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AGI YARGUS Operation And Maintenance Manual

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Bagging Hopper
Operation and Maintenance Manual
Read this manual before using product. Failure to
follow instructions and safety precautions can
result in serious injury, death, or property
damage. Keep manual for future reference.
Part Number: 8210-00031 R0
Revised: February 2022
Original Instructions

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  • Page 1 Bagging Hopper Operation and Maintenance Manual Read this manual before using product. Failure to Part Number: 8210-00031 R0 follow instructions and safety precautions can Revised: February 2022 result in serious injury, death, or property Original Instructions damage. Keep manual for future reference.
  • Page 2 This product has been designed and manufactured to meet general engineering standards. Other local regulations may apply and must be followed by the operator. All personnel must be trained in the correct operational and safety procedures for this product. Use the sign-off sheet below to record initial and periodic reviews of this manual with all personnel.

  • Page 3: Table Of Contents

    BAGGING HOPPER – CONTENTS 1. Safety............................... 4 1.1 Safety Alert Symbol and Signal Words..................4 1.2 General Safety Information....................... 4 1.3 Ladder Safety..........................5 1.4 Drives and Lockout Safety......................5 1.5 Personal Protective Equipment....................5 1.6 Safety Equipment ........................6 2.

  • Page 4: Safety

    1. SAFETY BAGGING HOPPER – 1. Safety 1.1. Safety Alert Symbol and Signal Words This safety alert symbol indicates important safety messages in this manual. When you see this symbol, be alert to the possibility of injury or death, carefully read the message that follows, and inform others.

  • Page 5: Ladder Safety

    BAGGING HOPPER – 1. SAFETY 1.3. Ladder Safety • Do not climb ladder if damaged, wet, icy, greasy, or slippery. • Remove slippery materials on platforms, rungs and gripping surfaces. • Maintain good balance by having at least three points of contact at all times.

  • Page 6: Safety Equipment

    1. SAFETY BAGGING HOPPER – 1.6. Safety Equipment The following safety equipment should be kept on site. • First-Aid Kit Have a properly-stocked first-aid kit available for use should the need arise, and know how to use it. 8210-00031 R0...

  • Page 7: Features

    BAGGING HOPPER – 2. FEATURES 2. Features The bagging hopper stores material used by the bagging unit. Its flow is controlled by the system. A ladder, handrail, and access ports allow for observation and cleanout. Description Item Ladder and Handrail Access Ports Hopper Vibrator (X 2)

  • Page 8: Operation

    3. OPERATION BAGGING HOPPER – 3. Operation Before continuing, ensure you have completely read and understood this manual’s Safety section, in addition to the safety information in the section(s) below. 3.1. Operation Safety • Always operate with guards, covers, and shields in place. •...

  • Page 9: Maintenance

    • Shut down and lock out power before maintaining equipment. • After maintenance is complete, replace all guards, service doors, and/or covers. • Use only genuine Yargus replacement parts or equivalent. Use of unauthorized parts will void warranty. If in doubt, contact Yargus or your local dealer.

  • Page 10: Periodic Maintenance

    4. MAINTENANCE BAGGING HOPPER – 4.3. Periodic Maintenance Inspect the bolts on the vibrating units weekly and tighten if required. Note Refer to vibrator and bagger system manufacturers' technical manuals attached to this manual for detailed Safety and Maintenance information. 8210-00031 R0...

  • Page 11: Limited Warranty

    Yargus in advance in writing. The provision of this warranty shall not apply to any Yargus product which has been subject to abuse, misuse, negligence, alteration, or accident, or which have been repaired in any way so as, in the reasonable judgment of Yargus, to affect adversely its performance and reliability.
  • Page 12 YARGUS is an AGI Brand. AGI is a leading provider of equipment solutions for agriculture bulk commodities including seed, fertilizer, grain, and feed systems with a growing platform in providing equipment and solutions for food processing facilities. AGI has manufacturing facilities in Canada, the United States, the United Kingdom, Brazil, South Africa, India and Italy and distributes its products globally.
  • Page 13 COMPAC M140 BAGGING MACHINE October OPERATION & MAINTENANCE MANUAL 2014...
  • Page 14 COMPAC M140 BAGGING MACHINE COMPAC M140 BAGGING MACHINE O P E R A T I O N & M A I N T E N A N C E M A N U A L CONTENTS 1 FOREWARD ..................... 4 2 SAFETY WARNINGS ..................
  • Page 15 COMPAC M140 BAGGING MACHINE 6.4 WEIGHER ..................... 27 6.5 AIR SUPPLY ..................28 7 OPERATING INSTRUCTIONS ..............29 7.1 CHECK SETTINGS AND READINGS ............29 7.2 ADJUSTMENT OF METERING VALVE ............. 29 7.3 SETTING SCALE PARAMETERS .............. 30 7.3.1 Introduction screen ............... 30 7.3.2 Selection Menu ................
  • Page 16 COMPAC M140 BAGGING MACHINE 8 PREVENTATIVE MAINTENANCE ............... 44 8.1 SAFETY ....................45 8.2 CONVEYORS ..................45 8.3 PNEUMATIC SYSTEM ................45 8.4 ELECTRICAL SYSTEM ................46 8.5 BAGGING MACHINE ................46 8.6 CONTAINER UNIT ................47 9 LUBRICATION ..................48 9.1 OIL AND GREASE SPECIFICATIONS ............

  • Page 17: General Safety Information

    COMPAC M140 BAGGING MACHINE 1 FOREWARD This manual is written to give the owner/operator the necessary operating, regular servicing, preventive and periodical maintenance instructions for the Compac M140 Bagging machine. Read this manual completely and carefully before operating and servicing the equipment.

  • Page 18: Safety Warnings

    COMPAC M140 BAGGING MACHINE 2 SAFETY WARNINGS DO NOT OPERATE THIS EQUIPMENT UNLESS YOU HAVE READ AND UNDERSTOOD THE INSTRUCTIONS IN THIS MANUAL AND MANUFACTURERS INFORMATION. IMPROPER MACHINE OPERATION IS DANGEROUS AND COULD RESULT IN INJURY. SAFE OPERATION CAN ONLY BE ACHIEVED IF THE EQUIPMENT IS CORRECTLY OPERATED AND MAINTAINED.
  • Page 19 COMPAC M140 BAGGING MACHINE The bird beak type bag clamp is for use with open mouth bags and is equipped with a safety feature to prevent accidents during operation. The clamp will only close after simultaneous operation of the two finger switches located on either side of the clamp.

  • Page 20: Electric Connections

    COMPAC M140 BAGGING MACHINE 3 ELECTRIC CONNECTIONS The Compac M140 is self-powered by a 3-cylinder Perkins marine diesel generator. It can also be supplied with power if the following specifications are met: Voltage: 400 VAC 3 phase + Neutral + Earth Frequency: 50 Hz Cable connection: 5 wire (3 phase, 1 earth and 1 neutral) External electrical connections to the machinery are the responsibility of the...

  • Page 21: General Description

    COMPAC M140 BAGGING MACHINE 4 GENERAL DESCRIPTION 4.1 BAGGING UNIT The bagging unit is a specially constructed unit measuring 20ft long, 8ft wide and 8ft6" high. The unit is equipped with approved unit fittings on all 8 corners and 2 pcs forklift pockets in the bottom construction to enable handling and transportation of the unit with all types of existing approved unit handling equipment.
  • Page 22 COMPAC M140 BAGGING MACHINE The four openings in the roof of the bagging unit allow the product to be fed from a hopper into the bagging unit closed during transportation or storage with covers bolted to the roof. Product Inlet A cable inlet in the side of the unit allow cables and connectors to enter the unit without risk of damage whilst enabling...

  • Page 23: Compressor, Airdryer And Airlines

    COMPAC M140 BAGGING MACHINE 4.2 COMPRESSOR, AIRDRYER AND AIRLINES. The separate compartment in the back of the bagging unit houses the air compressor, air tank, automatic water separator, membrane air dryer, intake fan and electrical box housing all pneumatic valves, control and power components of the Compac 140.
  • Page 24 COMPAC M140 BAGGING MACHINE A fine filter and air dryer set has been fitted to remove particles down to 0.01 microns from the compressed air and reduce the oil contents to 0.08 ppm. Air Dryer and filter set The compressed air passing through the airdryer is dried until a dew-point of -20 degrees C whereby all moisture in the air condenses, delivering virtually dry air at the outlet of the dryer, feeding all pneumatic components of the bagging unit.

  • Page 25: Main Distribution And Electric Control Box (Be)

    COMPAC M140 BAGGING MACHINE 4.3 MAIN DISTRIBUTION AND ELECTRIC CONTROL BOX (BE). The control box houses all the electrical safety devices, switchgear, pneumatic valves and bag counters. Inside the Control Box The Flex weigh controllers are located in the front of the box together with the switches for the induction fan, compressor and lighting.

  • Page 26: Weigher

    COMPAC M140 BAGGING MACHINE 4.4 WEIGHER The Compac M140 bagging machine is equipped with two bagging lines, each with two stainless steel net weighers, two dosing valves and two metering valves. The metering valves are located just below the product inlet in the roof. Metering Valve The metering valves control the product flow to the weigher.
  • Page 27 COMPAC M140 BAGGING MACHINE Each weigher is located immediately below the dosing valves. Each stainless steel weigh bunker is supported on three rubber dampers which are fitted to three load cells. Load cell and rubber damper...
  • Page 28 COMPAC M140 BAGGING MACHINE The weigher is equipped with locks to secure the weigher during transport. WARNING IT IS VERY IMPORTANT THAT THE TRANSPORT LOCKS ARE USED DURING TRANSIT OR LONG PERIODS OF STORAGE. IF THESE ARE NOT USED THEN IT IS POSSIBLE THAT THE LOAD CELLS WILL SUFFER DAMAGE AND NO LONGER WEIGH ACCURATELY.
  • Page 29 COMPAC M140 BAGGING MACHINE Each weigh bunker has a capacity of 110 litres and is capable of weighing up to 100kg if the density allows it. It is equipped with a pneumatic operating valve to discharge the product after completion of the weighing cycle. Bag clamp This discharges into the stainless steel bag clamp which is pneumatically operated and is operated by...
  • Page 30 COMPAC M140 BAGGING MACHINE The weigher is mounted on the roof of the container. This is equipped with a hinged system for easy access for cleaning and maintenance. Side covers provide access to the load cells and load cell dampers. A load cell junction box and the pneumatic tube connection are located at the front of the weigher.

  • Page 31: Stitcher

    COMPAC M140 BAGGING MACHINE 4.5 STITCHER The Compac M140 machine is fitted with 2 Newlong DS9C high speed stitchers. The stitchers are controlled by a sensor which activates the stitcher as the bag passes through the machine. The stitcher is mounted on a height adjustable stainless steel mounting column which includes yarn coil holders and yarn guides.

  • Page 32: Bag Conveyor

    COMPAC M140 BAGGING MACHINE 4.6 BAG CONVEYOR The bag conveyor is located underneath the bag clamp and stitcher. Bag Conveyor The slider bed type conveyor is centered between floor mounted guide strips for easy positioning. Locks keep the conveyor in secure position during transport and operation.

  • Page 33: Truck Conveyor

    COMPAC M140 BAGGING MACHINE 4.7 TRUCK CONVEYOR Truck conveyor The truck loading conveyor transfers the filled bags from the bag conveyor onto a truck. The conveyor height is adjusted for height using the winches. A pair of wheels are positioned at the midpoint for ease of repositioning.

  • Page 34: Truck Conveyor Turntables

    COMPAC M140 BAGGING MACHINE 4.9 TRUCK CONVEYOR TURNTABLES In operation mode the 2 turntables of the Compac truck conveyor system connected brackets positioned underneath the main doors. During storage and/or transportation, the turn tables are stored against the front doors inside the bagging unit.

  • Page 35: Positioning Of The Unit

    COMPAC M140 BAGGING MACHINE 5 POSITIONING OF THE UNIT 5.1 SELECTING THE CORRECT AREA FOR THE BAGGING UNIT Selection of a correct location for the operation of the bagging unit is required to ensure the safe and trouble free operation of the equipment. The position of the equipment is determined by both practical and logistical factors on-site, as well as the condition of the ground surface underneath the equipment.

  • Page 36: Positioning Of The Bagging Unit

    COMPAC M140 BAGGING MACHINE 5.2 POSITIONING OF THE BAGGING UNIT The bagging unit may be handled with all types of equipment approved for container handling. Prior to shifting the unit, make sure all doors are closed and secured and all components inside the unit are safely lashed and secured.

  • Page 37: Preparing The Equipment For Operation

    COMPAC M140 BAGGING MACHINE 6 PREPARING THE EQUIPMENT FOR OPERATION 6.1 POWER & AIR SUPPLY The supply should be as per the below mentioned specification. Before activating the main switch and circuit breakers check the voltage and frequency. For safety reasons make sure that all consumers are switched off before connecting the unit to the main supply.

  • Page 38: Truck Conveyor

    COMPAC M140 BAGGING MACHINE 6.2 TRUCK CONVEYOR The Conveyor power cable needs to be connected to the wall socket above the main door. It is started by pressing the green GO button on the Stitcher column. Controls on the Stitcher Column Run the conveyors and check the alignment of the belt, adjust if necessary.

  • Page 39: Bag Conveyor

    COMPAC M140 BAGGING MACHINE 6.3 BAG CONVEYOR The bag conveyor is secured with transport clamps. Remove these clamps and slide out the conveyors until the discharge end of the conveyor is in position relative to the tail of the truck conveyor. Attach the side fences, and adjust to suit the bag size.

  • Page 40: Weigher

    COMPAC M140 BAGGING MACHINE 6.4 WEIGHER The weigher is equipped with two transport locks. To unlock the weigher remove the side covers of the weigher cabinet. The transport locks are located at each side of the weigher. To unlock turn the flat washers with nuts away from the securing bar and lock them in position.

  • Page 41: Air Supply

    COMPAC M140 BAGGING MACHINE 6.5 AIR SUPPLY Power up the compressor, and adjust the air regulator to 6 bar pressure. Regulator The air regulator is equipped with a water filter. Note. The air supply should be oil free, filtered and dry.

  • Page 42: Operating Instructions

    COMPAC M140 BAGGING MACHINE 7 OPERATING INSTRUCTIONS 7.1 CHECK SETTINGS AND READINGS Prior to starting the bagging operation check the following readings and settings of the equipment. Voltage and frequency as per instructions chapter 6.1 Air-pressure setting 6 bar Tracking and tension of conveyor belts. Control boxes and scale covers are closed Water separator is empty 7.2 ADJUSTMENT OF METERING VALVE...

  • Page 43: Setting Scale Parameters

    COMPAC M140 BAGGING MACHINE 7.3 SETTING SCALE PARAMETERS Only basic settings are outlined in this manual. Skill and techniques develops as the operator gains knowledge of the machine. After switching on the power the controller will show the introduction screen. Press anywhere on the Orange area to proceed to the Selection Menu.

  • Page 44: Selection Menu

    COMPAC M140 BAGGING MACHINE 7.3.2 Selection Menu The Selection Menu as default is shown below. This main point navigating around the system. Information – Return the controller to the startup screen detailed in 7.3.1 Dosing – Operation screen. Statistics – Batch and machine totals. Settings –...

  • Page 45: Recipe

    COMPAC M140 BAGGING MACHINE 7.3.4 Recipe Each recipe parameter can be changed at any time (including when the machine is operating). Changes will only become active when the Save button is pressed and any subsequent weighing will be to these new settings.

  • Page 46: Statistics

    COMPAC M140 BAGGING MACHINE 7.3.5 Statistics The statistics screen shows 2 totals. The batch total and the machine total. The batch total can be reset at any time. The machine total cannot be reset. 7.3.6 Settings The settings menu allows you to switch off individual weighers maintenance...

  • Page 47: Disabling Weighers

    COMPAC M140 BAGGING MACHINE 7.3.7 Disabling weighers Pressing the tick or cross next to the weigher number will enable or disable individual weighers. 7.3.8 Logging in By pressing on the log-on/log-off button you will be taken to the enter password screen.

  • Page 48: Manual Operation

    COMPAC M140 BAGGING MACHINE 7.3.10 Manual Operation manual mode primarily maintenance and troubleshooting purposes. Each individual input is lit when the controller is receiving the signal. Outputs can be manually enabled to test a circuit or operation. Pressing on each of the inputs or output buttons takes you to each option.

  • Page 49: Select Weigher

    COMPAC M140 BAGGING MACHINE 7.3.12 Select Weigher Each weigh bunker must be calibrated individually. Pressing on each weigher takes you to the calibration menu. 7.3.13 Enter Calibration Code In order to comply with the certification of the controller the system records any changes.

  • Page 50: Indicator Calibration

    COMPAC M140 BAGGING MACHINE 7.3.14 Indicator calibration Each weigh bunker has a number of parameters to change for each weigher. 1. Show – View the current calibration set points installed in the system. 2. Points – Change, edit, delete current calibration set points.

  • Page 51: Calibration Points

    COMPAC M140 BAGGING MACHINE 7.3.15 Calibration points Delete the current calibration set points by using the + and – keys and the Delete button. Press yes to confirm each one. Create new set points one at 0kg and one at the weight around your chosen setpoint. In this example we use 50kg.

  • Page 52: Calibration Show

    COMPAC M140 BAGGING MACHINE 7.3.16 Calibration show To confirm that both set points have been saved by the controller press ‘Show’. This should show a higher CAL number and that there are 2 points present and saved. Calibration is complete. Press OK to return to the main menu.

  • Page 53: Starting And Stopping The Scales

    COMPAC M140 BAGGING MACHINE 7.4 STARTING AND STOPPING THE SCALES In order to start the operation of the machine please use the following instructions. 1) Press Start on the controller from the Dosing screen. (Section 7.3.3). 2) Perform Rest Discharge. Place a bag on the bag clamp. The bag clamp will close and both bunkers will open for 5 seconds.

  • Page 54: Weighing Speed And Weight Accuracy

    COMPAC M140 BAGGING MACHINE 7.6 WEIGHING SPEED AND WEIGHT ACCURACY Production speed and accuracy depends on various factor such as: Product density  Product flow characteristics  Moisture %  Dust %  Product supply capacity (Filling hopper)  Speed of take away from the bagging machine ...

  • Page 55: Bag Weight Checks

    COMPAC M140 BAGGING MACHINE 7.8 BAG WEIGHT CHECKS In order to verify that the machine is weighing correctly we recommend that random checks are carried out of complete bags using an independent calibrated check scale. We recommend that these are carried out on an ongoing basis during operations. The frequency of these check weights is dependent on how critical the weight accuracy is to the operation.

  • Page 56: Starting Bagging

    COMPAC M140 BAGGING MACHINE 7.9 STARTING BAGGING Set the scale parameter as per previous instructions. Check the display readings of the scale. The indicators must read 0 KG. Press the ZERO button in case the display is not zero. Start the conveyors by pressing the start button on the control box by the stitcher. To start &...

  • Page 57: Stitching The Bag

    COMPAC M140 BAGGING MACHINE IMPORTANT In order to achieve the maximum output from the machine the following should be adjusted carefully: Metering valve setting (start at 2/3 open) Time for the bunker to be open (Clamp time, empty level, empty time) Time of bag clamp to be closed (Discharge delay) Incorrect settings will reduce the output of the machine.

  • Page 58: Safety

    COMPAC M140 BAGGING MACHINE 8.1 SAFETY Authorised, trained and competent personnel only shall perform maintenance and repairs. Persons authorized to switch on remotely controlled parts of this equipment must take adequate precautions to ensure that there is no one checking or working on these parts.

  • Page 59: Electrical System

    COMPAC M140 BAGGING MACHINE The cause of pneumatic troubles is often a result of dirt and dust in the air system. It is therefore important to clean the equipment or parts before maintenance / repairs on pneumatic systems. When working on pneumatic pipes ensure that the open end of the pipes are covered with tape of caps to prevent the penetration of dust into the system.

  • Page 60: Container Unit

    COMPAC M140 BAGGING MACHINE 8.6 CONTAINER UNIT Paint damage should be repaired as soon as possible especially when handling corrosive products. A mix of corrosive products will lead to chemical reactions if not cleaned frequently. Keep door hinges and rubbers maintained. When moving units use only approved container-handling equipment and make sure the forklift pockets are fully used during lifting.

  • Page 61: Lubrication

    COMPAC M140 BAGGING MACHINE 9 LUBRICATION 9.1 OIL AND GREASE SPECIFICATIONS The oil and grease specifications are as follows. Grease NLGI NO 2 CALSIUM SOAP AND MINERAL OIL Conveyor motors B.P. GR-XP 100 Black Point Bel Ray 100 Castrol Alpha SP 100 Chevron NL Gear Compound 100 Citgo EP Compound 100 Elf Reductelf SP 100...

  • Page 62: Lubrication Maintenance Card

    COMPAC M140 BAGGING MACHINE 9.2 LUBRICATION MAINTENANCE CARD TC / SC conveyor motors Every 50,000 hours of service Conveyor hydraulic jack Change oil every year.

  • Page 63: Preparing Equipment For Transportation/Storage

    COMPAC M140 BAGGING MACHINE 10 PREPARING EQUIPMENT FOR TRANSPORTATION/STORAGE 10.1 PNEUMATIC SYSTEM Check the hoses and connections for leakage.  Drain the water separators and air tank.  Dismantle and clean the automatic drains and water separators.  Check the micro filter elements for dirt or oil parts. ...

  • Page 64: Scale

    COMPAC M140 BAGGING MACHINE 10.4 SCALE Clean thoroughly.  Secure the weigher for transport with the transport bracket plates.  Check rubber seals.  Check secured position of scale covers and bag clamp.  10.5 BAGGING UNIT Make sure that all parts stored in the units are lashed. ...

  • Page 65: Maintenance Recommendation

    COMPAC M140 BAGGING MACHINE 11 MAINTENANCE RECOMMENDATION 11.1 SAFETY Attach a 'DO NOT OPERATE' or similar warning tag to a start switch or controls before servicing or repairing the machine. Persons authorized to switch on remote controlled parts of this machine must take adequate precautions to ensure that there is no-one checking or working on these parts.

  • Page 66: Pneumatic System

    COMPAC M140 BAGGING MACHINE 11.2 PNEUMATIC SYSTEM Before maintenance or repairs on a pneumatic system open all drains and clean the machine or parts thoroughly. During repairs make sure that no dirt or dust enters the system. Mark the position of disconnected tubes and prevent penetration of dirt by covering the tubes with tape or caps.

  • Page 67: Conveyors

    COMPAC M140 BAGGING MACHINE 11.4 CONVEYORS Before maintenance and repairs on conveyor belts switch off the power supply. For safety reasons avoid working on a conveyor while in operation. Make sure that after repairs all tools are removed before operating the equipment. 11.5 BAGGING MACHINE Dirt and dust can cause excessive wear therefore clean the equipment thoroughly before maintenance or repairs.

  • Page 68: Periodical Service And Maintenance

    COMPAC M140 BAGGING MACHINE 12 PERIODICAL SERVICE AND MAINTENANCE 12.1 BEFORE OPERATING OR EVERY 12 HOURS OR BEFORE STORAGE PNEUMATIC SYSTEM Check the settings of the pressure in the pneumatic system.  WEIGHING MACHINE Remove any caked product from bunker or spout. ...

  • Page 69: Weekly Or Before Storage

    COMPAC M140 BAGGING MACHINE 12.2 WEEKLY OR BEFORE STORAGE All checks as per 12.1 and the following: PNEUMATIC SYSTEM Operate all scale and pneumatic control functions manually and check for  proper functioning. WEIGHING MACHINE Check the cylinder speed.  Check settings of the bag clamp and clamp rubbers for damage.

  • Page 70: Monthly Or Before Storage

    COMPAC M140 BAGGING MACHINE 12.3 MONTHLY OR BEFORE STORAGE All checks of per 12.2 and the following PNEUMATIC SYSTEM Check all pneumatic components and tubes for wear and leaks.  WEIGHING MACHINE Check tightness of bolts and nuts.  Check rubber damper of the loadcell connection. ...

  • Page 71: Manufacturers Documentation

    COMPAC M140 BAGGING MACHINE 14 MANUFACTURERS DOCUMENTATION The following manuals are supplied in pdf format. NMI CERTIFICATE WEIGHERS  GV TYPE DRUM MOTORS INSTRUCTIONS AND PARTS MANUAL  SMC FILTERS AND VALVES  KLOCKNER MOELLER DIL SWITCHES  LOADCELL INSTRUCTIONS ...

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