chantland 4190 - Choice Bagging Equipment

Transcription

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CHANTLAND 4190
Safety - Installation - Operation – Maintenance
Chantland 4190 Auger Packer Rev. A 2010
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FOREWARD
This manual has been prepared to assist you with your Choice Bagging Equipment, 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, Fax: (512) 352-3648
email: [email protected]
Website: www.findtherightbagger.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.
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 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.
If any clarification is required -- ASK US!
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TABLE OF CONTENTS
TOPIC
PAGE
WARNINGS
1. Before Operating Equipment ..................................................................................................... 5
2. When Operating Equipment ...................................................................................................... 5
3. Grounding Recommendations ………....................................................................................... 6
CHAPTER 1 – RECEIPT AND ASSEMBLY
1. Receipt and Inspection ................................................................................................................ 10
2. Assembly Procedures .................................................................................................................. 10
3. Solenoids/Pneumatics ................................................................................................................. 10
CHAPTER 2 – INSTALLATION
1. Installation Procedures ………………………………………………………….…..............….
2. Pneumatic Connections …………………………………………………………………....…..
3. Electrical Connections …………………………………………………………………..…...…
4. Finalization of Installation …………………………………………………….….............……..
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CHAPTER 3 – COMPONENT DESCRIPTION
1. Main Frame Assembly ...……………………………………………….……………….….…..
2. Front Post Assembly …………………………………………………………….………..........
3. Auger Screw Drive Tube Assembly ……………………………………...........................……
4. Auger Motor ……………………………………………………………………………….…….
5. Belt Drive Assembly …………………………………………………………………………….
6. Feed System Assembly ………………………………………………………………..….……
7. Auger Barrel Housing …………………………………………………………….…..………...
8. Auger Seal Assembly …………………………………………………...………………………
9. Inlet Hopper Assembly ……………………………………………………………….…………
10. Hopper Seal Assembly ………………………………………………….……………………..
11. Belt Guard Assembly …………………………………………………………….…………….
12. Bag Clamp Assembly ……………………………………………...…………………………..
13. Bag Chair Assembly ……………………………………………………………….…………..
14. Dust Collections Assembly …………………………………………....................…………...
15. Pneumatic Controls ………………………………………………………………..….……….
16. Electrical Controls ………………………………………………………………….…………..
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CHAPTER 4 – OPERATION
1. Principal of Operation ................................................................................................................. 24
2. Sequence of Operation ............................................................................................................... 24
A. Phase One ..................................................................................................................... 24
B. Phase Two ..................................................................................................................... 24
CHAPTER 5 – START-UP INSTRUCTIONS & ADJUSTMENTS
1. Pneumatic Control System for Bag Seal Adjustment ...............................................................
2. Auger Adjustment …………………………................................................................................
3. Bag Chair Positioning ................................................................................................................
4. Motovibrator Bag Settling Chair ................................................................................................
A. Operation & Maintenance of Motovibrator .................................................................
B. Adjusting the Intensity of Vibrations ............................................................................
C. Noise Level ……….. ....................................................................................................
D. Maintenance .................................................................................................................
E. Lubrication ……………………………………………….……………..…..….………..
F. Non-Influencing Spout …………………………………..……………..……..………..
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G. Replacing the Flex-Seal ………………………………………………....….….……… 31
CHAPTER 6 – MAINTENANCE
1. General Maintenance ................................................................................................ 34
1.2 Machine Guide ………………………………………………………...………… 34
2. Maintenance Tips ……………………………………………………...……….......... 37
CHAPTER 7 – TROUBLESHOOTING
1. General …………………………………………………………………………….……………
2. Troubleshooting Guide ………………………………………………….……………………..
2.1 Weight Variations …………………………………………………………………….
A. Bag Chair Height ………………………………………………………………..
B. Bag Size Check ………………………………………………………….………
C. Vibration ……………………………………………………………….…………
D. Misc. Influence ……………………………………………………….…...……..
E. Auger Influence ………………………………………………………….………
F. Spout Influence …………………………………………………………….........
2.2 Motors
A. Motor will not start ……………………………………………………....….. …..
B. Motor slow to start …………………………………………………….…...........
C. Repeated Stalling …………………………………………………….…............
D. Motor Runs Hot ……………………………………………………….….……...
E. Excessive Noise ………………………………………………………..……….
2.3 Bearings
A. Frozen Bearing …………………………………………………………..………
B. Excessive Noise ……………………………………………………….………..
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APPENDIX A: ASSEMBLY DRAWINGS / PART NUMBERS......................................................……… 43
APPENDIX B: LAYOUT DIAGRAMS AND WIRING SCHEMATICS......................................................
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WARNINGS
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.
BEFORE OPERATING EQUIPMENT:
1. Any personnel working directly with or on this equipment should read this manual before proceeding
with equipment use.
2. Electricians should familiarize themselves with the electrical drawings before initial start-up of
equipment.
3. Other appropriate operating and maintenance personnel should familiarize themselves with
mechanical layout and general arrangement drawings before start-up of equipment.
4. Determine location of all emergency switches.
5. Be sure all guards are in place and observe all warning signs.
6. Check oil level in all gear boxes.
7. Be sure electrical equipment is free of any accumulation of water.
8. Be sure all personnel are clear of operating mechanisms before connecting air.
9. 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.
WHEN OPERATING EQUIPMENT:
1. Observe extreme caution when switches are turned on. Operation may begin automatically after a
time delay.
2. 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.
3. Stop machine and disconnect power before servicing or repairing. Maintenance and adjustments
must be performed with all power disconnected unless otherwise specified in this manual.
4. Do not attempt to defeat any safety switches. Serious injury could result.
5. 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.
6. 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.
7. 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.
8. 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
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pressures trapped in airlines and cylinders, etc.
9. Keep fingers, hands, feet, etc. out of path of pneumatically operated components.
10. Safety glasses should be worn in equipment area.
11. Follow the safety regulations for your plant. ALWAYS USE GOOD JUDGEMENT!
WITHIN THE TEXT OF THIS MANUAL:
"WARNING" indicates possible injury to personnel.
"CAUTION" indicates possible damage to equipment.
"NOTE" is an informational comment.
Before you begin production AND as you continue working daily with the machine, these points should be
observed for continuous service. Service parts such as belts, stuffing box material, bearings, gears, fill spouts,
etc. are available for replacement and stock supplies through Choice Bagging Equipment.
GROUNDING RECOMMENDATIONS
ELECTRICAL NOISE CONSIDERATIONS
A major consideration in the installation of a successful system is the problem created by electrical noise. The
following paragraphs provide information to help the user avoid electrical noise problems. Though many potential
problems are presented, few, if any, will be encountered in an actual application using a suitably installed PLC
system, even in a relatively harsh industrial noise environment.
BACKGROUND NOISE
Electrical noise is defined as any unwanted electrical signal which enters the control equipment. Noise signals cover
the entire spectrum of frequencies and may have any wave shape. The largest single difficulty with noise is that it is
not always present. Continuous, or frequent, periodic noises are generally easy to detect and accommodate.
Intermittent noise sources that produce short, high0energy bursts at irregular and widely spaced intervals cause the
majority of problems. Noise has a number of different pathways into the control equipment. It can be conducted
through signal or power wiring or it can be radiated by electromagnetic waves. Conducted noise is typically coupled
into the signal or power wiring either electro-statically or magnetically. Electrostatic coupling occurs through parasitic
capacitance between the noisy line and the signal/power line. This typically would be the case for long wire runs in
the same conduit. Magnetic coupling occurs through parasitic mutual inductances between lines. This requires high
currents or high currents or high rate of change of current as well as significant mutual inductance, which may result
from proximity or wiring. Electromagnetically radiated noise is typically high frequency (radio waves). The control
system and its wiring may act as antennas in picking up noise signals. This pathway is least likely to present problem
levels of noise to a PLC, and its sources are rare industrial applications. The dominate sources of noise in industry
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are those devises (and their wiring) that produce and switch high voltages and currents. Typical examples include
large motors, welders, and contactors that switch heavily inductive loads such as brakes or clutches. Other examples
of noise sources are Triac/SCR motor control and power invertors.
EFFECTS OF ELECTRICAL NOISE
The predominant effect of noise on the system is to cause “soft” failures; that is, failures which do not damage the
system but do cause it to function improperly. Three main types of soft failures are encountered:
1. Logic memory alteration.
2. Register alteration.
3. Momentary I/O failure.
Logic memory alteration presents the most significant potential problem in that it may, in some cases, result in
improper machine operation. Register and temporary I/O failure, normally result only in nuisance failures such as
operation in the wrong mode, machine glitches or incorrect or non-existent error messages.
GROUNDING
A good grounding system is a major consideration in planning any electrical system. However, it is essential for
proper operation of the electronics that a low-impedance path to earth ground exist. All filtering devices internal to the
PLC require a good earth ground return. The structural ground present in many industrial environments does not
provide an adequate ground return. A supplementary grounding electrode should be used to reduce the impedance
of the earth ground return when direct-wire connection to the power system is not feasible. As a minimum, a No. 12
AWG stranded copper wire should be used to connect to the copper grounding electrode. The connection should
exhibit very low DC resistance (0.05 OHM) and low high-frequency impedance (such as copper lugs). Minimum wire
sizes, color coding, and general safety practices should comply with American National Standards and the National
Electrical Code. Other earth ground sources are not as desirable as a copper ground stake. Green wire earth
grounds (safety grounds) brought into the control system from plants distribution networks tend to be very noisy. In
most plants, the green wire earth ground system is characterized by ground loops, multiple terminations to different
references, and long wire runs adjacent to motor power and other high-power wiring. Conduit as an earth ground has
even more problems. Though many installations use these ground references successfully, the practice should by
avoided.
1. AC POWER CONSIDERATIONS
Electrical devices should not be operated at the low end of their input power voltage rating for extended
periods of time. When input voltage is low, current input is forced higher to provide the devise with the power
of needs. Additional current means additional heating. When a system is to be installed where long
brownouts are known to occur, the user is advised to supply the PLC with power from a voltage regulating
transformer. Use of this type of transformer will provide normal voltage to the devices and keep current within
normal range.
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CHAPTER 1
RECEIPT
AND
ASSEMBLY_____
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The Chantland 4190 Auger Packer consists of the packer assembly and various items as ordered.
1. RECEIPT AND INSPECTION
Upon receipt, a check should be made to see that all items ordered have arrived and are in good condition.
Any damage incurred in shipment should be reported to the delivering carrier immediately and a claim for the
damage should be filled. If anything is missing or damaged, contact Choice Bagging Equipment, Ltd. (512352-3694) so that replacement or repair can be initiated.
The Chantland 4190 Auger Packer is shipped with locking bolts installed to secure and protect the bag post
and weighing assembly during shipment.
2. ASSEMBLY PROCEDURES
1. Mark the centerlines of the packer, reference the
General Arrangement drawing.
2. Set the packer into place. It may be 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.
3. 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).
4. The weighing assembly is secured by a locking bolt that protects the scale from any damage during
shipment. Be sure to remove the locking bolt located underneath the top flexure plate before
attempting to operate the machine. (Some models may contain 2 locking bolts).
5. If the equipment uses a load cell scale weighing unit,
make certain that the load cell and parts suspended on
it are free from side friction.
6. 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.
3. SOLENOIDS/PNEUMATICS
1. 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.
2. Connect high-pressure air line of the packer to suitable
source of supply (1/2” pipe connection).
3. It is recommended that a suitable water trap (not
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supplied with machine) be installed between the high-pressure air line and the packer. Drain the
trap as required.
4. Connect air hoses to cylinder of bag chair for automatic bag discharge (optional equipment). If the
machine was ordered from the factory with the bag discharge option, this will already be done. If the
machine was not originally ordered with the bag discharge option, it should be pre-plumbed for
operation if the option is added at a later time.
5. Connect all air hoses which were disconnected for shipment. All hoses and related fittings are
correspondingly color coded for ease of re-assembly.
6. Install any attachments which have been shipped loose or separate from the packer. The
connection between the packer inlet the mating supply hopper should be made using a soft flexible
connection to minimize the transmission of vibration.
NOTE: Auger Packers are relatively trouble free as far as basis operation stands. Problems may occur with the
controller or electrical system. If problems occur do not hesitate to call us for information at (512) 352-3694.
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CHAPTER 2
INSTALLATION
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1. INSTALLATION PROCEDURES
Your system was assembled and tested in our factory. At disassembly, decals with match markings were
applied on matching parts to facilitate installation. Study the General Arrangement and other subassembly drawings to determine the location of items. The center point of the packer inlet must be located
and marked on the floor; accomplish this by suspending a plumb bob from the center of the mating supply
hopper overhead. Verify that this center point on the floor is the proper distance from the centerline of any
associated equipment. Once this match has been verified, the packer can be put into place and leveled.
NOTE:
Do not anchor any equipment to the floor at this time. Equipment should be anchored to the
floor only after a satisfactory alignment and start-up has been achieved. Care must be taken
in leveling the packer at this point. After the packer has been placed in the desired operating
location, level the packer by plumbing the front legs. Any deviation from the plumb between
the two legs should be compromised half-way. This will result in plumb center lines. This step
is important for the scale to function properly.
2. PNEUMATIC CONNECTIONS
Control air for the system should be supplied from a high pressure air source and should be clean and dry.
A minimum of 80 PSIG pressure at approximately 3-5 SCFM is required for proper operation of the system.
Air line connections must be ¾” or larger. All air line connections should be made sing a flexible hose to
minimize the transmission of vibration. Connect the pneumatic lines using the pneumatic schematic and
the color coded end connections.
3. ELECTRICAL CONNECTIONS
Control power for the system should be supplied from a clean power source and voltage verified to ensure
proper operation of the system.
NOTE: All wiring is to be accomplished in accordance with national electric code requirements.
All
electrical connections should be made using a flexible type conduit to minimize the transmission of
vibration.
CAUTION: When drilling holes for conduit, make sure that absolutely no drill chips enter the panel, as
they may create a short circuit in the control circuits. Check all terminal block connections. Tighten those
which may have come loose during shipment. Connect all sensor and motor wires per the electrical
schematic and the color coded end connections. Terminations from the main electrical control panel to
junction boxes may be required per the electrical schematic. Connect the weighing system’s load cell
cable per the electrical schematic.
NOTE: To avoid the effects of electrical noise on the weighing system, avoid routing load cell cables near any
high voltage source.
4.
FINALIZATION OF INSTALLATION
Check all wiring connections with either an ohm meter or a buzz to verify continuity of all wires. Wiring
and wire runs should be so as not to interfere with equipment operation and in accordance with
appropriate electrical code. Make a rotational check of all motors. If phases are reversed, this can be
corrected by changing two power wires in the motor junction box. Check oil level in all gear reducers
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to ensure proper operating temperature and prolonged life. Check air pressure at all regulators per the
pneumatic schematic and fill all the air lubricator reservoirs as required.
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CHAPTER 3
COMPONENT
DESCRIPTION
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The Chantland 4190 consists of the following assemblies:
1. MAIN FRAME ASSEMBLY
The main frame assembly consists of a rigid steel frame and a hinged motor base plate.
The motor base plate has threaded rod adjustment to allow for V-belt tensioning and the hinge
side of the motor base is adjustable to accommodate a wide range of motor sizes.
2. FRONT POST ASSEMBLY
The front post is the weighing mechanism on which the bag and product is supported during
the filling process. The front post is mounted to the main frame by one S-Type load cells and
two spring steel flexures. The load cell detects changes n its deflection caused by increasing
weight and sends a varying low voltage signal to the weight controller. The signal is then
interpreted by the weight controller to determine when the desired cut-off weight is reached.
3. AUGER SCREW DRIVE TUBE ASSEMBLY
The auger screw drive tube assembly provides unitizes the mounting of the auger support
bearing to allow for removal and re-installation of the auger without disturbing the placement of
the bearings, sheaves or drive belts. The delivery auger is supported by two self-centering
flange bearings which can be adjusted to provide proper auger alignment.
4. AUGER MOTOR
The delivery auger and inlet hopper is powered by a 5 H.P. TEFC motor. This machine also
features a plug reverse action of the auger at the end of each filling cycle. This feature
provides an immediate cut-off of product flow when the desired cut-off weight is reached and
withdraws excessive product from the spout to reduce spillage when the filled bag is removed.
This motor is specially designed to minimize heat generated during frequent start/stop/reverse
duty cycles.
5. BELT DRIVE ASSEMBLY
The belt drive assembly consists of two v type belts and sheaves to transmit power from the
auger motor to the auger. These components were selected for their low rotational inertia,
consistent with proper power transmission from the motor to the auger. A variety of sheave
combinations allows selection of the optimum auger speed for the product being packed.
6. FEED SYSTEM ASSEMBLY
The feed system consists of a delivery auger and spout assembly. The auger delivers product
from the auger barrel housing, through the spout, and into the bag being filled. All augers are
balanced and checked before leaving the factory. Care should be taken to be sure that the
auger is not bent or dropped during installation, cleaning or servicing of the packer. The
physical characteristics of products are especially important to consider when two or more
products are to be packaged on the same machine. If the physical characteristics of the
products vary greatly, it may be necessary to have a different auger for each product for best
results. The spout assembly consists of a cone and integral inner spout which is mounted to
the auger barrel, and an outer spout which is mounted to the front post. The outer spout is
mounted on the front post in order to detect weight. The cone and inner spout is provided to
make the transition from the auger barrel section through the outer spout to the point of
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product discharge. A flexible seal is provided as the connection between the inner and outer
spouts. This seal prevents the entrance of product between the spouts which can cause
influence to the weighing system. A movable tapered sleeve is also provided to seal the valve
during the filling process to minimize dust. Correct adjustment of the tapered sleeve is
important. When the bag seals onto this tapered sleeve, the internal bag sleeve must be
approximately 1” back from the mouth, or bottom edge, of the spout. Feed systems can be
manufactured in a wide variety of sizes, types, finishes, and materials to fit a particular
application.
7. AUGER BARREL HOUSING
The auger barrel housing receives product from the inlet hopper and houses the rear section
of the delivery auger. The auger barrel can be manufactured in a wide variety of finishes and
materials to fit any application.
8. AUGER SEAL ASSEMBLY
There are two types of auger seal assemblies which are used to prevent the escape of product
from the rear of the auger barrel. The stuffing box type and air seal type. The most commonly
used is the stuffing box type which utilizes compression shoes and either lambs wool or Teflon
packing material. Teflon packing is typically used for food grade applications. The stuffing box
is efficient, provided the wool or Teflon packing is clean. Abrasive particles of product under
pressure from the packing glands can cause sever wear to the auger shaft. For this reason it is
recommended that the wool or Teflon be inspected periodically, and replaced if necessary.
The air seal type auger seal utilizes three lip style oil seals. Grease is used between the seals
furthest from the auger barrel, and air is injected between the seals closest to the auger barrel.
Since the air cannot escape past the lip seals and grease, it slowly bleed into the auger barrel,
creating a positive pressure in the direction, and therefore preventing the escape of product.
9. INLET HOPPER ASSEMBLY
There are several types of inlet hopper assemblies which are used to receive and precondition product from the main supply hopper. There are “V” hoppers, spike and ribbon style
agitator hoppers. The “V” hopper does not contain any agitators and is used to simply
transition from the main supply hopper to the auger barrel. This type of hopper is used for freeflowing products only. The agitator hopper contains a single agitator to pre-condition the
product prior to the auger barrel and delivery auger. This type of hopper is used for products
with slight to moderate bridging characteristics. The agitator is powered by a shaft mounted
gearbox driven by a single v-belt from the auger shaft. All hoppers are equipped with an
access door and access door safety switch to provide maintenance/clean out access. Inlet
hoppers can be manufactured in a wide variety of finishes and materials to fit a particular
application.
10. HOPPER SEAL ASSEMBLY
There are two types of hopper seal assemblies which are used to prevent the escape of
product from the RA-5 agitator shaft. The stuffing box type and the air seal type as previously
described for the auger seal assembly.
11. BELT GUARD ASSEMBLY
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A belt guard assembly is provided to cover the auger and inlet hopper belt drives. These
guards should always be fully installed when the packer is in use. If it is necessary to service
the V-belts, the rear guard may be removed for access.
12. BAG CLAMP ASSEMBLY
There are several types of bag clamp assemblies which may be used to secure the bag during
the filling process. The most common of which are either manual or air operated. Manual
valve bag clamps are a simple over-center clamping devise requiring operator actuation prior
to starting the filling cycle. Air operated clamps, however, are actuated automatically
whenever the filling cycle is requested.
An inflatable valve sealer may also be used to seal the area between the filling spout and the
inside surface of the bag valve. In addition to the typical valve bag clamps, open mouth bag
and drum/box filling attachments are available. These attachments may also be manual or air
operated.
13. BAG CHAIR ASSEMBLY
There are several types of bag chair assemblies which may be used to support the bag
during the filling process. The most common of which are either manual or air operated, and
can be vibrating or non-vibrating. Manual bag chairs simply support the bag during the filling
process and pivot forward to assist in manual removal of the filled bag. Air operated bag
chairs are actuated automatically upon completion of the filling cycle and are used to
discharge the filled bag lengthwise across the take-away conveyor. The vibratory bag settlers
are used to settle and distribute product in the bag during the filling process. Both models
utilize a pair of motor driven counter weights which alternately raise and lower the bag
support pads. In addition to the typical valve bag chairs, open mouth bag and drum/box filling
roller racks are available. These attachments may also be either vibrating or non-vibrating.
The vibrating roller racks utilize a piston type vibrator to settle and distribute product in the
bag during the filling process.
14. DUST COLLECTOR ASSEMBLY
A dust collection shroud and 4” round diameter pick-up connection is provided to help control
the dust emissions which may be generated during the filling process. Ensure that this
connection is made using a flexible type hose to minimize the transmission of vibration.
15. PNEUMATIC CONTROLS
Generally, plant air systems are not adequately filtered. Filters and regulators are installed
before all components to assure clean air. This is necessary for smooth-acting, longer lasting
components.
The main system regulators should be set so that air pressure does not exceed 80 PSI.
Moisture collecting in the bottom of the filter bowl should be bled off as often as necessary.
The screens should be cleaned or replaced every 960 hours of operation. Watch for air leaks
around fittings and flexible hoses. Proper pressure and volume are necessary for this machine
to operate correctly.
In addition to the filters and regulators, a variety of solenoid and/or air piloted valves are used
throughout the system to control the various air operated components as required.
16. ELECTRICAL CONTROL
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The electrical assembly consists of the drive motor, motor starter panel and weight controller.
Refer to the electrical drawings provided in this manual for wiring details. In addition to the
drive motor, motor starter and weight controller, a variety of limit switches, proximity switches,
etc. may be used throughout the system to control various functions as required.
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CHAPTER 4
OPERATION
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1. PRINCIPLE OF OPERATION
An auger feed assembly is the main feature of the Chantland 4190 Auger Packer. The auger housing receives
bulk product from a surge bin and supplies a steady stream into the bag utilizing a flighted auger screw.
High-pressure air (80 PSIG), operates the solenoids and cylinders.
On actuation of Start signal by the operator the bag clamp clamps the bag to the fill spout, the auger begins to
rotate and feed material into the bag. When the target weight is reached, the machine initiates a plug reverse
function. This feature provides an immediate cut-off of product flow when the desired cut-off weight is reached and
withdraws excessive product from the spout to reduce spillage when the filled bag is removed.
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 Chantland 4190 Packer
2. SECUENCE 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 Chantland 4190. The sequences as drawn shows the optional timed
powered discharge and timed bag sealer.
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.
1. Controllers reach preset target weight.
2. The motor drive assembly stops the auger and the material from the product surge bin
above the machine stops flowing into the bag.
3. The bag clamp releases the bag and the bag is discharged from the machine. Since
material gravity flows into the machine it is continuously recharged.
Various optional features shown on the schematic operate as follows:
1. The valve sealer deflates - this can be timed to ensure material stabilization in the bag.
2. The powered discharge bag chair tilts to discharge the filled bag at the end of the sealer
deflation and returns.
The speed of these features is controlled with special electrical and 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 switch the
following conditions occur:
1. The bag clamp secures the bag to the filling tube.
2. The bag sealer inflates inside the valve of the bag (optional).
3. The drive assembly is activated by the motor controls spinning the auger assembly and
4.
5.
starting product flow from the housing, through the fill spout, and into the bag.
The material is weighed in the bag until the desired net weight is reached.
When the bag comes to weight, the "Stop" circuit energizes and the condition in Phase
One is in effect.
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6. 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.
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CHAPTER 5
START-UP
INSTRUCTIONS
AND
ADJUSTMENTS
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_______
The Chantland 4190 is an automatic packer. The operator is required to put an empty bag on the filling spout and
press the Start push button after the empty bag is in place. The Start button is the green push button located at a 10
o’clock position above the filling tube.
The bag is then filled and weighed automatically, and when equipped with powered bag chair, is discharged
automatically.
If for any reason it is desired to interrupt the filling operation in the middle of a cycle, a Stop pushbutton is provided.
This is the red push button located directly underneath the green Start push button. If the standard 355 controller is
used, press Stop once and it would pause the fill process, press twice and it would stop the fill process.
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 of machine.
 Pneumatic Control System
1. Open manual valve for incoming high-pressure air.
2. Adjust pressure regulator to 80 PSIG (with power off).
 Electrical control system is on.
Place an empty bag on the filling tube. Press the Start pushbutton.
1. PNEUMATIC CONTROL SYSTEM FOR BAG SEAL ADJUSTMENT
1) Adjust pressure regulator to 80 PSIG (with power off).
2) Place an empty bag on the filling tube putting machine in filling mode.
NOTE: Components should now be in Phase Two operation.
3) Adjust the bag seal pressure to 3 PSIG (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.
4) Further adjustment may be required during the next fill cycle
5) Press the Stop pushbutton to stop machine.
3. AUGER ADJUSTMENT
WARNING: SHUT OFF ELECTRICAL POWER AND LOCK OUT BEFORE NEXT
OPERATION CAN BE DONE SAFELY.
The auger should not rub on the fill spout at any time. If auger is found not to be centered in the fill
spout and it is rubbing the fill spout, proceed as follow:

Shut off electrical power to machine and lock out
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

Check which way the auger has to move to get the auger centered in fill spout
Go to the rear of the packer and do as follows:
1. loosen motor and remove belts
2. take two ¾” wrenches and loosen four ½” bolts
3. move bearing to make correct adjustment to the auger in fill spout
4. when the auger is aligned, put the bearings back together
5. re-install all belts
6. re-tighten motor
Adjust the position of the filling tube cutoff assembly so that it is centered around the auger with equal clearance on all
sides.
3. BAG CHAIR POSITION (Optional Feature)
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 s1ot 1 " be 1ow 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.
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 beam. Do not drop,
stand or jump on the bag chair.
4. MOTOVIBRATOR BAG SETTING CHAIR
On units featuring the motovibrator settler function, the settler can be run in different modes. They are:
Continuously through the entire fill cycle – In this mode in the controller can be adjusted as when to start and
stop the PLC.
Settling during the Bulk Cycle – In this mode the controller has to have bulk and dribble feature. When the
bulk set point (setpoint 1) is reached the settler will stop and drop down.
A. OPEATION AND MAINTENECE OF MOTOVIBRATOR
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WARNING: The motovibrator must only be operated by qualified personnel.



Disconnect the power supply to the motovibrator during disassembly and re-assembly operations
on the protection devices (earth and terminal board covers), checking current absorbed.
Remove the terminal board cover, power the motovibrator, and use ammeter pliers on all the
phases to ensure that the current absorbed does not exceed the value on the rating plate. If this is
not the case, ensure that the frame or flexible structure on which the motovibrator is positioned
conforms to the correct rules for application. Never touch the motovibrator when it is operating.
Never start the motovibrator without the protective covers on the earth and terminal boards. After
a brief period of operation, again check the elements fixing the motovibrator to the frame.
B. ADJUSTING THE INTENSITY OF VIBRATIONS
WARNING: The operation must be carried out only by a qualified technician, with the power
supply disconnected.


Remove the side covers after unscrewing the bolts.

Loosen the main bolt, shift the movable weight (or the lamellar weight) to the required position and
tighten the bolt again after fitting the respective washers. The weights must be adjusted so as to be
perfectly equal and in the same direction on both sides. Refit the covers, after replacing the OR
sealing ring without damaging it. N.B.: ALL STANDAR MOTOVIBRATORS ARE SUPPLIED
WITH THE WEIGHTS ADJUSTED TO THE MAXIMUM.
C. NOISE LEVEL
The weighted equivalent continuous noise level of the motovibrators is NEVER higher than 76
dB(A)*. *measurement made in normal operating conditions in accordance with standard ISO
6081/86, with simulated load consisting of a steel bench fitted on springs. It is, however,
COMPULSORY for the manufacturer of the machinery on which the motovibrator is fitted to
measure the final noise levels on the finished machinery or plant. It is also COMPULSORY for the
employer to measure the noise levels in the work area where the machinery or system with the
motovibrator is installed. These measurements must be done before starting up the plant. It is also
compulsory to use suitable devices for personal protection and train operators as specified by L.D.
626.
APART FROM WHAT HAS BEEN SPECIFIED ABOVE, IT IS NECESSARY TO RESPECT THE REGULATIONS
APPLICABLE IN THE COUNTRY IN WHICH THE MACHINE IS USED.
D. MAINTENANCE
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WARNING: Maintenance must be performed ONLY by qualified technicians, with the power
CAUTION: Before starting operation, ensure that the temperature of the motovibrator is not higher
than 40ºC.
E. LUBRICATION
All the motovibrators are initially lubricated by the manufacturer. Motovibrators which employ ball bearings
(pre-lubricated and shielded) do not require lubrication. Models with roller bearings require grease
replacement only after 3000 hours of operation. Use KLÜBER STABURAGS NBU 8 EP grease. For
disassembling and cleaning the bearings, refer to the paragraph below. Do not mix different types of grease
even if they have similar features. An excessive amount of grease may overheat the bearings and thus
damage them.
F. NON-INFLUENCING FILL SPOUT
WARNING: Maintenance on the non-influencing spout must be completed
by
ONLY by qualified technicians.
Disconnect the power supply to the 200 Auger Flow during disassembly and re-assembly of the noninfluencing fill spout. Maintenance should NEVER be performed with electrical power connected to
the machine.
G. REPLACING THE FLEX-SEAL EA-1003 (on the non-influencing fill spout).
1. Remove the wire (Item # 7) from the outer spout tip retainer. Remove the outer tip retainer.
2. Remove the out spout by removing four (4) 5/16” that secure the spout to the bag post of the
machine. Clean any old Flex-Seal or Tape off the end of the outer spout. Remove the inner spout
retainer ring. BE CAREFUL not to bend during removal. Clean any old Flex-Seal or Tap that may
be left on the inner spout.
3. Once both the inner and outer spouts are cleaned, take new sticky tape (1/2” wide) and put one
wrap all the way around each spout. DO NOT “DOUBLE-UP” OR OVERLAP THE TAPE!
4. Take Flex-Seal (Smaller End) and place it over the inner spout. Slide the inner spout retaining ring
over the Flex-Seal and onto top of inner spout until it is even with the outer edge. BE CAREFUL TO
START THE FLEX-SEAL STRAIGHT AND EVEN TO PREVENT TEARING THE SEAL!
5. Put the outer fill spout back on over the inner fill spout. Be sure that the clearance between the inner
and outer spout is equal all the way around. If it is uneven, adjust the nuts at the back end of the
outer spout in or out to correct the adjustment.
6. After the alignment has been checked, roll the Flex-Seal over the sticky tape on the outer spout. BE
CAREFUL TO START STRAIGHT AND EVEN TO PREVENT TEARING THE SEAL!
7. Slide the tip over the outer spout and align the wire groove on the outer spout with the wire groove
on the spout tip.
8. Take a new wire and work it into the combined groove created by aligning the outer spout and spout
tip. WHEN INSTALLING THE WIRE DO NOT USE GREASE OR ATTEMPT TO LUBRICATE THE
WIRE BECAUSE DOING SO WILL ATTRACT DUST. BE SURE NOT TO MAR, BEND OR
DAMAGE THE WIRE IN ANY WAY AS IT MAY INHIBIT SLIDING THE WIRE IN FULLY
THROUGH THE GROOVE.
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32 OF 54
CHAPTER 6
MAINTENANCE
____________
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WARNING: Maintenance must be performed ONLY by qualified technicians, with the power
1. GENERAL MAINTENANCE
The Chantland 4190 is designed to be operated and maintained by the user. It is suggested that
operation and maintenance personnel study and thoroughly understand the function and working
relationship of each part before any adjustment, maintenance, or troubleshooting is performed.
The following recommendations are based on general observations made in our factory and at
various installations. They may need to be adapted to suit your operating conditions. For this
reason, we recommend you keep a detailed log recording all maintenance, adjustments, replaced
parts and malfunctions. This will help when ordering spare parts by showing which parts most
often have to be worked on or replaced. The log should be reviewed weekly and used to set up a
preventative maintenance program. Keeping the system clean and well lubricated is most
important to insure maximum performance and service life of the equipment. Lubrication charts
and maintenance guides are provided on the following pages for your assistance. Only qualified
maintenance personnel should work on this equipment. Before attempting any maintenance be
sure to read the Important Notice section at the beginning of this manual regarding safety
precautions.
WARNING:
Always disconnect electrical and pneumatic utilities when servicing related
components.
For equipment not manufactured by Choice Bagging Equipment, Ltd. See appropriate
Manufacturer’s Bulletin.
1.2 Maintenance Guide
The following should be performed at regular intervals.
a. Front Post Assembly
Load cells
 Check the rubber boots for deterioration and/or leaking grease. Replace as required.
 Check for loose or missing mounting hardware. Tighten or replace as required.
Flexures
 Ensure that the flexure is not bent and/or out of level. Level or replace as required.
b. Bearing Base Assembly
Bearings
 Check the bearing seals for deterioration and/or leaking grease. Grease or replace as
required.
 Check for excessive vibration with the auger running. Replace as required.
c. Auger Motor
Bearings
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
Check the shaft seals for deterioration and/or leaking grease. Replace as required.
d. Belt Drive Assembly
V-Belts
 Check for proper belt tension. Adjust as required.
 Check for deterioration and/or cracking. Replace as required.
Sheaves
 Check for excessive wear. Re-align or replace as required.
e. Feed System Assembly
Auger
 Check that the auger is centered in the spout. Re-align as required.
 Check that the auger is not bent. Straighten or replace as required.
Spout
 Check for proper alignment of the spout and cone. Re-align as required.
 Check the flexible seals for deterioration and/or cracking.
 Remove any product build-up.
f. Auger Seal Assembly
Packing
 Check for proper packer compression. Adjust as required.
 Check packing material for cleanliness. Replace as required.
Air Seals
 Check the shaft seals for deterioration and/or cracking. Replace as required.
 Check for grease between rear shaft seals. Grease as required.
 Check air pressure and flow. Adjust as required.
g. Inlet Hopper Assembly
Bearings
 Check the bearing seals for deterioration and/or leaking grease. Grease or replace as
required.
 Check for excessive vibration with the agitator running. Replace as required.
h. Hopper Seal Assembly
Packing
 Check for proper packing compression. Adjust as required.
 Check packing material for cleanliness. Replace as required.
Air Seals
 Check the shaft seals for deterioration and/or cracking. Replace as required.
 Check for grease between rear shaft seals. Grease as required.
 Check air pressure and flow. Adjust as required.
i. Bag Clamp Assembly
Pivots
 Check for excessive wear. Grease or replace as required.
Pads
35 OF 54


Check for excessive wear. Replace as required.
Check for excessive pressure on the spout. Adjust as required.
j. Bag Chair Assembly
Pivots
 Check for excessive wear. Grease or replace as required.
Settler
 Check for excessive vibration.
k. Pneumatic
Filters
 Check for dirty filter elements. Clean or replace as required.
 Check for moisture accumulation. Drain as required.
Regulators
 Check regulators for proper pressure setting. Adjust as required.
Lubricators
 Check lubricator oil level. Fill as required.
 Check lubricator flow rate. Adjust as required.
Cylinders
 Check the piston rod end seals for deterioration and/or cracking. Replace as required.
 Check the piston rod for excessive wear. Replace as required.
 Check rod end cushions for smooth operation. Adjust as required.
Hoses
 Check all hoses for deterioration and/or cracking. Replace as required.
 Check for leaks around fittings, valves, seals, etc. Tighten or seal as required.
l. Electrical
Photo Eyes
 Clean all photo eyes and reflectors.
 Check alignment of photo eyes and reflectors. Adjust as required
Limit Switches
 Check alignment of limit switches and actuators. Adjust as required.
Proximity Switches
 Check alignment of proximity switches and actuators. Adjust as required.
Junction Boxes
 Check for loose/broken wires or components. Tighten or replace as required.
 Blow off any excessive build-up of product/dust.
Control Panels
 Check for loose/broken wires or components. Tighten or replace as required.
 Blow off any excessive build-up of product/dust.
2. MAINTENANCE TIPS
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2.1 Check on a regular basis the isolator rubber tubing for wear.
2.2 Check the belts for fraying and the bearings for wear or noise.
2.3 Grease bearings at least one a week or as needed per environment.
The stuffing box should be checked for proper operation. To order new stuffing the part number
is H-120. Remove the stuffing box end caps and take out the old, dirty stuffing. Pack the box
with new, clean stuffing. Using a hammer and blunt tool, pound the stuffing material solidly into
the stuffing box and fill completely. Repeat the process until the box is completely filled.
Replace end caps tightly.
2.4 As the auger is in operation, check the stuffing box. The jam nuts should be tightened back to
hold the stuffing inside. If material is seeping out the sides of the box or blowing out then the
box is not securely tight. Continue to tighten the nuts until the seepage stops. It does not need
to be done daily, but checked to make sure the box is functioning properly.
2.5 Check auger frequently for smooth operation. Check to see if it is warped or bent. Movement,
noise or vibrations are indications of problems.
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38 OF 54
CHAPTER 7
TROUBLESHOOTING
_
39 OF 54
1. GENERAL
All packers are designed so that they can be operated and maintained by the user. It is
suggested that operation and maintenance personnel study and thoroughly understand the
function and working relationship of each part before any adjustment, maintenance, or
troubleshooting is performed.
On the following pages are Troubleshooting Guides to assist you in determining causes of
malfunctions in your system and action required to rectify the condition.
Prior to using this Troubleshooting Section, check for loose or broken wires, binding part, etc.,
which may be the cause of the problem. Keeping the system clean and well lubricated is most
important to insure maximum performance and service life of the equipment. Lubrication charts
and maintenance guides are provided on the following pages for your assistance
Only qualified maintenance personnel should work on this equipment. Before attempting any
maintenance be sure to read the Important Notice section at the beginning of this manual
regarding safety precautions.
WARNING:
Always disconnect electrical and pneumatic utilities when servicing related
components. For equipment not manufactured by Choice Bagging Equipment, Ltd., see
appropriate Manufacturer’s Bulletin.
2. TROUBLESHOOTING GUIDE
2.1 Weight Variations
A. Bag Chair Height
Because of the wide variety of valve bags available, the bag rest adjustment should
best be done by trial and error. Correct adjustment can best be made with a filled bag.
Prior to removing the filled bag from the filling spout, verify that the weight of the bag is
resting on the bag saddle and not hanging from the packer spout. The paper at the top
of the bag should not be under tension.
Incorrect bag saddle adjustment is a common cause of off-weight and bag size
problems. 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 bag. If the saddle is not high enough, the bag capacity may be greatly reduced.
B. Bag Size Check
A frequent source of off-weight trouble is under-size bags. The bags should never be
jammed 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 about the auger.
The compression of the product in the spout will restrict the freedom of motion of the
scale system and will cause off-weight bags. If off-weights occur, and it appears that
the packer is functioning properly, it is suggested that the bag size be checked, as
outlined below. Set the packer scale to stop filling at 80% of the desired bag weight.
Fill several bags at the reduced capacity and check weights. If weights are good,
gradually increase the set weight until the weights again become erratic. If it is
determined that the bag is too small, consult the bag supplier for help in selecting a
bag of the proper size.
C. Vibration
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Check for vibration which may be transmitted to the weighing system from possible
sources such as loose or worn V-belts, dry or worn bearings, etc.
Other Equipment in close proximity to the packer may also be a source of vibration
and may require vibration dampening.
D. Misc. Influence
Check for possible sources of influence to the weighing system such as hoses or
cables, product build-up, loose or missing hardware, etc.
E. Auger Influence
Check that the auger is not bent or loose.
Ensure that the auger is centered in the spout.
F. Spout Influence
Check that the spout and cone are concentric and are not touching.
Check the flexible seal for damage or proper installation..
2.2 Motors
A. Motor will not start
No power- Examine fuses or circuit breaker in control panel. Inspect for loose terminal
connection. Replace electrical components if required.
Overload-Inspect for
obstruction to belt and material on belt. Look for frozen or sluggish pulley bearings.
Check size of heaters to see they are large enough. Damage to exterior wiringInspect conduit and wiring to and from control panel and motor. Damage to interior
wiring of motor- If repairs are required, install replacement units.
B. Motor slow to start
Overload- Inspect for obstruction to belt and material on belt. Look for frozen or
sluggish pulley bearings. Check size of heaters to see they are large enough.
Low line voltage- Check line voltage.
Loss of one of three phases- Inspect fuses in control panel and replace as required.
C. Repeated Stalling
Interruption of power- Excessive amperage causes heater to open circuit. Inspect for
overload.
D. Motor runs hot
Overload, too much drag- Look for binding of mechanical devices, excessive belt
tension, frozen or sluggish pulley bearings, etc.
Low line voltage- Check line voltage.
Loss of one of three phases- Inspect fuses in control panel and replace as required.
E. Excessive noise
Insufficient belt tension- Properly tension belt, then tighten down drive.
Drive sheaves mis-aligned- Reposition drive sheaves using a straight edge across the
sheave faces. Properly tension belt, then tighten down drive.
2.3 Bearings
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A. Frozen bearing
Damaged or worn bearing- Replace bearing
Dry bearing- Replace bearing
B. Excessive noise
Lack of lubrication- Lubricate or Replace as required
Damaged bearing- Replace bearing
Loose bearing- Tighten or Replace as required
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Appendix A:
Assembly Drawings
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Appendix B
Layout Diagrams
& Wiring Schematics
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chantland 4190 - Choice Bagging Equipment

Transcription

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