Erika HGS 1-3 600 Installation Manual
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 1 of 42
content
1.
Introduction and general
3 - 4
1.1.
Introduction
3
1.2.
Identification plate
4
2.
Basic safety instructions
5 - 8
2.1.
Obligation and liability
5
2.2.
Specific safety instructions of the manufacturer
6
2.3.
Protective equipment
6
2.4.
Safety instruction for the blades
7
2.5.
Installation and use according to purpose
7
2.6.
Danger from electric energy
8
2.7.
Instructions of the manufacturer concerning residual danger
8
2.8.
Constructional changes on the machine
8
3.
Description of the machine
9 - 10
3.1
Technical details
9
3.2.
Purpose
9
3.3
Description of the machine
9
3.4
Functional description
10
4. Machine parts and control elements
10 - 11
5.
Electrical connection
12
6.
Handling of the machine
12 - 13
6.1
Commissioning
12
6.2
Cleaning the machine
13
7.
Service and maintenance
14 - 26
7.1
Maintenance of the double-blade cutting system
14
7.2
Blade exchange
14
7.3
Adjustment of the blade tension
17
7.4
Adjustment of the tension rollers
20
7.5
Exchange the upper belt
22
7.6
Exchange the feed belt / lower belt
23
7.7
Maintenance the machine
25
8.
EC conformity declaration
26
9.
Exploded view drawings
28 - 40
page
10. Circuit diagram 41
11. Service stations 42
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 2 of 42
1. Introduction and general
1.1. Introduction
We thank for the confidence you had shown, and we are pleased to be able to regard you as
one of our esteemed clientele. We are quite confident, that the machine you purchased, works
to your full satisfaction.
These operating instructions are subject to the copyright which is held by the
KRUMBEIN.rationell company. Their reproduction, even if only of an extract, as well as adding
or removing pages, is not allowed.
These operating instructions have to be kept immediately and accessibly at the machine.
These operating instructions shall make possible to you to get to know the machine considering
all safety instructions and its functions, thus to achieve optimal exploitation.
The operating instructions will give you pieces of advice how to operate the machine safely,
properly and economically.
In order to minimize danger, down time and repair costs as well as to increase reliability and
lifetime of the machine, the pieces of advice from these operating instructions have to be
absolutely observed.
These operating instructions are to be completed
due to existing national rules
by orders about accident prevention and
environmental protection.
The operating instructions have to be permanently available at the place of operation.
The operating instructions have to be read by any person that is charged with work with or on
the machine.
The operating instructions contain safety instructions in form of pictograms, which point to
danger.
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 3 of 42
Meaning of the pictograms
Danger – warning about general danger
Danger – warning about voltage
Danger – warning about danger of injury
STOP – warning about property damage
1.2. Identification plate
There is an identification plate mounted on the machine from which one can gather the most
important details of the machine.
These operating instructions are only valid for machines of the following machine type.
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 4 of 42
2. Basic safety instructions
2.1. Obligation and liability
* Knowing the basic safety instructions and safety rules is the essential prerequisite of
trouble-free operation that fulfils the safety conditions.
* This documentation, in particular the safety instructions, must be heed by all persons, who
are working at the machine.
* Over and above that, the regulations and rules of accident prevention have to be observed
on the place of operation.
* The operator obliges himself, to assign only such personnel to work with the machine:
who have read the safety instructions and the warning notices, understood them and
confirmed these by signing it.
* The machine has been constructed according to the state-of-art and the recognized safety
regulations. Nevertheless by the use of the machine may occur danger to body and life of
the user or third persons respectively impairments of the machine and other material or
assets. The machine can be used only
=> in accordance with its purpose
=> in safety-perfect conditions
* Defects, which can impair safety, have to be remedied immediately.
* In principle our “general terms of sale and delivery” are effective.
Warranty and liability claims in case of personal injury and property damage are excluded,
if they are caused as follows by:
=> using the machine in a way in which it is not intended to be used
=> improper mounting, activation, operation and maintenance of the machine
=> operating the machine in case of defective safety devices or safety equipment and
protective devices that are unable to function
=> constructional changes of machine taken on one’s own authority
=> changes (e.g. driving, performance and number of revolutions ….)
=> insufficient monitoring of the machine parts that are subject to wear
=> repair carried out improperly
=> cases of disaster caused by foreign matters or elements and force majeure
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 5 of 42
2.2. Specific safety instructions of the manufacturer
* These safety instructions do not claim to be exhaustive.
In case of questions please contact KRUMBEIN.rationell company, Tabarz.
* Repair, installation, maintenance and cleaning work as well as transportation of the machine
is only allowed to be done, when drives are switched off and tools are motionless.
* Attention has to be paid that no persons are present of the area of the machine who do not
know or are not able to assess the dangers of the machine (e.g. children).
* Never let the machine running without supervision.
After having finished work and before leaving workplace the motor of the machine has
2.3. Protective equipment
* Before putting the machine into operation, all protective equipment must be proper and able
to function
* Protective devices are allowed to be removed
- after rest and
- after securing against restart of the machine (e.g. switching off power supply)
* The machine has to be checked at least once per day with regard to externally visible
damages and working order of the safety equipment.
* The protective equipment which can be opened (cover hoods), are equipped with
safety switches. Opening these protective covers while the machine is running, will
lead to an immediate stop of the machine.
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 6 of 42
2.4. Installation and use according to purpose
* Installation of the machine only in dry rooms.
* It is only allowed to use the machine to cut freshly and unfrozen products.
* Inappropriate use may lead to destruction of the machine and excludes any warranty claims.
* Use according to the purpose includes also observation of the operating instructions and
keeping of inspection and maintenance conditions.
2.5. Danger from electric energy
* Work on the electric supply is only allowed to be done by a qualified electrician.
* The electric equipment of the machine has to be checked regularly. Loose connections and
damaged cables have to be fixed immediately.
* The switch cabinet as well as the terminal boxes must be always closed.
Only authorized persons with key an approved tools should have access to the switch
cabinet and terminal boxes.
* a second person is needed in case of work on live parts. if necesary this person can actuate
the emergency switch
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 7 of 42
2.6. Instructions of the manufacturer concerning residual danger
The delivered machine meets a high safety standard, however, the following residual risk
factors remain:
* Damage of live circuits by external impacts
* Failure of protective equipment
* Using the machine in a way in which it is not intended to be used
* Setting up of machine without protective gloves
* Errors in operation occurring due to unqualified and untrained personnel
* Use of spare parts which not be admitted by the manufacturer
2.7. Constructional changes of the machine
Do not make changes, extensions or reconstruction of the machine without the manufacturer’s
permission. All reconstruction measures need a written permit from
KRUMBEIN.rationell
company.
Exchange immediately machine parts that are not in a proper condition! Use only original spare
and wear parts ! In case of outsourced parts it is not ensured that these are designed and
manufactured fulfilling the conditions of stress and safety.
2.8. Safety instruction for the blades
* Use only original KRUMBEIN HGS-blades in this machine.
* Don´t use blades with any damages.
All scales are labeled in metric system
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 8 of 42
3. Description of the machine
3.1 Technical details
Dimension in working position:
Length: 2000 mm With: 740 mm Height: 1320 mm
Dimension in park position:
Length: 1360 mm With: 740 mm Height: 1630 mm
Weight: app. 170 kg
max. cutting with: 600 mm
max. product height: 100 mm
min. cutting height: 5.0 mm (product-dependent)
Electr. connection: 230/400 V; 50 HZ; 3 Ph
Power consumption: 0,6 kW
3.2. Purpose
The machine is used for horizontal slicing of fresh and unfrozen baking goods in two or more
layers. Per pass, the product is separated into four layers.
3.3 Description of machine
•
1 Base frame, wheeled
•
2 Lower belt / feed belt
•
3 front-side protective cover
•
4 Cleansing sponge
•
5 Height adjustment upper belt
•
6 Display height adjustment
•
7 Height adjustment blades
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 9 of 42
•
1 upper belt / pressure belt
•
2 lower belt / feed belt
3.4. Functional description
The feed of the baking products is made by a special conveyor belt - below - and a
synchronized rotating contact pressure band - above -. The horizontal cut is carried out by a
special double-blade knife.
The upper belt and the blades can be adjusted by cranking to the desired heights.
The tape feed rate is adjustable designed, to adapt the machine for several product
characteristics.
The feed band is swivel-mounted at the inlet side. The feed band can lift, when the machine is
not in use to save space
4. Machine parts and control elements
Element Description
Electric control elements
•
1 Kill switch
•
2 Reset emergency shutdown
•
3 Start/Stop – switch
•
4 Potentiometer
•
5 Main switch
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 10 of 42
Machine in park position
•
Locking bolt at the feed band (detail)
Height adjustment upper band
•
1 crank for height adjustment
•
2 display of the height adjustment
Display height adjustment
•
1 Height of the upper belt
•
2 Height of the double-blade
Height adjustment double-blade
•
1 crank for the height adjustment
(in park position)
•
2 intake of the height adjustment
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 11 of 42
5. Electrical connection
The connection is restricted to a power grid, that corresponds with the (in the technical data
section 3) specified values for voltage and frequency.
The connection takes place via a 3-Ph-protective contact plug to the mains.
The grounding of the connection must be installed according to EC 536 - Class 1, NEC and
other current standards. An upstream RCDs must be designed for a fault current > 350 mA.
6. Handling of the machine
6.1. Commissioning
•
place the machine on the intended position, apply the roller-brakes, fold down the feed
band (thereto unlock the locking bolt)
•
Take care that no foreign element is in the machine before the machine is switched on
•
Verify the correct fit of all protective devices
•
It is also necessary to consider that no persons may be endangered or injured by the
start of the machine.
•
The blade system must be cleaned and must not be defect.
- Knives must be tensioned -
•
Connect to electrical power
•
Then, the machine can be started as follows:
- unlock Emergency-off switch (if necessary)
- activate main switch
- press Reset emergency shutdown
- Set cutting height and upper band height
•
apply the products to the feed belt
•
after the end of production, switch off the machine on the main switch and relax the
blades
•
The unlock of the knife is used to prevent the material fatigue of the clamping element
and to avoid the conglutination of the knife through product residues (see the following
point Cleaning)
Permanent tension of the blades leads to material fatigue of the plate springs
in the compensation unit and therefore to a shorter lifetime.
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 12 of 42
6.2. Cleaning the machine
The machine is switched off and protect against restart before cleaning .The exterior cleaning is
permitted only with a damp cloth. The use of chemical cleaners are permitted conditionally.
The cleaning with a water jet or pressure washer leads to disturbances in the mechanic, the
electric and the control device and is therefore prohibited. The cleaning of the tapes (feeding
belt / upper belt) takes place with the customary and approved cleaners for the material of PE.
The double-knife have to be cleaned in specific manner for hygienic reasons.
An optimal cleaning of exterior surfaces can be reached by cleaning sponge,
if the sponge is soaked with water, that is mixed with some citric acid.
The sponge runs several times through the machine with a fixed blade height of 20 mm / upper
band height of 40mm .
Product residues on the inner sides (tread section) are necessarily to remove, otherwise
the blades stick together and this can lead to cracks.
Thereto: remove the double blades (use the instructions in section 7.2 Blade exchange). To
avoid conglutination of the blades, it is recommended to apply a thin layer of food-save oil on all
sides of the blades.
Product residues must be removed from the crumb tray daily. Furthermore the cleaning brush
should periodically clean under running water or be washed in the dishwasher (cleaning brush
is located behind the crumb tray).
The feed belt have to be removed after an operating time of 40 hours, in order to clean the belt
and the rollers (use the instructions in section 7.6 feed belt change). Remove residues on
rollers and on feed table with a damp cloth. The drive and support rollers have to be cleaned
regularly.
7. Service and maintenance
7.1. Maintenance of the double-blade cutting system
To achieve an optimum of cutting results always, it is necessary, to moisten all sides of the
blades with a suitable and approved food-saved oil before starting the machine.
After a service life, of about 50 hours, the tension rollers of the double-blade system are to regreased with an approved grease.
The blade tension may decrease over time and should accordingly
be reviewed and possibly improved. (Section 7.3 Adjustment of the blade tension)
© KRUMBEIN.rationell HGS 1/3 600 V 02/2010 page 13 of 42
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