Use and Maintenance Manual Teknofill VMF-L (1)

USE AND
MAINTENANCE MANUAL
Machine :
Filling machine
Type :
VMF-L
Year :
2011 (edition 04-11)
SAFETY STANDARDS
CE
TRASPORT AND
INSTALLATION
GENERAL INFORMATION,
DESCRIPTION AND SAFETY DEVICES
USE MANUAL
VIDEO PAGES OF THE CONTROL
PANEL
MACHINE MAINTENCE
DIAGRAMS VOLUME
SPARE PARTS VOLUME
MACHINE DISMANTLING
MANUAL ATTACHMENTS
Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy
Tel. 0039.02.4886761 - Fax 0039.02.4882153 - Web www.teknoice.com
General introduction
The company Teknoice S.r.l. designed and built this machine according to the rules of the EU
Directive 2006/42/EC.
The machine is not dangerous for the operator, if used according to the supplied instructions of the
company Teknoice S.r.l. under the conditions of use.
Also safety devices must be kept always efficient and maintenance operations must be performed
as required, according to the indicated frequency.
This manual should be kept throughout the life of the machine and should always be available for
the operator and maintenance engineer.
The information contained in this manual are the property of Teknoice s.r.l.
The company Teknoice S.r.l. reserves the right to change, without notice, product features
described in this manual.
It’s forbidden to distribute and reproduce, even partially, this manual without written permission of
the company Teknoice S.r.l.
Technical service
Teknoice S.r.l.
Via Lazio, 37
20090 Buccinasco (MI)
Italy
Tel. 0039.02.4886761
Fax 0039.02.4882153
Web www.teknoice.com
Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy
Tel. 0039.02.4886761 - Fax 0039.02.4882153 - Web www.teknoice.com
Responsibilities of the Manufacturer
The Manufacturer Teknoice S.r.l. delivers to the buyer the goods in conformity with the laws of
Italy.
It is understood that any liability arising from goods, for events after the transfer of risks to the
buyer, including any damage to persons or things (even when they are accessory parts or
elements of the work center of Teknoice s.r.l.) will be exclusively charged to the buyer, who shall
indemnify the seller and also undertakes to ensure any relative risk in a proper way, without right of
recourse against the manufacturer.
Limitation of Liability of the Manufacturer
Unless fraud or gross negligence of the Manufacturer, any compensation for any damage to the
buyer may not exceed the share value of the machinery of the company Teknoice S.r.l. regarding
to the defective part.
Note for users
Every care has been taken in the realization and verification in order that the information contained
in this document would be complete, accurate and updated.
However, the company Teknoice S.r.l. cannot provide any guarantee on the performance and
results achieved by the use of this documentation and cannot be considered responsible for
damages or benefits arising from improper use of this documentation and devices to which it
relates.
The same applies to any person or company involved in the creation, production and distribution of
this documentation.
The company Teknoice S.r.l. also cannot guarantee that changes or updates to software or
devices, supplied by the third parties, to which this documentation refers, will be compatible with
the information contained in the documentation and will not modify the instructions and data.
General safety
The company Teknoice S.r.l. cannot be held responsible for injuries and damages of any kind
occurring to persons, property or otherwise, caused by improper use or abuse of the machine.
Modification / removal of equipment of the machine or modification / removal of guards and safety
devices provided by the company Teknoice s.r.l., lead to the immediate loss of warranty.
All the control devices are active only when all guards and safety devices work properly.
Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy
Tel. 0039.02.4886761 - Fax 0039.02.4882153 - Web www.teknoice.com
Warranty
The company Teknoice S.r.l. guarantees the machine for a period of 12 months from date of
shipment, referring to a shift of 8 working hours per day.
The company Teknoice S.r.l. should replace or repair any defective part during this period. The
warranty is limited to replacement or repair of defective part, not including delivery or labor costs.
The warranty does not cover parts subjected to wear, such as bushings, bearings, seals etc.
If a failure or damage of the machine is caused by its misuse or tampering, by the intervention of
unauthorized technicians or use of not original spare parts, the warranty expires.
The company Teknoice S.r.l. has no other obligations or fulfillments as for mentioned above.
For any technical communication with the company Teknoice Srl always make use of the following
communication form.
Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy
Tel. 0039.02.4886761 - Fax 0039.02.4882153 - Web www.teknoice.com
Communication form
CAUTION
Fulfill the top of the form and use the fulfilled page as original copy which should be duplicated and
used for the communication with the company Teknoice S.r.l.
Machine model:
Installation date:
Serial number:
Order number:
Description of the problem/defect :
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
Communication
Date:
date:
Signature and
Working hours:
stamp:
Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy
Tel. 0039.02.4886761 - Fax 0039.02.4882153 - Web www.teknoice.com
Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy
Tel. 0039.02.4886761 - Fax 0039.02.4882153 - Web www.teknoice.com
DECLARATION OF CONFORMITY CE
(in conformity with the Attachment II A – machine – of the Directive 2006/42/CE on Machinery)
The company Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy
Tel. 0039.02.4886761 - Fax 0039.02.4882153,
Declares under its responsibility that the concerned machine or system:
Order nr XXX.XXX
consisting of the following groups :
Type
Q.ty
Serial number
Code
Year
2011
2011
2011
2011
COMPLIES WITH:
the Directive 2006/42/CE on Machinery (as amended);
the Directive 2004/108/CE (as amended);
the Directive 2006/95/CE (as amended).
The signer of the Declaration of Conformity CE and who builds up the Technical Manual:
Surname :
Teknoice S.r.l
Name :
Location :
Buccinasco
Date :
___________
___________________
Signature :
Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy
Tel. 0039.02.4886761 - Fax 0039.02.4882153 - Web www.teknoice.com
Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy
Tel. 0039.02.4886761 - Fax 0039.02.4882153 - Web www.teknoice.com
EC standards
Machine :
FILLING MACHINE
Type :
VMF-L
EC Standards
Filling machine VMF-L
Page 1
Volume 01_ECS_Language
_Rev.00
EC standard
INDEX OF CHAPTER
EC STANDARDS ....................................................
......................................................................................................
.......................................................................................... 1
EC STANDARDS: ACCORDING TO DIRECTIVES 2006/42 EC AND SUBSEQUENT AMENDMENTS .................... 3
1.1.1 DEFINITIONS ................................................................................................................................................. 3
1.1.2 PRINCIPLES OF INTEGRATION OF SAFETY .............................................................................................. 3
1.1.3 MATERIAL AND PRODUCT........................................................................................................................... 4
1.1.4 LIGHTING ....................................................................................................................................................... 4
1.1.5 DESIGN OF THE MACHINE FOR TRANSPORTATION PURPOSES ........................................................... 4
1.2.1 SAFETY AND RELIABILITY OF THE CONTROL SYSTEMS......................................................................... 4
1.2.2 CONTROL DEVICES...................................................................................................................................... 4
1.2.3 START-UP ...................................................................................................................................................... 5
1.2.4 STOP DEVICES ............................................................................................................................................. 5
REGULAR STOP ............................................................................................................................................... 5
EMERGENCY STOP ......................................................................................................................................... 5
1.2.5 OPERATING MODE SELECTOR SWITCH.................................................................................................... 5
1.2.6 CONTROL DEVICES...................................................................................................................................... 5
1.2.7 MALFUNCTION OF THE CONTROL CIRCUIT .............................................................................................. 6
1.2.8 SOFTWARE.................................................................................................................................................... 6
1.3.1 STABILITY ...................................................................................................................................................... 6
1.3.2 RISKS OF BREAKAGE DURING OPERATION ............................................................................................. 6
1.3.3 RISKS DUE TO OBJECTS FALLING OR BEING THROWN.......................................................................... 6
1.3.4 RISKS DUE TO SHARP EDGES AND SURFACES....................................................................................... 6
1.3.5 PREVENTION OF RISKS DUE TO MOVING PARTS .................................................................................... 6
1.3.6 SELECTIONS FOR A PROTECTION AGAINST RISKS DUE TO MOVING PARTS...................................... 7
1.4.1 GENERAL REQUIREMENTS ......................................................................................................................... 7
1.4.2 PARTICULAR REQUIREMENTS FOR SAFETY ............................................................................................ 7
1.4.2.1 FIXED GUARDS .................................................................................................................................... 7
1.4.2.2 MOVING GUARDS ................................................................................................................................ 7
1.4.2.3 ADJUSTABLE GUARDS THAT LIMIT ACCESS.................................................................................... 7
1.5.1 RISKS DUE TO ELECTRICITY ...................................................................................................................... 7
1.5.3 RISKS DUE TO DIFFERENT ENERGY.......................................................................................................... 7
1.5.4 RISKS DUE TO ERRORS OF ASSEMBLY .................................................................................................... 8
1.5.5 RISKS DUE TO EXTREME TEMPERATURES .............................................................................................. 8
1.5.6 RISKS OF FIRE .............................................................................................................................................. 8
1.5.7 RISKS OF EXPLOSION.................................................................................................................................. 8
1.5.8 RISKS DUE TO NOISE................................................................................................................................... 8
1.5.9 RISKS DUE TO VIBRATIONS ........................................................................................................................ 8
1.5.10 RISKS DUE TO RADIATION ........................................................................................................................ 8
1.5.11 RISKS DUE TO OUTSIDE RADIATION ....................................................................................................... 8
1.5.12 RISKS DUE TO LASER DEVICES ............................................................................................................... 9
1.5.13 RISKS DUE TO GAS AND DUST EMISSIONS ............................................................................................ 9
1.5.14 RISK OF BEING TRAPPED IN THE MACHINE ........................................................................................... 9
1.5.15 RISKS OF FALLING ..................................................................................................................................... 9
1.6.1 MACHINE MAINTENANCE ............................................................................................................................ 9
1.6.2 MEANS OF ACCESS AT THE WORK PLACE AND INTERVENTION ........................................................... 9
1.6.3 INSULATION OF THE SOURCES OF ENERGY AND SUPPLY .................................................................... 9
1.6.4 INTERVENTION OF THE OPERATOR .......................................................................................................... 9
1.6.5 CLEANING OF THE INTERNAL PARTS ........................................................................................................ 9
1.7.1 INFORMATION DEVICES ............................................................................................................................ 10
1.7.2 WARNING DEVICES.................................................................................................................................... 10
1.7.3 WARNINGS AS TO RESIDUAL RISKS ........................................................................................................ 10
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Filling machine VMF-L
EC standards
EC Standards: according to Directives 2006/42 EC and
subsequent amendments
1.1.1 Definitions
1. By “dangerous zone” we mean an area of the machine which puts the individual’s safety and
health at risk (see layout).
2. By “exposed person” we mean a person located in a dangerous zone of the machine.
3. “Operator” is the person or persons appointed to install the machine, operate it and perform
maintenance on it.
1.1.2 Principles of integration of safety
a) Construction of the machine provides for it to operate, be adjusted and undergo maintenance
without these operations exposing risks to people, if performed in the conditions envisaged by
the Manufacturer. The purpose of the measures adopted is to eliminate the risk of injuries
during the machine’s foreseeable lifetime, including the assembly and disassembly states, even
if said risk should be the consequence of a foreseeable abnormal situation. Proof of what is
stated above will be illustrated in the following paragraphs of this report.
b) The machine is designed so as to almost completely eliminate risks due to moving parts. For
those cases in which these risks are not completely eliminated, appropriate guards that will be
described further on have been adopted.
c) The machine is designed to package food products, and can work only in this way. Other uses
must not be performed without written approval by the Manufacturer as indicated in the use
manual.
d) Particular effort on the part of the operator is not required because the control systems are
made up of push-buttons and not levers, flywheels, etc. During operation in cycle, the operator
controls the machine through an operator panel.
e) Carefully read the paragraph “Protection devices” in this manual for helpful references to
personal protection.
f) Special equipment: For the elements forming the machine, common equipment normally found
in all maintenance departments suffices.
Filling machine VMF-L
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EC standard
1.1.3 Material and product
Materials that could represent risks to the operator, such as asbestos, alloys containing beryllium,
etc., were not used.
The products used during processing which could be noxious are given in the manual, with the
relative instructions on how to manage said products, moreover following the instructions given by
the supplier with the relative safety sheets.
It is the responsibility of the operator to obtain the safety sheets of the products.
1.1.4 Lighting
The machine must be provided with adequate lighting both in the work zones, and in the areas
where the operator must perform maintenance.
1.1.5 Design of the machine for transportation purposes
The machine has been designed and built taking into account the requirements of transportation
and it is possible to dismantle it in several parts, depending on the type and with systems suitable
for handling.
1.2.1 Safety and reliability of the control systems
The control systems are safe and can stand normal service stresses and are wired with logic for
the machine cycle, while emergencies and safety functions are redundant and not subject to the
PLC logic.
The emergency push buttons all work in series on relays that, disconnecting, interrupt the supply of
the auxiliary equipment. All the outtakes of the PLC, not having an intake signal, disconnect all the
control relays.
1.2.2 Control devices
The control devices can be easily distinguished by the label placed on the electrical panel, with
description of the operation, and the practical uses and by the abbreviations given in the wiring
diagram for a clear and unequivocal identification.
Starting the machine occurs from a highly visible and safe position so that the safety of the
individuals is not compromised at the moment of start-up.
Use personal protection gear such as: masks, goggles and shoes.
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Filling machine VMF-L
EC standards
1.2.3 Start-up
Restarting the machine after a stop only occurs with a voluntary action.
With the connection of the general switch and/or because of lack of voltage and/or due to
emergency, the machine must be reset with the specific push button and all the operations
restarted.
1.2.4 Stop devices
Regular stop
There is a button for general stop. Regular stop is performed by operating the various stop buttons
which are available in every work zone.
Emergency stop
The emergency stop is done with the same push button (mushroom) placed in every work zone.
For the new start command, the push button must be unblocked and all the motors and the
operations restarted after having been reset.
1.2.5 Operating mode selector switch
Through the operator interface panel, one has the choice of selecting the method of the cycle with
which one wants to work the machine.
In the passage between the various modes there is no possibility of wrong movements of functions
but only those selected.
1.2.6 Control devices
Electrical circulation is performed in such a way that there is no early start-up, drop or discharge of
a mobile element of the machine or of a part of the machine, etc....
Lack of voltage blocks the machine in all its operations and, when voltage returns, the devices
must be restored and restarted.
The same applies to compressed air and oil pressure. In case of short circuit, the thermal magnets
trip; the same applies for an eventual discharge to ground or unexpected overload.
Filling machine VMF-L
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EC standard
1.2.7 Malfunction of the control circuit
The control circuit has been designed to avoid dangerous situations, and in particular:
• Early restart;
• Impediment in stopping machine;
• Ineffectiveness of safety devices.
1.2.8 Software
The software is designed so that no dangerous situations are created, is easy to manage and has
self-diagnosis system.
1.3.1 Stability
Stability is guaranteed by following the instructions given in this manual.
1.3.2 Risks of breakage during operation
All the elements used have sufficient resistance characteristics and are suitable for the
environment and their utilization; in particular, the elements subject to pressure and stress
(especially flexible and rigid pipes).
1.3.3 Risks due to objects falling or being thrown
None.
1.3.4 Risks due to sharp edges and surfaces
All the angles have been bevelled to avoid risks.
1.3.5 Prevention of risks due to moving parts
All the moving parts (rotating shafts, pistons, racks, etc.) are protected and/or separated by casing,
and the fixed safeguards are suitable for avoiding contact with the operator and therefore an
accident in accordance with UNI EN 12100 points 4.2.2.1 and 4.2.2.2.
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Filling machine VMF-L
EC standards
1.3.6 Selections for a protection against risks due to moving parts
The protections of moving parts are of fixed type with possibility of removal wit special tools and
are sturdily built. They comply with point 1.4.2.1 of the Machinery Directive 2006/42 and
EN12100 points 4.2.2.1 and 4.2.2.2.
1.4.1 General requirements
All the guards have been drawn and designed to resist mechanical stresses.
1.4.2 Particular requirements for safety
None.
1.4.2.1 Fixed guards
See point 1.3.6.
1.4.2.2 Moving guards
See point 1.3.6.
1.4.2.3 Adjustable guards that limit access
See point 1.3.6.
1.5.1 Risks due to electricity
The electrical system is designed and built in accordance with EN 60204-1 standards.
1.5.3 Risks due to different energy
The machine has been designed and built in order to prevent all risks due to the various systems
installed with signs and instructions.
The sources of energy are:
Air
For the operation of the pneumatic parts (6 bar).
Process elements
The flexible pipes for the elements of process are tested at 2 times the
operating pressure (see paragraph 1.3.2).
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EC standard
1.5.4 Risks due to errors of assembly
The direction of rotation of the motors is indicated on the casing of the motors with a “directional
arrow”.
The flexible pipes are marked with coloured heat-shrinking that indicate where they must be
mounted. Inversion therefore becomes impossible during assembly which could damage the
machine and create risks for the operator.
1.5.5 Risks due to extreme temperatures
The system when operating normally does not handle materials at high temperatures (max. 90 °C).
The parts relative to heating have been protected and insulated with insulating materials. The
temperatures on the uncovered parts of the machine are tolerable to human touch.
There are no components with temperatures under 0°C.
1.5.6 Risks of fire
The machine has been designed to avoid this risk. Adhere scrupulously to this volume.
1.5.7 Risks of explosion
None.
1.5.8 Risks due to noise
None.
1.5.9 Risks due to vibrations
None.
1.5.10 Risks due to radiation
None.
1.5.11 Risks due to outside radiation
None.
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EC standards
1.5.12 Risks due to laser devices
None.
1.5.13 Risks due to gas and dust emissions
The machine does not exhibit risks from emissions of dust.
1.5.14 Risk of being trapped in the machine
None.
1.5.15 Risks of falling
None.
1.6.1 Machine maintenance
Maintenance work must always be done with the machine stopped and by qualified personnel.
Adhere scrupulously to the instructions in the chapter “Machine Maintenance”.
1.6.2 Means of access at the work place and intervention
They are provided where necessary.
1.6.3 Insulation of the sources of energy and supply
See the wiring diagrams.
1.6.4 Intervention of the operator
It is limited to the regular production functions: “Start-Up”, “Stop” and “Control of the work
parameters”.
1.6.5 Cleaning of the internal parts
See the chapter “Maintenance”.
Filling machine VMF-L
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EC standard
1.7.1 Information devices
They are given on the electrical panel and on the operator command panel; see the chapter “Use
Manual” where they are clearly explained.
Moreover, an instruction manual is provided edited in conformity with the instructions given in EN
12100.
1.7.2 Warning devices
The machine is equipped with process warning signals identifiable by warning lights and acoustic
alarms.
1.7.3 Warnings as to residual risks
All the warnings relative to the operations of loading/unloading such as for example of the tanks,
are given in this instruction manual with specific references to the use of the personal safety
devices.
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Filling machine VMF-L
Transport and installation
Machine :
FILLING MACHINE
Type :
VMF-L
Transport and installation
Filling machine VMF-L
Page 1
Volume 02_TI_Language
_Rev.00
Transport and installation
INDEX
TRANSPORT AND INSTALLATION ....................................................
......................................................................................................
............................................................ 1
TRANSPORT AND HANDLING.................................................................................................................................... 3
TRANSPORT........................................................................................................................................................... 3
LOADING / UNLOADING ........................................................................................................................................ 3
PRECAUTIONS ....................................................................................................................................................... 3
TRANSPORT SYMBOLS ........................................................................................................................................ 4
TRANSPORT AND POSITIONING ............................................................................................................................... 5
PACKING DESCRIPTION ...................................................................................................................................... 6
OPENING THE CASES ........................................................................................................................................... 7
PACKING CHECK AFTER MACHINE DELIVERY .................................................................................................. 8
IN THE EVENT OF DAMAGE.................................................................................................................................. 8
MACHINE STORAGE.............................................................................................................................................. 8
PHYSICAL CHARACTERISTICS OF THE STORAGE AREAS.............................................................................. 8
POSITIONING THE MACHINE ..................................................................................................................................... 9
PROTECTION FROM ATMOSPHERIC AGENTS ................................................................................................... 9
SPACE REQUIREMENTS..................................................................................................................................... 10
ENVIRONMENTAL CHARACTERISTICS OF THE POSITIONING AREA ............................................................ 10
FIXING AND LEVELING ............................................................................................................................................. 11
FLOORING AND FOUNDATIONS......................................................................................................................... 11
TOOLS, EQUIPMENT AND CONSUMABLE MATERIALS.................................................................................... 11
INSTALLATION OF SECONDARY COMPONENTS.................................................................................................. 12
PIPING / FITTINGS FOR ICE-CREAM DOSING................................................................................................... 13
CELLS ................................................................................................................................................................... 13
WASHING.............................................................................................................................................................. 14
TESTING ............................................................................................................................................................... 14
MACHINE CONNECTIONS ........................................................................................................................................ 15
ELECTRICAL CONNECTION................................................................................................................................ 15
PNEUMATIC CONNECTION................................................................................................................................. 16
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Filling machine VMF-L
Transport and installation
Transport and handling
NOTE
If these instructions are not observed, Teknoice S.r.l. can not be held responsible for any machine
damages or performances not complying with the technical specifications provided.
Transport
The machine and its units are designed and built in order to be transported without damage by
means of vehicles (fork lift trucks) and suitable lifting means (bridge cranes, cranes, double chain
hoists).
Transport and/or lifting means must be proportional to the weight of the material to be transported.
To this regard, the lifting force or capacity must be at least 20% higher than that required for lifting
the machine and its packing.
Loading / Unloading
When loading and unloading from the means of transport and every time it is necessary to lift the
machine, a fork lift truck must be used to carry out these operations.
The machine and its units must be firmly anchored so they do not slip, overturn or fall from the lift
truck’s loading bed.
Precautions
Strictly follow the precautions and warnings described in the foregoing paragraphs in order to
guarantee stability and to prevent uncoupling as well as damages and risks during the handling of
the machine. Only skilled and trained personnel (slinging operators, lift truck operators, crane
operators, etc.) must carry out the handling and transport operations.
ATTENTION
Always carefully check the lifting devices conditions and their capacity.
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Transport and installation
Transport Symbols
Some goods require special identification for handling, so their packing has been marked or
labelled with the international symbols shown in the following table.
Eventual danger symbols are on the same sides of the marking. Indication of the centre of gravity
must also be shown on the lid and bottom of the case.
PRESCRIPTION
SYMBOL/MARK
EXAMPLE OF APPLICATION
Up
Fragile
Protect from damp
Anchor points for slinging
Centre of gravity
Centre of gravity (loadable)
Store indoors
Store in rooms with a temperature
higher than 0°C
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Transport and installation
Transport and positioning
Upon receipt, carefully check conditions of the cases to verify that there is no damage. Place the
case in a dry place.
The cases should be handled by a lift truck: pay attention to the position of the forks, it must match
the position shown in the figure above.
The machine is identified and marked, and the identification code is specified in the transport
document or delivery note.
The parcels are marked by highly visible writings, resistant to water and sunlight or by pre-printed
plates.
List of units composing the machine (the packing list) shows the marking, weight, dimensions and
position of the centre of gravity, to be transported separately without troubles.
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Transport and installation
Packing Description
1. Metal covering (only upon customer’s request);
2. Recipient Address and item identification number ;
3. Item centre of gravity (indicated only if goods inside the case are positioned in such a way as
to require special attention during transport and handling).
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Filling machine VMF-L
Transport and installation
Opening the cases
The packing includes one package containing:
•
•
•
Standard spare parts,
The electrical diagram,
The instruction manual.
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Transport and installation
Packing check after machine delivery
The packing must be inspected upon delivery according to the following criteria :
•
•
the cases must be intact and without any signs of crushing;
there must be no damage to the mechanical parts, such as guides, platens, etc.
If there is any damage, the goods are conditionally accepted, since goods integrity must be
checked. In case of any damages immediately contact Teknoice S.r.l. before removing any
packing from the machine units.
Check machine conditions by a visual inspection, inside and outside packing. Any deformations
could indicate impacts occurred during the transport, which could affect its normal working.
In particular check that the following items are in good condition:
•
•
•
•
Safety devices and guards (if present);
Pneumatic components and pipes;
Metal and painted surfaces;
Screws, nuts and bolts and fittings tightening
In the event of damage
It is necessary to verify the machine conditions before positioning it. Damages caused by transport
must be immediately reported to Teknoice S.r.l..
Any damage occurred during the transport, for whatever reason, could cause injuries to people or
damage to things and furthermore could affect the normal machine working. The Customer, or the
Customer’s representative, is asked to thoroughly examine the machine before positioning and
start-up.
Machine storage
If the machine has to be temporary stored due to the following conditions :
•
•
The machine is not installed immediately after its delivery ;
The machine is uninstalled and is stored awaiting a relocation.
The instructions specified in the following paragraph must be strictly observed.
Physical characteristics of the storage areas
In case of machine storage, a suitable space must be provided for movement and handling in
order to allow personnel to easily and safely carry out slinging and lifting operations.
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Filling machine VMF-L
Transport and installation
Positioning the machine
•
•
•
•
Put the machine in the selected place.
Level the machine using a "spirit level" by acting on the adjustable feet accordingly.
Leave at least 1000 mm free around the machine for maintenance operations.
If the machine has to work connected to an ice cream production line, position its pocket
conveyor belt and the gripping and release system.
Protection from atmospheric agents
The machine must be positioned in a covered area and protected from direct contact with
atmospheric agents.
Filling machine VMF-L
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Transport and installation
Space requirements
The layout drawing of the machine shows the minimum and maximum distances to be observed for
proper placing and positioning of the various component units. In addition to the overall dimensions
of the machine, it is necessary to provide additional space (at least 1000 mm) to allow :
•
•
•
•
Handling, lifting and assembling;
Maintenance;
Positioning of any push-button panels and/or control stations;
Installation of any accessories such as robots and manipulating automatisms, control units, etc.
Make reference to the relevant manuals for their overall dimensions.
Environmental characteristics of the positioning area
The environmental values allowed in the area where the machine is positioned are:
•
•
Environment temperature
Relative humidity
Volume 02_TI_Language
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5°C to 40°C
20% to 90%
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Filling machine VMF-L
Transport and installation
Fixing and leveling
The machine must be properly levelled and fixed to the ground in a suitable way. Follow these
instructions:
•
•
Lift the machine and position it on the floor;
Level it by means of the proper adjustments on the feet.
Flooring and foundations
The particular type of construction does not require heavy-duty types of foundation in regard to
flooring building works. For any details make reference to the enclosed layout drawing.
Check that the flooring has been subject to skid-proof treatment.
Tools, equipment and consumable materials
Handling:
Levelling check:
Assembly of mechanical / electrical parts:
Filling machine VMF-L
lifting equipment specified in this chapter
level / centesimal grading spirit level
commonly used tools
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Volume 02_TI_Language
_Rev.00
Transport and installation
Installation of secondary components
Before connecting the machine, it is necessary to carry out the installation of the following
components, if they are not yet connected :
• Product distribution belt
• Pipe / fittings for ice-cream dosing
• Cells
Product distribution belt
Product distribution belt is the final part of the production line.
The finished product is placed on the belt through the ejection device , in order to allow the
operator to take it.
To fix the product distribution belt it’s enough to put it on the crossbar and tighten the screws.
Volume 02_TI_Language
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Filling machine VMF-L
Transport and installation
Piping / fittings for ice-cream dosing
Before carrying out the electrical and air connections, it is necessary to connect the ice-cream
pipes input and output.
In case that some parts of the machines have been dismounted for transport, proceed to mount
them according to the diagrams included in the section “DIAGRAMS AND SPARE PARTS”.
Ice-cream input fitting, positioned at the top of the dosing unit, connects an ice-cream continuous
freezer/s (FC) to the dosing unit of the machine. According to the number of feeding machines
and/or to production requirements, there are several types of fittings.
Pipe between the freezer F.C. and the machine can be made of stainless steel or flexible, and their
diameter shall not be less than 1 ½ inches.
Cells
Cells are inserted into the linear table (chain). They have to support the ice cream cones.
They are fixed to the table by means of screws, supplied with the machine.
Cells could be different due to customer’s requirements.
To change (change of equipment) see section “PRODUCTION”.
Filling machine VMF-L
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Transport and installation
Washing
The machine can be equipped with the system of shutter washing. By using this system it’s
possible to clean the shutters by means of some nozzles positioned along the conveyor with water
or detergent solution, according to requirements.
Connect a washing system to the pipe input (shown in above figure).
Testing
The testing was carried out at the company Teknoice Ltd plant, where all mechanical calibration
and dimensional setups have been executed.
To have a proper installation, make sure to maintain the geometric characteristics set in the project
and specified in the mechanical drawings.
Technicians in charge of assembling the machine , must pay particular attention to the these
characteristics.
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Filling machine VMF-L
Transport and installation
Machine connections
Electrical connection
ATTENTION
The electrical connection must be carried out only by skilled personnel.
Follow these instructions :
•
•
•
•
•
Check the values shown on the identification plate to ensure that machine voltage and
frequency are compatible with local voltage and frequency.
Taking into account these data and the regulations in force of the country where the equipment
is installed, the section of the power supply cable must be no less than 6 mm2 for 400V , while
for 230V it must be 10 mm2 .
A safety switch should be installed according to the local regulations in force.
Lead the electrical cable to the machine from this switch.
Then connect the 3 phases to terminals "R-S-T" and the Earth to the relevant terminal on the
electrical power supply line.
WARNING
It is strictly forbidden to turn on the machine without an effective grounding, which must be
executed in accordance with the technical specifications indicated by regulations in force.
Before turning on the switch, make sure the voltage and frequency match the data on the machine
label.
Filling machine VMF-L
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Transport and installation
Pneumatic connection
Follow these instructions :
•
•
•
•
Connect the compressed air piping to the unit positioned on the side of the machine.
The required pressure is 6-8 bar.
A manual check valve should be installed on the compressed air line.
The hose must have no narrow passages or blockages, and the diameter must be no less than
the diameter of the compressed air inlet fitting (8 mm).
1 Pressure regulator
2 Pressure relay
3 Pressure gauge
4 General air valve
5 Moisture exhaust device
2
1
4
3
5
If not yet installed, it is recommended to mount a manual shut-off valve on the compressed air
line, near the machine.
WARNING
Compressed air containing impurities, moisture and oil residue could provoke a rapid wearing of
pneumatic valves. The machine is equipped with an air filtering system with automatic exhaust
device for moisture (see picture – 5 ), but, it’s however appropriate to install a drying filter
downstream the air compressor and carry out a rigorous maintenance.
Volume 02_TI_Language
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Filling machine VMF-L
General information, description and safety devices
Machine :
FILLING MACHINE
Type :
VMF-L
General information, description and safety devices
Filling machine VMF-L
Page 1
Volume 03_GIS_Language
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General information, description and safety devices
INDEX
GENERAL INFORMATION AND PURPOSE................................................................................................................ 3
MACHINE FUNCTIONS ................................................................................................................................................ 4
MACHINE DESCRIPTION – TYPE VMF – L - VERSATILE MULTIFILLER................................................................. 5
CONTAINERS FEEDING STATION WITH PNEUMATIC ACTIVATION ................................................................. 6
LIDS DISTRIBUTOR WITH PNEUMATIC ACTIVATION ......................................................................................... 6
LID PRESSING........................................................................................................................................................ 6
FINAL PRODUCT EJECTION BY THE PICK UP ROBOT (OPTION) ..................................................................... 7
MACHINE DESCRIPTION - TYPE VMF – L BULKS - VERSATILE MULTIFILLER .................................................... 8
CONTAINERS FEEDING WITH PNEUMATIC ACTIVATION .................................................................................. 9
LIDS DISTRIBUTOR WITH PNEUMATIC ACTIVATION – LID PRESSING – FINAL PRODUCT EJECTION...... 10
MACHINE DESCRIPTION - TYPE VMF – L CC - VERSATILE MULTIFILLER ......................................................... 11
CUPS FEEDING STATION - CONES FEEDING STATIONS ............................................................................... 12
LIDS DISTRIBUTOR WITH PNEUMATIC ACTIVATION ....................................................................................... 12
MACHINE DESCRIPTION - TYPE VMF – L CN - VERSATILE MULTIFILLER ......................................................... 14
CUPS FEEDING STATION - CONES FEEDING STATION .................................................................................. 15
LID DISTRIBUTOR WITH PNEUMATIC ACTIVATION ......................................................................................... 15
MACHINE DESCRIPTION - TYPE VMF – L CP- VERSATILE MULTIFILLER........................................................... 17
CONTAINER FEEDING STATION WITH PNEUMATIC ACTIVATION.................................................................. 18
LID DISTRIBUTOR WITH PNEUMATIC ACTIVATION ......................................................................................... 18
LID PRESSING...................................................................................................................................................... 18
OPTIONS............................................................................................................................................................... 19
PICK UP OF FINAL PRODUCTS BY THE ROBOT............................................................................................... 19
MACHINE DESCRIPTION - TYPE VMF – L SPECIAL OPTION FOR GRANITA - VERSATILE MULTIFILLER....... 20
CONTAINERS FEEDING STATION WITH PNEUMATIC ACTIVATION ............................................................... 21
VOLUMETRIC DOSING WITH PNEUMATIC ACTIVATION FOR GRANITA DOSING ......................................... 21
LID DISTRIBUTOR WITH PNEUMATIC ACTIVATION ......................................................................................... 21
LID PRESSING...................................................................................................................................................... 22
PICK UP OF FINAL PRODUCTS BY THE ROBOT............................................................................................... 22
MACHINE DESCRIPTION - TYPE VMF – L OPTION FOR TRUFFLE ICE-CREAM - VERSATILE MULTIFILLER.. 23
CONTAINER FEEDING STATION WITH PNEUMATIC ACTIVATION.................................................................. 24
FILLING STATION WITH ELECTRONIC ACTIVATION FOR ICE-CREAM DOSING............................................ 24
COCOA POWDER DISTRIBUTOR ....................................................................................................................... 24
LID DISTRIBUTOR WITH PNEUMATIC ACTIVATION – LID PRESSING ............................................................ 25
PICK UP OF FINAL PRODUCTS BY THE ROBOT............................................................................................... 25
MACHINE DESCRIPTION .......................................................................................................................................... 26
TECHNICAL CHARACTERISTICS........................................................................................................................ 28
MARKING ................................................................................................................................................................... 29
IDENTIFICATION PLATE ...................................................................................................................................... 29
RESIDUAL RISKS ...................................................................................................................................................... 30
MACHINE SAFETY DEVICES............................................................................................................................... 31
LOCATION OF THE EMERGENCY BUTTONS .................................................................................................... 31
GENERAL WARNINGS .............................................................................................................................................. 33
NOTES OF DANGER....................................................................................................................................... 33
NOTES OF CAUTION ........................................................................................................................................... 34
PERSONNEL QUALIFICATION ................................................................................................................................. 35
GENERAL EXPERTISES ...................................................................................................................................... 35
QUALIFIED PERSONNEL EXPERTISES ............................................................................................................. 35
PERSONAL PROTECTIVE EQUIPMENT - PPE ........................................................................................................ 36
OPERATOR PPE TABLE ...................................................................................................................................... 38
Volume 03_GIS_Language
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Filling machine VMF-L
General information, description and safety devices
General information and purpose
The purpose of this manual is to provide instructions and procedures of use for the personnel in
charge of working on the machine , according to the technical specifications and project data for
which it was built.
Its reading is essential, but it can not replace the competence of assigned personnel who must
have received an appropriate training.
The manual should be available to all personnel operating the machine, or in any way involved in
its functioning. The use of the machine is recommended for skilled operators , adequately
instructed and having good knowledge of all control functions.
In particular:
• the user operator ;
• the maintenance manager and operators ;
• the prevention and safety manager and operators.
The Customer Company must ensure that all staff have read and understood the contents of the
present manual with regard to its own competence.
This manual should be kept intact and in good conditions throughout the life of the machine.
Keep the original manual in a safe and protected place.
The Declaration of Conformity is the document that certifies its conformity with the Machinery
Directive. Therefore it must be carefully kept and eventually produced on request of the competent
authorities.
In case of loss or damage of the documentation it’s possible to get a new copy from the
manufacturer, specifying the order reference number, the machine serial number and the year of
construction.
The machine is built in accordance with the European Community regulations and technical
standards, as attested by the Declaration of Conformity CE issued by the manufacturer and
enclosed to this manual.
Filling machine VMF-L
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Volume 03_GIS_Language
_Rev.00
General information, description and safety devices
Machine functions
This is an automatic machine of new concept, designed for filling ice-cream into cups and tubs of
medium and large capacity.
Easy to handle in maintenance and cleaning, it complies with the most recent health and safety
standards. It is equipped with a system that allows a quick and easy change of the tubs size.
Its exceptional flexibility in size changing is the real peculiarity.
It’s enough to enter few data on the touch screen control panel, such as:
- Ice-cream quantity coming from the continuous freezer/s;
- Container capacity;
- Container height.
Taking into consideration these data, the machine automatically adjusts the movement of dosing
unit.
The machine basic version is supplied for only one container size with relevant lid.
Upon request the machine can be equipped with one or more sets of equipment for a quick change
of the container size.
Changing the containers size of is very simple, since containers supports , made of stainless steel,
are easily removable.
Even the stainless steel sections are removable, to allow easy access to the stations; furthermore
they can also be designed for different containers size, by increasing the possibility to fill different
tubs size.
The machine functioning is guarantee by an electronic drive motor and by a life lubricated indexing
box.
All basic movements of the machine are mechanical and they are electronically synchronized by
the PLC, so they are programmable.
Each working station is independent and is activated by the control panel with digital display.
Interface “machine / operator” is guaranteed by a touch screen panel mounted on the control
cabinet.
Volume 03_GIS_Language
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Filling machine VMF-L
General information, description and safety devices
Machine Description – type VMF – L - Versatile MultiFiller
Linear filling machine for ice-cream tubs.
Automatic filler for dosing, filling and sealing every container type which can be inserted into each
other.
Mechanical power from 5 to 25 strokes per minute per row.
Production capacity: depends on the type of container (to be confirmed upon receipt of samples)
Installed power: 2,5 Kw
Air consumption: 350 Nl / min
Compressed air: 6-8 bar
Control Panel Type "Touch Screen" for all control and check functions.
It can memorize all operations of each station in regard to each product.
The basic model is entirely made of stainless steel and equipped with a conveyor belt with
shutters.
The product size is excluded.
The machine functioning is guaranteed by an electronic drive motor and by a life lubricated
indexing box.
All basic movements of the machine are synchronized electronically, while the secondary
movements are activated pneumatically.
Each working station is independent and can be activated by the control panel. Internal auxiliary
circuit works at 24 volts.
The machine is protected by a safety system in accordance with the regulations.
The basic model is equipped with the following stations :
Filling machine VMF-L
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Volume 03_GIS_Language
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General information, description and safety devices
Containers feeding station with pneumatic activation
Dosing by electronic and pneumatic activation ; prepared for ice-cream dosing with solid inclusions
(max. dimensions 5/8 mm)
Lids Distributor with pneumatic activation
Lid pressing
Volume 03_GIS_Language
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Page 6
Filling machine VMF-L
General information, description and safety devices
Final product ejection by the pick up robot (option)
Filling machine VMF-L
Page 7
Volume 03_GIS_Language
_Rev.00
General information, description and safety devices
Machine description - type VMF – L bulks - Versatile MultiFiller
Linear filling machine for ice-cream tubs in 1 or 2 rows.
Automatic filler for dosing, filling and sealing every container type which can be inserted into each
other.
Mechanical power from 5 to 25 strokes per minute per row.
Production capacity: depends on the type of container (to be confirmed upon receipt of samples)
Installed power: 2,5 kW
Air consumption: 350 Nl / min
Compressed air: 6-8 bar
Control Panel type "Touch Screen" for all control and check functions.
It can memorize all operations of each station in regard to each product.
The basic model is made entirely of stainless steel and equipped with a conveyor belt with
shutters.
The product size is excluded.
The machine functioning is guaranteed by an electronic drive motor and by a life lubricated
indexing box.
All basic movements of the machine are synchronized electronically, while the secondary
movements are activated pneumatically.
Each working station is independent and can be activated by the control panel. Internal auxiliary
circuit works at 24 volts.
The machine is protected by a safety system in accordance with the regulations.
The basic model is equipped with the following stations:
Volume 03_GIS_Language
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Page 8
Filling machine VMF-L
General information, description and safety devices
Containers feeding with pneumatic activation
Dosing process by electronic and pneumatic activation, prepared for dosing ice-cream with solid
inclusions (max. dimensions 5/8 mm)
Filling machine VMF-L
Page 9
Volume 03_GIS_Language
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General information, description and safety devices
Lids distributor with pneumatic activation – Lid pressing – Final product ejection
Options :
• Crumbs distributor
• Dating device
Volume 03_GIS_Language
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Page 10
Filling machine VMF-L
General information, description and safety devices
Machine description - type VMF – L CC - Versatile MultiFiller
Linear filling machine for ice-cream cups and cones.
Automatic filler for dosing, filling and sealing every type of cups and cones which can be inserted
into each other.
Mechanical power from 5 to 25 strokes per minute per row.
Production capacity: depends on the container type (to be confirmed upon receipt of samples)
Installed power: 2,5 kW
Air consumption: 350 Nl / min
Compressed air: 6-8 bar
Control Panel Type "Touch Screen" for all control and check functions.
It can memorize all operations of each station in regard to each product.
The basic model is made entirely of stainless steel and equipped with a conveyor belt with
shutters.
The product size is excluded.
The machine functioning is guaranteed by an electronic drive motor and by a life lubricated
indexing box.
All basic movements of the machine are synchronized electronically, while the secondary
movements are activated pneumatically.
Each working station is independent and can be activated by the control panel. Internal auxiliary
circuit works at 24 volts.
The machine is protected by a safety system in accordance with the regulations.
The basic model is equipped with the following stations:
Filling machine VMF-L
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Volume 03_GIS_Language
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General information, description and safety devices
Cups feeding station - Cones feeding stations
Calibration of paper cones
Chocolate sprinkling
Dosing process by electronic and pneumatic activation, prepared for dosing ice-cream with solid
inclusions (max. dimensions 5/8 mm)
Chocolate dosing for topping
Crumbs distributor
Lids distributor with pneumatic activation
Volume 03_GIS_Language
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Page 12
Filling machine VMF-L
General information, description and safety devices
Lid pressing – Final product ejection
Filling machine VMF-L
Page 13
Volume 03_GIS_Language
_Rev.00
General information, description and safety devices
Machine description - type VMF – L CN - Versatile MultiFiller
Linear filling machine for ice-cream cones.
Automatic filler for dosing, filling and sealing every type of cups and cones which can be inserted
into each other.
Mechanical power from 5 to 25 strokes per minute per row.
Production capacity: depends on the container type (to be confirmed upon receipt of samples)
Installed power: 2,5 kW
Air consumption: 350 Nl / min
Compressed air: 6-8 bar
Control Panel type "Touch Screen" for all control and check functions.
It can memorize all operations of each station in regard to each product.
The basic model is made entirely of stainless steel and equipped with a conveyor belt with
shutters.
The product size is excluded.
The machine functioning is guaranteed by an electronic drive motor and by a life lubricated
indexing box.
All basic movements of the machine are synchronized electronically, while the secondary
movements are activated pneumatically.
Each working station is independent and can be activated by the control panel. Internal auxiliary
circuit works at 24 volts.
The machine is protected by a safety system in accordance with the regulations.
The basic model is equipped with the following stations:
Volume 03_GIS_Language
_Rev.00
Page 14
Filling machine VMF-L
General information, description and safety devices
Cups feeding station - Cones feeding station
Calibration of paper cones
Chocolate sprinkling
Dosing process by electronic and pneumatic activation, prepared for dosing ice-cream with solid
inclusions (max. dimensions 5/8 mm)
Chocolate dosing for topping
Crumbs distributor
Lid distributor with pneumatic activation
Filling machine VMF-L
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_Rev.00
General information, description and safety devices
Lid pressing – Final product ejection
Volume 03_GIS_Language
_Rev.00
Page 16
Filling machine VMF-L
General information, description and safety devices
Machine description - type VMF – L CP- Versatile MultiFiller
Linear filling machine for ice-cream cups in 3-4 rows.
Automatic filler for dosing, filling and sealing every type of cups and cones which can be inserted
into each other.
Mechanical power from 5 to 25 strokes per minute per row.
Production capacity: depends on the container type (to be confirmed upon receipt of samples)
Installed power: 2,5 kW
Air consumption: 350 Nl / min
Compressed air: 6-8 bar
Control Panel type "Touch Screen" for all control and check functions.
It can memorize all operations of each station in regard to each product.
The basic model is made entirely of stainless steel and equipped with a conveyor belt with
shutters.
The product size is excluded.
The machine functioning is guaranteed by an electronic drive motor and by a life lubricated
indexing box.
All basic movements of the machine are synchronized electronically, while the secondary
movements are activated pneumatically.
Each working station is independent and can be activated by the control panel. Internal auxiliary
circuit works at 24 volts.
The machine is protected by a safety system in accordance with the regulations.
The basic model is equipped with the following stations:
Filling machine VMF-L
Page 17
Volume 03_GIS_Language
_Rev.00
General information, description and safety devices
Container feeding station with pneumatic activation
Dosing process by electronic and pneumatic activation, prepared for dosing ice-cream with solid
inclusions (max. dimensions 5/8 mm)
Lid distributor with pneumatic activation
Lid pressing
Volume 03_GIS_Language
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Page 18
Filling machine VMF-L
General information, description and safety devices
Options
Pick up of final products by the robot
•
•
Crumbs distributor
Dating device
Filling machine VMF-L
Page 19
Volume 03_GIS_Language
_Rev.00
General information, description and safety devices
Machine description - type VMF – L special option for granita Versatile MultiFiller
Linear filling machine for granita (frozen juice in cup or cone).
Automatic filler for dosing, filling and sealing every type of cups and cones which can be inserted
into each other.
Mechanical power from 5 to 25 strokes per minute per row.
Production capacity: depends on the container type (to be confirmed upon receipt of samples)
Installed power: 2,5 kW
Air consumption: 350 Nl / min
Compressed air: 6-8 bar
Control Panel type "Touch Screen" for all control and check functions.
It can memorize all operations of each station in regard to each product.
The basic model is made entirely of stainless steel and equipped with a conveyor belt with
shutters.
The product size is excluded.
The machine functioning is guaranteed by an electronic drive motor and by a life lubricated device
of intermittence.
All basic movements of the machine are synchronized electronically, while the secondary
movements are activated pneumatically.
Each working station is independent and can be activated by the control panel. Internal auxiliary
circuit works at 24 volts.
The machine is protected by a safety system in accordance with the regulations.
The basic model is equipped with the following stations:
Volume 03_GIS_Language
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Page 20
Filling machine VMF-L
General information, description and safety devices
Containers feeding station with pneumatic activation
Volumetric dosing with pneumatic activation for granita dosing
Lid distributor with pneumatic activation
Filling machine VMF-L
Page 21
Volume 03_GIS_Language
_Rev.00
General information, description and safety devices
Lid pressing
Pick up of final products by the robot
Volume 03_GIS_Language
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Page 22
Filling machine VMF-L
General information, description and safety devices
Machine description - type VMF – L option for truffle ice-cream
- Versatile MultiFiller
Linear filling machine for “truffle” ice-cream.
Automatic filler for dosing, filling and sealing every type of container which can be inserted into
each other.
Mechanical power from 5 to 25 strokes per minute per row.
Production capacity: depends on the container type (to be confirmed upon receipt of samples)
Installed power: 2,5 kW
Air consumption: 350 Nl / min
Compressed air: 6-8 bar
Control Panel type "Touch Screen" for all control and check functions.
It can memorize all operations of each station in regard to each product.
The basic model is made entirely of stainless steel and equipped with a conveyor belt with
shutters.
The product size is excluded.
The machine functioning is guaranteed by an electronic drive motor and by a life lubricated
indexing box.
All basic movements of the machine are synchronized electronically, while the secondary
movements are activated pneumatically.
Each working station is independent and can be activated by the control panel. Internal auxiliary
circuit works at 24 volts.
The machine is protected by a safety system in accordance with the regulations.
The basic model is equipped with the following stations:
Filling machine VMF-L
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Volume 03_GIS_Language
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General information, description and safety devices
Container feeding station with pneumatic activation
Filling station with electronic activation for ice-cream dosing
Cocoa powder distributor
Volume 03_GIS_Language
_Rev.00
Page 24
Filling machine VMF-L
General information, description and safety devices
Lid distributor with pneumatic activation – Lid pressing
Pick up of final products by the robot
Filling machine VMF-L
Page 25
Volume 03_GIS_Language
_Rev.00
General information, description and safety devices
Machine description
It is an automatic filler machine for ice-cream cones, made of stainless steel.
The main parts of the machine are:
1 Loading station (cones)
2 Spraying station – calibration – paper calibration
3 Dosing station
4 Conveyor belt with cells
5 Chocolate topping station
6 Crumbs dosing station
7 Lids loading station
8 Crimping station
9 Ejection / unloading station
- product distribution belt
07
06
05
01
08
02
09
04
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Page 26
Filling machine VMF-L
General information, description and safety devices
From the loading station (1) cones are automatically taken and put into the cells of the chain (4),
this , by moving forward, regulates the production process.
In the SPRAYING - CALIBRATION station (2) there are two devices:
1. one device goes down into the cone and , by a light pressure, widens the product wrapping in
order to eliminate any paper folds , which could compromise a proper filling of the cone.
2. one device is connected to the external group (the chocolate pump) and sprays chocolate inside
the cone.
The dosing unit (3) provides for ice-cream filling into the cone (1-2 taste). Number and type of
dispensers can be different according to customer’s specific requests.
The dosing unit is controlled by a brushless motor during up and down movements , while the
dispensers opening and closing movements are controlled pneumatically by electronic cams,
which guarantee a proper filling of container.
After the dosing unit there is the TOPPING station (5), where it occurs dosing of liquid chocolate on
the upper part of the cone.
After this station , there could be the CRUMBS station (6), where the crumbs are distributed on the
cone by means of a feedbox. The quantity of crumbs is regulated manually.
LIDS LOADING station (7) follows the crumbs group, here the lid is placed on the cone by a
special device.
At the CRIMPING station (8) paper must be efficiently pressed around the lid. Vertical movement
of the station is provided by a pneumatic cylinder.
At the end of the production cycle there is the PRODUCT EJECTION station (9).
The final product is placed on the product distribution belt in order to allow the operator to take the
cones.
Upon request, a PENCIL FILLER station ( caramel injection in the cone) is available , as well as
other components that allow to diversify the final product decoration.
Always upon request, a dating device can be supplied , it can print the expiry date on the product
by an ink-jet printing
Filling machine VMF-L
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_Rev.00
General information, description and safety devices
The safety panels, mounted on every side of the machine, are an integral part of the machine and
they are designed according to the safety norms of the European Community.
SAFETY PANEL
Technical characteristics
Mechanical power:
Production capacity:
Installed power:
Air consumption:
Requested air pressure:
Dimensions of machine:
from 20 to 50 strokes/min.
from 4000 to 12000 portions/hour, per 4 rows
from 7000 to 18000 portions/hour, per 6 rows
12 kW
1200 NL/min.
6-8 bar
depending on configuration
Extra equipments
Upon request the machine can be supplied with extra equipments to allow the production of tubs
with different size and dimensions, thanks to a quick size change system.
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Page 28
Filling machine VMF-L
General information, description and safety devices
Marking
Self-adhesive safety labels are positioned on the machine as follows :
•
•
•
•
•
High voltage
Electric power
Danger
Voltage danger
Earth connection
inside electrical control cabinet
inside electrical control cabinet
inside electrical control cabinet
inside electrical control cabinet
inside electrical control cabinet
Before maintenance intervention on the machine, it is necessary to expose the warning advice
"MAINTENANCE IN PROGRESS" in well visible areas.
Identification plate
The machine is provided with the identification plate reporting the main technical data, in particular:
•
•
•
•
•
•
•
Model
Serial number
Voltage
Total installed power
Frequency
Number of phases
Type and charge of refrigerant
Plate example:
MODEL
SERIAL
ELECTRICL DATA
Volt
ph
Hz
Kw
REFRIGERANT
REFRIGERANT CHARGE
Filling machine VMF-L
Kg.
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Volume 03_GIS_Language
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General information, description and safety devices
Residual risks
Although the machine of the company Teknoice Srl is built in compliance with the current
technological knowledge and its functioning can be defined safe, it can become dangerous if used
improperly by unskilled personnel or for purposes different from the intended use.
During the machine operations there are residual risks for the operator, which are described from
time to time.
The residual risks can be eliminated by carefully following the procedures described in this manual
and using the required personal protection equipment (PPE).
The machine use, maintenance and repair operations must be carried out by assigned personnel,
duly skilled and acquainted about possible hazards.
The user is committed to use the machine only when it is in perfect conditions.
The operator must also guarantee that the machine is not used by unauthorized persons.
The safety devices of the machine must not be modified or altered without a written permission
from the company Teknoice Srl.
In case of damage or breakdown, the machine can not be used until the safety devices are in
serrvice again.
During service and maintenance operations, there is a HIGH RISK, that’s why they must be carried
out only if the machine is STOPPED and SWITCHED OFF.
The electrical failures can be repaired only by AUTHORIZED PERSONNEL.
The machine guards can be removed only for repair or maintenance. Before a new start-up of the
machine they must be remounted and fastened in its original position.
During the transportation, installation and start-up it’s necessary to follow the Directives about
Accident Prevention Measures, in their most updated edition.
Residual risks during machine working and when stopped :
•
•
Any items (excluding production pieces) accidentally left in the work area may cause a risk to
the operator;
It is forbidden for other people except the operator to stay in the safety area or in any case in
dangerous areas during the machine working.
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Filling machine VMF-L
General information, description and safety devices
Machine safety devices
Those machine components which could be potentially dangerous (for example: gears, belts etc…)
are protected by fixed guards (metal covers).
Location of the emergency buttons
Emergency button
=
CAUTION
To carry out maintenance operations, the machine must be stopped and its main switch must be in
OFF position.
The operator user is not allowed to access to the interior areas of the machine when it’s working.
The areas are dangerous and can cause risks of serious injury. Only one single operator can
handle the systems in this area.
Therefore the manufacturer is not liable for damages to persons or property which may result; in
this case the operator acts at his own risk. Therefore, the potentially dangerous areas are
protected by guards which comply with safety standards (a safe distance to prevent danger areas
being reached by upper limbs).
Filling machine VMF-L
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General information, description and safety devices
Operator position
During the production cycle the machine doesn’t need to be controlled.
The operator is normally in front of the tubs unloading station or close to the control panel (see
figure).
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Filling machine VMF-L
General information, description and safety devices
General warnings
Notes of danger
Always switch off all main and auxiliary power supply of
the machine before carrying out maintenance
operations.
Place specific warning signs MAINTENANCE IN
PROGRESS - DO NOT SWITCH ON POWER SUPPLY
on the main switches.
•
During the machine working , the moving
components
can cause serious injury to
persons. Avoid any contact with these
components.
•
Never exclude the safety and protection devices
installed on the equipment. If it becomes necessary,
indicate such conditions by proper warning signs
and act with utmost caution. Reassemble as soon as possible all safety and protection devices.
The general layout drawing, enclosed to this manual, shows the operator’s work positions.
•
If not earthed the machine can cause serious injury to persons. Always check earth
connections and their compliance with Standards.
•
Avoid using flammable or toxic solvents such as gasoline, benzene, ether and alcohol. It is
recommended the use of trichloroethylene or other compatible detergent, using the necessary
precautions.
•
Toxic waste such as production waste, lubricants etc., should be collected in special containers
labeled and disposed of according to local regulations in force.
•
Always make sure, before set in motion the machine, that the maintenance staff is at a safe
distance and that tools or materials are not left nearby.
•
Use safety glasses and protection gloves during maintenance operations.
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General information, description and safety devices
•
Never use water jets in case of fire on the machine, cut all power supply and use dry chemical
extinguisher Class ABC.
•
It is strictly forbidden to put combustible material near the electrical control panel.
•
The electrical control panel should always be locked and access should be allowed only to
authorized and skilled personal.
•
Operations inside the electrical control panel should be done only after switching off the
main power switch and disconnecting power supply.
•
Make sure to use tools in perfect conditions and provided with insulating handles if required.
Check that the insulator of machine cables and wires does not show any sign of breakage or
damage.
CAUTION
Before the installation of the machine, the customer is required to make the work
environment compliant to the local regulations in force regarding the "Safety in the
workplace” and to provide the qualified staff and operators with proper accident-prevention
clothing to guarantee the healthcare at work.
Notes of caution
• Before re-starting the machine after a failure, it is necessary to carefully inspect and check the
machine itself to find any damage.
• Always use dry air for cleaning; pressure can not exceed 2 bars.
• Always use tools in perfect conditions and suitable for the operation to be done, use of
inappropriate and inefficient tools can cause serious damages.
• Always check correct working and distribution of the lubrication. Lack of lubricant can damage the
machine.
• Never change the settings and limit switches positions of the machine : if modified, serious
damages to the machine and risks to the operator could occur.
CAUTION
Every preventive, ordinary and extraordinary maintenance operation has to be written in
the special register by reporting date, time, type of operation, operator’s name and any
useful information.
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Filling machine VMF-L
General information, description and safety devices
Personnel qualification
Maintenance operations can be carried out in safety conditions after reading and understanding
the recommendations and instructions provided by this manual.
Terms used for the operator:
User:
personnel authorized to the machine use
Maintenance technician:
qualified personnel authorized to the machine use, preparation
and maintenance.
General expertises
•
•
•
•
To know the construction and functions for special pieces production.
To know how to use and consult the machine documentation.
Take responsibility of making his own decisions regarding interventions on whole automatic
systems.
Take note any irregularity during production process and, if necessary, take appropriate
measures.
Qualified personnel expertises
The composition and qualification of the personnel teams, specified in the maintenance plan, are
those recommended by the company Teknoice Srl.
When necessary, the different operations can be also carried out by personnel with equal or higher
qualification who have followed specific training courses.
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General information, description and safety devices
Personal protective equipment - PPE
If the environmental analysis shows the fumes concentration higher
that those provided by the local laws or otherwise by the safety data
sheets of used products, the staff must wear an appropriate protective
mask.
In case of contact with the components immediately wash with water,
or otherwise follow the instruction of product safety sheet.
Install near the machine suitable eyewash or otherwise appropriate
water fountain.
The operator or maintenance technician working on the machine or
passing through must not wear clothing with loose sleeves, neither
straps nor belts which may cause danger.
Any long hair must be gathered up in a headgear to avoid a possible
danger.
The operator’s area must be cleared from foreign objects and treated
by anti-slip product (at Customer’s charge). Alternatively you can use
anti-skid carpets.
The operator should always wear safety shoes with rubber soul and
reinforced toe.
CAUTION
During machine working and maintenance operations, it’s necessary to use protective goggles,
gloves, helmet, gas masks and clothing covering completely the skin.
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Filling machine VMF-L
General information, description and safety devices
PROTECTIVE GOGGLES
Use: always
PROTECTIVE HELMET
Use: always
WATERPROOF RUBBER GLOVES
Use: always
SHOES WITH RUBBER SOUL
Use: always
PROTECTIVE MASK
Use: If the environmental analysis shows the fumes
concentration higher that those provided by the local
law or otherwise by the safety data sheets of used
products
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General information, description and safety devices
X
Appropriate gloves
X
X
Insulated gloves suitable for
max working voltage
X
X
X
X
X
X
X
X
X
X
X
X
X
Face shield
_Rev.00
X
X
Page 38
X
X
X
X
X
X
X
X
Safety shoes with insulating
soul
Safety clothing covering
the whole body (skin)
X
X
X
Glasses with transparent
glass when grinding or
drilling
X
X
X
Goggles or face shields, for
flame risks
Volume 03_GIS_Language
X
X
X
Safety shoes with antipunching soul
X
X
Gloves for high
temperatures
Glasses with transparent
glass
X
X
Gloves for manual work
Gloves for oil-based
detergents
Maintenance
X
Use of the machine
Testing
X
Operations on flexible pipes
/ temporary connections
under pressure for liquids
and gas
Wiring and electrical
control panel connection
X
Operations on elements
with electrical voltage
Pipes assembling and
mounting
Protective helmet
Cleaning
Operator PPE table
X
X
X
X
Filling machine VMF-L
Use manual
Machine :
FILLING MACHINE
Type :
VMF-L
Use manual
Filling machine VMF-L
Page 1
Volume 04_UM_Language
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Use manual
CONTENTS IN THIS CHAPTER
USE MANUAL....................................................
MANUAL......................................................................................................
............................................................................................... 1
INTRODUCTION ........................................................................................................................................................... 3
OPERATOR STATUS.............................................................................................................................................. 3
GENERAL RULES................................................................................................................................................... 3
PERSONNEL IN CHARGE OF THE START-UP .......................................................................................................... 4
OPERATOR............................................................................................................................................................. 4
QUALIFIED PERSONNEL ....................................................................................................................................... 4
WORKING MODES...................................................................................................................................................... 5
PRELIMINARY OPERATIONS ................................................................................................................................ 5
MOVEMENT OF THE CELLS CHAIN..................................................................................................................... 5
CONES AND LIDS FEEDING ....................................................................................................................................... 6
CHOCOLATE LOADING .............................................................................................................................................. 7
CRUMB LOADING........................................................................................................................................................ 8
PENCIL FILLER LOADING .......................................................................................................................................... 9
PERFORMANCE CHECK............................................................................................................................................. 9
PRODUCTION CYCLE CHECKING ........................................................................................................................... 10
CONES LOADING STATION................................................................................................................................. 10
DOSING UNIT ....................................................................................................................................................... 10
LIDS LOADING STATION ..................................................................................................................................... 11
UNLOADING STATION ........................................................................................................................................ 11
CHOCOLATE QUANTITY REGULATION ............................................................................................................. 12
AIR FLOW REGULATION ..................................................................................................................................... 12
SPEED DISTRIBUTOR REGULATION ................................................................................................................. 12
STARTUP PROCEDURE............................................................................................................................................ 13
EMERGENCY STOP ............................................................................................................................................. 13
PRODUCTION END AND STOP ........................................................................................................................... 14
CYCLE STOP ........................................................................................................................................................ 14
WASHING PROCEDURE ........................................................................................................................................... 14
CLEANING ............................................................................................................................................................ 15
SIZE CHANGE ............................................................................................................................................................ 15
CELLS REPLACEMENT........................................................................................................................................ 15
CONES LOADING STATION................................................................................................................................. 15
DOSING UNIT ....................................................................................................................................................... 16
LIDS LOADING STATION ..................................................................................................................................... 16
PRODUCTION DEBUGGING ..................................................................................................................................... 16
CONTROL PANEL AND OTHER COMPONENTS FUNCTIONS ............................................................................... 17
CODE / COLOUR OF THE PUSH-BUTTONS AND THEIR MEANING ................................................................. 17
COLOURS OF LIGHT INDICATORS AND THEIR MEANING............................................................................... 18
CONTROL PANEL................................................................................................................................................. 19
Volume 04_UM_Language
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Filling machine VMF-L
Use manual
Introduction
This chapter describes the operations required for the production of the final product.
Operator status
Personnel qualified to carry out the machine preparation and maintenance operations must be
instructed and have been properly trained as the different operations must be done in manual
mode, by excluding safety devices.
In particular the personnel must have been informed about how to carry out the procedures
described in this manual in a safe manner and must wear the personal protection equipment
required.
The machine preparation phase must be carried out only by authorized personnel in possession of
the keys and of any access codes which enable the machine preparation procedures.
General rules
Machine working process, the run/stop command, the alarm and emergency signals are located on
the Check panel.
It is a good rule to check the machine working and the warning signals shown by sensors and
failure indicators positioned on the Check panel.
Filling machine VMF-L
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Personnel in charge of the start-up
When starting the machine, for safety reasons, only those technicians duly assigned must be
present, in order to avoid any risks to the operators not specifically assigned to the start-up of the
machine.
The most important definitions reporting in this manual are provided below.
Operator
By operator it means personnel assigned to using and ordinary cleaning of the machine.
Qualified personnel
By qualified personnel, it means personnel instructed about the machine installation, assembly,
repair and servicing procedures and who have specific technical qualifications such as :
•
A technical training that authorizes them to work in accordance with the safety standards in
regard to the dangers due to electricity, circuits under pressure, etc...
•
A technical training or in any case specific instruction concerning the machine use and
maintenance procedures in safe conditions.
•
Training in the basic first aid measures.
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Filling machine VMF-L
Use manual
Working modes
Every operation can be Checkled by push-buttons or by the video pages of the operator panel.
Pressing a push-button or a function key brings the selected area to move, a following pressing of
the same key or the corresponding stop push-button causes the immediate stop.
For further explanations, refer to the chapter "OPERATOR PANEL VIDEO PAGES".
Preliminary operations
Before starting the machine check the following:
•
•
•
•
•
•
Check that the EMERGENCY push-button on the control panel is unlocked and the lamp
which signals the tension is ON. For detailed information on these devices see the section
PRODUCTION.
Check that the air valve, if supplied, is in work position; this valve, when supplied, is mounted
at the head of the air quick connection.
Switch ON the main switch on the electrical panel and push the RESET button.
Check if the pipes between freezers and dosing unit are assembled correctly.
Check if the pipes and connections between the chocolate pump and the machine are
assembled correctly.
Check if the machine is ready for the cone size you want to produce. For detailed information
on the size change contact the technical service of Teknoice S.r.l.
Movement of the cells chain
To check the correct direction of motor rotation proceed as follows:
1. Run the linear table (with cells) by holding pressed the button JOG on the control panel and
check that the motor turns clockwise.
If not, do the following:
•
•
•
•
Turn off the power supply by using the main switch
Block the switch with a lock
Open the control panel. Reverse two phases in motor power line
Close the control panel, turn on the main switch.
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Cones and lids feeding
Load cones and lids.
Access to the feeding area is allowed without removing the safety panels.
If one of the safety panels should be open the machine will stop automatically.
Safety Lids feeding
panels
area
•
Safety panels
Cones feeding
area
Insert the cones into the feeding area by adjusting the width according to the size of the
cones. You should operate on the bolts that fix the columns. Make sure that the cones are
not too pressed among them.
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Filling machine VMF-L
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•
Insert the lids into the feeding area by adjusting the width according to the size of the lid.
You should operate on the bolts that fix the columns. Close the door if it is open.
WARNING
Do not exclude safety devices by using the key selector on the control panel.
Only qualified technicians can use this key selector during machine settings and
extraordinary maintenance operations.
Chocolate loading
Load the chocolate in the proper tank positioned on the dosing device shown in the below picture.
Filling machine VMF-L
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Put water into the cavity through the suitable clamping connection (see picture below). Water is
essential for maintaining chocolate temperature during pump operation.
Crumb loading
WARNING
This operation should be done only if the machine has this option.
Load crumbs into the feedbox (see picture below).
The operation can be done while the machine is running. Periodically add crumbs by using any
type of container.
On the control panel there is a selector that allows to exclude the control of protection devices
during the opening of doors. This operation is only for maintenance purposes and must be done
only by qualified technicians to carry out maintenance interventions. Opening the door with
machine in service can provokes serious injuries to the operator.
Adjust manually the shutters on the feedbox to regulate the crumbs quantity falling onto the cone.
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Filling machine VMF-L
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Pencil filler loading
WARNING
This operation should be done only if the machine has this option.
Performance check
Before starting cones or cups production , it is possible to test the machine performance in order to
verify if the settings are correct.
This operation is done automatically by the by-pass valve (pneumatic valve), installed at the icecream input fitting in the upper side of the dosing unit.
Start a continuous freezer, so that the bypass valve automatically opens and sends ice cream to
the external pipe, under which you should put some container.
Once the ice cream has reached a certain consistency, start the dosing unit , in order that the
bypass valve automatically sends the ice cream to the dosing unit.
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Production cycle checking
•
•
Push RESET button on the control panel.
Push JOG button and hold it to start the table and check its functioning.
Cones loading station
•
•
•
•
•
Activate the cones feeding station by the control panel.
Press and hold the JOG button.
Pneumatic pick-up device goes upstroke , takes the cone and puts it into the cell.
The table moves one step forward, and the same operation is repeated with the next cone.
Once the cycle has been verified, release the button and turn off the unit.
Dosing unit
•
•
•
•
•
•
Activate the dosing unit by the control panel.
Press and hold the JOG button.
The dosing unit goes down to the tub, simulating an ice-cream dosing.
Check if it works well; check dosing unit height and functioning.
To work correctly the dosing unit should open during the downstroke movement, remain
open during the break of the cells table forwarding and close as soon as upstroke
movement starts.
Once the functioning of the unit has been verified , release the button and turn off the unit.
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Filling machine VMF-L
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Lids loading station
•
•
•
Activate the lids feeding station by the control panel.
Press and hold the JOG button.
When the tub reaches the feeding area a pneumatic device puts automatically the lid on
the cone.
WARNING
To avoid any failures , make sure that the photocell which detects the presence of the tub is
activated. For this function, press the SET button and open the configuration page referred to lids
loading
During trial cycle, if the photocell detects the absence of the tub, lids loading station doesn’t start.
Make sure that the lids are placed on the center of the cell.
If not, make sure that the suction cup holder is horizontal (both in upper and lower position).
If it needs to be adjusted, loosen the bolts with cylindrical head, which kept the suction cap to the
arm and turn it until it is properly adjusted. After that, tighten the bolts.
If the suction cup holder is horizontal, but the lids are still not placed in the center, this means that
the bars of the loading station are not adjusted properly.
If the cover appears on the left of the cell, it is necessary to shift all the bars to the left.
If the cover appears on the right of the cell, it is necessary to shift all the bars to the right.
Thus, make sure the loading unit is well-centered according to the lower cell and it properly closes
the containers.
If everything works well, release the button and turn off the group.
Unloading station
•
•
•
•
Activate the station by the control panel.
Press and hold the JOG button.
When the cone reaches the unloading station, grippers pick up it and put it on the conveyor
belt.
If everything works well, release the button and turn off the station.
Filling machine VMF-L
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Chocolate quantity regulation
It’s possible to regulate the chocolate flow in the spraying-calibration station in order to dose
chocolate quantity to be injected into the cone.
To carry out this operation, it is necessary to use the tap indicated by the arrow in the below picture
(adjust the chocolate flow by starting from the left).
Air flow regulation
In the spraying-calibration station, further to regulate the chocolate flow, it is also possible to adjust
the air flow to get a correct chocolate spraying.
To carry out this operation, it is necessary to use the regulator indicated by the arrow in the below
picture .
Speed distributor regulation
The ice cream quantity coming from the dosing unit can be set by means of the proper regulators
positioned on the pistons.
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Startup Procedure
•
•
•
•
•
•
•
•
Put a container under the dosing unit near the slide in order to collect any material in excess or
dosed without cones.
Start the continuous freezer, which feeds the machine.
Wait until the ice cream coming from the freezer has the required shape and consistency.
Make sure that all stations are not in service, except for the dosing unit, which should work to
simulate the following working conditions.
Turn on the machine and set the required production speed. For this operation, see the next
section.
Wait until the ice cream in the pipes reaches the required pressure (several minutes), turn on
the cones loading (see previous section), wait till when a few cones are put in the cells and turn
off the station.
Make sure that the cones are filled correctly. If not, increase or reduce the speed of freezer to
change the quantity of dosed product, and repeat the test until you get the desired result.
Turn on the cones loading , the lids loading and the unloading station (see previous
paragraph).
Emergency stop
If during production, you need to stop immediately all machine functions, press the emergency
button (Red Mushroom button).
All functions will be stopped and it will be not possible to restart them until the button will be
unlocked by turning it counterclockwise.
To restart the production, proceed as follows:
• Remove the nozzles from the dosing unit by means of the proper key in order to avoid a collision
with the linear table when the cycle is restarted.
• Release the emergency button turning it counterclockwise.
• Press the reset button on the control panel.
• Start up the machine. The machine will automatically recalculate the production data settings and
be automatically in the working position.
• Stop the machine again and reinstall the nozzles.
CAUTION
The emergency stop eliminates all risks related to moving parts of the whole machine. If it is
necessary to make any operation inside the machine, use the necessary personal protective
equipment.
Filling machine VMF-L
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Production end and stop
To finish the ice-cream production, do the following:
•
•
•
•
Wait for the next product.
Then push the STOP button of the machine.
The stations will stop in the rest position.
Disconnect all utilities.
Turn off the machine.
Cycle stop
At the end of the production cycle, stop the ice cream feeding from freezer, then turn off the
machine.
To turn off the machine, you should disconnect all units separately since they are independent one
from the other.
We recommend you turn off the units in this sequence:
1. Cones loading station
2. Dosing unit
3. Lids loading station
4. Unloading station
You can disconnect all stations/units by the control panel.
Washing procedure
At the end of the cycle the machine must be cleaned from any product residues.
First it is necessary to make the dosing unit prewsh by using the ice-cream feeding freezer.
For a correct pipes prewash , do the following:
•
•
•
•
Put a container under the dosing unit to collect water
Set up washing function from the freezer, feeding the machine with warm water
Wash with detergent solution
Carry out a final washing with clean water
After cleaning procedure, disconnect the dosing unit and freezer.
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Filling machine VMF-L
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Cleaning
CAUTION
Before carrying out any operation on the machine, make sure that the power supply and pneumatic
supply are turned off.
At the end of the production all components in contact with ice cream should be well cleaned.
To do this, disconnect the fitting of ice cream flow, remove the nozzles and the cells and make a
thorough cleaning.
Clean the linear table from possible ice-cream residues.
For a proper manual washing, do the following:
•
•
•
•
•
Prewash with warm water (about 40°)
Wash with detergent
Wash with water at room temperature
Wash with disinfectant, use disinfectant, dissolved in water in a ratio of 0.2%
Finally wash with water at room temperature
Size change
CAUTION
The components for size change are supplied only upon customer request in order to produce
different tubs size.
To change the tubs size it is necessary to replace some components of the machine.
In this section you will find relevant instructions.
CAUTION
Before carrying out any operation make sure that the main switch is turned off and blocked by a
lock. Also make sure that the compressed air supply is disconnected and the machine is
completely stopped..
Cells replacement
Replace the cells where the tubs are positioned, by removing the nuts which fix them to the linear
table (chain).
Cones loading station
Remove the screws that fix the cones loading station to the machine, remove the loading station by
moving it upwards and install the new one. Tighten the nuts and plug in the quick connections.
Load the new cones.
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Dosing unit
To remove the nozzles of the dosing unit which must be replaced, act on the fixing nuts by means
of an hexagonal key.
Install new nozzles and tighten the nuts.
To center new nozzles on a new tub, remove the nuts which fix the dosing devices to the support.
Manually adjust their position, moving the dosing devices along the horizontal axle, till they are
perfectly centered on the tub.
Height of the dosing device is set by the control panel.
Lids loading station
Disconnect the air supply to the station, by removing the four quick connections.
Remove the nuts that fix the lids loading station to the machine, remove the loading station by
moving it upwards and install the new one. Tighten the nuts and plug in the quick connections.
Replace the suction-caps system.
To do this, remove quick connections and the nuts that fix the pistons.
Replace the suction-cups device with the new one.
Production debugging
Put all replaced components in a distinct place where they will be protected from any bump and
are apart from other sizes in order to avoid any confusion.
Check whether you have forgotten tools in the machine and safety conditions are satisfied.
Connect the air compressed supply and turn on the main switch.
Press the RESET button.
Choose a recipe to produce and run the cycle, for this last operation, use the control panel (touch
screen).
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Filling machine VMF-L
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Control panel and other components functions
All push-buttons, selectors , signaling devices, and other control devices that are present on the
panels of the system are listed and described in this paragraph.
The machine is equipped with :
•
•
Electric cabinet ;
Auxiliary push-button operator panels.
Code / Colour of the push-buttons and their meaning
COLOUR
MEANING
EXPLANATION
RED
Emergency
Press in case of emergency or
danger
YELLOW
Abnormal
Press in case of anomalous
condition
APPLICATION EXAMPLE
Emergency stop
Beginning of the emergency function
Action to delete an anomalous
condition
Action to restart an interrupted
automatic cycle
GREEN
Safety
Press in case of safety
conditions or to prepare a normal
condition
BLU
Obligatory
Press in case of condition which
requires an obligatory action
No specific
meaning
Used for the general start of the
functions, except the emergency
stop (see the note)
Start (preferential)
WHITE
No specific
meaning
Used for the general start of the
functions, except the emergency
stop (see the note)
Start
No specific
meaning
Used for the general start of the
functions, except the emergency
stop (see the note)
Start
GREY
BLACK
Reset function
Stop
Stop
Stop (preferential)
NOTE
When an additional means of coding (for example: structure, shape, position) for the switches /
push-buttons identification is used, the same white, gray or black color can be used for different
functions (for example: white is used for start and stop buttons).
Filling machine VMF-L
Page 17
Volume 04_UM_Language
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Use manual
Colours of light indicators and their meaning
COLOUR
RED
MEANING
Emergency
EXPLANATION
Dangerous
conditions
Abnormal
Imminent critical
condition
GREEN
Safety
APPLICATION EXAMPLE
Pressure /temperature
Immediate action to
outside safety limits.
manage a dangerous
Voltage drop
situation (for ex. press
Interruption
outside the stroke
emergency button)
or stop position
Anomalous
conditions
YELLOW
OPERATOR’S
ACTION
Check and/or action
(for ex. To reestablish
the desired function)
Normal condition
Optional
Pressure /temperature above
the normal limits
Safety device activation
Pressure /temperature within
the normal limits
Authorization to proceed
BLU
WHITE
Volume 04_UM_Language
Obligatory
Indicates the
condition which
requires an
obligatory action
by the operator
Obligatory action
Instruction to fill in the
preselected values
No specific
meaning
Other conditions:
can be used
every time when
use of other
colors – red,
yellow, green,
blu – is in doubt
Check
General information
_Rev.00
Page 18
Filling machine VMF-L
Use manual
Control panel
The control panel is equipped with a touch screen and different push-buttons and selectors , in
particular :
1.
2.
3.
4.
5.
6.
7.
8.
9.
Lamp of tension signaling
Start push-button
Stop push-button
Jog push-button
Key selector (Washing)
Reset push-button
Zero setting push-button
Emergency mushroom button
Multifunctional Touch Screen
Main switch
CAUTION
This information is indicative, because the configuration of the panel can be different according to
machine version. For detailed information see the electrical diagram enclosed to this manual.
Filling machine VMF-L
Page 19
Volume 04_UM_Language
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Main switch
Turning on the main switch supplies voltage to the machine. Lamp number 1 lights up.
1. Lamp of voltage signaling
The lamp lights up when the main switch is ON.
2. Start button
Enables the production cycle. The push-button lights up when a cycle is running.
3. Stop button
Turns off the cycle and turns off the machine according to a determined sequence in order to
restart the production from the stop point. Normally it is used when cones are finished or to
take a break, stopping the machine in a work position but ready to continue the cycle.
4. Jog button
Press and hold the button to move the machine at a set speed. If the button is released, the
machine stops. It is used to verify the machine functioning.
5. Key selector (washing)
It is used to carry out the washing cycle.
6. Reset button
It resets the machine before starting or if any alarm has been occurred. If an alarm (or more)
occurs the push-button flashes.
7. Zero setting button
Press the button to reset all stations. This button should be pressed when a first start up is
done and every time the electrical power supply to the machine is interrupted. When pressed,
each station is set at cycle starting.
8. Emergency button
Pressing the button stops all machine functions, providing safety conditions. To reset the
system, you must before remove the cause for which the machine was stopped and unlock the
push-button by turning it counterclockwise. After that, the reset button number 6 can be
pressed.
9. Multifunctional Touch Screen
Allows the operator to work with the machine. It is described in the next volume.
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Filling machine VMF-L
Video pages of the control panel
Machine :
FILLING MACHINE
Type :
VMF-L
Video pages of the control panel
Filling machine VMF-L
Page 1
Volume 05_VPP_Language
_Rev.00
Video pages of the control panel
INDEX
VIDEO PAGES OF THE CONTROL PANEL....................................................
PANEL.................................................................................................... 1
CONTROL PANEL DESCRIPTION .............................................................................................................................. 3
MAIN PAGE ............................................................................................................................................................. 4
STATION SETTINGS PAGE.................................................................................................................................... 6
CUPS LOADING PAGE........................................................................................................................................... 7
SPRAYING PAGE ................................................................................................................................................... 8
DOSING PAGE........................................................................................................................................................ 8
DOSING SECONDARY MENU PAGE (FOR ELECTRICAL DOSING).................................................................... 9
VERTICAL MANUAL MOVEMENT MENU PAGE ................................................................................................. 10
CROSS MANUAL MOVEMENT MENU PAGE ...................................................................................................... 11
LONGITUDINAL MANUAL MOVEMENT MENU PAGE ...................................................................................... 12
DOSING PARAMETERS MENU PAGE................................................................................................................. 13
MICRO DOSING PAGE........................................................................................................................................ 14
TOPPING PAGE................................................................................................................................................... 14
COCOA PAGE....................................................................................................................................................... 15
LIDS LOADING PAGE........................................................................................................................................... 15
LIDS PRESSING PAGE ........................................................................................................................................ 16
FINAL PRODUCT UNLOADING PAGE................................................................................................................. 17
UNLOADING SECONDARY MENU PAGE (USED FOR THE MACHINE СС) ...................................................... 18
CRUMBS PAGE .................................................................................................................................................... 18
MAINTENANCE PAGE......................................................................................................................................... 19
MANUAL COMMANDS PAGE............................................................................................................................... 19
CHAIN PAGE......................................................................................................................................................... 21
PASSWORD AND PANEL MAINTENANCE PAGE............................................................................................. 22
CALIBRATION AND LANGUAGE CHOICE PAGE................................................................................................ 23
Volume 05_VPP_Language
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Page 2
Filling machine VMF-L
Video pages of the control panel
Control panel description
Any machine settings and control input are set up by a touch-screen panel and by the proper pushbuttons and selectors positioned on the machine front side.
For an easier use of the touch screen panel , it is suggested to utilise a narrow object like a
ballpoint pen with cap, a pencil or something similar.
Fingers might be too large for centring the sensitive areas.
The main page is automatically displayed when the panel is turned on.
Language set is the one used during previous cycle till turning off.
When the panel is ON, it is possible to choose in which language display machine data and
information.
To change the language, press the corresponding push-button in the first page of the monitor, as
shown in the picture.
After the language selection, press anywhere on the panel to enter the main menu.
It is also possible to change the language during the cycle from the “password menu” page,
described here below.
Filling machine VMF-L
Page 3
Volume 05_VPP_Language
_Rev.00
Video pages of the control panel
Main page
From the main page you can enter the most important control inputs for the machine working and
go to secondary menus.
Configuration
In this section, there are the configuration settings.
Chain
In this section, there are the chain settings
Speed (l / h)
It allows you to set the product quantity coming from the freezer to the machine (expressed in
l/h, where liters indicate the ice-cream quantity) and therefore the speed cycle
It can be set from 400 to 1000 l/h, depending on the available freezer capacity
Product
It refers to the type of recipe used. Select this item to open RECIPES menu.
Cones loading
Enables / disables the cones loading.
When the key is enabled , it gets a dark background.
It allows you to enter the Loading cones menu.
Dosing
Enable / disable the dosing group.
When the key is enabled, it gets a dark background.
It allows you to enter the dosing unit menu.
Lids loading
Enable / disable the lids loading.
When the key is enabled, it gets a dark background.
It allows you to enter the lids loading menu –
Volume 05_VPP_Language
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Page 4
Filling machine VMF-L
Video pages of the control panel
Cups loading
Enable / disable the loading of cups.
When the key is enabled, it gets a dark background.
It allows you to enter the cups loading menu.
Calibration
Enable / disable the calibration.
When the key is enabled, it gets a dark background.
It allows you to enter the calibration menu.
Topping
Enable / disable the topping.
When the key is enabled, it gets a dark background.
It allows you to enter the topping menu.
Micro dosing units
Enable / disable the micro dosing units for micro dosing .
When the key is enabled, it gets a dark background.
It allows you to enter the micro dosing menu .
Spraying of cacao
Enable / disable the spraying.
When the key is enabled, it gets a dark background.
It allows you to enter the spraying menu.
Cocoa
Enable / disable the cocoa dosing.
When the key is enabled, it gets a dark background.
It allows you to enter the cocoa dosing menu.
Unloading
Enable / disable the tubs unloading.
When the key is enabled, it gets a dark background.
It allows you to enter the tubs unloading menu.
Filling machine VMF-L
Page 5
Volume 05_VPP_Language
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Video pages of the control panel
Station settings page
By this page you can set the general settings of the selected station working and enter the
secondary menu of each station.
•
•
•
•
•
•
•
•
•
•
•
•
Cups loading (if pressed, setting page is displayed)
Cones loading (if pressed, setting page is displayed)
Calibration (if pressed, setting page is displayed)
Spraying (if pressed, setting page is displayed)
Dosing (if pressed, setting page is displayed)
Micro dosing (if pressed, setting page is displayed)
Topping (if pressed, setting page is displayed)
Cocoa (if pressed, setting page is displayed)
Lids loading (if pressed, setting page is displayed)
Pressing (if pressed, setting page is displayed)
Unloading station (if pressed, setting page is displayed)
Crumbs (if pressed, setting page is displayed)
If you press the push-button DATA the corresponding page is displayed.
Volume 05_VPP_Language
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Page 6
Filling machine VMF-L
Video pages of the control panel
Cups loading page
From “station settings” menu page, press SET (Settings) to enter the cups loading Menu.
On this page you can set the loading timing compared to the machine production speed.
Column CAMMA ON (CAM ON.) shows the values (angular degrees referred to cycle position)
when the operation starts.
Column AMPIEZZA (EXTENSION) shows the values (angular degrees referred to cycle position)
when the operation stops.
On this page you can set t:
•
•
•
•
•
Loading electrical valve
Shutter electrical valve
Blowing electrical valve
Vacuum electrical valve
Cams common correction
Filling machine VMF-L
Page 7
Volume 05_VPP_Language
_Rev.00
Video pages of the control panel
Spraying page
From “station settings” menu page, press SET (Settings) to enter the Spraying Menu.
On this page you can set spraying and pump ON/OFF time.
Column CAMMA ON (CAM ON.) shows the values (angular degrees referred to cycle position)
when the operation starts.
Column AMPIEZZA (extension) shows the values ( angular degrees referred to cycle position)
when the operation stops.
Dosing page
From “station settings” menu page, press SET (Settings) to enter the Dosing Menu.
On this page you can set :
• Electrical axle starting
• Dosing valve 1
• Dosing valve 2
• Cams common settings
• Cycle total duration
Column CAMMA ON (CAM ON.) shows the values (angular degrees referred to cycle position)
when the operation starts.
Column AMPIEZZA (extension) shows the values ( angular degrees referred to cycle position)
when the operation stops.
Volume 05_VPP_Language
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Page 8
Filling machine VMF-L
Video pages of the control panel
Dosing secondary menu page (for electrical dosing)
On this page you can set :
•
•
•
Vertical synchronization value
Cross synchronization value
Longitudinal synchronization value
•
•
•
Display the vertical dosing page
Display the cross dosing page
Display the longitudinal dosing page
Filling machine VMF-L
Page 9
Volume 05_VPP_Language
_Rev.00
Video pages of the control panel
Vertical manual movement menu page
By this page you can move manually (up-down) the vertical dosing axle.
The parameters which should be set and displayed are the following:
•
•
•
•
•
•
Dosing unit real value
Interference value in mm
Requested value in mm
Slope
Jog speed
Positioning speed
Volume 05_VPP_Language
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Page 10
Filling machine VMF-L
Video pages of the control panel
Cross manual movement menu page
By this page you can move manually (left-right) the cross dosing axle.
The parameters which should be set and displayed are the following:
•
•
•
•
•
•
•
Dosing unit real value
Max right value in mm
Max left value in mm
Requested value in mm
Slope
Jog speed
Positioning speed
Filling machine VMF-L
Page 11
Volume 05_VPP_Language
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Video pages of the control panel
Longitudinal manual movement menu page
By his page you can move manually (forward-back) the longitudinal dosing axle.
The parameters which should be set and displayed are the following:
•
•
•
•
•
•
•
Dosing unit real value
Max forward value in mm
Max backward value in mm
Requested value in mm
Slope
Jog speed
Positioning speed
Volume 05_VPP_Language
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Page 12
Filling machine VMF-L
Video pages of the control panel
Dosing parameters menu page
On this page there are the following parameters:
•
•
•
•
•
•
•
Total machine cycle duration in sec.
Machine break duration in sec.
Machine break degrees in°C
Settings of %, used for dosing
Dosing duration in sec.
Dosing degrees in °C
Dosing speed
Filling machine VMF-L
Page 13
Volume 05_VPP_Language
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Video pages of the control panel
Micro dosing page
From “station settings” menu page, press SET (Settings) to enter the Micro dosing.
On this page you can set the micro dosing timing compared to the machine production speed.
Column CAMMA ON (CAM ON.) shows the values (angular degrees referred to cycle position)
when the operation starts.
Column AMPIEZZA (extension) shows the values ( angular degrees referred to cycle position)
when the operation stops.
Topping page
From “station settings” menu page, press SET (Settings) to enter the Topping Menu.
On this page you can set the topping timing compared to the machine production speed.
Column CAMMA ON (CAM ON.) shows the values (angular degrees referred to cycle position)
when the operation starts.
Column AMPIEZZA (EXTENSION) shows the values ( angular degrees referred to cycle
position) when the operation stops.
Moreover, tank resistances and temperature values can be set in this page.
Volume 05_VPP_Language
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Page 14
Filling machine VMF-L
Video pages of the control panel
Cocoa page
From “station settings” menu page, press SET (Settings) to enter the Cocoa Dosing Menu.
On this page you can set the cocoa dosing timing compared to the machine production speed.
Column CAMMA ON (CAM ON.) shows the values (angular degrees referred to cycle position)
when the operation starts.
Column AMPIEZZA (EXTENSION) shows the values ( angular degrees referred to cycle
position) when the operation stops.
Lids loading page
From “station settings” menu page, press SET (Settings) to enter the Lids Loading Menu.
On this page you can set the lids loading timing compared to the machine production speed.
Column CAMMA ON (CAM ON.) shows the values (angular degrees referred to cycle position)
when the operation starts.
Column AMPIEZZA (EXTENSION) shows the values ( angular degrees referred to cycle
position) when the operation stops.
Filling machine VMF-L
Page 15
Volume 05_VPP_Language
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Video pages of the control panel
Lids pressing page
From “station settings” menu page, press SET (Settings) to enter the Lids Pressing Menu .
On this page you can set the lids pressing timing compared to the machine production speed.
Column CAMMA ON (CAM ON.) shows the values (angular degrees referred to cycle position)
when the operation starts.
Column AMPIEZZA (EXTENSION) shows the values ( angular degrees referred to cycle
position) when the operation stops.
Volume 05_VPP_Language
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Page 16
Filling machine VMF-L
Video pages of the control panel
Final product unloading page
From “station settings” menu page,press SET (Settings) to enter the Unloading Menu.
On this page you can set the unloading process timing compared to the machine production
speed.
On this page you can set:
•
•
•
•
Ejection solenoid valve
Motor
Lifting solenoid valve
Handling device solenoid valve (Pick-up grippers)
Column CAMMA ON (CAM ON.) shows the values (angular degrees referred to cycle position)
when the operation starts.
Column AMPIEZZA (EXTENSION) shows the values ( angular degrees referred to cycle
position) when the operation stops.
Filling machine VMF-L
Page 17
Volume 05_VPP_Language
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Video pages of the control panel
Unloading secondary menu page (used for the machine СС)
Page of Unloading.secondary menu.
The graphs display real values and possible manual correction of the data.
Crumbs page
From “station settings” menu page, press SET (Settings) to enter the Crumbs Dosing Menu.
On this page you can set the crumbs dosing timing compared to the machine production speed.
Column CAMMA ON (CAM ON.) shows the values (angular degrees referred to cycle position)
when the operation starts.
Column AMPIEZZA (EXTENSION) shows the values ( angular degrees referred to cycle
position) when the operation stops.
Volume 05_VPP_Language
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Page 18
Filling machine VMF-L
Video pages of the control panel
Maintenance page
Maintenance Menu Page.
On this page you can enable the stations and see the production data.
Manual commands page
By this page it is possible to set dosing data in manual mode..
By pressing push-button Manuali 1 (Manual 1), you enter the following page.
Filling machine VMF-L
Page 19
Volume 05_VPP_Language
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Video pages of the control panel
By this page it is possible to set the machine stations and their corresponding commands in
manual mode
By this page it is possible to set manual movements of the following stations :
•
•
•
•
Cups Loading
Cones Loading (if supplied)
Calibration
Spraying
If you press the push-button Manuali 2 (Manual 2), you enter the following page.
By this page it is possible to set manual movements of the following stations :
•
•
•
•
•
•
•
Lids loading
Final product unloading
Pressing
Microdosing
Topping
Cocoa
Crumbs
Volume 05_VPP_Language
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Page 20
Filling machine VMF-L
Video pages of the control panel
Chain page
From “station settings” menu page, press SET (Settings) to enter the Chain Menu .
On this page you can set chain movement start and chain pitch to optimize the machine
production speed.
Column CAMMA ON (CAM ON.) shows the values (angular degrees referred to cycle position)
when the operation starts.
Column AMPIEZZA (EXTENSION) shows the values ( angular degrees referred to cycle
position) when the operation stops.
On this page you can see:
• Master angular position in degrees
• Shutter position in mm
One more function is the Jog forward and backward movement of the shutters.
By pressing the SET DATA button you open the following page:
On this page all data referring to speed, movement and slope of the chain are displayed.
Filling machine VMF-L
Page 21
Volume 05_VPP_Language
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Video pages of the control panel
Password and panel maintenance page
Press PASSWORD from the Recipes Menu .
Access passwords for the different functions are set by 3 levels of users during the machine
testing :
• 1° level for the standard user (operator)
• 2°level for the line person in charge (maintenance technician)
• 3°level for the company person in charge
The passwords are supplied to the customer in a separate way from the present manual.
For detailed information contact the technical office of Teknoice Srl.
It’s possible to memorize the values which are different for every products in order to recall them
en bloc when the process production changes.
In this way it is not necessary to digit the values one by one and any risk of error is greatly
reduced.
Commands on this page are protected by the password = xxxx.
On this page you can:
• Create a new recipe
• Save the changes if an existing recipe has been corrected
• Choose a recipe from the saved recipes
• Transfer a recipe to PLC, in order to use it for production
• See the recipe in use
Volume 05_VPP_Language
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Page 22
Filling machine VMF-L
Video pages of the control panel
Calibration and Language choice page
On this page you can:
• Open the Recipes page
• Clean the screen display without making any operation
• Calibrate the touch screen contrast
• Regulate the digit pressure on the control panel
• Enable or disable the password
Press TEKNOICE, to come back to the main menu.
Filling machine VMF-L
Page 23
Volume 05_VPP_Language
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Video pages of the control panel
Volume 05_VPP_Language
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Page 24
Filling machine VMF-L
Maintenance of the machine
Machine :
FILLING MACHINE
Type :
VMF-L
Maintenance of the machine
Filling machine VMF-L
Page 1
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
INDEX
MAINTENANCE OF THE MACHINE ....................................................
......................................................................................................
............................................................ 1
SAFETY PRECAUTIONS ............................................................................................................................................. 3
INSPECTION ........................................................................................................................................................... 3
RESTORATION ....................................................................................................................................................... 3
REDUCING DOWNTIME AFTER FAILURE ...................................................................................................... 3
MAINTENANCE PRECAUTIONS ................................................................................................................................. 4
GENERAL INFORMATION...................................................................................................................................... 5
QUALIFICATION OF THE STAFF ........................................................................................................................... 5
PERIODICAL MAINTENANCE ..................................................................................................................................... 6
TABLE WITH MAINTENANCE SUMMARY.................................................................................................................. 6
EVERYDAY MAINTENANCE .................................................................................................................................. 7
DOSING DEVICES ............................................................................................................................................ 8
NOZZLES........................................................................................................................................................... 8
WORKTOP......................................................................................................................................................... 8
WEEKLY MAINTENANCE ....................................................................................................................................... 9
DOSING DEVICES ................................................................................................................................................ 10
CLASS OF TIGHTENING ................................................................................................................................ 10
TIGHTENING TORQUE (NM) .......................................................................................................................... 11
MONTHLY MAINTENANCE .................................................................................................................................. 13
WORKTOP....................................................................................................................................................... 13
CHAIN FOR MOVEMENT................................................................................................................................ 13
THREE-MONTH MAINTENANCE ......................................................................................................................... 15
YEARLY MAINTENANCE..................................................................................................................................... 17
ELECTRIC PARTS ................................................................................................................................................ 19
ELECTRIC MOTORS ............................................................................................................................................ 21
PNEUMATICS ....................................................................................................................................................... 23
COMMON REGULATIONS AND OPERATIONS ............................................................................................. 25
PRESSURE RELAY ................................................................................................................................................................................. 25
ELECTRIC VALVES ................................................................................................................................................................................. 25
PRESSURE REGULATOR....................................................................................................................................................................... 26
FLOW REGULATOR ................................................................................................................................................................................ 26
TROUBLESHOOTING........................................................................................................................................... 27
MAINTENANCE OPERATIONS REGISTRATION TABLES ...................................................................................... 31
EVERY DAY .......................................................................................................................................................... 31
EVERY WEEK ....................................................................................................................................................... 32
EVERY MONTH..................................................................................................................................................... 33
EVERY 4 MONTHS ............................................................................................................................................... 34
EVERY 6 MONTHS ............................................................................................................................................... 35
EVERY YEAR ........................................................................................................................................................ 36
Volume 04_MM_Language
_Rev.00
Page 2
Filling machine VMF-L
Maintenance of the machine
Safety precautions
According to the Regulation DIN 31051, the term "maintenance" includes the following fields of
activity:
Inspection
The inspection covers those measures intended to recognize the actual conditions of the machine,
that is to identify the reasons and ways in which the wear decreases.
Restoration
The restoration covers those actions to obtain the desired conditions, that is to compensate the
reduction of performance and restore the wear.
The personnel authorized to use and carry out the machine maintenance must be well trained and
must have a thorough knowledge of safety regulations.
Unauthorized personnel must remain outside of work area during maintenance operations.
Safety precautions must always be strictly respected during the operation and machine
maintenance in order to avoid any injury to personnel and any damage to machinery.
These precautions will be recalled and further detailed each time it will be required a procedure
which may cause any risk of harm or injury, by notes of CAUTION and DANGER.
•
CAUTION notes go before an operation, which may cause damage to equipment, if incorrectly
carried out.
•
DANGER notes go before an operation, which may expose to risk the operator, if incorrectly
carried out.
Reducing downtime after failure
Please note that a maintenance properly carried out can minimize downtime after a failure. Timely
repair prevents from further deterioration.
Use, where possible, original spare parts and do an accurate repair of the damaged components at
your plant or send them for repair to the company Teknoice Srl.
For any possible troubles or to order spare parts, contact the technical assistance of the company
Teknoice Srl.
Filling machine VMF-L
Page 3
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Maintenance precautions
CAUTION
It is recommended to carry out the maintenance operations without voltage and pressure supply to
the machine.
1. Before maintenance expose in well visible places the warnings “MAINTENANCE IN
PROGRESS".
2. Access to the machine is allowed only to authorized personnel.
3. The use of any cleaning solvent should be done carefully, paying particular attention to cables.
4. Do not modify or altered the machine structure, the sequence of operation or otherwise, without
a notice in writing to the company Teknoice Srl.
5. Maintenance operations must be reported in the enclosed tables at thet end of the chapter, by
reporting date, type of intervention and signature of who carries out the operation.
6. Any maintenance operation should refer to what is written in this chapter.
Volume 04_MM_Language
_Rev.00
Page 4
Filling machine VMF-L
Maintenance of the machine
General information
Write all functions subjected to inspection and maintenance in appropriate tables or lists to keep a
history of carried out operations and to be checked by employees of other level.
This form must include:
• Date;
• Type of intervention;
• Signature of person who carries out the operation.
The inspection items are to be distinguished regarding to control frequency, for example daily,
weekly, monthly; furthermore they have to carried out before a long shutdown of the system, for
example before holiday closing.
Maintenance and inspection required by law must be carried out irrespective of the objectives
related to the function preservation, since they guarantee the safety of personnel involved in the
machine use and to avoid any possible damage: the proper documentation of these operations
must be kept carefully by the Customer.
Technical documentation and the most important tools must be kept near the work place in order to
shorten as much as possible troubleshooting and the machine repair.
In case of removal of safety devices, before restarting the machine, check that they have
been reinstalled and are working.
Any use of cleaning solvents should be carried out with extreme care, paying a particular attention
to the cables.
Do not use organic solvents near hot surfaces.
It is preferable to use water-based solvents.
Any maintenance operation should refer to the instructions of this manual.
Qualification of the staff
Maintenance can be performed safely by skilled personnel authorized to the machine use,
preparation and maintenance, who have read and understood the recommendations and
instructions of this manual.
Filling machine VMF-L
Page 5
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Periodical maintenance
The recommended frequency of these operations regards an 8-hour workday and it is indicative.
If the machine is working in several shifts during 24 hours, the maintenance frequency should be
adjusted properly. Also, the maintenance frequency may vary depending on the type of production,
machine working environment, temperature, etc. The maintenance technicians should estimate the
frequency of operations basing on personal experience.
Table with maintenance summary
N°
GROUP
INTERVENTION
01
Machine
Everyday maintenance
02
Machine
Weekly maintenance
03
Machine
Monthly maintenance
04
Machine
Three-month maintenance
05
Machine
Annual maintenance
06
Electrical parts
Inspection and cleaning
07
Electrical motors
Inspection and maintenance
08
Pneumatics
Inspection and maintenance
09
Machine
Troubleshooting
Volume 04_MM_Language
_Rev.00
Page 6
EVERY
See form
See form
See form
See form
See form
See form
See form
See form
See form
Filling machine VMF-L
Maintenance of the machine
Everyday maintenance
FORM n° 01
† CLEANING
„ WASHING
† INSPECTION
† ELECTRIC UNIT
† MECHANICS
† PNEUMATICS
Group: machine
Intervention: washing
Operator: 1
At the end of production you should wash the following components:
• Dosing devices
• Nozzles
• Worktop
WARNING!
Identify the area of intervention and block by the appropriate lock the main switch in OFF position after putting all
components out of service.
Expose the sign "MACHINE MAINTENANCE - DO NOT TURN ON ELECTRICAL POWER" near the main switch.
Later on disconnect safety devices and remove guards.
The operator works in risk circumstances. Therefore the following rules must be respected:
• Authorized persons must be informed about the operations to be carried out and about any possible danger to which
they are exposed during such operations and about proper use of safety devices installed on the system.
• The operator must pay attention and work with caution.
• Before starting the inspection or maintenance the maintenance personnel shall turn off the system and use all safety
measures and precautions required.
Filling machine VMF-L
Page 7
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Dosing devices
At the end of production, do the automatic washing by using the freezers. Remember to put a
container under the dosing unit (there is a slide) to collect the detergent solution and dispose it.
See instruction about washing in the section Use manual.
Nozzles
At the end of production remove nozzles and wash them accurately, eliminate any incrustation and
impurity.
Worktop
At the end of production wash with water and detergent, eliminate any product residues on the
worktop of the machine.
The water after washing should be disposed in conformity with the local law in force.
CAUTION
• Don’t use acid detergents or detergents with chlorine, outside those recommended.
• Hydrochloric acid damages inox steel and chromium, generating micro pores.
• Don’t use temperature above 90 °C.
• Pay close attention to the choice of detergents and disinfectants, concentrations, temperature
and contact time with the machine components.
• Refer to the specifications for the use of the solutions recommended by the manufacturer.
Volume 04_MM_Language
_Rev.00
Page 8
Filling machine VMF-L
Maintenance of the machine
Weekly maintenance
FORM n° 02
† CLEANING
† WASHING
† INSPECTION
† ELECTRIC UNIT
„ MECHANICS
† PNEUMATICS
Group: machine
Intervention: mechanical maintenance
Operator: 1
CAUTION
To avoid any risk for the persons or the machine, we recommend that only the specialized
personnel perform the machine maintenance.
Before you remove the guards, push the emergency button and cut off power supply to the
machine by means of main switch
WARNING!
Identify the area of intervention and block by the appropriate lock the main switch in OFF position after putting all
components out of service.
Expose the sign "MACHINE MAINTENANCE - DO NOT TURN ON ELECTRICAL POWER" near the main switch.
Later on disconnect safety devices and remove guards.
The operator works in risk circumstances. Therefore the following rules must be respected:
• Authorized persons must be informed about the operations to be carried out and about any possible danger to which
they are exposed during such operations and about proper use of safety devices installed on the system.
• The operator must pay attention and work with caution.
• Before starting the inspection or maintenance the maintenance personnel shall turn off the system and use all safety
measures and precautions required.
Filling machine VMF-L
Page 9
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Dosing devices
Remove dosing devices, wash them and grease with Vaseline or food grease.
Dismantling of dosing device
To remove dosing device and nozzles proceed as follows:
1.
2.
3.
4.
5.
6.
disconnect air supply to the dosing unit by quick connections
unscrew nuts by using the key from accessories
remove the rod of the dosing device taking it off upwards
grease the gasket OR with Vaseline or food grease
wash nozzles, eliminate any incrustation and impurity
assemble all components following the instruction in the opposite direction
Class of tightening
In this section we determine the nominal torque values and their tolerances to be applied for
tightening of bolts, according to the applications, in order to ensure the functional aspects.
TOLERANCES
CLASS OF
TIGHTENING
APPLICATIONS
WITH REFERENCE TO
THE NOMINAL
TORQUE
I
Very demanding: for highly stressed connections,
subjected to vibration, shock, high traction or
abrupt movements, reduction gears, racks, rods,
arrests translation, alternating loads and
movement components in general, raised dynamic
loads.
± 5%
Must be checked every 6 months with torque
indicating wrench.
Demanding: for use not subjected to excessive
vibration, but where you need a good security of
tightness (frames, static raised loads, precise
clamping, pallets, rolls, tongs supports).
II
Must be checked yearly, torque indicating wrench
is recommended.
+ 5%
- 15%
Not very demanding: just a little stressed or minor
use (small blocks, references, platforms, guards).
III
Volume 04_MM_Language
Must be checked whenever working on the
machine, tightening characteristics can be
modified according to the operation performed.
_Rev.00
Page 10
+ 5%
- 35%
Filling machine VMF-L
Maintenance of the machine
Tightening torque (NM)
CLASS OF TIGHTENING
WRENCH
III
II
I
OPENING
OF THE
THREAD
SCREW
CLASS OF SCREW RESISTANCE
8,8
AND/OR
10,9
12,9
CLASS OF NUT RESISTANCE
NUT
8
10
12
M4
7
2,3
3,3
4
M5
8
4,8
6,8
8
M6
10
8
11,2
13,6
M8
13
20
28
32,8
M10
17
39,2
55,2
66,4
M12
19
68,8
96
116
M14
22
108
152
184
M16
24
168
236
284
M18
27
232
324
388
M20
30
328
464
552
M22
32
440
624
744
M24
36
568
800
960
M27
41
840
1200
1440
M30
46
1160
1600
1920
Filling machine VMF-L
Page 11
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Volume 04_MM_Language
_Rev.00
Page 12
Filling machine VMF-L
Maintenance of the machine
Monthly maintenance
FORM n° 03
† CLEANING
† WASHING
† INSPECTION
†ELECTRIC UNIT
„ MECHANICS
† PNEUMATICS
Group: machine
Intervention: mechanical maintenance
Operator: 1
Worktop
Grease bearings by the lubricator.
Chain for movement
Grease the chain using a brush.
To access to the chain remove the safety panel at the side of the machine.
WARNING!
Identify the area of intervention and block by the appropriate lock the main switch in OFF position after putting all
components out of service.
Expose the sign "MACHINE MAINTENANCE - DO NOT TURN ON ELECTRICAL POWER" near the main switch.
Later on disconnect safety devices and remove guards.
The operator works in risk circumstances. Therefore the following rules must be respected:
• Authorized persons must be informed about the operations to be carried out and about any possible danger to which
they are exposed during such operations and about proper use of safety devices installed on the system.
• The operator must pay attention and work with caution.
• Before starting the inspection or maintenance the maintenance personnel shall turn off the system and use all safety
measures and precautions required.
Filling machine VMF-L
Page 13
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Volume 04_MM_Language
_Rev.00
Page 14
Filling machine VMF-L
Maintenance of the machine
Three-month maintenance
FORM n° 04
† CLEANING
† WASHING
„ INSPECTION
† ELECTRIC UNIT
† MECHANICS
† PNEUMATICS
Group: machine
Intervention: transmission chain
Operator: 1
Check the chain tension that transmits the movement to the linear table.
If the chain is loosen (more than 1,5 cm) adjust it.
Filling machine VMF-L
Page 15
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
WARNING!
Identify the area of intervention and block by the appropriate lock the main switch in OFF position after putting all
components out of service.
Expose the sign "MACHINE MAINTENANCE - DO NOT TURN ON ELECTRICAL POWER" near the main switch.
Later on disconnect safety devices and remove guards.
The operator works in risk circumstances. Therefore the following rules must be respected:
• Authorized persons must be informed about the operations to be carried out and about any possible danger to which
they are exposed during such operations and about proper use of safety devices installed on the system.
• The operator must pay attention and work with caution.
• Before starting the inspection or maintenance the maintenance personnel shall turn off the system and use all safety
measures and precautions required.
Volume 04_MM_Language
_Rev.00
Page 16
Filling machine VMF-L
Maintenance of the machine
Yearly maintenance
FORM n° 05
† CLEANING
† WASHING
„ INSPECTION
†ELECTRIC UNIT
† MECHANICS
† PNEUMATICS
Group: machine
Intervention: inspection
Operator: 1
Dosing device
Replace the gaskets of dosing devices.
To carry out this operation, see Form n. 4.
Electrical scheme
Check the connections and preservation of cables.
Machine
Perform a general inspection.
WARNING!
Identify the area of intervention and block by the appropriate lock the main switch in OFF position after putting all
components out of service.
Expose the sign "MACHINE MAINTENANCE - DO NOT TURN ON ELECTRICAL POWER" near the main switch.
Later on disconnect safety devices and remove guards.
The operator works in risk circumstances. Therefore the following rules must be respected:
• Authorized persons must be informed about the operations to be carried out and about any possible danger to which
they are exposed during such operations and about proper use of safety devices installed on the system.
• The operator must pay attention and work with caution.
• Before starting the inspection or maintenance the maintenance personnel shall turn off the system and use all safety
measures and precautions required.
Filling machine VMF-L
Page 17
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Volume 04_MM_Language
_Rev.00
Page 18
Filling machine VMF-L
Maintenance of the machine
Electric parts
FORM n° 06
† CLEANING
† WASHING
† INSPECTION
„ ELECTRIC UNIT
† MECHANICS
† PNEUMATICS
Group: Electric unit
Intervention: Electric maintenance
Operator: 1
Check the correct operation of the following devices before starting each production cycle:
• Emergency button
• Warning lights and light push-buttons
• Mode selectors
Moreover, you must check any:
• Photocell
• Limit switch
• Guards
• Other safety devices installed.
Filling machine VMF-L
Page 19
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
WARNING!
Identify the area of intervention and block by the appropriate lock the main switch in OFF position after putting all
components out of service.
Expose the sign "MACHINE MAINTENANCE - DO NOT TURN ON ELECTRICAL POWER" near the main switch.
Later on disconnect safety devices and remove guards.
The operator works in risk circumstances. Therefore the following rules must be respected:
• Authorized persons must be informed about the operations to be carried out and about any possible danger to which
they are exposed during such operations and about proper use of safety devices installed on the system.
• The operator must pay attention and work with caution.
• Before starting the inspection or maintenance the maintenance personnel shall turn off the system and use all safety
measures and precautions required.
Check the filter on air intakes:
• Clean if dirty
• Replace if needed
Check correct working of the cooling fan.
Replace filter after one year.
CAUTION
Carry out all maintenance operations only when the system is switched off and there is no
electrical and pneumatic supply.
Volume 04_MM_Language
_Rev.00
Page 20
Filling machine VMF-L
Maintenance of the machine
Electric motors
FORM n° 07
† CLEANING
† WASHING
„ INSPECTION
„ ELECTRIC UNIT
† MECHANICS
† PNEUMATICS
Group: Machine
Intervention: Electrical motors
Operator: 1
Filling machine VMF-L
Page 21
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
WARNING!
Identify the area of intervention and block by the appropriate lock the main switch in OFF position after putting all
components out of service.
Expose the sign "MACHINE MAINTENANCE - DO NOT TURN ON ELECTRICAL POWER" near the main switch.
Later on disconnect safety devices and remove guards.
The operator works in risk circumstances. Therefore the following rules must be respected:
• Authorized persons must be informed about the operations to be carried out and about any possible danger to which
they are exposed during such operations and about proper use of safety devices installed on the system.
• The operator must pay attention and work with caution.
• Before starting the inspection or maintenance the maintenance personnel shall turn off the system and use all safety
measures and precautions required.
Check and clean the cooling filter of electrical motor.
See other details in the technical documentation enclosed to the manual.
Volume 04_MM_Language
_Rev.00
Page 22
Filling machine VMF-L
Maintenance of the machine
Pneumatics
FORM n° 03
† CLEANING
† WASHING
† INSPECTION
† ELECTRIC UNIT
† MECHANICS
„ PNEUMATICS
Group: Pneumatic unit
Intervention: Pneumatic maintenance
Operator: 1
The machine is equipped with pressure reducer / filter with automatic condensate discharge, which
allows to use compressed air, although if not previously treated.
The pneumatic system, limited to control of pressure of homogenization, control of mixture flow
and pasteurization water, doesn’t require special maintenance.
Filling machine VMF-L
Page 23
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
WARNING!
Identify the area of intervention and block by the appropriate lock the main switch in OFF position after putting all
components out of service.
Expose the sign "MACHINE MAINTENANCE - DO NOT TURN ON ELECTRICAL POWER" near the main switch.
Later on disconnect safety devices and remove guards.
The operator works in risk circumstances. Therefore the following rules must be respected:
• Authorized persons must be informed about the operations to be carried out and about any possible danger to which
they are exposed during such operations and about proper use of safety devices installed on the system.
• The operator must pay attention and work with caution.
• Before starting the inspection or maintenance the maintenance personnel shall turn off the system and use all safety
measures and precautions required.
The supplied air is filtered to 35 microns by means of the filter.
The operating pressure in the working circuit (6 bar) is set by the regulator and displayed on the
installed pressure gauge.
The supplied pressure must always be at least 1 bar higher than the pressure of the working
circuit, so that any pressure changes can not affect the proper functioning of the pneumatic circuit.
Check the pressure at the beginning of each workday.
CAUTION
Never clean the transparent cups of the filter with alcohol, but use gasoline or oil.
Volume 04_MM_Language
_Rev.00
Page 24
Filling machine VMF-L
Maintenance of the machine
Common regulations and operations
Pressure relay
The pressure relay in the figure (similar to the one used in the system) must be set at a pressure of
4 bar for the proper functioning of the machine. The adjustment can be done with a screwdriver or
an Allen wrench. In this way the machine will not start with a lower pressure than the set one.
Electric valves
The pneumatic electric valves of type ISO 1, ISO 2, ISO 3 showed in the figure can be driven
manually pushing at points B as shown.
Filling machine VMF-L
Page 25
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Pressure regulator
A pressure regulator allows to adjust the pressure in the pneumatic circuit to 6 bar, rotating the
knob as shown in the figure and checking the settings on the pressure gauge. Please note that the
supplied pressure of the network should be slightly higher than 6 bar (about one bar more in order
not to affect the smooth operation of the machine).
Flow regulator
The flow regulator is normally installed close to the place of use (pneumatic cylinder). The
adjustment must be carried out with a screwdriver and has to slow down (clockwise) or increase
(counterclockwise) the flow speed.
Volume 04_MM_Language
_Rev.00
Page 26
Filling machine VMF-L
Maintenance of the machine
Troubleshooting
FORM n° 09
† CLEANING
† WASHING
„ INSPECTION
† ELECTRIC UNIT
† MECHANICS
† PNEUMATICS
Group: Machine
Intervention: Troubleshooting and inspection
Operator: 1
PROBLEM
Power LED is off
CAUSE
SOLUTION
a) The lamp is broken
a) Replace
b) The main switch is off
b) Switch ON
c) The emergency device is
activated
c)
Disactivate and reset
d) Check
d) There is no power supply
a) There is no compressed air
b) Tunnel door is open
Motor of the chain
conveyer doesn’t c) Maintenance switches are ON
start or stop
d) Thermoswitch intervention
e)
Inverter allarm intervention
It’s not possible to
modify the motor a) – Limit values already reached
speed of the chain b) – Inverter allarm / failure
conveyer
Brush for trays
washing doesn’t
start or stop
Filling machine VMF-L
a)
Check
b)
Close
c)
Switch off
d)
Rearm
e)
Check any mechanical problem
a) b) - Rearm / replace
a) – Motor of the chain conveyer is
stopped
a) – Start
b) - Thermoswitch intervention
b) - Rearm
Page 27
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
WARNING!
Identify the area of intervention and block by the appropriate lock the main switch in OFF position after putting all
components out of service.
Expose the sign "MACHINE MAINTENANCE - DO NOT TURN ON ELECTRICAL POWER" near the main switch.
Later on disconnect safety devices and remove guards.
The operator works in risk circumstances. Therefore the following rules must be respected:
• Authorized persons must be informed about the operations to be carried out and about any possible danger to which
they are exposed during such operations and about proper use of safety devices installed on the system.
• The operator must pay attention and work with caution.
• Before starting the inspection or maintenance the maintenance personnel shall turn off the system and use all safety
measures and precautions required.
PROBLEM
CAUSE
Lifting cylinder
failure
Loading unit
Tubs ejection
cylinder failure
Unloading group
Pressure of compressed air is too
low, there is no compressed air
Pressure of compressed air is too
low there is no compressed air
Dosing unit
movement not
synchronized
Encoder failure
Encoder is broken or not correctly
connected
Proximity failure
Proximity is broken or not correctly
connected
Linear table
movement not
Dosing cycle is not set correctly
possible – Dosing
unit interference
Emergency device
An emergency button was pressed
intervention
Motor thermal
switch
Volume 04_MM_Language
Motor breaker of the linear table is
activated
_Rev.00
Page 28
SOLUTION
Check. Air pressure is set by the
proper reducer positioned in the lower
part of auxiliaries support. After you
have eliminated the cause, push the
RESET button on the control panel.
Check. Air pressure is set by the
proper reducer positioned in the lower
part of auxiliaries support. After you
have eliminated the cause, push the
RESET button on the control panel.
Check the motor. After you have
eliminated the cause, push the
RESET button on the control panel.
Check and replace. After you have
eliminated the cause, push the
RESET button on the control panel.
Bring nearer or replace.
Change settings.
After you have eliminated the cause,
push the RESET button on the control
panel.
After you have eliminated the cause,
push the RESET button on the control
panel.
Check the motor. After you have
eliminated the cause, push the
RESET button on the control panel.
Filling machine VMF-L
Maintenance of the machine
PROBLEM
CAUSE
Dosing unit motor Tension is not constant
fuses intervention
Inverter failures
Dosing process
failure
No air in the
machine
Tension is not constant. Torque
alarm intervention
Tension is not constant.
Pressure is low or there is no air
SOLUTION
Check tension. After you have
eliminated the cause, push the
RESET button on the control panel.
Check tension. Check if there is any
mechanical problem. After you have
eliminated the cause, push the
RESET button on the control panel.
Check tension. Check if there is any
mechanical problem. Use the
technical manual. After you have
eliminated the cause, push the
RESET button on the control panel.
Air pressure is set by the proper
reducer in the lower side of auxiliaries
support. Set on 6 bar.
Extra stroke
intervention
Dosing unit
upstroke
Check and correct After you have
Settings of production are not correct eliminated the cause, push the
RESET button on the control panel.
Extra-stroke
intervention
Dosing unit
downstroke
Check and correct After you have
Settings of production are not correct eliminated the cause, push the
RESET button on the control panel.
Production speed Speed is not correctly set
too high
Filling machine VMF-L
Page 29
Reduce. After you have eliminated the
cause, push the RESET button on the
control panel.
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Volume 04_MM_Language
_Rev.00
Page 30
Filling machine VMF-L
Maintenance of the machine
Maintenance operations registration tables
These tables have to be filled in by the Customer every time any maintenance operation has been
carried out.
Every day
DAY
MAINTENANCE
DATE
OPERATOR’S SIGNATURE
MONDAY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
TUESDAY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
WEDNESDAY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
THURSDAY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
FRIDAY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
SATURDAY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
SUNDAY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
NOTE:
Make copies of this page and keep always the tables updated.
Filling machine VMF-L
Page 31
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Every week
WEEK
MAINTENANCE
DATE
OPERATOR’S SIGNATURE
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
NOTE:
Make copies of this page and keep always the tables updated.
Volume 04_MM_Language
_Rev.00
Page 32
Filling machine VMF-L
Maintenance of the machine
Every month
MONTH
MAINTENANCE
DATE
OPERATOR’S SIGNATURE
JANUARY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
FEBRUARY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
MARCH
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
APRIL
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
MAY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
JUNE
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
JULY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
AUGUST
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
SEPTEMBER
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
OCTOBER
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
NOVEMBER
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
DECEMBER
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
Filling machine VMF-L
Page 33
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Every 4 months
MESE
MAINTENANCE
DATE
OPERATOR’S SIGNATURE
JANUARY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
APRIL
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
JULY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
OCTOBER
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
NOTE:
Make copies of this page and keep always the tables updated.
Volume 04_MM_Language
_Rev.00
Page 34
Filling machine VMF-L
Maintenance of the machine
Every 6 months
MESE
MAINTENANCE
DATE
OPERATOR’S SIGNATURE
JANUARY
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
JUNE
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
NOTE:
Make copies of this page and keep always the tables updated.
Filling machine VMF-L
Page 35
Volume 04_MM_Language
_Rev.00
Maintenance of the machine
Every year
YEAR
MAINTENANCE
DATE
OPERATOR’S SIGNATURE
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
___________________
___________________
___________________
______
1.____________________
2.____________________
3.____________________
___________
___________
___________
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NOTE:
Make copies of this page and keep always the tables updated.
Volume 04_MM_Language
_Rev.00
Page 36
Filling machine VMF-L
Diagrams volume
Machine :
FILLING MACHINE
Type :
VMF-L
Diagrams Volume
Filling machine VMF-L
Page 1
Volume 07_DV_Language
_Rev.00
Diagrams volume
INDEX OF CHAPTER
DIAGRAMS VOLUME.
VOLUME............................................................. ERRORE. IL SEGNALIBRO NON È DEFINITO.
INDEX OF DIAGRAMS ........................................................................ERRORE. IL SEGNALIBRO NON È DEFINITO.
Volume 07_DV_Language
_Rev.00
Page 2
Filling machine VMF-L
Diagrams volume
Index of diagrams
See all diagrams in the documentation on the Cd-rom and/or attached to the present manual.
•
Layout
•
Electric diagram
•
Pneumatic diagram
Filling machine VMF-L
Page 3
Volume 07_DV_Language
_Rev.00
Diagrams volume
Volume 07_DV_Language
_Rev.00
Page 4
Filling machine VMF-L
Spare parts volume
Machine :
FILLING MACHINE
Type :
VMF-L
Spare parts volume
Filling machine VMF-L
Page 1
Volume 08_SP_Language
_Rev.00
Spare parts volume
INDEX OF CHAPTER
SPARE PARTS VOLUME....................................................
VOLUME......................................................................................................
............................................................................. 1
STANDARD SPARE PART .......................................................................................................................................... 3
Volume 08_SP_Language
_Rev.00
Page 2
Filling machine VMF-L
Spare parts volume
Standard spare part
The machine is shipped with a set of standard spares.
They may be used for installation, such as piping, pipe clamps and rubber holders; for the machine
routine operation, or to quickly fix little problems that may occur in production.
See the documentation of Assemblies group.
Filling machine VMF-L
Page 3
Volume 08_SP_Language
_Rev.00
Spare parts volume
Volume 08_SP_Language
_Rev.00
Page 4
Filling machine VMF-L
Machine dismantling
Machine :
FILLING MACHINE
Type :
VMF-L
Machine dismantling
Filling machine VMF-L
Page 1
Volume 09_MD_Language
_Rev.00
Machine dismantling
INDEX OF CHAPTER
MACHINE DISMANTLING....................................................
DISMANTLING......................................................................................................
............................................................................ 1
WARNINGS................................................................................................................................................................... 3
INSTRUCTIONS FOR EXTENDED INACTIVITY .................................................................................................... 3
DEMOLITION........................................................................................................................................................... 3
RESIDUAL RISKS ................................................................................................................................................... 4
Volume 09_MD_Language
_Rev.00
Page 2
Filling machine VMF-L
Machine dismantling
Warnings
Before you start any operation on the machine, carefully read the sections “Use manual” and
“Machine maintenance”.
Carefully read the section related to Personal Protection Equipment.
Instructions for extended inactivity
No particular procedure is required for extended rest periods.
It is absolutely necessary to thoroughly clean the machine components, removing any material
residues.
Demolition
Once the machine has reached the end of its service lifetime, it must be put out of commission so it
can not be used for the purposes it was designed for and so as to make reuse of its parts and
materials possible.
The machine must be deactivated and demolished safely to prevent the risk of impacts due to the
presence of moving parts or stored energy. Teknoice S.r.l. declines all responsibility for damages
to things or injuries to people caused by reuse of the separate machine parts for functions other
than the original ones.
1. Disconnect the machine from any energy source (e.g.: electric, pneumatic, water, hydraulic,
etc.).
2. Disassemble the various components, if necessary referring to the diagrams and the layout
attached to this manual.
In the case of machine handling, lifting and transport, refer to the section “Transport and
installation” and to the assembly diagrams attached to this manual.
Disassemble the machine according to the various units, using tools and instruments normally
found in maintenance stores, so as to be moved and transported. Separate the potentially
hazardous components, such as:
•
•
•
Plastic or polymer-based materials, etc...
Electric components, cables, etc...
Metal components by type, such as aluminium, steel, etc.
Always bear in mind that the disposal of toxic and harmful waste is subject to special rules,
depending on the country. You must become familiar with these rules before carrying out any
operation of this type.
Contact the Teknoice S.r.l. Technical Service should you have any doubts or need further
information.
Filling machine VMF-L
Page 3
Volume 09_MD_Language
_Rev.00
Machine dismantling
Residual risks
The machine does not present residual risks if prepared for demolition according to the procedures
provided in the foregoing section.
Volume 09_MD_Language
_Rev.00
Page 4
Filling machine VMF-L
Manual attachments
Machine :
FILLING MACHINE
Type :
VMF-L
Manual attachments
Filling machine VMF-L
Page 1
Volume 10_MA_Language
_Rev.00
Manual attachments
INDEX OF CHAPTER
MANUAL ATTACHMENTS....................................................
ATTACHMENTS......................................................................................................
........................................................................... 1
CERTIFICATES ............................................................................................................................................................ 3
SUPPLIERS’ MANUALS .............................................................................................................................................. 3
Volume 10_MA_Language
_Rev.00
Page 2
Filling machine VMF-L
Manual attachments
Certificates
See all attachments of the “Use and maintenance manual” in the Cd-rom documentation and/or
attached to this manual.
Manufacturer/ Supplier
Documentation:
•
•
Declaration of Conformity
Certificat.
Teknoice
Siemens
Suppliers’ manuals
See all attachments of the “Use and maintenance manual” in the Cd-rom documentation and/or
attached to this manual.
Manufacturer/ Supplier
Documentation:
•
Use manual
Siemens
Filling machine VMF-L
Page 3
Volume 10_MA_Language
_Rev.00
Manual attachments
Volume 10_MA_Language
_Rev.00
Page 4
Filling machine VMF-L
Teknoice S.r.l.
Via Lazio, 37
20090 Buccinasco (MI)
Italy
Tel. 0039.02.4886761
Fax 0039.02.4882153
Web www.teknoice.com