CBE 730 AIR PACKER Safety - Installation - Operation - Maintenance

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1 CBE 730 AIR PACKER Safety - Installation - Operation - Maintenance 1 OF 20

2 FOREWARD This manual has been prepared to assist you with your Choice Bagging Equipment, Ltd. bag packaging equipment. The text contains instructions for installation and operation of your packing equipment, as well as directions for adjustment and maintenance. Following the text is the reference section which contains drawings; bills of materials, recommended spare parts, manufacturers' bulletins and any other information necessary to the successful operation of your equipment. If further information or assistance is needed, please call us. Choice Bagging Equipment, Ltd North Main Street, TX Phone: (512) , Fax: (512) Website: IMPORTANT NOTICE READ THIS MANUAL COMPLETELY before installing, starting-up, or operating this equipment. Be certain all personnel concerned with this machinery are fully alerted to the possible HAZARDS of the equipment and its utilities (electrical and pneumatic) before any operation is allowed. Choice Bagging Equipment, Inc. cannot emphasize enough the importance of good safety practices in the use of this equipment. Sound engineering and design practices have been applied to minimize the possibility of accidents. However, while using equipment of this type, good judgement and extreme caution are necessary on the part of all personnel. If any clarification is required -- ASK US! 2 OF 20

3 TABLE OF CONMTENT WARNINGS BEFORE OPERATING EQUIPMENT WHEN OPERATING EQUIPMENT CHAPTER 1 INSTALLATION Receipt inspection Assembly Procedures Solenoids/Pneumatics Fluidizing System CHAPTER 2 OPERATION Principle Operation Sequence of Operation Phase One Phase Two CHAPTER 3 START-UP INSTRUCTIONS & ADJUSTMENTS Pneumatics Control System Fluidizing System Scale Weight Adjustment Bag Chair Positioning Adjusting Fluidization CHAPTER 4 COMPONENT DESCRIPTION OF 20

4 WARNINGS The purpose of this section is to alert operating and maintenance personnel to the possible dangers of this type of equipment. Serious injury and/or equipment damage could result from not heeding these safety precautions. BEFORE OPERATING EQUIPMENT: 1) Any personnel working directly with or on this equipment should read this manual before proceeding with equipment use. 2) Electricians should familiarize themselves with the electrical drawings before initial start-up of equipment. 3) Other appropriate operating and maintenance personnel should familiarize themselves with mechanical layout and general arrangement drawings before start-up of equipment. 4) Determine location of all emergency switches. 5) Be sure all guards are in place and observe all warning signs. 6) Check oil level in all motors. 7) Be sure electrical equipment is free of any accumulation of water. 8) Be sure all personnel are clear of operating mechanisms before connecting air. 9) Never start equipment without first checking for loose objects, tools and trash. All persons in the immediate area of the equipment should be alerted prior to starting. WHEN OPERATING EQUIPMENT: 1) Observe extreme caution when switches are turned on. Operation may begin automatically after a time delay. 2) Do not open junction boxes or control panels unless you are a qualified electrician. Be sure power is off. Except when electricians are performing maintenance, electrical enclosures and junction boxes should always be securely closed. 3) Stop machine and disconnect power supply before servicing or repairing. Maintenance and adjustments must be performed with all power supply disconnected unless otherwise specified in this manual. 4) Do not attempt to defeat any safety switches. Serious injury could result. 5) While machine control power is on, do not activate limit switches manually. Serious injury and/or machine damage could result. Disable machine before attempting any maintenance or manual testing of components. 6) Gear motors will get warm to the touch and should not cause concern for equipment reliability and operation. A temperature rise is normal per new NEMA specifications. 7) If additional wire runs are added to any junction box or control panel, wiring practice should be such as to maintain prevailing electrical hazard classification. 8) High-pressure air systems are dangerous. Do not service or troubleshoot systems with air supply on. Be sure to bleed off any trapped air before working on components since it is possible to have high pressures trapped in airlines and cylinders, etc. 4 OF 20

5 9) Keep fingers, hands, feet, etc.; out of path of pneumatically operated components. 10) Safety glasses should be worn in equipment area. 11) Follow the safety regulations for your plant. Always use good judgment. WITHIN THE TEXT OF THIS MANUAL: "WARNING" indicates possible injury to personnel; "CAUTION" indicates possible damage to equipment; "NOTE" is an informational comment. 5 OF 20

6 6 OF 20

7 CHAPTER 1 INSTALLATION 7 OF 20

8 The Model 730 Pressure Flow Air Packer consists of the packer assembly and various items as ordered. Receipt and Inspection After uncrating the packer, a check should be made to see that all items ordered have been received and that all equipment is in good condition. Any damage incurred in shipment should be reported immediately to the delivering carrier and a claim for the damage should be filed. Also notify Choice Bagging Equipment, Ltd. so that replacement or repair may be initiated. The Model 730 Air Packer is shipped with 2 ¼ x 8 pieces of all-thread located at the top of the bag post. When packer is in final position, remove both pieces of all-thread to make the scale live. (See Picture) Assembly Procedures 1) Mark the centerlines of the packer, reference the General Arrangement drawing. 2) Set the packer into place. It may be desirable to defer final anchoring to the floor until after testing. Place the packer in the proper location, insuring the frame is level. Check the clearance and fit to the feed hopper and associated piping prior to securing it firmly to the floor. 3) Install pipe from the blower outlets to the air inlet valve of the chambers. 3A) Connect outlet of air valve to dust collection. 4) Install rubber connection sleeve between bin and hopper to isolate bin vibrations from packers. (Sleeve not provided with machine. Recommend wall thickness. Sleeve can be purchased from CBE separately). 5) If a multiple tube arrangement is to be made, remove filter regulator assemblies on all but the left-hand tube and set tubes on 36" centers. 6) The weighing assembly is secured by two shipping bolts that protect the scale from any damage during shipment. Be sure to remove the shipping bolts located above the bag chair post before attempting to operate the machine (See Picture above). 7) If the equipment uses an analog weighing unit, make certain that the load cell and parts suspended on it are free from side friction. 8) Adjust the fill tube on the bag post into alignment with the isolator tube and the chamber or housing. This is accomplished by loosening the fastening bolts that hold the bag post in position and adjusting the bag post either up or down into position. 8 OF 20

9 Solenoids/Pneumatics All pneumatic components (air valves & cylinders) are self lubricating and additional lubricated air is not required. If lubricated air is used then lubricated air must be used for the life of all the cylinders. 1) Connect high-pressure air line of the packer to suitable source of supply (1/2 pipe connection). 2) It is recommended that a suitable water trap (not supplied with machine) be installed prior to the regulator in the high-pressure air line and the packer. Drain the trap as required. 3) Connect air hoses to cylinder of bag chair for automatic bag discharge (optional equipment). If the machine was ordered from the factory with the bag discharge option, This will already be done. If the machine was not originally ordered with the bag discharge option, it should be preplumbed for operation if the option is added at a later time. 4) Connect all air hoses which were disconnected for shipment. All hoses and related fittings are correspondingly color coded for ease of re-assembly. Fluidizing System Lower Pressure Blower System: It is important that the blower be installed in a relatively dust free area. The intake should be extended to an area free of contamination outside the building. Be sure that the blower is running in the right direction - check the arrow on the motor housing near the drive shaft. If you are using a regenerative blower system, all air lines are pre-fitted and already connected. If you are using a positive displacement blower package, connect the low-pressure air inlet on the packer to the positive displacement blower (2-1/2" pipe connection). The gauge assembly is for use when the adjustment of the blower relief valve is made. High Pressure Blower System: If you are running high pressure air to fluidize, you will find two separate regulators located on the back of the machine. The supply air comes into one side and the other side is plumbed to the packer. The first regulator is se for PSI and the second regulator is set for 5 PSI. Now close the top air valve (2 gate valve) and the air pad air (3/4 ball valve). Place bag on fill spout and press start button. Begin to open the 3/4" ball valve until material appears. Open 2 gate valve a full turn to a turn and a half If you experience a hesitation in product flow from when the bag is started until it starts to flow, open the 3/4" ball valve more. 9 OF 20

10 Product should start to flow immediately when the pinch cutoff opens. If you have a 3/4 ball valve open all the way and still have hesitation, you may need to upsize the volume and upsize the line coming out of the double regulator to a 3/4" line. 10 OF 20

11 CHAPTER 2 OPERATION 11 OF 20

12 Principle of Operation A conditioning or pressure chamber is the main feature in the all pneumatic system of the Model 730 Pressure Flow Packer. This chamber receives and fluidizes the product material, prior to delivery to the bag. An intake gate at the top of the chamber opens to receive the material from the supply bin and closes to allow the chamber to be pressurized by the low-pressure air circuit (Blower). High-pressure air (80 PSIG), operates the solenoids and cylinders. On actuation of Start signal by the operator, a cutoff device opens to allow the air-solids mixture to be fed to the bag. The cutoff closes automatically when the material in the bag reaches a pre-determined weight. Bags are weighed during the filling operation on a unit consisting of bag support frame and filling tube mounted on the front of a scale beam. Filled bags are discharged automatically when the machine is equipped with an automatic discharge bag chair arrangement. All of the operation activity for each bag filling cycle takes place in a matter of seconds. This packing speed is important--not only to achieve high production rates, but also for proper function of the Model 730 Pressure Flow Packer. When fixed bed fluidization starts on closure of the feed gate, generally the rapid flow of the air-solids mixture through the filling tube to the bag takes place with little if any appreciable decay of the filling process. Sequence of Operation A representative arrangement of the packer is shown below. It serves to amplify the following description of a typical, TWO PHASE operational sequence for filling a bag. It should be noted, however, that a variety of constructions are optional for the Model 700. The sequences as drawn, show the optional timed powered discharge, timed bag sealer, and separate exhaust arrangement. PHASE ONE Phase One is the condition in effect at the end of a filling cycle. After actuation of the Stop (or scale) signal the following sequences occur. 1) The flexible pinch tube cutoff closes, stopping the flow of material to the bag. 2) The air intake valve closes off the air supply from the low/high-pressure, air system. 3) Chamber pressure is relieved. Depending on the material, this exhaust is accomplished in one or a combination of three ways: Through a timed separate exhaust, through the main in-feed gate, or through the disseminator. 4) The bag clamp releases, the bag is discharged and the feed gate opens to recharge the chamber with material, after a delay. With the optional features shown on the schematic, the exhaust is accomplished by the valve opening. The valve sealer deflates; this can be timed to ensure material stabilization in the bag. The powered discharge bag chair tilts to discharge the filled bag at the end of the sealer deflation. The timing of these features is done with specially designed pneumatic controls. During this non-bag filling phase, 'fixed bed fluidization" occurs as air from the blower source flows through the fluidizing air pad up through the material at the bottom of the chamber. During Phase One, the operator also places an empty bag on the filling tube after discharge of the previous bag. 12 OF 20

13 PHASE TWO Phase Two is the condition in effect during the filling cycle. After actuation of the start signal the following conditions occur: 1) The bag clamp secures the bag to the filling tube. 2) The bag chair retracts to a level position. 3) The bag sealer inflates inside the valve of the bag. 4) The feed gate (butterfly) closes, sealing off the chamber, allowing proper chamber pressure to build and cutting off additional material supply. 5) The air intake valve opens to allow air from the low/high pressure system to pressurize the chamber and fill the void left in the chamber when the material is packed into the bag. 6) The material is flows into the bag until the desired net weight is reached. 7) When the bag comes to weight, the controller trips the "Stop" circuit and the condition in Phase One is in effect. If the packer is equipped with the optional automatic starting device, the start signal is obtained automatically when the bag is placed on the filling tube and contacts the starter lever. 13 OF 20

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15 CHAPTER 3 START-UP INSTRUCTIONS & ADJUSTMENTS 15 OF 20

16 The CBE 730 Series Packer is an automatic packer. The operator is required to put an empty bag on the filling spout activating the auto start switch. The bag is then filled and weighed automatically, and when equipped with powered bag chair, is discharged automatically upon weighment complete. If for any reason it is desired to interrupt the filling operation in the middle of a cycle, a Stop pushbutton is provided. This is the red pushbutton facing the operator. It is recommended that the following adjustments be made to the packer before any material is delivered to the receiving hopper. Make sure all personnel are clear of machine. Pneumatic Control System 1) Open manual valve for incoming high-pressure air. 2) Adjust pressure regulator to 80 PSIG (with power off). High pressure fluidizing regulator to 20 PSI. 3) Place an empty bag on the filling tube activating the start switch putting the packer in the filling mode. NOTE: Components should now be in Phase Two operation. 4) Adjust the bag seal pressure to no more than 5 PSIG (optional equipment). The bag seal should expand just enough to secure the valve of the bag. NOTE: Excessive pressure may cause damage to the bag seal and tear the bag. 5) Further adjustment may be required during actual packing operation. Press the Stop pushbutton for emergency or broken bags. NOTE: Components should now be in Phase One operation. Fluidizing System Start the low pressure blower or high pressure regulator at 20 PSI output (regulator gauge reading). Operational adjustment may be required later to conform to characteristics of the product packed. Scale weight Adjustments. (MECHANICAL SCALE ONLY) 1) Turn low pressure blower off. 2) Press the start button to put the packer in PHASE TWO. 3) Place the exact weight that you want in the bag on the bag chair or hang from fill spout. 4) On the upper scale beam bar, if adjust the weights out for more weight or in for less weight. 5) Adjust the weights just until the beam moves up and the packer shuts off. 6) Turn low pressure blower on and fine adjust the first few bags. 16 OF 20

17 Bag Chair Positioning Bag chair is raised and lowered manually to adjust to bag length. A series of holes in the bag post accepts a pin on the bottom of the chair assembly, resulting in a secure setting. Pasted Bags: Place a bag on the filling tube and smooth the body of the bag down. Unfold the bottom of the bag to a horizontal position. Position the bag chair so that it touches the bag. Sewn Bags: Place a bag on the filling tube and smooth the body of the bag down. For first setting, position the bottom of the bag chair s1ot 1 " be 1ow the bottom of the bag. Because of the wide variety of valve bags available, trial and error experimentation may be required to obtain the optimum bag chair adjustment. Correct adjustment is best made with a filled bag. Prior to removing the filled bag from the filling spout, verify that the weight of the bag is resting on the bag chair and not hanging from the packer spout. The paper (or plastic) at the top of the bag should not be under tension. Incorrect bag chair adjustment is a common cause of off weight and bag size problems. Care should be taken that the bag chair position is high enough to allow the bag to fill out properly at the end of the filling cycle, especially in the upper portion of the bag. If the chair is not high enough, the bag capacity may be greatly reduced. CAUTION: Improper use of the bag chair can cause damage to the weigh beam. Do not drop, stand or jump on the bag chair. Adjusting Fluidization 1) Put product into pressure chamber. 2) Feed gate open (at "rest" position) 3) Turn both top and fluidizing air to air pad off. 4) Place a new empty bag on fill spout and start machine. 5) Start opening the ball valve (bottom air) leading to air pad, just until material starts flowing into the bag. 6) Adjust 2 gate valve (top air) open two full turns. NOTE: If you still have a hesitation of product flow after going through the procedure above, you may need to open the bottom air a little more. (DO NOT OVER FLUIDIZE THE MATERIAL ON THE AIR PAD.) 17 OF 20

18 700 Air Packer Rev. A OF 20

19 CHAPTER 4 COMPONENT DESCRIPTION 700 Air Packer Rev. A OF 20

20 Choice Bagging Equipment's Model 700A is an air-operated pneumatic packer as described below: 1. Feedgate (Illustration CBE-703-C) Controls the flow of product into the pressure chamber. In this instance, a feedgate consists of a butterfly valve actuated by a pneumatic cylinder. The feedgate opens and closes at the beginning and the end of each cycle Way Valve A three way cylinder actuated valve, which allows low-pressure air into top of chamber during the fill cycle. It is also used to exhaust the chamber when deenergized to allow for recharging the system with material between bag filling cycles. 3. Digital Filler Controller ( ) The digital filler controller controls all aspects of the bag filling cycle. It is directly responsible for controlling the solenoid valves and cylinder operated functions of the machine. 4. Analog Controller The analog filler controller controls all aspects of the filling cycle. It is directly responsible for controlling the solenoids and cylinders. 5. Solenoid/ Pneumatic Assembly ( ) 6. Bag Chair (Illustration CBE-106) 7. Cutoff Assembly (Illustration CBE-103A,B,C) 8. Filling Spout and Flow Tube Assembly (CA- 1008) The solenoids or pneumatic valve control the air operated functions of the machine. A configuration of three to six solenoid are located in the typical solenoid control panel. A pneumatically operated bag chair supports the bag while being filled, then pivots, by an air cylinder to discharge the filled bag. It should be adjusted to support the bag while filling to allow for the material to enter the bag unrestricted. Standard bulk only (CBE-103-A) cutoff allows product to flow through the filling tube and out the spout unrestricted into the bag until final weight is reached. Optionally, the bulk & dribble cutoff (CBE-103-A,B) uses two double acting cylinder to create a fast/slow feed throughout the filling process. This unit consists of a gum rubber tube which connects the pressure chamber with the filling spout via a intermediate connector. It is mounted within the cut-off assembly and is pinched when the packer reaches weight or any time the cycle is stopped. 9. Dust Collection Standard ductwork is supplied and located behind the front post and under the filling spout area. See the General Arrangement drawing for location and type of connection. It is used to direct dust into the customer's collection system. 10. Bag Clamp Assembly ( ) Pneumatically operated double acting cylinder which clamps the bag onto the spout during the fill cycle and releases automatically. CAUTION: Keep fingers clear of clamp when placing bag on spout. 11. Low Pressure Blower A positive displacement, high volume, low-pressure blower incorporating a weighted type relief valve. Pressure is regulated by placing weights on the valve to increase pressure and removing weights to decrease the pressure. The maximum volume is 187 SCFM at 6 PSI. 12. Disseminator (Illustration 703-B) 13. Lower Fluidizing Chamber (703-A) This unit is located inside of the upper pressure chamber and is connected to the intake gate. It serves to disseminate or disperse the incoming 'top' air to aid in fluidization of the material and to pressurize the chamber. The filter medium of disseminator prevents the product from traveling back into the blower. This is a canvas pad located at the bottom of the pressure chamber for dispersal of incoming bottom air, which aerates the material in the chamber. 700 Air Packer Rev. A OF 20