ProSeal GTR User manual

Serial No

GTR-3455

Doc Ref: Page: 1

Date: 13/01/13 Issue: H

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Tray Sealing Solutions

Operation and Maintenance Manual

GTR Rotary Table Heat Sealing Machine

Serial No

GTR-3455

Doc Ref: Page: 2

Date: 13/01/13 Issue: H

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Tray Sealing Solutions

AMENDMENT RECORDS

Issue

Author

Date Description of Change Background

A 10/05/07 First Issue

B AM 06/05/10 Declaration of Incorporation standards updated

C AM 26/11/10 Cleaning statement added

D AM 27/07/12 Supply of machinery document statement updated to

2008

E AM 27/07/12 Auto top tool clamp description added

F 13/01/13 Inverter error appendix added

G AM 9 May 13 Systems appendices added

H AM 26 Mar 14

Service schedule and fault finding updated

REVISION RECORDS

Revision Author Date Description of Change Background

Serial No

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CONTENTS

1. INTRODUCTION...................................................................................................................5

1.1 Materials................................................................................................................................5

1.2 Components..........................................................................................................................6

1.3 Important ...............................................................................................................................7

1.4 Scope....................................................................................................................................7

1.5 General Description...............................................................................................................7

1.6 Machine Footprint and Specifications ....................................................................................8

1.7 Technical specification...........................................................................................................9

1.8 Principle of Operation ..........................................................................................................10

1.9 GTR Control Panel ..............................................................................................................11

1.10 Machine safety and warning stickers ...................................................................................12

2. INSTALLATION ..................................................................................................................13

2.1 Foundations.........................................................................................................................13

2.2 Location...............................................................................................................................13

2.3 Lifting and Positioning..........................................................................................................13

2.4 Pneumatic Connection.........................................................................................................14

2.5 Gas Connection...................................................................................................................14

2.6 Electrical Connection...........................................................................................................14

2.7 Guarding..............................................................................................................................14

3. GTR MACHINE PRODUCTION RUNNING.........................................................................15

3.1 Start Up Procedure..............................................................................................................15

3.2 Emergency Shut Down Procedure.......................................................................................16

3.3 Film Feed Loading...............................................................................................................16

3.3.1 Registered Film Feed Loading............................................................................................18

3.3.2 Top Tool Auto Clamp (If Fitted)...........................................................................................19

3.3.3 Top Tool Auto Clamp Operation..........................................................................................19

3.4 GTR Tool Arrangement........................................................................................................20

3.5 GTR Production Settings.....................................................................................................21

3.5.1 Temperature Control...........................................................................................................21

3.5.2 Seal Dwell Time..................................................................................................................21

3.5.3 Film Feed Time...................................................................................................................21

3.5.4 Film Rewind Tension Settings.............................................................................................22

3.5.5 Gas Flush Time Settings.....................................................................................................22

3.5.6 Gas Flush Pressure Regulator Settings..............................................................................22

4. CLEANING OF YOUR PROSEAL MACHINE .....................................................................23

4.1 Machine Description............................................................................................................24

4.2 Control Cubicle....................................................................................................................25

4.2.1 Cleaning Instructions...........................................................................................................25

4.2.2 Control Cubicle Maintenance Checks .................................................................................25

4.3 GTR Control Panel ..............................................................................................................26

4.3.1 Control Panel Maintenance Checks....................................................................................26

4.4 Film Feed Assembly............................................................................................................27

4.4.1 Film Feed Maintenance Checks..........................................................................................27

4.5 Film Rewind Assembly.........................................................................................................28

4.5.1 Film Rewind Maintenance Checks......................................................................................28

4.6 Seal Station.........................................................................................................................29

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4.6.1 Seal Station Maintenance Checks.......................................................................................29

4.7 Table and Frame .................................................................................................................30

4.7.1 Table and Frame Maintenance Checks...............................................................................30

5. FAULT DIAGNOSIS............................................................................................................32

6. ADJUSTMENT AND MAINTENANCE ................................................................................35

6.1 Safety..................................................................................................................................35

6.2 General Safety Considerations............................................................................................36

6.3 Routine Maintenance...........................................................................................................36

6.3.1 Pneumatics.........................................................................................................................36

6.4 High Oxygen Gas Flush (IF FITTED)...................................................................................37

6.4.1 Turntable Removal..............................................................................................................37

6.4.2 Tool Changing.....................................................................................................................38

6.5 Cam Positioning, Damper Replacement and Setting ...........................................................39

6.5.1 Cam Positioning..................................................................................................................39

6.5.2 Damper Replacement and Setting ......................................................................................39

6.6 Gas springs .........................................................................................................................40

6.7 Machine Maintenance Schedule..........................................................................................41

6.8 Tooling Maintenance ...........................................................................................................42

6.8.1 Daily Pre-Start Routine .......................................................................................................42

6.8.2 Weekly (Including Daily Tasks)...........................................................................................42

6.8.3 Monthly (Including Weekly Tasks).......................................................................................42

6.8.4 Quarterly (Including Monthly Tasks)....................................................................................42

7. CONFIGURATION ..............................................................................................................43

7.1 Important .............................................................................................................................43

7.2 Scope..................................................................................................................................43

7.3 Recommended Reading......................................................................................................43

7.4 Inverter settings...................................................................................................................44

7.4.1 Film Feed Inverter...............................................................................................................44

8. DECLARATION OF CONFORMITY....................................................................................45

9. APPENDICIES ....................................................................................................................47

9.1 Appendix A – Inverter Errors And Fault Finding...................................................................47

9.2 Appendix B – Systems Set-Up Documents..........................................................................51

9.2.1 To set up a Mitsubishi D700 inverter (Ref MAP009)............................................................51

9.2.2 Temperature Controllers (Ref MAP021)..............................................................................52

9.2.3 To set up a reg film sensor (Ref MAP011) ..........................................................................53

9.2.4 Phase Monitor Set-Up (If Fitted) (Ref MAP016) ..................................................................54

9.2.5 To Communicate with an FX PLC (Ref MAP001)................................................................55

9.2.6 To Set Up A Temperature Controller (Ref MAP021) ...........................................................60

9.3 Appendix C – Spares...........................................................................................................61

9.4 Appendix D – Circuit Diagram..............................................................................................62

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1. INTRODUCTION

These are the original instructions and not a translation of the operation and maintenance of the

GTR machine.

This manual describes the Proseal standard GTR rotary table heat sealing system. The machine

automatically gas flushes the tray cavity whilst it cuts and seals coated reel fed film onto pre-formed

filled trays. The machine may also be supplied as a GTR-B version which is designed to seal pre-

formed board trays with pre-cut lids. In this mode the film feed and rewind assemblies will have

been removed.

The machine has been cleaned to a satisfactory engineering standard prior to dispatch. It is your

responsibility to ensure the machine is cleaned to the relevant food hygiene standard prior to

production.

All Proseal machines are designed and constructed using materials which are safe to use in the

food processing environment. Consideration has been given during the design of the machines to

reduce the risk of product spills and to ensure they can be cleaned easily and effectively.

Safety interlocked doors are provided enabling enclosed areas to be accessed for cleaning.

The operation of Proseal machines means they do not come into direct contact with food products

Components such as bearings; belts pneumatic and electrical components are industry standard

approved components for use in the food production environment.

Any lubricants used on the machine are foodsafe grades.

To ensure your Proseal machine remains hygienic, correct maintenance procedures should be

followed and any defective parts should be replaced

The correct cleaning of your Proseal machine is also vital.

1.1 Materials

Below is a list of materials used in the construction of a Proseal machine:

•5083 Anodised Aluminium

This material is widely used in the machine construction. The aluminium is anodised to minimise

corrosion when strong cleaning fluids are used in the cleaning of the machine.

•5083 Hard Anodised and PTFE Coated Aluminium

This material is used in areas where the part is subject to contact with moving parts of the machine

such a conveyor belt support plates.

•304 Stainless Steel

This material is used the construction of all the enclosures; conduits and guarding of the machine. It

is also widely used for components and structural parts of the machine.

•304 A2 Stainless Steel Fasteners

•All fasteners used on the machine are A2 (304) grade.

•Engineered Plastics

•Various plastic materials are used on Proseal machines such as Acetal; polyurethane; HDPE.

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1.2 Components

All Proseal machines are constructed using components which are safe to use in the food

processing environment.

Below is a list of typical components used in the construction of a Proseal machine:

•Roller Bearings

All roller bearings are stainless steel specification. Some have plastic housings which are resistant

to corrosion and inert to cleaning agents.

•Polymer Bearings

Polymer bearings are also used in Proseal machines. They do not require any lubrication and have

good chemical resistance to diluted cleaning agents which may be used to clean the machine.

•Conveyor Belts

All conveyor belts used on Proseal machines are FDA approved and are of a hygienic design to

reduce the chance of product contamination.

•Electrical Components

All electrical components which are exposed to possible water ingress due to their location are

specified to a minimum IP65 rating. This ensures that they can be carefully cleaned by hand, in-

situ. Components in the working area of the machine may be protected by covers to reduce their

exposure water ingress during cleaning. All other components are located in sealed stainless steel

enclosures.

•Pneumatic Components

All pneumatic components pipes and fittings are industry standard which are designed to withstand

the normal wash down procedures associated with Proseal machinery.

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1.3 Important

These are the original instructions and not a translation of the operation and maintenance of the

GTR machine.

Operation of the GTR should only be performed by suitably trained staff and on site engineers.

Incorrect operation or incorrect parameterisation can adversely affect the overall performance of

the machine.

1.4 Scope

This manual is intended to aid operators and on site engineers in the day to day running of the GTR

1.5 General Description

Film Rewind

Control Panel

Base Tool Location

Heat Seal Area

Table Handle

Air Preparation Unit

Film Feed

Direction of Rotation

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1.6 Machine Footprint and Specifications

Weight 230 Kg

Production Speed 8-15 cycles per minute

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1.7 Technical specification

Electrical Supply: 230 VAC 50 Hz

Electrical Supply Fuse Rating: 16 Amp anti-surge

208 VAC 60Hz (2 phase)

Electrical Supply Fuse Rating: 15 Amp anti-surge

Machine Power Rating: 3 Kw

Compressed Air Supply: 5.5-7 Bar

Compressed Air Consumption:

@ 50mm Stroke : 125 Bore Cylinder ≈97.7 nL/Min (3.5 CFM)

160 Bore Cylinder ≈162 nL/Min (5.7 CFM)

Compressed Air Input: 12mm

Machine Operating Temperature Range: 0°C to 40°C

Machine Operating Humidity Range: 35 – 85% RH Non-condensing

Airborne machine noise emissions: no greater than 70dB(A)

The machine is identified with a serial number plate. Always quote the serial number of the

machine when requesting information from Proseal as this will aid identifying the exact specification

of the machine.

This plate should not be removed from the machine

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1.8 Principle of Operation

1. Filled trays are loaded into the base tool.

2. The table is manually rotated 180 degrees until the stop position is automatically made.

3. The sealing tool moves fully down applying heat to the coated film to seal it to the rim of the tray.

The cutting operation is incorporated into the sealing operation. The sealing tool is automatically

retracted after a pre-set time and the reel fed film is automatically fed on. If the machine is

configured to carry out gas flushing the seal cylinder is stopped in a predetermined position above

the base tool and gas is flushed into the trays. After a set time the gas valve is closed and the seal

tool moves fully down to seal and cut the film to the tray. The cycle is then the same as the

standard cycle.

4. The table is again manually rotated 180 degrees until the stop position is automatically made.

5. The sealed trays are raised out of the base tool for easy removal from the base tool.

Note:

Guards are fitted front and back of the machine to allow access to the sealing tool. If either of the

guards is opened the machine will stop instantly. A further switch and isolation solenoid valve are

fitted to isolate air supply to the seal cylinder down when table is not in station.

Always check the machine prior to commencement of operation for any non-conformance.

Always Report and log any defects, damage, malfunctions or misalignments found whilst operating

the Proseal GTR machine. Report all matters to the supervisor immediately, no matter how minor

they appear to be.

Do not carry out any operation unless you have read and understood the operating instructions

contained in this document.

Never operate the Proseal GTR machine, with any personnel inside the guarded area.

If in doubt, ASK the supervisor in charge.

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