CW_CS4000 Maintenance Manual
Contents
1. Page 9 Eclipse 4000 Maintenance Manual MAINTENANCE NOTE When the conveyors are stopped the reject devise is disabled Therefore prior to undertaking any maintenance or cleaning work the conveyors MUST be stopped Regular cleaning down is the key to maintaining good system operation and optimum accuracy Therefore minimum cleaning and removal of product spillage should be carried out on a daily basis On a weekly basis a more thorough clean down and inspection of belts rollers and bearings should be carried out Any parts showing signs of ware should be replaced Conveyors Tension and tracking of the Checkweigher conveyor belts should be checked on a regular basis to prevent unnecessary ware or damage of components Belt tension On the Checkweigher conveyors it should be possible to grip the idle roller of the standard PU belt or multiple tape short conveyors without stalling the motor If the belt is over tensioned then tracking it will become very difficult Belt tracking When tracking any conveyor belt always remember that the belt will try to run towards the high point and it only needs a small amount of movement of the tracking roller to cause either a change in the direction or an increase in the speed of movement of the belt in the same direction Therefore always make a very small adjustment and wait a minute to note any change in belt position Also adjustment must be a mix of increase tension to one side and rele2. 7 eclipse Eclipse 4000 Maintenance Manual Introduction Included in this manual are sections on TRANSPORTING INSTALLING MAINTAINING and CLEANING the system This manual is also designed to give an engineer s view of the Eclipse Checkweigher and Sentry Metal Detector Combined system and as such is of a technical nature The complete system is detailed along with normal operation and also fault finding and repair The combined System can be operated in two modes 1 Where the metal detector handles its own rejects prior to the Checkweigher 2 Where the Checkweigher handles metal rejects on its outfeed conveyor It can also be configured as an INTEGRASEARCH which enables the metal detector set up parameters to be viewed on the Checkweigher display This system like all the other Cintex systems can be configured to confirm vital actions and or utilities are present such as a reject pack has left the line that the reject bin is not full obstructed that the correct air supply is available that the relevant photocells are not obstructed etc Any or all of these can be connected up to stop the line in the event of failure of any of them TRANSPORTATION 1 Checkweigher Motor Cables These are disconnected and temporarily tied up to prevent damage during transportation They must be released and connected prior to commissioning Ensure that the sealing rubber is secured with the cable and connect
3. 1 0 2 11 2 1 2 1 3 Cleaning page Checkweigher and Metal detector Clean down Procedure 1 0 Introduction Some Combined systems have been designed to IP65 standard This means that they will not withstand mid to high pressure hose down but will however easily cope with low pressure as per IP65 standard wash down The specification for IP65 with regards water ingress is as follows IP65 Protected against water jets at a flow of 12 5 I min and a pressure of 30KN m squared Other systems use a metal detector motor that is only to IP54 therefore these systems are permitted to be wipe down cleaned only with a wet cloth Check the system specification It should also be noted that reaching up from underneath the system guarding could access the metal detector drive motor pulley and belt Therefore all conveyors must be stopped before attempting cleaning of the system 1 1 General Please take note of the following cautionary measures Cleaning of the machine is only permitted when it is OUT of operation Stopped The cleaning process will naturally involve the opening of hinged lids or removal of cover guards and therefore the conveyor belt must be stopped
4. Before cleaning the system it is essential e For employees involved in cleaning to wear adequate protective clothing and hand protection as recommended by the manufacturer of any detergents being used 1 2 Detergents Some components of the Transport are manufactured from hard anodised Aly alloys which may be attacked by some detergents or disinfectants This can be detrimental to the operation of the machine and may also shorten the effective life of the system Care should be taken in the selection process for detergents and disinfectants used on the machine On the basis of pH value detergents can be classified as follows 1 Acid detergents 2 Neutral detergents 3 Alkaline detergents 01 12 02 V2 00 intex Page 11 Eclipse 4000 Maintenance Manual 1 Acid detergents Detergents with a pH value below 4 are potentially damaging to the equipment They are not suitable for daily cleaning and their use should be restricted to once a month at most followed by a thorough rinsing process with clean water 2 Neutral detergents Use preferably neutral detergents with a pH value of 7 2 Alkaline detergents Alkaline detergents with a pH value between 7 and 12 are normally suited to everyday cleaning However if any of these detergents are mixed with a Chlorine or strong oxidizing agent used to break down proteins and some vegetable staining such as carrot then special care must be taken to use not only the correct concentrat
5. 12 02 V2 00 intex Page 7 Eclipse 4000 Maintenance Manual WARNING LABEL HAZARD WARNING DO NOT INSERT HANDS OR ARMS INTO THIS APERTURE HEALTH SAFETY LABEL SAFETY FIRST READ THE MANUAL BEFORE OPERATING MACHINE ONLY TRAINED PERSONNEL SHOULD OPERATE CLEAN AND MAINTAIN MACHINE DO NOT OPERATE MACHINE WITHOUT GUARDS amp BIN IN PLACE STOP CONVEYORS BEFORE CLEARING PRODUCT BUILD UP OR BLOCKAGES e ALWAYS ISOLATE MACHINE BEFORE CLEANING OR MAINTENANCE Cintex Ltd M KE Featherstone Road Wolverton Mill AR R LAB EL N Milton Keynes UK MK12 5TH Tel 44 0 1908 629200 SYSTEM TYPE System Weight kg Serial No Year OIML Cert No Max Weight kg Min Weight g Max Speed m Sec Max Throughput PPM Supply 50 60Hz Phase Power 750 VA Air Pressure 4 to 6 Bar Temp Range 5 C to 35 C This system has been designed and manufactured in Accordance with the relevant harmonised European standards System types Metal Detector Followed by SENTRY SENTRY NEEDLESEARCH etc Checkweigher Followed by CS4000 CS2200 etc X Ray Followed by COMPACT or INSIGHT 300 etc 01 12 02 V2 00 Page 8 Eclipse 4000 Maintenance Manual Metal Detector Infeed Warning label metal detector head Conveyor Belt Checkweigher Infeed Only applies with non Combined systems Warning Label Infeed conveyor 01 12 02 V2 00
6. ard at the conveyor junctions plus the reject device on the outfeed conveyor If the system is used as a stand alone system then extra guarding around the outfeed end and reject device should be fitted NOTE When the conveyors are stopped the reject devise is disabled It is advisable to isolate the system before undertaking any maintenance or cleaning work Combined System CS4000 2 Cabinet Mains In Metal Detector Head CW Reject Hood MD Reject Bin 01 12 02 V2 00 intex Page 4 Eclipse 4000 Maintenance Manual Guarding for Combined System Incorporation After incorporation in the line extra guarding will be required in the two regions indicated shaded to fully comply with EN294 Location of reject device 01 12 02 V2 00 Page 5 Eclipse 4000 Maintenance Manual HAZARD WARNINGS Only suitably trained personnel should undertake cleaning and maintenance 1 systems are designed for incorporation into a line certificate of incorporation therefore the customer must take account of the potential pinch hazards that will exist at the interfaces with the rest of the line CINTEX has guarded up to the ends of their system At the outfeed end where the reject device is located It is not possible for CINTEX to fully guard to EN294 The customer therefore should take steps to protect their side of this and the infeed interface 2 There is a risk of injury due to reaching in and trapping
7. arms hands or fingers in an activated pusher diverter paddle or powered dipping or lifting conveyor reject if the customer does not guard their take off conveyor at this interface 3 Ifthe conveyor motors are stalled the temperature may rise above the normal operating temperature of 70 C and may cause a burn if contact made with bare skin 4 Burns may occur due to friction between conveyor belts if jammed 5 Injury may occur if air blast outlets are touched during operation Air pressure to the system MUST NOT exceed 10 BAR Normal operating pressure should be between 4 and 6 BAR 6 BEWARE of items ejected from the reject station during operation when either emptying a reject bin or working on or around that area Reject packs can be ejected from the line at high speeds especially by an air blast system Also beware of constituent parts of packs being blown off a line by an air blast device Always locate a receptacle under the REJECT HOOD where fitted in place of a bin prior to operation of the system If the system is to be used as a stand alone unit then beware of product falling off the end of the outfeed conveyor 7 Always STOP the conveyor system before undertaking cleaning of any part of or underneath the transport system There is a DANGER of trapping and injury to fingers in drives and rotating parts 8 NOT HOSE DOWN the system unless Cintex has given EXPRESS permission in writing 9 DO NOT ENTER THE TOP HATCH a
8. ase of tension to the other In that way the average belt tension is maintained and not increased Over tension will result in a greater difficulty to track the belt Belt replacement This can be easily and quickly achieved by stopping the system unplugging the motor cable and removing the two thumb screws in the side members The conveyor can then be rotated up and slid back out of the cradle Belt tension is released by rotating the idle roller up Then simply slide off the current belt or tapes and replace with the new ones Rotate the idle roller back down to restore tension refit into the conveyor into the cradle replace the thumbscrews and reconnect the motor cable Bearings The latest Checkweigher conveyors now use self aligning greaseable bearings for the drive roller Vegetable grease is used for these bearings To top up the grease requires a small nipple which is screwed into the bearing housing and grease inserted via a grease gun Bearings are located in special housings with oil seals either side The bearing is locked into the housing as is the roller shaft into the bearing with bearing lock The grease is then applied one stroke or pump only while the roller is spun to draw the grease into the bearing If the amount is exceeded it will result in displacement of the oil seal It is not recommended that untrained personnel replace bearings 01 12 02 V2 00 intex Page 10 Eclipse 4000 Maintenance Manual CLEANING contents
9. bove the weigh conveyor while the conveyors running Injury may result from contact with the activated reject device 10 Always or isolate the system before undertaking any system maintenance 11 When cleaning down debris and cleaning fluids will fall through to the floor and will need to be cleaned up to prevent a hazard from slipping or tripping NOISE LEVELS The Eclipse free standing Checkweighers and the Eclipse Checkweigher metal detector combinations systems produce less than 70 dB A of noise measured at the operator station Pneumatic rejects actuators other than air blast produce peak noise levels of less than 85 dB C measured at the operator station Air blast rejects produce peak noise levels of greater than 85dB C but les than 130dB C measured at the operator station All noise measurements were made using 010 SVANTEK SVAN912A noise meter from the operator station 01 12 02 V2 00 Page 6 Eclipse 4000 Maintenance Manual Checkweigher Outfeed Warning Label Hood or Bin Reject device Outfeed Conveyor If a Hood is fitted for weight rejects the system SHOULD NOT be operated without a suitable receptacle located under it to catch the ejected product NOTE Once the system has been installed into line the customer should take steps to guard their side of this interface to prevent access to the reject device and the pinch point between the transport conveyors 01
10. ct from on and under the transport conveyors 2 Application of detergent Apply the detergent either manually or under low pressure Use brushes where application is manual to aid in the freeing of stubborn dirt but do not use any abrasive tools which may damage belts or rollers The Checkweigher wide belt or multiple tape conveyors are designed for quick and easy release and removal This will allow for more thorough cleaning or maintenance of each 01 12 02 V2 00 intex Page 12 Eclipse 4000 Maintenance Manual 3 Allowing time for effectiveness The time required for the detergent to become effective and the concentration will depend on the detergent in use Always follow the manufacturers instructions and recommendations Once the time has elapsed final wash down must commence If activated detergent is left on for longer than the recommended time the concentration will increase as the water evaporates and may cause discolouration of the stainless steels surfaces With some activated detergents this effect is greater the better the quality of the stainless steel The rougher the surface the greater may be the effect of the discolouration because the detergent will stay on that surface for longer The rough surface can be caused by product particles adhering to it or even sprayed on disinfectant that is not rinsed off and allowed to dry 4 Final wash down rinse Final rinse is very important to prevent the discolouration or damage to m
11. etal surfaces Although there is a temptation in wash down environments to use high pressure water jets it must again be stressed that only low pressure is allowed This completes the clean down procedure 01 12 02 V2 00 intex Page 13
12. ion but also to thoroughly rinse it off Typical concentrations should not exceed 2 and must be rinsed off within the specified time typically 10 to 15 minutes not more than 20 to 30 minutes and should never be permitted to dry on the surface Since most detergents are sprayed on as a gel or foam it is important to thoroughly rinse it off this also applies to the disinfectant which if left to dry on a surface will increase the effect of the oxidizing agent in the detergent 1 3 Cleaning Process For most applications it will be perfectly acceptable to perform a wipe down of the system with a wet or damp cloth If the application is not messy i e boxed product then a wipe down will be adequate for the system If however the product is naturally messy then a wash down will be required A wash down is described as follows The wash down process can be broken down into steps Removal of product and coarse dirt Application of detergent Period to allow detergent to become effective Washing down and final rinsing E ce Please consult the manufacturer s instructions for detergent use and pH level and for any recommended protective clothing 1 Removal of product and coarse dirt The hinged lid on top of the system can first be opened and all product spillage and coarse dirt removed from on and around the transport conveyors especially the weigh conveyor Low air pressure may be used for the removal of loose dirt or produ
13. or 2 When lifting any machine and especially a combined system always use a forklift and support from under the lower frame bars Note that the centre of gravity will be between the CS4000 cabinet and the metal detector head since the majority of the weight will be in the metal detector head Where fitted always use the fork lifting brackets 3 Secure with ties through and over the lower frame DO NOT TIE DOWN OVER THE TOP OF THE COVER GUARDS OR THE CONVEYORS 4 DO LIFT OR PULL THE SYSTEM BY THE CONVEYORS 01 12 02 V2 00 intex Page 2 Eclipse 4000 Maintenance Manual LIFTING INSTRUCTIONS 01 12 02 V2 00 Page 3 Eclipse 4000 Maintenance Manual INSTALLATION 1 Once located into the correct position the system must be locked down to prevent movement and contact with adjacent line machinery It should also be level in operation Always use an RCD feed for the system 16 Amp rating Ensure that terminal covers are replaced after connection of the mains power cable Release the Checkweigher motor cables and connect to the motors and secure Ensure the sealing rubber is located in place prior to securing Connect a suitable air supply 4 to 6 BAR to the system MAXIMUM MUST NOT EXCEED 10 BAR Check that none of the conveyors are obstructed or in contact with adjacent equipment The customers should fit guarding at the interface of the CINTEX system with their own system There is a potential haz
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