Weber CCI 303 User manual

Operating instructions
Interleaver
CCI 303
D - Status: 07/08/2003
Weber EX1017
U.S. Patent No. 9,399,531
0001

Table of contents
Operating instructions Interleaver 2
Table of contents
1 General.................................................................................................................................................5
1.1 Standards, regulations and guidelines............................................................................................5
1.2 Abbreviations used.........................................................................................................................5
1.3 WEBER Contact address ...............................................................................................................5
1.4 Typography ....................................................................................................................................6
1.4.1 Instructions.........................................................................................................................6
1.4.2 List items............................................................................................................................6
1.4.3 Position numbers................................................................................................................6
1.5 Displays ………………………………………………………………………………………….6
1.5.1 Keys ...................................................................................................................................6
2 Safety....................................................................................................................................................7
2.1 Structure of the information...........................................................................................................7
2.2 Safety data sheet ............................................................................................................................8
2.3 General safety instructions.............................................................................................................9
2.4 Safety equipment .........................................................................................................................10
2.4.1 Operation-relevant safety equipment...............................................................................10
2.4.2 Safety equipment .............................................................................................................10
3 Hygiene...............................................................................................................................................11
3.1 Hygiene requirements ..................................................................................................................11
3.1.1 Food area .........................................................................................................................11
3.1.2 Spray area ........................................................................................................................11
3.1.3 Non-food area ..................................................................................................................11
3.2 Materials ......................................................................................................................................11
4 Functionality......................................................................................................................................12
4.1 Area of application.......................................................................................................................12
4.2 Function sequence........................................................................................................................12
5 Commissioning and decommissioning ............................................................................................13
5.1 Initial commissioning...................................................................................................................13
5.2 Commissioning ............................................................................................................................13
5.3 Decommissioning/EMERGENCY OFF ......................................................................................13
6 Machine overview .............................................................................................................................14
7 Operation...........................................................................................................................................16
7.1 Setting the parameters..................................................................................................................16
7.1.1 Brief description of the parameter settings on the touch screen ......................................16
7.1.1.1 Parameters Setting the interleaver paper length ..............................................16
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Table of contents
Operating instructions Interleaver 3
7.1.1.2 Parameters Setting the interleaver paper order ................................................17
7.1.1.3 Parameters Start of feed, interleaver................................................................18
7.1.1.4 Parameters Set end of feed, interleaver ...........................................................19
7.1.1.5 Parameter Position 1. Set slice.........................................................................20
7.1.2 Brief description of the parameter settings at the MPS3 control .....................................21
7.1.2.1 Paper length .....................................................................................................21
7.1.2.2 Interleaver waiting time ...................................................................................21
7.1.2.3 With sub-sheet .................................................................................................21
7.1.2.4 Deposit 1st slice ...............................................................................................22
7.1.2.5 Paper shortage..................................................................................................22
7.2 Setting up the interleaver with paper ...........................................................................................23
7.2.1 Opening the housing cover ..............................................................................................24
7.2.2 Insert the paper roll, thread in and align the paper (initial setting up).............................25
7.2.2.1 Applying a new paper roll ...............................................................................25
7.2.2.2 Guiding the paper via transport roller..............................................................26
7.2.2.3 Guiding the paper through the loop channel....................................................26
7.2.2.4 Guiding the paper through the paper control unit/paper brake........................27
7.2.2.5 The 90° deflection (mono operation)...............................................................27
7.2.2.6 The 90° deflection (tandem operation) ............................................................28
7.2.2.7 Disassembling the cutting edge/paper guide ...................................................29
7.2.2.8 Inserting the paper into the cutting edge/paper guide......................................31
7.2.2.9 Assembling the cutting edge/paper guide........................................................32
7.2.2.10 Checking the course of the paper...................................................................34
7.2.2.11 Fixing the paper roll and the paper course.....................................................35
7.2.2.12 Carrying out a run at creep speed/final inspection of the paper course.........37
7.2.3 Replacing/exchanging a used paper roll ..........................................................................38
7.2.4 Closing the housing cover................................................................................................41
7.3 Set negative pressure on the paper control unit/paper brake .......................................................42
7.4 Tandem operation/paper splitting (*optional) .............................................................................43
7.4.1 Align the paper splitting unit ...........................................................................................43
7.4.2 Setting up the blade guide of the paper splitting unit ......................................................44
7.4.3 Check, set and change blade ............................................................................................44
7.4.4 Setting up the distance of the paper halves......................................................................45
7.5 Removing, installing, and setting the cutting edge ......................................................................46
7.5.1 Removing the vertical cutting edge .................................................................................46
7.5.2 Removing the horizontal cutting edge/interleaver cutting edge ......................................47
7.5.3 Installing the horizontal cutting edge/interleaver cutting edge........................................47
7.5.4 Installing the vertical cutting edge...................................................................................48
7.5.5 Setting the cutting edge....................................................................................................49
7.6 Setting the side stop and vertical cutting edge.............................................................................50
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Table of contents
Operating instructions Interleaver 4
8 Technical data ...................................................................................................................................51
9 Faults..................................................................................................................................................52
9.1 Fault table on the touch................................................................................................................52
9.2 Fault table MPS3..........................................................................................................................52
10 Spare parts.......................................................................................................................................53
10.1 Spare parts order .......................................................................................................................54
11 Keyword directory..........................................................................................................................55
0004

Operating instructions Interleaver 5
General
1 General
These operating instructions were created for the supervisor and operator
of the Interleaver CCI 303.
These operating instructions of the interleaver CCI 303 are a supplement to the operating
instructions of the cutting line.
The interleaver CCI 303 is exclusively referred to as interleaver in this document.
1.1 Standards, regulations and guidelines
This chapter summarizes all relevant standards, regulations and guidelines for the interleaver
in a table.
Component
sStandards, regulations and guidelines
Electrical system EN 60204-1 Part 1
Interleaver EN 1672-2: 1997 Food processing machinery, Part 2
Hygiene requirements
1.2 Abbreviations used
In this section, all abbreviations used in these instructions are summarized in a table.
Abbreviati
on Explanation
Fig. Figure
Chap. Chapter
1.3 WEBER Contact address
In case of any questions, please contact:
… or your local customer service.
Maschinenbau GmbH & Co. KG
Formerstraße 3
D-35236 Breidenbach
Phone: [phone]
Fax: [phone]
Customer service hotline: [phone] Company stamp
0005

Operating instructions Interleaver 6
General
1.4 Typography
The typography describes which means are used to present and explain the technical
information in these operating instructions.
1.4.1 Instructions
Instructions are marked by a hyphen, e. g.:
– Tighten screw.
1.4.2 List items
List items are marked by a point, e. g.:
• 6 Hygiene screws
• 1 toggle screw
1.4.3 Position numbers
Components are marked in figures with grey numbers and position lines. Position lines indicate
the component by means of an arrow or a point.
In the text, reference is made with bold
numbers to the individual items of the
components of a figure.
Figures are provided with numbers to
which reference is made in the text.
See the following example:
– Remove pin screw (2) (Fig.
5).
Fig. 5 Disassemble pin screws
1.5 Displays
Centered texts in another font refer to a notice on the display of the control unit MPS 3.
Example:
MPS 3
READY FOR
OPERATION
1.5.1 Keys
Keys are shown in brackets and in upper case letters, e. g.: Key
[ENTER]
0006

Operating instructions Interleaver 7
Safety
2 Safety
2.1 Structure of the information
In these instructions, hazards or notes are shown as follows:
DANGER
DANGER TO LIFE
This safety notice warns when life is endangered by electrical voltage.
WARNING
RISK OF INJURY
This safety notice warns of potential sources of danger that can cause
personal injury.
CAUTION
RISK OF MATERIAL DAMAGE
This safety notice warns of potential sources of danger that can cause
material damage.
NOTE
This notice provides general tips for optimal use and other information.
0007

Operating instructions Interleaver 8
Safety
2.2 Safety data sheet
NOTE
The following safety instructions must be observed when operating,
cleaning, and maintaining the interleaver.
1. Before installation, commissioning, operation, cleaning and maintenance of the
interleaver, the entire operating instructions must be read. The operating instructions
must be precisely observed in all points. The supervisor must ensure that the operator
has read and understood the operating instructions.
2. Every working day before commissioning, the operator must check the functionality
of all safety equipment relevant for operation of the interleaver. Check electrical
connections for damage and tight fit.
3. The operator must report defects to the safety equipment or electrical connections
immediately to the supervisor.
4. The supervisor must ensure that defective safety equipment is replaced or repaired
immediately. The supervisor must provide work instructions for safe operation.
5. The interleaver may only be properly operated, cleaned and maintained by trained
personnel. Regular follow-up training, e. g. for operation, cleaning and maintenance is
required. The accident prevention regulation (according to VBG 20) must be part of
the training contents.
6. The cleaning method described in the cleaning instructions must be observed. The
supervisor must provide work instructions for safe cleaning work.
7. The maintenance work described in the maintenance instructions must be observed.
The supervisor must provide work instructions for safe maintenance work.
8. Safety equipment must be checked for proper function at least once a year by a
qualified person.
9. The interleaver must not be modified.
10. Only WEBER spare parts and WEBER accessories may be used.
11. The entire operating instructions must accompany the interleaver when it is resold.
0008

Operating instructions Interleaver 9
Safety
2.3 General safety instructions.
DANGER
DANGER TO LIFE
for damaged supply lines or defective safety equipment.
There is danger of life due to electrical voltage when accessing damaged
supply lines, exposed components and/or defective safety equipment.
– Have the defect rectified directly by WEBER customer service or
someone who has the appropriate qualification.
WARNING
RISK OF INJURY
through revolving components.
Clothing or hair can be caught in revolving components and cause
injuries.
– Deactivate the cutting line before performing adjustment work.
– Secure the insertion line with a padlock on the main switch from
being switched on by third parties.
CAUTION
RISK OF MATERIAL DAMAGE
by using high pressure cleaners.
High pressure cleaners may not be used for cleaning the insertion line
since water can penetrate the basic housing structure and damage
electrical components.
– Clean insertion line without high pressure.
0009

Operating instructions Interleaver 10
Safety
2
1
2.4 Safety equipment
This section lists all safety-relevant components and their qualities.
2.4.1 Operation-relevant safety equipment
The user-relevant safety equipment must be checked by the operator prior to each
commissioning.
Fig. 1 All operation-relevant safety equipment at a glance
Item no. +
component Component declaration
1. Sled of interleaver
units When the interleaver units are unlocked and the interleaver sled is subsequently pulled out, the safety query is interrupted and the
machine stops.
To continue cutting operations, the sled must be retracted
completely and the lock engaged.
2. Locking
bolts/interleaver
cutting edge
To check the correct assembly of the cutting edge, the locking
bolts of the cutting edge are queried pneumatically and the start of
the machine is prevented in the event of incorrect assembly.
This serves to prevent damage to the cutting edge by the circular
knife or sickle knife.
2.4.2 Safety equipment
All safety equipment must be checked by a qualified person at least once a year.
Compo
nent Component declaration
1. Motor and electrical
equipment Drive motors (protection type IP 54) and electrical equipment are
accommodated in the basic housing structure. The components
are sufficiently protected against the effect of cleaning agents and
disinfectants as well as cleaning water.
2. Electrical system Electrical system complies with EN 60204-1 Part 1.
0010

Operating instructions Interleaver 11
Functionality
3 Hygiene
3.1 Hygiene requirements
In accordance with EN 1672-2: 1997 Food processing machinery, Part 2 Hygiene requirements,
the entire cutting line is divided into three areas:
3.1.1 Food area
The food area includes all surfaces that come into contact with the product.
In addition, the food area includes the areas with which parts of the equipment can come into
contact under normal operating conditions and which are then returned to the overall product.
3.1.2 Spray area
The spray area comprises all areas of the machine housing that face the food area.
In addition, the spray area includes the surfaces, onto which parts of the food might by
sprayed or from which they might drain under normal operating conditions, but that do not
come into contact with the overall product again.
3.1.3 Non-food area
The non-food area includes all areas which are not defined under the section “Food area” and
“Spray area.”
3.2 Materials
The materials used in the food and spray area are
– corrosion resistant and have
– impermeable surfaces.
The code numbers of the materials (sheets, round and flat material) are 1.4301 and 1.4305.
The plastics POM and PETP used are food-compatible.
In the food and spray area, the surface roughness is < Rz25 μm; where technically possible, <
16 μm has been selected. The radii are > 3.2 mm, smaller in some areas. Weld seams are
continuous, have a uniform surface and are partially polished.
0011

Operating instructions Interleaver 12
Functionality
4 Functionality
4.1 Area of application
The interleaver may only be operated in conjunction with a WEBER slicer prepared for this
purpose. It serves to separate the cut slices of a portion by foils or paper inserts.
4.2 Function sequence
The interleaver enables the insertion of foil or paper inserts between the cut slices of a
portion. The foil or paper is located on a roll in the interleaver housing and is fed to the
cutting edge during the cutting process. In the cutting edge, the foil or paper is guided over a
roll around the desired length of the foil or paper insert and cut off together with the product
by the knife. The foil or paper insert is deposited together with the slice on the portioning belt
of the CCU.
In the following, the term “paper,” stands for all media to be processed by the interleaver.
NOTE
Paper widths of up to max. 180 mm can be inserted and processed.
0012

Operating instructions Interleaver 13
Functionality
5 Commissioning and decommissioning
5.1 Initial commissioning
The interleaver is firmly connected to the slicer. Initial commissioning is carried out
exclusively by WEBER Customer Service.
5.2 Commissioning
Before each commissioning of the interleaver, the completeness and correct assembly of all
components must be checked.
DANGER
DANGER TO LIFE
by opening the housing cover and the housing door on the interleaver.
The basic housing structure includes electrical components that are
supplied with life-threatening voltage. The housing cover and the
housing door protect against unauthorized intervention.
– Before commissioning and cleaning the insertion line, close the
housing cover and the housing door.
– Close the housing cover and the housing door of the interleaver.
(see chap. “Closing the housing cover” in the “Operating instructions” of the interleaver)
– Retract the CCU and install the portioning and control belt if necessary. (see
“Operating instructions” of the cutting line)
– Put the interleaver into operation via the parameter settings of the cutting line
(see “Operating instructions” and “Parameter description” of the cutting line).
5.3 Decommissioning/EMERGENCY OFF
Since the interleaver is electrically connected to the slicer, it is decommissioned via the slicer.
Decommissioning and the EMERGENCY-OFF function are explained in the operating
instructions of the cutting line.
– Decommission the interleaver via the parameter settings of the cutting line (see
“Operating instructions” of the cutting line).
0013

Operating instructions Interleaver 14
Machine overview
6 Machine overview
Fig. 2 Machine overview
Item no. +
component Component declaration
1. Interleaver housing The interleaver housing includes the drives and the paper or foil
supply
2. Paper roll Paper roll with the required paper or foil material
3. Transport roller The transport roller transports the paper at the necessary speed
further into the loop channel
4. Slip coupling The slip coupling compensates the different speeds of the paper
roller drive and the transport roller, thus enabling a uniform and
smooth paper delivery
5. Loop channel In the loop channel, a specific paper quantity supply is always
kept under tension by an artificially generated suction in order to
compensate fluctuations in the conveying speed at the cutting
edge.
6. Housing
cover/cleaning An additional housing cover is attached to the underside of the interleaver in order to facilitate the cleaning of the interleaver.
7. Paper control
unit/paper brake The paper control unit continues to keep the paper coming from
the loop channel tensioned and in position in order to prevent a
return and “wandering” of the paper during conveying breaks..
8. 90° deflection The 90° deflection guides the paper in the direction of the cutting
edge/cutting head housing.
9. Interleaver slider In order to prevent the ingress of water, cleaning agents and dirt,
the slider on the interleaver housing is closed upon deactivated
interleaver function and in the cleaning program.
0014

Operating instructions Interleaver 15
Machine overview
10. Deflection
shaft cutting
edge
After leaving the interleaver housing, the paper revolves around
the deflection shaft of the cutting edge in the lower area of the
cutting duct and continues to be directed towards the cutting edge
11. Interleaver cutting
edge The interleaver cutting edge consists of the components cutting edge and paper guide.
The paper is inserted via deflection and transport shafts and is
moved in front of the product at the cutting edge in a
predetermined length upon each cut.
0015

Operating instructions Interleaver 16
Operation
7 Operation
7.1 Setting the parameters
In order for the interleaver to work as desired, the parameters for fine tuning must be set via
the control of the slicer. Depending on the equipment, the slicer is equipped with an MPS3
control or a touch screen control.
NOTE
The respective menu navigation is described in detail in the operating
instructions of the cutting line and in its parameter description.
7.1.1 Brief description of the parameter settings on the touch screen
7.1.1.1 Parameters Setting the interleaver paper length
This parameter sets the length of the paper
sheets that separate the individual slices.
The entered paper length is conveyed by
the interleaver and cut off by the knife. In
setting “0,” the interleaver function is
deactivated. The adjustment takes place in
millimeters (mm).
Fig. 3 Paper length interleaver
– Select [Product Parameters] button.
– Select menu [Special].
– Select “Interleaver paper length” parameter.
– Increase or reduce the value with the button [ or ].
– The value is adopted.
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0016

Operating instructions Interleaver 17
Operation
7.1.1.2 Parameters Setting the interleaver paper order
This parameter sets the paper order in a
portion.
The hundreds position indicates whether a
sheet is to be cut under the first slice (1).
The tens position indicates in which order
the sheets are to be placed under the slices.
For example, in paper order 001,a sheet of
paper is placed underneath each slice, except
for the first one.
– Select [Product Parameters] button.
– Select menu [Special].
– Select the “Interleaver paper order” parameter.
– Increase or reduce the value with the button [ or ].
– The value is adopted.
Fig. 4 Interleaver paper order
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0017

Operating instructions Interleaver 18
Operation
7.1.1.3 Parameters Start of feed, interleaver
The start of the feed of the interleaver is set
with this parameter. The start of the feed
depends on the knife position at which the
interleaver can start to feed the paper at the
earliest. As a rule, the angle of the knife is set
in which the knife stands after it has cut off the
product. Setting takes place in degrees (°).
Fig. 5 Start of feed of the interleaver
– Select [Product Parameters] button.
– Select menu [Special].
– Select parameter “Start of interleaver feed.”
– Increase or reduce the value with the button [ or ].
– The value is adopted.
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0018

Operating instructions Interleaver 19
Operation
7.1.1.4 Parameters Set end of feed, interleaver
This parameter is used to set the end of the
interleaver feed. This means that the knife
position is specified, in which the interleaver
must stop the paper feed at the latest. Here, the
angle in which the knife stands is stated,
shortly before it starts cutting the paper.
Setting takes place in degrees (°)
Fig. 6 End of interleaver feed
– Select [Product Parameters] button.
– Select menu [Special].
– Select parameter “End of interleaver feed.”
– Increase or reduce the value with the button [ or ].
– The value is adopted.
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0019

Operating instructions Interleaver 20
Operation
7.1.1.5 Parameter Position 1. Set slice
The position of the first slice is corrected with this
parameter. This parameter is required when cutting
with the interleaver and can be necessary if, for
example, the first slice does not fall on a sheet paper
from the interleaver. By entering a negative value, the
position of the first slice to the slicer is corrected (Fig.
8). The adjustment takes place in millimeters (mm).
Fig. 7 Without correction
Fig. 8 Corrected
– Select [Product Parameters] button.
– Select menu [Special].
– Parameter “Position 1st slice.”
– Increase or reduce the value with the button [ or ].
– The value is adopted.
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0020