vc999 593.767, Original Operating Manual

Page 1: ...RIGINAL 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 info vc999 c...

Page 2: ...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 ti...

Page 3: ...y 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 operat...

Page 4: ......

Page 5: ...4 2 7 Warranty and liability 14 3 Description 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 Weigh...

Page 6: ...31 7 6 Installation of the protective rollers 32 7 7 Cleaning the machine 32 8 Start up 33 8 1 Initial start up 33 8 1 1 Installation check 33 8 1 2 Switching on the machine 34 9 Operation 35 9 1 Gen...

Page 7: ...ration 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...

Page 8: ...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...

Page 9: ...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 ma...

Page 10: ...ine 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 safe...

Page 11: ...a hazardous situation which if not avoided may result in minor or moderate injury NOTICE Indicates a situation which if not avoided may result in considerable damage to equipment or environmental harm...

Page 12: ...cing inspection maintenance repair work of the machine at the owner s company has to have carefully read and understood the entire operating manual and especially the chapter entitled Safety and warra...

Page 13: ...ays state the type of machine and the machine number according to the data on the name plate 2 4 Machine stability Machine stability is guaranteed on a flat surface during normal operation if the mach...

Page 14: ...ed and communicated by the owner to guarantee that health and safety regulations are observed Operators are obliged to make sure the machine is in efficient working order prior to operation and to in...

Page 15: ...veyor belt wire mesh conveyor belt integrated in the machine The products are then conveyed through the machine on this belt An economic shower process is switched on as soon as the conveyor belt is a...

Page 16: ...Height adjustable machine feet 20 Photoel sensor 7 Control panel with touch screen display 21 Electrical connection for peripheral devices 8 EMERGENCY STOP button 22 Access cover 9 Water tank 23 Solen...

Page 17: ...tank for warming up the spray water Steam heater The machine is connected to a central steam generation unit The spray water is warmed up using hot steam that enters the water tank via a steam distrib...

Page 18: ...ssed after opening the service door 15 The belt cartridge is fitted with a wire mesh belt and equipped with a pro tective roller at the both ends The protective rollers provide finger pinch protection...

Page 19: ...an emergency situation 3 3 Technical data Standard scope of supply Machine on 4 machine feet Triangular socket key Square socket key Electric or steam heater Dry run security Steam extraction controll...

Page 20: ...no 593 767 2009 11 12 3 3 1 Dimensions Fig 3 2 1 Power cord feedthrough top 5 Water discharge 2 Power cord feedthrough bottom 6 Steam extraction connection 3 Electrical connection peripheral devices...

Page 21: ...d 0 3 0 8 m s adjustable factory setting 0 5 m s 3 3 5 Water system Connection dimensions for water supply line R external Operating pressure Manometer 0 10 bar Required operating pressure min 2 bar P...

Page 22: ...approx 7 minutes 3 3 8 Decalcifying system optional Diaphragm metering pump Metering performance 18 5 l h for 4 0 bar 3 3 9 Electrical data 3 3 9 1 Power supply Equipment conforms to EN 60204 1 The el...

Page 23: ...r guidance Errors are shown on the display as plain text Some PLC outputs can be individually controlled and have their functioning checked via the display 3 3 10 Noise emission The measurement was ca...

Page 24: ...installation site For more information on this read the sub section Criteria for the installation site in the next section Setting up the machine 2 Remove the packing and check that the entire consig...

Page 25: ...lease contact the our Customer Service to have individual electrical components and or respective safety devices installed if necessary The same applies for rooms with a relative humidity of below 50...

Page 26: ...evel to horizontally level out the ma chine The feet 1 have to be raised or lowered using an open end spanner size 30 as follows clockwise to raise anticlockwise to lower Raise or lower until the spir...

Page 27: ...s The procedure for electrical installation is described in section Installation of the machine 6 2 Water connection The water supply line must be provided by the owner The machine is equipped with a...

Page 28: ...socket keys in a safe place 7 1 Electrical installation WARNING Electrical hazard Danger of death electric shock Only carry out electrical work if you are au thorized and appropriately trained and qua...

Page 29: ...ing installation Otherwise the spray nozzles may become blocked The customer must integrate the following elements into the water supply line to the machine Manometer 0 10 bar Shut off valve The owner...

Page 30: ...cific water drainage Please refer to section Technical data for the connection dimensions Procedure Remove the left hand casing panel 2 Use an open end spanner size 13 to loosen the two bolts 3 two tu...

Page 31: ...reducing valve see Technical data for the correct adjustment Safety valve see Technical data for the correct adjustment Shut off valve The owner is responsible for the installation of these elements W...

Page 32: ...artridge Install the protective rollers 1 at both sides of the belt cartridge Fig 7 4 7 7 Cleaning the machine Always clean the machine after installation Remove any adhesive tape and waste packaging...

Page 33: ...e Make sure the machine is stably placed on the floor If neces sary level out the machine according to the description in the section Leveling the machine Electrical connection Check that the machine...

Page 34: ...the section Operation Use the main switch 1 to switch on the machine Turn main switch to position I Press the RESET button 2 Press the START button 3 The machine is ready for operation when Ready for...

Page 35: ...not flawless Never use the machine to process products that can be damaged or destroyed by hot water 9 2 Requirements for operation The following requirements must be met before the machine can be put...

Page 36: ...uttons at the visual touch screen dis play 2 EMERGENCY OFF Switching off in an emergency de energizes individual machine compo nents 3 START I Depending on the operating status activation of the butto...

Page 37: ...ately The water tank is being emptied Flashing The warm up phase is active The set water temperature in the water tank has not yet been achieved HEATER lamp Illuminated The set temperature has been ac...

Page 38: ...Explanation of the elements via three masks A Machine type B Time C Main menu D Sub menu E Display further symbols to the left or right F Input field G Switch Position 0 OFF Position 1 ON H Status sy...

Page 39: ...y occurs via interactive language independent symbols A specific mask is called after pressing these symbols on the display The following table displays the various symbols and which mask sub menus th...

Page 40: ...evel 0 when the machine is switched on and off 2 0999 Supervisor of the operator The same as safety level 1 but with the following ex ception The access right is not reset to safety level 0 when the m...

Page 41: ...Shrink Tunnel VC999 ST2 ST2 D Operation 2009 11 12 Art no 593 767 Page 41 96 Fig 9 3...

Page 42: ...g 9 4 The main menu consists of four pages which can be opened one after the other by pressing the arrow on the right Press the symbols on the main menu page 1 to access the following sub menus Progra...

Page 43: ...isplayed in this mask Only possible from safety level 1 and higher Press the switch to unlock I or lock 0 the infeed belt for op eration These settings are not saved in the program Internal conveyor b...

Page 44: ...nd higher Press the switch to unlock I or lock 0 the shower for opera tion These settings are not saved in the program Programs Outfeed belt Fig 9 10 9 4 1 6 Programs Use this mask to load an existing...

Page 45: ...ure mask 9 4 2 Operating hours meter Press the Operating hours meter symbol on main menu page 1 to access further sub menus which can be opened one after the other via the arrow buttons These display...

Page 46: ...not reset to zero Reset meter The selected meter is reset to zero 9 4 3 Alarm list Press the Alarm list symbol on main menu page 1 to access a summary of all previously triggered alarms The mask infor...

Page 47: ...ain menu page 3 Main menu page 1 9 5 1 LOG IN Proceed as follows to access one of the safety levels 1 3 Press the LOG IN symbol Use the displayed keyboard to enter the password and con firm it by subs...

Page 48: ...seful for VC999 service personnel Operating status Analog value Safety level This information is described in the following sections Fig 9 20 9 5 3 1 Machine status Operating status The operating stat...

Page 49: ...rror is displayed here with the corresponding error number The meaning of error numbers is described in the section Troubleshooting Analog value Safety level 9 5 3 2 Analog value Analog value l1 The a...

Page 50: ...east safety level 1 Fig 9 24 Press the symbols on main menu page 3 to access the following sub menus Autostart Manual decalcification Empty water tank Main menu page 4 Main menu page 2 9 6 1 Autostart...

Page 51: ...the spray water is warmed up during automatic warm up Production is not started 9 6 1 2 Automatic decalcification optional NOTICE The function can only be programmed when the machine is equipped with...

Page 52: ...RT button and the STOP button flash The decalcification process has been completed when the message is no longer shown on the display and both buttons stop flashing Messages The integrated decalcifier...

Page 53: ...from and recommended by the machine manufacturer Add three full measuring cups of powered decalcifier or six full measuring cups of liquid decalcifier 50 citric acid to the water tank WARNING Risk of...

Page 54: ...the valve in the discharge line at the water tank and to empty the spray water The START button and the STOP button flash alternately and Emptying is shown on the display until the emptying process h...

Page 55: ...ing sub menus Machine settings Inputs Outputs Main menu page 3 9 7 1 Machine settings Press the Machine settings symbol to access the following sub programs Machine data Language time and weekday Temp...

Page 56: ...mask provides the following functions Temperature unit Hold temperature Fig 9 34 Temperature Press the right hand field to toggle between C and F NOTICE All the saved programs are automatically adjus...

Page 57: ...k is only relevant for connected infeed and outfeed belts optional A change of transport direction results in a mechanical conversion of the shrink tunnel This mechanical conversion must be carried ou...

Page 58: ...nveyor belt run continuously NOTICE When the Communication defect mode is switched on the frequency converter is controlled via an external signal The machine is only operated via the set fixed freque...

Page 59: ...The inputs X0 and X1 cannot be changed Outputs Logical program status Changing the output signal for the program logic Signal at the PLC output Fig 9 38 The signal at the PLC output can be manually s...

Page 60: ...9 Cancelling production Press the STOP button on the control panel START button flashing HEATER lamp illuminated Conveyor belt and hot water cascade are switched off The machine goes into Ready for o...

Page 61: ...ted in the machine settings under Hold temperature see the section Temperature the water in the water tank is held at the temperature or cools down This program cannot be overwritten 9 13 Decalcificat...

Page 62: ...when the mes sage is no longer displayed and the two buttons stop flashing 9 14 Switching off the machine Switch the machine off as follows 1 Wait until the last shrink bag has been discharged from th...

Page 63: ...illed during the decal cification process Message is not displayed when the machine is equipped with a decalcifying system optional Machine not ready for opera tion Message displayed after pressing th...

Page 64: ...e main switch and if nec essary replace it Mains fuse provided on site has blown Replace the mains fuse provided on site EMERGENCY STOP button has been pressed Reset the EMERGENCY STOP but ton Display...

Page 65: ...vice Department Photocell soiled Clean the photocell and the reflector Incorrect setting Re adjust the photocell Machine does not start up for incoming products Photocell defective Replace the photoce...

Page 66: ...e longer than 20 seconds If necessary contact the VC999 Customer Service Department F03 Communication Frequency con verter Communication be tween the PLC and the frequency converter faulty Check the c...

Page 67: ...at the display Conveyor belt too tight Check the transport area F31 Transport drives The gear motor defec tive Read error code and contact the VC999 Cus tomer Service Department F39 Photoel sensor Th...

Page 68: ...767 2009 11 12 11 Operating supplies Assembly Recommended products Decalcification process Supplier Liquid decalcifier with 50 citric acid 25 kg standard canister Manual or automatic decalcifica tion...

Page 69: ...switch and put on a padlock to prevent the machine being switched on inadvertently Keep the key out of the reach of other people CAUTION Risk of burns After switching off the machine wait for the mac...

Page 70: ...ieve Wipe the outer surfaces of the machine with a moist sponge or cloth Clean the photocell and the reflector Fig 3 1 Pos 20 16 with a moist sponge or cloth Weekly Clean the belt cartridge and both s...

Page 71: ...ter sieve Fig 12 1 5 Re attach the machine casing and open the shut off valve 12 1 4 Cleaning the steam supply line filter sieve VC999 ST2 D CAUTION Hot steam There is a risk of scalding from the disc...

Page 72: ...pull the belt cartridge 5 out of the machine Fig 12 2 4 Extract the sieve 6 from the belt cartridge 5 Pull the collecting tray 7 out of the ma chine 6 Clean all the dismantled parts Remove any packag...

Page 73: ...d without the protective rollers 9 installed at both sides of the belt cartridge 5 11 Install the belt cartridge 5 in the machine Make sure that the notch 10 on the belt cartridge cor responds to the...

Page 74: ...e door seals and protective curtains are functioning correctly and are not worn The sealing elements must be replaced if excessive steam escapes from the machine Contact the VC999 service team 12 2 1...

Page 75: ...s available on request for all maintenance and servicing work NOTICE Maintenance work also always includes the regular cleaning work and checks 12 3 1 Regular maintenance work If required Replace the...

Page 76: ...Procedure 1 Remove the lower machine casing 1 on the right hand side of the machine Use an open end spanner size 13 to loosen both bolts 2 two turns 2 Hold the lower edge of the casing panel 1 and pus...

Page 77: ...h Ensure that the main switch cannot be switched on acci dentally 13 1 Repairs to electronics or control system Do not under any circumstances carry out repairs to the electronics yourself Consult the...

Page 78: ...display mounting and remove the display from the front of the housing Installation occurs in reverse order NOTICE Ensure that no cables are not trapped when installing the display 13 1 3 Replace buff...

Page 79: ...ind the relevant part number on the spare parts list and make a note of the name of the part We require the following details for the order Characteristic data Company name address address to which to...

Page 80: ...cable local regulations He is required to comply with the following instructions in particular Before the machine is disassembled disconnect it from outside supply lines Power supply Disconnect the pl...

Page 81: ...Shrink Tunnel VC999 ST2 ST2 D Circuit diagrams 2009 11 12 Art no 593 767 Page 81 96 16 Circuit diagrams...

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Page 95: ...lation 28 EMERGENCY OFF button 36 EMERGENCY STOP 62 EMERGENCY STOP button 16 Emptying 63 Emptying the water tank 54 Error messages 66 F Fill decalcifier 53 63 Filter sieve 29 Frequency converter 58 Fu...

Page 96: ...aving program 45 Scope of supply 19 Service door 16 17 Setting up the machine 25 Shower 44 Sieves 16 Socket key 28 Spare parts 79 Star knob 16 START button 37 Starting production 60 Start up 33 Status...