AGF-2 Manual - TOMITEK Engineering
Contents
1. 2 5 jam buckets model AGF 2 Proper machine operation depends on correct use and adequate maintenance The manufacturer disclaims all responsibility due to negligence or failure to observe the rules given in the following booklet In addition it disclaims al responsibility deriving from improper use of the machine and the equipment Warranty The manufacturer guarantees its products for a period of twelve months from the date of delivery to plant This warranty is expressed solely in the repair and replacement free of charge of those parts that after a careful examination carried out by the manufacturer turn out to be defective Warranty is considered limited to solely material defects and ceases to have effect if the parts returned anyhow turn out to have been dismantled tampered with or repaired outside the manufacturer s factory Description on Machine and Limits of Use This machine is a custom filling sealing and labelling machine for 2 5L jam buckets The machine consists of a new indexed conveyor bucket dispenser unit bucket positioner and labeller and used the filling and sealing stationed pre owned by Aussie Growers Fruit The machine dispenses the buckets from the bucket dispenser using a number of synchronised pneumatic pistons The buckets are placed on the conveyor and are transported to the filling station to be filled with jam and then to the sealing station where a foil is applied to seal the bucket From the sealing stat2. ILLING MACHINE MODEL AGF 2 3 DRIVE SCALLING Drivers frequency at 100 of machine s speed can be set here 00000 009000 009090 Limits Index WAIN Scale The default settings ensure the speed of all devices will increase and decrease by the same rate when the speed of the machine is changed on the main screen The default settings of the drivers scaling are e Conveyor 7500 Hz 100 e Positioner 1500 Hz 100 e Labeller 1500 Hz 100 4 INDEX The conveyor s index parameters can be set on this screen Limits silts Index MAIN Scale The default index settings are e Conveyor stop x0 1 seconds 30 e Conveyor stop delay 379 mm e First Cycle Stops 1 The conveyor stop is the time the conveyor stops for at one step For precise positioning of the bucket at each station a sensor is used underneath the conveyor to stop it After the sensor sees a bucket holder fin it stops the conveyor after the Conveyor stop delay distance is reached Page 10 INLINE FILLING MACHINE MODEL AGF 2 The First Cycle Stops is the number of stops for the conveyor after the machine is started after which the bucket dispensing starts OPERATION PROCEDURE To start the machine turn ON the power from the Power ON OFF switch and press the Start Button If necessary check all the settings described previously in this manual and adjust them accordingly Set all the stations Bucket Dispenser Filling Sealing
3. IN 1 J INLINE FILLING MACHINE MODEL AGF 2 CONTENTS INTRODUCTION aisiais ao iii ii i ii a r i i i a i ai a i a i a a a 3 Va GIF AVE A e E rr ro r E ET E 3 Description O Machine and Limits of USS mre i iai sai i ai iii a i a a i a i 3 ABD VALIO NS onerosa ia i aa a i a a i i a i a bon a E E 3 Section 2 User SIV ali Wal cercen E S a A 5 S OBE EINS snp sua corn ates oa i i A boenen E ER 5 OPERA HONA SET IN GS oren E E E E E E EA E E D 5 1 MAINSCREEN Main cassiasecadssatecevedsiucadvontesavedavesaiasstecstandheasdventedeondavassioontesamunibnaddunatedeuedalaonseontavannbahensdusaSedensds 5 Zs CONTINUE SEALING ICOM AL errn A 6 3 ANGLE DELAY POSITINER AND TRIGGER DELAYS AND FLAG LENGTHS LABELLER DlyFlg 7 4 MOTOR SPEED ADJUSTMENTS Speed cncccasiavcsvesssecnsnoevccpsatsencasedshaxersasesacusetbestenahteecesaderensesysaceietaxsewetbormesanee 7 PROTECTED SETTINGS 55 aisiais sad E i i i p a a k a k 8 1 DRIVE ACCELERATIONS gt LaCie FS svainis si iniai ii a i i i i a a a 8 a MII Secs iai ii a i a i i o i i i a E 9 3e DRIVES CALUNG Aiseno a i o a eens 10 de INDEX omonteenta T nederweert a a ne 10 OPERATION PROCEDURE Adis aisiais iais onee a a a ni i a ns nord i a A 11 INSTA CONG LABELRE ELS esre e e e E eval tine iais o i i A i i i i i 12 Page 2 INLINE FILLING MACHINE MODEL AGF 2 INTRODUCTION This booklet describes the use instructions for the Inline Filling Machine for
4. Positioner and Label ON from the main screen Press the Main Conv button to start the conveyor Power ON OFF Emergency Button Start Button Stop Button Page 11 INLINE FILLING MACHINE MODEL AGF 2 INSTALLING LABEL REELS Put the reels onto the special disks and have the label paper tape pass around the roles and between the fork of the label sensor following the route shown in figure below Page 12
5. imum number of buckets in the dispenser and the maximum label length Drivers frequency at 100 of machine speed Se a The conveyor index settings The parameters 6 to 9 have been preset by the manufacturer to ensure smooth operation IRT of the machine Only appropriately trained and experienced staff should change these setting if they need to be modified All the settings above can be done by switching between the following screen s on the AGF 1 Model Display 1 MAIN SCREEN Main The on off buttons for most of the eguipment are on this screen OFF OFF lt ON OFF Stations Sealing Positioner OFF p ON OFF Conveyor Main Conv Eee EJ DiyiFg Speed The speed of the machine can also be adjusted on this screen Use the top window to increase or decrease the speed to suit the other equipment connected to the machine Page 5 INLINE FILLING MACHINE MODEL AGF 2 2 CONTINUE SEALING ContSeal If the machine is stopped during operation and there are buckets on the conveyor that are filled but not sealed and labelled please follow the following steps 1 7 Remove all the buckets released from the bucket dispenser that are between the bucket dispenser and the filling station all loose empty buckets If there is a bucket at the selling station that has not been sealed prior to stopping the machine remove this bucket and place it on the conveyor on the next available position after the other filled and n
6. ion the bucket is placed in a roller unit which positions it for labelling After the label is applied the conveyor transports the bucket to a turn table where the operator can check the product before applying the lid manually The machine is for use in regular food packaging operations and is not designed to operate in special environments such as ones with explosion hazard Abbreviations Page 3 INLINE FILLING MACHINE MODEL AGF 2 e ContSeal Continue sealing after emergency stop e DlyFlg Delay distance and flag length screen e Speed Speed adjustments screen e Sys System settings protected e Acc Dec Drives accelerations deceleration e Limits Minimum number of buckets in the dispenser and maximum label length e DriveScale Drivers scale Index Conveyor Index Settings Page 4 INLINE FILLING MACHINE MODEL AGF 2 Section 2 User s Manual SCREENS OPERATIONAL SETTINGS The following parameters need to be set for before starting the filling process The speed of the machine The speed of the conveyor positioner and label head The delay angle for the positioner a a The delay distance and flag length for the label head Additional settings include 5 Number of buckets to be sealed positioned and labelled after an emergency stop This number needs to be checked and set after each emergency stop if there are still buckets on the conveyor that need sealing Drivers accelerations decelerations Min
7. ot sealed buckets The sealing will start again with the next stop of the conveyor only In there is a bucket in the positioner that has not been positioned for labelling prior to stopping the machine leave this bucket in the positioner and rotate it manually to the right position The positioning will start again with the next stop of the conveyor only Count the buckets filled with jam that are on the conveyor before the sealing station there should not be gaps between these buckets and write this number in the Continue Sealing screen Press the Continue Sealing button On the main screen check that the Bucket Filling and Sealing buttons are OFF and the Positioner and Label buttons are ON Press the Main Conv Button The sealing positioning and labelling of buckets will start with the next stop of the conveyor and will stop after the number set in the Continue Sealing screen is reached CONTINUE Sealing Main Diy Fg Speed Page 6 INLINE FILLING MACHINE MODEL AGF 2 3 ANGLE DELAY POSITINER AND TRIGGER DELAYS AND FLAG LENGTHS LABELLER DlyFlg When the bucket reaches the positioner it is gripped between the rollers and turned After the sensor sees the bucket the positioner continues to rotate the bucket for the angle set on this screen The distance at which the labeller is triggered after the product sensor sees the product and the length of the label that protrude from the peel plate can also be set on this sc
8. reen Non zero delays must be zn t set here for all labellers 299 9mm T Ea Manual Trigger Labeller Dly Fg Speed While the positioner s stop delay and the flag length can be set to zero the labellers will not be automatically triggered when the machine is running unless a non zero trigger distance is set There is also a button on this screen for manual triggering the labeller for testing purposed 4 MOTOR SPEED ADJUSTMENTS Speed The speed of the conveyor labeller and positioner can be individually adjusted using this screen Dly Fg Speed Page 7 INLINE FILLING MACHINE MODEL AGF 2 PROTECTED SETTINGS SyS The AGF 02 Model has the following default settings These settings have been preset by the manufacturer to ensure smooth operation of all devices ic It is recommended that only properly trained and experienced staff modifies these values if they need changing for any reason 1 DRIVE ACCELERATIONS Labellers The acceleration and deceleration rates for the conveyor labeller and positioner can be set using this screen 99999 Hz Ams 99999 Hz Ams 39999 Hz 4ms Limits abs Index MAIN Scale To ensure smooth operation of the machine these drive accelerations were preset by the manufacturer to e Main Drive Acc Dec 75 Hz 4ms e Labeller Acceleration 25 Hz 4ms e Positioner Acc Dec 25 Hz 4ms Page 8 INLINE FILLING MACHINE MODEL AGF 2 2 LIMITS The minimum n
9. umber of bucket in the bucket dispenser can be set on this screen When the sensor on the bucket dispenser sees a gap there are no buckets above it the conveyor slows down to 20 of the machine speeds and continue the filling sealing and labelling for the number of buckets set on this screen after which it stops If this number is 0 the conveyor stops immediately when the sensor on the bucket dispenser sees a gap there are no buckets in the dispenser above it 9999 33999mm Limits Lien Index MAIN Scale A maximum label length must be set on this screen This length is the linear movement of the labeller s drive after which it stops regardless of the label sensor reading This is particularly useful in the event the support paper breaks It is also useful for the calibration of the label sensor when 5 7 labels have to pass through the sensor s fork The maximum label length must be bigger than the actual length of the label Otherwise the labeller will not work properly it will stop before completely releasing the label If for any reasons the maximum label length is reached the labeller stops and an error is displayed on the main screen Once the cause for error is rectified label breakage maximum label length too short etc the labeller should start again and the error message will disappear from the screen The default settings for the maximum label lengths are e Labeller Front 1 Maxim 145 mm Page 9 INLINE F
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