 mm or ½“.
• Correctly dispose of any condensation which has collected in the
pneumatic water separator (see maintenance tasks).
• The screw head motor will become hot during continuous operation. This
is the operational temperature of the motor and does not represent a
malfunction.
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1 Main circuit breaker:
Switches the TV2000 on/off
2 "Belt drive" button with indicator lamp:
Switches the belt drive on/off
3 "Screw head“ button with indicator lamp:
Switches the screw head on/off

Declaration of conformity
4. Adjusting the TV 2000
Preparing the capping unit
• Set down the capping machine on flat, level ground.
(engage the wheel brakes, use the support feet to keep the machine
upright if the floor is not level.)
• Connect the mains power cable.
• Connect the compressed air line.
• Adjust the pressure.
Adjust the pressure according to the specified weight exerted by the
screw cap . (e.g. MCA = 180 kg - 200 kg)
Pressure in bar 3 3,5 4 4,5 5
Exerted weight in kg 135 146 178 200 222
Sterilising the screw capping machine
Information/tip
Observe the following in order to guarantee a sterile capping process:
• Clean and sterilise the container before filling it with caps.
• Avoid the ingress of impurities such as foreign bodies, dust and fluids
during capping.
• After capping has been completed, remove any unused caps, clean the
container and cover with a cloth or film to prevent the ingress of dirt.
Suitable sterilisation agents are listed in the Technical Data section.
Sterilise the capping unit
• Switch off the screw capping machine at the main circuit breaker.
• Clean out the bottle cap container using a damp cloth.
• Disinfect the bottle cap container using suitable disinfectant sprays
(manual pump spray/spray can).
• Clean the bottle cap feeder and use a suitable disinfectant spray (manual
pump spray/spray can).
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Declaration of conformity
Adjusting the bottle cap feeder to the bottle height
• Open out the bottle feeder.
• Pull up the guard.
• Insert a bottle in the area of the screw cap feeder.
• Unscrew the hex socket head screw.
• Adjust the height using the knurled screw.
(adjust the feeder channel until there is 1 mm clearance between the
bottle/mouth and the feeder channel. The mouth of the bottle is at half the
height of the screw cap, see diagram).
• Tighten the hex socket head screw to lock the setting.
Adjusting the bottle guide to the bottle diameter
• Place three bottles on the belt, one at the start, one at the end, and one
under the screw head.
• Fit an unscrewed cap onto the middle bottle and interrupt the air supply.
The screw head will drop onto the bottle. Place the bottles at the start and
end of the belt in the centre of the belt.
• Adjust the bottle guides (bottle rail) at the front and rear until each is a
distance of 1 mm to the bottle.
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1
Hexagonal socket head
screw Set height of screw
cap feed
2 Knurled screw Adjust
height of screw cap feed

Declaration of conformity
Assembling the capping unit
Height adjustment of roll-on head
• Connect the machine to the compressed air supply
• Use the socket spanner to loosen the counternut on the hand-wheel
• Adjust the roll-on head upwards by turning the hand-wheel
• Place the spacer bolt on the bottle mouth and centre it under the roll-on
head
•
Turn the hand-wheel to move the roll-on head down and let it rest on the
spacer bolt

Declaration of conformity
Dismantling the screw cap separator prior to transportation
Caution
Possible malfunction at control valve!
Before tipping and transporting the machine, drain the condensation from the
water separator and air reservoir (see chapter 6, Maintenance and Care).
This prevents water from entering the control valve as the machine is tipped.
• Release the screw cap channel at the mouth section (screw).
• Release the screw cap channel at the screw cap separator (snap-fit).
• Unplug the motor for the screw cap separator.
• Lift the screw cap separator out of the suspension.
1
Screw cap separation
2 Motor connection (24V) for
screw cap separation
3 Screw cap channel
4 Mouth section screw cap
guide