vc999 RS420 User manual

MAINTENANCE MANUAL
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TOLL FREE : 1-800-235-2829
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Project Scope for Manuals
Machine Specifications
for
MERKLEY & SONS PACKING
SRS No.: RS35508410240
Web: 355
Index: 240
Loading: 650
Discharge: 450
Voltage: 220V 3ph/60 Hz
Product
Descriptions:
1. Bulk Links & Patties 2:1 2:1
2. Summer Sausage 4:1 4:1
Die Configurations:355/240(2:1) (4:1)
RS Flexible Material Specifications:
Form Web: 358 +/- 1mm
Non-Form Web 341 +/- 1mm
http://www.vc999.com/config/scope/ScopeManual.asp?mID=2154 (1 of 3)7/15/2008 4:58:13 AM

Project Scope for Manuals
Machine Components
Heater Rods
ELR452855 FORM Bent Heater Rods 3
ELR452855 SEAL Bent Heater Rods 2 3
Bladders
PRS457854 SEAL Bladders 2
Bladders 2 0
Bladders 3 0
Seal Gaskets
PLA362100 (Bulk Links & Patties 2:1) 1
PLA362101 (Summer Sausage 4:1 ) 1
Infeed Station
FUG462536 Assm, Film Unwind (Upper Unwind)F 355 1
ARS451796 Toolbox RS Series 1
Forming Station
STL456164 Assm, Forming Station 1
PRS457282 Assm, pneumatic panel 1
PRS458690 Assm, form heat valve 1
Loading Station
STL454772 Assm, Knee Free 355/650 1
FTR453262 Gripper Chain 14.78
FTR451137 Master Link 2
STL460984 Assm, Short Mach. Kit 1
Sealing Station
STL456154 Assm, Seal Station 355 1
ELR462003 Assm, pnl 220V/60 Hz 1
FUG457126 Assm, NF unwind 355 1
PRS456273 Assm, pneu sl st 1
VAR458343 Assm, vc vlv mnST 1 1
Discharge Station
STL456462 Assm, disc 355/450 1
TRM460216 Assm, trim revlv trim removal 1
ARS461242 Assm, KK Water Cooler 1
Cutting Station
LTC452857 Assm, Rotary knife quick release shft 355 2
LTC452487 Assm, Rotary knife assembly 1
LTCR60148 Assm, Rotary knife hub assembly 8
CCT457862 Assm, cross cut knife 355 1
Vacuum Systems
VAR456606 Assm, vacfox 100 (VC Kansas City) 1(Sealing)
Printers/Labelers
Language Stickers
ARS452484 English Stickers 1
http://www.vc999.com/config/scope/ScopeManual.asp?mID=2154 (2 of 3)7/15/2008 4:58:13 AM

Die Components
Dept Part # Description Qty
DFT 362010 form die top 355/240 1
DHP 362020 heater plate 355/240 2
DHP 362020_1htr back plate 355/240 2
DHP 362021 pyramid heat plate 355/240 1
DFB 362030 form die bottom 355/240 1
DFD 362040 div set 355/240 2:1 1
DFD 362041 div set 355/240 4:1 1
DFI 362042 div wall md 240/9.53 4
DFP 362052 fill plates 355/240 1
DFR 362050 radius plate 355/240 2:1 2
DFR 362051 radius plate 355/240 4:1 4
DST 362060 bladder seal die top 355/240 1
DPP 362070 bladder pusher plate 355/240 1
DSP 362071 total seal 355/240 1
DSB 362080 seal die bottom 355/240 1
DSS 362090 seal frame 355/240 2:1 1
DSS 362091 seal frame 355/240 4:1 1
PSP 362300 240/1680 loadsuprail 3
PSP 362301 240/450 disrail 3
PSP 362302 355/240/450 platform 1
PLA 362400 mold 355/230 2:1 1
PLA 362401 mold 355/230 4:1 1
DCA 362500 infeed die spacer 240/1680 2
DCA 362501 exit die spacer 240/1680 2
SGS 462586 assm, F grd 355/240/450 R (R65479) 1
SGS 462587 assm, F grd 355/240/450 L (R65480) 1
SGS 462588 assm, S grd 355/240/450 R (R65481) 1
SGS 462589 assm, S grd 355/240/450 L (R65482) 1
SGS 462590 assm,C grd 355.450.100r (R65483) 1

TABLE OF CONTENTS
SECTION 1 – SAFETY
SECTION 2 – TRANSPORTATION
SECTION 3 – INSTALLATION
SECTION 4 – INTERFACE / TOUCH SCREEN
SECTION 5 – MAINTENANCE & INSPECTION SCHEDULE
SECTION 6 – TROUBLESHOOTING GUIDE
SECTION 7 – PNEUMATIC DIAGRAMS
SECTION 8 – ELECTRICAL DIAGRAMS
SECTION 9 – PARTS LIST / ASSEMBLY DRAWINGS
SECTION 10 – DIE ASSEMBLY DRAWINGS

SECTION 1 - SAFETY

SAFETY
PROTECTIVE CLOTHING
The following protective clothing is suggested when operation or servicing the machine:
•Protective eye wear
•Gloves
•Ear plugs
•Hard hat
•Steel-toe shoes
Loose clothing or metal jewelry (ie, watches and rings) should not be worn during
operation of this machine.
MAIN SWITCH
Before doing any repair work or change over to the machine turn the main switch off and
lock out power, air, and water. Before removing power purge water if dies are to be
removed.
EMERGENCY STOP
The machine is equipped with two emergency stop buttons, one on the seal station and
the other on the form station. The emergency stop buttons will dump all air pressure and
cutoff electricity to high voltage components only (vacuum pump, main motor, trim
canister, and heaters). Disengage the emergency stop by turning the switch clockwise.
Main Switch Emergency
Stop

SAFETY
COMPRESSED AIR
Before doing any repair work to the machine depress the lock out valve located in the
pneumatic cabinet. This will release air pressure to the high and low pressure manifolds.
The regulators for each manifold should display 0 psi when lock out valve is depressed.
SEALING STATION (back side)
High Pressure Regulator Low Pressure Regulator
Lock Out Valve

SAFETY
HAZARD AREAS OF THE MACHINE
Non-Forming/Sealing Station
Discharge/Cutting Loading Forming Infeed
Station Station Station Station
•The hazard areas of the machine are protected by safety guards.
•Each guard is unique and fits on the machine only one way.
oMagnetic safety switches are used in the guards.
•When the guard is lifted off the machine, the magnetic safety switch will stop the
machine cycle.
•Safety guards are to be inspected on a daily basis.
•It is possible for the flat guards to chip or crack.
•Damaged flat guards must be replaced immediately.
•Please contact VC999 parts department and provide machine model, serial, and die
numbers.
NEVER REACH UNDER OR AROUND GUARDS WHILE MACHINE IS ON.

SAFETY
FILM INFEED
ROTARY MOTION - DANGER OF INJURY
Keep all loose clothing, jewelry and fingers out of machine when advancing the machine.
FORMING AND SEALING STATION
CLOSING MOVEMENT - DANGER OF CRUSHING
HOT HEATING PLATE - DANGER OF BURNING
NEVER REACH UNDER THE GUARD WHEN MACHINE IS IN OPERATION.
Before doing any work in the forming or sealing area remove the safety guard.
Note: Heating plate is located under the die top. Wear protective gloves and handle the
die top by its edges. Store the die top in a safe place allowing it to cool. The assistance
of another person may be necessary when handling heavy dies.
DISCHARGE / CUTTING STATION
LINEAR MOTION – DANGER OF INJURY
NEVER REACH UNDER THE GUARD WHEN MACHINE IS IN OPERATION.
Before doing any work in the cross cutting area remove the safety guard.
When changing blades lock out and tag out compressed air.
Wear protective gloves when handling blades.
If the cross cut unit is removed from the machine cover the blade prior to transporting.
Hold the cross cut unit from the ends or top. Do not reach into the cutting area.
ROTARY MOTION – DANGER OF INJURY
BE EXTREMELY CAREFUL WHEN CHANGING THE KNIVES.
Hold the knife shaft at its ends. Store the knife in a protective sleeve.

SECTION 2 - TRANSPORTATION

TRANSPORTATION
•Always lift the forming and sealing stations of the rollstock separately.
•If the machine is completely assembled, it is necessary to use two forklifts or pallet-
jacks to move the machine.
•NEVER lift the machine by the loading or discharge areas; as they will not support
the weight of the machine.
•Always lift the stations from the back side as shown in the illustration below.
•Take special care when moving the machine not to damage the film systems.
•Before moving the machine, remove all external equipment and/or exit conveyors.
•When lifting the separate stations, be careful not to put stress on the electrical or
pneumatic lines that connect the two stations.
•The maximum separation of the stations during this process should be no more than
the loading area length (see specifications).

SECTION 3 - INSTALLATION

INSTALLATION
LOADING AREA
•Using eight (8) M6x25mm socket head screws provided, install the loading area as
shown below.
•Use Loctite or similar substance when reassembling the machine.
•Reattach cable straps using M5 socket head screws provided.
•Remove stainless steel end caps to the forming and sealing station in preparation for
the chain installation.
LEVELING MACHINE
•Level the machine in machine direction as well as across the die tops in the order
indicated by the numbered arrows in the diagram below.
•It is critical that each die section be level.
oThis is best achieved by raising the machine slightly with a pallet jack and turning
the feet.
•Be careful to leave at least 10mm of the feet engaged into the machine for
stability.
•Never attempt to operate a machine that has not been properly leveled.
oThis could result in damage to the machine.

INSTALLATION
POWERING MACHINE
•Connecting main power should be carried out by qualified electricians.
•Observe all relevant regulations regarding cable sizing and insulation that apply
in the area in which the machine is being installed.
•All load information can be obtained from the data plate located on the back side
of the machine.
•The main cable can be routed either through the support column, as shown
below, or across the floor and beneath the machine depending on customer
preference.
oThe white column cap comes with a hole pre-drilled for a power cable.
oDepending on the gage of the wire used, this hole may require enlargement.
•The strain relief connector inside the machine must be properly tightened once
the main power has been connected.
oThis will insure a water tight seal around the cable where it enters the control
cabinet.
•Be sure to replace the safety guards on the main disconnect switch after
completing the connections.

INSTALLATION
CHAIN INSTALLATION
•Installing the transport chain should be done with care.
•Each side of the machine will require equal length of chain (see specifications)
oIn addition, one master link will also be required.
Beginning in the sealing station, insert chain into the lower guide of the loading area.
Loosen standoff jackscrew so standoff moves close to anchor block.
Following the arrows in the diagram, pull chain through until both ends meet in the
area shown in the sealing station.
•This area is the most accessible for installing the master link.
•The bolt in the tensioners should be positioned midway in the slot when the chain
is new.
•As the chain stretches with use, move these tensioners to keep the chain taut.
Insert master link and move standoff to position where chain in slightly loose using
jackscrew.
Tighten standoff bolt.
Use chain tensioners to apply appropriate chain tension.
For accurate chain advance, the chain must be taut.
•Over tightening will reduce chain life.
Lubricate the chain thoroughly with light weight oil.
•Recommended: Kluberoil 4 UH1-68 or an equivalent lubricant
Anchor Block Jackscrew
Apply
Master Link

INSTALLATION
AIR CONNECTION
•Compressed air connection is located on top of the right support column.
oThe machine requires 6-10 bar of dry compressed air.
oThe pneumatics system is equipped with an air filter, manual shut off valve,
automatic pressure release valve, and pressure switch.
Air supply lines containing high levels of moisture need proper drying equipment
to insure proper machine operation and long component life.
oThe manual shut off valve is utilized as a safety feature for doing maintenance on
the machine.
oThe automatic pressure release valve will open during an emergency stop, or if
power is turned off.
oThe pressure switch will shut down the machine if pressure drops below 4-5 bar.
When this occurs, an error message will appear in the alarm screen on the
operator interface.
WATER CONNECTION
•Cooling water connection is located next to the compressed air connection.
oA pressure switch in the pneumatic panel monitors pressure in the cooling lines.
An error message will appear in the alarm screen on the operator interface if
pressure falls below desired limits.
•A drain line is also required.
oThis connection is made under the seal die top utility block.
The fitting matches the inlet fitting.
This hose should be routed to the nearest drain, being careful not to route the
hose in the way of any moving parts.

INSTALLATION
GAS FLUSH CONNECTION (OPTIONAL)
•If the machine comes equipped with gas flush, now is the time to make necessary
connections.
oA gas accumulator tank is attached under the loading area.
A 1/4” hose connection is supplied for connection to the gas bottle.
The gas system requires 2.5 bar of gas pressure.
COVERS & GUARDS
•All covers and safety guards should now be replaced.
oAll covers are bolted or locked into place.
oAll safety guards are magnetically locked when in place.
•This should be done before the main power is turned on.

SECTION 4 – INTERFACE / TOUCH SCREEN

NOTE: SOME MACHINES MAY HAVE MORE OR LESS PUSHBUTTONS
DISPLAYED DEPENDING UPON THE MACHINE OPTIONS.
•CUTTING, SEALING, INDEX, FORMING, PRINTER, & ZIPPER: THESE BUTTONS WILL
DISPLAY MANUAL CONTROL SCREEN FOR THAT AREA OF THE MACHINE.
•SEAL DIE TEMP SET: ENTER SEAL DIE TEMPERATURE SETTING (DEG C)
•VACUUM PUMP SHUTDOWN DELAY:SET TIME (sec) THAT THE VACUUM PUMP WILL
RUN AFTER END OF AUTO CYCLE BEFORE SHUTTING DOWN.
•VACUUM PUMP SERVICE HOURS: VACUUM PUMP HOURS SINCE LAST TIMER RESET
•TOTAL MACHINE CYCLES:COUNTS CYCLES MACHINE PERFORMS IN AUTO CYCLE.
•TOTAL VACUUM PUMP HOURS: TOTAL HOURS OF VACUUM PUMP OPERATION.
THIS METER IS NOT RESETABLE.
•VACUUM PUMP SERVICE HOURS RESET: RESETS VACUUM PUMP SERVICE HOUR
METER. THIS SHOULD BE PRESSED AT THE END OF EVERY VACUUM PUMP
SERVICE.
•CROSS CUT MAINT RESET: RESETS CROSS CUT SERVICE HOUR METER.
•SET PASSCODE: OPENS PASSWORD SCREEN. THIS SCREEN ALLOWS YOU TO
CHANGE ALL PASSWORDS. YOU MUST HAVE MASTER PASSWORD TO OPEN THIS
SCREEN.
•ENTER LICENSE CODE: WILL APPEAR AFTER THE 24th DAY OF THE MONTH. THIS
BUTTON WILL OPEN THE PAYMENT CODE SCREEN. OPENING THIS SCREEN WILL
ALLOW YOU TO ENTER THE NEXT MONTHS PAYMENT CODE BEFORE THE END OF
THE MONTH.
•VACUUM SENSOR CALIBRATE: (OPTIONAL) OPENS VACUUM SENSOR CALIBRATION
SCREEN.