Cleveland Range MFS Operation Manual

METERING FILLING STATION

MODEL: MFS

(for Models built after June, 1994)

CLEVELAND RANGE INC.

1333 East 179th St. Cleveland, Ohio U.S.A. 44110 Toll Free 1-800-338-2204

SE95019 Rev.4

INSTALLATION, OPERATION AND SERVICE MANUAL

TABLE OF CONTENTS

Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Shipping Damage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Packaged Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Clipper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation Requirements - Compressed Air & Electrical . . . . . . . 1

Installation Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Operating Instructions General Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pumping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Approximate Volume Setting Instructions . . . . . . . . . . . . . . . . . . . 4

Cleaning Instructions Preproduction Sanitizing Procedure . . . . . . . . . . . . . . . . . . . . . . . 5

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Service Parts Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Piston Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Label Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Hose Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Thermal Assurance Package (option) . . . . . . . . . . . . . . . . . . . . . 13

Miscellaneous Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Piping Assemblies, "O" Rings, Gaskets & Seals. . . . . . . . . . . 15-16

"O" Rings, Gaskets & Seals (shown actual size) . . . . . . . . . . 17-18

Maintenance Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Oil Filling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Air Filter Replacement Procedure. . . . . . . . . . . . . . . . . . . . . . . . 19

Product Piston Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Adjustment & Setting of Air Cushion Equipped Pump Heads . . . 20

Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Pneupak Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . 21

Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Air Package Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Air Package Parts Drawing Legend . . . . . . . . . . . . . . . . . . . . . . 24

Point to Point Air Tubing Connections . . . . . . . . . . . . . . . . . . . . 23

Air Tube Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26

Spare Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

INSPECTION

Before unpacking visually inspect the unit for evidence of damage during shipping.

If damage is noticed, do not unpack the unit, follow shipping damage instructions.

SHIPPING DAMAGE INSTRUCTIONS

If shipping damage to the unit is discovered or suspected, observe the following guidelines in preparing a shipping damage claim.

1. Write down a description of the damage or the

reason for suspecting damage as soon as it is discovered. This will help in filling out the claim forms later.

2. As soon as damage is discovered or

suspected, notify the carrier that delivered the shipment.

3. Arrange for the carrier's representative to

examine the damage.

4. Fill out all carrier claims forms and have the

examining carrier sign and date each form.

PACKAGED ITEMS

Packaged items that are shipped loose with the unit include:

(1) 2" Wrench (1) 3" Wrench (2) Trash Containers (1) Assortment of spare "O" Rings (1) Air Hose Assembly (2) Food Hose Assemblies (1) Food Grade Grease (1) Spring (1) Bolt (1) Cleaning Hose (1) Brush Kit (1) 3" 90° Elbow (1) Lug Nut Wrench

ASSEMBLY

The Metering Filling Station is a mobile unit that requires no assembly to complete unless a clipper has been shipped with the unit.

It does however ship with a number of loose items that are required for its use.

These items should be stored in a convenient location.

CLIPPER

If a clipper is supplied with the unit, it must be mounted. Remove it from the box and connect it to the mounting bar using part #FA11509 bolt (supplied). Connect one end of the short air hose (supplied) to the clipper and the other end to the male quick connect on the end of the MFS.

INSTALLATION REQUIREMENTS

Compressed Air

This unit requires a constant 25 c.f.m. (cubic feet per minute) at 90 to 100 p.s.i. (pounds per square inch).

The air must be filtered of oil, moisture and dirt. The dew point of the supply air must be less than 65°F. The Metering Filling Station is equipped with its' own air oiler system, therefore, no oil should be added to the supply air. We recommend the compressed air system be equipped with a drier, filter, and automatic water dump on the air compressor receiver tank. If the distance between the tank and the unit is less than 100 feet then a minimum line size of 3/4" is required. A distance of 100 to 300 feet requires a minimum 1" line.

Connect one end of air line (supplied) to the metering filling station and the other end to the kettle air outlet fitting.

If you do not have a Cleveland kettle with air connection built-in then you must attach the female quick connect (supplied) to your air supply.

Electrical

No electrical connection is required unless the unit comes equipped with a Thermal Assurance Package (TAP) option. This requires a 115V. 1PH. grounded outlet.

INSTALLATION

INSTALLATION CHECKS

(see General Parts Drawing, page 3)

AIR PRESSURE

Complete the following steps with the 3" dia. Food Product Hose (15) not connected:

1. Connect supply air to metering filling station.

2. Open front Access Doors (17) on metering

filling station.

3. Set Stroke Selection Switch on Control Panel (1) for "CONSTANT PUMPING".

4. Hold Trigger Lever (10) and read Pressure Gauge (21) as pump is operating. Pressure should not drop less than 90 psi or exceed 110 psi.

5. Adjust Pressure Regulator Dial (20) or supply pressure if required.

Note: If there is no air to unit check:

A/ The kettle's Air Quick Connect is

pushed upward to the "OPEN" position.

Air Quick Connect on Mixer Kettle

B/ Open the back Access Doors (17) and check

that the Main Air Shut Off Valve (22) is pressed inwards.

SINGLE STROKE

Note: Use 3" gaskets in all hex nut couplings on food hose.

⇒ First, hand-tighten. ⇒ Then, snug with wrench.

1. Using 3" gasket, connect the 3" dia. Food Product Hose (15) to metering filling station and kettle.

2. Add water to kettle and open kettle's product discharge valve.

3. Open front Access Doors (17) of metering filling station.

4. Set Stroke Selection Switch on Control Panel (1) for "SINGLE STROKE".

5. Place bag over Discharge Nozzle (11).

6. Pull and hold Trigger Lever (10).

7. Product piston should go all the way forward,

then return and stop.

8. Release Trigger Lever (10).

9. Repeat test two to four times, product will start

to discharge into bag.

CLIPPER

Refer to clipper operating instruction manual for safety and operating procedures.

OPEN

OPERATING INSTRUCTIONS

OPERATING CONTROLS

NAME FUNCTION

Discharge speed Adjusts speed of product exiting

the discharge nozzle.

Suction speed Adjusts speed of product being

pulled from kettle and into pump.

Stroke selection Selects operating mode or OFF

when not in use.

General Parts Drawing

ITEM # DESCRIPTION FUNCTION

1. Control Panel . . . . . . . . . . . . . . . Includes: A/ speed adjusters for suction and discharge.

B/ stroke selection switch.

2. Flapper Valve . . . . . . . . . . . . . . Changes direction of product flow.

3. Piston Head

4. Large Lug Nuts . . . . . . . . . . . . . Holds product head to product cylinder.

5. Product Cylinder . . . . . . . . . . . . Cylinder product is drawn into and discharged from.

6. Product Piston . . . . . . . . . . . . . . Moves product within the cylinder.

7. Product Discharge Valve . . . . . . Air cylinder that opens and closes discharge opening

by moving plunger.

8. Plunger . . . . . . . . . . . . . . . . . . . Opens and closes product discharge opening.

9. Discharge Valve Body

10. Trigger Lever . . . . . . . . . . . . . . . Activates pumping action.

11. Discharge Nozzle . . . . . . . . . . . Directs the flow of discharge product.

12. 2" dia. Short Connector Pipe

13. 2" Elbow

14. 2" dia. Long Connector Pipe

15. 3" dia. Food Product Hose . . . . . 3" dia. hose to connect Metering Filling Station hose to kettle.

16. Brake . . . . . . . . . . . . . . . . . . . . Locks pump in position.

17. Access Doors

18. Clipper Bracket . . . . . . . . . . . . . Mounting bracket for optional clipper.

19. Adjusting Wheels . . . . . . . . . . . . Used for setting desired pumping volume.

20. Pressure Regulator Dial . . . . . . . Used to regulate air pressure.

21. Pressure Gauge . . . . . . . . . . . . Shows operating pressure.

22. Main Air Shut Off Valve . . . . . . .

Disconnects air supply to unit. (Back side of Metering Filling Station)

2220

DISCHAR GE

SPEED

FAST SLOW F AST SLOW

SINGLE STROKE CONSTA NT PUMPING

Cleveland

STROKE

SELECTI ON

OFF

7 8

FA ST SL OW FA ST SL OW

Cleveland

DI SC HA RG E

SP EE D

ST RO KE

SE LE CT IO N

SI NGLE STR OKE C ONS TANT PUM PING

O F F

SU CT IO N

SP EE D

SUCTION SPEED

4 36 5 15

PUMPING

Note: Use 3" gaskets in all hex nut couplings on

food hose.

⇒ First, hand-tighten. ⇒ Then, snug with wrench.

1. Using 3" gasket, connect one end of the 3" dia. Food Product Hose (15) to kettle.

2. Position metering filling station for ease of operation and connect other end of 3" dia. Food Product Hose (15) - if required use 3" 90° elbow.

3. Connect air hose to kettle and metering filling station.

4. Open the back Access Doors (17) and check that the Main Air Shut Off Valve (22) is pressed inwards.

5. Open front Access Doors (17) of metering filling station.

6. Set Stroke Selection Switch on Control Panel (1) for "SINGLE STROKE".

Approximate Volume Setting Instructions

7. Using a ruler, set desired quantity by measuring between Adjusting Wheels for correct setting.

8. Open product discharge valve on kettle.

9. Place bag over Discharge Nozzle (11).

10. With Stroke Selection Switch on Control Panel

(1) set on "SINGLE STROKE", pull and hold Trigger Lever (10) against Discharge Nozzle (11) until pump has stopped; if a second stroke is required, repeat process.

11. Move bag over to clipper and clip closed

(refer to clipper operating instruction manual).

12. Pump a couple of bags to check volume and

speed. ⇒ To adjust volume, measure between

Adjusting Wheels (19) for correct setting. ⇒ To adjust speed, turn Discharge Speed or

Suction Speed on Control Panel (1) as required.

⇒ Adjust pump speed faster for thinner products and slower for thicker.

13. Continue pumping until all product has been

emptied from kettle.

Adjusting

Wheels

Locked Position

A Volume

1 1/2" = 1 gallon 3 1/2" = 3 quarts 5 1/2" = 5 quarts

NOTE: Fine tune the distance during start up training.

Make a template for ease of adjustment.

Approximate

AS A SAFETY FEATURE THE DISCHARGE NOZZLE (11) WILL

AUTOMATICALLY CLOSE AND THE PUMP WILL REVERSE ANY TIME

YOU RELEASE THE TRIGGER LEVER (10).

PREPRODUCTION SANITIZING PROCEDURE

1. Fill kettle to hemisphere and start the agitator.

2. Add 5.25% bleach to make a 50 ppm solution

- refer to chart.

Amount of water

Amount (5.25%) of

in the kettle bleach to add

20 gal / 76L. . . . 5 tbsp / 75ml

30 gal / 114L. . . . 7 1/2 tbsp / 113ml

40 gal / 151L. . . . 10 tbsp (5/8 cup) / 150ml

50 gal / 190L. . . . 12 1/2 tbsp. (3/4 cup + 1 tbsp) / 188ml

60 gal / 227L. . . . 1 cup / 225ml

Sanitizing Solution Chart

3. Bring the temperature to 80°F (max.- 100°F)

or lukewarm.

NOTE:

Do NOT allow solution to get hot.

4. Attach the metering filling station to the kettle

and pump on "CONTINUOUS" setting for one minute.

5. Finish emptying the kettle by disconnecting

the 3" dia. Food Product Hose and letting the contents of the Metering Filling Station and kettle drain. Make sure the 3" dia. Food Product Hose does not drag on the floor.

FLUSHING

Between Recipes

1. To clean between batches of product, flush

kettle and Metering Filling Station with a warm water and mild detergent solution from kettle to loosen and remove food particles.

2. Remove product Discharge Nozzle and

replace it with cleaning hose.

3. Place end of cleaning hose over a drain.

4. Switch stroke selector switch to "CONSTANT

PUMPING".

5. Pull and hold trigger lever against discharge

valve nozzle until kettle has been emptied.

6. Add clean water to kettle, and repeat process

to rinse units.

NOTE:

The metering filling station must be

sanitized prior to the daily production run.

CLEANING INSTRUCTIONS

Flapper Valve

"O" Ring

Spring

Large Lug Nut

Flapper

Rotary Actuator

Cylinder Seal

Shaft

Piston Head

Discharge

Head

Assembly

2" Sani

Clamp

Bracket

Product Piston "O" Ring

2" Sani

Clamp

2" Sani

Clamp

Product

Discharge

Nozzle

Piston Cylinder

Product Piston

Discharge Valve Plunger Discharge Valve Body

Gasket

Short 2" dia. Pipe

Long 2" dia. Pipe

Push

Product Cylinder Piston Head Assembly

2" dia. Elbow

Gasket

3" dia. Food Hose

Gasket

DISASSEMBLY

Note: Remove "O" rings using a wooden or plastic picker; do NOT use a sharp object.

Note: Prepare a properly diluted solution of

authorized cleaning solution in a plastic soak bucket taken from a freshly filled sink to receive small parts, gaskets, and "O" rings.

1. Move slide valve on kettle's air quick connect to down position to vent air from metering filling station.

Air Quick Connect on Mixer Kettle

2. Disconnect main air line from Metering Filling

Station.

3. Remove air lines (quick-disconnect fittings)

from Discharge Valve.

4. Undo 2" Sani-Clamp, and remove Discharge

Nozzle.

5. With 2" wrench, loosen nut on Discharge Valve

Body and remove Discharge Head Assembly; place 2" gasket in warm water to soak.

6. To disassemble Discharge Head Assembly, follow in order;

⇒ Remove 2" Sani-Clamp that holds Discharge Head Assembly together.

⇒ Separate parts by pulling them apart.

Discharge Head Assembly

⇒ Using a wooden or plastic picker, remove "O" Rings from plunger.

⇒ Put "O" Rings in warm water to soak; do

NOT submerge discharge valve.

7. With 2" wrench, remove Short 2" dia. Pipe, 2"

dia. Elbow and Long 2" dia. Pipe. Place all gaskets in soak bucket.

8. Remove two air lines from Rotary Actuator on

Piston Head Assembly.

9. Using lug wrench, unscrew three Large Lug

Nuts, and remove Piston Head Assembly.

10. Dismantle Piston Head Assembly as follows in

order;

Piston Head Assembly

⇒ Push Rotary Actuator toward Piston Head to remove Flapper, place Flapper in soak bucket.

⇒ Remove Rotary Actuator, placing small spring in soak bucket.

⇒ Do NOT submerge Rotary Actuator.

11. Pull product cylinder off product piston.

⇒ Do NOT use pliers or any other tool that could damage the inside wall of the cylinder.

12. Using plastic or woden picker, remove "O"

ring from Product Piston.

CLEANING

WARNING: Do not submerge Discharge Valve or

Rotary Actuator in water, damage to air cylinders will result.

⇒ Always turn off equipment power before using water.

⇒ Never use steel wool for cleaning; particles may become embedded and rust.

⇒ Clean unit in the following order:

A/ Warm water and mild detergent solution. B/ Clear rinse. C/ Properly diluted sanitizing solution (see

Sanitizing Solution Chart) to sanitize after cleaning.

⇒ Do NOT use chloride cleaners; they may damage stainless steel surface.

⇒ For difficult cleaning applications, one of the following can be used: alcohol, baking soda, vinegar, or a solution of ammonia in water.

1. Clean all parts (except Discharge Valve and

Push yellow tab down to

release air pressure before

disconnecting air hose

Discharge

Valve

Plunger

"O" Rings

Discharge

Valve Body

2" Sani

Clamps

Piston Head

Flapper Valve

"O" Ring

Flapper

Shaft

Spring

Rotary Actuator

Rotary Actuator) with hot soapy water or run them through the dish washer.

2. Clean the interior of the 2" inch pipes and the

3" dia. food product hose using the brushes provided.

3. Inspect "O" rings and gaskets for cuts,

distortion, or wear, replace if required.

4. Leave part disassembled overnight.

ASSEMBLY

NOTE: To eliminate any chance of recontamination

of unit, wear sanitary disposable gloves during reassembly after cleaning.

This startup procedure assumes the unit is fully disassembled.

Attach Product Cylinder to Piston Cylinder as follows:

Product Piston/Cylinder Assembly

⇒ Inspect Product Piston "O" Ring (replace if worn) on Product Piston - lubricate with food grade grease.

⇒ Push Product Cylinder over Product Piston and seat firmly in groove (push pin must be located as illustrated).

Assemble Piston Head Assembly as follows in order:

Piston Head Assembly

⇒ Inspect Flapper Valve "O" ring on rotary actuator (replace if worn).

⇒ Lubricate "O" ring with food grade grease and put on shaft.

⇒ Put Spring on Shaft. ⇒ Slide Rotary Actuator Shaft thru hole in

Piston Head. ⇒ Mount Flapper to Shaft.

Assemble piston and piping as follows in order:

Note: Use 2" gaskets in all hex nut couplings.

2" Piping Assembly

⇒ Put Cylinder Seal in place. Lubricate exposed portion of Cylinder Seal then mount Piston Head to Product Cylinder, and fasten in place with large Lug Nuts using lug wrench for final tightening.

Piston Head

Flapper Valve

"O" Ring

Shaft

Spring

Rotary Actuator

Flapper

Push

Piston Cylinder

Product Piston

Product Piston "O" Ring

Product Cylinder

Gasket

2" dia. Elbow

Short 2" dia. Pipe

Long 2" dia. Pipe

Gasket

Product Cylinder

Cylinder

Seal

Lug Nut

Piston Head

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