Formax PowerMax 3000 Operating Manual

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SLICING SYSTEM

OPERATING MANUAL

PROVISUR TECHNOLOGIES • 9150 191st Street, Mokena, IL 60448 • Phone (708) 479-3500 • Fax (708) 479-3599 (98)

Europe: Schipholweg 315 • 1171 PL Badhoevedorp • The Netherlands • Phone +31-20-659-08-00 • Fax No. +31-20-659-08-01

Web Site: www.Provisur.com

AM2C

BEEHIVE

CASHIN

FORMAX

multitec

TST

WEILER

THE PROVISUR

FAMILY OF PROVEN BRANDS

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Page 1 PROVISUR TECHNOLOGIES • 9150 191st Street, Mokena, IL 60448 • Phone (708) 479-3500 • Fax (708) 479-3599 (98) Europe: Schipholweg 315 • 1171 PL Badhoevedorp • The Netherlands • Phone +31-20-659-08-00 • Fax No. +31-20-659-08-01 Web Site: www.Provisur.com ® AM2C BEEHIVE ® CASHIN ® FORMAX ® multitec WEILER ® THE PROVISUR ® FAMILY OF PROVEN BRANDS...
Page 3 PowerMax3000 Slicer to suit unique circumstances or product. The Formax Service, Engineering, and Training Departments are available to help with any questions about suitability of any procedure. IMPORTANT! Read and understand the entire procedure before doing any repair or setup operation.
Page 4 PowerMax3000 STANDARD FEATURES AND SPECIFICATIONS PRODUCTION • Touchscreen operator interface • Computer controlled machine operation • Backclamp Feed System • 1, 2, 3 or 4 loaves sliced together (depending on product size) • Automatic or Manual loading options • Variable slicing speed •...
Page 5 PowerMax3000 INSTALLATION DIMENSIONS...
Page 7: Table Of Contents
TABLE OF CONTENTS OPERATING SECTION SECTION 1 SAFETY Safety Information ......1-1 Safety Sign Locations ......1-2 Safety Interlocks .
Page 8 TABLE OF CONTENTS SECTION 3 TOUCHSCREEN CONTROLS (con't) “Production Data” Screen ..... . . 3-5 “Service Screen” ......3-6 SECTION 4 TOOLING Tooling Care .
Page 9 TABLE OF CONTENTS SECTION 7 PRODUCT CODE PARAMETERS Introduction ....... 7-1 Selecting a Product Code .
Page 11 TABLE OF CONTENTS MAINTENANCE SECTION SECTION M1 LUBRICATION Introduction ......M1-1 Procedures .
Page 12 TABLE OF CONTENTS SECTION M3 MOTION CONTROL / SERVO DRIVE SYSTEM (con't.) Motion Control Modules ..... . . M3-17 Servo Drive System ......M3-31 Servo Drive Modules .
Page 13 G-4500 Synthetic Grease ..MSDS-3 Formax H1 Gear Oil ..... . . MSDS-11 G.C.
Page 15: Safety
SAFETY RECOGNIZE SAFETY INFORMATION This is the Safety Alert Symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury or machine damage. Follow recommended precautions and safe operating practices. UNDERSTAND SIGNAL WORDS DANGER!, WARNING!, and CAUTION! are signal words that are used to alert the operator to potential hazards.
Page 16: Safety Sign Locations
(B-24636) (B-24631) (B-26018) (B-24631) These safety signs are available in other languages. Replacements can be purchased from the following: FORMAX, INC.-U.S.A. Customer Service Dept. 9150 191st Street Mokena IL 60448-0330 Phone: (708) 479-3500 FORMAX, INC.-EUROPE Customer Service Department Schipholweg 315...
Page 17 OF MACHINE (B-26018) These safety signs are (B-34324) available in other languages. (B-24631) Replacements can be purchased from the following: FORMAX, INC.-U.S.A. Customer Service Dept. 9150 191st Street Mokena IL 60448-0330 Phone: (708) 479-3500 FORMAX, INC.-EUROPE Customer Service Department Schipholweg 315...
Page 18 SAFETY INTERLOCK LOCATIONS #1 SIDE MASTER OFF “A4” SQ17 #1 SIDE SCANNER TOP DECEL LASER CURTAIN CONVEYOR GUARD #1 SIDE ACCESS GUARD #2 SIDE #2 SIDE ACCESS GUARD MASTER OFF INFEED STRUCTURE INTERLOCK SCALE CABINET INTERLOCK 031914...
Page 19: Safety System Overview
SAFETY SYSTEM OVERVIEW SAFETY ZONES FUNCTION BRANCH CONTACTOR Main Guard Function Stops all motions KA1/KA2 Clean Function Allows clean motions only: KA3/KA4 Structure Safety Laser Scanner Inhibits Motions: KA7/KA8 Product Lift Tray KA1/KA2 KA3/KA4 KA5/KA6 CONTACTOR CONTACTOR 031914...
Page 20: Lockout/Tagout
LOCKOUT/TAGOUT DEVICE LOCATIONS ADANGER! Follow your company’s Lockout/Tagout procedures before opening any guards or performing electrical/mechanical/pneumatic repairs. This equipment contains hazardous voltages and hazardous moving mechanical parts. Loss of life or severe personal injury can result if instructions contained in this manual are not followed.
Page 21: Theory Of Operation
THEORY OF OPERATION INTRODUCTION The following is a brief description of the key Slicer components as they relate to the “Theory of Operation.” This section is intended to give the machine user a better understanding of the Slicer operation. KNIFE INFEED COVER STRUCTURE...
Page 22: Move To Ready Position
“MOVE TO READY” BUTTON MOVE TO READY POSITION: The “Move To Ready” button is used to prepare the machine for operation after clean-up and whenever the Machine Power is turned “On.” The Infeed Structure will move to the “Run-Ready” position. All of the other Slicer components will move to their “Home”...
Page 23: Loaf Lift Tray
LOAF LIFT TRAY LOAF LIFT TRAY: The loaves of product are loaded into the Loaf Lift Tray when it is in the “down” position. (Illustration 5) The Loaf Lift Tray raises to the “up” position to grip the product. The “Raise Product Lift”...
Page 24: Loaf Tray Lift Cylinders
LOAF TRAY LIFT CYLINDER: The “Loaf Tray Lift” cylinder raises and lowers the Loaf Tray. (Illustration 8) After the Loaf Lift Tray raises, the Loaf Tray raises to the “up” position for gripping. The tray will remain in the “up” position until the Loaf Lift Tray lowers.
Page 25: Loaf Gate
LOAF GATE LOAF GATE: The Loaf Gate raises to the “up” position where the Lift Tray raises to hold the product and opens after the product is gripped and ready to feed into the Infeed Conveyor. (Illustration 10) The Loaf Gate is operated by 3 position Loaf Gate Air Cylinder.
Page 26: Gripper Drives
GRIPPER DRIVES: Each Gripper is independently driven by a Servo Motor. (Illustration 13) The travel distance of each Gripper is monitored through “Resolver” feedback from each Servo Motor to the Servo Drives. The travel distance of each Gripper controls the “thickness” of each slice, which determines the weight of each stack or draft.
Page 27 GRIPPERS: The Grippers hold the product as it feeds into the Knife. (Illustration 16) The Grippers are controlled by the XS5 Infeed Housing Manifold. PRODUCT GRIPPER XS5 receives operational instructions from the Computer via the Profibus Network. The #1 Gripper is controlled by the YV8 Directional Valve.
Page 28: Upper Infeed Hold Down Assembly
UPPER INFEED HOLD DOWN ASSEMBLY UPPER INFEED HOLD DOWN ASSEMBLY: The Upper Infeed Hold Down Assembly holds down the product while it is fed through the Shear Bar and into the Knife. (Illustration 18) Air Pressure is applied to the Hold Down Arms to hold the product firmly as it transfers into the Shear Bar.
Page 29: Knife
KNIFE: The Knife slices the product as it feeds through the KNIFE Shear Bar. (Illustration 21) The Knife mounts to an Orbiting Head and Counterweight. The Knife is the primary component COUNTERWEIGHT of the Slicer. For optimum slicing performance, it is necessary to keep the Knife sharp and in good condition.
Page 30: Slicing Conveyor
SLICING CONVEYOR SLICING CONVEYOR: The product is sliced onto the Slicing TRANSFER CONVEYOR Conveyor and then transfers to the Transfer Conveyor. (Illustration 23) SLICING CONVEYOR: The “Slicing” Conveyor travels to the top of its travel at the start of the stack or draft and lowers as the stack is created.
Page 31: Transfer Conveyor
TRANSFER CONVEYOR TRANSFER CONVEYOR: The Transfer Conveyor transfers the finished product to the Dynamic Scale Conveyors. (Illustration 26 and 28) The Transfer Conveyor is belt driven by the M5 Servo Motor and gearbox. The U6 Servo Drive controls the M5 Servo Motor.
Page 32: Dynamic Scale Conveyors
DYNAMIC SCALE DYNAMIC SCALE DYNAMIC SCALE CONVEYORS: Depending on the CONVEYOR #3 CONVEYOR #2 machine options, there can be up to 3 Dynamic Scale DYNAMIC SCALE Conveyors. (Illustration 29) Each Dynamic Scale CONVEYOR #1 Conveyor weighs the stack or draft from 1 loaf of product. The Dynamic Scale takes multiple weight samplings of the product as it transfers over the conveyor.
Page 33: Classifier Conveyors
ACCEPT/REJECT ACCEPT/REJECT CONVEYOR #3 CONVEYOR #2 CLASSIFIER CONVEYORS: The Classifier Conveyors transfer ACCEPT/REJECT the finished product to the next conveyor system. (Illustration 32) CONVEYOR #1 The Classifier Conveyors raise or lower to “reject” or “accept” the finished drafts or stacks. The Classifier Conveyor Belts are belt driven by the M16 Stepper Motor.
Page 35: Touchscreen Controls
TOUCHSCREEN CONTROLS INTRODUCTION The TouchScreen Control System has many different screens to support all the functions that the Slicer is capable of. This section is provided as a guide to access these different screens. The “Home” screen can be accessed from most screens by touching “Home.” To reduce space, this will be noted rather than a screen picture.
Page 36 “HOME” SCREEN 031914...
Page 37 “RUN” SCREEN 031914...
Page 38 “PRODUCT CODES” SCREEN 031914...
Page 39 “PRODUCTION DATA” SCREEN 031914...
Page 40: "Service" Screen
“SERVICE” SCREEN 031914...
Page 41 “SERVICE” SCREEN (con't.) 031914...
Page 42 “SERVICE” SCREEN (con't) 031914...
Page 43: Tooling
The Slicer Tooling consists of 3 major parts: the Knife, the Shear Bar, and the Gripper assemblies. The following information describes the care that must be taken to maintain the maximum life and receive the optimum performance from your Formax Tooling. KNIFE The Knife is the primary component of the Slicer.
Page 44: Shear Bar Care
SHEAR BAR The Shear Bar is an important part of the Slicer in that it creates a shear edge for the Knife. To receive the optimum life and performance from them, use the following procedures: 1. HANDLE WITH CARE The Shear Bar is made from high performance plastic. Although strong, the shear edge can easily be damaged.
Page 45 GRIPPER GRIPPER ASSEMBLY The Gripper Assemblies are used to hold the Butt End of the loaves. When the Grippers retract to allow the Loaf Gate to open, the Gripper Teeth and the Infeed conveyors hold up the Product. If the Grippers do not get a good bite on the Butt End, the loaf will break and fall into the Shear Bar.
Page 47: Classifier Conveyors
MACHINE ASSEMBLY “O”-RING RETAINING ROLLER IMPORTANT! SHAFT “Machine Assembly” requires 2 people to complete. Allow 30 minutes to assemble the machine. ADANGER! ILLUSTRATION 1 Follow your company’s lockout/tagout procedure before assembling the machine. BELTS END ROLLERS STEP 1 ASSEMBLE THE CLASSIFIER CONVEYORS 1.
Page 48 LARGEST SMALLEST STEP 2 ASSEMBLE THE TRANSFER CONVEYOR 1. Install Roller Brackets. (Illustration 4) Install smallest bracket in the #1 position. The second smallest in the #2 position and the largest in the #3 position 2. Insert the Roller shaft through the guide bushing in the Side Bracket.
Page 49: Transfer Conveyor
IDLER ROLLER IDLER SHAFT 6. Insert the Idler Shaft into the Idler Roller. (Illustration 8) 7. Install the conveyor belts. (Illustration 9) ILLUSTRATION 8 8. Install the Idler Roller under the belts and slide the flats of the shaft into the retaining slots in the side frame.
Page 50 DRIVE BUSHING DRIVE PULLEY STEP 3 ASSEMBLE THE DYNAMIC SCALE CONVEYORS 1. Install the drive bushing on the conveyor drive pulley. (Illustration 13) ILLUSTRATION 13 DRIVE PULLEY BELTS 2. Slide the drive pulley into the slots on the conveyor housing. (Illustration 14) 3.
Page 51 MOUNTING DRIVE 6. Loop the drive belt over the drive pulley and BRACKETS BELT slide the slots in the drive bushings into the mounting brackets. (Illustration 17) DRIVE PULLEY ILLUSTRATION 17 MOUNTING STUDS 7. Lower the rear mounting studs into the slots on the mounting brackets.
Page 52 INSTALL PAN DEBRIS RAIL STEP 4 ASSEMBLE THE DEBRIS CONVEYOR 1. Install the support pan. (Illustration 20) Make sure the debris rail is toward the front of the machine. 2. Pivot the Idler Mounting Bracket to the up position. ILLUSTRATION 20 SHAFT IDLER ROLLER 3.
Page 53 5. Install the Debris Conveyor Belt. (Illustration 23) INSTALL BELT ILLUSTRATION 23 PIVOT IDLER “DOWN” 6. Pivot the Idler Pulley “down” to tension the belt. (Illustration 24) ILLUSTRATION 24 7. Install the Debris Deflector on the mounting posts above the Debris Conveyor.
Page 54: Gripper Drive
DRIVE BELT GUIDE RAILS STEP 5 INSTALL THE GRIPPER DRIVE ASSEMBLY 1. Slide the #3 Gripper mounting bracket onto the guide rails with the teeth on the drive belt facing “up.” (Illustration 26) 2. Feed the Drive Belt between the side frame and the guide rails and install the belt over the #3 drive pulley.
Page 55 IDLERPULLEY 5. Slide the Idler Shaft in through all of the drive belts. (Illustration 29) Slide the Idler Pulleys onto the Idler Shaft. DRIVE BELTS IDLER SHAFT ILLUSTRATION 29 MOUNTING BRACKET 6. Slide the Idler Shaft into the mounting slots on the side brackets. (Illustration 30) 7.
Page 56 SLIDE MOUNTING STEP 6 INSTALL THE GRIPPERS GRIPPER BLOCKS 1. Slide the Grippers onto the mounting blocks. (Illustration 32) 2. Center the Grippers on the mounting blocks and tighten the retaining bolts with a 13 mm “T-handle” wrench. (Illustration 34) ILLUSTRATION 31 GUIDE RINGS 3.
Page 57 STEP 7 INSTALL THE LOWER INFEED LOWER INFEED CONVEYOR IDLER ASSEMBLY BELTS CONVEYORS 1. Install the Conveyor belts on the Lower Infeed Assembly. (Illustration 35) 2. Pivot the Idlers “up” to tension the belts. 3. Install the Drive Couplers for the #1 and #4 Infeed Conveyors.
Page 58: Shear Bar
INNER DRIVE 7. Slide the inner drive shaft through the SHAFT housing and gearboxes and into the conveyor assembly. (Illustration 37) Pivot the Drive Pulleys on the #2 Infeed Conveyor until the drive shaft fully engages. 8. Pivot the Drive shaft Retainer Arm “down”...
Page 59: Loaf Lift Tray
LOAF LIFTTRAY STEP 9 ASSEMBLE THE LOAF LIFT TRAY 1. Tilt the front of each Loaf Tray down and slide it forward until the front retaining bracket engages the front support shaft. Lower the back of the Tray until it latches in place. (Illustrations 41, 42 and 43) ILLUSTRATION 41 LOAF LIFTTRAY...
Page 60 STEP 10 INSTALL THE SLICING IDLER ROLLER CONVEYOR 1. Install the tray on the support posts. IDLER SHAFT (Illustration 44) 2. Install the conveyor belts. 3. Insert the Roller Shaft into the Idler Roller. (Illustration 45) ILLUSTRATION 44 4. Slide the Idler Roller and shaft under the belts.
Page 61: Slicing Conveyor
DRIVE SHAFT GEARBOX 8. Slide the Slicing Conveyor on to the mounting rail. Slide it over until the drive shaft engages in the gearbox and the alignment pins on the mounting rail. (Illustration 46 and 47) 9. Thread the retaining bolt into the Slicing Conveyor.
Page 62 KNIFE GUARD CARRIER STEP 11 INSTALL THE KNIFE ADANGER! DRIVE PIN The Knife is very sharp! Never transport or install the Knife without the Knife Guard/Carrier installed! Failure to do so can cause severe injury! 1. Use 2 people to align the Knife with the drive pin on the orbiting head and install it.
Page 63: Side Doors
INSTALL DOOR HINGES TIGHTEN KNOB STEP 12 INSTALL THE SIDE DOORS 1. Align the pins on the door hinges with the holes in the lower hinges mounted to the machine. (Illustration 52) 2. Slide the Doors onto the hinge pins. 3.
Page 64: Power On
STEP 14 TURN “ON” THE MAIN POWER AND AIR (Illustrations 56 and 57) ADANGER! Follow your company’s lockout/tagout procedure before assembling the machine. 1. Follow the Touchscreen prompts and calibrate the Touchscreen. STEP 15 MOVE THE MACHINE TO THE POWER ON “READY”...
Page 65: Operation
OPERATION “RUN” SCREEN INTRODUCTION This section describes the basic Slicer Operation and the Machine Adjustments necessary to operate and fine-tune the Slicer during production. These adjustments are accessed on the “Run” screen and on the “Adjustments” screen. (Illustration 1 and 2) The “Adjustments” screen is accessed by touching the “Adjustments”...
Page 66: Power On
STEP 2 TURN “ON” THE MAIN POWER AND AIR (Illustration 4) ADANGER! Follow your company’s lockout/tagout procedure before turning “On” the power to the machine. 1. Follow the Touchscreen prompts and calibrate the Touchscreen. POWER ON STEP 3 “LOGIN” TO THE MACHINE ILLUSTRATION 4 1.
Page 67 “MOVE TO READY” BUTTON STEP 4 MOVE THE SLICER TO THE “READY” POSITION “Touch” and “Hold” the “Move To Ready” button on the “Run” screen. (Illustration 8) 1. The Infeed structure will raise to the “Up” position. (Illustration 9) 2. All of the Slicer components will “Align” to their “Home”...
Page 68: Select Product Code
“PRODUCT CODES” DISPLAY WINDOW STEP 5 SELECT PRODUCT CODE 1. Touch the “Product Codes” display window on the “Home” screen. (Illustration 10) 2. Touch and highlight the correct Product Code on the “Product Code List” screen. (Illustration 11) 3. Touch the “OK” button to select the code.
Page 69: Load Product
STEP 7 LOAD PRODUCT When the Loaf Lift Tray is in the “down” position, the Loaf Lift saddle switch light will turn “green.” (Illustration 13) This indicates that the Safety Laser Scanner will allow access to the “Loading Zone” to load the product.
Page 70: Start Feed
STEP 8 START FEED “FEED” BUTTON “REMOVE PRODUCT” BUTTON To start the Product Feed, touch the “Cycle Start” button a second time. (Illustration 15) This will start the Grippers feeding the product into the Shear Bar. The “Status Window” will display “Slicing.”...
Page 71: Machine Adjustments
“RUN” SCREEN MACHINE ADJUSTMENTS The Machine Adjustments are necessary to operate and fine-tune the Slicer during production. These adjustments are accessed on the “Run” screen and on the “Adjustments” screen. (Illustration 17 and 18) The “Run” screen displays the basic adjustments necessary to operate the Slicer.
Page 72 “RUN” SCREEN The “Run” screen displays the basic adjustments necessary to operate the Slicer. The “Run” screen is accessed by touching the “Run” button on the “Home” screen. (Illustration 20) The “Move To Ready,” “Remove Product” and “Move To Clean” buttons are located in the “Tooling”...
Page 73 “MOVE TO READY” BUTTON MOVE TO READY: The “Move To Ready” button is used to prepare the machine for operation after clean-up and whenever the Machine Power is turned “On.” The Infeed Structure will move to the “Run-Ready” position. All of the other Slicer components will move to their “Home”...
Page 74 “REMOVE PRODUCT” BUTTON REMOVE PRODUCT: The “Remove Product” button is used when production is complete or when changing product before all of the loaves have been sliced. (Illustration 24) To the remove the product from the machine: “Touch” and “Hold” the “Remove Product” button.
Page 75 “MOVE TO CLEAN” BUTTON MOVE TO CLEAN: The Slicer must be put in the “Clean-up” position for assembly, disassembly and sanitation purposes. (Illustration 26) When the “Move To Clean” button is “touched” and “held”: 1. All Slicer components move to their “Clean-up”...
Page 76 “BLADE SPEED” ADJUSTMENT BLADE SPEED: The “Blade Speed” adjustment controls the revolutions per minute of the Knife Blade. (Illustration 28) The “Blade Speed” can also be pre-set in the “Product Code Parameters.” The “Slicing” Speed may vary from day to day depending on the product quality and temperature.
Page 77 “SLICE DENIALS” ADJUSTMENT SLICE DENIALS: The “Slice Denials” adjustment sets the number of uncut slices or blade rotations, between completed stacks or drafts. The Knife Blade retracts away from the product during the “Slice Denial” period. The Slice Denial period also allows time to transfer the completed stacks or drafts off the Jump Conveyor before the start of the next stacks or draft.
Page 78 To adjust the Slice Denials: 1. For small Slice Denial adjustments, use the “up/down” arrows next to the Slice Denial display window to adjust the number of “Denials.” (Illustration 34) “DOWN” “SLICE DENIAL” “UP” ARROW WINDOW ARROW 2. For large Slice Denial adjustments, ILLUSTRATION 34 touching the Denial window will display an adjustment keypad.
Page 79 “UPPER INFEED PRESSURE” UPPER INFEED PRESSURE: The “Upper ADJUSTMENT Infeed Pressure” adjustment controls the amount of air pressure that pushes down on the Product Holddown Arms that hold the product near the Shear Bar. (Illustration 37) This pressure helps hold the product still, while the Blade slices the product.
Page 80 PRODUCTION RATE: The “Production Rate” window displays the “portions per minute” of the Slicer. The “Production Rate” is determined by the Blade Speed and the Slice Denial setting. IMPORTANT! This window does not display the actual output of stacks or drafts per minute of the Slicer.
Page 81: Adjustments Screen
“ADJUSTMENTS” SCREEN ADJUSTMENTS SCREEN The “Adjustments” screen displays the machine adjustments necessary to fine-tune the Slicer operation during production. (Illustration 41) The “Adjustments” screen is accessed by touching the “Adjustments” button on the “Run” screen. Most of the adjustments can also be pre-programmed in the Product Codes to save time when the same product is run again.
Page 82 “BLADE BACKUP” ADJUSTMENT BLADE BACKUP: The “Blade Backup” adjustment controls the distance that the Blade retracts away from the product during the “Slice Denial” period. This adjustment is set as a percentage of one Slice Thickness. (Illustration 44) For most products, a setting of 75% is normal. ILLUSTRATION 44 SLICING START: The “Start Slicing”...
Page 83 FEED 1 START FEED 1 START DEGREE: The “Feed 1 Start DEGREE Degree” parameter controls “when” the #1 Gripper starts to feed the product through the Shear Bar to start slicing. (Illustration 47) This adjustment is set as a degree of Knife blade rotation. If the product starts feeding too late, you will have a thin first slice.
Page 84 PORTION TYPE SELECTION PORTION Stack Correction/Slice Spacing/Shaved Product Spacing: Depending on whether “Stack,” “Shingle” or “Shaved” mode is selected in the “Portion Type” parameter in the Product Code, determines which adjustment will display on the list. (Illustration 50) (“Stack” selected in the “Portion Type”): If “Stack”...
Page 85 “SLICE SPACING” ADJUSTMENT (“Shingle” selected in the “Portion Type”): If “Shingle” is selected, the “Slice Spacing” adjustment displays and controls the speed and travel distance of the Slicing Conveyor while shingling a draft. The larger the setting, the greater the slice spacing and the longer the overall draft length.
Page 86 SHAVED PRODUCT MOVE TIME SHAVED PRODUCT MOVE TIME: The “Shaved Product Move Time” adjustment is only displays when operating in “Shaved Mode.” (Illustration 58) The “Shaved Product Move Time” adjustment is programmed in milliseconds and sets the acceleration rate of the transfer Conveyor when transferring “bunched”...
Page 87 % CORRECTIONS WEIGHING % Corrections: The “% Correction” adjustment sets the percentage of “Weight Control Corrections” for the drafts or stacks that do not fall in the “Weight Tolerance” range. The adjustment range is 0 to 100 percent. The “% Correction” can also be adjusted on the “Weight Data”...
Page 88 “+” TOLERANCE: This parameter sets the upper “+” TOLERANCE limit of the “accepted” weight range. (Illustration 63) This parameter can also be adjusted on the “Weight Data” screen is accessed from the “Run” screen. ILLUSTRATION 63 “-” TOLERANCE “-” TOLERANCE: This parameter sets the lower limit of the “accepted”...
Page 89 “BOTTOM SLICE OFFSET” ADJUSTMENT SLICING BOTTOM SLICE OFFSET: The “Bottom Slice Offset” adjustment allows you to adjust the position for a selected number of slices in a stack or draft. (Illustration 65 and 66) The number of slices is selected in the “Bottom Slice Offset Count” adjustment.
Page 90 STACKER START POSITION STACKER START POSITION: The Stacker Start Position is used when slicing in the HIGH SPEED, and ULTIMATE stack or shingle modes. Setting the Stacker Start Position to 0.00 mm (0 in.) starts the Slicing conveyor at the full “UP” position for the start of each group of drafts or stacks.
Page 91 PRODUCT START-BUTT LENGTH START-BUTT LENGTH: The “Start Butt” setting tells the Computer how much of the tapered or irregular end of the loaf to slice off at the beginning of the each set of loaves. (Illustration 71) This portion will not be weighed and will automatically be rejected.
Page 92 TRANSFERRING “SLICING CONVEYOR START” ADJUSTMENT SLICING CONVEYOR START: The “Slicing Conveyor Start” adjustment programs “when” the Slicing Conveyor will start to transfer the completed product to the Transfer Conveyor. (Illustration 73) The “Slicing Conveyor Start” is set as a degree of Knife rotation from the “Home” position, in relationship to the start of the Slicing Conveyor transfer.
Page 93 TRANSFER CONVEYOR TRANSFER CONVEYOR ALIGNMENT: The ALIGNMENT “Transfer Conveyor Alignment” adjustment controls the height of the Transfer Conveyor and is used to fine-tune the transfer of product from the Slicing Conveyor to the Transfer Conveyor. (Illustration 77 and 78) The “Transfer Conveyor Alignment”...
Page 94 TRANSFER CONVEYOR DELAY TO RAPID: This parameter allows you to delay the rapid TRANSFER CONVEYOR DELAY TO RAPID acceleration of the product as the Transfer Conveyor sends the product to the Dynamic Scale Conveyors. (Illustration 80) This adjustment is set in milliseconds.
Page 95 GRIPPING “GRIP RETRACT” ADJUSTMENT GRIP RETRACT: The “Grip Retract” adjustment controls the “retract” distance of the Grippers after they have gripped the product. (Illustration 83) The “Gripper Retract” lifts the product off the Loaf Gate prior to opening. This adjustment is set in millimeters or inches.
Page 96 “GRIP OFFSET” ADJUSTMENT GRIP #1, #2 AND #3 OFFSET: The “Grip Offset” adjustment allows you to fine-tune the position of each Gripper when they “Grip” the product. (Illustration 85 and 86) The “Grip Offset” adjustment can be set from - 50.80mm (-2.0 inches) to +50.80mm (+2.0 inches).
Page 97 GRIP ADVANCE OFFSET (#1, #2 AND #3): The “Grip “GRIP ADVANCE OFFSET” ADJUSTMENT Advance Offset” adjustment aligns the start of the loaves with the edge of the Shear Bar after the loaves are “gripped” and lowered towards the Blade. (Illustration 88 and 89) The “Grip Advance Offset” adjustment can be set from - 50.80mm (-2.0 inches) to +50.80mm (+2.0 inches).
Page 98 “TS MAX SPEED OFFSET” ADJUSTMENT TS-MAX TS MAX SPEED OFFSET: The “TS Max Speed Offset” adjustment controls the speed of the product transferring to the packager. (Illustration 90) The TS Max Speed Offset is adjusted as a percentage of the Classifier speed. This setting can be use to control the spacing between the product going to the packager.
Page 99: Production Data Screen
PRODUCTION DATA SCREEN To access the Production Data screen, touch the “Production Data” button on the “Home” screen. (Illustration 93) The “Production Data” screen displays the production output of the Slicer for each Product Code. The output from each of the Dynamic Scales is monitored and displays on this screen.
Page 100: Weight Data Screen
WEIGHT DATA SCREEN “+” TOLERANCE TARGET “-” TOLERANCE “%” (TO1) WEIGHT (TU1) CORRECTION The “Weight Data” screen shows the “Accept/Reject” tolerances that have been programmed for this Product Code. (Illustration 94) They are: “+” Tolerances (TO1), “Target Weight” and “-“ Tolerances (TU1).”...
Page 101 “CLEAR ALL” BUTTON ADJUSTMENT KEYPAD TARGET WEIGHT: Set the “Target Weight” parameter to the desired weight of each stack or draft. The “Target Weight” can also be pre-set in the Product Code. If you want to change the “Target Weight,” touch the display window, enter the new setting in the keypad and touch the “OK”...
Page 102 “DYNAMIC SCALE CHECK” BUTTONS DYNAMIC SCALE CHECK: Each Scale has a “Dynamic Scale Check” button that allows you to verify the product weight for that scale on a known good scale. (Illustration 98) To Dynamically check a Scale: 1. Touch the “Scale Dynamic Check”...
Page 103: Product Code Parameters
PRODUCT CODE PARAMETERS “PRODUCT CODES” DISPLAY WINDOW INTRODUCTION This section describes selecting, editing, creating a Product Code and describes the functions of the Product Code Parameters. A new Product Code can be created with all Machine Adjustments and Parameter Settings pre-programmed, to make “Production Startup”...
Page 104: Editing A Product Code
EDITING A PRODUCT CODE Existing Product Code Parameters can be edited or adjusted to improve the machine performance the next time the Product Code is used. To “Edit” an existing Product Code: 1. Touch the “Product Codes” button on the “Home” screen. (Illustration 3) 2.
Page 105 “UP/DOWN” ARROWS 4. Touch the “Up/Down” arrows to scroll through the parameters. (Illustration 5) 5. Touch and highlight the parameter that needs editing and then touch the “Edit” button. A window will display with a keypad. (Illustration 6) The minimum and maximum adjustment settings will also display in the window.
Page 106: Creating A Product Code
CREATING A PRODUCT CODE After running and fine-tuning a new product, a pre-programmed Product Code can be created for use the next time you run the same product. To “Create” a New Product Code: 1. Touch the “Product Codes” button on the “Home”...
Page 107: Keyboard Buttons
KEYBOARD BUTTONS CAPS LOCK: Touching the “Caps Lock” button will change the letters to “Upper Case” and allow you to use all capital letters in the Product Code “Name.” SHIFT: Touching the “Shift” button will shift the next letter typed in the Product Code to a capital letter.
Page 108: Copy An Existing Product Code
COPY AN EXISTING PRODUCT CODE When creating a new Product Code that is very similar to an existing Product Code, it is quicker to copy the existing code and rename it. To “Copy” an existing Product Code: 1. Touch the “Product Codes” button on the “Home”...
Page 109: Rename An Existing Product Code
RENAME AN EXISTING PRODUCT CODE To “Rename” an existing Product Code: 1. Touch the “Product Codes” button on the “Home” screen. (Illustration 14) “PRODUCT CODES” BUTTON ILLUSTRATION 14 SELECT “PRODUCT CODE “RENAME” BUTTON 2. Touch and highlight the “Product Code” that you would like to “Rename.”...
Page 110: Delete A Product Code
DELETE A PRODUCT CODE To “Delete” an existing Product Code: 1. Touch the “Product Codes” button on the “Home” screen. (Illustration 17) “PRODUCT CODES” BUTTON ILLUSTRATION 17 SELECT “PRODUCT CODE “DELETE” BUTTON 2. Touch and highlight the “Product Code” that you would like to “Delete.” (Illustration 18) 3.
Page 111: Programming Product Code Parameters
PROGRAMMING PRODUCT CODE PARAMETERS The following section describes the functions of the different parameters in the Product Code. Many of these parameters will be set the same for each Product Code. (Illustration 20) IMPORTANT! After creating or editing a “Product Code,” you will still need to “select”...
Page 112 BLADE SPEED BLADE BLADE SPEED: The “Blade Speed” parameter controls the revolutions per minute of the Blade. (Illustration 22) The “Blade Speed” can also be adjusted on the “Run” screen. The Slicing Speed may vary from day to day depending on the product quality and temperature. The Blade Speed can be set from “1”...
Page 113 BLADE BACKUP BLADE BACKUP: The “Blade Backup” parameter controls the distance that the Blade retracts away from the product during the “Slice Denial” period. (Illustration 25) This parameter is set as a percentage of one Slice Thickness. For most products, a setting of 75% of 1 slice thickness is normal.
Page 114 STOP SLICING STOP SLICING: The “Stop Slicing” parameter controls when the Blade moves away from the Shear Bar, during the Denial time. (Illustration 28) This parameter is set as a degree of Knife Blade rotation. FEED 1 START DEGREE: The “Feed 1 Start Degree”...
Page 115 FEED 3 START DEGREE FEED 3 START DEGREE: The “Feed 3 Start Degree” parameter controls “when” the #3 Gripper starts to feed the product through the Shear Bar to start slicing. (Illustration 33) This adjustment is set as a degree of Blade rotation.
Page 116 STACK CORRECTION/SLICE SPACING: PORTION TYPE Depending on whether “Stack,” “Shingle” or “Shaved” mode is selected in the “Portion Type” parameter in the Product Code, determines which adjustment will display on the list. (Illustration 36) (“Stack” selected in the “Portion Type”): If “Stack”...
Page 117 SHAVED PRODUCT MOVE TIME SHAVED PRODUCT MOVE TIME: The “Shaved Product Move Time” is only used when operating in “Shaved Mode.” The “Shaved Product Move Time” parameter is programmed in milliseconds and sets the acceleration rate of the Transfer Conveyor when transferring “Bunched product”...
Page 118 PORTION DIVIDER PORTION DENIALS PORTION INDEX LENGTH 7-16 031914...
Page 119 WEIGHING INDIVIDUAL TARGET WEIGHTS: If “yes,” no Target Weight adds below 19 parameters. % CORRECTIONS % CORRECTIONS: The “% Correction” parameter sets the percentage of “Weight Control Corrections” for the drafts or stacks that do not fall in the “Weight Tolerance”...
Page 120 % TOTAL WEIGHTS ALLOWED BETWEEN TU1 AND TU2 % TOTAL WEIGHTS ALLOWED BETWEEN TU1 AND TU2: This parameter allows you to set the total number of acceptable stacks or drafts that the Computer will allow between the TU1 and TU2 weight ranges. (Illustration 44) It is set as a percentage from “0”...
Page 121 TO2 OVERRIDE: LANE 1 TARGET WEIGHT: LANE 1 “+” TOLERANCE: 031914 7-19...
Page 122 LANE 1 “+” TOLERANCE TO1. TO2: “+” TOLERANCE “+” TOLERANCE: This parameter sets the upper limit of the “accepted” weight range. (Illustration 46) This parameter can also be adjusted on the “Weight Data” screen is accessed from the “Run” screen. ILLUSTRATION 46 “+”...
Page 123 “-” TOLERANCE: This parameter sets the lower limit “-” TOLERANCE of the “accepted” weight range. (Illustration 47) This parameter can also be adjusted on the “Weight Data” screen is accessed from the “Run” screen. ILLUSTRATION 47 “-” TOLERANCE TU2: TO1 OVERRIDE: 031914 7-21...
Page 124 TO2 OVERRIDE: TU1 OVERRIDE: UU2 OVERRIDE: 7-22 031914...
Page 125 UPPER INFEED PRESSURE SLICING UPPER INFEED PRESSURE: The Upper Infeed Pressure parameter controls the amount of air pressure that pushes down on the front of the upper Infeed Conveyors to hold the product while it is sliced. (Illustration 48) This parameter allows you to increase or decrease this clearance.
Page 126 PRODUCT LOAF COUNT LOAF COUNT: The “Loaf Count” parameter selects the number of loaves that will be run at one time. It is adjustable from 1 to 4. (Illustration 51) ILLUSTRATION 51 START-BUTT LENGTH START-BUTT LENGTH: The “Start Butt” setting tells the Computer how much of the tapered or irregular end of the loaf to slice off at the beginning of the each set of loaves.
Page 127 TRANSFERRING SLICING CONVEYOR START SLICING CONVEYOR START: The “Slicing Conveyor Start” parameter programs “when” the Slicing Conveyor will start to transfer the completed draft or stack to the Transfer Conveyor. (Illustration 54) The “Slicing Conveyor Start” adjustment is set as a degree of Blade Rotation from the Home position, in relationship to the start of the Slicing Conveyor transfer.
Page 128 SLICING CONVEYOR INDEX LENGTH SLICING CONVEYOR INDEX LENGTH: The “Slicing Conveyor Index Length” parameter programs the travel distance of the Slicing Conveyor belts when transferring product onto the Transfer Conveyor. (Illustration 58) ILLUSTRATION 58 SLICING CONVEYOR DELAY TO RAPID SLICING CONVEYOR DELAY TO RAPID: The “Slicing Conveyor Delay to Rapid”...
Page 129 TRANSFER CONVEYOR ALIGNMENT TRANSFER CONVEYOR ALIGNMENT: The “Transfer Conveyor Alignment” parameter controls the height of the Transfer Conveyor and is used to fine-tune the transfer of product from the Slicing Conveyor to the Transfer Conveyor. The “Transfer Conveyor Alignment” parameter can be set from -50.8 mm (-2.0 inches) to +50.8 mm (+2.0 inches).
Page 130 SCALE CONVEYOR SPEED OVERRIDE SCALE CONVEYOR SPEED OVERRIDE: When the “Scale Conveyor Speed Override” is set to “Yes,” the Computer will automatically control the transfer speed of the Dynamic Scale Conveyors. (Illustration 64) When set to “No,” the Scale Conveyors will run at the speed set in the “Scale Conveyor Speed”...
Page 131 GRIPPING GRIP RETRACT GRIP RETRACT: The “Grip Retract” parameter adjusts the “retract” distance of the grippers after they have gripped the product. (Illustration 67) This lifts the product off the Loaf Gate prior to the opening. This parameter is set in millimeters or inches.
Page 132 GRIPPER TIME TO OPEN GRIPPER TIME TO OPEN: The “Gripper Time to Open” parameter controls how long the Grippers will stay open to drop the End Butts. (Illustration 70) This parameter is set in milliseconds. To give the End Butts more time to drop off the grippers, increase the “Gripper Time to Open”...
Page 133 GRIP OFFSET GRIP #1, #2 AND #3 OFFSET: The “Grip Offset” parameter allows you to fine-tune the position of each Gripper when they “Grip” the product. (Illustration 73) The “Grip Offset” parameter can be set from - 50.80mm (-2.0 inches) to +50.80mm (+2.0 inches). If the Grippers are traveling too far when they grip the product, decrease the setting.
Page 134 START BUTT EXIT START BUTT EXIT: The “Start Butt Exit” parameter allows you transfer the “Start Butt” slices forward onto the Transfer Conveyor (normal operation) or to “reverse” the Slicing Conveyor and drop the slices on the Debris Conveyor. (Illustration 76) The Debris Conveyor then transfers the product to the rework bucket.
Page 135 SMART WEIGH PERCENT DELAY: The “Smart Weigh SMART WEIGH PERCENT DELAY Percent Delay” parameter controls “when” and “how long” the Dynamic Scales weigh the product as it transfers across the Scale Conveyors. (Illustration 77) This parameter is set in percentage of the “total weight sampling time.”...
Page 136 TS-MAX SPEED OFFSET TS-MAX TS-MAX SPEED OFFSET: The “Takeaway Conveyor Speed” parameter allows you to control the speed of the Takeaway Conveyor. (Illustration 79) The speed of the Takeaway Conveyor is controlled in millimeters or inches per second. ILLUSTRATION 79 TIGHT DRAFT SPACING If you want to group the product on the Takeaway Conveyor closer together, decrease the setting to slow...
Page 137 TS-MAX REJECT SPEED OFFSET: TS-MAX REJECT DISTANCE: 031914 7-35...
Page 138 USE POWERSCANNER DATA POWERSCANNER USE POWERSCANNER DATA: The “Use PowerScanner Data” parameter allows you to turn “on” or “off” the Scanner Data that is sent to the Slicer. (Illustration 82) To run the Slicer using the Scanner Data, set the parameter to “Yes.”...
Page 139: Disassembly And Cleanup
DISASSEMBLY AND CLEANUP CLASSIFIER DAILY PROCEDURE CONVEYORS The following steps should be performed daily. IMPORTANT! “Machine Disassembly” requires 2 people to complete. Allow 30 minutes to disassemble the machine. STEP 1 RAISE THE CLASSIFIER CONVEYORS TO THE FULL UPRIGHT POSITION (Illustration 1) ILLUSTRATION 1 STEP 2...
Page 140: Power Off
ADANGER! Follow your company’s Lockout/Tagout procedure before disassembling the machine. STEP 3 TURN “OFF” THE MAIN POWER (Illustration 5) POWER OFF ILLUSTRATION 5 LOOSEN KNOB REMOVE DOOR STEP 4 REMOVE THE SIDE DOOR 1. Unscrew the doorknobs and open the door.
Page 141: Remove The Knife
KNIFE GUARD RETAINING BOLTS STEP 5 REMOVE THE KNIFE CARRIER ADANGER! The Knife is very sharp! Use extreme caution when reaching into this area! Never transport or remove the Knife without the Knife Guard/Carrier installed! Failure to do so can cause severe injury! 1.
Page 142: Cover Touchscreen
PLASTIC BAG STEP 6 COVER THE TOUCHSCREEN WITH A PLASTIC BAG 1. Cover the Touchscreen with a plastic bag to prevent water damage. (Illustration 10) ILLUSTRATION 10 STEP 7 DISASSEMBLE THE SLICING RETAINING CONVEYOR BOLT 1. Unscrew the retaining bolt from the Stacker/Jump Conveyor with a 13-mm wrench.
Page 143 LOOSEN KNOB STEP 8 DISASSEMBLE THE DEBRIS CONVEYOR 1. Loosen knob and open the right side door. (Illustration 14) OPEN DOOR ILLUSTRATION 14 DEBRIS DEFLECTOR 2. Lift and remove the Debris Deflector from the mounting posts above the Debris Conveyor. (Illustration 15) MOUNTING POSTS ILLUSTRATION 15 REMOVE BELT...
Page 144 MOUNTING BRACKETS 5. Slide the Idler Shaft and pulley out of the slots on the mounting bracket. (Illustration 17) IDLER ROLLER ILLUSTRATION 17 SHAFT IDLER ROLLER 6. Slide the Idler Shaft out of the Idler Pulley. (Illustration 18) ILLUSTRATION 18 REMOVE PAN 7.
Page 145: Remove Shear Bar
QUICK CONNECT AIRLINE STEP 9 REMOVE THE SHEAR BAR 1. Disconnect the Product Holddown airline. (Illustration 20) 2. Remove the 2 retaining bolts that secure the Shear Bar in place. (Illustration 20) 3. Slide the upper retaining bar and Holddown Assembly “up” out of the mounting bracket.
Page 146 SLIDE ASSEMBLY 2. Loosen the Infeed Assembly and drive TO BACK coupler retaining screws. (Illustration 24) 3. Slide the #1 and #3 drive couplers away from the drive shafts for the #1 and #3 Infeed Conveyors. IMPORTANT! It may be necessary to pivot the Idler Shafts “down”...
Page 147: Remove Grippers
GUIDE RINGS STEP 11 REMOVE THE GRIPPERS 1. Disconnect the airlines from the Grippers. Feed the Gripper airlines down through the guide rings and out of the way. (Illustrations 27 and 28) GUIDE RINGS ILLUSTRATION 27 RETAINING BOLT 2. Loosen the retaining bolts with a 13-mm “T-handle”...
Page 148: Disassemble The Gripper Drive Assembly
LOCKING ARM STEP 12 DISASSEMBLE THE GRIPPER DRIVE ASSEMBLY 1. Use an adjustable wrench and turn the tensioner arm counterclockwise to tension the belts. (Illustrations 30 and 31) ILLUSTRATION 30 MOUNTING SLOTS 2. Slide the Idler Shaft out of the mounting slots on the side brackets.
Page 149 5. Remove the #1 Drive Belt off the drive pulley and pull it out between the side frame and the guide rails. (Illustration 33) DRIVE BELTS ILLUSTRATION 33 DRIVE BELT GUIDE RAILS 6. Slide the #1 Gripper mounting bracket off the guide rails.
Page 150: Disassemble The Loaf Lift Tray
LATCH STEP 13 DISASSEMBLE THE LOAF LIFT TRAY 1. Push on the locking latch and slide the Loaf Tray back. (Illustrations 35, 36 and 37) Remove from the Loaf LOAF LIFTTRAY Lift Tray. 4. Place the Loaf Tray in the proper place on the Cleanup Cart.
Page 151: Disassemble The Classifier Conveyors
STEP 14 DISASSEMBLE THE RAISE TO RELIEVE TENSION CLASSIFIER CONVEYORS IDLER ROLLERS 1. Raise the Classifier conveyors to the full “up” position to relieve tension on the belts. (Illustration 38) 2. Remove the Idler Rollers from the conveyor housing and slide. 3.
Page 152: Disassemble The Dynamic Scale Conveyors
STEP 15 DISASSEMBLE THE DYNAMIC SCALE CONVEYORS 1. Use a 1/4 inch wrench and turn the jackscrew towards the front of the conveyor to unlock the mounting studs. (Illustration 41) 2. Lift the rear of the conveyor to remove the mounting studs out of the slots on the mounting brackets.
Page 153 4. Remove the Idler Shaft from the slots on SLOTS the conveyor housing and slide the Idler Shaft and Pulley out from under the belts. (Illustration 45) IDLER SHAFT ILLUSTRATION 45 IDLER SHAFT IDLER PULLEY 5. Slide the Idler Shaft out of the Idler Pulley. (Illustration 46) 6.
Page 154: Disassemble The Transfer Conveyor
STEP 16 DISASSEMBLE THE TRANSFER LATCH CONVEYOR 1. Raise the Transfer Guard to the “up” position. (Illustration 48) 2. Pull the knob out and turn it to the left, RAISE (counter-clockwise) to unlock the Infeed COVER section. (Illustration 49) Pivot the Infeed section “down”...
Page 155 LOCK KNOB 5. Turn the front Roller Shaft knob to the right (clockwise) to unlock the shaft. (Illustration 53) ILLUSTRATION 53 ROLLER ROLLER GUIDE SHAFT BUSHING 6. Slide the shaft out of the far guide bushing and remove the 3 Rollers as you slide the shaft “out.”...
Page 156 LOOSEN KNOB HINGES STEP 17 REMOVE THE BUTT CHUTE Loosen knob and lift door off the hinges. (Illustration 56) STEP 18 REMOVE END BUTT TUB AND SUPPORT BRACKET STEP 19 HANG LEFT AND RIGHT SIDE GUARDS ON MACHINE BUTT CHUTE ILLUSTRATION 56 8-18 031914...
Page 157 CLEANUP CART ILLUSTRATION 57 ILLUSTRATION 57 031914 8-19...
Page 158: Cleaning Instructions
CLEANING INSTRUCTIONS PLASTIC BAG DAILY PROCEDURE The following steps should be performed daily. This procedure must follow the “Disassembly” of the machine. Make sure the Touchscreen has been covered by a plastic bag. (Illustration 58) Wear any protective clothing, including eye protection that is required in your plant for cleanup operations.
Page 159 PARTS CART STEP 1 WIPE OFF THE MACHINE Wipe off all loose particles of meat and debris with a brush. (Illustration 61) 1. Wipe off the upper Infeed area. 2. Wipe off the Shear Edge area. 3. Wipe off the Knife Enclosure area. 4.
Page 160 STEP 2 PRE-RINSE THE MACHINE Thoroughly rinse off the machine starting at the top and working your way down. Rinse off as much of the food particles as possible. IMPORTANT! Do not use high pressure water to rinse the machine. ACAUTION! Avoid directly spraying the Touchscreen with high-pressure water! Make sure the...
Page 161 STEP 3 FOAM CLEAN THE MACHINE IMPORTANT! A mildly alkaline cleaner (pH of 7.0 to 10.5) is recommended to prevent the degradation of soft metals (e.g. aluminum, brass, etc.). 1. With a normal pressure hose, thoroughly soak all of the machine components and surfaces. 2.
Page 162 STEP 4 CLEAN THE MACHINE BRUSHES 1. Scrub the entire machine with a brush. (Illustration 61) Pay close attention to all belt pulleys for the lower Infeed Conveyors. 2. Scrub all of the parts in the Cleanup Cart with a brush. Pay close attention to the pulleys, belts and the inside of the Rollers.
Page 163 STEP 5 FINAL RINSE Thoroughly rinse off the machine starting at the top and working your way down. IMPORTANT! Do not use high pressure water to rinse the machine. ACAUTION! Avoid directly spraying the Touchscreen with high-pressure water! Make sure the Touchscreen is covered with a plastic bag or damage to the Touchscreen will occur! 1.
Page 164 STEP 7 SANITIZATION Quaternary ammonium based sanitizers are recommended for their residual bactericidal effects and non-corrosive properties. 1. Thoroughly soak the entire machine with the sanitizing solution. Allow it to dry on the machine. 2. Thoroughly soak the all of the parts on the Cleanup Cart with the sanitizing solution and allow it to dry.
Page 165 POWER ON Due to the wide variation in process materials and conditions, it is the ILLUSTRATION 63 responsibility of the Formax machine owner or operator to develop a specific cleaning and sanitizing solutions that complies with the owner’s or operator’s cleanliness standards, as well as any federal, state or local regulations.
Page 167 TRANSPORTATION AND INSTALLATION WARNING! MACHINE AS SHIPPED This machine weighs approximately CENTER OF GRAVITY 1905 cm (75 in.) 2159 Kg (4750 lbs). Make sure any lifting devices used are rated for this weight. The Scale Cabinet weighs approximately 568 Kg (1250 lbs). Use a pallet jack centered under the Scale Cabinet when transporting the scale.
Page 168 LOCATION REQUIREMENTS MAINTENANCE ACCESS - APPROXIMATELY 134,6 cm (51.0 in.) SPACE AROUND MACHINE The machine location should be away from access doors, emergency exits and aisles. The floor should be a relatively flat, non-slip surface for operator safety. Avoid placing the machine in a position where any of the legs are on a floor drain or grate.
Page 169 STEP 6 Mount the machine legs. (Illustration 5) STEP 7 Level the machine and the transfer system to the packaging machine. The machine supply requirements are as follows: 3 phase electrical supply in any of the following voltages: 200, 230, 380, 420, 460, or 575 volts AC, 50 or 60 hertz. The machine uses 40 kVA maximum, a 65 amp service will fill its requirements under any of the voltages specified.
Page 171: Lubrication
LUBRICATION INTRODUCTION The Slicing machine requires lubrication at specific intervals, with the recommended lubricants. If these intervals are observed, the machine will perform longer without maintenance interruptions. If any part of this procedure is unclear or is not fully understood, contact a customer service representative at the factory.
Page 172: Procedures
1. Do not operate the machine while the guards or covers are open. 2. Follow your company’s Lockout/Tagout procedures when performing any maintenance on your Formax machine. 3. While lubrication is being performed, all other personnel must keep clear of the machine.
Page 173: Daily
LUBRICATION - DAILY The daily lubrication is necessary after the machine has been washed down. Perform this lubrication of the bearings before production to prolong bearing life. LUBRICATE THE FOLLOWING WITH FOOD GRADE WHITE (MINERAL) OIL AT THE BEGINNING OF THE DAY OR EACH SHIFT. HOSE GRIPPER GRIPPER...
Page 174 LUBRICATION - DAILY 2 pumps grease each bearing. Use Formax Food Grade grease Part # 703337. GREASE ZERK LOAF TRAY PIVOT BEARING LOAF TRAY POSITION BLOCK (1 EACH SIDE) GREASE ZERK GREASE ZERK LOAF TRAY PIVOT BEARING M1-4 031914...
Page 175 LUBRICATION - DAILY 2 pumps grease each bearing. Use Formax Food Grade grease Part # 703337. LOAF TRAY POSITION BLOCK (1 EACH SIDE) GREASE ZERK 031914 M1-5...
Page 176: Weekly
LUBRICATION - WEEKLY Check the oil level in the pneumatic lubricator. Fill with white (mineral) oil when low. DO NOT OVERFILL! Fill so that the level can be seen in the sight glass. If the unit is overfilled, the oiler will not work correctly. LUBRICATOR ADJUSTMENT KNOB SET LUBRICATOR TO...
Page 177: Monthly
LUBRICATION - MONTHLY 2 pumps grease each bearing. Use Formax Food Grade grease Part # 703337. OUTER CLASSIFIER DRIVE BEARINGS GREASE ZERK GREASE ZERK GREASE ZERK 031914 M1-7...
Page 178 LUBRICATION - MONTHLY 2 pumps grease each bearing. Use Formax Food Grade grease Part # 703337. INNER CLASSIFIER DRIVE BEARINGS GREASE ZERK GREASE ZERK GREASE ZERK M1-8 031914...
Page 179 LUBRICATION - MONTHLY 2 pumps grease each bearing. Use Formax Food Grade grease Part # 703337. Remove the rear skin. STRUCTURE LIFT BEARINGS GREASE ZERKS 031914 M1-9...
Page 180 LUBRICATION - MONTHLY CHECK EVERY 2000 HOURS Check the oil level in all the gear boxes. DO NOT OVERFILL! REPLACE OIL EVERY 2000 HOURS. Remove and drain gearboxes. Refill oil to proper level. Give the infeed gearboxes one pump of grease once a year when changing gear oil.
Page 181 LUBRICATION - MONTHLY CHECK EVERY 2000 HOURS LEVEL DRAIN 031914 M1-11...
Page 183: Service Screens
SERVICE SCREENS INTRODUCTION The following section describes the different “Service” screens and how to use them to ® troubleshoot and maintain the PowerMax3000 Maintenance personnel with permission to access these screens should read the entire section carefully to understand all of the ®...
Page 184: Monitor I/O
MONITOR I/O SCREEN The “Monitor I/O” screen is provided to aid in testing and troubleshooting the Input and Output signals used in controlling and operating the Slicer. (Illustration 2) There are 4 types of Inputs and Outputs displayed on the Monitor I/O screen, “Digital Inputs,” “Digital Outputs,”...
Page 185 DIGITAL OUTPUTS Digital Outputs: The list of Digital Outputs display in the upper right of the Monitor I/O screen. (Illustration 3) The Digital Outputs allow you to check the operation of many of the components on the Slicer. Use the “Up/Down” arrows to scroll through the list of “Digital Outputs.”...
Page 186 Integer Inputs: The list for all of the Integer Inputs monitored by the Slicer Computer displays in the lower left window of the “Test I/O” screen. (Illustration 4) The “Integer Input” window allows you to check the status of some of the Input Components used on the Slicer.
Page 187 Integer Outputs: The list of Integer Outputs display in the lower right of the Monitor I/O screen. (Illustration 5) The Integer Outputs allow you to check the operation of many of the components on the Slicer. Use the “Up/Down” arrows to scroll through the list of “Digital Outputs.”...
Page 188: Chart Recorder
CHART RECORDER: The “Chart Recorder” screen allows you to monitor and chart all of the Inputs and Output signals. (Illustration 6) Up to 8 signals can be monitored at one time. The Chart Recorder can be set up and run, while using a different screen to operate the machine or one of the Machine Tests screens.
Page 189 To measure the Signal Time: “STOP” BUTTON 1. Touch the “Stop” button to stop the Chart. 2. Touch the “Cursor On” button to display the 2 Cursors. (Illustrations 8) The button will change to “Cursor Off.” 3. Position the Cursors at the beginning and end of the signals.
Page 190 To set up an “Event”: CHANNELS “TRIGGER SETUP” BUTTON Setting up an “Event” allows you to chart up to 8 signals using 1 of the signals as a trigger. When the “Trigger” signal occurs, the Chart Recorder will start and display all of the signals occurring at this time.
Page 191 5. Touch the “Delay Before Stop:” button to set the “Runtime” duration of the Chart. 6. Enter the “runtime” in the keypad and touch the “OK” button. 7. Touch the “Channel Setup” button to select the “Trigger Signal.” 8. Touch the “Signal Name” button. 9.
Page 192: Profibus Network
PROFIBUS NETWORK: The “Profibus Network” screen displays the status of each node in the Profibus Network. (Illustration 10) Each Node is indicated by a box around the “Address Setting” of the Node. When there is good communication, the Node Boxes will be green. If there is no communication with one of the nodes, the box will turn “blue.”...
Page 193: Scales
SCALES ADMINISTRATOR SCALES: The “Scales” screen is used for the Dynamic OPTIONS Scale Calibration for each of the Dynamic Scale Conveyor Load Cells. (Illustration 14) To calibrate a Load Cells: The following procedure must be done with the scale seals in the released position. The Slicer must be in the “RUN”...
Page 194 “OK” BUTTON STEP 3 SELECT THE SCALE 1. Enter the position number of the scale that needs to be calibrated. 2. Press 1, 2, or 3 depending on your machines configuration. Then press “OK.” (Illustration 15 and 16) STEP 4 REMOVE ALL WEIGHT FROM SCALE 1.
Page 195 STEP 6 PLACE A 1000-GRAM WEIGHT “OK” BUTTON STANDARD ON THE SCALE 1. Press the “OK” button. 2. The Computer will complete the calibration. This step will take approximately 5 seconds. STEP 7 CALIBRATION DONE - REMOVE WEIGHT 1. Remove the weight from the scale and press the “OK”...
Page 196: Fault Log
FAULT LOG: The “Fault Log” screen displays the last 100 Faults in order of occurrence. (Illustration 21) The most recent “Fault” displays at the top of the list. Use the Up/Down Arrows to scroll through the list of “Faults.” IMPORTANT! Touching the “Clear Faults”...
Page 197: Machine Data
MACHINE DATA: The “Machine Data” screen displays the “Machine Hour Meter,” the “Cycle Hour Meter,” the “Total Blade Revolutions,” the “Average Blade RPM,” the “Total Power Cycles” and the “Total Power Failures.” (Illustration 23) ILLUSTRATION 23 MACHINE OPTIONS: The Machine Options screen displays the options that are active on your PowerMax3000 Slicer.
Page 198: Machine Tests
MACHINE TESTS The “Machine Tests” screens allow you run each Servo Motor independently to troubleshoot or test the Servo Drive and Servo Motor. (Illustration 25) The “Machine Tests” screen displays all of the Servo Motors used on the Slicer. The “Exlar” Servo Motor screen will display by pushing the “Exlar Motors”...
Page 199 Loaf Lift: The Loaf Lift screen allows you to test the Loaf Lift operation. (Illustration 27) Raise: Moves the Loaf Lift from the “Load”position (down) to the “Sweep” position (up). Lower: Moves the Loaf Lift from the “Sweep” position (up) to the “Load” position (down).
Page 200 Feed Engine: The Feed Engine screen allows you to test the functions of the Lower Infeed Conveyor Belt Drives and Gripper Assemblies. (Illustration 29) Home: Moves the Grippers “up” to a hard stop then moves “down” to the Gripper Position setting. Move to Load: If the machine “Faults”...
Page 201 Lower Infeed #1, #2, #3: The Lower Infeed screens allow you to test the operation and travel accuracy of the Lower Infeed Conveyor Belts individually. (Illustration 30) Home: Homes the Lower Infeed Conveyor and Gripper to a hard stop HOME at the top.
Page 202 Upper Infeed #1, #2, #4: The Upper Infeed screen allows you to test the operation of the Gripper Drive Assembly. (Illustration 32) Home: Homes the Gripper. Move To ... : Enter the “Position” in the keypad and touch “enter” The Gripper will travel to the position setting.
Page 203 Exlar Motors: The Exlar Motors screen displays the test functions of the Exlar Motors. (Illustration 33) Transfer Lift: Allows you to test the operation of the Transfer Lift Linear Actuator. Enable: Home: Move: Enter a “Position” in the Keypad. Pressing “OK”...
Page 204 Slicing Engine: The Slicing Engine screen allows you to check the “operational” functions of the Knife Blade. (Illustration 34) Home: “Homes” the Knife Blade. Cycle: “Cycles” the Knife Blade. Move to Clean: Moves the Knife HOME Blade to the “Clean” position. CYCLE Reset Faults: Resets Faults.
Page 205 Blade Retract: The Blade Retract screen allows you to test the operation of the M2 Linear Actuator that retracts and advances the Knife Blade. (Illustration 36) Home: Moves Knife Blade away from the Shear Edge to the “Home” position. Move Forward: Moves Knife HOME Blade away from the Shear Edge.
Page 206 Classifier Engine: The Classifier Engine screen allows you to test the operation of the Classifier Accept/Reject Conveyors. (Illustration 37) Home: Moves the Transfer Conveyor to the “Home” position. RESUME HOLD Move To Ready: Moves the HOME Accept/Reject Conveyors to the lowered position.
Page 207 Conveyor Calibration: The Conveyor Calibration screen allows you to fine-tune the speed of the Scale Conveyors and the Classifiers Conveyors. (Illustration 38) The Calibration screen displays the speed that the Scale Conveyor Belts and the Classifier Conveyor Belts should be turning. To check and calibrate the speed of the Conveyor Belts: SCALE SPEED SCALE SPEED...
Page 208 Classifier #1, #2, and #3: The Individual Classifier screen allows you to test the operation of each Accept/Reject Conveyor. (Illustration 40) Accept: Raises the Accept/Reject Conveyor. Reject: Lowers the Accept/Reject Conveyor. Cycle: Cycles the Accept/Reject ACCEPT Conveyor “up” and “down.” REJECT Stop: Stops cycle of the Accept/Reject Conveyor.
Page 209 Transfer Conveyor: The Decel Conveyor screen allows you to test the operation of the Transfer Conveyor. (Illustration 42) Home: Does Not Apply. Move Forward: Jogs the Transfer Conveyor Belts forwards. Move Backwards: Jogs the Transfer Conveyor Belts backwards. Jog: Enter a “Speed” in the keypad, HOME then touch “OK.”...
Page 210 Slicing Conveyor: The Slicing Conveyor screen allows you to test the operation of the Slicing Conveyor Belts. (Illustration 44) Home: Does Not Apply. Move Forward: Jogs the conveyor Belts forward. Move Backward: Jogs the Conveyor Belts backwards. HOME Jog: Runs the Slicing Conveyor MOVE belts.
Page 211 Safety Clean On/Off: Touching the “Safety Clean” button will toggle the button between “On” and “Off.” (Illustration 46) Turning the “Safety Clean” button to the “On” position allows you to raise or lower the Infeed Structure and Knife Cover using the Machine Test screens.
Page 212: Programmer Options
PROGRAMMERS OPTIONS: The PROGRAMMER OPTIONS “Programmers Options” screen is set up and programmed by the Software Engineers prior to the machine shipment and should not be changed for any reason! (Illustration 47) ACAUTION! Do Not change the settings on this screen without specific instructions from the Software Engineers! ADMINISTRATOR OPTIONS: The...
Page 213 Language Editor: The Language Editor screen allows you to translate word and phrases used on the Touchscreen in any of 6 languages, Spanish, Portuguese, French, Danish, German and Italian. (Illustration 49) Some of the works and phrases have already been translated and will automatically appear on the screens.
Page 214 4. Touch and highlight the desired language and touch the “OK” button. 5. If it has already been translated, the translation will appear in the “Phrase” window. If it has not it will remain blank. (Illustration 50) 6. Touch the “Phrase” window. Type the translation into the keyboard and touch the “OK”...
Page 215 Access Codes: The “Access Codes” screen allows you to create new “Users” and set the “Access” permissions for all “Users” operating and servicing the Slicer. (Illustration 51) Use this screen to limit the Access of certain “Users” to only the screens that are required for their job.
Page 216: Schematics
SCHEMATICS: The “Schematics” screen is not currently active. (Illustration 52) This screen was made to display the Electrical and Pneumatic Schematics. SCHEMATICS ILLUSTRATION 52 ILLUSTRATIONS: The “Illustrations” screen is not currently active. (Illustration 53) This screen was made to display the Parts and Assembly Drawings.
Page 217: Motion Control/Servo Drive System
MOTION CONTROL/SERVO DRIVE SYSTEM U13 MOTION U11 MOTION U12 MOTION CONTROL CONTROL CONTROL INTRODUCTION MODULE MODULE MODULE The PowerMax3000™ uses a “Motion Control System” to accurately control the speed, direction and response time of the Servo Motors. (Illustration 1) The Motion Control System uses a “Closed Loop Control”...
Page 218: Profibus Network
PROFIBUS NETWORK The Computer communicates with the Motion Control Modules through the Profibus Interface board. (Illustration 4) The Profibus Network Cable runs in series to U11 Motion Control Module, through the AR9 Safety Computer and then through all of the Input/Output Nodes and A8 Modbus converter.
Page 219 MOTION CONTROL MODULES: The ETHERNET CABLES PowerMax3000 Slicer Computer sends operational information to the 3 Motion Control Modules over the Profibus Network. (Illustration 5) The Motion Control Modules are manufactured by PROFIBUS CABLES Siemens. The Motion Control Modules send control signals over an Ethernet Network to the Servo Drives to control all of the Servo Motors.
Page 220: Active Line Module
ACTIVE LINE MODULE: The “U3” Active U5 THROUGH U7 ACTIVE LINE HEAD SERVO SERVO DRIVE MODULES Line Module takes a 3 phase AC supply MODULE DRIVE voltage and rectifies it to approximately 650 VDC. (Illustration 7) The 650 VDC is sent to each of the Servo Drives on the DC Bus Bars running across the front of the Servo Drives and is sent on a power cable...
Page 221: Servo Motor
SERVO MOTORS: Each motor has a built in SERVO SERVO SERVO Resolver Feedback System that tells the Motion MOTOR MOTOR MOTOR Control Modules the exact speed, direction and position of the Servo Motor. (Illustration 9) The Motion Control Modules use this information to send control information to the Servo Drives that control the Servo Motors.
Page 222: Feedback Converters
FEEDBACK CONVERTERS FEEDBACK FEEDBACK FEEDBACK CONVERTOR CONVERTOR CONVERTOR The Servo Motors that are not manufactured by Siemens, use a different type of Resolver Feedback. These Resolver Feedback signals are first sent to a Feedback Converter that translates these signals into a format that that can be understood by the Siemens Motion Control Modules.
Page 223: Servo Motor Cables
SERVO MOTOR CABLES There are 2 cables connected to each Servo Motor. Each motor is connected to the Servo Drive by a “Motor Power” cable. (Illustration 12) POWER RESOLVER CABLE FEEDBACK The “Power Cable” sends the voltage, current CABLE and frequency to run the Servo Motor. There are 2 additional wires for motors equipped with the optional Holding Brake.
Page 224 Linear Actuator used to position height of the Transfer Conveyor used on the Slicer. The Servo Motor that drives the Linear Actuator is preprogrammed at Formax to perform the movements necessary to position the height of the Transfer Conveyor. The Servo Motor is driven using the 48 VDC supplied by the GS3 Power Supply.
Page 225 ROTARY AND LINEAR ACTUATOR CABLES: There are 3 cables attached to the Rotary Actuator, the Power Cable, the Control Cable and the Modbus Cable. (Illustration 15) The M17 Transfer Conveyor Alignment Actuator only has 2 cables attached, the Power Cable and the Modbus Cable. Power Cable: The Power Cable sends 48 VDC Motor Power voltage and 24 VDC Supply voltage to the Servo Motor connected to the Actuators.
Page 226 24 VDC STEPPER MOTORS: There are 24 VDC DYNAMIC SCALE MOTORS 24 VDC Stepper Motors used to drive the Dynamic Scale Conveyor Belts. (Illustration 16) Depending on the machine options, there can be up to 3 Dynamic Scale Motors. Each motor is controlled by a separate Stepper Drive Module.
Page 227: U3 Active Line Module: Electrical Overview
U3 ACTIVE LINE MODULE: ELECTRICAL Z1 EMI U3 ACTIVE SERVO OVERVIEW FILTER LINE MODULE DRIVES The “U3” Active Line Module takes a 3 phase AC supply voltage and rectifies it to approximately 650 VDC. (Illustration 17) The 650 VDC is sent to each of the Servo Drives on the DC Bus Bars located on the front of the Drives.
Page 228 48 VDC ROTARY/LINEAR ACTUATOR SERVO QF8 CIRCUIT GS3 POWER SUPPLY BREAKER MOTORS/24VDC DYNAMIC SCALE SERVO MOTORS: ELECTRICAL OVERVIEW High Voltage Cabinet: 1. The QF1 Circuit Breaker sends the 3-phase AC supply voltage to the QM3 Circuit Controller. (Illustration 20) The QM3 Circuit Controller is a hand operated, thermally protected Circuit Breaker that sends the 3-phase AC supply voltage to the KM3...
Page 229 4. The common wire (402) is sent directly to the M16 and M17 Rotary/Linear Actuator Motors on wire 402. The 401 wire takes the 48 VDC through the QF8 Breaker. The QF8 Circuit Breaker protects the GS3 Power Supply from over-current conditions.
Page 230 Scale Cabinet: KA1/KA2 8. The KM3 Contactor sends the 3-phase AC supply voltage to the GS2 Power Supply. (Illustration 24) The KM3 Contactor is energized by the 30 wire coming from the AR7 Safety Output. (Illustration 22) After all guards are closed and “Master Off” buttons are pulled out and the machine has moved to the “Run”...
Page 231 24 VDC DYNAMIC SCALE CONVEYOR AR15 SCALE DRIVER CONTROL NODE STEPPER MOTORS: The Stepper Drive Modules receive operating instructions from the Computer through the AR15 Scale Driver Control Node. (Illustration 25) Depending on the machine options, the PowerMax3000 Slicer can have up to 3 Dynamic Scale Conveyors.
Page 232: Motion Control Modules
MOTION CONTROL MODULES COMPONENT OVERVIEW: MOTION The PowerMax3000 Slicer Computer sends CONTROLLER operational information to the 3 Motion Control Modules over the Profibus Network. (Illustration 26) The Motion Control Modules are manufactured by Siemens. The Motion Control Modules send control signals over an Ethernet Network to the Servo Drives to control all of the Servo Motors.
Page 233 Network Communication Ports: The U1 ETHERNET NETWORK U1 Motion Control Module has Network Ports located on top of the module that are used for communication with the Servo Drives and Servo Motors under its control. (Illustration 28) Only the X100 Port and the X101 Port are currently used.
Page 234 X122 Terminal Connector: The X122 X122 X132 Terminal Strip receives Status Input Signals from various components on the Slicer. (Illustration 29 and 30) The U1 Motion Controller uses these inputs to determine which Servo Motors are safe to operate. Terminal 1: 24 VDC Input from the SQ12 Water Flow Sensor when water is flowing through the Servo Drive cooling plate.
Page 235 X132 Terminal Connector: The X132 Terminal Strip receives 24 VDC Status Input Signals and sends Output X126 PROFIBUS U11 MOTION Signals to various components on the Slicer. (Illustration 31) CABLE MODULE Terminal 1: 24 VDC Input Signal from the KA1/KA2 Safety Contactor when all guards are closed and all X136 “Master Off”...
Page 236 X120 Ethernet Connection: Ethernet Cable that connects to the A8 Ethernet Hub that allows communication with the U1 Motion Control Module with a Laptop Computer through the A3 Wireless Ethernet Module located in the Touchscreen. A Computer can also be directly connected for troubleshooting purposes.
Page 237 Status Indicator LED’s: There are Status LED’s on the U1 Motion Control Module that indicate the status of the operating system. (Illustration 33) The LED’s can illuminate “green,” “yellow,” “red” or “off.” RDY LED: The “Ready” LED shows the status of the U1 Motion Control Module and all of the Servo STATUS Drives and Servo Motors under its control.
Page 238 STOP LED: Not Used. SU/PF LED: Not Used. SF LED: “System Fault” LED. Normally flashing STATUS LED'S “Red” and “Off.” DP1 LED: Shows the status of the Profibus communication with the U9 Motion Control Module. Red LED: No Communication. Check Cable Connection and make sure the Terminating Resistor is in the “On”...
Page 239 U2 ETHERNET U2 MOTION CONTROL MODULE: CABLES MODULE The U1 Motion Controller sends command signals and operational information to the U2 and U9 Motion Control Modules. The U2 and U9 Modules use this information to send command and control information to the Servo Drives under their control. Each Motion Control Module is run by a Computer and each Module has a programmed Compact Flash Chip.
Page 240 X122 Terminal Connector: The X122 X122 X132 U2 MODULE Terminal Strip receives Status Input Signals from various components on the Slicer. (Illustration 37) The U2 Motion Controller uses these inputs to determine which Servo Motors are safe to operate. Terminal 7: Future use. Terminal 8: Future use.
Page 241 X124 TERMINAL MODULE X124 Terminal Connector: The Motion Control Modules require a 24 VDC Supply Voltage in order to operate. (Illustration 38) This voltage is sent from the QF9 Breaker to the X124 Terminals on each Module and connects to the “+” and “M” terminals. 24 VDC is sent on wire “7”...
Page 242 Status Indicator LED’s: There are Status LED’s U2 STATUS LED'S MODULE on the U2 Motion Control Module that indicate the status of the operating system. The LED’s can illuminate “green,” “yellow,” “red” or “off.” RDY LED: The “Ready” LED shows the status of the U2 Motion Control Module and all of the Servo Drives and Servo Motors under its control.
Page 243 U9 ETHERNET CABLES MODULE U9 MOTION CONTROL MODULE: The U1 Motion Controller sends command signals and operational information to the U2 and U9 Motion Control Modules. (Illustration 40) The U2 and U9 Modules use this information to send command and control information to the Servo Drives under their control.
Page 244 X122 Terminal Connector: The X122 X122 X132 U9 MODULE Terminal Strip can receive Status Input Signals from components on the Slicer. (Illustration 42) The X122 Terminal connector is not currently in use. X132 Terminal Connector: The X132 Terminal Strip receives a 24 VDC Status Input Signal from KA1/KA2 Safety Relay.
Page 245 X124 Terminal Connector: The X124 TERMINAL MODULE Motion Control Modules require a 24 VDC Supply Voltage in order to operate. (Illustration 43) This voltage is sent from the QF9 Breaker to the X124 Terminals on each Module and connects to the “+” and “M” terminals. 24 VDC is sent on wire “101”...
Page 246 Status Indicator LED’s: There are Status LED’s on U9 STATUS LED'S MODULE the U9 Motion Control Module that indicate the status of the operating system. (Illustration 44) The LED’s can illuminate “green,” “yellow,” “red” or “off.” RDY LED: The “Ready” LED shows the status of the U9 Motion Control Module and all of the Servo Drives and Servo Motors under its control.
Page 247: Servo Drive System
“Troubleshooting” on any of these components! Always observe the following precautions: 1. Follow your company's Lockout/Tagout procedures when performing any ® maintenance on your Formax Machine! (Illustration 47) 2. The DC Bus voltage stored in the ILLUSTRATION 46 Active Line Module and the Servo Drives is in excess of 650 VDC.
Page 248 X21 “Safe Off” Terminal Connector: The X21 Terminal Strip is connected to a “Safe Off” Relay. (Illustration 48) 24 X200 X201 U3 ACTIVE VDC is sent to terminals 3 and 4 on ETHERNET ETHERNET LINE MODULE wires 101 and 2 From the X24 Terminal CABLE CABLE Connector to energize the “Safe Off”...
Page 249 STATUS LED'S Status Indicator LED’s: There are Status LED’s on the U3 Active Line Module that indicate the status of operating system. (Illustration 49) The LED’s can illuminate “green,” “orange,” “red” or “off.” RDY LED: The “Ready” LED shows the status of the Active Line Module.
Page 250 DC LINK LED: The “DC LINK” LED shows the status of the 650 VDC on the DC Bus Bars. LED OFF: Indicates that there is no 24 VDC Control Voltage. Check the 24 VDC at the X24 Terminal Plug. Orange LED (RDY LED is Green): The Active Line Module is ready for operation and the DC Bus Voltage is present.
Page 251: Servo Drive Modules
1. Follow your company's Lockout/Tagout procedures when performing any maintenance on ® your Formax Machine! (Illustration 53) 2. The DC Bus voltage stored in the Active Line Module and the Servo Drives is in excess of 650 VDC.
Page 252 X21 and X22 “Safe Off” Terminal Connectors: The X21 and X22 Terminal SAFE OFF SERVO DRIVE Connectors are used on all of the Servo Drives TERMINAL except the U4 Knife Servo Drive. Each Servo Drive, except the Knife Servo Drive, controls 2 Servo Motors.
Page 253 U5, U6, U7, U8, U9, U10, U11, U12 Servo Drives: These Servo Drives control 2 separate Servo Motors and use 2 “Safe Off” Relays. Each “Safe Off” Relay will inhibit a different Axis that controls one of the Servo Motors. X21 “Safe Off”...
Page 254 U7 Servo Drive: The U7 Servo Drive controls 2 separate Servo Motors and use 2 “Safe Off” Relays. Each “Safe Off” Relay will inhibit a different Axis that controls one of Servo Motors. Each of the “Safe Off” Relays on the U7 Servo Drive is controlled by a different source.
Page 255 U3 Active Line Module, U4, U5, U6 and U7 Servo Drives: X200, X201, X202, X203 Ethernet Communication Ports: The U3 Active Line Module has Network Ports located on top of the module that are used for communication with the U1 Motion Control Module and U4, U5, U6 and U7 Servo Drives.
Page 256 U10, U11, U12, Servo Drives: ETHERNET CABLES X200, X201, X202, X203 Ethernet Communication Ports: The U6 Servo Drive has Network Ports located on top of the module that are used for communication with the U13 Motion Control Module and U7 and U8 Servo Drives. (Illustration 58) X200 Port: The “incoming”...
Page 257 DC Bus Bars: The “U3” Active Line Module takes a READY LED 3-phase AC supply voltage and rectifies (converts) it to approximately 650 VDC. (Illustration 61) The DC LINK 650 VDC is sent through the Bus Bars to the Servo Drives for use in running the Servo Motors.
Page 258 STATUS LED'S DC LINK LED: The “DC LINK” LED shows the status of the 650 VDC on the DC Bus Bars. (Illustration 58) LED OFF: Indicates that there is no 24 VDC Control Voltage. Check the 24 VDC at the X24 Terminal Plug.
Page 259 Servo Motor Power Cables: Each Of the Servo SERVO MOTOR Drives except the U4 have 2 Axes that send Servo POWER CABLES Motor Power Voltage to 2 Servo Motors. The U4 Servo Drive only controls 1 Servo Motor. (Illustration 59) The X1 and X2 Servo Motor Power Cables are connected to the bottom of the Servo Drives.
Page 260 U10 Servo Drive: SERVO MOTOR POWER CABLES Axis X1 sends power voltage to the M10 #1 Upper Infeed Motor on the W15-3K Power Cable. Axis X2 sends power voltage to the M11 Lower Infeed Servo Motor on the W17-3K Power Cable. U11 Servo Drive: Axis X1 sends power voltage to the M12 #2 Upper Infeed Conveyor Servo...
Page 261 SERVO MOTOR POWER VOLTAGE: SERVO DRIVES The Servo Drive takes a 650 VDC Supply Voltage and creates a 3 phase AC voltage and frequency to run the Servo Motors. The Servo Drive controls the speed, direction and current sent to the motors, based on the “Speed Command”...
Page 262: Servo Motors
SERVO MOTORS: Servo Motors are used to optimize the performance of the functions on the Slicer. (Illustration 62) A magnetic SERVO MOTOR SERVO RESOLVER POWER CABLE MOTOR field is created as the 3 phase AC voltage passes through the windings in the Servo Motor. A Servo Motor also has magnets built into the rotor of the motor.
Page 263: Resolver Feedback Converter Modules
FEEDBACK FEEDBACK FEEDBACK RESOLVER FEEDBACK CONVERTER CONVERTOR CONVERTOR CONVERTOR MODULES: There are 4 Servo Motors that are not manufactured by Siemens and require a Resolver Feedback Converter Module in order to communicate with the Motion Control Modules. (Illustration 63) The Converter Modules translates the Resolver Feedback signals from these motors into a format that the Motion Control Modules can understand.
Page 264 U0 Converter Module: X524 Port: 24 VDC Control Voltage. X500 Port: Feedback cable running to FEEDBACK CONVERTOR Port X202 on the U5 Servo Drive Feedback Port: Resolver Feedback Cable coming from the M2 Knife Retract Servo Motor. FEEDBACK CONVERTOR ILLUSTRATION 65 M3-48 031914...
Page 265 U13 Converter Module: X524 Port: 24 VDC Control Voltage. X500 Port: Feedback cable running to Port X203 on the U10 Servo Drive. Feedback Port: Resolver Feedback Cable coming from the M11 #1 Lower Infeed Servo Motor. U14 Converter Module: X524 Port: 24 VDC Control Voltage. X500 Port: Feedback cable running to FEEDBACK FEEDBACK...
Page 267: Motion Controller Replacement (U11)
CONTROL MODULE (U1) STEP 1 TURN “OFF” THE MAIN POWER AND AIR ADANGER! Follow your company’s Lockout/Tagout procedures when performing any maintenance on your Formax machine. (Illustration 1) MAIN POWER STEP 2 REMOVAL OF THE CONTROL MODULE HANDLE WITH LOCKOUT...
Page 268 STEP 3 INSTALLATION OF THE MOTION INSTALL FAN (PUSH IN TAB, PUSH UP) CONTROLLER (U1) (Illustration 4) RETAINING SCREW (TOP 1. Install the Motion Controller. (straight in, down) AND BOTTOM) 2. Tighten the top and bottom retaining screws. 3. Install the fan. (push in tab and push up) Reference wiring diagram - computer/controllers 4.
Page 269 CONTROL MODULE (U2 AND U9) STEP 1 TURN “OFF” THE MAIN POWER AND AIR ADANGER! Follow your company’s Lockout/Tagout procedures when performing any MAIN POWER maintenance on your Formax machine. HANDLE WITH LOCKOUT (Illustration 1) DEVICE ILLUSTRATION 1 STEP 2 REMOVAL OF THE CONTROL MODULE (U2 / U9) (Illustration 2) 1.
Page 270 STEP 3 INSTALLATION OF THE MOTION RETAINING SCREW (TOP AND BOTTOM) CONTROLLER (U2/U9) 1. Install the Motion Controller. (straight in, down) (Illustration 3) 2. Tighten the top and bottom retaining screws. Reference the wiring diagram - computer/controllers. 3. Push in the cables on the top of module. (X100- X103) (Illustration 4) 4.
Page 271: Active Line Module Replacement
ACTIVE LINE MODULE REPLACEMENT STEP 1 TURN “OFF” THE MAIN POWER AND AIR ADANGER! Follow your company’s Lockout/Tagout procedures when performing any maintenance on your Formax machine. (Illustration 1) MAIN POWER HANDLE WITH The Active Line Module, the Servo LOCKOUT DEVICE...
Page 272 24 VDC NUTS DC LINK DC BUS STEP 2 REMOVAL SUPPLY LINK (8mm) LINKS SCREW 1. Remove the (2) 8mm nuts from top of the module. (Illustration 5) 2. Remove the 24 VDC supply link retaining screw. 3. Pull out the DC link. 4.
Page 273 24 VDC NUTS DC LINK DC BUS STEP 3 INSTALLATION SUPPLY LINK (8mm) LINKS SCREW Remove/replace foil insulation strip, if in bad condition. Refer to the electrical wiring diagram – servo power. 1. Install the module onto the mounting studs. (Illustration 9) 2.
Page 275: Servo Module Replacement
SERVO MODULE REPLACEMENT STEP 1 TURN “OFF” THE MAIN POWER AND AIR ADANGER! Follow your company’s Lockout/Tagout procedures When performing any maintenance on your Formax machine. (Illustration 1) MAIN POWER HANDLE WITH The Servo Drive Modules, and the Servo LOCKOUT DEVICE...
Page 276 NUT (8mm) X201 X200 STEP 2 REMOVAL 1. Remove the cables from X200 and X201. (push tab in, and pull up) (Illustration 5) 2. Pull out the terminal plugs from X21 and X22. 3. Remove the nut (8mm) from top of the module.
Page 277 MOTOR POWER TOOL GROUNDING STEP 3 INSTALLATION CABLE CONNECTOR LUGS (TORX T10) (TORX T20) Replace the foil insulation strip if in bad condition. Refer to the electrical wiring diagram – servo power. 1. Install the motor power cable connectors. (Torx T10). (Illustration 8) 2.
Page 279: Feedback Converter Replacement U0
REPLACEMENT U0 STEP 1 TURN “OFF” THE MAIN POWER AND ADANGER! Follow your company’s Lockout/Tagout procedures when performing any maintenance on your Formax machine. (Illustration 1) MAIN POWER STEP 2 REMOVE THE COVER (Illustration 2) HANDLE WITH LOCKOUT DEVICE STEP 3...
Page 280 BRACKET STEP 4 INSTALL THE FEEDBACK CONVERTER 1. Install the module on the bracket. (Illustration 5) TANGS Reference the schematics - Feedback hub/converter wiring diagram. 2. Install the grounding lugs. (Torx T20) (Illustration 6) 3. Install the power cable. (X524) Install the terminal cables.
Page 281 U13, U14 AND U15 STEP 1 TURN “OFF” THE MAIN POWER AND AIR ADANGER! Follow your company’s Lockout/Tagout procedures when performing any maintenance on your Formax machine. (Illustration 1) MAIN POWER HANDLE WITH LOCKOUT DEVICE STEP 2 REMOVE THE COVER (13mm WRENCH)
Page 282 RESOLVER POWER CABLE TERMINAL CABLE STEP 3 REMOVE THE FEEDBACK CABLES (X524) (X500) CONVERTER (Illustration 3) 1. Remove the terminal cable. (X500) (push in the tab and pull up) (Illustration 5) 2. Remove the power cable. (X524) 3. Remove the grounding lugs. (Torx T20) 4.
Page 283 STEP 4 INSTALL THE FEEDBACK CONVERTER 1. Install the module on the holddown bracket. (hook the tangs on to bracket and push down) (Illustration 7) Refer to the Electrical schematics for the TANGS Feedback hub/converter wiring diagram ILLUSTRATION 7 2. Install the grounding lugs. (Torx T20) (Illustration 8) RESOLVER POWER CABLE...
Page 285: Electrical - Electronic
1. Follow your company's CONTROLLER Lockout/Tagout procedures when performing any maintenance on your ® Formax Machine! (Illustration 1) 2. The DC Bus voltage stored in the U3 Active Line Module and the Servo Drives is in excess of 650 VDC. There...
Page 286 Circuit Boards must be placed in a Static Shield bag as soon as they are removed from the machine. 6. Do Not attempt to repair the boards! The Formax Electronic Department has special anti-static equipment and test fixtures for circuit board repair.
Page 287 COMPUTER BOOT-UP “TOUCH” TARGETS The Computer System takes approximately 1 minute to “Boot-up” when the power is turned "on." The software compilation and data transfer period during “Boot-up” is very critical and any interruption of the power can cause data to become corrupted. To avoid data corruption, always wait for the system to completely “Boot-Up”...
Page 288: Electrical/Electronic System Overview
POWERMAX3000 ELECTRICAL/ELECTRONIC SYSTEM OVERVIEW COMPUTER The Computer determines the sequence requirements for the Slicer based on the “Machine Speed,” “Machine Adjustment” settings and the “Product Code Parameters” programmed in the Product Code. (Illustration 5) The Slicer Computer sends this information over the Profibus to the U1 Motion Control Module.
Page 289 PROFIBUS NETWORK The Profibus Network is a high speed communication system between the Computer and all of the components on the Powermax3000 Slicer. The Profibus Network starts at the Computer and carries Input/Output communications signals over the Profibus Cables to control all of the components on the machine.
Page 290 A1 Computer Assembly: The Computer sends Control Output Signals and receives Input Signals from the Slicer Components over the Profibus Network. The Profibus Communication is processed through the Profibus Interface Board. (Illustration 7 and 8) The Profibus Network requires a Terminating Resistor to be installed at the start of the network and at the end of the network.
Page 291 U1 Motion Control Module: The Main Profibus Cable travels from the AR1 Safety Computer to the U1 Motion Control Module and then out to the AR23 Main Frame I/O Node. (Illustration 9 and 10) The Terminating Resistors at U1 and A8 should be set to “off.” The U1 Motion Control Module uses a second Profibus Network Cable to communicate with the U2 and U9 Motion Control Modules.
Page 292 XS3 Main Frame Manifold: The Main Profibus Cable travels from the AR23 Main Frame Node to the XS3 Main Frame Manifold and then out to the A8 Modbus Module. (Illustrations 11 and 12) The XS3 Main Frame Manifold send output signals to operate the pneumatic directional valves that control the Safety Scanner Cover and the optional Slicing Conveyor pop-up pins...
Page 293 A8 Modbus Module: The Main Profibus Cable travels from the XS3 Main Frame Manifold to the AR8 Modbus Module and then out to the AR15 Driver Control Node. (Illustrations 14 and 15) The Terminating Resistor on this cable should be set to the “Off”...
Page 294 AR15 Driver Control Node: The Main Profibus Cable travels from the A8 Modbus Module to the AR15 Driver Control Node and then out to the XS4 Scale Housing Manifold. (Illustrations 17 and 18) The AR15 Driver Control Module sends “Control Signals” to the Stepper Driver Modules that operate the Dynamic Scale Conveyor Motors.
Page 295 XS4 Scale Housing Manifold: The Main Profibus Cable travels from the AR15 Driver Control Node to the XS4 Scale Housing Manifold and then to the optional Powerloader or Takeaway Conveyor. (Illustrations 20 and 21) If there is not a Powerloader or Takeaway Conveyor the Profibus will travel to the XS5 Infeed Housing Manifold.
Page 296 XS5 INFEED HOUSING MANIFOLD XS5 Infeed Housing Manifold: The Main Profibus Cable travels from the optional Powerloader or Takeaway Conveyor to the XS5 Infeed Housing Manifold. (Illustrations 23 and 24) If these options are not used, the cable will travel from the XS4 Scale Housing Manifold.
Page 297 HIGH VOLTAGE ENCLOSURE COMPONENTS QF10 BREAKER POWER SUPPLY CONTACTOR CONTACTOR ILLUSTRATION 25 SERVO DRIVE COMPONENTS Refer to the “Servo Drive” section for more information. Z1 EMI U3 ACTIVE LINE SERVO FILTER MODULE DRIVES ILLUSTRATION 26 031914 M4-13...
Page 298 MOTION CONTROL COMPONENTS/INFEED HOUSING COMPONENTS U10 MOTION U11 MOTION U12 MOTION U9 MOTION CONTROL CONTROL CONTROL CONTROL MODULE MODULE MODULE MODULE M10 SERVO MOTOR M12 SERVO MOTOR M14 SERVO MOTOR XS5 INFEED HOUSING MANIFOLD ILLUSTRATION 27 COMPUTER/MAIN ELECTRICAL CABINET COMPONENTS A1 COMPUTER AR1 SAFETY SAFETY I/O...
Page 299 SCALE CABINET COMPONENTS A8 MODBUS AR15 DRIVER MODULE CONTROL NODE GS3 POWER GS2 POWER SUPPLY SUPPLY ILLUSTRATION 29 XS4 SCALE HOUSING MANIFOLD ILLUSTRATION 30 031914 M4-15...
Page 300 LOWER MACHINE HOUSING COMPONENTS AR23 MAIN XS3 MAIN FRAME FRAME NODE MANIFOLD ILLUSTRATION 31 M4-16 031914...
Page 301: Electrical Overview (3-Phase Ac Supply Voltage)
IMPORTANT! MAIN POWER HANDLE WITH LOCKOUT DEVICE This section explains the electrical and electronic sub-systems that make up the Slicer Control System. Refer to the Electrical Schematic for more information as you review this section. ELECTRICAL OVERVIEW (3-PHASE AC SUPPLY VOLTAGE) 1.
Page 302 4. QM2 Circuit Controller/KM2 Contactor: QM2 Circuit Controller: The QM2 Circuit Controller provides the thermal overload protection for the AC supply voltage going to the M21 Debris Conveyor Motor. (Illustration 35) When switched to the “Off” position, the M21 Motor Power circuit is disabled. When in the “On”...
Page 303 5. QM3 Circuit Controller/KM3 Contactor: QM3 Circuit Controller: The QM3 Circuit Controller provides the thermal overload protection for the AC supply voltage going to the GS3 48 VDC Power Supply and the GS2 24 VDC Power Supply. (Illustration 37) When switched to the “Off”...
Page 304 QM4 CIRCUIT 6. QM4 Circuit Controller: The QM4 Circuit Controller provides the CONTROLLER thermal overload protection for the AC supply voltage going to the GS1 24 VDC Power Supply. (Illustration 39) When switched to the “Off” position, the GS1 Supply Voltage is disabled. When in the “On” position, QM4 supplies 3-phase AC Supply Voltage to the Power Supply.
Page 305 QM4 CIRCUIT PROTECTOR SYSTEM OVERVIEW - GS1 - 24 VDC POWER SUPPLY (COMPUTER/DISPLAY/CONTROL VOLTAGES) The GS1 Power Supply sends 24 VDC to the Computer, the Touchscreen, the AR8 Modbus Converter, the AR1 Safety Computer, the AR15 Driver I/O Node, the Servo Drives and the Linear/Rotary Actuator Motors.
Page 306 4. The QF3 Breaker transfers 24 VDC on wire “8” to KA1/KA2 KA3/KA4 the KA1/KA2 Relay. (Illustration 46) a. When the Slicer is in the “Ready” position and all guards are closed and all “Master Off” buttons are pulled out, the KA1/KA2 Relay energizes.
Page 307 5. The QF4 Breaker transfers 24 VDC on wire “7” to all of the Input/Output Modules and to operate the components controlled by the Remote Nodes. (Illustration 49) This voltage is “on” as long as the Slicer is powered up and the QF4 Breaker is closed. 6.
Page 308 SYSTEM OVERVIEW - GS3 - 48 VDC POWER SUPPLY (M16 Rotary Actuator/M17 Linear Actuator Servo Motor Power) The GS4 Power Supply supplies 48 VDC Servo Motor Power voltage to the M16 and M17 Linear and Rotary Actuators. (Illustration 51 and 52) This voltage is used to run the Servo Motors that operate these Actuators.
Page 309 SYSTEM OVERVIEW - GS2 - 24 VDC POWER SUPPLY (Dynamic Scale Driver Board Supply Power) The GS2 Power Supply supplies 24 VDC to the Stepper Drive Modules that create the Motor Power voltage to run the Dynamic Scale Conveyor Servo Motors. The GS2 Power Supply is adjustable and should be set to 24 +/- 1 VDC.
Page 310 AR1 SAFETY CPU/SAFETY INPUT/OUTPUT SYSTEM The Computer monitors and communicates with the AR1 Safety CPU Module through the Profibus Communication Network. (Illustration 56) The Safety CPU Module monitors and controls the “Safety Input” and “Safety Output” Modules to determine the status of the “Master Off” buttons, the “Guard Safeties”...
Page 311 PROFIBUS AR1 SAFETY MEMORY AR1 SAFETY CPU MODULE: The Safety CABLE MODULE CHIP CPU Module has a programmed Micro Memory Chip that monitors and runs the Safety System. (Illustration 58) All control TERMINATING signals from the Computer travel through the RESISTOR SET TO “OFF”...
Page 312 AR1 SAFETY AR2 POWER 5. There are 6 LED’s on the Safety CPU MODULE MODULE Module: (Illustration 60) “SF” - System Fault LED: Each “Safety “SF” LED Power Module,” “Safety Input Module” and “Safety Output Module” has a “System Fault” “BF”...
Page 313 “SYSTEM AR3 SAFETY INPUT STATUS AR3 SAFETY INPUT MODULE: The “AR3” Safety FAULT” LED MODULE LEDS Input Module monitors and reports the status of the normally closed contacts of the SB1 and SB2 “Master Off” Switches. (Illustration 62 and 63) Each “Master Off”...
Page 314 AR3 ADDRESS SETTINGS Rear SB3 Master Off: Future use. SB4 Master Off: Future use. IMPORTANT! Each of the “Safety Input,” Safety Output and Safety Power Modules has a specific address that must be set on the DIP Switches on the side of each module! (Illustration 65) When replacing any of these Safety DIP SWITCHES Modules, refer to the Electrical Schematic and make...
Page 315 AR4 SAFETY INPUT MODULE: The “AR4” Safety Input “SYSTEM AR4 SAFETY STATUS Module monitors and reports the status of the normally FAULT” LED INPUT MODULE LEDS open and closed contacts of the SQ1, SQ2, SQ3 and SQ4 “Guard Safety Proximity Switches.” (Illustration 67 and 68) Each “Guard Safety Proximity”...
Page 316 SQ3 #2 Side Access Guard Proximity: AR4 ADDRESS SETTINGS N.O. Contact - 24 VDC sent from terminal 4 through the N.O. contact to terminal 3. Turns LED #3 “On” when the guard is closed and “Off” when the guard is open. N.C.
Page 317 AR5 SAFETY INPUT MODULE: The “AR5” Safety Input “SYSTEM AR5 SAFETY STATUS Module monitors and reports the status of the normally and FAULT” LED INPUT MODULE LEDS closed contacts of the SQ5 Proximity Switch and the KA5/KA6 Relay. (Illustration 72, 73 and 77) Each “Guard Safety Proximity”...
Page 318 N.C. Contact - 24 VDC sent from terminal 6 through the N.C. contact to terminal 13. Turns KA9/KA10 GUARDS KA9/KA10 NOT GUARDS LED #9 “On” when the guard is open ENERGIZED CLOSED ENERGIZED OPEN and “Off” when the guard is closed. Spare Guard Proximity: N.O.
Page 319 AR6 SAFETY OUTPUT MODULE: The AR6 “SYSTEM AR6 SAFETY STATUS FAULT” LED OUTPUT MODULE LEDS Safety Output Module controls the output signals that energize the KA1/KA2 Safety Relay, the KA3/KA4 Clean Functions Relay, the YV3-12 and YV3-14 Directional Valve. (Illustration 78 and 79) When all “Safety” conditions are met, the “Safety CPU Module”...
Page 320 Terminals 9 and 10 are not used. AR6 ADDRESS SETTINGS LED 9: LED 9 will be “off.” YV3-12 Directional Valve Coil: When all Safety Conditions have been satisfied and there is no obstruction in the Laser Curtain, the Computer will energize the coil of the YV3-12 Directional Valve and send air to “raise”...
Page 321 “SYSTEM AR7 SAFETY STATUS AR7 SAFETY OUTPUT MODULE: The AR7 FAULT” LED OUTPUT MODULE LEDS Safety Output Module controls the output signals that energize the KM2 Contactor, the KM3 Contactor, the KM5 Contactor and also sends an Input Signal to the U11 Motion Control Module when all Safety Conditions are met and it is “Safe”...
Page 322 AR7 ADDRESS SETTINGS KM5 Contactor: When the KM5 Contactor is energized, the optional component will operate. LED 9: When all Safety Conditions are satisfied, the Computer will send 24 VDC from terminal 9 on wire “32” and the common on wire “33” from terminal 10 to energize the coil of the KM5 Contactor.
Page 323 AR8 SAFETY OUTPUT MODULE: The AR8 SAFETY OUTPUT MODULE AR8 Safety Output Module Controls the output signals that reset the Scanner, and energize the YV16-12 and YV16-14 Directional Valves (Illustration 86). When all “Safety” conditions are met, the Safety Computer enables all of the “AR8 Safety Output”...
Page 324 IMPORTANT! AR8 ADDRESS SETTINGS Each of the “Safety Input,” Safety Output and Safety Power Modules has a specific address that must be set on the DIP Switches on the side of each module! (Illustration 87) When replacing any of these Safety Modules, refer to the Electrical Schematic and make sure the “Address”...
Page 325 AR9 INPUT MODULE STATUS AR9 INPUT MODULE: The “AR9” Input Module monitors and LEDS reports the status of the KM2, KM3, KM5 Contactors and KA1/KA2 Relay. (Illustration 99, 100 and 101) The AR9 Input Module sends 24 VDC to a normally open contact of each Contactor and Relay.
Page 326 AR10 INPUT MODULE STATUS LEDS AR10 INPUT MODULE: The “AR10” Input Module monitors and reports the status of the KA10 Relay, the KA3/KA5 Relay and the QM2 Circuit Controller. (Illustration 103, 104 and 105) The AR10 Input Module sends 24 VDC to the normally open contacts on each Relay and on the Circuit Controller.
Page 327 STATUS AR11 INPUT LEDS MODULE AR11 INPUT MODULE: The “AR11” Input Module monitors and reports the status of the QM3 Circuit Controller and the QM5 Circuit Controller. (Illustration 107 and 108) The AR11 Input Module sends 24 VDC to the normally open contacts of each component.
Page 328 STATUS LEDS AR12 INPUT AR12 INPUT MODULE: The “AR12” Input MODULE Module monitors and reports the status of the A4 Safety Laser Scanner. (Illustration 110 and 111) The rest of the Inputs are not used and reserved as Spare Input locations. AR12 LED Information: A4 Safety Laser Scanner Error: LED 1 - If a “Fault”...
Page 329: System Overview - A4 Safety Laser Scanner
Important! The Socket Assembly that the A4 Laser Scanner plugs into, are programmed at Formax prior to shipping! (Illustration 115) If the Socket Assembly is not programmed correctly, the Laser Scanner will not work! It is possible to plug a new A4 Laser Scanner into an old Socket Assembly as long as the Assembly was already programmed.
Page 330 Safety Laser Scanner Input/ Output Terminals: Terminal 5 - 24 VDC “Reset” Input signal on wire 36 sent by the AR8 Safety Output Module when a “reset is required. Terminal 15 - 24 VDC Output signal to KA11 Relay, telling the AR12 Input Module that a “Reset is Required.”...
Page 331 REMOTE INPUT/OUTPUT NODES The Profibus Network Cables run in series to the Safety Computer, the U1 Motion Control Module, all of the Remote Input/Output Nodes and the A8 Modbus Converter. (Illustration 117) The Computer sends Control Signals to the Remote Nodes over the Profibus to operate the machine components.
Page 332 AR23 MAIN FRAME I/0 NODE: The Main Profibus Cable travels from the U1 Motion Control Module to the AR23 Main Frame I/O Node and then out to the XS3 Main Frame Manifold. (Illustration 118) The AR23 Main Frame I/O Node receives “Input” signals from the SQ19 Loaf Lift Saddle Switch and SP1 Pressure Switch.
Page 333 AR23 Gateway Module: The AR23 Gateway Module AR23 GATEWAY MODULE transfers “Output” signals from the Computer to the Output Modules and sends Input signals from the GW LED IOs LED “Input” Modules to the Computer. There are 4 “Status” LED’s on the AR23 Module. (Illustration 120) The LED’s are “GW,”...
Page 334 AR24 PNP Input Module: The AR24 Input Module receives input signals from the SP1 Pressure Switch when there is sufficient air pressure to operate the machine and the SQ19 Loaf Lift Saddle Switch. The AR24 Module sends this information through the AR23 Gateway Module to the Computer over the Profibus Cable.
Page 335 AR25 PNP INPUT MODULE AR25 PNP Output Module: The AR25 Output Module sends output signals to operate the green and red LEDs in the SQ19 Loaf Lift Saddle Switch. (Illustration 123) The Computer sends the control information through the AR23 Gateway Module to the AR25 Module over the Profibus Cable.
Page 336 AR26 PNP INPUT MODULE AR26 PNP Output Module: The AR26 Output Modules sends 24 VDC signals to illuminate the EL1 Status Light located on top of the Touchscreen. (Illustration 124) The EL1 Status Light will light up in “Green,” “Red,” “Yellow”...
Page 337 AR27 PNP INPUT MODULE AR27 NPN Output Module: The AR27 Output Module controls the HA1 Laser Scanner Horn. (Illustration 125) The HA1 Horn has 2 Warning “sound” variations. One for a Scanner Breach and one for raising and lower the Infeed Structure.
Page 338 XS3 MAIN HOUSING MANIFOLD/NODE: The Main Profibus Cable travels from the AR23 Main Frame I/O Node to the XS3 Main Housing Manifold and then out to the A8 Modbus Converter. The XS3 Main Housing Manifold sends Output signals to the directional valves that open and close the Laser Scanner Cover and raises and lowers the “pin plate”...
Page 339 XS3 Gateway Module: The XS3 Gateway XS3 GATEWAY MODULE Module transfers “Output” signals from the Computer to the Directional Valves over the BF LED PS LED Profibus Cable. There are 5 “Status” LED’s used on the XS3 Gateway Module. PL LED (Illustration 128) The LED’s are “BF,”...
Page 340 PL LED: Reports Power Load Supply Status. XS3 GATEWAY MODULE (Outputs/Valves) BF LED PS LED LED is Green: No Fault. LED is Flashing Green: Check for: PL LED 1. Undervoltage. SF LED 2. Turn Power “Off” and then back “On.” M LED SF LED: Reports System Fault Status.
Page 341 YV10 YV11 XS3 Directional Valves: The XS3 Main Housing Manifold sends Output signals to the directional valves that open and close the Laser Scanner Cover and raises and lowers the “pin plate” on the Slicing Conveyor (Illustration 130). The Computer sends control signals over the Profibus Cable to energize the Directional Valves, when required.
Page 342 A8 MODBUS CONVERTER: The Main Profibus Cable travels from the X3 Main Frame Manifold to the A8 Modbus Converter Node and then out to the AR15 Driver Control Node. (Illustration 131 and 133) The Terminating Resistor on this cable should be set to the “Off”...
Page 343 AR15 SCALE DRIVER CONTROL NODE: The Main Profibus Cable travels from the A8 Modbus Converter to the AR15 Scale Driver Control Node and then out to the XS4 Scale Housing Manifold. (Illustration 134) The AR15 Driver Control Node Sends the “Control Signals” to the AR17, AR18 and AR19 Stepper Modules that operate the Dynamic Scale Conveyor Motors.
Page 344 AR15 Gateway Module: The AR15 Gateway Module transfers “Output” signals from the Computer to the Combined I/O and the Stepper Modules and sends operational information over the Profibus Cable to the Computer. There are 4 “Status” LED’s on the AR15 Module. (Illustration 136) The LED’s are “Status,”...
Page 345 AR16 Power Supply Module: The AR16 Power Supply Module sends 24 VDC Control Voltage to the Combined I/O and Stepper Modules on an internal bus. The AR16 Module also sends 24 VDC Supply Voltage on wire 303 and a common on wire 302 to the Stepper Drive Modules to operate the Dynamic Scale Motors.
Page 346 AR16 Terminal Connections: Terminal 15 - 24 VDC Control Voltage from GS1 Power Supply through QF6 fuse on wire 83. Terminal 16 - Common Wire Terminal 24 - 24 VDC Supply Voltage from GS2 Power Supply through QF7 fuse on wire 303.
Page 347 AR17 Combined I/O Module: The AR17 Module sends control signals to operate the M26 Classifier Motor. The M26 Classifier Motor is a Rotary Actuator used to drive the Classifier Conveyor Belts. (Illustration 137) The AR17 Module has “Status” LED’s that indicate the status of the module and the I/O signals.
Page 348 AR17 Terminal Connections: Terminal 13 - Enable Signal to the M26 Classifier Conveyor Motor. Terminal 23 - Reset Signal to the M26 Classifier Conveyor Motor. Terminal 25 - +/- 0 to 10 VDC Speed Command signal telling the Classifier Conveyor Motor how fast to run the Rotary Actuator.
Page 349 AR18 Stepper Module #1: The AR18 Stepper Module sends the power voltage to operate the #1 Dynamic Scale Stepper Motor. (Illustration 138) The 24 VDC Supply Voltage used to run the Stepper Motors is sent from the AR16 Power Supply Module on wires 303 and 302.
Page 350 AR18 Terminal Connections: Terminal 13 - 24 VDC Power Voltage to the “A” Motor coil windings in the M18 Dynamic Scale Conveyor Stepper Motor. Terminal 23 - Common wire to the “A” Motor coil windings in the M18 Dynamic Scale Conveyor Stepper Motor. Terminal 14 - 24 VDC Power Voltage to the “B”...
Page 351 AR19 Stepper Module #2: The AR19 Stepper Module sends the power voltage to operate the #2 Dynamic Scale Stepper Motor. (Illustration 139) The 24 VDC Supply Voltage used to run the Stepper Motors is sent from the AR16 Power Supply Module on wires 303 and 302.
Page 352 AR19 Terminal Connections: Terminal 13 - 24 VDC Power Voltage to the “A” Motor coil windings in the M19 Dynamic Scale Conveyor Stepper Motor. Terminal 23 - Common wire to the “A” Motor coil windings in the M19 Dynamic Scale Conveyor Stepper Motor. Terminal 14 - 24 VDC Power Voltage to the “B”...
Page 353 AR20 Stepper Module #3: The AR20 Stepper Module sends the power voltage to operate the #3 Dynamic Scale Stepper Motor. (Illustration 140) The 24 VDC Supply Voltage used to run the Stepper Motors is sent from the AR16 Power Supply Module on wires 303 and 302.
Page 354 AR20 Terminal Connections: Terminal 13 - 24 VDC Power Voltage to the “A” Motor coil windings in the M20 Dynamic Scale Conveyor Stepper Motor. Terminal 23 - Common wire to the “A” Motor coil windings in the M20 Dynamic Scale Conveyor Stepper Motor. Terminal 14 - 24 VDC Power Voltage to the “B”...
Page 355 XS4 SCALE HOUSING MANIFOLD/NODE: The Main Profibus Cable travels from the AR15 Scale Driver Control Node to the XS4 Scale Housing Manifold and then out to the XS5 Infeed Housing Manifold. (Illustration 141) The XS4 Scale Housing Manifold sends Output signals to the directional valves that release the Scale Seals and raise and lower the Classifier Conveyors.
Page 356 XS4 Gateway Module: The XS4 Gateway Module XS4 GATEWAY MODULE transfers “Output” signals from the Computer to the Directional Valves (Illustration 143). There are 5 BF LED PS LED “Status” LED’s used on the XS4 Gateway Module. (Illustration ) The LED’s are “BF,” PS,” “PL,” “SF” PL LED and “M.”...
Page 357 PL LED: Reports Power Load Supply Status. XS4 GATEWAY MODULE (Outputs/Valves) (Illustration 144) BF LED PS LED LED is Green: No Fault. PL LED LED is Flashing Green: Check for: 1. Undervoltage. SF LED 2. Turn Power “Off” and then back “On.” M LED SF LED: Reports System Fault Status.
Page 358 XS4 Directional Valves: The “YV” Directional YV12 YV13 YV14 YV15 Valves operate the Pneumatic Cylinders that operate the directional valves that release the Scale Seals and raise and lower the Classifier Conveyors (Illustration 145). The Computer sends control signals over the Profibus Cable to energize the Directional Valves, when required.
Page 359 XS5 INFEED HOUSING MANIFOLD NODE: The Main XS5 INFEED HOUSING MANIFOLD Profibus Cable travels from the XS4 Scale Housing Manifold to the “In” Port on the XS5 Infeed Housing Manifold. There is a “Terminating Resistor” installed on the “Out” Port to the XS5 Infeed Housing Manifold. (Illustration 146) The XS5 Infeed Housing Manifold receives Input Signals from the Loaf Gate Position proximities.
Page 360 XS5 Gateway Module: The XS5 Gateway Module XS5 GATEWAY MODULE transfers “Output” signals from the Computer to the Output Modules and sends Input signals from the BF LED PS LED “Input” Modules to the Computer over the Profibus Cable (Illustration 148). There are 5 “Status” LED’s PL LED used on the XS5 Gateway Module.
Page 361 PL LED: Reports Power Load Supply Status. XS5 GATEWAY MODULE (Outputs/Valves) (Illustration 149) BF LED PS LED LED is Green: No Fault. PL LED LED is Flashing Green: Check for: 1. Undervoltage. SF LED 2. Turn Power “Off” and then back “On.” M LED SF LED: Reports System Fault Status.
Page 362 LOAF GATE XS5-1 Digital Input Module: The Loaf Gate is operated by a 3-position dual chamber air cylinder. (Illustration 150) The XS5-1 Module receives Input Signals from the Loaf Gate Proximity Switches. These Proximities signal the position of the Loaf Gate. The Proximities are mounted at each end of the 2 Air Cylinders that operate the Loaf Gate.
Page 363 XS5-2 Analog Input Module: The A5 and A6 Loaf Length Sensors send Loaf Length Information signals to the XS5-2 Input Module (Illustration 150 and 153). The XS5-2 Module sends this information through the XS5 Gateway Module to the Computer over the Profibus Cable.
Page 364 XS5 Directional Valves: YV4 Directional Valve: The YV4 Directional Valve is used to control the operation of the Loaf Gate. (Illustration 154) YV4-12: Is energized to move the Loaf Gate to the “Load” position. LED 12 will be lit. YV4-14: Is energized to move the Loaf Gate to the “Feed” or “Butt Drop”...
Page 365: Pneumatic Supply
PNEUMATIC LOCATIONS AND FUNCTIONS This section details pneumatic component locations and functions. Refer to the “Pneumatics Schematics” for more detailed information to aid in troubleshooting and line connections. PNEUMATIC SUPPLY A dry air supply of 6.9 bar (100 psi) at 140 L/M (5cfm) is required for optimum machine performance.
Page 366: Infeed Housing Manifold
INFEED HOUSING MANIFOLD The XS5 Infeed Housing Manifold is located in the Upper Cabinet along with BP2. (Illustration 2) The Infeed Housing Manifold contains the valves that controls the air distribution for the Loaf Gate, Grippers, and the Loaf Tray. XS5 INFEED HOUSING MANIFOLD ILLUSTRATION 3...
Page 367: Mainframe Manifold
MAIN FRAME MANIFOLD The XS3 Main Frame Manifold is located in the bottom of the machine cabinet. (Illustration 3) The XS3 Manifold has the directional valves that control the Scanner Cover and the optional pop-up pins on the Slicing Conveyor. XS3 LOAF TRAY MANIFOLD ILLUSTRATION 4 031914...
Page 368: Scale Manifold
SCALE MANIFOLD The XS4 Scale Manifold is located in the Scale Cabinet. (Illustration 5) The Scale Manifold contains the valves for the load cell seal and the classifer cylinders that raise and lower the conveyors. XS4 SCALE HOUSING MANIFOLD ILLUSTRATION 5 M5-4 031914...
Page 369: Pressure Switch
PRESSURE SWITCH The SP1 pressure switch sends an input signal to the Computer that the air supply is in the correct operating range. (Illustration 6) This switch should activate at 4.1 bar (60psi) on the rising pressure. Follow this procedure after replacing the SP1 pressure switch.
Page 371 Perform a static test. If the scale still fails, it can be repaired at the Formax factory. Contact the Formax Customer Service Department for information.
Page 372: Replace Scale Assembly
STEP 1 TURN “OFF”THE MAIN POWER AND THE MAIN AIR ADANGER! Follow your company’s Lockout/Tagout procedures when performing any MAIN POWER maintenance on your Formax machine. HANDLE WITH (Illustration 3) LOCKOUT DEVICE ILLUSTRATION 3 STEP 2 REMOVE THE DYNAMIC SCALE CONVEYORS 1.
Page 373 SCALE SUPPORT 3. Using 2, 5/16-18 nuts tighten them together SCREW and unscrew the scale support screw. (Illustration 7) ILLUSTRATION 7 4. Lift out the scale support. (Illustration 8) SCALE SUPPORT ILLUSTRATION 8 5. Unscrew the Scale connection cable inside SCALE CONNECTION CABLE the Scale cabinet.
Page 374 GROMMETS AND WASHERS (3) PLACES STEP 4 INSTALL NEW SCALE ASSEMBLY 1. Make sure that the load cell assembly has the grommets and washers installed. (Illustration 11) 2. Place the scale assembly on the mounting plate. Install and tighten the 3 support bolts. 3.
Page 375: Scale Calibration
SCALES ADMINISTRATOR OPTIONS SCALE CALIBRATION The following procedure must be done with the scale seals in the released position. The Slicer must be in the “RUN” position. All the guards must be closed, all “Master Off” buttons pulled out and the main air turned “ON.” IMPORTANT! The “Scale Calibration Procedure”...
Page 376 “OK” BUTTON STEP 7 SELECT THE SCALE 1. Enter the position number of the scale that needs to be calibrated. 2. Press 1, 2, 3 or 4 depending on your machines configuration. Then press “OK.” (Illustration 19 and 20) STEP 8 REMOVE ALL WEIGHT FROM SCALE 1.
Page 377 STEP 10 PLACE A 1000-GRAM WEIGHT “OK” BUTTON STANDARD ON THE SCALE 1. Press the “OK” button. 2. The Computer will complete the calibration. This step will take approximately 5 seconds. STEP 11 CALIBRATION DONE - REMOVE WEIGHT 1. Remove the weight from the scale and press the “OK”...
Page 379: Transfer Conveyor Repair
TRANSFER CONVEYOR REPAIR SEAL AND BEARING REPLACEMENT STEP 1 MOVE THE MACHINE TO THE “CLEAN” POSITION 1. Touch the “Run” screen button on the “Home” screen. (Illustration 1) “RUN” BUTTON ILLUSTRATION 1 “MOVE TO READY” BUTTON 2. Touch and “hold” the “Move to Clean” button on the “Run”...
Page 380 PULL “OUT” AND TURN STEP 3 DISASSEMBLE THE TRANSFER CONVEYOR 1. Pull the knob out and turn it to the left (counter-clockwise) to unlock the infeed section. (Illustration 4) Pivot the Infeed section “down” to remove tension from the belts. (Illustration 5) ILLUSTRATION 4 IDLER PIVOT INFEED...
Page 381 STEP 4 REMOVE THE INFEED PULLEY 1. Remove the 2 bolts from the pivoting spreader and slide out the pivot bushing on both sides of conveyor. (Illustration 7) PIVOT SPACER 2. Lift up on the pan and remove the pivot spacers from both sides.
Page 382 2. Clean out the bearing housings. Use a needle BEARING HOUSING greaser to fill the new bearings with food grade grease. Insert the bearing into the housing INNER with the ball bearing end going in first. The RACE needle roller bearing end faces out toward the seal.
Page 383 TRANSFER 7. Pivot the Infeed section “Up” to tension the CONVEYOR COVER Transfer Conveyor belts. (Illustration 14) IDLER ROLLER PIVOT INFEED 8. Push the retaining shaft knob “in” and turn the SECTION knob to the right (clockwise), to lock the infeed section in position.
Page 385: Honing The Knife
® POWERMAX KNIFE SYSTEM HONING PROCEDURE FOR “F4” AND “F2” SERRATED KNIVES “F4” SERRATED KNIFE “F2” SERRATED KNIFE ACAUTION! This is a honer for use in touching up a slightly dull knife edge. It IS NOT a grinder that will put a new cutting edge on a severely dull and/or damaged knife.
Page 386 STEP 2 OPEN THE DOOR LATCH HONING MECHANISM Check the honing mechanism to make sure that it is latched in the top position. (Illustration 2) ILLUSTRATION 2 KNIFE GUARD WITH RETAINING STEP 3 INSTALL THE KNIFE EDGE PROTECTOR KNOBS (3) UNDERNEATH 1.
Page 387 LOCATING PIN DANGER! The Knife is very sharp! Use caution when reaching into the hone area. 4. Remove the Knife guard/carrier and remove the edge protector. 5. Close the door and jog the Knife around until the center hub and Knife is in the position shown in Illustration 4.
Page 388 3. Turn the knurled knob to engage the Deburr Pad. Make sure there is about 2 mm (1/16 in.) compression. (Illustration 8) If there is not: a. Push and turn the knurled knob to retract the Deburr Pad. b. Loosen the locking bolt, the jam nut and the adjustment knob.
Page 389 LOCKING PIN STEP 6 CHECK THE HONE STONE 1. Initially set the Hone Stone angle to 3°. Engage the Hone Stone: hold it with one hand, pull out the locking pin until it releases and carefully lower to the Knife. (Illustration 11) 2.
Page 390 STEP 7 CHECK THE HONING ANGLE BLACK CAUTION! MARKER The deburr stone must be retracted to avoid damaging the cutting edge. KNIFE BLADE 1. Make sure the Knife is colored near the cutting edge using a water soluble black marker. (Illustration 14) This must be done ILLUSTRATION 14 in the area where the Honing Stone will contact the Knife when it is against the...
Page 391 STEP 8 HONE THE KNIFE THUMBWHEEL Engage the Hone Stone and the Deburr Fiber Pad. SWITCHES 1. Close the door. The system will not operate with the door open. 2. Pull out the “MASTER OFF” button. (Illustration 17) 3. Select the number of rotations on the SELECTOR SWITCH thumbwheel switch.
Page 392 STEP 9 REMOVE THE KNIFE LOCKING PIN 1. Press the “MASTER OFF” button and open the door. 2. Retract the deburr stone by pushing and turning the knob until it remains retracted. 3. Pull the hone assembly back towards you and engage the locking pin. (Illustration 18) CAUTION! The hone stone must be retracted to...
Page 393 KNIFE GUARD WITH RETAINING 5. Install the Knife edge cover and the Knife EDGE PROTECTOR KNOBS (3) guard/carrier. (Illustration 20) UNDERNEATH DANGER! Use extreme caution when reaching in near the Knife. Never transport the Knife without the Knife guard/carrier installed. Failure to do so will result in severe injury.
Page 394: Maintenance And Lubrication
MAINTENANCE AND LUBRICATION HONE STONE BEARINGS The PowerMax4000 Knife Honing system requires very little maintenance. SLIDE BUSHINGS THINGS TO CHECK: FOLLOWER 1. Check the condition of the hone stone every time you hone a Knife and perform lubrication. 2. Periodically check that the honing mechanism is tight and the slide bushings on the carriage have minimum free play.
Page 395 (Illustration 25) ILLUSTRATION 24 FILL AND VENT SPEED LUBRICATION — YEARLY REDUCER Drain the gear oil from the speed and gear reducers and refill with the Formax H1 Gear Oil (# 702293). LEVEL PLUG GEAR REDUCER DRAIN...
Page 397: Honing The Knife
® POWERMAX KNIFE SYSTEM HONING PROCEDURE FOR NON-SERRATED AND “F0” KNIVES SINGLE BEVEL DOUBLE BEVEL “F0” PARTIAL SERRATED KNIFE ACAUTION! This is a honer for use in touching up a slightly dull knife edge. It IS NOT a grinder that will put a new cutting edge on a severely dull and/or damaged knife.
Page 398 STEP 2 OPEN THE DOOR LATCH HONING MECHANISM Check the honing mechanism to make sure that it is latched in the top position. (Illustration 2) ILLUSTRATION 2 KNIFE GUARD WITH RETAINING STEP 3 INSTALL THE KNIFE EDGE PROTECTOR KNOBS (3) UNDERNEATH 1.
Page 399 DANGER! LOCATING PIN The Knife is very sharp! Use caution when reaching into the hone area. 4. Remove the Knife guard/carrier and remove the edge protector. 5. Close the door and jog the Knife around until the center hub and Knife is in the position shown in Illustration 4. 6.
Page 400 3. Turn the knurled knob to engage the honing stone. Make sure that the Knife overlaps into the hollow in the center of the hone stone about 2 mm (1/16 in.). (Illustration 8) If it does not: a. Push and turn the knurled knob to retract the honing stone.
Page 401 MIRROR STEP 7 CHECK THE HONING ANGLE CAUTION! CHECK ANGLE The deburr stone must be retracted to avoid damaging the cutting edge. 1. Make sure the Knife is colored near the cutting edge using a water soluble black marker. This must be done in the area where the Honing Stone will contact the Knife when it is against the Knife.
Page 402 STEP 8 CHECK THE DEBURR STONE LOCKING PIN 1. Engage the deburr stone: hold it with one hand and carefully lower to the Knife. Pull out the locking pin until it releases. (Illustration 14) 2. Close the door, pull out the “MASTER OFF”...
Page 403 STEP 9 HONE THE KNIFE THUMBWHEEL Just the hone stone should be engaged at this time. SWITCHES 1. Close the door. The system will not operate with the door open. 2. Pull out the “MASTER OFF” button. (Illustration 17) SELECTOR 3.
Page 404 STEP 10 REMOVE THE KNIFE LOCKING PIN 1. Press the “MASTER OFF” button and open the door. 2. Retract the hone stone by pushing and turning the knob until it remains retracted. 3. Pull the deburr assembly back towards you and engage the locking pin. (Illustration 18) CAUTION! The deburr stone must be retracted to...
Page 405 KNIFE GUARD WITH RETAINING 5. Install the Knife edge cover and the Knife EDGE PROTECTOR KNOBS (3) guard/carrier. (Illustration 20) UNDERNEATH DANGER! Use extreme caution when reaching in near the Knife. Never transport the Knife without the Knife guard/carrier installed. Failure to do so will result in severe injury.
Page 406: Maintenance And Lubrication
MAINTENANCE AND LUBRICATION DEBURR STONE BEARINGS The PowerMax4000 Knife Honing system requires very little maintenance. SLIDE BUSHINGS THINGS TO CHECK: FOLLOWER 1. Check the condition of the hone stones every time you hone a Knife and perform lubrication. 2. Periodically check that the honing mechanism is tight and the slide bushjngs on the carriage have minimum free play.
Page 407: Formax H1 Gear Oil
Gear Oil part number 702293 if the level is low. (Illustration 25) ILLUSTRATION 24 LUBRICATION — YEARLY Drain the gear oil from the speed and gear reducers and refill with the Formax H1 Gear Oil (# 702293). FILL AND VENT SPEED REDUCER LEVEL...

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