Stone Container 987 Auger Packer Manual SAFETY INSTALLATION OPERATION MAINTENANCE, Ltd. (512) 352-3694 Phone (512) 352-3648 Fax 1
Table of Contents Topic Reconditioned Machine Information Page Insert Chapter I: Safety in Operation.. 3 Chapter II: Before Operating Equipment 4 Chapter III: Caution During Operation... 4 Chapter IV: Installation 6 Chapter V: Lubrication Instructions... 7 Chapter VI: Trouble Check List for Auger Packers.. 9 Chapter VII: Principal of Operation 10 Chapter VIII: Sequence of Operation.. 10 A. Phase One 10 B. Phase Two 11 Chapter IX: Start Up Instructions and Adjustments.. 12 Chapter X: General Maintenance. 12 Chapter XI: Parts Pages. 14 Chapter XII: Electrical Schematics 22 2
I. Safety in Operation This manual has been prepared to assist you with your, Ltd. bag packaging equipment. The text contains instructions for installation and operation of your packing equipment, as well as directions for adjustment and maintenance. Following the text is the reference section which contains drawings; bills of materials, recommended spare parts, manufacturers' bulletins and any other information necessary to the successful operation of your equipment. If further information or assistance is needed, please contact us at: Choice Bagging Equipment, Ltd., 2561 US Hwy 95, Taylor, TX. 76574, Phone: (512) 352-3694, or Fax: (512) 352-3648, or email: kem@valvebagfiller.com. IMPORTANT NOTICE READ THIS MANUAL COMPLETELY before installing, starting-up, or operating this equipment. Be certain all personnel concerned with this machinery are fully alerted to the possible HAZARDS of the equipment and its utilities (electrical and pneumatic) before any operation is allowed., 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 are necessary on the part of all personnel. 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. 3
II. Before Operating Equipment Any personnel working directly with or on this equipment should read this material before proceeding with equipment use. Electricians should familiarize themselves with the electrical drawings before initial start-up of equipment. Other appropriate operating and maintenance personnel should familiarize themselves with mechanical layout and general arrangement drawings before start-up of equipment. These tips are important for safe operation: 1. As you uncrate the shipped machine, check carefully for any damage, loose connections, wires that are loose, etc. Be careful to note any discrepancies you find and BEFORE you start the machine call Choice Bagging Equipment to make sure the situation you see is or is not critical in nature. If severe damage has occurred, verify the damage with written reports AND pictures, call and call the trucking company or transportation provide. 2. Determine location of all emergency switches. 3. Be sure all guards are in place and observe all warning signs. 4. Check oil levels in all motors. 5. Be sure all electrical equipment is free of any accumulation of water. 6. Be sure all personnel are clear of operating mechanisms before connection air. 7. Never start equipment without first checking for loose objects, trash, dropped nuts and bolts, or other foreign items. All persons in the immediate area of the equipment should be alert to danger prior to starting III. Caution During Operation 1. Observe extreme caution when switches are turned on. Operation may in automatically after a time delay. 2. DO NOT open junction boxes or control panels unless you are a qualified technician. Be sure POWER IF OFF. Except when electricians are performing maintenance, electrical enclosures and junction boxes should REMAIN SECURELY CLOSED. 4
3. 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. 4. READ COMPLETELY any additional manual included in this manual that pertains to your specific controller. 5. DO NOT attempt to defeat any safety switches. Serious injury could result. 6. 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. 7. 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. 8. 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. 9. 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. 10. Keep fingers, hands, feet, clothing, etc., out of the path of pneumatically operated components. 11. Safety glasses should be worn in equipment area. 12. Follow the safety regulations for your plant. ALWAYS USE GOOD JUDGEMENT. NOTE: Before you begin production AND as you continue working daily with the machine, these points are recommended to observe for continuous service. Service parts such as belts, stuffing box material, bearings, gears, fill spouts, etc. are available for replacement and stock supplies through. 5
NOTE: After uncrating the packer, a check should be made to see that all items ordered have been received and that all equipment are in good order. Any damages incurred in the shipment process should be reported immediately to the shipper and the carrier. The majority of packers are shipped intact with the exceptions of large attachments. Packers should all have the scales and beams and movable parts secured to prevent damage. IV. Installation 1. Securing the Packer Secure the packer firmly in place with 1/2' bolts through the mounting holes in the packer base. Refer to the basic dimensional outline drawing in the manual. The foundation should be solid and free from vibrations which would be transmitted to the scale mechanism of the packer. 2. Leveling the Packer Place the packer in its operating location and bring it level by plumbing the front legs. Any deviation from plumb between the two legs should be compromised half way. This will result in plumb center lines. This step is important for the machine must be level for the scale to function properly. 3. Connection to Supply Hopper Connection to the supply hopper should be made with a flexible material in order to minimize transmission of vibration to the packer. Neoprene, rubber, or a 12- ounce canvas duck sock make a good connection material. 4. Connection to Power Source Punch a conduit hole in the electrical cabinet at a point convenient to connect the plant electrical power. Connect he power source of the proper voltage to the disconnect terminals in the packer. CAUTION: All Stoker packers are pre-wired to the customer's voltage specifications prior to leaving the factory. However, on all packers a check should be made to insure that the power source voltage corresponds to the wiring in the machine. All Stoker auger packers (except the Model VP Volumetric) are equipped with a transformer to provide 110 volt power to the control circuit. A visual inspection of 6
the transformer hookup will insure that the packer is wired to correspond to the power source voltage. On Volumetric Packers, the voltage of the coil in the starter will identify the voltage at which the machine is wired. 5. Bag Rest and Settler Height Adjustment Because of the wide variety and types of valve bags available, the bag rest adjustment should best be done by trial and error. The best indication for correct adjustment can be made after the bag has been filled. Prior to removing the filled bag from the filling spout, check to insure that the weight of the bag is resting on the bag saddle and not hanging from the packer spout. The top of the bag should also be well filled out and not taper down directly from the spout. The paper at the top of the bag should not be under tension. Incorrect bag saddle adjustment is a common cause for off-weights and problems with consistent measurements. Care should be taken that the bag saddle 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 bags. If the saddle is not high enough, the bag capacity may be greatly reduced. V. Lubrication Instructions All bearings are lubricated prior to leaving the factory. Listed below are the lubrication locations and a chart for finding all major types of lubricants needed. It is preferable that the bearings be greased while the packer is running to prevent breaking the seals. If the packer is stopped, while greasing, care should be taken to pump the grease in very slowly. Avoid over greasing in all cases. 7
1. Agitator ball bearings: *Grease approximately once a month while machine is running 2. Dashpot: *Check periodically 3. Auger ball bearings: *Grease while machine is running 4. Wool packing *Check periodically 8
5. Lubricator *Check monthly WARNING: Do not use motor oils that have a detergent additive in the lubrication process. VI. Trouble Check List for Auger Packers If the auger packer is giving weight variation or filling speed is reduced, check through the following list. If the packer is vibrating excessively, determine the source of the vibration by checking the causes listed below: 1. Check the "V" belt sheaves for looseness 2. Check "V" belt adjustment to be sure both belts are adjusted for the correct tension. 3. Check to be sure that the auger is straight and running concentric in the spout. A bent auger can be detected by doing the following: a. Empty the material from the packer b. Start the packer and observe the end of the auger for vibration 4. Incorrect bag size is a common cause of off weights. If the bag is too small it will cause back pressure. This back pressure will delay the cut off and cause over weights. Try a few bags at 75% of the normal weight packed into the bag. Good weights at this reduced quantity filled indicate the bag is too small. 5 The rubber dust seal which covers cone-spout gap must be flexible. 6. If the bag rest is not properly positioned it can cause erratic bag filling and off weights. 9
7. Check the weighing mechanism to be sure that it is moving freely. Object resting against or touching the weighing mechanism during the filling cycle will cause variation in weights. 8. If the packer is equipped with a dust hood remove the vacuum hose that connect it to the dust collection equipment. Run a few bags of material and check weights. If the bags now hold a uniform weight the flexible connection between the dust hood and the dust collection needs to be made more flexible. VII. Principal of Operation An auger feed assembly is the main feature of the Stone Container 987 Auger Packer. The auger housing receives bulk product from the surge bin and supplies a steady stream into the bag utilizing a 2" - 3" OD material delivery screw to convey product from the housing into the bag. In order to provide a solid cutoff, the auger briefly reverses to stop material flow from the auger housing. High-pressure air (80 PSI) operates two separate control sequences: Start and Stop. On actuation of Start signal by the operator, a auger transfers material from the hopper and feeds to the bag. The auger reverses when the material in the bag reaches a predetermined 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 at flexure assembly. 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 Stone Container 987 Packer. VIII. Sequence of Operation A typical "two-phase" operational sequence is used for filling a bag. The sequence below describes the optional timed powered discharge and bag sealer. A. Phase One: Phase One is the condition in effect at the end of the filling cycle. After actuation of the Stop (or Scale) signal the following sequences occur: 10
The auger spins forward and conveys product from the Agitator or V-Hopper, through the auger housing and through the fill tube into the bag. The motor drive assembly cuts off, then briefly reverses and the auger material feed assembly stops the flow of material from the auger housing into the bag. The bag clamp is released and the bag is removed from the machine. Since the material flows by gravity into the machine, it is continuously recharged. With the optional features shown on the schematic, the valve sealer deflates. This can be timed to ensure material stabilization into 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 one with specially designed pneumatic controls. 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: 1. The air operated bag clamp secures the bag to the filling tube. 2. The bag chair retracts to a level position. 3. The bag sealer inflates inside the valve of the bag. 4. The drive assembly is activated by the motor controls which spin the auger assembly and directs product flow from the housing, through the fill spout and into the bag. 5. The material is packed into the bag until the desired net weight is reached. 6. When the bag comes to weight, the scale beam trips the Stop circuit and the condition in Phase One is in effect. 7. 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 level. 11
IX. Start up Instructions and Adjustments The Stone Container 987 is an automatic packer. The operator is required to put an empty bag on the filling spout and press the Start pushbutton (Green) button after the empty bag is in place. The bag is then filled and weighed automatically and, when equipped with the powered bag chair option, the bag is discharged automatically. If for any reason it is desired to interrupt the filling operation in the middle of a cycle, a Stop pushbutton (Red) is provided. It is recommended that the following adjustments be made to the packer before any material is delivered to the receiving hopper. Make sure all personnel are clear from the machine and at a safe distance. 1. Open manual valve for incoming high-pressure air. 2. Adjust the pressure regulator to 80 PSI with the power OFF. 3. Place an empty bag on the filling tube. Press Start Pushbutton. Note: Components should now be in Phase Two Operation. 4. Adjust the bag seal pressure to 3 PSI (optional equipment). The bag seal should expand just enough to secure the valve of the bag. Note: Excessive pressure may cause damage to the bag seal and tear the bag. Further adjustment may be required during actual packing operation. 5. Press the Stop pushbutton. Note: Components should now be in Phase One Operation. X. General Maintenance Stone Container Packers are designed so they can be operated and maintained by the user. It is time well spent for the operator and maintenance staff to study and thoroughly understand the function and working relationship of each part before any adjustment or maintenance is undertaken. 12
It is also highly recommended to institute a preventative maintenance program. We suggest that the following procedures be done at regular intervals: * Before operation make sure there is oil in the agitator and gear reducer if applicable and all bearings are greased. Grease bearings once a week. * Clean off the equipment * Check all operating parts for freedom and ease of operation * Check beam motion and front plate freedom. These parts must be free and unrestricted for accurate weighing. * Check the auger screw alignment. It must be centered in the spout. Warping or bending, movement, or noise are indications of problems. * Check the "V" belts for tension and wear * Check the Model "B" settler, if supplied, to see that it is not transmitting vibration to the packer. * Check the scale beam cutoff point. * Check fill spouts for nicks and chips from daily usage. * Check the isolator rubber tubing for wear. * Stuffing boxes should be maintained. Make sure stuffing material is replaced and re-packed tightly every couple of months depending on the dust quality of the product. 13
Parts Pages 14
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Electrical Schematics 22
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