Choice Bagging Equipment, Ltd. 2561 Hwy 95, P.O. Box 81 Taylor, Texas 76574 P# (512)352-3694 F# 3648 www.valvebagfiller.com MHE Model 2010 Air Packer Manual SAFETY INSTALLATION OPERATION MAINTENANCE Choice Bagging Equipment, Ltd. (512) 352-3694 Phone (512) 352-3694 Fax 1
RECONDITIONED MACHINE INFORMATION In purchasing a reconditioned machine, please be aware that the literature that accompanies the machine for the manual may not match exactly what items have been put on your machine. We make every effort to provide literature that will be useful in the general operation and maintenance of the bagger by giving a broad scope of knowledge. The machine literature, or a close substitution, for the general type of machine, serves to give a basic understanding of the working processes and replaceable parts on the packer or a machine similar in model and function to the one you have purchased. The manual includes parts pages and itemized lists that correspond with the parts we at Choice Bagging Equipment have used to refurbish or upgrade the packer. These parts are available for replacement and/or spares. Electrical schematics provided give the best possible technical information for the operational components, pneumatic and electric, that will lead to smooth operation and maintenance. Please take a few minutes when you receive your manual to look at your machine and make notes as to what is and what is not included on your machine. If you have questions, please do not hesitate to call us and we will go through our records and make sure you have adequate information with regards to the features and options on your particular machine. Thank you for selecting Choice Bagging Equipment to provide for your bagging needs. We appreciate your business and value you as a customer. Call us anytime with questions or concerns at 512-352.3694. 2
Forward This manual has been prepared to assist you with the initial set up and daily operation of your new equipment. The text contains instructions for installation and operation as well as directions for adjustment and maintenance. Important Notice READ THIS MANUAL COMPLETEY before installing, starting up or operating your equipment. Be certain all personnel concerned with the routine operation of this equipment are fully alerted to the possible HAZARDS of the equipment and its utilities (electrical and pneumatic) before any operation is allowed. Choice Bagging Equipment, Ltd. cannot emphasize enough the importance of good safety practices in the use of this equipment. Sound engineering and design practices have been applied to minimize the possibility of accidents, however while using equipment of this type, good judgment and extreme caution is necessary on the part of all personnel. 3
Table of Contents Topic Page Chapter 1 Warning & Precautions-------------------------------------------- 4 1. Before Operating Equipment----------------------------------------- 4 2. When Operating Equipment------------------------------------------ 4 3. Terminology-------------------------------------------------------------- 5 Chapter 2 Installation------------------------------------------------------------- 6 1. Assembly Procedures--------------------------------------------------- 6 2. Solenoids and Pneumatics--------------------------------------------- 7 3. Fluidizing System ------------------------------------------------------- 7 4. Packer Table of Components----------------------------------------- 8 5. Principle of Operation-------------------------------------------------- 9 6. Sequence of Operation------------------------------------------------- 9 7. Bag Chair Positioning-------------------------------------------------- 10 8. Adjusting Fluidization------------------------------------------------- 11 9. Trouble Shooting Guide ---------------------------------------------- 11 10. Trouble Shooting Solutions------------------------------------------ 12 11. Trouble Shooting Chart ---------------------------------------------- 13 12. Important Points for Operating/Maintaining Packer---------- 14 4
Chapter 1 - WARNINGS AND PRECAUTIONS The purpose of this section is to alert operating and maintenance personnel to the possible dangers of this type of equipment. Serious injury and/or equipment damage could result from not heeding these safety precautions. 1. Before Operating Equipment A. Any personnel working directly with or on this equipment should read this manual before proceeding with equipment use. B. Electricians should familiarize themselves with the electrical drawings before initial start-up of equipment C. Other appropriate operating and maintenance personnel should familiarize themselves with mechanical layout and general arrangement drawings before startup of equipment. D. Determine location of all emergency switches. E. Be sure all guards are in place and observe all warning signs. F. Check oil level in all motors. G. Be sure electrical equipment is free of any accumulation of water. H. Be sure all personnel are clear of operating mechanisms before connecting air. I. Never start equipment without first checking for loose objects, tools and trash. All persons in the immediate area of the equipment should be alerted prior to starting. 2. When Operating Equipment A. Observe extreme caution when switches are turned on. Operation may begin automatically after a time delay. B. Do not open junction boxes or control panels unless you are a qualified electrician. Be sure power is off. Except when electricians are performing maintenance, electrical enclosures and junction boxes should always be securely closed. C. Stop machine and disconnect power supply before servicing or repairing. Maintenance and adjustments must be performed with all power supply disconnected unless otherwise specified in this manual. D. Do not attempt to defeat any safety switches. Serious injury could result. 5
E. While machine control power is on, do not activate limit switches manually. Serious injury and/or machine damage could result. Disable machine before attempting any maintenance or manual testing of components. F. Gear motors will get warm to the touch and should not cause concern for equipment reliability and operation. A temperature rise is normal per new NEMA specifications. G. If additional wire runs are added to any junction box or control panel, wiring practice should be such as to maintain prevailing electrical hazard classification. H. High-pressure air systems are dangerous. Do not service or troubleshoot systems with air supply on. Be sure to bleed off any trapped air before working on components since it is possible to have high pressures trapped in airlines and cylinders, etc. I. Keep fingers, hands, feet, etc., out of path of pneumatically operated components. J. Safety glasses should be worn in equipment area. K. Follow the safety regulations for your plant. Always use good judgment. 3. Terminology Within the text of this manual: "WARNING" indicates possible injury to personnel; "CAUTION" indicates possible damage to equipment; "NOTE" is an informational comment. 6
Chapter 2 Installation The MHE Model 2010 Air Packer consists of the packer assembly and various items as ordered. After uncrating the packer, a check should be made to see that all items ordered have been received and that all equipment is in good condition. Any damage incurred in shipment should be reported immediately to the delivering carrier and a claim for the damage should be filed. Also notify Choice Bagging Equipment, Ltd. so that the replacement or repair may be initiated. The Model 2010 Air Packer is shipped with locking bolts installed to secure and protect the bag post and weighing assembly during shipment. Be sure to unpack and inspect them for damage or missing items immediately. 1. Assembly Procedures A. Mark the centerlines of the packer, reference the General Arrangement drawing. B. Set the packer into place. It may e desirable to defer final anchoring to the floor until after testing. Place the packer in the proper location, insuring the frame is level. Check the clearance and fit to the feed hopper and associated piping prior to securing it firmly to the floor. C. Install pipe from the blower outlets to the air inlet valve of the chambers. D. Connect outlet of air valve to dust collection. E. Install rubber connection sleeve between bin and hopper to isolate bin, vibrations from packers. (Sleeve not provided with machine. Recommend 0.25 0.375 wall thickness. Sleeve can be purchased from CBE separately. F. If a multiple tube arrangement is to be made, remove filter regulator assemblies on all but the left-hand tube and set tubes on 36 centers. 9. G. The weighing assembly has been secured by a jamming bolt that protected the scale from damage during shipment. Be sure to remove the jamming bolt, which is located underneath the top flexure plate before you attempt to operate the machine. Some models may contain 2 locking bolts. H. If the equipment uses an analog weighing unit, make certain that the load cell and parts suspended on it are free from side friction. 7
I. Adjust the fill tube on the bag post into alignment with the isolator tube and the chamber or housing. This is accomplished by loosening the fastening bolts that hold the bag post in position and adjusting the bag post either up or down into position. 2. Solenoids and Pneumatics All pneumatic components (air valves & cylinders) are self lubricating and additional lubricated air is not required. If lubricated air is used then lubricated air must be used for the life of all the cylinders. A. Connect high-pressure air line of the packer to suitable source of supply (1/2) pipe connection. B. It is recommended that suitable water (not supplied with machine) be installed prior to the regulator in the high-pressure air line and the packer. Drain the trap as required. C. Connect air hoses to cylinder of bag chair for automatic bag discharge (optional equipment). D. Connect all air hoses which were discconnected for shipment. All hoses and related fittings are correspondingly color coded for ease of reassembly. 3. Fluidizing System It is important that the blower be installed in a relatively dust free area. The intake should be extended to an area free of contamination outside the building. Be sure that the blower is running in the right direction. Check the arrow on the motor housing near the drive shaft. If you are using a regenerative blower system, all air lines are pre-fitted and already connected. If you are using a positive displacement blower package, connect the low-pressure air inlet on the packer to the positive displacement blower (2-1/2 pipe connection). The gauge assembly is for use when the adjustment of the blower relief valve is made. 8
4. Packer Table of Components MHE's Model 2010 is an air-operated pneumatic packer as described below: 1. Feedgate (Illustration CBE-703-C) Controls the flow of product into the pressure chamber. In this instance, a feedgate consists of a butterfly valve actuated by a pneumatic cylinder. The feedgate opens and closes at the beginning and the end of each cycle. 2. 3-Way Valve A three way cylinder actuated valve, which allows low-pressure air into top of chamber during the fill cycle. It is also used to exhaust the chamber when de-energized to allow for recharging the system with material between bag filling cycles. 3. Digital Filler Controller (104-002) The digital filler controller controls all aspects of the bag filling cycle. It is directly responsible for controlling the solenoid valves and cylinder operated functions of the machine. 4. Analog Controller The analog filler controller controls all aspects of the filling cycle. It is directly responsible for controlling the solenoids and cylinders. 5. Solenoid/ Pneumatic Assembly (105-000) The solenoids or pneumatic valve control the air operated functions of the machine. A configuration of three to six solenoids is located in the typical solenoid control panel. 6. Bag Chair (Illustration CBE-106) 7. Cutoff Assembly (Illustration CBE-103A,B,C) 8. Filling Spout and Flow Tube Assembly (CA-1008) A pneumatically operated bag chair supports the bag while being filled, then pivots, by an air cylinder to discharge the filled bag. It should be adjusted to support the bag while filling to allow for the material to enter the bag unrestricted. Standard bulk only (CBE-103-A) cutoff allows product to flow through the filling tube and out the spout unrestricted into the bag until final weight is reached. Optionally, the bulk & dribble cutoff (CBE-103-A, B) uses a double acting cylinder working to open the flow tube. This unit consists of a gum rubber tube which connects the pressure chamber with the filling spout via an intermediate connector. It is mounted within the cut-off assembly and is pinched when the packer reaches weight or any time the cycle is stopped. 9. Dust Collection Standard ductwork is supplied and located behind the front post and under the filling spout area. See the General Arrangement drawing for location and type of connection. It is used to direct dust into the customer's collection system. 10. Bag Clamp Assembly (101-000) 11. Low Pressure Blower 12. Disseminator (Illustration 703-B) 13. Lower Fluidizing Chamber (703-A) A pneumatically operated cylinder which clamps the bag onto the spout during the fill cycle. CAUTION: Keep fingers clear of clamp when placing bag on spout. A positive displacement, high volume, low-pressure blower incorporating a weighted type relief valve. Pressure is regulated by placing weights on the valve to increase pressure and removing weights to decrease the pressure. The maximum volume is 187 SCFM at 6 PSI. This unit is located inside of the upper pressure chamber and is connected to the intake gate. It serves to disseminate or disperse the incoming 'top' air to aid in fluidization of the material and to pressurize the chamber. The filter medium of disseminator prevents the product from traveling back into the blower. This is a canvas pad located at the bottom of the pressure chamber for dispersal of incoming bottom air, which fluidizes the material in the chamber. 9
5. Principle of Operation A conditioning or pressure chamber is the main feature in the all pneumatic system of the Model 2010 Flow Packer. This chamber receives and fluidizes the product material, prior to delivery to the bag. An intake gate at the top of the chamber opens to receive the material from the supply bin and closes to allow the chamber to be pressurized by the low-pressure air circuit (Blower). High-pressure air (80 PSIG), operates the solenoids and cylinders. On actuation of Start signal by the operator, a cutoff device opens to allow the air-solids mixture to be fed to the bag. The cutoff closes automatically when the material in the bag reaches a pre-determined weight. Bags are weighed during the filling operation on a unit consisting of bag support frame and filling tube mounted on the front of a scale beam. Filled bags are discharged automatically when the machine is equipped with an automatic discharge bag chair arrangement. All of the operation activity for each bag filling cycle takes place in a matter of seconds. This packing speed is important--not only to achieve high production rates, but also for proper function of the Model 2010 Pressure Flow Packer. When fixed bed fluidization starts on closure of the feed gate, generally the rapid flow of the air-solids mixture through the filling tube to the bag takes place with little if any appreciable decay of the filling process. 6. Sequence of Operation A representative arrangement of the packer is shown below. It serves to amplify the following description of a typical; TWO PHASE operational sequence for filling a bag. It should be noted, however, that a variety of constructions are optional for the Model 2010 Air Packer. The sequences as drawn show the optional timed powered discharge, timed bag sealer, and separate exhaust arrangement. A. PHASE ONE Phase One is the condition in effect at the end of a filling cycle. After actuation of the Stop (or scale) signal the following sequences occur. The flexible pinch tube cutoff closes, stopping the flow of material to the bag. The air intake valve closes off the air supply from the low-pressure blower. Chamber pressure is relieved. Depending on the material, this exhaust is accomplished in one or a combination of three ways: Through a timed separate exhaust, through the main in-feed gate, or through the disseminator. The bag clamp releases, the bag is discharged and the feed gate opens to recharge the chamber with material, after a delay. With the optional features shown on the schematic, the exhaust is accomplished by the valve opening. The valve sealer deflates; this can be timed to ensure material 10
stabilization in the bag. The powered discharge bag chair tilts to discharge the filled bag at the end of the sealer deflation. The timing of these features is done with specially designed pneumatic controls. During this non-bag filling phase, 'fixed bed fluidization" occurs as air from the blower source flows through the fluidizing air pad up through the material at the bottom of the chamber. During Phase One, the operator also places an empty bag on the filling tube after discharge of the previous bag. B. PHASE TWO Phase Two is the condition in effect during the filling cycle. After actuation of the start signal the following conditions occur: The bag clamp secures the bag to the filling tube. The bag chair retracts to a level position. The bag sealer inflates inside the valve of the bag. The feed gate (butterfly) closes, sealing off the chamber, allowing proper chamber pressure to build and cutting off additional material supply. The air intake valve opens to allow air from the low pressure blower to pressurize the chamber and fill the void left in the chamber when the material is packed into the bag. The material is flows into the bag until the desired net weight is reached. When the bag comes to weight, the controller trips the "Stop" circuit and the condition in Phase One is in effect. If the packer is equipped with the optional automatic starting device, the start signal is obtained automatically when the bag is placed on the filling tube and contacts the starter lever. 7. Bag Chair Positioning The bag chair is raised and lowered manually to adjust to bag length. A series of holes in the bag post accepts a pin on the bottom of the chair assembly, resulting in a secure setting. Pasted bags: Sewn Bags: Place a bag on the filling tube and smooth the body of the bag down. Unfold the bottom of the bag to a horizontal position. Position the bag chair so that it touches the bag. Place a bag on the filling tube and smooth the body of the bag down. For first setting, position the bottom of the bag chair to 1 below the bottom of the bag. Because of the wide variety of valve bags available, trial and error experimentation may be required to obtain the optimum bag chair adjustment. Correct adjustment is best made with a filled bag. 11
Prior to removing the filled bag from the filling spout, verify that the weight of the bag is resting on the bag chair and not hanging from the packer spout. The paper or plastic at the top of the bag should not be under tension. Incorrect bag chair adjustment is a common cause of off weight and bag size problems. Care should be taken that the bag chair position is high enough to allow the bag to fill out properly at the end of the filling cycle, especially in the upper portion of the bag. If the chair is not high enough, the bag capacity may be greatly reduced. CAUTION: Improper use of the bag chair can cause damage to the weigh beams. Do not drop, stand or jump on the bag chair. 8. Adjusting Fluidization 1) Put the product into pressure chamber 2) Feed gate open (normal at rest position 3) Start low pressure blower 4) When filling begins, any pulsation noted, or felt, at the sides of the bag can be corrected by adjusting the regulating vale at the air intake valve. It may be necessary to raise or lower the pressure of the blower for faster filling. This is accomplished by adding or removing weight on the relief valve. It may be necessary to adjust the dribble opening to maintain bag weights also. 9. Trouble Shooting Guide Common trouble shooting techniques are used to isolate and then remedy the problems often found on the production line. Any problem with a filler can be narrowed down to a few simple sources: Mechanical Scale mechanism, pinch tubes, air cylinders feed gates weigh buckets, etc. Electrical Solenoid valves, limit switches, start/stop switches, bags in place, placer interference, load cells, controller malfunctions Pneumatic Solenoid valves, hoses, air cylinders, blowers, fittings, etc. When trouble shooting your equipment, remember that mechanical components are subject to wear and tear. This is opposed to electrical components which are not subject to these forces. You will most likely encounter a mechanical problem over an electrical one. 12
10. General Trouble Shooting Solutions A. STOP machine and DISCONNECT power supply before servicing or repairing. Maintenance and adjustments must be performed with all power supply disconnected unless otherwise specified in this manual. If your machine comes with a 5297, 4693 or GSE controller make sure the POWER IS OFF before working on the controllers or machines. B. HIGH-PRESSURE AIR SYSTEMS ARE DANGEROUS. Do not service systems with high-pressure air on but BLEED off any trapped air before beginning service or maintenance. C. A frequent source of off-weight trouble is under sized bags. The bags should never be filled to capacity or over filled since this causes the product in the spout to be compressed. The spout is part of the scale system and must be free to move up and down. If off-weights occur and it appears that the packer is functioning properly check the bag size. IF it is determined that the bag is too small, consult the bag supplied for help in s selecting a bag of the proper size. D. Check air compressor for proper operation. E. Check all connections, joints, fitting, hoses and tubes for air leaks. F. Remember pressure should be consistent when filling. Pressure should be consistent at cut-off. Additionally pressure should be consistent at re-fill. Always run several bags to make sure pressure and weights are within the accepted and expected ranges. 13
11. Trouble Shooting Chart PROBLEM PROBABLE CAUSE REMEDY Erratic Weights A. Pressure Chamber 1. Insure the chamber is completely refilled between cycles. Fill Time Excessive Chamber pressure does not drop to near zero during refill B. Material Flow While Packing 1. Lighter density material may overfill the bag. 2. Bulk and/or dribble cylinder sticking/binding or lack of lubrication 3. Obstruction between lower chamber and bag. 4. Either bulk/dribble valve sticking 5. Flow thru regulating valves were changed (air intake, fluidizing pads) C. Vibration or shock 1. Packer not secured to floor 2. Isolate packer from outside influences D, Venting of Air 1. If vented spout is used, be sure sleeve or valve is clear of opening 2. Vent in spout is plugged E. Mechanical Bind 1. Hoses touching, dragging bag chair A. Operator not putting bag far enough on spout 2. Material on floor touching bag post 3. Interference of post & shipping screws 1. See start-up procedures B. Excessive fluidization 1. Reduce air to pads C, Undersize bag for product 1. Resize bag A. Improper Exhaust 1. Check for sticky air cylinder or valve 2. Check length of time for exhaust 14
12. Important Point for Operating/Maintaining Packer MHE MODEL 2010 AIR PACKER On a regular basis check air pads for proper air flow, maintain clean pads. Check frequently to make sure disseminator is not clogged. Check for clogs or product sticking in chamber or spout Observe pressure gauges during operation Check pinch tubes, bag seals and cylinders Check fill spout for holes or leaks 15