ProSeal GTR Operation And Maintenance Manual
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ProSeal GTR Operation And Maintenance Manual

Rotary table heat sealing machine
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Serial No: GTR-3455
Doc Ref:
Date: 13/01/13
Operation and Maintenance Manual
GTR Rotary Table Heat Sealing Machine
Pr
seal
Tray Sealing Solutions
Page: 1
Issue: H
®
uk

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Summary of Contents for ProSeal GTR

  • Page 1 ® seal Serial No: GTR-3455 Tray Sealing Solutions Operation and Maintenance Manual GTR Rotary Table Heat Sealing Machine Doc Ref: Page: 1 Date: 13/01/13 Issue: H...
  • Page 2 ® seal Serial No: GTR-3455 Tray Sealing Solutions AMENDMENT RECORDS Issue Author Date Description of Change Background 10/05/07 First Issue 06/05/10 Declaration of Incorporation standards updated 26/11/10 Cleaning statement added 27/07/12 Supply of machinery document statement updated to 2008 27/07/12...

  • Page 3: Table Of Contents

    Pneumatic Connection ......................14 Gas Connection ........................14 Electrical Connection ......................14 Guarding ..........................14 GTR MACHINE PRODUCTION RUNNING ................. 15 Start Up Procedure ......................15 Emergency Shut Down Procedure ..................16 Film Feed Loading ....................... 16 3.3.1 Registered Film Feed Loading .................... 18 3.3.2 Top Tool Auto Clamp (If Fitted) ...................
  • Page 4 ® seal Serial No: GTR-3455 Tray Sealing Solutions 4.6.1 Seal Station Maintenance Checks..................29 Table and Frame ......................... 30 4.7.1 Table and Frame Maintenance Checks ................30 FAULT DIAGNOSIS ......................32 ADJUSTMENT AND MAINTENANCE ................35 Safety ..........................35 General Safety Considerations .................... 36 Routine Maintenance ......................

  • Page 5: Introduction

    The machine may also be supplied as a GTR-B version which is designed to seal pre- formed board trays with pre-cut lids. In this mode the film feed and rewind assemblies will have been removed.

  • Page 6: Components

    • Conveyor Belts All conveyor belts used on Proseal machines are FDA approved and are of a hygienic design to reduce the chance of product contamination.

  • Page 7: Important

    Incorrect operation or incorrect parameterisation can adversely affect the overall performance of the machine. Scope This manual is intended to aid operators and on site engineers in the day to day running of the GTR General Description Control Panel Film Rewind...

  • Page 8: Machine Footprint And Specifications

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Machine Footprint and Specifications Weight 230 Kg Production Speed 8-15 cycles per minute Doc Ref: Page: 8 Date: 13/01/13 Issue: H...

  • Page 9: Technical Specification

    70dB(A) The machine is identified with a serial number plate. Always quote the serial number of the machine when requesting information from Proseal as this will aid identifying the exact specification of the machine. This plate should not be removed from the machine...

  • Page 10: Principle Of Operation

    Always check the machine prior to commencement of operation for any non-conformance. Always Report and log any defects, damage, malfunctions or misalignments found whilst operating the Proseal GTR machine. Report all matters to the supervisor immediately, no matter how minor they appear to be.

  • Page 11: Gtr Control Panel

    ® seal Serial No: GTR-3455 Tray Sealing Solutions GTR Control Panel The following operator interfaces are provided to allow quick and simple operation of the GTR Button Function Reset Used to reset the emergency stop circuit. Emergency Stop Used in the event of an emergency where immediate stopping of the machine is required.

  • Page 12: Machine Safety And Warning Stickers

    ® seal Serial No: GTR-3455 Tray Sealing Solutions 1.10 Machine safety and warning stickers Below is a list of warning sign which may be fitted to the machine PICTOGRAM DESCRIPTION PICTOGRAM DESCRIPTION Warning sign Safety sign to signify indicating a potential...

  • Page 13: Installation

    ® seal Serial No: GTR-3455 Tray Sealing Solutions INSTALLATION Foundations The foundation surface should be level, flat, and of sufficient strength and thickness to support the weight of the machine. Location The machine should be located in a position that is free from draughts, from adjacent doors or windows, which could adversely affect the sealing operation.

  • Page 14: Pneumatic Connection

    When the machine is operating in gas flush mode the modified atmosphere packaging gas should be connected to the inlet port situated under the machine frame. Adjust the GTR pressure regulator to give a gauge reading of 1 to 1.5 Bar. The gas pressure is monitored via a pressure switch. If the value falls below a set level the guard lamp will flash and a beep sound will be heard.

  • Page 15: Gtr Machine Production Running

    ® seal Serial No: GTR-3455 Tray Sealing Solutions GTR MACHINE PRODUCTION RUNNING WARNING: - 1. Nothing in these instructions should be assumed to supersede any operating or safety procedures applicable at your own place of work. 2. Technically unqualified personnel should not attempt to open the control panel door or make any unauthorised machine adjustments.

  • Page 16: Emergency Shut Down Procedure

    RESET button. Film Feed Loading The GTR machine is fitted with a simple inverter driven film feed mechanism. The film will accept a maximum of Ø250mm reel, with a maximum of 330mm width. (Note: wider film up to 350mm can be accommodated.
  • Page 17 ® seal Serial No: GTR-3455 Tray Sealing Solutions 6. Follow the film path as shown in the film feed diagram. 7. Ensure the waste release knob is pushed in and rotated to its locked position. 8. Wrap excess film around the rewind shaft.

  • Page 18: Registered Film Feed Loading

    Slide the waste film easily off the rewind shaft. 3.3.1 Registered Film Feed Loading If the GTR machine is fitted with a registered film mechanism, the following film feed path should be used: Doc Ref:...

  • Page 19: Top Tool Auto Clamp (If Fitted)

    Orientation dowel Electrical connections The GTR may be fitted with an optional top tool auto clamp facility. This set-up allows for the clamping and electrical connection of the top tool via a single switch on the control panel. The tool clamp will only function when all the guards are closed the table is locked in station and the safety relay has been reset.

  • Page 20: Gtr Tool Arrangement

    ® seal Serial No: GTR-3455 Tray Sealing Solutions GTR Tool Arrangement Thermocouple Heater Plug Trimblade Seal Springs Element Clamp Plate Heater Mat Seal Profile PEEK Pad Film Clamp Plate (Optional) Film Spreader Clamp Rubber Seal Rubber Base Top Plate Doc Ref:...

  • Page 21: Gtr Production Settings

    ® seal Serial No: GTR-3455 Tray Sealing Solutions GTR Production Settings 3.5.1 Temperature Control 1. The temperature is adjustable from 0 ° to 300° C. 2. The temperature set point can be changed by pressing the up / down arrows on the temperature controllers.

  • Page 22: Film Rewind Tension Settings

    3.5.6 Gas Flush Pressure Regulator Settings The GTR modified atmosphere packaging gas pressure regulator should be set to give a gauge reading of 1 to 1.5 Bar. For applications where gas usage is not critical the pressure can be raised and the Gas Flush Time setting reduced to give a higher machine throughput.

  • Page 23: Cleaning Of Your Proseal Machine

    Tray Sealing Solutions CLEANING OF YOUR PROSEAL MACHINE Effective cleaning and sanitation of your Proseal machine is required to achieve the correct level of hygiene in food production. If these are not adhered to there is a greater risk of food becoming contaminated.

  • Page 24: Machine Description

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Machine Description The picture below indicates the different areas of the machine which will require attention during the cleaning of the machine. To aid the cleaning of the machine various interlocked guards and covers can be opened to access areas where product and contamination may accumulate.

  • Page 25: Control Cubicle

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Control Cubicle 4.2.1 Cleaning Instructions The control cubicle contains all the electrical components such as the PLC; inverters safety contactors etc. which control the machine. It is located above the working area of the machine.

  • Page 26: Gtr Control Panel

    ® seal Serial No: GTR-3455 Tray Sealing Solutions GTR Control Panel The electrical components of the control panel could easily be damaged by direct use of water or cleaning solutions. The facia and control buttons should only be cleaned with a soft damp cloth or sanitised wipes and wiped dry afterwards.

  • Page 27: Film Feed Assembly

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Film Feed Assembly The film feed assembly under normal operations should only require hand-cleaning using a soft damp cloth or sanitised wipes. If the film feed has a registered film option sensors will be fitted.

  • Page 28: Film Rewind Assembly

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Film Rewind Assembly The film rewind assembly under normal operations should only require hand-cleaning using a soft damp cloth or sanitised wipes. If waste film is still on the rewind shaft remove before cleaning Wipe down the rollers ensuring they are clean and are free to rotate.

  • Page 29: Seal Station

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Seal Station The seal station can be accessed by opening the rear and front doors. This area should only be cleaned by hand using sanitised wipes as there are electrical connections for the tooling at the rear of the machine.
  • Page 30 ® seal Serial No: GTR-3455 Tray Sealing Solutions Table and Frame The rotary table and frame has been designed to aid the cleaning of the machine. This area should only be cleaned by hand using sanitised wipes. Care should be taken not to disturb the pneumatic and electrical connections.
  • Page 31 After cleaning down, check nuts, bolts, screws and other fastenings are tight. CAUTION: - Under no circumstances should Proseal machines be hosed / pressure washed down or cleaned with large of quantities of water. TOP TOOL 1.

  • Page 32: Fault Diagnosis

    The table below details some potential faults which may occur during the operation of the machine. If a fault occurs which you are unable to diagnosis contact Proseal. If you have a fault condition: ELIMINATE THE "OBVIOUS"...
  • Page 33 Tool not sealing and cutting Cylinder pressure plate positioned Re-adjust cylinder pressure plate to correctly incorrectly. the correct position. Consult Proseal for advice. TOOLING Check tray is correct for tooling if in Tray supplier has changed Trays do not sit in base tool doubt consult Proseal.
  • Page 34 ® seal Serial No: GTR-3455 Tray Sealing Solutions TOOLING CONT. Move machine to a draught free Excessive draughts around the top tool location Check condition of heater and replace Faulty heater element if damaged. Check profile for flatness. Seal profile...

  • Page 35: Adjustment And Maintenance

    4. The GTR machine MAP gas inlet valve should be turned on slowly to release any gas left in the gas flushing circuit.

  • Page 36: General Safety Considerations

    Always check the machine prior to commencement of operation for any non-conformance. Always Report and log any defects, damage, malfunctions or misalignments found whilst operating the Proseal GTR machine. Report all matters to the supervisor immediately, no matter how minor they appear to be.

  • Page 37: High Oxygen Gas Flush (If Fitted)

    For more information the HSE provides an information sheet on the safe use of oxygen. See – www.hse.gov.uk/pubns/hse8.pdf. WARNING: - All the gas flushing components on the high oxygen version of the GTR Machine should only be serviced and maintained by Proseal engineers. Proseal are always available (24/7) with expert advice and assistance.

  • Page 38: Tool Changing

    ® seal Serial No: GTR-3455 Tray Sealing Solutions 6.4.2 Tool Changing The tooling could be very hot; gloves must be worn when changing tools. 1. Remove both base tools from the table. 2. On the main panel, switch the mains isolator to the off “0” position.

  • Page 39: Cam Positioning, Damper Replacement And Setting

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Cam Positioning, Damper Replacement and Setting 6.5.1 Cam Positioning Put the table in station with the damper removed. Loosen the locking screw and position the cam at top dead centre. Find this position by manually pushing the damper shaft towards the cam, whilst rotating the damper cam backwards and forwards.

  • Page 40: Gas Springs

    Tray Sealing Solutions Gas springs Proseal machines use a variety of gas springs on their range of machines. They are used primarily to hold open guards and machine assemblies to gain safe access during setting up or maintenance. The guard or assembly will normally be interlock to the safety circuit to ensure the machine is in a safe condition.

  • Page 41: Machine Maintenance Schedule

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Machine Maintenance Schedule The following schedule should be adhered too, to achieve maximum machine reliability. As the tool may be hot and the trimblades are very sharp the correct PPE has to be worn such as heat resistant gloves.

  • Page 42: Tooling Maintenance

    (e.g. “TEFLON”) ensure it is not damaged or worn. Replace as necessary. (It may be possible to refurbish the seal profile if damaged. If in doubt consult Proseal. All other faulty parts should be replaced. See spares list for part numbers) 6.

  • Page 43: Configuration

    Mitsubishi FX series FX1s PLC programming manual c) Electroserve Temperature controller product manual e) ProSeal UK Ltd. Operation and maintenance manual. A copy of these manuals can be obtained from ProSeal UK Ltd. Alternatively copies can be found in the product manual filing cabinet. Doc Ref:...

  • Page 44: Inverter Settings

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Inverter settings Using the tables below set the listed parameters. Once complete, run the inverter at the various required speeds and acceleration/deceleration profiles. Ensure smooth movement throughout the speed range. 7.4.1 Film Feed Inverter S520-0.2Kw Film Feed Inverter...

  • Page 45: Declaration Of Conformity

    Serial No: GTR-3455 Tray Sealing Solutions DECLARATION OF CONFORMITY The Proseal GTR machine has been designed in accordance with, and satisfies the requirements of the Machinery Directive 2006/42/EC by use of the following harmonised standards: Machinery Directive 2006/42/EC replaces 98/37/EC BS EN ISO 12100:2010 Safety of Machinery - General principles for design- Risk assessment and risk reduction.
  • Page 46 Health and Safety Requirements of the European Machinery Directive 2006/42/EC, Low Voltage Directive 2006/95/EC and EMC Directive 2004/108/EC. It is essential that Proseal are informed if the above equipment forms part of a production line. In this instance a declaration of incorporation shall be issued.

  • Page 47: Appendicies

    ® seal Serial No: GTR-3455 Tray Sealing Solutions APPENDICIES Appendix A – Inverter Errors And Fault Finding The following information details inverter error codes and troubleshooting guide. For more information consult the inverter manual. Doc Ref: Page: 47 Date: 13/01/13...
  • Page 48 ® seal Serial No: GTR-3455 Tray Sealing Solutions Doc Ref: Page: 48 Date: 13/01/13 Issue: H...
  • Page 49 ® seal Serial No: GTR-3455 Tray Sealing Solutions Doc Ref: Page: 49 Date: 13/01/13 Issue: H...
  • Page 50 ® seal Serial No: GTR-3455 Tray Sealing Solutions Doc Ref: Page: 50 Date: 13/01/13 Issue: H...

  • Page 51: Appendix B - Systems Set-Up Documents

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Appendix B – Systems Set-Up Documents 9.2.1 To set up a Mitsubishi D700 inverter (Ref MAP009) Prior to commissioning or following component replacement it will be necessary to set up the inverter. Working through the following procedure will set up the inverters.

  • Page 52: Temperature Controllers (Ref Map021)

    ® seal Serial No: GTR-3455 Tray Sealing Solutions 9.2.2 Temperature Controllers (Ref MAP021) Working through the following procedure will set up the temperature controllers 1. Ensure that the controller is powered up 2. Connect tool and other ancillary cabling 3. Confirm that controller is powered up and begins to operate as per the factory default...

  • Page 53: To Set Up A Reg Film Sensor (Ref Map011)

    ® seal Serial No: GTR-3455 Tray Sealing Solutions 9.2.3 To set up a reg film sensor (Ref MAP011) Ensure that the two dipswitches (under the sensor cover) are set as follows on the registered film sensor and on the print sensor. The dipswitches are set by the manufacturer before delivery to Proseal.

  • Page 54: Phase Monitor Set-Up (If Fitted) (Ref Map016)

    ® seal Serial No: GTR-3455 Tray Sealing Solutions 9.2.4 Phase Monitor Set-Up (If Fitted) (Ref MAP016) Some machines are fitted with Siemens 3UG4616 Phase Monitors to protect them from damage through faulty electrical supplies. These devices monitor the voltage between the 3 live phases and neutral, and can also be configured to monitor the rotation between the 3 live phases, to protect phase-sensitive devices such as vacuum pumps.

  • Page 55: To Communicate With An Fx Plc (Ref Map001)

    ® seal Serial No: GTR-3455 Tray Sealing Solutions 9.2.5 To Communicate with an FX PLC (Ref MAP001) Necessary Items Required:- Laptop with GX Developer installed E505 (Red) Programming Cable Optional Items Required:- Laptop with Tibbo VSP E595 (Grey) Standard Ethernet cable or...
  • Page 56 ® seal Serial No: GTR-3455 Tray Sealing Solutions Open up the PLC program in GX Developer and select ‘Online’ – ‘Transfer setup’. Ensure the com port selected is correct, COM 1 when using the red cable directly in the PLC or COM 9 if VSP is configured for connection through the screen.
  • Page 57 ® seal Serial No: GTR-3455 Tray Sealing Solutions The program should then read from the PLC and display the live program on the screen. When the upload is complete the program should be saved in a known location under a known file name by selecting ‘Project’...
  • Page 58 ® seal Serial No: GTR-3455 Tray Sealing Solutions To Monitor a PLC Program Via Serial Connection Open the PLC program and select the ‘Monitor’ icon. To Monitor a PLC Program Via Ethernet Connection (Through HMI) Refer to document ‘To communicate with E1032 and E1101 HMI’ to ensure correct HMI settings.
  • Page 59 Tray Sealing Solutions Select the VSP name from the drop down selection, the standard com port that Proseal use is com 9, and set the IP address to the same as the IP address of the screen and press ‘OK’.

  • Page 60: To Set Up A Temperature Controller (Ref Map021)

    ® seal Serial No: GTR-3455 Tray Sealing Solutions 9.2.6 To Set Up A Temperature Controller (Ref MAP021) Temperature Controllers Working through the following procedure will set up the temperature controllers 1. Ensure that the controller is powered up 2. Connect tool and other ancillary cabling 3.

  • Page 61: Appendix C - Spares

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Appendix C – Spares Recommended Spares – A Definition. Recommended spares can be classified into 3 main categories. Primary – Front line Spares • Secondary – Second Line Spares • • Service Spares There can be many variations on the definitions for these categories.

  • Page 62: Appendix D - Circuit Diagram

    ® seal Serial No: GTR-3455 Tray Sealing Solutions Appendix D – Circuit Diagram Doc Ref: Page: 62 Date: 13/01/13 Issue: H...

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