Ruhle IR 29 User manual

Lebensmitteltechnik
Translation of the original instructions
- Injector
Type: IR 29
Rühle GmbH, Beim Signauer Schachen 10, D-79865 Grafenhausen
Tel.: [phone], Fax: [phone]
www.original-ruehle.de

Injector IR 29
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Table of Contents
1 Safety Instructions............................................................................. 3
1.1 Safety instructions ................................................................... 3
1.2 Remaining risk of accidents .................................................. 6
1.3 Intended Use............................................................................... 6
2 Installation instructions ................................................................... 7
2.1 Machine transport and setup ............................................... 7
2.2 Workplace description............................................................. 8
2.3 Connecting the machine ......................................................... 8
3 Operating instructions...................................................................... 9
4 Cleaning instructions.......................................................................10
4.1 Safety instructions .................................................................10
4.2 Cleaning agents and disinfectants....................................12
4.3 Cleaning procedure.................................................................12
5 Service: Care, maintenance, repair.............................................13
5.1 Regular care ..............................................................................14
5.2 Regular maintenance.............................................................14
5.3 Repair and spare parts..........................................................15
6 Disposal................................................................................................15
7 Technical documentation ..............................................................16
7.1 Technical data ..........................................................................16
7.2 Electrical circuit diagram ......................................................17
8 EC Declaration of Conformity according to Directive
2006/42/EC........................................................................................18
Status: 05/08/2016
Changes reserved

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1Safety Instructions
!!! Observe the safety instructions during the installation, operation,
cleaning and maintenance of the Rühle Injector!
Hazard potentially causing irreversible injuries if disre-
garded.
Warning, potentially causing serious injuries if disre-
garded.
Note
Work on electrical equipment of the machine may only
be carried out by qualified technicians!
Always disconnect machine from the mains during this
process!
1.1 Safety instructions
!!! A supervisor (responsible person) must be appointed for the ma-
chine!
This person must:
a) Completely read and understand these operating instructions
before transport, commissioning, setup, operation, cleaning,
decommissioning, care / maintenance as well as dismantling /
disposal!
b) Prepare work instructions for the intended and safe
transport, commissioning, setup, operation, cleaning, decom-
missioning, care / maintenance as well as dismantling / dis-
posal!
c) Make sure that the qualified workers have completely read
and understood the respective work instructions according to
section 1.1b!
d) Proper functioning of the protective devices must be checked
at least once a year by a Rühle service technician!

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e) Provide personal protective equipment!
All life cycles phases:
Wear foot protection!
Wear hand protection!
Wear protective clothing!
Cleaning; care / maintenance; dismantling:
Wear eye protection!
Use light breathing mask!
!!! The operator must operate the machine according to the intended
use and strictly observe all points listed in the “Operation” work in-
structions prepared by the supervisor.
!!! Before putting the machine into operation for the first time and on
each working day, the operator must check the functionality of the
following safety devices:
a) Visual check for changes or damages on all machine sides
and accessible machine parts, e.g. the curing needles. The
machine must be shut down in the event of any damages or
changes!
b) Check the safety switches as follows:
Close curing compartment door with “Outlet” reach-protection
as well as the “Inlet” reach-protection.
–Start the machine. –Turn the main switch to “0 – Off”. –If the
machine has not switched off, it must be shut down immedi-
ately!
–Start the machine. –Lift the “Inlet” reach protection by 20
mm. –If the machine does not switched off, it must be shut

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down immediately!
–Start the machine. –Lift the “Outlet” reach protection by 20
mm. –If the machine does not switched off, it must be shut
down immediately!
c) Error messages of the control system must be heeded!
!!! To shut down the machine the main switch must be turned to “0” -
OFF" and the power plug pulled from the outlet! The machine must be
secured against further use!
!!! The supervisor must arrange for the repair of the non-functional
safety device by a Rühle service technician. Until the corresponding
parts have been repaired, the supervisor must ensure that the ma-
chine or parts of the machine are under no circumstances put into op-
eration!
!!! The cleaning personnel must observe the work procedures from the
“Cleaning” work instructions prepared by the supervisor.
!!! The maintenance personnel may only carry out work specified as
“Regular care”, unless any other authorisation has been issued in
writing by the manufacturer of the machine. The maintenance per-
sonnel must observe the work procedures from the “Maintenance”
work instructions prepared by the supervisor.
The power plug must be disconnected for maintenance work!
!!! The machine may not be modified.
!!! Only Rühle spare parts and accessories may be used.
!!! The operating instructions as well as all other technical documents
included must be supplied completely when reselling the machine.

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1.2 Remaining risk of accidents
!!! All life cycles phases
Error messages of the operating system must be heeded!
Non-compliance is strictly prohibited!
There is a risk of injury when touching or handling curing
needles or softer blades!
The safety notes of the manufacturers must be observed
when handling curing, cleaning or disinfecting agents!
!!! Stability
The machine is top-heavy; this represents an increased
risk of tipping over when moving it!
Clear all obstacles before moving the machines!
The castors must always be locked with the locking de-
vices except when moving the machine!
!!! Maintenance
The machine must be disconnected from the mains when
performing maintenance work!
The protective covers (control box) may be removed only
while performing maintenance!
The machine must not be operated if the pump has no fil-
ter basket!
1.3 Intended Use
The Injector may only be used for the injection of pickle into fish and
meat products. The max. room temperature may be 12 °C for reasons
of food hygiene!
This machine may not be operated by persons under the age of 18!
Claims of any type because of damages due to non-in-
tended use are ruled out!

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Misuse:
Any use other than the one listed above is strictly prohibited
and is considered misuse!
Operating the machine in explosion hazard areas is prohib-
ited!
Handling / processing products and materials not belonging
to food products is prohibited!
The loading ramp may only be loaded with max. 30 kg!
2Installation instructions
Installation and commissioning of the Injector may only be carried out
in the presence of a Rühle service technician or by persons author-
ised by Rühle.
Rühle GmbH Lebensmitteltechnik shall not be liable for any damage
resulting from non-compliance with these operating instructions.
2.1 Machine transport and setup
Please refer to the short instructions supplied with the machine re-
garding transport and setup of the Injector.
The machine and machine parts must be transported by 2
persons (1x operator of floor conveyor / 1x transport su-
pervision).
The power supply line must not be damaged by driving
over or pinching it!
The machine must be decommissioned until a damaged
power supply line has been repaired!
There is an increased risk of tipping over during transport
and movement!
To prevent this, do not drive over any objects such as
hoses or cables, etc. and watch out for protruding edges
or persons in the environment!

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The brakes at the two steering rollers on the outlet side
must always be locked except during transport!
Make sure the machine is stable!
2.2 Workplace description
The work area around the machine, plus a container on the outlet and
pump side, is at least 0.5 m on all sides; for maintenance work it is at
least 1 m; if used as passage way, it is at least 1.2 m.
2.3 Connecting the machine
The machine is connected to a three-phase current outlet; its data
(voltage, amperage) must agree with the specifications on the type
plate of the machine.
The machine must be decommissioned until a damaged
power supply line has been repaired!
The power supply line must be regularly checked!
Check the correct rotational direction of the machine by
starting it. A message appears on the display in case of in-
correct rotating field.
Swivel range of
curing compart-
ment door
Swivel range of curing compartment door
Swivel range of
feed ramp

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In such a case, an electrician must change the direc-
tion of rotation inside the mains plug.
The power supply to the machine must be fuse-pro-
tected with 16 A secured with an AC/DC sensitive
ground-fault circuit interrupter (type B).
3Operating instructions
Please refer to the short instructions supplied with your machine for
the operation of your Injector.
Follow also the safety instructions in Chapter 1.1!
In its respective life cycle phases (transport, commission-
ing, setup, operation, cleaning, decommissioning, care /
maintenance, dismantling / disposal) this machine is de-
signed for 1-person operation!
When using this machine, no other person may be present
near the machine!
The following is strictly prohibited and anyone disregard-
ing this prohibition acts gross negligently when:
lifting the lamella of the reach-protection on the out-
let side and reaching into the curing chamber during
operation; the same applies the inlet side!
operating the machine without protective enclosure!
operating the machine without perforated basket on
the pickle mixer / the intake!
manipulating the protective devices of the machine
or deactivating them!
Working on the machine without the protective enclosure
installed is only permitted to a Rühle service technician
during the service phase!

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The operator must make sure that
no persons, who do not know the hazards of the ma-
chine or cannot anticipate them, are about in the
area of the machine!
The control panel may only be operated by touching it
with the fingers. Using any objects (e.g. blade) is prohib-
ited!
4Cleaning instructions
The Injector IR 29 has been designed to allow for complete cleaning
both of the pickle carrying system and all parts that come into contact
with the food product.
4.1 Safety instructions
Follow also the safety instructions in Chapter 1.1!
The cleaning staff must notify the supervisor immediately of any
defects on the machine!
The cleaning staff must use the specified cleaning agents and
disinfectants!
Germ reduction is achieved only by correct cleaning and subse-
quent disinfection!
Appropriate material (e.g. brushes, rags, ...) is required and must
be provided for the proper procedures of the above!
Cleaning products and disinfectants approved for the food prod-
uct area and suitable against contamination (e.g. protein, lime-
scale, ...) must be used!
The cleaning agents and disinfectants must be prepared to a so-
lution as described in the product data sheet of the manufac-
turer!
Personal protective equipment must be worn!

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Cleaning with high-pressure cleaners
is permitted only for:
all external surfaces (all outside stainless steel sur-
faces + machine bases),
reach-protection (inlet),
reach-protection (outlet),
curing chamber door,
softer,
needle bar,
transport belt
filter
The control panel must be cleaned manually and may not
be exposed to a water jet!
All other parts and surfaces may be cleaned only with
normal water pressure!

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4.2 Cleaning agents and disinfectants
The following cleaning agents and disinfectants must be used:
Cleaning agents:
Alkaline cleaning:
Acidic cleaning:
P3 –topax 19, P3 –topax 66
P3 –topax 56
Disinfectants:
P3 –topax 91, P3 –topax 99
Supplier:
Henkel Hygiene GmbH
Bonner Str. 117
D-40589 Düsseldorf
Tel.: [phone]
Or:
Cleaning agents:
Alkaline cleaning:
Acidic cleaning:
Somplex F fat solvent
Somplex foam, acidic
Disinfectants:
Tego 2000, Tego IMC
Supplier:
Th. Goldschmidt AG
Goldschmidtstr. 100
D-45116 Essen
Tel. [phone]
4.3 Cleaning procedure
Please refer to the short instructions supplied with your machine for
carrying out the cleaning procedure.
Before starting with internal cleaning, remove coarse soiling and
product residues from the curing chamber under the hood.
Preparation for outside cleaning:
To ensure optimum cleaning, some components of the machine
must be removed!
Open the curing chamber door!
Remove the cleaning plate!
1) Hook the cleaning plate into the holder of the tool maga-
zine provided!
Remove the transport belt!
1) Hook the transport belt into the holder of the tool maga-
zine provided!

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2) If necessary, the rod mesh belt can be separated from the
belt frame and cleaned individually!
3) Fold the loading ramp to the cleaning position after re-
moving the transport belt!
Remove the softer if so equipped!
1) Hook the softer into the holder of the tool magazine pro-
vided!
Remove the filter!
1) Hook the filter into the holder of the tool magazine pro-
vided!
5Service: Care, maintenance, repair
Any work related in any way with service may be carried out only by
Rühle service technicians and by persons authorised by Rühle in writ-
ing. In this regard, a distinction is made between regular care and
maintenance and repair. The respective qualification certificate must
be issued explicitly for the corresponding work.
Follow also the safety instructions in Chapter 1.1!
Notify and obtain permission from Rühle customer service if
welding or cutting work is required on the machine!
Make sure when working on the electrical equipment of the
machine that
this is only done by qualified personnel!
the machine is always disconnected from power!
a waiting time of at least 10 minutes is observed after
switching off the machine to allow the capacitor of the
frequency converter to discharge to a safe voltage
level!

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5.1 Regular care
Regular care of the machine must be carried out at least once per
week. This prevents malfunctions and signs of wear.
Any abnormalities detected during regular care must be reported to
the supervisor! He must immediately initiate correction or mainte-
nance or notify Rühle Service!
Care schedule:
a) Disassemble the machine according to the cleaning instruc-
tions. Check for any parts moving with difficulty, material
abrasion or other signs of wear and tear!
b) Check softer blades for wear and tear, damage or broken
blades!
c) Check curing needles for wear, damages and clear passage!
d) Check the needle system for leakage integrity!
e) Inspection of all safety switches as outlined in Chapter 1.1
Safety Instructions!
f) Check the steering rollers and locking devices for damages
and proper function!
g) Visually check for changes or damages on all machine sides
and accessible machine parts, e.g. needle bar. The machine
must be shut down in the event of any damages or changes!
5.2 Regular maintenance
Regular maintenance of the machine must be carried out every 2000
hours of operation but at least once per year.
Maintenance schedule:
a) Inspect the safety devices as outlined in Chapter 1.1 Safety
Instructions!
b) Read the error memory (frequency converter)!
c) Replacement of the needle seals in the needle register!
d) Check curing needles for wear, damages and clear passage!

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e) Check softer blades for wear and tear, damage or broken
blades!
f) Resharpening of the softer blades!
g) Inspect the hoses (piping and needle system)!
h) Check the function of the pressure transmitter!
i) Fill all lubricating nipples and moving parts in the machine
compartment with grease!
j) Test run with open machine (caution: moving parts)!
k) Check the switching mechanism!
l) Check the belt frame for distortion!
m) Check the belt tension for distortion
n) Check the setting for the top position of the pump by the lift-
ing unit!
5.3 Repair and spare parts
As a damaged part on a machine is usually damaged due to causes
unrelated to the part, always carry out a fault diagnosis.
For this reason, contact our Service Hotline at [phone] for
spare parts or technical faults. Please keep the machine type and
number ready.
6Disposal
1. The following component contains oil or lubricant:
Beam drive and pump drive
All gear units / motors are equipped with oil draining screws.
Subsequently, dispose of the oil properly!
2. In addition, the lubricating oil and grease must be removed
correctly from all lubricated parts after which it must be dis-
posed of!
3. All other materials must be sorted and disposed of at a recy-
cling facility!

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7Technical documentation
7.1 Technical data
Connection voltage: 400 V, 50/60 Hz, 3-phase AC / N / PE
Power consumption: 6.1 kW
Full-load current: 12.6 A
Back-up fuse max.: 16 A
Protection class: IP54
Ambient temperature: +2 to 40 °C
Dimensions, W x H x D: 2824 x 2608 x 1847 mm
Machine weight: 410 kg
Transport weight: max.: 500 kg
Output max.: 3000 kg/h
Speed: Off: 0 strokes/min
Slow: 30 strokes/min
Fast: 60 strokes/min
Feed: 20 / 30 / 40 mm/stroke
Needle rows: 2 rows (1x 14 and 1x 15 needles)
Clear opening dimension,
W x H: 360 x 280 mm
Width of transport rake: 345 mm
Injection volume: 3% –70%
Operating pressure max.: 4.2 bar
Emission sound
pressure level: LpA = 78 dB(A)
Measured according to: DIN EN ISO 11201
accuracy class 2
Measured: while idling without product; at
maximum speed
The data on the type plate principally applies; it is located next to the
power supply line on the machine. In case of deviations contact the
manufacturer for a written confirmation of the data!

Rühle GmbH, Beim Signauer Schachen 10, D-79865 Grafenhausen
Tel.: [phone], Fax: [phone]
www.original-ruehle.de
①②③④ ⑤ ⑥
⑦⑧ ⑨ ⑩ ⑪
1) Access protection, outlet
2) Curing compartment
door
3) Frame
4) Centrifugal pump
5) Access protection, inlet
6) Feed ramp
7) Switch
8) Control panel (Mini-IPC)
9) Main switch
10) Cleaning plate
11) Filter
12) Type plate
13) Steering castor with
brake
14) Brine return pipe
15) Steering castor without
brake
16) Pickle mixer
17) Conveyor belt
18) Needle register
19) Spring magazine
20) Softer
⑳
⑲
⑱
⑰
⑯
⑮ ⑭ ⑬
⑫
①
②
Recipe
selection
1) Recipe start (press 1 sec.)
Change recipe name (press 2 sec.)
2) View info text (press 1 sec.)
Specify info text (press 2 sec.)
3) Injection pressure (press 2 sec.)
4) Stroke per min. (press 2 sec.)
5) Mixer setting (press 2 sec.)
6) Feed per stroke (press 2 sec.)
7) Softer setting (press 2 sec.)
8) Stopper setting (press 2 sec.)
9) Specify batch text (press 1 sec.)
Batch setting (press 2 sec.)
①
②
Confirm
selection
③
Back
③
Recipe start
Change recipe name
(= Create new recipe)
Quick installation guide
•Installing the machine
I
•Operation
II
•Recipe start / Recipe selection
III •Programming recipe IV •Create new recipe V
•Feed ramp
⑥•Centrifugal pump ④

IR 29
Copyright © 2016 by Rühle GmbH
30.03.2016
Stop
Soft Mix
Hard Mix
Installation:
Removal:
•Pickle mixer
⑯
•Softer installation and removal
⑳•Access protection
①•Access protection ⑤•Curing chamber door
②
•Needle change
⑱•Needle beam
VI
•Conveyor belt
⑰•Belt removal
VII
•Filter
⑪•Tool magazine VIII
•Cleaning
IX