vc999 ST2 Installation instructions

ORIGINAL OPERATING MANUAL
Art. no. 593.767
Shrink Tunnel
ST2/ST2 D
VC999 VERPACKUNGSSYSTEME AG Tel. ++41 (0) 71 35 35 900
Melonenstrasse 2 Fax ++41 (0) 71 35 35 901
CH-9100 Herisau / Switzerland E-Mail [email protected]

EC Declaration of Conformity
In accordance with Machinery Directive 2006/42/EC, Appendix II A
In accordance with EMC Directive 2004/108/EC
In accordance with Low Voltage Directive 2006/95/EC
Manufacturer Authorized Representative in the Community
VC999 VERPACKUNGSSYSTEME AG ............................................................
Melonenstrasse 2 ............................................................
CH-9100 Herisau ............................................................
We hereby declare that the following
product
Product name: Shrink Tunnel VC999 ST2/ST2 D
is in conformity with the relevant-
provisions of the above referenced
directives – including any valid
amendments at the time of the
declaration.
The following harmonized standards
have been applied:
EN ISO 12100-1 / -2 Safety of machinery, devices and systems
DIN EN 60 204-1 Electrical equipment for industrial machinery
Place: Date:
Herisau 12.02.2009
Document Custodian:
Uriel Inauen
VC999 VERPACKUNGSSYSTEME AG
Melonenstrasse 2
CH-9100 Herisau

Shrink Tunnel VC999 ST2/ST2 D
Handover declaration
2009-11-12 Art. no. 593.767 Page 3/96
NOTICE
The following handover declaration has to be completed by the owner. The owner is obliged to
return the original, completed handover declaration to us. The owner hereby certifies that
he/she has understood and taken full note of the operator manual. By signing this document
the owner certifies that he/she shall observe the safety instructions contained in the operator
manual and shall inform each and every machine user or persons working at the machine of the
relevant safety instructions.
The operator shall be liable for any personal injuries or damage to property resulting from non-
observance of the safety instructions.

Shrink Tunnel VC999 ST2/ST2 D
Contents
2009-11-12 Art. no. 593.767 Page 5/96
Contents
1Introduction ......................................................................................9
1.1 General information............................................................................9
1.2 Terms...............................................................................................10
1.3 Copyright protection.........................................................................10
2Safety and warranty.......................................................................11
2.1 Explanation of the safety instructions ..............................................11
2.1.1 Warning safety signs at the machine...............................................11
2.2 Residual risks...................................................................................12
2.3 General safety instructions...............................................................12
2.4 Machine stability...............................................................................13
2.5 Intended use.....................................................................................13
2.6 Requirements for operators .............................................................14
2.7 Warranty and liability........................................................................14
3Description of the machine...........................................................15
3.1 Operating principle...........................................................................15
3.2 Structure of the machine..................................................................16
3.2.1 Operator tasks..................................................................................19
3.3 Technical data..................................................................................19
3.3.1 Dimensions.......................................................................................20
3.3.2 Weight..............................................................................................21
3.3.3 Products...........................................................................................21
3.3.4 Belt cartridge....................................................................................21
3.3.5 Water system ...................................................................................21
3.3.6 Steam extraction ..............................................................................21
3.3.7 Steam heater (VC999 ST2 D)..........................................................22
3.3.8 Decalcifying system (optional) .........................................................22
3.3.9 Electrical data...................................................................................22
3.3.9.1 Power supply....................................................................................22
3.3.9.2 Output and Fuse protection..............................................................22
3.3.9.3 Controller..........................................................................................23
3.3.10 Noise emission.................................................................................23
4Packaging and transport...............................................................24
4.1 Packing the machine........................................................................24
4.2 Transporting the machine ...............................................................24
4.3 Unpacking the machine....................................................................24

Shrink Tunnel VC999 ST2/ST2 D
Contents
Page 6/96 Art. no. 593.767 2009-11-12
5Setting up the machine..................................................................25
5.1 Site requirements .............................................................................25
5.2 Foundations......................................................................................25
5.3 Safety clearances.............................................................................25
5.4 Leveling the machine........................................................................26
6Machine connections.....................................................................27
6.1 Electrical connection.........................................................................27
6.2 Water connection..............................................................................27
6.3 Steam heater connection (VC999 ST2 D)........................................27
7Installation of the machine............................................................28
7.1 Electrical installation.........................................................................28
7.2 Installation of the water supply line ..................................................29
7.3 Installation of the water discharge....................................................30
7.4 Installation of the steam supply line (VC999 ST2 D)........................31
7.5 Installation of the steam extraction system ......................................31
7.6 Installation of the protective rollers...................................................32
7.7 Cleaning the machine.......................................................................32
8Start-up............................................................................................33
8.1 Initial start-up....................................................................................33
8.1.1 Installation check..............................................................................33
8.1.2 Switching on the machine ................................................................34
9Operation.........................................................................................35
9.1 General instructions..........................................................................35
9.2 Requirements for operation..............................................................35
9.3 Operation..........................................................................................36
9.3.1 Control panel....................................................................................36
9.3.2 Switching on.....................................................................................37
9.3.2.1 Switching on after an EMERGENCY STOP.....................................37
9.3.3 Operation via the display..................................................................38
9.3.4 Access rights....................................................................................40
9.4 Main menu page 1............................................................................42
9.4.1 Program parameters.........................................................................42
9.4.1.1 Water temperature............................................................................43
9.4.1.2 Infeed belt.........................................................................................43
9.4.1.3 Internal conveyor belt.......................................................................43
9.4.1.4 Outfeed belt......................................................................................44
9.4.1.5 Shower .............................................................................................44
9.4.1.6 Programs..........................................................................................44
9.4.2 Operating hours meter .....................................................................45
9.4.3 Alarm list...........................................................................................46
9.5 Main menu page 2............................................................................47
9.5.1 LOG IN .............................................................................................47
9.5.2 LOG OUT .........................................................................................48
9.5.3 Information........................................................................................48
9.5.3.1 Machine status .................................................................................48

Shrink Tunnel VC999 ST2/ST2 D
Contents
2009-11-12 Art. no. 593.767 Page 7/96
9.5.3.2 Analog value.....................................................................................49
9.5.3.3 Safety level.......................................................................................49
9.6 Main menu page 3 ...........................................................................50
9.6.1 Autostart...........................................................................................50
9.6.1.1 Automatic warm-up ..........................................................................51
9.6.1.2 Automatic decalcification (optional)..................................................51
9.6.2 Manual decalcification......................................................................53
9.6.3 Emptying the water tank...................................................................54
9.7 Main menu page 4 ...........................................................................55
9.7.1 Machine settings ..............................................................................55
9.7.1.1 Machine data....................................................................................55
9.7.1.2 Language, time and weekday..........................................................56
9.7.1.3 Temperature.....................................................................................56
9.7.1.4 Further functions ..............................................................................57
9.7.2 Inputs / Outputs................................................................................59
9.8 Starting production...........................................................................60
9.9 Cancelling production.......................................................................60
9.10 Stopping production.........................................................................60
9.11 Changing the program .....................................................................61
9.12 Continuous operation.......................................................................61
9.13 Decalcification mode........................................................................61
9.14 Switching off the machine................................................................62
10 Operating messages and faults....................................................63
10.1 Info text.............................................................................................63
10.2 Malfunctions.....................................................................................63
10.2.1 Troubleshooting................................................................................64
10.3 Error messages................................................................................66
11 Operating supplies.........................................................................68
12 Maintenance....................................................................................69
12.1 Cleaning...........................................................................................69
12.1.1 Cleaning agents ...............................................................................69
12.1.2 Cleaning work...................................................................................70
12.1.3 Cleaning the water supply line filter sieve........................................71
12.1.4 Cleaning the steam supply line filter sieve (VC999 ST2 D).............71
12.1.5 Cleaning the belt cartridge and sieve...............................................72
12.2 Checks .............................................................................................74
12.2.1 Checking the belt tension.................................................................74
12.3 Maintenance work............................................................................75
12.3.1 Regular maintenance work ..............................................................75
12.3.1.1 Changing the standard decalcifier canister (optional)......................76
13 Repairs............................................................................................77
13.1 Repairs to electronics or control system..........................................77
13.1.1.1 Replace fuses...................................................................................77
13.1.2 Replacing the display.......................................................................78
13.1.3 Replace buffer battery of PLC control system .................................78

Shrink Tunnel VC999 ST2/ST2 D
Contents
Page 8/96 Art. no. 593.767 2009-11-12
14 Spare parts......................................................................................79
14.1 Ordering spare parts.........................................................................79
15 Disposal...........................................................................................80
16 Circuit diagrams.............................................................................81
17 Index ................................................................................................95

Shrink Tunnel VC999 ST2/ST2 D
Introduction
2009-11-12 Art. no. 593.767 Page 9/96
1 Introduction
1.1 General information
• This operator manual is an integral part of your machine. The information and safety instructions
contained herein have to be carefully read and adhered to by members of staff authorized to oper-
ate the machine. Superiors who are responsible for machine operation shall be liable for damages
and their consequences resulting from incorrect handling of the machine. It is therefore in the inter-
est of the operator that this operator manual is strictly adhered to.
• The manufacturer shall not be liable for any damages which occur due to non-observance of this
operator manual in its entirety.
• Only the information contained in this operator manual can prevent faults during operation and
guarantee trouble-free operation. It is therefore imperative that this operator manual is actually read
und understood by members of staff authorized to operate the machine
• This machine is a state-of-the-art device at the time of delivery. It complies with CE regulations and
the latest version of machinery directive 2006/42/EC at the time of delivery.
• In the unlikely event that problems should occur, or if questions arise, please do not hesitate to con-
tact our Customer Service.
• Due to technical changes and improvements to the machine some of the diagrams contained in this
operator manual may not be exact. However, the diagrams are fully understandable in order to ex-
plain processes or a course of action.
• We reserve the right to change dimensions and construction of the machine.
Customer Service Dept. Switzerland
The manufacturer’s address is displayed on the name plate. Always state the type of machine and the
machine’s serial number, which are also displayed on the name plate, when contacting us.
Manufacturer: VC999 VERPACKUNGSSYSTEME AG
Address: Melonenstrasse 2
CH-9100 Herisau / Switzerland
Phone: ++41 (0)71 35 35 900
Fax: ++41 (0)71 35 35 901
E-mail: [email protected]
Website: www.vc999.ch
Represented by:

Shrink Tunnel VC999 ST2/ST2 D
Introduction
Page 10/96 Art. no. 593.767 2009-11-12
1.2 Terms
The following terms are used in this operator manual to describe people who work at or who are in
some way involved with the machine:
Buyer
The buyer is the person who purchases the machine from the manufacturer or its representative, even if
he/she always allows a third party to use the machine. The buyer is also the manufacturer’s customer
and is the owner as defined by law.
Owner
The owner is the person who operates or uses the machine, even if he/she is not the actual owner as
defined by law. The owner also becomes liable for the legal risk resulting from operation or connected to
operation of the machine when operating the machine.
Operator, operating personnel
Operators or operating personnel are the people responsible and authorized to operate the machine.
These people should possess sufficient know-how in order to handle and operate the machine correctly.
Usually, one or several people are given responsibility for the machine and provided with the operator
manual for future reference.
It is expected that these people have been briefed about the machine and the operator manual on-site
and are especially aware of the safety regulations for correct handling of the machine and have been
expressly informed about compliance with the aforesaid regulations.
Specialist, specialist personnel
Specialists are specially trained people who, due to their vocational training, are qualified to carry out
special tasks at the machine.
These people are, e.g., electricians, mechanics, specialist engineers and appropriately qualified clean-
ing staff. These people also have to be familiar with the contents of the operating manual.
1.3 Copyright protection
This operator manual is confidential. All data and details contained herein are protected by copyright.
Violation is expressly prohibited by law, and may result in severe civil and criminal penalties.
This documentation contains information protected by copyright. Any reproduction, copying, scanning or
forwarding to third parties is expressly prohibited without the express prior permission of VC999
VERPACKUNGSSYSTEME AG. Violation is expressly prohibited by law, and may result in severe civil
and criminal penalties.