vc999 ST2 Original Operating Manual
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vc999 ST2 Original Operating Manual

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ORIGINAL OPERATING MANUAL
Art. no. 593.767
Shrink Tunnel
ST2/ST2 D
VC999 VERPACKUNGSSYSTEME AG
Melonenstrasse 2
CH-9100 Herisau / Switzerland
Tel. ++41 (0) 71 35 35 900
Fax ++41 (0) 71 35 35 901
E-Mail
info@vc999.ch

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  • Page 1 ORIGINAL OPERATING MANUAL Art. no. 593.767 Shrink Tunnel ST2/ST2 D VC999 VERPACKUNGSSYSTEME AG Tel. ++41 (0) 71 35 35 900 Melonenstrasse 2 Fax ++41 (0) 71 35 35 901 CH-9100 Herisau / Switzerland E-Mail info@vc999.ch...
  • Page 2 CH-9100 Herisau ............We hereby declare that the following product Product name: Shrink Tunnel VC999 ST2/ST2 D is in conformity with the relevant- provisions of the above referenced directives – including any valid amendments at the time of the declaration.
  • Page 3 Shrink Tunnel VC999 ST2/ST2 D Handover declaration NOTICE The following handover declaration has to be completed by the owner. The owner is obliged to return the original, completed handover declaration to us. The owner hereby certifies that he/she has understood and taken full note of the operator manual. By signing this document...

  • Page 5: Table Of Contents

    Products ................... 21 3.3.4 Belt cartridge ..................21 3.3.5 Water system ................... 21 3.3.6 Steam extraction ................21 3.3.7 Steam heater (VC999 ST2 D) ............22 3.3.8 Decalcifying system (optional) ............22 3.3.9 Electrical data................... 22 3.3.9.1 Power supply..................22 3.3.9.2 Output and Fuse protection..............
  • Page 6 Installation of the machine ............28 Electrical installation .................28 Installation of the water supply line ..........29 Installation of the water discharge............30 Installation of the steam supply line (VC999 ST2 D)......31 Installation of the steam extraction system ........31 Installation of the protective rollers...........32 Cleaning the machine...............32 Start-up....................33...
  • Page 7 Cleaning agents ................69 12.1.2 Cleaning work................... 70 12.1.3 Cleaning the water supply line filter sieve........71 12.1.4 Cleaning the steam supply line filter sieve (VC999 ST2 D) ..... 71 12.1.5 Cleaning the belt cartridge and sieve..........72 12.2 Checks ..................... 74 12.2.1 Checking the belt tension..............
  • Page 8 Shrink Tunnel VC999 ST2/ST2 D Contents Spare parts..................79 14.1 Ordering spare parts.................79 Disposal...................80 Circuit diagrams ................81 Index ....................95 Page 8/96 Art. no. 593.767 2009-11-12...

  • Page 9: Introduction

    Shrink Tunnel VC999 ST2/ST2 D Introduction Introduction General information • This operator manual is an integral part of your machine. The information and safety instructions contained herein have to be carefully read and adhered to by members of staff authorized to oper- ate the machine.

  • Page 10: Terms

    This documentation contains information protected by copyright. Any reproduction, copying, scanning or forwarding to third parties is expressly prohibited without the express prior permission of VC999 VERPACKUNGSSYSTEME AG. Violation is expressly prohibited by law, and may result in severe civil and criminal penalties.

  • Page 11: Safety And Warranty

    Shrink Tunnel VC999 ST2/ST2 D Safety and warranty Safety and warranty Explanation of the safety instructions All the safety instructions in this operating manual provide the operator with early warning of possible dangers, possible damage to the machine and peripheral equipment and of flawed, productive work.

  • Page 12: Residual Risks

    • Trapping fingers and general injuries from uncoordinated operation. • Risk of injury from unskilled transport or movement of the machine. • Risks from working on the electric equipment. * only machine type ST2 D General safety instructions Pay particular attention to the following instructions: •...

  • Page 13: Machine Stability

    Shrink Tunnel VC999 ST2/ST2 D Safety and warranty WARNING Electrical hazard! Danger of death - electric shock! If the operator manual expressly states that the power supply has to be disconnected for cer- tain tasks at the machine, these tasks should only be carried out after it has been ensured that accidental reconnection of the power supply cannot occur directly or via a third party.

  • Page 14: Requirements For Operators

    Shrink Tunnel VC999 ST2/ST2 D Safety and warranty The owner is responsible for the suitability, condition and characteristics of the shrink packaging. The machine manufacturer is not responsible for the content of the packages. NOTICE This machine can be dangerous if it is not used correctly and/or for its intended purpose. Cor- rect usage also includes observance of the installation, operation and repair work regulations specified by the manufacturer.

  • Page 15: Description Of The Machine

    Products hermetically sealed in shrink bags are fed into the machine either manually or via a conveyor belt, e.g. from a VC999 packaging machine. When the infeed photocell detects an incoming product, the control unit activates the conveyor belt (wire mesh conveyor belt) integrated in the machine.

  • Page 16: Structure Of The Machine

    Access cover Water tank Solenoid valve water supply Electric heater (VC999 ST2) Water filter 10 Steam distributor (VC999 ST2 D) Steam extraction fan 11 Belt cartridge (internal conveyor belt) Electric cabinet with wire mesh conveyor belt and 2 protec- Water connection...
  • Page 17 The water level in the water tank is monitored by three electronic sensors in both versions. The water can only be warmed up when the heating element (VC999 ST2) or the steam distributor (VC999 ST2 D) are completely submerged in water, thus guaranteeing dry run security.
  • Page 18 Shrink Tunnel VC999 ST2/ST2 D Description of the machine Control panel with touch screen display Operation occurs via the control panel at the front of the machine. Individual parameters can be dis- played and their values edited on the touch screen. A keyboard appears on the screen to enter data.

  • Page 19: Operator Tasks

    Shrink Tunnel VC999 ST2/ST2 D Description of the machine 3.2.1 Operator tasks One operator is required at the machine during production to carry out the following tasks: • To monitor and support the functional efficiency of the machine. • To actuate the EMERGENCY STOP button in an emergency situation.

  • Page 20: Dimensions

    Shrink Tunnel VC999 ST2/ST2 D Description of the machine 3.3.1 Dimensions Fig. 3/2 Power cord feedthrough (top) Water discharge Power cord feedthrough (bottom) Steam extraction connection Electrical connection peripheral devices Steam heater connection Water supply connection Operator position Page 20/96 Art.

  • Page 21: Weight

    5 min. Connection dimensions for water discharge external dia. 38 mm (hose connection) * The customer must install the manometer and the shut-off valve in the water supply line to the VC999 Shrink Tunnel ST2/ST2 D. 3.3.6 Steam extraction Connection dimensions for steam extraction internal dia.

  • Page 22: Steam Heater (Vc999 St2 D)

    8 bar Pressure reducing valve*, set to 6 bar * The customer must install the manometer and the two valves in the steam supply line to the VC999 Shrink Tunnel ST2 D. Warm-up time from 10 °C to 90 °C: Low pressure: 0.5 bar (approx.

  • Page 23: Controller

    Shrink Tunnel VC999 ST2/ST2 D Description of the machine 3.3.9.3 Controller SPS FX series from Mitsubishi, touch screen terminal A max. of 10 programs can be freely selected. The programs can be stored. Operation and programming occurs at the touch screen via multilingual operator guidance.

  • Page 24: Packaging And Transport

    Transporting the machine NOTICE Always ensure that the machine remains horizontal and is not tilted! Please contact the VC999 Customer Service Department if the machine was tilted or fell over during transportation! Unpacking the machine...

  • Page 25: Setting Up The Machine

    Site requirements The Shrink Tunnel VC999 ST2/ST2 D is designed to be used in rooms whose temperature is not under + 5 °C and not above + 30 °C. If the system is to be used in rooms with other ambient temperatures, please contact the our Customer Service to have individual electrical components and/or respective safety devices installed, if necessary.

  • Page 26: Leveling The Machine

    Shrink Tunnel VC999 ST2/ST2 D Setting up the machine Leveling the machine Procedure • Use a spirit level to horizontally level out the ma- chine. • The feet (1) have to be raised or lowered using an open end spanner (size 30) as follows:...

  • Page 27: Machine Connections

    Steam heater connection (VC999 ST2 D) The machine is prepared for connection to a central steam generation unit. The connection procedure is described in the section "Installation of the machine" under "Installation of the steam supply line" (VC999 ST2 D)". 2009-11-12 Art. no. 593.767...

  • Page 28: Installation Of The Machine

    Shrink Tunnel VC999 ST2/ST2 D Installation of the machine Installation of the machine Ensure that the machine is in a horizontal and stable position. If necessary, level out the machine ac- cording to the description "Leveling the machine". Casing Some parts of the casing must be removed for installation and maintenance tasks. An open end span- ner or one of the socket keys supplied with the machine must be used to remove the casing.

  • Page 29: Installation Of The Water Supply Line

    Do not connect the machine if there are any deviations in the data! The machine may only be switched on for the first time by VC999 Customer Service personnel! • The power cord can be routed into the electric cabinet from the top or the bottom (Fig. 3/1, Pos. 28).

  • Page 30: Installation Of The Water Discharge

    Shrink Tunnel VC999 ST2/ST2 D Installation of the machine Installation of the water discharge An electrically operated ball valve is fitted to the left-hand side of the water tank in order to empty it. This ball valve is opened by the control unit during the emptying process. The water then flows downwards and out of the tank.

  • Page 31: Installation Of The Steam Supply Line (Vc999 St2 D)

    Shrink Tunnel VC999 ST2/ST2 D Installation of the machine Installation of the steam supply line (VC999 ST2 D) This section describes the connection of the Shrink Tunnel (type VC999 ST2 D) to a central steam gen- eration unit. NOTICE Connection of the steam supply line must be carried out by an authorized expert in accordance with local regulations.

  • Page 32: Installation Of The Protective Rollers

    Shrink Tunnel VC999 ST2/ST2 D Installation of the machine Installation of the protective rollers CAUTION The machine should never be operated without the two protective rollers (1) installed at both sides of the belt cartridge! • Install the protective rollers (1) at both sides of the belt cartridge.

  • Page 33: Start-Up

    Start-up Initial start-up NOTICE The initial start-up may only be performed by VC999 Customer Service representatives! The customer’s personnel will receive thorough training at the same time. WARNING Unauthorized initial start-up itself can result in injury or damage to equipment or property! 8.1.1...

  • Page 34: Switching On The Machine

    Shrink Tunnel VC999 ST2/ST2 D Start-up 8.1.2 Switching on the machine An explanation of the operating elements can be found in the section "Operation". • Use the main switch (1) to switch on the machine. (Turn main switch to position I).

  • Page 35: Operation

    Shrink Tunnel VC999 ST2/ST2 D Operation Operation This section is addressed to the machine operator. It provides all the information needed for operating the machine, from starting the machine to operating and stopping it. General instructions • Do not package spoilt foodstuffs! •...

  • Page 36: Operation

    Shrink Tunnel VC999 ST2/ST2 D Operation Operation 9.3.1 Control panel Legend Display EMERGENCY OFF button Illuminated push button START (I), green Illuminated push button STOP (O), red Lamp HEATER Illuminated push button RESET Fig. 9/1 Functions Pos. Designation Function Display...

  • Page 37: Switching On

    Shrink Tunnel VC999 ST2/ST2 D Operation Explanation of the indicator lamps Operating elements Status Meaning START button Flashing The machine is ready for operation. Press the button to start production. Illuminated Machine is in operation, production running. STOP button Flashing The machine is in rundown mode and goes into "Ready"...

  • Page 38: Operation Via The Display

    Shrink Tunnel VC999 ST2/ST2 D Operation 9.3.3 Operation via the display The machine is basically operated and programmed via the interactive touch screen display. Masks The individual displays are referred to as masks. The background colors have the following meanings: White background There are no errors.
  • Page 39 Shrink Tunnel VC999 ST2/ST2 D Operation Status symbol (H) A status symbol indicates a machine function or a peripheral device connected to the machine. When switched on, the status symbol is displayed with a black background: Example: Menu Operator guidance basically occurs via interactive, language independent symbols. A specific mask is called after pressing these symbols on the display.

  • Page 40: Access Rights

    Shrink Tunnel VC999 ST2/ST2 D Operation 9.3.4 Access rights Access rights for machine operation via the display are classified into four safety levels. Each safety level is allocated to a specific group of people that have corresponding access rights for machine opera-...
  • Page 41 Shrink Tunnel VC999 ST2/ST2 D Operation Fig. 9/3 2009-11-12 Art. no. 593.767 Page 41/96...

  • Page 42: Main Menu

    Shrink Tunnel VC999 ST2/ST2 D Operation Main menu page 1 The main menu page 1 appears after switching on the ma- chine or when switching it on after an EMERGENCY STOP if the machine is free from errors and in the initial position.

  • Page 43: Water Temperature

    Shrink Tunnel VC999 ST2/ST2 D Operation 9.4.1.1 Water temperature The water temperature in the water tank is monitored by a temperature probe. Set point = set temperature Actual = actual temperature Only possible from safety level 1 and higher: Fig. 9/6 The set temperature can be changed after pressing the dis- played value.

  • Page 44: Outfeed Belt

    Shrink Tunnel VC999 ST2/ST2 D Operation 9.4.1.4 Outfeed belt The operating status of the outfeed belt (optional) is displayed in this mask. Only possible from safety level 1 and higher: Press the switch to unlock (I) or lock (0) the outfeed belt for operation.

  • Page 45: Operating Hours Meter

    Shrink Tunnel VC999 ST2/ST2 D Operation NOTICE symbol means that the program has been pre-programmed as "continuous operation" by the manufacturer and cannot be overwritten. For more information, refer the description in the section "Continuous operation". Saving program (only possible from safety level 1 and...

  • Page 46: Alarm List

    Shrink Tunnel VC999 ST2/ST2 D Operation Steam Fan for steam extraction extraction Water pump The pump which transports the water from the water tank to the spray nozzles. Decalcification The pump for the decalcification process (optional) Only possible from safety level 3 and higher: The operating hours, except the total operating hours of the machine, can be reset to zero as follows.

  • Page 47: Main Menu

    Shrink Tunnel VC999 ST2/ST2 D Operation Main menu page 2 Press the right facing arrow on main menu page 1 to open main menu page 2. Press the symbols on main menu page 2 to access the follow- ing sub-menus: Fig.

  • Page 48: Log Out

    Shrink Tunnel VC999 ST2/ST2 D Operation 9.5.2 LOG OUT The access rights for an unlocked safety level usually remain ac- tive until the LOG OUT symbol is pressed or, except safety level 2, the machine is switched off. The access lock must be activated when exiting an unlocked safety level.

  • Page 49: Analog Value

    Shrink Tunnel VC999 ST2/ST2 D Operation Operating Machine status Possible actions status Warm-up mode Change settings Ready for operation Change settings Start the machine via button command or external command Operation Rundown mode Decalcification program Emptying Error code A current error is displayed here with the corresponding error number. The meaning of error numbers is described in the section "Troubleshooting".

  • Page 50: Main Menu

    Shrink Tunnel VC999 ST2/ST2 D Operation Main menu page 3 Press the right facing arrow twice on main menu page 1 to open main menu page 3. Prerequisite: You must be logged in with at least safety level 1! Fig. 9/24...

  • Page 51: Automatic Warm-Up

    Shrink Tunnel VC999 ST2/ST2 D Operation 9.6.1.1 Automatic warm-up Use this mask to program the automatic warm-up of the spray water according to the weekday and switch-on time. The warm- up time is approx. 20-30 minutes. Automatic decalcification (optional) Fig. 9/26 The arrow buttons are only displayed when the machine is equipped with a decalcifying system (op- tional) and the function "Decalcification pump"...
  • Page 52 Shrink Tunnel VC999 ST2/ST2 D Operation NOTICE To ensure that the decalcification process can be started, the machine must be switched on and in the initial position at the programmed start time. NOTICE If production is running at the programmed start time, the decalcification process will not be started.

  • Page 53: Manual Decalcification

    Shrink Tunnel VC999 ST2/ST2 D Operation 9.6.2 Manual decalcification Use this mask to start the manual decalcification of the water tank and supply lines. The process lasts approx. 30-40 minutes. • Press the "Manual decalcification" symbol to start the decal- cification process.

  • Page 54: Emptying The Water Tank

    Shrink Tunnel VC999 ST2/ST2 D Operation 9.6.3 Emptying the water tank Press this button to open the valve in the discharge line at the water tank and to empty the spray water. The START button and the STOP button flash alternately and "Emptying"...

  • Page 55: Main Menu

    Shrink Tunnel VC999 ST2/ST2 D Operation Main menu page 4 Press the right facing arrow three times on main menu page 1 to open main menu page 4. Prerequisite: You must be logged in with at least safety level 3! Fig.

  • Page 56: Language, Time And Weekday

    Shrink Tunnel VC999 ST2/ST2 D Operation 9.7.1.2 Language, time and weekday This mask provides the following information: • Language (operator guidance) • Time • Weekday Press the set values to change them. Use the keyboard which Fig. 9/33 appears to carry out the desired changes.

  • Page 57: Further Functions

    Switching via this mask is only relevant for connected infeed and outfeed belts (optional). A change of transport direction results in a mechanical conversion of the shrink tunnel. This mechanical conversion must be carried out by a VC999 service technician. Please contact the VC999 Customer Service Department.
  • Page 58 Shrink Tunnel VC999 ST2/ST2 D Operation NOTICE When the "Photoel. sensor" defect mode is switched on, the monitoring of incoming products is no longer carried out. The outfeed belt (optional) and the machine internal conveyor belt run continuously. NOTICE When the "Communication" defect mode is switched on, the frequency converter is controlled via an external signal.

  • Page 59: Inputs / Outputs

    Shrink Tunnel VC999 ST2/ST2 D Operation 9.7.2 Inputs / Outputs Statuses of the PLC inputs and outputs are displayed in the two diagnosis masks. Inputs Fig. 9/36 Signal at the PLC input Program logic display Logical program status Fig. 9/37 NOTICE The inputs X0 and X1 cannot be changed.

  • Page 60: Starting Production

    Shrink Tunnel VC999 ST2/ST2 D Operation Starting production If a program has been created and the machine has been installed according to the description in the section "Installation of the machine" and is ready for operation, the warm-up process can be started.

  • Page 61: Changing The Program

    Shrink Tunnel VC999 ST2/ST2 D Operation 9.11 Changing the program A new program must be loaded in order to change the program. The program parameters of the new program are immediately accepted and executed. The program cannot be changed during production.

  • Page 62: Switching Off The Machine

    Shrink Tunnel VC999 ST2/ST2 D Operation • Start the decalcification process (duration 15 mins.). • Completely drain the water tank. • Fill fresh water up to the minimum level. • Flush the water lines (duration 5 mins.) • Completely drain the water tank.

  • Page 63: Operating Messages And Faults

    The information given below on troubleshooting covers the most usual type of malfunction. Consult the manufacturer's customer services at VC999 VERPACKUNGSSYSTEME AG, if you come up against a problem for which no troubleshooting instructions are given here.

  • Page 64: Troubleshooting

    Keep the key out of the reach of other people! All repairs must be carried out by the VC999 Customer Service Department! Fault Possible cause...
  • Page 65 Shrink Tunnel VC999 ST2/ST2 D Operating messages and faults Fault Possible cause Remedy Water temperature or Automatic water supply is faulty due to a Clean the filter sieve (see section "Clean- water level fluctuate soiled filter sieve ing the water supply line filter sieve".

  • Page 66: Error Messages

    Possible cause Remedy PLC state PLC error Switch the machine off and then on again. If the error re-occurs, contact the VC999 Cus- tomer Service Department. PLC battery This message appears The battery must be replaced as soon as pos- when the PLC buffer sible.
  • Page 67 EMERGENCY STOP. Check whether the float- water" or heater contac- ing switch "Low water" has switched correctly. tors) If the error re-occurs, contact the VC999 Cus- tomer Service Department. Water level One of the floating The floating switch may have to be replaced.

  • Page 68: Operating Supplies

    Shrink Tunnel VC999 ST2/ST2 D Operating supplies Operating supplies Assembly Recommended products Decalcification process Supplier Decalcification Liquid decalcifier Manual or automatic decalcifica- VC999 tion with 50% citric acid 25 kg standard canister Powdered decalcifier Manual decalcification VC999 Page 68/96 Art. no. 593.767...

  • Page 69: Maintenance

    This operating manual does not address these requirements. The Shrink Tunnel VC999 ST2/ST2 D is virtually maintenance free. However, regular care and a mini- mum amount of maintenance work are essential to guarantee perfect operation. These tasks include: •...

  • Page 70: Cleaning Work

    • When the Shrink Tunnel VC999 ST2 D is connected to a central steam generation unit: Clean the filter sieve in the steam supply line. The procedure is described in section "Cleaning the steam sup- ply line filter sieve (VC999 ST2 D)".

  • Page 71: Cleaning The Water Supply Line Filter Sieve

    Fig. 12/1 Re-attach the machine casing and open the shut-off valve. 12.1.4 Cleaning the steam supply line filter sieve (VC999 ST2 D) CAUTION Hot steam! There is a risk of scalding from the discharge of hot steam! Always close the shut-...

  • Page 72: Cleaning The Belt Cartridge And Sieve

    Shrink Tunnel VC999 ST2/ST2 D Maintenance 12.1.5 Cleaning the belt cartridge and sieve Procedure If installed at the machine, disconnect the optional infeed and outfeed roller conveyors (1, 2). They can be simply raised and re- moved without the need for tools.
  • Page 73 Shrink Tunnel VC999 ST2/ST2 D Maintenance 10. Ensure that the protective rollers (9) are in- stalled correctly at both sides of the belt cartridge (5). The protective rollers can also be inserted or removed with the belt car- tridge installed.

  • Page 74: Checks

    Check the belt tension at the belt cartridge (1). Situation A: The belt tension is correct. Situation B: The belt tension is not correct. The wire mesh belt must be replaced by the VC999 service team. Fig. 12/7 Page 74/96 Art. no. 593.767 2009-11-12...

  • Page 75: Maintenance Work

    Maintenance work is carried out on the machine to ensure trouble-free operation. We recommend you to subject the machine has a full maintenance cycle at least once a year. The VC999 Customer Service Department is available on request for all maintenance and servicing work.

  • Page 76: Changing The Standard Decalcifier Canister (Optional)

    Shrink Tunnel VC999 ST2/ST2 D Maintenance 12.3.1.1 Changing the standard decalcifier canister (optional) If the machine is equipped with an optional "Decalci- fying system", the respective standard canister (3) must be occasionally refilled with decalcifier or re- placed with a full canister.

  • Page 77: Repairs

    Maintenance and repair work must only be performed by trained specialists, as this work re- quires specialist knowledge and special skills. Neither are provided in this Operating Manual. If necessary, call in the VC999 Customer Service Department. You will find the Customer Service ad- dress with the contact numbers in the section "Introduction".

  • Page 78: Replacing The Display

    Shrink Tunnel VC999 ST2/ST2 D Repairs 13.1.2 Replacing the display Procedure Disconnect the machine from the power supply according to the description in the section "Main- tenance". Remove the cover plate from the inside (1). Use a screwdriver to unscrew the eight screws. This provides direct access to the inside of the control panel.

  • Page 79: Spare Parts

    Spare parts must correspond to the technical requirements of the machine manufacturer. Only use VC999 original spare parts! The VC999 Customer Service Department can provide you with a separate list of spare parts, on re- quest. Comply with the following instructions when you order spare parts: •...

  • Page 80: Disposal

    Shrink Tunnel VC999 ST2/ST2 D Disposal Disposal When purchasing lubricants and films always consider their environmental compatibility, any health risks they may present, the statutory regulations for their disposal and the local possibilities for correct disposal. The owner is responsible for disposing of the machine. He/She is responsible for ensuring that the ma- chine is disposed of carefully and in compliance with the applicable local regulations.

  • Page 81: Circuit Diagrams

    Shrink Tunnel VC999 ST2/ST2 D Circuit diagrams Circuit diagrams 2009-11-12 Art. no. 593.767 Page 81/96...
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  • Page 95: Index

    Checking the belt tension 74 Installation of the machine 28 Checks 74 Installation of the protective rollers 32 Circuit diagrams 81 Installation of the steam supply line (VC999 Cleaning 69 ST2 D) 31 Cleaning agent 69 Installation of the water discharge 30...
  • Page 96 Steam extraction 16, 21 Steam extraction fan 16, 18 Packaging 24 Steam heater 16, 17, 22 Password 40 Steam heater connection (VC999 ST2 D) 27 Peripheral devices 16 STOP-button 37 Photocell 16, 58 Stopping production 60 Power cord 16, 20...

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